TBS720 Turbo Starter For Avon Overhaul OCR

P U B L I C A T 'I ON T .
RANSM I T T A L
'\
ROLLS-ROYCE LIMITED AERO ENGINE DIVISION

P. O . BOX N0 .31
DERB Y T EL E-P H 0 . NE DE R BY ~ 2 ~ 2 ~ . TELEGRAMS ' R 0 y CA R' DERB y
March 1970
AVON AND NENE ACCESSORY OVERHAUL MANUAL
Publication Ref.O-AccAv & Ne
VOLUME 2
.
TRANSMITTAL LETTER No.ll
NOTE:
Remove: Incorporate:
The following topics all refer to the triple breech turbo

Reason for change:
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starter - TBS720 Mk.2 for Avon 100 series engines and the
pages are all dated Jan.7/70. To avoid unnecessary
reiteration these facts are not repeated.
5-2-1 Page 601 'Repair' - First issue
5-2-1 Pages 801 and 803 'Assembly' - First issue.

to 823
5-2-1 Pages 901,903 tq 'Fits, clearances and torque

905,907 to 913 loadings' - First issue.
and 915
'
Continued .................... .
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
Rol ls Royc e Li mited, (Date as above) Printed in G reat Brita in

\
-
Remove: Incorporate: Reason for change:
5-2-1 Pages 1001 and 'Rig test' - First issue.

1003 to 1006
Transmittal Record incorporation of this transmittal letter

record sheet and date of incorporation. Retain this
transmittal letter for record purposes.
ROLLS-ROYCE AERO ENGINES
- - - - - - - A C C IS S 0 R Y OV I RH A U L - - - - - - -
TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2
LIST OF SUBJECTS
Subject
Avon lOO series 5-2-1
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Jan.7/70 5-2
List of Subjects
-------AC C E 5 S 0 R Y OVERHAUL-------
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AVON lOO SERIES
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Description
Jan.7/70 5-2-l
Page l
-------ACCISSOitY OVIIlHAU L--------
Triple breech turbo starter- TBS 720 Mk 5 -Description (cont.)
To be issued later
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Triple breech turbo starter - TBS 720 Mk 2

Fig. 1
Description
Jan.7/70
5-2-1
Page 3
- - - - - - - A C C E 55 0 R Y OVERHAUL-------
SPECIAL TOOLS
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TABLE OF CONTENTS
Page
..... Disassembly and assembly 203
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Special tools
Jan.7/70 5-2-l
Page 201
-------ACCESSORY OVERHAUL--------
SPECIAL TOOLS
Ref. No. Part No. Description

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1. Disassembly and assembly
301 CX.l33280-13 Drift extractor for planet gear

assembly bearing.
302 CX.l33280-17 Drift extractor for casing bearing.
303 CX.l35287 Support stand for planet gear assembly.
304 CX.135288 Spring contractor for pressure
control valve.
305 CX.135289 Dog spanner for planet assembly idler
gears.
306 CX.135290 Assembly plug for gear casing oil seal.
307 CX.135291 Guide sleeve for gear casing oil seal.
308 CX.l35292 Holding plate for drive shaft.
309 CX.l35293 Dog spanner for drive shaft nut.
310 CX.l35294 Holding fixture for planet assembly
idler gear.
311 CX.135295 Strip and assembly plate for breech
base.
312 CX.l35526 Clamp for securing setscrews circlip.
313 CX.l36456-2 Assembly sleeve for thrust plate and
idler bearings.
314 CX.l36456-8 Assembly sleeve for ball race to drive
shaft.
315 CX.l36534 Checking fixture for axial clearance
of drive shaft bearing.
316 CX.139349 Ring spanner for breech barrel.
317 ex .139350 Checking fixture for rotor return
springs.
318 CX.l39351 Extractor for rotor thrust plate.
319 ex .153012 Extractor for bearing panel bearings.
320 ex .153067 Extractor for drive shaft bearing.
321 CX.l53068 Checking fixture for front sliding
bearing end float.
322 CX.l53111 Peening block and tool for breech
block assembly.
323 ex .153112 Swaging tool and block for spinning
breech cap shroud.
324 CX.l53273 Clamp for dismantling front sliding
bearing.
325 CX.l53274 Assembly block for breech barrels.
326 CX.153322 Test fixture for pressure control
valve.
Special tools
Jan. 7/70 5-2-1
Page 203
--------ACCESSORY OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2 - Special tools (cont.)
327 CX.l54186 Assembly fixture for dowels and idler

bearings to panel
328 CX.l74949 Hand cutting tool for breech base
valve seat.
329 44506 Starter acceptance gauge
330 38477 Special gauge for breech barrel
331 G.45855 Gauge for thrust plate spherical
332 G. 39477 Gauge for barrel bore
Special tools
5-2-'l Jan.7/70
Page 204
- - - - - - - A C C E 55 0 R Y OVERHAUL--------
DISASSEMBLY
:: TABLE OF CONTENTS
Page
General 303
Remove the external fittings 303
Separate the starter halves 303
Disassemble the breech end main assembly 304
Disassemble the pressure control valves 305
Remove the breech barrel housings 305
Remove the breech barrels 305
Disassemble the starter end main assembly 306
Remove the annulus gear and drive shaft from the gear casing 306
Remove the spherical bearing from the driving shaft 307
Disassemble the bearing panel 307
Remove the turbine rotor shaft and bearings 309
Remove the planet gears and bearings .. 310
Removing the mounting flange setscrews 311
Remove the breech base liners 311
Disassemble the breech caps 311
Disassembly
Jan.7/70 5-2-1
Page 301
ROLLS-ROYCE AEitO ENGINES
DISASSEMBLY
1. General
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A. Refer to 'Standard practices' (1-l) for general instructions pertaining
to disassembly.
B. Before disassembling the turbo starter, clean it externally in a paraffin

bath or spray.
C. To prevent mixing of components, place the parts in clearly identified

containers.
D. During disassembling it is convenient to deal with the turbo starter in

two separate halves, i.e., the front half comprising the three bree;;h
assemblies and the inlet casing; and the rear half comprising the bearing
panel, turbine assembly, reduction gear and its casing. The halves are
attached to the exhaust casing.
E. Before starting the disassembly procedure, check that there are no

cartridges in the breeches, remove the oil plug from the gear casing,
drain the oil and replace the plug. Remove the transportation blanks from
the stub pipes, electrical connections and pressure control valve; remove
the mounting flange protection cover.
F. A hardwood stand (fig.30l), which can be constructed locally, will

C)
facilitate disassembling.
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A. Remove the three breech caps.
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B. Remove the locking wire, release the three sleeve nuts and withdraw the
electrical connections from the breech bases. Release the tabwashers and
remove the nuts securing the harness clips and the support bracket to the
starter. Withdraw the conduit and harness from the starter.
C. Remove all accessible locking wire and release all accessible tabwashers.
D. Remove the stub pipe securing nuts and remove the three stub pipes.
3. Separate the starter halves
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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41'2 in. 5lt4 in.

DIA. DIA.
t----------7 in. DIA.----------1~
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
the ~
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
split 0
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
5-2-1
.Jan. 7/70
Page 304
Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)
F. Degrease the inlet casing to facilitate removal of the circlips, spring

ring retaining washers and split nozzle seal ring. Remove these items
from the six nozzle inlets.
CENTRAL ROD
SPRING CONTRACTOR G 3725
Pressure control valve spring contractor

Fig.302
5. Disassemble the pressure control valves (fig.302)
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.
6. Remove the breech barrel housings
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.
7. Remove the breech barrels
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
- - - - - - - A C C E 5 SORY OVERHAUL--------
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.
B. Repeat the disassemb ly procedure on the other two barrels.
/LOCKING RING
SPANNER
RETAINING RING
G 3726
Removing the breech barrels

Fig.303
8. Disassemb le the starter end main assembly
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
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 .
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RING NUT DOG SPANNER
VICE BLOCK
G3722
Removing the ring nut from the driving shaft

Fig.304
ll. Disassemble the bearing panel (fig.30G)
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
- - - - - - - - A C C I 55 0 R Y OV I RH A U L--------
Extracting the bearing from the driving shaft

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Fig.305 z
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C. Release the three cup washers and use the dog spanner,Ref.305, to remove :>
the three idler gear nuts.
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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
--------ACCESS 0 R Y OVERHAUL--------
THRUST PLATE EXTRACTOR
THRUST PLATE
G 3719
Removing the return mechanism thrust plate

Fig.306
12. Remove the turbine rotor shaft and bearings
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
-------ACCESS 0 R Y OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2 - Disassembly (cont.)
assembly of the parts in their correct relative positions. Release the

locking plates then remove and discard the eight nuts, bolts and locking
plates. Separate the rotor shaft and turbine with a soft faced hammer.
CAUTION: DO NOT STRIKE THE ROTOR BLADES WITH THE HAMMER.
13. Remove the planet gears and bearings (fig.307)
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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Removing the planet gear roller bearings

Fig. 307
Disassembly
5-2-1 Jan.7/70
Page 310
--------ACCESSOI'tY OVEI'tHAU L--------
14. Removing the mounting flange setscrews (fig.308)
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.
B. Remove the gear casing plug and washer.
SPRING RING
G3724
Removing the mounting flange setscrews

Fig.308
15. Remove the breech base liners
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.
16. Disassemble the breech caps
A. The following operations are only necessary if a breech cap has failed
the initial inspection.
B. Cut round the circumferen ce of the shroud with a hacksaw at a distance of

0.5in from the cover end then remove the two parts of the shroud. Safe-
guard the springs which are retained by the larger part of the shroud.
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
D. Remove the locking lever and extracting lever springs.
E. Unlock and remove the eight screws securing the cover to the cap;
separate the two parts.
F. Remove the firing pin spring and washers.
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.
H. Remove the buttons from the cover.
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.
CAUTION: DO NOT EXCEED THE ORIGINAL BORE DEPTH.
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
5-2-l
Jan.7/70
Page 312
- - - - - - - A C C E S S 0 lilY OVE Ill H A U L - - - - - - - -
CLEANING
TABLE OF CONTENTS
Page
General 403
Turbo starter components 403
Ball and roller bearings 403
Breech cap assembly 403
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Cleaning
Jan.7/70 5-2-l
Page 401
RO LLS-ROYCE AERO ENGINES
CLEANING
l. General
A. Refer to 'Standard practices' (l-1) for general instructions pertaining to

cleaning.
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.
CAUTION: DO NOT USE SHOT BLASTING AS A METHOD OF CLEANING COMPONENTS.
2. Turbo starter components
A. With the exception of the assembled breech caps, electrical components

and ball and roller bearings, wash all the turbo starter parts in a
paraffin bath or spray, then submit them to a cresol soap wash in
accordance with T.S.D. 594, O.P. 102.
B. After the soap wash, degrease the parts in accordance with T.S.D. 594,
O.P. 101,
3. Ball and roller bearings
A. Clean ball and roller bearings in accordance with T.S.D. 594, O.P. 112.
CAUTION: DO NOT DEGREASE BALL BEARINGS OR ROLLER BEARINGS.
4. Breech cap assembly (if not disassembled)
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.
CAUTION: DO NOT IMMERSE THE PARTS IN THE SOLVENT.
"-.--
Cleaning
Jan.7/70 5-2-l
Page 403
INSPECTION
TABLE OF CONTENTS
Page
General 503
Consumable items 503
Test for indications of cracks 503
Inspect the parts 504
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Inspection
Jan. 7/70 5-2-l
Page 501
ROllS-ROYCE AERO ENGINES
- TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2
INSPECTION
1. General
A. Refer to 'Standard practices' (1-3) for general information and

instructions pertaining to inspection.
B. The dimensional checks called for in this topic are detailed in 'Fits,
clearances and torque loadings'.
C. The inspection of the disassembled starter is to be carried out bearing in

mind that all components passed for re-use will be subject to a further
life.
2. Consumable items
A. Discard the following items, regardless of condition, before inspecting

the starter parts:
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
Breech cap (if disassembled)

Shroud
Tab washers
Firing pin screw
Firing pin plain washer
Firing pin glass sleeve
3. Test for indications of cracks
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
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
4. Inspect the parts
A. Breech cap assembly
(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'.
(7) If the locking or extracting levers are worn or sticking, or if there

is an electrical defect, remove the shroud and disassemble the breech
cap for further inspection, as detailed in 'Disassembly' (5-2-1).
Inspection
5-2-1 Jan.7/70
Page 504
--------ACCESSORY OVERHAUL--------
B. Firing lead harness
(l) This is normally discarded if the starter has completed an overhaul

life or if the harness has to be modified. If the harness is to be
retained, inspect it as follows:
(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.
( 3) If the seating face is unacceptable and has previously been machined

to salvage drawing CX.l6784l, reject the assembly.
(4) If the breech base is otherwise acceptable, hydraulically pressure

test it in accordance with schedule CX.l39312.
D. Pressure control valve assembly
(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,
,'"--
reject the valve.
Inspection
Jan.7/70 5-2-l
Page 505
- - - - - - - 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.
E. Nozzle and elbow assembly
(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.
( 3) Inspect the nozzle bore for diametral collapse, immediately downstream

from the insert; this condition is not acceptable.
(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
IJ)
plate CX.l52720 must be fitted in place of the standard joint washer. z
F. Breech base and nozzle elbow liners
(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
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.
J. Ball and roller bearings
(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
- - - - - - - 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
incorporate salvage scheme CX.2686l3 on the inlet casing by machining

across the tops of the bosses, and changing the breech securing stud
of each breech base to the salvage type.
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
Triple breech turbo starter- TBS 720 Mk 2 - Inspection (cont.)
(3) Examine the barrel for corrosion. Corrosion is acceptable unless it

significantly reduces the wall thickness.
(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'.
U. Thrust plate and seating rings
(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'.
V. Breech caps (disassembled)
(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
- - - - - - - A C C E 55 0 R Y OVERHAUL--------
(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
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
ASSEMBLY
TABLE OF CONTENTS
Page
General 803
Assemble the turbine rotor and shaft 803
Dynamically balance the rotor assembly 803
Assemble the planet gears 804
Determine the sliding bearing end float 806
Assemble the rotor shaft to the bearing panel 806
Adjust the turbine rotor axial clearance 807
Adjust the turbine travel 808
Determine the return mechanism spring loading 810
Assemble the gear casing 811

~
z Check the driving shaft bearing axial clearance 811
os
:> Fit the driving shaft 813
<
(.)
(.) Fit the annulus gear 814
<I
0
Assemble the bearing panel to the gear casing 815
Assemble the exhaust casing and fairing support ring 815
Assemble the breech bases and prP.ssure control valves 815
Assemble the breech barrels 817
Assemble the breech units to the inlet casing 818
Assemble the inlet casing to the exhaust casing 820
Acceptance test and dispatch 821
..,___ Assemble the breech caps after repair 821
Assembly
Jan.7/70 5-2-1
Page 801
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.
2. Assemble the turbine rotor and shaft

A. Fit the turbine rotor to the shaft so that the correlation marks are
aligned then secure it with eight new bolts, four double locking washers
and eight new special nuts. Fit the locking washers with the tabs towards
the shaft, so that, when the tabs are bent up, the centrifugal force set
up by the turbine keeps them in contact with the bolt heads. Tighten the
bolts and bend up the locking tabs.
B. Inspection/check
(l) Check that the nuts are correctly locked.
3. Dynamically balance the rotor assembly (fig.80l)
A. Dynamically balance the assembly at 1500 r.p.m. on an approved balancing
machine. Correct unbalance by drilling the bolt heads as required, with
a O.l875in diameter drill to a maximum depth of 0.050in. The maximum
acceptable unbalance is 0.010 oz in.
__j_
1 ---o 1875in. DIA. DRILL
0 050 in. MAX DEPTH
G 215
Balancing the rotor assembly

Fig.80l
Assembly
Jan.7/70 5-2-l
Page 803
Triple breech turbo starter- TBS 720 Mk 2- Assembly (cont.)
4. Assemble the planet gears (fig.802 and 803)
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
(l) Check that the circlips are correctly fitted.
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) Check that the circlips are correctly fitted.
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
Triple breech turbo starter- TBS 720 Mk 2 - Assembly (cont.)
DOG SPANNER
HOLDING FIXTURE
G3720
Tightening the planet gear nuts

Fig.802
DOWEL GUIDE
ASSEMBLY
FIXTURE
G 3727
Fitting the bearing panel dowel

Fig.803
Assembly
Jan.7/70 5-2-1
Page 805
- - - - - - - - A C C E 5 SOIIIY OVEIII H A U L - - - - - - - -
5. Determine the sliding bearing end float (fig.804)
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
Measuring the sliding bearing end float

Fig. 804
6. Assemble the rotor shaft to the bearing panel
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
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
(l) Check that the bearing circlip is correctly fitted.
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.
F. Check that the rotor shaft rotates freely in its bearings.
7. Adjust the turbine rotor axial clearance (fig.805 and 806)
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
Fitting the turbine shaft nut

Fig,805
. '-
Assembly
Jan. 7/70 5-2-l
Page 807
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.
(5) Add dimensions B and C, and record the sum as dimension G.
(6) Measure the depth of the fairing support ring spigot in the gear casing,
and record the measurement as dimension F.
(7) Add dimensions E and F, and record the sum as dimension H.
(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.
8. Adjust the turbine travel
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
- - - - - - - - A C C E 55 0 R Y OVERHAUL--------
the measurement as dimension J.
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
- - - - - - - - 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
Checking the return mechanism spring loading

Fig.807
Assembly
5-2-1 Jan.7/70
Page 810
F. Inspection/check
( l) Check that the rotor shaft retaining nut and the return mechanism
setscrews are correctly locked.
10. Assemble the gear casing (fig.808 and 809)
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
Fitting the starter mounting flange setscrews

Fig.808
11. Check the driving shaft bearing axial clearance (fig.810)
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
Triple breech turbo starter- TBS 720 Mk 2 -Assembly (cont.)
BEARING HOUSING
G 3730
Pressing the oil seal into the bearing housing

Fig.809
(])
z
o<l
~
(.)
(.)
<I
0
OIL SEAL
LOCATING PLUG
SLIP GAUGES
G3731
Checking the driving shaft bearing axial clearance

Fig.810
Assembly.
5-2-1
Jan.7/70
Page 812
- - - - - - - - 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.
D. Subtract dimension A from dimension B and record the difference as

dimension C. This dimension represents the axial clearance between the
bearing and thrust ring when the assembly is complete. Refer to 'Fits,
clearances and torque loadings' for the acceptance limits and if necessary
adjust the clearance by selecting a suitable adjusting washer from the
range provided.
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.
12. Fit the driving shaft (fig.8ll and 812)
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
Fitting the driving shaft ring nut

Fig.8ll
Assembly
Jan.7/70 5-2-l
Page 813
BEARING HOUSING
G3732
Fitting the driving shaft assembly

Fig.Bl2
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.
13. Fit the annulus gear
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
- - - - - - - 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.
14. Assemble the bearing panel to the gear casing
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.
~: The above instruction may ne amended by Rotax Limited to permit the

application of jointing compound between the joint faces.
15. Assemble the exhaust casing and fairing support ring
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
dimensions specified in 'Fits clearances and torque loadings'.
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
SPRING CONTRACTOR G 3725
Fitting the pressure control valve

Fig.813
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
17. Assemble the breech barrels (fig.815)
A. Fit the locking ring and the retaining ring over the breech base end of
each barrel.
B. Assemble the firing lead connection as follows:
(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.
PRESSURE REGULATOR WORKSHOP AIR SUPPLY

(NORMALLY SET TO 5P.S.I.)
/
TEST FIXTURE
/ ADDITIONAL
Q) ~WEIGHTS
z
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:>
<
(.)
(.)
<I MAIN WEIGHT_.....-_.....---
0
G3733
Setting the pressure control valve

Fig,814
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
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
Fitting the breech barrel

Fig.815
18. Assemble the breech units to the inlet casing (fig.816)
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
--------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
Numbering of breeches for assembly purposes

Fig.816
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
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.
19. Assemble the inlet casing to the exhaust casing
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
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.
20. Acceptance test and dispatch

A. On completing the assembly and with the starter suitably mounted, rotate
the rotor to ensure that no fouling exists. After satisfactory rig test,
tighten and lock the breech base tapping plugs and the exhaust stub pipes.
B. Remove the gear casing plug and drain the oil from the starter; refit and
lock the plug, Attach a label to the starter stating the following:
Before installation of the starter, prime the gear casing
with 200 C.C. of clean engine oil.
C. Check the protrusion of the driving shaft and the alignment of the breech
barrels on the acceptance gauge, Ref.329.
D. Fit the transportation blanks to the starter and stamp the Mod, plate to
indicate the modification standard of the starter,
21. Assemble the breech caps after repair (fig.817)

A. Fit the firing pin bush.
(1) Anneal the insert for two hours at a temperature of approximately
200 deg. C. to prevent it cracking when it is swaged into position in
I]) the breech cap.
z
a1! (2) Position the breech cap on the peening block, Ref.322, and press in the
:> firing pin bush. Fit the insert and use the peening tool (part of
<:t: Ref.322) to swage the insert into the breech cap.
(.)
(.)
<:t: (3) Fit the loose bush to the firing pin assembly and then insert the pin
I
0 through the firing pin bush.
B. Fit the electrical connection assembly.
(1) Thread the strip connection through the slot in the breech cap; position
the guard and the insulator where the strip connection passes through
the slot, then press the slip ring into position in the end of the
breech cap.
(2) Fit the spring washer, plain washer and insulating bush to the strip
connection setscrew. Fit the insulator to the breech cap, then secure
the strip connection to the breech cap with the setscrew.
(3) Secure the firing pin lead to the strip connection with the screw and
plain washer; tighten the screw and lock by soldering one side of the
lead to the firing pi~ lead.
Assembly
Jan.7/70 5-2-1
Page 821
I FIRING PIN
LOCKING
LEVER
SPRING
BREECH
CAP
Section showing locking levers G 3714
WASHER
FIRING PIN~~"'-"' ELECTRICAL

LEAD CONNECTION
ASSEMBLY
BUSH
INSULATOR
dNSULATOR
Part section showing Part section showing

extracting levers electrical connections assembly
G 3717
Breech cap assembly

Fig.817
Assembly
5-2-l Jan.7/70
Page 822
-------ACCESSORY OVERHAUL---------
c. Fit the locking levers and extracting levers
(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.
D. Fit the shroud.
(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
FITS, CLEARANCES AND TORQUE LOADINGS
TABLE OF CONTENTS
Page
Introduction 903
Fits and clearances 907
Torque loadings 915
Fits, clearances and torque loadings

Jan.7/70 5-2-l
Page 901
- - - - - - - A C C E 5 SOR Y OVERHAUL--------
FITS, CLEARANCES AND TORQUE LOADINGS
1. Introduction
A. Refer to 'Standard practices' (1-3 and 1-7) for general information

relating to fits and clearances and to torque tightening respectively.
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.
D. A diagram is included to facilitate reference to points of wear only; do

not regard it as a general arrangement drawing.
E. Use the topic in conjuction with the 'Assembly' topic as various checks
and clearances are detailed during assembly.

Jan.7/70 5-2-l
Page 903
- - - - - - - A C C E S S 0 lt Y OV E lt H A U L - - - - - - - -
Triple breech turbo starter- TBS 720 Mk 2- Fits and clearances (cont.)
To be issued later
Q)
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~
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<r:
(.)
(.)
<r:I
0

5-2-l Jan.7/70
Page 904
Triple breech turbo starter- TBS 720 Mk 2- Fits and clearances (cont.)
To be issued later
Q)
z
~
~
0
0
<l!
I
0

Jan. 7/70 5-2-1
Page 905
IMS/2 O-Acc Av & Ne Printed in Great Britain
c... PERMISSIBLE PERMISSIBLE N

Item DIMENSIONS CLEARANCE
Ill DESCRIPTION WORN WORN REMARKS
::s No. NEW NEW
DIMENSIONS CLEARANCE >Tj
-.l 1-'
........ r+
-.l l ROTOR SHAFT IN FRONT SLIDING (ll
0
BEARING - ROLLERS ON SHAFT Ill
Roller track - width 0.251 to 0.252 ::s ::1:11
0.
0.252 0.0008 to 0.0022* ()
,...
0
,...
1-'
0.0022 CD
ut
I
Roller - width 0.2498 to 0.2498 Ill ::1:11

'1 0
0.2502 Ill -<
::s() ~
m
CD
(ll
ROLLERS IN OUTER RACE
End float 0.001 to 0.002 End float is adjustable >b
0.002 ~~
m~,
~~~~
2 ROTOR SHAFT AND OUTER RACE
Total axial clearance 0.0018 to
0.0042
0.0042*
,.~~
~~
3 FRONT SLIDING BEARING - DIAMETRAL 0
CLEARANCE
Bearing sleeve - internal dia. 2.17500 to 2.17525
:~
>Tj 2.17525 0.001 to 0.002* ~[ijJj]
1-'
r+
(ll
0.002 ~~
Outer race - external dia. 2.17325 to 2.17325 r [ijJjJ
() 2.17400
1-'
CD
Ill
,..
m
'1 4 ROLLER BEARING - TOTAL DIAMETRAL ::1:11
CLEARANCE 0
()
CD m
(ll
Outer race - roller track z
*No wear permitted C\
Ill
internal dia. 1.8850 to 1.8855*
::s 1.8855 outside drawing z
0. m
ut
r+
Rotor shaft - roller track dia. 1.3840 to 1.3840* tolerance
0
'1
1.3845
.g Roller - dia 0.2499 to 0.2499*
CD 0.2501
"0 1-' Total diametral clearance 0.0003 to 0.0017*
Ill 0
(Jq Ill 0.0017
CD 0> 0.
I 1-'
WN::S
0 I (Jq
-.l 1-' (ll
"d ()l 1-rj
lll I f-'
(Jqtvrl- Item DIMENSIONS CLEARANCE PERMISSIBLE PERMISSIBLE
(1) I Ul
f--' ~
No, DESCRIPTION WORN WORN REMARKS
m NEW NEW
0 () DIMENSIONS CLEARANCE
00 f--'
<D 5 IDLER GEAR - ROLLER BEARING
lll
'1 Diametral clearance 0.0003 to 0.0013*
lll
:::-,
() 0.0013
<D
Ul
6 OUTER RACE IN BEARING PANEL
lll
:::-, Bearing panel - bore 1.18080 to 1.18105 ::a
Q. 0
n- 1.18105 Tight r-
o
'1
..a
0.00030
to
.
r-
"'
::a
~ 0.00045* 0
<D 0.00045 -c
n
f--'
Clear m
0
lll Outer race - outside dia. 1.1806 to 1.1806
....Q.
:::-, 1.1811 b
(Jq
Ul
7 IDLER GEAR - BALL BEARING
~~
Diametral clearance between :@
inner and outer races 0.0004 to 0.0006* *No wear permitted ~~
:11
0.0006 outside drawing
tolerance s ~~
8 OUTER RACE IN ENDPLATE I
0
!
Endplate - bore l. 31190 to l. 3125 ~~
!
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
9 REAR SLIDING BEARING - DIAMETRAL m

z
CLEARANCE a
Assembled bearing - dia. under 0.9810 to 0.9815 z
C..;
m
lll rollers 0.9815 0.00030 to 0.00105* Bearing cannot be "'
~
0.00105 dismantle d
-1 Rotor shaft - roller track dia. 0.98045 to 0.98045
'-...
-1 0.98070
0 ~~~----~---~-
IMS/2 0-Acc Av & Ne Printed in Great Britain

c... Item DIMENSIONS CLEARANCE PERMISSIBLE PERMISSIBLE

DESCRIPTION WORN WORN REMARKS
No. NEW NEW
DIMENSIONS CLEARANCE
-J
........ 10 THRUST PLATE AND ROTOR SHAFT -
-J
0 TOTAL DIAMETRAL CLEARANCE
Thrust plate - spherical dia- 1. 7500 to l. 7505 ,.,
........
0
l. 7505 0.0005 to 0.0015* Use gauge G.45855 to
Seating ring - spherical dia. l. 7490 to

0.0015 check spherical
,.,"'.
0
1.7495 1.7490 -<
n
Seating ring - bearing locating m
bore l. 5745 to Tight l. 5770
1.5770 0.0003 to 0.0027* ,.~
Bearing - outside dia. 1.5743 to
0.0027
Clear 1.5743
~~
l. 5748 :@
Ball bearing - diametral clearance ~~
between inner and outer races 0.0009 to 0.0011* ::1111
0.0011 -<~
Total diametral clearance when 0
assembled 0.0017 to 0.0053*
0.0053
:~
"%j
.....
;lJUi)
t+
Ul
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
insert size if necessary ; ~
19 I ROTOR SHAFT - GEAR ,~~

Dia. 11.519 to 1. 519
) 7~
1.524
)
>
m
~Check diameter over :ID
0
20 I IDLER GEAR )0.125 -0.0002 steel balls m
Dia. 12.4228 to 2.4228 )or rollers located in z
a
2.4278 )opposite or nearest
)opposite gaps
-m
z
c....
)
""
Pl
~ 21 ANNULUS GEAR )
-..] Internal dia. 5.663 to 5.670
........ )
-..] 5.670
0

PERMISSIBLE PERMISSIBLE
c:... Item DIMENSIONS CLEARANCE
WORN WORN REMARKS
No.
DESCRIPTION NEW NEW
-..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
:~
":!
~
Bore Clean out corrosion and
then use go - not go ;(JW
~~
r+
Ul gauge G.39477
(")
.- lJW
27 TRANSFER TUBES
I-'
Cl)
Ill Bore 0.6560 to 0.6570 ,..
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
~
r+
0
'i
.g
Cl)
"0 I-'
Ill 0
(IQ Ill
Cl) CJl p..
I ~
{!) 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)
r.>
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.
.....
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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]
~~
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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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Free length 3.792 i
....m
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PERMISSIBLE PERMISSIBLE
c.. Item DIMENSIONS CLEARANCE
Ill DESCRIPTION WORN WORN REMARKS
::s No. NEW NEW
-l
.......
-l Control valve outer spring -
0
when compressed to 3.150 173 lb 3 oz
to
"'....0
196 lb 9 oz ....
"'
I
Free length 4.440 "'-c

0
n
Return mechanism spring - m
when compressed to 2.550 6 lb 5 oz
to ~~
7 lb 1 oz g~
Return mechanism springs -
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when compressed to 2.050 23 lb to ~~
,.
25 lb 2 oz
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- - - - - - - A C C E 55 0 R Y OVERHAUL--------
Triple breech turbo starter- TBS 720 Mk 2- Torque loadings (cont.)
3. Torque loadings
A. Mandatory torque loadings
Item Applicati on Effective load
To be issued later
Q)
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o2l
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<:t:
(.)
(.)
<:t:
I
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Fits, clearance s and torque loadings

Jan.7/70 5-2-l
Page 915
RIG TEST
TABLE OF CONTENTS
Page
Introduction 1003
Safety precautions 1003
Pre-installation checks 1003
Install the starter on the test rig 1004
Effect the acceptance test 1005
Strip examination .. 1005
Effect the final test 1005
Q)
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<
(.)
(.)
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Rig test
Jan.7/70 5-2-l
Page 1001
- - - - - - - A C C E 55 OIIIY OVE Ill H A U L - - - - - - - -
RIG TEST
1. Introduction
A. Refer to 'Standard practices' (1-6) for general rig testing instructions.
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.
C. Cartridges are electrically fired, therefore ensure that they do not

come into contact with electrical equipment.
D. In the event of a misfire apparently due to a defective cartridge,wait

for five minutes, in case of a possible delayed action ignition, and then
unload the defective cartridge. Replace the defective cartridge in its
container and place it in the special box allocated for the purpose and
then carry out the Local Authority's disposal of explosives instructions.
Q)
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o<l
> 3. Pre-installation checks
<
C)
C) A. Test the insulation resistance between the separate firing circuits and
<I between each firing circuit and the casing with a 500 volt megger. The
0
resistance should not be less than 3 megohms.
B. Remove the three breech caps and test the resistance of each firing
circuit. The resistance should not exceed 13 ohms.
C. Check the continuity of the earth (ground) lead.
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
Triple breech turbo starter- TBS 720 Mk 2- Rig test (cont.)
4. Install the starter on the test rig
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.
B. Fit the pawl carrier assembly to the spring drive shaft.
~: 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
Triple breech turbo starter- 720 Mk 2- Rig test (cont.)
5. Effect the acceptance test
A. Pre-heat three cartridges of the current 720 gm No.lO type, in a thermo-

statically controlled water-circulated oven, at a temperature of between
43 deg.C and 47 deg.C for between 12 and 24 hours immediately before
firing.
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.
D. Check the operation of the flywheel air brake.
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.
F. Fire one cartridge from each breech in rotation allowing an interval of

ten minutes between each shot; record the pressure/time characteristic
for each shot. (This will involve changing the Dobbie Mcinnes Indicator
recording paper and the pressure pipe for each shot.) Also record the
maximum speed attained by the flywheel during each shot. The maximum
breech pressure recorded by the Indicator should be between 1175 p.s.i.
and 1250 p.s.i. thus proving the correct operation of the pressure
control valves. If the recorded pressure is outside these limits re-
(])
check the pressure control valve setting of the breech affected.
z
c!2l G. Remove the three spent cartridges from the starter and reload with three
:> cartridges at normal day temperature. Fire the cartridges with an
<:!!
(.) interval of one minute between each shot; record the pressure/time
(.)
<:!!
characteristics for the first shot, and the maximum speed attained by
I the flywheel for each shot. The maximum speed attained should be not
0
C-1
less than 1500 r.p.m. when using the standard No. 10 type cartridge, or
........ 1450 r.p.m. if the No. 10 Mk.3 type are used.
U'J.
:;;,:
H
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.
7. Effect the final test
A. Install the starter on the test rig as described in para. 4 A. to 4 L.

inclusive.
Rig test
Jan.7/70 5-2-l
Page 1005
Triple breech turbo starter- TBS 720 Mk 2- Rig test (cont.)
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.
D. Repeat the pre-installation checks given in para.3 A to 3 D inclusive.
E. If the starter is satisfactory, remove it from the test rig, check

external locking and fit the blanking covers.
Rig test
5-2-l Jan. 7/70
Page 1006

TBS720 Turbo Starter For Avon Overhaul OCR

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P U B L I C A T 'I ON T .

ROLLS-ROYCE LIMITED AERO ENGINE DIVISION

AVON AND NENE ACCESSORY OVERHAUL MANUAL

Publication Ref.O-AccAv & Ne

The following topics all refer to the triple breech turbo

5-2-1 Page 601 'Repair' - First issue

5-2-1 Pages 801 and 803 'Assembly' - First issue.

5-2-1 Pages 901,903 tq 'Fits, clearances and torque

Rol ls Royc e Li mited, (Date as above) Printed in G reat Brita in

5-2-1 Pages 1001 and 'Rig test' - First issue.

Transmittal Record incorporation of this transmittal letter

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

Avon lOO series 5-2-1

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

AVON lOO SERIES

Triple breech turbo starter - TBS 720 Mk 2

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

..... Disassembly and assembly 203

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

Ref. No. Part No. Description

301 CX.l33280-13 Drift extractor for planet gear

Triple breech turbo starter- TBS 720 Mk 2 - Special tools (cont.)

327 CX.l54186 Assembly fixture for dowels and idler

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

Remove the external fittings 303

Separate the starter halves 303

Disassemble the breech end main assembly 304

Disassemble the pressure control valves 305

Remove the breech barrel housings 305

Remove the breech barrels 305

Disassemble the starter end main assembly 306

Remove the spherical bearing from the driving shaft 307

Disassemble the bearing panel 307

Remove the turbine rotor shaft and bearings 309

Remove the planet gears and bearings .. 310

Removing the mounting flange setscrews 311

Remove the breech base liners 311

Disassemble the breech caps 311

TRIPLE BREECH TURBO STARTER - TBS 720 Mk 2

B. Before disassembling the turbo starter, clean it externally in a paraffin

C. To prevent mixing of components, place the parts in clearly identified

D. During disassembling it is convenient to deal with the turbo starter in

E. Before starting the disassembly procedure, check that there are no

F. A hardwood stand (fig.30l), which can be constructed locally, will

> 2. Remove the external fittings

3. Separate the starter halves

41'2 in. 5lt4 in.

t----------7 in. DIA.----------1~

Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)

F. Degrease the inlet casing to facilitate removal of the circlips, spring

SPRING CONTRACTOR G 3725

Pressure control valve spring contractor

5. Disassemble the pressure control valves (fig.302)

6. Remove the breech barrel housings

7. Remove the breech barrels

B. Repeat the disassemb ly procedure on the other two barrels.

Removing the breech barrels

8. Disassemb le the starter end main assembly

Triple breech turbo starter- TBS 720 Mk 2- Disassembly (cont.)

RING NUT DOG SPANNER

Removing the ring nut from the driving shaft

ll. Disassemble the bearing panel (fig.30G)

Extracting the bearing from the driving shaft