Preliminary Requirements

Safety Requirements

WARNING

IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS. THESE CONTAIN INFORMATION SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

Procedure

1. SUBTASK 72-00-00-110-056 Makeup of Engine Gas Path Cleaning Solution

   1. Refer to SPM TASK 70-11-48-110-501 makeup of cleaning solutions for the makeup of Solution Code 181 Engine Gas Path Cleaning Solution.

   2. Water for engine gas path cleaning must agree with the Potable Water Quality Specifications in SPM TASK 70-10-00-100-501.

   3. If the ambient temperature is 41.9 deg F (5.5 deg C) or less, use water mixed with CoMat 01-007 ETHYL ALCOHOL C2H5OH (DENATURED) or CoMat 01-124 ISOPROPYL ALCOHOL at the applicable ratio to prevent icing. Refer to Figure.

2. SUBTASK 72-00-00-110-053 Clean the Engine Gas Path

   1. Refer to Figure, Figure, Figure, Figure and Figure.

   2. 

      CAUTION

      DO NOT USE A DETERGENT WASH ON ENGINES WITH GAS PATHS THAT WERE EXPOSED TO DRY POWDER FIRE EXTINGUISHING AGENTS. THESE AGENTS ARE NOT WATER SOLUBLE. WATER WASHING WILL CAUSE THESE MATERIALS TO CAKE AND STICK ON ENGINE PARTS.

      

      CAUTION

      THE ENGINE EGT MUST BE BELOW 150 DEG F (65.6 DEG C) TO PREVENT ENGINE DAMAGE.

      Disconnect the PS3 sensing tube from the autostart probe. Install a plug. Refer to Figure.

   3. Disconnect the Air-to-P4.9 EEC tube at the fitting on the bottom of the turbine exhaust case. Install a plug. Refer to Figure.

   4. Disconnect the tenth stage cabin air bleed tube. Install a plug.

   5. Install the IAE 4J12031 Spray ring 1 off or the IAE 4J12034 Water wash tube 1 off.

      1. Install the IAE 4J12031 Spray ring 1 off as follows. Refer to Figure.

         1. 

            CAUTION

            WHEN YOU PUT THE SPRAY RING SEGMENTS THROUGH THE FAN BLADES, BE CAREFUL THAT THE SPRAY RING SEGMENTS DO NOT TOUCH THE ENGINE PARTS.

            Put each of the four spray ring segments (nozzle hole side to the rear) to the inlet of the fan outlet inner vane assembly through the fan blades.

         2. Install a spray ring with a coupling that connects to the long hose around the bottom of the fan outlet inner vane assembly.

         3. Install the clamp screws on the brackets of the spray ring segments through the fan blade. Hang the hook of the clamp screw on the LPC outlet guide vane.

         4. Tighten the wing nuts 8 off on the clamp screws by hand.

         5. Connect the couplings of the spray ring segments, then safety the spray ring assembly to the fan outlet inner vane assembly with the clamp screws and the wing nuts. Adjust the positions of the spray ring assembly as necessary.

         6. Connect one end of the long hose to the spray ring assembly and the other end to a pressure pump for the Portable water source.

         7. Safety the long hose to the common nozzle assembly with a clamp around the bottom of the common nozzle.

      2. Install the IAE 4J12034 Water wash tube 1 off as follows. Refer to Figure.

         1. Put the two thicker wooden clamps on the front and aft sides of the No. 4 and No. 5 struts.

         2. Let the grooves in the clamps touch the strut edges and safety the clamps with the two long bolts and wing nuts.

         3. Put the tube between the No. 4 and No. 5 struts from the rear side in parallel to the engine center line, then let it go through between the fan exit guide vanes carefully so the tube does not touch the vanes.

         4. Set the square end of the tube to the aft clamps. Make sure that the front bent part of the tube does not touch the trailing edges of the fan blades. If necessary, install the spacer(s) between the aft clamps and the square end.

         5. Put the tube nozzle between the leading edges of the inlet guide vanes.

         6. Hold the tube with the thicker clamps and the thinner wooden clamps and safety them with the four short bolts and wing nuts.

         7. Connect a wash fluid supply hose to the tube.

         8. Make sure again that the front bent part of the tube does not touch the trailing edges of the fan blades, that the tube nozzle does not touch the inlet guide vanes and that the direction of the tube nozzle is at the correct angle.

         9. If necessary, use spacers to adjust the positions of the clamps and the angle of the tube correctly.

         10. Safety the clamps tightly with the wing nuts.

   6. Check the oil level on the oil tank and add oil to the engine oil tank if required.

   7. Pull the ignition circuit breaker to shut off the engine ignition system.

   8. Prepare 20 US gal to 30 US gal (80 l to 120 l) of Solution Code 181 Engine Gas Path Cleaning Solution. Refer to Step.

      1. If the ambient temperature is below 40 deg F (4.4 deg C), use the applicable potable water/alcohol mixture as an alternative to plain potable water in the solution to prevent ice. Refer to Step.

   9. Disconnect the variable stator vane actuator from the crankshaft and manually set the stator vanes to full open and fit rigging pin. Refer to TASK 72-00-40-050-001 (REMOVAL-011).

   10. Do the subsequent wash-and-soak procedure two times/cycles and let the engine soak for 10 minutes minimum between the wash-and-soak procedure cycles:

       1. Motor the engine with the starter until N2 is at 2000 RPM minimum.

       2. While you continue to motor the engine at N2 of 2000 RPM minimum, spray 10 gal to 15 gal (40 l to 60 l) of Solution Code 181 Engine Gas Path Cleaning Solution in two minutes into the low pressure compressor.

       3. Stop motoring the engine.

          1. Let the engine soak for 30 minutes minimum after each third wash-and-soak procedure cycle to let the starter become cool.

          2. Let the engine soak for 10 minutes minimum after all other wash-and-soak procedure cycles.

   11. If the solution that comes out of the tailpipe continues to look dirty, an added wash-and-soak procedure cycle will help to increase the benefit of the gas path wash. Operators are permitted to do the wash-and-soak procedure again at their discretion.

       1. After each second (2nd) wash-and-soak procedure cycle, let the engine soak for 30 minutes to let the starter become cool.

   12. Exchange the detergent source for one that has a similar amount of potable water or portable water/alcohol mixture (refer to Step and Figure). Do the subsequent rinse procedure two times/cycles and let the engine drain for 10 minutes minimum between the rinse procedure cycles:

       1. Motor the engine with the starter until N2 is at 2000 RPM minimum.

       2. While you motor the engine, spray 10 gal to 15 gal (40 l to 60 l) of the potable water or potable water/alcohol mixture in two minutes into the low pressure compressor.

       3. Stop motoring the engine.

   13. Use one of the procedures in the subsequent list to clean the LPC 1st Stage (fan) Blades:

       1. Aqueous Degreaser Solution Procedure.

          1. Clean the blades by SPM TASK 70-11-03-300-503 SUBTASK 70-11-03-300-002 Aqueous Spray or Wipe (with Rinsing) Method.

       2. Engine Gas Path Cleaner Solution Procedure.

          1. Clean the blades with Solution Code 181 Engine Gas Path Cleaning Solution and a clean cloth.

          2. Rinse the blades thoroughly with potable water.

   14. Motor the engine with the starter for approximately 30 seconds to remove water.

   15. Disconnect the P2.5 at the EEC and purge the line. Remove all the plugs and the rigging pin, purge and connect all the lines and connect the variable stator vane actuator control rod. Refer to TASK 72-00-40-450-001 (INSTALLATION-011).

   16. Remove the IAE 4J12031 Spray ring or IAE 4J12034 Water wash tube.

   17. Set the ignition circuit breakers again and start the engine. Refer to TASK 71-00-00-700-053-A01, 71-00-00-700-B01 (TESTING-000 CONFIG-001 and CONFIG-002) or TASK 71-00-00-700-053-A02, 71-00-00-700-B02 (TESTING-000, CONFIG-001 and CONFIG-002). Operate the engine at a power setting that is sufficient to keep the oil temperature at a minimum of 220 deg F (104.5 deg C) for no less than 10 minutes. If the minimum oil temperature cannot be reached, it is necessary to do an oil check for water content.

       1. Take a 4 oz (100 ml) sample of oil from the engine.

       2. Do a Karl Fisher ASTMD-1744 water analysis to find the water content of the oil.

       3. If the water content is above 800 parts per million (ppm) by weight or by volume , drain the engine oil system. Refer to TASK 71-00-00-600-003 (SERVICING-003). Fill the system with new oil. Refer to TASK 71-00-00-600-002 (SERVICING-002).

Figure: Alcohol and water mixture ratio

Alcohol and water mixture ratio



Figure: Remove the PS3 sense line air tube assembly

Remove the PS3 sense line air tube assembly



Figure: Remove the P4.9 air tube assembly

Remove the P4.9 air tube assembly



Figure: Install the IAE 4J12031 Spray Ring

Install the IAE 4J12031 Spray Ring



Figure: Install the IAE 4J12034 water wash tube

Install the IAE 4J12034 water wash tube