Professional Documents
Culture Documents
RANSM I T T A L
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March 1970
VOLUME 2
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TRANSMITTAL LETTER No.ll
NOTE:
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CHECK THAT ALL ~.R_EVIOUS TR ANSMITTALS HAV.E BEE N INCO RPORATE,D if any have not been rece 1ved please
advise
Tec ~11kal Publkatio ns Depa rtment. Rolfs Royce Limited. East Kilb ride. Lan arkshire , Scotland
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LIST OF SUBJECTS
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Jan.7/70 5-2
List of Subjects
ROLLS-ROYCE AERO ENGINES
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Description
Jan.7/70 5-2-l
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ROLLS-ROYCE AERO ENGINES
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Triple breech turbo starter- TBS 720 Mk 5 -Description (cont.)
To be issued later
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SPECIAL TOOLS
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TABLE OF CONTENTS
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Special tools
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ROLLS-ROYCE AERO ENGINES
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SPECIAL TOOLS
Special tools
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ROLLS-ROYCE AERO ENGINES
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Special tools
5-2-'l Jan.7/70
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ROLLS-ROYCE AERO ENGINES
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DISASSEMBLY
:: TABLE OF CONTENTS
Page
General 303
Remove the annulus gear and drive shaft from the gear casing 306
Disassembly
Jan.7/70 5-2-1
Page 301
ROLLS-ROYCE AEitO ENGINES
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DISASSEMBLY
1. General
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A. Refer to 'Standard practices' (1-l) for general instructions pertaining
to disassembly.
C. Remove all accessible locking wire and release all accessible tabwashers.
D. Remove the stub pipe securing nuts and remove the three stub pipes.
A. Unlock and remove the nuts securing the gear casing to the exhaust casing
then tap out the bolts. Withdraw the gear casing from the exhaust casing
\,.,___ and lift off the support ring and rear fairing.
Disassembly
Jan.7/70 5-2::-1
Page 303
ROLLS-ROYCE AUO ENGINES
- - - - - - - A C C IS SORY OVI R H A U L - - - - - - - -
Triple breech turbo starter - TBS 720 Mk 2- Disassem bly (cont.)
""a in.
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G 3736
Hardwood stand
Fig.301
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4. Disassem ble the breech end main assembly z
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A. Release the tabwash ers and remove the nuts securing the inlet casing to
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exhaust casing. Tap out the six bolts and separate the two casings. (.)
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B. Remove the three transfer tubes then remove the retainin g sleeves and I
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sealing rings. If necessar y soak the tubes in a paraffin bath to release
the sleeves.
C. Release the tabwash ers and remove the nuts and bolts which secure the
breech bases to the inlet casing; tap out the bolts.
D. Invert the assembly and remove the three nuts adjacen t to the pressure
control valves and then separate the breech bases from the inlet casing.
E. Release the tabwash ers and remove the two nuts and setscrew s securing
each
of the nozzle and elbow assembl ies to the breech bases, then remove the
assembl ies from the breech bases. Discard the joint washers.
Disassem bly
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Page 304
ROLLS-ROYCE AERO ENGINES
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CENTRAL ROD
A. During this operation ensure that the parts of each pressure control valve
are kept with the breech to which they belong.
WARl'HNG: THE VALVE SPRINGS ARE UNDER CONSIDERABLE LOAD IN THE HOUSING;
DO NOT ATTEMPT TO REMOVE THE HOUSING WITHOUT USING THE PRESSURE
CONTROL VALVE SPRING CONTRACTOR REF.304.
B. Fit the spring contracting tool,Ref.304 over the spring housing and screw
the central rod into the spring seating; tighten the tool until the spring
tension can be felt.
C. Release the three tabwashers and remove the nuts securing the pressure
control valve to the breech base; lift the pressure control valve from the
breech base, remove the three bolts and unscrew the valve from the tool.
Remove the thrust peg, valve spring seating, and the valve springs from
the housing. Extract the adjusting washer and valve from the valve casing.
A. Unlock and remove the six nuts which secure the three barrel housings to
the barrels. Remove the bolts and tabwashers then lift out the sealing
rings. Remove the housings from the barrels.
CAUTION: KEEP THE SPLIT HOUSING HALVES TOGETHER AND IDENTIFY THEM WITH
THEIR MATING BARREL.
A. Fit the plate Ref.311 into a vice and secure the breech base to it. Remove
. "'---
Disassembly
Jan.7/70 5-2-1
Page 305
ROLLS-ROYCE AEIO ENGINES
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Triple breech turbo starter- TBS 720 Mk 2- Disassemb ly (cont.)
the retaining ring and locking ring from the barrel. Put a correlatio n
mark on the barrel and on the base to facilitat e identific ation on assembly.
Use the spanner Ref.316 to remove the barrel from the breech base; discard
the sealing ring.
/LOCKING RING
SPANNER
RETAINING RING
G 3726
A. Release the eight tabwasher s and remove the nuts securing the steel bearing
panel to the gear casing then remove the panel, complete with turbine
rotor from the gear casing.
9. Remove the annulus gear and drive shaft from the gear casing
A. Unlock and remove the eight setscrews which secure the two annulus gear
locating plates; remove the tabwasher s and locating plates then withdraw
the annulus from the driving shaft.
B. Release the four tabwasher s and remove the nuts securing the bearing
housing to the gear casing; tap out the bolts and remove the bearing
assembly complete with the driving shaft, from the gear casing.
C. Remove the bearing housing adjusting washer which abuts the bearing then
press the bearing housing from the gear casing and remo.ve the oil seal.
Disassemb ly
5-2-1 Jan.7/70
Page 306
ROLLS-ROYCE AERO ENGINES
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10. Remove the spherical bearing from the driving shaft (fig.304 and 305)
A. Fit the vice block, Ref.308 into a vice and fit the toothed end of the
driving shaft into the block. Unlock the ring nut and use the dog spanner
Ref.309 to remove the nut. Remove the lockwasher then remove the assembly
from the vice block.
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B. Cse the extractor, Ref.320, to extract the bearing from the driving shaft;
separate the bearing from its seating ring.
C. Remove the adjusting washer and the locking plate from the driving shaft.
D. Press the oil seal from the bearing housing and discard the oil seal .
....,
VICE BLOCK
G3722
A. :\lount the bearing panel assembly on the support stand, Re.303, and ensure
that the gears mesh with, the teeth of the support stand; secure the assembly
with the two slave nuts.
B. Release the rotor shaft cup washer and remove the rotor shaft retaining nut
then lift off the packing washer. Attach the packing washer to the panel
to facilitate identification for re-assembly.
Disassembly
Jan.7/70. 5-2-l
Page 307
ROLLS-ROYCE AERO ENGINES
- - - - - - - - A C C I 55 0 R Y OV I RH A U L--------
Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)
D. Release the tabwashers and remove the six nuts which secure the end plate <I
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to the bearing panel, and the three return mechanism setscrews.
E. Use the extractor, Ref.318, to remove the return mechanism thrust plate;
attach the three stop plates to the thrust plate.
F. Remove the rotor shaft rear ball bearing from the guide together with the
two seating rings; remove the seating rings from the bearing.
G. Remove the three spherical washers, spring outer sleeves, springs, spring
guides and dowelled outer guides from the end plate; retain the stop
plates and spherical washers in their matched sets to facilitate
identification on re-assembly
NOTE: There may also be one or two additional adjusting washers fitted
to each of the spherical washers.
Disassembly
5-2-1 Jan. 7/70
Page 308
ROLLS-ROYCE AERO ENGINES
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THRUST PLATE
G 3719
A. Release the three tabwashers and remove the nuts securing the rotor shaft
roller bearing assembly to the bearing panel. Remove the tabwashers and
withdraw the bearing assembly from the rotor shaft.
B. Turn the support stand,Ref.303, on to one of its sides then withdraw the
rotor assembly from the bearing panel.
C. Remove the end plate from the other side of the bearing panel.
D. Remove the deflector assembly from the bearing panel and then withdraw the
turbine bearing sleeve.
E. Extract the circlip retaining the rotor shaft front roller bearing. Slide
the outer track towards the turbine, clear of the rollers,then use the
clamp, Ref.324, to remove the rollers from the shaft.
F. Withdraw the outer track, roller cage , the rotor shaft oil seal and the
packing washer from the turbine rotor shaft.
. ,__. G. Put a correlation mark on the turbine rotor and shaft to facilitate correct
Disassembly
Jan.7/70 5-2-l
Page 309
ROLLSROYCE AERO ENGINES
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A. Remove the internal eirclips and washers which retain the planet gear
ball bearings in the end plate then use the drift extractor Ref.30l, to
remove the bearings from the end plate.
B. Remove the three internal circlips and washers which retain the roller
bearings ~n the bearing panel. Use the tool Ref.319, to extract the
bearings from the panel. If necessary heat the bearing 9anel to
facilitate removal of the bearings.
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Disassembly
5-2-1 Jan.7/70
Page 310
ROLLS-ROYCE AERO ENGINES
--------ACCESSOI'tY OVEI'tHAU L--------
Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)
A. Attach the clamp Ref.312, to each of the gear casing mounting flange set-
screws in turn, and remove the spring rings. Release the clamp and remove
the setscrews.
SPRING RING
G3724
A. Unlock and remove the two plugs from each breech base and apply penetrating
oil, Item 1042, to the support pieces and liners.
B. After an elapsed time of ten minutes, remove the liner support pieces and
extract the liners from the three breech bases.
A. The following operations are only necessary if a breech cap has failed
the initial inspection.
C. Cut the larger portion of the shroud longitudina lly and open it out, then
remove the retaining ring.
Disassembly
Jan.7/70 5-2-1
Page 311
ROLLS-ROYCE AEIO ENGINES
-------ACCESSORY OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)
E. Unlock and remove the eight screws securing the cover to the cap;
separate the two parts.
G. Tap out the pins and remove the levers and buttons from the cover.
CAUTION: IF THE PINS ARE SEIZED IN THE LUGS OR LEVERS,DO NOT USE FORCE
OR THE LUGS WILL BE DAMAGED; APPLY PENETRATING OIL, ITEM 1042,
TO THE PARTS AND ALLOW TEN MINUTES TO ELAPSE BEFORE ATTEMPTING
TO REMOVE THE PINS.
J. Unsolder the screw securing the firing lead to the strip connection then
remove the firing pin and the loose bush from the cap. Prise out the
insert which retains the second b.1sh in the ca.p then drill or ream out
the bush.
K. Remove the screws securing the strip connection to the cap; remove the
insulation bush, insulation piece, insulation strip and guard, then with-
draw the connections assembly complete with the slip ring and insulating
ring.
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Disassembly
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ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E S S 0 lilY OVE Ill H A U L - - - - - - - -
CLEANING
TABLE OF CONTENTS
Page
General 403
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Cleaning
Jan.7/70 5-2-l
Page 401
RO LLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
CLEANING
l. General
B. Remove stubborn carbon deposits with power driven wire, bristle, fibre
and linen rotary brushes; avoid prolonged concentration on any one point
with a rotary brush.
B. After the soap wash, degrease the parts in accordance with T.S.D. 594,
O.P. 101,
A. Clean ball and roller bearings in accordance with T.S.D. 594, O.P. 112.
A. Wipe the breech cap assembly and the electrical connections with a dry
cloth or, if a solvent is necessary, with a clean cloth dipped in carbon
tetrachloride.
"-.--
Cleaning
Jan.7/70 5-2-l
Page 403
ROLLS-ROYCE AERO ENGINES
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INSPECTION
TABLE OF CONTENTS
Page
General 503
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Inspection
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ROllS-ROYCE AERO ENGINES
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INSPECTION
1. General
B. The dimensional checks called for in this topic are detailed in 'Fits,
clearances and torque loadings'.
2. Consumable items
Starter:
Tabwashers
Lock washers
Cup washers
Lock plates
Split rings
Joint washers
Copper rings
Nozzle securing bolts
Turbine rotor securing bolts
Turbine rotor securing nuts
A. Use a magnetic crack detection process to check the following parts for
indications of cracks.
Annulus gear
Idler gear
.....__ Rotor shaft
Driving shaft
Inspection
Jan.7/70 5-2-1
Page 503
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2- Inspection (cont.)
Outer race
Bearing sleeve
Locating plate
B. Use a dye penetrant crack detection process to check the following parts
for indications of cracks.
Turbine rotor
Locking levers
Extracting levers
(1) Check the continuity of the firing pin circuit with the pin in both the
free and compressed positions. Reject the breech cap if the continuity
resistance exceeds 0.25 ohm with the pin in either position.
(2) Check the insulation of the firing pin circuit by connecting a 500 volt
megger across the slip ring and the end of the firing pin. Reject the
breech cap if the resistance is less than 2 megohms, with the pin in
either position.
(3) Check the action of the breech cap locking and cartridge release
mechanisms by fitting an empty cartridge case to the breech cap, and
check for correct engagement and locking of the mechanism by visual
examination and by attempting to pull the case from the breech cap.
Reject the breech cap if the case can be pulled from it without
releasing the locking levers.
(4) Check the locking pawl engagement by screwing the cap, with the
cartridge case still in position, fully on to a slave starter barrel.
Reject the cap if it moves when an attempt is made to unscrew it with-
out depressing the pawl release plunger.
(5) Depress the release plunger and check that the breech cap unscrews
freely. Check that the cartridge case is still held correctly by the
locking levers, then depress both cartridge release plungers and check
that the case comes away freely.
(6) Examine the locking pawls for excessive wear and the slip ring for
pitting and frettage. Examine the breech cap thread for frettage, and
if necessary, make a dimensional check. Reject if outside the limits
specified in 'Fits, clearances and torque loadings'.
Inspection
5-2-1 Jan.7/70
Page 504
ROLLS-ROYCE AERO ENGINES
--------ACCESSORY OVERHAUL--------
(2) Check the insulation resistance between the individual leads, and
between each lead and the external metal fittings, with a 250 volt
megger. Accept not less than 3 megohms.
( 3) Check the continuity resistance of the negative lead; accept not more
than 0.25 ohms.
(4) Visually check the insulation for overheating, chafing and damage.
Discard the harness if damage is evident.
( 5) Remove the circlips securing the lead pins and withdraw the pins,
springs, cup and resistors. Check the resistance of each resistor,
which should be between 9 and ll ohms. Check that the lead pin and
cup are free to move within the springs.
(6) Reassemble the firing lead connections and check the resistance value
of each lead with an ohmmeter. Accept not more than 13 ohms.
C. Breech bases
(l) Inspect each breech base for thermal cracks, particularly where the
gas ports blend into the hemispherical base. Accept cracks not more
than 0.25in long at the port outlets and blend them in, providing thay
do not pass the radius. Reject the base if it is cracked in the hemi-
spherical area.
( 2) Examine the pressure control valve seat for erosion and cracks. A
small amount of lapping is permitted to restore the seating face to a
good condition. If excessive erosion and cracking is present, the
seating face may be re-machined to salvage drawing CX.l6784l. Check
that the mating faces for the nozzle elbows are in good condition and
free from distortion.
(l) Inspect the seating face of the valve for erosion and thermal cracks.
If the seating face will not clean up by lightly lapping with a base,
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reject the valve.
Inspection
Jan.7/70 5-2-l
Page 505
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E 5 SORY OVERHAUL--------
(2) Examine the thrust peg for corrosion and cracks. Reject the cracked
pegs but accept light corrosion.
(3) Dimensionally check the length of the springs under the loads specified
in 'Fits, clearances and torque loadings'. Reject distorted springs
and springs outside the specified length under load.
(4) Examine the spring housing for damage. Reject the housing if it is
cracked or the threads are damaged.
(l) The nozzle and elbow assemblies are normally rejected after one over-
haul life but in the event that the assemblies have not completed
their life, inspect them as follows:
(2) Inspect the elbows for erosion and thermal cracks; only superficial
cracks are acceptable providing they do not extend, and are not likely
to propagate, into the sealing face.
(4) Check the elbow mating face for damage and tiistortion. Damage is not
acceptable if it cannot be rectified in accordance with salvage drawing
CX.l52719. A maximum distortion of 0.003in is acceptable provided it
does not extend over the joint face, and a gas-tight joint can be made,
otherwise repair the mating face in accordance with salvage drawing
CX.l52719. When the salvage parts are assembled, the salvage elbow
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plate CX.l52720 must be fitted in place of the standard joint washer. z
(1) The liners are normally rejected after one overhaul life, if the liners
have not completed their life, examine them for cracks, excessive
erosion and distortion. Discard cracked, eroded or distorted liners.
G. Turbine shaft
(1) Check that a plug is fitted in the rotor shaft. Examine the bearing
groove for corrosion. Accept corrosion up to a maximum of 0.375in
round groove area.
(2) Inspect the turbine shaft rotor bolt holes for wear. Dimensionally
check the bearing journals and the oil seal journal. Refer to 'Fits,
clearances and torque loadings' for the acceptance limits.
(3) Examine the gear teeth for signs of wear, overloading and corrosion.
Inspection
5-2-l Jan.7/70
Page 506
ROLLS-ROYCE AERO ENGINES
-------ACCESS 0 R Y OVERHAUL--------
Reject the shaft if the teeth are chipped or worn, or if there are
signs of overloading or corrosion.
(4) Examine the bearing tracks for damage, in accordance with T.S.D.594
O.P.2ll.
H. Turbine rotor
(1) Establish the unexpired shot life of the rotor. Reject the rotor if
there is insufficient shot life remaining to complete a further starter
life.
(2) Dimensionally check the rotor diameter to detect blade growth. Refer
to 'Fits, clearances and torque loadings' for the acceptance limit.
( 3) Dimensionally check the rotor blade width. Reject the turbine if any
blade is outside the limits specified in 'Fits, clearances and torque
loadings'.
(4) Inspect the rotor blades for damage, corrosion and cracks. Slight
erosion of the blade edges, and cracks up to 0.031 inches in the blade
edges, above the fail safe hole may be blended out providing the final
blade width is not less than the limits specified in 'Fits, clearances
and torque loadings'. Accept slight scoring of the blade tips. Reject
the rotor if any blade is cracked below the fail safe hole. Accept
cracks in the blade roots providing they are less than 0,03lin long
and that not more than four consecutive blade roots are so cracked,
and that no crack is likely to propagate towards the rotor rim.
Reject the rotor if any blade is cracked or eroded around the fail safe
hole.
(l) Inspect and assess the condition of the ball and roller bearings in
accordance with the instructions given in T.S.D.594 O.P.2ll.
K. Idler gears
(1) Dimensionally check the roller bearing and ball bearing journals of
each gear. Reject any gear which is outside the limits specified in
'Fits, clearances and torque loadings'.
(2) Examine the gear teeth for pitting and scores; reject the gear if any
tooth is excessively pitted, scored or shows signs of overloading.
(3) Examine the threads on the idler gears and nuts, and the nut locking
slots for damage. Reject gears with damaged threads, and nuts with
damaged slots and threads.
Inspection
Jan.7/70 5-2-1
Page 507
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E S S 0 lt Y OVERHAUL--------
L. Annulus gear
(1) Dimensionally check the internal diameter of the gear teeth in accordance
with the instructions in 'Fits, clearances and torque loadings'.
Reject the gear if it is outside the specified limits.
(2) Examine the gear teeth for signs of wear, damage and overloading.
Reject the gear if it is worn or damaged or if there are signs of
overloading.
(3) Inspect the teeth for locating the driving shaft for signs of fretting.
Reject the gear if it is fretted.
M. Driving shaft
(l) Dimensionally check the driving shaft splines and the oil seal bearing
surface. Reject the shaft if it is outside the limits given in 'Fits,
clearances and torque loadings'.
(2) Examine the shaft for damage, particularly to the oil seal bearing
surface and the gear teeth. Reject the shaft if it is damaged.
(3) Examine the thread for damage; reject the shaft if the thread is damaged.
N. Exhaust casing
(l) Check that the casing joint flange, on the breech side, is within
0.005in of the spigot joint flange. Dimensionally check the outside
diameter of the spigot. Reject the casing of the spigot outside
diameter is less than 6.164in. If the spigot outside diameter is
greater than 6 .l64in but the spigot .joint flange and the joint flange
on the breech side of the casing are outside the 0.005in limit,
incorporate salvage scheme CX.l98493.
(2) Examine the spigot for cracking in the areas adjacent to the nozzle
positions. Superficial cracking is acceptable but if the cracking
is excessive, reject the casing.
0. Inlet casing
(l) Examine the casing for cracking in the area adjacent to the nozzle
outlets. Reject the casing if any crack has propagated through the
nozzle drillings or onto the sealing areas. Blend out superficial
cracking at the ports. Regardless of the presence or degree of
cracking, radius the narrow section of the ports to 0.050in minimum.
(2) Dimensionally check the casing for distortion by comparing the heights
of the bosses, on the breech side. If the distortion is less than 0.025in
I nspectio11
5-2-l Jan.7/70
Page 508
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
P. Bearing panel
(l) Dimensionally check the bore for the bearing sleeve and the bores for
idler gear bearing outer races. Reject the panel if it is outside the
limits specified in 'Fits, clearances and torque loadings'.
(2) Examine the panel for indications of cracks. Reject the panel if it is
cracked.
(3) Examine the spigot diameters for corrosion. Reject the panel if the
spigot diameters are corroded. Accept corrosion on the panel face.
( 4) Examine the threaded inserts for damage and check the circlip grooves
for disassembly damage. Rectify damage as necessary.
( 5) Examine the flange for distortion. Accept not more than 0.005in
distortion.
(6) Check that the dowel hole has been drilled in the panel; if not, machine
the panel in accordance with CX.l22229.
- Q. Gear casing
(l) Examine the studs and thread inserts for damage, examine the mounting
flange spigot for damage and the oil hole from the flange to the bearing
panel mounting face for obstruction. Reject the gear casing if it is
cracked. Repair light damage as necessary.
(2) Check that the dowel has been fitted in the joint flange, if the dowel
has not been fitted incorporate salvage scheme CX.l52109.
(3) Examine vent plug for drunage and if necessary incorporate salvage
modification CTS.438. If this modification has already been embodied,
a further salvage, CX.l53915 may be embodied if the modified vent plug
is damaged.
R. Breech barrels
(l) Use special gauge Ref.330, to check the barrel bore. Reject the barrel
if it is outside the gauge limits.
(2) Examine the locking serrations for damage and corrosion, accept three
adjacent damaged or corroded serrations but reject the barrel if more
than three adjacent serrations are damaged.
Inspection
Jan.7/70 5-2-l
Page 509
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2 - Inspection (cont.)
(4) Check the thread for damage. Damage which can be rectified by lapping
the barrel in a base is acceptable.
(5) Exa~ine the sealing spigot (for copper ring) at the base of the barrel,
for corrosion which has destroyed the spigot at any point. This
condition is not acceptable.
S. Transfer tubes
(1) Examine the transfer tubes for damage and corrosion. Accept light
corrosion.
(2) Dimensionally check the bore of each transfer tube and the size of each
retaining sleeve. Reject parts which are outside the limits given in
'Fits, clearances and torque loadings'.
T. Return spring
(1) Examine the springs for damage and distortion. Discard damaged or
distorted springs.
(2) Dimensionally check the spring loading. Reject the springs which are
outside the limits given in 'Fits, clearances and torque loadings'.
(l) Examine the thrust plate for damage and distortion. Reject the thrust
plate if it is damaged or distorted.
(2) Dimensionally check the bearing housing. Reject the thrust plate if the
bearing housing is outside the limits specified in 'Fits, clearances
and torque loadings'.
(3) Examine the seating rings for damage and distortion. Reject damaged
or distorted seating rings,
(4) Dimensionally check the seating rings bores. Reject seating rings
which are outside the limits specified in 'Fits, clearances and torque
loadings'.
(1) Examine the breech cap for damage and corrosion, and examine the thread
for da~age. Reject the cap if the thread is damaged.
Inspection
5-2-1 Jan.7/70
Page 510
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E 55 0 R Y OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2- Inspection (cont.)
(2) Restore the bore for the slip ring to 3.850in diameter.
(3) Examine the firing pin bush for indications of cracks, burning or
damage. Discard the bush if it is damaged, burned or cracked.
Dimensionally check the bush bore; discard the bush if it is outside
the limits specified in 'Fits, clearances and torque loadings'.
(4) Examine the cover for damage and the plunger bore for signs of wear.
Reject the cover if it is damaged or worn. Check the lever locating
lugs for indications of cracking. Reject the cover if any lug is
cracked.
( 5) Examine the retaining ring for damage or distortion. Reject the ring
if it is damaged or distorted.
(6) Examine the firing pin assembly for distortion and signs of wear.
Reject the firing pin assembly if the pin is distorted or if it is
outside the wear limits given in 'Fits, clearances and torque loadings'.
(7) Examine the locking levers and their securing pins for distortion and
signs of wear, test the levers for indications of cracks. Reject
damaged, cracked or distorted levers and pins, and parts which are
outside the limits specified in 'Fits, clearances and torque loadings'.
(8) Examine the extracting levers and pins for distortion and signs of wear,
test the levers for indications of cracks. Reject damaged, cracked or
distorted levers and pins, and parts which are outside the limits
specified in 'Fits, clearances and torque loadings'.
( 9) Examine the springs for signs of wear. Reject the springs showing
signs of wear or flats.
(10) Examine the electrical connection assembly for signs of damage. Reject
the assembly if the thread in the terminal plate is damaged or if the
insulation is defective.
W. Deflector
(l) Examine the deflector for distortion and erosion. Reject the deflector
if it is distorted or heavily eroded.
Inspection
Jan.7/70 5-2-1
Page 511
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
REPAIR
TABLE OF CONTENTS
NOTE: Salvage drawings marked with an asterisk (*) have been issued previousl y
and are available on applicatio n to Rotax Limited Coventry England.
.::
.-I
m
+->
.-I
1-1
* CX.l52109 Gear casing assembly
o:l
+->
ro
* ex. 152719 Nozzle and elbow
a>
1-1
* CX.l52915 Gear casing
".::
.-I
"Cl
* CX.l67841 Breech base
a>
+->
.::
.-I
* CX.l22229 Bearing panel
1-1
a. * CX.268613 Inlet casing and breech base stud
. "--
Repair
Jan.7/70 5-2-l
Page 601
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
ASSEMBLY
TABLE OF CONTENTS
Page
General 803
Assembly
Jan.7/70 5-2-1
Page 801
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
ASSEMBLY
l. General
A. Refer to 'Standard practices' (l-5) for general information and
instructions pertaining to assembly.
B. During assembly, lightly coat all gears, bearings and shafts with engine
lubricating oil.
C. Refer to 'Fits, clearances and torque loadings' for specified limits.
__j_
1 ---o 1875in. DIA. DRILL
G 215
Assembly
Jan.7/70 5-2-l
Page 803
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
A. Fit the three planet gear ball bearings into their respective housings.
Fit the bearing washers and retain them with the circlips.
B. Inspection/check
C. Measure the protrusion of the three fitted dowels in the end plate. The
dimension must be between 0.150 and O.l25in.
D. Enter the three planet gears with the threaded part of each gear shaft
through the bearing, from the circlip side. Fit a new cup washer and nut
to each shaft.
E. Mount the end plate in the holding fixture Ref.310, and locate the gears
on the three pegs. Use the dog spanner Ref.305, to tighten the nuts.
Lock the nuts by punching the cup washers into two diametrally opposite
slots in each nut.
F. Inspection/check
(l) Check that the planet gear nuts are correctly locked with the cup washers.
G. Support the bearing panel on the assembly fixture Ref.327, and use the
guide plate to fit the dowel. Fit the three screwed inserts for the
return mechanism setscrews into the bearing panel; tighten the inserts
and check that they are not less than 0.005in below the surface.
ill
H. Inspection/check z
o:il
(l) Check that the inserts are correctly fitted. >
~
i.)
J. Use the assembly sleeve Ref.314, to press the planet gear roller bearings i.)
~
into their housings in the bearing panel. Fit the bearing washers and I
0
retain them with the internal circlips.
K. Inspection/check
L. Fit the end plate and gears assembly to the bearing panel; tap them
together with a light hammer. Insert the retaining bolts, fit the tab-
washers and nuts; fully tighten the nuts. Check that the gears rotate
freely, then lock the nuts with the tabwashers. If the gears do not
rotate freely, locate and rectify the cause before proceeding with the
assembly.
M. Inspection/check
(l) Check that the gears rotate freely.
Assembly
5-2-l Jan.7/70
Page 804
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
DOG SPANNER
HOLDING FIXTURE
G3720
DOWEL GUIDE
ASSEMBLY
FIXTURE
G 3727
Assembly
Jan.7/70 5-2-1
Page 805
ROLLS-ROYCE AERO ENGINES
- - - - - - - - A C C E 5 SOIIIY OVEIII H A U L - - - - - - - -
A. Press the bearing rollers into the cage; these are a snap-in fit through
the outside of the cage. Fit the cage and rollers assembly to the bearing
outer track and retain it with the washer and internal circlip.
B. Mount the assembly on the checking fixture Ref.32l, with the circlip
uppermost. Measure the end float of the rollers, and check whether the
end float is within the limits specified in 'Fits, clearances and torque
loadings'. If necessary, select a retaining washer from the range
provided to obtain the specified end float.
C. When an acceptable end float has been obtained, disassemble the bearing.
RELEASE LEVERS
()
C'
G3728
A. Insert the bearing sleeve into the bearing panel with the oil holes
aligned. Fit the exhaust deflector to the spigot on the bearing panel.
B. Fit the three long D-headed bolts through the turbine shaft oil seal then
fit the seal over the shaft. Fit the packing washer over the shaft and
into the recess in the seal.
C. Place the roller bearing outer track over the shaft then fit the cage.
Press the rollers into the cage, and fit the outer track over the rollers;
fit the selected retaining washer with the chamfer outwards and retain
it with the circlip.
Assembly
5-2-l Jan.7/70
Page 806
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
CAUTION: IF A NEW ROTOR SHAFT OR A NEW OUTER RACE IS BEING FITTED, DO NOT
FIT EITHER WITH A ROLLER TRACK DIAMETER ON THE HIGH LIMIT OF
TOLERANCE, OTHERWISE INADEQUATE ROLLER DIAMETRAL CLEARANCE MAY
RESULT.
D. Inspection/c heck
E. Fit the turbine rotor shaft assembly to the bearing panel, passing the
three bolts through the holes in the panel, Fit the rotor shaft rear
roller bearing over the shaft and bolts, check that the flats on the bolts
engage the oil seal then fit and tighten the nuts and lock them with their
tabwashers. Check that each nut has a flat parallel to the edge of the
panel assembly.
A. Fit a thrust plate seating ring to each side of the ball bearing and
insert the assembly into the thrust plate. Check that the assembly moves
freely in the plate seating.
B. Mount the bearing panel assembly into the support stand, Ref.303, and
secure it with three slave nuts.
(])
z
o<l
> SUPPORT STAND
<:t: STANDARD
() RING SPANNER
()
<:t:
I
0
G 3718
. '-
Assembly
Jan. 7/70 5-2-l
Page 807
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
C. Refer to 'Fits, clearances and torque loadings' for the specified turbine
axial clearance, then measure and adjust the axial clearance as follows:
(l) Use the sleeve, Ref.313, to press the thrust plate onto the turbine
shaft. Fit the packing washer, cup washer and rotor shaft ret&ining
nut to the rotor shaft. If necessary, fit a second packing washer
below the cup washer to ensure that the bearing is clamped securely.
Tighten but do not lock the securing nut.
(2) Measure the distance from the panel mounting face of the stand, to the
underface of the turbine rotor wheel adjacent to the blades. Record
the measurement as dimension E.
(3) Temporarily clamp the inlet casing and exhaust casing together, then
measure the distance from the rear face of the exhaust casing to the
nozzle face of the inlet casing. Record this measurement as dimension B.
(4) Measure the thickness of the fairing support ring flange, and record
the measurement as dimension C.
(6) Measure the depth of the fairing support ring spigot in the gear casing,
and record the measurement as dimension F.
(8) Subtract dimension H from dimension G and record the difference as the
axial clearance between the turbine rotor wheel and the inlet casing
nozzle face when the rotor is in the 'full gas' position.
'>
~
(9) Adjust the turbine rotor axial clearance by fitting a 0.005in shim and 0
a suitable rotor shaft adjusting washer from the range provided. Record 0
~
the thickness of the required adjusting washer. I
0
(10) Do not remove the bearing panel assembly from the support stand at this
stage.
D. Inspection/check
(l) Check that the calculations are correct and confirm the dimension of the
required rotor shaft adjusting washer.
A. Refer to 'Fits, clearances and torque loadings' for the specified rotor
travel, then measure, and if necessary, adjust the rotor travel as follows:
(l) Measure the distance from the panel mounting face of the stand, to the
underface of the turbine rotor wheel adjacent to the blades. Record
Assembly
5-2-l Jan.7/70
Page 808
ROLLS-ROYCE AERO ENGINES
- - - - - - - - A C C E 55 0 R Y OVERHAUL--------
NOTE: The required rotor shaft adjusting washer and shim must be
fitted before establishing dimension J.
(2) Remove the thrust plate assembly from the rotor shaft together with the
cup washer, and packing washer. Do not remove the adjusting washer or
shim.
(3) Fit the three spring guide sleeves, a set of matched springs, the outer
sleeves and the dowelled guides. Place a spherical washer of nominal
thickness on each outer sleeve. (Final selection of the spherical
washers is described in para.9.).
ill
z
a<l
Rotor shown in "full-gas" position G 216
::>
<r:
C)
C)
<r: Measuring the turbine rotor axial clearance
I
0
Fig.806
(4) Check that the selected rotor shaft adjusting washer and a 0.005in
C\1
.....___ shim are fitted over the turbine shaft then use the sleeve, Ref.313, to
m
:;::s press the thrust plate onto the turbine shaft. Fit the packing washer,
H
cup washer and rotor shaft retaining nut ~o the rotor shaft. Tighten
but do not lock the retaining nut.
(5) Fit a stop plate on top of each of the lugs on the thrust plate, then
secure the thrust plate to the bearing panel with the return mechanism
setscrews and tabwashers; do not lock the setscrews at this stage.
(6) Measure the clearance between the panel mounting face of the stand,
and the underface of the turbine rotor wheel, adjacent to the blades.
Record the measurement as dimension K.
Assembly
Jan.7/70 5-2-l
Page 809
ROLLS-ROYCE AERO ENGINES
- - - - - - - - A C C E 55 0 R Y OVERHAUL--------
(7) Subtract dimension K from dimension J and record the difference as the
turbine travel.
(8) If necessary adjust the turbine travel by fitting suitable stop plates
from the range provided.
CAUTION: FIT THREE STOP PLATES OF IDENTICAL THICKNESS.
9, Determine the return mechanism spring loading (fig.807)
A. Remove the assembly from the support stand and secure it to the setting
fixture, Ref.317, with slave nuts.
B. Place the checking weights on the end of the turbine rotor shaft and check
that the springs support the load specified in 'Fits, clearances and torque
loadings' before axial movement occurs, and at the limit of travel.
C. Depress the turbine assembly to its limit of travel several times and check
that free movement is obtained throughout the full traveL. Repeat the
spring pressure checks; any change in the results obtained indicates
excessive friction. If necessary, adjust the spring loading by selecting
suitable spherical washers from the range provided. In addition one
adjusting washer may be fitted to each spherical washer.
CAUTION: FIT THREE SPHERICAL WASHERS OF IDENTICAL THICKNESS.
D. Inspection/check
(1) Check that the spring loading is within the specified limits.
E. When the turbine axial clearance, turbine travel and spring loading
adjustments are satisfactorily completed, lock the turbine rotor shaft
nut and bend up the locking tabs on the return mechanism setscrews.
a.>
z
<2
>
<t:
(.)
(.)
<t:
I
0
CHECKING
WEIGHTS
C\1
'-....
C/1
:;;;
>-<
SETTING
FIXTURE
G3729
F. Inspection/check
( l) Check that the rotor shaft retaining nut and the return mechanism
setscrews are correctly locked.
A. If a new gear casing is to be fitted, fit the eight studs, entering the
ends with the longest screw thread into the casing. Check that when the
studs are fully home, they protude from the face by approximately 0.550in.
Press a new ventilating disc into the casing and fit a new dial, which
must be driven in as far as possible.
B. Insert the setscrews complete with plain and spring washers, into the holes
in the starter mounting flange. Use the clamp,Ref.312, against each set-
screw head, in turn, to facilitate fitting the retaining spring rings.
C. Fit the oil seal, rim leading, into the bearing housing then, use the
plug, Ref.309, to press the seal into the housing.
il)
z CLAMP
~
~
(.)
(.)
~
I
0 SPRING RING
G 3724
A. Fit the thrust ring, chamfered side leading, into the bearing housing,
followed by the bearing and adjusting washer.
Assembly
Jan. 7/70 5-2-l
Page 811
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2 -Assembly (cont.)
BEARING HOUSING
G 3730
(])
z
o<l
~
(.)
(.)
<I
0
OIL SEAL
LOCATING PLUG
SLIP GAUGES
G3731
Assembly.
5-2-1
Jan.7/70
Page 812
ROLLS-ROYCE AERO ENGINES
- - - - - - - - A C C E 55 0 Ill Y OV E Ill H A U L - - - - - - - -
B. Mount the assembly on the checking fixture, Ref.315, protecting the oil
seal with the locating plug. Use slip gauges to measure the distance
between the base of the fixture and the underside of the bearing housing
flange. Record the measurement as dimension A.
C. Measure the distance from the fixture base to the adjusting washer.
Record the measurement as dimension B.
E. Inspection/check
(l) Check that the adjusting washer selected will give the axial clearance
specified in'Fits, clearances and torque loadings'.
F. When the appropriate adjusting washer has been selected, remove the assembly
from the fixture and extract the washer and bearing assembly from the
housing. Fit the housing to the gear casing.
A. Position the bearing locking plate and adjusting washer over the driving
shaft, then use the sleeve, Ref.313, to press the bearing onto the driving
C]) shaft.
z
~
~
0
C) RING NUT
<x: DOG SPANNER
I
0
VICE BLOCK
G3722
Assembly
Jan.7/70 5-2-l
Page 813
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
BEARING HOUSING
G3732
B. Fit the locking washer and nut to the drive shaft then mount the shaft on
the holding plate, Ref.308, and use the dog spanner Ref.309, to fully (!)
tighten the nut; lock the nut with the lock washer. z
02l
C. Inspection/check
~
0
(1) Check that the ring nut is correctly locked. 0
<I
0
D. Place the thrust ring, chamfered side leading, into the bearing housing.
Fit the oil seal guide Ref.307, over the driving shaft, then fit the shaft
assembly to the housing and press it into position ensuring that the
thrust ring remains in its correct position.
E. Secure the assembly with the four bolts, inserted from the inside of the
gear casing. Fit the four tabwashers and nuts; tighten the nuts and lock
them with the tabwashers.
A. Place the annulus gear over the driving shaft and fit the two locating
plates into the recess in the shaft, with the machine groove in the plates
towards the bearing housing.
Assembly
5-2-l Jan.7/70
Page 814
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E 55 0 R Y OVERHAUL--------
B. Secure the gear and locating plates with the eight setscrews and tabwashers;
tighten the setscrews and lock them with the tabwashers.
C. Inspection/check
(l) Check that the setscrews are correctly locked with the tabwashers.
A. Check that the rotor axial movement is free and that the locating dowel
is fitted in the gear casing.
B. Fit the bearing panel to the gear casing, correctly locating it on the
dowel, then secure the assemblies with the eight tabwashers and nuts;
tighten the nuts and lock them with the tabwashers.
A. If a new exhaust casing is to be fitted, fit the six studs into the casing,
entering the end with the 0.375in length of thread into the casing.
B. Fit the fairing support ring to the casing, aligning the hole in the ring
with the milled out portion of the casing.
C. Assemble the exhaust casing assembly to the gear casing and secure them
together with the seven short bolts, tabwashers and nuts; tighten the
nuts but do not lock them at this stage.
NOTE: The remaining two holes accommodate longer bolts which also secure
the bracket for the firing lead socket; these items are fitted at
a later stage.
D. Inspection/check
(l) Insert the thumb and finger through one of the exhaust ports and
attempt to rotate the deflector. If the deflector moves disassemble
the starter and fit another deflector.
16. Assemble the breech bases and pressure control valves (fig.813 and 814)
A. Check that the breech base stud is fitted into each breech base,and that
the salvage stud is fitted if the inlet casing has been salvaged to
salvage drawing CX.268613.
B. Check that the pressure control valve guide bore has been reamed to the
Assembly
Jan.7/70 5-2-l
Page 815
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
C. Remove the valve from the casing and examine the valve and seat for traces
of lapping compound. If necessary wash the parts in clean paraffin.
D. Fit the valve into the valve casing and fit the casing to the breech base.
Fit the adjusting washer (standard) to the thrust peg and insert the peg
into the valve.
E. Insert the inner and outer springs into the spring housing and fit the
spring seating, threaded end inwards, into the inner spring. Fit the
spring contractor, Ref.304, into the spring housing and screw the central
rod of the contractor into the spring seating. Compress the springs with
the contractor.
F. Fit the spring housing assembly over the valve casing and secure the
pressure control valve assembly to the breech base with the securing
bolts. No.l assembly is secured with three D-headed bolts, tabwashers and
nuts. No.2 assembly is secured with two D-headed bolts and one shouldered
bolt,three tabwashers and nuts; the shouldered bolt is fitted in the hole
nearest the transfer tube seating. The No.3 assembly is identical to the
No.2 assembly. Do not lock the nuts at this stage.
CENTRAL ROD
G. Remove the spring contractor and mount each breech base on the test
fixture, Ref.326. Set the valves to open at a pressure of between 1205 p.s.i.
and 1230 p.s.i. and cheGk that they hold a pressure of 1000 p.s.i. for a
minimum period of one minute without leaking. If necessary lap the seats
to obtain the necessary sealing. If the opening pressure is outside the
limits select a second adjusting washer from the range provided.
WARNING: THE VALVE SPRINGS EXERT A CONSIDERABLE LOAD ON THE SPRING HOUSING
DO NOT ATTEMPT TO REMOVE THE COVER WITHOUT USING THE SPRING
CONTRACTOR REF.304.
Assembly
5-2-l Jan.7/70
Page 816
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
A. Fit the locking ring and the retaining ring over the breech base end of
each barrel.
(l) Fit the insulating channel to the contact spring securing setscrew.
(2) Fit the insulating bush over the setscrew and fit the contact assembly,
with the contact opposite the opening in the contact spring support
and the contact surface facing towards the setscrew head.
(3) Fit the contact spring backing spring so that it aligns with the contact
spring, then fit the insulating washer and the contact spring clamping
pad; locate the recess in the clamping pad on the iasulating bush.
(4) Remove the setscrew from the assembled parts but retain the parts to-
gether. Fit the setscrew complete with tabwasher to the barrel housing
then position the assembled parts on the setscrew with the contact
opposite the adaptor. Enter the setscrew into the threaded clamping
pad then tighten and lock the setscrew. Fit the adaptor sealing ring.
/ ADDITIONAL
Q) ~WEIGHTS
z
o<l
:>
<
(.)
(.)
<I MAIN WEIGHT_.....-_.....---
0
G3733
C. Fit the split housings in mated pairs and to the barrels from which they
were removed during disassembly. Fit a new sealing ring to each housing.
Secure each pair of split housings with the bolts, tabwashers and nuts;
do not tighten the nuts at this stage.
Assembly
Jan. 7/70 5-2-l
Page 817
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
D. Check that with the securing nuts fully tight, the housings can just be
moved round the barrel.
E. Mount each breech base on the assembly plate, Ref.3ll, and then insert a
new, annealed copper joint washer into each base. Use the spanner,
Ref.316, to screw the barrels into their breech bases; tighten the barrels
by striking the spanner with a soft metal mallet. Fit the locking ring
into the slots of the breech base and secure it in position with the
locking ring retaining ring.
LOCKING RING
G 3726
A. Check that the inlet casing is to the modification standard of the breech
bases, i.e. both parts to salvage drawing CX.268613, or both parts standard.
B. If a new inlet casing is to be fitted, fit the 2 B.A. studs with the long
threaded ends into the casing and check that they protrude above the
surface by approximately 0.300in. Similarly, screw the long threaded ends
of the 0.3125in diameter studs into the casing so that, when tightened,
they protrude approximately 0.950in above the surface.
C. Insert the twelve nozzle split sealing rings, two in each nozzle, position
the ring gaps at 180 to each ~ther. Secure each pair of split sealing
rings with a retaining washer and circlip. Approximately position the
six nozzle and elbow assemblies.
Assembly
5-2-l Jan. 7/70
Page 818
ROLLS-ROYCE AERO ENGINES
--------ACCESS 0 R Y OVERHAUL--------
D. Identify the breech base liners and the liner support pieces; they are
marked A and B and are inserted into the correspondingly marked ports of
the breech bases. Fit the long liners through the access plug drillings
and the short liners through the nozzle; align the liners so that their
joint faces mate inside the breech base.
E. Fit the correct liner support pieces and secure them with the plugs and
tabwashers. Tighten and lock the plugs.
~
r-4
Cl! F. Determine the modification standard of the breech bases and fit new
+>
...
r-4 corrugated joint washers or salvage plates, as appropriate, to each of the
a:! nozzle elbow faces on the breech bases; check that the port in the joint
+>
Cl!
washer or salvage plate aligns with the liner.
...
c
(!)
~
r-4
'0
(!)
+>
~
r-4
...
p..
-BREECH No.1
(!)
z
~ BREECH No.3-
>
.:X:
(.)
(.)
<I FIRING LEAD
0 ASSEMBLY G 182
G. Place the assembly block, Ref.325, on the bench so that the boss marked
with the figure three is towards the front of the bench and the zero mark
is on the left side. Place the barrels of the breech and barrel assemblies,
which are numbered l, 2 and 3, on the numbered bosses l, 2 and 3 respectively;
ensure the split housing assemblies fit together in the correct sequence.
H. Assemble the inlet casing and nozzle units to the breech assemblies with
the 2 B.A. stud on the casing,facing towards the zero mark on the assembly
block.
Assembly
Jan.7/70 5-2-l
Page 819
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
J. Smear the twelve locking plates with grease to prevent them turning when
the nuts and setscrews are tightened. Fit two setscrews through six of
the locking plates and fit the setscrews through the nozzle assemblies
and joint washers (or salvage plates) into the breech bases. Do not
tighten the setscrews at this stage. Fit the six support bolts through the
outer holes in the breech bases, and through th~ nozzle elbows. Fit the
six remaining bolts through the six remaining holes in the breech bases
nozzle elbows. Fit the six remaining locking plates over the bolts and
fit the nuts. Check that the locking flats on the twelve bolts engage
the flats in the breech bases; tighten the nuts finger tight.
K. Fit the three tabwashers to the breech base studs and fit the nuts; do not
tighten the nuts at this stage.
L. Fit the t~ree tabwashers and nuts to the inlet casing studs.
M. Evenly tighten the six 0.3125in nuts, the twelve 0.25in nuts and the
twelve setscrews. Fully tighten all the nuts and setscrews and lock them
with their tabwashers and locking plates. Tighen and lock the breech
base plugs.
N. Inspection/check
(1) Check that the three breech base studs which protrude through the inlet
casing are tight and correctly locked.
A. Fit a split sealing ring to each of the six transfer tube retaining
sleeves and press the sleeves into the tubes, but do not trap the rings (j)
z
with the sleeves. ~
;>
B. Insert the three tube assemblies into their sockets in the pressure <
C,)
control valve casings. C,)
<I
C. Smear the joint faces of the inlet casing and the exhaust casing with 0
jointing compound, Item 423, and allow five minutes to elapse.
D. Assemble the exhaust casing assembly to the inlet casing assembly and
position the 2 B.A. studs in the inlet casing approximately in line with
the opening in the fairing support ring and enter the three transfer tubes
into their sockets in the exhaust casing. Secure the assemblies together
with the three 0.25in and the three 0.3125in bolts and tabwashers; tighten
the nuts and lock them with the tabwashers.
E. Fit the three connector plugs to their respective sockets and check that
the firing lead pin is a tight push fit in the contact spring support.
If necessary, open up the slot in the firing lead pin to obtain correct
fit. Fit the firing lead clips, the conduit clip, and fit the earth lead
tag under one of the lead clips. Secure the clips with the tabwashers and
Assembly
5-2-1 Jan. 7/70
Page 820
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
nuts; tighten and lock the nuts. Wire lock the electrical connections
with locking wire, Item 944. Fit, tighten and lock the firing lead
socket securing bolts.
F. Fit the three breech caps to the barrels. Temporarily fit the three breech
base tapping plugs, the exhaust stub pipes and the oil drain plug.
Assembly
Jan.7/70 5-2-1
Page 821
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
I FIRING PIN
LOCKING
LEVER
SPRING
BREECH
CAP
WASHER
BUSH
INSULATOR
dNSULATOR
Assembly
5-2-l Jan.7/70
Page 822
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL---------
(l) Fit the buttons into the cover then smear the pivot pins with grease,
Item 405A
(2) Fit the extracting levers and retain them in position with the pivot pins.
Check that the levers move freely on the pins.
( 3) Fit the locking levers and retain them in position with the pivot pins.
Check that the levers movefreely on the pins.
(4) Fit the spring and plain washer over the firing pin. Check that the
guide and washer are fitted in the cover, then fit the cover to the
cap and secure it in position with the eight tabwashers and screws;
tighten the screws and lock them with the tabwashers.
(1) Place the locking levers and extracting levers springs into their
positions in the outside of the cap. Retain the springs in position,
whilst fitting the shroud, with a strip of 0.500in wide strip of shim
steel, formed into a piston ring type clamp, which will slide over the
cap and springs.
(2) Fit the shroud over the cap assembly and push the temporary clamp from
the springs; remove the temporary clamp.
(3) Fit the retaining ring into the open end of the shroud.
(4) Check that the buttons and levers operate correctly and check the
continuity and insulation resistance as described in 'Inspection' (5-2-1)
(5) Screw the breech cap to the fixturo, Ref.323, then mount the assembly
in a lathe.
(6) Press the shroud firmly against the breech cap with that part of the
fixture mounted in the lathe tail stock.
(7) Mount the roller part of the swaging tool in the lathe tool post, then
rotate the breech cap assembly at approximately 200 r.p.m. and apply
the rollers to the rim of the shroud.
(B) Manipulate the lathe feeds as necessary to swage the shroud to the
breech cap.
(9) Remove the roller tool and fit a cutting tool to the post. Reverse the
lathe, and finish off the swaged rim with a light cut, and emery cloth,
Item 914, to produce a good finish.
(10) Remove the breech cap from the fixture and repeat the continuity and
. '-- insulation resistance checks described in 'Inspection' (5-2-1) .
Assembly
Jan. 7/70 5-2-l
Page 823
ROLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
TABLE OF CONTENTS
Page
Introduction 903
1. Introduction
B. The topic contains the dimensions to which mating parts may be checked
during overhaul. The dimensions are expressed in inches and decimals of
an inch.
C. Parts whose dimensions are within the limits quoted are acceptable. If
the limits cannot be met but the operator considers the parts to be
acceptable, Rolls-Royce Service Department should be consulted. Operators
wishing to institute additional inspection standards should first consult
Rolls-Royce Service Department for confir~mation.
E. Use the topic in conjuction with the 'Assembly' topic as various checks
and clearances are detailed during assembly.
Triple breech turbo starter- TBS 720 Mk 2- Fits and clearances (cont.)
To be issued later
Q)
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Triple breech turbo starter- TBS 720 Mk 2- Fits and clearances (cont.)
To be issued later
Q)
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0
0
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0
1.31215 Tight
0.00030 I ~IJUU
0.00045*
to
Clear I
~22
0.00045 ,.. IJU1J
Clear
Outer race - outside dia. l. 3117 to 1.3117 l>
m
1.3122 ::a
0
0.0011 -<~
Total diametral clearance when 0
assembled 0.0017 to 0.0053*
0.0053
:~
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.....
;lJUi)
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11 DRIVING SHAFT SPHERICAL BEARING
Ball bearing - diametral clearance
~~
between inner and outer races 0.0007 to *No wear permitted out-
,.. lJUiJ
(') 0.0009*
.....
<1) 0.0009 side drawing tolerance ,.
Ill
'1 ,.,m
12 DRIVING SHAFT 0
(')
<1) End float 0.002 to 0.004 End float adjustable by m
Ul z
0.004 washer C'l
Ill z
::l m
p..
13 ROTOR SHAFT "'
t+
0 Travel 0. 500 to Actual dimension deter- !
'1
.g 0.600 mined during Acceptance
<1) Test
'tl .....
Ill 0
aq Ill
<1) ()1 p..
I f-'
<Otv::l ---L- _ _ _ L,__
0 I aq
<Of-'Ul
"':!
~----~------~-----------~-------+ PERHISSIBL:~
"' ()1
Pl I f-'
oq IV .-+ PERMISSIBLE
Item DIMENSIONS CLEARANCE
(!) I to WORN
DESCRIPTION NEW WORN REMARKS
....... ~
No, NEW
(!) DIMENSIONS CLEARANCE
....... (')
0 .......
(!) 14 SPRINGS - ROTOR RETURN MECHANISM
Ill
1-j TOTAL SPRINGING PRESSURE
Ill
~ No load condition 20 lb. min.
(')
(!) Full load condition 75 lb. to
{I)
85 lb.
Ill :ID
~ 0
p,. r-
15 ROTOR r-
.-+
0
1-j
Dia. 5.705 to 5. 709 Not to be reground ""
I
:ID
,c 5.709 0
c(!) -c
n
m
I-' 16 ROTOR TO NOZZLE
0
Clearance at full load position 0.010 to 0.010 Actual dimension deter-
~b
Ill
p,.
1-' 0.020 mined during Acceptance
~
oq Test ~~
{I)
17 I NOZZLE
:
Bore I0.265
0.267
to Parallel portion of bore ;
. ,. ~
w1ll collapse ~ ~
()e
I NOZZLE INSERT
18
Bore I 0.256 to
0.258
Ream out nozzle bore to :~
0
PERMISSIBLE PERMISSIBLE
c:... Item DIMENSIONS CLEARANCE
WORN WORN REMARKS
No.
DESCRIPTION NEW NEW
DIMENSIONS CLEARANCE
-..J
.....__
-..J 22 ROTOR BLADES
0 After cleaning
Width 0.4500
:a
23 ROTOR SHAFT BOLT HOLES FOR ROTOR ,...
0
,...
SECURING BOLTS
Dia. 0.2559 to 0.2564
.
~
:a
0
0.2564 -c
n
m
24 DRIVING SHAFT
Oil seal surface dia. 1.3120 to 1.3115 ,.~
l. 3125 g~
Splines 0.6988 to
0.7020
0.6988
:@
I ~~
:11
25 EXHAUST CASING
Spigot dia. 6.1640 -< ~':3
0
26 BARREL
:~
":!
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Bore Clean out corrosion and
then use go - not go ;(JW
~~
r+
Ul gauge G.39477
(")
.- lJW
27 TRANSFER TUBES
I-'
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m
'i
Ill 0.6565 :a
::I 0
(")
Cl) m
Ul 28 TRANSFER SLEEVES :z
Dia. 0.6570 to See Must be good fit in a
remarks item 27 :z
p.. 0.65725 m
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0
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Ill 0
(IQ Ill
Cl) CJl p..
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{!) I'V ::I
I-' I (IQ
1--'1--'Ul
'1:j()l>rj CLEARANCE PERMISSIBLE PERMISSIBLE
I ..... Item DIMENSIONS
111 DESCRIPTION WORN WORN REMARKS
Oil t'-'.-T No. NEW NEW
<l) I Ul DIMENSIONS CLEARANCE
t-'~
(p
t-' (") 29 BREECH CAP
2.85 m.m.*
t-'
"' <l)
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Firing pin bush - bore 2.778 m.m. *No wear permitted out-
side drawing tolerance
'1 to
Ill
::l 2.85 m.m.
(")
<l)
Ul ::a
Cover - bore for plunger 0.7500 to 0.7533 0
Ill r-
0.7505
::l
0. .....
r-
rl ::a
0 Plunger - dia. 0. 7490 to 0.746 0
'1 -c
..c 0.7495 t"'
t:
<l) "'
Lever pivot pin bores in levers
]lo~
t-'
0
ID and cover 0.1562 to 0.1572*
0.
.....
::l
0.1572 ~~
Oil
Ul
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Pivot pins - dia. 0.1542 to 0.1542*
0.1552 ,.~~
Firing pin - length 0.655 Measured from lower face ~~
of contact strip to 0
contact point of pin :~
;[M]
~~
r- lMl
SPRINGS Jllo
30
Control valve inner spring - "'
::a
0
when compressed to 3.150 106 lb to I m
120 lb :z
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:z
Free length 3.792 i
....m
I
c..
Ill
::;
-J
...____
-J - - '- ----~ -- -- L__ --~ -- ---- --- --------~---- ------ ----- ----
PERMISSIBLE PERMISSIBLE
c.. Item DIMENSIONS CLEARANCE
Ill DESCRIPTION WORN WORN REMARKS
::s No. NEW NEW
DIMENSIONS CLEARANCE
-l
.......
-l Control valve outer spring -
0
when compressed to 3.150 173 lb 3 oz
to
"'....0
196 lb 9 oz ....
"'
I
3. Torque loadings
To be issued later
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RIG TEST
TABLE OF CONTENTS
Page
Introduction 1003
Q)
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(.)
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Rig test
Jan.7/70 5-2-l
Page 1001
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C E 55 OIIIY OVE Ill H A U L - - - - - - - -
RIG TEST
1. Introduction
B. At least three different types of starter test rigs are in use, but
apart from the installation procedure, the method of rig testing is
the same for each type. The installation instructions given here, apply
to the starter test rig type J.62645.
2. Safety precautions
A. Remove the breech caps and check that a cartridge has not been loaded.
B. Remove the power supply fuse from the firing circuit and fit it only
when a test is to be made.
B. Remove the three breech caps and test the resistance of each firing
circuit. The resistance should not exceed 13 ohms.
D. Check the electrical continuity between each of the breech barrels and
their bases. The resistance should not exceed 2 ohms.
2
E. Check that the test rig flywheel is 256 lb ft (inertia).
Rig test
Jan.7/70 5-2-1
Page 1003
ltOLLS-ROYCE AERO ENGINES
-------ACCESSORY OVERHAUL--------
A. Smear the splines and driving dogs of the spring drive assembly with
engine oil and enter the spring drive shaft, which is identical to that
fitted to the engine, into the recess of the test rig shaft which carries
the flywheel.
~: If single and triple breech starters are tested on the rig, two
different types of starter spring drive shafts will be supplied.
The drive shaft for the triple breech starter is the larger of the
two and has the pawl carrier assembly fitted. The adjusting shim
supplied has been selected during the construction of the test rig
and must be fitted.
c. Fit the starter drive reduction gear assembly to the studs on the adaptor
and engage the pawl carrier of the starter drive.
D. Fit the slave gear pinion to the starter drive shaft and secure it with
the setscrew and tabwasher. Fit a joint washer to the mounting face of
the starter; ensure that the oil hole in the gasket is aligned with the
oil hole in the reduction gear mounting face, secure the starter with
the eight securing setscrews.
E. Remove the oil filler plug from the top of the starter and prime the unit
with 200 cm2 of engine oil: refit and tighten the plug.
F. Fill the starter drive gear assembly with engine oil through the
connection at the top of the adaptor until oil issues from the level plug
on the right-hand side of the adaptor. tl)
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~
G. Check that the oil level is visible in the Dobbie Mcinnes Indicator
pressure transmitter pipe connection; if necessary top it up with >
<
medium viscosity mineral oil. 0
0
<I
H. Fit the correct three pressure pipes to the three breech connections and 0
connect the pipe from No.l breech (No.l breech is at the 9 o'clock
position) to the connection on the pressure transmitter.
J. Remove the blanking caps from the starter exhaust stubs and fit the
test rig exhaust pipes.
K. Fit a new sheet of paper to the Dobbie Mcinnes Indicator drum and
secure it with an elastic band.
L. Check that the firing circuit fuse is removed and then connect the
supply cable to the starter harness firing lead connection.
Rig test
5-2-l Jan.7/70
Page 1004
ROLLS-ROYCE AERO ENGINES
-------ACCESS 0 R Y OVERHAUL--------
B. Load a pre-heated cartridge into each breech cap and fit them into the
starter barrels. Check that the breech caps are fully home and correctly
locked.
C. Check that the firing switches are safe and then fit the firing circuit
fuse.
E. Set the selector switch for triple breech operation, switch on the
Dobbie Mcinnes Indicator, switch on the master switch and check that the
red light comes on.
6. Strip examination
A. Remove the starter from the rig and return it for a partial disassembly
and examination. If the examination reveals no defect reassemble the
starter and effect a final test. If major parts are replaced during the
strip examination, submit the starter to a further acceptance test and
strip examination.
B. Load a No.lO type cartridge, at normal day temperature, into each of the
three breeches. Fire the cartridges with an interval of one minute
between each shot, and record the maximum speed attained by the flywheel
during each shot. The flywheel speed should be not less than 1500 r.p.m.
for each shot if standard No.lO type cartridges are used, or 1450 r.p.m.
if No.lO Mk.3 type cartridges are used.
C. In the event that the flywheel speed is less than 1500 r.p.m. (or 1450 r.p.m.)
during one of these shots, one additional cartridge may be fired through
the breech affected, providing that the previous cartridge fired in the
breech produced an acceptable flywheel speed. If the flywheel speed is
acceptable on firing the additional cartridge, the starter may be
accepted.
Rig test
5-2-l Jan. 7/70
Page 1006