CMM 49-25-89 Gas Turbine Engine

Engines, Systems & Services
Phoenix, Arizona
TO: HOLDERS OF UNIT NOMENCLATURE COMPONENT MAINTENANCE/OVERHAUL MANUAL,

ATA NO. 49-25-93, DATED AUGUST 5, 2003.
THIS REVISED PUBLICATION IS ISSUED FOR USE IN SUPPORT OF THE FOLLOWING AIRCRAFT.
ENGINE/
COMPONENT ENGINE AIRCRAFT
PART NO. MODEL NO. APPLICATION
3800726-1 RE100[LJ] Learjet 45
REVISION NO. 1 DATED NOVEMBER 11/05
This is a PARTIAL revision with a COMPLETE REPRINT. The pages revised are listed below, together with
the Highlights of the revision. The pages of prior issues which are not affected retain the previous revision
dates. Please discard the entire manual of previous issue(s) and replace with this complete manual. Enter on
the Record of Revisions the date the pages are inserted.
HIGHLIGHTS
Subject/Page Description of Change
Title Page
Page T-1 Revised to latest revision date.
Safety/Warranty/Liability
Page SWLA-1/SWLA-2 Revised Warranty/Liability Advisory statement.
Record of Revisions
Page RR-1 Added Revision 1.
Record of Temporary Revisions

Page TR-1 Added Temporary Revisions 49-1.
Service Bulletin List

Page SB-1 Added Service Bulletin 49-7787.
List of Effective Pages

Pages LEP-1 through LEP-4 Revised to reflect latest change pages.
Introduction
Page INTRO-3 Revised Table 2. to match latest information.
Description and Operation

Page 5 Revised Key to Figure 1 for latest information.
Testing and Fault Isolation

Pages 104 and 105 Revised Table 101. Special Tools,
Fixtures and Equipment.
Page 111 Revised Key to Figure 101 (Sheet 1) for latest

information.
HIGHLIGHTS Page 1 of 6
ATA NO. 49-25-93 Nov 11/05
Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Phoenix, Arizona
HIGHLIGHTS (Cont)
Page 113 Revised Step 1.E.2(j) for latest information.
Page 119 Revised Step 1.F.(10) for latest information.
Page 120 Revised Step F.(12)(e), (h) and (i) for latest
information.
Page 122 Revised Steps 1.G.(6) and (10) for latest

information.
Page 123 Revised Step 1.H.(5) for latest information.
Disassembly
Pages 301 through 305 Revised Table 302 Special Tools, Fixtures and
Equipment.
Page 307 and 308 Revised Table 303 for latest information.
Page 310 Revised Figure 301 for latest information.
Page 311 Revised Key to Figure 301 and Step 1.E.(1)(d) for
latest information.
Page 317 Revised Key to Figure 303 and Step 1.F.(1)(a) for
latest information.
Page 319 Revised Key to Figure 304 and Steps 1.F.(2)(b) and
(c) for latest information.
Page 321 Revised Step 1.F.(3)(c) for latest information.
Page 323 Revised Key to Figure 306 and Step 1.F.(4)(d) for
latest information.
Page 326 Revised Figure 308.
Page 327 Revised Key to Figure 308 and Steps 1.F.(6)(g) and
(h) for latest information.
49-25-93 Nov 11/05
Phoenix, Arizona
HIGHLIGHTS (Cont)
Page 335 Revised Key to Figure 311 and Steps 1.F.(9)(b)

through (d) for latest information.
Page 337 Revised Key to Figure 312 and Step 1.F.(10)(a)for

latest information.
Page 353 Revised Key to Figure 320 and Steps 1.F.(18)(c), (d)
and (f) for latest information.
Page 361 Revised Step 1.F.(22)(h) for latest information.
Page 375 Revised Key to Figure 330 and Steps 1.F.(27)(a), (f)
and (g) for latest information.
Cleaning
Pages 402 and 403 Revised Table 401 Cleaning Methods for latest
information.
Page 404 Revised Table 401 Cleaning Methods and Table 402
Materials and Compounds for latest information.
Page 405 Revised Table 402 Materials and Compounds for

latest information
Check
Page 501 Added Paragraph 1.B. and Table 501 Materials and
Compounds and renumbered subsequent tables.
Page 502 Revised Table 502. Special Tools, Fixtures and

Equipment and step 1.C.(1) for latest information.
Page 506 Revised Step 1.E.(1) for latest information.
Page 507 Added page ‘This Page Intentionally Left Blank’.
49-25-93 Nov 11/05
Phoenix, Arizona
HIGHLIGHTS (Cont)
Page 509 Revised Figure 501 Check Procedures for latest

information.

information.

information.

information.

information.
Page 546 Revised Figure 519 (Sheet 2) for latest information.

information.
Assembly (With Storage)
Page 701 Revised Table 701 Materials and Compounds for

latest information.
Pages 702 through 708 Revised Table 702 Special Tools, Fixtures and
Equipment for latest information.
Page 715 Revised Step 3.A.(2) and WARNING per Temporary

Revision 49-1.
49-25-93 Nov 11/05
Phoenix, Arizona
HIGHLIGHTS (Cont)
Page 759 Revised Key to Figure 719 and Step 3.M.(5) for latest
information.
Page 763 Revised Key to Figure 721 and Step 1.(2)(e) for
latest information.
Page 767 Revised Step 3.N.(5) for latest information.
Page 797 Revised Key to Figure 734 and Step 3.P.(15)(a) for
latest information.
Page 798.1 Revised Key to Figure 735 for latest information.
Page 798.4 Revised Figure 737 for latest information.
Page 798.5 Revised Key to Figure 737 and Step 3.P.(18)(a) for
latest information.
Page 798.8 Revised Step 3.Q.(1)(h) for latest information.
Page 798.11 Revised Key to Figure 739 and Steps 3.Q.(2)(e) and
(f) for latest information.
Page 798.17 Revised Key to Figure 741 and Step 3.Q.(4)(b) for
latest information.
Page 798.18 Revised Steps 3.Q.(4)(k) through (m) for latest

information.
49-25-93 Nov 11/05
Phoenix, Arizona
HIGHLIGHTS (Cont)
Page 798.27 Revised Key to Figure 745 and Steps 3.Q.(9)(a) and
(b) for latest information.
Page 798.29 Revised Key to Figure 746 and Steps 3.Q.(10)(a) and
(d) for latest information.
Page 798.32 Added Paragraph 4.A.NOTE.
Fits and Clearances

Page 801 Revised Table 801. Fits and Clearances for latest
information.
Pages 804 and 805 Revised Table 804. Specified Torque for latest
information.
Special Tools, Fixtures

and Equipment
Pages 901 through 909 Revised Table 901. Special Tools, Fixtures and
Equipment for latest information.
49-25-93 Nov 11/05
Phoenix, Arizona
GAS TURBINE ENGINE
PART NO.
3800726-1
COMPONENT MAINTENANCE MANUAL
This document and all information and expression contained herein are the property of Honeywell
International Inc., are provided in confidence, and may be used by persons required by Federal Aviation
Regulation Part 21.50 to comply with any of the terms of these instructions. Except as set forth above, no
person may, in whole or in part, use, duplicate or disclose this information for any purpose without the prior
written permission of Honeywell International Inc.
This publication is distributed by:

Honeywell Engines, Systems & Services
Technical Data Distribution
M/S 64-01/2101-201
P.O. Box 52170
Phoenix, AZ 85072-2170
To order a document, please go to our web-site at

www.honeywelltechpubs.com
Inquiries of a technical nature regarding this

publication should be directed to:
Honeywell Engines, Systems & Services

Customer Support Center
M/S 26-06/2102-323
P.O. Box 29003
Phoenix, AZ 85038-9003
Phone: (Domestic) 800-601-3099
Phone: (International) 602-365-3099
Fax: 602-365-3343
Page T-1
ATA NO. 49-25-93 Aug 5/03
Revised Nov 11/05 No. 1
Copyright 2003, 2005 Honeywell International Inc. All rights reserved.
Phoenix, Arizona
SAFETY ADVISORY
WARNING: BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE
HANDLING, STORAGE AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE
MANUFACTURER OR SUPPLIER. FAILURE TO OBEY THE MANUFACTURERS' OR
SUPPLIERS' RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE.
This publication describes physical and chemical processes which can make it necessary to use chemicals,
solvents, paints, and other commercially available materials. The user of this publication must get the Material
Safety Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or suppliers of the materials to be
used. The user must know the manufacturer/ supplier data and obey the procedures, recommendations,
warnings and cautions set forth for the safe use, handling, storage, and disposal of the materials.
WARRANTY/LIABILITY ADVISORY
WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT

WHICH IS NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH
HONEYWELL'S PUBLISHED INSTRUCTIONS AND/OR HONEYWELL'S FAA/SFAR 36
REPAIR AUTHORIZATION. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY
FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER
THAN HONEYWELL.
INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR

DECREASE THE LIFE OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL
TOOLING OR TEST EQUIPMENT CAN RESULT IN DAMAGE TO THE PRODUCT
COMPONENTS OR GIVE UNSATISFACTORY RESULTS.
SWLA-1\SWLA-2
ATA NO. 49-25-93 Nov 11/05
RE100[LJ]
RECORD OF REVISIONS
REV ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY
ORIG Aug 5/03
1 Nov 11/05
Page RR-1
49-25-93 Nov 11/05
RE100[LJ]
RECORD OF REVISIONS (CONT)
REV ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY
Page RR-2
49-25-93 Aug 5/03
RE100[LJ]
RECORD OF TEMPORARY REVISIONS

INCORPO-
RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
49-1 715 Mar 16/04 Nov 11/05 1
Page TR-1
49-25-93 Nov 11/05
RE100[LJ]
RECORD OF TEMPORARY REVISIONS (CONT)

INCORPO-
RATED INTO
TR PAGE ISSUE DATE DATE MANUAL BY
NO. NO. DATE INSERTED BY REMOVED BY REV NO.
Page TR-2
49-25-93 Aug 5/03
RE100[LJ]
SERVICE BULLETIN LIST
SB DATE
NO. INCORPORATED TITLE
49-7400, Rev 1 Aug 5/03 Replace Lube Pump, Part No. 3881739-2 with Part
No. 3881800-1, Gearbox Housing, Part No. 3863409-1/-2
with Part No. 3863409-3/-4 (Respectively), and O-ring, Part
No. M83248/1-116 with Part No. M83248/1-115.
49-7447 No Effect Replace Compressor Rotor, Part No. 3822523-2 with Part
No. 3822523-003.
49-7456 No Effect Replace Thermocouple, Part No. 3876315-1 with

Thermocouple, Part No. 3876315-2.
49-7457 No Effect Replace Turbine Plenum, Part No. 3846734-1 with

Turbine Plenum, Part No. 3846743-1.
49-7489 Aug 5/03 Replace Oil Filler Neck and Cap, Part No. 2A1126
(527-510-9001) with Oil Filler Neck and Dipstick Cap,
Part No. 2A7732 (361-530-9354).
49-7523, Rev 3 No Effect Replace Low Oil Pressure Switch Part No. 3876255-2
with Part No. 3876351-1 and Re-identify Lube Pump from
Part No. 3881800-1 to Part No. 3881825-1.
49-7530, Rev 2 No Effect Replace Lube Pump, Part No. 3881800-1 with Part No.
3881825-1.
49-7535 No Effect Replace Tee Divider, Part No. 3883921-1 with Part No.
3883921-2.
49-7563, Rev 1 No Effect Replace Generator Seal, Part No. 3863387-1 With Part No.
3863504-1.
49-7576 No Effect Inspect and Remove Applicable Serial Number, Low Oil
Pressure Switch, Part No. 3876351-1.
49-7787 No Effect Replace Low Oil Level Switch, Part No. 3876318-1 with
Part No. 3876318-2.
Page SB-1
49-25-93 Nov 11/05
RE100[LJ]
SERVICE BULLETIN LIST
SPARE PARTS DATE

BULLETIN INCORPORATED TITLE
GTE1127 No Effect Replace Annular Ball Bearing, Part No. 3822515-1 with Part
No. 3822570-1.
GTE1215 No Effect Replace Deswirl Deflector, Part No. 3827403-1 with

Part No. 3827403-2.
GTE1222 No Effect Replace Gearbox Assembly, Part No. 3863409-3 with

Part No. 3863409-5.
GTE1249 No Effect Authorizes the Use of Identification Plate, Part No.

S21002-5 in place of Part No. S20002-5.
Page SB-2
49-25-93 Aug 5/03
RE100[LJ]
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page * T-1 Nov 11/05 * 104 Nov 11/05

* 105 Nov 11/05
Safety Advisory 106 Aug 5/03
Warranty/Liability 107 Aug 5/03
Advisory * SWLA-1 Nov 11/05 108 Aug 5/03
SWLA-2 Blank 109 Aug 5/03
110 Aug 5/03
Record of * 111 Nov 11/05
Revisions * RR-1 Nov 11/05 112 Aug 5/03
RR-2 Aug 5/03 * 113 Nov 11/05
114 Aug 5/03
Temporary 115 Aug 5/03
Revisions * TR-1 Nov 11/05 116 Aug 5/03
TR-2 Aug 5/03 117 Aug 5/03
118 Aug 5/03
Service * 119 Nov 11/05
Bulletin List * SB-1 Nov 11/05 * 120 Nov 11/05
SB-2 Aug 5/03 121 Aug 5/03
* 122 Nov 11/05
List of Effective * 123 Nov 11/05
Pages * LEP-1 Nov 11/05 124 Aug 5/03
* LEP-2 Nov 11/05 125 Aug 5/03
* LEP-3 Nov 11/05 126 Aug 5/03
* LEP-4 Nov 11/05 127 Aug 5/03
128 Aug 5/03
Table of 129 Aug 5/03
Contents TC-1 Aug 5/03 130 Aug 5/03
TC-2 Blank 131 Aug 5/03
132 Aug 5/03
Introduction INTRO-1 Aug 5/03 133 Aug 5/03
INTRO-2 Aug 5/03 134 Aug 5/03
* INTRO-3 Nov 11/05
INTRO-4 Aug 5/03 Disassembly * 301 Nov 11/05
INTRO-5 Aug 5/03 * 302 Nov 11/05
INTRO-6 Aug 5/03 * 303 Nov 11/05
* 304 Nov 11/05
Description and * 305 Nov 11/05
Operation 1 Aug 5/03 306 Aug 5/03
2 Aug 5/03 * 307 Nov 11/05
3 Aug 5/03 * 308 Nov 11/05
4 Aug 5/03 309 Aug 5/03
* 5 Nov 11/05 * 310 Nov 11/05
6 Aug 5/03 * 311 Nov 11/05
7 Aug 5/03 312 Aug 5/03
8 Aug 5/03 313 Aug 5/03
9 Aug 5/03 314 Aug 5/03
10 Aug 5/03 315 Aug 5/03
Testing and * 316 Nov 11/05
Fault Isolation 101 Aug 5/03 * 317 Nov 11/05
102 Aug 5/03 318 Aug 5/03
103 Aug 5/03 * 319 Nov 11/05
Page LEP-1
*The asterisk indicates pages changed, added or deleted. 49-25-93 Nov 11/05
RE100[LJ]
320 Aug 5/03 371 Aug 5/03

* 321 Nov 11/05 372 Aug 5/03
* 322 Nov 11/05 373 Aug 5/03
* 323 Nov 11/05 * 374 Nov 11/05
324 Aug 5/03 * 375 Nov 11/05
* 325 Nov 11/05 376 Aug 5/03
* 326 Nov 11/05 377 Aug 5/03
* 327 Nov 11/05 378 Aug 5/03
328 Aug 5/03 379 Aug 5/03
* 329 Nov 11/05 380 Aug 5/03
330 Aug 5/03 381 Aug 5/03
331 Aug 5/03 382 Aug 5/03
332 Aug 5/03
333 Aug 5/03 Cleaning 401 Aug 5/03
* 334 Nov 11/05 * 402 Nov 11/05
* 335 Nov 11/05 * 403 Nov 11/05
* 336 Nov 11/05 * 404 Nov 11/05
* 337 Nov 11/05 * 405 Nov 11/05
338 Aug 5/03 406 Aug 5/03
339 Aug 5/03
340 Aug 5/03 Check * 501 Nov 11/05
341 Aug 5/03 * 502 Nov 11/05
342 Aug 5/03 503 Aug 5/03
343 Aug 5/03 504 Aug 5/03
344 Aug 5/03 505 Aug 5/03
* 345 Nov 11/05 * 506 Nov 11/05
346 Aug 5/03 * 507 Nov 11/05
347 Aug 5/03 * 508 Nov 11/05
348 Aug 5/03 * 509 Nov 11/05
349 Aug 5/03 510 Aug 5/03
350 Aug 5/03 * 511 Nov 11/05
351 Aug 5/03 * 512 Nov 11/05
* 352 Nov 11/05 513 Aug 5/03
* 353 Nov 11/05 514 Aug 5/03
354 Aug 5/03 515 Aug 5/03
* 355 Nov 11/05 * 516 Nov 11/05
356 Aug 5/03 * 517 Nov 11/05
357 Aug 5/03 518 Aug 5/03
358 Aug 5/03 519 Aug 5/03
359 Aug 5/03 520 Aug 5/03
360 Aug 5/03 521 Aug 5/03
* 361 Nov 11/05 * 522 Nov 11/05
362 Aug 5/03 * 523 Nov 11/05
363 Aug 5/03 524 Aug 5/03
364 Aug 5/03 525 Aug 5/03
365 Aug 5/03 * 526 Nov 11/05
366 Aug 5/03 527 Aug 5/03
367 Aug 5/03 * 528 Nov 11/05
368 Aug 5/03 529 Aug 5/03
369 Aug 5/03 * 530 Nov 11/05
370 Aug 5/03
Page LEP-2
RE100[LJ]
531 Aug 5/03 728 Aug 5/03

532 Aug 5/03 729 Aug 5/03
533 Aug 5/03 730 Aug 5/03
* 534 Nov 11/05 731 Aug 5/03
* 535 Nov 11/05 732 Aug 5/03
536 Aug 5/03 733 Aug 5/03
537 Aug 5/03 734 Aug 5/03
538 Aug 5/03 735 Aug 5/03
539 Aug 5/03 736 Aug 5/03
540 Aug 5/03 737 Aug 5/03
541 Aug 5/03 738 Aug 5/03
542 Aug 5/03 739 Aug 5/03
543 Aug 5/03 740 Aug 5/03
544 Aug 5/03 * 741 Nov 11/05
545 Aug 5/03 742 Aug 5/03
* 546 Nov 11/05 743 Aug 5/03
* 547 Nov 11/05 744 Aug 5/03
548 Aug 5/03 745 Aug 5/03
549 Aug 5/03 746 Aug 5/03
550 Aug 5/03 747 Aug 5/03
551 Aug 5/03 748 Aug 5/03
552 Aug 5/03 749 Aug 5/03
750 Aug 5/03
Assembly * 751 Nov 11/05
with Storage * 701 Nov 11/05 752 Aug 5/03
* 702 Nov 11/05 753 Aug 5/03
* 703 Nov 11/05 754 Aug 5/03
* 704 Nov 11/05 * 755 Nov 11/05
* 705 Nov 11/05 756 Aug 5/03
* 706 Nov 11/05 * 757 Nov 11/05
* 707 Nov 11/05 758 Aug 5/03
* 708 Nov 11/05 * 759 Nov 11/05
709 Aug 5/03 760 Aug 5/03
710 Aug 5/03 761 Aug 5/03
711 Aug 5/03 762 Aug 5/03
712 Aug 5/03 * 763 Nov 11/05
713 Aug 5/03 764 Aug 5/03
714 Aug 5/03 765 Aug 5/03
* 715 Nov 11/05 766 Aug 5/03
716 Aug 5/03 * 767 Nov 11/05
717 Aug 5/03 768 Aug 5/03
718 Aug 5/03 769 Aug 5/03
719 Aug 5/03 770 Aug 5/03
720 Aug 5/03 771 Aug 5/03
721 Aug 5/03 772 Aug 5/03
722 Aug 5/03 773 Aug 5/03
723 Aug 5/03 774 Aug 5/03
724 Aug 5/03 * 775 Nov 11/05
725 Aug 5/03 776 Aug 5/03
726 Aug 5/03 777 Aug 5/03
727 Aug 5/03 778 Aug 5/03
Page LEP-3
RE100[LJ]
779 Aug 5/03 * 798.32 Nov 11/05

780 Aug 5/03 798.33 Aug 5/03
781 Aug 5/03 798.34 Aug 5/03
782 Aug 5/03
783 Aug 5/03 Fits and
784 Aug 5/03 Clearances * 801 Nov 11/05
* 785 Nov 11/05 802 Aug 5/03
786 Aug 5/03 803 Aug 5/03
787 Aug 5/03 * 804 Nov 11/05
788 Aug 5/03 * 805 Nov 11/05
789 Aug 5/03 806 Aug 5/03
790 Aug 5/03
* 791 Nov 11/05 Special Tools
792 Aug 5/03 Fixtures and
793 Aug 5/03 Equipment * 901 Nov 11/05
794 Aug 5/03 * 902 Nov 11/05
* 795 Nov 11/05 * 903 Nov 11/05
* 796 Nov 11/05 * 904 Nov 11/05
* 797 Nov 11/05 * 905 Nov 11/05
798 Aug 5/03 * 906 Nov 11/05
* 798.1 Nov 11/05 * 907 Nov 11/05
798.2 Aug 5/03 * 908 Nov 11/05
* 798.3 Nov 11/05 * 909 Nov 11/05
* 798.4 Nov 11/05 910 Aug 5/03
* 798.5 Nov 11/05
* 798.6 Nov 11/05
* 798.7 Nov 11/05
* 798.8 Nov 11/05
798.9 Aug 5/03
798.10 Aug 5/03
* 798.11 Nov 11/05
798.12 Aug 5/03
798.13 Aug 5/03
798.14 Aug 5/03
798.15 Aug 5/03
* 798.16 Nov 11/05
* 798.17 Nov 11/05
* 798.18 Nov 11/05
798.19 Aug 5/03
798.20 Aug 5/03
798.21 Aug 5/03
798.22 Aug 5/03
* 798.23 Nov 11/05
798.24 Aug 5/03
798.25 Aug 5/03
* 798.26 Nov 11/05
* 798.27 Nov 11/05
* 798.28 Nov 11/05
* 798.29 Nov 11/05
798.30 Aug 5/03
* 798.31 Nov 11/05
Page LEP-4
RE100[LJ]
TABLE OF CONTENTS
SECTION PAGE
Introduction .................................................................................................................................... INTRO-1
Description and Operation .......................................................................................................................... 1
Testing and Fault Isolation...................................................................................................................... 101
Automatic Test Requirements (ATLAS)....................................................................................................... *
Disassembly............................................................................................................................................ 301
Cleaning .................................................................................................................................................. 401
Check ...................................................................................................................................................... 501
Repair........................................................................................................................................................... *
Assembly (With Storage) ........................................................................................................................ 701
Fits and Clearances ................................................................................................................................ 801
Special Tools, Fixtures and Equipment .................................................................................................. 901
Illustrated Parts List ..................................................................................................................................... *
* Not applicable
Page TC-1/TC-2
49-25-93 Aug 5/03
RE100[LJ]
INTRODUCTION
1. Gas Turbine Engine Introduction
A. General
(1) This publication gives maintenance instructions for the equipment shown in Table 1
which is made by:
- Honeywell Engines, Systems & Services, Phoenix, Arizona.
(2) This publication is written in agreement with the Air Transport Association of America
Specification No. 100.
(3) The exploded view illustrations shown in the ILLUSTRATED PARTS CATALOG (IPC)
and the ILLUSTRATED PARTS LIST (IPL) section are also referenced in the
DISASSEMBLY and/or CHECK sections of this manual. Illustrations that support the
individual items are identified in a key to figure by the item nomenclature, and in
parenthesis, the item number followed by the basic figure number, i.e., washer (90,
IPL Figure 1).
Table 1. Equipment Identification List for Part No. 3800726-1
Effectivity Series Change Service

Code No. No. Description Bulletin No.
Symbol
1 Original Configuration
2 Series 1 plus
changes 1, 3 and 4
1 Replace PN 3881739-2 Lube 49-7400

Pump with PN 3881800-1.
Replace PN 3863409-1
Gearbox Housing with PN
3863409-3 Gearbox Housing.
Replace PN M83248-1-116 O-
ring with PN M83248-1-115
O-ring.
3 Replace PN 3846734-1 49-7457

Turbine Plenum with PN
3846743-1 Turbine Plenum.
4 Replace PN 3876315-1 49-7456

Thermocouple with PN
3876315-2 Thermocouple.
Page INTRO-1
49-25-93 Aug 5/03
RE100[LJ]
Table 1. Equipment Identification List for Part No. 3800726-1 (Cont)
Effectivity Series Change Service

Code No. No. Description Bulletin No.
Symbol
3 Series 2 plus change

2
2 Replace PN 3822523-2 with 49-7447

PN 3822523-003.
4 Series 1 plus
changes 3 and 4

5
5 Replace PN 527-510-9001 49-7489

with PN 361-530-9354.

7
7 Replace PN 3883921-1 Flow 49-7435

Divider Assy with PN
3883921-2 Flow Divider Assy.

6
6 Replace PN 3881800-1 Lube 49-7530

Pump with PN 3881825-1
Lube Pump.

8
8 Replace PN 3863387-1 49-7583

Generator Seal with PN
3863504-1.

4
Page INTRO-2
49-25-93 Aug 5/03
RE100[LJ]
B. Equipment Identification
(1) The configuration of the equipment is shown by the part number, dash number, series
number, and change number stamped on the identification plate. Compare this
information with the information shown in Table 1 (through last alpha suffix).
(2) The special procedures or illustrations necessary for each configuration will be
identified by a part number, a service bulletin number (Pre SB-, Post SB-) or an
effectivity code symbol. The procedures and illustrations not identified apply to all the
configurations of the equipment.
C. Measurement Conversion
(1) If the measurements, weights, dimensions, pressure or torque values are changed to
the metric equivalents, they are shown in parentheses after the United States
measurements.
D. Temperature Conversion
(1) The temperatures shown in degrees Fahrenheit use the symbol F. Celsius
(centigrade) is shown with the symbol (C).
E. Applicable Publications
(1) The component publications applicable to this unit are shown in Table 2.
Table 2. Applicable Publications List
Nomenclature Part No. Publication Type
Gas Turbine Engine 3800726-1 49-25-89 IPC

Fuel Control Assembly 3883900-1 49-31-79 CMM
Lube Pump Assembly 3881739-2 49-91-59 CMM
Wiring Harness 3888411-3 49-11-07 CMM
Oil Level Switch 3876318-1 49-90-59 CMM
Oil Level Switch 3876318-2 49-90-59 CMM
F. Geometric Tolerance Symbols
(1) If applicable, the geometric symbols are used on the illustrations in CHECK and
REPAIR sections of the manual. These symbols are shown in Figure 1.
Page INTRO-3
49-25-93 Nov 11/05
RE100[LJ]
Geometric Tolerance Symbols

Figure 1 (Sheet 1 of 2)
Page INTRO-4
49-25-93 Aug 5/03
RE100[LJ]
Geometric Tolerance Symbols

Figure 1 (Sheet 2)
Page INTRO-5
49-25-93 Aug 5/03
RE100[LJ]
G. Coding System Description
(1) The purpose of the effectivity coding system is to identify the differences between unit
configuration.
(2) These differences are caused by the modifications to the basic unit. This makes it
necessary to reidentify the unit. For example (Part No. 123456-1 becomes Part No.
123456-2).
(3) A single effectivity code is given to each different part number and dash number.
(4) If no effectivity codes or part numbers are shown in the text, the procedures apply to
all the configurations of the unit.
(5) If one or more effectivity codes are shown for a part number, the procedure in the text
will apply only to the coded parts.
(6) The Equipment Identification List, Table 1, shows the part number and effectivity code
for each unit.
Page INTRO-6
49-25-93 Aug 5/03
RE100[LJ]
DESCRIPTION AND OPERATION
1. General
A. This section includes the description and operation of the gas turbine engine and its
assemblies. Refer to Table 1 for the Leading Particulars.
Table 1. Leading Particulars
Parameter Specification
Engine Ratings
Combined Pneumatic and Shaft Power Output
[(At 93 Percent Operation) Corrected to a 103º°F (37ºC)
Standard Sea-level-day Conditions at Turbine Discharge
Temperature of 1160ºF (62ºC) Nominal]
Bleed Air Flow 35.0 lb/min (16 kgm)

Minimum Bleed Air Pressure 50.0 psia (345 kPa)
Minimum Shaft Horsepower 12.5 shp
Speed
Turbine Rotor
Nominal Full-Load Governed Speed 100 ±1 percent (70,200 rpm)
Generator Output Drive Pad (clockwise rotation) 12,000 rpm
Electrical System
Voltage 14 to 30 vdc
Lubrication System
Lubricant (MIL-PRF-7808 or MIL-PRF-23699) Refer to Table 2-Approved Oils
Maximum Sump Capacity 1500cc
Fuel System
Fuel MIL-DTL-5624, Grades JP-4/JP-5 or ASTM
D1655-Type A aviation kerosene
Page 1
49-25-93 Aug 5/03
RE100[LJ]
Table 1. Leading Particulars (Cont)
Parameter Specification
Automatic Shutdown Features (Cont)

Low Oil Pressure (95 percent plus 4 seconds) below 31 psig (214 kPa)
Loss of EGT Open thermocouple circuit
High Oil Temperature Loss of HOT
DC Power Loss of DC
ECU Failure Loss of ECU
No Flame 20 seconds after start
B. All brands of lubricants shown in Specification MIL-PRF-7808 or MIL-PRF-23699 are not

necessarily acceptable for commercial use. Table 2 shows the approved oils.
Table 2. Approved Oils
Ambient Temperature
Approved Lubrication Brand Name Minimum Maximum
3 Centistoke Oils
Type I Aeroshell Turbine Oil 390 -65ºF (-54ºC) 275ºF (135ºC)
Brayco 880 -65ºF (-54ºC) 275ºF (135ºC)
BP Aero Turbine Oil 15 -65ºF (-54ºC) 275ºF (135ºC)
Castrol 3C -65ºF (-54ºC) 275ºF (135ºC)
Castrol 325 -65ºF (-54ºC) 275ºF (135ºC)
Exxon or Esso Turbo Oil 2389 -65ºF (-54ºC) 275ºF (135ºC)
3.5 Centistoke Oil

MIL-PRF-7808
Type I Castrol 4000 -65ºF (-54ºC) 275ºF (135ºC)
5 Centistoke Oils
MIL-PRF-23699
Type II Aeroshell 560 -40ºF (-40ºC) 325ºF (163ºC)
Exxon ETO 85 -40ºF (-40ºC) 325ºF (163ºC)
Hatcol 3611 -40ºF (-40ºC) 325ºF (163ºC)
Mobil Jet Oil II -40ºF (-40ºC) 325ºF (163ºC)
Mobil Jet Oil 254 -40ºF (-40ºC) 325ºF (163ºC)
Page 2
49-25-93 Aug 5/03
RE100[LJ]
Table 2. Approved Oils (Cont)
Ambient Temperature
Approved Lubrication Brand Name Minimum Maximum
5 Centistoke Oils
MIL-PRF-23699
Type II Aeroshell 560 -40ºF (-40ºC) 325ºF (163ºC)
Exxon ETO 85 -40ºF (-40ºC) 325ºF (163ºC)
Hatcol 3611 -40ºF (-40ºC) 325ºF (163ºC)
Mobil Jet Oil II -40ºF (-40ºC) 325ºF (163ºC)
Mobil Jet Oil 254 -40ºF (-40ºC) 325ºF (163ºC)
Royco 899 -40ºF (-40ºC) 325ºF (163ºC)
Royco or Aeroshell Turbine Oil 500 -40ºF (-40ºC) 325ºF (163ºC)
Royco or Aeroshell Trubine Oil 555 -40ºF (-40ºC) 325ºF (163ºC)
7.5 Centistoke Oil

MIL-PRF-23699
Type II Castrol 98 -40ºF (-40ºC) 325ºF (163ºC)
Page 3
49-25-93 Aug 5/03
RE100[LJ]
RE100 Gas Turbine Engine

Figure 1
Page 4
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 1
10. WIRING HARNESS ASSEMBLY 90. GEARBOX MATCHED SET

(IPC, SECTION 49-00-00 HOUSING ASSEMBLY (IPC,
FIG. 3 ITEM 250A) SECTION 49-20-00, ITEM 1)
20. PLUMBING INSTALLATION 100. IGNITER PLUG ELECTRICAL LEAD
(IPC, FIG. 4) (IPC, SECTION 49-40-00
30. GEARBOX VENT TUBE FIG. 1 ITEM 110A)
(IPC, ITEM 40) 110. LOW VOLTAGE IGNITION PLUG
40. TURBINE HOUSING (IPC, ITEM 120)
IPC, FIG 2 ITEM 40) 120. LOW VOLTAGE IGNITION UNIT
50. COMPRESSOR INLET DUCT (IPC, ITEM 150)
(IPC, FIG 6, ITEM 300) 130. IMMERSION THERMOCOUPLE
60. FUEL CONTROL ASSEMBLY (IPC, SECTION 49-70-00, FIG. 3 ITEM 20)
(IPC, SECTION 49-30-00 140. SPEED SENSOR (IPC, FIG. 2 ITEM 20)
FIG. 3 ITEM 30) 150. AIR TEMPERATURE BULB (IPC,
70. FUEL SOLENOID VALVE (IPC, SECTION 49-70-00 FIG. 1 ITEM 10)
FIG. 2 ITEM 40) 160. OIL TEMPERATURE BULB (IPC, ITEM 30)
80. LUBE PUMP ASSEMBLY 170. OIL LEVEL SWITCH (IPC, SECTION
(IPC, SECTION 49-93-00 49-93-00 FIG. 4 ITEM 20)
FIG. 3 ITEM1)
2. Description
A. The pneumatic and shaft power gas turbine engine is a self-contained power source and
requires only a source of fuel and electrical power for operation. Start, acceleration, and
operation of the engine is controlled by an integral system of automatic and coordinated
pneumatic and electro-mechanical controls.
B. The APU has: (Refer to Figure 1.)
a wiring harness assembly a speed sensor

a plumbing installation (fuel tubes) an oil level switch
a start counter* an immersion thermocouple (EGT)
a fuel solenoid valve an igniter plug electrical lead
a fuel control assembly a low voltage ignition plug
a low oil pressure switch* a low voltage ignition unit
a chip detector and debris monitor* (remotely located)*
a generator adapter* an inlet baffle*
a lube pump assembly an idler bearing cover*
a transfer tube* a gearbox matched set housing assembly
a turbine housing a compressor inlet housing
a liquid level rod cap gage* a bleed air valve*
a bleeder plug* an electronic control unit (ECU)
an inlet temperature bulb (T2 sensor) (remotely located)*
an oil temperature bulb (HOT sensor) a power section (Refer to Figure 2.)
*Not shown in figure
Page 5
49-25-93 Nov 11/05
RE100[LJ]
RE100 Power Section (Partial Breakdown)

Figure 2
Page 6
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 2
10. IDLER BEARING COVER (IPC, 80. ENGINE COMPRESSOR HOUSING

SECTION 49-20-00 FIG. 2 ITEM 40) ASSEMBLY (IPC, ITEM 270)
20. PRIMARY/SECONDARY FUEL 90. COMPRESSOR DESWIRL DEFLECTOR
NOZZLES (IPC, SECTION 49-30-00 (IPC, ITEM 130)
FIG. 3 ITEMS 30, 60) 100. INTERSTAGE SEAL ASSEMBLY
30. COMBUSTOR CHAMBER (IPC, (IPC, ITEM 220)
SECTION 49-20-00 FIG. 4 ITEM 50) 110. PERFORATED COMPRESSOR
40. TURBINE NOZZLE ASSEMBLY (IPC, ITEM 290)
(IPC, FIG. 6 ITEM 110) 120. IDLER GEARSHAFT ASSEMBLY
50. GAS TURBINE ENGINE TURBINE (IPC, FIG. 9 ITEM 10)
ROTOR (IPC, ITEM 200) 130. GENERATOR GEARSHAFT ASSEMBLY
60. CENTRIFUGAL COMPRESSOR (IPC, ITEM 50 )
ROTOR (IPC, ITEM 260) 140. ENGINE COMPRESSOR GEARSHAFT
70. TURBINE ROTOR TIE ROD ASSEMBLY (IPC, ITEM 110)
(IPC, ITEM 210)
C. The power section has: (Refer to Figure 2.)
an idler bearing cover

a primary and secondary fuel nozzle assembly
a primary and secondary fuel manifolds*
a combustor chamber
a turbine nozzle
a gas turbine engine turbine rotor
a centrifugal compressor rotor
a turbine rotor tie rod
an engine compressor housing assembly
an engine compressor diffuser assembly*
inner and outer pilot rings*
a compressor deswirl deflector
an interstage seal assembly
a perforated compressor inlet
an idler gearshaft assembly
a generator gearshaft assembly
an engine compressor gearshaft assembly
*Not shown in figure.
Page 7
49-25-93 Aug 5/03
RE100[LJ]
ECU Maintains Safe Operation of the APU

Figure 3
Page 8
49-25-93 Aug 5/03
RE100[LJ]
APU Operational Envelope

Figure 4
Page 9
49-25-93 Aug 5/03
RE100[LJ]
3. Operation
The engine uses control components which automatically control the engine and hold required engine
speed and safe operating temperatures from start initiation to full load. Some of the control
components require connection with customer-supplied switches and relays for proper operation.
(Refer to Figures 3 and 4.)
When the starter is energized, it provides rotation to the gear train housed in the gearbox. The gear
train drives the compressor and turbine rotating components, the oil pump and the fuel control unit.
As the compressor and turbine rotate, ambient air is drawn in the compressor inlet duct into the single-
stage centrifugal compressor. The air is compressed and flows through a diffuser into the turbine
housing assembly and some of the air enters the combustor chamber.
When engine speed reaches approximately 5 percent, the APU electronic control unit (ECU)
completes a circuit to the fuel shutoff valve and ignition unit. (Refer to Figure 3.) The fuel shutoff
valve opens to let fuel flow to the fuel nozzle assemblies. The ignition unit causes the igniter plug to
fire and ignite the fuel-air mixture in the combustor chamber.
Combustion increases the energy level of the fuel-air stream. The combustion gases flow through the
turbine nozzle to the turbine rotor blades. The heat and pressure energy caused by the gases turns
the turbine rotor faster and causes increased mechanical power to drive the compressor gearshaft
faster. The compressor gearshaft drives the gearbox gear train and accessories. More power is
available for customer use when governed speed (100 percent) is reached.
When the APU reaches 50 percent speed the starter/generator shuts off.
As engine speed increases and reaches 95 percent plus four seconds, the ECU opens the circuits to
the ignition unit and stops igniter spark. Continuous engine speed increases to governed speed (100
percent).
At engine governed speed, the fuel control assembly controls fuel flow and automatically controls
turbine discharge temperature and rpm within safe, set limits.
APU bleed-load conditions are available at engine speeds above 95 percent plus four seconds. Once
the ECU receives a customer-supplied bleed load signal, the bleed air valve (BAV) torque motor is
energized and causes the BAV to open to the “low flow” position. The valve remains in the “low flow”
position for 20 seconds until the ECU commands the valve to go to the “high flow” position. The valve
stays in the "high flow" position unless the pilot shuts off the valve or an EGT over temperature
condition occurs that automatically commands it to the “low flow” position. During an EGT over
temperature condition, the valve remains in a “low flow” condition until the EGT over temperature
condition is removed or the pilot or ECU commands a total shut down of bleed air.
During engine operation, the ECU monitors engine speed, oil temperature, exhaust gas temperature
(EGT) and oil pressure. The ECU contains circuitry that shuts down the engine for engine pre-start
and running conditions. (Refer to APU Fault Isolation.)
At engine speeds above 95 percent, the ECU records engine operating time and number of engine
starts.
An integrated lube pump assembly, oil pressure regulating valve, and oil filter element provide engine
lubrication.
Page 10
49-25-93 Aug 5/03
RE100[LJ]
TESTING AND FAULT ISOLATION
1. APU Testing and Fault Isolation
A. General
(1) All shutoff valves must be closed, air pressure must be set at zero, and the electrical
power must be shut off at the start of each test.
(2) Monitor APU for engine test requirements and operating limits as shown in Table 101.
Table 101. APU Operating Limits
Type Limit Tolerance Remarks
Leakage:
(a) Fuel control drain No leakage permitted
(b) Gearbox vent 5.0 cm3/hr Maximum
(c) Elbow drain No leakage permitted Located on Compressor Inlet Duct
(d) Orifice fitting No leakage permitted Fuel leakage from turbine plenum
drains permitted only after false
start or blowout
Plumbing installation No leakage permitted
Speed:
(a) Acceleration Time 45 seconds Maximum Measured from APU start time to
governed speed condition (100%)
(b) Nominal governed 70,130 to 70,270 rpm ± 1% 100% rotor speed

speed
(c) Overspeed 75,816 rpm Maximum Do not exceed
Lubricant:
(a) Oil consumption 5.0 cm3/hr Total oil usage.
(b) Oil level 1500 cm3 Maximum

Measure at oil pressure port at
(c) Oil pressure ± 40 psig (276 kPa) Minimum 300ºF (149ºC) maximum.
(d) Oil pressure ± 2psig (13,8 kPa) Maximum Measure at oil pressure port under
fluctuation steady-state operation.
Page 101
49-25-93 Aug 5/03
RE100[LJ]
Table 101. APU Operating Limits (Cont)
Type Limit Tolerance Remarks
Temperatures:
(a) Compressor inlet air 158ºF (70ºC) Maximum
(b) Oil 300ºF (149ºC) Maximum
(c) Exhaust gas 1275ºF (691ºC) Maximum Measure from the APU immersion
temperature (EGT) thermocouple at steady-state
condition.
(d) Average EGT from 12 1600ºF (871ºC) Maximum Measure from APU start to 50%
lab tailpipe speed.
thermocouples 1275ºF (69ºC) Maximum Measure at governed speed.
(e) EGT differential 130ºF (54ºC) Maximum Difference between the 12 EGT
measurements at steady-state
condition.
(f) EGT measurement 30ºF (-1ºC) Maximum Difference between (c) EGT and
differential (e) EGT differential.
Starter Motor Duty Cycle:

(a) With no start With Battery: In one hour; Maximum Unit may be immediately restarted
two-30 second engine roll after roll-down, provided starter
over attempts with no start duty cycle is not exceeded.
and then a minimum of 20
minutes off. After 20 minutes
off, another two-30 second
engine roll over attempts with
no start is allowed. The
remainder of the 1 hour must
pass before subsequent start
attempts.
Stiff Bus: In one hour; two-15
second engine roll over
attempts with no starts
maximum. 20-minutes
minimum off-time is required,
then two additional start
attempts may be made. Four
roll over attempts with no
starts are allowed per hour.
(b) With start Six engine starts with 10
minutes off between each
start. After six engine starts,
1 hour must be allowed
before subsequent starts.
Page 102
49-25-93 Aug 5/03
RE100[LJ]
(3) Complete and keep records of all test information on data sheets. A separate set of
records and data sheet must be used for each engine and kept as a permanent record
on the engine. Sample data sheets are supplied. (Refer to Tables 108 and 109.)
(4) Write the part numbers and serial numbers of the APU and ECU under test on the
data sheet. Write the date the units are tested on the data sheet.
(5) Calculations may be necessary to change certain values to standard values. When
such calculations are necessary, the instructions, charts, curves, tables, or other data
are shown in the text.
B. Materials and Compounds
(1) Table 102 shows the materials and compounds necessary to do the tests.
Table 102. Materials and Compounds
Material/Compounds Description/Manufacturer
NOTE: Equivalent materials/compounds can be used.
Fuel (JP-4/JP-5) (MIL-T-5624G) Commercially available
Oil (MIL-PRF-7808, Type I) Commercially available
Oil (MIL-PRF-23699, Type II) Commercially available
Page 103
49-25-93 Aug 5/03
RE100[LJ]
C. Special Tools, Fixtures and Equipment
(1) Table 103 shows the special tools, fixtures and equipment necessary to do the tests.
Table 103. Special Tools, Fixtures and Equipment
Part No.
Nomenclature Manufacturer
Note: Equivalent tools, fixtures and equipment can be used.
Part No. 2119552-2 Honeywell Engines, Systems & Services,

Nomenclature Ground Support Equipment
717 N. Bendix Dr.,
South Bend, IN 46628-1000
Telephone: 574-231-3987
Part No. 3876322 Honeywell Engines, Systems & Services,

Nomenclature Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987

Universal test stand Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987

Inlet instrumented bellmouth duct Ground Support Equipment
assembly 717 N. Bendix Dr.,
Telephone: 574-231-3987

Inlet bellmouth Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987

Test stand assembly Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 104
49-25-93 Nov 11/05
RE100[LJ]
Table 103. Special Tools, Fixtures and Equipment (Cont)
Part No.

Bleed transition duct adapter Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987

Duct adapter Ground Support Equipment
717 N. Bendix Dr.,
Telephone: 574-231-3987
Part No. 23093002 TRW Lucas Aerospace,

Starter/Generator Aeronautical Systems,
1900 Richmond Road
Cleveland OH 44124
Telephone: 703-648-0831
http://www.trw.com
Accelerometer Customer furnished
Airflow measuring section Customer furnished
Compressor discharge pressure probe Customer furnished
Electrical power (28 vdc) Customer furnished

(operates the starter motor)
Electrical power (28 vdc) Customer furnished

(operates the ECU)
Exhaust gas temperature (EGT) meter Customer furnished
Fuel flow meter Customer furnished
Fuel inlet pressure indicator Customer furnished
Gearbox sump pressure fitting Customer furnished
Generator control unit Customer furnished
Oil pump test port fitting Customer furnished
Tailpipe Customer furnished
Test cell computer and monitor Customer furnished

(386 processor chip or higher)
Page 105
49-25-93 Nov 11/05
RE100[LJ]
Part No. Manufacturer
Test cell master control panel Customer furnished

Test cell manual flow control valve Customer furnished
Vibration mount (Frequency Meter) Customer furnished
Wiring/adapter cables Customer furnished
(2) Calibrate all instrumentation to recognized standards. Manometers must be zeroed or

set to barometer reading as applicable and at least once a day. Errors in
instrumentation that exceed the accuracy limits, as shown in Table 104, must be
adjusted before tests begin.
(3) All instrumentation and gages used in the test and for troubleshooting must be
calibrated and accurate.
(4) Table 104 shows accuracy limits and ranges for the instruments used in the tests.
The table also shows symbols for temperatures, pressures, flow, speed and vibration
measurements used by the engine manufacturer.
Table 104. Instrumentation, Range and Accuracy Limits
APPLICATION SYMBOL INSTRUMENTATION RANGE ACCURACY
TEMPERATURE
Compressor inlet air total CIT Temperature indicator 0 to 160ºF (-18 to ±2ºF (1ºC)
71ºC)
Bleed-air discharge total Tb Temperature indicator 0 to 600ºF (-18 to ±2ºF (1ºC)

316ºC)
Engine exhaust EGT Tail pipe with 12 thermocouples 0 to 2000ºF (-18 ±2ºF (1ºC)
temperature to 1093ºC)
Oil sump total Tres Temperature indicator 0 to 350ºF (-18 to ±2ºF (1ºC)
177ºC)
Bleed-air orifice inlet total Torf Temperature indicator 0 to 600ºF (-18 to ±2ºF (1ºC)
316C)
Test cell ambient total Test cell temperature gage 0 to 160ºF (-54 to ±2ºF (1ºC)
71ºC)
Page 106
49-25-93 Aug 5/03
RE100[LJ]
Table 104. Instrumentation, Range and Accuracy Limits (Cont)
APPLICATION SYMBOL NSTRUMENTATION RANGE ACCURACY
PRESSURE
Bleed-air orifice delta P Dporf Test cell pressure gage 0 to 100 in. H20 ±0.25 %
Bleed-air orifice inlet total Porf Test cell pressure gage 0 to 100 Hg ±0.25 %
Compressor discharge Pcd Test cell pressure gage 0 to 60 psig ±0.5 %

(414 kPa)
Fuel pump inlet Pf Test cell pressure gage 0 to 50 psig ±0.5 %

(345 kPa)
Oil pump discharge Poil Test cell pressure gage 0 to 200 psig ±0.5 %
(1380 kPa)
Oil sump Psump Test cell pressure gage 0 to 300 psig ±0.2 %
(2070 kPa)
Test cell ambient Pbar Test cell barometer 0 to 31 in. HgA ±0.1 %
FLOW
Fuel flow WF Flow meter 0 to 250 pph ±2 %
SPEED
Output speed N Accelerometer 0 to 100,000 rpm ±10 rpm
TIME
Second hand Sec or Min Clock or Timer 24-hour ±1 sec
VIBRATION
Engine total VIB Frequency Meter 0 to 2 in./sec ±2 percent

(0 to 2000 Hz)
TORQUE
Shaft load Ampere Meter 0 to 500 amp ±2 amp
D. APU Master Control Panel Interface
(1) The APU uses a master control panel to supply certain simulated aircraft commands
and loads. (Refer to Figure 103.)
(2) Table 105 shows the operation of the panel switches and lamps.
Page 107
49-25-93 Aug 5/03
RE100[LJ]
Table 105. Master Control Panel Description
Item Operation
MASTER ON/OFF Switch Supplies power to the master control panel.
ECU RUN/OFF Switch When in the RUN position, sends power to the ECU and commands the ECU to
do a BITE check.
APU START Switch Momentary action switch commands power to Starter Relay, ECU, Generator
Control Unit and APU start system.
Bleed Load Control Valve BLCV commands the ECU to open or close the APU bleed air valve (BAV).
(BLCV) OPEN/CLOSE (Equivalent to operation of the aircraft environmental control system)
Switch
EMERGENCY Set in the up position, commands the ECU to shut down the APU and removes
SHUTDOWN Switch all electrical power to the ECU. Inhibits a subsequent APU start until the ECU is
cleared and reset.
APU FIRE Switch Sends an electrical signal to the ECU and shows the fire test system is on.
AIR/GROUND Switch Sends an electrical signal to the ECU and shows aircraft is IN-FLIGHT (AIR) or
ON GROUND [Weight on Wheels (WOW)].
APU SPEED Meter Shows APU turbine percent speed in RPM.
APU EGT Meter Shows APU exhaust gas temperature (EGT) in degrees Fahrenheit.
ON Lamp Shows power to the master panel and ECU are supplied.
APU RELAY ENGAGE Shows relay to ECU has been engaged and has sent 28Vdc to ECU Start Relay.
Lamp
OK TO START Lamp Shows that the ECU has done a BITE check and the APU is ready for a start.
FUEL ON Lamp Shows the APU at 10 percent speed and stays on during APU operation. All
faults or the master switch set to OFF causes the light to go off.
IGNITION ON Lamp Shows that the APU has passed 50 percent speed and ignition system starts the
light-off condition.
RTL Lamp Shows that the APU has reached 95 percent speed plus 4 seconds and is ready
to load (RTL).
BLCV OPENED Lamp Shows the bleed air valve has opened (This occurs 20 seconds after BLCV
OPEN/CLOSE switch has been set to OPEN).
Page 108
49-25-93 Aug 5/03
RE100[LJ]
Table 105. Master Control Panel Description (Cont)
Item Operation
ADD OIL Lamp Shows that the oil level is 200 cm3 below full level.
LOW OIL QUANTITY Lamp Shows that the oil level is 500 cm3 below full level.
FAULT Lamp Shows that the ECU causes a commanded shut down or an APU start inhibit.
SERIAL PORT Connector Shows plug-in port for DE-9 type connector for cable or laptop computer
connection.
Page 109
49-25-93 Aug 5/03
RE100[LJ]
APU Test Setup

Page 110
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 101 (SHEET 1)
1. START COUNTER CONNECTOR 10. FITTING (MODIFIED AN815-4 FITTING)

2. FUEL SOLENOID VALVE CONNECTOR 11. LUBE PUMP BOLT
3. FUEL CONTROL UNIT CONNECTOR 12. WASHER
4. IGNITION UNIT CONNECTOR 13. PRESSURE FITTING (MODIFIED
5. FUEL CONTROL UNIT MS9557-11 BOLT)
6. LUBE PUMP ASSEMBLY 14. CIT GAGE
7. PLUG 15. GEARBOX VENT TUBE
8. PACKING 16. STARTER/GENERATOR
9. TEST PRESSURE PORT (PN 23093002)
E. APU Test Setup
(1) Use universal test stand (5838060-1) and test stand assembly (5838405-1) or test-
facility equipment that turns at high speed.
(2) Prepare the Auxiliary Power Unit (APU) for tests and install the test equipment as
follows.
(a) Disconnect start counter connector (1). (Refer to 101, Sheet 1.)
(b) Disconnect fuel solenoid valve connector (2).
(c) Disconnect fuel control unit connector (3).
(d) Disconnect ignition unit connector (4).
(e) Put a container below the fuel control unit (5) and a container below lube
pump assembly (6) to collect fuel or oil leakage.
WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE

AN ADDITIVE CALLED TRICRESYL PHOSPATE IN IT. THIS
CHEMICAL IS POISONOUS, CAN BE ABSORBED THROUGH THE
SKIN AND CAN CAUSE ASPHYXIA.
(f) Remove plug (7) and packing (8) from lube pump test pressure port (9) and
replace with oil pressure/temperature fitting (10) (modified AN815-4 fitting) or
equivalent. Set aside plug (7) for subsequent assembly. Discard packing (8).
NOTE: Lube Pump Assembly Component Maintenance Manual (CMM)

shows disassembly of the plug. (Refer to the Illustrated Parts
Catalog, ATA 49-25-89, for CMM number.)
(g) Remove lube pump bolt (11), washer (12) and replace with gearbox sump
pressure fitting (13) (modified MS9557-11 bolt) or equivalent. Set lube pump
bolt (11) and washer (12) aside for subsequent assembly.
Page 111
49-25-93 Nov 11/05
RE100[LJ]
APU Test Setup

Figure 101 (Sheet 2)
Page 112
49-25-93 Aug 5/03
RE100[LJ]
17. CHIP DETECTOR AND DEBRIS 22. PACKING

MONITOR 23. OIL TEMPERATURE GAGE
18. FUEL INLET PORT ELBOW 24. BOLT
19. OIL FILTER 25. WASHER
20. TEMPERATURE BULB 26. PROBE (MODIFIED MS9489-5 BOLT)
ELECTRICAL CONNECTOR 27. INLET DUCT DRAIN
21. OIL TEMPERATURE BULB 28. GEARBOX
(h) Install compressor inlet temperature (CIT) gage (14).
WARNING: USE THE CORRECT PERSONAL PROTECTION. FUEL AND FUEL

FUMES ARE POISONOUS AND HIGHLY EXPLOSIVE. FUEL CAN
CAUSE DEATH OR INJURY TO PERSONS.
(i) Loosen and remove gearbox vent tube (15) and place the loose end in a
container to collect and measure oil if discarded out of gearbox vent tube (15).
(j) Install a fuel supply line to fuel inlet port elbow (18). (Refer to Figure 101,
Sheet 2.)
(k) Disconnect temperature bulb electrical connector (20) and remove

temperature bulb (21), packing (22) and replace with oil temperature gage
(23).
(l) Remove bolt (24), washer (25) and replace with compressor discharge
pressure (Pcd) probe (26) (modified MS9489-5 bolt) or equivalent. Set bolt
(24) and washer (25) aside for subsequent assembly.
(m) Put a container below the compressor inlet duct drain (27) to collect fluid
leakage.
(n) Install starter/generator (16). (Refer to Figure 101, Sheet 1.)
(o) Install a generator control unit (GCU) and attach cables (not shown in figure).
(p) Install a dc load bank and attach cables (not shown in figure).
Page 113
49-25-93 Nov 11/05
RE100[LJ]
APU Test Fixture Installation (Typical)

Page 114
49-25-93 Aug 5/03
RE100[LJ]
1. BLEED TRANSITION DUCT 5. ORIFICE MEASURING SECTION

2. DUCT ADAPTER (PN 5838424) 6. BLEED FLOW CONTROL VALVE
3. BLEED AIR VALVE 7. TAILPIPE ASSEMBLY (PN 85G-01-0003)
4. DUCT ADAPTER (PN 5838425)
(3) Install test fixtures and instrumentation to the APU.
(a) Install bleed transition duct (1). (Refer to Figure 102, Sheet 1.)
(b) Install duct adapter (2).
(c) Install bleed air valve (3).
(d) Install duct adapter (4).
(e) Install orifice measuring section (5).
(f) Install bleed flow control valve (6).
(g) Install tailpipe assembly (7) with thermocouples to measure the lab average
EGT.
Page 115
49-25-93 Aug 5/03
RE100[LJ]
APU Test Instrumentation Installation (Typical)

Page 116
49-25-93 Aug 5/03
RE100[LJ]
8. TEMPERATURE GAGE 13. KILOWATT METER

9. TEMPERATURE GAGE 14. FREQUENCY METER
10. PRESURE GAGE 15. PRESSURE GAGE
11. PRESSURE GAGE 16. FLOW METER
12. PRESSURE GAGE
(h) Install temperature gage (8) to measure bleed-air orifice inlet temperature
(Torf). (Refer to Figure 102, Sheet 2.)
(i) Install temperature gage (9) to measure bleed-air discharge total temperature
(Tb).
(k) Install pressure gage (10) to measure bleed-air orifice pressure differential
(Dporf).
(l) Install pressure gage (11) to measure bleed-air orifice inlet pressure (Porf).
(m) Install pressure gage (12) to measure bleed-air discharge total pressure (Pb).
(n) Install kilowatt meter (13) to measure shaft load.
(o) Install frequency meter (14) to measure rotor speed (N).
(p) Install pressure gage (15) to measure fuel pressure (Pf).
(q) Install flow meter (16) to measure fuel flow (Wf).
(r) Connect the APU wiring harness to the electronic control unit (ECU).
(s) Connect cables to the master control panel interface.
NOTE: All test fixtures and instrumentation data is seen through a test cell
monitor. Flow, temperature, pressure and electrical
measurements are processed through a software program
specifically for the APU. All corrected and actual performance
measurements are calculated by the same software program.
(Refer to APU Performance Test.)
Page 117
49-25-93 Aug 5/03
RE100[LJ]
Master Control Panel Interface

Figure 103
Page 118
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 103
1. MASTER ON/OFF SWITCH 13. BLEED LOAD CONTROL VALVE

2. ON LAMP (BLCV) OPENED LAMP
3. APU RELAY ENGAGE LAMP 14. EMERGENCY SHUTDOWN SWITCH
4. ECU RUN/OFF SWITCH 15. APU FIRE SWITCH
5. APU SPEED METER 16. AIR/GROUND SWITCH
6. APU EGT METER 17. ESSENTIAL MODE SWITCH
7. OK TO START LAMP 18. ADD OIL LAMP
8. APU START SWITCH 19. LOW OIL QUANTITY LAMP (LOQ)
9. FUEL ON LAMP 20. FAULT LAMP
10. IGNITION ON LAMP 21. CONNECTOR PORT
11. READY TO LOAD LAMP (RTL)
12. BLEED LOAD CONTROL VALVE
(BLCV) OPEN/CLOSE SWITCH
F. Oil Pressure and APU Priming Tests
(1) Set fuel supply pressure to fuel inlet port (16, Figure 102) at 10 to 55 psig (69 to 379,5
kPa).
(2) Supply 28 vdc to the APU.
(3) Supply a different 28 vdc source to the ECU.
(4) Set MASTER ON/OFF switch (1), APU START switch (8) and ECU switch (4) down.
(Refer to Figure 103.)
NOTE: When a switch is set in the up position, it is ON or energized.
(5) Set BLCV OPEN/CLOSE switch (12) to CLOSE.
(6) Set EMERGENCY SHUTDOWN switch (14) down.
(7) Set AIR/GROUND switch (16) down.
(9) Set MASTER ON/OFF switch (1) to ON and ON lamp (2) comes on.
(10) When the ECU BITE check is complete and the APU is ready to start, set ECU
RUN/OFF switch (4) to RUN.
(11) OK TO START lamp (7) comes on.
(12) As APU START switch (8) is set up and held, start a timer or clock and monitor as
follows.
(a) FUEL ON lamp (9) comes on.
(b) APU RELAY ENGAGE lamp (3) comes on.
(c) APU SPEED meter (5) increases.
(d) Oil pressure as shown on oil pressure/temperature fitting (10) increases.

Page 119
49-25-93 Nov 11/05
RE100[LJ]
(e) When FAULT lamp (20, Figure 103) comes on, stop the timer or clock.
(f) ECU commands an APU shutdown and the APU rolls down.
(g) APU SPEED meter (5) decreases.
(h) Oil pressure as shown on oil pressure/temperature fitting (10, Figure 101)
decreases.
(i) APU RELAY ENGAGE lamp (3, Figure 103) goes off.
(l) FUEL ON lamp (9) goes off.
(m) OK TO START lamp (7) goes off.
(13) Set APU START switch (8) down.
(14) Write the seconds from set APU START switch (8) up until FAULT lamp (20) comes
on. Write the data on the Data Sheet. (Refer to Table 107.)
(15) Write down pass or fail for APU RELAY ENGAGE lamp (3), FUEL ON lamp (9) and
OK TO START lamp (7) on the Data Sheet. (Refer to Table 107.)
(16) Set ECU RUN/OFF switch (4) to OFF. Set ECU RUN/OFF switch (4) on again
momentarily then off.
(17) When ECU RUN/OFF switch is set to OFF, then RUN, then OFF all faults in the ECU
are cleared.
(18) Set MASTER ON/OFF switch (1) to OFF.
WARNING: ALLOW THE APU TO COOL. ENGINE OIL AND COMPONENTS CAN BE
HOT AND CAN CAUSE BURNS.
(19) Remove and examine the chip detector and debris monitor (17, Figure 101) for metal
particles. (Refer to DISASSEMBLY.)
(20) If the chip detector contains metal particles do as follows.
(a) Drain the oil from the gearbox (28).
(b) Replace the oil filter (19) (Refer to Lube Pump Assembly Component
Maintenance Manual DISASSEMBLY AND ASSEMBLY).
(c) Install the chip detector and debris monitor (17). (Refer to ASSEMBLY.)
(d) Set MASTER ON/OFF switch (1, Figure 103) to ON and ECU RUN/OFF
switch (4) to RUN. Monitor LOW OIL QUANTITY lamp (19) and ADD OIL
lamp (18).
(e) If LOW OIL QUANTITY lamp (19) and ADD OIL lamp (18) are on, add only
500cm3 of approved oil or until both lamps go out. (If only the ADD OIL lamp
(18) is on, add enough approved oil until ADD OIL lamp (18) goes off.
(f) Do the oil pressure and priming tests again.
Page 120
49-25-93 Nov 11/05
RE100[LJ]
(g) Inspect the chip detector and debris monitor (17, Figure 101) again.
(21) Continue chip detector inspection until no metal particles are found. If metal particles
are found after two repeated inspections, reject the unit.
(22) Place contaminated chip detector and or debris monitor (17) in a tightly sealed plastic
bag and return to the manufacturer for Oil Analysis (SOAP).
(23) Install the chip detector and debris monitor (17) and continue to the Run-In Test.
(24) Set ECU RUN/OFF switch (4, Figure 103) and MASTER ON/OFF switch (1) to OFF.
G. Run-In Test
(1) Connect the APU electrical connectors as follows.
(a) Connect fuel solenoid valve electrical connector (2). (Refer to Figure 101.)
(b) Connect fuel control unit electrical connector (3).
(c) Connect ignition unit electrical connector (4).
(2) Do an acceleration to ready-to-load (RTL) check as follows.
(a) Set MASTER ON/OFF switch (1) to ON. (Refer to Figure 103.)
(b) Set ECU RUN/OFF switch (4) to RUN.
(c) Set APU START switch (8) up and with a timer or clock measure APU
acceleration.
(d) Monitor APU EGT meter (6) for smooth increase in temperature.
(e) Stop timer or clock when APU SPEED meter (5) reaches 95 percent speed.
(f) After APU SPEED meter (5) has reached 95 percent speed, RTL lamp (11)
comes on.
(3) Operate the engine at 100 percent speed, as shown on APU SPEED meter (5), for
five minutes.
(4) During 100 percent speed operation (governed speed) monitor the master control
panel and APU test equipment as follows.
(a) Monitor APU SPEED meter (5, Figure 103) on master control panel for
smooth operation. Check that frequency meter (14, Figure 102) rpm agrees
with APU SPEED meter (5).
(b) Monitor APU EGT meter (6) for acceptable temperature range of no greater
than 1200ºF (649ºC).
(c) Check the difference between APU EGT meter (6, Figure 103) temperature
measurement and tailpipe assembly (7, Figure 102) temperature
measurement. The difference must be no greater than 30ºF (-1ºC).
Page 121
49-25-93 Aug 5/03
RE100[LJ]
(d) Monitor temperature gage from fitting (10, Figure 101) for a temperature
measurement of no greater than 300ºF (149ºC).
(e) When the temperature from fitting (10) is at a steady state, monitor the oil
pressure from fitting (10) for a range of 38 psig to 167 psig. (262 kPa to 1152
kPa).
(f) When the temperature from fitting (10) is at a steady state and measures
300ºF (149ºC), monitor oil sump pressure gage (13) for a range of -3 psig to -
7 psig (-21 kPa to –48 kPa).
(g) Inlet air temperature as shown on CIT gage (14, Figure 101)) must not be
greater than 158ºF (70ºC).
(5) Set ECU RUN/OFF switch (4, Figure 103) to RUN then to OFF. The APU shuts
down.
(6) Set the MASTER ON/OFF switch (1) to OFF.
(8) Examine inlet duct drain (27, Figure 101) for fuel leakage. No fuel leakage must be
found.
NOTE: Fuel leakage is permitted from the orifice fitting only after start attempts with
no acceleration and after blowouts.
(9) Examine gearbox vent tube (15, Figure 101) container for oil leakage. No more than
5.0 cm3 of oil is allowed.
NOTE: If more than 5.0 cm3 of oil leakage is found from the gearbox vent tube, the
gearbox contains too much oil. Check the level of oil from the gearbox
dipstick.
(10) If the gearbox dipstick shows too much oil in the gearbox, drain the gearbox and add
the acceptable amount of oil. (Refer to Oil Pressure and Priming Tests, Step (20) (a).)
(11) Examine all engine plumbing for leaks. No leakage must be found.
(12) When the APU shows an acceptable Run-In Test, do an Automatic Start Test.
H. Automatic Start Test
(1) Follow the starter/generator starter duty cycle requirement during this test. (Refer to
Table 101.)
(2) Do an automatic start test as follows.
(a) Set MASTER ON/OFF switch (1, Figure 103) to ON.
Page 122
49-25-93 Nov 11/05
RE100[LJ]
acceleration.
must come on.
(g) Operate the engine at 100 percent speed, as shown on APU SPEED meter
(5), for a minimum of one minute.
(h) When the temperature from fitting (10, Figure 101) is at a steady-state, the oil
pressure gage from fitting (10) shows a range of 38 psig to 167 psig (262 kPa
to 1152 kPa).
(i) Monitor ADD OIL lamp (18, Figure 103) and LOW OIL QUANTITY lamp (19).
(3) Set EMERGENCY SHUTDOWN switch (14) up. The APU shuts down.
(4) Set EMERGENCY SHUTDOWN switch (14) down.
(5) Set the ECU RUN/OFF switch (4) and MASTER ON/OFF switch (1) to OFF.
(6) Repeat Steps (2) through (6) two more times.
(7) After three Automatic Start Tests have been run, examine all engine plumbing for
leaks. No leakage must be found.
(9) If LOW OIL QUANTITY lamp (19, Figure 103) showed during the test, check the level
of oil from the gearbox dipstick and add a maximum of 500cm3 of approved oil.
(10) When the APU shows an acceptable Automatic Start Test, do a Control System Test.
I. Control System Test
(1) Do an acceleration to ready-to-load (RTL) check as follows.
(a) Set MASTER ON/OFF switch (1) to ON. (Refer to Figure 103)
acceleration.
Page 123
49-25-93 Nov 11/05
RE100[LJ]
must come on.
(2) Operate the engine for five minutes at 100 percent speed as shown on APU SPEED
meter (5).
(3) During 100 percent speed operation (governed speed), monitor the master control
panel and APU test equipment as follows.
(a) Monitor APU SPEED meter (5, Figure 103) on master control panel for
steady-state operation. Check that frequency meter (14, Figure 102) rpm
agrees with APU SPEED meter (5, Figure 103).
(b) Monitor APU EGT meter (6, Figure 103) for acceptable temperature range of
no greater than 1200ºF (649ºC).
(c) The difference between APU EGT meter (6, Figure 103) temperature
measurement and tailpipe assembly (7, Figure 102) temperature
measurement must be no greater than 30ºF (-1ºC).
(d) Monitor temperature gage from fitting (10, Figure 101) for a temperature
measurement of no greater than 300ºF (149ºC).
(e) When the temperature from fitting (10) is at a steady state, monitor the oil
pressure from fitting (10) for a range of 38 psig to 167 psig (262 kPa to 1152
kPa).
(f) When the temperature from fitting (10) is at a steady state and measures
300ºF (149ºC), monitor oil sump pressure gage (13) for a range of -3 psig to -
7 psig (-21 kPa to –48 kPa).
(g) Inlet air temperature from CIT gage (14) must be no greater than 158ºF
(70ºC).
(4) Close bleed flow control valve (6, Figure 102.)
(5) Use a DC load bank and apply a 400 ampere electrical load, as shown by kilowatt
meter (13, Figure 102), to starter/generator (16, Figure 101).
(6) Monitor the master control panel as BLCV OPEN/CLOSED switch (12, Figure 103) is
set to OPEN.
(7) Bleed air valve lamp (13) comes on.
(8) No engine blowout occurs.
(9) APU SPEED meter (5) shows a range of 70130 to 70270 rpm.
(10) APU EGT meter (6) shows a temperature of no greater than 1200ºF (649ºC).
(11) Slowly open bleed flow control valve (6, Figure 102) until APU EGT meter (6, Figure
103) shows a temperature of 1160ºF (627ºC).
(12) Run the engine for five minutes at a steady-state condition.
Page 124
49-25-93 Aug 5/03
RE100[LJ]
(13) Monitor the master control panel as BLCV OPEN/CLOSE switch (12) is set to CLOSE.
(14) Bleed air valve lamp (13) goes off.
(15) No engine surge occurs.
(16) APU SPEED meter (5) shows a range of 70130 to 70270 rpm.
(17) APU EGT meter (6) shows a temperature of no greater than 1200ºF (649ºC).
(18) Close bleed flow control valve (Item 6, Figure 102).
(19) Keep the engine operational and do an APU Performance Test.
J. APU Performance Test
(1) Do a combination bleed and shaft load performance check as follows.
(a) APU SPEED meter (5, Figure 103) shows a range of 70130 to 70270 rpm.
(b) RTL lamp (11) is on.
(c) Temperature as shown from tailpipe assembly (7, Figure 102) is no greater
than 1200ºF (649ºC).
(d) Apply 12.5 hp corrected electrical load to starter/generator (16, Figure 101) as
shown by the equation as follows.
NOTE: If the EGT temperature, as shown on tailpipe assembly (7, Figure

102), goes out of operational limits, close the bleed flow control
valve until the limit is reached.
SHP corr = SHP actual

d
WHERE:
SHP actual = (Output Volts)(Output Amps)(1.341)

0.76
d= Pbar (in HgA)

2922
(e) With bleed flow control valve (Item 6, Figure 102) closed, set BLCV
OPEN/CLOSE switch (12, Figure 103) to OPEN.
(f) Slowly open bleed air valve (3, Figure 102) until a corrected lab average EGT
of 960ºF (516ºC) is reached.
(g) Run engine until bleed orifice temperature becomes stable as shown by gage
(8).
(h) Calculate the corrected combination bleed and shaft load as follows.
Page 125
49-25-93 Aug 5/03
RE100[LJ]
WHERE: EGT Corr = Lab Average EGT
WF Corr = WF actual +dWF (Refer to Table 106.) -0.7

d
PB corr = PB act +dPB (Refer to Table 106.) -1.03

d
PB act = PB + Pbar
TB corr = TB + dTB (Refer to Table 106.) +2.0
WB corr = WB act +dWB (Refer to Table 106.) -3.6

d
d = Pbar (in HgA)

2992
(i) Set BLCV OPEN/CLOSE switch (12) to CLOSE. (Refer to Figure 103.)
(j) Close bleed air valve (3, Figure 102).
(k) Remove 12.5 hp corrected electrical load from starter/generator (16, Figure
101).
(l) Set ECU RUN/OFF switch (4, Figure 103) momentarily to RUN. The APU
shuts down.
(m) Set MASTER ON/OFF switch (1) to OFF.
Table 106. Combination Load Lapse Rate
T1 F dWB (lb/min) dPB (psia) dTB (F) dWF (lb/hr)
1 -23.2 -5.87 102.4 -26.8

2 -23.0 -5.81 101.4 -26.5
3 -22.7 -5.75 100.4 -26.2
4 -22.5 -5.69 99.3 -26.0
5 -22.2 -5.63 98.3 -25.7
6 -21.9 -5.58 97.3 -25.4
7 -21.7 -5.52 96.3 -25.1
8 -21.4 -5.46 95.2 -24.8
9 -21.2 -5.40 94.2 -24.5
10 -20.9 -5.34 93.2 -24.2
11 -20.7 -5.28 92.2 -24.0
12 -20.4 -5.22 91.2 -23.7
13 -20.2 -5.16 90.1 -23.4
14 -19.9 -5.10 89.1 -23.1
15 -19.7 -5.04 88.1 -22.8
Page 126
49-25-93 Aug 5/03
RE100[LJ]
Table 106. Combination Load Lapse Rate (Cont)
T1 (F) dWB (lb/min) dPB (psia) dTB (F) dWF (lb/hr)
16 -19.4 -4.98 87.1 -22.6

17 -19.2 -4.92 86.1 -22.3
18 -18.9 -4.86 85.1 -22.0
19 -18.7 -4.81 84.0 -21.7
20 -18.4 -4.75 83.0 -21.4
21 -18.2 -4.69 82.0 -21.2
22 -18.0 -4.63 81.0 -20.9
23 -17.7 -4.57 80.0 -20.6
24 -17.5 -4.51 79.0 -20.3
25 -17.2 -4.45 78.0 -20.1
26 -17.0 -4.39 77.0 -19.8
27 -16.7 -4.33 75.9 -19.5
28 -16.5 -4.27 74.9 -19.2
29 -16.2 -4.22 73.9 -19.0
30 -16.0 -4.16 72.9 -18.7
31 -15.8 -4.10 71.9 -18.4
32 -15.5 -4.04 70.9 -18.1
33 -15.3 -3.98 69.9 -17.8
34 -15.0 -3.92 68.9 -17.6
35 -14.8 -3.86 67.9 -17.3
36 -14.5 -3.80 66.8 -17.0
37 -14.3 -3.74 65.8 -16.7
38 -14.0 -3.68 64.8 -16.5
39 -13.8 -3.62 63.8 -16.2
40 -13.6 -3.56 62.8 -15.9
41 -13.3 -3.50 61.8 -15.6
42 -13.1 -3.44 60.8 -15.4
43 -12.8 -3.38 59.8 -15.1
44 -12.6 -3.31 58.8 -14.8
45 -12.4 -3.25 57.8 -14.5
46 -12.1 -3.19 56.7 -14.3
47 -11.9 -2.68 55.7 -14.0
48 -11.6 -3.07 54.7 -13.7
49 -11.4 -3.02 53.7 -13.5
50 -11.2 -2.96 52.7 -13.2
51 -10.9 -2.90 51.7 -12.9
52 -10.7 -2.84 50.7 -12.7
53 -10.5 -2.78 49.7 -12.4
54 -10.2 -2.72 48.7 -12.1
55 -10.0 -2.66 47.7 -11.9
56 -9.8 -2.60 46.7 -11.6
57 -9.5 -2.54 45.7 -11.3
58 -9.3 -2.48 44.7 -11.1
59 -9.1 -2.42 43.6 -10.8
60 -8.9 -2.37 42.6 -10.5
61 -8.6 -2.31 41.6 -10.3
Page 127
49-25-93 Aug 5/03
RE100[LJ]
62 -8.4 -2.25 40.6 -10.0

63 -8.2 -2.19 39.6 -9.8
64 -8.0 -2.13 38.6 -9.5
65 -7.7 -2.07 37.6 -9.0
66 -7.5 -1.73 36.2 -9.2
67 -7.3 -1.96 35.6 -8.7
68 -7.1 -1.90 34.6 -8.5
69 -6.8 -1.84 33.6 -8.2
70 -6.6 -1.79 32.6 -8.0
71 -6.4 -1.73 31.6 -7.7
72 -6.2 -1.67 30.6 -7.4
73 -6.0 -1.62 29.6 -7.2
74 -5.8 -1.56 28.6 -6.9
75 -5.5 -1.50 27.6 -6.7
76 -5.3 -1.45 26.6 -6.4
77 -5.1 -1.39 25.6 -6.2
78 -4.9 -1.33 24.6 -5.9
79 -4.7 -1.28 23.6 -5.7
80 -4.5 -1.22 22.6 -5.4
81 -4.3 -1.17 21.6 -5.2
82 -4.1 -1.11 20.6 -5.0
83 -3.9 -1.06 19.7 -4.7
84 -3.7 -1.01 18.7 -4.5
85 -3.5 -0.95 17.7 -4.2
86 -3.3 -0.90 16.7 -4.0
87 -3.1 -0.84 15.7 -3.7
88 -2.9 -0.79 14.7 -3.5
89 -2.7 -0.74 13.7 -3.3
90 -2.3 -0.68 12.8 -3.0
91 -2.3 -0.63 11.8 -2.8
92 -201 -0.58 10.8 -2.6
93 -1.9 -0.52 9.8 -2.3
94 -107 -0.47 8.8 -2.1
95 -1.5 -0.42 7.8 -1.8
96 -1.3 -0.37 6.9 -1.6
97 -1.1 -0.31 5.9 -1.4
98 -0.9 -0.26 4.9 -1.1
99 -0.7 -0.21 3.9 -0.9
100 -0.6 -0.16 2.9 -0.7
101 -0.4 -0.10 2.0 -0.5
102 -0.2 -0.05 1.0 -0.2
103 0.0 0.00 0.0 0.0
104 0.2 0.05 -1.0 0.2
105 0.4 0.10 -2.0 0.5
107 0.7 0.20 -3.9 0.9
108 0.9 0.25 -4.9 1.1
109 1.1 0.31 -5.9 1.4
Page 128
49-25-93 Aug 5/03
RE100[LJ]
110 1.3 0.36 -6.8 1.6

111 1.5 0.41 -7.8 1.8
112 1.6 0.46 -8.8 2.0
113 1.8 0.51 -9.8 2.3
114 2.0 0.56 -10.7 2.5
115 2.2 0.61 -11.7 2.7
116 2.3 0.66 -12.7 2.9
117 2.5 0.71 -13.7 3.1
118 2.7 0.76 -14.6 3.4
119 2.9 0.81 -15.6 3.6
120 3.0 0.85 -16.6 3.8
K. Data Sheet Instructions
(1) Write in the Data Sheet when the field is blank. When a table block is shaded no
information is necessary. (Refer to Table 107 and Table 108.)
(2) If the APU (unit) does not pass a test point, the "Actual" table block can be used to
show the data that caused the unit to fail the test.
(3) If the unit does not pass one or all of the tests or does not show the data as specified,
the unit must be rejected.
Page 129
49-25-93 Aug 5/03
RE100[LJ]
Table 107. APU Acceptance Data Sheet
Test Date:_________ Barometric Pressure:

_________________
Unit Part Unit Serial Number:_______ ECU Part ECU Serial Number:_______
Number:___________ Number:_________
Test Oil Pressure/Priming Run-in Automatic Start Control System

Pass Fail Actual Pass Fail Actual Pass Fail Actual Pass Fail Actual
OK to Start Lamp-ON
Fuel On Lamp- ON
Relay Engage Lamp-ON
Speed Meter-Increases
Oil Fitting shows
Press/Temp-Increase
Fault Lamp-ON (20 sec)
Speed Meter Decreases
Oil Fitting shows
Press/Temp-Decrease
Relay Engage Lamp-
OFF
Fuel On Lamp- OFF
OK to Start Lamp-OFF
Speed Meter at 95% in
45 seconds
RTL Lamp -ON
Steady State Range-
70,130 to 70,270 RPM
EGT Meter < 1200F
(649C)
Oil Temp </= 300ºF
(149ºC)
Oil Pressure Range 38
psig to 167 psig (262
kPa to 1152 kPa)
Oil Sump Pressure
Range -3 psig to -7 psig
(-21 kPa to -48 kPa)
CIT 158ºF (70ºC) max
Oil Level
Oil Condition
Fault Lamp-ON
BAV Lamp-ON
No Engine Blowout
Bleed Flow Control
Valve Open-EGT shows
1160ºF(627ºC)
BAV Lamp-OFF
No Engine Surge
Page 130
49-25-93 Aug 5/03
RE100[LJ]
Table 108. APU Performance Data Sheet
Test Date:_________ Barometric Pressure:

_________________
Unit Part Unit Serial Number:_______ ECU Part ECU Serial Number:_______
Number:___________ Number:_________
Test Combination Bleed and Shaft Load

Pass Fail Actual
Steady State Range-70,130 to 70,270 RPM
RTL Lamp -ON
EGT Meter < 1200ºF (649ºC)
EGT= 960ºF (516ºC)
Corrected Combination Bleed and Shaft Load
ECU to RUN-APU Shutdown
L. Fault Isolation
(1) Refer to Table 109 for fault isolation of the unit.
(2) Before rejection of an APU, do a general troubleshooting procedure and check as

follows.
(a) All applicable electrical supply requirements are met.
(b) All applicable electrical connectors are tight.
(c) Fuel supply is connected and is turned on.
(d) All switches are set in the applicable position.
Table 109. Fault Isolation
Problem Probable Cause Corrective Action
APU fails to operate when start switch APU binds Replace APU
is activated
Starter/generator will not rotate APU Starter/generator Check starter/generator

to start for brush condition and
for broken shaft. If bad
replace starter
generator.
ECU Check, if bad replace.
Page 131
49-25-93 Aug 5/03
RE100[LJ]
Table 109. Fault Isolation (Cont.)
Starter/generator will not rotate APU Power Cable Check for loose cables
to start (Cont) connection to the
generator or short to
ground. Repair or
replace.
APU runs down when start switch is Bad ignition Replace igniter plug,
released or RPM remains below 53% lead or unit if required.
Bad fuel control assembly Check ECU bite.

Replace fuel control
assembly if required.
Bad flow divider tee Check, if bad replace.
Bad fuel solenoid valve Check, if bad replace.
At governed speed, APU runs down Bad LOP switch Check ECU BITE.
after 10 second delay Replace if required.
Low oil pressure Connect fitting to oil

pump to check output
and replace if required.
Starter generator starts APU but APU Fuel control out of adjustment Replace ECU if required.
shuts down at governed speed
Starter generator starts APU but APU FUEL control assembly governor out of Replace ECU or fuel
speed exceeds 110% adjustment control assembly if
required.
Starter generator starts APU but APU Starter generator binding Check, if bad replace.
does not reach governed speed or
rate of acceleration is too slow
Bad APU Check, if bad replace.
Exhaust gas temperature too high on Bad fuel nozzle shroud Check, if bad replace.
start
Thermocouple out of adjustment Check, if bad replace.
Bad fuel control assembly Check, if bad replace.
Bad ECU Check, if bad replace.
Bad APU Check, if bad replace.
Page 132
49-25-93 Aug 5/03
RE100[LJ]
Table 109. Fault Isolation (Cont.)
APU operates at governed speed but Bad fuel Check and replace fuel
APU speed is not steady. filters if required.
APU operates at governed speed but Bad fuel control assembly Check and replace if
excessive oil smoke from tailpipe required.
Improper oil level Check and correct level.
APU operates at governed speed but Bad fuel control assembly Check, if bad replace.
flame comes from tailpipe on start
Bad fuel nozzle shroud Check, if bad replace.
Bad ECU Check, if bad replace.
APU operates at governed speed but Bad flow divider tee Check, if bad replace.
when load is applied APU RPM drops
more than 3.6%
Bad thermocouple Check, if bad replace.
Bad fuel filter, fuel control assembly or Check, if bad replace.

fuel nozzle shroud
High oil temperature warning light ECU Check, if bad replace.

comes on when APU is operational
HOT switch Check, if bad replace.
LOP indication LOP switch Check, if bad replace.
ECU Check, if bad replace.
Page 133
49-25-93 Aug 5/03
RE100[LJ]
THIS PAGE INTENTIONALLY LEFT BLANK
Page 134
49-25-93 Aug 5/03
RE100[LJ]
DISASSEMBLY
1. Disassembly of Gas Turbine Engine Assembly
A. General
(1) These procedures include a complete disassembly of the Gas Turbine Engine
Assembly.
B. Compounds and Materials
(1) Table 301 shows the compounds and materials necessary for disassembly.
(1) Table 302 shows the special tools, fixtures and equipment necessary to do the
disassembly procedures.
Part No.
NOTE: Equivalent tools, fixtures and equipment can be used.

Transport cart assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 301
49-25-93 Nov 11/05
RE100[LJ]
Part No.
Part No. 5838404-2 Honeywell Engines, Systems & Services

Bearing support (Component of Ground Support Equipment,
Part No. 5838401-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Socket (Component of Part No. 5838401-1) Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Bar (Component of Part No. 5838401-1) Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Nut (Component of Part No. 5838401-1) Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor rotor remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 302
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Compressor bearing remover assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor bearing remover Ground Support Equipment,
(Component of Part No. 5838416-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Cylindrical roller bearing remover assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Split plate (Component of PN 583817-1) Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Split plate remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 303
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Spline adapter installer and remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Split plate (Component of Ground Support Equipment,
Telephone: 574-231-3987

Telephone: 574-231-3987

Generator seal rotor and bearing remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing split plates remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing split plates remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler gearshaft driver Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 304
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Generator splined wrench Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor rotor support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Seal assembly wrench Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Pilot ring remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Split plate Ground Support Equipment,
Telephone: 574-231-3987

Shaft stretcher kit Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Industrial marking ink (Violet 127 ½) The Pannier Corp.,

207 Sandusky St.,
Pittsburgh, PA 15212-5823
Phone: 412-323-4900
www.pannier.com
Page 305
49-25-93 Nov 11/05
RE100[LJ]
D. General Disassembly Procedures
(1) Refer to TESTING and FAULT ISOLATION to find the condition of the unit and the
level of disassembly necessary to repair the unit.
(2) Do the disassembly procedures in a dry, bright, clean room.
(3) Be careful to prevent damage to parts that can be used again.
(4) Apply lubricating oil to parts and put them in a protective container to prevent
corrosion until the parts can be cleaned and examined.
(5) Do not disassemble staked, welded, riveted, soldered, swaged or press-fit

assemblies. Do not remove plates, passage hole plugs or threaded inserts unless
replacement is necessary.
(6) Examine all bearings for roughness, brinelling, and damaged races or retainers.
These conditions can be an indication of possible damage.
(7) Install caps, plugs and covers on openings after disassembly of the unit.
(8) Make a record of the quantities and thickness of the shims and washers. This will
help when the part is assembled.
(9) Remove the electrical connectors.
(a) Remove threaded connectors.
1 Use connector pliers to loosen the coupling rings.
CAUTION: TO PREVENT DAMAGE TO CONNECTORS, DO NOT USE

TOO MUCH FORCE. DO NOT PULL ON THE ATTACHED
WIRES.
2 Pull on the connector body and turn the coupling ring until the
connector is apart.
3 Use caps or plastic bags to keep dirt and unwanted material out of
the receptacles.
(b) Remove the bayonet connector.
1 Turn the coupling ring in a counterclockwise direction to remove the

bayonet connector.
(10) Note method of lockwire installation for duplication at assembly.
(11) Honeywell recommends that the parts shown in Table 303 be replaced at each
disassembly.
NOTE: In-service experience can be used for actual replacement of parts.
Page 306
49-25-93 Aug 5/03
RE100[LJ]
Table 303. Parts to Be Replaced at Each Disassembly
Figure Item
No. No. Nomenclature Quantity
302 -25 Packing 1
303 10A Rivet 2
304 10 Splined adapter 1

30 Spline key snap ring 1
307 60 Packing 1
80 Packing 1
308 60 Packing 1
80 Filter 1
90 Packing 1
200 Packing 1
220 Packing 1
309 20 Packing 1
40 Packing 1
50 Packing 1
70 Packing 1
105 Packing 1
110 Packing 1
130 Packing 1
310 30 Packing 1
311 50 Packing 1
60A Filter element 1
70A Packing 1
80 Retaining ring 1
110 Packing 1
130 Packing 1
140 Packing 1
150 Packing 1
160 Packing 1
314 40 Packing 1
315 30 Packing 1
317 50 Packing 1
60 Packing 1
318 40 Preformed packing 6
- ITEM NOT ILLUSTRATED
Page 307
49-25-93 Nov 11/05
RE100[LJ]
Table 303. Parts to Be Replaced at Each Disassembly (Cont)
Figure Item
No. No. Nomenclature Quantity
320 60 Packing 1
70A Packing 1
321 110 Packing 1
322 20 Packing with retainer 3

70 Packing with retainer 1
323 90 Packing with retainer 19
324 160 Packing 1

170 Packing 1
190 Packing 1
330 10 Encased plain seal assembly 1

20 Packing 1
-60 Packing 1
-70 Packing 1
-80 Packing 1
332 70 Nut locking key 1
Page 308
49-25-93 Nov 11/05
RE100[LJ]
Page 309
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Electrical Installation

Figure 301
Page 310
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 301
10. BOLT (IPC, SECTION 170. CLAMP

49-00-00 FIG. 3) 180. BOLT
20. CLAMP 190. CLAMP
40. BOLT 210. BOLT
50. SELF-LOCKING NUT 220. SELF-LOCKING NUT
70. BRACKET 240. HI-TEMP NUT (IPC, SECTION 49-70-00
80. BOLT FIG. 3 ITEM 40)
90A. SELF-LOCKING NUT 250. HI-TEMP LOCKNUT (IPC, ITEM 30)
100A. CLAMP 260. BRANCHED WIRING HARNESS
150. BOLT (IPC, SECTION 49-00-00 FIG. 3 ITEM 250A)
E. Remove the electrical and plumbing installation.
(1) Remove the electrical installation as follows. (Refer to Figure 301.)
(a) Remove bolt (10) and clamp (20) from the clamp on the fuel solenoid flow
tube.
NOTE: The procedures for clamp removal from the fuel solenoid flow tube
is shown at plumbing installation removal. (Refer to Step (2).)
(b) Remove bolt (40), self-locking nut (50) and clamp (60) from branched wiring
harness (260) and bracket (70).
(c) Remove the bolt from the lube pump assembly and remove bracket (70).
NOTE: Retain the bolt from the lube pump assembly for subsequent
assembly.
(d) Remove bolt (80), self-locking nut (90A) and clamp (100A) from the clamp on
the gearbox vent tube.
NOTE: The procedures for clamp removal from the gearbox vent tube is
shown at plumbing installation removal. (Refer to Step (2).)
(e) Remove bolt (150) and clamp (170) from the clamp on the fuel solenoid flow
tube.
(f) Remove bolt (180) and clamp (190) from the clamp on the gearbox vent tube.
(g) Remove bolt (210), self-locking nut (220) and clamp (230) from the gearbox
vent tube.
Page 311
49-25-93 Nov 11/05
RE100[LJ]
(h) Remove hi-temp nut (240) and hi-temp locknut (250) from the leads of
branched wiring harness (260) and the immersion thermocouple.
NOTE: Retain hi-temp nut (240) and hi-temp locknut (250) with the
immersion thermocouple.
(i) Disconnect all electrical connectors of branched wiring harness (260) from the
engine and remove the wiring harness.
(j) Put protective coverings on all electrical connectors of branched wiring

harness (260).
Page 312
49-25-93 Aug 5/03
RE100[LJ]
Page 313
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Plumbing Installation

Figure 302
Page 314
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 302
10. FUEL CONTROL SOLENOID TUBE 90. CLAMP (IPC, ITEM 200)
(IPC, SECTION 49-00-00 FIG. 4) 100. CLAMP (IPC, ITEM 240)
20. UNION 110. GEARBOX VENT TUBE (IPC, FIG.4
- 25. PACKING ITEM 40)
30. BOLT (IPC, SECTION 49-20-00 120. CLAMP (IPC, FIG. 3 ITEM 160)
FIG. 2 ITEM 10) 130. CLAMP (211-592-9003)
40. WASHER (IPC, ITEM 20) 140. CLAMP (IPC, SECTION 49-00-00
50. BRACKET (IPC, SECTION 49-00-00 FIG. 3 ITEM 30)
FIG. 3 ITEM 110) 150. FUEL SOLENOID FLOW TUBE (IPC,
60. BOLT (MS 9556-04) FIG. 4 ITEM 80)
70. NUT (525-610-9006) 160. DRAIN TUBE (IPC, ITEM 30)
80. CLAMP (IPC, SECTION 49-00-00
FIG. 3 ITEM 103)
(2) Remove the plumbing installation as follows. (Refer to Figure 302.)

AN ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS
(a) Remove drain tube (160).
(b) Remove bolt (60) and nut (70) from clamp (130).
(c) Remove gearbox vent tube (110) and clamps (80, 90, 100).
(d) Remove fuel solenoid flow tube (150) and clamps (120, 130, 140).
(e) Remove bolt (30), washer (40) and bracket (50).
NOTE: Retain bolt (30) and washer (40) with the idler bearing cover.
(f) Remove fuel control solenoid tube (10).
(g) Remove union (20) and packing (- 25). Discard the packing.
Page 315
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Engine Nameplate

Figure 303
Page 316
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 303
10A. RIVET (IPC, SECTION 20. NAMEPLATE

49-00-00 FIG. 2)
F. Disassemble the engine assembly.
(1) Remove engine nameplate as follows.
NOTE: Remove nameplate (20) only when damage is found or replacement is

necessary.
(a) Remove rivets (10A). Discard rivets. (Refer to Figure 303.)
(b) Remove nameplate (20).
Page 317
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Splined Adapter from the Generator Gearshaft Assembly

Figure 304
Page 318
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 304
1. SPLINE ADAPTER INSTALLER AND 20. KEY WASHER (IPC, ITEM 120)
REMOVAL TOOL (PN 5838419-1) 30. SPLINE KEY SNAP RING (IPC, ITEM 130)
2. RETAINER NUT
10. SPLINED ADAPTER (IPC,
SECTION 49-00-00 FIG. 2 ITEM 110)
(2) Remove the splined adapter as follows.
(a) Install 5838419-1 spline adapter installer and removal tool (1) to the generator
adapter and attach with two retainer nuts (2). (Refer to Figure 304, Detail A.)
(b) Remove splined adapter (10), key washer (20) and spline key snap ring (30)
from generator gearshaft assembly (IPC, Section 49-20-00 FIG 1, item 50).
(c) Remove spline key snap ring (30, Figure 304) and key washer (20) from
splined adapter (10). (Refer to Detail C.)
(d) Discard spline key snap ring (30) and splined adapter (10).
Page 319
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Start Counter

Figure 305
Page 320
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 305
10. SCREW (IPC, SECTION 20. START COUNTER

49-00-00 FIG. 5)
(3) Remove the start counter as follows.
(a) Remove screws (10). (Refer to Figure 305.)
(b) Remove start counter (20).
(c) Use industrial marking ink (Violet 127½) to make a mark on the tab of start
counter (20) and bracket to align and refer to at assembly.
Page 321
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Secondary and Primary Fuel Manifolds and Flow Divider Tee
Figure 306
Page 322
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 306
10. SECONDARY FUEL MANIFOLD (IPC, 40A. WASHER

SECTION 49-30-00 FIG. 1) 50. FLOW DIVIDER TEE
20. PRIMARY FUEL MANIFOLD
30A. NUT
(4) Remove the fuel manifolds and flow divider tee as follows.

FUMES ARE POISONOUS AND HIGHLY EXPLOSIVE AND CAN
CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
(a) Put a container below the APU turbine housing to catch all remaining fuel.
(b) Loosen the jam nuts and remove secondary fuel manifold (10).
(c) Loosen the jam nuts and remove primary fuel manifold (20).
(d) Remove nut (30A) and washer (40A).
(e) Remove flow divider tee (50).
Page 323
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Fuel Solenoid Valve

Figure 307
Page 324
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 307
10. BOLT (IPC, SECTION 49-30-00 FIG. 2) 50. REDUCER

20. WASHER 60. PACKING
30. STARTER COUNTER BRACKET 70. REDUCER
40. FUEL SOLENOID VALVE 80. PACKING
(5) Remove the fuel solenoid valve as follows. (Refer to Figure 307.)
(a) Remove bolt (10) washer (20) and starter counter bracket (30).
(b) Remove fuel solenoid valve (40).
(c) Remove reducers (50, 70) and packings (60, 80).
(d) Discard packings.
Page 325
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Fuel Control Assembly

Figure 308
Page 326
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 308
10. COUPLING CLAMP (IPC, SECTION 140. WASHER

49-30-00 FIG. 3) 150. BOLT
20. PACKING 160. WASHER
30. FUEL CONTROL ASSEMBLY 170. BRACKET
40. BOLT 180. ELBOW (IPC, SECTION 49-00-00
50. FILTER COVER FIG 2, ITEM 90)
60. PACKING 190. NUT (ITEM 100)
80. FILTER 200. PACKING (ITEM 110)
90. PACKING 210. UNION (ITEM 120)
130. BOLT 220. PACKING (ITEM 130)
(6) Remove the fuel control assembly as follows.
NOTE: For complete breakdown of the unit, refer to ATA 49-31-79, Fuel Control
Assembly Component Maintenance Manual.

FUMES ARE POISONOUS AND HIGHLY EXPLOSIVE AND CAN
CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
(a) Put a container below the fuel control assembly (30) to collect all fuel. (Refer
to Figure 308.)
(b) Remove coupling clamp (10) and fuel control assembly (30).
(c) Remove packing (20). Discard packing.
(d) Remove bolt (40), filter cover (50) and packing (60). Discard the packing.
(e) Remove filter (80) and packing (90). Discard filter and packing.
(f) Remove bolts (130, 150), washers (140, 160) and bracket (170).
(g) Remove elbow (180), nut (190) and packing (200). Discard packing.
(h) Remove union (210) and packing (220). Discard packing.
Page 327
49-25-93 Nov 11/05
RE100[LJ]
(Post SB 49-7489) Removal of the Chip Detector, Debris Monitor, Oil Level Switch, Liquid Level Rod Cap
Gage and Tube Bleeder Plug
Figure 309
Page 328
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 309
10. CHIP DETECTOR (IPC, SECTION 80. OIL LEVEL SWITCH (IPC, ITEM 20)
49-93-00 FIG. 1 ITEM 30) 90. NUT (IPC, ITEM 10)
20. PACKING (IPC, ITEM 40A) - 100. FILLER NECK AND CAP (IPC, SECTION
30. DEBRIS MONITOR (IPC, ITEM 50) 49-93-00 FIG. 1 ITEM 10)
40. PACKING (IPC, ITEM 60) 100A. LIQUID LEVEL ROD CAP GAGE (IPC,
50. PACKING (IPC, SECTION 49-70-00 ITEM 10A)
FIG. 1, ITEM 40) 105. PACKING (IPC, ITEM 25)
60. OIL TEMPERATURE BULB 110. PACKING (IPC, ITEM 20)
(IPC, ITEM 30) 120. TUBE BLEEDER PLUG (IPC, ITEM 70)
70. PACKING (IPC, SECTION 130. PACKING (IPC, ITEM 80)
49-93-00 FIG. 2 ITEM 30)
- TEM NOT ILLUSTRATED
(7) Remove the chip detector, debris monitor, oil level switch, liquid level rod cap gage
and tube bleeder plug as follows.

(a) Remove chip detector (10) and packing (20). (Refer to Figure 309, Detail A.)
Discard the packing.
WARNING: USE EYE PROTECTION WHEN YOU CUT THE LOCKWIRE.

WHEN YOU CUT THE LOCKWIRE, PIECES THAT BREAK OFF
CAN HIT YOUR EYES AND CAUSE INJURY.
(b) Remove the lockwire from debris monitor (30).
(c) Remove debris monitor (30) and packing (40). Discard the packing.
(d) Remove nut (90), oil level switch (80) and packing (70). Discard the packing.

(e) (Pre SB 49-7489) Remove the lockwire from filler neck and cap (-100).
(f) (Post SB 49-7489) Remove the lockwire from liquid level rod cap gage
(100A).
(g) (Pre SB 49-7489) Remove the filler neck and cap (-100) and packing (105).
Discard the packing.
(h) (Post SB 49-7489) Remove liquid level rod cap gage (100A) and packing
(105). (Refer to Detail B.) Discard the packing.
Page 329
49-25-93 Nov 11/05
RE100[LJ]

(i) Remove the lockwire from tube bleeder plug (120).
(j) Remove tube bleeder plug (120) and packing (130).
(k) Discard the packing.
Page 330
49-25-93 Aug 5/03
RE100[LJ]
Page 331
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Low Oil Pressure Switch

Figure 310
Page 332
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 310
10. NUT (IPC, SECTION 49-93-00 FIG. 2) 30. PACKING

20. LOW OIL PRESSURE SWITCH
(8) Remove the low oil pressure switch as follows. (Refer to Figure 310.)

(a) Remove nut (10), low oil pressure switch (20) and packing (30).
(b) Discard packing.
Page 333
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Lube Pump Assembly

Figure 311
Page 334
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 311
10. BOLT (IPC, SECTION 49-93-00 FIG. 3) 90. SCREEN

20. WASHER 100. SHAFT COUPLING
30. LUBE PUMP ASSEMBLY 110. PACKING
40A. FILTER HOUSING 120. TRANSFER TUBE
50. PACKING 130. PACKING
60A. FILTER ELEMENT 140. PACKING
70A. PACKING 150. PACKING
80. RETAINING RING 160. PACKING
(9) Remove the lube pump assembly as follows. (Refer to Figure 311.)
NOTE: For a complete breakdown of the unit, refer to ATA 49-91-59, Lube Pump
Assembly Component Maintenance Manual.

(a) Remove bolts (10), washers (20) and lube pump assembly (30).
(b) Remove filter housing (40A).
(c) Remove packing (50) from filter housing (40A). Discard packing.
(d) Remove filter element (60A) and packing (70A). Discard filter element and
packing.
(e) Remove retaining ring (80) and screen (90). Discard retaining ring (80).
(f) Remove shaft coupling (100).
(g) Remove transfer tube (120) and packings (130). Discard packings.
(h) Remove packings (140, 150, 160). Discard packings.
Page 335
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Low Voltage Electrical Lead and Igniter Plug

Figure 312
Page 336
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 312
110A. ELECTRICAL IGNITER PLUG LEAD 130. METAL SPARK PLUG GASKET
(IPC, SECTION 49-40-00 FIG. 1)
120. LOW VOLTAGE IGNITER PLUG
(10) Remove the electrical igniter plug lead as follows.
(a) Remove electrical igniter plug lead (110A) from the low voltage igniter plug
(120). (Refer to Figure 312.)
(b) Remove low voltage igniter plug (120) and metal spark plug gasket (130).
Page 337
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Air Temperature Bulb

Figure 313
Page 338
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 313
10. ELECTRICAL RESISTANCE 20. GASKET

TEMPERATURE BULB (IPC, SECTION
49-70-00 FIG. 1)
(11) Remove the electrical resistance temperature bulb (air temperature bulb) as follows.
(a) Remove air temperature bulb (10). (Refer to Figure 313.)
(b) Remove gasket (20).
Page 339
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Oil Temperature Bulb

Figure 314
Page 340
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 314
30. ELECTRICAL RESISTANCE 40. PACKING

TEMPERATURE BULB (IPC, SECTION
49-70-00 FIG. 1)
(12) Remove the electrical resistance temperature bulb (oil temperature bulb) as follows.
(a) Remove oil temperature bulb (30). (Refer to Figure 314.)
(b) Remove packing (40). Discard packing.
Page 341
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Speed Sensor

Figure 315
Page 342
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 315
10. NUT (IPC, SECTION 49-70-00 30. PACKING

FIG. 2)
20. SPEED SENSOR
(13) Remove the speed sensor as follows.
(a) Remove nut (10). (Refer to Figure 315.)
(b) Remove speed sensor (20) and packing (30). Discard packing.
Page 343
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Immersion Thermocouple

Figure 316
Page 344
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 316
10. BOLT (IPC, SECTION 49-70-00 FIG. 3) 30. HI-TEMP LOCKNUT

20. IMMERSION THERMOCOUPLE 40. HI-TEMP NUT
(14) Remove the immersion thermocouple as follows.
(a) Remove bolt (10). (Refer to Figure 316.)
(b) Remove immersion thermocouple (20).
NOTE: Retain the hi-temp locknut (30) and hi-temp nut (40) removed at
disassembly of the branched wiring harness with the immersion
thermocouple. (Refer to Figure 301.)
Page 345
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Idler Bearing Cover

Figure 317
Page 346
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 317
10. BOLT (IPC, SECTION 49-20-00 FIG. 2) 50. PACKING

30. BRACKET
40. IDLER BEARING COVER
(15) Remove the idler bearing cover as follows. (Refer to Figure 317.)
(a) Remove bolts (10), washer (20) and bracket (30).
NOTE: If the bracket is installed, remove the bracket.
(b) Remove idler bearing cover (40).
(c) Remove packings (50, 60). Discard packings
Page 347
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Fuel Nozzle Installation

Figure 318
Page 348
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 318
10. BOLT (IPC, SECTION 49-20-00 FIG. 3) 40. PREFORMED PACKING

20. WASHER 50. FUEL NOZZLE SHROUD
30. PRIMARY FUEL NOZZLE ASSEMBLY 60. SECONDARY FUEL NOZZLE ASSEMBLY
(16) Remove the primary fuel nozzle assembly and secondary fuel nozzle assembly as
follows.
(a) Remove bolts (10) and washers (20) from the primary fuel nozzle installation.
CAUTION: USE EXTREME CARE WITH PRIMARY FUEL NOZZLE ASSEMBLY

(30). OIL AND DIRT FROM HANDS CAN CLOG AND CAUSE
DAMAGE TO THE NOZZLES.
(b) Remove primary fuel nozzle assembly (30), preformed packing (40) and fuel
nozzle shroud (50).
(c) Put protective coverings on primary fuel nozzle assembly (30).
(d) Remove bolts (10) and washers (20) from the secondary fuel nozzle
installations.
(e) Remove secondary fuel nozzle assembly(60) and preformed packing (40).
Discard preformed packing.
(f) Put protective coverings on secondary fuel nozzle assembly (60).
Page 349
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Chamber Combustor

Figure 319
Page 350
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 319
10. BOLT (IPC, SECTION 49-20-00 FIG. 4) 40. TURBINE HOUSING

20. BRACKET 50. CHAMBER COMBUSTOR
(17) Remove the chamber combustor as follows.
(a) Remove bolts (10), brackets (20) and turbine housing (40). (Refer to Figure
319.)
(b) Remove chamber combustor (50).
Page 351
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Seal Assembly

Figure 320
Page 352
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 320
10. RETAINING RING 50. SEAL RETAINER

(IPC, SECTION 49-20-00 FIG. 5) - 50A. SEAL ASSEMBLY
20. RETAINER SEAL 60. PACKING
30. SPRING WASHER 70A. PACKING
40. RETAINING RING
-ITEM NOT ILLUSTRATED
(18) Remove the generator seal assembly.
(a) Remove retaining ring (10). (Refer to Figure 320.)
(b) Use two scribes that have tips that are bent at a 90 degree angle. With a
scribe in each hand, place the scribe tips into the groove of retainer seal (20).
At the same time, push the scribes away from the center of retainer seal (20)
and lift the seal straight up out of the gearshaft assembly.
(c) (Pre SB 49-7563) Remove retainer seal (20) with packing (70A), retaining ring
(40), seal retainer (50) and packing (60).
(Post SB 49-7563) Remove retainer seal (20) with packing (70A), retaining
ring (40), seal assembly (-50A) and packing (60).
(d) Remove spring washer (30).
(e) (Pre SB 49-7563) Remove retaining ring (40), seal retainer (50) and packing
(60) from retainer seal (20). Discard packing.
(Post SB 49-7563) Remove retaining ring (40), seal assembly (-50A) and
packing (60) from retainer seal (20). Discard packing.
(f) Remove packing (70A) from retainer seal (20). Discard packing.
Page 353
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Generator Adapter

Figure 321
Page 354
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 321
80. BOLTS (IPC, SECTION 49-20-00 100. GENERATOR ADAPTER

FIG. 5) 110. PACKING
90. WASHER
(19) Remove the generator adapter as follows.
(a) Remove bolts (80) and washers (90). (Refer to Figure 321.)
(b) Remove generator adapter (100) and packing (110). Discard packing.
Page 355
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Lube Pump Gear Baffle and Gearbox Bolts

Figure 322
Page 356
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 322
10. BOLT (IPC, SECTION 49-20-00 FIG. 6) 50. WASHER

20. PACKING WITH RETAINER 60. BOLT
30. LUBE PUMP GEAR BAFFLE 70. PACKING WITH RETAINER
40. BOLT
(20) Remove the lube pump gear baffle and gearbox bolts and washers as follows.
(a) Remove bolts (10), packing with retainer (20). Discard packing with retainer.
(b) Remove lube pump gear baffle (30).
(c) Remove bolts (40) and washers (50) from the gearbox assembly.
(d) Remove bolt (60) and packing with retainer (70) from the gearbox assembly.
Discard packing with retainer.
Page 357
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Turbine Nozzle

Figure 323
Page 358
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 323
80. BOLT (IPC, SECTION 49-20-00 110. TURBINE NOZZLE

FIG. 6) 120. TURBINE NOZZLE SHIM
90. PACKING WITH RETAINER 130. COMPRESSOR DESWIRL DEFLECTOR
100. RETAINER NOZZLE
(21) Remove the turbine nozzle as follows.
(a) Turn the compressor inlet duct, with installed perforated inlet assembly, to get
to and remove all bolts (80) and packing with retainers (90). (Refer to Figure
323, Detail A.)
(b) Remove all bolts (80) and packing with retainers (90). Discard packing with
retainers.
(c) Remove retainer nozzle (100). (Refer to Figure 322.)
(d) Remove turbine nozzle assembly (110).
(e) Remove turbine nozzle shim(s) (120).
(f) Measure and write down the number and thickness of turbine nozzle shims
(120) used. Use this data to refer to at assembly.
NOTE: Measure each turbine nozzle shim (120) used. Write the
measurement and the number of shims used to refer to at
assembly.
1 Total number of turbine nozzle shims (120) removed. __________
2 Measurement of each turbine nozzle shim (120) removed. ________
(g) Remove compressor deswirl deflector (130).
Page 359
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Gearbox Ball Bearing Cover, Turbine Rotor and Engine Compressor Diffuser Assembly
Figure 324
Page 360
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 324
140. BOLT (IPC, SECTION 49-20-00 FIG. 6) 190. PACKING

150. GEARBOX BALL BEARING COVER 200. GAS TURBINE ENGINE TURBINE ROTOR
160. PACKING 210. TURBINE ROTOR TIE ROD
170. PACKING 220. INTERSTAGE SEAL ASSEMBLY
180. TIE SHAFT NUT
(22) Remove the gearbox ball bearing cover, gas turbine engine turbine rotor and engine
compressor diffuser assembly as follows.
(a) Remove bolts (140). (Refer to Figure 324.)
(b) Remove gearbox ball bearing cover (150) and packing (160). Discard
packing.
(c) Remove packing (170). Discard packing.
WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. APPLY AND
DECREASE PRESSURE SLOWLY AND THREAD TOOL ON THE
CENTER OF THE SHAFT.
(d) Assemble 834740-1 stretch fixture (1) as follows. (Refer to Figure 706 in the
Assembly section.)
(e) Install 5838404-2 bearing support (2) on annular ball bearing (130) inner race.
(f) Install 5838404-4 bar (4) and 5838404-3 socket (3) then tighten 5838404-4
bar (4) to engage threads of turbine rotor tie rod (210).
(g) Engage 5838404-3 socket (3) with tie shaft nut (180). Tighten 5838404-4 bar
(4), 5838404-5 nut (5) and 5838404-3 socket (3) to hand tight.
(h) Assemble 834740-1 stretch fixture (1) pressure gage to 5838404-2 bearing
support (2).
(i) Increase ram pressure to 2900 psig (20010 kPa). Tighten 5838404-5 nut (5)
to hand tight.
(j) Loosen 5838404-3 socket (3) three full turns and then tighten one full turn.
(k) Slowly release all ram pressure.
(l) Remove 834740-1 stretch fixture (1) as follows.
(m) Remove stretch fixture (1) pressure gage.
(n) Remove 5838404-5 nut (5), 5838404-4 bar (4), 5838404-3 socket (3) and
5838404-2 bearing support (2).
Page 361
49-25-93 Nov 11/05
RE100[LJ]
CAUTION: REMOVAL OF SUBSEQUENT PART CAUSES FREEDOM OF

MOVEMENT TO ATTACHED PARTS. SUPPLY SUPPORT FOR
ATTACHED PART(S).
(o) Loosen tie shaft nut (180.). When tie shaft nut (180) is loose, gas turbine
engine turbine rotor (200) can loosen.
(p) Support gas turbine engine turbine rotor (200) and remove tie shaft nut (18)
from turbine rotor tie rod (210).
(q) Remove gas turbine engine turbine rotor (200) with attached turbine rotor tie
rod (210).
(r) Remove packing (190) from turbine rotor tie rod (210). Discard packing.
(s) Remove interstage seal assembly (220).
(t) Remove engine compressor diffuser (230).
Page 362
49-25-93 Aug 5/03
RE100[LJ]
Page 363
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Turbine Rotor Tie Rod from Turbine Rotor

Figure 325
Page 364
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 325
1. NUT (3/8 in. X 24) 200. GAS TURBINE ENGINE TURBINE ROTOR
180. TIE SHAFT NUT (IPC, SECTION 210. TURBINE ROTOR TIE ROD
49-20-00 FIG. 6)
(23) Remove the turbine rotor tie rod from the gas turbine engine turbine rotor.
(a) Use a double-nut procedure to remove turbine rotor tie rod (210) from gas
turbine engine turbine rotor (200). (Refer to Figure 325.)
(b) Install nut (1) (3/8 in. X 24) to turbine rotor tie rod (210). Tighten nut (1) until it
bottoms out on turbine rotor tie rod (210).
(c) Install tie shaft nut (180) to turbine rotor tie rod (210). Tighten tie shaft nut
(180) until it bottoms out on nut (1).
(d) Secure gas turbine engine turbine rotor (200) to torque nut (1) and loosen
turbine rotor tie rod (210).
(e) Remove turbine rotor tie rod (210), tie shaft nut (180) and nut (1).
Page 365
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Centrifugal Compressor Rotor

Figure 326
Page 366
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 326
1. COMPRESSOR ROTOR REMOVER 260. CENTRIFUGAL COMPRESSOR ROTOR

(PN 5838410-1) 270. ENGINE COMPRESSOR HOUSING
240. OUTER PILOT RING (IPC, SECTION ASSEMBLY
49-20-00 FIG. 6) 280. TURBINE COMPRESSOR SHIM
250. INNER PILOT RING 300. COMPRESSOR INLET DUCT
(24) Remove the centrifugal compressor rotor.
(a) Remove outer pilot ring (240). (Refer to Figure 326.)
(b) Use 5838410-1 compressor rotor remover (1) and remove centrifugal
compressor rotor (260) with the inner pilot ring attached.
(c) Remove engine compressor housing assembly (270) from compressor inlet
duct (300).
(d) Remove turbine compressor shim(s) (280) and write as follows.
NOTE: Measure each turbine compressor shim (280) used. Write the
measurement and the number of shims used to refer to at
assembly.
1 Total number of turbine compressor shims (280) removed.

_________
2 Measurement of each turbine compressor shim (280)

removed. _________
Page 367
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Inner Pilot Ring from Centrifugal Compressor Rotor

Figure 327
Page 368
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 327
1. PILOT RING REMOVER (PN 5838435-1) 250. INNER PILOT RING (IPC, SECTION
2. SPLIT PLATE (PN 5838435-2) 49-20-00 FIG. 6)
(COMPONENT OF 5838435-1) 260. CENTRIFUGAL COMPRESSOR ROTOR
(25) Remove the inner pilot ring from the centrifugal compressor rotor as follows.
(a) Use pilot ring remover (1) to remove inner pilot ring (250). (Refer to Figure
327, Detail A.)
(b) Attach split plate (2) of removal tool to inner pilot ring (250).
(c) Tighten tooling bolts and torque center screw a couple of turns to lift pilot ring.
(d) Loosen tooling bolts and attach split plate (2) further around inner pilot ring
(250). (Refer to Detail B.)
(e) Tighten tooling bolts again and completely remove the inner pilot ring from
centrifugal compressor rotor (260.)
Page 369
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Perforated Compressor Inlet and Compressor Inlet Duct

Figure 328
Page 370
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 328
290. PERFORATED COMPRESSOR INLET 300. COMPRESSOR INLET DUCT

(26) Remove the perforated compressor inlet and compressor inlet duct as follows.
NOTE: All bolts, washers and packing with retainers were removed at disassembly
of the lube pump gear baffle. (Refer to Step F. (20).)
(a) Remove perforated compressor inlet (290). (Refer to Figure 328.)
(b) Remove compressor inlet duct (300).
Page 371
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Inlet Baffle

Figure 329
Page 372
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 329
10. BOLT (IPC, SECTION 49-20-00 FIG. 7) 30. COMPRESSOR INLET DUCT
20. BAFFLE
(27) Remove the inlet baffle as follows.
(a) Remove bolts (10). (Refer to Figure 329.)
(b) Remove baffle (20) from compressor inlet duct (30).
Page 373
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Matched Set Inlet Housing

Figure 330
Page 374
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 330
1. SEAL ASSEMBLY WRENCH - 50. OIL JET BEARING SPACER

(PN 5838433-1) - 60. PACKING
10. ENCASED PLAIN SEAL ASSEMBLY - 70. PACKING
(IPC, SECTION 49-20-00 FIG. 8) -80. PACKING
20. PACKING 140A. INLET HOUSING (FIG. 10)
30. COMPRESSION SPRING WASHER
- 40. COMPRESSOR SEAL ROTOR
(27) Remove the inlet housing as follows.
(a) Use a screwdriver or equivalent tool and raise the break in the seal material
on encased plain seal assembly (10) from inlet housing (140A). (Refer to
Figure 330, Detail A.)
(b) Use 5838433-1 seal assembly wrench (1) and loosen encased plain seal
assembly (10). (Refer to Detail B.)
(c) Remove encased plain seal assembly (10) with packing (20). Discard
encased plain seal assembly with packing. (Refer to Detail C.)
(d) Remove compression spring washer (30).
(e) Remove compressor seal rotor (- 40), oil jet bearing spacer (- 50) and packing
(- 60). Discard packing. (Refer to Figure 716, Detail A in the Assembly
Section.)
(f) Remove packings (- 70, - 80) from inlet housing (140A). (Refer to Figure 716
Detail A in the Assembly Section.) Discard packings.
(g) Remove inlet housing (140A) from compressor gearshaft assembly and
gearbox housing.
Page 375
49-25-93 Nov 11/05
RE100[LJ]
Removal of the Idler Gearshaft

Figure 331
Page 376
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 331
10. IDLER GEARSHAFT (IPC, SECTION 40. ANNULAR BALL BEARING

49-20-00 FIG. 9) 150. GEARBOX HOUSING
30. ANNULAR BALL BEARING (IPC, FIG. 10)
(29) Remove the idler gearshaft, bearings and spring washer as follows.
(a) Carefully remove idler gearshaft with attached bearings from the gearbox
housing (150). (Refer to Figure 331, Detail A.)
(b) Install 5838423-2 and 5838423-3 idler bearing remover split plates to annular
ball bearing (30) and idler gearshaft (10). (Refer to Detail B.)
(c) Install split plate and gearshaft assembly on a steady surface below an arbor
press.
(d) Install 5838423-5 idler gearshaft driver to idler gearshaft (10) and with the
arbor press push annular ball bearing (30) off idler gearshaft (10).
(e) Remove the split plates and repeat the removal steps to disassemble annular
ball bearing (40) from idler gearshaft (10). (Refer to Detail C.)
Page 377
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Gearshaft Assemblies

(Generator Gearshaft)
Figure 332
Page 378
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 332
50. GENERATOR GEARSHAFT 90. ANNULAR BALL BEARING

(IPC, SECTION 49-20-00 FIG. 9) 100. ANNULAR BALL BEARING
60. ROUND PLAIN NUT 160. GEARBOX HOUSING (IPC, FIG. 10
70. NUT LOCKING KEY ITEM 150)
80. GENERATOR ROTOR SEAL
(30) Remove the generator gearshaft as follows.
(a) Remove generator gearshaft (50) from the gearbox housing (160) and install
on 5838432-3 generator gearshaft support. (Refer to Figure 332, Detail A.)
(b) Use pliers and make nut locking key (70) straight.
(c) Use 5838426-1 generator spline wrench and remove round plain nut (60).
(Refer to Detail B.)
(d) Remove nut locking key (70). Discard nut locking key.
(e) Use 5838422-1 generator seal rotor and bearing remover and remove
generator rotor seal (80).
(f) Install 5838421-2 and 5838421-3 split plates to generator gearshaft (50) and
annular ball bearing (90). (Refer to Detail C.)
(g) Put the split plates and gearshaft assembly on a steady surface below an
arbor press.
(h) Install 5838422-5 generator gearshaft driver to generator gearshaft (50) and
with the arbor press push annular ball bearing (90) off the generator
gearshaft.
(i) Remove the split plates and repeat the removal steps to disassemble annular
ball bearing (100) from generator gearshaft (50). (Refer to Detail D.)
Page 379
49-25-93 Aug 5/03
RE100[LJ]
Removal of the Gearshaft Assemblies

(Compressor Gearshaft)
Figure 333
Page 380
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 333
1. CYLINDRICAL ROLLER BEARING 110. COMPRESSOR GEARSHAFT ASSEMBLY

REMOVER ASSEMBLY (PN 5838417-1) (IPC, SECTION 49-20-00 FIG. 9)
2. SPLIT PLATE (PN 5838417-2) - 120. COMPRESSION SPRING WASHER
3. COMPRESSOR BEARING 130. ANNULAR BALL BEARING
REMOVER (PN 5838716-1) 140. HSP GEAR
4. SPLIT PLATE (PN 5838418-1) HALF 150. CYLINDRICAL ROLLER BEARING
5. SPLIT PLATE(PN 5838418-1) HALF
6. IDLER GEARSHAFT DRIVER
(PN 5838423-5)
(31) Remove the compressor gearshaft assembly as follows.
(a) Remove compressor gearshaft assembly (110) and compression spring

washer (- 120) from the gearbox housing. (Refer to Figure 333, Detail A.)
(b) Use 5838417-1 cylindrical roller bearing remover assembly (1) and 5838417-
2 split plate (2) and remove cylindrical roller bearing (150). (Refer to Detail
B.)
(c) Use 5838416-1 compressor bearing remover (3) and remove annular ball
bearing (130). (Refer to Detail C.)
(d) Use 5838418- 1split plate ( 4, 5) and 5838423-5 idler gearshaft driver (6) and
remove HSP gear (140).
Page 381
49-25-93 Aug 5/03
RE100[LJ]
Page 382
49-25-93 Aug 5/03
RE100[LJ]
CLEANING
1. Auxiliary Power Unit Cleaning
A. General
(1) This section includes the cleaning procedures for the APU engine.
(2) Standard cleaning practices.
(a) Refer to the Standard Practices Manual (SPM), ATA No. 20-00-02/70-00-01
for general cleaning instructions, preparation of cleaning solutions and for
cleaning procedures.
(b) For protection of cleaned parts, refer to the instructions given in the SPM.
(3) Clean component parts.
(a) Clean the parts with the specified procedures as shown in Table 401. When
more than one procedure to clean a part is shown in the table, use only the
procedure necessary to satisfactorily clean the part.
NOTE: The alpha letters in Table 401 refer to the alpha letter suffix for
Method 203 as shown in SPM, ATA 20-00-02/70-00-01.
(Example: Method A in Table 401 refers to cleaning Method 203A
(Using Petroleum Solvent) in the SPM.)
(b) Ball or roller bearing assemblies must be replaced or analyzed by a repair

facility specializing in the repair of bearing assemblies.
(c) Find internal component part cleaning methods in the separate component
maintenance manual (CMM) for the part. Go to the INTRODUCTION section
of this manual for the list of separate CMMs. (Refer to Table 2. Applicable
Publications List.)
Table 401. Cleaning Methods
Cleaning Methods – Refer to Method 203

IPL/IPC (Alpha Suffix) in SPM
Figure Item
No. No. Nomenclature A E J K L M Q
All standard metallic hardware X X
Plumbing and Fittings X
Electrical Components X
Section 49-00-00
2 110 Splined Adapter X

120 Key Washer X
Page 401
49-25-93 Aug 5/03
RE100[LJ]
Table 401. Cleaning Methods (Cont)

Figure Item
3 250A Branched Wiring Harness X
4 10 Fuel Control Unit Solenoid X X

Tube
40 Gearbox Vent Tube X X
80 Fuel Solenoid Flow Tube X X
Section 49-20-00
2 40 Idler Bearing Gearbox Cover X
3 30 Fuel Nozzle Assembly X X

(Primary)
50 Fuel Nozzle Shroud X X
60 Fuel Nozzle Assembly (Secondary) X X
4 40 Turbine Housing X X
50 Chamber Combustor X X
5 20 Retainer Seal X X
-50A Seal Assembly X X
6 30 Lube Pump Gear Baffle X X

100 Retainer Nozzle X X
110 Turbine Nozzle Assembly X X
120 Turbine Nozzle Shim X X
130 Compressor Deswirl Deflector X X
150 Ball Bearing Gearbox Cover X X
200 Gas Turbine Engine Turbine Rotor X X
210 Turbine Rotor Tie Rod X X
220 Interstage Seal Assembly X X
230 Engine Compressor Diffuser Assembly X X
240 Outer Pilot Ring X X
250 Inner Pilot Ring X X
260 Centrifugal Compressor Rotor X X
270 Engine Compressor Housing Assembly X X
280 Turbine Compressor Shim X X
290 Perforated Compressor Inlet X X
300 Compressor Inlet Duct X X
Page 402
49-25-93 Nov 11/05
RE100[LJ]

Figure Item
7 20 Inlet Baffle X
8 50 Oil Jet Bearing Spacer X
9 10 Idler Gearshaft X
30 Annular Ball Bearing X
50 Generator Gearshaft X
80 Generator Rotor Seal X
110 Compressor Gearshaft Assembly X
140 HSP Gear X
150 Cylindrical Roller Bearing X
10 140A Inlet Housing X

150 Gearbox Housing X
Section 49-30-00
1 10 Fuel Manifold Assembly (Secondary) X

20 Fuel Manifold Assembly (Primary) X
50 Flow Divider Tee X
2 40 Fuel Solenoid Valve X
3 10 Clamp Coupling X
30 Fuel Control Assembly X
Section 49-40-00
1 110A Electrical Igniter Plug Lead X X

120 Low Voltage Igniter Plug X X
150 Ignition Unit X X
Section 49-70-00
1 10 Electrical Resistance Temperature Bulb X

30 Electrical Resistance Temperature Bulb X
3 20 Immersion Thermocouple X
Page 403
49-25-93 Nov 11/05
RE100[LJ]

Figure Item
Section 49-93-00
1 -10 Filler Neck and Cap X

10A Liquid Level Rod Cap X
Gage
30 Chip Detector X
50 Debris Monitor X
70 Tube Bleeder Plug X
3 30 Lube Pump Assembly X

120 Transfer Tube X
4 20 Oil Level Switch X
(1) Table 402 shows the materials and compounds necessary to do the special cleaning
procedures.
Alkaline cleaner (Ridoline-909) (MIL-S-5002) Henkel Surface Technologies,

32100 Stephenson Hwy,
Madison Heights, MI 48071
Phone: 800-521-6895 (248-583-9300)
Aqueous cleaner/degreasing solution Magnaflux, Division of Illinois Tool Works Inc.,

(Aqueous Cleaner) (Daraclean 282) 3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
Chromic acid flake Commercially available
Cloth, lint-free Commercially available
Page 404
49-25-93 Nov 11/05
RE100[LJ]
Table 402. Materials and Compounds (Cont)
Corrosion-preventive compound Commercially available

(MIL-C-6529, Type III)
De-oxidizer (Oakite 34M) Chemetall Oakite,

50 Valley Rd.,
Berkeley Heights, NJ 07922
Phone: 908-464-6900
Nitric acid (Commercial item description Commercially available

A-A-59105)
Powder (Iridite No. 14-2) (MIL-DTL-81706) MacDermid Inc.,

245 Freight St.,
Waterbury, CT 06702
Phone: 203-575-5748
Rust stripper (Oakite Rustripper) Chemetall Oakite,

50 Valley Rd.,
Berkeley Heights, NJ 07922
Phone: 908-464-6900
Solvent (Isopropyl alcohol) Commercially available
(1) None
D. Special Cleaning Procedures for Specified Components
(1) Clean the low voltage igniter plug as follows.
NOTE: Combustion deposits in the gap area of the low voltage igniter plug semi-
conductor material must not be removed. If deposits must be removed
from other areas of the low voltage igniter plug gap, use a wooden scraper
and do not remove deposits from the semi-conductor material.
(2) Use a lint-free cloth and wipe off all combustion deposits on the outside of the low
voltage igniter plug.
(a) Use a cotton swab with alcohol or mineral spirits and clean the low voltage
igniter plug connector end.
Page 405
49-25-93 Nov 11/05
RE100[LJ]
Page 406
49-25-93 Aug 5/03
RE100[LJ]
CHECK
1. Gas Turbine Engine Check
A. General
(1) This section includes the check procedures for the gas turbine engine.
(1) Table 501 shows the materials and compounds necessary to do the checks.
Magnetic base oil (Magnaglo Carrier II) Magnaflux, Division of Illinois Tool Works Inc.,
3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
Magnetic particles compound Magnaflux, Division of Illinois Tool Works Inc.,

(Magnaglo Dry Concentrate No. 14A) 3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
Magnification glass (5X) Commercially available
Penetrant oil (SAE AMS 2644) Commercially available
Page 501
49-25-93 Nov 11/05
RE100[LJ]
(1) Table 502 shows the special tools, fixtures and equipment necessary to do the check
procedures.
Part No.
Demagnetizing unit (Model SB2824T) Magnaflux, Division of Illinois Tool Works Inc.,
3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
Fluorescent penetrant unit (Model ZA-28) Magnaflux, Div. of Illinois Tool Works,
3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
Magnetizing unit (Model H720) Magnaflux, Division of Illinois Tool Works Inc.,
3624 W. Lake Ave.,
Glenview, IL 60025
Phone: 847-657-5300
D. General Check Procedures
(1) These general check procedures are in addition to the basic knowledge of repair
personnel. Because of the precision equipment used in these procedures the
manufacturer recommends they be followed.
(a) Examine threaded parts.
1 Examine all threaded parts for crossed, stripped, or broken threads.

Discard the part if threads are damaged.
2 Examine threaded inserts for looseness and the condition of the

threads. Discard the part if the inserts are loose or damaged.
(b) Examine all seal surfaces and flanges for nicks, dents and scratches.
Discard the part if the seal surfaces or flanges are damaged.
Page 502
49-25-93 Nov 11/05
RE100[LJ]
(2) Penetrant or magnetic particle inspection.
NOTE: It is not necessary to do the penetrant or magnetic particle inspection on

anodized, plated or painted surfaces, unless wear or physical damage is
found.
(a) Do a penetrant inspection. Refer to ASTM E1417.
1 If necessary, remove anodize or paint from the surface.
2 Remove all rust, scale, burrs, dirt, grease and any other
contaminants. Make sure the part is dry. (Refer to CLEANING.)
3 Refer to the manufacturer's instructions to use fluorescent penetrant
unit and penetrant oil.
4 When completed, remove all penetrant oil. (Refer to CLEANING.)
5 If necessary, apply anodize or paint.
(b) Do a magnetic particle inspection. Refer to ASTM E1444 and use the wet
continuous DC method.
1 If necessary, remove paint from the surface.
2 Remove all rust, scale, burrs, dirt, grease and other contaminations
from the part. Make sure that the part is dry. (Refer to CLEANING.)
3 Magnetize the part.
NOTE: Refer to the magnetizing unit manufacturer's instructions

to use the magnetizing unit, magnetic base oil, and
magnetic particles compound.
a Magnetize the part in the longitudinal direction.
b Do the check.
c Magnetize in the circumferential direction.
d Do the check.
4 When completed, use the demagnetizing unit to demagnetize the part

to a maximum of 10 gauss.
5 After the part is demagnetized, remove all the magnetic base oil.
(Refer to CLEANING.)
6 If necessary, paint the part.
Page 503
49-25-93 Aug 5/03
RE100[LJ]
(3) Visual checks.
(a) Use a strong light and 5X magnification to examine the parts.
(b) Refer to the detailed check procedures if a part shows a condition that could
have caused wear.
(c) Dimensional checks are given for parts that wear. If a visual check shows no
damage or wear, but a dimensional check is necessary, specific instructions
are given.
(d) Examine the gear and spline teeth.
1 Examine the part for spalling, fretting, surface flaking, chipping,

splitting, rubbing and corrosion. Replace the part if any of these
defects are found.
2 Examine the part for corner loading. Replace the part if the wear
pattern shows loading of less than three-fourths of the normal length
of tooth bearing contact area.
3 Examine the part for metal displacement. Replace the part if there is
damage.
4 Examine the part for signs of healed scuffing (shown by a dull gray
finish or burnished color) of tooth involute surface. Healed scuffing is
permitted if the damaged area is not more than 30 percent of the
pattern width, the involute contour looks unchanged, and no spalling
or fretting is found.
5 Examine the part for discoloration caused by too much heat. If

discoloration is found, replace the part unless told differently.
6 Examine the teeth for signs of unusual or deep wear patterns. If a

visual check shows wear, dimensionally check over or between pins
or balls put in the wear area. Refer to detailed check procedures.
7 Examine the part for uneven wear on the axial length of the spline
teeth. If wear is found, continue as follows.
a Set the spline shaft in a V-block. Use a dial indicator to

measure the wear. Move the spline tooth axially from a non-
worn to a worn area.
b Wear of the spline tooth must not be more than 0.004 inch
(0,10 mm). If both sides of the spline tooth are worn, the sum
of the two wear measurements must be used.
Page 504
49-25-93 Aug 5/03
RE100[LJ]
(4) Terms for Inspection show definitions of damage and typical causes used in the
check procedures.
Terms for Inspection
Term Definition Typical Cause
Abrasion Shows as rough areas on the Foreign particles between parts that move
material. Light to heavy rough
areas can be seen
Blistering Shows as plated or painted Gas, heat or moisture causes a poor bond to
material that starts to break release the layers of material
away from the surface
Brinelling Shows as dents on ball or

roller bearings
Burning Shows as discoloration on the Lack of lubrication to the material

material or a loss of material
Burr Shows as a sharp piece of Excessive wear of material

material or rough edge
Chafing Shows as loss or wear of Wrong fit or assembly

material as two or more
materials have rubbed against
each other
Chipping Shows as small pieces of Stress placed on the part by shock , nicks or
material that breaks away scratches
from the surface
Corrosion Shows as wear or pitting on Material surface not treated correctly or excess
treated material surfaces exposure to chemicals that cause corrosion.
Crack Shows as material breaks Stress and material fatigue due to shock, heat,
from the original surface or overload or all of these
material
Crossed Shows as diagonal grooves Wrong alignment of part during installation

across the threads of a nut,
bolt, screw or fitting
Distortion Shows as a twist of material or Exposure to excessive heat or a part that has fallen
a change in form
Flaking Shows as small pieces of Exposure to excessive heat or excessive load or

material that breaks away improper surface bond
from the surface
Page 505
49-25-93 Aug 5/03
RE100[LJ]
Terms for Inspection (Cont)
Term Definition Typical Cause
Galling Shows as material that has Low lubrication levels, wrong installation or not
been rubbed from one surface enough clearance for parts
on a part onto another part
Gear or Spline Tooth Shows as small holes in Material is close to or has reached limit for fatigue
Pitting material of 0.015 inch
Gear Tooth Frosting Shows as very small holes in Low levels of lubrication or excessive heat within
material (less than 0.0001 the gear splines
inch) which makes it look like
an etch finish has been
applied
Gear Tooth Scoring Shows as radial marks on the Low level of lubrication or excessive heat within the
gear tooth wear pattern gear splines
Grooving Shows as score marks with Parts out of alignment or material has reached limit
round edges on the surface of for wear
the material
Nick Shows as a sharp grooving on Foreign particles between moving parts

the surface of the material
Scoring Shows as deep marks in the Foreign particles between moving parts
surface of the material
Scratches Shows as narrow and shallow Foreign particles between moving parts
marks on the surface of the
material
Spalling Shows as different shapes in Material surface in high load areas is close to or has
pits on the surface of the reached limit for fatigue
material. Cracks can come
from the edges of the pits
Stripped Shows as damage to threads Part has been over tightened or is close to or
on a nut, bolt, screw or fitting reached limit for fatigue
E. Detailed Check Procedures
(1) These procedures have an illustration followed by a table that gives detailed check
procedures for parts shown in that illustration. Do the detailed checks as specified in
Figure 501, and subsequent figures and tables that may be required.
Page 506
49-25-93 Nov 11/05
RE100[LJ]
Page 507
49-25-93 Nov 11/05
RE100[LJ]
Branched Wiring Harness Inspection

Figure 501
Page 508
49-25-93 Nov 11/05
RE100[LJ]
Figure 501. Check Procedures
Item
No. Nomenclature Check Procedure Limits
260 Branched wiring harness Visually examine wiring harness If found, refer to the applicable
sheathing for chafes, scores or CMM for disposition.
tears.
Visually examine electrical If found, refer to the applicable

connectors for breaks in wire CMM for disposition.
insulation, pinched wires, loose
or missing backshells,
disconnected pins or plugs, tears
in pin or plug isolators.
20 Loop clamp Visually examine for wear that If found, replace the unit.
60 can cause scores or tears to
100A harness sheathing.
170
190
230
Page 509
49-25-93 Nov 11/05
RE100[LJ]
Plumbing Inspection
Figure 502
Page 510
49-25-93 Aug 5/03
RE100[LJ]
Item
10 Fuel control solenoid tube Visually examine tube for nicks, If found, replace the unit.
burrs, scores, dents, kinks or
blockage.
20 Union Visually examine threads for If found, replace the unit.

nicked, crossed, galled or
stripped edges.
80 Clamp Visually examine for wear that If found, replace the unit.
90 can cause scores or gouges to
100 tubes.
110 Gearbox vent tube Visually examine tube for nicks, If found, replace the unit.
blockage.
120 Clamp Visually examine for wear that If found, replace the unit.
130 can cause scores or gouges to
140 tubes.
150 Fuel solenoid flow tube Visually examine tube for nicks, If found, replace the unit.
blockage.
Page 511
49-25-93 Nov 11/05
RE100[LJ]
Fuel Manifold and Flow Divider Tee Inspection

Figure 503
Page 512
49-25-93 Nov 11/05
RE100[LJ]
Item
10 Secondary fuel manifold Visually examine tube for nicks, If found, replace the unit. If
burrs, scores, dents, kinks or blockage is found, clean the
blockage. unit again. (Refer to
CLEANING.)
20 Primary fuel manifold Visually examine tube for nicks, If found, replace the unit. If
burrs, scores, dents, kinks or blockage is found, clean the
blockage. unit again. (Refer to
CLEANING.)
50 Flow divider tee Visually examine threads for If found, replace the unit.
nicks, crossed, galled or stripped
edges.
Visually examine for nicks, burrs, If found, replace the unit. If

scores, or blockage. blockage is found, clean the
unit again. (Refer to
CLEANING.)
Page 513
49-25-93 Aug 5/03
RE100[LJ]
Fuel Nozzle Shroud Inspection

Figure 504
Page 514
49-25-93 Aug 5/03
RE100[LJ]
Item
60 Fuel nozzle shroud Visually examine for cracks If found, replace the unit.
between holes
Visually examine for burn- If found, replace the unit.

through on the unit.
Measure DIM A. DIM A must be If measurement is not as

0.128 to 0.130 in. (3,25 to 3,3 specified, replace the unit.
mm).
Measure DIM B. DIM B must be If measurement is not as

0.5515 to 0.5520 in. (14,1 to specified, replace the unit.
14,02 mm).
Page 515
49-25-93 Aug 5/03
RE100[LJ]
Elbow Inspection
Figure 505
Page 516
49-25-93 Nov 11/05
RE100[LJ]
Item
190 Nut Visually examine threads for If found, replace the unit.
edges.
180 Elbow Visually examine threads for If found, replace the unit.
edges.
210 Union Visually examine threads for If found, replace the unit.
edges.
Page 517
49-25-93 Nov 11/05
RE100[LJ]
Fuel Solenoid Valve Inspection

Figure 506
Page 518
49-25-93 Aug 5/03
RE100[LJ]
Item
40 Fuel solenoid valve Visually examine threads for If found, replace the unit.
edges.
Visually examine unit connector If found, replace the unit.

for bent or broken pins.
Visually examine unit connector If found, replace the unit.

threads for nicks, crossed, galled
or stripped edges
Visually examine valve orifices If found, clean the unit. (Refer

for blockage from foreign objects. to CLEANING.)
Page 519
49-25-93 Aug 5/03
RE100[LJ]
Fuel Control Assembly Inspection

Figure 507
Page 520
49-25-93 Aug 5/03
RE100[LJ]
Item
10 Coupling clamp Visually examine for tight fit. If loose, replace the unit.
30 Fuel control assembly Visually examine the unit per fuel Refer to the INTRODUCTION
control assembly CMM. for the applicable CMM.
Page 521
49-25-93 Aug 5/03
RE100[LJ]
Lube Pump Assembly Inspection

Figure 508
Page 522
49-25-93 Nov 11/05
RE100[LJ]
Item
30 Lube pump assembly Visually examine the unit per Refer to the INTRODUCTION
lube pump assembly CMM. for the applicable CMM.
40A Housing filter Visually examine the unit per Refer to the INTRODUCTION
60A Filter element Visually examine the unit per Refer to the INTRODUCTION
120 Transfer tube Visually examine for nicks, burrs, If found, replace the unit. If
scores or blockage. blockage is found, clean the
unit again. (Refer to
CLEANING.)
Page 523
49-25-93 Nov 11/05
RE100[LJ]
(Pre SB 49-7489) Filler Neck and Cap Inspection

Figure 509
Page 524
49-25-93 Aug 5/03
RE100[LJ]
Item
70 Filler neck and cap Visually examine the cap for tight If the cap is loose and does
(Pre SB 49-7489) fit. not close to hand tight, replace
the unit.
Visually examine cap screen for If found, replace the unit.

tears or holes.
Visually examine filler neck If found, replace the unit.

threads for nicked, crossed,
galled or stripped edges.
Page 525
49-25-93 Aug 5/03
RE100[LJ]
(Post SB 49-749) Liquid Level Rod Cap Gage Inspection

Figure 510
Page 526
49-25-93 Nov 11/05
RE100[LJ]
Item
10A Liquid level rod cap gage. Visually examine gage threads If found, replace the unit.
(Post SB 49-7489) for nicks, crossed, galled or
stripped edges.
Visually examine screen for tears If found, replace the unit.

or holes.
Page 527
49-25-93 Aug 5/03
RE100[LJ]
Tube Bleeder Plug Inspection

Figure 511
Page 528
49-25-93 Nov 11/05
RE100[LJ]
Item
70 Tube bleeder plug Visually examine threads for If found, replace the unit.
edges.
Page 529
49-25-93 Aug 5/03
RE100[LJ]
Debris Monitor Inspection

Figure 512
Page 530
49-25-93 Nov 11/05
RE100[LJ]
CAUTION: KEEP THIS UNIT AWAY FROM ALL ALTERNATING (AC) CURRENT AND
MAGNETIC FIELDS. IF CONTACT IS MADE WITH AC OR THE UNIT IS NEAR A
MAGNETIC FIELD, DAMAGE TO THE UNIT CAN OCCUR.
Item
30 Chip detector Visually examine detents for If found, replace the unit.
cracks or chipped edges.
Visually examine the magnet for If found, do a test for lift.

cracks or chipped edges.
Do a test for lift The chip detector must lift a

7/8 in. (22,23 mm) diameter
carbon steel weight. If not,
replace the unit.
50 Debris monitor Visually examine screen for tears If found, replace the unit.
or holes.
Visually examine threads for If found, replace the unit.

edges.
NOTE: Place a good unit in a package by itself. A caution must be placed on the package
to keep the unit away from tools and instruments that produce magnetic fields and
areas where magnetic particle inspections are done.
Page 531
49-25-93 Aug 5/03
RE100[LJ]
Oil Level Switch Inspection

Figure 513
Page 532
49-25-93 Aug 5/03
RE100[LJ]
Item
20 Oil level switch Visually examine switch If found, replace the unit.
connector and body for cracks or
dents.
Visually examine the unit per the Refer to the INTRODUCTION

oil level switch CMM. for the applicable CMM.
Page 533
49-25-93 Aug 5/03
RE100[LJ]
Electrical Igniter Plug Lead Inspection

Figure 514
Page 534
49-25-93 Nov 11/05
RE100[LJ]
Item
110A Electrical igniter plug lead Visually examine wiring If found, replace the unit.
sheathing for chafes, scores or
tears.
Visually examine for wear in If found, replace the unit.

sheathing.

edges.
Page 535
49-25-93 Nov 11/05
RE100[LJ]
Low Voltage Igniter Plug Inspection

Figure 515
Page 536
49-25-93 Aug 5/03
RE100[LJ]
Item
40 Low voltage igniter plug Visually examine the unit for If found, replace the unit.
cracks or chips in the shell.
(Refer to View B.)
Visually examine the contact pin If the contact pin is loose and if
for tightness and damage. (Refer the contact pin is bent, broken
to View C.) or burned, replace the unit.
Measure DIA B for wear. (Refer If DIA B is greater than 0.335

to View A.) in. (8,51 mm), replace the unit.
Measure DIM C. If DIM C if greater than 0.070

in. (1,78 mm), replace the unit.
Visually examine the shell for If found replace the unit.

fretting and wear.
Visually examine the shell for If found, replace the unit.

distortion and crossed threads.
NOTE: Nominal diameter (DIA A) for a unit in new condition is 0.225 inch (5,72 mm).
Page 537
49-25-93 Aug 5/03
RE100[LJ]
Immersion Thermocouple Inspection

Figure 516
Page 538
49-25-93 Aug 5/03
RE100[LJ]
Item
20 Immersion thermocouple Visually examine for burrs, nicks If found, replace the unit.
and scratches.

nicked, crossed, galled or
stripped edges.
Visually examine probe for burrs, If found, replace the unit.

nicks and scratches
Visually examine the unit terminal If a terminal is loose or cracks

connections for fit. Terminal must are found, replace the unit.
be finger tight with no cracks in
isolation material.
Page 539
49-25-93 Aug 5/03
RE100[LJ]
Key Washer Inspection

Figure 517
Page 540
49-25-93 Aug 5/03
RE100[LJ]
Item
120 Key washer Visually examine for burrs, nicks If found, replace the unit.
and scratches.
Page 541
49-25-93 Aug 5/03
RE100[LJ]
Idler Bearing Gearbox Cover Inspection

Figure 518
Page 542
49-25-93 Aug 5/03
RE100[LJ]
Item
40 Idler bearing gearbox cover Visually examine the tube on the If found, replace the unit.
cover for nicks, burrs, scores,
dents, kinks or blockage.
Page 543
49-25-93 Aug 5/03
RE100[LJ]
Combustion Chamber
Page 544
49-25-93 Aug 5/03
RE100[LJ]
Item
30 Combustion chamber Do a fluorescent penetrant If found, replace the unit.

inspection for cracks.
1 Parent material Visually examine for cracks that If found, replace the unit.
join one or more holes. (Refer to
Figure 519, Sheet 1.)
Visually examine for deformation If found, replace the unit.

of the unit.
2 Outer liner Dimensionally examine for Material thickness must not be

decrease in thickness of material less than 0.025 in. (0,635). If
or holes from heat or wear. less than specified, replace the
(Refer to View A) unit.
3 Dome Dimensionally examine for Material thickness must not be

decrease in thickness of material less than 0.015 in. (0,381 mm).
or holes from heat or wear. If less than specified, replace
the unit.
4 Inner liner Dimensionally examine for Material thickness must not be

decrease in thickness of material less than 0.025 in. (0,635). If
or holes from heat or wear. less than specified, replace the
unit.
5 Flange Dimensionally examine for Material thickness must not be

decrease in thickness of material less than 0.015 in. (0.381 mm).
the unit.
6 Ring Dimensionally examine for Material thickness must not be

decrease in thickness of material less than 0.015 in. (0,381 mm).
the unit.
7 Outer liner seam Visually examine for separation If found, replace the unit.
from the parent material
8 Inner liner seam Visually examine for separation If found, replace the unit.
from the parent material
Page 545
49-25-93 Aug 5/03
RE100[LJ]
Combustion Chamber Inspection

Page 546
49-25-93 Nov 11/05
RE100[LJ]
Figure 519. Check Procedures (Cont)
Item
9 Area of the weld Visually examine for cracks in the If found, replace the unit.
weld.
10 Area of the weld Visually examine for cracks in the If found, replace the unit.
weld.
11 Igniter boss Visually examine welds for If found, replace the unit.
separation or cracks. (Refer to
Figure 519, Sheet 2, View B-B)
12 Ferrule Visually examine for cracks or If found, replace the unit.

separation.
13 Retainer Visually examine for cracks or If found, replace the unit.

separation. (Refer to View C-C)
15 Weld area Visually examine for cracks in the If found, replace the unit.
weld.
16 Nozzle boss (Airblast) Visually examine for cracks in the If found, replace the unit.
weld. (Refer to Figure 519, Sheet
2, Detail E.)
17 Weld area Visually examine welds for If found, replace the unit.
separation or cracks.
18 Nozzle boss (Fuel) Visually examine for cracks or If found, replace the unit.
separation. (Refer to View F-F.)
Page 547
49-25-93 Nov 11/05
RE100[LJ]
Chamber Combustion Inspection

Page 548
49-25-93 Aug 5/03
RE100[LJ]
Figure 519. Check Procedures (Cont)
Item
19 Deflector Visually examine for cracks or If found, replace the unit.

separation. (Refer to Figure 519,
Sheet 3, Detail H.)
weld.
21 Deflector Visually examine for cracks or If found, replace the unit.

separation. (Refer to Detail J.)
weld.
Page 549
49-25-93 Aug 5/03
RE100[LJ]
Centrifugal Compressor Rotor Inspection

Figure 520
Page 550
49-25-93 Aug 5/03
RE100[LJ]
Item
260 Centrifugal compressor Measure DIM. A. DIM. A must If measurement is not as

rotor measure 1.4086 to 1.4146 in. specified, replace the unit.
(35,78 to 35,93 mm).
Measure DIM B. for pocket If measurements are not as

depth. Individual depths must specified in either pocket depth
measure 0.249 to 0.261 in. (6,33 measurement, replace the unit.
to 6,63 mm). Average pocket
depth of all measurements must
be 0.252 to 0.258 in. (6,40 to
6,55 mm).
Measure DIM C. for distance If measurements are not as

between individual pockets. specified in either pocket
Individual distances must distance measurement,
measure 0.052 to 0.064 in. (1,32 replace the unit.
to 1,63 mm). Average pocket
distance of all measurements
must be 0.054 to 0.062 in. (1,37
to 1,58 mm).
Measure DIA A. DIA A must If measurement is not as

measure 6.098 to 6.102 in. specified, replace the unit.
(154.89 to 154.99 mm.)
Measure DIA B. DIA B must If measurement is not as

measure 1.5632 to 1.5635 in. specified, replace the unit.
(39,704 to 39,714 mm.)
Page 551
49-25-93 Aug 5/03
RE100[LJ]
Page 552
49-25-93 Aug 5/03
RE100[LJ]
ASSEMBLY
1. Assembly of the Gas Turbine Engine Assembly
A. General
(1) This section includes the procedures necessary to assemble the gas turbine engine
auxiliary power unit (APU).
(1) Table 701 shows the materials and compounds necessary to assemble the APU.
Anti-seize compound Lockrey Co. Inc., P.O. Box 1269,

(Liqui-Moly, NV Thread Compound) 2517 Finlaw Ave.,
Merchantville, NJ 08109
Phone: 856-665-4794
Barrier material (MIL-PRF-131, Type I, Class III) Commercially available
Desiccant (MIL-D-3464, Type I & II) Commercially available
Jointing compound Marston Bentley Ltd.,

(Hylomar PL32L, Type 1; PL32M, Type 2; 9 Naylor St.,
PL32H, Type 3) Liverpool, L3 6DS United Kingdom
Lubricant (Royco HF-825) Anderol Inc.,

P.O. Box 518, 215 Merry Lane,
East Hanover, NJ 07936
Phone: 973-887-7410
pH Neutral paper (MIL-P-130, Type II) Commercially available
(1) Table 702 shows the special tools, fixtures and equipment necessary to assemble the
APU.
Page 701
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Bearing support (Component of Part No. Ground Support Equipment,
834740-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearbox pinion bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 702
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Gearbox idler bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearbox generator bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor rotor removal tool Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

Splined adapter installer and remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 703
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Generator idler position fixture Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor gearshaft driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Driver (Component of Part No. Ground Support Equipment,
5838427-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Support (Component of Part No. Ground Support Equipment,
5838427-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 704
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Rotor pilot ring driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Pilot ring driver (Component of Part No. Ground Support Equipment,
5838428-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

5838428-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor shaft bearing driver and Ground Support Equipment,
support 717 N. Bendix Dr.,
Telephone: 574-231-3987

Cylindrical bearing driver (Component of Ground Support Equipment,
Telephone: 574-231-3987
Page 705
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Compressor gearshaft support Ground Support Equipment,
Telephone: 574-231-3987

Annular bearing driver (Component of Ground Support Equipment,
Telephone: 574-231-3987

Telephone: 574-231-3987

Idler gear bearing driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing driver (Component of Part No. Ground Support Equipment,
5838431-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 706
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Idler gearshaft support (Component of Part Ground Support Equipment,
No. 5838431-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearshaft bearing driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Ball bearing driver (Component of Part No. Ground Support Equipment,
5838432-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Generator gearshaft support (Component Ground Support Equipment,
of Part No. 5838432-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 707
49-25-93 Nov 11/05
RE100[LJ]
Part No.

717 N. Bendix Dr.,
Telephone: 574-231-3987

Turbine rotor run out fixture Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Stretch fixture kit Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Industrial marking ink (Violet 127 ½) The Pannier Corp.,

207 Sandusky St.,
Pittsburgh, PA 15212-5823
Phone: 412-323-4900
www.pannier.com
Page 708
49-25-93 Nov 11/05
RE100[LJ]
D. Check Point Notes
(1) The Check Points in this section are used by Honeywell at/or after critical build
operations. Table 703 shows the Check Points.
Table 703. Check Point Summary
Check Point Operation Page
10 Write the serial number and/or lot number of annular ball 715
bearing (130) to keep as a permanent record of this part.
20 Write the serial number and/or lot number of centrifugal 719

compressor rotor (260) to keep as a permanent record of
this part.
30 Write the serial number and/or lot number of gas turbine 721
engine turbine rotor (200) to keep as a permanent record of
this part.
40 Make a record of the shaft to bearing face measurement 729

before stretch.
50 Verify overall rotor group length before stretch. 729
60 Make a record of the shaft to bearing face measurement 733

after the stretch.
70 Calculate and verify DIM. C. 733
80 Measure and verify gas turbine engine turbine rotor 735

run out.
90 Measure and verify the dimension from the inlet housing 755
to the compressor seal rotor.
100 Verify the actual measurement of trial shims. 761
110 Verify and write the centrifugal compressor rotor tip clearance. 767
120 Verify and write the measurement for the gas turbine 769
engine turbine rotor zero tip clearance.
130 Calculate and write the measurement for the trial turbine 769
nozzle shim dimension.
140 Verify the final turbine rotor tie rod stretch dimension. 779
150 Measure and write the actual measurement for turbine 782
nozzle shims as found for TW1.
Page 709
49-25-93 Aug 5/03
RE100[LJ]
Table 703. Check Point Summary (Cont)
Check Point Operation Page
160 Verify the final gas turbine engine turbine rotor clearance. 787
170 Measure and write the actual turbine rotor run out 789
measurement.
E. General Assembly Instructions
NOTE: The assembly procedures are in order of the illustration first then the text on either
the same page or facing pages where practical. All necessary information is given
so that the unit can be assembled without reference to another part of the manual.
(1) Assembly operations shall be followed with the most careful attention to details as
shown in this manual. Highest standards of precision shop procedures shall be used
throughout the entire reassembly. Keep fits and tolerances as specified.
(2) Exercise extreme care so that dirt, dust or foreign particles can not enter the engine.
If a foreign particle enters the engine during assembly, stop assembly until the foreign
particle is located and removed. Remove all foreign particles even if this causes
considerable disassembly.
(3) To protect the engine, cover large openings with tape and cardboard; small openings
with tape or a clean cloth. Cap open tube ends. Use only caps or similar coverings
on fuel system components, not tape. If the unit is to be left in a partially
disassembled state, even for a short period, cover all openings.
(4) If parts were coated with corrosion-preventive compound, remove all traces of this
compound and all accumulated foreign matter. Clean all parts thoroughly before
assembly. Wipe all parts and surfaces with a clean, lint-free cloth.
(5) When special measurements to shim or fit are made on parts or on assembled parts
prior to installation in the next higher assembly, tag these parts as measured
components of the higher assembly and keep with that assembly. If damage or other
reason causes replacement of a measured component, repeat all measurements on
and use the new component.
(6) When bolts, studs, nuts, or screws are assembled, coat all threaded surfaces forward
of aft end of inlet plenum with lubricating compound (Liqui-Moly, Grade N\/), or aft of
inlet plenum with high temperature compound (Fel-Pro C5-A) unless otherwise
specified. When splines or gear teeth are to be mated, coat surfaces with oil (MIL-
PRF-7808 or MIL-PRF-23699).
(7) When laminated shims are used, use a new shim and peel off laminations for required
thickness. Old shims may be used if the required shim thickness is the same or is to
be reduced and laminations can be peeled off without damage to the shims.
Page 710
49-25-93 Aug 5/03
RE100[LJ]
(8) Use only the required force to assemble the unit. If an assembly is difficult,
disassemble the unit and inspect for burrs or other interference.
(9) To install packings, use a lubricant compatible with the system in which the packing is
located (i.e. packings used in the oil system are to be coated with oil MIL-PRF-7808 or
MIL-PRF-23699). One more approved method is to use lubricant (OS-124 or
Santovac 5) on all packings prior to installation.
(10) Duplicate lockwiring as seen during disassembly.
F. Safety Fastening Methods
(1) Attached parts may be locked with various methods as applicable to the part. These
methods include use of self-locking nuts, use of cotter pins and use of lockwire.
Follow these general instructions to install locking devices.
(2) Duplicate the method to lock parts as seen in disassembly.
NOTE: To “run-down” a self-locking nut, note the run-down resistance (frictional

torque) of the last rotation just before clearance is removed between parts.
The self-locking nut then shall be tightened to the specified torque value
plus the noted frictional torque.
(3) Install self-locking nuts and use standard shop procedures for that nut type.
Page 711
49-25-93 Aug 5/03
RE100[LJ]
Life Limited Part Card

Figure 701
Page 712
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 701
1. LIFE LIMITED PART CARD 7. ENGINE SERIAL NUMBER

2. PART NUMBER 8. AIRCRAFT SERIAL NUMBER
3. PART NAME 9. TIME ON PART THIS INSTALLATION
4. SERIAL NUMBER 10. TOTAL TIME ON PART
5. ASSY PART NUMBER 11. REMARKS
6. DATE INSTALLED 12. LIFE LIMITED PART REPAIR RECORD
2. Permanent Record Documentation
A. Before assembly of the gas turbine engine, make a permanent record of the specified gas
turbine engine part identification numbers as follows. (Refer to Figure 701.)
(1) Check Points 10, 20 and 30 give each component that requires a permanent record.
(a) As an example, use Life Limited Part Card (1) to write the Part Number (2) of
the component.
(b) Write in Part Number (2) as shown on the part.
(c) Write in Part Name (3) as shown from the illustrated parts catalog (IPC) for
the part.
(d) Write in Serial Number (4) as shown on the part.
(e) Write in Assy Part Number (5) as shown on the nameplate for the APU.
(f) Write in the actual date of installation in Date Installed (6).
(g) Write in Engine Serial Number (7) as shown on the nameplate for the APU.
(h) If known, write in data for Aircraft Serial Number (8).
(i) If known, write in Time On Part This Installation (9).
(j) If known, write in Total Time On Part (10).
(k) Write in applicable information in Remarks (11).
(l) If known, write in Life Limited Part Repair Record (12) information, as
applicable.
(2) If Life Limited Part Card (1) is not available, as a minimum, write the part number,
serial number, part name, engine serial number and date installed in the engine log
book.
Page 713
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Bearings to the Compressor Gearshaft

Figure 702
Page 714
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 702
110. COMPRESSOR GEARSHAFT 130. ANNULAR BALL BEARING

ASSEMBLY (IPC, SECTION 49-20- 140. HSP GEAR
00 FIG. 9) 150. CYLINDRICAL ROLLER BEARING
3. Gas Turbine Engine Power Section
A. Assemble the compressor gearshaft assembly
Check Point 10: Write the serial number and/or lot number of annular ball bearing
(130) to keep as a permanent record of this part.
WARNING: USE THE CORRECT PERSONAL PROTECTION. HEATED PARTS WILL

CAUSE BURNS.
(1) Heat HSP gear (140) in an oven at 350ºF (177ºC) for 10 minutes.
WARNING: USE CORRECT PERSONAL PROTECTION WHEN HANDLING LIQUID

NITROGEN AND PARTS COOLED BY LIQUID NITROGEN.
(2) Chill compressor gearshaft assembly (110) in liquid nitrogen for 1.5 to 2 minutes.
Time chilling to coincide with removal of HSP gear (140) from oven.
(3) Install 5838427-3 support to compressor gearshaft (110) and put the assembly on a
flat surface below an arbor press. (Refer to Figure 702, Detail A.).
(4) Install HSP gear (140) to compressor gearshaft (110) and with 5838427-2 driver and
an arbor press, push the HSP gear on to the flange of the compressor gearshaft.
Remove the driver.

CAUSE BURNS.
(5) Heat annular ball bearing (130) in an oven at 350ºF (177ºC) for 10 minutes.
(6) Install annular ball bearing (130) to compressor gearshaft (110). (Refer to Detail B.)
Page 715
49-25-93 Nov 11/05
RE100[LJ]
(7) With 5838430-2 annular bearing driver and an arbor press, push annular ball bearing
(130) on to the flange of the compressor gearshaft (110).
(8) Remove the outer race of cylindrical roller bearing (150) and set aside for installation
later. Heat inner race of cylindrical roller bearing (150) in an oven at 350ºF (177ºC)
for 10 minutes.
(9) Remove 5838430-3 compressor gearshaft support from gearshaft assembly (110).
(10) Rotate and install compressor gearshaft (110) to 5838429-3 compressor gearshaft
support. (Refer to Detail C.).
(11) Install the inner race of cylindrical roller bearing (150) to compressor gearshaft (110)
and with 5838429-2 cylindrical bearing driver and an arbor press, push the inner race
on to the flange of the compressor gearshaft.
Page 716
49-25-93 Aug 5/03
RE100[LJ]
Page 717
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Pilot Rings on the Centrifugal Compressor Rotor

Figure 703
Page 718
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 703
240. OUTER PILOT RING (IPC, SECTION 260. CENTRIFUGAL COMPRESSOR

49-20-00, FIG. 6) ROTOR
250. INNER PILOT RING
B. Inner and Outer Pilot Ring Assembly (Refer to Figure 703.)
Check Point 20: Write the serial number and/or lot number of centrifugal
compressor rotor (260) to keep as a permanent record of this
part.

CAUSE BURNS.
(1) Heat inner pilot ring (250) in 400ºF (202ºC) oven for 5 minutes.
WARNING: USE THE CORRECT PERSONAL PROTECTION. DRY ICE WILL CAUSE
BURNS. CARBON DIOXIDE REMOVES OXYGEN FROM THE AIR. THIS
CAN CAUSE ASPHYXIATION.
(2) Chill centrifugal compressor rotor (260) in dry ice for 10 minutes.
(3) Install 5838428-3 support to centrifugal compressor rotor (260). Put the assembly on
a flat surface below an arbor press.
(4) Put inner pilot ring (250) around the flange of centrifugal compressor rotor (260).
(Refer to Figure 703, Detail A.)
(5) Use 5838428-2 pilot ring driver and an arbor press to push inner pilot ring (250) on to
centrifugal compressor rotor (260). (Refer to Detail B.) Remove the driver and
support.
(6) Either side of inner pilot ring (250) can be installed to the flange of centrifugal
compressor rotor (260).
(7) Inner pilot ring (250) must make a smooth surface with the flange of centrifugal
compressor rotor (260). If not, remove the pilot ring, reheat for 10 minutes and install
again. (Refer to DISASSEMBLY for removal of the pilot ring.)
(8) Install outer pilot ring (240) (cavity side up) to inner pilot ring (250). (Refer to Detail C
and D.)
Page 719
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Turbine Rotor Tie Rod and Gas Turbine Engine Turbine Rotor
Figure 704
Page 720
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 704
1. SPARE NUT (0.375-24UNJF-3B) 200. GAS TURBINE ENGINE TURBINE

180. TIE SHAFT NUT (IPC, SECTION ROTOR
49-20-00, FIG. 6) 210. TURBINE ROTOR TIE ROD
C. Turbine Rotor Tie Rod and Gas Turbine Engine Turbine Rotor Assembly
Check Point 30: Write the serial number and/or lot number of gas turbine engine
turbine rotor (200) to keep as a permanent record of this part.
CAUTION: TURBINE ROTOR TIE ROD (210) THREADS MUST CORRECTLY ENGAGE
WITH GAS TURBINE ENGINE TURBINE ROTOR (200) THREADS TO
PREVENT THREAD DAMAGE.
(1) Carefully install turbine rotor tie rod (210) to gas turbine engine turbine rotor (200).
(2) Install tie shaft nut (180) and a spare nut (1) to turbine rotor tie rod (210).
(3) Use a calibrated torque wrench and socket and tighten tie shaft nut (180) to 50 inch-
pound (5,68 Nm).
(4) Remove the spare nut (1) and tie shaft nut (180).
(5) Put turbine rotor tie rod (210) and gas turbine engine turbine rotor (200) assembly to
the side.
Page 721
49-25-93 Aug 5/03
RE100[LJ]
Stretch and Balance Group Assembly

Figure 705
Page 722
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 705
40. COMPRESSOR SEAL ROTOR (IPC, 140. HSP GEAR

SECTION 49-20-00 FIG. 8) 150. CYLINDRICAL ROLLER BEARING
110. COMPRESSOR GEARSHAFT 260. CENTRIFUGAL COMPRESSOR
ASSEMBLY (FIG. 9) ROTOR (FIG. 6)
130. ANNULAR BALL BEARING
D. Stretch the Rotor Group Assembly
(1) Install the outer race (tapered end first) of cylindrical roller bearing (150) over the
bearing and allow it to rest on annular ball bearing (130). (Refer to Figure 705, Detail
A.)
(2) Install compressor seal rotor (40) to the compressor gearshaft assembly (110) and
cylindrical roller bearing (150).
(3) Install centrifugal compressor rotor (260) to the compressor gearshaft assembly.
(4) Carefully rotate and install the entire assembly on to 5838427-3 support. (Refer to
Detail C.)
(5) Put the outer race of cylindrical roller bearing (150) in the center of centrifugal
compressor rotor (260).
(6) Put the assembly on a flat surface below an arbor press and with 5838429-2
cylindrical bearing driver push the compressor gearshaft assembly on to centrifugal
compressor rotor (260). (Refer to Detail D.) Set the assembly aside.
Page 723
49-25-93 Aug 5/03
RE100[LJ]
Stretch Fixture Assembly

Figure 706
Page 724
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 706
1. STRETCH FIXTURE (PN 834740-1) 130. ANNULAR BALL BEARING

2. BEARING SUPPORT (PN 5838404-2) 140. HSP GEAR
(COMPONENT OF PN 834740-1) 180. TIE SHAFT NUT (IPC, FIG. 6)
3. SOCKET (PN 5838404-3) 200. GAS TURBINE ENGINE TURBINE
(COMPONENT OF PN 834740-1) ROTOR
4. BAR (PN 5838404-4) 210. TURBINE ROTOR TIE ROD
(COMPONENT OF PN 834740-1) 240. OUTER PILOT RING
5. NUT (PN 5838404-5) 260. CENTRIFUGAL COMPRESSOR
(COMPONENT OF PN 834740-1) ROTOR
110. COMPRESSOR GEARSHAFT
ASSEMBLY (IPC, SECTION 49-20-00
FIG. 9)
(7) Place outer pilot ring (240), with cavity side down, over the turbine rotor tie rod (210)
and around the center of gas turbine engine turbine rotor (200). (Refer to Figure 706.)
CAUTION: INSTALL CENTRIFUGAL COMPRESSOR ROTOR AND THE ATTACHED

ASSEMBLIES AS SPECIFIED. IF YOU DO NOT, YOU CAN CAUSE
DAMAGE TO EQUIPMENT.
(8) Install centrifugal compressor rotor (260) and compressor gearshaft assemblies on
the center of outer pilot ring (240) and gas turbine engine turbine rotor assembly
(200).
(9) Install tie shaft nut (180) to gas turbine engine turbine rotor (200). Tighten nut to hand
tight.
WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. INCREASE AND
DECREASE PRESSURE SLOWLY AND THREAD TOOL ON THE CENTER
OF THE SHAFT.
(10) Assemble 834740-1 stretch fixture (1) as follows.
(a) Install 5838404-2 bearing support (2) on annular ball bearing (130) inner race.
(b) Install 5838404-4 bar (4) and 5838404-3 socket (3) then tighten 5838404-4
(c) Engage 5838404-3 socket (3) with tie shaft nut (180). Tighten 5838404-4 bar
(d) Assemble stretch fixture (1) pressure gage to 5838404-2 bearing support (2).
Page 725
49-25-93 Aug 5/03
RE100[LJ]
(11) Increase ram pressure to 1000 psig (6900 kPa).
(12) Tighten 5838404-5 nut (5) and 5838404-3 socket (3) to hand tight.
(13) Slowly release all ram pressure.
(14) Remove 834740-1 stretch fixture as follows.
(a) Remove stretch fixture (1) pressure gage.
(b) Remove 5838404-5 nut (5), 5838404-4 bar (4), 5838404-3 socket (3) and
(15) Put the rotor group on a flat surface.
Page 726
49-25-93 Aug 5/03
RE100[LJ]
Page 727
49-25-93 Aug 5/03
RE100[LJ]
Rotor Group DIM. A Stretch Dimension

Figure 707
Page 728
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 707
1. MARK 150. CYLINDRICAL ROLLER BEARING

2. MARK 180. TIE SHAFT NUT (IPC, FIG. 6)
110. COMPRESSOR GEARSHAFT 200. GAS TURBINE ENGINE
(IPC, SECTION 49-20-00 TURBINE ROTOR
FIG. 9) 210. TURBINE ROTOR TIE ROD
130. ANNULAR BALL BEARING 260. CENTRIFUGAL COMPRESSOR ROTOR
140. HSP GEAR
(16) Make a mark (1) with industrial marking ink (Violet, No. 127 ½ ) on the end of turbine
rotor tie rod (210). (Refer to Figure 707, Detail A.)
(17) Make one more mark (2) on the inner race of annular ball bearing (130) that aligns
with mark (1)
Check Point 40: Make a record of the shaft to bearing face measurement
before stretch.
(a) Measure the distance from mark (1) to mark (2).
(b) Write this measurement as: shaft to bearing face before stretch.
Shaft to Bearing Face Before Stretch inch (mm)
Check Point 50: Verify overall rotor group length before stretch.
(18) Measure from mark (1) to the surface where gas turbine engine turbine rotor (200)
touches. Write this measurement as DIM. A.
Dimension A inch (mm)
OF THE SHAFT.
(19) Assemble 834740-1 stretch fixture as follows. (Refer to Figure 706.)
Page 729
49-25-93 Aug 5/03
RE100[LJ]
(20) Increase ram pressure to 1000 psig (6900 kPa) and tighten tie shaft nut (180) with
5838404-3 socket (3). Tighten 5838404-3 socket (3) and 5838404-5 nut (5) to hand
tight.
tight.
tight.
Page 730
49-25-93 Aug 5/03
RE100[LJ]
Page 731
49-25-93 Aug 5/03
RE100[LJ]
Rotor Group DIM. B Stretch Dimension

Figure 708
Page 732
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 708
1. MARK 140. HSP GEAR

2. MARK 150. CYLINDRICAL ROLLER BEARING
110. COMPRESSOR GEARSHAFT 180. TIE SHAFT NUT (IPC, FIG. 6)
ASSEMBLY (IPC, SECTION 49-20-00 200. GAS TURBINE ENGINE TURBINE ROTOR
FIG. 9) 210. TURBINE ROTOR TIE ROD
Check Point 60: Make a record of the shaft to bearing face measurement after the stretch.
(27) Find the distance between turbine rotor tie rod (210) and annular ball bearing (130) as
follows. (Refer to Figure 708 Detail A.)
(a) Measure the distance from mark (1) to mark (2).
(b) Write this measurement as: shaft to bearing face after stretch.
Shaft to Bearing Face After Stretch inch (mm)
(28) Measure from mark (1) to the surface where gas turbine engine turbine rotor (200)
touches. Write this measurement as DIM. B.
Check Point 70: Calculate and verify DIM. C.
(29) Find DIM. C (or the overall group stretch) as follows.
Dimension B inch (mm) (from Step 3.D.(28))

Dimension A - inch (mm) (from step 3.D.(18))
Dimension C = inch (mm)
NOTE: DIM. C must be 0.026 to 0.027 inches (0.66 to 0.69 mm).
(30) If DIM. C is not as specified, stretch the group assembly again to loosen the rotor
assembly. Do the stretch procedures again to find DIM. A and DIM. B until DIM. C is
as specified.
(31) When DIM. C is reached, use 5838466-1 turbine rotor run out fixture to lock annular
ball bearing (130) in place and support the group assembly for the run out
measurement.
Page 733
49-25-93 Aug 5/03
RE100[LJ]
Turbine Rotor Run Out Measurement

Figure 709
Page 734
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 709
110. COMPRESSOR GEARSHAFT 150. CYLINDRICAL ROLLER BEARING

ASSEMBLY (IPC, SECTION 49-20- (IPC, FIG. 9)
00 FIG. 9) 180. TIE SHAFT NUT (IPC, FIG. 6)
130. ANNULAR BALL BEARING 200. GAS TURBINE ENGINE TURBINE ROTOR
140. HSP GEAR (IPC, FIG. 6) 260. CENTRIFUGAL COMPRESSOR ROTOR
(32) Place the stylus of the tool on the hub of the gas turbine engine turbine rotor. (Refer
to Figure 709, Detail A.)
Check Point 80: Measure and verify gas turbine engine turbine rotor run out.
(33) Turn the rotor group by hand and measure the run out of the gas turbine engine
turbine rotor (200). Write this measurement as turbine rotor run out DIM. E.
NOTE: If DIM. E measures greater than 0.002 inch (0,051 mm) stretch the group
assembly again to loosen the rotor assembly. Do the stretch procedure
again to find DIM. C and do the run out procedure again until DIM. E is as
specified.
Dimension E inch (mm) (from Step (33))
Page 735
49-25-93 Aug 5/03
RE100[LJ]
Rotor Alignment Marks after Final Run-out Measurement

Figure 710
Page 736
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 710
40. COMPRESSOR SEAL ROTOR 150. CYLINDRICAL ROLLER BEARING

(IPC, SECTION 49-20-00 FIG. 8) 200. GAS TURBINE ENGINE
110. COMPRESSOR GEARSHAFT TURBINE ROTOR (IPC, FIG. 6)
ASSEMBLY (IPC, FIG. 9) 210. TIE SHAFT NUT
(34) Make reference (radial) marks on the rotor group in seven places. (Refer to Figure
710.)
(a) Make a radial mark with industrial marking ink (Violet, No. 127 ½) on
compressor gearshaft (110) that aligns with radial marks on tie shaft nut (210)
and annular ball bearing (130).
(b) Make radial marks with industrial marking ink (Violet, No. 127 ½) on the inside
race of cylindrical roller bearing (150), compressor seal rotor (40), centrifugal
compressor rotor (260) and gas turbine engine turbine rotor (200).
(35) All radial marks must align with each other after all stretch and balance
measurements are as specified. If not, the rotor group assembly will not rotate
correctly during engine operation.
(36) If all radial marks are not aligned as specified, disassemble the components and do
the stretch and balance procedure again. (Steps 3.D.(1) through (34))
(37) Remove the rotor group assembly from 5838466-1 turbine rotor run out fixture.
Disassemble the rotor group assembly.
Page 737
49-25-93 Aug 5/03
RE100[LJ]
Centrifugal Compressor Rotor Removal

Figure 711
Page 738
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 711
1. COMPRESSOR ROTOR REMOVAL 260. CENTRIFUGAL COMPRESSOR ROTOR

TOOL (PN 5838410-1) (IPC, SECTION 49-20-00 FIG. 6.)
E. Rotor Group Disassembly
OF THE SHAFT.
(1) Assemble 834740-1 stretch fixture (1) as follows.
(2) Increase ram pressure to 2900 psig (20010 kPa). Tighten 5838404-5 nut (5) to hand
tight.
(3) Loosen 5838404-3 socket (3) three full turns and then tighten one full turn.
(5) Remove 834740-1 stretch fixture (1) as follows.
(6) Remove tie shaft nut (180) from turbine rotor tie rod (210).
(7) Remove gas turbine engine turbine rotor (200) and turbine rotor tie rod (210) from the
rotor group assembly.
(8) Use 5838410-1 compressor rotor removal tool (1) to remove centrifugal compressor
rotor (260) from compressor gearshaft assembly (110). (Refer to Figure 711, Detail A
and B.)
Page 739
49-25-93 Aug 5/03
RE100[LJ]
Generator Gearshaft Splined Adapter Assembly

Figure 712
Page 740
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 712
50. GENERATOR GEARSHAFT 120. KEY WASHER

ASSEMBLY (IPC, SECTION 130. SPLINE KEY SNAP RING
49-20-00 FIG. 9)
110. SPLINED ADAPTER (IPC,
SECTION 49-00-00 FIG. 2)
F. APU Splined Adapter Assembly
(1) Install key washer (120) in splined adapter (110). (Refer to Figure 712, Detail A.)
(2) Install spline key snap ring (130) in the groove of splined adapter (110).
(3) Turn the assembled splined adapter over and install in generator gearshaft assembly
(50). (Refer to Detail B.)
(4) Use 5838419-1 spline adapter installation and removal tool and press spline key snap
ring (130), key washer (120) and splined adapter assembly in generator gearshaft
assembly (50).
(5) Install the splined adapter assembly far enough into the generator gearshaft assembly
so the groove of generator gearshaft assembly (50) can be seen.
Page 741
49-25-93 Nov 11/05
RE100[LJ]
Generator Gearshaft Bearings and Rotor Seal Assembly

Figure 713
Page 742
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 713
50. GENERATOR GEARSHAFT ASSEMBLY 80. SEAL ROTOR

(IPC, SECTION 49-20-00 FIG. 9) 90. ANNULAR BALL BEARING
60. ROUND PLAIN NUT 100. ANNULAR BALL BEARING
70. NUT LOCKING KEY
G. Generator Gearshaft Bearings and Seal Rotor Assembly

CAUSE BURNS.
(1) Heat annular ball bearing (100) in oven at 350ºF (177ºC) for 10 minutes.
(2) Install generator gearshaft assembly (50) to 5838432-3 generator gearshaft support.
(3) With bearing-race mark up, install annular ball bearing (100) to the generator
gearshaft assembly (50).
(4) Use 5838432-2 gearshaft bearing driver and arbor press and press annular ball
bearing (100) to the flange of generator gearshaft assembly (50). (Refer to Detail B.)

CAUSE BURNS.
(6) Remove generator gearshaft assembly (50) from 5838432-3 generator gearshaft
support. Turn and install the other end of the generator gearshaft assembly on to
5838432-3 generator gearshaft support. (Refer to Detail C.)
(7) Install annular ball bearing (90) to generator gearshaft assembly (50).
(8) Use 5838432-2 gearshaft bearing driver and arbor press and install annular ball
bearing (90) to the flange of generator gearshaft assembly (50). (Refer to Detail D.)
(9) Install seal rotor (80) with flat side up to annular ball bearing (90). (Refer to Detail E.)
Page 743
49-25-93 Aug 5/03
RE100[LJ]
(10) Install nut locking key (70) and round plain nut (60) on generator gearshaft assembly
(50) as follows.
(a) Apply anti-seize compound (Liqui Moly) to the threads of round plain nut (60)
and install to generator gearshaft assembly (50).
(b) Install nut locking key (70) with the “T” in the channel of generator gearshaft
assembly (50).
(c) Tighten round plain nut (60) 300 to 325 inch-pound (33,9 to 36,7 Nm).
(d) Loosen round plain nut (60) and tighten again to at least 300 inch-pound (33,9
Nm) until nut locking key (70) and a channel in the round plain nut (60) are
aligned. (Refer to Detail F.)
(e) Use pliers to bend nut locking key (70) away from channel of round plain nut
(60).
CAUTION: ROTATIONAL RUB FROM NUT LOCKING KEY (70) CAN CAUSE
DAMAGE TO EQUIPMENT.
(f) Use a metal file and grind nut locking key (70) flat with the outside diameter of
round plain nut (60).
Page 744
49-25-93 Aug 5/03
RE100[LJ]
Page 745
49-25-93 Aug 5/03
RE100[LJ]
Idler Gearshaft Bearing Assembly

Figure 714
Page 746
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 714
10. IDLER GEARSHAFT (IPC, SECTION 40. ANNULAR BALL BEARING

49-20-00, FIG. 9)
H. Idler Gearshaft Bearing Assembly

CAUSE BURNS.
(2) Install idler gearshaft (10) to 5838431-3 idler gearshaft support. (Refer to Figure 714,
Detail A.)
(3) Point annular ball bearing (30) part number away from the gear and install to idler
gearshaft (10).
(4) Use 583843-2 idler ball bearing driver and an arbor press and press annular ball
bearing (30) to the flange on idler gearshaft (10). (Refer to Detail B.)

CAUSE BURNS.
(6) Remove idler gearshaft (10) from 5838431-3 idler gearshaft support. Turn and install
the other end of idler gearshaft (10) to 5838431-3 idler gearshaft support. (Refer to
Detail C.)
(7) Point annular ball bearing (40) part number away from the gear and install to idler
gearshaft (10).
(8) Use 5838431-2 idler ball bearing driver and arbor press and press annular ball
bearing (40) to the flange of idler gearshaft (10). (Refer to Detail D.)
Page 747
49-25-93 Aug 5/03
RE100[LJ]
Gears and Gearbox Assembly

Figure 715
Page 748
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 715
1. GEARBOX PINION BEARING RETAINER 5. IDLER GEARSHAFT RETAINER

(PN 5838406-1) (PN 5838407-1)
2. RETAINER BOLT 6. RETAINER BOLT
3. GENERATOR BEARING RETAINER 110. COMPRESSION SPRING WASHER
(PN 5838408-1) (IPC, SECTION 49-20-00 FIG. 9 ITEM 120)
4. RETAINER BOLT
I. Gears and Gearbox Assembly
(1) Install compression spring washer (110) and compressor gearshaft assembly into the
forward end of the gearbox housing. (Refer to Figure 715.)
(2) Attach the assembly with 5838406-1 gearbox pinion bearing retainer (1) and retainer
bolts (2). Tighten retainer bolts (2) to 60 inch-pound (6,78 Nm).
(3) Install the generator gearshaft assembly into the aft end of the gearbox housing.
(4) Carefully mesh the splines of generator gearshaft assembly with the HSP gear
splines.
(5) Attach the generator gearshaft assembly to the gearbox housing with 5838408-1
generator bearing retainer (3) and retainer bolts (4). Tighten retainer bolts (4) to 60
inch-pound (6,78 Nm).
(6) Install the idler gearshaft assembly into the aft end of the gearbox housing.
(7) Carefully mesh the splines of the idler gearshaft with the HSP gear splines.
(8) Attach the idler gearshaft assembly to the gearbox housing with 5838407-1 idler
gearshaft retainer (5) and bolts (6). Tighten retainer bolts (6) to 60 inch-pound (6,78
Nm).
(9) Place the gearbox housing assembly on a flat surface, forward side down.
Page 749
49-25-93 Aug 5/03
RE100[LJ]
Inlet Housing Assembly

Figure 716
Page 750
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 716
20. SPRING WASHER (IPC, 140. INLET HOUSING (IPC, FIG. 10, ITEM 140A)
SECTION 49-20-00 FIG. 9) 150. CYLINDRICAL ROLLER BEARING
70. PACKING (IPC, FIG. 8) (IPC, FIG. 9)
80. PACKING 160. MATCHED GEARBOX HOUSING
90. PIN (IPC, FIG.10) ASSEMBLY (IPC, FIG. 10, ITEM 150)
110. COMPRESSOR GEARSHAFT
ASSEMBLY (IPC, FIG. 9)
J. Inlet Housing Assembly
(1) Lubricate packing (80) with grease and install in inlet housing (140). (Refer to Figure
716, Detail A.)
(2) Lubricate packing (70) with grease and install in inlet housing (140).
(3) Lubricate spring washer (20) with grease and install in inlet housing (140).
(4) Lubricate the outer race of bearing (150) with grease and install, bevel edge first, in
inlet housing (140).
(5) Heavily lubricate the roller bearings of cylindrical roller bearing (150) with assembly
grease.
(6) By hand, compress the roller bearings so the grease holds them in place.
NOTE: All roller bearings must stay compressed to install inlet housing assembly
(140) and outer race of cylindrical roller bearing (150). (Refer to Detail B.)
(7) Match the guide pin hole on inlet housing (140) with pin (90) in gearbox housing (160).
(8) Align outer race grooves on generator gearshaft assembly bearings with pins (90) in
inlet housing (140).
(9) Carefully install inlet housing (140) and outer race of bearing to cylindrical roller
bearing (150).
NOTE: Slight hand pressure may be necessary to install inlet housing (140) guide
pin hole on to pin (90).
If extreme pressure is used and inlet housing (140) does not install as
specified, remove inlet housing (140) and examine the roller bearings and
outer race of cylindrical roller bearing (150).
Page 751
49-25-93 Nov 11/05
RE100[LJ]
(10) If the roller bearings are not compressed, apply more assembly grease to the rollers.
(11) Repeat the installation of inlet housing (140) to gearbox housing (160) until inlet
housing (140) and gearbox housing (160) make a continuous surface.
(12) Attach inlet housing (140) to gearbox housing (160) with three equally spaced retainer
bolts.
Page 752
49-25-93 Aug 5/03
RE100[LJ]
Page 753
49-25-93 Aug 5/03
RE100[LJ]
Compressor Seal Rotor Assembly and Measurement

Figure 717
Page 754
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 717
40. COMPRESSOR SEAL ROTOR (IPC, 60. PACKING

SECTION 49-20-00 FIG. 8) 140. INLET HOUSING (IPC, FIG. 10, ITEM 140A)
50. OIL JET BEARING SPACER
K. Compressor Seal Rotor Assembly and Measurement.
(1) Lubricate new packing (60) with grease and install in inlet housing (140). (Refer to
Figure 717, Detail A)
(2) Install oil jet bearing spacer (50) in inlet housing (140).
(3) Install compressor seal rotor (40) in inlet housing (140). (Refer to Detail B.)
Check Point 90: Measure and verify the dimension from the inlet housing to the
compressor seal rotor.
(4) Measure from the top of inlet housing (140) to compressor seal rotor (40) and write as
DIM. G. (Refer to Detail C.)
Dimension G inch (mm)
(5) DIM. G must measure 0.559 to 0.573 inch (14,199 to 14,554 mm).
Page 755
49-25-93 Nov 11/05
RE100[LJ]
Encased Plain Seal Assembly

Figure 718
Page 756
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 718
10. ENCASED PLAIN SEAL ASSEMBLY 30. COMPRESSION SPRING WASHER

(IPC, SECTION 49-20-00 FIG. 8) 140. INLET HOUSING (IPC, FIG. 10, ITEM 140A)
20. PACKING
L. Encased Plain Seal Assembly
(1) Install compression spring washer (30) in inlet housing (140).
(2) Lubricate a new packing (20) with grease and install on encased plain seal assembly
(10).
CAUTION: MAKE SURE THREADS ARE CORRECTLY ENGAGED BEFORE TORQUE

IS APPLIED. PARTS CAN BE DAMAGED DUE TO INCORRECTLY
ENGAGED THREADS.
(3) Apply anti-seize compound (Liqui Moly) only to the threads of encased plain seal
assembly (10). (Refer to Figure 718, Detail A.)
(4) Install encased plain seal assembly (10) to inlet housing (140).
(5) Use 5838433-1 seal assembly wrench and tighten encased plain seal assembly (10)
to 60 inch-pound (6,78 Nm). (Refer to Detail B.)
(6) Encased plain seal assembly (10) must make a smooth surface with inlet housing
(140). If not, remove encased plain seal assembly (10) and install as specified.
(7) Seal encased plain seal assembly (10) as follows.
(a) With a hammer and punch, hit the outer edge of encased plain seal assembly
(10).
(b) Make a break in the outer edge of the seal assembly in one of the grooves on
inlet housing (140). (Refer to Detail C.)
(c) Repeat (a) and (b) in at least two of the four channels on inlet housing (140).
(d) Outer edge of encased seal assembly (10) must be as specified. If not,
repeat Step (6) until as specified.
Page 757
49-25-93 Nov 11/05
RE100[LJ]
Compressor Inlet Duct Assembly

Figure 719
Page 758
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 719
10. BOLTS (IPC, SECTION 49-20-00 FIG. 7) 150. MATCHED SET GEARBOX HOUSING
20. INLET BAFFLE ASSEMBLY (IPC, FIG. 10)
40. BOLT (IPC, FIG. 6) 290. PERFORATED COMPRESSOR INLET
50. WASHER (IPC, FIG. 6)
60. BOLT 300. COMPRESSOR INLET DUCT
70. WASHER
M. Compressor Inlet Duct Assembly
(1) Install inlet baffle (20) in compressor inlet duct (300). (Refer to Figure 719, Detail A.)
(2) Install bolts (10) to compressor inlet duct (300) and inlet baffle (20). Tighten bolt (10)
to 60 inch-pound (6,78 Nm).
(3) Remove the retainer bolts from the matched set gearbox assembly.
(4) Align bolt holes and make sure compressor inlet duct (300) drain is at 6 o’clock
position with the gearbox. Install compressor inlet duct (300).
(5) Align holes of perforated compressor inlet (290) and install to compressor inlet duct
(300) and attach with bolt (40) and washer (50). (Refer to Detail B.)
(6) Install bolt (40), washer (50), bolt (60) and washer (70). (Refer to Detail C.)
(7) Tighten all bolts to 120 inch-pound (13,56 Nm).
Page 759
49-25-93 Nov 11/05
RE100[LJ]
Assembly of the Engine Compressor Housing and Shim Assembly

Figure 720
Page 760
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 720
160. MATCHED GEARBOX HOUSING 280. TURBINE COMPRESSOR ROTOR SHIM

ASSEMBLY (IPC, SECTION 49-20-00 300. ENGINE COMPRESSOR INLET DUCT
(FIG. 10 ITEM 150)
270. ENGINE COMPRESSOR HOUSING
ASSEMBLY (IPC, SECTION 49-20-00
FIG. 6)
N. Centrifugal Compressor Rotor and Gas Turbine Engine Turbine Rotor Tip Clearances
(1) Assemble engine compressor housing (270) and turbine compressor rotor shim (280)
as follows.
(a) Use a precision measuring tool and find the thickness of turbine compressor
rotor shim (280).
(b) The thickness must be from 0.0155 to 0.0165 inch (0,394 to 0,419 mm). If
not, use turbine compressor rotor shim (280) that is the thickness as
specified.
(c) Use a maximum of three turbine compressor rotor shims (280) that measures
a thickness of 0.0465 to 0.0495 inch (1,181 to 1,257 mm).
NOTE: Greater shim thickness decreases centrifugal compressor rotor tip

clearance.
Check Point 100: Verify the actual measurement of trial shims.
(d) Write the actual total thickness of turbine compressor rotor shims (280) as
DIM. H.
Dimension H inch (mm) (Step 3.N.(1)(d))
(e) Install turbine compressor rotor shims (280) to compressor inlet duct (300).
(f) Install engine compressor housing assembly (270).
(g) Install three retainer bolts and washers equally spaced to engine compressor
housing assembly (270), turbine compressor rotor shims (280) and
compressor inlet duct (300).
(h) Tighten the retainer bolts to 60 inch-pound (6,78 Nm).
Page 761
49-25-93 Aug 5/03
RE100[LJ]
Assembly for the Compressor Rotor Tip Clearance Measurement

Figure 721
Page 762
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 721
1. RETAINER BOLT 110. COMPRESSOR GEARSHAFT ASSEMBLY

2. GEARBOX PINION BEARING (IPC, SECTION 49-20-00 FIG. 9)
RETAINER (PN 5838406-1) 160. MATCHED GEARBOX HOUSING
3. GENERATOR IDLER POSITION ASSEMBLY (IPC, FIG. 10, ITEM 150)
FIXTURE (PN 5838420-1) 180. TIE SHAFT NUT (IPC, FIG. 6)
4. TIE SHAFT SIMULATOR 240. OUTER PILOT RING
(PN 5838409-1) 260. CENTRIFUGAL COMPRESSOR ROTOR
5. STRETCH FIXTURE 300. COMPRESSOR INLET DUCT
(PN 834740-1)
(2) Install the centrifugal compressor rotor and tie shaft simulator.
(a) Remove the retainer bolts (1) and 5838406-1 gearbox pinion bearing retainer
(2) from matched gearbox housing assembly (160). (Refer to Figure 721.)
(b) Replace 5838406-1 gearbox pinion bearing retainer (2) with 5838420-1
generator idler position fixture (3). Attach 5838420-1 generator idler position
fixture (3) with retainer bolts (1) to the gearbox housing.
(c) Install 5838409-1 tie shaft simulator (4) to outer pilot ring (240).
(d) Install tie shaft nut (180) to tie shaft simulator (4) and tighten by hand.
(e) Align all reference (radial) marks before installation of 834740-1 stretch fixture
(5).
WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. INCREASE

PRESSURE SLOWLY, TIGHTEN NUT OFTEN, DECREASE
PRESSURE AND THREAD TOOL CENTER FURTHER ON THE
SHAFT.
(f) Assemble and use 834740-1 stretch fixture (5) as shown in Step 3.D.(10).
NOTE: Engage threads of tie shaft simulator (4) instead of the turbine
rotor tie rod.
(g) Increase ram pressure to 2900 psig (20100 kPa).
(h) Tighten tie shaft nut (180).
(i) Slowly release all ram pressure.
(j) Remove stretch fixture (5) as shown in Step 3.D.(14).
Page 763
49-25-93 Nov 11/05
RE100[LJ]
(k) Remove retainer bolts (1) and 5838420-1 generator idler position fixture (3)
from matched gearbox housing assembly (160).
(l) Replace 5838420-1 generator idler position fixture (3) with 5838406-1
gearbox pinion bearing retainer (2). Attach 5838406-1 gearbox pinion bearing
retainer (2) with retainer bolts (1) to the gearbox housing.
Page 764
49-25-93 Aug 5/03
RE100[LJ]
Page 765
49-25-93 Aug 5/03
RE100[LJ]
Centrifugal Compressor Rotor Wire Gage Measurement

Figure 722
Page 766
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 722
260. CENTRIFUGAL COMPRESSOR 270. ENGINE COMPRESSOR HOUSING

ROTOR (IPC, SECTION 49-20-00 ASSEMBLY
FIG. 6)
(3) Use a wire gage and measure each blade on centrifugal compressor rotor (260) until
the nearest blade from the rotor to the surface of engine compressor housing
assembly (270) is found. (Refer to Figure 722 Detail A.)
(4) The smallest wire gage measurement must be 0.030 to 0.034 inch (0,762 to 0,864
mm) for this measurement.
(5) If not, disassemble centrifugal compressor rotor (260), engine compressor housing
assembly (270) and shim(s) (280, IPC Section 49-20-00, Figure 6).
(6) Repeat the centrifugal compressor rotor tip clearance procedure from Step 3.N.(1) to
(5).
NOTE: If the wire gage measurement is greater than 0.034 inch (0,864 mm),
increase the thickness of shim (280) as shown in Step 3.N.(1)(d).
If the wire gage measurement is less than 0.030 inch (0.762 mm),
decrease the thickness of shim (280) as shown in Step 3.N.(1)(d).
Check Point 110: Verify and write the centrifugal compressor rotor tip clearance.
(7) When the measurement is as specified, write the measurement as centrifugal

compressor rotor tip clearance, DIM. J. (Refer to Detail B.)
Dimension J inch (mm) Step 3.N.(7)
Page 767
49-25-93 Nov 11/05
RE100[LJ]
Turbine Rotor Zero Clearance Dimension

Figure 723
Page 768
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 723
110. TURBINE NOZZLE (IPC, SECTION 200. GAS TURBINE ENGINE TURBINE ROTOR
49-20-00 FIG. 6)
(8) Find gas turbine engine turbine rotor (200) zero clearance dimension as follows.
(a) Install gas turbine engine turbine rotor (200) to the support . (Refer to Detail
A.)
(b) Carefully install turbine nozzle (110) on to the blades of gas turbine engine
turbine rotor (200).
(c) Set a micing bar on turbine nozzle (110) and with industrial marking ink (Violet
127 ½) make two reference marks where the turbine nozzle and micing bar
touch. (Refer to Detail B.)
(d) Set a micrometer, or equivalent measuring tool, on the micing bar and
measure from the top of the micing bar to the top of gas turbine engine
turbine rotor (200) hub.
(e) Before removal of the measuring tool, use an industrial marking ink (Violet
127 ½) and on either side of the measuring tool make two "Preference Marks"
on gas turbine engine turbine rotor (200) hub.
Check Point 120: Verify and write the measurement for the gas turbine
engine turbine rotor zero tip clearance.
(f) Write the measurement as shown on the micrometer as DIM. R. (Refer to

Detail B.)
Dimension R inch (mm) (Step 3.N.(8)(f))
Check Point 130: Calculate and write the measurement for the trial turbine nozzle
shim dimension.
(9) Calculate and find turbine nozzle trial shim dimension as follows.
(a) Write the calculated answer as TW1.
Dimension R inch (mm) (from Step 3.N.(8)(f))

Mean clearance + 0.023 (0,584) inch (mm)
TW1 = inch (mm)
Page 769
49-25-93 Aug 5/03
RE100[LJ]
(10) Remove tie shaft simulator (4) from the centrifugal compressor rotor assembly as
follows. (Refer to Figure 721.)
(a) Remove the retainer bolts (1) and the gearbox pinion bearing retainer (2).
WARNING: THE TOOL CAN LOOSEN AND CAUSE INJURY. INCREASE

PRESSURE SLOWLY, TIGHTEN NUT OFTEN, DECREASE
PRESSURE AND THREAD TOOL CENTER FURTHER ON THE
SHAFT.
(b) Assemble and use 834740-1 stretch fixture (5) as shown in Step 3.D.(10).
NOTE: Engage threads of tie shaft simulator (4) instead of the turbine
rotor tie rod.
(c) Increase ram pressure to 2900 psig (20010 kPa).
(d) Loosen tie shaft nut (180).
(e) Slowly release all ram pressure.
(f) Remove stretch fixture (5) as shown in Step 3.D.(14).
(g) Remove tie shaft simulator (4).
(h) Install 5838406-1 gearbox pinion bearing retainer (2) and attach with retainer
bolts (1).
Page 770
49-25-93 Aug 5/03
RE100[LJ]
Page 771
49-25-93 Aug 5/03
RE100[LJ]
Interstage Seal Assembly and Engine Compressor Diffuser Assembly.

Figure 724
Page 772
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 724
220. INTERSTAGE SEAL ASSEMBLY 260. CENTRIFUGAL COMPRESSOR ROTOR

(IPC, SECTION 49-20-00 FIG. 6) 270. ENGINE COMPRESSOR HOUSING
230. ENGINE COMPRESSOR ASSEMBLY
DIFFUSER ASSEMBLY
(11) Assemble the engine compressor diffuser assembly and interstage seal assembly as
follows. (Refer to Figure 724.)
(a) Install engine compressor diffuser assembly (230) to engine compressor

housing assembly (270).
(b) With the raised-rivet side down, install interstage seal assembly (220) to
engine compressor diffuser assembly (230).
(c) Make a radial mark on engine compressor diffuser assembly (230) that aligns
with the compressor gearshaft assembly. (Refer to Step 3.D.(34))
(12) Carefully install turbine rotor tie rod (210) to gas turbine engine turbine rotor (200).
(Refer to Figure 704.) (Use Step 3.C. Installation Procedure.)
Page 773
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Engine Compressor Diffuser and Gas Turbine Engine Turbine Rotor
Figure 725
Page 774
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 725
1. RETAINER BOLT 180. TIE SHAFT NUT (IPC, FIG. 6)

3. GENERATOR IDLER POSITION 200. GAS TURBINE ENGINE TURBINE ROTOR
FIXTURE (PN 5838420-1) 210. TURBINE ROTOR TIE ROD
160. MATCHED GEARBOX HOUSING 220. INTERSTAGE SEAL ASSEMBLY
ASSEMBLY (IPC, SECTION 49-20-00 230. ENGINE COMPRESSOR DIFFUSER
FIG. 10, ITEM 150)
(13) Find the radial mark on the compressor gearshaft assembly (Refer to Step 3.D.(34)).
and make a radial mark on the engine compressor diffuser assembly (230) that aligns
with the compressor gearshaft assembly. (Refer to Figure 725.)
(14) Install the gas turbine engine turbine rotor (200) with turbine rotor tie rod (210) to the
(15) Align the mark on the gas turbine engine turbine rotor (200) made in Step 3.D.(34)
with the radial mark on the engine compressor diffuser assembly (230).
(16) All radial marks must align with each other during assembly. If not, disassemble the
components and repeat all steps necessary to align all radial marks. (Steps 3.D.,
3.E., and 3.N.)
(17) Assemble 834740-1 stretch fixture as follows. (Refer to Figure 706.)
tight.
tight.
tight.
Page 775
49-25-93 Nov 11/05
RE100[LJ]
(25) When all radial marks are aligned, install tie shaft nut (180) to turbine rotor tie rod
(210). Tighten tie shaft nut (180) to finger tight.
(26) Install 5838420-1 generator idler position fixture (3) and attach with retainer bolt (1).
(27) Remove retainer bolt (1) and 5838420-1 generator idler position fixture (3).
Page 776
49-25-93 Aug 5/03
RE100[LJ]
Page 777
49-25-93 Aug 5/03
RE100[LJ]
Final Turbine Rotor Tie Rod Stretch and Measurement

Figure 726
Page 778
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 726
1. STRETCH FIXTURE (PN 834740-1) 130. ANNULAR BALL BEARING (IPC,

2. BEARING SUPPORT (PN 5838404-2) SECTION 49-20-00 FIG. 9)
(COMPONENT OF PN 834740-1) 150. MATCHED GEARBOX HOUSING
3. SOCKET (PN 5838404-3) ASSEMBLY (IPC, FIG. 10)
(COMPONENT OF PN 834740-1) 180. TIE SHAFT NUT (IPC, FIG. 6)
4. BAR (PN 5838404-4) 190. PACKING
(COMPONENT OF PN 834740-1) 210. TURBINE ROTOR TIE ROD
5. NUT (PN 5838404-5)
(COMPONENT OF PN 834740-1)
(28) Lubricate packing (190) with grease and install over turbine rotor tie rod (210) to
annular ball bearing (130) face. (Refer to Figure 726, Detail A.)
(29) Apply anti-seize compound (Liqui Moly) to the threads of tie shaft nut (180) and install
to turbine rotor tie rod (210). Tighten nut to hand tight.
(30) Assemble 834740-1 stretch fixture as follows.
(b) Install 5838404-4 bar (4) and 5838404-3 socket (3) then turn 5838404-4 bar
(4) to engage threads of turbine rotor tie rod (210).
socket (3). Tighten 5838404-3 socket (3) and 5838404-5 nut (5) to hand tight.
Page 779
49-25-93 Aug 5/03
RE100[LJ]
tight.
socket (3). Tighten 5838404-3 socket (3) and 5838404-5 nut (5) to hand tight.
(37) Find the annular ball bearing face dimension as follows.
Check Point 140: Verify the final turbine rotor tie rod stretch dimension.
(a) Measure from mark (1) to mark (2). (Refer to View A.) Write this as DIM. M.
(b) Distance between turbine rotor tie rod (210) to annular ball bearing (130) face
must be 0.026 to 0.027 inches (0,66 to 0,69 mm). (Same measurement
range as DIM. C.)
(38) If DIM. M and DIM. C are not in the same measurement range, stretch turbine rotor tie
rod (210) until as specified.
(39) When DIM. M and DIM. C are in the same measurement range, write the final
measurement as DIM. M.
Dimension M inch (mm)

Dimension C inch (mm) (from Step 3.D.(29))
Page 780
49-25-93 Aug 5/03
RE100[LJ]
Page 781
49-25-93 Aug 5/03
RE100[LJ]
Trial Turbine Nozzle Shim Installation

Figure 727
Page 782
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 727
80. BOLT (IPC, SECTION 49-20-00 - 130. COMPRESSOR DESWIRL DEFLECTOR

FIG. 6) 200. GAS TURBINE ENGINE TURBINE ROTOR
100. NOZZLE RETAINER 230. ENGINE COMPRESSOR DIFFUSER
110. TURBINE NOZZLE ASSEMBLY ASSEMBLY
120. TURBINE NOZZLE SHIM 290. PERFORATED COMPRESSOR INLET
(40) Install turbine nozzle shim(s) (120), turbine nozzle assembly (110) and nozzle retainer
(100) as follows. (Refer to Figure 727.)
(a) Remove bolts (40, 60) and washers (50, 70). (Refer to Figure 719.)
(b) Remove the three retainer bolts and washers. (Refer to Figure 720.)
(c) Align tab of compressor deswirl deflector (-130) and install in slot of the
Check Point 150: Measure and write the actual measurement for turbine
nozzle shims as found for TW1.
Actual thickness inch (mm) Step 3.N.(9)(a)
(d) Install turbine nozzle shim(s) (120) to engine compressor diffuser assembly
(230).
(e) Align the holes on turbine nozzle assembly (110) with the pins on engine
compressor diffuser assembly (230).
(f) Install turbine nozzle assembly (110) to engine compressor diffuser assembly
(230).
(g) Install nozzle retainer (100) to turbine nozzle assembly (110).
(h) Install bolts (80) through the inlet port of the engine compressor inlet housing
to attach shim(s) (120), turbine nozzle assembly (110) and nozzle retainer
(100) to the perforated compressor inlet (290). Tighten bolts (80) to 60 inch-
pound (6,78 Nm).
Page 783
49-25-93 Aug 5/03
RE100[LJ]
Gearbox Ball Bearing Cover Installation

Figure 728
Page 784
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 728
1. ALIGNMENT PIN 150. GEARBOX BALL BEARING

2. GUIDE PIN HOLE COVER (IPC, FIG 6)
140. BOLT (IPC, SECTION 160. PACKING
49-20-00 FIG. 6) 170. PACKING
(IPC, FIG. 9)
(41) Install the gearbox ball bearing cover (150) as follows.
(a) Lubricate packing (160) with grease and install on gearbox ball bearing cover
(150). (Refer to Figure 728.).
(b) Lubricate packing (170) with grease and install on the gearbox housing.
(c) Find the guide pin hole (2) in annular ball bearing (130) outer race.
(d) Engage alignment pin (1) of gearbox ball bearing cover (150) with bearing
guide pin hole (2) and install gearbox ball bearing cover (150).
(e) Apply anti-seize compound to bolts (140) and install.
(f) Tighten bolts (140) to 60 inch-pound (6,78 Nm).
Page 785
49-25-93 Nov 11/05
RE100[LJ]
Final Turbine Rotor Shim Measurement

Figure 729
Page 786
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 729
110. TURBINE NOZZLE (IPC, SECTION 200. GAS TURBINE ENGINE TURBINE ROTOR
49-20-00 FIG. 6)
120. TURBINE NOZZLE SHIM
(42) Measure the final gas turbine engine turbine rotor clearance dimension as follows.
Check Point 160: Verify the final gas turbine engine turbine rotor clearance.
(a) Put the micing bar on the micing bar marks and a micrometer, or equivalent
measuring tool, on the micing bar and between the "Preference Marks".
(b) Measure at six equal spaces on the hub around gas turbine engine turbine
rotor (200) with the measuring tool. Write each measurement and calculate
the average.
(c) Write the average measurement as TW2.
TW2 inch (mm) Step 3.N.(42)(c)
(d) TW2 must be within 0.002 inch (0,051 mm) of TW1. (Refer to Step 3.N.(8)
(a).)
(e) If TW2 is not as specified, add or subtract the number of trial turbine nozzle
shims (120) until the specified limit is made.
NOTE: A maximum of three shims are allowed to be installed for gas

turbine engine turbine rotor tip clearance.
Page 787
49-25-93 Aug 5/03
RE100[LJ]
Final Gas Turbine Engine Turbine Rotor Run Out

Figure 730
Page 788
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 730
200. GAS TURBINE ENGINE TURBINE ROTOR

(43) Verify gas turbine engine turbine rotor (200) run out as follows.
(a) Place the stylus of the measuring tool on the hub of the gas turbine engine
turbine rotor (200). (Refer to Figure 730.)
(b) By hand, turn the blades of gas turbine engine turbine rotor (200).
(c) As the blades turn, measure the run out of gas turbine engine turbine rotor
(200).
Check Point 170: Measure and write the actual turbine rotor run out
measurement
Run out inch (mm) Step 3.N.(43)(c)
(d) The run out measurement must measure less than 0.002 inch (0.051 mm). If
not, repeat the turbine nozzle shim procedure. (Refer to Step 3.N.(8) to
3.N.(43)(d).)
Page 789
49-25-93 Aug 5/03
RE100[LJ]
Lube Pump Gear Baffle and Gearbox Bolts Installation

Figure 731
Page 790
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 731
10. BOLT (IPC, SECTION 49-20-00 FIG. 6) 50. WASHER

20. PACKING WITH RETAINER 60. BOLT
30. LUBE PUMP GEAR BAFFLE 70. PACKING WITH RETAINER
40. BOLT
O. Assemble the Lube Pump Gear Baffle and Gearbox Bolts
(1) Install new packing with retainer (20) to bolt (10). (Refer to Figure 731.)
(2) Install bolt (10) to lube pump gear baffle (30).
(3) Install new packing with retainer (20) to bolt (10).
(4) Install lube pump gear baffle (30) in gearbox cavity.
(5) Tighten bolts (10) to 120 inch-pound (13,56 Nm).
(6) Install new packing with retainer (70) to bolt (60).
NOTE: Bolts (40, 60), washer (50) and packing with retainer (70) were removed at
Step 3.N.(40)(a).
(7) Install bolt (60) to gearbox housing cavity. Tighten bolt (60) to 120 inch-pound (13,56
Nm).
(8) Install washers (50) and bolts (40). Tighten bolts (40) to 120 inch-pound (13,56 Nm).
(9) Remove retainer bolt (4) and 5828408-1 generator bearing retainer (3) from the
gearbox assembly. (Refer to Figure 715.)
(10) Remove retainer bolt (6) and 5838407-1 idler gearshaft retainer (5).
Page 791
49-25-93 Nov 11/05
RE100[LJ]
Combustion Chamber, Turbine Housing and Bracket Installation

Figure 732
Page 792
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 732
10. BOLT (IPC, SECTION 49-20-00 FIG. 4) 40. TURBINE HOUSING

20. BRACKET 50. COMBUSTOR CHAMBER
P. Assemble the Power Section and Engine Assembly
(1) Install combustion chamber (50) to the engine turbine nozzle. (Refer to Figure 732.)
(2) Align combustion chamber (50) so igniter hole is at 4 o'clock position at top dead
center (TDC) bolt hole on turbine housing (40).
(3) Install turbine housing (40) to TDC bolt hole and attach with bolts (10).
(4) Examine alignment of combustion chamber (50) igniter hole with igniter boss on
turbine housing (40). If igniter hole and igniter boss are not aligned, remove the
combustion chamber (50) and align again. (Refer to Detail B.)
(5) When combustion chamber (50) igniter hole and igniter boss on turbine housing (40)
are aligned, remove bolt (10) and turbine housing (40).
(6) Push combustion chamber (50) on to the engine turbine nozzle.
(7) Clean the flanges of the turbine housing and inlet duct housing with solvent and allow
the parts to dry.
(8) Apply a thin layer of jointing compound (Hylomar PL32L, Type 1; or PL32M, Type 2;
or PL32H, Type 3) to the flange of turbine housing (40) and the flange of the inlet duct
housing. Allow the parts to dry for 10 minutes.
(9) Install turbine housing (40) to the inlet duct housing and attach with bolts (10).
(10) Again, examine alignment of combustion chamber (50) igniter hole with the igniter
boss on turbine housing (40). If igniter hole and igniter boss are not aligned, remove
bolts (10) and align again. (Refer to Detail B.)
(11) When alignment is as specified, install bolts (10) and brackets (20) in eight places.
(Refer to Detail A.)
(12) Tighten all bolts (10) to 60 inch-pound (6,78 Nm).
Page 793
49-25-93 Aug 5/03
RE100[LJ]
Fuel Nozzle and Low Voltage Igniter Plug Installation

Figure 733
Page 794
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 733
10. BOLT (IPC, SECTION 50. FUEL NOZZLE SHROUD

49-20-00 FIG. 3) 60. SECONDARY FUEL NOZZLE
20. WASHER 120. LOW VOLTAGE IGNITER PLUG
30. PRIMARY FUEL NOZZLE (IPC, 49-40-00 FIG. 1)
ASSEMBLY 130. SPARK PLUG METAL
40. PREFORMED PACKING GASKET
(13) Install the fuel nozzles as follows.
CAUTION: USE EXTREME CARE WITH PRIMARY FUEL NOZZLE ASSEMBLY.

OIL AND DIRT FROM HANDS CAN CLOG AND DAMAGE
NOZZLES.
(a) Install fuel nozzle shroud (50) to primary fuel nozzle assembly (30). (Refer to
Figure 733.)
(b) Install preformed packing (40) to primary fuel nozzle assembly (30).
(c) Install primary fuel nozzle assembly (30), with nozzle end forward, to the
engine turbine housing and attach with washer (20) and bolt (10). Tighten bolt
(10) to 60 inch-pound (6,78 Nm).
(d) Bend tabs down on washers (20) to lock bolts (10) in place.
(14) Install the low voltage igniter plug as follows.
(a) Install metal spark plug gasket (130) to low voltage igniter plug (120).
(b) Install low voltage igniter plug (120) in the igniter boss on the turbine housing.
(c) Tighten the plug to 250 inch-pound (28,25 Nm).
Page 795
49-25-93 Nov 11/05
RE100[LJ]
Fuel Manifolds and Flow Divider Tee Installation

Figure 734
Page 796
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 734
10. SECONDARY FUEL MANIFOLD 30A. NUT

(IPC, SECTION 49-30-00 FIG. 1) 40A. WASHER
20. PRIMARY FUEL MANIFOLD 50. FLOW DIVIDER TEE
(15) Install the fuel manifolds and flow divider tee as follows.
(a) Install flow divider tee (50) and attach with washer (40A) and nut (30A).
(b) Install primary fuel manifold (20) to flow divider tee (50) and attach to the
primary fuel nozzle assemblies.
(c) Install secondary fuel manifold (10) to flow divider tee (50) and attach to the
secondary fuel nozzle assemblies.
Page 797
49-25-93 Nov 11/05
RE100[LJ]
Immersion Thermocouple Installation

Figure 735
Page 798
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 735
10. BOLT (IPC, SECTION 49-70-00 30. HIGH TEMP LOCKNUT

FIG. 3) 40. HIGH TEMP NUT
20. IMMERSION THERMOCOUPLE
(16) Assemble the immersion thermocouple as follows.
(a) Install immersion thermocouple (20) and attach with bolt (10). (Refer to
Figure 735.)
(b) Tighten bolt (10) to 60 inch-pound (6,78 Nm).
(c) Install high temp locknut (30) to the large post on immersion thermocouple
(20). Tighten locknut to hand tight.
(d) Install high temp nut (40) to the small post on immersion thermocouple (20).
Tighten nut to hand tight.
NOTE: The final torque value for high temp locknut (30) and high temp nut
(40) is given at assembly of the branched wiring harness.
Page 798.1
49-25-93 Nov 11/05
RE100[LJ]
Idler Bearing Cover Installation

Figure 736
Page 798.2
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 736
10. BOLT (IPC, SECTION 49-20-00 40. IDLER BEARING COVER

FIG. 2) 50. PACKING
30. BRACKET - 70. BRACKET (IPC, SECTION 49-00-00 FIG 3)
(17) Assemble the idler bearing cover as follows.
(a) Lubricate new packing (50) with grease and install on the round flange of idler
bearing cover (40). (Refer to Figure 736.)
(b) Lubricate new packing (60) with grease and install in the oblong cut out of the
cover.
(c) Install idler bearing cover (40) to the gearbox and attach with bolts (10) and
washers (20). Tighten bolts (10) to hand tight.
(d) Attach bracket (30) to idler bearing cover (40) with bolt (10) and washer (20).
Tighten all bolts (10) to 60 inch-pound (6,78 Nm).
NOTE: Retain one bolt (10) and washer (20). Use these items to install
bracket (70) at assembly of the branched wiring harness.
Page 798.3
49-25-93 Nov 11/05
RE100[LJ]
Generator Seal Assembly and Generator Adapter Installation

Figure 737
Page 798.4
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 737
10. RETAINING RING (IPC, SECTION 70A. PACKING

49-20-00 FIG. 5) 80. BOLT (IPC, FIG. 10 ITEM 10)
20. RETAINER SEAL 90. WASHER (IPC, ITEM 20)
30. SPRING WASHER 100. GENERATOR ADAPTER (IPC, ITEM 30)
40. RETAINING RING 110. PACKING (IPC, ITEM 40)
50. SEAL RETAINER 120. MATCHED GEARBOX HOUSING
- 50A. SEAL ASSEMBLY ASSEMBLY (IPC, ITEM 150)
60. PACKING
(18) Assemble the generator seal assembly and generator adapter as follows.
(a) Lubricate new packings (60,70A) with grease and install on retainer seal (20).
(b) (Pre SB 49-7593) Install seal retainer (50) in retainer seal (20) and attach with
retaining ring (40).
(Post SB 49-7593) Install seal assembly (- 50A) in retainer seal (20) and
attach with retaining ring (40).
(c) Lubricate packing (110) with grease and install on generator adapter (100).
(d) Install seal retainer (20) with assemblies to generator adapter (100) with
packing (110). (Refer to Detail C.)
(e) Attach retaining ring (10) to generator adapter (100) to keep all seal
assemblies together. (Refer to Detail D.)
(f) Lubricate spring washer (30) with grease and install to generator adapter
(100).
(g) Install generator adapter (100) with assembled parts in matched gearbox
housing assembly (120) and attach with washers (90) and bolts (80).
(h) Tighten bolts (80) to 60 inch-pound (6,78 Nm).
Page 798.5
49-25-93 Nov 11/05
RE100[LJ]
Lube Pump Assembly and Engine Transfer Tube Installation

Figure 738
Page 798.6
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 738
10. BOLT (IPC, SECTION 49-93-00 80. RETAINING RING

FIG. 3) 90. SCREEN
20. WASHER 100. SHAFT COUPLING
30. LUBE PUMP ASSEMBLY 110. PACKING
-30A. LUBE PUMP ASSEMBLY 120. TRANSFER TUBE
-30B. LUBE PUMP ASSEMBLY 130. PACKING
40A. FILTER HOUSING 140. PACKING
50. PACKING 150. PACKING
60A. FILTER ELEMENT -150A. PACKING
70A. PACKING 160. PACKING
Q. Assemble the APU engine
(1) Assemble the lube pump assembly and engine transfer tube as follows.
NOTE: Remove all protective coverings on lube pump assembly, if installed.

(a) Lubricate new packings (130) with grease and install on transfer tube (120).
(b) (Pre SB 49-7400) Lubricate new packing (110) with grease and on install lube
pump assembly (30) housing.
(Post SB 49-7400) (Pre SB 49-7530) Lubricate new packing (110) with grease
and install on lube pump assembly (- 30A) housing.
(Post SB 49-7530) Lubricate new packing (110) with grease and install on
lube pump assembly (- 30B) housing.
(c) (Pre SB 49-7400) Lubricate new packings (140, 160) with grease and install
on lube pump assembly (30) housing.
(Post SB 49-7400) (Pre SB 49-7530) Lubricate new packings (140, 160) with
grease and install on lube pump assembly (- 30A) housing.
(Post SB 49-7530) Lubricate new packings (140, 160) with grease and install
on lube pump assembly (- 30B) housing.
(d) (Pre SB 49-7400) Install screen (90) to lube pump assembly (30) and attach
with retaining ring (80).
Page 798.7
49-25-93 Nov 11/05
RE100[LJ]
(Post SB 49-7400) (Pre SB 49-7530) Install screen (90) to lube pump

assembly (- 30A) and attach with retaining ring (80).
(Post SB 49-7530) Install screen (90) to lube pump assembly (- 30B) and
attach with retaining ring (80).
(e) (Pre SB 49-7400) Lubricate a new packing (150) with grease and install on
lube pump assembly (30).
(Post SB 49-7400) (Pre SB 49-7530) Lubricate a new packing (- 150A) with

grease and install on lube pump assembly (- 30A).
(Post SB 49-7530) Lubricate a new packing (- 150A) with grease and install
on lube pump assembly (- 30B).
(f) (Pre SB 49-7400) Carefully mesh splines and install shaft coupling (100) into
lube pump assembly (30).
(Post SB 49-7400) (Pre SB 49-7530) Carefully mesh splines and install shaft
coupling (100) into lube pump assembly (- 30A).
(Post SB 49-7530) Carefully mesh splines and install shaft coupling (100) into
lube pump assembly (- 30B).
CAUTION: PACKINGS (140, 150, 160) MUST NOT SHOW OUTSIDE THE
ORIFICES ON THE PUMP HOUSING OR GEARBOX HOUSING
AFTER INSTALLATION. IF PACKINGS SHOW, DAMAGE TO THEM
CAN OCCUR WHEN BOLTS (10) ARE TIGHTENED.
(g) (Pre SB 49-7400) Attach lube pump assembly (30) to the gearbox housing
with washers (20) and bolts (10). Tighten bolts to 145 inch-pound (16,39
Nm).
(Post SB 49-7400) (Pre SB 49-7530) Attach lube pump assembly (- 30A) to

the gearbox housing with washers (20) and bolts (10). Tighten bolts to 145
(Post SB 49-7530) Attach lube pump assembly (- 30B) to the gearbox

housing with washers (20) and bolts (10). Tighten bolts to 145 inch-pound
(16,39 Nm).
(h) Install bracket (170, IPC Section 49-30-00, Figure 3) to the lube pump
housing and attach with washer (160) and bolt (150). Tighten bolt (150) to 60
Page 798.8
49-25-93 Nov 11/05
RE100[LJ]
Page 798.9
49-25-93 Aug 5/03
RE100[LJ]
Chip Detector and Debris Monitor; Filler Neck and Cap; Tube Bleeder Plug, Oil Temperature Bulb and Oil
Level Switch Installation
Figure 739
Page 798.10
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 739
10. CHIP DETECTOR (IPC, SECTION 80. OIL LEVEL SWITCH (IPC, ITEM 20)
49-93-00 FIG. 1 ITEM 30) 90. NUT (IPC, ITEM 10)
20. PACKING (IPC, ITEM 40A) -100. FILLER NECK AND CAP (IPC,
30. DEBRIS MONITOR (IPC, ITEM 50) FIG. 1 ITEM 10)
40. PACKING (IPC, ITEM 60) 100A. LIQUID LEVEL ROD CAP GAGE (IPC,
50. PACKING (IPC, SECTION 49-70-00 ITEM 10A)
FIG. 1 ITEM 40) 105. PACKING (IPC, ITEM 25)
60. OIL TEMPERATURE BULB 110. PACKING (IPC, ITEM 20)
(IPC, ITEM 30) 120. TUBE BLEEDER PLUG (IPC, ITEM 70)
70. PACKING (IPC, SECTION 130. PACKING (IPC, ITEM 80)
49-93-00 FIG. 4 ITEM 30)
(2) Assemble chip detector and debris monitor; filler neck and cap; tube bleeder plug, oil
temperature bulb and oil level switch as follows. (Refer to Figure 739.)

(a) Lubricate packing (20) with oil (MIL-PRF-7808 or MIL-PRF-23699) and install
on chip detector (10).
(b) Install chip detector (10) to debris monitor (30).
(c) Lubricate packing (40) with oil (MIL-PRF-7808 or MIL-PRF-23699) and install
on debris monitor (30.)
(d) Install chip detector and debris monitor to the gearbox housing . Tighten
debris monitor (30) to 25 inch-pound (2,8 Nm) and attach with lockwire.
(e) Lubricate packing (40) with oil (MIL-PRF-7808 or MIL-PRF-23699) and install
on oil temperature bulb (60).
(f) Install oil temperature bulb (60) and tighten to 60 inch-pound (6,78 Nm).
(g) Lubricate packing (70) with oil (MIL-PRF-7808 or MIL-PRF-23699) and install
to oil level switch (80).
(h) Install oil level switch (80) and attach with nut (90). Tighten nut (90) to 50
(i) (Pre SB 49-7489) Lubricate packing (110) with oil (MIL-PRF-7808 or MIL-
PRF-23699) and install on filler neck and cap (- 100).
Page 798.11
49-25-93 Nov 11/05
RE100[LJ]
(j) (Post SB 49-7489) Lubricate packing (110) with oil (MIL-PRF-7808 or MIL-
PRF-23699) and install on liquid level rod cap gage (100A).
(k) (Pre SB 49-7489) Install liquid level rod cap gage (100A) and tighten to 70
inch-pound (7,91 Nm). Attach liquid level rod cap gage (100A). with lockwire.
(l) (Post SB 49-7489) Install filler neck and cap (- 100) and tighten to 70 inch-
pound (7,91 Nm). Attach filler neck and cap (- 100) with lockwire.
(m) Lubricate packing (130) with oil (MIL-PRF-7808 or MIL-PRF-23699) and

install on tube bleeder plug (120).
(n) Install tube bleeder plug (120) and tighten to 70 inch-pound (7,91 Nm).
Attach tube bleeder plug (120) with lockwire.
Page 798.12
49-25-93 Aug 5/03
RE100[LJ]
Page 798.13
49-25-93 Aug 5/03
RE100[LJ]
Air Temperature Bulb, Speed Sensor and Gearbox Vent Tube Elbow Installation
Figure 740
Page 798.14
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 740
10. NUT (IPC, SECTION 50. GASKET (IPC, ITEM 20)

49-00-00, FIG. 4 ITEM 50) 60. NUT (IPC, FIG. 2 ITEM 10)
20. PACKING (IPC, ITEM 70) 70. SPEED SENSOR (IPC, ITEM 20)
30. ELBOW (IPC, ITEM 60) 80. PACKING (IPC, ITEM 30)
40. AIR TEMPERATURE BULB (IPC,
SECTION 49-70-00 FIG. 1 ITEM 10)
(3) Assemble the air temperature bulb, speed sensor and the elbow assembly for the
gearbox vent tube as follows.
(a) Lubricate new packing (80) with oil (MIL-PRF-7808 or MIL-PRF-23699) and
install on speed sensor (70). (Refer to Figure 740.)
(b) Install speed sensor (70) and attach with nut (60). Tighten nut to 50 inch-
pound (5,67 Nm).
(c) Install gasket (50) to air temperature bulb (40).
(d) Install air temperature bulb (40) and tighten to 120 inch-pound (13,56 Nm).
(e) Lubricate new packing (20) with oil (MIL-PRF-7808 or MIL-PRF-23699) and
install on elbow (30).
(f) Install elbow (30) and attach with nut (10). Tighten nut to 60 inch-pound (6,78
Nm).
Page 798.15
49-25-93 Aug 5/03
RE100[LJ]
Fuel Control Assembly Installation

Figure 741
Page 798.16
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 741
10. COUPLING CLAMP (IPC, 130. BOLT

SECTION 49-30-00 FIG. 2) 140. WASHER
20. PACKING 150. BOLT
30. FUEL CONTROL ASSEMBLY 160. WASHER
40. BOLT (IPC, SECTION 170. BRACKET
50. FILTER COVER 180. ELBOW (IPC, SECTION
60. PACKING 49-00-00 FIG.4 ITEM 100)
80. FILTER 190. NUT (IPC, ITEM 90)
90. PACKING 200. PACKING (IPC, ITEM 110)
(4) Prepare the fuel control for assembly as follows.
NOTE: If fuel control assembly (30) was removed in DISASSEMBLY, go to the

assembly procedures. If the unit has come from storage or is new, do the
steps as follows.
WARNING: USE THE CORRECT PERSONAL PROTECTION. FUEL IS

POISONOUS AND EXPLOSIVE. FUEL CAN CAUSE DEATH OR
INJURY TO PERSONS.
(a) Remove the installed plug and packing from the fuel control orifice where
packing (-25) and union (20) will be installed. (Refer to Figure 744.)

(b) Remove all preservative oil from fuel control assembly (30, Figure 741).
(c) With a clean cloth, wipe off all preservative oil. Discard the plug and packing.
(5) Assemble the fuel control assembly as follows.

INJURY TO PERSONS.
(a) Lubricate new packing (20) with fuel and install on fuel control assembly (30).
(b) Open coupling clamp (10). Loosely and temporarily assemble to fuel control
assembly (30) with the t-bolt on coupling clamp (10) up.
(c) Locate guide pin on fuel control assembly (30) and engage the pin with the
guide pin hole in the lube pump assembly.
Page 798.17
49-25-93 Nov 11/05
RE100[LJ]
(d) Install fuel control assembly (30) and attach with coupling clamp (10).
(e) Tighten nut on coupling clamp (10) to 20 inch-pound (2,26 Nm).
(f) Install bracket (170) and attach to fuel control assembly (30) with bolts (130
150) and washers (140, 160). Tighten bolt (130, 150) to hand tight. (Refer to
Figure 741.)

INJURY TO PERSONS.
(g) Lubricate a new packing (90) with fuel and install on a new filter (80).
(h) Lubricate a new packing (60) and install on filter cover (50).
(i) Install the fuel filter assembly into the fuel filter cover assembly and assemble
to the fuel control assembly.
NOTE: Refer to the fuel control assembly Component Maintenance

Manual for torque values and all special procedures. (Refer to the
INTRODUCTION in this manual to get the appropriate ATA
Number.)
(j) Attach the filter cover assembly with bolt (40).

INJURY TO PERSONS.
(k) Lubricate a new packing (200) with fuel and install on elbow (180).
(l) Install nut (190) and elbow (180) to fuel control (30).
NOTE: Turn elbow (180) to the 2 o’clock position.
(m) Keep elbow (180) at specified position and tighten nut (190)) to 60 inch pound
(6,78 Nm).
Page 798.18
49-25-93 Nov 11/05
RE100[LJ]
Page 798.19
49-25-93 Aug 5/03
RE100[LJ]
Vacuum Check of the Gearbox

Figure 742
Page 798.20
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 742
1. GEARBOX VENT PORT 3. GAGE

2. VACUUM PUMP
(6) Do a vacuum and pressure check of the gearbox and generator seal as follows.
(a) Install vacuum pump (2) with in-line gage (3) to gearbox vent port (1). (Refer
to Figure 742.)
(b) Apply a vacuum of 5 inches (3,048 mm) of mercury with vacuum pump (2).
(c) Monitor gage (3) for a steady reading for one minute.
(d) If gage (3) decreases during the check, stop the check and find the leak.
(e) After the leak is found and fixed, repeat vacuum check.
(f) Put oil (MIL-PRF-7808 or MIL-PRF-23699) on generator seal and apply

pressure of 2 psig (13,8 kPa) to generator seal.
(g) Monitor the generator seal for leaks. If leaks are found, fix the leakage area.
(h) Do Steps (f) and (g) again until no leakage is found.
Page 798.21
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Fuel Solenoid Valve and Start Counter

Figure 743
Page 798.22
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 743
10. BOLT (IPC, SECTION 60. PACKING

49-30-00 FIG. 2) 70. REDUCER
30. STARTER COUNTER BRACKET 90. SCREW
40. FUEL SOLENOID VALVE (IPC, SECTION 49-00-00 FIG. 5, ITEM 10)
50. REDUCER 100. START COUNTER (IPC, ITEM 20)
(7) Assemble the fuel solenoid valve and start counter as follows.

(a) Lubricate packings (60, 80) with oil (MIL-PRF-7808 or MIL-PRF-23699) and
install on reducers (50, 70). (Refer to Figure 743.)
(b) Install reducers (50, 70) to fuel solenoid valve (40). Tighten reducers (50, 70)
to 60 inch-pound (6,78 Nm).
(c) Install fuel solenoid valve (40) to bracket on fuel control assembly and attach
with starter counter bracket (30) bolts (10) and washers (20). Tighten bolt
(10) to 60 inch-pound (6,78 Nm).
(d) Align the mark made during disassembly on start counter (100) with the mark
on the bracket. (Refer to Figure 743.)
(e) Install start counter (100) and attach with screws (90). Tighten screws (90) to
7 inch-pound (0,79 Nm).
Page 798.23
49-25-93 Nov 11/05
RE100[LJ]
Assembly of the Engine Plumbing

Figure 744
Page 798.24
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 744
10. FUEL CONTROL SOLENOID TUBE 90. CLAMP (IPC, ITEM 200)
(IPC, SECTION 49-00-00 FIG. 4) 100. CLAMP (IPC, ITEM 240)
20. UNION 110. GEARBOX VENT TUBE (IPC, FIG.4
- 25. PACKING ITEM 40)
30. BOLT (IPC, SECTION 49-20-00 120. CLAMP (IPC, FIG. 3 ITEM 160)
FIG. 2 ITEM 10) 130. CLAMP (211-592-9003)
40. WASHER (IPC, ITEM 20) 140. CLAMP (IPC, SECTION 49-00-00
50. BRACKET (IPC, SECTION 49-00-00 FIG. 3 ITEM 30)
FIG. 3 ITEM 110) 150. FUEL SOLENOID FLOW TUBE (IPC,
60. BOLT (MS 9556-04) FIG. 4 ITEM 80)
70. NUT (525-610-9006) 160. DRAIN TUBE (IPC, ITEM 30)
80. CLAMP (IPC SECTION 49-00-00
FIG. 3 ITEM 103)
(8) Assemble the engine plumbing as follows.
(a) Install drain tube (160). (Refer to Figure 744.)
(b) Install fuel solenoid flow tube (150) and tighten the jam nuts to hand tight.
(c) Install bracket (50) and attach with bolt (30) and washer (40). Tighten bolt
(30) to hand tight.
NOTE: If bracket (50), bolt (30) and washer (40) have been installed at the
idler bearing cover installation, go to Step (d).
(d) Install clamp (130) to fuel solenoid flow tube (150). Align clamp (130) with
bracket (50) and attach with bolt (60) and nut (70). Tighten bolt (60) to 60 in-
lb (6,78 Nm).
(e) Install clamps (140, 130, 120) to fuel solenoid flow tube (150). Tighten jam
nuts on fuel solenoid flow tube (150) to final torque.
NOTE: The procedures to attach clamps with bolts are shown at the
electrical installation.
(f) Install gearbox vent tube (110). Tighten jam nuts to hand tight.
NOTE: Flow arrow on the tube must point from the gearbox to the exhaust
end of the engine.
(g) Install clamps (90, 100) to gearbox vent tube (110).
NOTE: The procedures to attach clamps with bolts are shown at the
electrical installation.
Page 798.25
49-25-93 Aug 5/03
RE100[LJ]
Assembly of the Electrical Igniter Plug Lead

Figure 745
Page 798.26
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 745
110A. IGNITER PLUG ELECTRICAL LEAD 120. LOW VOLTAGE IGNITION PLUG
(IPC, SECTION 49-40-00 FIG.1) 150. LOW VOLTAGE IGNITION UNIT
(9) Assemble the electrical igniter plug lead as follows.
(a) Connect igniter plug electrical lead (110A) to low voltage ignition unit (150)
(remotely located). Tighten the nut on the igniter plug electrical lead to 100
inch-pound (11,3 Nm). (Refer to Figure 745.)
(b) Connect igniter plug electrical lead (110A) to low voltage ignition plug (120).
Tighten the nut on the igniter plug electrical lead to 150 inch-pound (16,95
Nm).
Page 798.27
49-25-93 Nov 11/05
RE100[LJ]
Electrical Installation
Figure 746
Page 798.28
49-25-93 Nov 11/05
RE100[LJ]
KEY TO FIGURE 746
10. BOLT (IPC, SECTION 170. CLAMP

49-00-00 FIG. 3) 180. BOLT
40. BOLT 210. BOLT
50. SELF-LOCKING NUT 220. SELF-LOCKING NUT
70. BRACKET 240. HI-TEMP NUT (IPC, SECTION 49-70-00
80. BOLT FIG 3, ITEM 40)
90A. SELF-LOCKING NUT 250. HI-TEMP LOCKNUT (IPC, ITEM 30)
100A. CLAMP 260. BRANCHED WIRING HARNESS
150. BOLT (IPC, SECTION 49-00-00 FIG. 3, ITEM 250)
(10) Assemble the brackets and clamps for the electrical installation as follows.
(a) Install clamp (230) and align with the clamp on the gearbox vent tube. Attach
clamp (230) and clamp on gearbox vent tube with bolt (210) and self-locking
nut (220). Tighten bolt (210) to 60 inch-pound (6,78 Nm). (Refer to Figure
746.)
(b) Install clamp (190) and align with the clamp on the gearbox vent tube. Attach
clamp (190) and clamp on gearbox vent tube with bolt (180). Tighten bolt
(180) to 60 inch-pound (6,78 Nm).
(c) Install clamp (170) and align with the clamp on the fuel solenoid flow tube.
Attach clamp (170) and clamp on fuel solenoid flow tube with bolt (150).
Tighten bolt (150) to 60 inch-pound (6,78 Nm).
(d) Install clamp (100A) and align with the clamp on the gearbox vent tube.
Attach clamp (100A) and clamp on gearbox vent tube with bolt (80) and self-
locking nut (90A). Tighten bolt (80) to 60 inch-pound (6,78 Nm).
(e) Remove bolt from the lube pump assembly. Install bracket (70) and attach
with the bolt. Tighten the bolt to 145 in-lb (16,39 Nm).
(f) Install clamp (60) to branched wiring harness (260) and to bracket (70).
Attach with bolt (40) and self-locking nut (50). Tighten bolt (40) to 60 inch-
pound (6,78 Nm).
(g) Install clamp (20) and align with the clamp on the fuel solenoid flow tube.
Attach clamp (20) with bolt (10). Tighten bolt (10) to 60 inch-pound (6,78
Nm).
Page 798.29
49-25-93 Nov 11/05
RE100[LJ]
Branched Wiring Harness Installation

Figure 747
Page 798.30
49-25-93 Aug 5/03
RE100[LJ]
KEY TO FIGURE 747
10. THERMOCOUPLE LEADS 120. AIR TEMPERATURE BULB (IPC, FIG. 1

20. IMMERSION THERMOCOUPLE ITEM 10)
(IPC, SECTION 49-70-00 FIG. 3) 130. ELECTRICAL CONNECTOR P2
30. ELECTRICAL CONNECTOR P8 140. OIL LEVEL SENSOR (IPC,
40. IGNITION UNIT (IPC, SECTION SECTION 49-93-00 FIG. 4 ITEM 20)
49-40-00 FIG. 1 ITEM 150) 150. ELECTRICAL CONNECTOR P10
50. ELECTRICAL CONNECTOR P4 160. OIL TEMPERATURE BULB
60. FUEL SOLENOID VALVE (IPC, SECTION 49-70-00 FIG. 4 ITEM 10)
(IPC, SECTION 49-30-00 170. ELECTRICAL CONNECTOR P3
FIG. 2 ITEM 40) 180. LOW OIL PRESSURE SWITCH (IPC,
70. ELECTRICAL CONNECTOR P5 SECTION 49-93-00 FIG. 2 ITEM 20)
80. START COUNTER (IPC, SECTION 190. ELECTRICAL CONNECTOR P7
49-00-00 FIG. 5 ITEM 20) 200. FUEL CONTROL UNIT (IPC, SECTION
90. ELECTRICAL CONNECTOR P9 49-30-00 FIG. 3 ITEM 30)
100. SPEED SENSOR (IPC, SECTION 210. ELECTRICAL CONNECTOR J1
49-70-00 FIG. 2 ITEM 20) 220. BRANCHED WIRING HARNESS (IPC,
110. ELECTRICAL CONNECTOR P11 SECTION 49-00-00 FIG. 3 ITEM 250A)
(11) Install the branched wiring harness as follows.
NOTE: Refer to the Component Maintenance Manual, as shown in the

Introduction, for further details on the branched wiring harness.
(a) Remove protective cover from electrical connector P7 (190). Install electrical
connector P7 (190) on fuel control unit (200). (Refer to Figure 747.)
(b) Remove protective cover from electrical connector P3 (170). Install electrical
connector P3 (170) on low oil pressure switch (180).
(c) Remove protective cover from electrical connector P10 (150). Install
electrical connector P10 (150) on oil temperature bulb (160).
(d) Remove protective cover from electrical connector P2 (130). Install electrical
connector P2 (130) on oil level sensor (140).
(e) Remove protective cover from electrical connector P11 (110). Install
electrical connector P11 (110) on air temperature bulb (120).
(f) Remove protective cover from electrical connector P9 (90). Install electrical
connector P9 (90) on speed sensor (100).
(g) Remove protective cover from electrical connector P5 (70). Install electrical
connector P5 (70) on start counter (80).
(h) Remove protective cover from electrical connector P4 (50). Install electrical
connector P4 (50) on fuel solenoid valve (60).
Page 798.31
49-25-93 Nov 11/05
RE100[LJ]
(i) Remove protective cover from electrical connector P8 (30). Install electrical
connector P8 (30) on remotely located ignition unit (40).
(j) Remove the nuts from immersion thermocouple (20). Connect the chromel
(+) lead (10) and attach with nut. Connect alumel (-) lead (10) and attach with
nut. Tighten nuts to 25 inch-pound (2,8 Nm).
NOTE: Install the chromel (+) lead to the small stud and the alumel (-) lead
to the large stud on the immersion thermocouple. Incorrect
installation of leads can cause incorrect temperature indications.
4. Storage Instructions
A. General
NOTE: The APU storage/preservation procedures are guidelines only and represent best
practices for the protection of stored units against damage from worst-case
exposure to moisture, debris, and other environmental conditions during extended
periods storage. The manual should be used as a baseline to establish what
precautions should be taken at and/or after storage based on each operator’s
region and experience.
(1) Most parts made today do not need age control. Age control is not necessary for
assemblies, silicon rubber, fluorocarbon rubber, fuel tank synthetics, or static seals
used with fasteners.
(2) Age Controls of Age-Sensitive Elastomeric Material for Aerospace Applications is

specified in SAE AS1933. Refer to this standard for all military and commercial use.
Assemblies that contain age-sensitive material in this specification are limited by
failure rates, in service use, and system life estimated by the user.
(3) Bad weather conditions can cause damage to parts. Such conditions are, but not
limited to:
Moisture
High temperature (over 125ºF (52ºC))
Fuel or solvents that have expanded
Fumes that can cause corrosion
Mechanical stresses
Ultraviolet light
(4) Parts that have been in bad storage conditions must be examined for damage and
replaced as necessary.
B. Prepare unit for storage
(1) Clean the external surfaces with a clean, lint-free cloth.
(2) Put covers on all openings.
(3) Put the unit in pH neutral paper.
Page 798.32
49-25-93 Nov 11/05
RE100[LJ]
CAUTION: MAKE SURE THE DESICCANT DOES NOT TOUCH THE UNIT. IF THE
DESICCANT TOUCHES THE UNIT, DAMAGE CAN OCCUR.
(4) Put desiccant on the pH neutral paper.
(5) Put the unit in the barrier material.
(6) Install a humidity monitor plug.
(7) Seal to remove air.
(8) Put cushions at all sharp corners to prevent damage to the barrier material.
(9) Put the unit in the container.
C. Monitor storage conditions
(1) Keep the unit in an area away from high temperatures, dust, moisture and corrosive
fumes.
(2) The recommended storage temperature is less than 100ºF (38ºC) and must not be
more than 125ºF (52ºC).
(3) Control the humidity to prevent moisture on the unit.
(4) If the time in storage is more than 12 months, refer to TESTING AND FAULT
ISOLATION and test the unit before it is put in service.
Page 798.33
49-25-93 Aug 5/03
RE100[LJ]
Page 798.34
49-25-93 Aug 5/03
RE100[LJ]
FITS AND CLEARANCES
1. Fits and Clearances
A. General
(1) This section contains a separate list for the fits and clearances and for the torque
values used in the procedures of this manual.
(1) None
(1) None
D. Fits and Clearances
(1) Table 801 shows the fits and clearances that can be found in ASSEMBLY.
Table 801. Fits and Clearances
Nomenclature/Description Requirement/Dimension
(Item and Figure No.)
Shaft to bearing face before stretch as measured

(1, 2 Figure 707)
DIM. A/Turbine rotor tie rod length as measured

(Figure 707)
Shaft to bearing face after stretch as measured

(1, 2 Figure 708)
DIM. B/Turbine rotor tie rod length as measured

(Figure 708)
DIM. C/Overall group stretch 0.026 to 0.027 inch (0,66 to 0,69 mm)
(Figure 708)
DIM. E/Turbine rotor run out 0.00 to 0.002 inch (0,00 to 0,051 mm)
(200, Figure 709)
DIM. G/Top of inlet housing to compressor seal rotor 0.559 to 0.573 inch (14,199 to 14,554
(140, 40 Figure 717) mm)
DIM. H/Total thickness of shim 0.0465 to 0.0495 inch (1,181 to 1,257

(280, Figure 720) mm)
Page 801
49-25-93 Nov 11/05
RE100[LJ]
Table 801. Fits and Clearances (Cont)
Nomenclature/Description Requirement/Dimension
(Item and Figure No.)
DIM. J/Centrifugal compressor rotor tip clearance 0.030 to 0.034 inch (0,762 to 0,864 mm)
(260, Figure 722)
DIM. R/Turbine rotor zero clearance as measured

(200, Figure 723)
TW1/Trial turbine nozzle shim dimension as calculated

(Figure 723)
DIM. M/Annular ball bearing face dimension 0.026 to 0.027 inch (0,66 to 0,69 mm)
(1,2 Figure 726)
TW1/Actual turbine nozzle shim dimension as measured

(120, Figure 727)
TW2/Turbine rotor clearance average +/- 0.002 inch (0,051 mm) of TW1
(200, Figure 729)
Final turbine rotor run out less than 0.002 inch (0,051 mm)
(200, Figure 730)
E. Torque Values
(1) Tighten nuts, bolts, screws, and tube fittings to the standard torque unless specified
differently. Refer to FAA Manual AC65-9A, Airframe and Powerplant Mechanics
General Handbook, for standard torque.
(2) Tighten fasteners installed through non-elastic boundaries to remove visible clearance
between the parts. Monitor the rundown torque necessary just before the fastener
becomes tight. Then tighten to the final torque (refer to Table 802 for the correct
thread size) and add the rundown torque. This procedure is sufficient for all fasteners
not shown under torque values below. Table 803 shows procedures for final torque.
Page 802
49-25-93 Aug 5/03
RE100[LJ]
Table 802. Torque Data
Torque pound-inches (Nm)
Thread Size Aluminum Fastener Cres Fastener
6-32 5 (0,565) 10 (1,13)

8-32 10 (1,13) 20 (2,26)
10-24 15 (1,695) 35 (3,955)
1/4-20 45 (5,085) 75 (8,475)
5/16-10 80 (9,04) 160 (18,08)
3/8-24 140 (15,82) 275 (31,075)
Table 803. Final Torque Data
Thread Size Approximate Turn After Run-Down
6-32 45 deg
8-32 60 deg
10-24 40 deg
1/4-20 40 deg
5/16-18 40 deg
3/8-24 60 deg
(1) Tighten fasteners installed through elastic boundaries (sealed by means of a

diaphragm or similar elastomeric gasket) equally to get a pressure tight seal.
F. Specified Torque Values
(1) Table 804 gives information necessary to tighten fasteners to specified torque.
Values shown do not include frictional torque caused by self-locking devices or
rundown resistance. Frictional torque values must be added to the specified torque.
Page 803
49-25-93 Aug 5/03
RE100[LJ]
Table 804. Specified Torque
Figure Item Torque

No. No. Nomenclature lb-in (Nm)
704 180 Tie shaft nut 50 (5,68)
713 60 Round plain nut 300 (33,9)
718 10 Encased plain seal assembly 60 (6,78)
719 10 Bolt 120 (13,56)

40 Bolt 120 (13,56)
60 Bolt 120 (13,56)
727 80 Bolt 60 (6,78)
728 140 Bolt 60 (6,78)
731 10 Bolt 120 (13,56)

40 Bolt 120 (13,56)
60 Bolt 120 (13,56)
732 10 Bolt 60 (6,78)
733 10 Bolt 60 (6,78)

120 Low voltage igniter plug 250 (28,25)
735 10 Bolt 60 (6,78)

736 10 Bolt 60 (6,78)
737 80 Bolt 60 (6,78)
738 10 Bolt 145 (16,39)

150 Bolt 60 (6,788
739 30 Debris monitor 25 (2,8)

60 Oil temperature bulb 60 (6,78)
90 Nut 50 (5,65)
100 Filler neck and cap 70 (7,91)
120 Tube bleeder plug 70 (7,91)
740 10 Nut 60 (6,78)

40 Air temperature bulb 120 (13,56)
60 Nut 50 (5,67)
Page 804
49-25-93 Nov 11/05
RE100[LJ]
Table 804. Specified Torque (Cont)
Figure Item Torque

No. No. Nomenclature lb-in (Nm)
741 10 Nut (on coupling clamp) 20 (2,26)

130 Bolt 60 (6,78)
150 Bolt 60 (6,78)
190 Nut 60 (6,78)
743 10 Bolt 60 (6,78)

50 Reducer 60 (6,78)
70 Reducer 60 (6,78)
90 Screw 7 (0,79)
744 60 Bolt 60 (6,78)
745 10 Bolt 60 (6,78)

30 Igniter plug electrical lead (to ignition unit) nut 100 (11,3)
Igniter plug electrical lead (to igniter plug) nut 150 (16,95)
746 10 Bolt 60 (6,78)

40 Bolt 60 (6,78)
80 Bolt 60 (6,78)
150 Bolt 60 (6,78)
180 Bolt 60 (6,78)
210 Bolt 60 (6,78)
747 Nut (to immersion thermocouple) 25 (2,8)
Page 805
49-25-93 Nov 11/05
RE100[LJ]
Page 806
49-25-93 Aug 5/03
RE100[LJ]
SPECIAL TOOLS, FIXTURES AND EQUIPMENT
1. General
A. Procedures shown in this publication, that need special tools, fixtures and equipment, can be
done with the use of the special tools, fixtures and equipment shown in Table 901.
Part No.

Universal test stand Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Transport cart assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Bearing support (Component of Part No. Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 901
49-25-93 Nov 11/05
RE100[LJ]
Part No.

717 N. Bendix Dr.,
Telephone: 574-231-3987

Test stand assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearbox pinion bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearbox idler bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearbox generator bearing retainer Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor rotor removal tool Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 902
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Compressor bearing remover assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Telephone: 574-231-3987

Bearing remover assembly Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Telephone: 574-231-3987

Split plate remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Splined adapter installer and remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 903
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Generator idler position fixture Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Telephone: 574-231-3987

Telephone: 574-231-3987

Generator seal rotor and bearing remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing split plate remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing split plate remover Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler gearshaft driver Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 904
49-25-93 Nov 11/05
RE100[LJ]
Part No.
Part No. 5838424 Honeywell Engines, Systems & Services

Bleed transition duct adapter Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Part No. 5838425 Honeywell Engines, Systems & Services

Duct adapter Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor gearshaft driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Driver (Component of Part No. 5838427- Ground Support Equipment,
1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

5838427-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 905
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Rotor pilot ring driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Pilot ring driver (Component of Part No. Ground Support Equipment,
5838428-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

5838428-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Compressor shaft bearing driver and Ground Support Equipment,
support 717 N. Bendix Dr.,
Telephone: 574-231-3987

Cylindrical bearing driver (Component of Ground Support Equipment,
Telephone: 574-231-3987
Page 906
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Telephone: 574-231-3987

Annular bearing driver (Component of Ground Support Equipment,
Telephone: 574-231-3987

Telephone: 574-231-3987

Idler gear bearing driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Idler bearing driver (Component of Part No. Ground Support Equipment,
5838431-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 907
49-25-93 Nov 11/05
RE100[LJ]
Part No.

Idler gearshaft support (Component of Part Ground Support Equipment,
No. 5838431-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Gearshaft bearing driver and support Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987

Ball bearing driver (Component of Part No. Ground Support Equipment,
5838432-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

Generator gearshaft support (Component Ground Support Equipment,
of Part No. 5838432-1) 717 N. Bendix Dr.,
Telephone: 574-231-3987

717 N. Bendix Dr.,
Telephone: 574-231-3987
Page 908
49-25-93 Nov 11/05
RE100[LJ]
Part No.

717 N. Bendix Dr.,
Telephone: 574-231-3987

Telephone: 574-231-3987

Shaft stretcher kit Ground Support Equipment,
717 N. Bendix Dr.,
Telephone: 574-231-3987
Industrial marking ink (Violet 127- 1/2) Pannier Corp., 207 Sandusky Street
Pittsburg, PA. 15212
Page 909
49-25-93 Nov 11/05
RE100[LJ]
Page 910
49-25-93 Aug 5/03

CMM 49-25-89 Gas Turbine Engine

Uploaded by

Copyright:

Available Formats

CMM 49-25-89 Gas Turbine Engine

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

CMM 49-25-89 Gas Turbine Engine

Uploaded by

Copyright:

Available Formats

Engines, Systems & Services

TO: HOLDERS OF UNIT NOMENCLATURE COMPONENT MAINTENANCE/OVERHAUL MANUAL,

3800726-1 RE100[LJ] Learjet 45

REVISION NO. 1 DATED NOVEMBER 11/05

Subject/Page Description of Change

Record of Temporary Revisions

Service Bulletin List

List of Effective Pages

Description and Operation

Testing and Fault Isolation

Page 111 Revised Key to Figure 101 (Sheet 1) for latest

Subject/Page Description of Change

Page 113 Revised Step 1.E.2(j) for latest information.

Page 119 Revised Step 1.F.(10) for latest information.

Page 122 Revised Steps 1.G.(6) and (10) for latest

Page 123 Revised Step 1.H.(5) for latest information.

Page 310 Revised Figure 301 for latest information.

Page 316 Revised Figure 303 for latest information.

Page 321 Revised Step 1.F.(3)(c) for latest information.

Page 322 Revised Figure 306 for latest information.

Page 325 Revised Key to Figure 308 for latest information.

Page 326 Revised Figure 308.

Page 329 Revised Key to Figure 309 for latest information.

Subject/Page Description of Change

Page 334 Revised Figure 311 for latest information.

Page 335 Revised Key to Figure 311 and Steps 1.F.(9)(b)

Page 336 Revised Figure 312 for latest information.

Page 337 Revised Key to Figure 312 and Step 1.F.(10)(a)for

Page 345 Revised Key to Figure 316 for latest information.

Page 352 Revised Figure 320 for latest information.

Page 355 Revised Key to Figure 321 for latest information.

Page 361 Revised Step 1.F.(22)(h) for latest information.

Page 374 Revised Figure 330 for latest information.

Page 405 Revised Table 402 Materials and Compounds for

Page 502 Revised Table 502. Special Tools, Fixtures and

Page 506 Revised Step 1.E.(1) for latest information.

Page 507 Added page ‘This Page Intentionally Left Blank’.

Page 508 Revised Figure 501 for latest information.

Subject/Page Description of Change

Page 509 Revised Figure 501 Check Procedures for latest

Page 511 Revised Figure 502 Check Procedures for latest

Page 512 Revised Figure 503 for latest information.

Page 516 Revised Figure 505 for latest information.

Page 517 Revised Figure 505 Check Procedures for latest

Page 522 Revised Figure 508 for latest information.

Page 523 Revised Figure 508 Check Procedures for latest

Page 526 Revised Figure 510 for latest information.

Page 528 Revised Figure 511 for latest information.

Page 530 Revised Figure 512 for latest information.

Page 534 Revised Figure 514 for latest information.

Page 535 Revised Figure 514 Check Procedures for latest

Page 546 Revised Figure 519 (Sheet 2) for latest information.

Page 547 Revised Figure 519 Check Procedures for latest

Assembly (With Storage)

Page 701 Revised Table 701 Materials and Compounds for

Page 715 Revised Step 3.A.(2) and WARNING per Temporary

Page 741 Revised Key to Figure 712 for latest information.

Page 751 Revised Key to Figure 716 for latest information.