PRATT & WHITNEY CANADA

MAINTENANCE MANUAL
MANUAL PART NO. 3034342

LIST OF EFFECTIVE PAGES

CHAPTER
SECTION PAGE DATE
LEP 1 Apr 11/2008
2 blank Apr 11/2008

Contents 1 Apr 11/2008

2 Apr 11/2008

72-20-00 1 Jun 18/2004

Description and 2 Jun 18/2004
Operation

72-20-00 201 Apr 11/2008

Maintenance 202 Apr 11/2008
Practices 203 Apr 11/2008
204 Apr 11/2008
205 Apr 11/2008
206 Apr 11/2008
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208 Apr 11/2008
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72-20 LEP Apr 11/2008
 PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3034342

TABLE OF CONTENTS
SUBJECT PAGE

COMPRESSOR AIR INLET - DESCRIPTION AND OPERATION 72-20-00

1. General 1

2. Description and Operation 1

A. Compressor Inlet Case 1

B. Air Inlet Screen 1

COMPRESSOR AIR INLET - MAINTENANCE PRACTICES 72-20-00

1. General 201

2. Consumable Materials 201

3. Special Tools 201

4. Fixtures, Equipment and Supplier Tools 201

5. Removal/Installation 202
A. Removal of Air Inlet Screen 202

B. Removal of Oil Tank Pressurizing Valve 202

C. Installation of Air Inlet Screen 202
D. Installation of Oil Tank Pressurizing Valve 203

6. Cleaning/Painting 203
A. Cleaning of Air Inlet Screen 203
B. Cleaning of Pressurizing Valve 203

7. Inspection/Check 203

A. Inspection of Air Inlet Screen 203

B. Inspection of Air Inlet Case 203

C. Inspection of Oil Level Sight Gage 205

D. Inspection of Oil Tank Pressurizing Valve 205
E. Inspection of the Compressor Air Inlet Surfaces 205

8. Approved Repairs 205

A. Repair of Corrosion - Compressor Inlet Case 205

Page 1
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 PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3034342

TABLE OF CONTENTS
SUBJECT PAGE

COMPRESSOR AIR INLET - MAINTENANCE PRACTICES (Cont’d) 72-20-00

B. Repair of Air Inlet Screen Edge 210

C. Repair of Oil Tank Pressurizing Valve (Heavy Maintenance
Only) 211

Page 2
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 PRATT & WHITNEY CANADA
MAINTENANCE MANUAL
MANUAL PART NO. 3034342

COMPRESSOR AIR INLET - DESCRIPTION AND OPERATION

1. General

A. The compressor inlet case is a component of the engine gas generator assembly and
directs incoming air to the compressor rotor assembly. An air inlet screen prevents
debris entering the compressor inlet.

2. Description and Operation (Ref. Fig. 1)

A. Compressor Inlet Case

The compressor inlet case is a circular casting that forms an annular plenum chamber
for the passage of air to the compressor rotor. Two mounting flanges are incorporated;
Flange F at the front provides mounting for the gas generator case while Flange G at
the rear, provides mounting for the accessory gearbox. The inlet case also forms a
compartment for, and the forward face of the integral oil tank. An oil level sight gage
is located on the side of the inlet case at the 10 o’clock position. The oil tank pressurizing
valve and oil cooler return adapter are located at the 11 and 12 o’clock positions
respectively.

Housed in the inlet case is the No. 1 bearing assembly with its associated rotor and
stator seals and the No. 1 bearing oil jet. The guide vanes in the inlet case plenum
chamber are hollow and direct P2.5 interstage air, released by the compressor bleed
valve, into the incoming air via a series of openings cut in the guide vanes. This
tangential air flow creates a swirl effect known as ‘‘jet flap function’’, to reduce compressor
stall during starting and low power conditions.

B. Air Inlet Screen

The air inlet screen is an open mesh screen wrapped around the periphery of the inlet
case to prevent entry of large objects that may bypass the airframe cowling inertial
separator vanes.On both the PT6A-60 and PT6A-61 engines, the air inlet case is
used in conjunction with a compressor bleed air case.

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MAINTENANCE MANUAL
MANUAL PART NO. 3034342

INLET AIR

INLET SCREEN

AIR INLET CASE

HOLLOW STRUT

P2.5 INTER− TANGENTIAL

STAGE AIR FLOW (’JET FLAP’)

FIRST−STAGE
COMPRESSOR
BLADE

NO. 1 BEARING
(REF.)

C10224A

Compressor Inlet Case and Air Inlet Screen Installation

Figure 1

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MANUAL PART NO. 3034342

COMPRESSOR AIR INLET - MAINTENANCE PRACTICES

1. General

A. Maintenance personnel should make reference to the INTRODUCTION section and

Chapter 70-00-00 STANDARD PRACTICES of this manual to familiarize themselves
with general procedures.

B. Install suitable protective caps/covers over all disconnected tubes/lines and component
openings.

C. Lockwire, unless otherwise specified, shall comply with specification AMS 5687, heat
and corrosion resistant steel wire MS9226-03, 0.025 inch diameter, and will not be
specified in instructions.

2. Consumable Materials

The consumable materials listed below are used in the following procedures.

Item No. Name

PWC04-004 Grease, High Temperature
PWC04-005 Grease, Extreme Pressure
PWC05-019 Compound, Lapping
PWC05-037 Enamel, Aluminized
PWC05-061 Cloth, Coated Abrasive
PWC05-064 Solution, Anodize Touch-Up
PWC05-101 Cloth, Abrasive
PWC05-145 Use PWC05-019
PWC08-002 Adhesive, Fluorosilicone
PWC11-012 Acetone, Methyl
PWC11-014 Alcohol, Isopropyl
PWC11-016 Use PWC11-014
PWC11-027 Solvent, Petroleum
PWC11-031 Cleaner, Engine
PWC13-001 Primer, Epoxy
3. Special Tools

Not Applicable

4. Fixtures, Equipment and Supplier Tools

Not Applicable

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MANUAL PART NO. 3034342

5. Removal/Installation

A. Removal of Air Inlet Screen

CAUTION: KEEP COMPRESSOR INLET AREA CLEAR OF ALL FOREIGN OBJECTS

THAT COULD BE INGESTED BY ENGINE DURING SUBSEQUENT
OPERATION.

(1) Remove Pre-SB13131 bleed air case (Ref. 72-30-04).

(2) Remove self-locking nuts (2, Fig. 201), washers (3, Pre-SB13371) and bolts (4)
fastening air inlet screen (1) flanges at 4 o’clock position.

(3) Carefully open screen and withdraw from around compressor inlet case.

CAUTION: IF ANY OBJECT FALLS INTO ENGINE COMPRESSOR INLET, ALL WORK
MUST CEASE UNTIL OBJECT IS RECOVERED.
(4) To protect compressor inlet area from foreign object ingress, cover entire inlet area
with suitable polyethylene or similar sheeting.

B. Removal of Oil Tank Pressurizing Valve

(1) Remove nuts (1, Fig. 202) and bolts (3) fastening bracket (14) to rear mount ring.

(2) Remove bolts (2) and washer fastening bracket (14), cover (4) and gasket (5)
to compressor inlet case.

(3) Withdraw valve assembly (11) from inlet case and internal breather tube.

(4) Install suitable protective cover to compressor inlet case.

(5) Install valve (Ref. Para. D.) or repair (Ref. Para. 8.) as required.

C. Installation of Air Inlet Screen

CAUTION: IF ANY OBJECT FALLS INTO ENGINE COMPRESSOR INLET, ALL WORK
MUST CEASE UNTIL OBJECT IS RECOVERED.
(1) Remove any protective covering from compressor inlet area, and make sure area is
free of foreign material or loose components.

(2) Apply grease (PWC04-004) or (PWC04-005) to inner circumference of rubber rims

of air inlet screen.

(3) Carefully install air inlet screen (1, Fig. 201) over compressor inlet case, inserting
screen between case and external fittings and lines. Locate flange mating faces at
4 o’clock position, midway between ends of compressor wash ring on rear
mount ring.

(4) Insert bolts (4) through screen flanges, and install self-locking nuts (2) and washers
(3, Pre-SB13371). Tighten self-locking nuts 12 to 15 lb.in.

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MANUAL PART NO. 3034342

D. Installation of Oil Tank Pressurizing Valve

(1) Install new lubricated preformed packing (10, Fig. 202) on valve assembly (11) and
insert through compressor inlet case into internal breather tube.

(2) Install new gasket (5), cover (4) and support bracket (14), to compressor inlet case
with bolts (2) and washer (13). Tighten bolts 36 to 40 lb.in. and lockwire.

(3) Install support bracket (14) to rear mount ring using bolts (3) and self-locking nuts
(1). Tighten nuts 36 to 40 lb.in.

6. Cleaning/Painting

A. Cleaning of Air Inlet Screen

(1) Clean wire mesh using solvent (PWC11-027) or (PWC11-031). Dry with clean, dry
compressed air.

B. Cleaning of Pressurizing Valve

(1) Clean components by flushing or spraying with solvent (PWC11-027) or

(PWC11-031). Make sure bores are clean and free of obstructions. Dry components
using clean, dry compressed air.

7. Inspection/Check

A. Inspection of Air Inlet Screen

(1) Examine air inlet screen wire mesh for cleanliness and/or damage. Clean as
necessary.

(2) Examine rubber sealing rims and flanges for proper attachment and/or damage.

B. Inspection of Air Inlet Case

(1) Examine struts for cracks. None are allowed. If cracks are found send case to an
approved overhaul facility.

(2) Examine inlet case expansion plugs as follows (Ref. Fig. 203):

(a) Drain oil (Ref. 72-00-00, SERVICING, Lubricating Oil System).

(b) Remove oil filter and filter housing (Ref. 79-20-02).

(c) Insert suitable mirror through oil filter housing bore and with a strong light
source, locate upper and lower expansion plugs on front face of inlet case.
Check for looseness of plugs.

(d) If plug(s) is/are loose, send engine to an approved overhaul facility for
repair/replacement of plug(s).

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MANUAL PART NO. 3034342

4 DETAIL A

3 1
2

C3924A

Removal/Installation of Air Inlet Screen

Figure 201

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MANUAL PART NO. 3034342

Key to Figure 201

1. Air Inlet Screen

2. Self-locking Nut
3. Washer (Pre-SB13371)
4. Bolt

C. Inspection of Oil Level Sight Gage

(1) Examine the sealing and mating surfaces for scratches, scoring and other surface
damage.

(2) Check the sealing of lens within the sight gage for possible leakage. Replace the
sight gage as required.

D. Inspection of Oil Tank Pressurizing Valve

(1) Examine for wear or corrosion. Valve seats must be free of scoring and/or pitting.
Repair as required (Ref. Para. 8.).

E. Inspection of the Compressor Air Inlet Surfaces

(1) Remove the air inlet screen (Ref. Para. 5.A.).

(2) Use a suitable mirror or flash light to inspect the inlet throat area, struts, radii and
mating surfaces for corrosion.

(3) If any corrosion is found, then repair the damaged area (Ref. Para. 8., Approved
Repairs).

8. Approved Repairs

A. Repair of Corrosion - Compressor Inlet Case

(1) For aluminum compressor air inlet cases only:

(a) Allowable limits of corrosion

1 Corrosion must not be deeper than 0.010 in. on the inlet struts and
adjacent radii.

2 Local wall thinning (in all areas, except for struts) up to 0.025 in. Max.
locally within a 1 in. sq. area and must not exceed 10 percent of the total
surface of the inlet case.

3 If corrosion exceeds depth of 0.025 in. on casing, remove Gas Generator

Module (Ref. 72-00-00, SERVICING) and send to an approved P&WC
overhaul facility.

(b) Apply a suitable covering material over the compressor section.

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MAINTENANCE MANUAL
MANUAL PART NO. 3034342

1 2

NO WASHER
THIS LOCATION

REAR FIRESEAL (REF.)

3
14
4
13 5

12 7

11 9

10

COMPRESSOR INLET CASE (REF.)

C41057A

Removal/Installation of Oil Tank Pressurizing Valve

Figure 202

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MANUAL PART NO. 3034342

Key to Figure 202

1. Nut
2. Bolt
3. Bolt
4. Cover
5. Gasket
6. Seat
7. Piston
8. Spring
9. Housing
10. Preformed Packing
11. Valve Assembly
12. Pin
13. Washer
14. Bracket

(c) Clean the surface of the area to be repaired with a swab soaked in isopropyl
alcohol (PWC11-014) and crocus cloth (PWC05-061).

(d) Remove all traces of corrosion (aluminum oxide) using a suitable steel brush,
crocus cloth (PWC05-061), abrasive cloth (PWC05-101), file or grit paper.
Remove all traces of debris using a vacuum cleaner.

(e) Flush the area with clean water at room temperature.

(f) Locally clean the repaired surface and surrounding area using a swab soaked
in perchlorethylene (PWC11-016) or acetone (PWC11-012) and a crocus cloth
(PWC05-061). Remove all debris using a vacuum cleaner.

(g) Apply anodize touch-up solution (PWC05-064) using a swab or brush for three
to four minutes.

NOTE: 1. Repeat the application frequently to make sure that the affected
surface is continually wet with the solution.

NOTE: 2. If the solution does not wet the surface, remove the solution with a
clean cloth and repeat Step (d). Also, clean the first-stage compressor
if the solution has been inadvertently applied.

(h) Allow the surface to air dry or wipe off solution with a cloth soaked in clean
water.

(i) Examine the coating and make sure that the repair surface is completely
covered. Reapply the treatment again as necessary.

NOTE: After the successful completion of Step (i), the engine may be
returned to service for the next 100 hours.

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MAINTENANCE MANUAL
MANUAL PART NO. 3034342

PLUGS CAN BE VIEWED THROUGH

OIL FILTER HOUSING BORE

VIEW OF COMPRESSOR INLET CASE

WITH ACCESSORY GEARBOX
OMITTED FOR CLARITY

UPPER EXPANSION PLUG

LOWER EXPANSION PLUG

VIEW ON ARROW A

C41939

Compressor Inlet Case Expansion Plugs

Figure 203

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MANUAL PART NO. 3034342

(j) For a more durable repair, do the following:

1 Do Steps (c) through (g) again.

2 Dry the affected area thoroughly.

3 Apply two coats of primer (PWC13-001).

NOTE: The primer can be diluted with 10% solvent.

4 Allow the primer to air dry for eight hours before applying enamel paint.
Use compressed air at 29 psig to accelerate the drying time.

5 Apply three to four coats of enamel (PWC05-037) to the primed surface.

Allow the surface of the enamel to become tacky (approximately 15
minutes) between each coat. Allow a final coat of enamel paint to dry for
24 hours before returning the engine to service.

NOTE: Drying time can be reduced with the use of a heat gun at a low
setting. Refer to the manufacturers instructions.

(k) If the corrosion repair is more than the maximum permitted limits, inspect the
repaired area again, at intervals not exceeding 10 flight hours. The engine
must be returned to an approved overhaul facility within 50 flight hours for a
repair to be done.

(2) For P/N 3114679-01 and Post-SB13263 magnesium compressor air inlet cases only
(Ref. Fig. 204):

(a) Repairable limits of corrosion except for specific areas (Ref. Fig. 204)

1 Corrosion must not be deeper than 0.010 in. on the inlet struts and adjacent
radii.

2 Local wall thinning (in all areas, except for struts) up to 0.025 in. Max.
locally within a 1 in. sq. area and must not exceed 10 percent of the total
surface of the inlet case.

3 If corrosion exceeds repairable limits on casing, remove Gas Generator

Module (Ref. 72-00-00, SERVICING) and send to an approved P&WC
overhaul facility.

(b) Apply a suitable covering material over the compressor section.

(c) Clean the surface of the area to be repaired with a swab soaked in isopropyl
alcohol (PWC11-014) and crocus cloth (PWC05-061).

(d) Remove all traces of corrosion (magnesium oxide) using a suitable steel brush,
crocus cloth (PWC05-061), abrasive cloth (PWC05-101), file or grit paper.
Remove all traces of debris using a vacuum cleaner.

(e) Flush the area with clean water at room temperature.

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MANUAL PART NO. 3034342

(f) Dry the area with clean compressed air at 29 psig.

WARNING: REFER TO THE MATERIAL SAFETY DATA SHEETS BEFORE YOU

USE THESE MATERIALS FOR INFORMATION SUCH AS
HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL
CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH
HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND
CONTROL MEASURES. SOME OF THESE MATERIALS CAN BE
DANGEROUS. YOU CAN GET THE DATA SHEETS FROM THE
MANUFACTURERS OR THE SUPPLIERS OF THESE
MATERIALS.
(g) Prepare a chrome pickle solution (Ref. Chap. 70-00-00, MAINTENANCE
PRACTICES, Touch-Up Solution).

(h) Using a swab or a brush, apply the chrome pickle solution, at a temperature of
17° to 29°C (55° to 85°F), to the prepared surface, for 30 to 45 seconds.

NOTE: Repeat the application frequently to make sure that the affected surface
is continually wet with the solution.

(i) Swab the area with clean water until successive swabs are no longer stained
yellow.

(j) Dry the area with local heating (air dry or a heat gun at a low setting).

(k) Clean the affected area with a rag soaked in clean water.

(l) Dry the area with clean, compressed air at 29 psig.

(m) Apply two coats of primer (PWC13-001).

NOTE: The primer can be diluted with 10% solvent.

(n) Allow the primer to air dry for eight hours before applying enamel paint. Use
compressed air at 29 psig to accelerate the drying time.

(o) Apply three to four coats of enamel (PWC05-037) to the primed surface. Allow
the surface of the enamel to become tacky (approximately 15 minutes)
between each coat. The final coat of enamel must dry for 24 hours before
returning the engine to service.

NOTE: Drying time for the primer and paint can be reduced with the use of a
heat gun at a low setting. Refer to the manufacturers instructions.

(p) If the corrosion repair is more than the maximum permitted limits, inspect the
repaired area again, at intervals not exceeding 10 flight hours. The engine
must be returned to an approved overhaul facility within 50 flight hours for a
repair to be done.

B. Repair of Air Inlet Screen Edge

(1) Clean area (Ref. Para. 6.), and apply adhesive (PWC08-002) to mating surfaces of
loose rims or flanges.

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MANUAL PART NO. 3034342

(2) Allow to dry for two hours at room temperature. Full bond strength will be obtained
after 72 hours.

C. Repair of Oil Tank Pressurizing Valve (Heavy Maintenance Only)

(1) Remove roll pin (12, Fig. 202) fastening valve seat (6), piston (7) and spring (8) in
valve housing (9).

(2) Clean valve components (Ref. Para. 6.).

(3) Lap valve seat (6) to give 360 degree surface contact using compound (PWC05-019)
or (PWC05-145).

(4) After lapping, thoroughly clean the valve seat (Ref. Cleaning/Painting) to remove all
traces of the compound.

(5) Insert spring (8) and piston (7) into housing (9). Screw valve seat (6) in until travel
stops, to compress spring to minimum height.

(6) Back off valve seat (6) 2.5 turns (0.104 in.).

(7) Fasten the valve components in housing (9) with spring pin (12).

(8) Install the valve assembly in the compressor inlet case (Ref. Para. 5.).

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MANUAL PART NO. 3034342

SEE
DETAIL A

SEE
DETAIL B

P/N 3114679-01 and Post-SB13263 only C79512

Repair of Corrosion - Compressor Inlet Case

Figure 204 (Sheet 1 of 2)

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MANUAL PART NO. 3034342

MAXIMUM CIRCUMFERENTIAL ALLOWABLE LENGTH = 5.000 IN.

INLET CASE

.250

EXTENT OF
.500 TOUCH−UP
REPAIR

COMPRESSOR SHROUD
DETAIL A

EXTENT OF
TOUCH−UP
REPAIR .060

DETAIL B

P/N 3114679-01 and Post-SB13263 only C79513

Repair of Corrosion - Compressor Inlet Case
Figure 204 (Sheet 2)

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