DMWR_GTE_1-2835-213&P__30_Sep_2103_for_W911N219R0020.pdf

*DMWR 1-2835-213&P

DEPOT MAINTENANCE WORK REQUIREMENT

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

ENGINE, GAS TURBINE

PART NO. 3800232-1-1 NSN 2835-01-180-0452 (EIC: NA)

PART NO. 3800232-1-2 NSN 2835-01-180-0452 (EIC: NA)

PART NO. 3800232-1-3 NSN 2835-01-180-0452 (EIC: NA)

PART NO. 3800232-1-4 NSN 2835-01-180-0452 (EIC: NA)

* This manual supersedes DMWR 1-2835-213, dated 24 February 2012, including all changes.

DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited.

U.S. ARMY AVIATION AND MISSILE COMMAND

30 SEPTEMBER 2013

DMWR 1-2835-213&P

WARNING SUMMARY

Personnel performing operations, procedures and practices which are included or implied in this work require-ment shall observe the followingwarnings. Disregard of thesewarnings and precautionary information can cause serious injury, death, or destruction of material.

WARNING

An operating procedure, practice, etc. which, if not strictly observed, could result in personnel injury or loss of life.

WARNING

An operating procedure, practice, etc. which, if not strictly observed, could result in damage to, or destruction of equipment.

WARNING

CONSUMABLES

Observe all cautions and warnings on containers when using consumables. When applicable, wear necessary protective gear during handling and use. If a consumable is flammable or explosive,make certain consumable and their vapors are kept away fromheat, spark and flame.

Make certain firefighting equipment is readily available prior to use. Ensure fire extinguisher is of type required for the consumable being used, as specified by National Fire Code.

WARNING

CLEANING SOLVENTS

Dry cleaning solvents is toxic to skin, eyes and respiratory tract. Skin and eye protection are required. Avoid prolonged breathing or contact with solution. Solvent flash point must not be less than 212 °F (100 °C). Good general ventilation is normally adequate.

WARNING

CLEANING SOLVENT, DS-108

DS-108 is combustible reactive with strong oxidizers, and toxic to eyes, skin and respiratory tract. Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact.

Use only in well ventilated areas or use approved respirator as determined by local safety/in-dustrial hygiene personnel. Keep away from open flames or other sources of ignition. Do not mix or cross-apply with other cleaners or chemicals.

a Change 1

WARNING SUMMARY – Continued

WARNING

ACETONE

Acetone is flammable and toxic to eyes, skin, and respiratory tract. Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas or use approved respirator as determined by local safety/industrial hygiene personnel. Keep away from open flames, sparks or other sources of ignition.

WARNING

COMPRESSED AIR

Compressed air is dangerouswhen directed towards yourself or another person. The airstream or material blown by the airstream can cause injury, particularly to eyes and face. Use goggles to protect eyes and face. Do not exceed 30 psi.

WARNING

TOXIC POISONS

Lubricating oil contains additives which are poisonous and are readily absorbed through the skin. Avoid prolonged contact with the skin.

WARNING

NOISE

Operating andmaintenance personnel shall wear ear protection devises when working near or around an operating transmission test stand.

WARNING

HEATED COMPONENTS

Heated components can pose a serious burn potential. Wear insulated mittens when handling heated components.

Change 1 b

WARNING SUMMARY – Continued

WARNING

DRY ICE AND LIQUID NITROGEN

CGA-G6.2 Avoid contact with dry ice. Contact will cause severe frostbite on exposed skin.

Avoid breathing vapor. Prolonged inhalation may cause shortness of breath, nose/throat irritation, watery eyes and headache. Prolonged overexposure may cause coma and death.

If solid carbon dioxide contacts skin, immediately flush area with lukewarm water. Do not rub affected area. See medical attention. If other symptoms of overexposure appear, seek fresh air and possible medical attention. CAUTION: do not place solid carbon dioxide in sealed containers; heat will sublime ice to form gas, increasing pressure and resulting in explosion. Do not put head or limbs into dry ice containers. Protection: goggles/face shield, heavy approved gloves, thick full-body protective clothing.

WARNING

VERTREL SDG SPECIALTY FLUID

VERTREL SDG specialty fluid is combustible, toxic to eyes, skin, and respiratory tract, and decomposes into other hazardous products when exposed to extreme heat. Wear chemical protective gloves and goggles/face shield. Avoid repeated or prolonged contact. Avoid breath-ing vapors ormist. Use only inwell-ventilated areas. If ventilation is not adequate, use approved respirator as determined by local safety/industrial hygiene personnel. Keep away from open flames, sparks, or other sources of ignition. Refer to MSDS for specific requirements about components, reactivity, physical hazards, spill procedures, health hazards, first aid procedures, and Personal Protective Equipment (PPE).

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CHANGE U. S. ARMY AVIATION AND MISSILE COMMAND

NO. 1 REDSTONE ARSENAL, AL, 6 JUNE 2016

DEPOT MAINTENANCE WORK REQUIREMENT

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

ENGINE, GAS TURBINE

PART NUMBER 3800232-1-1 NSN 2835-01-180-0452 (EIC: NA)

PART NUMBER 3800232-1-2 NSN 2835-01-180-0452 (EIC: NA)

PART NUMBER 3800232-1-3 NSN 2835-01-180-0452 (EIC: NA)

PART NUMBER 3800232-1-4 NSN 2835-01-180-0452 (EIC: NA)

CURRENT AS OF 6 JUNE 2016

DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited.

DMWR 1-2835-213&P, 30 SEPTEMBER 2013, is updated as follows:

1. File this sheet in front of the manual for reference.

2. New or updated text is indicated by a vertical bar in the margin of the page.

3. Added or changed illustrations are indicated by a vertical bar adjacent to the figure number. Changed illustrations are indicated by a miniature pointing hand adjacent to the updated area and a vertical bar adjacent to the figure number.

4. Remove old pages and insert new pages as indicated below.

Remove Pages Insert Pages a through c/d blank a through c/d blank A/B blank A/B blank i-ii i-ii

5. Replace the following work packages with their revised version.

Work Package Number

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FOR THE COMMANDER

K. TODD ROYAR

COL, AV

Chief of Staff

OFFICIAL:

MARK MOE

DIRECTOR

ALC Supportability & Sustainment Directorate

A1619505

LIST OF EFFECTIVE PAGES/WORK PACKAGES

INSERT LATEST UPDATED PAGES/WORK PACKAGES. DESTROY SUPERSEDED DATA.

Dates of issue for original and changed pages/work packages are:

Original..0...30 Sept 2013 Change1..1...June 6, 2016

THE TOTAL NUMBEROF PAGES FOR FRONT AND REARMATTER IS 15 AND THE TOTAL NUM-

BER OFWORK PACKAGES IN THIS MANUAL IS 64 CONSISTING OF THE FOLLOWING:

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* DMWR 1-2835-213&P

U. S. ARMYAVIATION ANDMISSILE COMMAND

REDSTONE ARSENAL, AL, 30 SEPTEMBER 2013

DEPOT MAINTENANCE WORK REQUIREMENT

INCLUDING REPAIR PARTS AND SPECIAL TOOLS LIST

FOR

ENGINE, GAS TURBINE

PART NO. 3899232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can improve this manual. If you find any mistakes or if you know of a way to improve these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), located in the back of this manual, directly to: Commander, U.S. Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL 35898-5000. A reply will be furnished to you. You may also send in your comments electroni-cally to our E-mail address: 2028@redstone.army.mil or by fax 256-842-6546/DSN 788-6546. For the World Wide Web use: https://amcom2028.redstone.army.mil. Instructions for sending an electronic 2028 may be found at the back of this manual immediately preceding the hard copy 2028. A reply will be furnished to you.

CURRENT AS OF 6 JUNE 2016

* This manual supersedes DMWR 1-2835-213, dated 24 February 2012, including all changes.

DISTRIBUTION STATEMENT A – Approved for public release; distribution is unlimited.

i Change 1

TABLE OF CONTENTS

WPSequence No.

WARNING SUMMARY

HOW TO USE THIS MANUAL

CHAPTER 1 – GENERAL INFORMATION, EQUIPMENT

DESCRIPTION AND THEORY OF OPERATION

General Information.................................................................................................. ..........................0001 00 Equipment Description and Data.........................................................................................................0002 00 Theory of Operations ................................................................................................ ..........................0003 00

CHAPTER 2 – DEPOT TROUBLESHOOTING PROCEDURES

Preshop Analysis...................................................................................................... ..........................0004 00 Troubleshooting – Starter Motor Malfunctions.....................................................................................0005 00 Troubleshooting – Starting Malfunctions................................................................... ..........................0006 00 Troubleshooting – Acceleration Malfunctions......................................................................................0007 00 Troubleshooting – No-Load Governed SpeedMalfunctions...................................... ..........................0008 00 Troubleshooting – Full Load Governed SpeedMalfunctions................................................................0009 00 Troubleshooting – Engine ShutdownMalfunctions..............................................................................0010 00

CHAPTER 3 – DEPOT MAINTENANCE INSTRUCTIONS

General Requirements.............................................................................................. ..........................0011 00 Engine ...................................................................................................................... ..........................0012 00 Starter Motor............................................................................................................. ..........................0013 00 Fuel Control Assembly.............................................................................................. ..........................0014 00 LCV Butterfly Shutoff Valve....................................................................................... ..........................0015 00 Gearbox Assembly..............................................................................................................................0016 00 Rotary Pump Assembly.......................................................................................................................0017 00 Power Section.....................................................................................................................................0018 00 Facilities..............................................................................................................................................0019 00 Overhaul Inspection Procedures for Major Assemblies and Components................. ..........................0020 00 Overhaul Inspection Procedures for Starter Motor Components ............................... ..........................0021 00 Overhaul Inspection Procedures for Fuel Control Assembly Components ................ ..........................0022 00 Overhaul Inspection Procedures for LCV Butterfly Shutoff Valve Components....................................0023 00 Overhaul Inspection Procedures for Gearbox Assembly Components...................... ..........................0024 00 Overhaul Inspection Procedures for Rotary PumpComponents ............................... ..........................0025 00 Overhaul Inspection Procedures for Power Section Components............................. ..........................0026 00 Depot Mobilization .................................................................................................... ..........................0027 00 Quality Assurance Requirements........................................................................................................0028 00

CHAPTER 4 – SUPPORTING INFORMATION

References............................................................................................................... ..........................0029 00 Repair Parts and Special Tools Introduction.............................................................. ..........................0030 00

REPAIR PARTS AND SPECIAL TOOLS LIST

Group 090201 Engine Plumbing andGTEWiring Harness -Mounting Pad End...........................0031 00 Group 09020101 Engine Plumbing andWiring Harness - Hot End ........................ ..........................0032 00 Group 09020102 Wiring Harness Assembly ......................................................... ..........................0033 00 Group 090002 Electrical Assemblies ................................................................ ..........................0034 00 ii

TABLE OF CONTENTS – Continued WPSequence No.

Group 0501 Controls..................................................................................... ..........................0035 00 Group 090202 Combustion Section.............................................................................................0036 00 Group 090203 Compressor Inlet Ducts ............................................................. ..........................0037 00 Group 090001 Basic Engine........................................................................................................0038 00 Group 090003 Direct Current Motor Assembly.................................................. ..........................0039 00 Group 040301 Fuel Control Metering Section..............................................................................0040 00 Group 040302 Fuel Filtering Section................................................................. ..........................0041 00 Group 040303 Fuel Control Section .................................................................. ..........................0042 00 Group 040304 Fuel Control Unit, Pumping Section ........................................... ..........................0043 00 Group 040305 Fuel Control Body Assembly................................................................................0044 00 Group 050101 Load Control Valve, Regulating Section..................................... ..........................0045 00 Group 050102 Load Control Valve, Plumbing Section....................................... ..........................0046 00 Group 050103 Load Control Valve, Actuating Section....................................... ..........................0047 00 Group 050104 Load Control Valve, Flow Section.........................................................................0048 00 Group 090404 Gearbox Input Drive Section ..................................................... ..........................0049 00 Group 090405 Gearbox Accessory Drive Section........................................................................0050 00 Group 0702 Gearbox Oil Pressure and Regulating System........................... ..........................0051 00 Group 070201 Oil Pressure Regulating Valve..............................................................................0052 00 Group 0901 Gearbox Accessory Drive Housing Set Assembly................................................0053 00 Group 070101 Gearbox Oil PumpHousing Assembly....................................... ..........................0054 00 Group 0701 Rotary Oil Pump Assembly ..................................................................................0055 00 Group 090302 Compressor and Turbine Assembly........................................... ..........................0056 00 Group 090303 Rotating Section........................................................................ ..........................0057 00 Group 090401 Accessory Drive Section ........................................................... ..........................0058 00 Group Special Tools........................................................................................................0059 00 National Stock Number Index..............................................................................................................0060 00 Part Number Index.................................................................................................... ..........................0061 00 Expendable and Durable List .................................................................................... ..........................0062 00 Tools List................................................................................................................... ..........................0063 00 Mandatory Replacement Parts............................................................................................................0064 00 iii

HOW TO USE THIS MANUAL

HOW TO USE THIS MANUAL

Purpose and Scope

ARRANGEMENT, IDENTIFICATION, AND LOCATIONOF FRONTMATTER, CHAPTERS, WORK PACKAGES, AND REAR MATTER

Front Matter

The front matter includes such items as the Warning Summary, List of Effective Pages, Table of Contents and How To Use.

Chapters and Work Packages

TheWP’s contain informationpertinent to theperformanceof specific tasks. EachWP ismaintainedasa separate entity. TheWP’s are grouped into Chapters based on overall content. WP’s are arranged in numerical sequence regardless of chapter division. The chapter divisions and theWP’s contained within the chapters are listed in the Table Of Contents.

Chapter 1 – General Information, Equipment Description, and Theory of Operation. Information required to provide the user with a physical and functional explanation of how the equipment operates.

Chapter 2 – Troubleshooting Procedures. The troubleshooting procedures are presented according to the fault symptoms observed during the operational check procedures in Chapter 4.

Chapter 3 – Maintenance Instructions. This chapter provides information on performing preventive and corrective maintenance actions. Included are instructions concerning inspection, preventive maintenance checks and services, operational check and repair actions including subassembly/component removal and installation procedures.

Chapter 4 – Supporting Information. This chapter provides information to support the maintenance actions in Chapter 4. Included are a list of referencematerial, tools andmandatory replacement parts.

FINDING INSTRUCTIONS YOU NEED

Primary paragraph title heads in bold upper case letters.

Secondary level paragraphs are denoted by bold headings set inUpper andLowerCaseType. Theseparagraphs always relate to and are subordinate to the most recent primary paragraph heading.

Tables are titled, numbered, and listed in the table of contents under the chapter and WP they appear and if you follow the leader line the last digit is the page number of the WP where the table is shown.

Limited Applicability

Some portions of this publication are not applicable to all services. These portions are prefixed to indicate the services to which they pertain. (A) for Army, (F) for Air Force, (N) for Navy, and (MC) for Marine Corps. Positions not prefixed are applicable to all services.

iv

CHAPTER 1

GENERAL INFORMATION,

EQUIPMENT DESCRIPTION AND THEORY OF OPERATION

FOR

ENGINE, GAS TURBINE

(PART NO. 3800232-1-1) (NSN: 2835-01-180-0452)

(PART NO. 3800232-1-2) (NSN: 2835-01-180-0452)

(PART NO. 3800232-1-3) (NSN: 2835-01-180-0452)

(PART NO. 3800232-1-4) (NSN: 2835-01-180-0452)

DMWR 1-2835-213&P 0001 00

ENGINE, GAS TURBINE

PART NO. 3800232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452 EIC: NA

GENERAL INFORMATION

SCOPE

These instructions are for use by depot/contractor personnel. They apply to the Pneumatic and Shaft Power Gas Turbine Engine (GTE) Assembly, Part Number 3800232-1, Model GTCP36-50[H], used on Aviation Ground Power Unit (AGPU). In case of conflict, they take precedence over all other documents pertinent to depot main-tenance of the item. Condition of overhauled engine shall be that utility and performance is equal to that of a condition code A as defined in AR 725-50.

Currently the Model GTCP 36-50H GTE assembly could be of the four series, 3800232-1-1 through -1-4. The GTE series -1-1 and -1-2 shall be upgraded to a series -1-3. Series -1-3 and -1-4 shall stay the same. All GTE assemblies overhauled by these instructions will have the following upgrades incorporated:

• Improved compressor inlet carbon seals.

• Improved starter clutch bearings and spline shaft.

• Improved planet gear bearings.

• Improved oil pump idler gear configuration.

• Modified load control valve.

• Improved thermal insulating compound.

MAINTENANCE FORMS, RECORDS, AND REPORTS

Department of the Army forms and procedures used for equipment maintenance will be those prescribed by (as applicable) DAPAM750-8, The Army Maintenance Management System (TAMMS) Users Manual; DAPAM 738-751, Functional Users Manual for the Army Maintenance Management Systems - Aviation (TAMMS-A); or AR 700-138, Army Logistics Readiness and Sustainability.

REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR)

Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose the "Submit Quality Deficiency Report" bar). The Internet form lets you choose to submit an EIR, a Product Quality Deficiency Report (PQDR), or a Warranty Claim Action (WCA). You may also submit your information using an SF368 (Product Quality Deficiency Report). You can send your SF368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DAPAM750-8, Functional Users Manual for the Total Army Main-tenanceManagement System (TAMMS).Wewill send you a reply. For submitting PQDR’s using either the AEPS website, email tocfo@redstone.army.mil, or mail directly to: U.S. Army AMCOM, ATTN: AMSAM-MMC-MA-NM, Sparkman Center, Redstone Arsenal, Alabama, 35898-5000.

CORROSION PREVENTION AND CONTROL (CPC)

Corrosion Prevention and Control (CPC) of Army material is a continuing concern. It is important that any corro-sion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure tomoisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degra-dation is caused by thermal (heat), oxidation (oxygen), salvation (solvents), or photolytic (light, typically UV) pro-cesses. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. The form should be submitted to the address specified in DAPAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

0001 00-1

0001 00 DMWR 1-2835-213&P

DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE

For procedures to destroy this equipment to prevent its use by the enemy, refer to TM750-244-1-3, Procedures for Destruction of Aviation Ground Support Equipment (FSC 1700) to Prevent Enemy Use.

PREPARATION FOR STORAGE OR SHIPMENT

NA

LIST OF ABBREVIATIONS/ACRONYMS

AGPU Aviation Ground Power Unit AMCOM Aviation Missile Command AR Army Regulation CAGE Commercial and Government Entity Code CPC Corrosion Prevention and Control ºC Celcius DA Department of the Army ea each EIC End Item Code EIR Equipment Improvement Recommendation °F Fahrenheit fig figure ft feet in inch lb pound MAC Maintenance Allocation Chart NA not applicable NIIN National Item Identification Number NSN National Stock Number PAM Pamphlet PMCS Preventative Maintenance Checks and Services P/N Part Number psi pounds per square inch PQDR Product Quality Deficiency Report qty quantity RPSTL Repair Parts and Special Tools List SF Standard Form SMR Source Maintenance and Recoverability TAMMS The Army Maintenance Management System TAMMS-A The Army Maintenance Management System - Aviation TM Technical Manual TMDE Test, Measurement, and Diagnostic Equipment U/M Unit of Measure UOC Usable on Code WCA Warranty Claim Action WP Work Package

QUALITY OF MATERIAL

Material used for replacement, repair, or modification must meet the requirements of DMWR 1-2835-213, Gas Turbine Engine. If quality of material requirements are not stated in this manual, the material must meet the re-quirements of the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment.

SAFETY, CARE, AND HANDLING

NA

0001 00-2

DMWR 1-2835-213&P 0001 00

ENGINEERING CHANGE PROPOSALS

Engineering Change Proposals (ECPs) will be submitted using AMSAM-RDForm523 (Engineering Change Pro-posal [Short Form]). (Refer to MIL-HDBK-61A, Configuration Management, for instructions.) Completed forms should bemailed directly to Commander, U.S. Army Aviation andMissile Command, ATTN: AMSAM-RD-SE-TD- CM, Redstone Arsenal, AL 35898-5000. A reply will be furnished to you.

DEVIATIONS AND EXCEPTIONS

Requests for deviations or exceptions to this Depot Maintenance Work Requirement (DMWR) or National Main-tenanceWork Requirement (NMWR) will be processed in accordance with ISO9000 Series standards, or equiv-alent.

Contractors. These instructions are for use by contractor personnel. They apply to requests for work devia-tions and exceptions and take precedence over similar procedures specified in application Depot Maintenance WorkRequirement (DMWR).Caremust be taken toassure that all activeMaintenanceEngineeringOrder (MEOs) relevant to the DMWR have been considered.

When any work segment as set forth in a Depot Maintenance Work Requirement (DMWR) cannot be accom-plished or can be accomplished only in a manner other than specified, the contractor shall submit a Request for Depot Engineering Support (AMSAV-M-1379-R-E), located in the back of this manual, through the Contracting Officer to AMSAM-MMC-VS-C with a copy to AMSAM-MMC-BM-D. The request shall state the problems, the reason for urgency, and give the specifics listed below:

1. Serial number (if applicable). Part Number (PN), and National Stock Number (NSN) of the affected equipment.

2. Work elements that will not be completed or will not be accomplished as specified herein.

3. Reason for non-accomplishment or deviation.

4. Action taken to correct condition causing non-accomplishment or need for deviation.

5. Data relative to non availability of parts required, if applicable.

6. Estimated man-hours.

7. Instructions and inspection required to maintain the integrity of the end item having such omission or deviation.

Depots. Defects shall be processed in accordance with AMCOM-R 702-2.

MOBILIZATION REQUIREMENTS

All requirements of this DMWR will be exempted or revised in the event of mobilization. Only those procedures necessary to return the equipment to a serviceable condition will be performed. The exemptions and revisions are explained in WP 0027 00 .

COST CONSIDERATIONS

This work requirement shall be the basis for establishing the extent of overhaul while taking into consideration cost factors. A determination shall be made on all subassemblies/ assemblies to replace worn or damaged com-ponents which are available in supply, if acquisition cost is less than the cost to repair and restore to the DMWR standard. The cost to repair/restore any individual itemwith an establishedMaintenanceExpenditure Limit (MEL) to the DMWR standard shall not exceed theMEL, unless a waiver has been approved in accordance with AMC-R 750-51. This requirement does not apply to items exempted from MEL in accordance with AMC-R 750-51.

SUPPORTING INFORMATION FOR REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT EQUIPMENT

SPECIAL TOOLS AND EQUIPMENT

Required special tools and equipment are listed inWP0059 00 andWP0063 00. Possession of all the tools listed is not to be construed as mandatory when the contractor/depot may have similar tools at its facility or can locally purchase or manufacture adequate tools to accomplish all job functions in a competent and efficient manner.

INSPECTION AND TEST EQUIPMENT

Inspection and test equipment listed inWP0059 00 andWP0063 00 are used to determine conformance to spec-ifications and requirements contained in this manual.

0001 00-3

0001 00 DMWR 1-2835-213&P

SUPPORTING INFORMATION FOR REPAIR PARTS, SPECIAL TOOLS, TMDE, AND SUPPORT

EQUIPMENT – CONTINUED

REPAIR PARTS AND SPECIAL TOOLS

Repair parts are listed and illustrated in the repair parts and special tools list Chapter 4.

COMMON TOOLS AND EQUIPMENT

For authorized common tools and equipment, refer to theModified Table ofOrganization andEquipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), or CTA 8-100, Army Medical Department Expendable/Durable Items, as applicable to your unit.

0001 00-4

DMWR 1-2835-213&P 0002 00

PART NO. 3800232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452 EIC: NA

EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES

BasicEngine. The engine is designed to provide pneumatic power for aircraft Main EngineStart (MES) and air cycle refrigeration systems and shaft power for hydraulic and electrical system operation. The engine also shall provide air for general aircraft maintenance requirements.

The engine has three major sections; the compressor, turbine and accessory section.

Compressor Section. The single-stage compressor section is the source of compressed air for the turbine and bleed air for general aircraft use. Air enters the compressor inlet, is compressed in a centrifugal impeller and discharged through a two-stage diffuser into the turbine section.

Turbine Section. The turbine section consists of a turbine-wheel assembly, plenum, nozzle and single-can-type combustion chamber assembly. The turbine plenum serves as a receiver for compressor discharge air and as an enclosure for the combustion chamber and torus. The compressed air received by the turbine plenum is directed through the combustion chamber where fuel is introduced and burned; the hot gases then flow into the torus, which directs the flow into the turbine. The single-stage turbine consists of a radial, fixed-area nozzle and a radial, inward-flow turbine wheel that drives the compressor and gearbox. After passing through the turbine wheel, the gas discharges axially through a short diffusing section.

Accessory Secton. The accessory section provides two separate output pads to drive a hydraulic pump and a generator at 8000 rpm, the control systems and accessories required for engine operation. Control systems and accessories include; fuel system, lubrication system, low-energy type ignition system, electric starter, load control valve, LowOil Pressure (LOP) switch, high oil temperature switch, monopole speed sensor, EGT thermo-couple, hourmeter and the associated wiring harness. These items provide complete automatic engine control when used in conjunction with the 2117404-4 electronic control unit (provided separately from the engine).

Electronic Control Unit (ECU) and Fuel Control. Provide isochronous closed loop speed control by moni-toring speed and modulating fuel flow.

Automatic engine shutdown is provided by the ECU in the event of overspeed, exhaust gas overtemperature, ex-cess current draw in the control circuit, high oil temperature or low oil pressure. These driver circuits can actuate fault lights on a malfunction indicator panel to display the specific shutdown mode; fault circuits are latching with a "first fault wins" mode.

0002 00-1

0002 00 DMWR 1-2835-213&P

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS

DATA PLATES

Figure 1. Data Plates.

0002 00-2

DMWR 1-2835-213&P 0002 00

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS – CONTINUED

The engine, fuel control assembly, load control valve and electric starter motor have identification plates (Figure 1). The identification plates provide the operator with original manufacturer’s data. Vendor overhaul data plate (Figure 1, Detail E) will contain as a minimum: vendors’s name, overhaul date, series modification (if applicable) and contract number.

The engine, fuel control assembly, load control valve and electric starter motor will require overhaul data plates when overhaul occurs. The identification and overhaul data plates will be affixed to the respective component.

EQUIPMENT DATA

Table 1. Equipment Data.

System Specifics Overall Engine Dimensions (approx)

Length 32.8 inches Width 20.8 inches Height 24.8 inches Weight (dry) 140 pounds

APU Type Compressor Rotor Single stage centrifugal Turbine Rotor Single stage radial flow

APU Temperatures Compressor Air Inlet -65 to 125 °F Turbine Exhaust Gas (continuous operation) 1205 to 1255 °F (1255 °F maximum) Turbine Exhaust Gas (during start) 1600 to 1800 °F (2 seconds maximum)

Engine Speeds Turbine Rotor

Nominal Full-Load Governed Speed 58,167 to 59,034 rpm (99 to 101 percent speed) MaximumAllowable Rotor Speed 64,611 rpm (110 percent) Actuate Overspeed Switch 109 percent

Alternator Output Drive Pad 8000 rpm (clockwise rotation)

Hydraulic PumpOutput Drive Pad 8000 rpm (clockwise rotation)

Fuel System Consumption

Range 0 to 250 ±2 pounds per hour Fuel Specification

MIL-T-5624

Grade JP-4 -65 to 115 °F at 10,000 feet and 135 °F at sea level Grade JP-5 *-30 to 135 °F

MIL-DTL-83133

Grade JP-8 *-30 to 135 °F

ASTM-D1655

Jet A, A1, B *-40 to 135 °F

0002 00-3

0002 00 DMWR 1-2835-213&P

EQUIPMENT DATA – CONTINUED

Table 1. Equipment Data. – Continued

System Specifics Inlet Pressure 5 to 40 psig maximumwith a maximum of 2 1/2 psig fluctuation Fuel Leakage (accessory drain) 3 cc/per hour maximum Fuel Leakage (plenum drain) Fuel leakage from the plenum drain is permitted only after a false start or blowout

* Or at a temperature corresponding to a fuel viscosity of not more than 12 centistokes Lubrication System

Oil Temperature 275 °F maximum Oil Specification MIL-PRF-7808, MIL-PRF-23699, viscosity shall not exceed 13,000 centistokes Oil Consumption 10 cc per hour maximum Oil Leakage (accessory drain) 3 cc/per hour maximum Oil Leakage (from each output shaft seal) 5 cc/per hour maximum Oil Pressure (measured at oil pump) 35 to 55 psig Oil Sump Tank Capacity (total) 2.3 quarts Oil Sump Tank (usable) 1.6 quarts

Electrical System Supply 16 to 30vdc, 10 ampere maximum steady state Vibration 0.6 inch/second maximum Automatic Shutdown Features

Overspeed 110% +1 RPM Overtemperature 1300 to 1350 °F at 100 percent rpm Overcurrent 4.0 ampere maximum Low Oil Pressure (10 seconds above 95 percent rpm)

31 psig minimum

Loss of EGT Open thermocouple circuit Loss of RPM Openmotional pickup transducer circuit High Oil Temperature 275 °F maximum

EQUIPMENT CONFIGURATION

The engine Part Number 3800232-1, Model GTCP36-50[H] is the only configuration presented in this DMWR.

Currently there are 4 series to this part number, they are as follows:

3800232-1-1: Original series manufactured by Garrett Auxiliary Power Division.

3800232-1-2: Modified the combustion cap assembly to incorporate a heat shield.

3800232-1-3: Upgraded spring washer in the main roller bearing assembly in power section.

3800232-1-4: Incorporated new data plate identifying Honeywell as the manufacturer.

0002 00-4

DMWR 1-2835-213&P 0003 00

PART NO. 3800232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452 EIC: NA

THEORY OF OPERATIONS

NA

0003 00-1/2 blank

CHAPTER 2

DEPOT MAINTENANCE

TROUBLESHOOTING PROCEDURES

FOR

ENGINE, GAS TURBINE

(PART NO. 3800232-1-1) (NSN: 2835-01-180-0452)

(PART NO. 3800232-1-2) (NSN: 2835-01-180-0452)

DMWR 1-2835-213&P 0004 00

DEPOT MAINTENANCE

ENGINE, GAS TURBINE

PART NO. 3800232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452

PRESHOP ANALYSIS

INITIAL SETUP:

Materials/Parts Solvent, Dry Cleaning, MIL-PRF-680 (WP 0062 00, Item 85)

SCOPE

The purpose of preshop analysis operations is to determine prior to beginning overhaul, at the highest assembly level possible, the work required to return the Pneumatic and Shaft Power Gas Turbine Engine Assembly (en-gine) to a serviceable condition as specified in the DMWR.

If inspection at the highest level of assembly is precluded by missing, damaged or diagnosed defective assem-blies, consideration will be given to techniques that would allow continued inspection at that level. If this is not possible, inspection will proceed at the next lower level.

The preshop analysis checklist will be used to record the results of the analysis and any required maintenance.

When a 100 percent teardown overhaul will be accomplished, a preshop analysis is not mandatory.

INSPECTION OF FORMS

Check all tags and forms attached to the engine to determine the reason for removal from service and other dis-crepancies. Do not remove tags from the engine. If tags aremissing, information they contained will be furnished by the previous owning activity.

0004 00-1

0004 00 DMWR 1-2835-213&P

REMOVAL OF ENGINE FROM SHIPPING CONTAINER, PACKAGE OR STORAGE

Figure 1. Removing Engine fromCardboard orWood Shipping and Storage Container.

0004 00-2

REMOVAL OF ENGINE FROM SHIPPING CONTAINER, PACKAGE OR STORAGE – CONTINUED

Figure 2. Removing Engine fromMetal Shipping and Storage Container.

0004 00-3

REMOVAL OF ENGINE FROM SHIPPING CONTAINER, PACKAGE OR STORAGE – CONTINUED

1. If engine is shipped in a cardboard or wooden container proceed as follows:

a. Cut straps (Figure 1, Item 2) to open shipping container (Figure 1, Item 1).

b. Attach hoist to engine (Figure 1, Item 4) lifting lug, take up slack.

c. Be sure there is no slack so that the engine is supported by hoist.

d. Remove all protective covers from engine.

e. Hoist engine (Figure 1, Item 4) clear of shipping container (Figure 1, Item 1).

2. If engine was shipped in a reuseable metal shipping container proceed as follows:

NOTE

When engine is shipped to the overhaul facility in a metal shipping container (NSN 8145-01- 460-9393 or equivalent), the overhauling facility shall return engine back to customer in same or like container.

a. Loosen all 10 latches (Figure 2, Item 3) and removemetal shipping container top (Figure 2, Item 1).

b. Attach hoist to lifting lug engine (Figure 2, Item 7) and take up slack so engine (Figure 2, Item 4) is supported.

c. Remove pin from rear engine support (Figure 2, Item 5).

d. Remove 8 bolts from left and right side of engine mounts (Figure 2, Item 6).

e. Remove all protective covers from engine.

f. Hoist engine (Figure 2, Item 4) clear of shipping container (Figure 2, Item 2).

g. Reassemble and placemetal shipping container (Figure 2, Item 1 and 2) in suitable storage location.

INSTALLING ENGINE IN ASSEMBLY FIXTURE

Position engine over engine maintenance stand. Lower onto stand and secure engine.

EXTERNAL INSPECTION

Visually inspect overall condition of engine for any missing or damaged parts.

CLEANING

Wipe the exterior of the engine thoroughly with Solvent, Dry Cleaning, MIL-PRF-680 prior to performing preshop analysis (if required).

INSPECTION

Perform preshop analysis (Table 1) (if required) by performing all inspection points in the order specified.

TEMPORARY PRESERVATION/PROTECTION

1. Ensure that all protective caps and plugs are firmly in place.

2. Place the engine in a covered container and provide adequate protection as necessary to prevent damage.

ANALYSIS MAINTENANCE ACTIONS

PreshopAnalysisChecklist. Table 1 provides a checklist for preshop analysis of the engine. Instructions are given to evaluate the items to determine the extent of repair or replacement needed to make the item completely serviceable. Perform each check in Table 1. in sequence to determine maintenance action required. Results of the Army Oil Analysis Program (AOAP) shall be used for analysis when AOAP sample report was rationale for component or assembly being programmed for overhaul.

0004 00-4

ANALYSIS MAINTENANCE ACTIONS – CONTINUED

Scheduled Maintenance. When it is determined that 100 percent teardown will be done, a preshop analysis is not mandatory.

INSPECTION DATA SHEET

Review historical records to ensure correct documents are available (i.e., DA Form 2410, DD Form 1577-2, SF 368 etc). Complete Component/Airframe Disassembly Inspection Data Sheet on each component inducted, overhauled, repaired or overhauled as per instruction on back of form (CCADFORM28), Table 2. In completing the data form, provide a qualifying statement encompassing the location and degree of each discrepancy, defect or failure observed. Ensure all applicable form fields are completed. PSD Data Form, DA Form 2410, DA Form 2408-20, DDForm 1577-2, DDForm 1577-3 and SF 368 will be forwarded to the following organization for each component processed:

U.S. Army Aviation and Missile Command.

ATTN: AMSAM-MMC-RE-FC

Redstone Arsenal, AL 35898-5000

0004 00-5

PRESHOP ANALYSIS

FOR

P/N

Serial No.

MWOsRequired

Reason(s) for Overhaul/Repair

Unpacking Secondary ItemsRequired?

Reviewed Tags?

Reviewed Forms?

Name (please print)

Signature Date

0004 00-6

Table 1. Preshop Analysis Checklist.

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Engine Oil Filter Metal contamination present.

Rebuild engine

Carbon Seals Will not hold vacuum on good gearbox.

Rebuild power section

Gearbox Assembly Oil leaks, missing hardware or other visible damage

Repair

Leaks during pressure test.

Repair

0004 00-7

Table 1. Preshop Analysis Checklist. – Continued

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Harness Shrink Sleeving

Missing, cracked or deteriorated.

Replace

Harness Boots Cracked or deteriorated.

Replace

Harness Leads Missing or damaged insulation.

Replace

Harness Connectors Cracked or broken shells, bent or broken pins.

Repair and/or Replace

0004 00-8

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Thermocouple Damaged leads or thermocouple junction.

Replace

Clamps Supporting Harness

Cushion torn or missing.

Replace

Time Totalizing Meter Damaged terminals, indicators or casing.

Replace

Harness Identification Straps

Illegible. Remark straps

0004 00-9

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Temperature Switch Visible damage to switch body.

Replace

Low Oil Pressure Switch

Visible damage to switch body.

Replace

Motional Pickup Transducer

Visual damage to pickup body.

Replace

Metal particles on monopole.

Rebuild engine

0004 00-10

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Ignition Unit Dents, cracks or other visible damage.

Replace

Igniter Plug Electrical Lead

Frayed shielding. Replace

Fuel Lines Kinked, cracked, flattened or chaffed.

Replace

Fuel Lines and Fittings Fuel leaks. Replace

0004 00-11

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Fuel Nozzle Assembly Cracks, clogs or other visible damage.

Replace

Fuel Control Adapter Cracks or other visible damage.

Replace

Fuel Control Assembly

Fuel leaks or other visible damage.

Repair

Fuel Filter Contamination present

Clean fuel system and replace filter

0004 00-12

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Solenoid Valve Fuel leaks or visible damage to valve body.

Replace

Torque Motor Cracks or other visible damage.

Replace

Identification Plate Illegible, missing or damaged.

Replace

Lifting Lug Cracks or other visible damage.

Replace

0004 00-13

Inspection Point Condition Action Remarks Date Chec-ked

Checked by

Power Section Freedom of rotation or other visible damage.

Repair

Starter Motor Cracks or other visible damage.

Repair

0004 00-14

Table 2. Component/Airframe Disassembly Inspection Data Sheet.

1. NOMENCLATURE 2. SERIAL NO. 3. PART NO. 4. FAILURECODE 5. PRIORO/H

6. USAGESINCENEW 7. USAGESINCEO/H 8. RMVD FROMNOMENCLATURE 9. MODEL

10. SERIAL NO. 11. FIELD TAG STATED REASON

12. MAG PLUG 13. OIL FILTER 14. REMOVAL DATE

CLEAN CONTAM CLEAN CONTAM

15. PRIME CAUSEOF FAILURE

16. NOUN PART NO. SERIAL NO. FAILUREMODE

17. CONDITION/DISCREPANCY

18.SEQUENCENO. 19. CONTRACT NO. (PCN) 20. INDUCTIONDATE

21. PREPARED BY: 22. PHONE NO.

CCAD Form 28, 1 Jan 88 (Previous Editions Obsolete)

0004 00-15

INSTRUCTIONS

1. Nomenclature of component being inducted from DA Form 2410 Block #1.

2. Serial number of component being inducted from DA Form 2410 Block #4.

3. Part number of component being inducted from Block #6.

4. Failure code stated in DA Form 2410 Block #8.

5. Prior number of overhauls from DA Form 2410 Block #9a.

6. Usage since new from DA Form 2410 Block #9b.

7. Usage since overhaul from DA Form 2410 Block #9c.

8. Removed from nomenclature from DA Form 2410 Block #11.

9. AGPU model from DA Form 2410 Block #12.

10. AGPU serial number from DA Form 2410 Block #14.

11. Field tag stated reason for removal.

12. Inspect magnetic plug and circle the word describing condition. If contaminated, provide description of contamination.

13. Inspect oil filter and circle theword describing condition. If contaminated, provide description of contam-ination.

14. Removal date from field tag or any other document.

15. Preshop analysis determination of primary cause of failure.

16. Failed parts noun, part number, serial number and failure mode.

17. Conditionof component being inductedanddiscrepancies discoveredduring testing, evaluationanddis-assembly.

18. Sequence number: Identification code for processed items.

19. Contract number (PCN).

20. Induction date: Date item was inducted for processing.

21. Name of person that prepared this form.

22. Telephone number of person that prepared this form.

23. Copy of this data sheet will be forwarded to the following address:

Commander Aviation and Missile Command U.S Army ATTN: AMSA-MMC-RE-FC Redstone Arsenal, AL 35898-5000

TEL:

DSN 746-6538

COM (256) 876-6538

END OF WORK PACKAGE

0004 00-16

DMWR 1-2835-213&P 0005 00

ENGINE, GAS TURBINE

PART NO. 3800232-1-1 NSN 2835-01-180-0452

PART NO. 3800232-1-2 NSN 2835-01-180-0452

PART NO. 3800232-1-3 NSN 2835-01-180-0452

PART NO. 3800232-1-4 NSN 2835-01-180-0452

TROUBLESHOOTING – STARTER MOTOR MALFUNCTIONS

INITIAL SETUP: References

WP 0013 00

INTRODUCTION

CAUTION

Damage to the ignition unit will occur if the electrical lead to the igniter plug is disconnected at the igniter plug or at the ignition unit while the ignition system is energized.

Before troubleshooting a system, perform the following checks:

1. Check all lines, hoses and wiring for proper routing. All connectors and fittings for security and obvious obstructions.

2. Pay particular attention to recently replaced components in the system that have gone through the trou-bleshooting procedures.

3. Check for evidence of FOD.

TROUBLESHOOTING PROCEDURE

MOTOR FAILS TO OPERATE

STEP

1. Check starter terminals.

CONDITION/INDICATION

Are terminals properly connected and power available?

DECISION

YES–Proceed to Step 2. NO–Connect terminals and/or supply dc power.

STEP

2. Check end play.

CONDITION/INDICATION

Is end play within limits?

DECISION

YES–Proceed to Step 3. NO–Correct end play (WP 0013 00).

STEP

3. Check insulator for cracks.

CONDITION/INDICATION

Is insulator serviceable?

DECISION

YES–Proceed to Step 4. NO–Replace insulator (WP 0013 00).

0005 00-1

0005 00 DMWR 1-2835-213&P

STEP

4. Check mating of brush connections to armature.

CONDITION/INDICATION

Is there proper mating?

DECISION

YES–Proceed to Step 5. NO–Repair stator Correct brush connections (WP 0013 00).

STEP

5. Check stator assembly.

CONDITION/INDICATION

Is stator assembly serviceable?

DECISION

YES–Proceed to Step 6. NO–Repair stator assembly (WP 0013 00).

STEP

6. Check motor armature assembly for shorts.

CONDITION/INDICATION

Is motor armature assembly serviceable (not shorted)?

DECISION

YES–Proceed to Step 7. NO–Replace armature assembly.

STEP

7. Check starter bearings.

CONDITION/INDICATION

Is bearing serviceable?

DECISION

YES–Replace armature assembly. NO–Proceed to Step 8.

MALFUNCTION

Motor fails to operate.

CORRECTIVE ACTION

8. Service or replace bearing.

MOTOR OPERATES IN WRONG DIRECTION

STEP

9. Check stator assembly terminals.

CONDITION/INDICATION

Are terminals connected to brushes in proper sequence?

DECISION

YES–Replace stator assembly and/or armature (WP 0013 00). NO–Proceed to Step 10.

0005 00-2

DMWR 1-2835-213&P 0005 00

MALFUNCTION

Motor operates in wrong direction.

CORRECTIVE ACTION

10. Correct terminals connected to brushes (WP 0013 00).

MOTOR RUNS AT LESS THAN SPECIFIED SPEED

STEP

11. Check end play.

CONDITION/INDICATION

Is end play within limits?

DECISION

YES–Proceed to Step 12. NO–Correct end play (WP 0013 00).

STEP

12. Check commutator finish.

CONDITION/INDICATION

Is it smooth?

DECISION

YES–Proceed to Step 13. NO–Machine commutator.

STEP

13. Check commutator and motor armature.

CONDITION/INDICATION

Are they serviceable (not shorted)?

DECISION

YES–Proceed to…