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TB3-117

MAINTENANCE MANUAL

EXHAUST SECTION · DESCRIPTION AND OPERATION

1. General

1.1. The exhaust section ia intended to expel the engine. exhaust gas overboard either t6 th�
right or to the lett o f the engine, upwards at an angle of 75 or 105 deg relative to the
horizontal plane or vertically downwards depending on whether the engine is assembled
in a right-hand or left-hand layout version.

1.2. The exhaust section. i:ocorporates the following major assembli es;
- A housing of the fourth and tifth support assemblies.
- kn exhaust stack.
- A coupling clamp,

2. Description.

2,1, The fourth and fifth support assemblies housing consists of front·flange (2) (Ref.
Fig. 1), rear flange (21), outer flange (4), cones (5) and (9), struts (7), inner hous­
ing (B), flange (11), and baffle (10).

The bearing casings of the fourth and fifth support assemblies aie secured to the
flanges of inner housing (BJ.· Flanges (21) and (11) serve for attachment of the ex­
haust stack, while flange (12) carries the casing of the helicopte� main _gearbox
sphere. Cone (9) is provided with access hales used for mounting the free turbine ro­
tor speed lllductive transducers.

The fourth and fifth support assemblies housing is bolted at its flange· (2) to rear
flange (1) of the free turbine stage 2 NGV housing.

The outer fla.n.ge of' the housing carries flanges designed :for attachmef!t of two Jlipes
(18) (Ref. Section H-H) venting the interior o� the second-support assembly, ejector
(20) (Ref. Section rr-rr) and pipes (19) (Ref. Section rr-rr) which effects venting of the
oil tank.

Cone (5) is joined to inner hous.ing (8) with four hollow struts (7),

2,2, Exhaust stack (6) incorporates three flanges (22), (23), and (14) and a shaped wall,

The exhaust stack is secu red with its front flange (22) to rear flange (21) of the
fourth and fifth support assemblies housing and with flange (23) to cone flange (11),

The wall of the exhaust stack terminates in stamped fl8.llge (14) which serves for at­
tachment of the helicopter's t ail pipe.

2.3: Coupl;ni clamp (15) comprises two halves and serves for attachment of helicopter's
tail pipe (17) to flange (14) of the exhaust stack.

The coupling clamp halvea are joined together with two screws ( 13),
EFFECTIVITY: ALL 072.58.QO,
Pages 1/2
Jan 15/86
TB3-117
MAINTENANCE MANUAi-

Looking forward
,, J 6 n JI Arrangement of discharge pipes (Lff eflgi11e)

H-H

7
!8
74

JO

(/ - f1 p-f
+----·--·--·--·--·--·--·------1-#1-1-

20

Guaranteed clearance
( Tliermaf compensator)

1. Turbine Stage 15. Clamp


4 NGV Housing Rear 16. Sealing Cord
Flange 17. '!'ail Pipe
2. Fourth and Fifth 18. Drain Pipe
Support Assemblies 19. Pipe
Housing Front Flange 20. Ejector
4, Ring 21, Fourth and Fifth
5. Cone SQpport Assemblies
6. Exhaust Stack Housing Rear Flange
7. Strut 22. Exhaust Stack
8. Housing Front Flange
9. Cone 23, l'lange Attaching
10. Shield Exhaust Stack to
11. Plange l'ourth and Fifth
Exhaust Section 12. Ji'lange Support Assemblies
Figure 1 13. Coupling Screw Housing Cone Flange
14. Flange for 24. Air Inlet Connection
EFFECTIVITY: ALL 072.58.00 Attachment of from Behind Compres­
fail Pipe sor Stage 5
Pages J/4

Nov 17/93
EXHAUST SECTION - MAINTENANCE PRACTICES
PAGES
TO M.S. TASK CARD No. 201
201 to 202

M.S. ITEM PROCEDURE: INSPECTION OF EXHAUST STACK

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) ACTIONS BY
1. Examine the exhaust stack in accessible places to ascertain it is free from cracks
Tolerable: five cracks, including two cracks in the area of the flange attaching the helicopter Stop-drill the ends of
tail pipe up to 200 mm, with the cracks tota� length not exceeding 450 mm cracks with a drill of
NOTE: If the ends of a crack have been stop-drilled in a· wrong way or the crack has 1.5 to 2.0 mm dia
progressed in another direction, the crack may be stop-drilled once more, provided
its total length is within 220 mm.
No cracks are acceptable in the area of exhaust stack attachment flange (zone "A", ref. Fig. 201)
as well as c.racks tending to form a closed contour in zone 611
11 •
When acceptable limits
are exceeded, replace
exhaust stack (Ref.
Task Card No. 202)

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Bit brace
2. Drill, 1.5 to 2.0-mm dia
3. Straight-edge
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) 'CORRECTIVE CHECKED
ACTIONS BY

For Reference When Inspecting Exha�t Stack


Figure 201
PAGES
TO M.S. TASK CARD No. 202 203 to 209/210

PROCEDURE: REPLACEMENT OF EXHAUST STACK


> MS. ITEM
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OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) CORRECTIVE CHECKEQ


. ACTIONS BY

CAUTION: CARRY OUT REPLACEMENT OF .THE EXHAUST STACK ON THE REMOVED ENGINE.

1. Removal

1.1. Install the engine on a mounting trolley or a transportation stand (Ref.


012.00.00 1 Fig. 1001), but do not fit the rear trwuiion to the engine.

CAUTION: IN ORDER TO PREVENT SAGGING OF THE ENGINE, FIT THE . MIDDLE SUPPO�S TO
THE FLANGE OF THE SECOND SUPPORT ASSEMBLY.

�: The replacement of. the exhaust stack may be carried out on the engine
mounted on the hoisting device in a position convenient for work.

1.2. Unsafety and remove twelve screws (1) (Ref. Fig. 202) securing the exhaust stack
to the flange of cone (4)

1,3, Remove clamping segments (J) from·flange (5) of the exhaust stack.

1. 4, Unscrew self-locking nuts (6). and remove bolts (11) attaching the exhaust stack
to flange (7) of the fourth and fifth support assemblies housing, leaving a bolt
in one of the upper holes. to prevent the exhaust stack from falling -down during
0 its removal
.....__.
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1.5 . Gently wobbling the exhaust stack, shift it a little, remove the remaining bolt
and withdraw the exhaust stack from the engine.
(J1
•ex,
.._ "d
Ill
Mm: Remove shim (8), if it was fitted between cone flange. (12) and exhaust
..... stack flange (5),

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OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) CORRECTIVE CHECKED
ACTIONS BY

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1• Sorew
2. Tab Washer
3. Clamping Segments
4. Cone
5. Exhaust Stack Plange

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I

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0 For Reference When Replacing Exhaust stack

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Figure 202 (Sheet 1 ot J)
OPERATIONS A ND TECHNICAL REQUIREMENTS (T.R.) CORRECTIVE CHECKED
ACTIONS BY

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6 7 9 10 II

6. Nut. 9. Fibreglass Thread


7, Fourth and Fifth Support 10, Exhaust Stack Flange
Assemblies Housing Flange 11 , Bolt
0 a. Shim 12. Housing'Flange

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0 For Reference When Replacing Exhaust Stack

0 Figure 202 (Sheet 2 of 3)


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OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) CORRECTIVE CHECKED
ACTIONS BY

0 5. Bxhauat stack Plange


..._. 12. Cone Plange
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co
0 Por Rererenoe When Replaoing Bxbauet .staok

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Pigure 202 ( Sheet 3 or 3)
Operations and technical requirements (T.R.) Corrective actions

1.6. Remove fibreglass thread (9) fitted between flange (7) of the fourth and fifth support assem­
blies housing and exhaust stack flange (10).
1.7. Remove the remnants of the siloxane enamel from the faces of flanges (12) and (7) and
wash them with gasoline and then either with thinner P-5 or acetone.

2. Installation
2.1. Wash flanges (5) and (10) of a new exhaust stack with gasoline and air-dry for a period of
15 to 20 min.
2.2. Fit the new exhaust stack to the housing of the fourth and fifth support assemblies.
NOTE. If shim (8) was fitted earlier, fit the exhaust stack together with the same shim.
2.3. Attach the exhaust stack at flanges (7) and (10) with the aid of six to ten bolts (11) and
tighten the nuts.
2.4: Using a feeler gauge, check the amount of clearance between flanges (12) and (5) from the
inside of the exhaust stack.
CAUTION! ENSURE THE CLEARANCE WITHIN THE LIMITS OF 0.02 TO 0.4 mm BY
SELECTIVE FITMENT OF SHIM (8) (AVAILABLE IN THREE SIZE
GROUPS: 0.5, 0.8, AND 1.0 mm THICK). IT IS ALLOWED TO FIT UP TO
TWO SHIMS.
2.5. Remove the exhaust stack attachment bolts.
2.6. Dismantle the exhaust stack from the engine.
2.7. Using a brush, apply a thin coat of the siloxane enamel to flanges (5), (7), (10), and (12) and
air-dry for a period of 15 to 20 rnin at room temperature.
2.8. Fit new fibreglass thread (9) to flange (7) of the fourth and fifth support assemblies housing.
Operations and technical requirements (T.R.) Corrective actions �
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>.

2.9. Fit the exhaust stack to the engine together with shim (8) (if necessary), having aligned
marks <<0>> or the lines on flange (10) of the exhaust stack and flange (7) of the fourth and
fifth support assemblies housing.
2.10. Attach the exhaust stack at the flange by means of four bolts (11) and at flange (5) by
means of two screws (1), having first installed clamping segments (3) and tab washers (2)
on flange (5) and coated the bolts and the screws with antistick agent.
CAUTION! COAT 1WEN1Y LOWER BOLTS (EXCEPT FOR THE THREADED
PORTION) WITH SILOXANE ENAMEL BEFORE INSTALLING.
2.11. Smear the threaded portions of remaining bolts (11) with antistick agent, insert the bolts
into the holes in flange (10) of the exhaust stack and screw on self-locking nuts (6).
2.12. Uniformly tighten nuts (6) in a criss-cross manner proceeding in the clockwise direction.
2.13. Screw in screws (I) and lock them with tab washers (2). Tighten the screws in a criss)cross
manner proceeding in the clockwise direction.
2.14. Remove the excess siloxane enamel from the jointing flanges of the exhaust stack and engine.
2.15. Air-dry the assembled unit for a period of 2 hours.
CAUTION! DO NOT ATTEMPT TO START THE ENGINE WITHIN A TIME PERIOD
OF TWO HOURS AFTER INSTALLATION OF THE EXHAUST STACK.
·u

Operations and technical requirements (T.R.) Corrective actions �


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Test equipment Tools and fixtures Materials

L Socket wrench, S = 10 mm 1. Siloxane enamel


2. Socket wrench, S = 8 mm 2. Thinner P-5 or acetone
3. Brush 3. Gasoline
4. Cotton cloth pieces
5. Fibreglass thread EC6-34x3Z100
6. Tab washer 3464A-6 (available in set
of spare parts)
7. Antistick agent (Ref. Appendix 2)
ToM.S. Pages 211 to 212
No. TASK CARD No. 203

M.S. Item Procedure: Turbine of Exhaust Stack

Operations and technical requirements (T.R.) Corrective actions

CAUTION! THE OPERATION OF TURNING THE EXHAUST STACK TO ALTERNA­


TIVE POSITION MUST BE CARRIED OUT WITH THE ENGINE REMO­
VED FROM THE HELICOPTER.
1. Removal
1.1. Effect Steps 1.1 thru 1.7 (Ref. Task Card No. 202).

2. Installation
2.1. Using a bmsh, apply a thin coat of the siioxane enamel to flanges (5) (Ref. Fig. 202), (7),
(10), and (12) and air-dry for a period of 15 to 20 min at room temperature.
2.2. Fit new fibreglass thread (9) to flange (7).
2.3. Tum the exhaust stack to the required position aligning the respective correlation marks
(lines) on flanges (10) (Ref. Fig. 202) and (7).
CAUTION! IF SHIM (8) WAS FITTED EARLIER, MOUNT THE EXHAUST STACK
TOGETHER WITH THE REMOVED SHIM.
2.4. Fit the exhaust stack to the engine.
2.5. Effect Steps 2.10 thn1 2.15 (Ref. Task Card No. 202).
2.6. Couple the plug connectors (Ref. Section 072.03.00, Fig. 3).
Operations and technical requirements (T.R.) Corrective actions ..::.:: :>-
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Test equipment Tools and fixtures Materials

1. Socket wrench, S = 10 mm 1. Siloxane enamel


2. Socket wrench, S = 8 mm 2. Thinner P-5 or acetone
3. Brush 3. Gasoline
4. Cotton cloth pieces
5. Fibreglass thread EC6-24X3Zl00
6. Antistick agent (Ref. Appendix 2)

trl I TO M.S.
I TASKCARDNo. 204
I PAGES
ll3to216

�I

M.S. ITEM
PROCEDURE: INSPECTION AND REPLACEMENT OF HELICOPTER TAIL PIPE A TI ACHMENT
CLAMP COUPLING

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS {T.R.)
ACTIONS BY
After O 1.06.87 - the steel clamps are manufactured instead of the titanium ones.
After 01.04.92 - the steel clamps are manufactured with a stamped eye made of high-
temperature alloy.
The new clamp distinctive feature is change of location of a hole for locking the clamping screw
(Ref. Fig. 203). The new clamp is interchangeable with the old steel and titanium clamps. The
reverse change is intolerable.

1. Inspection
1.1. Remove the titanium clamp attaching the exhaust stack and, using the XS magnifying glass,
inspect the clamp on both sides for absence of cracks and wear of the clamping screw thread.
On detection of cracks or wear, replace the clamp by the steel one with stamped eye made of
hlgh-temperature alloy.
On the engines manufactureB or repaired at the manufacturing plant after 01.06.87 till
01.04.92, furnished with the steel clamps, inspect the clamp eyes (without removal of the clamp),
using a magnifying glass or mirror, for absence of cracks on the weld seam or eye body.
On detection of cracks, replace the clamp by the steel one with stamped eye made of
high­temperature alloy.

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CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) ACTIONS BY

1. Clamping Screw
2. Clamp Half
3. Sealing Cord
4. Exhaust Stack Flange
5. Eye

After 01.04.92

Locking hole

3
4

For Reference When Replacing Helicopter Tail Pipe Attachment Coupling Clamp
Figure 203
CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) ACTIONS BY
CAUTION: 1. STEEL CLAMPS (7857.9550) WITH STAMPED EYE MADE OF HIGH-
TEMPERATURE ALLOY ARE NOT SUBJECT TO INSPECTION.
2. WHEN OPERATING THE ENGINES IN THE SEA CONDITIONS, Replace the clamp
THEY SHOULD BE PROVIDED WITH CLAMPS 7857.9550.
2. Removal
2.l. Unlock and drive out uniformly screws (1) (Ref. Fig. 203) on both sides, coupling the
clamp halves.
2.2. Remove the clamp halves, tail pipe (exhaust extension) and sealing cord (3).
CAUTION: DO NOT REMOVE THE CLAMP BY DRIVING OUT THE COUPLING
SCREW ON ONE SIDE AND WITHDRAWING THE CLAMP ENDS A
SIDE.
2.3. Lnspect the clamp halves to make certain that edge "JI" is free from peening.
CAUTION: 1. IF PEENING IS AVAILABLE, INSPECT THE SURFACE NEAR THE
HELICOPTER TAIL PIPE FLANGE FOR FREEDOM FROM ROLLS;
THE ROLLS ARE INTOLERABLE.
2. CHECK FOR THE LACK OF FLATNESS OF THE HELICOPTER '.fAIL
· PIPE COUPLED WITH THE EXHAUST STACK FLANGE, WHICH
SHOULD NOT EXCEED 0.8 mm.
3. Installation
3.1. Impregnate new sealing cord (3) with siloxane enamel.
3.2. Install sealing cord (3) on exhaust stack flange (4); when installing the cord arrange the
cord ends joint against the clamp joints.
3.3. Couple the tail pipe with the exhaust stack flange and secure it by the clamp, having driven
in manually the coupling screws on both sides, preliminarily coated with antistick agent.
CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) ACTIONS BY
3.4. Tighten the coupling screws on both sides to the 0.4 to 0.5 kgf·m torque, lightly tapping
with a wooden mallet on the clamp to ensure its uniform fit.
3.5. Slacken the clamp and finally tighten the clamping screws uniformly on both sides to the
0.35 to 0.40 kgf.m, visually maintaining the equal clearances between the flanges on both
sides.
CAUTION: WHEN THE CLAMP IS TIGHTENED, ITS EDGE 11J111 SHOULD NOT
CONTACT THE EXHAUST EXTENSION SURF ACE.
3.6. Remove the siloxane enamel ousted when tightening the clamp.
3.7. Lock the clamping screws with wire.
3.8. ln case of necessity to remove the tail pipe, for ensuring the correct relative position of the
exhaust stack, clamp and tail pipe, prior to removing the clamp, apply several reference
marks to the joints of the indicated parts with a piece of chalk or a crayon. During the
subsequent installation of the tail pipe, align. the reference marks on the indicated parts.

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

l. Torque wrench available in helicopter tool kit 1. 0.8-mm dia locking wire
2. Wooden mallet 2. Siloxane enamel
3. Cotton cloth
4. Sealing cord available in SPTA set
5 .1 Antistick agent
6�Gasoline
PAGES
TO M.S. TASK CARD No. 205
217/218

M.S. ITEM PROCEDURE: INSPECTION AND CLEANING OF DRAIN PIPE OF OIL TANK BREATHER PIPE

CORRECTIVE CHECKED
OPERATIONS AND TECHNICAL REQUIREMENTS (T.R.) ACTIONS BY
1. Inspect the drain pipe hole of oil t� breather pipe (5) (Ref. Fig. 204, Section 072.53.00) on the
exhaust stack inner side, from the right -above, looking forward (Ref. Fig. I, Section JI-JI).
2. On detection of carbonized oil sediment inside the pipe, clean the pipe with the aid of hand
milling cutter Y6402-0384.
3. In case of difficult cleaning (hard deposits, poor accesses), drive out screws (4) (Ref. Fig. 204,
Section 072.53.00), without applying an excessive effort, move the drain pipe aside, remove the
flange with pipe.
4. C�an the pipe on the removed flange. If necessary, it is permissible to use such. tools as
scraper, file, emery paper, etc.
5. Coat the upper and lower gaskets with silo�ane enamel, install the flange with pipe and pipe (5),
coat the scr�ws with antistick agent, drive them in and lock with wire.

TEST EQUIPMENT TOOLS AND FIXTURES MATERIALS

1. Milling cutter Y6402-0384 1. Gaskets 0780579160 - 2 pcs


"00
� --.:a 2. 0.8-mm dia. safety wire
Z Vl
(l) N

O
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- (JI 3. Antistick agent
0 .....:i QO
.i:,.. ...... • f Siloxane enamel
8�
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