Avon UTC 1535c6

INDUSTRIAL AVON GAS GENERATOR
MAINTENANCE
CHAPTER 6
PREVENTIVE MAINTENANCE
CONTENTS
Para
GENERAL INFORMATION 1
Blanks and Blanking Procedure 1.1
Change of Component Procedure 1.2
Functional Testing of Equipment 1.3
Safety Warnings and Cautions 1.4
System safety 1.4.1
Igniter/high energy ignition unit function 1.4.2
testing
Torque Tightening Technique 1.5
General 1.5.1
Lubrication 1.5.2
Retightening of nuts 1.5.3
Preliminary smoothing of threads and mating 1.5.4
faces
Torque tightening involving locking device 1.5.5
Torque tightening sequence 1.5.6
Hand torque wrench 1.5.7
Power wrenches 1.5.8
Torque multiplier 1.5.9
Extension spanners 1.5.10
In-built (locking) torque for self locking 1.5.11
fasteners
Fitting non self locking nuts to studs or 1.5.12
bolts; also fitting bolts, used as setscrews,
in non self locking thread holes
Fitting self locking nuts to studs and bolts; 1.5.13
also bolts used as setscrews, in self
locking wire thread inserts or in self
locking thread captive nuts
Tube connections (union nuts, tube and hose 1.5.14
connections)
Screwed unions and hexagon headed blanking 1.5.15
plugs
Fitting serrated head sealing plugs 1.5.16
Fitting studs 1.5.17
Specified Torque Loads 1.6
CONVERSION TABLES 2
GASEOUS FUEL MANDATORY REQUIREMENTS 3

Acceptability of the Gas 3.1
Gas Index Number 3.2
Gas Pressure 3.3
Gas Temperature 3.4
CONTENTS
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May/00 Prelim 1
MAINTENANCE
Para
Liquid Hydrocarbon and Hydrates 3.5

Water and Foreign Matter 3.6
Sulphur Content 3.7
Sodium and Potassium Salts 3.8
CONTAMINATION OF GAS GENERATOR COMPONENTS 4

General Information 4.1
Cadmium Contamination 4.2
Chlorinated Solvents (or other Halogens) 4.3
CLEANING OF PARTS 5
TEMPORARY MARKING OF PARTS 6

General 6.1
Marking Media 6.2
ASSEMBLING OF PARTS 7
Assembling Procedure 7.1
Nomenclature 7.2
Modification Status 7.3
Correlation Marks 7.4
Torque Tightening 7.5
Methods of Locking 7.6
Tools 7.7
Consumable Materials 7.8
Lubrication 7.9
Apply Jointing Compound 7.10
Sealing Rings 7.11
Backlash Checks on Bevel Gears 7.12
Identification of 12 Point Self Locking Nuts for 7.13
Low and High Temperature Applications
WIRE LOCKING OF COMPONENTS 8

Introduction 8.1
Points to Observe When Fitting Lock Wire 8.2
Procedure for Fitting Lock Wire 8.3
ROUTINE INSPECTION AND MAINTENANCE 9

General 9.1
Routine Inspection Period 9.2
Inspect the Gas Generator for External Leakage 9.3
INSPECTION OF HYDRAULIC, AIR AND ELECTRICAL SYSTEMS 10

Inspect the Hydraulic Oil Drainage System 10.1
Inspect the Gas Generator Air Intake 10.2
Check the Starter Motor Insulation Resistance 10.3
Inspect the Exhaust Unit (where specified) and 10.4
the Turbine Assembly
Inspect the Gas Generator Generally 10.5
Renew the Igniter Plugs 10.6
CONTENTS
6 1535-GAS
Prelim 2 May/00
MAINTENANCE
Para
Inspect the Lubricating Oil Feed Filter 10.7

Inspect the Lubricating Oil Magnetic Chip 10.8
Detectors
Inspect the Static Oil Level in the Intake Guide 10.9
Vanes Ram
Inspect the P2 Air Filter 10.10
Check the Lubricating Oil Acidity Level 10.11
Check the Gas Generator Vibration Monitoring 10.12
System
RUBBER AND SYNTHETIC RUBBER PARTS - SHELF LIFE, STORAGE 11
AND INSPECTION
Shelf Life 11.1
Cure Date Marking 11.2
Storage of Parts 11.3
Inspection of Parts 11.4
LUBRICATING OIL GUIDANCE NOTES 12
General 12.1
Check the Acidity Level of the Oil 12.2
SERVICING AND STORAGE MATERIALS 13
COMPRESSOR - INSPECTION 14
Inspections Made Through the Air Intake 14.1
General 14.1.1
Inspect the blading through the air intake 14.1.2
Compressor Front Casing Inspection 14.2
Inspect the front compressor casing 14.2.1
INSPECT THE FRONT SUSPENSION BOLTS AND SPHERICAL 15
BEARINGS FOR LUBRICATION
TABLES
Table Title Page
1 Range of in-built torque limits for self locking 14

wire thread inserts and captive nuts
2 Torque check gauges 15
3 Standard torque loads for fitting non self locking 16
nuts and bolts
4 Standard torque loads for fitting self locking 17
nuts and bolts
5 Standard torque loads for tube connections 18
6 Torque tightening values for unions and hexagon 19
headed blanking plugs
CONTENTS
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May/00 Prelim 3
MAINTENANCE
Table Title Page
7 Standard torque loads for fitting serrated head 20

sealing plugs (unified or Whitworth threads)
8 Identification or rubber sealing rings 45
9 Locking wire specification 49
10 Inspection checks 56
ILLUSTRATIONS
Fig Page
1 Pipe and component blanks 3
2 Tightening sequence for flange fasteners 8
3 Tightening sequence for half casing 8
4 Fixed ratchet type torque wrench and extension 12
5 Torsion bar type torque wrench and extension 12
6 Sodium and potassium salts graph 36
7 Tabwasher locking - Examples 41
8 Typical pilot and sleeve assembling tool 47
9 Maximum span of twisted lock wire between tension 51
points (right-hand threaded fasteners are
illustrated)
10 Examples of wire locking for right-hand threaded 51
fasteners
11 Examples of wire locking for right-hand threaded 53
pipe unions
12 Double twist method of wire locking (right-hand 54
threaded fasteners are illustrated)
13 Looped lock wire passing under strand from hole 54
(right-hand threaded fastener is illustrated)
14 Maximum distance of twisted lock wire to units 54
(right-hand threaded fasteners are illustrated)
15 Limits of damage to leading and trailing edges of 78
stage 00 rotor blade
16 Limits of damage to tip of stage 00 rotor blade 78
17 Unacceptable indentations with cracks - 79
Stage 00 stators
18 Compressor front casing cracking 81
19 Location of grease nipples fitted to front 82
suspension bolts
CONTENTS
6 1535-GAS
Prelim 4 May/00
MAINTENANCE
CHAPTER 6
1. GENERAL INFORMATION
(1) Use only approved tools as listed in Chapter 9.
(2) Ensure the gas generator oil levels are acceptable

before starting the gas generator.
1.1 Blanks and Blanking Procedure
(1) Ensure that the open ends of disconnected pipes are

covered by protective caps. Apertures uncovered by
the removal of components must be suitably covered
until the components are replaced.
CAUTION: DO NOT USE TAPERED, NON THREADED, PUSH-IN TYPE

PIPE BLANKS.
(2) All blanks should be either the external screw type,

external screw cap or an internal type with a large
flange. Refer to Fig 1.
(3) Before using blanks it is essential that the

following procedure is adopted:
(a) The blank to be used is of the correct type,

size, clean and is not damaged or split.
(b) Ensure before fitting the blank that no other

smaller blank is trapped inside the blank to be
fitted.
(c) Ensure the component to which the blanks are

being fitted is clean, that no dirt has entered
the component, and the line is clear.
(d) On removal of blanks, immediately prior to

assembly, a similar inspection as in (c) should
be undertaken.
(e) If a component cannot be correctly blanked care

should be taken to ensure that the component is
suitably bagged and sealed.
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MAINTENANCE
1.2 Change of Component Procedure
(1) Ensure that all tools and replacement parts are

accounted for after job completion.
(2) Fit new sealing washers, joint washers and locking

devices whenever such items are disturbed. Discarded
items should be disposed of in the correct manner and
not left lying about in the vicinity of the gas
generator.
(3) Unless otherwise stated apply jointing compound to

cool end component faces and dry film lubricant to
hot end. Refer to this Chapter, for details of the
jointing compound and dry film lubricant.
(4) Ensure that the gas generator oil levels are

acceptable before starting the gas generator.
Replenish the tank as necessary after any check run.
(5) Carry out the appropriate functional checks on all

newly fitted components and examine for fuel, oil and
air leaks immediately after any check run.
(6) It is important that the system of records be

maintained accurately and kept up-to-date.
(7) All torque loading and tightening of nuts, bolts and

locking devices removed and replaced during
corrective maintenance, is to be carried out in
accordance with standard practices with the exception
of those requiring special torque loads as indicated
in text.
(8) All electrical connectors should be wire locked when

secured.
(9) Defective or damaged wire thread inserts must be

replaced.
(10) Ensure that all gas generators are serviced, repaired

and overhauled by RRPEplc approved personnel and
repair facilities.
(11) Ensure that where new or replacement components are

fitted, they are genuine RRPEplc parts and that they
all carry RRPEplc part numbers in locations and in
the manner as prescribed by RRPEplc (information on
this will be supplied to recognised owner/operators).
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FIG 1 PIPE AND COMPONENT BLANKS
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MAINTENANCE
(12) Instruct the overhaul base to deface any life expired

components in such a way as to make cosmetic
refurbishment impossible, eg. a notch cut or ground
into the leading edge of a blade aerofoil.
WARNING: THE SYNTHETIC LUBRICATING OIL USED IN THIS

ENGINE CONTAINS ADDITIVES WHICH AFTER PROLONGED
SKIN CONTACT CAN BE TOXIC THROUGH ABSORPTION.
CAUTION 1: THE OIL SPECIFIED FOR USE IN THIS OIL SYSTEM

IS INJURIOUS TO PAINTWORK AND CERTAIN TYPES OF
RUBBER AND MUST NOT BE ALLOWED TO CONTAMINATE
THOSE PARTS OF THE ENGINE NOT NORMALLY IN
CONTACT WITH IT. ANY OIL SPILT MUST BE
IMMEDIATELY WIPED UP.
CAUTION 2: CONTAMINATION BY MINUTE AMOUNTS OF CERTAIN

ALKALINE CLEANING FLUIDS CAN CAUSE COMPLETE
BREAKDOWN OF SYNTHETIC OIL. USE SCRUPULOUSLY
CLEAN CONTAINERS AND EQUIPMENT.
1.3 Functional Testing of Equipment
(1) When any sub-assembly, accessory, component or its

attachments are disturbed then the installation of
the item must be checked for conformance with the
required standards.
(2) Where practical, the item and its associated circuits

must be function tested to prove correct operation
before the unit is started up.
(3) Where items cannot be tested prior to running the

unit then their operation must be proved before the
unit is declared serviceable.
(4) This testing should be carried out on every occasion

that an item is disturbed.
1.4 Safety Warnings and Cautions
WARNING: THE ELECTRICAL DISCHARGE FROM THE HIGH ENERGY

IGNITION UNITS IS LETHAL. THEREFORE THE LOW
TENSION (LT) SUPPLY TO THE UNIT MUST BE
DISCONNECTED AND NOT LESS THAN TEN MINUTES
ALLOWED TO ELAPSE BEFORE ATTEMPTING TO
DISCONNECT THE HIGH TENSION (HT) CONNECTOR.
CAUTION: IF A GAS FUEL CONNECTION HAS BEEN DISTURBED, OR
MAY HAVE BEEN DISTURBED, SINCE THE GAS GENERATOR
WAS LAST OPERATED, IT IS MANDATORY THAT THE
CONNECTION IS CHECKED FOR INTEGRITY AND GAS
TIGHTNESS BEFORE STARTING THE GAS GENERATOR.
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MAINTENANCE
1.4.1 System safety
Ensure that electrical circuits, fuel, lubricating

oil, hydraulic oil and fire extinguishing systems are
isolated and safe in accordance with Local Orders and
Maintenance Manual instructions before commencing any work
on the equipment. Live function testing must only be
undertaken by an authorised competent person.
1.4.2 Igniter/high energy ignition unit function testing
In ALL cases a DRY motoring cycle MUST be carried out

immediately prior to function testing igniters, high
energy ignition units or their related circuits.
1.5 Torque Tightening Technique
1.5.1 General
(1) A predetermined torque load is applied to nuts, bolts

and setscrews to prevent overstressing and to provide
optimum security. During assembling of the parts and
assembling of the complete gas generator, nuts, bolts
and setscrews must be tightened to either a special
load for a particular application or to a standard
load for the size of screw thread used. The parts to
be torque tightened to special loads are listed in
the relevant topic. Standard torque loads are shown
in Tables 1 to 7. Parts for which no special load is
specified in the relevant chapter should be tightened
to the standard loads listed in the tables.
1.5.2 Lubrication
(1) Lubrication is of great importance in achieving the

correct tension in a threaded assembly because most
of the applied torque is absorbed by friction at the
screw thread and on the mating faces of the parts.
(2) The standard lubricant to be used is clean

lubricating oil, ie. any of the approved oils used
for the gas generator lubrication system or Rocol
ASC251 which should be applied to the bolt threads
and nut abutment faces.
(3) Rocol ASC251 is the only lubricant, as an alternative

to lubricating oil, which is approved for general use
on threaded parts. The use of any other lubricants,
including solid film lubricants in any form
containing molybdenum disulphide is prohibited unless
specifically instructed.
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MAINTENANCE
(4) When a special lubricant is required, eg. for

extremely high torque loading or high temperature
operating zones of the gas generator, the correct
lubricant will be specified in the relevant area.
(5) The mean tensile load induced by the same applied
torque can be as much as 80 per cent greater using an
incorrect lubricant. In these circumstances fasteners
can be severely overstressed to the point of failure
either during assembly or gas generator operation.
1.5.3 Retightening of nuts
CAUTION: FAILURE TO CARRY OUT THE FOLLOWING INSTRUCTION
COULD RESULT EITHER IN AN ADEQUATE CLAMPING LOAD
OR, IF THE CORRECT TORQUE LOAD IS EXCEEDED IN AN
ATTEMPT TO INCREASE THE CLAMPING LOAD, IN DAMAGE
TO THE THREADS. THIS MAY NOT BE OBVIOUS AT THE
TIME BUT MAY CAUSE FAILURE OF THE JOINT DURING
SERVICE.
Whenever it becomes necessary to retighten nuts,
remove the nuts, clean and lubricate the threads and
abutment faces, refit the nuts and retighten to the
specified torque load.
1.5.4 Preliminary smoothing of threads and mating faces
(1) Smooth the threads.
NOTE: Smoothing the threads is necessary only when
threaded parts are being fitted with loads in
excess of 250 lbf ft. being applied.
(a) Lubricate the threads and mating faces of the
nut and washer with clean lubricating oil or
Rocol ASC251 unless otherwise instructed.
(b) Tighten the nut until approximately half the
recommended torque load value is obtained.
(c) Remove the nut, re-lubricate threads and mating
faces, then retighten until the full torque load
value is reached.
(2) Smooth the mating faces.
(a) Shrouded tabwashers are prone to 'dishing'
during manufacture and do not always flatten
satisfactorily with a single torque tightening
application; therefore, where shrouded tabwashers
are used, effect a double tightening procedure
as follows:
(i) Lubricate the screw threads and mating faces
with clean lubricating oil or Rocol ASC251
unless otherwise instructed.
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MAINTENANCE
(ii) Tighten the nut to the full torque load.
(iii) Remove the nut, re-lubricate threads and

mating faces, then retighten until the full
torque load value is obtained.
1.5.5 Torque tightening involving locking device
(1) Where locking plates, tabwashers or split pins

(cotter pins) are used as locking devices the
following instructions must be complied with:
CAUTION 1: FAILURE TO COMPLY WITH THESE INSTRUCTIONS

MAY RESULT IN FAILURE OF THE UNIT OR GAS
GENERATOR.
CAUTION 2: DO NOT SLACKEN THE NUT TO OBTAIN THE

LOCKING POSITION.
(a) If a single torque load value is specified, it

is permissible, and in many instances necessary,
to exceed the prescribed torque load value by
continuing to tighten the nut until the next
locking position is reached.
(b) If a minimum and a maximum torque load value is

quoted, the final torque load value applied must
be within the prescribed range.
1.5.6 Torque tightening sequence
(1) Where close pitch bolting is used and where it is

necessary to make a seal, adjacent fasteners should
not be tightened successively; tighten in a
symmetrical pattern to ensure that strain is not
induced into the structure. Unless specified
otherwise in the manual, the following procedure is
recommended:
(a) On flanges, lightly nip two fasteners

approximately opposite to each other and then
lightly nip up another pair approximately at
90 degrees to the first pair; bisect the
resulting angles and proceed as before; refer to
Fig 2. When the faces are in light contact with
all fasteners lightly nipped, apply the
specified tightening torque in a similar
sequence.
(b) On half casing joints, eg. compressor casings,

use the same method but tighten the mid section
positions first and then work outwards from the
centre. Refer to Fig 3.
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MAINTENANCE
FIG 2 TIGHTENING SEQUENCE FOR FLANGE FASTENERS
FIG 3 TIGHTENING SEQUENCE FOR HALF CASING
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MAINTENANCE
1.5.7 Hand torque wrench
(1) Fixed ratchet type.
(a) On fixed ratchet type torque wrenches the

desired torque value is preset by means of a
mechanism in the handle. When torque is
developed at the wrench head, the calibrated
mechanism within the wrench moves. When the
preset level of torque is reached, the release
is triggered, causing an audible 'click' and a
simultaneous release of tension, followed by
several degrees of free handle movement.
(b) When applying the torque, the handle should be

gripped lightly with one hand. The pull must be
applied at right angles (90°) to the centre line
of the wrench. The position of the hand should
not be altered so as to change the concentration
of the force.
CAUTION: DO NOT EXCEED THE TORQUE CAPACITY OF THE

WRENCH.
(c) The following list shows fixed ratchet type

torque wrenches and their torque load ranges:
Part No. Range Square

drive
PCT55270 30 to 200 lbf in. 3/8 in.
PCT55271 150 to 1000 lbf in. 3/8 in.
LOT16014 15 to 100 lbf ft. 3/8 in.
PCT46548 30 to 200 lbf ft. 1/2 in.
(d) All wrenches must be checked periodically on a

setting rig to ensure that they are reading
accurately. The ratchet mechanism should be
cleaned and lubricated periodically with light
grade oil to help ensure safe performance. Do
not use torque wrenches to loosen fasteners as
the sudden shock during release could cause
permanent damage. Interchangeable sockets,
adapters and extension bars are provided for use
with all wrenches.
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MAINTENANCE
(2) Torsion bar type.
(a) The torsion bar type torque wrench has a fixed

head and a direct reading dial. As torque is
applied the pointer on the dial indicates the
precise amount of torque applied.
(b) As this type of wrench does not depend on the

lever principle, its accuracy is unaffected by
hand position or by the use of extension handles
to increase leverage. Pull must be applied at
right angles (90°) to the centre line of the
wrench.
CAUTION: DO NOT EXCEED THE TORQUE CAPACITY OF THE

WRENCH.
(c) The following shows the torsion bar type torque

wrench and the torque load range:
Part No. Range Square

drive
PCT55269 0 to 75 lbf in. 1/4 in.
(d) All wrenches must be checked periodically on a

setting rig to ensure that they are reading
accurately. The ratchet mechanism should be
cleaned and lubricated periodically with light
grade oil to help ensure safe performance. Do
not use torque wrenches to loosen fasteners as
the sudden shock during release could cause
permanent damage. Interchangeable sockets,
adapters and extension bars are provided for use
with all wrenches.
1.5.8 Power wrenches
Power wrenching must be used only for preliminary

tightening of nuts and bolts. The power wrench must be set
to give 50 per cent of the final torque load, and the
final torque applied using the approved hand torque
wrench.
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MAINTENANCE
1.5.9 Torque multiplier
The torque multiplier is a mechanical gearbox or

hydraulic unit used in conjunction with the torque wrench,
in order to achieve higher torque loads than those
possible with the normal range of torque wrenches. It is
essential therefore, that the torque wrench scale reading
is correlated to the ratio of the unit being used. The
torque multiplier should be calibrated at regular
intervals and maintained in accordance with the
manufacturer's instructions.
CAUTION: WHEN MEASURING TORQUE DO NOT USE UNIVERSAL

JOINTS AS THESE MAY PRODUCE SERIOUS
INACCURACIES.
1.5.10 Extension spanners
(1) Extension spanners can be used in either of two

angular positions relative to the torque wrench.
Whenever extension spanners are used the following
rules and formula must be used.
(2) It is essential that, unless inaccessibility dictates

otherwise, the extension spanner should always be in
line with the torque wrench and the torque wrench
scale readings adjusted accordingly.
(3) Where the extension has to be fitted at the

alternative position because of limited access, the
shortest possible extension shall be used and care
taken to apply the load of the wrench handle at right
angles to the length of the wrench, to avoid errors.
(4) It is also essential to note that with the extension

spanner in the alternative 90 degrees angular
position, the torque reading correction factor does
not normally apply, if the extension spanner is of
the correct design.
Scale reading = Required torque x Length of Lever (A)

Total lever length (B)
NOTE 1: Length B should be measured parallel to the

torque wrench lever as shown in Fig 4.
NOTE 2: Length C can be considered to be equal to

length A for short extensions.
NOTE 3: This calculation is not required when the

extension spanner is in the alternative
position shown in Fig 4 and Fig 5.
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MAINTENANCE
FIG 4 FIXED RATCHET TYPE TORQUE WRENCH AND EXTENSION
FIG 5 TORSION BAR TYPE TORQUE WRENCH AND EXTENSION
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(5) Fixed ratchet type.
(a) Adjust the micrometer to required torque

setting.
(b) Determine the length of lever 'A' from the

centre of the handle to the centre of the square
drive.
(c) Determine total lever length 'B'.
(d) Calculate corrected torque setting.
(e) Adjust micrometer to corrected torque setting.
(f) Redetermine length of lever 'A' for new torque

setting.
(g) Redetermine total lever length 'B'.
(h) Calculate final corrected torque setting.
(j) Adjust micrometer to final corrected torque

setting.
(6) Torsion bar type.
(a) Determine length of lever 'A' from 'effective

length' marked on handle to centre of square
drive.
(b) Determine total lever length 'B'.
(c) Calculate scale reading.
1.5.11 In-built (locking) torque for self locking fasteners
(1) The in-built torque is the torque required to start

the nut or setscrew turning when (refer to Table 1):
(a) The nut is engaged on the stud or bolt (or the

setscrew is engaged in the insert or captive
nut) with the full chamfer of the stud or bolt
(or setscrew) extending beyond the locking
device of the nut, insert or captive nut.
(b) There is no axial load on the nut or bolt.
(2) Do not alter the in-built torque of a nut or insert

by crimping the locking device or by easing it with a
thread tap.
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(3) There are various methods of checking locking torque

but the ultimate criterion is that the correct
locking torque must be present when the bolt, nut or
setscrew is finally fitted, and in principle all such
self locking fasteners should be checked at that
stage. In practice it is not always necessary to
measure locking torque during final fitting, and some
relaxation is possible depending upon the particular
application. The following procedures take this into
account:
(a) No.10 UN and 0.250 in. fasteners used in

applications for which no special instructions
are given in the manual, may be checked for
correct locking torque by hand during final
fitting. If the locking device cannot be fully
engaged when tightened as much as possible with
the fingers, then the fastener is acceptable.
IN-BUILT LOCKING TORQUE

Nominal
thread Minimum Maximum
size - in.
Nm lbf in. Nm lbf in.
4 UN 0,056 0.50 0,338 3.0
6 UN 0,113 1.00 0,676 6.0
8 UN 0,169 1.50 1,017 9.0
10 UN 0,225 2.00 2,030 18.0
0.250 in. 0,394 3.50 3,390 30.0
0.3125 in. 0,733 6.50 6,780 60.0
0.375 in. 1,070 9.50 9,040 80.0
0.4375 in. 1,580 14.00 11,300 100.0
0.500 in. 2,030 18.00 17,000 150.0
0.5625 in. 2,710 24.00 22,600 200.0
0.625 in. 3,620 32.00 33,900 300.0
0.750 in. 5,650 50.00 45,200 400.0
0.875 in. 7,910 70.00 67,800 600.0
Nm lbf ft.
1.000 in. 10,4 92.00 90,30 66.60

1.125 in. 13,2 117.00 102,00 5.00
1.250 in. 16,2 143.00 113,00 83.30
TABLE 1 Range of In-Built Torque Limits for Self

Locking Wire Thread Inserts and Captive Nuts
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(b) All other applications of No.10 UN and 0.250 in.

fasteners involve joints where high integrity is
essential and are covered by special
instructions in the manual. In all these
instances, the locking torque must be measured
during final fitting.
(c) On all fastener sizes above 0.250 in., whether

the torque load is standard or non-standard, the
actual locking torque must be measured during
final fitting.
(4) To ensure the correct locking torque during final

fitting, fasteners may be checked before this stage
using the gauges listed in Table 2. By this means,
the need to remove and replace fasteners during final
fitting can be avoided.
CAUTION: CONTAMINATION OF SILVER PLATED NUTS OR INSERTS

BY CADMIUM OR MOLYBDENUM DISULPHIDE CAN RESULT
IN SERIOUS FAILURE DURING SUBSEQUENT SERVICE.
GAUGES USED ON SILVER PLATED FASTENERS MUST NOT
BE USED FOR CHECKING ANY OTHER PARTS.
THREAD BASIC SIZE GAUGE NO.

0.190 - 43 HC27139
0.250 - 28 HC21740
0.3125 - 24 HC21741/2
0.375 - 24 HC21742/1
0.4375 - 20 HC22844/1
0.500 - 20 HC22845/1
0.5625 - 18 HC22846/1
0.625 - 18 HC22860
TABLE 2 Torque Check Gauges
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1.5.12 Fitting non self locking nuts to studs or bolts; also

fitting bolts, used as setscrews, in non self locking
thread holes
Apply the standard torque loads listed in Table 3

unless special torque loads are specified elsewhere.
TIGHTENING TORQUE - NON SELF LOCKING

Nominal thread Unplated and Cadmium Plated
size - in. Silver Plated
No.6 UNF 1,10 10 0,90 8
No.8 UNF and 2BA 1,70 15 1,10 10
No.10 UNF 4,00 35 2,80 25
1BA 5,70 50 4,00 35
0.250 in. 11,30 100 8,50 75
0.3125 in. 19,20 170 15,30 135
0.375 in. 33,90 300 26,60 235
0.4375 in. 50,90 450 40,70 360
0.500 in. 84,80 750 65,00 575
0.5625 in. 107,40 950 83,60 740
0.625 in. 152,60 1350 118,7 1050
TABLE 3 Standard Torque Loads for Fitting Non Self

Locking Nuts and Bolts
1.5.13 Fitting self locking nuts to studs and bolts; also bolts
used as setscrews, in self locking wire thread inserts or
in self locking thread captive nuts
(1) Apply the standard torque loads listed in Table 4

unless special torque loads are listed elsewhere.
(2) Self locking nuts and inserts have a limited life

which depends, mainly, on their ability to retain
their in-built locking torque. For values of
acceptable range of in-built torque, refer to
Table 1.
6 1535-GAS
Page 16 May/00
MAINTENANCE
TIGHTENING TORQUE - SELF LOCKING

Nominal thread Unplated and Cadmium Plated
size - in. Silver Plated
No.6 UNF 1,40 12 1,10 10
No.8 UNF and 2BA 2,30 20 1,70 15
No.10 UNF 4,50 40 3,40 30
0.250 in. 11,30 100 10,20 90
0.3125 in. 23,30 210 19,20 170
0.375 in. 41,80 370 35,00 310
0.4375 in. 55,40 490 46,30 410
0.500 in. 89,30 790 72,30 640
0.5625 in. 114,10 1010 93,80 830
0.625 in. 163,90 1450 135,60 1200
TABLE 4 Standard Torque Loads for Fitting Self

Locking Nuts and Bolts
1.5.14 Tube connections (union nuts, tube and hose connections)
CAUTION: PREVENT DAMAGE TO PIPES AND UNIONS BY USING A

SUITABLE SPANNER TO PREVENT ROTATION OF THE
UNION WHEN ASSEMBLING OR DISASSEMBLING A PIPE
CONNECTION.
(1) Apply the torque load values listed in Table 5 to all

standard tube/pipe connections unless otherwise
instructed.
(2) Bed in nut and nipple connections as follows:
(a) Using clean lubricating oil as a lubricant on

the threads and abutment faces, assemble nut and
nipple to the union and tighten to the
recommended torque load value.
(b) Loosen the connections by slackening the nut

half a turn.
(c) Tighten and loosen twice more.
(d) Finally tighten to recommended torque load

value.
CAUTION: DO NOT EXCEED THE SPECIFIED TORQUE LOAD

VALUE WHEN TRYING TO ACHIEVE A SATISFACTORY
SEAL.
1535-GAS 6
May/00 Page 17
MAINTENANCE
(3) Rectify a leaking connection by disassembling the nut

and nipple connection examining parts for cause of
failure to seal, and if necessary, fitting new parts.
Reassemble as detailed in sub-paras (2) (a) to (d).
TIGHTENING TORQUE - TUBE CONNECTIONS

Nominal thread Nm lbf in. lbf ft.
size - in.
0.4375 - 20 16,50 145 -
0.5000 - 20 19,00 170 -
0.6250 - 18 24,00 215 -
0.6875 - 16 27,00 240 -
0.7500 - 16 30,00 265 -
0.8125 - 16 33,00 295 -
0.8750 - 14 37,00 325 -
1.0625 - 12 47,00 420 -
1.1875 - 12 56,00 500 -
1.3125 - 12 67,90 590 -
1.6250 - 12 99,00 - 73
1.8750 - 12 135,00 - 99
TABLE 5 Standard Torque Loads for Tube Connections
1.5.15 Screwed unions and hexagon headed blanking plugs
(1) The torque tightening values for both unions and

hexagon headed blanking plugs are identical for given
thread diameters and are given in Table 6. The values
are based on the practice of tightening the union to
a torque approximately 20 per cent higher than for
the union nut; this reduces the tendency for the
union to turn when the tube nut is tightened or
loosened.
(2) When fitting unions or plugs, clean lubricating oil

should be used to lubricate the threads, except when
the fittings are to be screwed into magnesium alloys.
If they are to be fitted to magnesium alloys the
threads and abutment face of the unions or plugs
should be smeared with jointing compound PL32L which
must be allowed to air dry for approximately
10 minutes before assembly.
6 1535-GAS
Page 18 May/00
MAINTENANCE
(3) After ensuring that the items are clean, and fitting
any necessary joint washers, they should be assembled
to the torque values specified in Table 6.
UNIONS AND HEXAGON HEADED BLANKING PLUGS

Nominal thread Tightening torque
size - in.
Nm lbf in. lbf ft.
0.250 - 28 5 44 -
0.3125 - 24 9 80 -
0.3750 - 24 12 110 -
0.4375 - 20 20 175 -
0.500 - 20 23 205 -
0.5625 - 18 26 230 -
0.6250 - 18 29 260 -
0.750 - 16 36 320 -
0.8125 - 16 40 355 -
0.875 - 14 44 390 -
1.0625 - 12 57 505 -
1.1875 - 12 68 - 50
1.3125 - 12 80 - 59
1.6250 - 12 120 - 87.5
1.8750 - 12 160 - 119
TABLE 6 Torque Tightening Values for Unions

and Hexagon Headed Blanking Plugs
1.5.16 Fitting serrated head sealing plugs
(1) Apply the torque loads listed in Table 7 to sealing

plugs fitted into either aluminium or magnesium
unless special values are specified elsewhere.
(2) When fitting sealing plugs, clean lubricating oil

should be used to lubricate the threads, except when
the plug is to be screwed into magnesium alloys. If
they are to be fitted to magnesium alloys the threads
and abutment face of the plug should be smeared with
jointing compound, PL32L, which must be allowed to
air dry for approximately 10 minutes before assembly.
1535-GAS 6
May/00 Page 19
MAINTENANCE
(3) Do not overtightening sealing plugs beyond the

recommended torque load value to cure a leak. If
necessary, fit a new sealing plug and/or recondition
the plug seating.
TIGHTENING TORQUE -
SERRATED HEAD SEALING PLUGS
Nominal Nm lbf in.
diameter - in.
0.250 2,26 20.0
0.3125 3,39 30.0
0.375 5,08 45.0
0.4375 7,34 65.0
0.500 10,2 90.0
0.5625 10,2 90.0
0.625 15,8 140.0
0.6875 20,3 180.0
0.750 20,3 180.0
TABLE 7 Standard Torque Loads for Fitting Serrated Head

Sealing Plugs
(Unified or Whitworth Threads)
1.5.17 Fitting studs
Studs are usually fitted as replacements, when

fitting replacement studs refer to the relevant topic.
6 1535-GAS
Page 20 May/00
MAINTENANCE
1.6 Specified Torque Loads
Effective
Applications Load Remarks
Anti-Icing Hot Air Valve

Screws, securing anti- 30 to 60 lbf in.
icing hot air valve rear (3,39 to 6,78 Nm)
elbow to compressor
outlet casing
Electro-Magnetic Speed
Pick-Up Unit
Nut, securing drive shaft 75 lbf ft.
(101,68 Nm)
Locknut, securing 142 lbf in.
electro-magnetic speed (16,05 Nm)
pick-up in housing
Compressor Air Bleed Valve
Screws, securing bleed 80 lbf in.

valves to compressor casing (9,04 Nm)
Compressor Casing
Nuts, 0.312 in. (7,925 mm.) 135 lbf in.

securing front bearing (15,26 Nm)
housing to stage '00'
compressor casing
Nuts, 0.250 in. (6,350 mm.) 75 lbf in.

securing front bearing (8,47 Nm)
housing to stage '00'
compressor casing
Nuts, 0.312 in. (7,925 mm.) 135 lbf in.

securing stage '00' to (15,26 Nm)
front compressor casing
Nuts, 0.250 in. (6,350 mm.) 75 lbf in.

securing stage '00' to (8,47 Nm)
front compressor casing
Nuts, securing front 220 lbf in.

compressor casing halves (24,86 Nm)
Nuts, securing intermediate 220 lbf in.

Nuts, securing stage '00' 220 lbf in.

1535-GAS 6
May/00 Page 21
MAINTENANCE
Effective
Application Load Remarks
Compressor Outlet Casing
Screws, securing outlet 135 lbf in.

casing to compressor (15,26 Nm)
intermediate casing
Exhaust Unit (Mk.161G/162G)
Nuts, securing exhaust 100 lbf in.

unit to nozzle box rear (11,30 Nm)
casing
Flame Tubes and Air Casing
Screws, securing 170 lbf in.

combustion air casing to (19,21 Nm)
compressor outlet casing
Free Power Turbine

(Mk.170G/171G)
Nuts, securing free power 100 lbf in.

turbine ducting to gas (11,30 Nm)
generator
Front Bearing Housing
Nuts, securing extension 75 lbf in.

ring and hot air manifold (8,47 Nm)
to front bearing housing
Pivot pin, securing master 75 lbf in.

inlet guide vane cranked (8,47 Nm)
operating lever to inlet
guide vane ram spring
coupling eyebolt
Locknut, securing cranked Ensure that the

operating lever pivot pin spherical bush
remains free and
unnipped in the
lever arm forks
when tightening
the locknut
6 1535-GAS
Page 22 May/00
MAINTENANCE
Effective
Front Suspension
Nuts, securing bell 100 to 260 lbf in.) Apply anti-
cracks to compressor (11,30 to 29,38 Nm) seize compound,
intermediate casing ) Rocol 251,
) to the nut
Nuts, securing shackle 100 to 260 lbf in.) threads and
links to compressor (11,30 to 29,38 Nm) abutment faces
intermediate casing ) and to the bolt
) threads and
Nuts, securing 50 to 120 lbf in. ) shanks.
suspension tubes to (5,65 to 13,56 Nm ) Torque to be
bell cracks ) achieved by
) selective
Nuts, securing 50 to 120 lbf in. ) assembly if
suspension tubes or (5,65 to 13,56 Nm ) necessary
suspension struts to )
shackle links )
Fuel Burners
Reach bolts or screws, 80 lbf in.
with or without stud (9,04 Nm)
extension securing burner
feed arm to compressor
outlet casing
Igniter Plugs
High energy igniter plugs 100 lbf in. Apply anti-
(11,30 Nm) seize compound,
Rocol 251,
to the threads
Intake Guide Vane Ram
Bleed valve control unit 75 lbf in.
adjustment locknut (8,47 Nm)
Pivot pin, securing 75 lbf in.
operating lever to ram (8,47 Nm)
spring coupling eyebolt
Nozzle Box
Nuts, securing front half 100 lbf in.
cooling air manifold and (11,30 Nm)
combustion air casing to
nozzle box front outer
casing
Nuts, securing gas 170 lbf in.
generator mounting trunnions (19,21 Nm)
to nozzle box front outer
casing and front half of
cooling manifold
1535-GAS 6
May/00 Page 23
MAINTENANCE
Effective
Nuts, securing nozzle box 170 lbf in.

intermediate casing to (19,21 Nm)
front outer casing
Nuts, securing nozzle box 100 lbf in.

intermediate casing to rear (11,30 Nm)
casing
Screws, securing mounting 170 lbf in.

trunnions to spokes (19,21 Nm)
Slotted screw in gas 100 lbf ft. Applicable only

generator mounting trunnion (135,58 Nm) at gas
(Mk.162G) generator
installation
Oil Pipes and Fittings
Bolt securing filter 90 lbf in.

cover to lubrication (10,17 Nm)
connection block
Chip detector body unit 130 lbf in. Apply jointing

in lubrication connection (14,69 Nm) compound PL32
block (light) to the
threads
Rear Bearing Housing
Screws, securing hand hole 100 lbf.in.

covers to rear bearing (11,30 Nm)
housing
Screws, securing rear 100 lbf.in.

bearing housing to (11,30 Nm)
compressor outlet casing
Starter Drive
Ringnut securing pawl 75 lbf ft.

carrier to compressor shaft (101,67 Nm)
Nut, securing coupling 120 lbf ft.

shaft to coupling bearing (162,69 Nm)
housing
6 1535-GAS
Page 24 May/00
MAINTENANCE
2 CONVERSION TABLES
CENTIMETRES - INCHES
cm. in. cm. in. cm. in. cm. in.
2.54 1 0.3937 66.04 26 10.2362 129.54 51 20.0787 193.04 76 29.9213
5.08 2 0.7874 68.58 27 10.6299 132.08 52 20.4724 195.58 77 30.3150
7.62 3 1.1811 71.12 28 11.0236 134.62 53 20.8661 198.12 78 30.7087
10.16 4 1.5748 73.66 29 11.4173 137.16 54 21.2498 200.66 79 31.1024
12.70 5 1.9685 76.20 30 11.8110 139.70 55 21.6535 203.20 80 31.4961
15.24 6 2.3622 78.74 31 12.2047 142.24 56 22.0472 205.74 81 31.8898
17.78 7 2.7559 81.28 32 12.5964 144.78 57 22.4409 208.28 82 32.2835
20.32 8 3.1496 83.82 33 12.9921 147.32 58 22.8346 210.82 83 32.6772
22.86 9 3.5433 86.36 34 13.3858 149.86 59 23.2283 213.36 84 33.0709
25.40 10 3.9370 88.90 35 13.7795 152.40 60 23.6220 215.90 85 33.4646
27.94 11 4.3307 91.44 36 14.1732 154.94 61 24.0157 218.44 86 33.8583
30.48 12 4.7244 93.98 37 14.5669 157.48 62 24.4094 220.98 87 34.2520
33.02 13 5.1181 96.52 38 14.9606 160.02 63 24.8031 223.52 88 34.6457
35.56 14 5.5118 99.06 39 15.3543 162.56 64 25.1969 226.06 89 35.0394
38.10 15 5.9055 102.60 40 15.7480 165.10 65 25.5906 228.60 90 35.4331
40.64 16 6.2992 104.14 41 16.1417 167.64 66 25.9843 231.14 91 35.8268
43.18 17 6.6929 106.68 42 16.5354 170.18 67 26.3780 233.68 92 36.2205
45.72 18 7.0866 109.22 43 16.9291 172.72 68 26.7717 236.22 93 36.6142
48.26 19 7.4803 111.76 44 17.3228 175.26 69 27.1654 238.76 94 37.0079
50.80 20 7.8740 114.30 45 17.7165 177.80 70 27.5591 241.30 95 37.4016
53.34 21 8.2677 116.84 46 18.1102 180.34 71 27.9528 243.84 96 37.7953
55.88 22 8.6614 119.38 47 18.5039 182.88 72 28.3465 246.38 97 38.1890
58.42 23 9.0551 121.92 48 18.8976 185.42 73 28.7402 248.92 98 38.5827
60.96 24 9.4488 124.46 49 19.2913 187.96 74 29.1339 251.46 99 38.9764
63.50 25 9.8425 127.00 50 19.6850 190.50 75 29.5276 254.00 100 39.3701
SQ. CENTIMETRES - SQ. INCHES
sq cm. sq in. sq cm. sq in. sq cm. sq in. sq cm. sq in.
6.452 1 0.155 167.742 26 4.030 329.032 51 7.905 490.322 76 11.780
12.903 2 0.310 174.193 27 4.185 335.483 52 8.060 496.773 77 11.935
19.355 3 0.465 180.645 28 4.340 341.935 53 8.215 503.225 78 12.090
25.806 4 0.620 187.096 29 4.495 348.386 54 8.370 509.676 79 12.245
32.258 5 0.775 193.548 30 4.650 354.838 55 8.525 516.128 80 12.400
38.710 6 0.930 200.000 31 4.805 361.290 56 8.680 522.579 81 12.555
45.161 7 1.085 206.451 32 4.960 367.741 57 8.835 529.031 82 12.710
51.613 8 1.240 212.903 33 5.115 374.193 58 8.990 535.483 83 12.865
58.064 9 1.395 219.354 34 5.270 380.644 59 9.145 541.934 84 13.020
64.516 10 1.550 225.806 35 5.425 387.096 60 9.300 548.386 85 13.175
70.968 11 1.705 232.258 36 5.580 393.548 61 9.455 554.838 86 13.330
77.419 12 1.860 238.709 37 5.735 399.999 62 9.610 561.289 87 13.485
83.871 13 2.015 245.161 38 5.890 406.451 63 9.765 567.741 88 13.640
90.322 14 2.170 251.612 39 6.045 412.902 64 9.920 574.192 89 13.795
96.774 15 2.325 258.064 40 6.200 419.354 65 10.075 580.644 90 13.950
103.226 16 2.480 264.516 41 6.355 425.806 66 10.230 587.096 91 14.105
109.677 17 2.635 270.967 42 6.510 432.257 67 10.385 593.547 92 14.260
116.129 18 2.790 277.419 43 6.665 438.709 68 10.540 599.999 93 14.415
122.580 19 2.945 283.870 44 6.820 445.160 69 10.695 606.450 94 14.570
129.032 20 3.110 290.322 45 6.975 451.612 70 10.850 612.902 95 14.725
135.484 21 3.255 296.774 46 7.130 458.064 71 11.005 619.354 96 14.880
141.935 22 3.410 303.225 47 7.285 464.515 72 11.160 625.805 97 15.035
148.387 23 3.565 309.677 48 7.440 470.967 73 11.315 632.257 98 15.190
154.838 24 3.720 316.128 49 7.595 477.418 74 11.470 638.708 99 15.345
161.290 25 3.875 322.580 50 7.750 483.878 75 11.625 645.160 100 15.500
1535-GAS 6
May/00 Page 25
MAINTENANCE
CUBIC CENTIMETRES - CUBIC INCHES

cu cm. cu in. cu cm. cu in. cu cm. cu in. cu cm. cu in.
16.387 1 0.0610 426.064 26 1.5866 835.740 51 3.1122 1245.417 76 4.6378
32.774 2 0.1220 442.451 27 1.6476 852.127 52 3.1732 1261.804 77 4.6988
49.161 3 0.1831 458.838 28 1.7087 868.514 53 3.2343 1278.191 78 4.7599
65.548 4 0.2441 475.225 29 1.7697 884.901 54 3.2953 1294.578 79 4.8209
81.935 5 0.3051 491.612 30 1.8307 901.288 55 3.3563 1310.965 80 4.8819
98.322 6 0.3661 507.999 31 1.8917 917.675 56 3.4173 1327.352 81 4.9429
114.161 7 0.4272 524.386 32 1.9528 934.062 57 3.4784 1343.739 82 5.0040
131.097 8 0.4882 540.773 33 2.0138 950.449 58 3.5394 1360.126 83 5.0650
147.484 9 0.5492 557.160 34 2.0748 966.837 59 3.6004 1376.513 84 5.1260
163.871 10 0.6102 573.547 35 2.1358 983.224 60 3.6614 1392.900 85 5.1870
180.258 11 0.6713 589.934 36 2.1969 999.611 61 3.7225 1409.288 86 5.2481
196.645 12 0.7323 606.321 37 2.2579 1015.998 62 3.7835 1425.675 87 5.3091
213.032 13 0.7933 622.708 38 2.3189 1032.385 63 3.8445 1442.062 88 5.3701
229.419 14 0.8543 639.096 39 2.3799 1048.772 64 3.9055 1458.449 89 5.4311
245.806 15 0.9154 655.483 40 2.4410 1065.159 65 3.9666 1474.836 90 5.4922
262.193 16 0.9764 671.876 41 2.5020 1081.546 66 4.0276 1491.223 91 5.5532
278.580 17 1.0374 688.257 42 2.5630 1097.933 67 4.0886 1507.610 92 5.6142
294.967 18 1.0984 704.644 43 2.6240 1114.320 68 4.1496 1523.997 93 5.6752
311.354 19 1.1595 721.031 44 2.6851 1130.707 69 4.2107 1540.384 94 5.7363
327.741 20 1.2205 737.418 45 2.7461 1147.094 70 4.2717 1556.771 95 5.7973
344.128 21 1.2815 753.805 46 2.8071 1163.481 71 4.3327 1573.158 96 5.8583
360.515 22 1.3425 770.192 47 2.8681 1179.868 72 4.3937 1589.545 97 5.9193
376.902 23 1.4036 786.579 48 2.9292 1196.255 73 4.4548 1605.932 98 5.9804
393.290 24 1.4646 802.966 49 2.9902 1212.642 74 4.5158 1622.319 99 6.0414
409.677 25 1.5256 819.353 50 3.0512 1229.295 75 4.5768 1638.706 100 6.1024
LITRES - IMPERIAL GALLONS
litres Imp.gall. litres Imp.gall. litres Imp.gall. litres Imp.gall.
4.546 1 0.2200 118.195 26 5.7914 231.844 51 11.2187 345.493 76 16.7181
9.092 2 0.4400 122.741 27 5.9393 236.390 52 11.4387 350.039 77 16.9381
13.638 3 0.6599 127.287 28 6.1593 240.936 53 11.6587 354.585 78 17.1581
18.184 4 0.8799 131.833 29 6.3793 245.482 54 11.8787 359.131 79 17.3780
22.730 5 1.0999 136.379 30 6.5993 250.028 55 12.0986 363.677 80 17.5980
27.276 6 1.3199 140.925 31 6.8192 254.574 56 12.3186 368.223 81 17.8180
31.822 7 1.5398 145.471 32 7.0392 259.120 57 12.5386 372.769 82 18.0380
36.368 8 1.7598 150.017 33 7.2592 263.666 58 12.7586 377.315 83 18.2579
40.914 9 1.9798 154.563 34 7.4792 268.212 59 12.9785 381.861 84 18.4779
45.460 10 2.1998 159.109 35 7.6991 272.758 60 13.1985 386.407 85 18.6979
50.006 11 2.4197 163.655 36 7.9191 277.304 61 13.4185 390.953 86 18.9179
54.552 12 2.6397 168.201 37 8.1391 281.850 62 13.6385 395.499 87 19.1379
59.098 13 2.8597 172.747 38 8.3591 286.396 63 13.8584 400.045 88 19.3578
63.643 14 3.0797 177.293 39 8.5790 290.942 64 14.0784 404.591 89 19.5778
68.189 15 3.2996 181.839 40 8.7990 295.488 65 14.2984 409.137 90 19.7978
72.735 16 3.5196 186.384 41 9.0190 300.034 66 14.5184 413.683 91 20.0178
77.281 17 3.7396 190.930 42 9.2390 304.580 67 14.7383 418.229 92 20.2377
81.827 18 3.9596 195.476 43 9.4589 309.125 68 14.9583 422.775 93 20.4577
86.373 19 4.1795 200.022 44 9.6789 313.671 69 15.1783 427.321 94 20.6777
90.919 20 4.3995 204.568 45 9.8989 318.217 70 15.3983 431.866 95 20.8977
95.465 21 4.6195 209.114 46 10.1189 322.763 71 15.6182 436.412 96 21.1176
100.011 22 4.8395 213.660 47 10.3388 327.309 72 15.8382 440.958 97 21.3376
104.557 23 5.0594 218.206 48 10.5588 331.855 73 16.0582 445.504 98 21.5576
109.103 24 5.2794 222.752 49 10.7788 336.401 74 16.2782 450.050 99 21.7776
113.649 25 5.4994 227.298 50 10.9988 340.947 75 16.4981 454.596 100 21.9975
6 1535-GAS
Page 26 May/00
MAINTENANCE
US GALLONS - IMPERIAL GALLONS

US gall. Imp.gall. US gall. Imp.gall. US gall. Imp.gall. US gall. Imp.gall.
1.201 1 0.832 31.225 26 21.649 61.248 51 42.466 91.272 76 63.283
2.402 2 1.665 32.426 27 22.482 62.449 52 43.299 92.473 77 64.116
3.603 3 2.498 33.627 28 23.315 63.650 53 44.132 93.674 78 64.948
4.804 4 3.331 34.828 29 24.147 64.851 54 44.964 94.875 79 65.781
6.005 5 4.163 36.029 30 24.980 66.052 55 45.797 96.076 80 66.614
7.206 6 4.996 37.229 31 25.813 67.253 56 46.630 97.277 81 67.446
8.407 7 5.829 38.430 32 26.645 68.454 57 47.462 98.478 82 68.279
9.608 8 6.661 39.631 33 27.478 69.655 58 48.295 99.679 83 69.112
10.809 9 7.494 40.832 34 28.311 70.856 59 49.128 100.880 84 69.944
12.010 10 8.327 42.033 35 29.143 72.057 60 49.960 102.081 85 70.777
13.210 11 9.159 43.234 36 29.976 73.258 61 50.793 103.282 86 71.610
14.411 12 9.992 44.435 37 30.809 74.459 62 51.626 104.483 87 72.442
15.612 13 10.825 45.636 38 31.641 75.660 63 52.458 105.684 88 73.275
16.813 14 11.657 46.837 39 32.474 76.861 64 53.291 106.885 89 74.108
18.014 15 12.490 48.038 40 33.307 78.062 65 54.124 108.086 90 74.940
19.215 16 13.323 49.239 41 34.139 79.263 66 54.956 109.286 91 75.773
20.416 17 14.155 50.440 42 34.972 80.464 67 55.789 110.487 92 76.606
21.617 18 14.988 51.641 43 35.805 81.665 68 56.622 111.688 93 77.438
22.818 19 15.821 52.842 44 36.637 82.866 69 57.454 112.889 94 78.271
24.019 20 16.653 54.043 45 37.470 84.067 70 58.287 114.090 95 79.104
25.220 21 17.486 55.244 46 38.303 85.267 71 59.120 115.291 96 79.936
26.421 22 18.319 56.445 47 39.135 86.468 72 59.952 116.492 97 80.769
27.622 23 19.151 57.646 48 39.968 87.669 73 60.785 117.693 98 81.602
28.823 24 19.984 58.847 49 40.801 88.870 74 61.618 118.894 99 82.434
30.024 25 20.817 60.047 50 41.634 90.071 75 62.450 120.095 100 83.267
KILOGRAMMES - POUNDS
kg. lb. kg. lb. kg. lb. kg. lb.
0.453 1 2.204 11.793 26 57.320 23.133 51 112.436 34.473 76 167.551
0.907 2 4.409 12.247 27 59.525 23.587 52 114.640 34.927 77 169.756
1.361 3 6.614 12.701 28 61.729 24.040 53 116.845 35.380 78 171.961
1.814 4 8.818 13.154 29 63.934 24.494 54 119.050 35.834 79 174.165
2.268 5 11.023 13.608 30 66.139 24.948 55 121.254 36.287 80 176.370
2.722 6 13.228 14.061 31 68.343 25.401 56 123.459 36.741 81 178.574
3.175 7 15.432 14.515 32 70.548 25.855 57 125.663 37.195 82 180.779
3.629 8 17.637 14.969 33 72.753 26.308 58 127.868 37.648 83 182.984
4.082 9 19.842 15.422 34 74.957 26.762 59 130.073 38.102 84 185.188
4.536 10 22.046 15.876 35 77.162 27.216 60 132.277 38.555 85 187.393
4.990 11 24.251 16.329 36 79.366 27.669 61 134.482 39.009 86 189.598
5.443 12 26.455 16.783 37 81.571 28.123 62 136.687 39.463 87 191.802
5.897 13 28.660 17.237 38 83.776 28.576 63 138.891 39.916 88 194.007
6.350 14 30.865 17.690 39 85.980 29.030 64 141.096 40.370 89 196.211
6.804 15 33.069 18.144 40 88.185 29.484 65 143.300 40.823 90 198.416
7.257 16 35.274 18.597 41 90.390 29.937 66 145.505 41.277 91 200.621
7.711 17 37.479 19.051 42 92.594 30.391 67 147.710 41.731 92 202.825
8.165 18 39.479 19.504 43 94.799 30.844 68 149.914 42.184 93 205.030
8.618 19 41.888 19.958 44 97.003 31.298 69 152.119 42.638 94 207.235
9.072 20 44.092 20.412 45 99.208 31.751 70 154.324 43.091 95 209.439
9.525 21 46.297 20.865 46 101.413 32.205 71 156.528 43.545 96 211.644
9.979 22 48.502 21.319 47 103.617 32.659 72 158.733 43.999 97 213.848
10.433 23 50.706 21.772 48 105.822 33.112 73 160.937 44.452 98 216.053
10.886 24 52.911 22.226 49 108.026 33.566 74 163.142 44.906 99 218.258
11.340 25 55.116 22.680 50 110.231 34.019 75 165.347 45.359 100 220.462
1535-GAS 6
May/00 Page 27
MAINTENANCE
KG/SQ.CM. - LBF/SQ.IN.
kg/sq.cm. lbf/sq.in. kg/sq.cm. lbf/sq.in. kg/sq.cm. lbf/sq.in. kg/sq.cm. lbf/sq.in.
0.0703 1 14.2233 1.8280 26 369.81 3.5857 51 725.39 5.3433 76 1080.97
0.1406 2 28.45 1.8983 27 384.03 3.6560 52 739.61 5.4136 77 1095.20
0.2109 3 42.67 1.9686 28 398.25 3.7263 53 753.84 5.4839 78 1109.42
0.2812 4 56.89 2.0389 29 412.48 3.7966 54 768.06 5.5543 79 1123.64
0.3515 5 71.12 2.1092 30 426.70 3.8669 55 782.28 5.6246 80 1137.87
0.4218 6 85.34 2.1795 31 440.92 3.9372 56 796.51 5.6949 81 1152.09
0.4921 7 99.56 2.2498 32 455.15 4.0075 57 810.73 5.7652 82 1166.31
0.5625 8 113.79 2.3201 33 469.37 4.0778 58 824.95 5.8355 83 1180.54
0.6328 9 128.01 2.3904 34 483.59 4.1481 59 839.18 5.9058 84 1194.76
0.7031 10 142.23 2.4607 35 497.82 4.2184 60 853.40 5.9761 85 1208.98
0.7734 11 156.46 2.5310 36 512.04 4.2887 61 867.62 6.0464 86 1223.21
0.8437 12 170.68 2.6014 37 526.26 4.3590 62 881.85 6.1167 87 1237.43
0.9140 13 184.90 2.6717 38 540.49 4.4293 63 896.07 6.1870 88 1251.65
0.9843 14 199.13 2.7420 39 554.71 4.4996 64 910.29 6.2573 89 1265.88
1.0546 15 213.35 2.8123 40 568.93 4.5699 65 924.52 6.3276 90 1280.10
1.1249 16 227.57 2.8826 41 583.16 4.6403 66 938.74 6.3979 91 1294.32
1.1952 17 241.80 2.9529 42 597.38 4.7106 67 952.96 6.4682 92 1308.55
1.2655 18 256.02 3.0232 43 611.60 4.7809 68 967.19 6.5385 93 1322.77
1.3358 19 270.24 3.0935 44 625.83 4.8512 69 981.41 6.6089 94 1336.99
1.4061 20 284.47 3.1638 45 640.05 4.9215 70 995.63 6.6792 95 1351.22
1.4764 21 298.69 3.2341 46 654.27 4.9918 71 1009.86 6.7495 96 1365.44
1.5467 22 312.91 3.3044 47 668.50 5.0621 72 1024.08 6.8198 97 1379.66
1.6171 23 327.14 3.3747 48 682.72 5.1324 73 1038.30 6.8901 98 1393.89
1.6874 24 341.36 3.4450 49 696.94 5.2027 74 1052.53 6.9604 99 1408.11
1.7577 25 355.58 3.5153 50 711.17 5.2730 75 1066.75 7.0307 100 1422.33
MILLIMETRES OF MERCURY (ABSOLUTE) -
POUNDS FORCE PER SQUARE INCH -
INCHES OF MERCURY (ABSOLUTE)
mm hg. lbf sq.in. in hg. mm hg. lbf sq.in. in hg.
760 14.7 29.9211 1536 29.7 60.46
786 15.2 30.94 1587 30.7 62.50
812 15.7 31.96 1639 31.7 64.53
838 16.2 32.98 1691 32.7 66.57
863 16.7 33.99 1743 33.7 68.60
889 17.2 35.01 1794 34.7 70.64
915 17.7 36.03 1846 35.7 72.68
941 18.2 37.05 1898 36.7 74.71
967 18.7 38.06 1949 37.7 76.75
993 19.2 39.08 2001 38.7 78.78
1019 19.7 40.10 2053 39.7 80.82
1044 20.2 41.12 2105 40.7 82.86
1070 20.7 42.14 2156 41.7 84.89
1096 21.2 43.15 2208 42.7 86.93
1122 21.7 44.17 2260 43.7 88.96
1148 22.2 45.19 2311 44.7 91.00
1174 22.7 46.21 2363 45.7 93.04
1200 23.2 47.23 2415 46.7 95.07
1225 23.7 48.24 2467 47.7 97.11
1251 24.2 49.26 2518 48.7 99.14
1277 24.7 50.28 2570 49.7 101.18
1329 25.7 52.32 2622 50.7 103.22
1381 26.7 54.35 2673 51.7 105.25
1432 27.7 56.39 2725 52.7 107.29
1484 28.7 58.42 2777 53.7 109.32
2829 54.7 111.36
6 1535-GAS
Page 28 May/00
MAINTENANCE
POUNDS FORCE INCHES - NEWTON METRES

1 lbf in. = 0,11299 Nm 1 Nm = 8.8508 lbf in.
lbf in. Unit Nm lbf in. Unit Nm
8.8508 1 0,11299 88.5075 10 1,12985
17.7015 2 0,22597 177.0150 20 2,25970
26.5523 3 0,33896 265.5230 30 3,38955
35.4030 4 0,45194 354.0300 40 4,51940
44.2538 5 0,56493 442.5380 50 5,64925
53.1045 6 0,67791 531.0450 60 6,77910
61.9553 7 0,79089 619.5530 70 7,90895
70.8060 8 0,90388 708.0600 80 9,03880
79.6568 9 1,01687 796.5680 90 10,16870
885.0750 100 11,29850
POUNDS FORCE FEET - NEWTON METRES

1 lbf ft. = 1,35582 Nm 1 Nm = 0.73756 lbf ft.
lbf ft. Unit Nm lbf ft. Unit Nm
0.73756 1 1,3558 7.37562 10 13,5582
1.47512 2 2,7116 14.75120 20 27,1164
2.21269 3 4,0675 22.12690 30 40,6746
2.95025 4 5,4233 29.50250 40 54,2328
3.68781 5 6,7791 36.87810 50 67,7910
4.42537 6 8,1349 44.25370 60 81,3492
5.16293 7 9,4907 51.62930 70 94,9074
5.90050 8 10,8466 59.00500 80 108,4660
6.63806 9 12,2024 66.38060 90 122,0240
73.75620 100 135,5820
1535-GAS 6
May/00 Page 29
MAINTENANCE
KILOGRAMME CENTIMETRES - POUND INCHES

1 lbf in. = 1,15 kg cm. 1 kg cm = 0.87 lbf in.
lbf in. Unit kg cm. lbf in. Unit kg cm.
0.87 1 1,15 8.67 10 11,52
1.74 2 2,30 17.36 20 23,04
2.60 3 3,46 26.04 30 34,56
3.47 4 4,61 34.72 40 46,09
4.34 5 5,76 43.39 50 57,61
5.21 6 6,91 52.08 60 69,12
6.08 7 8,06 60.75 70 80,65
6.94 8 9,22 69.43 80 92,17
7.81 9 10,37 78.11 90 103,69
86.79 100 115,21
KILOGRAMME METRES - POUNDS FORCE FEET

1 lbf ft. = 0,138 kg m. 1 kg m. = 7.23 lbf ft.
lbf ft. Unit kg m. lbf ft. Unit kg m.
7.23 1 0,138 72.33 10 1,383
14.47 2 0,276 144.66 20 2,765
21.70 3 0,415 216.99 30 4,148
28.93 4 0,553 289.32 40 5,530
36.17 5 0,691 361.65 50 6,913
43.40 6 0,830 433.98 60 8,295
50.63 7 0,968 506.31 70 9,678
57.86 8 1,106 578.64 80 11,060
65.10 9 1,244 650.97 90 12,443
723.30 100 13,826
6 1535-GAS
Page 30 May/00
MAINTENANCE
TEMPERATURE
CENTIGRADE - FAHRENHEIT
ABSOLUTE ZERO = -273 DEG C = -459.4 DEG F
Deg C °F or °C Deg F Deg C °F or °C Deg F Deg C °F or °C Deg F
-73.3 -100 -148.0 -6.1 21 69.8 17.2 63 145.4

-70.6 -95 -139.0 -5.6 22 71.6 17.8 64 147.2
-67.8 -90 -130.0 -5.0 23 73.4 18.3 65 149.0
-65.0 -85 -121.0 -4.4 24 75.2 18.9 66 150.8
-62.2 -80 -112.0 -3.9 25 77.0 19.4 67 152.6
-59.4 -75 -103.0 -3.3 26 78.8 20.0 68 154.4
-56.7 -70 -94.0 -2.8 27 80.6 20.6 69 156.2
-53.9 -65 -85.0 -2.2 28 82.4 21.1 70 158.0
-51.1 -60 -76.0 -1.7 29 84.2 21.7 71 159.8
-48.3 -55 -67.0 -1.1 30 86.0 22.2 72 161.6
-45.6 -50 -58.0 -0.6 31 87.8 22.8 73 163.4
-42.8 -45 -49.0 0.0 32 96.6 23.3 74 165.2
-40.0 -40 -40.0 0.6 33 91.4 23.9 75 167.0
-37.2 -35 -31.0 1.1 34 93.2 24.4 76 168.8
-34.4 -30 -22.0 1.7 35 95.0 25.0 77 170.6
-31.7 -25 -13.0 2.2 36 96.8 25.6 78 172.4
-28.9 -20 -4.0 2.8 37 98.6 26.1 79 174.2
-26.1 -15 +5.0 3.3 38 100.4 26.7 80 176.0
-23.3 -10 +14.0 3.9 39 102.2 27.2 81 177.8
-20.6 -5 +23.0 4.4 40 104.0 27.8 82 179.6
-18.3 -1 +30.2 5.0 41 105.8 28.3 83 181.4
-17.8 0 +32.0 5.6 42 107.6 28.9 84 183.2
-17.2 1 33.8 6.1 43 109.4 29.4 85 185.0
-16.7 2 35.6 6.7 44 111.2 30.0 86 186.8
-16.1 3 37.4 7.2 45 113.0 30.6 87 188.6
-15.6 4 39.2 7.8 46 114.8 31.1 88 190.4
-15.0 5 41.0 8.3 47 116.6 31.7 89 192.2
-14.4 6 42.8 8.9 48 118.4 32.2 90 194.0
-13.9 7 44.5 9.4 49 120.2 32.8 91 195.8
-13.3 8 46.4 10.0 50 122.0 33.3 92 197.6
-12.8 9 48.2 10.6 51 123.8 33.9 93 199.4
-12.2 10 50.0 11.1 52 125.6 34.4 94 201.2
-11.7 11 51.8 11.7 53 127.4 35.0 95 203.0
-11.1 12 53.6 12.2 54 129.2 35.6 96 204.8
-10.6 13 55.4 12.8 55 131.0 36.1 97 206.6
-10.0 14 57.2 13.3 56 132.8 36.7 98 208.4
-9.4 15 59.0 13.9 57 134.6 37.2 99 210.2
-8.9 16 60.8 14.4 58 136.4 37.8 100 212.0
-8.3 17 62.6 15.0 59 138.2 38.3 101 213.8
-7.8 18 64.4 15.6 60 140.0 38.9 102 215.6
-7.2 19 66.2 16.1 61 141.8 39.4 103 217.4
-6.7 20 68.0 16.7 62 143.6 40.0 104 219.2
1535-GAS 6
May/00 Page 31
MAINTENANCE
40.6 105 221.0 67.8 154 309.2 95.0 203 397.4

41.1 106 222.8 68.3 155 311.0 95.6 204 399.2
41.7 107 224.6 68.9 156 312.8 96.1 205 401.0
42.2 108 226.4 69.4 157 314.6 96.7 206 402.8
42.8 109 228.2 70.0 158 316.4 97.2 207 404.6
43.3 110 230.0 70.6 159 318.2 97.8 208 406.4
43.9 111 231.8 71.1 160 320.0 98.3 209 408.2
44.4 112 233.6 71.7 161 321.8 98.9 210 410.0
45.0 113 235.4 72.2 162 323.6 99.4 211 411.8
45.6 114 237.2 72.8 163 325.4 100.0 212 413.6
46.1 115 239.0 73.3 164 327.2 100.6 213 415.4
46.7 116 240.8 73.9 165 329.0 101.1 214 417.2
47.2 117 242.6 74.4 166 330.8 101.7 215 419.0
47.8 118 244.4 75.0 167 332.6 102.2 216 420.8
48.3 119 246.2 75.6 168 334.4 102.8 217 422.6
48.9 120 248.0 76.1 169 336.2 103.3 218 424.4
49.4 121 249.8 76.7 170 338.0 103.9 219 426.2
50.0 122 251.6 77.2 171 339.8 104.4 220 428.0
50.6 123 253.4 77.8 172 341.6 107.2 225 437.0
51.1 124 255.2 78.3 173 343.4 110.0 230 446.0
51.7 125 257.0 78.9 174 345.2 112.8 235 455.0
52.2 126 258.8 79.4 175 347.0 115.6 240 464.0
52.8 127 260.6 80.0 176 348.8 118.3 245 473.0
53.3 128 262.4 80.6 177 350.6 121.1 250 482.0
53.9 129 264.2 81.1 178 352.4 123.9 255 491.0
54.4 130 266.0 81.7 179 354.2 126.7 260 500.0
55.0 131 267.8 82.2 180 356.0 129.4 265 509.0
55.6 132 269.6 82.8 181 357.8 132.2 270 518.0
56.1 133 271.4 83.3 182 359.6 135.0 275 527.0
56.7 134 273.2 83.9 183 361.4 137.8 280 536.0
57.2 135 275.0 84.4 184 363.2 140.6 285 545.0
57.8 136 276.8 85.0 185 365.0 143.3 290 554.0
58.3 137 278.6 85.6 186 366.8 146.1 295 563.0
58.9 138 280.4 86.1 187 368.6 148.9 300 572.0
59.4 139 282.2 86.7 188 370.4 154.4 310 590.0
60.0 140 284.0 87.2 189 372.2 160.0 320 608.0
60.6 141 285.8 87.8 190 374.0 165.6 330 626
61.1 142 287.6 88.3 191 375.8 171.1 340 644
61.7 143 289.4 88.9 192 377.6 176.7 350 662
62.2 144 291.2 89.4 193 379.4 182.2 360 680
62.8 145 293.0 90.0 194 381.2 187.8 370 698
63.3 146 294.8 90.6 195 383.0 193.3 380 716
63.9 147 296.6 91.1 196 384.8 198.9 390 734
64.4 148 298.4 91.7 197 386.6 204.4 400 752
65.0 149 300.2 92.2 198 388.4 210.0 410 770
65.6 150 302.0 92.8 199 390.2 215.6 420 788
66.1 151 303.8 93.3 200 392.0 221.1 430 806
66.7 152 305.6 93.9 201 393.8 226.7 440 824
67.2 153 307.4 94.4 202 395.6 232.2 450 842
6 1535-GAS
Page 32 May/00
MAINTENANCE
237.8 460 860 510.0 950 1742 1037.8 1900 3452

243.3 470 878 515.6 960 1760 1048.9 1920 3488
248.9 480 896 521.1 970 1778 1060.0 1940 3524
254.4 490 914 526.7 980 1796 1071.1 1960 3560
260.0 500 932 532.2 990 1814 1082.2 1980 3596
265.6 510 950 537.8 1000 1832 1093.3 2000 3632
271.1 520 968 548.9 1020 1868 1104.4 2020 3668
276.7 530 986 560.0 1040 1904 1115.6 2040 3704
282.2 540 1004 571.1 1060 1940 1126.7 2060 3740
287.8 550 1022 582.2 1080 1976 1137.8 2080 3776
293.3 560 1040 593.3 1100 2012 1148.9 2100 3812
298.9 570 1058 604.4 1120 2048 1160.0 2120 3848
304.4 580 1076 615.6 1140 2084 1171.1 2140 3884
310.0 590 1094 626.7 1160 2120 1182.2 2160 3920
315.6 600 1112 637.8 1180 2156 1193.3 2180 3956
321.1 610 1130 648.9 1200 2192 1204.4 2200 3992
326.7 620 1148 660.0 1220 2228 1215.6 2220 4028
332.2 630 1166 671.1 1240 2264 1226.7 2240 4064
337.8 640 1184 682.2 1260 2300 1237.8 2260 4100
343.3 650 1202 693.3 1280 2336 1248.9 2280 4136
348.9 660 1220 704.4 1300 2372 1260.0 2300 4172
354.4 670 1238 715.6 1320 2408 1271.1 2320 4208
360.0 680 1256 726.7 1340 2444 1282.2 2340 4244
365.6 690 1274 737.8 1360 2480 1293.3 2360 4280
371.1 700 1292 748.9 1380 2516 1304.4 2380 4316
376.7 710 1310 760.0 1400 2552 1315.6 2400 4352
382.2 720 1328 771.1 1420 2588 1326.7 2420 4388
387.8 730 1346 782.2 1440 2624 1337.8 2440 4424
393.3 740 1364 793.3 1460 2660 1348.9 2460 4460
398.9 750 1382 804.4 1480 2696 1360.0 2480 4496
404.4 760 1400 815.6 1500 2732 1371.1 2500 4532
410.0 770 1418 826.7 1520 2768 1382.2 2520 4568
415.6 780 1436 837.8 1540 2804 1383.3 2540 4604
421.1 790 1454 848.9 1560 2840 1404.4 2560 4640
426.7 800 1472 860.0 1580 2876 1415.6 2580 4676
432.2 810 1490 871.1 1600 2912 1426.7 2600 4712
437.8 820 1508 882.2 1620 2948 1437.8 2620 4748
443.3 830 1526 893.3 1640 2984 1448.9 2640 4784
448.9 840 1544 904.4 1660 3020 1460.0 2660 4820
454.4 850 1562 915.6 1680 3056 1471.1 2680 4856
460.0 860 1580 926.7 1700 3092 1482.2 2700 4892
465.6 870 1598 937.8 1720 3128 1493.3 2720 4928
471.1 880 1616 948.9 1740 3164 1504.4 2740 4964
476.7 890 1634 960.0 1760 3200 1515.6 2760 5000
482.2 900 1652 971.1 1780 3236 1526.7 2780 5036
487.8 910 1670 982.3 1800 3272 1537.8 2800 5072
493.3 920 1688 993.3 1820 3308 1565.6 2850 5162
498.9 930 1706 1004.4 1840 3344 1593.3 2900 5252
504.4 940 1724 1015.6 1860 3380 1621.1 2950 5342
1026.7 1880 3416 1648.9 3000 5432
1535-GAS 6
May/00 Page 33
MAINTENANCE
3 GASEOUS FUEL MANDATORY REQUIREMENTS
3.1 Acceptability of the Gas
(1) The acceptability of a particular gas for use as a

fuel for the gas generator depends on the following:
(a) Gas index number.
(b) Pressure at entry to the fuel control system.
(c) Saturated vapour line.
(d) Quantity and type of impurities.
(e) Burner design.
3.2 Gas Index Number
(1) Gaseous fuels suitable for use with the gas generator
shall have an index number of not less than 600. In
addition the index number should not vary by more
than ± 10% or at a rate exceeding 0.5% per second.
(2) The gas index number (G) is calculated as follows:
Lower calorific value (Btu/cu ft.)

G = Specific gravity of the gas relative to air at
15 deg C (59 deg F)
where the lower calorific value is defined as the

calorific value of the gas at 15 deg C (59 deg F) and
29.92 in Hg (14.7 psia).
3.3 Gas Pressure
(1) The gas pressure required is dependent on the

following:
(a) The type of fuel control system.

(b) The gas index number.
(c) The gas temperature.
(d) The gas generator power required.
(2) Any pressure fluctuations within a range of 3 to

200 Hz should not exceed the equivalent fuel heat
input of 230 kJ/sec (216 Btu/sec).
(3) The minimum gas pressure at inlet to the pressure
regulating valve for a natural gas of approximately
90% methane, is typically 1515kPa (220 psia).
6 1535-GAS
Page 34 May/00
MAINTENANCE
3.4 Gas Temperature
(1) The temperature at the inlet to the gas generator

system should not be less than 20 deg C (36 deg F)
above the saturated vapour temperature of the gas at
the regulated supply pressure.
(2) For the absolute maximum temperature at the inlet to

the fuel control system, refer to the Plant
Manufacturer's Manual.
3.5 Liquid Hydrocarbon and Hydrates
(1) The gas fuel supplied to the gas generator fuel

control system must not contain liquid hydrocarbons
since these can cause rapid fluctuations in gas
generator conditions.
(2) It must be ascertained that, at the operating

temperature and pressure the gas will not form liquid
or solid hydrates.
3.6 Water and Foreign Matter
The gas must not contain any free water or foreign

matter.
3.7 Sulphur Content
The sulphur content of the gas must be less than 1.3%

by weight.
3.8 Sodium and Potassium Salts
(1) The maximum tolerable level of sodium plus potassium

in the fuel entering the gas generator at a uniform
rate must not exceed 0.6 wppm provided no sodium and
potassium are present in the air ingested by, or
water injected into the gas generator.
(2) Because sodium and potassium are cumulative in

causing corrosion an overall limit has been placed on
the total concentration of sodium and potassium
entering the gas generator as follows:
(a) 0.6 wppm of sodium in the fuel or 0.025 wppm of

sodium chloride in the air. Refer to Fig 6.
1535-GAS 6
May/00 Page 35
MAINTENANCE
FIG 6 SODIUM AND POTASSIUM SALTS GRAPH
6 1535-GAS
Page 36 May/00
MAINTENANCE
(b) For calculation purposes it may be assumed that:
1 part of sodium is equivalent to 2 parts of

potassium by weight
1 part of sodium is equivalent to 2.54 parts of

sodium chloride by weight
(c) 0.01 wppm of sodium chloride in air is

equivalent to 0.36 wwpm of sodium in the fuel.
4 CONTAMINATION OF GAS GENERATOR COMPONENTS
4.1 General Information
(1) Some materials used in the construction of gas

generators are adversely affected by surface
contamination.
(a) Contamination of a material by a low melting

point alloy can, at certain temperatures, lead
to intercrystalline penetration and subsequent
embrittlement and cracking.
(b) Contamination of components by materials, used

in the processing, if not thoroughly cleaned can
on some titanium alloys cause intercrystalline
penetration with subsequent embrittlement and
cracking when the component temperature is
raised either through normal gas generator
operation or by the application of heat during a
repair cycle.
4.2 Cadmium Contamination
(1) The cadmium contamination of titanium alloy

components invariably arises from the transfer of the
soft electroplated cadmium from or by fixtures and
hand tools.
(2) Although for many years cadmium protective coatings

have been prohibited from use on tools and fixtures
thus avoiding direct transfer, it is still possible
for secondary transfer to occur from the use of tools
previously in contact with cadmium plated components
or fasteners.
(3) Vigilance in shop practices is therefore required to

ensure that both the obvious and less obvious sources
of cadmium contamination are eliminated.
1535-GAS 6
May/00 Page 37
MAINTENANCE
4.3 Chlorinated Solvents (or other Halogens)
(1) Materials containing chloride ions (or other

halogens) can if left on the surface of certain
titanium alloy components cause embrittlement and
cracking if heat is applied.
(2) To avoid any problems on these components

the instructions issued in the manual relating
to cleaning, inspection, repair, assembly,
transportation and storage (refer to Chapter 10) must
be strictly adhered to.
(3) The contaminating chlorides can originate from

organic solvents, tap water, certain adhesive tapes
and hand contact.
5 CLEANING OF PARTS
(1) Wash all parts using clean kerosene or clean paraffin

prior to any other method of cleaning. Due to the
possible detrimental effect of some cleaning
chemicals on gas generator components, use only
Rolls-Royce approved cleaning materials and
procedures. If doubt exists, seek advice from
Customer Support Department, Rolls-Royce Power
Engineering plc, Ansty, Coventry CV7 9JR, England.
NOTE: Trichloroethane (Genklene) is no longer

recommended for use in connection with
Rolls-Royce gas generators.
(2) Observe the following general WARNING when using

compressed air.
COMPRESSED AIR CAN BE LETHAL OR CAUSE PERMANENT HARM

IF MISUSED. NEVER DIRECT COMPRESSED AIR TOWARDS
ANOTHER PERSON AND AVOID DIRECTING COMPRESSED AIR
NEAR TO THE HUMAN SKIN. THE WEARING OF SUITABLE EYE
PROTECTION AND APPROPRIATE PROTECTIVE CLOTHING IS
MANDATORY WHEN USING COMPRESSED AIR.
WARNING: DO NOT SMOKE WHEN USING METHYLENE CHLORIDE;

ENSURE THAT THE WORKPLACE IS WELL VENTILATED.
CAUTION: METHYLENE CHLORIDE IS TO BE USED SPARINGLY WHEN

APPLIED TO JOINT FACES AS IT CAN DAMAGE AND
REMOVE PAINT.
Remove the jointing compound using a clean cloth

moistened with methylene chloride.
6 1535-GAS
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6 TEMPORARY MARKING OF PARTS

6.1 General
During maintenance it may be necessary when making

checks to mark certain parts.
CAUTION 1: CHINA CLAY BASED PENCILS, EG. CHINAGRAPH

PENCILS MUST NOT BE USED.
CAUTION 2: GRAPHITE PENCILS GIVE CARBON PENETRATION AT
HIGH TEMPERATURES AND MUST NOT BE USED. MARKS
INADVERTENTLY MADE BY GRAPHITE PENCILS MUST BE
COMPLETELY REMOVED BEFORE HEAT TREATMENT OR
ASSEMBLY.
6.2 Marking Media
(1) The following media are approved for the marking of

all parts; refer to Para 13 of this Chapter for
specifications and suppliers.
(a) Pencil/crayon temporary marker.
(b) Felt or fibre tip temporary marker.
(c) Marking ink.
(2) Any other marking media not listed in Para 13 of this

Chapter, must be approved by RRPEplc before use.
7 ASSEMBLING OF PARTS
7.1 Assembling Procedure
CAUTION: UNLESS OTHERWISE STATED, DO NOT USE GREASE OR

ANY OTHER SUBSTANCE ON GASKETS, SPHERICALS AND
MATING JOINT FACES IN AIR/FUEL SYSTEMS. NEGLECT
OF THIS PRECAUTION HAS LED TO BLOCKAGE OF AIR OR
FUEL PASSAGES AND HENCE TO PARTIAL OR COMPLETE
POWER LOSS.
(1) The assembling techniques and any special checks to

be effected on any unit or assembly are described in
the appropriate chapters of this Manual.
(2) Before commencing work on any assembly, check that
all parts are available; ensure also that the parts
are clean, and that joint faces are free from minor
handling damage.
(3) If studs or inserts are loose, refer to the
appropriate chapter.
(4) Refer to Para 6.2 of this Chapter for approved media
for temporary marking of parts.
1535-GAS 6
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MAINTENANCE
7.2 Nomenclature
The terms 'upper', 'lower', 'left-hand' and

'right-hand' are used to describe the positions of parts
and assemblies relative to a gas generator lying
horizontal with its top position uppermost and viewed from
the rear. Some parts are identified by numbering them from
the gas generator top position in an anti-clockwise
direction, viewed from the rear.
7.3 Modification Status
(1) Check that the modification status of all parts is

compatible.
(2) Record the modification status of the parts.
7.4 Correlation Marks
If new parts are to be fitted, lightly vibro-engrave

any necessary correlation marks; using a smooth abrasive
stone remove any burrs raised by the engraving tool.
7.5 Torque Tightening
Refer to Para 1.5 for a description of the torque

tightening technique and for standard torque loading
figures.
7.6 Methods of Locking
(1) Tabwasher locking.
(a) Examples of correct and incorrect tabwasher

locking are illustrated in Fig 7. The points to
note are as follows:
(i) Ensure that the tang of the washer is

properly located in the hole as close as
possible to the nut.
(ii) Bend back the lock tab at a slightly acute

angle so that the forked portions of the
tab, which must lie flush with the flat or
flats of the nut, are firmly locked.
(iii) When the tab must be bent to cover two

adjacent flats on the nut, ensure that the
'V' of the tab is located exactly at the
intersection of the two flats.
6 1535-GAS
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MAINTENANCE
FIG 7 TABWASHER LOCKING - EXAMPLES
1535-GAS 6
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MAINTENANCE
(2) Cupwasher locking.

(a) Where possible lock all cupwashers at two
opposite positions.
(b) Do not punch locking dimples so that they
encroach on previous dimples which have been
reformed.
(c) Do not form locking dimples nearer to a repair
scallop than a distance equal to the depth of
the scallop.
(3) Split pin locking for castellated nut.

(a) Use only the correct pin for the particular nut
to be locked.
(b) On all oscillating or rotating parts, position
the split pin tangentially to the line of
centrifugal force.
(c) Trap the head of the pin in the slot of the nut
with the short leg uppermost then bend back the
legs.
(d) Do not trim the pin after fitting.
7.7 Tools
When using plastic, rubber or hide-faced mallets to
tap parts into position, select a mallet which is soft
enough to avoid damaging the parts, but do not use a
mallet head which is liable to disintegrate in use, and
allow fragments to enter the gas generator.
7.8 Consumable Materials
Consumable materials, lubricants, greases and sealing
components are listed in Para 13 of this Chapter.
7.9 Lubrication
(1) Except where otherwise stated, use gas generator
lubrication oil to lubricate screw threads,
serrations, pipe gland nuts, splines and all parts
that are a 'push' or 'press' fit.
(2) Unpack new or repaired bearings in a clean area.
Operators must wear clean PVC polythene or PVC faced
gloves when handling bearings. The packing medium is
compatible with engine oil. There is no requirement
for complete removal of the packing medium or priming
with clean engine oil, prior to fitment. Bearings
must not be subjected to paraffin wash, vapour or
solvent degreases, drying with compressed air, left
in a dry condition or packed with vaseline/grease.
6 1535-GAS
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MAINTENANCE
(3) Lubrication of sealing rings is detailed in

Para 7.11.
7.10 Apply Jointing Compound
WARNING: DO NOT SMOKE WHEN USING METHYLENE CHLORIDE;

ENSURE THAT THE WORKPLACE IS WELL VENTILATED.
CAUTION 1: ENSURE THAT METHYLENE CHLORIDE IS APPLIED ONLY

TO JOINT FACES AS IT CAN DAMAGE AND REMOVE
PAINT.
CAUTION 2: DO NOT APPLY TOO MUCH JOINTING COMPOUND TO THE

JOINT FACES; EXTRUDED COMPOUND CAN BLOCK
INTERNAL OIL AND/OR AIR PASSAGES.
CAUTION 3: ALLOW A PERIOD OF AT LEAST 10 MINUTES AIR

DRYING TIME TO ENSURE THAT THE SOLVENT IN THE
COMPOUND HAS EVAPORATED; THE SOLVENT CAN CAUSE
CORROSION.
(1) Clean the joint faces using a clean cloth moistened

with methylene chloride; allow the faces to dry.
(2) Using a clean stiff brush moistened with methylene

chloride, spread a thin film of jointing compound
PL32 over both joint faces and allow to air dry for
at least 10 minutes. Close the compound container to
prevent evaporation of the solvent.
NOTE: Avoid using a brush with bristles set in glue

or rubber.
(3) Bring the joint faces together and torque tighten the
securing features to the specified loading. Allow at
least four minutes to elapse to allow the joint to
settle then retighten the securing features. Repeat
the settling and retightening procedure until no
further loss of torque is experienced. The settling
period is unimportant provided it exceeds four
minutes.
NOTE: It may be found that minor joints do not

require repetitive tightening.
(4) Clean the brush in methylene chloride.
1535-GAS 6
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MAINTENANCE
7.11 Sealing Rings

(1) Identification.
(a) Rubber sealing ring identification is by the
part number which is shown on the envelope in
which sealing rings are individually packed. On
the envelope (and on all associated packaging)
is marked, as a minimum, the following
information (examples given in brackets).
Description of parts .. .. (ring, sealing)

Quantity.. .. .. .. .. (one, 1)
Rolls-Royce part number.. .. (000,000)
Cure date .. .. .. .. (2Q68)
(b) The sealing ring material is identified by self
colouring of the ring or by colour coding
markings on the ring. A sealing ring which has
become separated from its envelope can be
identified as follows:
(i) Match the colour code marking on the sealing
ring with the same marking in the
identification or rubber sealing rings table
which follows. Record the material code
shown in Table 8.
(ii) Refer to the 1535-2G Illustrated Parts
Catalogue which relates the material code to
the sealing ring part number, material
description, dimensions and location.
(2) Lubrication.
(a) Avoid indiscriminate use of lubricants when
fitting rubber sealing rings; use only the
recommended lubricant and apply sparingly
immediately before fitting the rings to a unit
or gas generator. Failure to observe the
foregoing instructions can result in premature
swelling of the rubber sealing rings during
assembling.
CAUTION 1: DO NOT USE A LUBRICANT ON RUBBER SEALING
RINGS OTHER THAN THAT RECOMMENDED FOR THE
PARTICULAR APPLICATION.
CAUTION 2: UNLESS OTHERWISE STATED, DO NOT USE
GREASE OR ANY OTHER SUBSTANCE ON GASKETS,
SPHERICALS AND MATING JOINT FACES IN
AIR/FUEL SYSTEMS. NEGLECT OF THIS
PRECAUTION HAS LED TO BLOCKAGE OF AIR OR
FUEL PASSAGES AND HENCE TO PARTIAL OR
COMPLETE POWER LOSS.
6 1535-GAS
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Identification Colour Code

Base Colour Number and Colour of Spots Material Code
or Lines
Black 1 yellow FE or WAD

Black 1 yellow, 1 white PE/FK or WAJ
Black 1 yellow, 1 blue, 1 green R/G or WAG
Black 2 yellow E/ORK
Black 2 yellow, 1 blue PE/EK or WAM
Black 2 yellow, 2 green VE/S or WAT
Black 3 yellow PE/OZR or WAK
Black 4 yellow VE/KR or WAS
Black part number in white ink PE/DRC or WAL
Black 1 white, 1 blue PE/EKR
Black 1 white, 2 blue B/SK or WAB
Black 1 white, 2 green E/PVC or WAQ
Black 1 white, 1 blue, 1 yellow E/XCF or WAP
Black 1 blue, 1 green E/ORP
Black 1 blue, 1 white, 1 green PE/ERS
Black 1 blue, 1 white, 1 yellow N/GP or WAC
Black 2 blue E/ORS
Black 3 blue N/Q
Black 1 green, 1 white PE/FR
Black 1 green, 1 yellow E/OR
Black 1 green, 2 yellow E/ORK or WAN
Black 3 green PE/RN
Black 4 green VE/HT or WAR
Brick red 2 black graphite SE/DT

Red 1 green GF/ST
Red None, self coloured E/ET

Orange None, self coloured SE/MP or WAH
Green None, self coloured SE/F
Blue None, self coloured SE/G
Pale Blue None, self coloured SE/CH or WAU
Grey None, self coloured SE/FM
Brown None, self coloured SE/MH
Brownish Red None, self coloured SE/DTA
Light Brown WAF
Brown None, packaged WAY

Brown None, packaged WAZ
TABLE 8 Identification of Rubber Sealing Rings
1535-GAS 6
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MAINTENANCE
(b) The choice of lubricant is controlled by the

environment of the rubber sealing rings,
ie. air, fuel or oil system, rather than by the
type of material from which they are
manufactured. As a general guide and unless
otherwise instructed, the lubricants to be used
during the fitting of rubber sealing rings are
as follows:
(i) Air system - Silicone rubber lubricant.
(ii) Fuel system - Liquid paraffin.
(iii) Oil system - Clean engine oil.
NOTE: These lubricants should be sparingly

applied to the sealing rings and any
surplus removed with a clean, dry
lint-free cloth.
(3) Fitting.
(a) Use new rubber sealing rings when assembling

units or gas generators.
(b) Ensure that the life and condition are as

detailed in Para 11 for sealing rings before
fitting them in a unit or gas generator.
(c) Ensure that grooves and mating faces, to which

the rubber sealing rings are to be fitted, are
clean and smooth then lightly smear the grooves
and mating faces with the recommended lubricant.
Apply the lubricant, sparingly, to the total
surface area of the rubber sealing rings before
fitting.
(d) Take care to avoid stretching or twisting the

rubber sealing rings whilst fitting; ensure that
when fitted the rings are not twisted and that
they are correctly seated in their grooves.
(e) Do not fit rubber sealing rings to any section

of the gas generator whilst it is still hot,
otherwise the sealing rings may stretch and be
more liable to damage.
(f) Prevent rubber sealing ring breakages when

fitting these items in such locations as fuel
pipe double grooved ferrules by using a suitable
pilot and sleeve assembling tool (Fig 8).
6 1535-GAS
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(g) Before fitting ferrules and tubes into their

mating sockets check that the exposed surfaces
of the rubber sealing rings are thinly coated
with the recommended lubricant. Use a straight
pushing movement to fit the ferrules and tubes
into their sockets; this action will prevent
twisting of the rubber sealing rings.
FIG 8 TYPICAL PILOT AND SLEEVE ASSEMBLING TOOL
1535-GAS 6
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MAINTENANCE
7.12 Backlash Checks on Bevel Gears
(1) Effect the following checks when assembling bevel

gears.
(a) Straight cut bevels.
(i) If the evidence of bedding from previous

running indicates satisfactory setting, and
care has been taken to ensure that the parts
being rebuilt are the original mating parts,
it is sufficient to check that there is some
backlash at all positions.
(b) Spiral bevels.
(i) If the evidence of bedding from previous

running indicates satisfactory setting, and
care has been taken to ensure that the parts
being rebuilt are the original mating parts,
it is sufficient to check that there is some
backlash at all positions.
(ii) If the bedding is unsatisfactory, or if

replacement parts are to be fitted, use the
fixture listed in the relevant section of
the 1535-2G Illustrated Parts Catalogue to
select the appropriate size adjusting
washer.
7.13 Identification of 12 Point Self Locking Nuts for Low and

High Temperature Applications
(1) These two types of self locking nuts are

geometrically similar, but with the following
distinguishing features.
(a) Nuts that must be used in the hotter gas

generator zones, in working temperatures of
230 deg C (446 deg F) to 650 deg C (1202 deg F)
are non magnetic, silver plated and partially
knurled on the flange.
(b) Nuts that are restricted to use in the colder

gas generator zones, in working temperatures not
exceeding 230 deg C (446 deg F) are magnetic,
cadmium plated and coated with molybdenum
disulphide (black). They feature a plain flange.
(c) Positive identification of used nuts into these

two broad groups, can only be done by
individually checking each nut with a magnet.
6 1535-GAS
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MAINTENANCE
(d) Ensure that only the correct nut (as defined in

the Illustrated Parts Catalogue) is fitted. It
must not be assumed that all low temperature
zones of the gas generator feature magnetic
cadmium plated nuts, as quite often high
temperature type nuts are by design to be found
in these areas.
8 WIRE LOCKING OF COMPONENTS
8.1 Introduction
(1) The purpose of this section is to advise and

illustrate the correct methods of wire locking for
components that are designed for, and require to be,
secured by this method.
(2) The lock wire material shall be corrosion resistant

steel to Specification DTD189A. The first preference
is for wire of 0.036 in. (0,9 mm.) diameter; but for
smaller hole applications, and where specified, wire
of 0.028 in. (0,7 mm.) diameter, may be used.
Alternative lock wire may be specified in particular
applications, for example, high temperature areas.
(3) New lock wire will be used on each application. At

disassembly any lock wire removed to release a
component shall be disposed of and will not be
reused.
8.2 Points to Observe When Fitting Lock Wire
(1) The lock wire will be pulled tight whilst being

twisted.
(2) For guidance the number of twists in the wire for

each 1.00 in. (25 mm.) length of twisted lock wire is
shown in Table 9 below, this representing current
general practice.
LOCK WIRE NUMBER OF TWISTS RECOMMENDED HOLE

PER 1.00 IN. DIA. FOR WIRE
DIAMETER (25 MM.) LENGTH (FOR REFERENCE ONLY)
INS MM. OF TWISTED WIRE
0.036 0,9 6 TO 12 0.063 in. (1,6 mm.)
0.028 0,7 8 TO 13 0.047 in. (1,2 mm.)
TABLE 9 Locking Wire Specification
1535-GAS 6
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MAINTENANCE
(3) Caution must be exercised during the wire twisting

operation to ensure that the lock wire is kept taut
without overstressing it.
(4) General light abrasions on the lock wire that can be
caused by commercially available wire twisting pliers
are considered acceptable. Any deep abrasions or
nicks that significantly affect the lock wire
diameter, or any kinks or other mutilations caused by
these pliers or any improper tooling or wiring
techniques are not acceptable; and any lock wire to
this unacceptable condition must be removed, the old
wire discarded, and replaced with new lock wire to
the correct standard.
(5) Gripping surfaces of pliers shall have their edges
sufficiently rounded to preclude damage to the lock
wire.
(6) The maximum span of twisted lock wire between tension
points shall be not greater than 3.15 in. (80 mm.)
unless otherwise specified. Refer to Fig 9.
(7) Where more than two fasteners are to be wire locked
in series, the number of fasteners shall not exceed
that which can be accommodated by a 25.5 in.
(650 mm.) length of lock wire (equivalent to a
12.7 in. (325 mm.) length of twisted lock wire) and
even then an adequate length must be available, after
the last fastener in the series, to secure the wire
end(s).
(8) In adjacent units it is desirable that the lock wire
holes in the fasteners are in approximately the same
relationship to each other as that shown in Figs 10
and 11. These illustrations show fasteners with a
right-hand thread and the lock wire configuration
should be reversed for fasteners with left-hand
threads. In either case the lock wise shall be
installed to present a diagonal configuration to the
fastener lock wire holes, in such a manner that the
wire strand through the lock wire hole in the
fastener will have a tendency to pull the fastener in
a direction to tighten it.
(9) Where a pipe adapter is used the pipe union shall be
wire locked to the component, not to the adapter.
Examples of wire locking for pipe unions are shown in
Fig 11.
(10) Where a lock wire traverses the body of the part
being locked, the angle of the wire approach to the
longitudinal axis of the part must be not less than
45 degrees. Refer to Fig 11.
6 1535-GAS
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MAINTENANCE
FIG 9 MAXIMUM SPAN OF TWISTED LOCK WIRE BETWEEN

TENSION POINTS
(RIGHT-HAND THREADED FASTENERS ARE ILLUSTRATED)
FIG 10 EXAMPLES OF WIRE LOCKING FOR RIGHT-HAND

THREADED FASTENERS
1535-GAS 6
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MAINTENANCE
8.3 Procedure for Fitting Lock Wire
CAUTION: LOCK WIRE SHALL NOT BE INSTALLED IN SUCH A

MANNER AS TO CAUSE THE WIRE TO BE SUBJECT TO
CHAFING, FATIGUE THROUGH VIBRATION, OR
ADDITIONAL TENSION, OTHER THAN THE TENSION
IMPOSED ON THE WIRE TO PREVENT IT LOOSENING. ANY
INSTALLED LOCK WIRE THAT IS INADVERTENTLY
DAMAGED WHILST WORKING ON A NEARBY COMPONENT
MUST BE REPLACED.
NOTE 1: Lock wiring is the securing together of two or

more parts with safety wire, at least one of the
parts being a threaded component. It is installed
in such a manner that any tendency for the
threaded part to loosen will be counteracted by
an additional tightening of the wire.
NOTE 2: Before fitting the lock wire, ensure that

threaded components to which it is fitted are
torque tightened within the specified limits, and
at the same time have their lock wire holes in
the correct relevant position to other components
that they will be lock wired to. Should the
fastener lock wire hole position be unobtainable
within the fastener specified torque tightening
limits, the fastener must be changed.
NOTE 3: The method of installing lock wire shall consist

of two strands of wire twisted together (the so
called "double twist" method) where one twist is
considered to be produced by twisting the wires
through an arc of 180 degrees (equivalent to half
of a complete turn). Refer to Figs 10, 11 and 12.
(1) Insert lock wire through hole in first unit. The

direction of wrap and twist of strands shall be such
that any loop around a component comes under the wire
strand protruding from the hole, so that the loop
will stay down and not tend to slip upwards and leave
the loop slack. Refer to Fig 13.
(2) Twist the strands so that the first twist in the wire
abuts the first unit, then twist the strands until
the twisted wire is just short of the hole in the
second unit. Insert the uppermost strand of lock wire
through the hole in the second unit and pull the
twisted wire taut. Ensure that the twisted portion of
the wire is within 0.118 in. (3 mm.) of the hole in
either the first or second unit. Refer to Fig 14.
6 1535-GAS
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FIG 11 EXAMPLES OF WIRE LOCKING FOR RIGHT-HAND

THREADED PIPE UNIONS
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MAINTENANCE
FIG 12 DOUBLE TWIST METHOD OF WIRE LOCKING

FIG 13 LOOPED LOCK WIRE PASSING UNDER STRAND FROM HOLE

(RIGHT-HAND THREADED FASTENER IS ILLUSTRATED)
FIG 14 MAXIMUM DISTANCE OF TWISTED LOCK WIRE TO UNITS

6 1535-GAS
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MAINTENANCE
(3) If there are more than two units, repeat sub-

paras (1) and (2) above for the remaining fasteners.
(4) After wiring the last unit, produce a loop by bending

the twisted wire back on itself through 180 degrees.
The length of twisted wire to produce the loop should
be kept as short as possible to avoid fatigue
failures due to vibration but the end of the twisted
wire, from the bend, shall have a minimum of four
double twists to ensure that it will not unravel.
(5) Cut off excess wire and discard. Bend the looped wire
in towards the last wire locked unit and stow neatly
to ensure that cut edges will not be exposed or
become a hazard.
9 ROUTINE INSPECTION AND MAINTENANCE
9.1 General
(1) The importance of high standard routine maintenance

at the regular recommended time intervals cannot be
over emphasised as a contributory factor towards long
gas generator life and trouble free operation.
(2) It is essential that the work detailed in this Manual

is carried out by trained and competent personnel,
and that only approved parts meeting Rolls-Royce
Power Engineering plc quality standards are used
during the maintenance of the Avon Industrial Gas
Generator.
(3) It is a requirement that users of this publication be

familiar with and observe local health and safety
regulations and requirements that may affect the
publication contents.
(4) Fibre optic equipment may be used to facilitate

inspection of the flame tubes, HP nozzle guide vanes,
turbine blades, discharge nozzles, snouts and part of
the compressor assembly.
9.2 Routine Inspection Period
(1) Table 10 lists the recommended routine inspection

checks required on the gas generator.
(2) These checks may be effected when convenient but the

period between checks must not exceed that stated in
Table 10.
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INSPECTION CHECK PERIOD

Inspect the gas generator for 500 starts or 500 hours
external leakage whichever is sooner
(peak load operation)
Inspect the gas generator
drainage systems OR
Inspect the gas generator air 4000 hours

intake (flare, extensions, (base load operation)
casing, struts, starter fairing,
intake guide vanes and visible
compressor blades)
Check the gas generator mounted
starter motor resistance
Inspect the exhaust unit and
turbine assembly
Inspect the gas generator
generally
Renew the igniter plugs 500 starts or 500 hours
whichever is sooner
(peak load operation)
or 4000 hours (base
load operation)
Inspect the lubricating oil feed After the first
filter : on new sites 25 hours
: thereafter On each routine
inspection, ie. 500
hours (peak load
operation) or 4000
hours (base load
operation)
Inspect the lubricating oil After the first
magnetic chip detectors 25 hours
On each routine
inspection, ie. 500
hours (peak load
operation) or 4000
hours (base load
operation)
Inspect the static oil level in Every 500 hours or
the intake guide vane ram three months whichever
is the sooner
TABLE 10 Inspection Checks
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INSPECTION CHECK PERIOD

Inspect the front suspension Every 1000 hours
bolts and spherical bearing for (Pre-Mod.4513) or
lubrication 4000 hours (Mod.4513)
or every six months,
whichever is the sooner
Inspect the P2 air filter On each routine
inspection, ie. 500
hours (peak load
operation) or 4000
hours (base load
operation)
Check the lubricating oil Every eight weeks
acidity level on Castrol
Perfecto GT3, Castrol 5000,
Castrol 580 or Esso/Exxon 2380
lubricating oils. Refer to
Service Bulletin No.48. Check
other lubricating oils every 12
weeks
Clean the compressor See Chapter 8
Check the gas generator One seismic transducer
vibration monitoring system - every 4000 hours
or
Two seismic transducers
– every 4000 hours
or
every six months,
whichever is the sooner
Endoscope inspection On each routine
inspection, ie every
500 hours (peak load
operation) or
4000 hours (base load
operation). Refer to
Chapter 12
Inspect the stage 00 compressor Refer to Service
disc Bulletins 32 and 45
TABLE 10 Inspection Checks Continued
9.3 Inspect the Gas Generator for External Leakage

(1) Remove the acoustic hood (if fitted).
(2) Run the gas generator at idling rpm (see relevant
Operating Limitations supplied with gas generator
installation) and carry out the following inspection
checks:
(a) Inspect, for gas fuel leakage, the gas fuel
manifold, burners and connecting pipes.
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MAINTENANCE
(b) Inspect, for hydraulic oil leakage, the

hydraulic oil distributor block, pipes, intake
guide vane ram and bleed valve rams.
(c) Inspect, for lubricating oil leakage, the filter
housing and connection block, the lubrication
connecting block and the oil pipes.
(d) Inspect, for air leakage, the compressor
casings, the distributor block, the P2 air
filter and air pipes.
(e) Inspect, for hot gas leakage, the combustion
casing, turbine assembly and, when specified,
the exhaust unit.
(3) Stop the gas generator, rectify as necessary then

replace the acoustic hood.
10 INSPECTION OF HYDRAULIC, AIR AND ELECTRICAL SYSTEMS
10.1 Inspect the Hydraulic Oil Drainage System
(1) Inspect the hydraulic oil drainage at the intervals

specified in Table 10 of this Chapter.
(2) If the drainage rate exceeds the limits specified in

Chapter 7 Para 10.2, isolate the unit responsible as
detailed in that Chapter.
10.2 Inspect the Gas Generator Air Intake
(1) Inspect the intake flare; if cracked, fit a new flare

as instructed in Chapter 7 Para 4.2 to 4.5. Repair
all damage, other than cracks, as instructed in that
chapter.
(2) Inspect the extension ring(s); if the wall is
punctured or the locating flanges cracked, fit a new
extension ring as instructed in Chapter 7 Paras 4.2
to 4.5.
(3) Inspect the front bearing housing with particular
attention to the tangential support struts.
If cracked, contact Customer Support Manager,
Rolls-Royce Power Engineering plc.
(4) Inspect the starter fairing for scores and dents.
Rectify, if necessary, as instructed in Chapter 7
Para 4.8 and 4.9.
(5) Inspect the intake guide vanes and visible compressor
blades for security and damage as detailed in
Para 14.1.2 of this chapter.
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10.3 Check the Starter Motor Insulation Resistance

(1) Gas generator mounted starters only.
(2) Remove the covers from the starter lead junction
boxes on the top and the left-hand side of the gas
generator.
(3) Unscrew the screw which secures the external supply
lead to each junction box then withdraw the lead from
the junction box; do not disturb either of the
starter motor to junction box leads.
(4) Measure the insulation resistance by connecting one
lead of a 500 volt megger to the starter motor cable
in the junction box on the top of the gas generator
and the other lead to any point on the gas generator;
the reading should be not less than 40,000 ohms.
(5) If the reading is satisfactory, remove the megger and
connect the starter leads.
(6) If the reading is less than 40,000 ohms, remove the
starter and check the insulation resistance as
described in Chapter 7 Para 4.13, applying the limits
given there.
10.4 Inspect the Exhaust Unit (where specified) and the Turbine
Assembly
Remove the transition section and inspect the exhaust
unit as instructed in Chapter 7 Para 17.4.
10.5 Inspect the Gas Generator Generally
Inspect the gas generator generally for damage. Check
the security of the components. Check the security of the
gas generator mountings.
10.6 Renew the Igniter Plugs
Remove and renew the igniter plugs as instructed in
Chapter 7 Para 18.
10.7 Inspect the Lubricating Oil Feed Filter
Remove and inspect the filter for cleanliness as
instructed in Chapter 7 Para 8.3.3 to 8.3.5.
10.8 Inspect the Lubricating Oil Magnetic Chip Detectors
Remove and inspect the magnetic chip detectors
for cleanliness as instructed in Chapter 7 Paras 8.3.6
to 8.3.8.
10.9 Inspect the Static Oil Level in the Intake Guide Vanes Ram
Inspect the static oil level in the intake guide
vanes ram and replenish, if necessary, as instructed in
Chapter 7 Para 5.3.
1535-GAS 6
May/00 Page 59
MAINTENANCE
10.10 Inspect the P2 Air Filter
Inspect, and if necessary, clean the P2 air filter

element as instructed in Chapter 7 Para 22.
10.11 Check the Lubricating Oil Acidity Level
Check that the acidity level of the lubricating oil

is within the limits specified in Para 12.2 of this Chapter.
10.12 Check the Gas Generator Vibration Monitoring System
Check the integrity of the system if facilities at

the site are available. If no facilities are available to
calibrate the vibration accelerometers, return to Customer
Services, Ansty where a calibration service is available.
11 RUBBER AND SYNTHETIC RUBBER PARTS - SHELF LIFE, STORAGE

AND INSPECTION
11.1 Shelf Life
(1) The cure date is the reference point from which the
shelf life of rubber and synthetic rubber parts is
calculated. It is marked on the parts and/or on their
associated packaging and applies to all 'uninstalled'
rubber or synthetic rubber parts, bonded rubber to
metal parts, cables, harnesses, hoses and hose
assemblies but not to assembled units and accessories
(such as fuel units).
(2) The cure date is shown as the quarter of the year

(expressed as a single figure) and the year
(expressed as a double figure) of manufacture
separated by the letter Q; eg. 2Q68 is the cure date
for a part manufactured in the second quarter of
1968. The year is divided into quarters as follows:
(a) January, February, March.
(b) April, May, June.
(c) July, August, September.
(d) October, November, December.
NOTE: On some parts, the month of manufacture may be

shown in brackets after the cure date,
eg. 2Q68(May).
(3) The age of the part is calculated from the end of

the quarter in which the part was manufactured. Thus
a part with the cure date 2Q68 would be one year
old at the end of the second quarter of 1969,
ie. 30th June, 1969.
6 1535-GAS
Page 60 May/00
MAINTENANCE
11.2 Cure Date Marking
(1) The method of showing the cure date of 'uninstalled'

or 'separate' rubber or synthetic rubber parts is as
follows:
(a) Individual parts (except sealing rings) large

enough to be marked, eg. diaphragms and bulkhead
seals, are stamped or stencilled with a
permanent marking fluid of a contrasting colour.
(b) Individual parts which cannot be marked owing to

size, and sealing rings, are packed in marked
envelopes supplemented by labels attached to the
part or batch.
(c) All basic envelopes, bags or packages and all

intermediate and/or exterior containers in which
the items are packaged are marked with the cure
date. In addition each envelope, bag or package
shows the manufacturer's name or reference,
Rolls-Royce part number and batch number.
(d) Hoses are marked with two separate groups of

figures and letters which are repeated along the
full length of hose. The first group gives
manufacturing data such as 'mix' information,
whilst the second group gives length or batch
number and cure date as follows:
First 4 figures - length or batch number
Next or middle - quarter symbol)

figure and letter and 'Q' )
) cure date
Final 2 figures - year symbol )
Example: 01012Q68 - 101st length or batch

produced in the second
quarter of 1968
(e) Hose assemblies are, in addition to the coding

on the hose element, marked by the following
identification tabs:
(i) Coding tab (repeat of hose coding).
(ii) Identification tab (showing hose piece

number, test date, inspector's stamp and
marker's identification).
(iii) Cure date tab (showing cure date of hose).
1535-GAS 6
May/00 Page 61
MAINTENANCE
(f) All basic packaging and all intermediate and/or

external containers for hoses and hose
assemblies are marked with the cure date.
11.3 Storage of Parts
(1) Maintain rubber and synthetic rubber parts in good

condition and ensure maximum shelf life by careful
attention to storage conditions. Store parts under
conditions which provide the maximum possible
protection against the effects of strain, direct
sunlight, ozone, moisture, excessive circulation of
air, extremes of temperature, physical damage and
contamination by fuels, oils, greases or solvents. If
the parts are supplied packed in envelopes, plastic
bags or cartons, they should be kept in this
condition until required for service. Avoid excessive
shelf storage time by relating level of stocks to
rate of use and by issuing parts on an 'age' basis,
that is, oldest items, as shown by cure date, first.
Do not allow direct contact between rubber parts and
metals (especially containers made from copper).
(2) Store parts in a relaxed position free from tension

and, wherever possible, in their normal shape. Avoid
excessive vertical stacking of parts as this can
cause permanent distortion of the lower layers. Store
flexible hoses in straight lengths, wherever
possible, as 'coiling' produces tension in the
outside of each coil and increases the risk of ozone
cracking.
(3) Provide sufficient ventilation to prevent

condensation but prevent currents of air from coming
into contact with the stored parts. Avoid, as much as
possible, sources of ozone such as mercury vapour
lamps, electrical machinery and an excess of outdoor
air which, in temperate climates, always contains
ozone. Ensure that parts are shielded from direct
sunlight.
(4) Store lip type seals in such a manner that damage and
distortion to the sealing edge is avoided, and do not
tie labels directly to the seals. Do not fit sealing
rings to ferrules or bobbins until immediately before
installation into a gas generator or unit as
stretching and exposure to light can cause
deterioration.
6 1535-GAS
Page 62 May/00
MAINTENANCE
(5) Maintain storage temperature within the preferred

range of 15 to 21 deg C (59 to 70 deg F) with a
minimum of 5 deg C (41 deg F) and a maximum of
38 deg C (100 deg F) and an air relative humidity of
65 per cent. Store parts at least three feet from any
unscreened source of heat.
(6) If stored under the preceding recommended conditions

the shelf life of rubber parts is virtually
unlimited, subject at specified intervals in certain
cases to a monitoring inspection. For this purpose,
rubber types have been divided into three groups:
Group A Material Specification
Natural rubber MS717
These can be supplied to a customer up to 5 years

from cure date. The subsequent shelf life is
unlimited, subject to satisfactory inspection (see
Para 11.4) of a sample of the oldest stock at least
every two years.
Group B Material Specification
Butyl MS754, 757
Neoprene MS710, 716 (BS2752 grade
(Chloroprene) C3 or C4)
These can be supplied to a customer up to seven years

from cure date. The subsequent shelf life is
unlimited, subject to satisfactory inspection (see
Para 11.4) of a sample of the oldest stock at least
every three years.
Nitrile MS727, 735, 743, 744, 747, 765
MSRR9454, 9455
BSEM602
DTD5509, 5595, 5607
These can be supplied to a customer up to 10 years

from cure date. The ultimate life is 15 years.
Group X Material Specification

Silicone ) MS732, 741, 751, 756, 761, 771
Fluorosilicone ) MSRR9450 (MS762), 9451 (MS782)
Fluorocarbon ) 9452 (MS766), 9453, 9490
(Viton) ) BSEM608, 734
DTD900/4822A, 5543, 5603, 5612
5613
There is no life limit for supply to a customer or
for storage. Cure date marking has been retained only
to assist stock monitoring.
1535-GAS 6
May/00 Page 63
MAINTENANCE
NOTE 1: Rubber parts in Groups A and B (except

Nitrile) supplied to a customer for
immediate use on gas generators and
therefore not intended to be stored, may
have exceeded the cure date limit. This is
acceptable since the vendors storage
conditions are close to ideal.
NOTE 2: Material specification numbers are marked on

packaged components only.
NOTE 3: If rubber parts to material specifications

not listed in this chapter are encountered,
please contact RRPEplc.
11.4 Inspection of Parts
(1) Examine parts for signs of 'ageing' or degradation

due to oxidation. This is shown by surface cracks and
deterioration. To check, flex the part gently and
discard if cracks are present before or after
flexing.
(2) Do not automatically discard parts due to the

presence of a white or coloured 'bloom' on their
surface. Such blooms are often desirable anti-ageing
layers and originate from the anti-oxidants used in
high grade rubber.
(3) Examine, and discard if faulty, all parts for:
(a) Permanent distortion, flats and other obvious

defects.
(b) Tackiness or surface hardening or softening.
(c) Blistering, peeling or cracks when rubber is

extended or flexed.
(d) Chafing of outer coverings and corrosion of, or

damage to, end fittings of hose assemblies and
cable harnesses.
(e) Corrosion of metal elements in bonded rubber to

metal assemblies.
(f) Obstruction of the bore (flexible hoses).
6 1535-GAS
Page 64 May/00
MAINTENANCE
(4) Pressure test flexible hoses as instructed in the

relevant sections of this Manual. If it is essential
to fit a flexible hose when no facilities for
pressure testing exist, then the hose must be removed
for testing at the first available opportunity. On
completion of pressure testing, drain the hose, blow
through with clean air and seal the ends with blanks.
(5) Test electrical cables and harnesses for resistance,
leakage and conductivity, as well as for chafing of
the loom and satisfactory condition of the end
fittings.
12 LUBRICATING OIL GUIDANCE NOTES
12.1 General
(1) The lubricating oils which have been approved by
Rolls-Royce for use in the gas generator are listed
in Para 13 of this Chapter.
(2) The use of any other type of lubricating oil in the
gas generator must have the prior approval of
Rolls-Royce.
WARNING: THE SYNTHETIC LUBRICATING OIL IN THIS GAS
GENERATOR MAY CAUSE SKIN IRRITATION IF SKIN
CONTACT IS REPEATED OR PROLONGED.
CAUTION 1: USE ONLY SCRUPULOUSLY CLEAN CONTAINERS AND
EQUIPMENT DURING TESTING. CONTAMINATION OF THE
OIL BY FOREIGN MATERIAL, EG. CLEANING FLUIDS,
CAN DESTROY THE LUBRICATING PROPERTIES OF THE
OIL AND FOUL THE FILTERS.
CAUTION 2: THE OIL SPECIFIED FOR USE IN THE GAS GENERATOR
OIL SYSTEM IS INJURIOUS TO PAINTWORK AND
CERTAIN TYPES OF RUBBER AND MUST NOT BE
ALLOWED TO CONTAMINATE THOSE PARTS OF THE
ENGINE NOT NORMALLY IN CONTACT WITH IT. ANY
OIL SPILT MUST BE IMMEDIATELY WIPED UP.
12.2 Check the Acidity Level of the Oil
(1) Routine sampling of lubricating oils has recorded
high acidity levels and several instances of acid
attack on gas generator casings and rubber oil seals
have been observed. Operators are recommended to
check the acidity of the oil as follows:
(a) Submit a sample of the oil for laboratory
analysis at the interval specified in Table 10
of this Chapter.
(b) If the acidity level exceeds 2 mg KOH/g, discard
the oil in the gas generator and the associated
plant supply system and refill with fresh oil.
The acidity level of this fresh oil must be less
than 1 mg KOH/g.
1535-GAS 6
May/00 Page 65
MAINTENANCE
13 SERVICING AND STORAGE MATERIALS
MATERIAL APPLICATION SPECIFICATION MANUFACTURER

SUPPLIER OR BRAND
BRITISH AMERICAN CANADIAN
WARNING: THE SYNTHETIC LUBRICATING OIL IN THIS GAS Viscosity 3cSt
GENERATOR MAY CAUSE SKIN IRRITATION IF SKIN Castrol Aero 325
CONTACT IS REPEATED OR PROLONGED. Castrol Perfecto GT3
CAUTION: USE ONLY SCRUPULOUSLY CLEAN CONTAINERS AND Aeroshell Turbine Oil 390
EQUIPMENT DURING TESTING. CONTAMINATION OF Exxon/Esso Turbo Oil 15
THE OIL BY FOREIGN MATERIAL, EG. CLEANING Viscosity 4.5cSt
FLUIDS, CAN DESTROY THE LUBRICATING
Castrol Perfecto GT5
PROPERTIES OF THE OIL AND FOUL THE FILTERS.
Oil Lubrication of: Viscosity 5cSt
1. Gas generator Castrol Aero 5000
Caltex SATO 5s
2. Oil system Caltex SATO 99
sealing rings Aeroshell Turbine Oil 500
Aeroshell Turbine Oil 560
3. Securing nuts Royco 500
(unless Royco 560
otherwise Mobil Jet Oil II
specified) Exxon/Esso Turbo Oil 2380
Turbo Nycoil 600
Total Jet Turbine 530
Elf Turbojet 2
NOTE: cSt=centistokes
Low Lubrication of DTD.825B MIL-G- 3-GP-683A Esso Petroleum Co.Ltd.
temperature control rod fork 2327A or
ester-base and ball joints Shell (UK) Ltd.
grease and intake guide
vane ram spindle
6 1535-GAS
Page 66 May/00
MAINTENANCE

SUPPLIER OR BRAND
Gas Lubrication of Lubri- Any reputable supplier

generator ball and roller cating oil
lubricating bearings
oil
Assembly Fuel system Turbo 10

fluid rubber rings
where specified
Silicon Lubrication of DTD.900/ MIL-I-8660 MS4 - Midland Silicones

rubber silicon rubber 4298 Limited
lubricant sealing rings DC4 - Dow Chemical
MS4 or DC4 where specified Corporation
Anti-seize Lubrication of: DTD.900/ Rocol Ltd.

compound Front suspension 6128
bolt threads Rocol 251
HE igniter plug
threads
Grease - Lubrication of: Rocol Rocol Ltd.

High Front suspension BG.741
temperature bolts
Spherical bearing
Front suspension
bell crank
1535-GAS 6
May/00 Page 67
MAINTENANCE

SUPPLIER OR BRAND
Jointing For sealing metal DTD.900/ Marston Lubricants

compound, to metal joints. 4586 Ltd.
wide Resistant to fuel Hylomar Med-Lab Ltd.
temperature and ester-base PL32 W.R. Sales and
range oils. Effective (Light) Marketing Ltd.
(PL32) over the Rolls-Royce Inc.
temperature range
of minus 50°C to
plus 300°C (in
air) and plus
150°C (in oil)
Temporary External DEF.2331 MIL-C- Shell (UK) Ltd.
rust protection and 16173B
preventive protection of Grade 2
exposed bolt
heads
Trichloro- ) Triklone N )
ethylene ) External )
) cleaning of gas ) Any reputable
White ) generator BS.245 ) supplier
spirit ) )
Reprotecting E3892 ) P.P.G. Industries
Air drying aluminium finish PJP1912A ) (UK) Ltd.
enamel 8000 ) Med-Lab Ltd.
(PL82) )
)
Reprotecting grey CO5153/ ) International Paint
finish 693 ) Company Inc.
PJP1721D )
6930 )
6 1535-GAS
Page 68 May/00
MAINTENANCE

SUPPLIER OR BRAND
Air drying Primer for enamel CO5151 ) P.P.G. Industries

primer PJP1721P ) (UK) Ltd.
4011 ) Med-Lab Ltd.
)
Air drying Reprotecting CO5187 ) International Paint
varnish clear finish PJP1721C ) Co. Inc.
8187 )
Alocrom Reprotecting DTD.900/ Med-Lab Ltd.

1200 magnesium casings 4413
Silica gel Desiccant and BS.2540 J. Crosfield & Sons

humidity
indicator used in
gas generator
packing
Vapour
Phase Anti-corrosion RR MS.644 J. Chadwick & Sons Ltd.
Inhibitor protection of (VPI/CHC)
impregnated internal parts of
paper gas generator
French DTD.527 Any reputable supplier

Chalk
(Technical
grade)
Acetone BS.509 Federal Any reputable supplier

Spec.
0-A-51
1535-GAS 6
May/00 Page 69
MAINTENANCE

SUPPLIER OR BRAND
Adhesive For binding the Scotchboy RRPEplc

tape ends of the LT No.33
harness cables
Lacing tape Thermocouple TG.20 RRPEplc

analyser system
Adhesive Electrical Celoplast RRPEplc

tape harness
Methanol ) BS.506 I.C.I. Limited

) Alternative
Isopropyl ) anti-freeze BS.1595 or
Alcohol ) additives for
) compressor
Ethylene ) cleaning BS.2537 Any reputable supplier
Glycol )
6 1535-GAS
Page 70 May/00
MAINTENANCE

SUPPLIER OR BRAND
Cleaning Fuel burner Turco 4228 Turco Chemical

fluid cleaning Products Limited
Inhibiting Compressor Steelgard Vapor Tek Limited

fluid inhibiting (Formula
521 or
522)
Ardrox ) Ardrox Limited

3961 )
) or
)
) Brent Europe Limited
Castrol Burmah Castrol

Rustilo Industrial Limited
DWX 24
Penetrating
oil
Lusol Rocep-Lusol
Plus-gas Plus-Gas Co. Ltd.
1535-GAS 6
May/00 Page 71
MAINTENANCE

SUPPLIER OR BRAND
Cleaning Compressor Castrol ) Burmah Castrol

additive cleaning ICE 113 ) Industrial Limited
)
Castrol )
ICD 177 )
)
Ardrox ) Ardrox Limited
6345 )
) or
Ardrox )
6357 ) Brent Europe Limited
B&B 3100 B & B Chemicals

Co. Inc.
Riveneas
G21 I. Riveneas Limited
ZOK27
Airworthy Limited
6 1535-GAS
Page 72 May/00
MAINTENANCE

SUPPLIER OR BRAND
Pencil/ ) Berol )
crayon ) Verithin )
temporary ) Staedtler )
marker ) Mars )
) Onichrome, )
) No Blot )
) ink pencil )
) )
Felt or ) Soft )
fibre tip ) chalk, )
temporary ) Berol )
marker ) valve )
) marker, ) Med-Lab Limited
) Marking of Pentel )
) components felt or MIL-I-8660 )
) fibre pen, )
) Vari line )
) marker )
) )
Marking ink ) American )
) black, )
) Ardrox )
) 386W, )
) Spectra )
) colour )
1535-GAS 6
May/00 Page 73/74
MAINTENANCE
14 COMPRESSOR INSPECTION
14.1 Inspections Made Through the Air Intake
14.1.1 General
(1) The purpose of making an inspection through the air

intake is:
(a) To determine if the gas generator is acceptable

without rectification.
(b) If not, to determine if the gas generator can be

rejected immediately without the need for
further examination.
(c) Metallic bodies (nuts, washers, etc.) entering

the compressor invariably cause a great deal of
primary and secondary damage to the later stages
of the compressor. Therefore, as soon as it is
established that a metallic body has entered and
damaged the compressor, the gas generator should
be rejected immediately. The particular
indications to look for are screw thread
impressions or regular shapes (eg. hexagonal or
circular) on the blading.
(d) Non metallic bodies (eg. stones) usually cause

less damage to the later stages than do metallic
bodies. Stones are usually shattered by the
leading edges of the stage 00 rotor blades and
the damage beyond this stage is usually
acceptable. Characteristic of this type of
damage is the very marked change between the
damage to the stage 00 rotor and that to the
stage 0 and subsequent stages. In this case, the
serviceability of the gas generator can
frequently be assessed by examination of the
damage to the 00 and 0 stages only.
(e) If an object, greater in area than 36 sq in.,

has been trapped in front of the compressor so
that it has caused a blockage for a period of
more than two hours gas generator running time,
the gas generator must be rejected even if no
visible blade damage has occurred.
1535-GAS 6
May/00 Page 75
MAINTENANCE
14.1.2 Inspect the blading through the air intake
(1) At the routine inspection periods specified in Para 9

of this chapter, or when it is suspected that the
compressor has ingested a foreign body, remove the
air intake flare and make the following examinations
through the air intake. Apply the limits given and
accept or reject the gas generator as appropriate.
(a) Examine the intake guide vanes (IGV's) for dents

and cracks and for evidence of metallic
ingestion.
Acceptable Unacceptable
Smooth indentations Evidence of metallic

without cracks ingestion
Minor damage to the Sharp indentations with
leading edge cracks
(b) Disconnect the IGV ram coupling from the master

IGV operating lever as instructed in Chapter 7,
Para 5.1. Move the IGV's several times through
their complete range of movement, to check for
ease of operation. Afterwards, leave the IGV's
at the fully open position.
Free unrestricted Restricted or tight

movement movement
(c) Turn the gas generator slowly by hand, checking

and listening for evidence of a foul between the
rotors and stators.
Compressor turns Foul indicated

freely without
indication of foul
6 1535-GAS
Page 76 May/00
MAINTENANCE
(d) Check the stage 00 rotor blades for bending, for

evidence of metallic ingestion, for nicks, tears
or cracks. If any blade is bent slightly
forward, check that with the bent blade held
forward, it does not contact any IGV.
Bent blade held Evidence of metallic
forward does not ingestion
contact any IGV
Nicks, tears or damage Bent blade when held
marks on both leading forward contacts an IGV
edges, provided they
can be blended out More than two blades
within the limits bend forward more than
shown in Fig 15 0.100 in.
Damage to the outer Damage marks which
tip of the leading cannot be blended out
or trailing edge within the limits shown
(but not both) of in Fig 15
only one blade
provided the damage Damage to the outer tip
can be blended out of a blade which cannot
within the limits be blended out within
shown in Fig 16 the limits shown in
Fig 16 or damage
occurring on more than
one blade
(e) Examine the stage 00 stators for nicks, tears

and dents and for cracking at the welds.
Rounded indentation Obvious cracking on the
on the aerofoil aerofoil section
section less than
0.100 in. deep without
associated cracking
Indentations and Any cracking associated
scoring less than with a damage mark as
0.075 in. deep on shown on Fig 17
the leading edge
without associated Sharp indentations or
cracking indentations deeper
than 0.100 in. on the
Cracks less than aerofoil section
0.200 in. long in the
spot or trailing edge Indentations or scoring
welds deeper than 0.075 in.
on the leading edge
1535-GAS 6
May/00 Page 77
MAINTENANCE
FIG 15 LIMITS OF DAMAGE TO FIG 16 LIMITS OF DAMAGE TO

LEADING AND TRAILING TIP OF STAGE 00 ROTOR
EDGES OF STAGE 00 ROTOR BLADE
6 1535-GAS
Page 78 May/00
MAINTENANCE
FIG 17 UNACCEPTABLE INDENTATIONS WITH CRACKS

STAGE 00 STATORS
1535-GAS 6
May/00 Page 79
MAINTENANCE
14.2 Compressor Front Casing Inspection
14.2.1 Inspect the front compressor casing
(1) Inspect both sides of the compressor upper half

casing for cracks, paying particular attention to the
areas between the stage 7 bleed valve and the casing
horizontal joint face (Fig 18), at the period
specified in Table 10 of this Chapter. The casing
must also be inspected if, at any time during the gas
generator life, a leak is observed from the stage 7
bleed valve ram.
NOTE: These cracks originate from the rear of the

stage 7 bleed valve port and propagate
circumferentially towards the horizontal joint
face on either side of the casing.
(2) Apply the following acceptable standards:
(a) Accept cracking on the left hand side of the

casing, which has propagated to the horizontal
joint face provided that the right hand side
horizontal joint face is crack free.
(b) Accept cracks on the right hand side of the

casing, which have propagated to the horizontal
joint face provided that the left hand side
horizontal joint face is crack free.
(c) Reject the gas generator if the casing is

cracked through both the left hand and right
hand side horizontal joint faces.
(d) Reject the gas generator if a crack has

propagated into the lower half casing from
either side of the upper half casing.
(3) Monitor acceptable cracks at convenient intervals not

exceeding 50 hours running time.
15 INSPECT THE FRONT SUSPENSION BOLTS AND SPHERICAL BEARINGS

FOR LUBRICATION
Re-lubricate the front suspension bolts and spherical

bearing, as necessary, using the lubricant specified in
Para 13 of this Chapter. Refer to Fig 19.
6 1535-GAS
Page 80 May/00
MAINTENANCE
FIG 18 COMPRESSOR FRONT CASING CRACKING
1535-GAS 6
May/00 Page 81
MAINTENANCE
FIG 19 LOCATION OF GREASE NIPPLES FITTED TO FRONT

SUSPENSION BOLTS
6 1535-GAS
Page 82 May/00

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INDUSTRIAL AVON GAS GENERATOR

GASEOUS FUEL MANDATORY REQUIREMENTS 3

Liquid Hydrocarbon and Hydrates 3.5

CONTAMINATION OF GAS GENERATOR COMPONENTS 4

TEMPORARY MARKING OF PARTS 6

WIRE LOCKING OF COMPONENTS 8

ROUTINE INSPECTION AND MAINTENANCE 9

INSPECTION OF HYDRAULIC, AIR AND ELECTRICAL SYSTEMS 10

Inspect the Lubricating Oil Feed Filter 10.7

Table Title Page

1 Range of in-built torque limits for self locking 14

Table Title Page

7 Standard torque loads for fitting serrated head 20

(1) Use only approved tools as listed in Chapter 9.

(2) Ensure the gas generator oil levels are acceptable

1.1 Blanks and Blanking Procedure

(1) Ensure that the open ends of disconnected pipes are

CAUTION: DO NOT USE TAPERED, NON THREADED, PUSH-IN TYPE

(2) All blanks should be either the external screw type,

(3) Before using blanks it is essential that the

(a) The blank to be used is of the correct type,

(b) Ensure before fitting the blank that no other

(c) Ensure the component to which the blanks are

(d) On removal of blanks, immediately prior to

(e) If a component cannot be correctly blanked care

1.2 Change of Component Procedure

(1) Ensure that all tools and replacement parts are

(2) Fit new sealing washers, joint washers and locking

(3) Unless otherwise stated apply jointing compound to

(4) Ensure that the gas generator oil levels are

(5) Carry out the appropriate functional checks on all

(6) It is important that the system of records be

(7) All torque loading and tightening of nuts, bolts and

(8) All electrical connectors should be wire locked when

(9) Defective or damaged wire thread inserts must be

(10) Ensure that all gas generators are serviced, repaired

(11) Ensure that where new or replacement components are

FIG 1 PIPE AND COMPONENT BLANKS

(12) Instruct the overhaul base to deface any life expired

WARNING: THE SYNTHETIC LUBRICATING OIL USED IN THIS

CAUTION 1: THE OIL SPECIFIED FOR USE IN THIS OIL SYSTEM

CAUTION 2: CONTAMINATION BY MINUTE AMOUNTS OF CERTAIN

1.3 Functional Testing of Equipment

(1) When any sub-assembly, accessory, component or its

(2) Where practical, the item and its associated circuits

(3) Where items cannot be tested prior to running the

(4) This testing should be carried out on every occasion

1.4 Safety Warnings and Cautions

WARNING: THE ELECTRICAL DISCHARGE FROM THE HIGH ENERGY

1.4.1 System safety

Ensure that electrical circuits, fuel, lubricating

1.4.2 Igniter/high energy ignition unit function testing

In ALL cases a DRY motoring cycle MUST be carried out

1.5 Torque Tightening Technique

(1) A predetermined torque load is applied to nuts, bolts

(1) Lubrication is of great importance in achieving the

(2) The standard lubricant to be used is clean

(3) Rocol ASC251 is the only lubricant, as an alternative

(4) When a special lubricant is required, eg. for