FedEx Turbine Engine Event

JT9D Maintenance Procedure for removal of Thrust Reverser PDU


FedEx Turbine Engine Event
Type: Training
Date: 03/13/2013 - 03/14/2013
Summary:

FedEx PDU Removal 

FedEx PDU Install

JT9D Maintenance Procedure for removal of Thrust Reverser PDU
A. General

(1) This procedure provides removal information necessary for removal of pneumatic drive unit (PDU).

B. Procedure

PDU removal - See Figure 401. http://amtsociety.org/pdf/Fig401.pdf
(1) Disconnect electrical connector DS304 from PDU.
(2) Remove lower clamp with screw, washer, and nut attaching flexible shaft to fan case.
(3) Remove lockwire, screws (9) and washers (10) attaching flexible drive shaft to PDU and remove shaft.
(4) Disconnect hoses from PDU.
(5) Remove coupling (2) connecting flexible ducting to PDU.
(6) Remove bolts, nuts, and washers attaching PDU to brackets.
(7) Remove PDU (1) from fan case and place on table.
(8) Inform the judge that the three (3) unions (3, 5, and 11) and O-rings (packing’s 13, 4, and 12) have been swapped, union threads lubricated, and that the PDU (1) has been inspected and approved for installation.
(9) Inspect flange of pneumatic flexible duct (2). If damage is found, inform the judge and
remove/replace the duct using the following instructions;

Removal

See figure 501 http://amtsociety.org/pdf/Fig501.pdf
(a) Remove bolt (11), washer (6), and nut (12) attaching support link to pneumatic flexible duct
(2).

(b) Disconnect flexible hose from pneumatic flexible duct.

(c) Remove couplings (10) from ends of pneumatic flexible duct. Remove duct (2) and place on table.  

(d) Inform the judge that the union has been swapped, union threads lubricated, and the duct is approved for installation.

Installation

(e) Position pneumatic flexible duct (2) at pressure regulating and shutoff valve and install
coupling (10) and torque to 70-80 in-lbs. (Verify torque value with judge before torque is applied).

(f) Install bolt (11), washer (6), and nut (12) attaching support link to pneumatic flexible duct

(g) Connect flexible hose coupling to pneumatic flexible duct and torque coupling to 190-200 in-lbs. (Verify torque value with judge before torque is applied).  

JT9D Maintenance Procedure for installation of Thrust Reverser PDU

A. General
(1) This procedure provides information necessary for the installation of the pneumatic drive unit (PDU).

B. Procedure

PDU installation - See Figure 401  http://amtsociety.org/pdf/Fig401.pdf

(1) Position PDU (1) on brackets, align flexible duct with PDU and install bolts (6) in upper forward and lower aft brackets (if necessary tap bolts with soft face mallet).

(2) Install bolts (6), washers (7), and nut (8) in upper aft brackets, install bolt (6) and washer (7) in  lower forward bracket, and torque nut to 170-190 in-lbs. (Verify torque value with judge before torque is applied).  

(3) Install washers (7) and nuts (8) on bolts in upper forward and lower aft brackets and torque nuts to 170-190 in-lbs. (Verify torque value with judge before torque is applied).

(4) Align flexible duct and PDU. Install coupling (15) and flexible duct on PDU and torque coupling to 70-80 in-lbs. (Verify torque value with judge before torque is applied).

(5) Connect electrical connector DS304 to PDU (1) finger-tight plus one-eighth turn.

(6) Install flexible shaft on PDU with screws (9) and washers (10). Torque screws to 20-25 in-lbs. (Verify torque value with judge before torque is applied) and install lockwire.

(7) Install lower clamp with screw, washer, and nut attaching flexible shaft to fan case.

(8) Connect hose to reducer on lower forward of PDU and torque coupling to 100-110 in-lbs. (Verify torque value with judge before torque is applied).

(9) Connect hose to lower union on PDU and torque to 140-150 in-lbs. Verify torque value with Judge before torque is applied.

(10) Connect hose to aft upper union and torque coupling to 190-200 in-lbs. (Verify torque value with Judge before torque is applied.

(11) Place all tools on table and clean work area.

(12) Announce completion of work task to judge.