tfe 731 chap 70 (1)

Garret TFE 731 Turbofan Engine (CAT C)

CHAPTER 70

of 18 FOR TRAINING PURPOSES ONLY © TFE 731 - ISSUE 2, 2010


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INTRODUCTION

0 TABLE OF CONTENTS

1 Foreword 3 2 Technical Publications 4 3 ATA 100 7 4 Service Manual Contents 10 5 Light Maintenance Manual Contents 11 6 Service Bulletins 12 7 Illustrated Parts Catalogue (IPC) 13 8 Illustrated Tool and Test Equipment Manual 15 9 Service Information Letters 16 10 Training Material 17


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INTRODUCTION

1 FOREWORD AlliedSignal Aerospace provides training Study Guides for the limited purpose of presenting familiarisation, illustrations, and general information to students in support of a specific training course only. Information contained herein is intended only as a general description of operation to permit intelligent maintenance and systematic troubleshooting of the subject system or components described herein. Contents herein are subject to change without notice. The reader of this manual is reminded that all values of pressure, temperature, speed, power, etc. are chosen for their illustrative meaning only and are not necessarily representative of true values. For actual values, the applicable maintenance manual must be consulted. Official publications pertaining to operating procedures, limits, and capabilities of engines or their components are the responsibility of the airframe manufacturer. The airframe manufacturer installs the engine in its airframe, designs and/or selects instruments, and flight tests the aircraft. The airframe manufacturer determines how and under what limitations engines will be operated for all modes of taxi and flight. As an engine and engine component manufacturer support company, AlliedSignal Aerospace has the responsibility to alert airframe manufacturers that their aircraft manuals not permit operation beyond the limits of an engine's capabilities. AlliedSignal may suggest and advice - but not dictate - operational and maintenance practices it feels best for the engine. Some aircraft manufacturers will assimilate AlliedSignal Aerospace manuals into their own publications while other manufacturers may simply refer the owner/operator to AlliedSignal Aerospace published manuals.

Official publications, which apply to all engines and systems, are listed below (with the highest ranking manual first): 1. Aircraft Flight Manual 2. Aircraft Maintenance Manual 3. Engine Maintenance Manual and Service Bulletins 4. Engine Overhaul Manual and Service Bulletins 5. Component Overhaul Manual and Service Bulletins It was not accidental that this training manual is not included in the above list of publications. NOTE: The training manual has no official status. In all instances,

information contained in official publications shall govern


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2 TECHNICAL PUBLICATIONS

2.1 Publication Priority

A wide range of maintenance publications is available in support of the TFE731 engine. Of these publications, some are directive in nature while others are informative and unofficial. This section will outline these publications, explain their type and precedence and provide instructions on how to use them. It is important for the maintenance technician to understand the precedence of each type publication and to recognise the priority of the FAA approved documents as they apply to the operation and maintenance of the engine and aircraft. Any conflicting instructions that may exist between information contained in various publications must be recognised as to precedence. In all cases, the aircraft flight manual -- sometimes called pilot's operating handbook or pilot's operating manual takes precedence over maintenance manuals and, as such, is considered the first priority. Aircraft maintenance manuals take precedence over engine maintenance manuals. Notice in the list above that the engine manuals are listed last in priority. This priority system is particularly important when there is conflicting information between manuals. It must be stressed at this point, that the material presented in this training guide has no official status, and as such should never be used in aircraft or engine maintenance.


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2.2 Publications Related to Line Maintenance

Aircraft manuals will usually refer the operator to the engine manufacturer's maintenance manuals for detailed instructions relative to maintaining the TFE731 engine. This list identifies the engine publications related to line maintenance. The service manual provides instructions to detail the maintenance, servicing and inspection procedures that can be accomplished without the aid of special tools or test equipment. Maintenance procedures requiring special tools or test equipment are contained in the light maintenance manual. The light maintenance manual (LMM) provides engine description and operation, troubleshooting and all authorised maintenance level instructions. The LMM instructions are self-contained and no reference to other publications except the illustrated parts catalogue (for parts ordering) is required. The illustrated parts catalogue (IPC) illustrates and lists parts of the engine as produced from the factory and as modified by service bulletins during maintenance. All engine parts are listed except those replaceable only at a major service centre or heavy maintenance facility. Service bulletins provide special information concerning equipment or provide modification instructions. Service information letters (SIL) provide unofficial information to the engine operator concerning engine operation and maintenance. While the service manual, LMM, and service bulletins are FAA approved documents, the IPC and SIL's, while prepared generally in accordance with Air Transport Association Specification No. 100, are not.


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2.3 Additional Publications

Additional publications that are used to maintain the TFE731 engine are listed above. The heavy maintenance manual (HMM) provides engine performance testing instructions and maintenance practices for the compressor zone of the engine. Use of this manual requires additional tooling not normally found at the line service centre. The HMM instructions, with referenced LMM instructions, provide all maintenance practices applicable to the TFE731 engine. The repair manual provides repair information for engine parts that have been determined unserviceable and not repairable in accordance with the LMM or HMM. The data contained in the repair manual is beyond the scope of the LMM and HMM and is intended for use by Garrett authorised repair facilities. Component maintenance manuals provide testing and troubleshooting, disassembly, and repair procedures for engine components by specific part number. Each component maintenance manual contains an illustrated parts list. Exploded-view type illustrations provided in the manual correspond to figure numbers in the illustrated parts list. The illustrated tool and test equipment manual is a catalogue of all tooling and equipment required to maintain the TFE731 engine. The catalogue provides an illustration of each tool and a short explanation of how the tool is used. Spare parts bulletins are issued periodically to announce new interchangeable part numbers to be introduced into service after attrition of the replaced part.


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3 ATA 100

3.1 Manual Format

Subjects are located in the manuals by an ATA 100 numbering system. This numbering system was developed by the Air Transport Association to maintain consistency and standardisation in aircraft and engine manuals. The manuals are divided into chapters, sections, and subjects using a six digit, three-element number separated by dashes. The first and second digits identify the chapter or major system and are assigned by ATA specification. The third and fourth digits identify the sub-system, or section and are assigned by ATA specification. The fifth and sixth digits identify the unit, or subject and are assigned by the manufacturer. The following example illustrates and describes use of each element of the number: Typical Chapter - Section Subject Number - 73-10-01 73- This number designates a major system. Chapter 73 is "Engine Fuel and

Control". -10- This number designates a section or sub-system breakdown of material

in Chapter 73. In this example: "Distribution". -01- This number designates a specific component or unit of a section. In this

case, -01 represents "Fuel Manifold and Splash Shield Installation".


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3.2 Chapters

Maintenance procedures for components and systems are located in various chapters and sections within the manual as shown here. Chapter 71 "Power Plant" is part of the aircraft maintenance manual and is not listed here. Refer to ATA Specification No. 100 for a complete listing of all chapter/section numbers.


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3.3 Topics and Assigned Pages

The complexity and volume of material contained in the maintenance manual dictates the need for breaking the subjects within manual chapters down into reasonably small topics for ready reference and ease of revision. To accomplish this, page number blocks are used to separate subjects into topics. It is necessary to use a standard page block system so that topics may be broken out for special distribution. In the case of relatively simple components, coverage for description and operation and other topics may not be required. In such cases, the unused page number blocks are omitted. When topics are brief, they are combined into one topic entitled, for example Fuel System Installation Maintenance Practices. Topics covered in this manner are page numbered within the 201 through 300 page number blocks. Maintenance Practices consists of a combination of the following topics: Servicing, Removal/Installation, Adjustment/Test, Inspection/ Check, Cleaning/Painting, and Approved Repairs.


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4 SERVICE MANUAL CONTENTS The service manual contains general procedures used by the flight line mechanic. Chapter 70 briefly outlines standard practices and general maintenance procedures. The service instructions within this publication detail the maintenance procedures that are required to support Recommended Routine Periodic Inspection Requirements and limited Troubleshooting and Adjustment/ Test procedures. These procedures can generally be accomplished with a minimum of special tools or test equipment. Some of the instructions and information contained in the service manual are applicable only to specific engine model numbers, engine series/serial number, or pre or post service bulletin configurations of engines. When this occurs, the applicability of the material is noted at the beginning of the paragraph, procedural step, table title, or figure title. Warnings, Cautions, and Notes are found throughout this manual preceding the applicable procedures. The following definitions apply to Warnings, Cautions, and Notes. WARNING: PROCEDURES THAT MAY RESULT IN PERSONAL INJURY

OR LOSS OF LIFE IF NOT CAREFULLY FOLLOWED. CAUTION: PROCEDURES THAT MAY RESULT IN DAMAGE TO

EQUIPMENT IF NOT CAREFULLY FOLLOWED. NOTE: Procedures that are considered essential to emphasise.

Refer to the Introduction Tab, "How to Use Instructions", for a complete description of the manual, abbreviations used, and a listing of other applicable publications.


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5 LIGHT MAINTENANCE MANUAL CONTENTS The light maintenance manual contains chapters 70 through 79. Chapter 70 outlines the standard practices and general maintenance instructions. Frequent reference to this section is necessary since those general procedures are not repeated in subsequent chapters. Chapter 72 commands the majority of the LMM. It provides engine description and operation, troubleshooting, servicing and all authorised maintenance level instructions. An extensive troubleshooting section is provided in Chapter 72 as an aid in locating the cause of a malfunction based on the symptoms it produces. The troubleshooting instructions consist of troubleshooting tables, troubleshooting procedures, check instructions, schematics and diagrams. Though primarily intended for use by maintenance personnel, these instructions may help a pilot give more meaningful information thereby reducing the time required to locate and correct an engine problem. In all cases, the aircraft flight manual and/or appropriate aircraft document is to be used as a basis for operating, adjusting, and evaluating the performance of the engine installed in the aircraft. Detailed maintenance procedures are provided for all systems, 72 through 79, in the light maintenance manual. Warnings, Cautions, and Notes are found throughout the manual preceding the applicable procedure and are as described for the service manual. A review of the "Introduction" section of the LMM will simplify your use of the manual.


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6 SERVICE BULLETINS Service bulletins are FAA approved notices which publish special information concerning equipment or that provide modification instructions. There are two types of service bulletins. The standard bulletin is printed on white paper. Alert notices require special attention and are printed on blue paper. Service bulletins are numbered in accordance with the ATA format. For example, bulletins issued for the engine are numbered 72, for fuel systems 73, lubrication system are numbered 79, etc. An example of special information contained within a service bulletin is SB 72-3001, which establishes service life limits of certain critical engine components. Service bulletins also provide recommended intervals for performing periodic inspections based upon engine operating hours since new or last inspection. A complete list of service bulletins to include latest revisions and new service bulletins is included in the front of the LMM and IPC. Service bulletins referenced in front of the service manual are applicable only to service manual procedures.


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7 ILLUSTRATED PARTS CATALOGUE (IPC) The illustrated parts catalogue consists of two primary sections, a numerical index and a detailed parts list. The numerical index lists all part numbers contained in the detailed parts list alphabetically and numerically to provide a means of locating a part. The detailed parts list consists of a series of individual parts lists, listing all engine components. Each individual parts list is accompanied by a figure to illustrate the listed parts. Index tabs are used to subdivide and identify groups of parts by function and/or location. The primary divisions (yellow tabs) are Chapters 72 (Engine), 73 (Engine Fuel and Control), 74 (Ignition), 75 (Air), 76 (Engine Controls), 77 (Engine Indicating), and 79 (Oil). A table of contents listing components or component groups by chapter/section/subject and figure number follows each yellow tabbed chapter sheet. When a chapter is unusually complex, it is further divided into groups by system function (per ATA 100) with white tabs. Detailed instructions on how to use the IPC can be found in the "Introduction" section of the manual. Included in this section is an explanation of the terms and symbols used in the catalogue, the Garrett part numbering system and a listing of manufacturers of non-Garrett components of the engine. An extremely handy table of "Standard Hardware" used on the TFE731 engine is also located in the Introduction section. This table lists standard hardware by P/N, thread size, length, plating, head marking, and description. Use of this section can save valuable time in locating the exact fastener needed. Detailed parts lists for line replaceable units (LRU) are not included in the IPC. Refer to the component maintenance manual for exploded-view type illustrations of LRU's with specific detailed part numbers. Each engine is provided with a nameplate for identification of the engine. Information supplied on the nameplate includes part number and serial number. The part number defines a group of specific configurations. All engines with the same part number are interchangeable. A series number supplements the part number and, if applicable, change numbers to define a specific configuration. A series number is assigned at engine manufacture or overhaul to identify a group of product improvement changes incorporated beyond the initially

manufactured configuration. Individual changes incorporated, which are not within the series grouping, are identified separately by change numbers. Changes incorporated since engine production is listed in the engine logbook. The engine logbook enables the operator of Garrett turbofan engines to maintain the engine records required by the Federal Aviation Administration and local Aviation Authorities. Ample space is provided in the logbook to record the total time in service on the engine, the inspections performed and the maintenance accomplished. The book has the following sections: Engine Service Record. This section contains pages for recording engine hours, cycles, and maintenance actions. Service Bulletin Compliance Record. Pages suitable for maintaining records of compliance with Garrett service bulletins. Airworthiness Directives. Records of compliance with Federal Aviation Administration airworthiness directives are maintained in this section. Engine Location. This section is provided for recording changes in the installation location of this engine.


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Life Limited Parts. A copy of SB TFE731-72-3001 - Service Life Limits of Critical Life Limited Components is filed in this section. As revisions to this service bulletin are issued, extra copies will be mailed to the operator for insertion into this section of the logbook. Life Limited Parts Change Record. This section contains an area for recording changes of parts that are required to be time/cyclic controlled in accordance with appropriate approved service bulletins. If any Life Limited Part is removed from the engine, appropriate entries must be recorded in this section and on the parts log card. Life Limited Parts Log Cards. Individual log cards for each of the life limited parts in the engine are inserted into this section. The cards contain historical data concerning that specific part. The cards also provide an area for recording maintenance actions performed on the parts. The log cards, with appropriate entries must be with the parts when returned for any reason, otherwise the parts may be scrapped and no credit given to the returnee. Experience has shown that recording maintenance actions and service bulletin compliance on components in only the logbook has proven to be inadequate. When components are removed from the engine (or aircraft in the case of electronic controls), the component operating hours as well as maintenance history can be lost. Service Bulletin TFE731-72-3397 implemented a Component Maintenance/Modification Record Card to document maintenance actions. Once established, the card will preclude a logbook search for such things as part and serial numbers, last inspection, service bulletin compliance, maintenance performed and component operating hours. Upon removal of a component from service, remove the Component Maintenance/ Modification Record from the engine logbook, attach the record card to the component and forward it to the appropriate repair station. When installing a component, make the appropriate entry on the record card and insert the card into the engine logbook. The record card is not limited to specific component parts - it may be used on any part to maintain a history of maintenance or inspections.


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Refer to Service Bulletin TFE731-72-3397 for complete instructions on form entries and maintenance of the Component Maintenance/ Modification Record Card. The engine logbook is critically important as a record-keeping device. Accurate record keeping in a vital part of efficient and effective maintenance.

8 ILLUSTRATED TOOL AND TEST EQUIPMENT MANUAL The illustrated tool and test equipment manual, commonly called a tool catalogue, provides information on the special tools and test equipment required for support of the TFE731 engines. Off-the-shelf tools and test equipment, which are commercially available, are not included in this manual. The manual contains an alphanumeric listing of all special tools and test equipment to support TFE731 engines. Included in this listing is the maintenance level at which the item is used, and the total number of items required to perform a single maintenance action. Illustrations of the tool and a brief description of its use are included for all tools and test equipment that is manufactured by Garrett. This manual is most useful in determining required tooling and test equipment to support any level maintenance activity. Revisions to this manual are made periodically as tooling and procedural changes warrant.


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9 SERVICE INFORMATION LETTERS Through its customer support organisation, service centres, engineering flight test activities, pilot-to-pilot contacts, technical representatives, and many other sources, Garrett gathers information on the operation of its turboprop and turbofan engines. This information is evaluated; and if an improvement or change in procedures is indicated, it is recommended to the airframe manufacturer for include in the aircraft flight manual. Service information letters, operating instructions and operational tips, and the "Contact" newsletter are used to provide the information to operators and maintenance in the field. Information should be considered supplementary to and definitely not changes to the aircraft flight manual. As always, the aircraft flight manual is the final authority for operation of the aircraft and engines. Service information letters are generally cancelled after the information they contain has been incorporated into the appropriate engine maintenance manual. SIL's are also revised as necessary. The current status and revision number for all active TFE731 SIL's can be found in SIL F731-index.


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10 TRAINING MATERIAL It must be emphasised that training material produced by the AlliedSignal Technical Training Centre for customer, pilot, and maintenance personnel is for training purposes only. This material

is representative and should not be used in place of the official FAA approved publications.


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tfe 731 chap 70 (1)

Documents

training manual

engine maintenance manual

engine overhaul manual

aircraft maintenance

service manual contents

applicable maintenance

aircraft flight manual

training purposes