PW-127H Maintenance Manual Chapter 72-02

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CHAPTERSECTION PAGE DATE

LEP 1 Aug 13/20042 blank Aug 13/2004

Contents 1 Aug 13/20042 blank Aug 13/2004

72-02-00Removal/Installation

401 Aug 13/2004402 Aug 13/2004403 Aug 13/2004404 Aug 13/2004405 Aug 13/2004

406 Aug 13/2004407 Aug 13/2004408 Aug 13/2004409 Aug 13/2004410 Aug 13/2004411 Aug 13/2004412 Aug 13/2004413 Aug 13/2004414 Aug 13/2004415 Aug 13/2004416 Aug 13/2004417 Aug 13/2004

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PRATT & WHITNEY CANADAMAINTENANCE MANUAL

MANUAL PART NO. 3045542

LIST OF EFFECTIVE PAGES

Page 1/272-02 LEP Aug 13/2004


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ENGINE MODULES - REMOVAL/INSTALLATION 72-02-00

1. General 4012. Consumable Materials 401

3. Special Tools 401

4. Fixtures, Equipment and Supplier Tools 402

5. Reduction Gearbox/Turbomachinery Module Replacement 402

A. Reduction Gearbox Module 402

B. Turbomachinery Module 403

6. Separation of Reduction Gearbox and Turbomachinery Modules 403

A. Procedure 403

7. Removal 408

A. Reduction Gearbox from Stand (PWC34200) and AssociatedComponents 408

B. Turbomachinery from Stand (PWC34200) and AssociatedComponents 408

C. Reduction Gearbox from Stand (PWC34300) 409

D. Turbomachinery from Stand (PWC34300) 409

8. Installation 411

A. Turbomachinery in Stand (PWC34300) 411

B. Reduction Gearbox in Stand (PWC34200) and AssociatedComponents 413

C. Turbomachinery in Stand (PWC34200) and AssociatedComponents 413

9. Mating of Reduction Gearbox and Turbomachinery Modules 413

A. Procedure 413

TABLE OF CONTENTSSUBJECT PAGE



Page 1/272-02 CONTENTS Aug 13/2004


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ENGINE MODULES - REMOVAL/INSTALLATION

1. General

A. This section provides instructions necessary for separation, replacement and mating of

reduction gearbox and turbomachinery modules. It also covers removal and installationof modules in engine stand and individual rotating stands.

B. When engine is separated, cover with plastic sheeting to prevent ingress of moistureand foreign material.

C. Effective locking of self-locking nuts to studs or bolts during assembly and mating ofmodules requires full engagement of all nut threads.

WARNING: WEAR GOGGLES WHEN CUTTING, INSTALLING OR REMOVINGLOCKWIRE.

WARNING: GLOVES MUST BE WORN TO PROTECT SKIN WHEN DECONTAMINATING

AREAS CONTAINING GASKETS OR PACKINGS WHICH HAVEDECOMPOSED DUE TO HIGH TEMPERATURES. HYDROFLUORIC ACID ISPRODUCED WHEN THE MATERIAL DECOMPOSES. MEDICALTREATMENT IS REQUIRED AS SOON AS POSSIBLE IF THE ACIDTOUCHES BARE SKIN.

CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLECOMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLEWITH THOSE REPLACED.

NOTE: Use engine oil (PWC03-001) to lubricate packings, threads and mating faces,unless otherwise stated.

2. Consumable Materials

The consumable materials listed below are referred to in this section. For more data, refer tothe CONSUMABLE MATERIALS section at the beginning of this manual.

WARNING: READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESEMATERIALS. SOME MATERIALS CAN BE DANGEROUS.

Item No. Name

PWC03-001 Oil, Engine

PWC05-018PWC05-018A

Marker, Silver Pencil

3. Special Tools

Special tools are identified in procedural text by part number in parentheses.

Tool No. Name

PWC32396 Jackscrews

PWC34200 Stand

PWC34294 Support



72-02-00 Page 401ENGINE MODULES - REMOVAL/INSTALLATION Aug 13/2004


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Tool No. Name

PWC34300 Stand

PWC37106 Support

PWC37107 Support

PWC37108 SupportPWC37109 Support

PWC37110 Adapter

PWC37650 Adapter

PWC38001 Adapter

PWC38114 Support

PWC38161 Support

PWC38212 Adapter

PWC38255 Sling, Reduction Gearbox

PWC38307 Adapter

PWC54002 Sling, Engine/Turbomachinery

PWC54212 Adapter, Front

PWC54213 Adapter, Rear

4. Fixtures, Equipment and Supplier Tools

The fixtures, equipment and supplier tools listed below are referred to in procedural text.

Name

Hoist, 1000 lb. (453.6 kg)

5. Reduction Gearbox/Turbomachinery Module Replacement

NOTE: If a module is installed to replace one removed due to being contaminated bydebris in the oil system, flush oil system (Ref. 72-00-00, SERVICING) afterinstallation. Refer to Aircraft Maintenance Manual for additional flushingrecommendations.

A. Reduction Gearbox Module

(1) Separate and remove reduction gearbox module from turbomachinery (Ref. Paras.6. and 7. A.).

(2) Remove characterization plugs from EEC and AFU (Ref. 72-01-10).

NOTE: The plugs are matched to and must remain with the reduction gearbox.

(3) Install replacement reduction gearbox module on turbomachinery (Ref. Paras. 8.and 9.).





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(4) Check characterization plug classes are the same as those called up on thereduction gearbox identification plate.

NOTE: 1. Plug classes are determined during test of reduction gearbox.

NOTE: 2. Values on EEC characterization plug decal, R3xxxx and R4xxxx must beidentical to those on RGB identification plate Q2Bxxxx (offset) andQ2Gxxxx (gain), respectively.

NOTE: 3. The characterization plug classes of AFU are recorded on RGBidentification plate as follows:

CLxxxx, where first two digits are offset value, last two digits, gain value.

(5) Install characterization plugs on EEC and AFU (Ref. 72-01-10).

B. Turbomachinery Module

(1) Separate and remove turbomachinery module from reduction gearbox (Ref. Paras.6. and 7. A.).

(2) Remove characterization plugs from EEC and AFU (Ref. 72-01-10) and retain withreduction gearbox.

(3) Install replacement turbomachinery module (Ref. Paras. 8. and 9.).

(4) Check characterization plug classes are the same as those called up on thereduction gearbox identification data plate.

NOTE: 1. Values on EEC characterization plug decal, R3xxxx and R4xxxx must beidentical to those on RGB identification plate Q2Bxxx (offset) and

Q2Gxxx (gain), respectively.

NOTE: 2. The characterization plug classes of AFU are recorded on RGBidentification plate as follows:

CLxxxx, where first two digits are offset value, last two digits, gain value.

(5) Install characterization plugs on EEC and AFU (Ref. 72-01-10).

6. Separation of Reduction Gearbox and Turbomachinery Modules (Ref. Fig. 401)

A. Procedure

(1) Drain oil (Ref. 72-00-00, SERVICING).

(2) Disconnect overspeed governor pressure sensing tube (Ref. 72-01-30).

(3) Disconnect fuel (Ref. 72-01-40) and oil tubes to fuel-cooled oil cooler (Ref.72-01-50).





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1

2

3

4

65

816 17 12

14

7

8

15

1820

1920

218

13

C38976

Stand PWC34200 - Separation/Mating of ModulesFigure 401 (Sheet 1 of 3)





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Key to Figure 401

1. Bolt

2. Packing with Retainer

3. Cover

4. Packing

5. Bolt

6. Keywasher

7. Nut

8. Washer

9. Bracket

10. Bracket11. Bracket

12. Bolt

13. Bolt

14. Jackscrew

15. Support

16. Support

17. Nut

18. Coupling Shaft

19. Transfer Tube

20. Packing

21. Packing22. Adapter

23. Sling

24. Bolt

25. Ball Lockpin

26. Support

27. Bolt

28. Adapter

29. Stand

30. Support

31. Bracket

32. Bracket

33. Bracket

34. Bracket





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VIEW AT A B

SECTION DDSECTION BB

SECTION AA

SCHEMATIC REAR VIEW OF FLANGE

TYPICAL INSTALLATION

8

11 9

33

713

32

7

8

12 13

7

8

12 13

1031

31

11

10

7 8 137 8 13

7

8

7

7

8 12

8 13

8

8

12

13

7

7

7 8 78

8

7

8

7

329 33

D

D

B

B

B

A

A

A

A

A

34

19o

C63380

Stand PWC34200 - Separation/Mating of ModulesFigure 401 (Sheet 2)





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29

30

26

25

24

27

28

23

22

C14953B

Stand PWC34200 - Separation/Mating of ModulesFigure 401 (Sheet 3)





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(4) Disconnect P7 and P9 electrical harness connectors and remove nuts, bolts andwiring harness clamp assemblies as required (Ref. 72-01-10, REMOVAL/INSTALLATION).

(5) Disconnect RGB scavenge tube (Ref. 72-01-50).

(6) Remove bolts (1, Fig. 401), packing with retainer (2), cover (3) and packing (4)from front inlet case. Discard packing.

(7) Remove bolts (5) and keywashers (6) from coupling shaft flange. Discardkeywashers.

(8) Remove nuts (7), washers (8), brackets (9, 10, 11, 31, 32, 33, 34) and bolts (12,13).

(9) Install jackscrews (PWC32396) (14) and separate reduction gearbox fromturbomachinery.

(10) Roll reduction gearbox clear of turbomachinery and install support (PWC38114)(15) on front inlet case flange and support (PWC38161) (16) on coupling shaft(18). Secure support (16) with two nuts (17).

(11) Remove transfer tube (19) and packings (20). Discard packings.

(12) Remove and discard packing (21).

7. Removal

A. Reduction Gearbox from Stand (PWC34200) and Associated Components (Ref. Fig.401)

(1) If required, separate RGB from turbomachinery (Ref. Para. 6.).

(2) Install sling (PWC38255) (23) and adapters (PWC37650) (22) on RGB.

(3) Attach sling to hoist and apply enough tension to sling to allow removal of bolts(24) and ball lockpin (25).

CAUTION: DO NOT ATTEMPT TO RAISE A GEARBOX THAT IS ATTACHED TO THESTAND.

(4) Lower support (26) and raise RGB clear of stand (PWC34200) (29).

(5) Remove bolts (27) and adapters (28).

(6) Install shipping closures and plugs if RGB is to be shipped.

B. Turbomachinery from Stand (PWC34200) and Associated Components (Ref. Fig. 402)

(1) If required, drain oil (Ref. 72-00-00, SERVICING) and separate RGB fromturbomachinery (Ref. Para. 6.).





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(2) If turbomachinery is to be shipped, remove support (PWC38161) (1) and installshipping cap (Ref. 72-00-00, SERVICING).

(3) Remove ball lockpin (12) and roll support (PWC38114) (11) clear.

(4) Install sling (PWC54002) (2) with front adapter (PWC54212) (13) and rear adapter(PWC54213) (14).

(5) Attach sling to hoist and apply enough tension to sling to allow removal of nuts (3),bolts (4) and ball lockpins (5).

CAUTION: DO NOT ATTEMPT TO RAISE A TURBOMACHINERY THAT IS ATTACHEDTO THE STAND.

(6) Lower support (6) and raise turbomachinery clear of stand (PWC34200) (9).

(7) Remove bolts (7) and adapters (8).

C. Reduction Gearbox from Stand (PWC34300) (Ref. Fig. 404)

NOTE: Steps (1), (2) and (3)must be done just prior to mating RGB to turbomachinery.

(1) While RGB is still in stand (PWC34300), measure Dim. A (Ref. Fig. 403). Itmust be 1.807 in. (45.898 mm).

(2) If less than required, tilt RGB rear downward and rotate propeller shaft until1.807 in. (45.898 mm) is achieved.

(3) If more than required, tilt RGB rear upward and rotate propeller shaft until 1.807 in.(45.898 mm) is achieved.

(4) Install adapter (PWC37650) and sling (PWC38255) (1, Fig. 404) on RGB.

CAUTION: DO NOT ATTEMPT TO RAISE A GEARBOX THAT IS ATTACHED TO THESTAND.

(5) Attach sling to hoist and apply enough tension to sling to allow removal of nuts (8)and bolts (7). Adjust eye on sling to ensure a level lift.

(6) Raise RGB (4) from stand (PWC34300) (5) and move stand away.

(7) Remove bolts (2) and adapters (PWC38001) (3).

(8) Store bolts (2) in bolt holes of adapters (3).

D. Turbomachinery from Stand (PWC34300) (Ref. Fig. 405)

CAUTION: DO NOT ATTEMPT TO LIFT TURBOMACHINERY THAT IS STILLATTACHED TO THE STAND.

(1) Attach sling (PWC54002) (1), front adapter (PWC54212) (9) and rear adapter(PWC54213) (10) on turbomachinery (4).





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2

1

4

87

3

106

5

12

9

11

13

14

15

C11976D

Stand PWC34200 - Turbomachinery Removal/InstallationFigure 402





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(2) Attach sling to hoist (adjust eye of sling to ensure a level lift) and apply enoughtension to sling to allow removal of nuts (8) and bolts (7).

CAUTION: DO NOT ATTEMPT TO LIFT TURBOMACHINERY THAT IS STILLATTACHED TO STAND.

(3) Raise turbomachinery (4) out of stand (PWC34300) (5) and move stand away.

(4) Remove bolts (2) and adapters (PWC37110) (3).

(5) Store bolts (2) in bolt holes of adapters (3).

8. Installation

A. Turbomachinery in Stand (PWC34300) (Ref. Fig. 405)

NOTE: Turbomachinery is suspended on sling (PWC54002) (1) with front adapter(PWC54212) (9), rear adapter (PWC54213) (10) and hoist.

(1) Remove bolts (2) from bolt storage holes of adapters (PWC37110) (3).

(2) Install adapters on turbomachinery (4) with bolts (2). Torque bolts 290 to 325 lb.in.(32.77-36.73 Nm).

(3) Position stand (PWC34300) (5) under turbomachinery.

(4) Lower turbomachinery and align adapters (3) with shear pads (6).

(5) Secure adapters to shear pads using bolts (7) and nuts (8).

(6) Remove sling (PWC54002) (1), front adapter (PWC54212) (9), rear adapter(PWC54213) (10) and hoist.

Key to Figure 402

1. Support

2. Sling

3. Nut4. Bolt

5. Ball Lockpin

6. Support

7. Bolt

8. Adapter

9. Stand

10. Support

11. Support

12. Ball Lockpin

13. Adapter, Front

14. Adapter, Rear





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A

1.807 IN.(45.898 mm)

VIEWA

CLOSE TORLERANCEBOLT HOLES

C17226B

Reduction Gearbox Input Shaft Coupling Assembly - Dimension CheckFigure 403





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B. Reduction Gearbox in Stand (PWC34200) and Associated Components (Ref. Fig. 401)

(1) With reduction gearbox suspended on sling (PWC38255) (23), adapters (PWC37650)(22) and hoist, install adapters (PWC38307) (28) and bolts (27). Torque bolts 720 to800 lb.in. (81.36-90.40 Nm).

(2) Position stand (PWC34200) (29) under gearbox and apply stand brake.

(3) Lower gearbox onto stand and align front support (PWC37107) (30) with adapter(28).

(4) Install bolts (24).

(5) Raise front support (PWC37106) (26).

(6) Align support with adapter and install bolt (24) and ball lockpin (25).

(7) Remove sling, adapters, hoist and shipping closures.

C. Turbomachinery in Stand (PWC34200) and Associated Components (Ref. Fig. 402)

(1) With turbomachinery suspended on sling (PWC54002) (2), front adapter(PWC54212) (13), rear adapter (PWC54213) (14) and hoist, install adapters(PWC38212) (8) and bolts (7); torque bolts 290 to 325 lb.in. (32.77-36.73 Nm).

(2) Position stand (PWC34200) (9) under turbomachinery and apply stand brake.

(3) Lower turbomachinery onto stand and align adapter (8) with support (PWC37109)(10).

(4) Install bolt (4) and nut (3).

(5) Raise support (PWC37108) (6).

(6) Align support with adapter and install bolt (4), nut (3) and ball lockpin (5).

(7) Remove sling with adapters and hoist.

(8) Install support (PWC38114) (11) and ball lockpin (12).

9. Mating of Reduction Gearbox and Turbomachinery Modules (Ref. Fig. 401)

A. Procedure

NOTE: Both RGB and turbomachinery are assumed to be in stand (PWC34200) (Ref.

Para. 8. B. and C., respectively).

(1) Lubricate with engine oil (PWC03-001) and install packing (21).

(2) Lubricate packings (20) with oil (PWC03-001) and install on transfer tube (19).Install tube.





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1

5

4

7

3

8

6

2

C14122C

Stand PWC34300 - Reduction Gearbox Removal/InstallationFigure 404





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(3) If required, use a marker (PWC05-018) to identify the three close tolerance bolt holesin the RGB coupling shaft flange.

(4) Remove nuts (17) and support (PWC38161) (16), securing RGB coupling shaft (18)and roll gearbox to mate with turbomachinery.

(5) Remove support (PWC38114) (15).

(6) Install bolts (12, 13), washers (8), brackets (9, 10, 11, 31, 32, 33, 34) and nuts (7).Torque nuts 85 to 95 lb.in. (9.61-10.74 Nm).

CAUTION: ENSURE INPUT SHAFT TO FLANGE B (DIMENSION A, REF. FIG. 403)IS 1.807 in. (45.898 mm) (REF. PARA. 7. C.).

(7) Turn propeller shaft to centralize gearbox components. Check dimension from inputcase to coupling shaft is 1.807 in. (45.898 mm).

(8) Install keywashers (6) and bolts (5) in the three marked close tolerance bolt holes

in the RGB coupling shaft flange. Install the three remaining keywashers (6) andbolts (5). Torque bolts 85 to 95 lb.in. (9.61-10.74 Nm) and lock keywashers.

NOTE: Rotating propeller shaft to centralize bearings and locate couplings willmake mating operation easier.

(9) Lubricate packing (4) with engine oil (PWC03-001) and install on cover (3).

(10) Install cover, packing with retainer (2) and bolts (1). Torque bolts 36 to 40 lb.in.(4.07-4.52 Nm).

(11) Connect RGB scavenge tube (Ref. 72-01-50).

(12) Connect P7 and P9 electrical harness connectors and secure harness brancheswith clamps assemblies (Ref. 72-01-10).

(13) Install fuel and oil tubes on fuel-cooled oil cooler (Ref. 72-01-40 and 72-01-50).

(14) Connect overspeed governor pressure sensing tube (Ref. 72-01-30).

(15) Fill engine with oil (Ref. 72-00-00, SERVICING).

Key to Figure 404

1. Sling

2. Bolt

3. Adapter4. RGB

5. Stand

6. Shear Pad

7. Bolt

8. Nut





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4

5

7

3

2

6

8

91

10

C14120A

Stand PWC34300 - Turbomachinery Removal/InstallationFigure 405





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Key to Figure 405

1. Sling

2. Bolt

3. Adapter4. Turbomachinery

5. Stand

6. Shear Pad

7. Bolt

8. Nut

9. Front Adapter

10. Rear Adapter



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PW-127H Maintenance Manual Chapter 72-02

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