Accessory repair and LRU managementCompetence and excellency in MRO solutions

An MTU Aero Engines Company

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MTU Maintenance is the world’s largest inde-pendent provider of commercial engine mainte-nance services. A business unit of MTU AeroEngines, Germany’s leading engine manufac-turer, MTU Maintenance benefits from its par-ent’s over 75 years of experience in the devel-opment and production of aircraft engines.

MTU Maintenance has grouped all activitiesrelating to the repair of components, modulesand accessories for aircraft engines and indus-trial gas turbines under the umbrella of MTURepair Services. The company operates aworldwide network of maintenance, repair andoverhaul shops, among them renowned cen-ters of excellence, all of which stand out fortheir unique expertise in the field of accessoryand component repairs as well as specializedhigh-tech repair processes.

True to its motto “repair beats replacement”,MTU Maintenance continues to develop its in-house repair capabilities. It has a strong focuson innovative high-tech MRO-processes as wellas custom-tailored management solutions thatoffer its customers added value and reducedmaintenance costs. Airlines, maintenance pro-viders and parts brokers alike are relying onMTU Maintenance’s competence and excel-lence in parts, accessory and LRU repair andmanagement solutions.

Repair beats replacement

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MTU Repair Services provides comprehensiveservices, its portfolio covering the whole rangefrom all major internal engine components tomodules and accessories.

In addition, customers can opt for MTU’s TotalPart Care (TPC®) service package, an all-roundcarefree solution comprising maintenance andrepair, technical and logistic support and sparepart services.

Thanks to its one-of-a-kind repair expertise,MTU Repair Services is setting benchmarks inthe industry worldwide. Apart from OEM re-pair processes (in accordance with the enginestandard manual or special repairs), MTU Re-pair Services uses high-tech methods that aredeveloped in-house and are certified by regu-latory agencies, such as the Federal AviationAdministration (FAA) and the European AviationSafety Agency (EASA).

MTU Repair Services

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High-performance engineering

MTU Maintenance has specialized in repairdevelopment, not only for engines in whichMTU has a development or production stake,but also for engines that do not form part ofthe company’s OEM portfolio.

The key to success is a highly qualified team of engineers that can draw on an extensive in-house OEM experience and know-how. Toensure the necessary transfer of knowledgethey closely cooperate with universities andresearch institutions. MTU’s goal is to devel-ope and provide intelligent solutions, whichresult in significant cost reductions for thecustomer.

MTU has a distinct advantage over its com-petitors: The company combines technical ex-pertise in complete engine maintenance withthe specialist know-how of an engine manu-facturer that also develops innovative enginecomponents and materials. MTU owes its suc-cess also to the highly advanced technologiesit developed under the many military programsin which it had or has a stake.

Services:• Hardware condition monitoring• Development and approval of

alternative repairs and processes• Best practices engineering, technical

support and consulting• Failure and damage analyses

Laser powder cladding is one of MTU’s repair specialties.

MTU Aero Engines is headquartered in Munich.

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MTUPlus repairs: Top qualitywith high-tech processes

As a production facility and independent pro-vider of MRO services, MTU Maintenance candraw on extensive experience and technicalexpertise in the development of repair proces-ses which are independent of or complementthose of the OEMs. The result are high-techrepairs, developed in-house and unrivaledworldwide. These repairs have been brandedas MTUPlus repairs. They are approved by aviation authorities, such as the FAA and theEASA.

These innovative and highly cost-effective ad-vanced repair technologies enable MTU tomeet individual customer requirements witheven greater flexibility. MTUPlus processes arebased on first-class know-how and satisfy themost demanding criteria, extending the serv-ice life of components, increasing repair yieldand improving part functionality. MTU-repairedparts stand out by their above average per-formance and extended on-wing times.

In close cooperation with each customer, MTUMaintenance further optimizes highly efficientprocesses and develops new repairs which areunique in the world of engine maintenance.Engine accessories, for example, can be givena second lease on life, thus reducing capitalexpenditures, saving resources and protectingthe environment.

Thanks to its comprehensive and leading-edgerepair expertise MTU Maintenance can repairall core components and the majority of acces-sories of an engine. The company uses highlysophisticated repair processes to restore partsto top-notch condition.

An accessory is being tested in an oil flow stand.

Benefits:• Highest quality standards• High repair yields• Reduced maintenance costs• Improved reliability

LVPS plasma spraying is part of MTU's repair portfolio.

MTU has extensive expertise in techno-logically advanced repair processes.

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A worldwide leader in engine MRO services,MTU Maintenance also refurbishes and repairsengine accessories. Accessories include partswhich are not integral to the engine but areessential for its operation, such as starters,fuel and hydraulic pumps, actuators, sensors,valves and tubing.

MTU Repair Services offers a first-class com-prehensive spectrum of in-house repairs, whichis constantly being widened and fine-tuned.Customers benefit in many ways from thisadditional competence: MTU Maintenance per-forms repairs of the highest quality that satisfythe most stringent standards, while turnaroundtimes are significantly reduced. This pays offfor the customers as their engines are returnedas quickly as possible to revenue service.

The repair of accessories requires expertiseand experience. MTU Maintenance has both.The company has been supporting commer-cial customers for many years, and MTU AeroEngines has been handling practically all avia-tion propulsion systems in service with theGerman Air Force and is responsible for theirtechnologically advanced accessories. In addi-tion, a dedictated team of engineers is com-mitted to the development of new accessoryrepair processes.

Accessory repair and LRU management

MTU Maintenance has developed all-roundcarefree service packages under which it notonly repairs line-removed accessories but alsoprovides support for all of the customer’s linereplaceable units (LRUs) that include engineaccessories such as oil coolers, starters orfuel pumps. Customers can choose from sev-eral support levels ranging from maintenanceand repair services to comprehensive LRUmanagement and support programs. Full LRUmanagement is part of MTU Maintenance’sTotal Part Care (TPC®) program.

Engine accessory portfolio:• IAE V2500• CF6-50• CF6-80• CFM56• PW2000• CF34• GE90

IGT accessory portfolio:• LM2500/LM2500+• LM5000• LM6000

Services:• Bench checks• Repairs• Overhaul (refurbishments)

MTU Maintenance’s repair portfolio alsoincludes accessories.

Accessories are put through their paces at MTU Maintenance Canada, MTU’s centerof excellence for accessories.

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True to the principle of “one face to the cus-tomer”, MTU Repair Services handles all as-pects of accessories repair for aircraft enginesand industrial gas turbines within the MTUMaintenance group. MTU Repair Services candraw on the support of a global network ofaccessory repair shops which are located inEurope and North America. Each customerhas one contact to take care of all of his repairneeds—no matter where in the world the workis carried out. Streamlined operation struc-tures ensure smooth and fast processing ofrepair orders.

MTU Aero Engines operates a large accessorytest and repair center in Erding, near Munich,Germany. It was set-up in cooperation with theGerman Air Force. For decades, the locationhas been servicing nearly all engines on behalfof the customer and is responsible for techno-logically advanced accessories both for mili-tary and commercial engines.

MTU Maintenance Canada in Richmond, BritishColumbia is the North American member ofthe MTU Maintenance network of companies.The company operates a shop in the vicinity

Global network with one faceto the customer

of Vancouver’s international airport where itrepairs both engines and accessories and per-forms engine tests. It is the group’s center ofexcellence for accessories.

MTU Maintenance Hannover in Langenhagen,Germany is the flagship facility of the group’sworldwide MRO network and the center ofexcellence for the maintenance, repair andoverhaul of large commercial engines, high-tech repairs and repair development.

Throughout its locations, MTU Repair Servicesoffers a wide portfolio of in-house accessoryrepairs. It features fuel system test benchesfor components such as nozzles, pumps andgovernors, pneumatic system test benches forall pneumatic components such as valves,starters, pressure switches as well as hydrau-lic and lubrication system test benches forcomponents including actuators, pumps, oilcoolers, valves, filters and regulators.

In addition to individual component repair andoverhaul, MTU also offers LRU (Line Replace-able Unit) management services.

MTU Aero Engines operates a center for technologi-cally advanced accessories in Erding, near Munich.

MTU Maintenance Hannover is the group’s flagshipfor MRO services.

Vancouver-based MTU Maintenance Canada isMTU’s centre of excellence for accessories.

Service CenterEurope, Africa and Middle EastMTU Maintenance HannoverMTU Aero Engines

Service Center Asia-Pacific (planned)MTU Maintenance Zhuhai

Service Center AmericasMTU Maintenance Canada

Regional coverage – Accessory and LRU Service Centers

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One-stop shop solutions for engine accessories

While other maintenance providers source outthe repair of engine accessories and QuickEngine Change (QEC) items to third parties,MTU Maintenance offers one-stop maintenanceservices for accessories. The in-house capa-bilities that were originally developed to betterserve the company’s own network are nowalso being offered directly to airlines, overhaulshops and parts brokers.

One-stop systems expertiseMTU Repair Services offer a comprehensivespectrum of fast and reliable accessory re-pairs, which is constantly being widened andfine-tuned. Customers benefit from MTU’s ex-panded capabilities in several ways:

Accessory repair activities benefit greatly fromin-house development know-how, and manynew repair techniques for accessories havebeen introduced. Due to its long-standing ex-pertise and experience, both in engine MROas well as in parts and accessory repair, MTUMaintenance assumes overall system respon-sibility and provides a world-class service thatsubstantially reduces maintenance turnaroundtimes and costs.

MTU Maintenance now offers complete main-tenance solutions, covering engine and acces-sories. Customers can rely on a single pointof contact to resolve all their technical needs,thus reducing their administrative load.

A turbine starter test stand—part of MTU’s extensiveequipment.

MTU Maintenance offers a wide portfolio of in-house accessory repairs.

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Accessory repairs at MTU quality standards

MTU Maintenance performs repairs of thehighest quality that satisfy the most stringentstandards. A global company, MTU Mainte-nance holds certifications from the world’sthree most significant aviation authorities:EASA, FAA, and CAAC. Individual locations ad-ditionally hold all applicable approvals issuedin their respective countries and required fromtheir customers.

The customer’s needs for efficiency and cost-effective-ness are the driving force behind the work of MTUMaintenance.

In addition, the Hannover and Vancouver loca-tions are active members of the CoordinatingAgency for Supplier Evaluation (C.A.S.E.). Theagency has created an internationally recog-nized aviation quality standard, compliancewith which is regularly audited.

At all locations, work processes are clearlydefined and documented in integrated man-agement systems. Regular audits, optimiza-tions and re-certifications ensure high levelsof transparency and effectiveness.

MTU Aero Engines approvals and certificates:• IQNet Business Excellence Class (IBEC)• EMAS • GQA Certificate• OHSAS 18001:2007 • Production Organization Approval

according to EASA Part 21G • Design Organization Approval

according to EASA Part 21J • Maintenance Organization Approval

according to EASA Part 145 • Maintenance Organization Approval

according to CFR 145 • Maintenance Organization Approval

according to CCAR 145 • Aviation Organization for Military

Aircraft

MTU Maintenance Canada approvals and certificates:• Transport Canada (TCCA)• Approved Maintenance Organisation

(AMO)• Approved Training Organisation (ATO)• Civil Aviation Authority of Singapore

(CAAS)• Civil Aviation Department—Hong Kong

(CAD)

MTU Maintenance Hannoverapprovals and certificates:• OHSAS 18001:2007 • EMAS • AZWV • Design Organization Approval

according to EASA Part 21J • Maintenance Organization Approval

according to EASA Part 145 • Maintenance Organization Approval

according to CFR 145 • Maintenance Organization Approval

according to CCAR 145

ISO certified MTU Maintenance locations:

MTU Aero Engines:• ISO 9001:2008 • ISO 14001:2004 • EN 9100:2009

MTU Maintenance Canada:• ISO 9001-2008

MTU Maintenance Hannover:• ISO 9001• EN 9100 • EN 9110

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Actuator Fuel Shut OffFire DetectorHarness

Nomenclature

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Pressure Switch ●

CF3

4

CF6

-50

CF6

-80

CFM

56

GE

90

PW20

00

V25

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LM 2

500/

5000

/600

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Cabin Air Solenoid ValveHigh Stage Temperature Sensor ●

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Thermal Sensor ●

CoolerIDG HarnessIDG Oil Pressure Relief Valve

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Drain ModuleEngine Mount AftEngine Mount FwdHarnessTMF LeadVibration Pick-Up

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Bellcrank Vane SupportEngine Mount FwdFan Speed Trim Probe HarnessManifold AssemblyNozzle OilProbeSensorShrouded Fuel Nozzle Feeder TubeTube

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Actuator Variable GeometryData Entry PlugElectrical CableFilterFMUFuel PumpHarnessHMUManifold AssemblyMECNozzle FuelNozzle OilProbeSensorServo Fuel HeaterSwitchThermocoupleTubeValve

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In-house accessory maintenance, repair andoverhaul capability

Nomenclature CF3

4

CF6

-50

CF6

-80

CFM

56

GE

90

PW20

00

V25

00

LM 2

500/

5000

/600

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Pneumatic StarterSwitchValve Starter Control

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Harness ●

Actuator BallscrewActuator LPC MasterActuator LPC SlaveActuator Master BallscrewActuator VBVActuator VSVFeedback Cable VBV/VSVFlex ShaftSensorStop MechanismValveValve Actuator TCValve PlateValve TCC

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AccelerometerCableDetectorJunction BoxProbeSensorThermocoupleThermocouple HarnessThermocouple LeadThermocouple Twin ElementTransducer

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CoolerDetectorHeat ExchangerOil PumpOil TankSensorSwitchThermocoupleTransducerTransmitterValve

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Ignition ExciterIgnition Lead ●

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ATA 21-00-00 Air Conditioning

ATA 26-00-00 Fire Protection

ATA 24-00-00 Electrical Power

ATA 71-00-00 Power Plant

ATA 72-00-00 Engine

ATA 73-00-00 Engine Fuel and Control

ATA 74-00-00 Ignition

ATA 80-00-00 Starting

Wire List

ATA 75-00-00 Air

ATA 77-00-00 Engine Indication

ATA 79-00-00 Oil

ATA 29-00-00 Hydraulic Power

ATA 36-00-00 Pneumatic

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Accessory component andLRU support programs

As part of MTU’s Total Part Care (TPC®), aninnovative one-stop-shop service solution provided by MTU Maintenance for individualengine and industrial gas turbine parts, cus-tomers can adapt their specific repair needsto include full management of accessories andLine Replaceable Units (LRUs). Such integratedservice packages are the key to success, reli-able operations and short turn-around times.Furthermore, TPC® can assist the operator to streamline its organization and drive costreductions.

MTU Repair Services offers three basic levelsof accessory and LRU support. Each programcan be further adapted to satisfy the cus-tomers’ needs.

Level I MTU Maintenance acts as the operator’svendor during an off-wing engine shop visitat one of its facilities and offers fixed pricingfor all LRU and accessories handled duringa shop visit—including material supply andmajor repairs/overhauls.

Program benefitsMTU Maintenance ensures cost control andcost predictability for individual shop-visitrelated accessory management. Customersbenefit from MTU Maintenance’s in-depthengine MRO system knowledge and com-petence as well as access to its pool of newand used parts.

Level IIA Level II support program represents apartnership between MTU Maintenance andthe operator and offers a “one-stop-shop”solution for all accessory and LRU repairs,no matter whether they are removed duringline maintenance or during an off-wing shopvisit.

Program benefitsThe operator deals with one major supplierfor all his LRUs and accessories. MTU Main-tenance controls all vendors and passes onvolume discounts it is able to negotiate withits suppliers. In addition, MTU Maintenanceis able to offer fixed pricing for all majorcomponent workscopes. Due to a high levelof “no fault found” and customized work-scopes and by eliminating vendor adminis-tration, customers benefit from further costreductions.

Level III A Level III support program provides a fullyintegrated technical and logistical supportsolution for the operator.

Program benefitsOne vendor handles all LRUs and acces-sories removed during the engine shop visit.While vendor control is performed by MTUMaintenance, vendor administration for thecustomer is reduced to a minimum. In com-bination with a power-by-the-hour rate, costpredictability is further improved. Exchangeand material replacement programs areavailable and can be designed according tothe customer’s needs.

In combination with accessory support levelsII & III, customers are offered the ultimate LRUservice solution to keep their business up andrunning—24 hours a day, seven days a week.

The following options are available:

Pool access:Pool inventory will be put on stock at the world-wide network of MTU Maintenance facilities toguarantee a seamless up-front exchange pro-cess and support any customer LRU-removalsfor a determined parts list.

Main base kit (MBK):A quantity of determined accessories will belocated directly at the customer base to im-mediately support line maintenance events.

Pool access and MBK:A combination of both options to perfectlysupport the customer’s flight operations.

Integrated service packages are the key to success forthe operator.

GER

10/

15/M

UC

/000

00/D

E/EB

/E

An MTU Aero Engines Company

MTU Aero Engines GmbHDachauer Straße 66580995 Munich • GermanyTel. +49 89 1489-0Fax +49 89 1489-5500info@mtu.dewww.mtu.de

MTU Maintenance Hannover GmbHMünchner Straße 3130855 Langenhagen • GermanyTel. +49 511 7806-0Fax +49 511 7806-2111AOG +49 171 4314333hannover@mtu.dewww.mtu-hannover.de

MTU Maintenance Canada Ltd.6020 Russ Baker Way Richmond, BC V7B 1B4 • CanadaTel +1 604 233-5700 Fax +1 604 233-5701accessories@mtucanada.comwww.mtu-canada.com

MTU Repair ServicesTel +49 511 7806-4084Fax +49 511 7806-4772AOG +49 171 4314333partsrepair@mtu.de

Sales North America Tel +1 678 362-7811 Fax +1 770 569-7524

Sales South AmericaTel +1 706 761-5471Fax +1 770 569-7524

Sales Europe/Middle East/Asia Tel +49 89 1489-6718Fax +49 89 1489-95195AOG +49 171 7344 333