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FJ44-2C
LINE MAINTENANCE MANUAL
- FJ44-2C
Initial Issue:
Jul 01/00
WI P/N 64135
Revision 42
Page 2
00-Titlepage Blank
LINE MAINTENANCE MANUAL - FJ44-2C
SUMMARY OF CHANGES
FJ44-2C Line Maintenance Manual - FJ44-2C
P/N 64135
701 701 71-00-03 71-00-03-170-803 Clean the Power Plant – Compressor Wash
(1) Changed step order - washing the fan and
bypass area precedes washing the compressor
core. (2) Added step to inspect rinse water for the
presence of cleaning fluid.
201 201 71-00-23 71-00-23-620-804 Installed Engine Preservation - Nine Months or
Less
Changed the note directing external engine
cleaning to refer to cleaning methods and
procedures, 70-21-00.
201 201 71-00-25 71-00-25-510-804 Engine Shipping
Added reference to engine preservation task for
MPI engine removal, and W.I. contact task for all
others.
401 401 72-00-60 72-00-60-020-801 Remove the Gearbox Assembly
Added note to use a plastic gasket scraper to
remove the gearbox gasket.
401 401 73-12-01 73-12-01-050-801 Remove the Fuel Nozzle Assembly
Changed tool nomenclature for TL37212 - Socket,
Fuel Nozzle Adapter.
601 601 73-12-01 73-12-01-730-801 Check Fuel Nozzle Spray Pattern
Added dry cleaning solvent (MAT-024) as optional
fluid for performing fuel nozzle spray pattern check.
601 601 74-22-01 74-22-01-220-801 Visually Inspect the Igniter Plugs
Added criteria to audibly check for cracked ceramic
by shaking the igniter plug.
401 401 75-35-01 75-35-01-450-802 Install the Acceleration Bleed System Lever
Revised instructions and illustration for installation
of acceleration bleed cable ball end to reflect new
retaining pin configuration.
401 401 75-37-01 75-37-01-050-802 Remove the Acceleration Bleed System Cable
Revised instructions and illustration for removal
of acceleration bleed cable ball end to reflect new
retaining pin configuration.
401 401 75-37-01 75-37-01-450-802 Install the Acceleration Bleed System Cable
Revised instructions and illustration for installation
of acceleration bleed cable ball end to reflect new
retaining pin configuration.
401 401 77-20-02 77-20-02-050-801 Remove the ITT Probes
Added note stating that MAT-005 can be applied to
assist in the disassembly of seized ITT probes.
TABLE OF CONTENTS
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
RECORD OF REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INTRODUCTION
STANDARD PRACTICES
ASSEMBLY/DISASSEMBLY MAINTENANCE
PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-00-01
Assembly/Disassembly Maintenance
Practices - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Page i
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Page ii
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
POWER PLANT
Page iii
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-00
Engine - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Page iv
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-30
Spinner - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-30-10
Spinner - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Spinner - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
Page v
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Page vi
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
IGNITION
AIR
Page vii
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
ENGINE CONTROLS
ENGINE INDICATING
Page viii
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
OIL
Page ix
Table of Contents Dec 12/17
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Page x
Table of Contents Dec 12/17
RECORD OF REVISIONS
Page 1
Dec 12/17
Page 2
Dec 12/17
None
Page 1
Dec 12/17
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
CHAPTER 00
INTRODUCTION
Page 1
00-INTRODUCTION Dec 12/17
Page 2
00-INTRODUCTION Blank
LINE MAINTENANCE MANUAL - FJ44-2C
Chapter 00
List of Effective Page Blocks
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Chapter 00
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
SUBTASK 00-00-00-860-106
A. This manual (P/N 64135) contains maintenance information prepared for the Williams International
FJ44-2C turbofan engine by Williams International.
This manual is part of the Instructions for Continued Airworthiness (ICA). Deviations from the ICA
procedures and inspections may warrant additional analyses to assess the potential effect on
airworthiness characteristics.
SUBTASK 00-00-00-860-107
A. The manual is written to A.T.A. Specification No. 100 (Revision 28). The contents are organized
using the three element (six digit) Chapter-Section-Subject number (CH-SE-SU). The first element is
the Chapter, the second element is the Section, and the third element is the Subject.
(1) The chapter number and the first digit of the section number are assigned by the ATA
100 specification. This promotes continuity of contents between the manuals of different
manufacturers.
(2) The second digit of the section number and the subject number are assigned by the
manufacturer to identify the subject component with a unique designation.
(4) This numbering system is adjusted to identify removal/installation of core engine modules. This
allows engine build-up tasks to be grouped together in the manual. In these cases, the Section
number is moved to the third element and "00" is used for the second "middle" element.
B. Contents are further divided within a CH-SE-SU number by topic. Each topic is identified by a
separate range of page numbers. These Page Blocks organize the task information within a Subject.
A full list of topic Page Blocks for this manual are:
EFFECTIVITY: FJ44-2C
00-00-00
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C. This manual is written to conform to the requirements of the Aircraft Maintenance Task Oriented
Support System (A.M.T.O.S.S.). This system is designed to facilitate automated data retrieval. Each
Page Block task is divided into Tasks and Subtasks which carry an A.M.T.O.S.S. number in bold
print. A.M.T.O.S.S numbers are an expansion of the ATA 100 CH-SE-SU number and provide a
numerical identity for work requirements. They are assigned as follows:
ELEMENT NUMBER: 1 2 3 4 5
Element 5 Numeric Indentifier - Used to make similarly numbered tasks and subtasks unique
Table 2 Function Codes for A.M.T.O.S.S. Task/Subtask Numbering (Fourth Element - 72-00-00-XXX-000)
Code Description
000 Disassemble (General)
010 Remove Engine
020 Remove Engine Modular Sections
030 Disassemble Engine Modular Sections
040 Disassemble Engine Subassemblies
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630 Depreserving
730 Fuel Flow Testing
750 Electrical Testing
760 Engine Testing
770 Accessory Testing
780 Pressure Check
810 Fault Isolation
820 Adjust/Align/Calibrate
830 Rigging
860 Description and Operation
870 Maintenance Practices
940 Balance
941 Standard Equipment
942 Consumables
943 Special Tools
944 Expendable Parts
945 Reference Information
3. Revisions
SUBTASK 00-00-00-860-108
The List of Effective Page Blocks will list the correct date for each page block within the Chapter.
(1) For CD-ROM/On-line distribution, revised text will not have any revision bars adjacent to the
text. A new CD-ROM will be issued for each revision. The Transmittal Letter (in the PDF
version) and the Revision and Changes (in the electronic version) will document all changes for
each revision.
B. If you suspect that the manual you are using is not current, do not use the procedures. Contact
Williams International immediately for a listing and/or copy of the current revision. Refer to task
00-00-00-860-829 for instructions for contacting Williams International Product Support.
EFFECTIVITY: FJ44-2C
00-00-00
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C. If you find an error in this manual or feel that important information has been left out, please submit
your comments to Williams International Product Support as described in task 00-00-00-860-829.
SUBTASK 00-00-00-860-109
A. The instructions for maintenance and maintenance practices of the engine contained in this manual,
particularly those related to removal, installation, and repair of critical (life-limited) parts, have been
written to keep parts in serviceable condition during their service lives.
B. Instructions are written to permit, wherever possible, the use of standard shop practices when doing
tasks. However, where instructions are specific as to means and method, it is important that you do
not use alternate methods unless alternatives are agreed upon with Williams International. Even
minor deviations from manual instructions may require careful evaluation to avoid abuse, which
may not be detectable by routine inspection.
C. Where changes to the specified instructions or standards are required and cannot be approved at
the originating source under the terms of approval granted by the appropriate regulatory authority,
then details of the required technical variance should be submitted to Williams International for
consideration.
D. To comply with the certification and recording requirements involved in revisions or amendments to
manual instructions, Williams International in approving a submission, will provide to the originating
source a Technical Variance document and covering Temporary Revision as proof of approval.
E. It is the responsibility of the originating source to record and preserve these documents in a manner
and locality which complies with appropriate regulatory authority requirements.
F. These instructions are written to return engines and hardware to service when used in normal
operations. Aircraft accidents/incidents induce additional investigation requirements which are
not covered in these instructions. For Williams International policy involving engines that were
installed on an aircraft that experienced an accident/incident please contact Williams International
Product Support.
5. References
SUBTASK 00-00-00-860-110
A. The following manuals are referenced in the text and are to be used along with this Maintenance
Manual:
EFFECTIVITY: FJ44-2C
00-00-00
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The IPC shows the relationship of all parts and assemblies and lists all part numbers.
References to specific parts for maintenance use (found under the Equipment and Materials
listing at the front of each task) are by IPC figure and item number.
B. Consumable materials are assigned a MAT number and are listed under Equipment and Materials at
the front of each task. A complete listing of consumable materials is found in 70-10-01, P.B. 201.
6. General
The FJ44-2C is a two-spool co-rotating, axial flow turbofan engine with medium bypass ratio, mixed
exhaust, and high cycle pressure ratio. The engine produces a minimum of 2400 pounds of takeoff thrust,
uninstalled at sea level, at an ambient temperature of 72°F.
Engine control is provided by an integrated fuel control unit (IFCU). Thrust is managed through power
lever input to the IFCU which is mounted to and driven by the engine gearbox.
7. Major Components
SUBTASK 00-00-00-860-001
A. The FJ44-2C is comprised of five distinct groups: LP shaft module, fan group, core module, LP
turbine group and accessory gearbox.
The LP shaft module consists of the LP shaft, the No.1 and No. 1.5 bearing supports, the No. 1
ball bearing, and No. 1.5 roller bearing, and No.1 carbon seal.
B. The fan group consists of the spinner, the fan rotor, the fan housing and fan stator, the 3-stage IP
compressor, and the IP stator stages.
C. The core module is made up of the interstage housing with integral oil tank and first reduction bevel
gear, the high pressure compressor (HPC) and compressor cover, the HP shaft, pinion gear and No.
2 ball bearing, the diffuser assembly, combustor cover assembly, fuel manifold and seal assembly,
fuel slinger and seal, and HP turbine nozzle and primary plate assembly, the HP turbine, and the first
low pressure turbine (LPT) nozzle, including the No. 3 and No. 4 roller bearings and seals.
D. The LP turbine group consists of the LP turbine module (first stage LP turbine rotor, the second stage
LP turbine nozzle assembly, the second stage LP turbine rotor), rear housing, a heat exchanger,
and the rear case with exhaust mixer.
E. The fifth group is the accessory gearbox module and engine mounted accessories.
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Page 7
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8. General
EFFECTIVITY: FJ44-2C
00-00-00
Page 9
Dec 12/17
Abbreviation Definition
hr hour
HSI Hot Section Inspection
ID inner diameter
IFCU integrated fuel control unit
Inc incorporated
IP intermediate pressure
IPC Illustrated Parts Catalog
IPM integrated propulsion module
ITT interturbine temperature
LH left-hand
LMM Line Maintenance Manual
LP low pressure
LPT low pressure turbine
max maximum
MAT Consumable Material Code (Ref. 70-10-01)
MHRV metering head regulating valve
min minimum
ml milliliters
mm millimeters
MM Maintenance Manual
MPI Major Periodic Inspection
MRV motive regulating valve
NDI non-destructive inspection
N.m Newton-Meter
N1 low pressure rotary group shaft speed
N2 high pressure rotary group shaft speed
OAT outside air temperature
OD outer diameter
OEI One Engine In-Operative
P pressure
EFFECTIVITY: FJ44-2C
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Abbreviation Definition
PB Page Block
pH hydrogen-ion concentration
PLA power lever angle
PMA permanent magnet alternator
P/N part number
ppm parts per million
PRESS pressure
PRSOV pressure regulating shutoff valve
psi pounds per square inch
psid pounds per square inch differential
psig pounds per square inch gauge
PSOV pressurizing shutoff valve
PT2 total inlet pressure
QPM Quiet Power Mode
RH right-hand
rpm revolutions per minute
RV relief valve
sec second
S/G starter/generator
SOV shut-off valve
SP Standard Practices
spec specification
S/N serial number
SSL safe service life
SYNC synchronization
T temperature
TBO time between overhaul
TEMP temperature
TOBI tangential on-board injection
TT2 total inlet temperature
EFFECTIVITY: FJ44-2C
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Abbreviation Definition
UV ultraviolet
V velocity
WI Williams International, Inc.
°C degrees Celsius
°F degrees Fahrenheit
% percent
9. General
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FJ44-72-079 No Effect
FJ44-72-080 No Effect
FJ44-72-085 No Effect
FJ44-72-086 No Effect
FJ44-72-098 No Effect
FJ44-72-104 No Effect
FJ44-72-105 No Effect
FJ44-72-106 No Effect
FJ44-72-107 No Effect
FJ44-72-108 No Effect
FJ44-72-109 No Effect
FJ44-72-111 No Effect
FJ44-72-119 No Effect
FJ44-72-123 No Effect
FJ44-72-126 No Effect
FJ44-72-129 No Effect
FJ44-72-134 No Effect
FJ44-72-140 No Effect
FJ44-72-142 No Effect
FJ44-72-143 No Effect
FJ44-72-147 Incorporated
FJ44-72-149 No Effect
FJ44-72-150 No Effect
FJ44-73-016 No Effect
FJ44-73-018 No Effect
FJ44-73-130 No Effect
FJ44-74-004 No Effect
WISB-75-1000 Incorporated
FJ44-77-005 No Effect
FJ44-79-007 No Effect
EFFECTIVITY: FJ44-2C
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FJ44-79-011 No Effect
FJ44-79-012 No Effect
FJ44-79-015 No Effect
10. General
Williams International provides full technical support for all of our products. In order to give you the best
possible service, we ask that you use the methods below, in the order shown, to contact our Technical
Representatives:
1. Submit your question or issue to Williams International Product Support by using the “Ask a
Question” feature of our website at www.williams-int.com.
EFFECTIVITY: FJ44-2C
00-00-00
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CHAPTER 05
05-10-00 201 Dec 12/17 05-17-10 201 Dec 12/17 05-50-00 201 Dec 12/17
05-12-00 201 Dec 12/17 05-20-00 601 Dec 12/17
Chapter 05
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 05
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16
and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
This task gives the maximum approved lives for life-limited parts. Do not allow parts to exceed these
approved lives.
CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.
SUBTASK 05-10-00-870-019
A. Engine operating life limits are determined by mechanical and thermal stresses which occur during
engine operation. It is therefore necessary to record flight cycles (both partial and full) in addition to
operating hours. The total true cycles will be the sum of the number of full and partial cycles accrued
during each flight and must be recorded in the aircraft log book for each individual engine at the
completion of each flight. Cycles will be computed as follows:
Full Cycle: Engine start, takeoff power setting, followed by engine shutdown, regardless of duration.
B. Partial Cycle:
(2) Full stop landing without engine shutdown shall be recorded as .50 cycle.
(3) Ground Running: Idle to max continuous thrust shall be recorded as .50 cycle.
(4) Throttle movement associated with low approaches are not counted as cycles.
EFFECTIVITY: FJ44-2C
05-10-00
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SUBTASK 05-10-00-870-020
A. Refer to table 201 for the component name, part number, and approved part life.
EFFECTIVITY: FJ44-2C
05-10-00
Page 202
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B. The following critical non-life-limited engine parts table 202 have been developed based on
engineering analysis that assumes this product will be operated and maintained using the procedures
and inspections provided in the Instructions for Continued Airworthiness supplied with this product
by the type certificate holder. Repairs or alterations to the following parts using other data warrant
additional analyses to assess the potential effect on airworthiness characteristics.
SUBTASK 05-10-00-870-021
A. The safe service lives (SSLs) for each of the critical parts listed under Airworthiness Limitations are
calculated based on the flight profile duty cycle shown in Figure 201. It is in the Owner/Operator’s
interest to monitor his own flight profile and notify Williams International if:
(1) The average profile of his operation exceeds, at any point, the power settings shown in Figure
201.
(2) The average profile of his operation exceeds the profile shown in Figure 201 for the number of
times the power setting goes from low to high to low (as in a touch-and-go).
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SUBTASK 05-10-00-870-022
CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.
A. Time in service, with respect to maintenance time records, means the time from the moment an
aircraft leaves the surface of the runway until it touches it at the next point of landing. Engine
operating hours and Flight Hours shall be considered the same as aircraft time in service.
SUBTASK 05-10-00-870-023
A. The critical parts listed under the Airworthiness Limitations, 5-10-00, P.B. 201, are part of a life
management program that validates the declared life declarations through component technical life
reviews. The program consists of component inspections at 1/3 service life, 2/3 service life, and at
the end of each component’s service life as defined in Figure 201, as well as inspection of other
engine components that are accessed during these component inspections. The life management
plan applies to all Life-Limited Parts defined in Figure 201.
This program applies to those engines which are the fleet leaders in regards to flight cycles. The fleet
leaders are defined as the six engines in the fleet that have the highest number of flight cycles. Fleet
leaders can change over the course of time, depending upon individual engine usage.
For purpose of illustration, the life management inspection intervals for the fan rotor are defined as
2000, 4,000 and 6000 flight cycles. This is based on a service life of 6000 cycles. The six engines
that reach each inspection interval first will be part of the life management program inspection.
Williams International will monitor fleet usage to determine which engines will be effected by the life
management program. Owners / Operators that are effected will be contacted and arrangements
made for component / engine inspections.
EFFECTIVITY: FJ44-2C
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05-10-00
206
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Since critical parts cannot be practicably marked to track service history or life, a record system must be
kept to ensure that they don’t exceed their safe service lives (SSL).
2. Life Recording
SUBTASK 05-12-00-870-002
An internal record system must be maintained for the life-limited parts designated in Airworthiness
Limitations 05-10-00, P.B. 201. This includes parts held serviceable in stores pending issue to an
assembly/engine. As these records are important to controlling the part’s life, they must be accurate
and up-to-date.
(1) Record the part number, serial number and life status of the part against the part’s total life.
Recording is logged numerically by flight cycles and/or hours, as applicable.
B. When a life-limited part is rejected, record engine and component hours and cycles on Component
Life Limited card. Component Life Limited card should be stored with component.
C. Before refitting a life-limited part to the engine, calculate its remaining life to determine if it has
sufficient life to re-install into the engine.
CAUTION SERVICE LIVES FOR PARTS ARE DECLARED IN OPERATING HOURS AND/OR
FLIGHT CYCLES. REFER TO AIRWORTHINESS LIMITATIONS (05-10-00, P.B. 201)
TO DETERMINE THE SERVICE LIFE FOR A PART AND HOW IT IS MEASURED.
D. After fitting a life-limited part into the engine, record engine hours and cycles on the Component
Life Limited card.
EFFECTIVITY: FJ44-2C
05-12-00
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05-12-00
202
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task references information about specific FJ44 engine assemblies and engine parts which Williams
International has declared are unserviceable and not approved for use.
2. Unserviceable Parts
SUBTASK 05-17-10-870-001
A. Refer to Williams International Service Bulletin FJ44-05-002 for a detailed listing of:
FJ44 engine assemblies (listed by part number/serial number) which are unserviceable and
not approved for use.
FJ44 engine parts (listed by part number/serial number) which are unserviceable and not
approved for use. This listing also includes the engine part number/serial number from which
the part was removed.
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05-17-10
202
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains intervals for routine and major periodic inspection of the engine and requirements for
routine periodic inspections. Refer to the following:
table 606
NOTES: 1 The time limits in this schedule are the minimum necessary to keep
an engine in serviceable condition.
SUBTASK 05-20-00-210-020
C. Hourly - Special inspection or maintenance at the engine operating hours interval shown.
E. Check 2 - Inspections at every 600 engine operating hours, but no more than 300 engine operating
hours after Check 1 was performed.
SUBTASK 05-20-00-210-014
A. Major Periodic Inspections are performed at intervals of engine operating hours. The intervals
for specific engines are determined by: (1) engine maintenance program enrollment, and (2)
incorporation of certain Service Bulletins.
EFFECTIVITY: FJ44-2C
05-20-00
Page 601
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B. To determine Major Periodic Inspection intervals for specific engines, answer the questions in table
601, below, and follow the reference to the applicable table.
START
↓
Engine requires 1750 hour Major Periodic
Is engine enrolled in Total Assurance NO
Inspection Intervals as defined in table 603,
Program (TAP) or TAP Advantage? →
below.
YES
↓
Is engine included on the Effectivity list for
Engine requires 2500 hour Major Periodic
any of the Service Bulletins listed in table NO
Inspection Intervals as defined in table 605,
602, below? (Refer to Service Bulletin for →
below.
specific engine serial number effectivity).
YES
↓
Has engine complied with all of the Service Engine requires 2000 hour Major Periodic
NO
Bulletins from table 602 which it is affected Inspection Intervals as defined in table 604,
→
by? below.
YES
↓
Engine requires 2500 hour Major Periodic
Inspection Intervals as defined in table 605,
below.
EFFECTIVITY: FJ44-2C
05-20-00
Page 602
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Table 603 Major Periodic Inspections for Engines Which Require 1750 Hour Interval
The Major Periodic Inspection intervals shown in this table are applicable only to engines which require a
1750 hour interval as defined in table 601
NOTE If engine has accumulated 1750 engine operating hours after Check 3/5/7 was performed
but has not accumulated 3500 operating hours since new or after Check 4/6/8, then Check
3/5/7 may be repeated. Check 4/6/8 must still be performed at the 3500 hour interval.
Check 3 Perform inspection at 1750 engine operating hours.
Check 4 Perform inspection 1750 engine operating hours after Check 3 was performed, but
no later than 3500 total operating hours (whichever occurs first).
Check 5 Perform inspection 1750 engine operating hours after Check 4 was performed.
EFFECTIVITY: FJ44-2C
05-20-00
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Table 603 Major Periodic Inspections for Engines Which Require 1750 Hour Interval (Continued)
Check 6 Perform inspection 1750 engine operating hours after Check 5 was performed, but
no later than 3500 hours after Check 4 (whichever occurs first).
Check 7 Perform inspection 1750 engine operating hours after Check 6 was performed.
Check 8 Perform inspection 1750 engine operating hours after Check 7 was performed, but
no later than 3500 hours after Check 6 (whichever occurs first).
Table 604 Major Periodic Inspections for Engines Which Require 2000 Hour Interval
The Major Periodic Inspection intervals shown in this table are applicable only to engines which require a
2000 hour interval as defined in table 601
NOTE If engine has accumulated 2000 engine operating hours after Check 3/5/7 was performed
but has not accumulated 4000 operating hours since new or after Check 4/6/8, then Check
3/5/7 may be repeated. Check 4/6/8 must still be performed at the 4000 hour interval.
Check 3 Perform inspection at 2000 engine operating hours.
Check 4 Perform inspection 2000 engine operating hours after Check 3 was performed, but
no later than 4000 total operating hours (whichever occurs first).
Check 5 Perform inspection 2000 engine operating hours after Check 4 was performed.
Check 6 Perform inspection 2000 engine operating hours after Check 5 was performed, but
no later than 4000 hours after Check 4 (whichever occurs first).
Check 7 Perform inspection 2000 engine operating hours after Check 6 was performed.
Check 8 Perform inspection 2000 engine operating hours after Check 7 was performed, but
no later than 4000 hours after Check 6 (whichever occurs first).
Table 605 Major Periodic Inspections for Engines Which Require 2500 Hour Interval
The Major Periodic Inspection intervals shown in this table are applicable only to engines which require a
2500 hour interval as defined in table 601
NOTE If engine has accumulated 2500 engine operating hours after Check 3/5/7 was performed
but has not accumulated 5000 operating hours since new or after Check 4/6/8, then Check
3/5/7 may be repeated. Check 4/6/8 must still be performed at the 5000 hour interval.
Check 3 Perform inspection at 2500 engine operating hours.
Check 4 Perform inspection 2500 engine operating hours after Check 3 was performed, but
no later than 5000 total operating hours (whichever occurs first).
Check 5 Perform inspection 2500 engine operating hours after Check 4 was performed.
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Table 605 Major Periodic Inspections for Engines Which Require 2500 Hour Interval (Continued)
Check 6 Perform inspection 2500 engine operating hours after Check 5 was performed, but
no later than 5000 hours after Check 4 (whichever occurs first).
Check 7 Perform inspection 2500 engine operating hours after Check 6 was performed.
Check 8 Perform inspection 2500 engine operating hours after Check 7 was performed, but
no later than 5000 hours after Check 6 (whichever occurs first).
SUBTASK 05-20-00-210-037
5. Storage Limits
SUBTASK 05-20-00-210-023
NOTE Storage shelf life limits are the maximum allowable when the unit is packaged
and stored per the component maintenance manual specification requirements.
If storage time limits for the following components are exceeded, contact
Williams International Product Support per 00-00-00-860-829.
SUBTASK 05-20-00-943-004
A. Refer to 70-53-00 P.B. 201 for maintenance and calibration requirements for special tools.
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7. Job Set-up
SUBTASK 05-20-00-010-004
(2) Open the cowl doors. Refer to the Aircraft Maintenance Manual.
SUBTASK 05-20-00-210-024
A. Do the inspection checks at the time interval given. Refer to table 606.
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9. Job Close-up
SUBTASK 05-20-00-410-004
(1) Close the cowl doors. Refer to the Aircraft Maintenance Manual.
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1. General
The following guidelines have been established to help minimize corrosion or similar type environmental
effects on engine hardware. The following guidelines for Water Rinse frequency are considered to be the
minimum necessary. It is the operator’s responsibility to determine, based on their operating environment,
the Water Rinse frequency required to prevent deterioration of engine hardware. Additional general
corrosion control information and geographical corrosive environments can be found in Federal Aviation
Administration Advisory Circular AC43-4A. If assistance is needed in establishing these preventative
measures please contact Williams International Product Support.
2. Water Rinse
SUBTASK 05-50-00-870-002
A. Perform this fresh water rinse procedure to remove salt or other corrosive substances from
the interior of the engine (71-00-03 P.B. 701). Operating or storing your engine in a corrosive
environment may initiate corrosion on engine hardware. Water rinsing the engine, as soon after
contamination as possible, minimizes the initiation of corrosion by helping to dissolve and flush out
contaminants. Running the engine immediately after rinsing drives out the water and the majority of
the contaminants. This will also eliminate the moisture that could set up galvanic cells and initiate
surface pitting and crevice corrosion.
NOTE Operation in a marine atmosphere is typically defined as operation over salt water
or within 5 miles (8 kilometers) of a body of salt water. The actual boundaries of
a marine atmosphere can be affected by weather patterns and winds.
(1) If the aircraft is operated in any of the flight conditions listed below, perform the water rinse
procedure at the end of flight operations for the day:
(a) In a marine atmosphere below 4000 feet for more than 30 minutes.
(b) Smog-laden environment or where there is known local air quality issues.
(2) If the aircraft is operated in any of the flight conditions listed below, perform the water rinse
procedure at least once per week:
(a) In a marine atmosphere below 4000 feet for less than 30 minutes.
(3) If the aircraft is not going to be utilized for an extended period of time, you should water rinse
the engine prior to initiating storage. Be sure to run the engine sufficiently to dry all moisture
prior to storage. See chapter 71-00-23 of this manual for additional storage procedures.
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3. Compressor Cleaning
SUBTASK 05-50-00-870-003
A. Perform compressor cleaning procedure (using an approved engine cleaning fluid) to improve
compressor efficiency by removing normal accumulations of dirt and grime (71-00-03, P.B. 701).
If engine performance has gradually degraded (increase in ITT, increase in N2, increase in fuel
consumption), perform the compressor cleaning procedure.
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CHAPTER 70
STANDARD PRACTICES
Page 1
70-STANDARD PRACTICES Dec 12/17
Page 2
70-STANDARD PRACTICES Blank
LINE MAINTENANCE MANUAL - FJ44-2C
70-00-01 201 Dec 12/17 70-10-01 201 Dec 12/17 70-42-11 801 Dec 12/17
70-01-05 201 Dec 12/17 70-12-00 201 Dec 12/17 70-42-12 801 Dec 12/17
70-01-07 201 Dec 12/17 70-12-04 201 Dec 12/17 70-42-15 601 Dec 12/17
70-01-11 201 Dec 12/17 70-21-00 701 Dec 12/17 70-51-00 201 Dec 12/17
70-02-01 201 Dec 12/17 70-31-01 201 Dec 12/17 70-53-00 201 Dec 12/17
70-04-01 201 Dec 12/17 70-33-01 601 Dec 12/17 70-61-01 201 Dec 12/17
Chapter 70
List of Effective Page Blocks
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Dec 12/17
Chapter 70
List of Effective Page Blocks
Page 2
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Standard maintenance practices for engine maintenance are provided in this task. These practices
are recommended by the engine manufacturer.
SUBTASK 70-00-01-941-001
A. Standard Equipment
Handheld Surface Temperature Probe
Induction Coil
Oven
Heat Gun
SUBTASK 70-00-01-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-004 Oil, Corrosion Preventive
MAT-005 Oil, Penetrating
MAT-011 Assembly Fluid, No. 1
MAT-072 Gloves, Plastic, Disposable, Rubber Vinyl
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SUBTASK 70-00-01-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-01-05 201 Temporary Marking of Parts - Maintenance Practices
70-10-01 201 Consumable Materials - Maintenance Practices
SUBTASK 70-00-01-870-003
A. Use the following general procedures for disassembly and removal of engine and accessory
components.
(1) Review maintenance tasks to be performed in full using the Line Maintenance Manual before
doing the work. Verify all required tooling and consumables for the given task are on-hand
before beginning the work.
(2) Whenever accessed, examine all visible components for signs of burning, scoring, chafing,
evidence of leaks and other defects. These signs may not be apparent after components are
cleaned. Parts and components that are unserviceable must have the defect area marked for
investigation and/or possible repair. Refer to Temporary Marking of Parts, 70-01-05, P.B.
201, for approved marking methods.
(3) Cover all ports, and openings, of tubes and assemblies when performing any maintenance
action to prevent contamination.
(4) Place disassembled components on a clean workbench in order of disassembly. Tag and
mark all parts as to their location. Put small parts in trays or cups to prevent loss or damage.
Clean small parts in trays.
(5) Coat all steel parts with corrosion preventive oil, MAT-004, after disassembly, unless cleaning
and inspection procedures are to begin immediately. Place disassembled components on a
storage rack, covering parts with plastic sheets or protective covers to prevent contamination.
Use protective cases for rotors.
(a) A penetrating oil, MAT-005, can be applied at disassembly to allow careful removal of
seized engine components.
(6) Record thickness and quantity of all shims and spacers removed. Tag with location for
reference during assembly procedures.
(7) Do not use a scribe to mark any rotating components. Use approved marking pencil or marker
only and the methods for marking as given in Temporary Marking of Parts, 70-01-05.
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(8) Tube assemblies, riveted assemblies, threaded inserts and fasteners, etc., are not normally
dismantled. Unless specified in the disassembly procedures, such items will be dismantled
for repairs only.
(9) Discard all gaskets, packings, O-rings and rubber parts at each disassembly. Make sure new
parts to be installed have no signs of deterioration from storage.
B. When heating parts to assist in assembly/disassembly, make sure that you do not exceed the
maximum temperature listed for the operation. When cooling parts, make sure you follow specific
procedures. Excessive heating or cooling may impact material properties.
(1) Oven: An oven used to heat components during assembly/disassembly must be clean, have
current calibration and must be able to maintain uniformity of heating to ± 25°F.
(2) Heat Gun: A heat gun used to heat a component during assembly/disassembly must be clean
and well maintained. A handheld surface temperature probe must be used to determine part
surface temperature.
(3) Induction Heating: An induction coil used to heat a component during assembly/disassembly
must be clean and well maintained. The coil must be sized for the specific joint being heated. A
handheld surface temperature probe must be used to determine part surface temperature.
C. Inspection requirements for specific components which are listed as “interface inspection only”,
are limited to visual inspection of the assembled component or module. Some features of the
components which are listed in the detailed inspection criteria are not accessible or visible when the
module is assembled. Interface inspection is limited to visible/accessible features only. Disassembly
is required if a part must be replaced or further inspection is needed.
SUBTASK 70-00-01-870-004
A. Use the following general procedures for assembly and installation of engine and accessory
components. Refer to the Consumable Materials Listing 70-10-01, P.B. 201for applicable materials.
(1) Review maintenance tasks to be performed in full using the Line Maintenance Manual before
doing the work. Verify all required tooling and consumables for the given task are on-hand
before beginning the work.
(2) Before assembling or installing any part, make sure it is thoroughly clean. Use care to prevent
unwanted particles, dirt, or dust from entering the engine. If any attaching parts (i.e., screws,
washers, nuts) or unwanted matter are dropped into the engine during maintenance, stop work
immediately and remove object from engine.
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(3) Use protective closures and covers on large openings. Cap open tube ends to prevent
contamination. Do not leave engine unattended without covering.
(4) You must maintain the highest standards of precision shop practices during all stages of
assembly. Close attention to detailed procedures is required.
(5) Support equipment must be cleaned before and after use to prevent any dirt or metal build-up
that may transfer to engine components.
(6) Lube all O-rings and packings with a light coat of engine oil MAT-001 or assembly fluid
MAT-011,per the maintenance procedures, prior to installation. Lube bearings with engine oil,
MAT-001 . The gearbox/interstage gasket is installed clean and dry (no lubricant required).
(7) During assembly, lube all fastener threads and bearing surfaces with engine oil MAT-001.
Deviations from this practice will be specified within the specific instruction.
(8) Parts coated with a corrosion preventive compound, MAT-004, must be cleaned of unwanted
compound and matter that has collected on it before assembling part in engine.
(9) Do not handle bearings with bare hands. To prevent fingerprint damage, always handle
bearings with plastic-type gloves MAT-072.
(10) Each specific maintenance task specifies torque values as applicable. When torque values are
not specified, use standard shop practices or these sources: FAA Manual AC65-9, Airframe
and Powerplant Mechanics General Handbook.
(11) During engine build, check all part numbers with the Illustrated Parts Catalog (IPC) and record
serial numbers of all serialized parts in the engine logbook.
(12) Before installing engine cowlings and enclosures, inspect all visible components for signs of
burning, scoring, chafing, evidence of leaks and other defects.
(13) Conical seals are not approved for use with flare fitting-type tube assemblies.
B. When heating parts to assist in assembly/disassembly, make sure that you do not exceed the
maximum temperature listed for the operation. When cooling parts, make sure you follow specific
procedures. Excessive heating or cooling may impact material properties.
(1) Oven: An oven used to heat components during assembly/disassembly must be clean, have
current calibration and must be able to maintain uniformity of heating to ± 25°F.
(2) Heat Gun: A heat gun used to heat a component during assembly/disassembly must be clean
and well maintained. A handheld surface temperature probe must be used to determine part
surface temperature.
(3) Induction Heating: An induction coil used to heat a component during assembly/disassembly
must be clean and well maintained. The coil must be sized for the specific joint being heated. A
handheld surface temperature probe must be used to determine part surface temperature.
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C. When installing a serviceable part from a different engine, refer to 05-20-00, P.B. 601 and determine
all routine and major periodic inspection requirements for the part. Check inspection history for the
used part you are installing and make sure that it will not reach the required interval before the
engine is due for inspection.
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206
Page
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1. General
This task defines the acceptable materials for the temporary marking of parts.
SUBTASK 70-01-05-942-001
A. Consumables
Reference Designation
MAT-030 Pencil, Silver
MAT-032 Marker, Broad Line
MAT-033 Marker, Fine Line
SUBTASK 70-01-05-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-10-01 201 Consumable Materials - Maintenance Practices
3. Procedures
SUBTASK 70-01-05-870-001
3 ALL MARKS MADE WITH FELT TIP MARKER MAT-032 OR MAT-033 MUST
BE REMOVED BEFORE PARTS ARE EXPOSED TO TEMPERATURES
ABOVE 400°F (204°C) OR ARE ASSEMBLED ON ENGINES
A. During maintenance, it may be necessary to mark certain parts to highlight defects or aid in assembly.
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B. Use the materials listed under Consumable Materials (above) for temporary marking of parts. These
are detailed in the Consumable Materials Listing, 70-10-01, P.B. 201.
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1. General
This task provides the standard practices for marking of repaired parts.
Figure 201
SUBTASK 70-01-07-941-001
A. Standard Equipment
Electrochemical Etch Marking Equipment
Vibro-Engraving Tool
SUBTASK 70-01-07-942-001
B. Consumables
Reference Designation
MAT-004 Oil, Corrosion Preventive
MAT-050 Coating, Chemical Conversion (Iridite)
3. Procedures
SUBTASK 70-01-07-870-001
A. Parts which have been subjected to certain repairs are identified by permanent marking with repair
symbols. These repairs include welding, plating, plasma spray or hard anodizing. The repair may
have been performed during original manufacture or after the part was fielded.
B. Repair symbols are shown onFigure 201 . The symbols consist of a triangle (▲) or diamond (♦)
which encloses an alphabetic code representing the repair process.
(1) Vibro Engraving. Use a Vibro-Engraving Tool. Depth of engraving must be 0.001 - 0.006 inch
(0.025 - 0.152 mm). When aluminum cases are marked, the marked area must be protected by
applying a chemical conversion coating MAT-050.
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(2) Electrochemical Etch. Use Electrochemical Etch Marking Equipment. Depth of marking must
be the minimum sufficient to provide a marked image that can be read without magnification.
The electrolyte and cleaner/neutralizer shall be used in accordance with the supplier’s
instructions. The marked material shall be thoroughly neutralized and cleaned after etching as
any salt from the electrolyte left on the part will cause corrosion. After cleaning and neutralizing,
a corrosion preventative treatment MAT-004 shall be applied.
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204
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1. General
2. Procedures
SUBTASK 70-01-11-870-001
A. Molybdenum disulfide lubricants (Molykote), MAT-008 break down at temperatures above 572° F.
(300° C). They also release sulphur which can cause corrosion and failure of engine parts. Most of
the bolt materials used in the higher temperature zones of the engine can be damaged by sulphur.
B. Never use lubricants that have molybdenum disulfide except in cases where it is specifically called
out in the manual.
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202
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1. General
SUBTASK 70-02-01-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 70-02-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-61-01 201 Storage of Parts that have Shelf Life Limits - Maintenance Practices
3. Identification
SUBTASK 70-02-01-870-002
A. To identify new O-rings, read the part number on the envelope in which they are packed. Each
envelope lists:
(2) Quantity
B. The storage life of an seal ring can be determined by the cure date on the envelope. There is a listing
of storage periods in 70-61-01. The year is divided into quarters as follows:
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The quarter number and the year, isolated by the letter Q, show the cure date. A cure date of 2Q91
shows the cure date to be in the second quarter (April, May, or June) of 1991. The storage life can
be calculated from this date.
C. You can identify the seal ring material by looking up its basic part number (MS number) in the table
below.
PART NUMBER MATERIAL
M25988 Fluorosilicone
M83248 Fluorocarbon
MS9020 Nitrile
MS9021 Nitrile
ST88628 Fluorosilicon
ST88629 Fluorocarbon
4. Lubrication
SUBTASK 70-02-01-870-003
A. To prevent seal ring damage and to permit easier assembly of parts, you must lubricate the seal rings
before their installation. The lubricant must be compatible with the engine system in which a seal
ring is installed. Use small quantities of the approved lubricant immediately before the installation
of the part.
(2) All other seal rings - assembly fluid No. 1 MAT-011 or engine oil MAT-001, according to the
maintenance task procedures.
5. Installation
SUBTASK 70-02-01-870-004
A. Check the shelf life (refer to 70-61-01, P.B. 201) the condition of the seals. Ensure there are no flat
spots, cuts, or other damage.
B. Make sure that grooves and mating faces, to which the seal rings are to be installed, are clean,
smooth, and free from damage. When installed, make sure that the seal rings are not twisted and
are correctly seated in the grooves.
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D. Do not install seal rings to any section of the engine while it is still hot. The seal rings can stretch
and be damaged.
E. Use a suitable pilot and sleeve assembly tool to prevent damage to seal rings when you install them
to double grooved ferrules.
F. Use a straight push to install ferrules and tubes into their correct sockets; this will prevent twisting
and damage to the seal rings.
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1. General
This task provides maintenance practices for electrical connectors on components and harnesses.
SUBTASK 70-04-01-942-001
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
3. Procedures
SUBTASK 70-04-01-870-001
Inspect the exterior of the connector for dirt, debris, or obvious damage. Debris such as dirt or metal
particles can find their way inside the connector when it is disconnected. If necessary clean the
outside of the connector as described below.
B. Disconnecting Connectors:
(1) For round connectors, unscrew the nut on the harness plug and pull to remove the connector.
Never pull on the harness leads. For the rectangular connectors used on the FADEC/ECU, fully
loosen both retainer screws before disconnecting the harness from the jack. If there is binding
or excess friction, inspect the connector threads for damage or debris.
(2) Use plastic end caps to cover un-mated connectors. Never store connectors with the contact
end exposed.
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(1) Examine the connectors for obvious defects or damage such as badly worn plating or deformed
threads.
(3) Connector nuts should move smoothly and be free of burrs, loose metal particles, and rough
spots.
(4) Light burnishing, light scratches, or other cosmetic imperfections on the connector shell or
contacts is normal.
(5) Inspect all surfaces of the connector for dirt and debris. If necessary, clean as described below.
D. Cleaning Connectors:
(1) Use Isopropyl alcohol (MAT-027) to clean connectors. Use with lint-free cloths or swabs and
use the least amount of solvent possible. Use solvents in liquid rather than spray form. Apply
the solvent to the cloth or swab and not directly to the connector.
(2) Use clean, dry compressed air to dry the connector and/or remove loose debris.
(4) When you have cleaned a connector, always be sure that it is completely dry before
reassembling it.
E. Reconnecting Connectors:
(1) Align the connectors carefully and make the preliminary connection lightly. The connector nut
should move smoothly. If any binding or excessive friction is noticed, remove the connector
and re-inspect for damage or debris.
(2) A line is located on the receptacle as a visual reference. The line is typically red in color and
will be completely covered by the plug when the connector is fully engaged.
(3) The connectors are designed to be assembled by hand and a wrench should not be required.
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1. General
This section describes the consumable materials and other shop supplies required to perform the
maintenance on Williams International engines. Each maintenance task contains a listing of consumable
materials by name and MAT-number. The MAT-numbers are listed here, in numerical order, to reference
the applicable specification, part number, or manufacturer.
Specification numbers applying to consumable materials in this list are basic numbers and include all
revisions and amendments.
All warnings and cautions applicable to the products listed here are shown in the text where the product is
used.
2. Consumable Materials
SUBTASK 70-10-01-942-001
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1. General
2. Procedures
SUBTASK 70-12-00-870-001
A. Some materials used in engines can be contaminated through contact with other materials.
(1) When a material is contaminated by a low melting point alloy, it can, at certain temperatures,
become brittle and crack.
(2) Contamination of certain titanium alloy parts by materials used in processing can, if not
thoroughly cleaned, react with the surface at low temperature and form brittle intermetallic
compounds. This happens when the part temperature is raised either through normal engine
operation or by the application of heat during a repair cycle.
3. Cadmium Contamination
SUBTASK 70-12-00-870-002
A. Cadmium contamination of titanium alloy components is normally caused by the transfer of the soft
electroplated cadmium from or by fixtures and hand tools.
B. Although cadmium platings are no longer used on tools and fixtures (thus avoiding direct transfer),
secondary transfer is still possible. This can occur from the use of a tool which was previously in
contact with cadmium plated components or fasteners.
C. Other low melting point alloys to avoid include: lead, zinc, tin, mercury, and silver. Lead hammers or
shop aids are not to be used. A silver pencil must not be used on titanium parts.
D. You must be extremely careful to make sure that you eliminate both the obvious and the less obvious
sources of contamination.
SUBTASK 70-12-00-870-003
A. Materials containing chloride ions (or other halogens) can, if left on the surface of titanium alloy parts,
stress corrode or embrittle the material when heat or load is applied. Chlorides can come from
organic solvents, tap water, and hand contact.
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B. To avoid any problems with these materials, you must strictly follow the instructions issued in this
manual relating to cleaning, inspection, repair, assembly, transportation, and storage.
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1. General
This Standard Practice gives the approved procedures for the following locking techniques:
Wire locking
Self-locking fasteners
2. Wire Locking
SUBTASK 70-12-04-870-003
3. Self-Locking Fasteners
SUBTASK 70-12-04-870-004
A. General
(1) Fasteners with self-locking capability can be used a limited number of times before the
self-locking feature wears out. These fasteners must be checked at installation to make sure
that they have the proper locking torque.
(2) Wear may occur to either the self-locking fastener or to the fastener that is used with it. For
example, a self-locking nut may not meet the minimum torque requirement if the bolt that goes
into it is worn. If a self-locking threaded insert or a self-locking swage nut fails to meet the
minimum torque requirement, check it with a new bolt before replacing.
(1) Self-locking nuts, bolts, and helical coil inserts must meet the torque requirements in the
table below:
FINE THREAD SERIES COARSE THREAD SERIES
Mating Bolt Max Min Mating Bolt Max Min
Thread Size Locking Break-away Thread Size Locking Break-away
Torque* Torque Torque* Torque
.112 -48 NF-2A 3 0.5 .112 -40 NC-2A 3 0.5
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1. General
This chapter describes methods and procedures required for cleaning engine components. Cleaning of
engine components must do the following:
(1) Permit components to be examined for any flaws or dimension loss from abrasion and wear.
SUBTASK 70-21-00-941-001
A. Standard Equipment
Rinse Tank
Spray Booth
Air Compressor,
Ultrasonic Tank
SUBTASK 70-21-00-942-001
B. Consumables
Reference Designation
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-026 Ultrasonic Cleaner, Detergent
MAT-027 Alcohol, Isopropyl
MAT-202 Cleaner, General Wet
SUBTASK 70-21-00-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-10-01 201 Consumable Materials - Maintenance Practices
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3. Cleaning Policy
SUBTASK 70-21-00-870-001
A. These instructions apply to the cleaning of engine components. Refer to the specific cleaning
procedure for each component in the Engine Manual. The instructions must be followed completely.
B. Selection of a cleaning procedure for each part must take the following into consideration.
(1) Cleaning materials selected must consider the nature of the deposits, type of metal, type of
coating, and how clean the part must be to permit correct inspection.
(2) Engine parts operating in relatively low-temperature ranges (i.e., cold section parts) can usually
be cleaned using standardized methods and processes such as dry cleaning solvent spray
washing.
(3) Combustion and turbine "hot section" engine parts may require more extensive cleaning
procedures, involving a series of carefully controlled ultrasonic and alkali baths and water
rinses.
(4) To maintain part durability, the recommended cleaning method must meet the following
requirements:
(a) It must clean part sufficiently to allow correct inspection by recommended method.
(b) Prohibit use of cleaning methods on parts where cleaning agent(s) can get trapped and
not completely removed by the neutralizing process.
(c) The physical attributes of the part must not be altered by the cleaning procedure.
(a) Extensive cleaning is not necessary for parts that don’t require crack detection, or
require only magnetic inspection. However, extensive cleaning is required for penetrant
inspected parts.
(b) Leave stains on nickel-cadmium plated parts. They do not impair magnetic particle
inspection. Scrubbing may remove plating.
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NOTE Cleaning materials and solutions specified with each cleaning procedure
are not supplied by Williams International. However, these items are
identified by their trade names or part/specification number in the
listing of Consumable Materials. Other equivalent products under a
different trade name may be used as materials and solutions identified
in this Consumable Materials list are only a representative sample.
Also, use of these products does not constitute an unconditional
approval of, or guarantee of them by Williams International. Cleaning
materials listed in the Unacceptable Cleaning Materials table are
products not permitted for use in cleaning.
Give special attention to specific cleaning instructions and the information listed in this section
concerning the cleaning of certain component materials.
(1) The cleaning solution temperature, strength and part immersion time must be monitored
continuously to avoid part damage.
(2) Ultrasonic cleaning solutions must be tested on a regular basis for maintenance of proper
concentration or pH levels. This will avoid possible damage to costly engine parts.
(3) Avoid using any solvent to clean the painted composite inlet assembly. The fireproof coating
will be damaged.
(4) Some cleaning solutions, when used on flame sprayed, plasma sprayed and union carbide
flame plated parts, can cause corrosion of different intensity levels. Parts with these coatings
must be cleaned using only those procedures and solutions recommended in the Engine
Manual and Consumable Materials List.
(5) Damage to or stripping of chromium plated parts can occur through use of certain cleaning
solutions. These parts must be cleaned using only the procedures recommended in the
Engine Manual.
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(6) Do not clean titanium assemblies and components with vapor/solvent degreasers to avoid
stress corrosion. This is linked to chlorine-containing materials being trapped in tight fitting
areas. Surface contamination on titanium or titanium alloy parts can be cleaned with ultrasonic
cleaner MAT-023 or MAT-026, dry cleaning solvent MAT-024, wet cleaning solvent MAT-202, or
isopropyl alcohol MAT-027. Use clean water for final rinse of titanium parts.
(7) Do not use ultrasonic cleaning or ultrasonic agitation for aluminum parts or parts with thermal
spray coatings.
4. Procedures
SUBTASK 70-21-00-110-001
A. Primary Cleaning
Primary cleaning removes oil, grease, and loose carbon deposits from parts. Cleaners are described
under Consumable Materials, 70-10-01, P.B. 201.
There are two permitted methods for primary cleaning. One method uses a dry cleaning solvent
MAT-024 and the other uses a wet cleaning solvent MAT-202.
WARNING CLEANING SOLUTION CAN CAUSE SKIN RASH AND EMIT HARMFUL
VAPORS. WEAR PROTECTIVE CLOTHING, RUBBER GLOVES,
APRON, AND FACE SHIELD/GOGGLES DURING USE. USE IN
WELL-VENTILATED AREAS AWAY FROM OPEN FLAME.
(a) Hand scrub parts with dry cleaning solvent MAT-024 using a soft fiber brush or pad
to remove contaminants.
(b) If any residue remains after cleaning, use a stiff fiber brush to remove residue. Repeat
procedure (a).
(c) Using an Air Compressor,, blow components dry with clean, filtered shop air.
(a) Hand scrub, using a soft fiber brush or pad. Spray, dip, sponge, or ultrasonically clean
parts with wet cleaning solvent MAT-202 to remove contaminants.
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1 If surface to be cleaned is vertical or difficult to reach, use the gel form of wet
cleaning solvent.
(b) Once the contamination has emulsified into a water soluble solution, rinse them away
with water. It will leave a film-free surface.
(c) If any residue contamination remains after cleaning, use a stiff fiber brush to remove
residue. Repeat above procedures (a) and (b).
SUBTASK 70-21-00-130-001
B. Standard/Ultrasonic Cleaning
The recommended cleaning of most components is an ultrasonic tank cleaning system; however, a
non-ultrasonic tank cleaning procedure can be used in a spray booth, but part must stay in cleaner for
a longer period of time. Standard cleaning requires preparation of two tanks for two types of cleaning
procedures: caustic and detergent. A separate rinse tank is prepared with water.
(b) If necessary, clean components with carbon and oil build-up in accordance with
instructions for primary cleaning before putting in ultrasonic or still tank.
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(c) Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove wet
cleaning solvent MAT-202 by rinsing part with water.
(e) Remove parts from solution and inspect parts for cleanliness. If necessary, use a fiber
brush to remove residue.
(f) Turn parts over and put parts back in solution for five to seven minutes.
(g) Repeat cycle as necessary to clean. Make sure you do not exceed maximum exposure
time for parts.
(h) Remove parts from cleaning solution and put in rinse tank for two to three minutes.
(i) Remove parts from rinse tank and dry with shop air.
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1. General
This section provides step-by-step procedural information for correctly screening and processing used
bearings. It covers the cleaning environment, cleaning procedures, packaging and identification. Refer
to the following illustration(s):
Figure 201
SUBTASK 70-31-01-941-001
A. Standard Equipment
Soak Tank (Cleaner)
Soak Tank (Lubricant)
Face Shield/goggles
Apron, Chemical Resistant
Magnetometer (Gaussmeter)
Soak Tank (Fingerprint Remover)
Handling Tweezers
Thermometer (Room Temp. Gauge)
Demagnetizer
SUBTASK 70-31-01-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-004 Oil, Corrosion Preventive
MAT-020 Mineral Spirits
MAT-024 Solvent, Dry Cleaning
MAT-072 Gloves, Plastic, Disposable, Rubber Vinyl
MAT-075 Gloves, Cotton
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3. Job Set-up
SUBTASK 70-31-01-010-001
A. Do not mix sets of bearings or mix components of separable bearings. Make sure that all bearings
are correctly tagged and identified.
B. Before bearings are cleaned, do an initial visual inspection; refer to TASK 70-31-01-220-801 .
C. There are separate procedures for cleaning contaminated bearings (Subtask 70-31-01-110-001), and
cleaning bearings with carbon/varnish build-up (Subtask 70-31-01-110-002).
E. The following equipment is used or recommended for this task: Magnetometer (Gaussmeter),
Demagnetizer, Thermometer (Room Temp. Gauge), Soak Tank (Fingerprint Remover), Soak
Tank (Cleaner), Soak Tank (Lubricant), Handling Tweezers, Apron, Chemical Resistant, Face
shield/goggles.
4. Procedures
SUBTASK 70-31-01-200-001
(1) Fingerprints
Bearings must not come in contact with bare skin or other moist surfaces. When handling
bearings, you must wear one of the following types of gloves:
(b) Clean cotton gloves MAT-075. Whenever cotton gloves are used, typically when handling
hot parts, they must be changed frequently to avoid the possibility of the gloves becoming
perspiration soaked.
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The majority of bearing defects are the result of contamination from dust, dirt, and metal
particles. Particulate contaminants, whether those particles are soft or hard, large or small, will
cause some damage to bearings. Even polymer particles, though quite soft, will extrude when
over-rolled and cause large but shallow dents (see Figure 201, bottom photo). Harder particles
create smaller but sharper dents (see Figure 201 top photo). All of these dents are detrimental
but the harder the particle, the sharper the dent and the higher the stress concentrations at the
edges. Therefore, typically, hard particle contamination is more damaging than soft particle
contamination. Both types of particles still do damage so keeping the bearings clean during
installation and operation is critical to avoid both denting and wear As the particles mix with
the lubricant, they act as an abrasive and cause surface damage in the form of indentations,
metal displacement, and premature wear.
Areas of localized stress generate too much friction, causing fatigue flaking of the surface
which occurs at an increased rate, leading to early bearing failure.
The bearing cleaning area is equipped with the standard and recommended equipment and materials
listed in the paragraph, Equipment and Materials. The equipment and materials have the following
purpose.
(2) Demagnetizer
Handling gloves, apron and face shield are used to protect bearing cleaning personnel from
caustic chemicals.
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SUBTASK 70-31-01-100-001
C. Bearing Cleaning
Bearings must be clean before final inspection TASK 70-31-01 P.B. 201, (Subtask 70-31-01-200-002).
You must clean bearings when one or more of the following conditions exist:
(2) Bearing turns rough or binds when one race is held stable and the other race is turned slowly
by hand while applying a load in the thrust direction.
(3) There was a mechanical failure of the engine. This may have caused contamination in the
bearing with chips or other unwanted material.
SUBTASK 70-31-01-110-001
(1) Demagnetizer may be used, as required, to demagnetize bearings. Bearings should be passed
slowly through the demagnetization coil and then tested for residual magnetism employing a
gaussmeter. If the residual magnetism is over five gauss, demagnetization shall be repeated
until a satisfactory value is obtained.
(a) Support bearing in a soak tank, above any sludge or contamination that may have
collected near the bottom of container.
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(b) Put bearing fully into soak tank, containing MAT-020 or MAT-024 for five (5) minutes
minimum. Occassionally agitate by hand.
(3) Rinse
(a) Rinse with MAT-020 or MAT-024 in a rinse booth, allowing the bearing to rotate slowly to
make sure the part is flushed of contamination.
NOTE Initial rinse procedure requires rotating the bearing very slowly
for complete purging of any contamination. Subsequent rinse
procedures are designed to remove different chemical solvents
from the bearing, and do not require slow rotation.
Soak and rinse operations may be repeated, as required. If carbon/varnish deposits remain,
perform additional cleaning.
WARNING WHEN USING COMPRESSED AIR, USE EQUIPMENT (NOZZLE, ETC.) THAT
MEETS APPLICABLE LOCAL SAFETY REGULATIONS. USE APPROVED
PERSONAL PROTECTIVE EQUIPMENT (GOGGLES/FACE SHIELD). DO
NOT DIRECT AIRFLOW TOWARD SELF OR OTHERS.
Blow dry bearing using filtered, dry air until moisture is removed. Make sure bearing does not
spin while drying. Filter is at point of use.
(6) Inspect
(a) Inspect bearing to determine whether contamination (or carbon deposits) have been
removed.
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(b) You must inspect for contamination or subsequent damage and receive permission to
use cleaned bearings before being returning them to the supply cycle.
(c) When bearings have suspected contamination from related engine failure or mechanical
indications of rough bearing rotation, check the rotational freedom of the bearings again.
(7) Lubrication
Suspend bearing in engine oil MAT-001 bath or corrosion preventive oil MAT-004 bath after
final inspection.
NOTE All bearings require either lubricant or preservative coating before use
or storage. Engine oil MAT-001 is used for short term storage, while
corrosion preventive oil MAT-004 is used to preserve bearings when you
think there may be long term storage (30 days or more).
After cleaning and lubricating, place bearings into clean polypropylene zip-lock plastic bags.
Residual fluid from the cleaning process may be absorbed with a clean, lint-free paper towel.
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Fig. 201 Hard Particle Dent (Top) and a Soft Particle Dent (Bottom) Can Both Be Damaging
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5. General
This task provides step-by-step procedural information for initial inspection and final inspection of ball and
roller bearings. Refer to the following illustrations:
Figure 202
Figure 203
Figure 204
Figure 205
Figure 206
Figure 207
Figure 208
Figure 209
Figure 210
Figure 211
Figure 212
Figure 213
Figure 214
Figure 215
SUBTASK 70-31-01-941-002
A. Standard Equipment
Magnification (1X)
.040 Inch (1.016 Mm) Radius Stylus
Scribe (Bearing Surface Tester)
Handling Tweezers
SUBTASK 70-31-01-942-002
B. Consumables
Reference Designation
MAT-072 Gloves, Plastic, Disposable, Rubber Vinyl
7. Procedures
SUBTASK 70-31-01-210-001
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(1) Check for Damage. Inspect bearings in accordance with visual inspection criteria shown in
Figure 203. If bearing shows evidence of damage, reject bearing. There is no need to clean
damaged bearings.
(3) All bearings that have passed initial visual inspection must be cleaned in accordance with
TASK 70-31-01-110-801 (if TASK determines cleaning is necessary). Clean bearings with
carbon/varnish build-up per Subtask 70-31-01-110-002.
SUBTASK 70-31-01-200-002
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The following bearing inspection flow charts are used to determine the acceptability of an
imperfection. The flow chart is set-up to generate a decision path at each test point (diamond
symbol). When the direction on the flow chart is followed, a reliable disposition for accepting
or rejecting a bearing anomaly can be made.Figure 203, Figure 204, Figure 205, Figure 206,
Figure 207, Figure 208, Figure 209
(b) No. 2 bearings shall be removed from the 1st reduction bevel gear.
(c) No. 3 bearing outer ring and the No. 4 bearing rollers shall be removed from their
assembled housings.
(e) No. 4 bearing inner race shall remain on the 1st LP turbine.
(f) Main shaft accessory drive bearings shall be removed from their housings and shafts.
(g) Gearbox bearings shall remain installed in the gearbox or installed on their shafts.
(a) Visually inspect all bearings, using 1X magnification, to find any contamination or
carbon/varnish buildup on the bearings. Magnification of 1X is defined as 16-18 in.
distant and illumination must be 100 foot candles (1000 lux) minimum. Used bearings
must be 100 percent screened and processed.
(b) Magnification may be used to measure the size of a defect if the scribe test is not capable
of verifying the size. Magnification is not to be used to find defects, only measure size or
determine classification, (i.e., skidding versus spalling).
(4) Use of a Radius Stylus. The scribe test is conducted once a visual imperfection is found. No
magnification is permitted during the scribe test. If the imperfection is felt during the scribe test,
continue to follow the applicable bearing inspection flow chart. Refer to Figure 210.
(a) All scribe tests will be conducted with a 0.040 inch radius scriber (stylus).
(b) The stylus shall be allowed to float between the fingers and thumb while guided across
the surface to be inspected. Do not grasp the stylus or push it towards the surface. The
stylus shall only apply its own weight against the surface.
(c) As the scribe passes over the imperfection, the operator must definitely feel the
imperfection without magnification. An inspection mirror and supplemental lighting may
be used to facilitate inspection in confined installations.
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(d) The scriber tip must be inspected at least once each six month period and replaced if
the scriber tip finish has deteriorated. Use of a scribe with imperfections can cause an
acceptable part to be rejected.
(e) For inspection, bearings shall not be removed from their installation except as noted
in the paragraph Level of DIsassembly.
(5) Rotational Check for Non-Separable Bearings. Check rotational freedom of non-separable
bearings. Check bearing by hand for roughness of rotation or indications of binding.
(a) Check bearing by hand for roughness or indications of too much torque. The hand feel
test will usually identify internal contamination or important surface degradation, justifying
rejection of the part. This does not work to identify bearing cage cracks which start at the
ball or roller pockets. This area is normally not easy to access for inspection, and even
when it is, the beginning cracks are not always visually detectable.
(b) Hold one race stationary and rotate the other race slowly by hand while applying a
load in the thrust direction. The applied load should be enough to ensure that all the
rotating elements are loaded. Note any binding or rough turning. Rough spots should be
oscillated over to distinguish between a defect and the chattering of the cage. If a rough
spot is found, reclean the bearing to insure that it is not contaminated. Up to a total of
four bearing cleanings and subsequent inspections are allowed. Any binding or rough
turning following the completion of this cycle is cause for rejection.
(6) The following equipment is used for inspecting the bearings: Handling Tweezers, Scribe
(Bearing Surface Tester), .040 inch (1.016 mm) Radius Stylus, Magnification (1X).
C. Definitions.
(a) Functional Surfaces. Functional surfaces are all active surfaces of a bearing.
1 Rolling elements. All surfaces except the corners of the rollers. Roller corners at the
point of intersection with the roller profile and roller end are functional.
2 Rings. Raceways and adjacent guide flanges for roller bearings, but not
track-to-guide undercuts or fillet radii.
3 Cage (retainer). Entire pocket (except retention features) and control land surface.
The control land surface is the cage surface that pilots the cage.
(b) Non-Functional Surfaces. Non-functional surfaces are all surfaces other than those
defined as functional.
(2) Non-Separable Bearings. Certain bearings, such as those used for the gearbox, towershaft,
and some mainshaft bearings, cannot be disassembled for detailed component inspection.
These bearings should first be screened by rotational check. The functional, non-functional, and
cage surfaces which are visible should be inspected as defined in the applicable flow charts.
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(3) Imperfections
(a) Brinelling (True). True brinelling is plastic flowed indentations in raceways and rolling
elements usually equally spaced corresponding to rolling element spacing. They are
characterized by smooth, shiny bottomed indentations. True brinelling is the same as a
dent for rejection criteria. Refer to Figure 211.
(c) Corrosion. Broken or pitted surface with discoloration around the perimeter of pits. Also,
surface discoloration without breaks or pits appearing to be iron oxide. Corroded surface
may exhibit an orange peel appearance. Refer to Figure 212.
(d) Dent. A light, smoothly rounded hollow with a rim usually caused by a hit from an
unwanted object. The rim may be raised material or a polished ring around the hollow.
Dents usually occur because of handling damage or elements rolling over foreign
particles during bearing operation. Refer to Figure 213.
(f) Flaking or Blistering of Plating. Flaking, or blistering of silver plating due to inadequate
adhesive bond.
(g) Fretting Corrosion. Fretting corrosion is rapid oxidation of surfaces of closely fitted
parts. It is characterized by rusty appearing surfaces ranging from black to fairly bright
reddish brown.
(h) Frosting of Balls. Frosting of the balls are bands or whole surfaces of a white "frosted"
appearance or loss of luster due to many fine scratches.
(i) Heat Discoloration. Heat discoloration of carbon steel bearing surfaces is shown in colors
ranging from pale yellow to purple and even black. Used carbon steel bearings have the
following discoloration from heat within these approximate ranges:
From 430° to 480°F (221° to 249°C) - Very pale yellow through dark yellow
(j) Nicks. A sharp surface indentation caused by a hit from an object. Nicks occur when a
foreign object is pressed into the bearing surface. The object does not travel far along the
surface or scratches or gouges will result. Refer to Figure 213.
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(k) Pits. Small cavities in the surface, free of discoloration around the perimeter, usually dark
at the bottom and generally circular in shape.
(l) Raised Material. Material disturbed such that it has been raised above the surrounding
surface.
(m) Retention Feature Interference. Cage retention feature showing evidence of contact with
the ball or roller during operation.
(n) Rivet Imperfection. Non-uniform view of rivet heads on either side of the cage is an
indication of a process problem.
(o) Roller Banding. Visible band on roller that may or may not have depth.
(p) Scoring. Scoring is deep, multiple grooves caused by sliding on either the race or
rollers. Scoring is caused by foreign material that is trapped in the bearing and pushed
by the rollers.
(q) Scratch. A linear depression with a sharp bottom caused by movement of a sharp object
or particle across a surface. Refer to Figure 213.
(r) Skidding. Skidding is excessive slipping between rolling elements and raceways.
Skidding marks on the rolling elements appear as a frosted band or speckled wear
pattern on the otherwise highly polished surface. Skidding marks on the raceway will
appear as a burnished or irregular frosted or smeared areas. Microscopic examination
shows that the film is a transfer of metal. Refer to Figure 214.
(s) Spalling. Spalling is exhibited by irregular shaped cavities of flaked-out metal from a
raceway or rolling element surface with jagged bottoms caused by rolling contact fatigue.
(t) Stain. Surface discoloration with surface not broken, including tarnishes other than those
associated with corrosion or heat discoloration.
(u) Wear. Deterioration or surface finish or perceptible removal of material. Refer to Figure
215.
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Fig. 205 Bearing Functional Surfaces Inspection - Scratch or Scoring (Center Roller)
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Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This section defines the accept/reject criteria for surfaces of all mainshaft carbon seals.
Figure 601
Figure 602
Figure 603
2. Definitions
SUBTASK 70-33-01-870-002
B. Seal Face: The surface(s) designed to mate with adjoining surface(s) to seal off fluid or other media
to be retained by the seal.
D. Chips: Discontinuities on the edge resulting from pieces of the material being broken and separated
from the edge.
E. Chip Width: The maximum dimension of a chip measured perpendicular to the edge along the
surfaces forming the edge. Chips have two width dimensions; each one measured along the surface
that forms the edge.
F. Chip Length: The maximum dimension of a chip measured along the edge.
G. Scratch: A random, shallow, linear depression caused by a sharp object (see lay).
H. Lay: The predominate surface pattern caused by the marks of tools used to finish the surface.
I. Crack:. A linear discontinuity resulting from the fracture (rupture) of the material by internal or
external stress.
3. Carbon Face Seal Quality Requirements (No. 1 and No. 2 Carbon Seals)
SUBTASK 70-33-01-870-003
NOTE Carbon face seals and runners should always be replaced together to avoid
excessive wear rates. If either the seal or runner shows coking or wear, both
parts should be replaced with new or relapped parts.
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B. Chips, pits, nicks, dents, and scratches shall be in accordance with table 601.
C. Seal Hang-Up. If the carbon seal is compressed into its metal case and does not extend without
assistance, both runner and seal should be replaced.
D. Coking and Carbon Deposits. Soft deposits that break up easily are not cause for rejection if not
accompanied by seal hang-up or hard deposits. The seal should be cleaned and reused. Hard
deposits on the seal runner that are not easily removed by wiping with a soft cloth are cause for
rejection. Both runner and seal should be replaced.
E. Stringers. Stringers are long, thin formations of coked material. If stringers are soft, easily smeared
and not accompanied by seal hang-up or hard deposits, the seal should be cleaned and reused. If
stringers are hard, gritty or accompanied by seal hang-up or hard material build-up on seal runner,
both seal and runner should be replaced.
4. Banded Ring Carbon Seal Quality Requirements (No. 3 and No. 4 Carbon Seals).
SUBTASK 70-33-01-870-004
SUBTASK 70-33-01-870-001
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
Seal Face(Except Pits, Dents, Nicks Depth - 0.015 inch Defects 0.005 inch
Edges) (0.381 mm) or 20% of (0.127 mm) width and
section - whichever is less - no limit. Defects
smaller. Width - 0.15 over 0.005 inch (0.127
inch (3.81 mm) or 20% mm) - sum of defect
of dimension across areas not to exceed
surface - whichever is 0.1% of face area.
smaller.
One pit may be up to
0.015 inch (0.381 mm)
x 0.027 inch (0.685
mm) as long as it is
0.030 inch (0.762 mm)
from nearest edge.
Scratches (includes lay) Scratches are
acceptable if they
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Table 601 Carbon Face Seal Surface Quality Requirements — FJ44 (Continued)
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
cannot be felt with a
0.030 inch diameter
stylus. The stylus
used for inspection
must not create a
scratch that can be
felt with the same
instrument. If surface
profile recorder traces
are used, the limitation
is 0.0002 inch (0.005
mm) deep.
Other Faces(Except Pits, Dents, Nicks Depth - 0.015 inch Defects 0.005 inch
Edges) (0.381 mm) or 20% of (0.127 mm) width and
section - whichever is less - no limit.Defects
smaller.Width - 0.030 over 0.005 inch (0.127
inch (0.762 mm) or mm) - not to exceed 10
20% of dimension per face or 30 total per
across surface - part, whichever is less.
whichever is smaller.
Scratches Scratches are
acceptable if they
cannot be felt with a
0.060 inch diameter
stylus. The stylus
used for inspection
must not create a
scratch that can be
felt with the same
instrument. If surface
profile recorder traces
are used, the limitation
is 0.001 inch (0.025
mm) deep.
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Page 603
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Table 601 Carbon Face Seal Surface Quality Requirements — FJ44 (Continued)
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
Edges (Seal Face and Chips 0.015 inch (0.381 mm) Chips 0.007 (0.177
O-ring Groove) or 20% of face width - mm) and smaller - no
whichever is smaller. limit. Chips over 0.007
inch wide - the sum of
the chip lengths shall
not exceed 10% of
edge length.
Edges (Other Face) Chips 0.032 inch (0.812 mm) Chips 0.016 (0.406
or 20% of face width - mm) and smaller - no
whichever is smaller. limit. Chips over 0.016
inch wide - the sum of
the chip lengths shall
not exceed 10% of
edge length.
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This repair task must be performed when directed, in the relevant Inspection/Check task for the part
being repaired.
SUBTASK 70-42-11-942-001
A. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-041 Pad, Abrasive
MAT-042 Paper, Abrasive, Silicone Carbide
MAT-043 Stone, Sharpening
3. Instructions
SUBTASK 70-42-11-870-003
A. Parts repaired to these instructions must be restored as near to their original shape and surface
condition as possible. After repair, parts must not exceed the worn dimension limits detailed in
the relevant Inspection/Check task.
B. Standard workshop equipment is required to do these repairs. Special tooling is not required.
Consumable materials to perform this task are: MAT-040 Abrasive Cloth, MAT-041 Abrasive Pad,
MAT-042 Silicon Carbide Abrasive Paper, MAT-043 Sharpening Stone.
SUBTASK 70-42-11-350-001
CAUTIONS: 1 YOU MUST NOT USE ALUMINUM OXIDE TYPE WHEELS, STONES, AND
ABRASIVES ON TITANIUM PARTS. USE ONLY SILICON CARBIDE TYPES.
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(1) Remove high spots, burrs and pick-up, and pick-up on threads. Use hand stones and light
hand polishing.
(1) Remove pitting by blending. Use hand stones and light hand polishing.
(1) Remove distortion and dents by blending. Use hand stones and light hand polishing.
D. Repair of Nicks
(1) Remove nick by blending, scalloping, and/or hand polishing to a smooth shape.
(1) Dress, Blend, and polish burned areas. For standards, refer to the relevant Inspection/Check
task for the part under repair.
F. Repair of Cracks
(1) Blend and/or scallop affected area. Use a rotary file and hand polish. For standards, refer to
the relevant Inspection/Check task for the part under repair.
G. Repair of Battering
(1) Blend edges of battering marks. Blend to the general surface profile of the part and hand polish.
(2) Scallop battering on leading and trailing edges. Scallop to a 5: 1 minimum length/depth ratio
and hand polish. For standards, refer to the relevant Inspection/Check task for the part under
repair.
SUBTASK 70-42-11-220-001
A. Inspect and Crack Test. Refer to the relevant Inspection/Check task for the part under repair to
determine the method and instruction for inspection and crack test.
SUBTASK 70-42-11-350-002
A. Repair Surface Protection. Refer to 70-42-12, P.B. 801 and/or relevant Repair task for the part
under repair.
EFFECTIVITY: FJ44-2C
70-42-11
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1. General
This task must be performed to restore protective coating to surfaces which have been damaged or
repaired.
SUBTASK 70-42-12-942-001
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
MAT-033 Marker, Fine Line
MAT-050 Coating, Chemical Conversion (Iridite)
MAT-052 Polyurethane Topcoat, Color Anodize
Repair
3. Instructions
SUBTASK 70-42-12-870-003
A. Make sure that all damaged/repaired surfaces are blended smoothly and match the surface finish of
the surrounding area.
B. Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl alcohol
MAT-027 to clean.
EFFECTIVITY: FJ44-2C
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Page 801
Dec 12/17
SUBTASK 70-42-12-870-004
(1) Apply touch-up chemical coating to damaged/repaired area. Overlapping of touch-up coating
to base coating is allowed.
(2) Allow coating to dry for one to five minutes. Wipe off excess coating with a damp cloth.
(3) If the repair is on an area that has blue chemical coating, it is allowable to touch-up the repaired
area with a dark blue fine line marker (MAT-033).
(1) Lightly abrade the area with a moist pad, wipe with a damp lint-free cloth and let dry.
(2) Coat the area in even overlapping strokes and allow to dry.
(3) Re-coat the area within 5 minutes by applying at 90 degrees to the first coat (cross pattern).
(1) Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl
alcohol MAT-027 to clean.
(2) Apply touch-up chemical coating MAT-050 to damaged/repaired area. Overlapping of touch-up
coating to base coating is allowed. Allow coating to dry in accordance with manufacturer’s
instructions.
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Page 802
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(3) To ensure that surface is clean and free of contamination, perform water break test by spraying
the surface to be painted with a mist of distilled water:
(a) If water droplets tend to coalesce into large lenses lasting for 25 seconds (without a
sudden flash out), the surface is acceptable.
(b) If water gathers into droplets within 25 seconds (if the surface shows a “water break”
within that time), or if the water forms a continuous film by flashing out suddenly over the
surface area, the surface is not acceptable and must undergo further cleaning.
(4) Mask off areas of part which do not require application of topcoat.
(6) Apply the topcoat over the damaged area. The topcoat can be applied by brush or spray.
(7) The topcoat takes 7 days to fully cure at room temperature. It is acceptable to continue
processing the coated hardware after 12 hours at room temperature. It is acceptable to fly
after 72 hours.
SUBTASK 70-42-12-870-005
A. Refer to component maintenance task(s) for application of protective coatings on polished aluminum
surfaces.
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70-42-12
804
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers the penetrant method of inspection for the detection of cracks and other discontinuities
open to the surface.
SUBTASK 70-42-15-942-001
A. Consumables
The penetrant test materials used for inspection per this task shall be as specified in AMS-2644.
SUBTASK 70-42-15-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-21-00 701 Cleaning Methods and Procedures - Cleaning
72-00-00 601 Engine - Cleaning
3. General
SUBTASK 70-42-15-110-001
A. Parts inspected must be clean and free from oil, grease, dirt, cleaning solution, and other
contamination which could prevent adequate penetration of discontinuities or hold penetrant and
cause non-relevant indications. . Clean parts in accordance with the methods specified in Engine
Manual 72-00-00, P.B. 601 and the general requirements of 70-21-00, P.B. 701.
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4. Procedures
SUBTASK 70-42-15-870-003
A. Inspection Process
(1) Materials
The penetrant test materials used for inspection per this task shall be as specified in AMS-2644,
and shall be from one manufacturer’s family. The penetrant system shall be purged when
penetrant families and/or materials are changed. A family is defined as a penetrant and
post-emulsified combination, unless otherwise directed by Williams International.
(2) Processes
Parts that are inspected in accordance with this task shall be processed and inspected per
ASTM E 1417. The individual process specifications/methods, as called-out in specific
inspection instructions for parts, are detailed in the subtasks which follow:
SUBTASK 70-42-15-230-001
Type Methods Developer Sensitivity Level
I A, B (Note 5) or D a, (b,c)(Note 1) 2 or 3
SUBTASK 70-42-15-230-003
Type Methods Developer Sensitivity Level
I A, B(Note 5), D(Note a, (b,c)(Note1) 3 or 4
2)
SUBTASK 70-42-15-230-004
Type Methods Developer Sensitivity Level
I A, B(Note 5), C a(Note 4), (b,c)(Note 4
(Note 6), D(Note 2) 1), d
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3 Developer not required, inspect opposite side surface for evidence of thru leaks
5. Acceptance Criteria
SUBTASK 70-42-15-870-004
A. Parts shall meet the acceptance criteria (class) specified in the detailed inspection instructions.
Acceptance criteria classes are defined in table 601
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(a) The cumulative length of all indications must not be greater than the max size of
indications times the max number of indications specified; e.g., Class F permitted
indication/size mixtures include: 3 at 0.060 inch, 6 at 0.030 inch, 5 at 0.036 inch, etc
B. Parts exhibiting indications may be evaluated using additional non-destructive test methods to
determine the relevancy and severity of the indications.
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SUBTASK 70-42-15-870-005
A. Inspection Process
The inspecting activity shall establish an inspection process defining, as a minimum, the following:
Brand name, type and group designation of penetrant and developer (if used)
Surface preparation
Dwell time
Wash method
B. Process Controls
The inspecting activity shall be responsible for conducting process control tests per ASTM E 1417.
7. Notes
SUBTASK 70-42-15-870-006
A. Nonrelevant Indications
All indications revealed by liquid penetrant inspection do not necessarily represent detrimental
defects since nonrelevant indications are sometimes encountered. They may be caused by rough
areas or by insufficient rinsing following penetrant applications. Nonrelevant indications can be wiped
off without reappearing and not show the brilliance of true indications. Regard any indication which
is believed to be nonrelevant as unacceptable until the indication is either eliminated by surface
conditioning or it is evaluated by other nondestructive means and demonstrated to be nonrelevant.
B. Relevant Indications
Relevant indications are those which result from mechanical discontinuities. Linear indications are
those indications in which the length is more than five times the width. Linear indications can be
caused by such discontinuities as cracks, laps, laminations, seams, tears, etc. Rounded indications
are indications which are circular or ellipticalo with the length less than five times the width. Cracks,
seams, laps, and cold shuts appear as lines. Porosity is revealed by round spots. Growing or
bleeding spots are indicative of subsurface cavities. For estimating the extent of a defect, it is helpful
to examine under white light preferably with 10x (area) magnification.
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8. Inspection of Components
SUBTASK 70-42-15-870-010
A. Refer to NDI tasks for specific components for inspection methods and acceptance criteria.
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1. General
This task provides information for torque tightening technique. Refer to the following illustration(s):
Figure 201
SUBTASK 70-51-00-941-001
A. Standard Equipment
Hand Torque Wrench, Flexible Beam Type
Hand Torque Wrench, Screwdriver Type
SUBTASK 70-51-00-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
3. Information
SUBTASK 70-51-00-870-002
A. A predetermined torque load is applied to nuts, bolts, fittings, and screws to prevent overstressing
and to give optimum security. All threaded fasteners on the engine are tightened to either:
B. Torque values for all threaded fasteners are given at the point of application in the maintenance
manual.
4. Lubrication
SUBTASK 70-51-00-870-003
A. You must apply lubricant to the threads on parts to get the correct torque load at assembly. This
lubrication is necessary because most of the applied torque is absorbed by :
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B. Lubricate all steel tube nut fittings prior to assembly with engine oil MAT-001. Do not apply lubricant
to inside of tubes.
C. Lubricate all other threaded fasteners with MAT-001 engine oil (unless otherwise specified).
D. You must not use any other lubricants unless specifically told otherwise in the specific procedure in
the manual.
E. If you use the wrong lubricant, the mean tensile load, when you apply torque, can increase by 80
percent. This can put severe stress on the fastener.
5. Retightening of Nuts
SUBTASK 70-51-00-870-004
CAUTION IF YOU DO NOT DO THE INSTRUCTIONS THAT FOLLOW, THE RESULT CAN
BE AN INADEQUATE CLAMPING LOAD. IF YOU GO PAST THE CORRECT
TORQUE LOAD IN AN ATTEMPT TO INCREASE THE CLAMPING LOAD, YOU
CAN DAMAGE THE THREADS OF PARTS. THIS MAY NOT BE OBVIOUS AT
FIRST BUT CAN CAUSE FAILURE OF THE JOINT DURING SERVICE.
A. Whenever you must tighten nuts again, do the procedure that follows:
(2) Clean and apply lubricant to the threads and abutment faces.
SUBTASK 70-51-00-870-005
A. When you use close-pitch bolting, and when you must make a seal, do not tighten adjacent fasteners
successively. Tighten in a symmetrical pattern to prevent the induction of strain into the structure. Do
the procedure that follows, unless you are told differently in the manual.
(1) On flanges, lightly tighten two fasteners approximately opposite to each other; then lightly
tighten another pair at approximately 90° to the first pair. Bisect the resultant angles and
continue as before. When the faces touch with all fasteners lightly tightened, apply the
prescribed torque in a similar sequence. Refer to Figure 201 for an example of a typical torque
sequence.
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SUBTASK 70-51-00-870-006
(1) Standard equipment flexible beam type wrenches include: Hand torque wrench, flexible beam
type, 1/4-in. drive and Hand torque wrench, flexible beam type, 1/4-in. drive.
(2) To get a correct reading, hold the handle lightly with one hand. Pull the handle at right-angles
(90 degrees) to the center-line of the wrench. The handle must be free to move on the pivot
point; this will keep the force or load at the correct point. Do not move the position of the
handle. If you do, this will change the concentration of the force from the pivot point to another
position on the handle.
(3) Use a torque wrench which will show you torque value in the higher range of the scale. This will
make sure that you get the greatest possible accuracy when you look at the scale values.
B. Screwdriver type
(1) Standard equipment screwdriver type wrench includes: Hand torque wrench, screwdriver
type, 1/4-in drive.
(2) To get a correct reading, hold the handle like a screwdriver. Turn the handle smoothly until you
can see the required torque load.
(3) Examine screwdriver-type wrenches for accuracy. When there is no load, make sure that
the pointer shows zero on the scale. If necessary, adjust the wrench in accordance with
manufacturer instructions.
SUBTASK 70-51-00-870-007
A. The use of an adapter on the torque wrench lengthens the effective working arm of the torque wrench,
except when the adapter is used at right angles (90°) to the wrench handle. When the adapter is used
in such a manner that it lengthens the arm of the torque wrench, adjust the torque values as follows:
(1) Measure the length of the torque wrench from the center of the drive to the center of the
handle. This is dimension A (Figure 201).
(2) Measure the length of the torque wrench with the adapter attached. This measurement
(dimension B) is taken from the center of the handle to the centerline of the adapter.
(4) Multiply the conversion factor by the torque value given for the nut to get the torque reading
that should be used with the adapter on the wrench.
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Dimension A on the torque wrench is 12.5 inches. With an adapter installed, dimension B is 14.3
inches. A + B = 12.5 ÷ 14.3 = 0.87. This is the conversion factor. Multiply the conversion factor
by the nominal torque.
SUBTASK 70-51-00-870-008
A. Refer to Locking Techniques for Threaded Parts, 70-12-04, P.B. 201, for a description of the proper
use and minimum run-down torques for self-locking fasteners.
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Fig. 201 Typical Torque Sequences and Torque Calculation for the Use of Extensions and Adapters
EFFECTIVITY: FJ44-2C
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70-51-00
206
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task describes the maintenance practices required to keep special tools for engines in proper working
condition. Special tools require regular inspection and maintenance to ensure safety of operation and/or
accuracy of measurement.
SUBTASK 70-53-00-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-005 Oil, Penetrating
MAT-041 Pad, Abrasive
3. Procedures
SUBTASK 70-53-00-870-001
(1) Damage: Tools that are cracked, chipped, or otherwise damaged should not be used. Nicks,
burrs, or raised material should be blended smooth. Areas on tools where a protective surface
is removed should be recoated to prevent corrosion.
(2) Wear: Contact surfaces should be inspected for areas of excessive wear that would prevent the
tool from functioning properly. Threaded diameters and contact surfaces should be lubricated
with clean engine oil MAT-001 to reduce friction. Replace tools that are excessively worn.
(3) Cleanliness: All tools are potential sources of engine contamination and should be properly
cleaned before use. Assembly tools must be held to the same standards of cleanliness as
engine parts in the system in which they are used.
(4) Corrosion: Corrosion may impair the function of a tool, shorten its life-span, or weaken it.
Remove corrosion with an abrasive pad MAT-041. All steel tools, including those which have
black oxide coating, should be coated with penetrating oil MAT-005 to inhibit corrosion. In areas
of high humidity, tools should be sealed in plastic bags or stored in rust-inhibiting paper.
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(5) Proper Configuration: Tools that are composed of multiple piece-parts should be checked for
proper assembly and/or configuration. Refer to the detailed instructions in the Maintenance or
Engine Manual.
B. Non-Destructive Inspection (NDI): Tools which are under high stress during operation must be
periodically checked with fluorescent penetrant to detect cracks or weaknesses which would
otherwise be invisible. Perform NDI inspection at intervals indicated in table 201.
C. Calibration: In order to assure accuracy of measurement, service facilities shall maintain a program
for calibrating engine tools. Tools which require periodic calibration are identified in table 201.
Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools
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Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools (Continued)
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70-53-00
204
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task describes the maintenance practices required for storage of parts that have shelf life limits.
2. Shelf Life
SUBTASK 70-61-01-870-002
A. The date which the shelf life of rubber and synthetic rubber parts is calculated is the cure date.
This cure date is shown on the parts and/or on their associated packaging. It is applicable to the
following types of parts:
(2) Cables
(3) Harnesses
B. The cure date is shown as the quarter of the year (given as a single figure) and the year (given as a
double figure) when the part was manufactured. The letter Q separates the single figure and double
figure. For example, 2Q91 is the cure date for a part made in the second quarter of 1991. The
year is divided into quarters as follows:
C. Calculate the age of any part from the end of the quarter in which the part was made. For example, a
part with the cure date 2Q91 would be one year old at the end of the second quarter of 1992, i.e.
30 June, 1992.
SUBTASK 70-61-01-870-003
A. The method that shows the cure date of uninstalled or separate rubber or synthetic rubber parts is
as follows:
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(1) Individual parts (except seal rings) are stamped or stencilled with a permanent marking fluid of
a contrasting color. The parts are large enough for marks to be made on them. Examples of
these parts are diaphragms and bulkhead seals.
(2) Seal rings (O-rings) and individual parts, which are too small to mark on, are put into identifiable
envelopes. Labels are attached to the part or batch.
(3) The cure date is on all basic envelopes, bags, or packages and all intermediate and/or exterior
containers into which the items are put. Additionally, each envelope, bag, or package shows
the manufacturer’s name or reference, the Williams International part number, and the batch
number.
4. Storage of Parts
SUBTASK 70-61-01-870-004
A. Keep rubber and synthetic rubber parts in good condition. Look carefully at the storage conditions
in order to get the maximum shelf life. Keep parts in conditions that give the maximum protection
against these effects:
(1) Strain
(3) Ozone
(4) Moisture
B. If parts are supplied in envelopes, plastic bags, or cartons, keep them in this condition until you need
them. Monitor level of stocks to rate of use to prevent excessive storage time. You must remove
parts from the shelf on the basis of age. The cure date shows you how old the part is. Do not let
rubber parts and metals (especially copper) touch each other.
C. Store parts in a relaxed position. They must be free from tension and, wherever possible, in their
normal shape. Do not put too many parts in a vertical stack. This can cause permanent distortion of
the lower layers. Put flexible hoses in straight lengths, wherever possible, as coiling causes tension
in the outside of each coil. It also increases the risk of ozone cracking.
D. Give sufficient ventilation to prevent condensation, but do not let currents of air come into contact
with the stored parts. Keep parts away from sources of ozone. These are:
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E. When you put lip-type seals into storage, make sure that you do not cause damage and distortion to
the edges. Only attach seal rings to ferrules or bobbins immediately before installation into an engine
or unit. Prolonged exposure to light can cause deterioration to the seal rings.
F. Keep temperature within the preferred range of 59 to 70 degrees F (15 to 21 degrees C). The
minimum temperature must be 41 degrees F (5 degrees C) and the maximum must be 100 degrees
F (38 degrees C). The relative air humidity will be 65 percent. Put parts at least 3 feet (1 meter)
from any unscreened source of heat.
G. If you store parts in the recommended conditions in paragraph F, the shelf life of rubber and rubber
synthetic parts is virtually unlimited. In certain cases, examine and monitor the parts at specified
intervals. For this purpose, materials are divided into three groups.
(1) Group A
The customer can receive these up to five years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
two years (see paragraph 4, Inspection of Parts).
(2) Group B
(a) Butyl
The customer can receive these up to seven years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
three years (see paragraph 4, Inspection of Parts).
(c) Nitrile
The customer can receive these up to 10 years from cure date. The ultimate life is 15
years.
(3) Group X
There is no life limit for supply to a customer or for storage. Cure date marks are on
these parts to help monitor stock.
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5. Inspection of Parts
SUBTASK 70-61-01-870-005
A. Examine parts for signs of aging or degradation because of oxidation; this is shown by surface cracks
and deterioration. Bend the part gently and discard it if you see cracks.
B. Do not automatically discard parts because you see a white or colored bloom on their surface. The
layers of blooms help to prevent ageing. They come from the anti-oxidants which are in high-grade
rubber.
C. Examine parts for conditions as follows; discard them if they are faulty:
(4) Chafing of outer coverings and corrosion of, or damage to, end fittings of hose assemblies
and cable harnesses
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CHAPTER 71
POWER PLANT
Page 1
71-POWER PLANT Dec 12/17
Page 2
71-POWER PLANT Blank
LINE MAINTENANCE MANUAL - FJ44-2C
71-00-00 101 Dec 12/17 71-00-22 201 Dec 12/17 71-00-32 601 Dec 12/17
71-00-00 201 Dec 12/17 71-00-23 201 Dec 12/17 71-00-40 601 Dec 12/17
71-00-00 401 Dec 12/17 71-00-24 201 Dec 12/17 71-00-50 601 Dec 12/17
71-00-00 501 Dec 12/17 71-00-25 201 Dec 12/17 71-00-52 601 Dec 12/17
71-00-03 701 Dec 12/17 71-00-26 201 Dec 12/17
71-00-21 201 Dec 12/17 71-00-30 601 Dec 12/17
Chapter 71
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 71
List of Effective Page Blocks
Page 2
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Use this task to isolate specific faults in the engine systems. Refer to the list of troubleshooting top
events and their corresponding troubleshooting trees.
SUBTASK 71-00-00-941-029
A. Standard Equipment
Multimeter (Digital).
Hi Pot Tester
Jumper Wires
Megohm Meter
Borescope
3. Instructions
SUBTASK 71-00-00-810-006
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
A. Standard equipment for this task includes: Borescope, Hi pot tester, Jumper wires, Megohm meter,
Multimeter (Digital).
B. The following troubleshooting instructions are provided as an aid in locating the cause of a
malfunction based on the symptoms it produces.
C. The listing of troubleshooting "top events" serves as an index which references malfunction
symptoms to the corresponding troubleshooting tree. The list of top events is arranged in sequence
of normal engine operation:
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SUBTASK 71-00-00-810-007
Figure 101
Figure 102
Figure 103
Figure 104
Figure 105
Figure 106
Figure 107
Figure 108
Figure 109
Figure 110
IDLE MALFUNCTIONS
Figure 111
Figure 112
Figure 113
ACCELERATION MALFUNCTIONS
Figure 114
Figure 115
Figure 116
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TAKE-OFF MALFUNCTIONS
Figure 117
Figure 118
Figure 119
Figure 120
Figure 121
Figure 122
Figure 123
Figure 124
Figure 125
DECELERATION MALFUNCTIONS
Figure 126
SHUTDOWN MALFUNCTIONS
Figure 127
Figure 128
OTHER MALFUNCTIONS
Figure 129
Figure 130
Figure 131
Figure 132
Figure 133
Figure 134
Figure 135
Figure 136
Figure 137
Figure 138
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Figure 139
Figure 140
Figure 141
Figure 142
Figure 143
Figure 144
Figure 145
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Fig. 107 No/Slow Acceleration (Hung Start) N2 ≤ 42% 20 Sec After Light (2 sheets)
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Fig. 107 No/Slow Acceleration (Hung Start) N2 ≤ 42% 20 Sec After Light (2 sheets)
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Fig. 135 Oil Filter Delta P Indicator Extended
71-00-00
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1. General
This task provides procedures to change a No. 1 (left hand) engine to a No. 2 (right hand) engine or a No.
2 (right hand) engine to a No. 1 (left hand) engine.
NOTE We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
SUBTASK 71-00-00-943-035
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
SUBTASK 71-00-00-945-035
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-71 401 Rear Bypass Duct Assy - Removal/Installation
77-11-01 401 LP Magnetic Speed Pickup Assembly - Removal/Installation
79-31-01 401 Oil Filler Cap and Dipstick - Removal/Installation
79-33-11 401 Oil Sight Glass - Removal/Installation
3. Procedures
SUBTASK 71-00-00-570-004
A. To change a No.1 (left hand) engine to a No. 2 (right hand) engine or a No.2 (right hand) engine
to a No.1 (left hand) engine:
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NOTE The No. 2 (right hand) engine requires that the N1 (LP) magnetic speed
pickup assembly be installed on the outboard (right hand) side of the engine.
This is so that the pickup will be accessible for maintenance. The No. 1 (left
hand) engine requires that the N1 (LP) magnetic speed pickup assembly be
installed on the left side to be accessible for maintenance.
(1) Remove the N1 (LP) speed pickup; refer to 77-11-01, P.B. 401. Remove the plug from the LP
speed pickup port located on the opposite side of the interstage housing from the installed
pickup. Change positions of the LP speed pickup and the plug.
(2) Remove the rear bypass duct; refer to 72-00-71, P.B. 401. Reposition the rear mount ring to
the opposite side (clock position). Make sure that the lifting lugs are at the 1:00 and 11:00
o’clock positions.
NOTE There is no forward or aft orientation required when installing the rear mount ring.
(3) Install the rear bypass duct; refer to 72-00-71, P.B. 401.
NOTE The engine must be hanging from the engine lifting sling,
08-0119-8000, to do the following task
(4) Move the eight mounting pad hole plugs to the opposite side of the engine. Torque plugs
90-100 inch-pounds (10.1-11.2 N.m).
(5) The dipstick assembly must be installed on the outboard side. Change positions of dipstick
assembly and filler port plug assembly, as required. Refer to 79-31-01, P.B. 401.
(6) The sight glass must be installed on the outboard side. The cover plate blank must be installed
on the inboard side. Change positions of the sight glass and cover plate blank. Refer to
79-33-11, P.B. 401.
(7) The fan bleed port cover may need to be swapped. The cover is always on the outboard
side of the duct.
(a) Attach the fan bleed port cover on the outside of the duct, with the flat edge of the
cover oriented aft.
(b) Install the gasket underneath the cover, using six screws (head inside of duct), six
washers (under the screws), six nuts, and six washers under the nuts. Torque 5 to 7
inch-pounds (0.57 to .79 N.m) above prevailing torque. Refer to 72-00-71, P.B. 401.
EFFECTIVITY: FJ44-2C
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1. General
This task provides procedures for removing the engine from the build stand. Refer to the following
illustration(s):
Figure 401
Figure 402
SUBTASK 71-00-00-941-036
A. Standard Equipment
Overhead Hoist
SUBTASK 71-00-00-943-036
B. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-0147C4000 Sling, Engine Lift
08-2021-0000 Stand, Engine
K-2032 Adapter, Engine Stand
SUBTASK 71-00-00-945-036
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
EFFECTIVITY: FJ44-2C
71-00-00
Page 401
Dec 12/17
3. Procedures
SUBTASK 71-00-00-010-041
CAUTION INSPECT LIFT SLING FOR DAMAGE BEFORE USE. MAKE SURE THAT
SHACKLE BOLTS ON LIFT ARMS ARE SECURELY FASTENED. MAKE
SURE THAT ADJUSTMENTS FOR LENGTH AND CENTER-OF-GRAVITY
ARE CORRECT FOR ENGINE MODEL/TYPE.
(1) Adjust lift sling for length and/or center-of-gravity to match engine model/type. Tighten bolts
securely. Refer to Figure 401.
(a) Connect lift sling front arm to front lift bracket on forward interstage housing flange using
detent pin.
(b) Connect lift sling outboard rear arm to outboard lift point on rear mount ring using detent
pin.
NOTE The inboard rear arm of lift sling has two mounting holes. Use the
upper hole for level installation. Use the lower hole if the engine
needs to be rolled slightly for aircraft installation.
(c) Connect lift sling inboard rear arm to inboard lift point on rear mount ring using detent pin.
(3) Connect lifting sling to overhead hoist. Adjust position of engine build stand and/or hoist, as
required, and raise hoist until there is light, equal tension on lifting sling arms.
SUBTASK 71-00-00-010-036
B. After connecting lifting sling to engine and hoist, remove engine from 08-2021-0000 engine stand
as follows:
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71-00-00
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Dec 12/17
(1) Remove two detent pins from pivoting support arm yokes on the engine build stand. Retract
the pivoting support arm.
(2) Remove two detent pins from gear-driven support arm yokes and disengage engine mount
adapters from yokes.
(3) When engine and mount adapters are completely clear of build stand support arms, raise hoist
and/or remove engine build stand.
(4) Remove sixteen bolts and four engine mount adapters, K-2032, from four engine mount pads
on the interstage housing. After removal, attach engine mount adapters to build stand.
SUBTASK 71-00-00-010-037
NOTE If engine is to be used on right hand side of aircraft, install forward engine mounts
on left hand mounting pads. If engine is to be used on left hand side of aircraft,
install forward engine mounts to right hand mounting pads.
C. Install two forward engine mounts on two mounting pads on the interstage housing. Install eight plugs
to the mount holes on the other two pads. Torque the plugs 90 to 100 inch-pounds (10.1-11.2 N.m.).
4. Job Close-up
SUBTASK 71-00-00-410-036
A. Install the engine into the aircraft. Refer to the Aircraft Maintenance Manual.
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Page 403
Dec 12/17
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Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
Fig. 402 Engine in Build Stand - Removal/Installation 71-00-00
Page 405
Dec 12/17
5. General
This task provides procedures for installing the engine in the build stand. Refer to the following
illustration(s):
Figure 403
Figure 404
SUBTASK 71-00-00-941-037
A. Standard Equipment
Overhead Hoist
SUBTASK 71-00-00-943-037
B. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-0147C4000 Sling, Engine Lift
08-2021-0000 Stand, Engine
K-2032 Adapter, Engine Stand
SUBTASK 71-00-00-945-037
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
EFFECTIVITY: FJ44-2C
71-00-00
Page 406
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7. Job Set-up
SUBTASK 71-00-00-010-040
CAUTION INSPECT LIFT SLING FOR DAMAGE BEFORE USE. MAKE SURE THAT
SHACKLE BOLTS ON LIFT ARMS ARE SECURELY FASTENED. MAKE
SURE THAT ADJUSTMENTS FOR LENGTH AND CENTER-OF-GRAVITY
ARE CORRECT FOR ENGINE MODEL/TYPE.
(1) Adjust lift sling for length and/or center-of-gravity to match engine model/type. Tighten bolts
securely. Refer to Figure 403.
(a) Connect lift sling front arm to front lift bracket on forward interstage housing flange using
detent pin.
(b) Connect lift sling outboard rear arm to outboard lift point on rear mount ring using detent
pin.
NOTE The inboard rear arm of lift sling has two mounting holes. Use the
upper hole for level installation. Use the lower hole if the engine
needs to be rolled slightly for aircraft installation.
(c) Connect lift sling inboard rear arm to inboard lift point on rear mount ring using detent pin.
(3) Connect lifting sling to overhead hoist. Adjust position of hoist, as required, and raise hoist until
there is light, equal tension on lifting sling arms.
B. Complete removal of engine from aircraft or shipping container. Refer to Aircraft Maintenance
Manual for engine removal task.
SUBTASK 71-00-00-010-041
C. Remove two forward engine mounts from two mounting pads on the interstage housing. Remove
plugs from the other two mounting pads, if applicable. Refer to the Aircraft Maintenance Manual.
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8. Procedures
SUBTASK 71-00-00-410-037
(1) Install four engine mount adapters, K-2032, to the four engine mount pads on the interstage
housing. Torque 16 mounting bolts 200 to 245 inch-pounds (22.5 to 27.6 N.m).
(2) Rotate the gear-driven support arm, if necessary, to put it in the vertical position. Lock rotation
crank.
(3) Retract the pivoting support arm to make room for installation of the engine.
CAUTION MAKE SURE ALL DETENT PINS ARE SECURELY INSERTED AND LOCKED
IN PLACE WHEN USING THE ENGINE SLING AND BUILD STAND.
(4) Move the engine build stand, 08-2021-0000, into position as shown in Figure 404. Guide two
engine mount adapters into the gear-driven support arm yokes and lock in place with detent
pins.
(5) Swing the pivoting support arm into the vertical position and slide it inward to engage the other
two engine mount adapters. Lock the adapters and the support arm yokes with detent pins.
(6) Remove engine lifting sling from the engine by removing detent pins.
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EFFECTIVITY: FJ44-2C
Fig. 404 Engine in Build Stand - Removal/Installation 71-00-00
Page 410
Dec 12/17
1. General
This task lists the types of ground running tests that are necessary after engine maintenance. Refer
to the following tables:
table 501
table 502
NOTE The tests which are referred to in this task are found in 71-00-00, P.B. 501
SUBTASK 71-00-00-945-019
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-00-00 1301 Engine - Testing
73-25-01 401 Fuel Manifold Filter Assy - Removal/Installation
74-00-10 501 Ignition System - Adjustment/Test
77-20-02 601 Intermediate Turbine Temperature (ITT) Probe - Inspection/Check
79-25-01 501 Oil Pressure Regulating Valve - Adjustment/Test
3. Procedures
SUBTASK 71-00-00-760-028
EFFECTIVITY: FJ44-2C
71-00-00
Page 501
Dec 12/17
B. Refer to the table below for specific tests that are necessary after engine maintenance or
replacement of the engine, basic engine components, or engine line replaceable units (LRUs). The
Oil Consumption Check is required to evaluate a suspected oil consumption problem.
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Page 502
Dec 12/17
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71-00-00
Page 503
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71-00-00
Page 504
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Page 505
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7 Ensure the oil pressure falls within the operating band. Refer to 79–25–01, P.B. 501.
8 In the event of Fuel Flow Transmitter failure, remove the Fuel Manifold Filter
Assembly and inspect for debris. Refer to 73–25–01, P.B. 401.
4. General
This task gives operational procedures and limits for the engine. Refer to the following illustration(s):
Figure 501
Figure 502
Figure 503
Figure 504
Figure 505
Figure 506
Figure 507
Figure 508
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2 The procedures outlined in this task are generic guidelines covering operation of the
engine and do not take into consideration installation-specific requirements. Please refer
to the Aircraft Operation Instructions to ensure appropriate procedures are followed.
3 When you run the engine on the ground, set HP bleed OFF (unless test instructions
specify ON) and use minimal electrical and hydraulic power.
4 When you are doing more than one test, group them, if possible, during the one
engine cycle. This prevents unnecessary operation of the engine.
5 When operating the engine, monitor the engine parameters to make sure
the engine does not go past its operating limits.
6 Operate the thrust levers slowly and smoothly and keep ground running to the minimum
level of power and time required. You should not move the thrust lever quickly unless
you are doing snap acceleration or deceleration tests. This causes the engine
temperature to change quickly which is not good for the life of the engine.
SUBTASK 71-00-00-945-026
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-00-01 301 Approved Engine Fuel - Servicing
6. Procedures
SUBTASK 71-00-00-700-007
EFFECTIVITY: FJ44-2C
71-00-00
Page 509
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(d) To monitor the effect which a replacement unit can have on the operation of a system or
the performance of the engine.
(a) When you do ground-run tests, look at the areas that are dangerous before you go near
the aircraft. Refer to Figure 501.
(b) Point the nose of the aircraft into the wind. If this is not possible (and if the speed of the
wind is more than 10 knots), you must not operate the engines above 60 percent N1 until
the aircraft rolling speed is greater than the tailwind component.
(c) Make sure that you have ground fire-extinguishing equipment available at all times.
(d) Close the cowling doors when you operate the engine. Leave them open only when told
to do so in a task.
(e) Make sure that there is no equipment or unwanted material near the engine exhaust
and inlet.
1 Keep ground runs to the minimum level of power and time that is necessary to do
the tests.
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Page 510
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(a) Icing can be expected to occur when visible moisture is present such as cloud or fog with
low visibility, rain, snow, sleet, ice crystals, or with standing water, ice or snow present on
the ground. If icing conditions exist or are anticipated, all aircraft engine anti-ice systems
should be switched on. Takeoff and maximum continuous thrust settings for operation
with the various bleed levels are defined in the Williams International approved N1 power
settings charts in the engine parts list.
(a) Oil Pressure - Engine oil pressure limits are listed under operating limits. For nominal
engine operation, the oil pressures shown in Figure 502 apply.
(b) Oil Temperature - High oil temperatures and associated low oil pressures can occur when
returning to ground idle from high power. Therefore ground operation at or near takeoff
thrust should be limited in duration to avoid oil temperatures rising above 90° C (194°F)
or perform a part power cool down prior to returning to ground idle.
(c) Starting under cold weather conditions - When starting a cold soaked engine below
freezing temperature, high oil pressure can occur. As oil temperature rises with engine at
idle, oil pressure will fall. Oil Pressure limits are listed in table 503.
(d) Oil Consumption - The maximum permissible oil consumption is 0.023 gal/hr. If oil
consumption is exceeded, refer to 71-00-00-00, Troubleshooting.
(a) It is highly recommended that while the aircraft is unattended, the inlet and exhaust
covers are installed to prevent windmilling.
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71-00-00
Page 511
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7. Operating Limitations
SUBTASK 71-00-00-700-008
CAUTIONS: 1 OBEY THE OPERATING LIMITS SPECIFIED IN THE TEXT AND THE
FIGURES WHEN YOU OPERATE THE ENGINE. IF YOU DO NOT, IT WILL
DECREASE THE OPERATING LIFE OF THE ENGINE.
NOTES: 1 The conditions defined herein are the minimum/maximum as noted for the
engine. Other information is supplied for operator convenience. Any instances
of the operating limits being exceeded must be recorded and reported
together with duration and degree of excess. The operator should take
whatever action is necessary, to keep operation within limits.
2 Long term shifts in engine shaft speeds (N1 and N2) or ITT readings can be useful
in tracking trends in engine health. It is in the best interest of the operator to notify
Williams International if any sudden or gradual changes are detected over time.
NOTE Fuel leakage rate is for normal operations. However, after an aborted start, fuel
leakage may exceed 2ml/min. If this occurs, clear fuel from combustor by
motoring the engine. Refer to instructions given under Failure of Engine to Light.
B. Starting Limits:
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71-00-00
Page 512
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2 Time to light-off is defined as the time after the power lever is moved
from SHUTOFF to START position until light-off is indicated.
3 For ground start only. For in-flight windmill and starter assisted
starts, refer to FJ44-2C Operating Instructions.
THRUST TIME LIMIT ITT TEMP N2 RPM - % N1 RPM - % OIL PRESS OIL TEMP
SETTING (minutes) °C psig °C
see Figure
START 506 -40 - 135
(8)
IDLE 35 MIN 100
CONTINUOUS -40 - 135 (7)
(gnd & flt) MAX (6)
820 max.
TAKEOFF (1) See Figure 40,900-99.3 18,300-106.1 45-90 10 - 135
504
MAXIMUM
(2) 805 max 40,900-99.3 18,300-106.1 45-90 (3) 10 - 135
CONTINUOUS
see Figure see Figure seeFigure 23 MIN (4)
TRANSIENT 149 (4)
503 507 508 100 MAX (5)
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NOTES: 1 Takeoff thrust settings are defined in the Williams International approved
N1 power setting charts in the engine parts list. Time at takeoff thrust
is limited to 5 minutes maximum (10 minutes maximum with one engine
inoperative) beginning when the thrust lever is advanced.
2 Max continuous climb thrust and max continuous cruise thrust settings are
defined in the Williams International approved N1 power setting charts
in the engine parts list. Continuous operation is acceptable provided
maximum continuous engine limits are not exceeded.
6 Maximum allowable oil pressure is 100 psig for up to five minutes maximum.
SUBTASK 71-00-00-700-009
A. Engine Pre-Start
(1) Verify battery or ground power supply meets the starter/generator manufacturer’s requirements.
(4) Set bleed air -OFF. (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Table 2-1))
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71-00-00
Page 514
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B. Engine Start
(5) Monitor ITT. ITT may not exceed the limits defined in Figure 506
(6) Between 40% N2 and idle, set starter - OFF. Refer to starter-generator manufacturer for
optimum starter cut-out speed.
(8) If applicable, at 48% N2 or above, set generator ON, ignition OFF, and fuel boost pump OFF
(and motive flow ON).
(9) When the engine reaches stable RPM, start is complete. Scan the engine instruments and
warning lamps for normal indications.
SUBTASK 71-00-00-700-010
C. Engine Shutdown
EFFECTIVITY: FJ44-2C
71-00-00
Page 515
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NOTE Allow engine to remain at ground idle for a minimum of two minutes
prior to shutdown to increase component life and allow hot section
component temperatures to equalize.
(3) Set bleed air - OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in table 503)
SUBTASK 71-00-00-700-011
(3) Set bleed air - OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in table 503
(4) Set engine starter switch - ON, for time duration as specified by starter/generator
manufacturer’s operation duty cycle limit.
SUBTASK 71-00-00-700-012
Whenever an engine fails to start within 10 seconds after moving the power lever to the idle position:
(b) Continue to motor engine with starter (within manufacturer’s operational duty cycle limits)
to clear fuel from the combustor.
B. No N1 Speed at 25% N2
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71-00-00
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71-00-00
Page 517
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71-00-00
Page 518
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71-00-00
Page 519
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10. General
This task checks idle performance and ensures there are no fuel, oil or air leaks. You must do this test
after engine maintenance as required by the Test List matrix in 71-00-00, P.B. 501. Refer to the following
illustration(s):
Figure 509
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-942-009
A. Consumables
Reference Designation
MAT-002 Oil, Preservative
SUBTASK 71-00-00-945-009
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
79-30-01 601 Magnetic Chip Collector - Inspection/Check
12. Definitions
SUBTASK 71-00-00-760-013
A. A leak is defined as the formation of a fluid droplet on the engine after completion of the final run. In
areas where, due to location, a droplet cannot form, fluid may be collected by wiping the surface
of the component with a finger. If enough fluid can be collected from an area to form a droplet, it
is considered a leak.
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B. Fluid caught between mating surface at fluid line joints, or a discolored (wetted) surface is not a
leak. If a droplet has not formed or enough fluid cannot be collected on the finger to form a droplet,
it is not a leak.
C. Fuel leakage from the fuel drains following false or aborted starts in which unburnt fuel is introduced
to the engine is acceptable. During engine operation, allowable leak rate from the fuel control/fuel
pump drain is 0.10 ml per minute, or approximately 2 drops per minute.
D. A wetting of the oil breather exit port is acceptable to the extent that no more than three drops
are present on the port lip.
F. Bypass air leakage around the fuel manifold tube, bypass duct flanges, Service Islands, and ITT
probes is acceptable; however, if the air is abnormally hot, please contact Williams International
Product Support for further guidance.
SUBTASK 71-00-00-010-009
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
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14. Procedures
SUBTASK 71-00-00-760-018
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
A. If maintenance has been performed on the engine fuel system or the aircraft fuel system, or if the
engine fuel system has been preserved with preservative oil MAT-002, purge the fuel system
as follows:
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOUROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(2) Loosen the two loop clamps securing the fuel line tubes together. Disconnect the Fuel Union to
Manifold tube at both ends.
(3) Install drain hose to the flowmeter fitting and direct open end of hose into a bucket.
(4) Disconnect flex tube from start fuel nozzle and cap tube.
(5) Move power lever to IDLE and motor engine until a steady stream of fuel flows into the bucket.
Dispose of fuel in accordance with local regulations.
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(6) Remove drain hose. Reconnect the Fuel Union to Manifold tube at both ends. Torque tube nuts
450 to 500 inch-pounds (50.4 to 57.0 N.m.).
(7) Remove cap from flex tube. Reconnect flex tube to fuel nozzle per 73-10-01, P.B. 401.
B. Set the power lever to the SHUT-OFF position. Motor the engine for 30 seconds, refer to General
Operating Procedures, 71-00-00, P.B. 501.
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
F. Start the engine to ground idle. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE The OAT indicator reading must be within ±3° C of actual airfield ambient temperature.
(1) Ground idle speed must be within the tolerance of the value shown onFigure 509 .
(2) If ground idle speed exceeds limit, shut down engine and refer to Troubleshooting, 71-00-00,
P.B. 101.
I. Refer to TEST LIST, 71-00-00, P.B. 501 to determine if leak check must be run at max continuous
power. If not, set speed in accordance with paragraph (1), below. If so, set speed in accordance
with paragraph (2), below:
(1) Leak Check at Intermediate Power. Slowly advance the power lever and let engine become
stable at or above N2 speed of 75% (±1.0%). Remain at this speed for 3 minutes then decel
to idle.
(2) Leak Check at Max Continuous Power. Refer to the Aircraft Flight Manual and determine the
max continuous N1 speed setting. Slowly advance the power lever to the N1 speed setting
required for max continuous operation. Remain at max continuous for 10 minutes, then decel
to idle.
J. Check for signs of fuel or oil leaks; look carefully around the gearbox, fuel pump and lubrication
pump, breather plumbing, breather exit, and all drains.
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K. Apply a soap and water solution to air tube connections and look for leaks. The compressor
discharge pressure (CDP) tube has a moisture drain hole. Disregard this hole. Some air (CDP) may
escape the internal fitting. This is normal and is not a defect. Dirt or discoloration on adjacent
surfaces is acceptable.
L. Stop the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
M. Check the engine for signs of leakage. If there are leaks, repair as necessary.
N. If an engine hot section component has been removed/installed since the engine was last run, check
the oil supply and scavenge tube flanges with a borescope to make sure there are no leaks.
O. If there are signs of leaks at the core engine tubes, repair as necessary.
SUBTASK 71-00-00-410-009
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Fig. 509 Ground Idle N2 Speed Check
Dec 12/17
16. General
This task checks the level of vibration and the source. You must do this test after engine maintenance as
required by the Test List matrix in 71-00-00, P.B. 501. Refer to the following illustration(s):
Figure 510
Figure 511
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-941-024
A. Standard Equipment
Vibration Analyzer – ACES Model 1700, 4040
(OPTIONAL)
Vibration Analyzer – DynaVibe GX3 (OPTIONAL)
SUBTASK 71-00-00-943-024
B. Special Tools
Reference Designation
TL37253 Mount, Engine Vibration
SUBTASK 71-00-00-945-024
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-024
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(3) Remove lockwire and remove plug from the engine mount pad hole (upper outboard side,
upper forward hole as installation allows). Install TL37253, engine vibration mount into mount
pad hole. Torque 70 - 80 inch-pounds (7.9 - 9.0 N.m). Refer to Figure 510.
(5) Hook-up vibraton pick-up assembly to Vibration Analyzer – ACES Model 1700, 4040
(OPTIONAL) or Vibration Analyzer – DynaVibe GX3 (OPTIONAL) (or equivalent) and set unit
to record vibration data in accordance with manufacturers instructions.
19. Procedures
SUBTASK 71-00-00-760-034
WARNINGS: 1 MAKE SURE THAT PEOPLE AT WORK NEAR THE AIRCRAFT KNOW
OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE THAT
PEOPLE ARE NOT KILLED OR BADLY INJURED.
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
(6) Advance the power lever from idle, at a uniform rate over a period of approximately 100
seconds (not less than 90 seconds) until takeoff is achieved.
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(8) Move the power lever back, at a uniform rate over a period of approximately 90 seconds
(not less than 60 seconds), to idle.
(9) Review the recorded vibration data and compare it with the following limits:
(a) Allowable vibration level - peak (1E HP, Radial) = 1.1 IPS (inch per second).
(b) Allowable vibration level - peak (1E LP, Radial) = 0.37 IPS (inch per second).
(10) Stop the engine or continue with the next ground run test, if applicable. Refer to General
Operating Procedures, 71-00-00, P.B. 501.
(11) If vibration levels exceed limits, refer to Troubleshooting (High vibration with or without noise),
71-00-00, P.B. 101.
(12) If LP vibration levels exceed limits, refer to Trim Balance Procedures, Task 71-00-00-760-825..
SUBTASK 71-00-00-410-024
(1) Remove the vibration pick-up assembly from TL37253 engine vibration mount
(2) Remove the TL37253 engine vibration mount from the engine mount pad.
(3) Install plug into engine mount pad hole. Install lockwire to retain plugs.
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21. General
This task provides procedures for trim balance which reduce the 1E LP radial vibration to acceptable
levels. Refer to the following illustration(s):
Figure 512
Figure 513
Figure 514
Figure 515
NOTE The following are the two methods for trim balancing:
• The Vector Subtraction Method: This is the initial method used for trim balancing.
• The 3-Weight Method: This is the second method used, if further reduction of
1E LP is required. This method may also be used if phase information (from
the ACES Analyzer) is not available.
SUBTASK 71-00-00-941-020
A. Standard Equipment
Vibration Analyzer – ACES Model 1700, 4040
(OPTIONAL)
Cabling (between Accelerometers And Analyzers)
Vibration Analyzer – DynaVibe GX3 (OPTIONAL)
Accelerometer (radial UOMP)
Setscrews
Accelerometer Mounting Bracket
SUBTASK 71-00-00-942-020
B. Consumables
Reference Designation
MAT-033 Marker, Fine Line
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SUBTASK 71-00-00-944-020
C. Expendable Parts
NOTE In order to perform trim balance, a trim balance-capable spinner must be installed on
the engine. Setscrew weights are also required. Refer to the Illustrated Parts Catalog.
IPC Reference
Subject Fig. Item Nomenclature
72-00-30 01 39 Setscrew
72-00-30 01 40 Setscrew
SUBTASK 71-00-00-945-020
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
23. Procedures
SUBTASK 71-00-00-760-030
(1) Install accelerometer (radial UOMP) radially at the upper outboard mount pad (UOMP) location.
Additional accelerometers and/or microphones may be installed as required to monitor engine
response.
(2) Hook up the Vibration Analyzer – ACES Model 1700, 4040 (OPTIONAL) or Vibration Analyzer
– DynaVibe GX3 (OPTIONAL) (or equivalent), accelerometer mounting bracket, cabling
(between accelerometers and analyzers) and N1 speed light sensor.
B. Setup Procedures:
(1) Using MAT-033 marker, alignment "match-mark" the spinner, spinner pilot plate, locking plate,
and fan rotor as new baseline. Put the "match-mark" in line with one of the spinner mount bolts.
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(2) Note the condition of the fan tip shroud and mark, if necessary, to document any subsequent tip
rubs.
(3) Place MAT-201 reflective tape on tip of spinner. Use a piece of tape about ¼ inch wide and 1
inch long. Put the long dimension of the tape along the spinner axis in line with the "match-mark.
The tape and "match-mark" will be the 0 degree reference point. Refer to Figure 512.
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the ACES analyzer. Perform a slow decel to idle.
(b) Shutdown engine per General Operating Procedures 71-00-00 P.B. 501, and examine
fan tip shroud for new tip rubs.
NOTE Weight(s) are setscrews, available in various sizes and weights, ranging
from 0.0442 ounces (1.25 grams) to 0.1500 ounces (4.25 grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(a) Remove the spinner and install 1 trim weight in the first hole CW (aft looking forward)
from the 0 degree reference mark. Screw in approximately 1/8 to ¼ inch below flush.
NOTE For longer trim balance screws, it is acceptable for the screw to stand
proud of the surface, as long as it is bottomed in the hole.
(b) Reinstall spinner to baseline position. Refer to 72-00-30, P.B. 401 for spinner installation.
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the analyzer. Perform a slow decel to idle.
(b) Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501 and examine
fan tip shroud for new tip rubs.
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(a) If the 1E LP vibration level has not been reduced to acceptable levels, a Third Run is
needed.
(b) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the analyzer. Perform a slow decel to idle.
(c) Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501and examine
fan tip shroud for new tip rubs.
(d) If the 1E LP vibration level has not been reduced to acceptable levels, a Fourth Run is
needed.
(b) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the ACES analyzer or equivalent. Perform a slow decel to
idle. Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501.
(c) If this method, (Trim Balance Testing by Vector Subtraction Method), results in vibration
levels that are not sufficiently reduced, do the following:
1 Verify lowest vibration levels (at the speed of interest) were obtained during the
final run.
2 Verify vibrations (at other speeds) were not reached or exceeded the limit.
3 If above verifications apply, one additional weight may be used in the location
adjacent to the weight that is already installed. The procedures must be repeated to
verify that vibration levels at all speeds are satisfactory. No more than two weights
may be used.
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(d) If the 1E LP vibration level has not been reduced to acceptable levels, proceed to Trim
Balance by 3-Weight Method.
NOTE Weight(s) are setscrews, available in various sizes and weights (grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(1) Perform an initial run per step C(3). Only the 1E amplitude is needed.
(a) Baseline Weight Location: If this effort is a follow-on to the Vector Subtraction Method,
then the fourth run (of the vector subtraction method) will be the 1st weight run and the
initial run, step C(3) is the initial.
(a) Relocate trim weight 120 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power (over
a 90 second time frame), 1 minute dwell at T.O., followed by a slow decel to idle (over
90 seconds).
(4) Shut down and examine fan tip shroud for new tip rubs.
(a) Relocate trim weight to 240 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power (over
a 90 second time frame), 1 minute dwell at T.O, followed by a slow decel to idle (over
90 seconds).
(c) Shutdown and examine fan tip shroud for new tip rubs.
(c) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power (over
a 90 second time frame), 1 minute dwell at T.O., followed by a slow decel to idle (over
90 seconds).
(d) Shutdown and examine fan tip shroud for new tip rubs.
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(8) If this method, (Trim Balance Testing by 3-Weight Method), results in vibration levels that
are not sufficiently reduced, do the following:
(a) Verify lowest vibration levels (at the speed of interest) were obtained during the final run.
(b) Verify vibrations (at other speeds) were not reached or exceeded the limit.
(9) If above verifications apply, one additional weight may be used in the location adjacent to the
weight that is already installed. The procedures must be repeated to verify that vibration levels
at all speeds are satisfactory. No more than two weights may be used.
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Page 543
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Dec 12/17
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24. General
This task checks the engine stability and ensures that engine acceleration time is within limits. You must
do this test after engine maintenance as required by the Test List matrix in 71-00-00, P.B. 501.
Figure 516
Figure 517
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-941-004
A. Standard Equipment
Stopwatch
SUBTASK 73-00-00-942-003
B. Consumables
Reference Designation
MAT-061 Lockwire, .020
SUBTASK 71-00-00-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
73-18-01 501 Fuel Control Unit - Adjustment/Test
SUBTASK 71-00-00-010-004
A. Before performing stability/acceleration ground run, adjust integrated fuel control unit acceleration
control to the maximum internal stop in accordance with Task 73-18-01-820-801, 73-18-01, P.B.
501 and the following instructions:
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(1) Turn internal hex adjustment screw up to 1½ turns clockwise, or until the screw reaches the
internal stop, whichever is less.
(2) Install lockwire MAT-061 to to protect adjustment or re-apply torque paint to recessed hex to
protect adjustment.
27. Procedures
SUBTASK 71-00-00-760-003
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WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
F. Accel engine 87% to 89.3% N2. One should see the bleed valve move to closed position. Decel
engine to idle. One should see the bleed valve move to open position. Remove WOW overide
per A.M.M.
G. Read the outside air temperature (OAT) and refer toFigure 517 to determine the takeoff N1 speed
setting.
H. Determine 98 percent of the takeoff N1 speed setting. Perform a rapid acceleration from 64.3% N2 to
the takeoff N1 speed setting by advancing the throttle in less than one second. Using a stopwatch,
time the acceleration from initial throttle advance to 98% of the takeoff N1 speed setting.
J. Rapidly (less than 1 second) move the power lever back to the ground idle position, observing the N2
speed indicator. Maintain the power lever at ground idle for a minimum of 1 minute, then rapidly (less
than 1 second) advance the power lever from ground idle to takeoff N1.
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CAUTION POWER LEVER SLAM WILL TEND TO OVERSHOOT TAKEOFF N1; ADJUST
POWER LEVER POSITION WHEN N1 REACHES TAKEOFF VALUE TO AVOID
OVERSPEED AND REMAIN WITHIN APPROVED LIMITS.
K. Maintain the power lever at takeoff N1 for a minimum of 20 seconds. The engine must operate
normally without flame-out during the entire max-ground idle-max transient.
(1) Slowly (greater than 20 seconds) reduce the power lever position to 77.7% N2 and maintain
this position for a minimum of 30 seconds.
(2) Rapidly (less than 1 second) move the power lever back to the ground idle position. The
engine must operate normally without flame-out during the entire intermediate-ground idle
decel transient.
(3) Repeat steps (1) and (2) (above) two more times.
(4) Slowly advance the power lever position from ground idle to 72.8% N2 and maintain this
position for a minimum of 30 seconds.
(5) Rapidly (less than 1 second) move the power lever back to the ground idle position. The
engine must operate normally without flame-out during the entire intermediate-ground idle
decel transient.
(6) Repeat steps (4) and (5) (above) two more times.
(7) Slowly advance the power lever position from ground idle to 68% N2 and maintain this position
for a minimum of 30 seconds.
(8) Rapidly (less than 1 second) move the power lever back to the ground idle position. The
engine must operate normally without flame-out during the entire intermediate-ground idle
decel transient.
(9) Repeat steps (7) and (8) (above) two more times.
M. Rapidly advance the power lever from ground idle to the predetermined takeoff N1 speed setting as
indicated on the vertical N1 speed indicators. Check, with the stopwatch, the time between ground
idle and 98 percent of the takeoff speed setting.
O. Repeat the acceleration and timing procedure (steps M and N) at least three times and average
the results to reduce timing errors.
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NOTE The OAT indicator reading must be ±3° C of actual airfield ambient temperature.
P. Observe the outside air temperature (OAT) and compare the acceleration time with Figure 516. If
acceleration time exceeds limits, refer to Troubleshooting (Slow Acceleration), 71-00-00, P.B. 101.
Retest as required.
SUBTASK 71-00-00-410-004
A. Shut-Down the engine or continue with the next ground run test, if applicable. Refer to General
Operating Procedures, .71-00-00, P.B. 501
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Fig. 516 Max Allowable Accel Time for Ground Checks - 64.3% N2 to 98% of Takeoff N1
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29. General
This task ensures the engine performance is within limits. You must do this test after engine maintenance
as required by the Test List matrix in 71-00-00, P.B. 501. Refer to the following illustration(s):
Figure 518
Figure 519
Figure 520
Figure 521
Figure 522
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-942-015
A. Consumables
Reference Designation
MAT-021 R-MC Cleaner
SUBTASK 71-00-00-945-015
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-31-20 801 Fan Rotor - Repair
SUBTASK 71-00-00-010-015
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32. Procedures
SUBTASK 71-00-00-760-024
(1) Make sure the fan rotor is clean. Clean as required using MAT-021.
(2) Inspect fan rotor for damage and repair as required. Refer to 72-31-20, P.B. 801.
(3) Visually inspect bypass area for debris or other blockage. Remove any blockage.
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
E. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE The OAT indicator reading must be within ±3° C of actual airfield ambient temperature.
G. Observe N2 speed and outside air temperature (OAT) and compare to Figure 518.
(1) Ground Idle speed must be within the tolerance of the value shown onFigure 518 .
(2) If ground idle speed exceeds limit, shut-down engine and refer to Troubleshooting, 71-00-00,
P.B. 101.
I. Slowly advance the power lever to the N1 speed setting required for takeoff thrust and stabilize
for two minutes.
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J. Monitor the engine ITT and refer to Figure 520 to determine if it is within allowable limits. If not,
repeat the Performance Check with the HP bleed air ports capped:
(1) Remove the HP bleed air tubes from the right and left hand service adapters. Install HP bleed
port cap to each port. Refer the Aircraft Maintenance Manual. Reference figure below for
locations of the HP bleed air ports on the engine (Figure 522).
(2) Monitor the engine ITT with the HP bleed air ports capped and refer to Figure 3 to determine
if it is within allowable limits. If not, shut down engine and refer to Troubleshooting (High
ITT), 71-00-00, P.B. 101.
K. Monitor the engine N2 speed and refer to Figure 521 to determine if it is within allowable limits. If not,
shut-down engine and refer to Troubleshooting (Overspeed N2), 71-00-00, P.B. 101.
M. Shut down the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
N. Remove the HP bleed port caps from the right and left hand service adapters. Install the HP bleed
tubes, to each port. Refer to the Aircraft Maintenance Manual.
SUBTASK 71-00-00-410-015
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Page 557
Fig. 518 Ground Idle N2 Speed Check
Dec 12/17
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Page 558
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EFFECTIVITY: FJ44-2C
71-00-00
Page 560
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 561
Dec 12/17
34. General
This task monitors and calculates oil consumption. You must do this test as required by Troubleshooting,
71-00-00 P.B. 101.
SUBTASK 71-00-00-942-011
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 71-00-00-945-011
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
36. Procedures
SUBTASK 71-00-00-760-020
A. Service oil system with MAT-001 engine oil, if required. DO NOT top off oil level to full line. Refer
to 72-00-03, P.B. 301.
EFFECTIVITY: FJ44-2C
71-00-00
Page 562
Dec 12/17
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
B. Start the engine and run for five minutes at idle to warm oil. Refer to General Operating Procedures,
71-00-00 P.B. 501.
C. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
NOTE Carefully time engine run time in decimal hours. This information will
be used to calculate oil consumption.
E. Start the engine and run for a minimum of one hour at 85 to 90% N2. Refer to General Operating
Procedures, 71-00-00 P.B. 501. Engine run can be performed on the ground or in flight.
F. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
G. Carefully check the oil level while still warm. Add small, measured amounts of oil, and continue
checking level, until oil is at the original recorded level. Record amount of oil added (used).
(1) Convert recorded amount of oil used to gallons. Use one of the following conversion factors, as
required:
(2) Divide gallons of oil used by engine run time (decimal hours). This is oil consumption in gallons
per hour.
EFFECTIVITY: FJ44-2C
71-00-00
Page 563
Dec 12/17
SUBTASK 71-00-00-760-021
I. The maximum allowable limit for oil consumption is 0.023 gallons (or 2.94 ounces) per hour. If oil
consumption exceeds this limit, reject engine.
37. General
This task checks that the engine performs correctly at high power. You must do this test after engine
maintenance as required by the Test List matrix in the List of Test Procedures,71-00-00, P.B. 501. Refer
to the following illustration(s):
Figure 523
Figure 524
Figure 525
Figure 526
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-945-006
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
73-24-01 201 Electronic Control Unit - Maintenance Practices
SUBTASK 71-00-00-010-006
EFFECTIVITY: FJ44-2C
71-00-00
Page 564
Dec 12/17
40. Procedures
SUBTASK 71-00-00-760-004
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
C. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE The OAT indicator reading must be within ±3° C of actual airfield ambient temperature.
E. Observe N2 speed and outside air temperature (OAT) and compare to Figure 523.
(a) FOR FJ44-2A and FJ44-2C ONLY: Idle speed must within the specified tolerance shown
in figure.
(b) All other models: Must be at or below the value shown in the figure.
(2) If idle speed exceeds limit, shut-down engine and refer to Troubleshooting, 71-00-00, P.B. 101.
NOTE (FJ44-2A Only) There are alternate charts for N1 Speed@Takeoff depending on
the ECU software version. To determine ECU software effectivity code, refer to
ECU Software Effectivity List (73-24-01, P.B. 201), or FJ44-2A IPC
EFFECTIVITY: FJ44-2C
71-00-00
Page 565
Dec 12/17
G. Slowly advance the power lever to the N1 speed setting required for takeoff thrust and stabilize
for two minutes.
H. Monitor the engine ITT to determine if it is within allowable limits. Refer to Figure 525. If not,
shut-down engine and refer to Troubleshooting (High ITT), 71-00-00, P.B. 101.
I. Monitor the engine N2 speed to determine if it is within allowable limits. Refer to Figure 526. If not,
shut-down engine and refer to Troubleshooting (Overspeed N2, 71-00-00, P.B. 101.
K. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE If the engine did not perform within allowable limits at take-off power, remove the
HP bleed tubes and repeat the ground-run test with the bleed ports capped. If
engine performs within limits with bleed ports capped, troubleshoot aircraft bleed
system in accordance with the Aircraft Maintenance Manual.
SUBTASK 71-00-00-410-006
EFFECTIVITY: FJ44-2C
71-00-00
Page 566
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 567
Fig. 523 Ground Idle N2 Speed Check
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 568
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 570
Dec 12/17
42. General
This task contains instructions for performing a capped bleed engine run. Refer to the following
illustration(s):
Figure 527
Figure 528
SUBTASK 71-00-00-943-005
A. Special Tools
Reference Designation
TL-240226 Wrench, Special Crowsfoot
SUBTASK 71-00-00-945-005
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-005
A. To prepare engine for test, remove the cowling. Refer to the Aircraft Maintenance Manual.
45. Procedures
SUBTASK 71-00-00-760-051
A. Disconnect the aircraft bleed air plumbing from the HP bleed air fittings on the right and left hand
service adapters. Install an HP bleed port cap to each port. Reconnect/clamp aircraft plumbing.
Refer to the Aircraft Maintenance Manual and see Figure 528.
EFFECTIVITY: FJ44-2C
71-00-00
Page 571
Dec 12/17
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE Make sure that atmospheric conditions are measured at the time
of test and are recorded accurately.
(6) (FOR FJ44-2A ONLY) If in manual mode, determine the takeoff thrust N1 speed setting.
(7) Take data as shown on Figure 527for Ground Power Check stabilizing three minutes before
recording data at each powersetting.
(8) Return to idle for two-minute cool-down and stop the engine. Refer to General Operating
Procedures, 71-00-00, P.B. 501.
SUBTASK 71-00-00-410-005
B. Install HP bleed adapter and tighten to 590 to 610 inch-pounds (66.6 to 68.9 N.m) using special
crows foot TL-240226.
EFFECTIVITY: FJ44-2C
71-00-00
Page 572
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 573
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-00
Page 574
Dec 12/17
1. General
This task provides procedures to clean the power plant with fresh water. Perform this task to remove salt
and other corrosive substances from the engine.
Figure 701
Figure 702
SUBTASK 71-00-03-941-001
A. Standard Equipment
Pressure Washer Spray Equipment (50 To 100 Psi)
SUBTASK 71-00-03-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-50-00 201 Recommended Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
3. Procedures
SUBTASK 71-00-03-170-001
NOTE There are two separate cleaning tasks for the power plant. The water rinse is a
water-only wash for removing salt or other corrosive substances from the interior of
the engine. The compressor wash procedure uses approved cleaning fluids to remove
dirt and grime from the gas path and improve compressor efficiency.
A. Water Rinse
(1) If ambient temperature is below 32°F (0°C) and engine has been shut down for more than
30 minutes, engine must be warmed up. Start engine and run at idle for a minimum of five
minutes. Operate engine in accordance with General Operating Instructions Task of 71-00-00,
P.B. 501. Shut down engine.
EFFECTIVITY: FJ44-2C
71-00-03
Page 701
Dec 12/17
NOTE To ensure that fluid reaches the engine core, initial spray cleaning should
be performed with the engine static (not running). Rotation of the fan
(LP spool) forces the flow outwards into the bypass area.
(4) While engine is static (not running), use Pressure Washer Spray Equipment (50 to 100 psi).
Spray 2.5 to 3.5 gallons of clean water (drinking purity) into the engine core and around the
circumference of the fan shroud. Direct the spray towards the base of the spinner and the fan
blade root area and the fan shroud. Spray 360 degrees around.
(5) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the fan starts to rotate, spray
2.5 to 3.5 gallons of clean water into the engine core flowpath. Direct the spray at a 30 degree
angle relative to the axial engine center line, in the same direction as the rotor rotation. Hold
the spray nozzle at the appropriate radius to enter the core Figure 702. To confirm that water
has entered the core, observe water dripping from the engine diffuser drains (aircraft drain
mast). If water is not observed, change the direction of spray and repeat starter crank.
(7) Perform Post-Rinse Engine Ground Run in accordance with the subtask that follows.
SUBTASK 71-00-03-170-003
EFFECTIVITY: FJ44-2C
71-00-03
Page 702
Dec 12/17
NOTE Please reference the Aircraft Maintenance Manual (AMM) for post-rinse
engine run procedures. Operate engine in accordance with General
Operating Procedures,71-00-00, P.B. 501. Shut down engine. If the
AMM does not contain post-rinse engine run procedures, run the
engine in accordance with the following step.
(1) After completing water rinse procedure, start engine and run at idle for a minimum of five
minutes (with bleed air OFF) to ensure that all water is evaporated or blown from the engine.
Operate engine in accordance with General Operating Procedures Task of 71-00-00, P.B.
501. Shut down engine.
EFFECTIVITY: FJ44-2C
71-00-03
Page 703
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-03
Page 704
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-03
Page 705
Dec 12/17
4. General
This task provides procedures to clean the power plant using an approved cleaning fluid. The compressor
wash procedure removes dirt and grime from the gas path to improve compressor efficiency.
Figure 703
Figure 704
NOTES: 1 R-MC MAT-021 is the preferred cleaning fluid. R-MC is a non-flammable, non-toxic,
biodegradable fluid. Gas Path Cleaner MAT-031 is also approved for use.
SUBTASK 71-00-03-941-001
A. Standard Equipment
M83248/1-904 O-ring For HP Compressor Wash
Nozzle And Borescope Port Plug
Hose For Connecting Pressure Washer Tank To –4
AN Male Fitting On HP Compressor Wash Nozzle
Pressure Washer Tank (50-150 Psi, 2.5 Gallons
Minimum Volume)
SUBTASK 71-00-03-942-001
B. Consumables
Reference Designation
MAT-021 R-MC Cleaner
MAT-031 Cleaner, Gas Path
SUBTASK 71-00-03-943-001
C. Special Tools
Reference Designation
TL109739 Nozzle Wash, HP Compressor, FJ44
TL99920 Nozzle, Wash, HP Compressor
EFFECTIVITY: FJ44-2C
71-00-03
Page 706
Dec 12/17
SUBTASK 71-00-03-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-50-00 201 Recommended Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
6. Job Set-up
SUBTASK 71-00-03-010-001
7. Procedures
SUBTASK 71-00-03-170-002
(1) If ambient temperature is below 42°F (5.5°C) and engine has been shut down for more than
30 minutes, engine must be warmed up. Start engine and run at idle for a minimum of five
minutes. Operate engine in accordance with General Operating Instructions task in 71-00-00,
P.B. 501. Shut down engine.
(4) Open the cowling to access the engine. Refer to the Aircraft Maintenance Manual.
(5) Disconnect (separate) the aircraft (or engine-mounted precooler) bleed piping from the engine
bleed fittings on the service adapters.
(6) Cover the aircraft side of the bleed piping with a plastic bag, or equivalent, to prevent entry of
water. Leave piping disconnected so that water can drain from the engine bleed fittings.
(7) (If engine configuration has a CDP line, perform this step) Remove heatshield, if required,
for access to CDP elbow.
EFFECTIVITY: FJ44-2C
71-00-03
Page 707
Dec 12/17
(8) (If engine configuration has a CDP line, perform this step) Disconnect CDP air-to-elbow tube
assembly from FCU elbow. Refer to 73-10-01, P.B. 401 .
(1) With engine shut down, wipe readily accessible inlet area, spinner, and fan blades free of all
dirt and grime using a cloth wetted with cleaner MAT-021 or MAT-031.
(2) While engine is static, use pressure washer spray equipment (50–150 psi) and spray
approximately 32-64 ounces (946-1892 ML) of cleaner MAT-021 or MAT-031 into the engine.
Direct the spray near the spinner and between the fan blades, concentrating on the core of the
engine. Spray 360 degrees around the spinner. Let engine stand five minutes.
(3) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the fan starts to rotate, spray
32-64 ounces (946-1892 ML) of cleaner MAT-021 or MAT-031 into the engine core. Direct
spray near the fan/spinner to concentrate the cleaner into the core of the engine as shown in
Figure 703. Move spray wand 360 degrees around the spinner to ensure cleaner can reach
all areas of the core.
(4) Spray some cleaner around the remaining inlet area to clean bypass duct flow path. Spray
32-64 ounces (946-1892 ML) of cleaner MAT-021 or MAT-031 during this procedure. Repeat
starter cranking if necessary. Observe starter duty cycle limits. Allow engine to stand 10
minutes.
(5) Repeat steps (2) and (3) using 2.5 to 3.5 gallons of clean water (drinking purity).
EFFECTIVITY: FJ44-2C
71-00-03
Page 708
Dec 12/17
M83248/1-904 O-ring for HP Compressor Wash Nozzle and Borescope Port Plug
TL109739 or TL99920 HP Compressor Wash Nozzle
(2) Fill pressure washer tank with 32-64 ounces (946-1892 ML) of cleaner MAT-021 or MAT-031
and pressurize the canister to 100–150 psi.
(3) Remove the borescope plug/IP bleed port from the top of the interstage housing. Refer
to Figure 704.
(4)
Install HP compressor wash nozzle into the borescope port at the top of the interstage housing.
Tighten the nozzle securely.
(5) Connect the pressure washer spray equipment to the -4 AN fitting on the end of the HP
compressor wash nozzle and torque 90 to 100 inch-pounds (10.1 to 11.2 N.m).
(7) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the starter is activated, spray
32-64 ounces (946-1892 ML) of cleaner MAT-021 or MAT-031 until the starter-crank cycle is
complete.
(8) Disconnect the pressure washer spray equipment from the wash nozzle. Fill the pressure
washer spray equipment with 32-64 ounces (946-1892 ML) of clean water (drinking purity)
and pressurize the canister to 100-150 PSI.
(9) Connect the pressure washer spray equipment to the wash nozzle and torque 90 to 100
inch-pounds (10.1 to 11.2 N.m).
EFFECTIVITY: FJ44-2C
71-00-03
Page 709
Dec 12/17
(10) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the starter is activated,
spray 32-64 ounces (946-1892 ML) of 100-150 psi pressurized water until the starter-crank
cycle is complete.
(11) Visually inspect the water draining from the compressor core for the presence of cleaning fluid.
Repeat step (10) until cleaning fluid is no longer present.
(12) Disconnect the pressure washer spray equipment from wash nozzle. Remove wash nozzle
from the borescope port.
(13) Install borescope plug/IP bleed port and O-ring into interstage housing. Torque the plug
assembly 90 to 100 inch-pounds (10.1 to 11.2 N.m) .
(1) If engine is equipped with CDP line, blow out any residual water from the CDP line. Reattach
CDP air-to-elbow tube assembly to FCU. Refer to 73-10-01, P.B. 401.
(2) Remove plastic bag from aircraft bleed piping and reconnect piping to engine bleed fittings.
Refer to the Aircraft Maintenance Manual or Engine Maintenance Manual (if applicable to
engine configuration). If torque was disturbed on HP bleed fittings, torque fittings 590 to 610
inch-pounds (66.6 to 68.9 N.m).
E. Ensure aircraft bleed system is still set OFF/CLOSED. Run engine at idle for five minutes to ensure
excess cleaning fluid and water is evaporated or blown from the engine and that there are no bleed
leaks. Operate engine in accordance with General Operating Procedures Task of 71-00-00, P.B.
501. Shut down engine.
F. Perform a Performance / High Power Check in a accordance with the table “Tests Required after
Maintenance or Component Replacement” (List of Test Procedures) in 71-00-00, P.B. 501 for HP
bleed tube assembly installation.
8. Job Close-up
SUBTASK 71-00-03-410-001
EFFECTIVITY: FJ44-2C
71-00-03
Page 710
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-03
Page 711
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-03
Page 712
Dec 12/17
1. General
This task provides procedures for the storage of an engine for nine months or more. The engine must be
preserved. Refer to the following illustration(s):
Figure 201
Figure 202
NOTES: 1 Before preserving, clean the power plant externally (installed or uninstalled).
Refer to 70-21-00, P.B. 701, Cleaning Methods and Procedures.
2 Engines stored more than six months require periodic inspection. Refer
to 71-00-24, P.B. 201, Storage Inspection.
SUBTASK 71-00-21-942-001
A. Consumables
Reference Designation
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-21-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-21-00 701 Cleaning Methods and Procedures - Cleaning
71-00-00 401 Power Plant - Removal/Installation
71-00-22 201 Preserving Installed Engine for Nine Months or More - Maintenance
Practices
71-00-24 201 Storage Inspection - Maintenance Practices
71-00-25 201 Engine Shipping/Receiving - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
71-00-21
Page 201
Dec 12/17
3. Job Set-up
SUBTASK 71-00-21-010-001
A. Preserve the engine fuel system before removing the engine from the aircraft. Refer to 71-00-22,
P.B. 201.
SUBTASK 71-00-21-010-002
CAUTION WHEN USING THE SLING, THE ENGINE SHOULD BE MOVED ONLY BY
THE SUPPLIED HANDLE OR THE SLING BRACKET. THE ENGINE OR
ITS EXTERNAL COMPONENTS SHOULD NOT BE USED TO ROTATE OR
MOVE THE ENGINE. IT MAY BE NECESSARY TO HAVE ONE PERSON
HOLD THE TOP OF THE SLING WHILE ANOTHER PERSON ROTATES THE
ENGINE USING THE SUPPLIED HANDLE. THIS METHOD MUST BE USED
TO PREVENT DAMAGE TO EXTERNAL COMPONENTS.
B. Remove the engine using engine lifting sling. Refer to Aircraft Maintenance Manual.
4. Procedures
SUBTASK 71-00-21-620-003
(1) With the engine hanging from lifting sling or installed in engine maintenance stand, drain
the engine oil. Refer to 72-00-03, P.B 301.
SUBTASK 71-00-21-620-005
(2) If engine is on a sling, remove the eight plugs which are located on the engine mount pads of
the interstage housing, if applicable to engine configuration. Place them into a cloth bag and
attach them near the mount pads.
(3) Using MAT-176 barrier material make a bag to cover the engine. Slip bag over the engine
from the underside.
EFFECTIVITY: FJ44-2C
71-00-21
Page 202
Dec 12/17
(4) Cut small openings in the barrier material at each engine mount pad.
(6) Heat seal the top edge of the barrier bag. Cut a small opening along the seam and vacuum the
air from the bag until it is drawn snugly around the engine. Reseal the bag.
(7) To install engine into an engine build stand to store the engine, refer to 71-00-00, P.B 401. To
install engine into a shipping/storage container to store the engine, refer to 71-00-25, P.B. 201.
EFFECTIVITY: FJ44-2C
71-00-21
Page 203
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-21
Page 204
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-21
Page 205
Dec 12/17
71-00-21
206
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for preserving an installed engine for more than nine months. Refer
to the following illustration(s):
Figure 201
2 Engines stored more than six months require periodic inspection. Refer to 71-00-24, 201.
SUBTASK 71-00-22-942-003
A. Consumables
Reference Designation
MAT-002 Oil, Preservative
SUBTASK 71-00-22-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-21-00 701 Cleaning Methods and Procedures - Cleaning
71-00-24 201 Storage Inspection - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Procedures
NOTE This procedure is for the engine which will remain on the aircraft and on the ground for
nine months or more. The engine fuel and oil system must be drained.
SUBTASK 71-00-22-620-007
EFFECTIVITY: FJ44-2C
71-00-22
Page 201
Dec 12/17
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(2) Disconnect the fuel tube (fuel union to manifold) at the fuel flowmeter end.
(3) Disconnect the flex fuel tube from the fuel nozzle. Insert the end of tube into a suitable container.
(4) Disconnect the airframe motive flow outlet tube from the fuel control unit. Install a plug with an
O-ring to cap the fuel control motive flow port.
(5) Remove the aircraft supplied fuel inlet line to the engine fuel pump.
(6) Install a drain tube to the fuel flowmeter fitting. Insert the opposite end of the tube into an
appropriate container.
(7) Connect the preservation oil supply hose to the inlet port on the engine fuel pump.
(11) Let preserving oil flow into engine’s fuel pump and out the drain tube which is attached to the
oil cooler.
NOTE Only MAT-002, MIL-L-6081, grade 1010 oil is approved for preservation
of this engine. Other fluids may damage the fuel system.
(12) Continue flowing preserving oil until you see a clean flow of oil.
(13) Stop motoring the engine and set the power lever to OFF.
EFFECTIVITY: FJ44-2C
71-00-22
Page 202
Dec 12/17
(15) Reinstall the airframe motive flow tube assembly to the fuel control unit.
(16) Disconnect the preservation oil tubes from the engine and reinstall the fuel tube (fuel union
to manifold) at the flowmeter end. Plug the aircraft supplied fuel inlet port on the engine fuel
pump. Torque the fuel tube 450 to 500 inch-pounds (50.4 to 57.0 N.m).
(17) Install the flex fuel tube to the fuel nozzle. Torque 70 to 120 inch-pounds (7.9 to 13.5 N.m).
(18) Secure a warning tag to the engine to indicate that engine has been preserved and that it
should not be operated or rotated until it has been depreserved.
(19) Clean all fuel and preservation oil from the engine.
SUBTASK 71-00-22-620-008
SUBTASK 71-00-22-620-009
(1) Secure a warning tag to the aircraft controls to indicate the engine has been preserved and
it should not be operated.
EFFECTIVITY: FJ44-2C
71-00-22
Page 203
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-22
Page 204
Dec 12/17
1. General
This task provides procedures for preserving an installed engine for nine months or less.
NOTES: 1 Before preserving, clean the engine externally (installed or uninstalled). Refer
to 70-21-00, 701, Cleaning Methods and Procedures.
2 Engines stored more than six months require periodic inspection. Refer
to 71-00-24, P.B. 201, Storage Inspection.
SUBTASK 71-00-23-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-21-00 701 Cleaning Methods and Procedures - Cleaning
71-00-24 201 Storage Inspection - Maintenance Practices
3. Procedures
SUBTASK 71-00-23-430-001
NOTE This procedure is for an aircraft which will remain on the ground for nine months or less.
The engine fuel system must not be drained or flushed. The fuel which remains in the
engine’s fuel system is enough to preserve the fuel system for this period of time.
EFFECTIVITY: FJ44-2C
71-00-23
Page 201
Dec 12/17
71-00-23
202
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Engines which have been preserved must be inspected periodically for signs of corrosion or deterioration
of preservation materials.
SUBTASK 71-00-24-942-001
A. Consumables
Reference Designation
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-24-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-21 201 Preserving Uninstalled Engine - Maintenance Practices
3. Procedures
SUBTASK 71-00-24-550-001
A. Perform the following inspections every six months if uninstalled engine has been enclosed in a
barrier bag:
(1) Make sure there is no apparent deterioration of the MAT-176 barrier bag sealing the engine. If
the bag is deteriorated, replace the bag and the MAT-175 desiccant bags. Refer to 71-00-21,
P.B. 201.
B. Perform the following inspections every six months if engine is installed or if it has not been enclosed
in a barrier bag:
(1) Remove inlet and exhaust covers and check for signs of corrosion or foreign material on the
fan or in the inlet and bypass duct.
(2) Rotate the fan by hand (CCW, facing aft) and check for smooth rotation.
(3) Check the external area of the engine for corrosion or damage.
EFFECTIVITY: FJ44-2C
71-00-24
Page 201
Dec 12/17
(4) If fan rotation is not smooth or there are indications of corrosion, foreign material, or damage,
contact Williams International Product Support.
EFFECTIVITY: FJ44-2C
71-00-24
Page 202
Dec 12/17
1. General
This task provides the procedures to prepare the engine for shipping. Refer to the following illustration(s):
Figure 201
Figure 202
Figure 203
Figure 204
Figure 205
Figure 206
SUBTASK 71-00-25-943-006
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-0147C4000 Sling, Engine Lift
SUBTASK 71-00-25-944-006
B. Parts Required
Refer to table of shipping preparation caps and closures
SUBTASK 71-00-25-945-006
C. Reference Information
CH-SE-SU Pg Block Nomenclature
00-00-00 1 Manual Introduction - Description and Operation
71-00-00 401 Power Plant - Removal/Installation
71-00-22 201 Preserving Installed Engine for Nine Months or More - Maintenance
Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
71-00-25
Page 201
Dec 12/17
3. Procedures
SUBTASK 71-00-25-620-006
NOTE NOTE: Preserving the engine may negate the need to ship the engine as hazmat.
(1) If the engine is being removed for maintenance in addition to or other than a major periodic
inspection, contact W.I. for additional instructions (00-00-00 P.B. 1).
(2) If the engine is being shipped for a major periodic inspection, preserve the engine in
accordance with 71-00-22, P.B. 201 Preserving Installed Engine for Nine Months or More.
C. If needed, the engine may be wiped clean using a general wet cleaner (MAT-202) and a lint free
cloth (MAT-071).
SUBTASK 71-00-25-510-050
D. Make sure that all engine-installed aircraft parts are removed in accordance with the Aircraft
Maintenance Manual.
SUBTASK 71-00-25-510-009
E. Prepare the engine and the container for engine installation as follows:
NOTE Make sure that SAE grade 5 bolts are used when assembling
the shipping container.
(1) (Metal Engine Container Only) Assemble two engine shipping mount supports to the shipping
mount plates using four screws, four locknuts and four washers. Torque 90 to 100 foot-pounds
(122 to 136 N.m).
EFFECTIVITY: FJ44-2C
71-00-25
Page 202
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 203
Dec 12/17
(3) Install inlet and exhaust closures or secure a liner around the inlet and exhaust openings
with a rubber band.
(4) Cover oil tank sightglass with cardboard. Tape in place (no masking tape allowed).
CAUTION MAKE SURE THE ENGINE LIFT SLING IS RATED FOR THE LOAD
BEING LIFTED. ADDING ACCESSORIES TO THE ENGINE CAN
SIGNIFICANTLY INCREASE THE WEIGHT.
(5) Using engine lifting sling 08-0119-8000 or 08-0147C4000, remove engine from build stand.
Refer to 71-00-00, P.B. 401
(6) Install four engine shipping mounts to the engine using 16 screws and 16 washers. Torque
140 to 160 inch-pounds (15.8 to 18.0 N.m).
SUBTASK 71-00-25-510-010
(1) Lower the engine into the container and secure it to the engine shipping mount supports
using four bolts, four nuts, four lockwashers, and eight flat washers. Torque bolts 800 to 885
inch-pounds (90.4 to 100 N.m).
(2) Assemble and secure removable panel plastic engine container as follows:
EFFECTIVITY: FJ44-2C
71-00-25
Page 204
Dec 12/17
(e) If banding is required for shipment, use edge protectors and do not over-tighten banding.
(3) Assemble and secure hinged panel plastic engine container as follows:
(e) If banding is required for shipment, use edge protectors and do not over-tighten banding.
(a) Align the upper collar of the shipping container to the lower collar.
(b) Place the engine log book in a suitable container for protection.
(d) Install the container sides on the shipping pallet. Install the lid and secure the container
using MAT-007 steel strapping and edge protectors.
SUBTASK 71-00-25-550-004
G. Storage (Stacking) of Engine Containers. FJ44 containers can be stacked two high when empty
(no engine installed).
EFFECTIVITY: FJ44-2C
71-00-25
Page 205
Dec 12/17
Fig. 201 Metal Container – Assemble Engine Shipping Mounts and Supports
EFFECTIVITY: FJ44-2C
71-00-25
Page 206
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 207
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 208
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 209
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 210
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 211
Dec 12/17
4. General
This task provides procedures for receiving the engine. Refer to the following illustration(s):
Figure 207
Figure 208
Figure 209
Figure 210
Figure 211
Figure 212
SUBTASK 71-00-25-943-001
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-0147C4000 Sling, Engine Lift
SUBTASK 71-00-25-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 401 Power Plant - Removal/Installation
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
6. Procedures
SUBTASK 71-00-25-520-001
(1) Remove the container lid by removing the steel strapping and the edge protectors and/or
releasing the keylock fasteners.
NOTE The engine log book must be kept with the engine.
(2) Remove the upper collar of the container of the metal container. Remove the engine log book.
EFFECTIVITY: FJ44-2C
71-00-25
Page 212
Dec 12/17
CAUTION MAKE SURE THE ENGINE LIFT SLING IS RATED FOR THE LOAD
BEING LIFTED. ADDING ACCESSORIES TO THE ENGINE CAN
SIGNIFICANTLY INCREASE THE WEIGHT.
(3) Install engine lifting sling to hoist. Refer to table below for engine lift sling tool number(s).
Attach sling to engine lift points on the rear mount ring and interstage housing. Refer to
71-00-00, P.B. 401.
Engine Lift Sling
08-0119-8000 Engine Lift Sling (alternate)
08-0147C4000 Engine Lift Sling (alternate)
(4) Adjust position of hoist as required and raise hoist until there is equal tension on sling cables.
(5) Remove four bolts, four nuts, four lockwashers, and eight washers which secure the engine
mounts to the container support.
(7) Prepare metal shipping container for return shipment or storage as follows:
(a) Remove the four engine shipping mounts and store them in the container.
(b) Remove engine inlet and exhaust closures. Store them inside the container
(c) Remove engine shipping mount supports and store inside the container.
(d) Fold the upper collar of the container and store it inside the container.
(8) Prepare removable panel plastic shipping container for return shipment or storage as follows:
(a) Remove four engine shipping mounts and store them in engine mount storage container.
See Figure 210.
(b) Break down the container lid assembly and store the sides inside the container as shown
in Figure 211
(9) Prepare hinged panel plastic shipping container for return shipment or storage as follows:
(a) Remove four engine shipping mounts and store them in engine mount storage container.
See Figure 210.
EFFECTIVITY: FJ44-2C
71-00-25
Page 213
Dec 12/17
SUBTASK 71-00-25-520-002
(1) Visually inspect the container for any obvious damage such as damaged hinges, torn labels, or
other visual damage.
(2) Visually inspect the engine for any obvious damage such as dents in the bypass duct.
SUBTASK 71-00-25-620-001
EFFECTIVITY: FJ44-2C
71-00-25
Page 214
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 215
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 216
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 217
Dec 12/17
Fig. 211 Plastic Engine Container – Break Down of Lid for Return Shipment
EFFECTIVITY: FJ44-2C
71-00-25
Page 219
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-25
Page 220
Dec 12/17
1. General
NOTE Engine should be in a condition suitable for motoring with systems connected
and engine accessories installed.
SUBTASK 71-00-26-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Procedures
SUBTASK 71-00-26-630-001
A. Depreservation/purging of the engine fuel system is performed during ground run after engine
installation. Refer to 71-00-00, P.B. 501, Idle Speed and Leak Check Run.
SUBTASK 71-00-26-630-002
EFFECTIVITY: FJ44-2C
71-00-26
Page 201
Dec 12/17
71-00-26
202
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains detailed procedures for borescope inspection of the HP and IP compressor sections
and the diffuser inlet vanes. Refer to the following illustration(s):
Figure 601
Figure 602
Figure 603
Figure 604
Figure 605
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International., Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International., Walled Lake, Michigan, USA for service.
SUBTASK 71-00-30-941-002
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia (or Smaller)
X 50 Inch Long (or Longer)
SUBTASK 71-00-30-943-002
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-30-944-002
C. Expendable Parts
EFFECTIVITY: FJ44-2C
71-00-30
Page 601
Dec 12/17
IPC Reference
Subject Fig. Item Nomenclature
75-35-01 02 131 O-ring
3. Job Set-up
SUBTASK 71-00-30-010-002
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-30-870-002
NOTE A Flexible, steerable fiberscope, 6mm dia (or smaller) x 50 inch long (or longer) is
standard equipment for borescoping inspection procedures.
SUBTASK 71-00-30-220-002
B. Inspect the IP compressor rotor blades leading edges (stage 1 only). Refer to Figure 601.
(1) Insert the borescope through the fan blades and fan stator vanes to examine the IP rotor blades
leading edge (area A). Inspect as follows:
C. Inspect the IP stator leading edges (stage 1 only). Refer to Figure 601.
(1) Insert the borescope through the fan blades, fan stator vanes, and IP rotor blades to examine
the IP stator vanes leading edge (area B). Inspect as follows:
D. Remove the borescope plug assembly and O-ring from the top of the interstage housing. Refer
to Figure 602 .
(1) Adjust the flexible fiberscope so that it points forward, toward the IP compressor (area C).
Inspect as follows:
EFFECTIVITY: FJ44-2C
71-00-30
Page 602
Dec 12/17
F. Inspect the HP compressor rotor. Refer to Figure 603 and Figure 604.
(1) Adjust the flexible fiberscope so that it points aft, toward the HP compressor.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox. Refer
to Figure 605
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
(5) Position the borescope between HP compressor rotor blades and rotate HP rotary group to
inspect diffuser vanes (area G) for:
G. With borescope still located between HP compressor rotor blades, turn tip radially outward to inspect
the HP compressor cover. Rotate HP rotary assembly and inspect the compressor cover for:
(2) Loss of abradable coating in bleed hole Contact Williams International for current
area (area H). limits.
EFFECTIVITY: FJ44-2C
71-00-30
Page 603
Dec 12/17
(3) Rub indications in zone outboard and Contact Williams International for current
inboard of bleed holes. limits.
NOTE Craze crack indications in the abradable coating in the area forward
of the bleed holes are acceptable.
I. Withdraw borescope from gas path and insert it through the bleed valve opening. Inspect the
compressor cover bleed holes (area H) for:
(1) Fretting or galling where the valve meets Accept as long as valve movement is not
the case restricted.
(1) Install plug into port on interstage housing bleed port cover.
5. Job Close-up
SUBTASK 71-00-30-410-002
EFFECTIVITY: FJ44-2C
71-00-30
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-30
Page 605
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-30
Page 606
Dec 12/17
Fig. 603 HP and IP Compressor Blades and Diffuser Vanes - Borescope Inspection
EFFECTIVITY: FJ44-2C
71-00-30
Page 607
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-30
Page 608
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-30
Page 609
Dec 12/17
71-00-30
610
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains detailed procedures for checking for an internal oil leak with a borescope. Refer
to the following illustration(s):
Figure 601
Figure 602
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-32-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia (or Smaller)
X 50 Inch Long (or Longer)
3. Job Set-up
SUBTASK 71-00-32-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
71-00-32
Page 601
Dec 12/17
4. Procedures
SUBTASK 71-00-32-220-002
NOTE A Flexible, steerable fiberscope, 6mm dia (or smaller) x 50 inch long (or longer)
is standard equipment for borescoping inspection procedures.
NOTE Visible oil is not cause for engine rejection. The Oil Consumption Check in
71-00-00, P.B. 501 will determine engine acceptability.
(1) Move the borescope through the front case, past the fan and the fan stator vanes. Borescope
should remain in the bypass airflow area and face the bottom (6 o’clock) strut in the interstage
housing.
(2) Move the borescope to the right side (facing aft) of the interstage housing 6:00 strut and inspect
for signs of oil leakage. Oil coming from the carbon seal scupper drain on this side of the
strut originates from the No. 2 carbon seal.
(3) Move the borescope to the left side (facing aft) of the interstage housing strut and inspect for
signs of oil leakage. Oil coming from the carbon seal scupper drain on this side of the strut
originates from the No. 1 carbon seal.
(4) Inspect for the following conditions. If oil is visible, perform an Oil Consumption Check in
71-00-00, P.B. 501.
(a) Visible oil puddles are present in the bypass duct, the origin of which are traceable to the
No. 1 or No. 2 scupper drains.
and/or
(b) Oil streams/drops are present on the bypass duct and/or core (i.e. diffuser) which
originate from the No. 1 or No. 2 scupper drains.
and/or
(c) A visible drop of oil is present on the respective scupper drain outlets.
and/or
(5) Inspect the front bypass duct fairing assembly for signs of oil leakage. Oil leaking from this
area means an oil tank cover leak.
EFFECTIVITY: FJ44-2C
71-00-32
Page 602
Dec 12/17
(6) Inspect the oil scavenge and supply tube bosses on the interstage housing/tube connections
for signs of oil leakage.
5. Job Close-up
SUBTASK 71-00-32-410-001
EFFECTIVITY: FJ44-2C
71-00-32
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-32
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-32
Page 605
Dec 12/17
71-00-32
606
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
TASK 71-00-40-220-801 Inspect the Combustor, Fuel Slinger, and HP Turbine Blade Leading
Edges with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the combustor, fuel slinger, and HP
turbine blades leading edge. Refer to the following illustration:
Figure 601
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-40-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia (or Smaller)
X 50 Inch Long (or Longer)
SUBTASK 71-00-40-943-001
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-40-945-001
C. Reference Information
EFFECTIVITY: FJ44-2C
71-00-40
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 71-00-40-010-001
(2) Open the aircraft circuit breakers to isolate engine electrical supply.
4. Procedures
SUBTASK 71-00-40-220-001
NOTE A Flexible, steerable fiberscope, 6mm dia (or smaller) x 50 inch long (or longer)
is standard equipment for borescoping inspection procedures.
A. Remove the two igniter plugs from the service adapters on the front bypass duct. Refer to 74-22-01,
P.B. 401.
(1) Insert the borescope through the right hand igniter port.
(2) Move the borescope forward in the space between the outside of the combustor cover and
the inside of the diffuser.
C. Insert the borescope into the combustor area through either igniter port.
EFFECTIVITY: FJ44-2C
71-00-40
Page 602
Dec 12/17
NOTE If inspection reveals foreign object damage, you must also do a compressor
inspection. Refer to 71-00-30, P.B. 601.
(1) Move the borescope through the HP nozzle vanes and into the area behind the primary plate.
(1) Insert the borescope into the combustion area and inspect the primary plate (area C) for
erosion and cracks. Contact Williams International for current limits.
(2) Inspect combustor cover (area D) for erosion and cracks. Contact Williams International for
current limits.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
G. Inspect the HP turbine nozzle vanes (area F) for cracks and pitting. Evaluate damage as follows:
EFFECTIVITY: FJ44-2C
71-00-40
Page 603
Dec 12/17
(1) Move the borescope around and down between the HP nozzle vanes to point at the HP
turbine blades.
(2) Have someone slowly turn the HP rotary assembly to allow inspection of all the blades.
(3) Inspect the blade roots, leading edges, and blade tips of the 43 blades for any damage, erosion,
cracks, nicks, or any other visual defects. Contact Williams International for current limits.
(2) Locate the combustor cover key (area H) on the HP nozzle. It is radially in-line with the
right-hand igniter port and slightly forward. It locates the large indexing slot on the outside
edge of the combustor cover.
5. Job Close-up
SUBTASK 71-00-40-410-001
EFFECTIVITY: FJ44-2C
71-00-40
Page 604
Dec 12/17
Fig. 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection
EFFECTIVITY: FJ44-2C
71-00-40
Page 605
Dec 12/17
71-00-40
606
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains detailed procedures for borescope inspection of the 1st LP turbine rotor blades trailing
edge and the 2nd LP turbine rotor blades leading edge. Refer to the following illustration(s):
Figure 601
Figure 602
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-50-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia (or Smaller)
X 50 Inch Long (or Longer)
SUBTASK 71-00-50-942-001
B. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 71-00-50-944-001
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
EFFECTIVITY: FJ44-2C
71-00-50
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 71-00-50-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-50-870-001
NOTE A Flexible, steerable fiberscope, 6mm dia (or smaller) x 50 inch long (or longer) is
standard equipment for borescoping inspection procedures.
SUBTASK 71-00-50-220-001
A. Remove fuel drain tube from the rear bypass duct. Refer to the Aircraft Maintenance Manual.
B. Remove two screws, two nuts, and four washers which attach the rear fuel drain adapter to the rear
bypass duct. Remove adapter and O-ring. Refer to Figure 601.
C. Using one of the screws removed, install screw into end of tube and remove fuel drain transfer
tube and two O-rings.
D. Insert appropriate hex key (1/4 inch)through the fuel drain port through the rear housing boss.
Remove the borescope plug from the 2nd nozzle case.
E. Insert borescope through the fuel drain port. Move borescope forward and locate the trailing edge of
the 1st LP turbine rotor blades (area A). Inspect blades as follows:
EFFECTIVITY: FJ44-2C
71-00-50
Page 602
Dec 12/17
(1) Slowly rotate the LP rotary assembly and inspect the blade root, trailing edge, and blade tip
platforms of the 70 blades on the 1st LP turbine rotor. Refer to Figure 602. Contact Williams
International for current limits.
F. Move borescope aft and find the 2nd LP turbine rotor blades (area B). Inspect blades as follows:
(1) Slowly rotate the LP rotary assembly and inspect the blade root, leading edge, and tip platform
of 65 LP turbine rotor blades. Contact Williams International for current limits.
I. Lube two O-rings with assembly fluid (MAT-011) and install on rear fuel drain transfer tube.
K. Install O-ring with assembly fluid and install on rear fuel drain adapter. Attach rear fuel drain adapter
to adapter boss using two screws, four washers, and two nuts. Torque screws 31 to 35 inch-pounds
(3.5 to 3.9 N.m).
SUBTASK 71-00-50-401-001
5. Job Close-up
SUBTASK 71-00-50-410-001
EFFECTIVITY: FJ44-2C
71-00-50
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-50
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
71-00-50
Page 605
Dec 12/17
71-00-50
606
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
TASK 71-00-52-220-801 Inspect the HP Nozzle/HP Turbine Trailing Edge and 1st LP Turbine
Leading Edge with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the HP nozzle/HP turbine trailing edge
and the 1st LP turbine leading edge. Refer to following illustration:
Figure 601
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-52-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia (or Smaller)
X 50 Inch Long (or Longer)
SUBTASK 71-00-52-943-001
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-52-945-001
C. Reference Information
EFFECTIVITY: FJ44-2C
71-00-52
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 71-00-52-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-52-040-001
A. Remove any one of the six ITT probes from the front bypass duct. Refer to 77-20-02, P.B. 401.
SUBTASK 71-00-52-870-001
B. A Flexible, steerable fiberscope, 6mm dia (or smaller) x 50 inch long (or longer) is standard
equipment for borescoping inspection procedures.
SUBTASK 71-00-52-220-001
C. Insert the borescope through the ITT port and into the core airflow path.
(1) Move the borescope aft, between the 1st LP nozzle vanes, and locate the 1st LP turbine
rotor blades (area A).
(2) Slowly rotate the LP rotary assembly. Inspect the blade root, leading edge, and blade tip
platforms of each of the 70 1st LP turbine rotor blades for any damage, erosion, cracks, nicks,
or any other visual defects. Contact Williams International for current limits.
EFFECTIVITY: FJ44-2C
71-00-52
Page 602
Dec 12/17
(1) Turn the borescope so it is facing forward and locate the HP turbine rotor blades.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
(3) Inspect the blade root, trailing edge, and blade tip platform of each of the 43 blades (area B) for
any damage, erosion, cracks, nicks, or any other visual defects. Contact Williams International
for current limits.
(1) Move the borescope forward until it passes through the HP turbine rotor blades and the HP
nozzle vanes are visible.
(2) Have someone slowly turn the HP rotary assembly. The HP turbine rotor will carry the
borescope around the engine’s circumference, allowing inspection of the HP turbine nozzle
vanes.
(3) Inspect the trailing edges of the HP turbine nozzle vanes (area C) for any damage, erosion,
cracks, nicks, or any other visual defects. Contact Williams International for current limits.
SUBTASK 71-00-52-440-001
H. Install ITT probe to front bypass duct. Refer to 77-20-02, P.B. 401.
5. Job Close-up
SUBTASK 71-00-52-410-001
EFFECTIVITY: FJ44-2C
71-00-52
Page 603
Dec 12/17
Fig. 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"
EFFECTIVITY: FJ44-2C
71-00-52
Page 604
Dec 12/17
CHAPTER 72
ENGINE
Page 1
72-ENGINE Dec 12/17
Page 2
72-ENGINE Blank
LINE MAINTENANCE MANUAL - FJ44-2C
72-00-00 1 Dec 12/17 72-02-00 1 Dec 12/17 72-32-20 801 Dec 12/17
72-00-01 301 Dec 12/17 72-30-10 601 Dec 12/17 72-35-22 601 Dec 12/17
72-00-03 301 Dec 12/17 72-30-10 801 Dec 12/17 72-60-01 401 Dec 12/17
72-00-05 201 Dec 12/17 72-31-15 601 Dec 12/17 72-60-02 401 Dec 12/17
72-00-30 401 Dec 12/17 72-31-20 601 Dec 12/17 72-60-02 601 Dec 12/17
72-00-31 401 Dec 12/17 72-31-20 801 Dec 12/17 72-71-10 601 Dec 12/17
72-00-32 401 Dec 12/17 72-32-10 601 Dec 12/17 72-71-20 601 Dec 12/17
72-00-60 401 Dec 12/17 72-32-10 801 Dec 12/17
72-00-71 401 Dec 12/17 72-32-20 601 Dec 12/17
Chapter 72
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 72
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The gearbox assembly supplies shaft power and mounting for the engine accessories. It is bolted to the
interstage housing and is located at the bottom of the engine. Refer to the following illustration(s):
Figure 1
Figure 2
2. Description
SUBTASK 72-00-00-860-002
A. The gearbox assembly connects to the interstage housing and is driven off the HP shaft by an
accessory drive shaft. The gearbox provides rotational power to four mount pads for accessories.
These accessories are the starter/generator, fuel control unit (IFCU or FDU), the lube and scavenge
pump, and the hydraulic pump. The shaft drives are oil-wetted except for the hydraulic pump
shaft. Carbon seals are provided at each mount pad except the lube and scavenge pump mount
pad. The lube and scavenge pump mount pad uses internal passages to transfer oil to and from
the gearbox assembly.
The starter/generator pad is on the forward end of the gearbox. The lube and scavenge pump pad is
directly aft of the starter/generator pad. Drive for the starter/generator and lube and scavenge pump
is provided by the same drive gear. Next to the oil pad is the fuel control unit pad. The hydraulic pad
is also forward and adjacent to the starter/generator pad.
3. Operation
SUBTASK 72-00-00-860-003
A. The gearbox receives its rotational power from the HP shaft, via an accessory drive shaft. Two
reduction bevel gears, one at the top and one at the bottom of the accessory drive shaft, reduce
the HP shaft rotational speed for accessory operation. The gearbox provides mounting and drive
provisions for the accessories. Oil wetted shafts provide lubrication for accessory shafts. The
gearbox provides internal passages for the engine oil system.
EFFECTIVITY: FJ44-2C
72-00-00
Page 1
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-00
Page 2
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-00
Page 3
Dec 12/17
4. General
The bypass duct group includes the front bypass duct assembly, the rear bypass duct assembly, and their
related parts. The function of the bypass duct group is to route a part of the air received from the fan
around the core and into the exhaust. The engine air bypass-to-core ratio is 3.31 : 1. The bypass flow
allows operation of high core temperatures and pressure, while decreasing the velocity and temperatures
of the engine exhaust. Refer to the following illustration(s):
Figure 3
5. Description
SUBTASK 72-00-00-860-002
A. The front bypass duct assembly is made from sheet aluminum that is formed and seam welded.
Access holes for ITT probes are provided toward the aft flange. Spacers, retainers, plates, and
retaining rings are used to seal the thermocouple bosses. The front duct also houses the service
adapters which supply access ports for fuel, HP bleed air, CDP air, and igniter plugs. A boss is
provided on the front duct for mounting of the fuel nozzle. Fuel drain ports are located at the bottom
of the duct.
B. The rear bypass duct assembly is also made from sheet aluminum that is formed and seam welded.
It also has a fuel drain port located on the bottom side of the duct. The rear duct contains a trip lever
housing and cable attachment as part of the LP trip system that shuts down the engine if the shaft
separates. The rear duct also includes a bracket for external mounting of the start nozzle control
valve. On some engines, a fan bleed port is also provided.
C. The rear mount ring is mounted between the front and rear bypass duct. The rear mount ball socket
changes location depending on which side of the aircraft the engine is mounted on.
EFFECTIVITY: FJ44-2C
72-00-00
Page 4
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-00
Page 5
Dec 12/17
6. General
These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:
7. Description
SUBTASK 72-00-00-860-005
Spinner
Case assembly
(1) The spinner bolts onto the front of the fan rotor. The spinner shape provides a smooth airflow
into the engine. The sharp point prevents accumulation of ice.
(2) The fan rotor (LP axial compressor) is a 16 blade titanium blisk (blades and disc are integral).
The fan is attached to the LP shaft with one nut. The fan is splined but there is no master
keyway to clock the position.
(3) The fan stator is located directly behind the fan rotor. It contains 41 vanes set in an aluminum
case and secured and damped with polyurethane. The ID seal on the rear side seals with
the IP compressor.
EFFECTIVITY: FJ44-2C
72-00-00
Page 6
Dec 12/17
(4) The IP compressor rotor is a three stage axial compressor. It consists of three titanium blisks
welded together to form an integral assembly. The IP compressor is installed on the LP shaft
and is secured by the installation of the fan and front LP retaining nut.
(5) The IP stator is comprised of three stages. The 1st and 2nd IP stator stages are integral to the
IP compressor case and forged and machined inconel 718. This stator and case assembly is
divided into three equal circumferential segments that are bolted together to form the complete
assembly. The 3rd stator is a one piece assembly made from forged and machined inconel 718.
All three stages are bolted together to the interstage housing. The IP stator assembly is covered
by an aerodynamic splitter fairing that divides the fan air flow into core and bypass air flows.
(6) The HP compressor is a centrifugal compressor made from forged and machined titanium. It is
attached to the HP shaft and is powered by a single HP turbine. The HP compressor, along
with the diffuser, increase the pressure of the incoming axial compressor air before combustion.
The compressor is pressed onto the HP shaft and is secured by the installation of the fuel
slinger/seal assembly, HP turbine, and the rear HP nut. These parts are locked together by
curvic couplings on the rear of the HP compressor, front and back of the fuel slinger/seal,
and the front of the HP turbine disc.
(7) The diffuser case assembly is made from inconel 718. The diffuser forward flange bolts to
the interstage housing. The rear flange is the single mounting point for all the hot section
components. In addition to directing HP compressor air flow, the diffuser also houses the fuel
supply tube and fuel manifold which supplies fuel to the fuel slinger/seal assembly. The diffuser
also has two pads on its OD which allow extraction of compressor discharge pressure (CDP)
and HP bleed. The diffuser also contains ports for the igniter plugs and fuel delivery
8. Operation
SUBTASK 72-00-00-860-006
A. The rotation of the compressor and turbine assemblies moves air into the engine. The diameter of
the compressors and stators narrows from front to rear. This increases the pressure and velocity of
the airflow.
B. The airflow goes from the fan (LP compressor) to the IP compressor. The splitter fairing, which is
part of the IP stator, divides the airflow into core air and bypass air. Core air is routed to the HP
compressor and then into the diffuser. The diffused air then enters the combustor section where it is
mixed with fuel and burned. Bypass air is ducted around the core and mixes with the exhaust.
C. The LP turbines drive the fan and IP compressors. The HP turbine drives the HP compressor. The
LP shaft passes through the HP shaft and connects the LP turbines with the fan and IP compressor.
The HP shaft connects the HP turbine with the HP compressor. Both shafts rotate in the same
direction but not at the same speed. The HP shaft speed is slightly more than twice as fast as the
LP shaft speed.
EFFECTIVITY: FJ44-2C
72-00-00
Page 7
Dec 12/17
72-00-008
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task lists approved fuels and additives for the engine. It is the responsibility of the operator to
ensure that all fuel delivered to the engine meets the requirements of the approved fuel specifications in
all respects.
NOTES: 1 The fuels and additives listed as approved are not necessarily approved for
use in the aircraft. Refer to the aircraft Operating Instructions.
2 It is the responsibility of the operator to ensure that all fuel delivered to the engine
meets the requirements of the approved fuel specifications in all respects.
2. Approved Fuels
SUBTASK 72-00-01-610-006
A. The fuel specifications and additives listed below are based on the results of engine testing. The
fuels and additives listed as approved are not necessarily approved for use in the aircraft. Refer
to the aircraft Operating Instructions.
Grade (type) Specification
Jet A NOTE 1 ASTM-D1655
Jet A1
Jet B NOTE 1 ASTM-D1655
JP-4 NOTE 1 MIL-T-5624
JP-5 NOTE 1 MIL-T-5624
JP-8 NOTE 1 MIL-T-83133
Chinese #3 Jet Fuel NOTE 1 & 3 GB 6537-94
TS-1 NOTE 2 C.I.S. GOST # 10227
RT NOTE 2 C.I.S. GOST # 10227
EFFECTIVITY: FJ44-2C
72-00-01
Page 301
Dec 12/17
2 Fluid I (C.I.S. GOST 8313) or Fluid IM (C.I.S. TU-6-10-1458) fuel system icing
inhibitor is allowed in amounts between 0.1% and 0.3% by volume.
3. Mixing of Fuels.
SUBTASK 72-00-01-610-007
EFFECTIVITY: FJ44-2C
72-00-01
Page 302
Dec 12/17
TASK 72-00-03-610-801 Service the Engine Using Dipstick Oil Fill Port
1. General
This task contains procedures for checking the oil level, draining, and filling the engine with oil via the
dipstick oil fill port. Do this task as required by scheduled maintenance checks. Refer to the following
illustration(s):
Figure 301
Figure 302
Figure 303
CAUTIONS: 1 DO NOT LET OIL FALL ONTO ENGINE PARTS WHICH ARE NOT USUALLY
IN TOUCH WITH OIL. RUB OFF ANY OIL WHICH FALLS ONTO THE ENGINE.
THE OIL CAN DAMAGE PAINTWORK AND RUBBER PARTS.
2 USE ONLY CLEAN CONTAINERS AND EQUIPMENT. THE OIL WILL BREAK
DOWN IF MIXED WITH ANY ALKALINE FLUID.
SUBTASK 72-00-03-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-071 Cloth, Lint Free
SUBTASK 72-00-03-943-001
B. Special Tools
EFFECTIVITY: FJ44-2C
72-00-03
Page 301
Dec 12/17
Reference Designation
TL37255 Fitting, Oil Drain
SUBTASK 72-00-03-944-001
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-30-01 1 25, O-ring (2)
55
SUBTASK 72-00-03-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
79-30-01 401 Magnetic Chip Collector - Removal/Installation
3. Job Set-up
SUBTASK 72-00-03-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-00-03-610-001
NOTES: 1 When oil is drained, Williams International recommends that only Mobil
Jet II is used for total oil replacement.
2 Mobil 254 may be used for total oil replacement only if Mobil 254 has been used
as the replenishing (topping-off) oil for at least the last 150 flight hours or if Mobil
254 was used for total oil replacement at the last oil change.
A. Drain engine oil (if required) using TL37255 oil drain fitting
EFFECTIVITY: FJ44-2C
72-00-03
Page 302
Dec 12/17
(2) Remove the self-closing plug from the bottom rear of the lube pump (port labeled TANK DRAIN).
(3) Install oil drain fitting, TL37255, to self-closing fitting and drain oil tank oil into a suitable
container.
(4) Lubricate new O-ring with engine oil (MAT-001) and install on self-closing plug.
(6) Remove the self-closing plug from the bottom of the gearbox.
(7) Install oil drain fitting, TL37255, to self-closing fitting and drain gearbox oil into a suitable
container.
(8) Lubricate new O-ring with engine oil and install on self-closing plug.
SUBTASK 72-00-03-610-002
(1) (FJ44-2A Only) Actuate low oil level sensor (if engine is so equipped) in accordance with aircraft
flight manual. If low oil is indicated, check oil with dipstick and service oil system, as required.
(2) Check the oil sight glass (if engine is so equipped), or insert and remove the (oil fill cap)
dipstick from the fill port.
(3) Wipe the oil from the dipstick using a clean, lint-free cloth (MAT-071). Install the dipstick and
then remove it to get an accurate reading of the oil level on the dipstick.
NOTE Filling the oil tank above the FULL mark on the dipstick or the sight glass will
not harm the engine, but will ultimately result in overflow from the fill port.
(4) You must add oil (MAT-001) if level is at or below the ADD mark on the dipstick or the sight
glass. To avoid overfilling, add oil in increments and check the level after each addition.
EFFECTIVITY: FJ44-2C
72-00-03
Page 303
Dec 12/17
NOTE If it appears that the oil is over-full or there is more oil registering than
has been added, smell the oil to detect the possible presence of fuel.
If you smell fuel in the oil, reject the engine.
(5) Inspect the dipstick O-ring for damage and replace, if required. To avoid binding, rotate dipstick
on filler port plug so offset bend faces aft of engine. Install dipstick in fill port and secure by
turning and folding down lever against base portion of cap to lock. Refer to Figure 303.
SUBTASK 72-00-03-610-004
SUBTASK 72-00-03-610-005
2 Mobil 254 may be used for total oil replacement only if Mobil 254 has been used
as the replenishing (topping-off) oil for at least the last 150 flight hours or if
Mobil 254 was used for total oil replacement at the last oil change.
(1) Make sure that magnetic chip collector plugs are properly installed. Refer to 79-30-01, P.B. 401.
(2) Fill the tank with oil (approximately 3.7 quarts [3.5 liters]).
(3) To avoid binding, rotate the dipstick on the filler port plug so the offset bend faces aft of the
engine. Install the dipstick in the fill port and secure by turning and folding down the lever
against the base portion of the cap to lock. Refer to Figure 303.
(4) Motor the engine to approximately 14% N2 rpm for positive oil pressure indication. Refer to
71-00-00, P.B. 501 Engine Operating Instructions.
EFFECTIVITY: FJ44-2C
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Page 304
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(5) When N2 rpm decreases to "0", remove the dipstick and wipe it with a clean, lint-free cloth.
Reinstall and remove it to get an accurate reading of the oil level. If required, add oil to bring
the level up to the FULL mark on the dipstick or sight glass. To avoid overfilling, add oil in
increments and check the level after each addition.
(6) Inspect the dipstick O-ring for damage and replace, if required. To avoid binding, rotate the
dipstick on the filler port plug so the offset bend faces aft of the engine. Install the dipstick in
the fill port and secure by turning and folding down the lever against the base portion of the
cap to lock.
(7) Record amount and type of oil added in the engine logbook.
SUBTASK 72-00-03-610-007
5. Job Close-up
SUBTASK 72-00-03-410-001
EFFECTIVITY: FJ44-2C
72-00-03
Page 305
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-03
Page 307
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-03
Page 308
Dec 12/17
1. General
This task contains procedures for changing the oil filter and submitting it to be analyzed as part of
the oil filter analysis program. This program provides the operator and maintenance personnel with
valuable information about engine health. Do this task as directed by periodic maintenance checks or
other maintenance procedures.
SUBTASK 72-00-05-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 72-00-05-944-001
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-21-01 01 20 O-Ring
79-21-01 01 30 Filter, Oil-Disposable
79-21-01 01 40 O-Ring
SUBTASK 72-00-05-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
79-21-01 401 Oil Filter - Removal/Installation
3. Job Set-up
SUBTASK 72-00-05-010-001
EFFECTIVITY: FJ44-2C
72-00-05
Page 201
Dec 12/17
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-00-05-020-001
A. Remove the oil filter and place it in the container provided with the oil filter analysis kit. Install a new
oil filter. Refer to 79-21-01, P.B. 401.
SUBTASK 72-00-05-510-001
(6) Contact name, e-mail, and phone number (if not enrolled in a maintenance program)
SUBTASK 72-00-05-610-001
C. Service the engine with oil (MAT-001). Refer to 72-00-03, P.B. 301.
SUBTASK 72-00-05-510-002
D. Send the oil filter to our approved Williams International Repair Station for analysis, located at
the following address:
Williams International
EFFECTIVITY: FJ44-2C
72-00-05
Page 202
Dec 12/17
NOTES: 1 The oil filter analysis kit includes a label (U.S. domestic) or form
(international) with the proper ship-to address.
5. Job Close-up
SUBTASK 72-00-05-410-001
EFFECTIVITY: FJ44-2C
72-00-05
Page 203
Dec 12/17
72-00-05
204
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LINE MAINTENANCE MANUAL - FJ44-2C
SPINNER - REMOVAL/INSTALLATION
1. General
This task covers removal of the spinner from the engine. Refer to the following illustration(s):
Figure 401
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-30-942-001
A. Consumables
Reference Designation
MAT-032 Marker, Broad Line
MAT-033 Marker, Fine Line
SUBTASK 72-00-30-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
3. Job Set-up
SUBTASK 72-00-30-010-001
(2) Open the circuit breakers to isolate the engine electrical system.
EFFECTIVITY: FJ44-2C
72-00-30
Page 401
Dec 12/17
4. Procedures
SUBTASK 72-00-30-020-001
(1) Using MAT-033 or equivalent MAT-032 marker, alignment match-mark the spinner and fan rotor
as a baseline. Put the match mark in line with one of the spinner mount bolts.
(2) Remove six bolts (1-20) and six washers (1-30) which attach the spinner (1-10) to the engine.
(3) After removal of spinner, make an alignment mark on the pilot plate, locking plate, and LP shaft
in-line with the mark on the fan. Use MAT-033 marker (or equivalent).
EFFECTIVITY: FJ44-2C
72-00-30
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-30
Page 403
Dec 12/17
5. General
This task covers installation of the spinner. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-30, Fig. 01
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
3 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
4 This part must undergo routine and major periodic inspection. If a serviceable, used
spinner from another engine is to be installed, make sure that it has undergone all
scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 72-00-30-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-096 Primer, Epoxy
SUBTASK 72-00-30-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
EFFECTIVITY: FJ44-2C
72-00-30
Page 404
Dec 12/17
7. Procedures
SUBTASK 72-00-30-420-001
A. If a replacement spinner is being installed, make sure that any trim balance weights from previous
spinner are transferred to new spinner. Remove weights and transfer to same relative position(s)
on the new spinner. Position of weights is relative to the alignment mark with the fan. Secure the
balance weights using epoxy primer (MAT-096).
B. Install Spinner
NOTE The pilot area of the spinner touches the spinner pilot plate
assembly and the fan locking plate when installed. There will be
a gap between the spinner and the fan.
(1) Inspect the pilot area of the spinner for burrs. Remove any burrs in accordance with standard
practices. Refer to 70-42-11, P.B. 801.
(2) Make sure that the LP nut locking plate (1-30, 72-00-31) is installed on the front LP nut and
that all six pilot plate bolt holes are visible.
(3) Insert one bolt (1-20) and washer (1-30) through the spinner and align the spinner with the
spinner pilot plate and with alignment marks made at removal. Install the bolt into one of
the six pilot plate holes, finger tight.
(6) Check for gap between spinner and fan. Gap should be 0.002 inch (0.050 mm) minimum.
EFFECTIVITY: FJ44-2C
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8. Job Close-up
SUBTASK 72-00-30-410-002
SUBTASK 72-00-30-760-001
B. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
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Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-30
Page 407
Dec 12/17
72-00-30
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers removal of the fan rotor from the engine. Refer to the following illustrations:
Figure 401
Figure 402
Figure 403
Figure 404
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-31-941-002
A. Standard Equipment
Depth Micrometer
Hydraulic Hand Pump With Gauge
SUBTASK 72-00-31-942-002
B. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 72-00-31-943-002
C. Special Tools
Reference Designation
TL-114435 Cylinder, Hydraulic (Alternate)
TL-239281 Puller Assy, Spinner Pilot Plate (Alternate)
TL37102-11 Puller Rod
TL37102-12 Puller Adapter, LP
EFFECTIVITY: FJ44-2C
72-00-31
Page 401
Dec 12/17
TL37102-13 Nut
TL37102-14 Cap, Hydraulic Cylinder
TL37102-61 Pusher Adapter, LP
TL37102-7 Cylinder, Hydraulic (Alternate)
TL99501 Puller Assembly, Spinner Pilot Plate (Alternate)
TL99502 Puller Assembly, Fan
SUBTASK 72-00-31-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-30 401 Spinner - Removal/Installation
3. Job Set-up
SUBTASK 72-00-31-870-002
A. Update life history records for the removed component in the engine log book.
SUBTASK 72-00-31-020-003
4. Procedures
SUBTASK 72-00-31-020-004
(a) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly. Refer to Figure 401.
(3) Remove the fan retainer nut (1-20) using shaft stretch tool as follows (Figure 402):
(a) Install the TL37102-12 LP shaft adapter on the TL37102-11 rod so that the large threaded
ID of the adapter is located on the end of the rod.
EFFECTIVITY: FJ44-2C
72-00-31
Page 402
Dec 12/17
(b) Lubricate threads withMAT-001 engine oil and install the rod/adapter to the front of the LP
shaft. After the adapter is hand tight on the LP shaft, back-off one turn.
(d) Install the TL-114435 or TL37102-7 hydraulic cylinder over the rod with the piston side
facing forward.
(e) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
(g) Support the TL37102-61 LP pusher while the hydraulic pressure is increased. Do not
allow the pusher to contact the fan nut and keep pusher centered around the nut. Have
one person operate the hydraulic hand pump with gauge until the gauge indicates 7100
psig and the fan retainer nut can be loosened by rotating it with a screwdriver on the
forward outside diameter. If nut does not become loose at 7100 psig:
(h) Release pump pressure and remove all details of stretch tooling.
(4) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly.
(6) Install TL99501 or TL-239281 on the pilot plate assembly. Remove the pilot plate from the LP
shaft. Refer to Figure 403.
EFFECTIVITY: FJ44-2C
72-00-31
Page 403
Dec 12/17
(7) Install TL99502 puller on the fan and remove the fan from the LP shaft. Refer to Figure 404.
EFFECTIVITY: FJ44-2C
72-00-31
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 408
Dec 12/17
5. General
This task covers installation of the fan rotor on the engine. Refer to the following illustrations:
Figure 405
Figure 406
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-31, Fig. 01
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
3 This part must undergo routine and major periodic inspection. If a serviceable, used fan
from another engine is to be installed, make sure that it has undergone all scheduled
inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 72-00-31-941-004
A. Standard Equipment
Depth Micrometer
Hydraulic Hand Pump With Gauge
SUBTASK 72-00-31-942-004
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-013 Magnesium Hydroxide
MAT-017 Lubricant, Rapid GT
SUBTASK 72-00-31-943-004
C. Special Tools
EFFECTIVITY: FJ44-2C
72-00-31
Page 409
Dec 12/17
Reference Designation
TL-114435 Cylinder, Hydraulic (Alternate)
TL37102-11 Puller Rod
TL37102-12 Puller Adapter, LP
TL37102-13 Nut
TL37102-14 Cap, Hydraulic Cylinder
TL37102-61 Pusher Adapter, LP
TL37102-7 Cylinder, Hydraulic (Alternate)
SUBTASK 72-00-31-945-004
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
7. Procedures
SUBTASK 72-00-31-420-005
(1) Install the fan rotor (1-10) on the LP shaft against the IP compressor rotor. Align marks on fan
rotor and LP shaft made at removal.
(2) Install the pilot plate assembly (1-40) with the thick flange against the fan. Make sure that the
locating pin is aligned with the hole in the fan flange.
NOTE You must seat the fan rotor on the LP shaft using shaft stretch
tool before installing the LP nut.
(3) Seat the fan rotor using shaft stretch tool as follows (Figure 405).:
(a) Install the TL37102-12 LP shaft adapter on the TL37102-11 rod so that the large threaded
ID of the adapter is located on the end of the rod.
(b) Lubricate threads with engine oil and install the rod/adapter to the front of the LP shaft.
After the adapter is hand tight on the LP shaft, back-off one turn.
EFFECTIVITY: FJ44-2C
72-00-31
Page 410
Dec 12/17
(d) Install the TL-114435 or TL37102-7 hydraulic cylinder over the rod with the piston side
facing forward.
(e) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
(g) Operate the hydraulic hand pump with gauge until the gauge indicates 7100 psi. This
seats the fan rotor on the LP shaft.
(h) Release pump pressure and remove all details of stretch tooling.
SUBTASK 72-00-31-220-003
(1) Using a depth micrometer, measure from the front face of the LP shaft to the forward face of
the pilot plate assembly. Refer to Figure 406.
SUBTASK 72-00-31-420-006
(1) Lubricate the face and threads of the fan retainer nut (1-20) and LP shaft with Rapid GT
lubricant (MAT-017, preferred) or magnesium hydroxide (MAT-013) and install it on LP shaft,
hand tight.
(2) Tighten fan retainer nut using shaft stretch tool as follows:
(a) Lubricate threads with engine oil (MAT-001) and install the TL37102-11 rod and
TL37102-12 adapter to the front of the LP shaft. After the adapter is hand tight on the LP
shaft, back-off two turns.
EFFECTIVITY: FJ44-2C
72-00-31
Page 411
Dec 12/17
(c) Install the TL-114435 or TL37102-7 hydraulic cylinder over the rod with the piston side
facing forward.
(d) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
(f) Support the TL37102-61 LP pusher while the hydraulic pressure is increased. Do not
allow the pusher to contact the fan nut and keep pusher centered around the nut. Have
one person operate the hydraulic hand pump until the gage indicates 7100 psi. Tighten
the fan retainer nut by turning it on the forward outside diameter with a flat screwdriver
until finger tight.
(h) To make sure parts are seated properly, operate hand pump again and make sure that
nut is able to be loosened (by hand) at 7100 psi (±50 psi). Tighten nut. If gage reading is
above or below limit, remove fan and reinstall until you get a proper reading.
SUBTASK 72-00-31-220-004
(1) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly.
(3) Subtract unstretched dimension from stretched dimension to determine shaft stretch. Shaft
stretch must be 0.018 - 0.022 inch (0.457 - 0.558 mm).
8. Job Close-up
SUBTASK 72-00-31-420-007
A. Install the fan locking plate (1-30) ensuring teeth engage the grooves on the fan nut.
EFFECTIVITY: FJ44-2C
72-00-31
Page 412
Dec 12/17
SUBTASK 72-00-31-420-008
SUBTASK 72-00-31-410-004
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
SUBTASK 72-00-31-760-002
D. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
72-00-31
Page 413
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 414
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-31
Page 415
Dec 12/17
72-00-31
416
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers removal of the case and insert and fan stator from the engine. Refer to the following
illustration(s):
Figure 401
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-32-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-32-10 801 Case and Insert Assembly - Repair
74-10-01 401 Igniton Exciter - Removal/Installation
3. Job Set-up
SUBTASK 72-00-32-010-002
(2) Open the circuit breakers to isolate the engine electrical system.
SUBTASK 72-00-32-020-005
EFFECTIVITY: FJ44-2C
72-00-32
Page 401
Dec 12/17
SUBTASK 72-00-32-020-006
C. Remove the fan rotor (1-10, 72-00-31). Refer to 72-00-31, P.B. 401.
SUBTASK 72-00-32-020-007
D. Remove the ignition exciter(s) (1-10, 74-10-01). Refer to 74-10-01, P.B. 401 in the Maintenance
Manual.
4. Procedures
SUBTASK 72-00-32-020-008
(1) Remove 33 nuts (1-60), 33 bolts (1-30 and 1-40), and 60 washers (1-50) from the inlet flange.
Remove the harness clamps, lifting bracket, the oil supply tube clamp bracket, and the forward
ignition exciter bracket from flange.
CAUTION FAN STATOR VANE MAY BE LOOSE AND MAY FALL OUT OF INLET
CASE DURING REMOVAL. USE CARE TO PREVENT DAMAGE.
(2) Carefully remove the case and insert assembly (1-10) from the interstage housing.
(3) Separate the fan stator vane assembly (1-20) by removing it from the aft side of the case
and insert assembly.
(4) Cover front of the interstage housing to prevent dirt from entering the engine.
NOTE If case and insert assembly is to be rejected from the engine, remove the
engine identification plate and transfer it to the new case and insert assembly.
Refer to 72-32-10, P.B. 801, Repair in the Maintenance Manual.
EFFECTIVITY: FJ44-2C
72-00-32
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-32
Page 403
Dec 12/17
5. General
This task covers installation of the fan stator in the case and insert assembly, and installation of the case
and insert assembly in the engine. Refer to the following illustrations:
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-32, Fig. 01
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
3 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
4 This part must undergo major periodic inspection. If a serviceable, used case and
insert from another engine is to be installed, make sure that it has undergone all
scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 72-00-32-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-009 Petrolatum
SUBTASK 72-00-32-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
EFFECTIVITY: FJ44-2C
72-00-32
Page 404
Dec 12/17
7. Procedures
SUBTASK 72-00-32-420-005
(1) Make sure that the fan stator is correctly installed in the case and insert assembly. For fan
stator vane assembly with aluminum keys: Align the wider, non-grooved area (on fan stator
OD) with the area (on case and insert ID) where there is a wider gap between the locating keys.
All aluminum key inserts will engage the fan case keys. The tooling hole through the fan stator
outer shroud will vary from engine-to-engine and may be in any orientation for installation.
(2) Apply a thin layer of petrolatum MAT-009 to the shroud for the IP forward labyrinth seal on the
ID of the fan stator. Wipe excess lubricant from the edges of the seal.
(3) Hold stator in place and align and install the case and insert assembly on the interstage housing.
(4) Install the lifting bracket at the forward, 12:00 o’clock position on the flange. Secure with three
bolts (1-30), three washers (1-50), and three nuts (1-60).
Harness clamps
(6) Install the oil supply tube clamp bracket (1-70, 79-26-01) on the aft side of the flange. Secure
with one bolt (1-30), one washer (1-50), and one nut (1-60).
EFFECTIVITY: FJ44-2C
72-00-32
Page 405
Dec 12/17
8. Job Close-up
SUBTASK 72-00-32-420-006
SUBTASK 72-00-32-420-007
SUBTASK 72-00-32-420-008
SUBTASK 72-00-32-410-004
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
SUBTASK 72-00-32-760-002
E. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
72-00-32
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-32
Page 407
Dec 12/17
72-00-32
408
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers removal of the gearbox assembly from the engine. Removal procedures for
gearbox-mounted accessory items are referenced to the appropriate Maintenance Manual page block.
Refer to the following illustration(s):
Figure 401
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-60-941-001
A. Standard Equipment
Plastic Gasket Scraper
SUBTASK 72-00-60-943-001
B. Special Tools
Reference Designation
TL37255 Fitting, Oil Drain
TL37270 Torque Adapter, 3/8"
TP-216022 Cover, Gearbox Assy Breather Port
SUBTASK 72-00-60-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
72-00-60
Page 401
Dec 12/17
3. Job Set-up
SUBTASK 72-00-60-010-001
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the cowling.
SUBTASK 72-00-60-020-001
(1) Drain oil from the engine using TL37255, oil drain fitting. Refer to 72-00-03, P.B. 301 in the
Maintenance Manual.
(2) Refer to the Illustrated Parts Catalog and determine if the gearbox assembly includes a
magnetic chip collector. If the magnetic chip collector is not part of the gearbox assembly,
remove the magnetic chip collector assembly. Refer to 79-30-01, P.B. 401.
(3) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(4) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(5) Remove the gearbox magnetic speed pickup. Refer to 77-12-01, P.B. 401 in the Maintenance
Manual.
(6) Remove the fuel control unit/fuel delivery unit. Refer to 73-18-01, P.B. 401 in the Maintenance
Manual.
(7) Remove the fuel pump from the gearbox, if applicable. Refer to in the Maintenance Manual.
(8) Remove the lube oil cooler from the gearbox. Refer to 79-22-01, P.B. 401 in the Maintenance
Manual.
(9) Remove the lube and scavenge pump from the gearbox. Refer to 79-24-01, P.B. 401 in the
Maintenance Manual.
EFFECTIVITY: FJ44-2C
72-00-60
Page 402
Dec 12/17
(10) Remove the oil filter from the gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.
4. Procedures
SUBTASK 72-00-60-020-002
(1) If applicable, disconnect gearbox breather tube discharge plumbing. Refer to the Aircraft
Maintenance Manual.
(2) Remove bolt (1-150) and nut (1-160) which secures breather tube loop clamp (1-170) to
bracket (1-140).
(3) If applicable, remove screw (1-220) from bracket (1-210) which secures the elbow (1-200) in
the service island. Remove O-ring (1-215) from elbow.
NOTE The breather tube flange O-ring (1-130) is present only on engines
with magnetic carbon seal configuration gearbox assemblies. On
gearbox assemblies with spring-loaded carbon seals, the O-ring is
located on the carbon seal as part of the gearbox.
(4) Remove two bolts (1-110) and two washers (1-120) which attach breather tube assembly (1-90)
flange and O-ring (1-130) to gearbox. Use TL37270, as required.
SUBTASK 72-00-60-020-006
(1) Remove two bolts (1-110) and washers (1-120) which retain breather outlet boss (1-90).
Remove breather outlet boss.
(2) Remove four nuts (1-40), four washers (1-50), two bolts (1-20), and two washers (1-30) which
attach the gearbox to the engine.
EFFECTIVITY: FJ44-2C
72-00-60
Page 403
Dec 12/17
NOTE To avoid damage to the gearbox flange surface, use a plastic gasket
scraper to remove the gearbox gasket (1-60).
(3) Carefully remove the gearbox (1-10), gearbox gasket (1-60) and the accessory drive shaft
(1-70) from the engine.
NOTE Check the accessory drive shaft for wear or damage. If worn or damaged
contact Williams International Product Support for inspection criteria.
EFFECTIVITY: FJ44-2C
72-00-60
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-60
Page 405
Dec 12/17
5. General
This task covers installation of the gearbox assembly. Installation procedures for gearbox-mounted
accessory items are referenced to the appropriate Maintenance Manual page block. Refer to the following
illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-60, Fig. 01
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
3 During installation, make sure all parts are clean and free from burrs or high metal that
might cause misalignment, interference to mating flanges, or damage to O-rings.
4 Lubricate all threads and contact surfaces of nuts and bolts with clean engine oil
(MAT-001) before installation unless otherwise noted in text.
5 This part must undergo major periodic inspection. If a serviceable, used gearbox
assembly from another engine is to be installed, make sure that it has undergone all
scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 72-00-60-942-002
A. Consumables
EFFECTIVITY: FJ44-2C
72-00-60
Page 406
Dec 12/17
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 72-00-60-943-002
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
TL37270 Torque Adapter, 3/8"
TL99924 Torque Adapter
SUBTASK 72-00-60-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-00-60 01 260 O-ring
SUBTASK 72-00-60-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-42-12 801 Local Surface Protection - Repair
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-18-01 401 Fuel Control Unit - Removal/Installation
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
79-21-01 401 Oil Filter - Removal/Installation
79-22-01 401 Lube Oil Cooler - Removal/Installation
79-24-01 401 Lube and Scavenge Pump - Removal/Installation
79-30-01 401 Magnetic Chip Collector - Removal/Installation
EFFECTIVITY: FJ44-2C
72-00-60
Page 407
Dec 12/17
7. Procedures
SUBTASK 72-00-60-420-002
(1) Make sure that mount pads on interstage housing and gearbox assembly are clean and dry.
(2) The gearbox mounting gasket (1-60) may be re-used if it passes the following criteria:
(a) No evidence of sealing material (rubber) delamination or pull-away from base metal
groove side walls permitted.
(b) Cracks, splits, or other defects which may affect sealing in the rubber component are
not permitted.
(c) Raised metal in the sealing surface areas not permitted. It is permitted to stone raised
metal and touch up anodize per 70-42-12, P.B. 801.
(d) Scratches or defects in the anodize coating may be repaired per 70-42-12, P.B. 801.
(e) Gearbox gasket must be replaced at the compressor zone inspection interval (Check 4).
(3) Install gearbox mounting gasket (1-60) (dry) on gearbox (1-10). Make sure oil passages and
bolt holes are aligned.
NOTE Check the accessory drive shaft for wear or damage. If worn or damaged
contact Williams International Product Support for inspection criteria.
(4) Install the accessory drive shaft (1-70) into the gearbox assembly and engage it with reduction
gear. Use TL37244 inserted into the starter/generator mounting spline as needed to align
splines.
(5) Align bolt holes and install the gearbox assembly on the interstage housing. Make sure that the
accessory drive shaft engages with the reduction bevel gear in the interstage housing. Attach
gearbox with four washers (1-50), four nuts (1-40), two washers (1-30) and two bolts (1-20).
(6) Torque nuts (1-40) 110 to 123 inch-pounds (12.4 to 13.8 N.m). Use TL99924 torque adapter as
required.
SUBTASK 72-00-60-420-006
EFFECTIVITY: FJ44-2C
72-00-60
Page 408
Dec 12/17
NOTE The breather tube flange O-ring (1-130) is present only on engines
with magnetic carbon seal configuration gearbox assemblies. On
gearbox assemblies with spring-loaded carbon seals, the O-ring is
located on the carbon seal as part of the gearbox.
(a) For magnetic carbon seal gearbox configuration, lubricate a new O-ring (1-130) with
assembly fluid (MAT-011) and install on breather tube (1-80) flange.
(b) For spring-loaded carbon seal gearbox configuration, make sure that O-ring is present on
the OD of the installed carbon seal assembly.
(2) Carefully position the breather tube flange on the gearbox housing.
(3) Install two bolts (1-110) and washers (1-120) to attach breather tube (1-80) flange to gearbox.
If fuel pump is installed, use TL37270 torque adapter. Torque screws 49 to 55 inch-pounds
(5.5 to 6.2 N.m).
(4) Install loop clamp to breather tube. Secure loop clamp bracket with one bolt and one nut.
Torque 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(5) Lubricate elbow O-ring with assembly fluid (MAT-011) and install on elbow. Secure breather
tube elbow in service island by attaching with a bracket and screw. Torque 31 to 35 inch-pounds
(3.5 to 4.0 N.m).
(6) Connect the breather tube discharge plumbing to the breather tube, if applicable. Refer to
the Aircraft Maintenance Manual.
8. Job Close-up
SUBTASK 72-00-60-420-002
EFFECTIVITY: FJ44-2C
72-00-60
Page 409
Dec 12/17
(1) Install oil filter to gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.
(2) Install the hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
(3) Install the starter/generator to the gearbox. Refer to the Aircraft Maintenance Manual.
(4) Install the magnetic chip collector assembly (if not already installed as part of the gearbox
assembly). Refer to 79-30-01, P.B. 401.
(5) Install the lube and scavenge pump to the gearbox. Refer to 79-24-01, P.B. 401 in the
Maintenance Manual.
(6) Install the fuel pump to the gearbox, if applicable. Refer to in the Maintenance Manual.
(7) Install the fuel control unit/fuel delivery unit. Refer to 73-18-01, P.B. 401 in the Maintenance
Manual.
(8) Install the lube oil cooler to the gearbox. Refer to 79-22-01, P.B. 401 in the Maintenance
Manual.
(9) Install the gearbox magnetic speed pickup. Refer to 77-12-01, P.B. 401 in the Maintenance
Manual.
SUBTASK 72-00-60-610-001
B. Service the engine with oil. Refer to 72-00-03, P.B. 301 in the Maintenance Manual.
SUBTASK 72-00-60-410-002
(1) Refer to Aircraft Maintenance Manual (A.M.M.) and install the cowling.
SUBTASK 72-00-60-760-001
D. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
72-00-60
Page 410
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-60
Page 411
Dec 12/17
72-00-60
412
Page
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LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers removal of the rear bypass duct assembly from the engine. Refer to the following
illustration(s):
Figure 401
Figure 402
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-71-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 72-00-71-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and do the following:
EFFECTIVITY: FJ44-2C
72-00-71
Page 401
Dec 12/17
4. Procedures
SUBTASK 72-00-71-020-002
(1) Remove the two screws (280, 76-20-01) and the two washers (20, 76-20-01) which attach the
cover plate (290, 76-20-01) to the LP trip sensor housing. Remove the cover plate.
(2) Measure and record trigger pin end play. Refer to 76-20-01, P.B. 501 in the Maintenance
Manual.
(3) Remove two screws (1-270, 76-20-01), four washers (1-20, 76-20-01), and two nuts (1-260,
76-20-01) which attach the cable actuator housing (1-240, 76-20-01) to the LP trip sensor
housing. Refer to Figure 401.
(4) (FJ33 Only) Remove the trip sensor cable from the FDU support boss.
(5) Remove the cable actuator housing by sliding the housing straight forward. Wrap a protective
covering on the open end of the housing to prevent contamination and accidental actuation.
(7) While holding the LP trip lever (1-50, 76-20-01) (through the trip lever housing), push
adjustment spring (1-40, 76-20-01) located on rear housing forward to release the trip lever.
Remove the trip lever through the trip lever housing.
NOTE Trip lever adjustment spring and spring shaft are not normally
removed during engine disassembly.
(8) If trip lever adjustment spring or spring shaft require removal, remove from bracket on rear
case/mixer as follows:
(9) If required, remove drain fitting (160) and O-ring (150) from transfer tube adapter.
(10) Remove two screws (1-90), four washers (1-80), and two nuts (1-70) and remove the external
transfer tube adapter (1-140) from bottom of duct. Refer to Figure 402.
(11) Remove the transfer (drain) tube (1-110) from the boss in the duct by installing an 8-32 screw
into the tube end. Remove two O-rings (1-120 and 1-100) from the tube.
(12) Index mark front bypass duct, rear mount ring, and rear bypass duct and brackets for assembly
purposes.
(13) If applicable, remove the rear mount sleeve (65) from the rear mount ring.
EFFECTIVITY: FJ44-2C
72-00-71
Page 402
Dec 12/17
SUBTASK 72-00-71-020-003
(1) Remove 24 screws (1-40), 24 nuts (1-30), washers (1-20), and 10 brackets (1-50) securing the
rear bypass duct to the front bypass duct. Remove the rear bypass duct (1-10) from the engine.
SUBTASK 72-00-71-020-005
C. To remove fan bleed port covers, remove six screws (190), nuts (220), countersunk washers
(200) and flat washers (210) (If applicable) from each fan bleed port cover (170). Remove two
covers and gaskets (180).
EFFECTIVITY: FJ44-2C
72-00-71
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 405
Dec 12/17
5. General
This task covers installation of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 403
Figure 404
Figure 405
Figure 406
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
4 Lubricate all threads and contact surfaces of nuts and bolts with clean engine oil
(MAT-001) before installation unless otherwise noted in text.
5 This part must undergo major periodic inspection. If a serviceable, used rear bypass
duct from another engine is to be installed, make sure that it has undergone all
scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 72-00-71-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-019 Acetone
EFFECTIVITY: FJ44-2C
72-00-71
Page 406
Dec 12/17
SUBTASK 72-00-71-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-00-71 01 100 O-ring
72-00-71 01 120 O-ring
72-00-71 01 130 O-ring
72-00-71 01 150 O-ring
76-20-01 01 230 Gasket, cable housing
SUBTASK 72-00-71-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
7. Procedures
SUBTASK 72-00-71-420-001
EFFECTIVITY: FJ44-2C
72-00-71
Page 407
Dec 12/17
(1) Clean the bottom 180 degrees of the flange area mating surfaces of the rear bypass duct,
mount ring, and front bypass duct. Use a cloth soaked with isopropyl alcohol (MAT-027) or
acetone (MAT-019).
(2) Apply RTV sealant MAT-090 to the bottom 180 degrees of the flange mating surfaces of the
rear bypass duct, mount ring, and front bypass duct. See Figure 405.
NOTE RTV sealant must also be applied to the rear flange of the rear
bypass duct and the tailpipe flange.
SUBTASK 72-00-71-420-004
NOTE For the FJ44-2A 56000–103, bolt holes must be aligned with the
uniball slightly raised from horizontal. Align bolt holes with uniball in
the horizontal position for all other models.
(1) Install the rear mount ring (1-60). Make sure that the uniball mount is located on the inboard
side of the engine.
(2) Install the rear bypass duct assembly (1-10), aligning the index mark made during disassembly.
Attach with 24 screws (1-40), 24 nuts (1-30), 10 brackets (1-50), and 48 washers (1-20).
Torque nuts 25 to 28 inch-pounds. Refer to Figure 406 for ITT bracket locations.
SUBTASK 72-00-71-420-005
(1) Lube two O-rings (1-120 and 1-100) with assembly fluid (MAT-011) and install on transfer tube
(1-110). Install transfer tube into port. Refer to Figure 403.
EFFECTIVITY: FJ44-2C
72-00-71
Page 408
Dec 12/17
(2) Lube new O-ring (1-130) with assembly fluid and install on transfer tube adapter (1-140). Install
transfer tube adapter and attach with two screws (1-90), four washers (1-80), and two nuts
(1-70). Torque 18 to 20 inch-pounds (2.0 to 2.3 N.m)
(3) If drain fitting (160) was removed, lube new O-ring (150) with assembly fluid and install on fitting.
Install drain fitting into transfer tube adapter and torque 60 to 70 inch-pounds (6.8 to 7.9 N.m).
SUBTASK 72-00-71-420-006
D. Install gaskets (180) and fan bleed port covers (170). Secure each cover with six screws (190),
countersunk washers (200), washers (210), and nuts (220). Torque nuts 5 to 7 inch-pounds (0.6 to
0.8 N.m).
SUBTASK 72-00-71-420-007
E. Install the LP trip lever and related parts as follows (Figure 404):
(a) Insert the trigger pin through the LP trip sensor housing bushing to check for free travel.
Insert both ends of the pin and slide it all the way to the adjustment screw. Reject trigger
pin if it binds. Remove trigger pin from bushing.
(b) If lever adjustment spring and shaft were removed from the rear case/mixer, install them
as follows:
1 Install the shaft (1-40, 76-20-01) and position on the forward side of the bracket
2 Coat the threads of the bolt (1-10) with retaining compound (MAT-093).
3 Install the washer (1-20) and spring (1-30) on the bolt. Install the bolt into the shaft
from the aft side of the bracket.
(c) Slide the trip lever assembly (1-50, 76-20-01) through the trip sensor housing and the
rear housing strut with the trip lever notch facing forward. Push the adjustment spring
(1-40, 76-20-01) (located on the rear housing) forward to allow trip lever to enter. Release
the adjustment spring when the trip lever notch is aligned with the slot in the adjustment
spring bolt. Move the lever axially to make sure that it does not bind.
(d) Insert the trigger pin (1-100, 76-20-01) through the bushing on the LP trip sensor housing
assembly (part of the rear bypass duct).
(e) Position the trip lever by pulling it radially outward until the pin contacts the top of the trip
lever cup. Look through the witness hole at the bottom of the lever cup to make sure
that the pin is seated properly.
EFFECTIVITY: FJ44-2C
72-00-71
Page 409
Dec 12/17
(f) Check to make sure that the trip mechanism has not actuated by pushing on the inner
cable (1-250, 76-20-01) from the fuel control end. If the mechanism is set (not actuated)
the cable should not move.
(g) Adjust the LP trip lever/recalculate trigger pin length (76-20-01, P.B. 501 in the applicable
Maintenance Manual) if any of the following conditions apply:
1 Trigger pin end play dimension was not acceptable before disassembly.
NOTE If the trigger pin was damaged or lost, the trigger pin dimension must
be recalculated. Refer to 76-20-01, P.B. 501. If trip mechanism was
actuated, mechanism must be reset. Refer to 76-20-01 P.B. 501.
F. Remove protective covering and install cable actuator housing (1-240, 76-20-01) and gasket (1-230,
76-20-01).
G. Attach the housing and gasket with two screws (1-270, 76-20-01), four washers (1-20, 76-20-01),
and two nuts (1-260, 76-20-01). Torque screws 31 to 35 inch-pounds (3.5 to 4.0 N.m) .
H. Install the cover plate (1-290, 76-20-01) to the LP trip sensor housing. Attach the cover plate with
two screws (1-280, 76-20-01) and washers (1-20, 76-20-01). Torque screws 31 to 35 inch-pounds
(3.5 to 4.0 N.m).
8. Job Close-up
SUBTASK 72-00-71-410-002
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and do the following:
(a) Make sure that the rear mount ring is properly connected to the aircraft rear mount.
EFFECTIVITY: FJ44-2C
72-00-71
Page 410
Dec 12/17
SUBTASK 72-00-71-760-001
B. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
72-00-71
Page 411
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 412
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 413
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 414
Dec 12/17
EFFECTIVITY: FJ44-2C
72-00-71
Page 415
Dec 12/17
72-00-71
416
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
TASK 72-02-00-860-801 Internal Cooling and Sealing Air System - Description and Operation
1. General
Cooling air is important in maintaining the long life of the core engine parts by keeping them from getting
too hot. Pressurized air is used to seal one area of the engine from another. Intermediate pressure (IP)
compressor air, high pressure (HP) compressor air, and compressor discharge pressure (CDP) air are
used for sealing and cooling engine areas and parts.
SUBTASK 72-02-00-860-002
A. Air Seals
The primary function of the air seals is to prevent air pressure from leaking at different areas of the
engine. Another function of the air seals is to vent cooling air to hot engine parts, mainly the HP
and LP turbine rotors.
Compressor discharge pressure (CDP) air from the diffuser is routed to the heat exchanger where it
is cooled and returned via the 1st LP nozzle to the No. 3 and 4 carbon seals and bearing cavities.
The rest of the CDP air is routed to the LP turbine discs through integral 1st nozzle air tubes.
B. Oil Seals
The No. 3 and No. 4 bearing cavity oil seals receive CDP sealing air through the 1st LP turbine
nozzle.
C. Cooling Air
Cooling air from the HP compressor cools the HP nozzle (hollow) vanes, the HP turbine disc fir trees,
and the fuel slinger/seal assembly.
D. Breather System
Sealing air is mixed with oil in the bearing cavities and is then scavenged back to the gearbox. The
gearbox contains an air/oil separator to remove the air from the oil. After separation, the air is
routed overboard by a breather tube.
EFFECTIVITY: FJ44-2C
72-02-00
Page 1
Dec 12/17
72-02-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
SPINNER - INSPECTION/CHECK
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-30, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-30-10-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-30-10 801 Spinner - Repair
3. Procedures
SUBTASK 72-30-10-220-002
A. Visual Inspection
EFFECTIVITY: FJ44-2C
72-30-10
Page 601
Dec 12/17
(a) Blunted condition within the limits of Repair, refer to 72-30-10, P.B. 801
repair.
(b) Nicks within the limits of repair. Repair, refer to 72-30-10, P.B. 801
(d) Scratches/gouges within the limits of Repair, refer to 72-30-10, P.B. 801
repair
(f) Dents within the limits of repair. Repair, refer to 72-30-10, P.B. 801
(3) If spinner is rejected, record the size and position of any trim balance weights. Remove weights
and transfer to same relative position(s) on the new spinner. Position of weights is relative to
the alignment mark with the fan. Secure the balance weights using epoxy primer (MAT-096).
EFFECTIVITY: FJ44-2C
72-30-10
Page 602
Dec 12/17
SPINNER - REPAIR
1. General
This task contains procedures for repairing the spinner by blending out damage and restoring the correct
profile of the tip. Do this task if the component inspection/check task indicates that the damage is
repairable. Refer to the following illustration(s):
Figure 801
SUBTASK 72-30-10-941-004
A. Standard Equipment
Handstone
SUBTASK 72-30-10-942-004
B. Consumables
Reference Designation
MAT-050 Coating, Chemical Conversion (Iridite)
SUBTASK 72-30-10-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
70-42-12 801 Local Surface Protection - Repair
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
71-00-00 501 Power Plant - Adjustment/Test
3. Procedures
SUBTASK 72-30-10-350-002
(1) Surface blends must be made to a concave diameter at least 10 times the blend depth. Use
handstone for blending.
EFFECTIVITY: FJ44-2C
72-30-10
Page 801
Dec 12/17
(2) Minor erosion, evidenced by a rough surface and multiple small, shallow pits closely grouped,
is acceptable to a maximum depth of 0 .005 inches. Only light smoothing with handstone is
necessary to remove any roughness.
(3) All blends must be touched up with chemical conversion coating. Refer to 70-42-12, P.B. 801.
B. Blend Limits
(1) The maximum damage allowed is that which can be repaired by grinding the tip to a maximum
radius of:
(2) Machine the spinner tip within the limits of repair (Figure 801). Refer to 70-42-11, P.B. 801.
EFFECTIVITY: FJ44-2C
72-30-10
Page 802
Dec 12/17
(3) Apply chemical conversion coating MAT-050 to finished surface. Refer to 70-42-12, P.B.801 .
4. Job Close-up
SUBTASK 72-30-10-350-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
’Bird Strike or Foreign Object Ingestion’ chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2C
72-30-10
Page 803
Dec 12/17
EFFECTIVITY: FJ44-2C
72-30-10
Page 804
Dec 12/17
1. General
This task covers visual inspection of the spinner pilot plate assembly. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-31-15, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-31-15-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
EFFECTIVITY: FJ44-2C
72-31-15
Page 601
Dec 12/17
3. Procedures
SUBTASK 72-31-15-220-002
A. Visually inspect the spinner pilot plate assy (1-40, 72-00-31) for:
EFFECTIVITY: FJ44-2C
72-31-15
Page 602
Dec 12/17
EFFECTIVITY: FJ44-2C
72-31-15
Page 603
Dec 12/17
72-31-15
604
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers visual inspection of the fan rotor. Refer to the following illustration(s):
Figure 601
Figure 602
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-31, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-31-20-942-001
A. Consumables
Reference Designation
MAT-021 R-MC Cleaner
MAT-031 Cleaner, Gas Path
EFFECTIVITY: FJ44-2C
72-31-20
Page 601
Dec 12/17
SUBTASK 72-31-20-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-30 601 IP and HP Compressors (Borescope) - Inspection/Check
72-31-20 801 Fan Rotor - Repair
3. Job Set-up
SUBTASK 72-31-20-010-003
4. Procedures
SUBTASK 72-31-20-220-001
CAUTION FAN ROTOR IS MADE OF TITANIUM. DO NOT CLEAN THE FAN ROTOR
WITH ETHANOL OR METHANOL ALCOHOL.
A. Clean the fan before inspection. Use compressor cleaner (MAT-021 or MAT-031).
(a) Dents, nicks, or erosion within limits Repair, refer to 72-31-20, P.B. 801
of repair.
EFFECTIVITY: FJ44-2C
72-31-20
Page 602
Dec 12/17
(c) Bend on blade tip. Evaluate and repair blade tip in accordance
with Repair Station Instruction 72507. If
fan P/N is not covered by repair instruction,
reject fan.
(2) Inspect the blade trailing edges (Zones E1 and E2) for:
NOTE You should inspect the trailing edges by feel. If you feel damage,
or if there is excessive damage on leading edge, remove the fan
for detailed inspection and repair.
(a) Nicks or dents within limits of repair Repair, refer to 72-31-20, P.B. 801
(c) Bend on blade tip. Evaluate and repair blade tip in accordance
with Repair Station Instruction 72507. If
fan P/N is not covered by repair instruction,
reject fan.
(3) Inspect the blade face surfaces and blade root edges (Zones A and F). Refer to the following
figure for definition of blade surface inspection zones (by engine model/type): Figure 602.
(a) Defects, damage, or blended areas Erosion or scratch, refer to72-31-20, P.B.
in zone A 801. Nicks or other damage – Reject.
If blended areas are present in zone A,
contact Williams International Product
Support.
(b) Nicks in zone F within the limits of Repair, refer to 72-31-20, P.B. 801
repair
(a) Rub indications, build-up, or face Refer to 72-31-20, P.B. 801 for blend repair
nicks within the limits of repair limits
EFFECTIVITY: FJ44-2C
72-31-20
Page 603
Dec 12/17
SUBTASK 72-31-20-220-006
C. Inspect fan blade leading and trailing edges for mid-span deformation. If deformation is evident,
measure and disposition as follows:
(1) Lay a straight edge on the blade at the location of the deformation.
(2) Using gage pins, determine the largest diameter pin that will just fit between the deformed
surface and the straight edge.
(3) Deflection may be repaired by hot straightening in accordance with Repair Instruction 72680 if
it is within the following requirements:
(b) Hot straightening is not allowed if deflection is inboard of a point that is either 0.250
inches above the rim or 20% of blade span (distance between hub and tip of blade),
whichever is greater.
(c) No more than three locations on a leading or trailing edge may be straightened.
SUBTASK 72-31-20-220-003
D. If fan rotor is removed (per scheduled maintenance requirements) inspect the bore/spline/web face
areas of fan rotor bore for:
(d) Slight deformation of spline leading Remove raised material with hand stone
edge due to assembly damage up to
0.020 inch (0.50 mm) long x 0.002
inch (0.050 mm) deep.
EFFECTIVITY: FJ44-2C
72-31-20
Page 604
Dec 12/17
(d) Scratches up to 0.005 inch deep Polish with 600 grit aluminum oxide cloth
on the OD of the aft bore (largest to remove defect.
diameter, farthest aft).
(3) Inspect the forward and aft clamp faces of the bore for:
(c) Nicks up to 0.005 inch (0.13 mm) Remove raised material with hand stone.
deep in the ID chamfer of the aft Do not blend onto pilot ID.
clamp face.
(d) Nicks up to 0.010 inch (0.25 mm) Hand stone to smooth blend in the
deep on the forward and aft clamp circumferential direction in a minimum 5:1
faces width-to-depth ratio. Multiple blends must
be separated by two times the largest
blend. Blending is not to exceed 20%
of the clamp face area. Perform local
penetrant inspection.
(a) Burr on edge from tool contact. Remove raised material with hand stone
and smooth sharp edge with aluminum
oxide cloth. Perform NDI inspection on
repaired area.
SUBTASK 72-31-20-220-007
E. Visually inspect the aft face of the OD of the fan hub for contact with the fan stator:
EFFECTIVITY: FJ44-2C
72-31-20
Page 605
Dec 12/17
(1) Light build-up of material Hand stone or polish with silicone carbide
or aluminum oxide 180 grit paper to
remove build-up.
SUBTASK 72-31-20-220-005
(1) Measure clearance at 12 o’clock position. Max radial tip clearance must be 0.079
inch (2.0 mm)
(2) Measure clearance at 3 and 9 o’clock Max radial tip clearance must be 0.067
positions. inch (1.70 mm)
(3) Measure clearance at 6 o’clock position. Max radial tip clearance must be 0.055
inch (1.39 mm)
EFFECTIVITY: FJ44-2C
72-31-20
Page 606
Dec 12/17
EFFECTIVITY: FJ44-2C
72-31-20
Page 607
Dec 12/17
Fig. 602 Fan Blade Surfaces – FJ44-2A and FJ44-2C – Inspection Zones
EFFECTIVITY: FJ44-2C
72-31-20
Page 608
Dec 12/17
1. General
This task contains procedures for repairing the fan rotor by blending and restoring the surface finish to
damaged areas. This task also describes the extent of damage which may be repaired by this method.
Refer to 72-31-20, P.B. 601 for visual inspection criteria. Refer to the following illustration(s):
Figure 801
Figure 802
Figure 803
SUBTASK 72-31-20-941-005
A. Standard Equipment
Carborundum Stone
SUBTASK 72-31-20-942-005
B. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-042 Paper, Abrasive, Silicone Carbide
SUBTASK 72-31-20-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
71-00-00 501 Power Plant - Adjustment/Test
72-31-20 601 Fan Rotor - Inspection/Check
EFFECTIVITY: FJ44-2C
72-31-20
Page 801
Dec 12/17
3. Job Set-up
SUBTASK 72-31-20-010-005
4. Procedures
SUBTASK 72-31-20-350-002
EFFECTIVITY: FJ44-2C
72-31-20
Page 802
Dec 12/17
(2) Examine the fan blades with a bright light and 5x magnification to check the amount of damage.
Refer to Figure 801, Figure 802, Figure 803and the table of blend limits to determine the
quantity, size, and location of repairable defects. If defects exceed limits, reject fan.
EFFECTIVITY: FJ44-2C
72-31-20
Page 803
Dec 12/17
NOTES: 1 Total number of Zones B, D, or E2 blends per rotor not to exceed 8 of each kind.
No more than four adjacent blended blades of any of these types per rotor.
2 Total allowable length of Zone C and E1 blends per rotor is limited to:1.5
x Length of All Zone C Blends + Length of All Zone E1 Blends = 15 Inch
Max. No more than three adjacent blended blades allowed per rotor.
3 For multiple nicks less than 0.050 inch in length x 0.015 inch in depth, in
Zones:B,C,D, and F, light smoothing to remove raised metal is allowed.
EFFECTIVITY: FJ44-2C
72-31-20
Page 804
Dec 12/17
(a) Repair damage to blades by blending. Refer to Blend Limits table and Figure 801 Figure
802 for a definition of reparable areas. Blend in accordance with the following general
requirements:
2 The surface length of all leading and trailing edge blends must be 5 times the
maximum blend depth.
3 Surface blends must be made to a concave diameter 5 times the blend depth.
4 To maintain rotor balance when blending damaged airfoils in the field, equal material
must be removed from the blade closest to 180 degrees opposite the blended blade.
This material should be removed from the same area as the blend. If repair limits
do not allow removing material from the opposite blade, return fan to Authorized
Repair Facility for balancing.
5 All blends made on leading and trailing edges must leave a full radius on the air foil
(see Figure 802).
(c) If blending installed fan, use vacuum to remove metal particles from inlet case.
(5) Visually inspect the repaired areas. Make sure they conform to the limits and contours in
Figure 801 .
5. Job Close-up
SUBTASK 72-31-20-230-003
A. Check repaired areas for cracks using local penetrant inspection. Refer to 70-42-15, P.B. 601 for
non-destructive inspection (NDI) methods. No cracks are allowed.
SUBTASK 72-31-20-350-050
B. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
’Bird Strike or Foreign Object Ingestion’ chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2C
72-31-20
Page 805
Dec 12/17
EFFECTIVITY: FJ44-2C
72-31-20
Page 806
Dec 12/17
EFFECTIVITY: FJ44-2C
72-31-20
Page 807
Dec 12/17
Fig. 803 Fan Blade Surfaces – FJ44-2A and FJ44-2C – Inspection Zones
EFFECTIVITY: FJ44-2C
72-31-20
Page 808
Dec 12/17
1. General
This task covers visual inspection of the inlet case and fan shroud insert. Refer to the following illustrations:
Figure 601
Figure 602
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-32-10-941-001
A. Standard Equipment
0.080 Inch Pin Gauge
Handstone
SUBTASK 72-32-10-942-001
B. Consumables
EFFECTIVITY: FJ44-2C
72-32-10
Page 601
Dec 12/17
Reference Designation
MAT-040 Cloth, Abrasive
SUBTASK 72-32-10-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
71-00-00 501 Power Plant - Adjustment/Test
72-32-10 801 Case and Insert Assembly - Repair
3. Procedures
SUBTASK 72-32-10-220-001
NOTES: 1 If the case and insert assembly is rejected and requires replacement, the engine
identification plate must be removed and installed on the new case and insert
assembly. Refer to 72–32–10, P.B. 801 in the Maintenance Manual.
(a) Corrosion with pitting of ID surface of Remove corrosion products with stiff nylon
nitronic steel case or bristle brush, emery cloth, or scotch
brite pad. Do not use metallic brush.
Alternate method to brush is to use 600 grit
aluminum oxide or silicon carbide paper
(MAT-040).
If rust spots remain, clean with 5%
phosphorus acid solution.
Reclean part.
EFFECTIVITY: FJ44-2C
72-32-10
Page 602
Dec 12/17
(4) Inspect the outer surfaces and inner flowpath of the inlet case for:
(c) Wear mark on outer case forward of Blend down to 0.010 inch max depth with
weld up to 0.008 inch (0.20 mm) deep brite boy rubberized stone. Perform local
x 0.170 inch (4.31 mm) wide x 0.666 penetrant inspection on repaired area.
inch (16.9 mm) long.
SUBTASK 72-32-10-220-002
NOTE For insert designs which include abradable surfaces, corrosion limits do not apply to
the abradable surface itself, but only the aluminum sheet metal surface.
EFFECTIVITY: FJ44-2C
72-32-10
Page 603
Dec 12/17
(4) Nicks, gouges, dents up to 0.080 inch (2.03 Blend to remove raised material or sharp
mm) depth (areas other than seal ribs). corners using handstone.
(7) Fan shroud abradable damage is allowed Blend to remove raised material or sharp
up to a maximum circumferential length of edges.
two fan blade spaces (positioning fan blade
over center of damaged area, damage must
not extend to both adjacent fan blades).
Cumulative abradable damage is limited
to a maximum of 5.8 square inches (3742
square mm). Abradable damage may
expose bare metal, but no visible damage
to bare metal allowed. No sharp edges,
cracks, or loose material allowed.
(8) Rub indications or erosion on fan shroud Blend to remove raised material or sharp
abradable coating are allowed up to 0.025 edges.
inch (0.63 mm) deep. Damage may extend
360 degrees in circumference, provided
depth limits are maintained. No sharp
edges, cracks, or loose material allowed.
SUBTASK 72-32-10-220-004
EFFECTIVITY: FJ44-2C
72-32-10
Page 604
Dec 12/17
SUBTASK 72-32-10-220-005
4. Job Close-up
SUBTASK 72-32-10-220-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
’Bird Strike or Foreign Object Ingestion’ chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2C
72-32-10
Page 605
Dec 12/17
EFFECTIVITY: FJ44-2C
72-32-10
Page 606
Dec 12/17
Fig. 602 Case and Insert Assembly - Flange and Shroud Inserts
EFFECTIVITY: FJ44-2C
72-32-10
Page 607
Dec 12/17
72-32-10
608
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains procedures for removing the engine identification plate from the inlet case and installing
it on a new case and insert assembly. If applicable, a N1/ITT trim value plate must also be installed. Refer
to the following illustration(s):
Figure 801
SUBTASK 72-32-10-942-005
A. Consumables
Reference Designation
MAT-096 Primer, Epoxy
SUBTASK 72-32-10-944-005
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-32-10 1 90 Stud, Grooved (4)
3. Procedures
SUBTASK 72-32-10-350-002
CAUTION USE CARE NOT TO DAMAGE THE DATA TAG OR INLET CASE, OR
DEFORM MOUNTING HOLES IN THE INLET CASE.
(1) Carefully insert a skin wedge (or similar tool) between the inlet case and the identification tag,
near the corners to loosen the rivets.
(2) Once the rivets have raised sufficiently, use pliers to pull the rivets straight out of the Inlet Case.
(4) Install identification plate on four mounting holes. Identification plate is to be oriented so that it
can be read, from left to right, when looking at bottom of engine, looking aft.
EFFECTIVITY: FJ44-2C
72-32-10
Page 801
Dec 12/17
(5) Coat four grooved studs with epoxy primer MAT-096 and tap into case to secure identification
plate.
EFFECTIVITY: FJ44-2C
72-32-10
Page 802
Dec 12/17
Fig. 801 Case and Insert Assembly - Engine Identification Plate - Replace
EFFECTIVITY: FJ44-2C
72-32-10
Page 803
Dec 12/17
72-32-10
804
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers visual inspection of the fan stator. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-32, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-32-20-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-00-32 401 Case and Insert Assy - Removal/Installation
72-32-20 801 Fan Stator - Repair
EFFECTIVITY: FJ44-2C
72-32-20
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 72-32-20-010-001
SUBTASK 72-32-20-020-001
SUBTASK 72-32-20-020-002
SUBTASK 72-32-20-020-003
D. Remove the case and insert assembly. Refer to 72–00–32, P.B. 401. Remove fan stator from
case and insert.
4. Procedures
SUBTASK 72-32-20-220-002
(a) Erosion within limits of repair. Repair, refer to 72-32-20, P.B. 801
(c) Nicks or pits within limits of repair. Repair, refer to 72-32-20, P.B. 801
(2) Inspect the leading and trailing edges of the stator vanes (Zone B for FJ44-1A; Zones B and C
for FJ44-1AP, FJ44-2 and FJ44-3):
(a) Nicks or dents within the limits of Repair, refer to 72-32-20, P.B. 801
repair.
EFFECTIVITY: FJ44-2C
72-32-20
Page 602
Dec 12/17
(c) Erosion on leading edge within limits Repair, refer to 72-32-20, P.B. 801
of repair.
NOTE Gouges that penetrate the outer casing are acceptable in one defect area
only. Gouges must not penetrate stiffening ring. Gouges that penetrate
an area where there is no stiffening ring are not acceptable.
(a) Gouges, dents, or holes within the Repair, refer to 72-32-20, P.B. 801
limits of repair
(a) Gouges or dents within the limits of Repair, refer to 72-32-20, P.B. 801
repair
(a) Rips on inner casing metal within the Repair, Refer to 72-32-20, P.B. 801
limits of repair.
EFFECTIVITY: FJ44-2C
72-32-20
Page 603
Dec 12/17
(c) Wear in the outer urethane due to Wear that has gone through the urethane
contact with the fan case anti-rotation with some material loss on the vane is
keys. acceptable. Wear that has gone through
the vane is not acceptable.
SUBTASK 72-32-20-220-003
B. Inspect the forward shoulder of the center body which supports the rubber seal for the fan ID. If
damage is present (dents), repair by cold straightening to best possible condition. Any amount of
deflection is acceptable provided that there are no cracks. Visually inspect for cracks after repair.
EFFECTIVITY: FJ44-2C
72-32-20
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
72-32-20
Page 605
Dec 12/17
72-32-20
606
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task contains procedures for repairing the fan stator by blending and restoring the surface finish to
damaged areas or welding. This task also describes the extent of damage which may be repaired by
these methods. Refer to the following illustration(s):
Figure 801
SUBTASK 72-32-20-941-004
A. Standard Equipment
Handstones
5x Magnification
SUBTASK 72-32-20-942-004
B. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-050 Coating, Chemical Conversion (Iridite)
SUBTASK 72-32-20-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-00-32 401 Case and Insert Assy - Removal/Installation
3. Job Set-up
SUBTASK 72-32-20-010-002
EFFECTIVITY: FJ44-2C
72-32-20
Page 801
Dec 12/17
SUBTASK 72-32-20-020-004
SUBTASK 72-32-20-020-005
SUBTASK 72-32-20-020-006
D. Remove the case and insert assembly. Refer to 72–00–32, P.B. 401. Remove fan stator from
case and insert.
4. Procedures
SUBTASK 72-32-20-350-003
NOTE If the inspection task reveals damage to the stator vanes, the vanes can be
dressed and blended, as permitted by the limits in this repair.
(2) Examine the fan stator vanes with a bright light and 5x magnification to check the amount of
damage. Refer to Figure 801 and the blend limits below to determine the quantity, size, and
location of repairable defects. If defects exceed limits, reject fan stator.
SUBTASK 72-32-20-350-005
EFFECTIVITY: FJ44-2C
72-32-20
Page 802
Dec 12/17
EFFECTIVITY: FJ44-2C
72-32-20
Page 803
Dec 12/17
SUBTASK 72-32-20-350-006
(1) Repair damage to vanes by blending using handstones. Refer to Blend Limits table and Figure
801 for maximum repair limits. Blend in accordance with the following general requirements:
(a) The surface length of all leading and trailing edge blends must be 5 times the maximum
blend depth.
(b) Surface blends must be made to a concave diameter at least 10 times the blend depth.
(c) Corner blends must have a length which is 2.5 times the depth
(d) All blends made on leading and trailing edges must leave a full radius on the air foil
(see Figure 801).
(e) All casing damage should be blended by removing any raised metal and smoothing rough
edges. Dents should be carefully peened back to flush with adjacent casing surface.
D. Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure 801.
E. Apply anodic solution (iridite) (MAT-050) to repaired areas. Refer to 70-42-12, P.B. 801 in the
Maintenance Manual.
5. Job Close-up
SUBTASK 72-32-20-350-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
’Bird Strike or Foreign Object Ingestion’ chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2C
72-32-20
Page 804
Dec 12/17
EFFECTIVITY: FJ44-2C
72-32-20
Page 805
Dec 12/17
72-32-20
806
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers a dimensional run-out check of the forward end of the LP shaft. Do this task, as directed
by troubleshooting, to determine if the LP shaft is bent or damaged.
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure listed, you should keep
the part for a possible future repair procedure and/or contact Williams
International, Walled Lake, Michigan, USA for service.
SUBTASK 72-35-22-941-003
A. Standard Equipment
Dial Indicator
SUBTASK 72-35-22-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
3. Job Set-up
SUBTASK 72-35-22-010-007
EFFECTIVITY: FJ44-2C
72-35-22
Page 601
Dec 12/17
SUBTASK 72-35-22-020-007
4. Procedures
SUBTASK 72-35-22-220-006
(1) Take a run-out measurement on the inside diameter of the LP shaft, approximately 0.125
inch (3.17 mm) from the front end of the shaft. Take the measurement at the 3 o’clock or 6
o’clock location on the shaft.
(a) If shaft run-out is 0.006 inch (0.152 mm) or less, shaft is acceptable. Go to Job Close-up
(b) If shaft run-out is more than limits in previous step, remove fan rotor and perform LP
shaft OD measurement in next subtasks.
SUBTASK 72-35-22-020-008
SUBTASK 72-35-22-220-007
(1) Take a run-out measurement on the outside diameter of the LP shaft on the forward fan pilot
diameter near the forward end of the shaft.
(a) If shaft run-out is 0.003 inch (0.076 mm) or less, shaft is acceptable.
(b) If shaft run-out is more than limits previous step, reject the engine.
5. Job Close-up
SUBTASK 72-35-22-420-003
A. Install the fan rotor (if removed). Refer to 72-00-31, P.B. 401.
SUBTASK 72-35-22-420-004
SUBTASK 72-35-22-410-001
EFFECTIVITY: FJ44-2C
72-35-22
Page 602
Dec 12/17
EFFECTIVITY: FJ44-2C
72-35-22
Page 603
Dec 12/17
72-35-22
604
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers removal of any of the magnetic carbon seal assemblies from the 4k configuration
gearbox. Refer to the following illustration(s):
Figure 401
Figure 402
Figure 403
Figure 404
Figure 405
EFFECTIVITY: FJ44-2C
72-60-01
Page 401
Dec 12/17
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-01-945-005
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 402
Dec 12/17
3. Job Set-up
SUBTASK 72-60-01-010-006
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-60-01-020-005
A. STARTER/GENERATOR. Use the procedure that follows to remove magnetic carbon seals from
the starter/generator location:
(1) Remove starter/generator from gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove six bolts and washers attaching adapter (100) to gearbox housing.
(4) Remove and discard both the adapter O-ring and the O-ring on face of gearbox housing.
EFFECTIVITY: FJ44-2C
72-60-01
Page 403
Dec 12/17
(b) Position the oil jet off the edge of your workspace to prevent damage.
(c) Use a small-diameter tool in the three holes provided to carefully, evenly drive the magnet
(114) out of the adapter by hand (no hammer).
SUBTASK 72-60-01-050-007
B. FUEL CONTROL UNIT/FUEL PUMP UNIT. Use the procedure that follows to remove magnetic
carbon seals from the fuel control/fuel pump location:
(1) Remove fuel control from gearbox. Refer to 73-18-01, P.B. 401.
(2) Remove two bolts and washers attaching fuel pump adapter (60) to gearbox housing.
(3) Use slide-hammer in the two machine-screw threads to carefully remove adapter. Hold
gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
(a) Remove the retaining ring (23) from the adapter bore.
(d) Use a plastic or nylon driver to gently, evenly push the magnet (74) out of the adapter by
hand (no hammer).
SUBTASK 72-60-01-020-006
C. HYDRAULIC PUMP AND BREATHER TUBE. Use the following procedure to remove magnetic
carbon seals from the Hydraulic Pump Adapter and Breather Tube locations:
EFFECTIVITY: FJ44-2C
72-60-01
Page 404
Dec 12/17
NOTE The hydraulic pump gearshaft must be removed from the gearbox when
reinstalling or replacing the aft magnetic carbon seal.
(1) Remove hydraulic pump from gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove four bolts and washers that attach the hydraulic pump adapter (20) to gearbox housing.
NOTE Hydraulic pump gearshaft may come out of the gearbox with the adapter.
(b) Carefully, evenly drive the magnet (114) out of the adapter by hand (no hammer).
(7) Remove forward and aft carbon seal cases (35 and 115) from gearshaft.
(9) Remove the aft magnet from the gearbox housing breather port. Use a clean, nylon drift, if
required.
EFFECTIVITY: FJ44-2C
72-60-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
Fig. 401 Gearbox Magnetic Seals - Removal/Installation 72-60-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 408
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 409
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 410
Dec 12/17
TASK 72-60-01-050-805 Remove Type 1 Spring-Loaded Carbon Seals from the 4k Gearbox
5. General
This task covers removal of the type 1 spring-loaded carbon seal assemblies from the 4k configuration
gearbox.
Gearbox Carbon Seal Replacement Videos are available for review on our website. Access is available for
authorized service facility technicians only – contact us for access.
Refer to the appropriate subtask for the applicable seal location on the gearbox. Refer to the following
illustration(s):
Figure 406
EFFECTIVITY: FJ44-2C
72-60-01
Page 411
Dec 12/17
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-60-01-943-003
A. Special Tools
Reference Designation
TL-220685 Kit, Gearbox Seal Installation/Removal
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-945-053
B. Reference Information
EFFECTIVITY: FJ44-2C
72-60-01
Page 412
Dec 12/17
7. Job Set-up
SUBTASK 72-60-01-010-053
(2) Open the circuit breakers to isolate the engine electrical supply.
8. Procedures
SUBTASK 72-60-01-020-054
A. STARTER/GENERATOR. Use the following procedure to remove spring-loaded carbon seal from
the starter/generator location:
(1) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove six bolts (40) and washers (50) attaching the starter/generator adapter (100) to the
gearbox housing. Carefully remove the adapter.
(3) Remove O-ring (105) and O-ring (107) from the adapter.
(4) Remove carbon seal (123) from the starter/generator adapter bore using driver TL99696-08
from TL99696 kit .
EFFECTIVITY: FJ44-2C
72-60-01
Page 413
Dec 12/17
(5) Remove seal runner (125) from the gearshaft. use puller TL99696-02 with TL99696-06 plug
from TL99696 kit or puller TL-220685-02 with TL-220685-06 plug from TL-220685 kit. Hold
gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
(6) Inspect the inner diameter of gearshaft for damage; photograph and submit any evidence of
damage to WIProductSupport@williams-int.com.
SUBTASK 72-60-01-020-055
B. FUEL CONTROL/FDU. Use the following procedure to remove spring-loaded carbon seal from the
fuel control/fuel delivery unit location:
(1) Remove the fuel control/fuel delivery unit from the gearbox. Refer to 73-18-01, P.B. 401.
(2) Remove two bolts (80) and washers (90) attaching the fuel pump adapter (60) to the gearbox
housing.
(3) Carefully remove the adapter. There are two machine-screw threads in the adapter to facilitate
removal of the adapter by gently using a slide-hammer. Hold gearshaft in place during removal
to prevent dislodging gearshaft/bearing from housing.
(5) Remove the carbon seal (70) from the fuel pump adapter bore using driver TL99696-10 from
the kit.
(6) Remove the seal runner (74) from the gearshaft using 3-jaw puller TL-99696-02 with
TL-99696-07 plug or TL-220685-02 puller with TL-220685-07 plug. Hold gearshaft in place
during removal to prevent dislodging gearshaft/bearing from housing.
(7) Inspect the inner diameter of gearshaft for damage; photograph and submit any evidence of
damage to WIProductSupport@williams-int.com.
SUBTASK 72-60-01-020-056
C. HYDRAULIC PUMP. Use the following procedure to remove spring-loaded carbon seal from the
hydraulic pump location:
(1) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
EFFECTIVITY: FJ44-2C
72-60-01
Page 414
Dec 12/17
(2) Remove four bolts (40) and washers (50) attaching the hydraulic pump adapter (20) to the
gearbox housing. Carefully remove the adapter.
NOTE Hydraulic pump gearshaft may come out of gearbox with the adapter.
(4) Remove the hydraulic pump gearshaft from the gearbox housing (or separate it from the
adapter) and place it on a clean surface.
(5) Remove the carbon seal (120) from the hydraulic pump adapter bore using driver TL99696-09
from the kit.
(6) Remove the seal runner (115) from the gearshaft. using 3-jaw puller TL-99696-02 with
TL-99696-07 plug or TL-220685-02 puller with TL-220685-07 plug.
SUBTASK 72-60-01-020-057
D. BREATHER TUBE. Use the following procedure to remove the spring-loaded carbon seal from the aft
side of the hydraulic pump gearshaft (breather tube port):
(1) Remove the breather tube from the gearbox. Refer to 72-00-60, P.B. 401. Make sure that the
breather tube hose is disconnected from the breather tube elbow.
(2) Remove the OD O-ring and the spring-loaded carbon seal (30) from the gearbox housing
breather port.
(3) Remove the hydraulic pump adapter and the hydraulic pump gearshaft in accordance with
Subtask 72-60-010-020-052, above. It is not necessary to remove the hydraulic pump carbon
seal or seal runner, as long as the sealing surfaces are protected from damage and cleaned
before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump gearshaft
using 3-jaw puller TL-99696-02 with TL-99696-07 plug or TL-220685-02 puller with
TL-220685-07 plug.
(5) Place gearshaft in plastic bag and cover all open gearbox ports to prevent contamination.
EFFECTIVITY: FJ44-2C
72-60-01
Page 415
Dec 12/17
Fig. 406 Gearbox Carbon Seals – Type 1 Spring-Loaded Configuration (4k)– Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 416
Dec 12/17
TASK 72-60-01-050-807 Remove Type 2 or Type 3 Spring-Loaded Carbon Seals from the 4k
Gearbox
9. General
This task covers removal of the type 2 or type 3 spring-loaded carbon seal assemblies from the 4k
configuration gearbox.
Gearbox Carbon Seal Replacement Videos are available for review on our website. Access is available for
authorized service facility technicians only – contact us for access.
EFFECTIVITY: FJ44-2C
72-60-01
Page 417
Dec 12/17
2 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-60-01-943-003
A. Special Tools
Reference Designation
TL-220685 Kit, Gearbox Seal Installation/Removal
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-945-053
B. Reference Information
CH-SE-SU Pg Block Nomenclature
00-00-00 1 Manual Introduction - Description and Operation
EFFECTIVITY: FJ44-2C
72-60-01
Page 418
Dec 12/17
SUBTASK 72-60-01-010-053
(2) Open the circuit breakers to isolate the engine electrical supply.
12. Procedures
SUBTASK 72-60-01-020-054
A. STARTER/GENERATOR. Use the following procedure to remove spring-loaded carbon seal from
the starter/generator location:
(1) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove six bolts (40) and washers (50) attaching the starter/generator adapter (100) to the
gearbox housing. Carefully remove the adapter.
(3) Remove O-ring (105) and O-ring (107) from the adapter.
(4) Remove wave spring (26 – type two / 28 – type three) from adapter bore.
(5) Remove spring washer (108 – type two / 109 – type three) from adapter bore.
(6) Remove carbon seal (123) from the starter/generator adapter bore using driver TL99696-08
from TL99696 kit.
(7) Remove seal runner (125) from the gearshaft. Use puller TL99696-02 with TL99696-06 plug
from TL99696 kit or puller TL-220685-02 with TL-220685-06 plug from TL-220685 kit.
EFFECTIVITY: FJ44-2C
72-60-01
Page 419
Dec 12/17
(8) Inspect the inner diameter of gearshaft for damage; photograph and submit any evidence of
damage to WIProductSupport@williams-int.com.
SUBTASK 72-60-01-020-055
B. FUEL CONTROL UNIT/FUEL DELIVERY UNIT. Use the following procedure to remove spring-loaded
carbon seal from the fuel control/fuel delivery unit location:
(1) Remove the fuel control/fuel delivery unit from the gearbox. Refer to 73-18-01, P.B. 401.
(2) Remove two bolts (80) and washers (90) attaching the fuel pump adapter (60) to the gearbox
housing.
(3) Carefully remove the adapter. There are two machine-screw threads in the adapter to facilitate
removal of the adapter by gently using a slide-hammer. Hold gearshaft in place during removal
to prevent dislodging gearshaft/bearing from housing.
(5) Remove the carbon seal (70) from the fuel adapter bore using driver TL99696-10 from kit.
(6) Remove the seal runner (74) from the gearshaft using 3-jaw puller TL-99696-02 with
TL-99696-07 plug or TL-220685-02 puller with TL-220685-07 plug. Hold gearshaft in place
during removal to prevent dislodging gearshaft/bearing from housing.
(7) Inspect the inner diameter of gearshaft for damage; photograph and submit any evidence of
damage to WIProductSupport@williams-int.com.
SUBTASK 72-60-01-020-056
C. HYDRAULIC PUMP. Use the following procedure to remove spring-loaded carbon seal from the
hydraulic pump location:
(1) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove four bolts (40) and washers (50) attaching the hydraulic pump adapter (20) to the
gearbox housing.
EFFECTIVITY: FJ44-2C
72-60-01
Page 420
Dec 12/17
NOTE Hydraulic pump gearshaft may come out of gearbox with the adapter.
If this occurs, reinstall the hydraulic pump gearshaft by centering
it in the housing bore and engaging the aft bearing pilot diameter.
Rotate as required to mesh gear teeth.
(5) Remove the wave spring (26 – type two / 28 – type three) from the adapter bore.
(6) Remove the spring washer (27 — type two / 29 — type three) from the adapter bore.
(7) Remove the carbon seal (120) from the hydraulic pump adapter bore using driver using driver
TL99696-09 from the kit.
(8) Remove the seal runner (115) from the gearshaft using 3-jaw puller TL-99696-02 with
TL-99696-07 plug or TL-220685-02 puller with TL-220685-07 plug.
SUBTASK 72-60-01-020-057
D. BREATHER TUBE. Use the following procedure to remove the spring-loaded carbon seal from the aft
side of the hydraulic pump gearshaft (breather tube port):
(1) Remove the breather tube from the gearbox. Refer to 72-00-60, P.B. 401. Make sure that the
breather tube hose is disconnected from the breather tube elbow.
(2) Remove the O-ring and the spring-loaded carbon seal (30) from the gearbox housing breather
port.
(3) Remove the hydraulic pump adapter in accordance with Subtask 72-60-010-020-056 (above)
and remove the hydraulic pump gearshaft from the gearbox. It is not necessary to remove the
hydraulic pump carbon seal or seal runner, as long as the sealing surfaces are protected from
damage and cleaned before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump
gearshaft. Use 3-jaw puller TL-99696-02 with TL-99696-07 plug or TL-220685-02 puller with
TL-220685-07 plug.
(5) Place gearshaft in plastic bag and cover all open gearbox ports to prevent contamination.
EFFECTIVITY: FJ44-2C
72-60-01
Page 421
Dec 12/17
Fig. 407 Gearbox Carbon Seals – Type 2 Spring-Loaded Configuration (4k) – Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 422
Dec 12/17
13. General
This task covers installation of any of the magnetic carbon seals in the 4k configuration gearbox. Refer
to the following illustration(s):
Figure 409
Figure 410
Figure 411
Figure 412
Figure 413
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-01, Fig. 02
EFFECTIVITY: FJ44-2C
72-60-01
Page 424
Dec 12/17
SUBTASK 72-60-01-941-006
A. Standard Equipment
SUBTASK 72-60-01-942-006
B. Consumables
SUBTASK 72-60-01-944-006
C. Expendable Parts
IPC Reference
Subject Fig Item Nomenclature
72-60-01 02 25 O-Ring
72-60-01 02 32 O-Ring (2)
EFFECTIVITY: FJ44-2C
72-60-01
Page 425
Dec 12/17
SUBTASK 72-60-01-450-002
D. Repair Parts
IPC Reference
Subject Fig Item Nomenclature
72-60-01 01 30 Magnetic Seal
72-60-01 01 70 Magnetic Seal
72-60-01 01 110 Magnetic Seal
SUBTASK 72-60-01-945-006
E. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 426
Dec 12/17
15. Procedures
SUBTASK 72-60-01-420-005
A. STARTER/GENERATOR. Use the procedure that follows to install magnetic carbon seals to the
starter/generator location:
(a) Clean adapter bore and keeper using alcohol (MAT-027) and a lint-free wiper. Make sure
parts are free of oil, dirt, and foreign material.
(2) Prepare new magnetic carbon seal (110) for installation as follows:
(a) Verify correct carbon seal at each installation. Refer to the Illustrated Parts Catalog
72–60–01, Fig. 02.
(b) When removing seal from packaging, seal case (115) must be separated from the magnet
(114). Pull seal case straight away from magnet (DO NOT slide seal case across magnet).
(c) Clean the sealing surfaces of the new carbon seal. Saturate a lint-free cloth with alcohol
and then gently rotate the seal and magnet (use wrist motion), facedown, on the cloth.
(d) Lubricate the installed O-rings on the seal case and magnet with assembly fluid
(MAT-011).
EFFECTIVITY: FJ44-2C
72-60-01
Page 427
Dec 12/17
(b) Install magnet into adapter bore with the highly polished and umarked surface (mating
face) facing up. Verify magnet is seated.
(d) Install the magnet keeper (97) against the magnet. Make sure the keeper is not loose
after installation.
(e) Clean mating faces of the magnet and seal case with alcohol or clean engine oil
(MAT-001) and a lint-free cloth or foam swab.
(f) Apply two or three drops of clean engine oil to the carbon seal or magnet.
(g) Carefully install (mate) the carbon face of the seal case onto the magnet in the adapter.
Make sure the seal case has its carbon face down and is centered on the polished
magnet seal face.
(h) Lube adapter O-rings (105 and 107) with assembly fluid and install on adapter groove
and face of gearbox.
(a) Clean gearshaft outer diameter using alcohol and a clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
EFFECTIVITY: FJ44-2C
72-60-01
Page 428
Dec 12/17
NOTE Maintain constant pressure on the adapter, holding it tightly against the
gearbox housing, until two opposing bolts are installed.
(a) Align the adapter/carbon seal assembly with the gearshaft end.
(b) Using constant pressure, PUSH the assembled adapter into place until the bearing is
engaged in the adapter bore and the face is seated against the gearbox. It will take some
force to overcome the adapter O-ring press fit.
(6) Attach adapter to gearbox housing with bolts. Use on washer under each bolt.
SUBTASK 72-60-01-420-006
B. FUEL CONTROL UNIT/FUEL PUMP UNIT. Use the procedure that follows to install magnetic carbon
seals to the fuel control/fuel pump location (73-18-01, P.B. 401):
(1) Prepare fuel pump adapter (60) for seal installation as follows:
(a) Clean adapter bore, keeper, wave spring, and retaining ring using alcohol (MAT-027) and
a lint-free wiper. Make sure parts are free of oil, dirt, and foreign material.
(2) Prepare new magnetic carbon seal (70) for installation as follows:
(a) Verify correct carbon seal at each installation. Refer to the Illustrated Parts Catalog
72–60–01, Fig. 02.
(b) When removing seal from packaging, the seal case (75) must be separated from the
magnet (74). Pull seal case straight away from magnet (DO NOT slide seal case across
magnet).
(c) Clean the sealing surfaces of the new carbon seal. Saturate a lint-free cloth with alcohol
and then gently rotate the seal and magnet (use wrist motion), facedown, on the cloth.
(d) Lubricate the installed O-rings on the seal case and magnet with assembly fluid.
(e) Inspect installed O-rings for twists or waves. Straighten O-rings as required.
EFFECTIVITY: FJ44-2C
72-60-01
Page 429
Dec 12/17
(b) Install magnet into adapter bore with highly polished and unmarked surface (mating face)
facing up. Verify the magnet is seated.
(f) Clean mating faces of the magnet and seal case with alcohol or clean engine oil
(MAT-001) and a lint-free cloth or foam swab.
(g) Apply two or three drops of clean engine oil to the carbon seal or magnet.
(h) Carefully install (mate) the carbon face of the seal case onto the seal runner magnet in
the adapter. Make sure that the seal case has its carbon face down and is centered on
the polished magnet seal face.
(i) Lube adapter O-ring (65) with assembly fluid and install on adapter groove.
(4) Prepare the gearshaft for installation of the carbon seal/adapter as follows:
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(a) Align the adapter/carbon seal assembly with the gearshaft end.
EFFECTIVITY: FJ44-2C
72-60-01
Page 430
Dec 12/17
(b) Using constant pressure, PUSH the assembled adapter into place until the bearing is
engaged in the adapter bore and the face is seated against the gearbox. It will take some
force to overcome the adapter O-ring press fit.
(6) Attach the adapter to the gearbox housing with bolts. Use one washer under each bolt.
SUBTASK 72-60-01-420-007
C. HYDRAULIC PUMP AND BREATHER TUBE. Use the procedure that follows to install the magnetic
carbon seals to the Hydraulic Pump Adapter and Breather Tube locations:
NOTE The (forward) hydraulic pump mount adapter and the hydraulic pump gearshaft
were removed from the gearbox to allow aft carbon seal replacement.
(a) Clean gearshaft outer diameters using alcohol (MAT-027) and a clean, lint-free cloth.
(b) Apply a light coating of assembly fluid (MAT-011) to the gearshaft outer diameters.
(2) Install hydraulic pump gearshaft by centering it in housing bore and engaging aft bearing pilot
diameter. Rotate, as required, to mesh gear teeth.
(3) Prepare hydraulic pump adapter (20) for seal installation as follows:
(a) Clean adapter bore and keeper using alcohol and a lint-free wiper. Make sure parts
are free of oil, dirt, and foreign material.
(4) Prepare new magnetic carbon seal (110) for installation as follows:
EFFECTIVITY: FJ44-2C
72-60-01
Page 431
Dec 12/17
(a) Verify correct carbon seal at each installation. Refer to the Illustrated Parts Catalog
72–60–01, Fig. 02.
(b) When removing seal from packaging, the seal case (115) must be separated from the
magnet (114). Pull seal case straight away from magnet (DO NOT slide seal case across
magnet.
(c) Clean the sealing surfaces of the new carbon seal. Saturate a lint-free cloth with alcohol
and then gently rotate the seal and magnet (use wrist motion), facedown, on the cloth
(d) Lubricate the installed O-rings on the seal case and magnet with assembly fluid.
(e) Inspect installed O-rings for twists or waves. Straighten O-rings as required.
(a) Install magnet into adapter bore with the highly polished and unmarked surface (mating
face) facing up. Verify the magnet is seated.
(c) Install the magnet keeper (96) against the magnet. Ensure the keeper is not loose after
installation.
(d) Clean mating faces of the magnet and seal case with alcohol or clean engine oil
(MAT-001) and a lint-free cloth or foam swab.
(e) Apply two or three drops of clean engine oil to the carbon seal or magnet.
(f) Carefully install (mate) the carbon face of the seal case onto the seal runner magnet in
the adapter. Make sure the seal case has its carbon face down and is centered on
the polished magnet seal face.
(g) Lube adapter O-ring (25) with assembly fluid and install on adapter groove.
(a) Align the adapter/carbon seal assembly with the gearshaft end.
EFFECTIVITY: FJ44-2C
72-60-01
Page 432
Dec 12/17
(b) Using constant pressure, PUSH the assembled adapter into place until the bearing is
engaged in the adapter bore and the face is seated against the gearbox. It will take some
force to overcome the adapter O-ring press fit.
(7) Attach adapter to gearbox housing with bolts. Use one washer under each bolt.
(a) Verify correct carbon seal at each installation. Refer to the Illustrated Parts Catalog
72–60–01, Fig. 02.
(b) When removing seal from packaging, the seal case (35) must be separated from the
magnet (34). Pull seal case straight away from magnet (DO NOT slide seal case across
magnet).
(c) Clean the sealing surfaces of the new carbon seal. Saturate a lint-free cloth with alcohol
and then gently rotate the seal and magnet (use wrist-motion), facedown, on the cloth.
(d) Lubricate the installed O-rings on the seal case and magnet with assembly fluid.
(e) Inspect installed O-rings for twists or waves. Straighten O-rings as required.
(f) Clean mating faces of the magnet and seal case with alcohol or clean engine oil and a
lint-free cloth or foam swab.
(g) Apply two or three drops of clean engine oil to the carbon seal or magnet.
EFFECTIVITY: FJ44-2C
72-60-01
Page 433
Dec 12/17
(h) Carefully mate the carbon face of the seal case onto the seal runner magnet. Make sure
the seal case has its carbon face down and is centered on the polished magnet seal face.
(i) Lubricate the breather port of the gearbox housing with assembly fluid.
(10) With seal case facing into gearbox, carefully install carbon seal assembly into breather port
seal bore until the magnet is fully seated in the machined pocket in gearbox housing. Use
constant, uniform pressure while keeping assembly perpendicular to the bore.
SUBTASK 72-60-01-420-008
SUBTASK 72-60-01-410-007
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
SUBTASK 72-60-01-760-003
B. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
72-60-01
Page 434
Dec 12/17
EFFECTIVITY: FJ44-2C
Fig. 409 Gearbox Magnetic Seals - Removal/Installation 72-60-01
Page 435
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 436
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 437
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 438
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 439
Dec 12/17
17. General
This task covers installation of the type 1 spring-loaded carbon seal assemblies into the 4k configuration
gearbox.
Gearbox Carbon Seal Replacement Videos are available for review on our website. Access is available for
authorized service facility technicians only – contact us for access.
Refer to the appropriate subtask for the applicable seal location on the gearbox. Refer to the following
illustration(s):
Figure 414
Figure 415
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-01, Fig. 03
EFFECTIVITY: FJ44-2C
72-60-01
Page 440
Dec 12/17
SUBTASK 72-60-01-942-052
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-943-051
B. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-944-051
C. Expendable Parts
EFFECTIVITY: FJ44-2C
72-60-01
Page 441
Dec 12/17
IPC Reference
Subject Fig Item Nomenclature
72-60-01 03 25 O-Ring
72-60-01 03 36 O-Ring
72-60-01 03 65 O-Ring
72-60-01 03 105 O-Ring
72-60-01 03 107 O-Ring
SUBTASK 72-60-01-945-054
D. Reference Information
CH-SE-SU Pg Block Nomenclature
00-00-00 1 Manual Introduction - Description and Operation
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 442
Dec 12/17
19. Procedures
SUBTASK 72-60-01-420-050
A. STARTER/GENERATOR. Use the following procedure to install spring-loaded carbon seal at the
starter/generator location on the gearbox.
(1) Prepare new carbon seal (123) and seal runner (125) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 03 or .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
EFFECTIVITY: FJ44-2C
72-60-01
Page 443
Dec 12/17
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(2) Prepare starter/generator adapter assembly (100) for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(3) Install the carbon seal (123) into the adapter bore using driver TL99696-08 from the TL99696
kit to push the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated
in the adapter pocket. Use care to prevent damage to the seal face and O-ring.
(4) Apply assembly fluid to new O-ring (105) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(6) Install the seal runner (125) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(7) Apply assembly fluid to new O-ring (107) and install on face of gearbox housing.
(8) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth to remove all
residual assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(9) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(10) Align bolt holes and then carefully install the adapter onto the gearbox. Use care not to
damage carbon seal during installation.
EFFECTIVITY: FJ44-2C
72-60-01
Page 444
Dec 12/17
(11) Install six bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
B. Install the starter/generator to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-051
C. FUEL PUMP (FCU/FDU). Use the following procedure to Install spring-loaded carbon seal at the fuel
pump (FCU/FDU) location.
(1) Prepare new carbon seal (70) and seal runner (74) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 03 or .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.
EFFECTIVITY: FJ44-2C
72-60-01
Page 445
Dec 12/17
(3) Install the carbon seal (70) into the adapter bore using driver TL99696-10 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
(4) Apply assembly fluid to new O-ring (65) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(6) Install the seal runner (74) onto the gearshaft with the sealing surface (etched-pattern or highly
polished face) facing out, towards you. Push the seal runner down the shaft until it stops
against the gearshaft flange. Use care to prevent damage to the seal face and O-ring.
(7) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth to remove all
residual assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(8) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(9) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(10) Install two bolts (80) and washers (90) to secure adapter. Torque bolts 46 to 51 inch-pounds
(5.3 to 5.7 N.m).
D. Install the fuel control unit or fuel delivery unit onto the gearbox. Refer to 73-18-01, P.B. 401 or .
SUBTASK 72-60-01-420-052
E. HYDRAULIC PUMP. Use the following procedure to install spring-loaded carbon seal at the hydraulic
pump location.
EFFECTIVITY: FJ44-2C
72-60-01
Page 446
Dec 12/17
(1) Prepare new carbon seal (120) and seal runner (115) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 03 or .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.
(3) Install the carbon seal (120) into the adapter bore using driver TL99696-08 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
(4) Apply assembly fluid to new O-ring (25) and install on adapter.
NOTE Make sure that the aft hydraulic pump (breather tube) carbon seal runner is
clean and properly installed before the gearshaft is installed in the gearbox.
(5) Install the hydraulic pump gearshaft by centering it in the housing bore and engaging the aft
bearing pilot diameter. Rotate as required to mesh gear teeth.
EFFECTIVITY: FJ44-2C
72-60-01
Page 447
Dec 12/17
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(7) Install the seal runner (115) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(8) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth to remove all
residual assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(9) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(10) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(11) Install four bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
F. Install hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-053
G. BREATHER TUBE PORT. Use the following procedure to install spring-loaded carbon seal at the aft
side of the hydraulic pump gearshaft (breather tube port).
(1) Prepare new carbon seal (30) and seal runner (32) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 03 or .
EFFECTIVITY: FJ44-2C
72-60-01
Page 448
Dec 12/17
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
NOTE The hydraulic pump gearshaft was removed from the gearbox when the carbon
seal runner was removed. The new seal runner should be installed on the aft
end of the gearshaft before the gearshaft is installed in the gearbox.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(c) Apply a coating of assembly fluid to the breather tube bore of the gearbox housing.
(3) Install the seal runner (32) onto the aft end of the gearshaft with the highly-polished sealing
surface facing out. Push the seal runner down the shaft until it seats against the end of the
gearshaft. Use care to prevent damage to the seal face and O-ring.
(4) Reinstall both the hydraulic pump gearshaft and hydraulic pump adapter into the gearbox in
accordance with Subtask 72-60-01-420-052 (above).
(5) Use alcohol (MAT-027) or engine oil (MAT-001) and a clean, lint-free cloth to remove all residual
assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(6) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
EFFECTIVITY: FJ44-2C
72-60-01
Page 449
Dec 12/17
(7) Install the carbon seal (30) into the gearbox housing bore so that it mates with the seal runner;
hold the carbon seal in place.
(8) Apply assembly fluid to breather tube O-ring (36) and install around OD of installed carbon
seal, flush against gearbox housing face. Work the O-ring into the groove between the housing
and the carbon seal.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
SUBTASK 72-60-01-410-050
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
B. Perform ground run testing in accordance with the requirements of the Test List. Refer to 71–00–00,
P.B. 501.
EFFECTIVITY: FJ44-2C
72-60-01
Page 450
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 452
Dec 12/17
21. General
This task covers installation of the type 2 spring-loaded carbon seal assemblies into the 4k configuration
gearbox.
Gearbox Carbon Seal Replacement Videos are available for review on our website. Access is available for
authorized service facility technicians only – contact us for access.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
EFFECTIVITY: FJ44-2C
72-60-01
Page 453
Dec 12/17
SUBTASK 72-60-01-942-052
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-943-051
B. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-944-051
C. Expendable Parts
EFFECTIVITY: FJ44-2C
72-60-01
Page 454
Dec 12/17
IPC Reference
Subject Fig Item Nomenclature
72-60-01 04 25 O-Ring
72-60-01 04 36 O-Ring
72-60-01 04 65 O-Ring
72-60-01 04 105 O-Ring
72-60-01 04 107 O-Ring
SUBTASK 72-60-01-945-054
D. Reference Information
CH-SE-SU Pg Block Nomenclature
00-00-00 1 Manual Introduction - Description and Operation
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 455
Dec 12/17
23. Procedures
SUBTASK 72-60-01-420-050
A. STARTER/GENERATOR. Use the following procedure to install spring-loaded carbon seal at the
starter/generator location.
(1) Prepare new carbon seal (123) and seal runner (125) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct part numbers for carbon seal, runner, spring washer, and wave spring at
each installation. Refer to the Illustrated Parts Catalog 72-60-01, Fig. 04 .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
EFFECTIVITY: FJ44-2C
72-60-01
Page 456
Dec 12/17
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(2) Prepare starter/generator adapter assembly (100) for seal installation, as follows:
(a) Clean the adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.
(3) Install the carbon seal (123) into the adapter bore using driver TL99696-08 from TL99696 kit to
push the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
NOTES: 1 Assembly fluid (MAT-011) is used to retain the spring washer and wave
spring in the adapter bore when the adapter is installed on the gearbox.
Engine oil is a solvent for assembly fluid. Verify these parts are clean
and free of engine oil before applying assembly fluid.
(4) Apply three drops of assembly fluid to the spring washer (108) and then install the washer
into the adapter bore.
(5) Apply three drops of assembly fluid to wave spring (26) and then snap it into the adapter bore
directly on top of the spring washer. The wave spring must directly contact the spring washer in
three locations. Position the wave spring split-line in between the two rows of cooling holes in
the adapter. (See Figure 419 and Figure 420.)
(6) Apply assembly fluid to new O-ring (105) and install on adapter.
EFFECTIVITY: FJ44-2C
72-60-01
Page 457
Dec 12/17
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(8) Install the seal runner (1-130) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(9) Apply assembly fluid to new O-ring (107) and install on face of gearbox housing.
(10) Use alcohol (MAT-027) or engine oil (MAT-001) and a clean, lint-free cloth to remove all residual
assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(11) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(12) Align bolt holes and then carefully install the adapter onto the gearbox. Use care not to
damage carbon seal during installation.
(13) Install six bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
B. Install the starter/generator to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-051
C. FUEL CONTROL UNIT/FUEL DELIVERY UNIT. Use the following procedure to Install spring-loaded
carbon seal at the fuel pump (FCU/FDU) location. .
(1) Prepare new carbon seal (70) and seal runner (74) for assembly as follows:
EFFECTIVITY: FJ44-2C
72-60-01
Page 458
Dec 12/17
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 04 .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.
(3) Install the carbon seal (70) into the adapter bore using driver TL99696-10 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
(4) Apply assembly fluid to new O-ring (65) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
EFFECTIVITY: FJ44-2C
72-60-01
Page 459
Dec 12/17
(6) Install the seal runner (1-130) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it stops
against the gearshaft flange. Use care to prevent damage to the seal face and O-ring.
(7) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth to remove all
residual assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(8) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(9) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(10) Install two bolts (80) and washers (90) to secure adapter. Torque bolts 46 to 51 inch-pounds
(5.3 to 5.7 N.m).
D. Install the fuel control unit/fuel delivery unit onto the gearbox. Refer to 73-18-01, P.B. 401.
SUBTASK 72-60-01-420-052
E. HYDRAULIC PUMP. Use the following procedure to install spring-loaded carbon seal at the hydraulic
pump location.
(1) Prepare new carbon seal (120) and seal runner (115) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct part numbers for carbon seal, runner, spring washer, and wave spring at
each installation. Refer to the Illustrated Parts Catalog 72-60-01, Fig. 04.
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
EFFECTIVITY: FJ44-2C
72-60-01
Page 460
Dec 12/17
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.
(3) Install the carbon seal (120) into the adapter bore using driver TL99696-08 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
CAUTION WHEN INSTALLING SPRING WASHER (27) AND WAVE SPRING (26),
VERIFY YOU ARE INSTALLING THE CORRECT PART NUMBERS PER
THE ILLUSTRATED PARTS CATALOG. INSTALLATION OF INCORRECT
PART NUMBER SPRING WASHER AND/OR WAVE SPRING WILL CAUSE
GEARBOX BEARING FAILURE. THE WIDTHS OF THE WAVE SPRINGS
ARE DIFFERENT BETWEEN THE TYPE 2 AND TYPE 3 GEARBOX CARBON
SEAL CONFIGURATIONS. CHECK THE WIDTH OF THE WAVE SPRING TO
MAKE SURE YOU ARE INSTALLING THE CORRECT PART (FIGURE 421).
NOTES: 1 Assembly fluid (MAT-011) is used to retain the spring washer and wave
spring in the adapter bore when the adapter is installed on the gearbox.
Engine oil is a solvent for assembly fluid. Verify these parts are clean
and free of engine oil before applying assembly fluid.
(4) Apply three drops of assembly fluid to the spring washer (27) and then install the washer
into the adapter bore.
(5) Apply three drops of assembly fluid to wave spring (26) and then snap it into the adapter bore
directly on top of the spring washer. The wave spring must directly contact the spring washer in
three locations. Position the wave spring split-line in between the two rows of cooling holes in
the adapter. (See Figure 422 and Figure 423.)
EFFECTIVITY: FJ44-2C
72-60-01
Page 461
Dec 12/17
(6) Apply assembly fluid to new O-ring (25) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(8) Install the seal runner (1-130) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(9) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth or foam swab to
remove all residual assembly fluid and debris from the mating faces of the carbon seal and
seal runner.
(10) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(11) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(12) Install four bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
F. Install hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-053
G. BREATHER TUBE. Use the following procedure to install spring-loaded carbon seal at the aft side of
the hydraulic pump gearshaft (breather tube port).
(1) Prepare new carbon seal (30) and seal runner (32) for assembly as follows:
EFFECTIVITY: FJ44-2C
72-60-01
Page 462
Dec 12/17
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 04.
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(c) Apply a coating of assembly fluid to the breather tube bore of the gearbox housing.
(3) Install the seal runner (32) onto the aft end of the gearshaft with the sealing surface
(etched-pattern or highly polished face) facing out, towards you. Push the seal runner down
the shaft until it seats against the end of the gearshaft. Use care to prevent damage to the
seal face and O-ring.
(4) Reinstall the hydraulic pump gearshaft and then reinstall hydraulic pump adapter into the
gearbox in accordance with Subtask 72-60-01-420-052.
(5) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth or foam swab to
remove all residual assembly fluid and debris from the mating faces of the carbon seal and
seal runner.
EFFECTIVITY: FJ44-2C
72-60-01
Page 463
Dec 12/17
(6) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(7) Install the carbon seal (30) into the gearbox housing bore so that it mates with the seal runner;
hold the carbon seal in place.
(8) Apply assembly fluid to breather tube O-ring (36) and install around OD of installed carbon
seal, flush against gearbox housing face. Work the O-ring into the groove between the housing
and the carbon seal.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
SUBTASK 72-60-01-410-050
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
B. Perform ground run testing in accordance with the requirements of the Test List. Refer to 71–00–00,
P.B. 501.
EFFECTIVITY: FJ44-2C
72-60-01
Page 464
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 466
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 467
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 468
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 469
Dec 12/17
Fig. 421 Type 2 Wave Spring - Starter/Generator Adapter and Hydraulic Pump Adapter, 4k Gearbox
EFFECTIVITY: FJ44-2C
72-60-01
Page 470
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 471
Dec 12/17
Fig. 423 Properly Assembled Type 2 Hydraulic Pump Adapter, 4k Gearbox— Detail
EFFECTIVITY: FJ44-2C
72-60-01
Page 472
Dec 12/17
25. General
This task covers installation of the type 3 spring-loaded carbon seal assemblies into the 4k configuration
gearbox.
Gearbox Carbon Seal Replacement Videos are available for review on our website. Access is available for
authorized service facility technicians only – contact us for access.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
EFFECTIVITY: FJ44-2C
72-60-01
Page 473
Dec 12/17
SUBTASK 72-60-01-942-054
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-943-053
B. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-944-053
C. Expendable Parts
EFFECTIVITY: FJ44-2C
72-60-01
Page 474
Dec 12/17
IPC Reference
Subject Fig Item Nomenclature
72-60-01 04 25 O-Ring
72-60-01 04 36 O-Ring
72-60-01 04 65 O-Ring
72-60-01 04 105 O-Ring
72-60-01 04 107 O-Ring
SUBTASK 72-60-01-945-056
D. Reference Information
CH-SE-SU Pg Block Nomenclature
00-00-00 1 Manual Introduction - Description and Operation
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 475
Dec 12/17
27. Procedures
SUBTASK 72-60-01-420-067
A. STARTER/GENERATOR. Use the following procedure to install spring-loaded carbon seal at the
starter/generator location.
(1) Prepare new carbon seal (123) and seal runner (125) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct part numbers for carbon seal, runner, spring washer, and wave spring at
each installation. Refer to the Illustrated Parts Catalog 72-60-01, Fig. 05 .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
EFFECTIVITY: FJ44-2C
72-60-01
Page 476
Dec 12/17
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(2) Prepare starter/generator adapter assembly (100) for seal installation, as follows:
(a) Clean the adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.
(3) Install the carbon seal (123) into the adapter bore using driver TL99696-08 from TL99696 kit to
push the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
NOTES: 1 Assembly fluid (MAT-011) is used to retain the spring washer and wave
spring in the adapter bore when the adapter is installed on the gearbox.
Engine oil is a solvent for assembly fluid. Verify these parts are clean
and free of engine oil before applying assembly fluid.
(4) Apply three drops of assembly fluid to the spring washer (109) and then install the washer
into the adapter bore.
(5) Apply three drops of assembly fluid to wave spring (28) and then snap it into the adapter bore
directly on top of the spring washer. The wave spring must directly contact the spring washer in
three locations. Position the wave spring split-line in between the two rows of cooling holes in
the adapter. (See Figure 427 and Figure 428.)
(6) Apply assembly fluid to new O-ring (105) and install on adapter.
EFFECTIVITY: FJ44-2C
72-60-01
Page 477
Dec 12/17
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(8) Install the seal runner (125) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(9) Apply assembly fluid to new O-ring (107) and install on face of gearbox housing.
(10) Use alcohol (MAT-027) or engine oil (MAT-001) and a clean, lint-free cloth to remove all residual
assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(11) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(12) Align bolt holes and then carefully install the adapter onto the gearbox. Use care not to
damage carbon seal during installation.
(13) Install six bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
B. Install the starter/generator to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-068
C. FUEL CONTROL UNIT/FUEL DELIVERY UNIT. Use the following procedure to Install spring-loaded
carbon seal at the fuel pump (FCU/FDU) location. .
(1) Prepare new carbon seal (70) and seal runner (74) for assembly as follows:
EFFECTIVITY: FJ44-2C
72-60-01
Page 478
Dec 12/17
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 05 .
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.
(3) Install the carbon seal (70) into the adapter bore using driver TL99696-10 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
(4) Apply assembly fluid to new O-ring (65) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
EFFECTIVITY: FJ44-2C
72-60-01
Page 479
Dec 12/17
(6) Install the seal runner (1-130) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it stops
against the gearshaft flange. Use care to prevent damage to the seal face and O-ring.
(7) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth to remove all
residual assembly fluid and debris from the mating faces of the carbon seal and seal runner.
(8) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(9) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(10) Install two bolts (80) and washers (90) to secure adapter. Torque bolts 46 to 51 inch-pounds
(5.3 to 5.7 N.m).
D. Install the fuel control unit/fuel delivery unit onto the gearbox. Refer to 73-18-01, P.B. 401.
SUBTASK 72-60-01-420-069
E. HYDRAULIC PUMP. Use the following procedure to install spring-loaded carbon seal at the hydraulic
pump location.
(1) Prepare new carbon seal (120) and seal runner (115) for assembly as follows:
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct part numbers for carbon seal, runner, spring washer, and wave spring at
each installation. Refer to the Illustrated Parts Catalog 72-60-01, Fig. 05.
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
EFFECTIVITY: FJ44-2C
72-60-01
Page 480
Dec 12/17
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.
(3) Install the carbon seal (120) into the adapter bore using driver TL99696-08 from the kit to push
the seal into place. Use hand pressure only. Ensure the carbon seal is fully seated in the
adapter pocket. Use care to prevent damage to the seal face and O-ring.
CAUTION WHEN INSTALLING SPRING WASHER (109) AND WAVE SPRING (28),
VERIFY YOU ARE INSTALLING THE CORRECT PART NUMBERS PER
THE ILLUSTRATED PARTS CATALOG. INSTALLATION OF INCORRECT
PART NUMBER SPRING WASHER AND/OR WAVE SPRING WILL CAUSE
GEARBOX BEARING FAILURE. THE WIDTHS OF THE WAVE SPRINGS
ARE DIFFERENT BETWEEN THE TYPE 2 AND TYPE 3 GEARBOX CARBON
SEAL CONFIGURATIONS. CHECK THE WIDTH OF THE WAVE SPRING TO
MAKE SURE YOU ARE INSTALLING THE CORRECT PART (FIGURE 429).
NOTES: 1 Assembly fluid (MAT-011) is used to retain the spring washer and wave
spring in the adapter bore when the adapter is installed on the gearbox.
Engine oil is a solvent for assembly fluid. Verify these parts are clean
and free of engine oil before applying assembly fluid.
(4) Apply three drops of assembly fluid to the spring washer (109) and then install the washer
into the adapter bore.
(5) Apply three drops of assembly fluid to wave spring (28) and then snap it into the adapter bore
directly on top of the spring washer. The wave spring must directly contact the spring washer in
three locations. Position the wave spring split-line in between the two rows of cooling holes in
the adapter. (See Figure 430 and Figure 431.)
EFFECTIVITY: FJ44-2C
72-60-01
Page 481
Dec 12/17
(6) Apply assembly fluid to new O-ring (25) and install on adapter.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(8) Install the seal runner (1-130) onto the gearshaft with the sealing surface (etched-pattern or
highly polished face) facing out, towards you. Push the seal runner down the shaft until it seats
against the bearing inner race. Use care to prevent damage to the seal face and O-ring.
(9) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth or foam swab to
remove all residual assembly fluid and debris from the mating faces of the carbon seal and
seal runner.
(10) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(11) Align bolt holes and then carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(12) Install four bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
F. Install hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-070
G. BREATHER TUBE. Use the following procedure to install spring-loaded carbon seal at the aft side of
the hydraulic pump gearshaft (breather tube port).
(1) Prepare new carbon seal (30) and seal runner (32) for assembly as follows:
EFFECTIVITY: FJ44-2C
72-60-01
Page 482
Dec 12/17
NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation. Refer to the
Illustrated Parts Catalog 72-60-01, Fig. 05.
(b) Clean the sealing surfaces of the new carbon seal and seal runner. Saturate a lint-free
cloth with alcohol (MAT-027) and then rotate the seal and runner (use wrist motion),
face-down, on the cloth.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect installed O-rings for twists or waves. Straighten O-rings as follows: For the seal,
the O-ring should be pushed towards the carbon face side of the O-ring groove. For the
seal runner, the O-ring should be pushed towards the sealing surface.
(e) Apply several drops of fresh engine oil (MAT-001) directly to the carbon portion of the
seal. Gently and carefully deflect carbon seal several times, allowing oil to flow behind
the carbon. Verify that the seal moves freely. Reject the seal if it does not move freely.
(a) Clean gearshaft outer diameter and bearing inner race using alcohol (MAT-027) and a
clean, lint-free cloth.
(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.
(c) Apply a coating of assembly fluid to the breather tube bore of the gearbox housing.
(3) Install the seal runner (32) onto the aft end of the gearshaft with the sealing surface
(etched-pattern or highly polished face) facing out, towards you. Push the seal runner down
the shaft until it seats against the end of the gearshaft. Use care to prevent damage to the
seal face and O-ring.
(4) Reinstall the hydraulic pump gearshaft and then reinstall hydraulic pump adapter into the
gearbox in accordance with Subtask 72-60-01-420-052.
(5) Use alcohol (MAT-027) or Engine Oil (MAT-001) and a clean, lint-free cloth or foam swab to
remove all residual assembly fluid and debris from the mating faces of the carbon seal and
seal runner.
EFFECTIVITY: FJ44-2C
72-60-01
Page 483
Dec 12/17
(6) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.
(7) Install the carbon seal (30) into the gearbox housing bore so that it mates with the seal runner;
hold the carbon seal in place.
(8) Apply assembly fluid to breather tube O-ring (36) and install around OD of installed carbon
seal, flush against gearbox housing face. Work the O-ring into the groove between the housing
and the carbon seal.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
SUBTASK 72-60-01-410-052
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
B. Perform ground run testing in accordance with the requirements of the Test List. Refer to 71–00–00,
P.B. 501.
EFFECTIVITY: FJ44-2C
72-60-01
Page 484
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 486
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 487
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 488
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 489
Dec 12/17
Fig. 429 Type 3 Wave Spring — Starter/Generator Adapter and Hydraulic Pump Adapter, 4k Gearbox
EFFECTIVITY: FJ44-2C
72-60-01
Page 490
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-01
Page 491
Dec 12/17
Fig. 431 Properly Assembled Type 3 Hydraulic Pump Adapter, 4k Gearbox — Detail
EFFECTIVITY: FJ44-2C
72-60-01
Page 492
Dec 12/17
1. General
This task covers removal of the oil filter delta P indicator from the gearbox. Refer to the following
illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-02-941-001
A. Standard Equipment
Oil Drain Pan
3. Job Set-up
SUBTASK 72-60-02-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
72-60-02
Page 401
Dec 12/17
4. Procedures
SUBTASK 72-60-02-020-001
NOTE If indicator is suspected of leaking, confirm location of leak by wiping off oil and
making sure that the leak repeats. If removal is necessary, note the condition
of the O-rings and the gearbox housing sealing surfaces.
(1) Cut and remove the lockwire which attaches the delta P indicator to the gearbox.
(2) Place an oil drain pan or other suitable container below the indicator to catch oil.
EFFECTIVITY: FJ44-2C
72-60-02
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-02
Page 403
Dec 12/17
5. General
This task covers installation of the oil delta P indicator into the gearbox. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-02, Fig. 01
SUBTASK 72-60-02-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-060 Lockwire, .032
SUBTASK 72-60-02-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-60-02 01 30 O-ring
72-60-02 01 40 O-ring
SUBTASK 72-60-02-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
EFFECTIVITY: FJ44-2C
72-60-02
Page 404
Dec 12/17
7. Procedures
SUBTASK 72-60-02-420-001
(1) Lube O-rings with assembly fluid (MAT-011) and install on delta P indicator.
(2) Wipe threads on delta P indicator with a clean cloth to remove excess oil.
(3) Install delta P indicator in gearbox port. Torque indicator 145 to 155 inch-pounds (16.4 - 16.9
N.m).
(4) Install safety wire (MAT-060) between delta P indicator and gearbox spring-valve retainer.
8. Job Close-up
SUBTASK 72-60-02-610-001
SUBTASK 72-60-02-410-002
SUBTASK 72-60-02-760-001
C. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501
EFFECTIVITY: FJ44-2C
72-60-02
Page 405
Dec 12/17
NOTE If indicator is suspected of leaking, confirm location of leak by wiping off oil and
making sure that the leak repeats. If removal is necessary, note the condition
of the O-rings and the gearbox housing sealing surfaces.
EFFECTIVITY: FJ44-2C
72-60-02
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-02
Page 407
Dec 12/17
72-60-02
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
TASK 72-60-02-780-801 Perform Functional Verification of the Mechanical Oil Filter Delta P
Indicator
1. General
This task performs a pressure check on the oil filter delta P indicator to ensure proper function. Refer
to the following illustration(s):
Figure 601
SUBTASK 72-60-02-941-004
A. Standard Equipment
20 To 100 Psi Shop Air
Stopwatch Or Clock
Hair-dryer Or Low Temperature Heat Gun
Infrared Laser Thermometer
SUBTASK 72-60-02-943-004
B. Special Tools
Reference Designation
TL-110118 Test Block, Indicator, Delta P, Oil Filter and Fuel Filter
SUBTASK 72-60-02-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-60-02 401 Filter Differential Pressure (Delta P) Indicator - Removal/Installation
3. Procedures
SUBTASK 72-60-02-780-001
A. Remove oil filter delta P indicator from engine. Refer to 72-60-02, P.B. 401.
B. TL-110118 test fixture is used to check the functionality of the oil filter delta P indicator. The indicator
is functioning properly when increasing delta pressure triggers the red indicator pin to extend.
EFFECTIVITY: FJ44-2C
72-60-02
Page 601
Dec 12/17
(1) Completely close the air inlet valve before connecting to air source.
(4) Connect source of 20 to 100 psi shop air to the inlet valve on the side of test unit. Do not apply
air pressure at this time.
E. Install the oil filter delta P indicator to the test unit as follows:
(1) Make sure that both O-rings are in place on the delta P indicator.
(2) Install delta P indicator in the fitting provided on the top of the test unit. Torque to 30 to
50 inch-pounds (3.4 to 5.6 N.m).
(4) Using a hair-dryer or low temperature heat gun, heat the body of the oil filter delta P indicator
and test block to 160 °F (71° C) as measured with a Infrared Laser Thermometer.
(2) Using the inlet valve and flow control valve, slowly increase pressure to 11 psi.
(2) Using a hair-dryer or low-temperature heat gun, heat the body of the oil filter delta P indicator
and test block to 160°F (71°C) as measured with a laser thermometer.
(3) Using the inlet valve and flow control valve, slowly increase pressure to 18 psi and then start
the stopwatch.
EFFECTIVITY: FJ44-2C
72-60-02
Page 602
Dec 12/17
(4) The red indicating pin should extend within 5 seconds after 18 psi is reached.
(6) Manually reset by depressing the indicator, ensure that the indicator remains in the reset
(depressed) position.
H. Test Evaluation:
Reject the oil filter delta P indicator if it fails any of the criteria in the:
SUBTASK 72-60-02-420-002
I. Install the oil filter mechanical delta P indicator. Refer to 72-60-02, P.B. 401.
EFFECTIVITY: FJ44-2C
72-60-02
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
72-60-02
Page 604
Dec 12/17
1. General
This task covers visual inspection of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. If there is
no approved repair procedure, you should keep the part for a possible future repair
procedure and/or contact Williams International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-71-10-941-001
A. Standard Equipment
Stylus Probe
SUBTASK 72-71-10-942-001
B. Consumables
Reference Designation
MAT-050 Coating, Chemical Conversion (Iridite)
EFFECTIVITY: FJ44-2C
72-71-10
Page 601
Dec 12/17
SUBTASK 72-71-10-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
72-00-71 401 Rear Bypass Duct Assy - Removal/Installation
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 72-71-10-020-001
A. Remove the rear bypass duct assembly. Refer to 72-00-71, P.B. 401.
4. Procedures
SUBTASK 72-71-10-220-001
NOTE If the rear bypass duct is replaced, a new LP shaft sensor trigger pin
must be installed. Refer to 76-20-01, P.B. 501.
(b) Elongation of bolt holes and scratches Smooth blend to remove raised material
due to bolt contact and sharp edges. Apply chemical
conversion coating (Refer to 70-42-12,
P.B. 801 in the Maintenance Manual).
Perform florescent penetrant inspection to
make sure that there are no cracks.
EFFECTIVITY: FJ44-2C
72-71-10
Page 602
Dec 12/17
(d) Chafing or fretting damage. Damage Blend to remove damage using hand
may be removed as long as a stones. Width of blend to be five (5)
minimum of 0.040 inch sheet metal times the depth. Total blended area not
thickness remains after blending. to exceed 1.0 inch (25.4 mm) diameter.
Total blended area must not exceed Touch-up blended area with chemical
1.0 in diameter. If two blends are in conversion coating.
close proximity (i.e. within the longest
bend length of each other), they
should be counted as one. No more
than 5 areas may be blended on any
one duct.
(3) Inspect duct sheet metal for crack indications along weld seam:
Areas of crazing are acceptable in a band that extends 0.5 inches either side of the axial weld
on the duct wall. This area shall extend for the entire axial length of the duct. No evidence
of crazing is to be allowed outside of this area. Linear indications, up to 0.100 inch in length,
are permissible in this area only. No more than ten indications are permitted throughout the
allowable zone and the minimum distance between adjacent indications shall not be less
than four times the length of the longer of the two indications. No indication shall extend
through the duct wall.
(4) Inspect drain boss, trip sensor housing, and brackets for:
5. Job Close-up
SUBTASK 72-71-10-420-001
EFFECTIVITY: FJ44-2C
72-71-10
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
72-71-10
Page 604
Dec 12/17
1. General
This task covers visual inspection of the rear mounting ring assembly. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. If there is
no approved repair procedure, you should keep the part for a possible future repair
procedure and/or contact Williams International, Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-71-20-941-001
A. Standard Equipment
Stylus Probe
3. Job Set-up
SUBTASK 72-71-20-020-001
A. Remove the rear bypass duct assembly. Refer to 72-00-71, P.B. 401.
EFFECTIVITY: FJ44-2C
72-71-20
Page 601
Dec 12/17
4. Procedures
SUBTASK 72-71-20-220-001
A. Visually inspect the rear mounting ring assembly (1-60, 72-00-71) as follows (Figure 601):
(1) Loss of black chromate outer coating up to Accept at unscheduled or HSI interval;
75% of part surface area for P/N 50613 recoat in accordance with
Repair Station Instruction 50613 at CSI.
(2) Loss (flaking) of Ni-Cad plating For P/N 50613, recoat in accordance with
Repair Station Instruction 50613 at CSI.
SUBTASK 72-71-20-220-002
EFFECTIVITY: FJ44-2C
72-71-20
Page 602
Dec 12/17
5. Job Close-up
SUBTASK 72-71-20-420-001
A. Install the rear bypass duct assembly. Refer to 72-00-71, P.B. 401.
EFFECTIVITY: FJ44-2C
72-71-20
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
72-71-20
Page 604
Dec 12/17
CHAPTER 73
Page 1
73-ENGINE FUEL AND CONTROL Dec 12/17
Page 2
73-ENGINE FUEL AND CONTROL Blank
LINE MAINTENANCE MANUAL - FJ44-2C
73-00-00 1 Dec 12/17 73-12-01 601 Dec 12/17 73-18-01 601 Dec 12/17
73-10-01 401 Dec 12/17 73-14-01 401 Dec 12/17 73-23-01 401 Dec 12/17
73-10-01 601 Dec 12/17 73-18-00 1 Dec 12/17 73-23-01 601 Dec 12/17
73-11-01 401 Dec 12/17 73-18-01 401 Dec 12/17 73-25-01 401 Dec 12/17
73-12-01 401 Dec 12/17 73-18-01 501 Dec 12/17 73-27-01 201 Dec 12/17
Chapter 73
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 73
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The purpose of the fuel system is to supply metered fuel for combustion in the engine combustion section.
Refer to the following illustration:
Figure 1
2. Description
SUBTASK 73-00-00-860-014
B. The fuel filter is contained in a stainless steel bowl that is threaded into the pump housing. The filter
is located between the boost pump and the gear pump to protect the gear pump from any fuel tank
contaminants. The fuel filter element is 20 micron.
C. The fuel filter electrical indicator (delta P switch) is installed on the fuel pump. It allows fuel to continue
to flow into the gear pump if the differential pressure between the filter inlet and outlet passages
reaches 10 psid. When 4.5 psid is present, an annuciator light in the cockpit will illuminate, indicating
impending bypass. The lamp will remain illuminated until differential pressure drops below 1.5 psid.
E. The engine has a fixed flow, stationary fuel nozzle for improved altitude re-start reliability. This
nozzle provides approximately 9 pph of additional fuel flow, continuously, during all engine operation.
The nozzle receives high pressure (P2) metered fuel from the fuel control unit, via the start nozzle
control valve.
F. The fuel manifold supplies fuel to the fuel slinger in the combustion section. The manifold tube goes
through the front bypass duct by way of the right service island and enters the diffuser case. The
manifold supplies fuel to the under side of the rotating fuel slinger.
EFFECTIVITY: FJ44-2C
73-00-00
Page 1
Dec 12/17
G. The fuel slinger is located on the HP shaft between the combustor cover and the primary plate. It
is part of the seal and fuel slinger assembly. Fuel is supplied to the under side of the slinger by
the fuel manifold. The fuel is ejected radially outward into the combustion zone through a series
of holes in the slinger.
H. The lube oil cooler is a fuel/oil heat exchanger mounted on the engine gearbox. It uses fuel from the
fuel control to cool engine oil.
3. Operation
SUBTASK 73-00-00-860-015
A. Additional fuel for engine relight is continuously supplied from the HMU to the fuel nozzle where it
is sprayed directly into the combustion zone.
Fuel enters the FCU where it is pressurized and routed to the fuel/oil heat exchanger. The fuel is
heated (oil cooled) to prevent icing and returned to the fuel filter element. After filtering, fuel is moved
by the positive displacement pump to the fuel metering section of the FCU. Metered fuel is split as
it leaves the FCU. Approximately 9 pph is routed to an atomizing nozzle positioned in the burner
to enhance cold day and altitude start capability. The remainder of metered flow passes through
the fuel flow meter (airframe provided) then enters the core engine through the fuel manifold tube.
A last chance filter is located in the manifold tube. The manifold tube follows the contour of the
diffuser to a fuel distribution manifold where the fuel is supplied to the underside of the fuel slinger.
The fuel slinger, which rotates with the HP rotary group, ejects the fuel radially through a series of
delivery holes into the combustion zone.
4. Fuel Shutdown
SUBTASK 73-00-00-860-016
A. A fuel shutoff valve, which is controlled by power lever movement, provides the normal means
for engine shutdown.
B. A mechanical LP (N1) shaft separation detection device, mounted on the engine, will detect LP shaft
rearward movement of 0.050 inch (1.27 mm) or greater. This safety device will prevent an LP turbine
rotor overspeed condition, and possible turbine burst, in case of LP shaft separation. It does this by
automatically shutting off fuel flow to the fuel control unit via mechanical linkage.
EFFECTIVITY: FJ44-2C
73-00-00
Page 2
Dec 12/17
EFFECTIVITY: FJ44-2C
73-00-00
Page 3
Dec 12/17
73-00-004
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 401
Figure 402
2 During removal of parts, group all components together to make assembly easier.
3 Use this task to remove any of the external fuel tube assemblies. The tube
assemblies covered by this task are as follows:
SUBTASK 73-10-01-945-007
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 73-10-01-010-007
EFFECTIVITY: FJ44-2C
73-10-01
Page 401
Dec 12/17
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-10-01-050-004
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(1) Loosen tube nuts on fuel tube. Use a backup wrench on fittings and/or reducers.
EFFECTIVITY: FJ44-2C
73-10-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
73-10-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
73-10-01
Page 404
Dec 12/17
5. General
This task provides procedures for installing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 403
Figure 404
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
SUBTASK 73-10-01-942-008
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 73-10-01-945-008
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-10-01-450-004
EFFECTIVITY: FJ44-2C
73-10-01
Page 405
Dec 12/17
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
NOTE Conical seals are not approved for use with flare fitting-type tube assemblies.
(1) Apply engine oil MAT-001 to entire circumference of the male thread, the backside of the flare,
and the shoulder of the coupling nut (i.e. nut/flare contact area). Lubricant shall be applied
sparingly and shall provide an even coating on the surfaces. Excess lubricant shall be removed.
Care shall be exercised to avoid introducing lubricant into internal portions of the tube or fitting.
(2) Re-bending of tubing at assembly to achieve alignment and/or minimum clearances shall be
permissible provided that re-bending does not:
(c) Result in a variation of the as-received configuration greater than 0.100 inch (2.54 mm).
(3) Align and install the fuel tube. Allow a minimum of 0.060-inch (1.524 mm) space between fuel
tubes and other components. Hand-tighten coupling nut to seated position (as evident by a
sudden increase in torque). If nut cannot be seated by hand, disassemble and check alignment.
(4) Torque tube nuts in accordance with table 401 and torque clamps in accordance with table 402.
Use a back-up wrench on fittings and/or reducers. Re-torque tube nuts after a minimum of
one (1) minute.
EFFECTIVITY: FJ44-2C
73-10-01
Page 406
Dec 12/17
(1) Make sure fittings are aligned and torque both ends of the flex tube assembly.
(2) Install loop clamp on fuel tube. Secure loop clamp (and igniter lead loop clamp) onto bracket
with spacer, screw, and nut. .
EFFECTIVITY: FJ44-2C
73-10-01
Page 407
Dec 12/17
8. Job Close-up
SUBTASK 73-10-01-410-008
SUBTASK 73-10-01-760-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-10-01
Page 408
Dec 12/17
EFFECTIVITY: FJ44-2C
73-10-01
Page 409
Dec 12/17
EFFECTIVITY: FJ44-2C
73-10-01
Page 410
Dec 12/17
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-10-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 73-10-01-945-009
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
3. Procedures
SUBTASK 73-10-01-220-001
NOTE Any nicks or high metal that are otherwise within acceptable limits should be
repaired in accordance with 70-42-11, P.B. 801.
(1) Damage:
EFFECTIVITY: FJ44-2C
73-10-01
Page 601
Dec 12/17
(3) Nicks:
(4) Galled:
EFFECTIVITY: FJ44-2C
73-10-01
Page 602
Dec 12/17
1. General
This task provides procedures for removing the fuel drain tube assembly. Refer to the following illustration:
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-11-01-941-003
A. Standard Equipment
.250-28 2 To 3-inch Bolt
SUBTASK 73-11-01-943-003
B. Special Tools
Reference Designation
TL65047 Puller, Drain Tube
SUBTASK 73-11-01-945-051
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 73-11-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
73-11-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 73-11-01-020-003
A. Remove the aircraft fuel drain line from the fuel drain boss at the 6:00 o’clock location on the front
bypass duct. Refer to the Aircraft Maintenance Manual.
SUBTASK 73-11-01-020-004
(1) Remove one screw and loop clamp brackets and remove drain plug from the aft drain tube port
of the fuel drain boss on the front bypass duct. Remove O-ring from drain fitting.
(2) Pull the forward drain tube from fuel drain boss. Remove O-rings and seal from tube.
(3) Insert a .250-28 2 to 3-inch bolt (or TL65047) into the aft drain tube port on the fuel drain boss
and install it into the aft (short) fuel drain tube. Remove aft drain tube from port. Remove
O-ring and seal from drain tube.
EFFECTIVITY: FJ44-2C
73-11-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
73-11-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the fuel drain tube assembly. Refer to the following illustration:
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-11-01, Fig. 01
SUBTASK 73-11-01-941-003
A. Standard Equipment
.250-28, 2 To 3-inch Long Bolt
SUBTASK 73-11-01-942-004
B. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-11-01-943-004
C. Special Tools
Reference Designation
TL65047 Puller, Drain Tube
SUBTASK 73-11-01-944-004
D. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-11-01 01 30 O-ring (2)
73-11-01 01 10 Seal, Drain Tube (2)
73-11-01 01 40 O-ring (2)
EFFECTIVITY: FJ44-2C
73-11-01
Page 404
Dec 12/17
SUBTASK 73-11-01-945-004
E. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-11-01-420-003
(1) Install one drain tube seal on the ball end of both the forward and the aft fuel drain tubes.
Make sure that the spring side of the seal is visible (facing the core of the engine), when
installed. Lubricate two O-rings with MAT-011 assembly fluid and install on the flat end of the
forward and aft fuel drain tubes. Install one O-ring with MAT-011 assembly fluid and install on
forward drain tube.
(2) Install a .250-28, 2 to 3-inch long bolt (or TL65047) into the threaded end of the aft (short)
fuel drain tube. Insert the tube through the aft drain tube port and into the fuel drain boss on
the diffuser. Remove bolt.
(3) Insert the forward (long) tube through the forward drain tube port and into the fuel drain boss
on the diffuser.
(4) Lubricate O-ring with assembly fluid and install on drain plug.
(5) Rotate the forward drain tube, as required to align drain passage and allow seating of drain
plug. Install drain plug into aft drain tube port. Install screw and loop clamps. Torque screw 31
to 35 inch-pounds (3.5 to 4.0 N.m).
SUBTASK 73-11-01-420-004
B. Install the aircraft fuel drain tube to the fuel drain boss. Refer to the Aircraft Maintenance Manual.
EFFECTIVITY: FJ44-2C
73-11-01
Page 405
Dec 12/17
8. Job Close-up
SUBTASK 73-11-01-410-004
SUBTASK 73-11-01-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-11-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
73-11-01
Page 407
Dec 12/17
73-11-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 401
Figure 402
Figure 403
Figure 404
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-12-01-942-001
A. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-029 Alkaline Cleaner, HDL-202
SUBTASK 73-12-01-943-001
B. Special Tools
EFFECTIVITY: FJ44-2C
73-12-01
Page 401
Dec 12/17
SUBTASK 73-12-01-945-051
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 73-12-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-12-01-020-001
EFFECTIVITY: FJ44-2C
73-12-01
Page 402
Dec 12/17
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(1) Remove the flexible tube assembly from the fuel nozzle.
(2) Loosen the bulkhead nut which holds the fuel nozzle assembly.
(3) Turn the fuel nozzle assembly counter-clockwise and remove from the fuel nozzle adapter
assembly. If necessary, apply dry cleaning solvent (MAT-024) between nozzle and adapter to
loosen carbon deposits. Remove O-ring and bulkhead nut from the fuel nozzle assembly.
NOTE If the fuel nozzle assembly cannot be removed from the adapter due to carbon
build-up, it is acceptable to remove the adapter with the nozzle still installed.
This requires cutting and replacement of the seals. To remove the adapter
with the fuel nozzle still installed, slotted fuel nozzle adapter socket must be
used. After removal, ultrasonically clean with MAT-020, MAT-023, MAT-024,
or MAT-029, and then separate the fuel nozzle assembly from the adapter.
Refer to Figure 403. Contact Williams International Product Support.
B. Remove fuel nozzle port seals and fuel nozzle adapter assembly, as follows:
(1) Remove retaining ring, fuel nozzle plate seal, and fuel nozzle ring seal from the fuel nozzle port.
(2) Insert fuel nozzle adapter socket wrench into the fuel nozzle port and engage it onto the slots in
the top face of the bearing retainer nut. Loosen nut and remove fuel nozzle adapter assembly
from the fuel nozzle port.
C. Visually check the fuel nozzle adapter for fretting or other damage to mid-span area (Zone D).
Refer to Figure 404. If there is fretting or other damage in this area, reject the adapter and contact
Williams International Product Support.
EFFECTIVITY: FJ44-2C
73-12-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 406
Dec 12/17
Fig. 404 Fuel Nozzle Adapter - Visual Inspection for Damage to Mid-Span (Zone D)
EFFECTIVITY: FJ44-2C
73-12-01
Page 407
Dec 12/17
5. General
This task provides procedures for installing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 405
Figure 406
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-12-01, Fig. 01
2 This part must undergo routine periodic inspection. If a serviceable, used fuel start
nozzle assembly from another engine is to be installed, make sure that it has undergone
all scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
SUBTASK 73-12-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-015 Lubricant, Anti-seize
MAT-017 Lubricant, Rapid GT
SUBTASK 73-12-01-943-002
B. Special Tools
EFFECTIVITY: FJ44-2C
73-12-01
Page 408
Dec 12/17
SUBTASK 73-12-01-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-12-01 01 110 O-ring
SUBTASK 73-12-01-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
7. Procedures
SUBTASK 73-12-01-420-001
A. If removed, install the fuel nozzle port seals and fuel nozzle adapter assembly as follows:
(1) Apply anti-seize compound (MAT-015) or (MAT-017) to threads of fuel nozzle adapter retaining
nut.
EFFECTIVITY: FJ44-2C
73-12-01
Page 409
Dec 12/17
(2) Install fuel nozzle adapter assembly into fuel nozzle port. Using fuel nozzle adapter socket
wrench, torque bearing retainer nut 300 to 325 inch-pounds (33.9 to 36.7 N.m) .
(3) Install fuel nozzle ring seal, fuel nozzle plate seal, and retaining ring.
NOTE Back-off the bulkhead nut enough to allow sufficient space for the fuel
nozzle torque procedure to be properly performed in step (3).
(2) Lubricate new O-ring with assembly fluid (MAT-011) and install on fuel nozzle assembly.
(3) Insert the fuel nozzle assembly into the fuel nozzle adapter and torque nozzle 50 to 54
inch-pounds (5.6 to 6.1 N.m) to initially seat the nozzle. Turn nozzle counter-clockwise one-half
turn to loosen and then re-torque to a final torque nozzle 20 to 24 inch-pounds (2.2 to 2.7 N.m) .
NOTE When torquing fuel nozzle assembly or bulkhead nut, use a backup wrench
on the fuel nozzle adapter assembly to keep it from turning.
(5) Install the flexible tube assembly to the fuel nozzle. Refer to 73-10-01, P.B. 401.
8. Job Close-up
SUBTASK 73-12-01-410-002
SUBTASK 73-12-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-12-01
Page 410
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 411
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 412
Dec 12/17
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601
Figure 602
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-12-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 73-12-01-942-004
A. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-029 Alkaline Cleaner, HDL-202
SUBTASK 73-12-01-945-004
B. Reference Information
EFFECTIVITY: FJ44-2C
73-12-01
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 73-12-01-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
SUBTASK 73-12-01-020-003
B. Remove the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
4. Procedures
SUBTASK 73-12-01-220-001
A. Visually inspect:
(a) Signs of coking on nozzle (signs Clean with mineral spirits (MAT-020) or dry
of solid carbon or varnish build-up cleaning solvent (MAT-024) and a nylon
which may interfere with the normal brush while blowing 35 psi filtered air
operation of the nozzle). through nozzle. Ultrasonic cleaning with
MAT-023 is also acceptable. You may also
use Alkaline Cleaner HDL-202 (MAT-029)
for ultrasonic or primary cleaning.
EFFECTIVITY: FJ44-2C
73-12-01
Page 602
Dec 12/17
(d) Damage to jam nut threads, fuel line Clean thread damage using file or 7/16–20
elbow threads, or adapter threads that die.
is a maximum of 0.030 inch (0.762
mm) deep and 20 percent of thread
circumference Figure 601. Multiple
threads may be damaged, but each
must meet this criteria.
B. Visually inspect:
(h) Fretting or other damage in Zone D Reject and contact Williams International
Figure 602 Product Support.
EFFECTIVITY: FJ44-2C
73-12-01
Page 603
Dec 12/17
5. Job Close-up
SUBTASK 73-12-01-420-003
A. Install the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
SUBTASK 73-12-01-410-004
EFFECTIVITY: FJ44-2C
73-12-01
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 605
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 606
Dec 12/17
6. General
This task provides procedures for checking the fuel nozzle spray pattern. Refer to the following
illustration(s):
Figure 603
SUBTASK 73-12-01-941-005
A. Standard Equipment
Fuel Nozzle Spray Test Equipment
SUBTASK 73-12-01-942-005
B. Consumables
Reference Designation
MAT-003 Fuel, Jet A, Jet A-1, or Jet B
MAT-018 Petroleum Distillates
MAT-020 Mineral Spirits
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-037 Fluid, Calibration
SUBTASK 73-12-01-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
73-12-01 401 Fuel Nozzle Assembly - Removal/Installation
8. Job Set-up
SUBTASK 73-12-01-010-006
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
73-12-01
Page 607
Dec 12/17
SUBTASK 73-12-01-020-004
B. Remove the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
9. Procedures
SUBTASK 73-12-01-730-001
A. Check fuel nozzle spray pattern, using one of the approved fluids listed below:
Fuel – MAT-003
(1) Connect the fuel nozzle to fuel nozzle spray test equipment.
(2) Set flow rate on spray test equipment to 100 psig, minimum.
(3) Flow approved fluid through the nozzle and observe the spray pattern. Refer to Figure 603.
EFFECTIVITY: FJ44-2C
73-12-01
Page 608
Dec 12/17
NOTE If nozzle tip is pointing down, fluid will drain out of the nozzle which
may appear as drips from the nozzle orifice.
(a) The spray pattern should be conical with no visible streaks or voids.
(b) If the spray pattern is not acceptable, refer to ultrasonic cleaning procedure, Subtask
73-12-01-730-002.
(4) Disconnect the fuel nozzle from the fuel nozzle spray test equipment.
SUBTASK 73-12-01-730-002
NOTE To avoid debris plugging, ensure that the fuel nozzle is securely placed in
the ultrasonic tank with the tip facing upward.
(1) Ultrasonically clean the fuel nozzle using caustic ultrasonic solution (MAT-023), mineral spirits
(MAT-020), or dry cleaning solvent (MAT-024).
(3) Recheck nozzle flow pattern. Reject nozzle if flow pattern does not meet flow requirements.
SUBTASK 73-12-01-420-004
SUBTASK 73-12-01-410-005
EFFECTIVITY: FJ44-2C
73-12-01
Page 609
Dec 12/17
EFFECTIVITY: FJ44-2C
73-12-01
Page 610
Dec 12/17
1. General
This task provides procedures for removing the fuel filter from the fuel pump. Refer to the following
illustration:
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-14-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 73-14-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
73-14-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 73-14-01-020-002
(2) Remove the filter bowl from the FCU housing using wrench on bowl wrench flats. Remove
the filter and O-ring from the FCU housing.
NOTE Removal of sharp edges and raise material of the wrench flats of the
filter bowl will ensure hardware in close proximity is not damaged during
installation/removal and personnel are not injured. Rounding of the corners will
not affect functionality of the bowl or inhibit the ability to remove/install.
(3) Inspect and remove sharp edges and raise material on the removal nut feature on the filter bowl.
EFFECTIVITY: FJ44-2C
73-14-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
73-14-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the fuel filter on the fuel pump. Refer to the following
illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-14-01, Fig. 01
SUBTASK 73-14-01-942-004
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-060 Lockwire, .032
SUBTASK 73-14-01-944-004
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-14-01 01 30 Filter
73-14-01 01 35 O-Ring
73-14-01 01 40 O-Ring
SUBTASK 73-14-01-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
EFFECTIVITY: FJ44-2C
73-14-01
Page 404
Dec 12/17
7. Job Set-up
SUBTASK 73-14-01-010-001
NOTE Removal of sharp edges and raise material of the wrench flats of the filter bowl
will ensure hardware in close proximity is not damaged during installation/removal
and personnel are not injured. Rounding of the corners will not affect functionality
of the bowl or inhibit the ability to remove/install.
A. Inspect and remove sharp edges and raise material on the removal nut feature on the filter bowl.
8. Procedures
SUBTASK 73-14-01-420-002
CAUTION CHECK TO MAKE SURE THAT THERE IS NO DEBRIS INSIDE THE FILTER
AND THAT THE INTERNAL O-RING IS PROPERLY INSTALLED.
(1) Lube the filter O-ring with a light coat of MAT-011assembly fluid and install the filter on the FCU.
(2) Lube the filter bowl O-ring with assembly fluid and install on the filter bowl.
(3) Install the filter bowl over the filter. Torque the filter bowl 80 to 100 inch-pounds (9.0 to 11.2
N.m).
(4) Install MAT-060 lockwire to safety the filter bowl to the FCU housing.
9. Job Close-up
SUBTASK 73-14-01-410-004
EFFECTIVITY: FJ44-2C
73-14-01
Page 405
Dec 12/17
SUBTASK 73-14-01-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-14-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
73-14-01
Page 407
Dec 12/17
73-14-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The fuel control unit controls the fuel flow to the combustion section.
2. Description
SUBTASK 73-18-00-860-002
A. The FCU is a hydromechanical fuel metering unit. It provides steady-state and transient HP
compressor rotor speed control. The FCU contains an integral fuel pump and is mounted on the back
side of the gearbox. The following is a list of FCU integral components/systems.
EFFECTIVITY: FJ44-2C
73-18-00
Page 1
Dec 12/17
3. Operation
SUBTASK 73-18-00-860-003
A. Fuel enters the FCU where it is pressurized and routed to the fuel/oil heat exchanger. The fuel is
heated (oil cooled) to prevent icing and returned to the fuel filter element. After filtering, fuel is moved
by the positive displacement pump to the fuel metering section of the FCU. Metered fuel is split as
it leaves the FCU. Approximately 9 pph is routed to an atomizing nozzle positioned in the burner
to enhance cold day and altitude start capability. The remainder of metered flow passes through
the fuel flow meter (airframe provided) then enters the core engine through the fuel manifold tube.
A last chance filter is located in the manifold tube. The manifold tube follows the contour of the
diffuser to a fuel distribution manifold where the fuel is supplied to the underside of the fuel slinger.
The fuel slinger, which rotates with the HP rotary group, ejects the fuel radially through a series of
delivery holes into the combustion zone.
EFFECTIVITY: FJ44-2C
73-18-00
Page 2
Dec 12/17
1. General
This task provides procedures for removing the integrated fuel control unit. Refer to the following
illustration(s):
Figure 401
Figure 402
Figure 403
Figure 404
Figure 405
Figure 406
2 During removal of parts, group all components together to make assembly easier.
4 In order to enable troubleshooting of the removed IFCU, make sure that operating
conditions and engine parameters observed during test are recorded on
Figure 406
and returned with the suspect part.
SUBTASK 73-18-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
SUBTASK 73-18-01-943-001
B. Special Tools
Reference Designation
TL-111884 T-Handle Wrench, Fuel Control Remove/Install (optional)
EFFECTIVITY: FJ44-2C
73-18-01
Page 401
Dec 12/17
3. Job Set-up
SUBTASK 73-18-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-18-01-020-001
B. Remove the throttle control linkage and components as required from the PLA shaft on the bottom of
the FCU. Refer to the Aircraft Maintenance Manual.
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(2) Disconnect the following tubes from FCU, removing clamps as needed:
• Flex Tube
EFFECTIVITY: FJ44-2C
73-18-01
Page 402
Dec 12/17
(3) Remove fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
(4) Disconnect the acceleration bleed cable from the acceleration bleed lever on the top of the
interstage housing. Refer to 75-37-01, P.B. 401.
CAUTION GRIPPING THE FCU PLUNGER WITH PLIERS OR OTHER TOOL WILL
DAMAGE THE COATED SURFACE OF THE ROD AND CAUSE FUEL LEAKS.
(5) Insert a 0.125 inch (3.175 mm) rod through the hole in the side of the FCU plunger to keep
it from turning. Loosen the inner cable jam nut on the FCU side of the acceleration bleed
cable assembly and unthread by turning the cable (inner) at the IP bleed boss end. Remove
inner cable jam nut.
(6) Remove the outer cable front jam nut which attaches the (outer) cable assembly to the FCU.
Remove cable.
(7) Disconnect the LP trip sensor cable from the FCU as follows:
NOTE Note the routing of the LP trip cable. A reference mark may be used on the
LP trip cable body (near FCU) as a clocking aid for installation.
(a) Cut the safety wire and disconnect the jam nut which attaches the forward end of the
cable to the FCU.
(b) Remove two screws, four washers, and two nuts which attach the cable actuator housing
to the LP trip sensor housing. Remove the cable actuator housing by pulling it forward
with a hard pull.
(c) Slide the cable assembly straight back to remove from the FCU.
NOTE Fittings and O-rings may be removed before or after FCU removal
from the engine. If fittings are going to be removed after FCU
removal from engine, loosen the fittings at this point.
(a) Removing three nuts and three washers securing FCU to the gearbox. Use TL-111884
wrench (optional).
(10) (If not removed) Remove fittings/O-rings from the following ports of FCU:
• WF
EFFECTIVITY: FJ44-2C
73-18-01
Page 403
Dec 12/17
• SN
• P3
• Drain
(11) If fuel control unit is to be packaged for shipment, rotate the fuel control unit in all attitudes and
shake to verify no fuel remains in the unit. Install protective plugs with O-rings to all open
ports. Double-bag the unit with a minimum bag thickness of four thousandths of an inch (i.e.,
0.004 inches) and zip-tie the bag.
(12) Complete the attached discrepancy report Figure 406and include with removed fuel control unit.
EFFECTIVITY: FJ44-2C
73-18-01
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Fig. 401 IFCU - Removal/Installation Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 408
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 409
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 410
Dec 12/17
5. General
This task provides procedures for installing the integrated fuel control unit. Refer to the following
illustration(s):
Figure 407
Figure 408
Figure 409
Figure 410
Figure 411
Figure 412
Figure 413
Figure 414
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-18-01, Fig. 01
2 Lubricate all threads and contact surfaces of nuts and bolts with clean MAT-001engine
oil before installation unless otherwise indicated in text.
SUBTASK 73-18-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-061 Lockwire, .020
SUBTASK 73-18-01-943-002
B. Special Tools
Reference Designation
TL-111375 Tool, Spline Alignment (optional)
TL-111884 T-Handle Wrench, Fuel Control Remove/Install (optional)
EFFECTIVITY: FJ44-2C
73-18-01
Page 411
Dec 12/17
SUBTASK 73-18-01-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-18-01 01 40 O-Ring
73-18-01 01 50 O-Ring
73-18-01 01 70 O-Ring (Qty 2)
73-18-01 01 90 O-Ring
73-18-01 01 110 O-Ring
73-18-01 01 130 O-Ring
73-18-01 01 160 O-Ring
73-10-01 01 70 O-Ring
SUBTASK 73-18-01-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
EFFECTIVITY: FJ44-2C
73-18-01
Page 412
Dec 12/17
7. Procedures
SUBTASK 73-18-01-420-001
A. Lubricate O-rings with MAT-011assembly fluid and install on fittings and/or locations as identified in
table 401. Torque fittings.
Table 401
(1) Do not remove plug. Torque plug 30 to 40 inch-pounds (3.39 to 4.52 N.m). Torque for slot-head
screw within plug is 13 to 16 inch-pounds (1.46 to 1.80 N.m).
(2) If proper torque cannot be obtained, remove existing lockwire from plug. Do not remove plug
EFFECTIVITY: FJ44-2C
73-18-01
Page 413
Dec 12/17
NOTE TL-111375 is used to align the splines of the IFCU and the gearbox to a
common index position. If this optional tool is used, the splines can be
aligned before the IFCU is installed and there should be no need to remove
the starter/generator to allow rotation of the gearbox.
D. Align IFCU and gearbox splines using TL-111375 alignment tool. Refer to Figure 408.
(1) Install the male spline of the TL-111375 alignment tool into the gearbox IFCU gearshaft.
Rotate the tool, in the direction shown by the arrow marked on the arm of the tool, until the
alignment cup can be installed onto the top mounting stud on the gearbox. Remove alignment
tool from the gearbox.
CAUTION ALWAYS ROTATE THE IFCU DRIVE SPLINE IN THE DIRECTION SHOWN
BY THE ARROW MARKED ON THE ARM OF THE ALIGNMENT TOOL.
(2) Install the female spline of the TL-111375 alignment tool onto the IFCU drive spline. Rotate
the tool, in the direction shown by the arrow marked on the arm of the tool, until the alignment
pin can be installed into the top mounting hole on the IFCU flange. Remove alignment tool
from the IFCU.
CAUTION DRIVE SPLINE TEETH MUST BE CORRECTLY ENGAGED BEFORE MATING THE
FCU. THE PUMP SHAFT MUST BE INDEXED BY GEARBOX ROTATION. DO NOT
USE THE FCU MOUNTING STUDS TO DRAW THE FCU ONTO THE GEARBOX.
E. Engage spline of FCU into drive spline of gearbox. Noting the LP trip cable routing, slide FCU into
contact with gearbox and secure with three washers and nuts. Use TL-111884 wrench (optional).
Torque the nuts 110 to 123 inch-pounds (12.4 to 13.8 N.m) using TL37220 torque adapter. (Use
TL99924 torque adapter as required.)
(1) Ensure the FCU end of cable has two nuts and two washers installed.
(2) Space the washers and nuts approximately one-quarter inch apart to allow the threaded portion
of the cable to slip through the slot in the FCU support boss.
(3) Finger tighten the nuts to secure the cable in the FCU support boss.
(4) Install cable actuator housing and gasket to the LP trip sensor housing.
(5) Attach the cable actuator housing with two screws, four washers, and two nuts. Torque nuts 25
to 28 inch-pounds (2.8 to 3.2 N.m).
EFFECTIVITY: FJ44-2C
73-18-01
Page 414
Dec 12/17
2 The actuator plunger in the FCU must be pulled out and held against
its stop while the cable gap is being set.
(6) Push the cable all the way aft so that it is seated in the trip mechanism. Adjust the gap between
the shutoff plunger (in FCU) and the cable to 0.001 - 0.005 inch (0.025 - 0.127 mm).
(7) Torque the jam nut 85 to 95 inch-pounds (23.1 to 25.7 N.m) Using MAT-061, lockwire jam
nuts to each other.
Table 402
H. Install the acceleration bleed cable assembly. Refer to 75-37-01, P.B. 401.
Table 403
EFFECTIVITY: FJ44-2C
73-18-01
Page 415
Dec 12/17
K. Install the throttle control linkage and components. Refer to the Aircraft Maintenance Manual.
8. Job Close-up
SUBTASK 73-18-01-410-002
SUBTASK 73-18-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-18-01
Page 416
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Fig. 407 IFCU - Removal/Installation Page 417
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 418
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 419
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 420
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 421
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 422
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 423
Dec 12/17
Fig. 414 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
73-18-01
Page 424
Dec 12/17
1. General
Do this procedure, as directed by Troubleshooting, to change engine acceleration time. Refer to the
following illustration(s):
Figure 501
SUBTASK 73-18-01-942-003
A. Consumables
Reference Designation
MAT-061 Lockwire, .020
SUBTASK 73-18-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
3. Job Set-up
SUBTASK 73-18-01-010-003
4. Procedures
SUBTASK 73-18-01-820-001
EFFECTIVITY: FJ44-2C
73-18-01
Page 501
Dec 12/17
(1) Remove lockwire from end of threaded sleeve or clean out torque paint from recessed hex as
required.
(a) Turn internal hex adjustment screw counterclockwise (CCW) to decrease fuel flow and
reduce acceleration rate.
NOTE Half a turn (180°) is approximately 1.2% change in fuel flow. This
adjustment affects both acceleration and deceleration fuel flow. Total
adjustment range is ±3% from factory setting. Increasing fuel flow
(CW rotation) is limited by an internal stop on the adjustment screw.
Decreasing fuel flow (CCW rotation) is limited by an internal stop
independent of the adjustment screw. Adjusting the screw more than
3.0 turns CCW from the maximum CW adjustment screw position will
have no effect on the acceleration schedule. Do not turn screw more
than 3.0 turns from the maximum CW adjustment screw position.
SUBTASK 73-18-01-790-001
(1) Measure acceleration times and perform stability check. Refer to the 71-00-00, P.B. 501.
(a) If engine acceleration time is within limits, proceed to recording the adjustment in the
engine log book.
(b) If engine acceleration time is too slow, increase acceleration schedule by adjusting screw.
(c) Retest engine and repeat adjustment/testing until engine is within acceleration time limits.
5. Job Close-up
SUBTASK 73-18-01-410-003
EFFECTIVITY: FJ44-2C
73-18-01
Page 502
Dec 12/17
EFFECTIVITY: FJ44-2C
73-18-01
Page 503
Dec 12/17
73-18-01
504
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-18-01, Fig. 01
NOTE You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International., Commerce Twp, Michigan, USA.
SUBTASK 73-18-01-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-18-01 401 Fuel Control Unit - Removal/Installation
3. Procedures
SUBTASK 73-18-01-220-001
(2) Loose hose, tube, or linkage connections Tighten. Refer to 73-18-01, P.B. 401
(3) Loose hex plug in TT2 sensor housing. Torque hex plug to 30 to 40 inch-pounds.
If necessary, torque center screw 13 to 16
inch-pounds. Re-install safety wire.
(4) External leakage around mating surfaces, Re-install FCU Refer to 73-18-01, P.B. 401
mounting surfaces, plugs, shafts, or
connections
EFFECTIVITY: FJ44-2C
73-18-01
Page 601
Dec 12/17
73-18-01
602
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the fuel filter indicator. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
4 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 73-23-01-943-001
A. Special Tools
Reference Designation
TL39454 Torque Adapter, Fuel Indicator
SUBTASK 73-23-01-945-052
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 73-23-01-010-001
EFFECTIVITY: FJ44-2C
73-23-01
Page 401
Dec 12/17
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-23-01-020-001
SUBTASK 73-23-01-050-001
B. Using TL39454 torque adapter, remove the delta P switch. Cap port to prevent contamination.
EFFECTIVITY: FJ44-2C
73-23-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
73-23-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the fuel filter indicator. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-23-01, Fig. 01
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
3 This part must undergo major periodic inspection. If a serviceable, used fuel filter
indicator from another engine is to be installed, make sure that it has undergone all
scheduled inspections (per requirements in 05-20-00, P.B. 601) before installation.
4 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 73-23-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-061 Lockwire, .020
SUBTASK 73-23-01-943-002
B. Special Tools
Reference Designation
TL39454 Torque Adapter, Fuel Indicator
SUBTASK 73-23-01-944-002
C. Expendable Parts
EFFECTIVITY: FJ44-2C
73-23-01
Page 404
Dec 12/17
IPC Reference
Subject Fig. Item Nomenclature
73-23-01 01 20 O-Ring
73-23-01 01 30 O-Ring
SUBTASK 73-23-01-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-23-01-420-001
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(1) Lubricate two O-rings with assembly fluid (MAT-011). Install one O-ring at O-ring groove at
bottom of delta P switch, and one O-ring at boss seal flange.
SUBTASK 73-23-01-450-001
B. Using TL39454 torque adapter, torque delta P switch 145 to 155 inch-pounds (16.3 to 17.4 N.m).
EFFECTIVITY: FJ44-2C
73-23-01
Page 405
Dec 12/17
SUBTASK 73-23-01-450-003
SUBTASK 73-23-01-450-004
8. Job Close-up
SUBTASK 73-23-01-410-002
SUBTASK 73-23-01-760-001
B. Perform engine testing per the Table Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-23-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
73-23-01
Page 407
Dec 12/17
73-23-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
TASK 73-23-01-220-801 Visually Inspect the Fuel Filter Indicator (Delta P Switch)
1. General
This task covers visual check of the fuel filter indicator. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog: 73-23-01, Fig. 01
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 73-23-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
3. Procedures
SUBTASK 73-23-01-020-002
A. Remove the fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
SUBTASK 73-23-01-220-001
EFFECTIVITY: FJ44-2C
73-23-01
Page 601
Dec 12/17
EFFECTIVITY: FJ44-2C
73-23-01
Page 602
Dec 12/17
TASK 73-23-01-780-801 Perform Functional Verification of the Fuel Filter Indicator (Delta P
Switch)
4. General
This task performs a pressure check on the fuel filter indicator to ensure proper function. Refer to the
following illustration(s):
Figure 602
Figure 603
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 73-23-01-941-004
A. Standard Equipment
Continuity Tester Or Ohmmeter
Stopwatch Or Clock
5 To 100 Psi Shop Air
SUBTASK 73-23-01-943-004
B. Special Tools
Reference Designation
TL-109543 Test Block, Indicator, Delta P
TL-110118 Test Block, Indicator, Delta P, Oil Filter and Fuel Filter
SUBTASK 73-23-01-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
EFFECTIVITY: FJ44-2C
73-23-01
Page 603
Dec 12/17
6. Procedures
SUBTASK 73-23-01-780-001
A. Remove fuel filter delta P switch from engine. Refer to 73-23-01, P.B. 401.
B. TL-109543 or TL-110118 (optional) test fixtures are used to check the functionality of the fuel filter
delta P switch. The switch is functioning properly when increasing delta pressure triggers an internal
switch and closes a contact. During operation, this indicates to the aircrew that the pressure across
the fuel filter is high and should be reported to maintenance personnel.
(1) Completely close the air inlet valve before connecting to air source.
(4) Connect source of 5 to 100 psi shop air to the inlet valve on the side of test unit. Do not apply
air pressure at this time.
D. Install the fuel filter delta P switch to the test unit as follows:
(1) Make sure that both O-rings are in place on the delta P switch.
(2) Install delta P switch in the fitting provided on the top of the test unit. Torque to 30 to 50
inch-pounds (3.4 to 5.6 N.m).
(1) Connect a Continuity Tester or Ohmmeter to pins C and B of the Delta P switch.
(2) The bulb on the continuity tester should illuminate (or the ohmmeter should indicate continuity).
(2) Using the inlet valve and flow control valve, slowly increase pressure to 4.5 psi and then
start the stopwatch.
(3) With the tester connected to pins C and B, the bulb on the continuity tester should extinguish (or
the ohmmeter should indicate loss of continuity/open circuit). This may require several seconds.
(4) After the bulb on the continuity tester extinguishes (or the ohmmeter indicates a loss of
continuity/open circuit), disconnect tester leads from pins C and B.
EFFECTIVITY: FJ44-2C
73-23-01
Page 604
Dec 12/17
(5) Connect the tester to pins A and C. The bulb on the continuity tester should illuminate (or the
ohmmeter should indicate continuity). This may require several seconds.
(6) After the bulb on the tester illuminates (or the ohmmeter indicates continuity), stop the
stopwatch.
(7) Total time must be less than 180 seconds for the delta P switch to respond for steps (1)
through (5).
NOTE Tester should still be connected to pins A and C with 4.5 psi of pressure applied.
(2) Using the inlet valve and flow control valve, slowly decrease the pressure to 0 psi and then
start the stopwatch.
(3) With the tester connected to pins A and C, the bulb on the tester should extinguish (or the
ohmmeter should indicate loss of continuity/open circuit) within 180 seconds.
H. Test Evaluation:
If sensor fails any of the following modes, return to Williams International Repair Station for repair
per 119916:
SUBTASK 73-23-01-420-002
I. Install the fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
EFFECTIVITY: FJ44-2C
73-23-01
Page 605
Dec 12/17
EFFECTIVITY: FJ44-2C
73-23-01
Page 606
Dec 12/17
EFFECTIVITY: FJ44-2C
73-23-01
Page 607
Dec 12/17
73-23-01
608
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the fuel manifold filter. Do this task as required by periodic
maintenance. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-25-01-941-001
A. Standard Equipment
Ultrasonic Cleaning Equipment
SUBTASK 73-25-01-945-052
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 73-25-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
73-25-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 73-25-01-020-001
(2) Remove the fuel filter from the engine service adapter fuel port.
EFFECTIVITY: FJ44-2C
73-25-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
73-25-01
Page 403
Dec 12/17
5. General
This tasks provides procedures for installing the fuel manifold filter. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-25-01, Fig. 01
SUBTASK 73-25-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-25-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-25-01 01 10 Filter, Assembly, Fuel Manifold
73-25-01 01 20 O-ring
SUBTASK 73-25-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
EFFECTIVITY: FJ44-2C
73-25-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 73-25-01-420-001
(1) Lubricate O-ring with assembly fluid (MAT-011) and install on the fuel filter assembly.
(2) Apply a light coat of engine oil (MAT-001) to threads of the fuel filter.
(3) Install the fuel manifold filter into the service adapter fuel port and torque 38 to 42 inch-pounds
(4.2 to 4.7 N.m).
(4) Install the fuel tube assembly. Refer to 73-10-01, P.B. 401.
8. Job Close-up
SUBTASK 73-25-01-410-002
SUBTASK 73-25-01-760-001
B. Perform engine testing per the table Test Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-25-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
73-25-01
Page 406
Dec 12/17
1. General
This task provides procedures for resetting the fuel shutoff valve. Refer to the following illustration(s):
Figure 201
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International., Commerce Twp, Michigan, USA.
3 Lubricate all threads and contact surfaces of nuts and bolts with
clean engine oil before installation.
SUBTASK 73-27-01-942-002
A. Consumables
Reference Designation
MAT-060 Lockwire, .032
SUBTASK 73-27-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
71-00-50 601 LP Turbines (Borescope) - Inspection/Check
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 73-27-01-010-002
EFFECTIVITY: FJ44-2C
73-27-01
Page 201
Dec 12/17
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-27-01-210-002
CAUTION YOU MUST FULLY IDENTIFY THE REASON WHY THE FUEL SHUTOFF VALVE
TRIPPED BEFORE PUTTING THE ENGINE BACK IN SERVICE.
A. Before placing an engine that has had the FCU shutoff valve activated by the LP trip sensor back
into service, do the following:
(1) Refer to 71-00-50, P.B. 601. Inspect the LP shaft end and LP turbines with a borescope. Look
through the port in the rear housing and inspect for:
SUBTASK 73-27-01-020-002
B. Remove cable assembly and cable actuator housing. Refer to 76-20-01, P.B. 501.
SUBTASK 73-27-01-830-005
NOTE The shutoff valve plunger, when in the open position, holds the reset pin
in. When the shutoff valve is closed, the plunger is pushed forward and
the pin comes across to hold it in the closed position.
(1) Push in the reset pin on the FCU. This allows you to move the shutoff valve arm back in
the open position holding the reset button in.
SUBTASK 73-27-01-830-006
D. Reset the LP shaft trip sensor mechanism. Refer to 76-20-01, P.B. 501.
SUBTASK 73-27-01-420-003
EFFECTIVITY: FJ44-2C
73-27-01
Page 202
Dec 12/17
SUBTASK 73-27-01-820-002
SUBTASK 73-27-01-420-004
(1) Ensure the FCU end of cable has two nuts and two washers installed.
(2) Space the washers and nuts approximately one-quarter inch apart to allow the threaded portion
of the cable to slip through the slot in the FCU support boss.
(3) Finger tighten the nuts to secure the cable in the FCU support boss.
2 The actuator plunger in the FCU must be pulled out and held against
its stop while the cable gap is being set.
(4) Push the cable all the way aft so that it is seated in the trip mechanism. Adjust the gap between
the shutoff plunger (in FCU) and the cable to 0.001 - 0.005 inch (0.025 - 0.127 mm).
(5) Torque jam nuts 85 to 95 inch-pounds (9.6 to 10.7 N.m). Using MAT-060 lockwire jam nuts.
5. Job Close-up
SUBTASK 73-27-01-410-002
SUBTASK 73-27-01-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
73-27-01
Page 203
Dec 12/17
EFFECTIVITY: FJ44-2C
73-27-01
Page 204
Dec 12/17
CHAPTER 74
IGNITION
Page 1
74-IGNITION Dec 12/17
Page 2
74-IGNITION Blank
LINE MAINTENANCE MANUAL - FJ44-2C
74-00-00 1 Dec 12/17 74-20-01 401 Dec 12/17 74-22-01 601 Dec 12/17
74-00-10 501 Dec 12/17 74-20-01 601 Dec 12/17 74-22-01 701 Dec 12/17
74-10-01 401 Dec 12/17 74-22-01 401 Dec 12/17
Chapter 74
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 74
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The ignition system supplies spark to ignite the fuel/air mixture in the combustor. Refer to the following
illustration(s):
Figure 1
2. Description
SUBTASK 74-00-00-860-002
B. The two ignition exciters are high energy, capacitive discharge devices. The parts for each ignition
exciter are contained in a corrosion resistant, case which is sealed against air. Both ignition exciter
cases are mounted to the engine interstage housing. The spark rate is one to six sparks per
channel, per second. The exciters can operate continuously with input voltage ranging from 10 to
30 volts, 3.5 Joules stored energy.
C. The igniter leads are made from a low-loss coaxial cable which is designed for use at 18 to 24 Kv.
The right and left leads are different lengths.
D. The igniter plugs are sealed against air and have precious metal electrodes. The igniter plug case is
made of high temperature, corrosion resistant alloys.
3. Operation
SUBTASK 74-00-00-860-003
A. The ignition switch in the cockpit activates the ignition exciters. The ignition exciters draw current
from the battery and sends current through each igniter lead, independently, at a rate of one to six
sparks per second. The igniter plugs ignite the fuel/air mixture in the combustor. Igniters continue to
fire until the ignition switch is turned off.
EFFECTIVITY: FJ44-2C
74-00-00
Page 1
Dec 12/17
EFFECTIVITY: FJ44-2C
74-00-00
Page 2
Dec 12/17
1. General
SUBTASK 74-00-10-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
3. Job Set-up
SUBTASK 74-00-10-010-001
4. Procedures
SUBTASK 74-00-10-770-001
(1) Switch the ignition system to the ON position. Refer to the Aircraft Maintenance Manual.
(2) Listen for the igniters firing. The igniters may start out firing together or they may start out
alternately firing. In either case, they will drift from one mode to the other. If you can hear both
igniters firing in this way, functional test is complete. If you cannot hear both igniters firing in
this way, one or both of the igniters are malfunctioning.
EFFECTIVITY: FJ44-2C
74-00-10
Page 501
Dec 12/17
(c) Remove igniter leads from igniters. Use a backup wrench on igniter plug flats.
(d) Remove igniter plug nuts and remove igniter plugs from engine.
(e) Install igniter leads to igniter plugs. Use a backup wrench on igniter plug flats.
(f) Let igniters hang down below engine for operational test.
(b) From a distance of at least 10 feet (3 meters), visually make sure that igniters fire (make
a spark).
(c) If either igniter fails to fire, refer to troubleshooting task Low/No Sound of Igniter(s) Firing
71-00-00, P.B. 101.
5. Job Close-up
SUBTASK 74-00-10-410-001
EFFECTIVITY: FJ44-2C
74-00-10
Page 502
Dec 12/17
EFFECTIVITY: FJ44-2C
74-00-10
Page 503
Dec 12/17
74-00-10
504
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the ignition exciters. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 74-10-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 74-10-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 74-10-01-050-001
EFFECTIVITY: FJ44-2C
74-10-01
Page 401
Dec 12/17
(1) Disconnect the two electrical connectors from the forward side of the two ignition exciters.
(3) Remove lockwire from the igniter lead connectors and disconnect igniter leads from the ignition
exciters. Put protective covers on the cable ends.
(4) Remove four nuts, eight washers, and four bolts from the ignition exciter clamps and brackets.
Remove the two exciter clamps.
(5) Remove the ignition exciters, put in a protective bag and identify as required.
EFFECTIVITY: FJ44-2C
74-10-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
74-10-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the ignition exciters. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-10-01, Fig. 01
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 74-10-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 74-10-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
74-00-10 501 Ignition System - Adjustment/Test
EFFECTIVITY: FJ44-2C
74-10-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 74-10-01-420-001
(1) Install ignition exciters onto the forward and rear mounting brackets. Locate the igniter leads
toward the aft end of the engine.
(2) Attach the ignition exciters with two clamps, four bolts, eight washers and four nuts. Torque
nuts 2 to 5 inch-pounds (0.22 to 0.56 N.m) above the prevailing run-on torque.
(3) Remove protective covers from the igniter leads and install the two cables into the two ignition
exciters. Torque each lead 140 to 150 inch-pounds (15.7 to 16.8 N.m). Install lockwire
(MAT-061) to the igniter lead nuts.
(5) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
8. Job Close-up
SUBTASK 74-10-01-410-002
SUBTASK 74-10-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
74-10-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
74-10-01
Page 406
Dec 12/17
1. General
This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 74-20-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
3. Job Set-up
SUBTASK 74-20-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 74-20-01-020-001
(1) Remove aircraft power leads from the two ignition exciters.
EFFECTIVITY: FJ44-2C
74-20-01
Page 401
Dec 12/17
(5) Remove fuel tubes, as required, to gain access to the igniter lead clamps. Refer to 73-10-01,
P.B. 401
(6) Remove the screws from the clamps which secure the igniter lead to the brackets. Note that
one of the clamps has a spring screw and is released by turning the screw 90°.
(7) Disconnect the igniter lead from the igniter plug. Use a back-up wrench on the igniter plug flats.
Remove the igniter lead.
EFFECTIVITY: FJ44-2C
74-20-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
74-20-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the igniter leads. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-20-01, Fig. 01
SUBTASK 74-20-01-942-002
A. Consumables
Reference Designation
MAT-061 Lockwire, .020
SUBTASK 74-20-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
74-00-10 501 Ignition System - Adjustment/Test
7. Procedures
SUBTASK 74-20-01-420-001
(1) If not already installed, install .025-inch spiral wrap to igniter leads. Secure spiral wrap with
nylon strap locks and trim ends of strap locks flush.
EFFECTIVITY: FJ44-2C
74-20-01
Page 404
Dec 12/17
SUBTASK 74-20-01-450-003
B. Install the straight end of the igniter lead to the ignition exciter.
SUBTASK 74-20-01-450-002
NOTE Prior to connecting igniter leads, verify that all electrical interface points
are clean, show no signs of corrosion, and are free of debris.
(2) Install the 90° end of the igniter lead to the igniter plug.
(3) Torque the igniter lead at the ignition exciter end 140 to 150 inch-pounds (15.7 to 16.8 N.m).
(4) Torque the igniter lead at the igniter end 240 to 250 inch-pounds (27.1 to 28.2 N.m).
(5) Lockwire the two igniter lead nuts together with .020 inch lockwire (MAT-061).
(b) Carefully close the clamps on the leads, slotted clamp first.
(c) Align the "T" nut on the clamp screw with the slots in the clamp arm and the clamp base,
then push through and lock into position.
CAUTION ADJUST IGNITER LEAD SLACK IN LOOP CLAMPS TO MAKE SURE THAT
IGNITER LEADS DO NOT CONTACT TUBE ASSEMBLIES.
(7) Install other lead clamps and torque clamp bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(8) Install the fuel tubes that were removed for access to the igniter leads. Refer to 73-10-01,
P.B. 401.
(10) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
EFFECTIVITY: FJ44-2C
74-20-01
Page 405
Dec 12/17
8. Job Close-up
SUBTASK 74-20-01-410-002
SUBTASK 74-20-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501..
EFFECTIVITY: FJ44-2C
74-20-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
74-20-01
Page 407
Dec 12/17
74-20-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for visually inspecting the igniter leads.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-20-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 74-20-01-942-003
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
SUBTASK 74-20-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
74-20-01 401 Igniter Lead - Removal/Installation
3. Procedures
SUBTASK 74-20-01-020-002
SUBTASK 74-20-01-220-001
EFFECTIVITY: FJ44-2C
74-20-01
Page 601
Dec 12/17
(g) Missing or damaged spiral wrap Install new spiral wrap. Refer to 74-20-01,
P.B. 401
SUBTASK 74-20-01-420-002
EFFECTIVITY: FJ44-2C
74-20-01
Page 602
Dec 12/17
1. General
This task provides procedures for removing the igniter plugs. Refer to the following illustration(s):
Figure 401
Figure 402
Figure 403
Figure 404
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 74-22-01-942-001
A. Consumables
Reference Designation
MAT-013 Magnesium Hydroxide
SUBTASK 74-22-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-40 601 Combustor, Fuel Slinger, and HP Turbine Blades Leading Edge
(Borescope) - Inspection/Check
3. Job Set-up
SUBTASK 74-22-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
74-22-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 74-22-01-020-001
(1) Disconnect the aircraft electrical leads from the ignition exciters.
(3) Use a back-up wrench on the igniter plug wrench flats and disconnect the igniter lead from the
igniter plug. Put a protective cover on the igniter cable end.
(4) Remove igniter plug nut and igniter plug from the igniter boss on the service island. If the igniter
plug adapter loosens from the diffuser port during igniter plug nut removal, do the following:
(b) Remove retaining ring, igniter plug ring seal, and igniter plug plate seal.
(c) Remove igniter plug nut, igniter plug, and igniter plug adapter as an assembly from the
engine. The spacer will come out separately.
(d) Separate igniter plug nut from the igniter plug adapter.
(e) Reinstall igniter plug adapter and spacer into igniter boss on the service island. Lubricate
igniter plug adapter threads with MAT-013 and torque 590 to 610 inch-pounds (66.6
to 68.9 N.m).
(5) Remove the internal retaining ring which holds the igniter plug to the igniter plug nut. Separate
the igniter plug from the igniter plug nut.
(1) Check for fretting or other damage in Zone C. Refer to Figure 403. If there is fretting or other
damage in this area, reject igniter plug and contact Williams International Product Support.
EFFECTIVITY: FJ44-2C
74-22-01
Page 402
Dec 12/17
NOTE The following step applies to igniters with four radially-mounted, pin-type
ground electrodes located in the electrode tip (4-pole configuration). It does
not apply to igniters with a round annular ground electrode.
(2) Inspect tip of 4-pole igniter plug to verify that all four ground electrodes are intact. Refer to
Figure 404. If one or more electrode is missing, reject igniter plug and perform borescope
inspection, 71-00-40, P.B. 601
EFFECTIVITY: FJ44-2C
74-22-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 404
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 406
Dec 12/17
Fig. 404 4-Pole Igniter Plug – Visual Inspection for Missing Electrode
EFFECTIVITY: FJ44-2C
74-22-01
Page 407
Dec 12/17
5. General
This task provides procedures for installing the igniter plugs. Refer to the following illustration(s):
Figure 405
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-22-01, Fig. 01
SUBTASK 74-22-01-942-002
A. Consumables
Reference Designation
MAT-013 Magnesium Hydroxide
MAT-015 Lubricant, Anti-seize
SUBTASK 74-22-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
74-00-10 501 Ignition System - Adjustment/Test
7. Procedures
SUBTASK 74-22-01-420-001
EFFECTIVITY: FJ44-2C
74-22-01
Page 408
Dec 12/17
(1) Insert the igniter plug into the igniter plug nut and install the internal retaining ring. Ensure
retaining ring is installed below the last thread in the igniter plug nut.
(2) Apply magnesium hydroxide MAT-013 or anti-seize lubricant MAT-015 to the igniter plug nut
threads.
(3) Following the angle of the igniter boss, insert the igniter plug and igniter nut into the diffuser
and locate in the hole in the combustor.
NOTE The igniter plug nut will not thread on the boss if the igniter plug is
not located in the combustor primary plate.
(4) Torque the igniter plug nut 300 to 325 inch-pounds (33.8 to 36.7 N.m).
(5) Remove protective covering from the igniter lead and install on the igniter plug. Hold the
igniter plug with a back-up wrench and torque the igniter lead 240 to 250 inch-pounds (27.1 to
28.2 N.m).
(7) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
8. Job Close-up
SUBTASK 74-22-01-410-002
EFFECTIVITY: FJ44-2C
74-22-01
Page 409
Dec 12/17
SUBTASK 74-22-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
C. Indicate in the engine logbook the hours/cycles that igniter was installed.
EFFECTIVITY: FJ44-2C
74-22-01
Page 410
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 411
Dec 12/17
74-22-01
412
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Perform this task at the interval shown in Routine Periodic Inspections, 05-20-00, P.B. 601. Refer to the
following illustration(s):
Figure 601
Figure 602
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog: 74-22-01, Fig. 01.
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 74-22-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
71-00-40 601 Combustor, Fuel Slinger, and HP Turbine Blades Leading Edge
(Borescope) - Inspection/Check
74-22-01 401 Igniter Plug - Removal/Installation
74-22-01 701 Igniter Plug - Cleaning
3. Procedures
SUBTASK 74-22-01-020-002
EFFECTIVITY: FJ44-2C
74-22-01
Page 601
Dec 12/17
SUBTASK 74-22-01-220-001
NOTE The following step applies to igniters with four radially-mounted pin-type ground
electrodes located in the electrode tip (4-pole configuration). It does not
apply to igniters with a round annular ground electrode
B. Inspect tip of 4-pole igniter plug to verify that all four ground electrodes are intact. Refer to Figure
602. If one or more electrode is missing, reject igniter plug and perform borescope inspection,
71-00-40, P.B. 601.
(6) Fretting or chafing wear in Zone C Reject and contact Williams International
Product Support
D. Audibly check for cracked ceramic by holding the monoball sleeve in place and shaking the igniter
plug.
EFFECTIVITY: FJ44-2C
74-22-01
Page 602
Dec 12/17
NOTE When checking for binding of spherical pivot, make sure that pivot area is
clean and free from anti-seize compound residue.
EFFECTIVITY: FJ44-2C
74-22-01
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 604
Dec 12/17
Fig. 602 4-Pole Igniter Plug - Visual Inspection for Missing Electrode
EFFECTIVITY: FJ44-2C
74-22-01
Page 605
Dec 12/17
4. General.
This task covers dimensional inspection of the igniter plugs tip gap diameter. Part numbers 55396 and
70161 require this inspection. Do this task as required by scheduled maintenance, 05-20-00, P.B. 601.
Refer to the following illustration(s):
Figure 603
SUBTASK 74-22-01-941-004
A. Standard Equipment
Caliper
SUBTASK 74-22-01-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
74-22-01 601 Igniter Plug - Inspection/Check
SUBTASK 74-22-01-220-001
A. Perform both Electrode Depth Inspection and Tip Gap Diameter Inspection on P/N 70161.
IGNITER PART NUMBER Electrode Depth Inspection Tip Gap Diameter Inspection
70161 Refer to 74-22-01-220-803 See procedures below
55396 Not applicable See procedures below
EFFECTIVITY: FJ44-2C
74-22-01
Page 606
Dec 12/17
7. Procedures
SUBTASK 74-22-01-220-002
EFFECTIVITY: FJ44-2C
74-22-01
Page 607
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 608
Dec 12/17
8. General.
This task covers dimensional inspection of the igniter plugs for erosion or wear. Part numbers 57846,
68032, 70161, 78214, and 114220 require this inspection. Do this task as required by scheduled
maintenance, 05-20-00, P.B. 601. Refer to the following illustration(s):
Figure 604
SUBTASK 74-22-01-941-005
A. Standard Equipment
Depth Micrometer Or Caliper (probe Diameter 0.100
Inch [2.54 Mm] Or Less)
SUBTASK 74-22-01-945-005
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
74-22-01 401 Igniter Plug - Removal/Installation
SUBTASK 74-22-01-220-001
A. Perform both Electrode Depth Inspection and Tip Gap Diameter Inspection on P/N 70161.
EFFECTIVITY: FJ44-2C
74-22-01
Page 609
Dec 12/17
IGNITER PART NUMBER Electrode Depth Inspection Tip Gap Diameter Inspection
11. Procedures
SUBTASK 74-22-01-220-003
A. Measure the internal wear groove in the tip using a Depth Micrometer or Caliper (probe diameter
0.100 inch [2.54 mm] or less)as follows:
(1) Measure the distance between the face of the igniter tip and the center electrode. Refer to
Figure 604. Check the igniter part number and compare the dimension with the evaluation
criteria in the table below:
IGNITER PART NUMBER ACCEPT REJECT
68032 0.215 inch (5.461 mm) or less Greater than 0.215 inch (5.461 mm)
78214 See Note
57846
70161 0.134 inch (3.403 mm) or less Greater than 0.134 inch (3.403 mm)
114220 See Note
SUBTASK 74-22-01-420-002
EFFECTIVITY: FJ44-2C
74-22-01
Page 610
Dec 12/17
EFFECTIVITY: FJ44-2C
74-22-01
Page 611
Dec 12/17
74-22-01
612
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
SUBTASK 74-22-01-942-006
A. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-028 Alcohol, Methyl, Wood, or Methanol
SUBTASK 74-22-01-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
74-22-01 401 Igniter Plug - Removal/Installation
3. Procedures
SUBTASK 74-22-01-020-003
SUBTASK 74-22-01-120-001
EFFECTIVITY: FJ44-2C
74-22-01
Page 701
Dec 12/17
(2) Terminal well may be cleaned with a felt swab saturated in mineral spirits MAT-020 or methyl,
wood, or methanol alcohol MAT-028.
SUBTASK 74-22-01-420-003
EFFECTIVITY: FJ44-2C
74-22-01
Page 702
Dec 12/17
CHAPTER 75
AIR
Page 1
75-AIR Dec 12/17
Page 2
75-AIR Blank
LINE MAINTENANCE MANUAL - FJ44-2C
75-00-00 1 Dec 12/17 75-35-01 401 Dec 12/17 75-37-01 401 Dec 12/17
75-30-01 601 Dec 12/17 75-35-01 501 Dec 12/17
Chapter 75
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 75
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The FJ44 is a two spool, axial flow, bypass turbofan engine. The bypass ratio is 3.3 : 1. The engine has
three compressors: a low pressure (LP) axial compressor, an intermediate pressure (IP) axial compressor,
and a high pressure (HP) centrifugal compressor. The LP compressor (fan) and IP compressor are driven
by two LP turbines. The HP compressor is driven by a single HP turbine. When the mixture of fuel and
compressed air is ignited in the combustor section, the expanding gases drive the turbines.
SUBTASK 75-00-00-860-006
A. Bypass Principal.
The bypass principal lets part of the air passing through the fan bypass the IP compressor, HP
compressor, combustor section and HP and LP turbines. This permits the engine to use high cyclic
temperatures and pressures and still produce a low jet exhaust velocity. Bypass air also decreases
the velocity and temperature of the exhaust gases. This combination creates high thermal efficiency
and high propulsive efficiency. In addition, the bypass air decreases the noise level and increases
the power/weight ratio for a given engine thrust.
B. Cooling Air
Cooling air comes from the HP compressor at the diffuser flange. It is known as compressor
discharge pressure (CDP). CDP air moves through the 1st LP turbine nozzle to cool the two LP
turbines. Diffused air cools the HP nozzle and the HP turbines.
The acceleration bleed system is operated by the fuel control unit (FCU). The acceleration bleed
cable connects the FCU with a butterfly valve in the interstage housing. The butterfly valve is open
at engine start and is closed by the FCU when the engine reaches 87% to 89.3% N2. This allows
unloading of the HP compressor during acceleration.
D. HP Bleed
The engine is equipped to provide both HP compressor and fan bleed air for aircraft use. Two HP
bleed air ports are located on the forward bypass duct service islands ahead of each igniter at the
5:30 and 7:30 o’clock positions. HP compressor bleed air can be extracted from either or both of
these ports. Two fan bleed ports are located on the aft bypass duct immediately ahead of the nozzle
mounting flange and at the 3:00 and 9:00 o’clock positions.
EFFECTIVITY: FJ44-2C
75-00-00
Page 1
Dec 12/17
75-00-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-37-01, Fig. 02
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 75-30-01-942-001
A. Consumables
Reference Designation
MAT-008 Lubricant, Molybdenum Disulfide
MAT-040 Cloth, Abrasive
MAT-089 Sealant, RTV 103
SUBTASK 75-30-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
75-35-01 501 Acceleration Bleed System Lever - Adjustment/Test
EFFECTIVITY: FJ44-2C
75-30-01
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 75-30-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-30-01-220-001
(1) Minor damage to outer cable insulation Repair with adhesive sealant MAT-089
(RTV 103, black)
(2) Shrink tubing pulled away from cable at fuel Apply a shrink tube splice
control side.
(5) Light wear on inner cable Polish the wear out with 400 grit abrasive
cloth MAT-040. Apply molybdenum
disulfide lubricant MAT-008.
SUBTASK 75-30-01-220-004
(1) Cracked inner cable nylon coating Strip nylon coating back to a point 2.3
inches (58.42 mm) back from tip of the
swaged ball. All nylon coating that exhibits
cracks, splits, peeled coating or bare areas
shall be reworked if defects occur with in
this 2.3 inch region.
Apply a 1.90 inch (48.2 mm) long piece of
teflon shrink tube over bare cable. Overlay
end of nylon coating. Shrink tube ends
shall have a smooth transition. Trim to
allow full closure of bleed valve.
EFFECTIVITY: FJ44-2C
75-30-01
Page 602
Dec 12/17
SUBTASK 75-30-01-220-002
5. Job Close-up
SUBTASK 75-30-01-410-001
EFFECTIVITY: FJ44-2C
75-30-01
Page 603
Dec 12/17
Fig. 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection
EFFECTIVITY: FJ44-2C
75-30-01
Page 604
Dec 12/17
1. General
This task provides procedures for removing the acceleration bleed system lever and the IP bleed port
cover. Refer to the following illustration(s):
Figure 401
Figure 402
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 75-35-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 75-35-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-35-01-020-002
A. Remove the acceleration bleed system lever as follows. Refer to Figure 401.
(1) Remove one bolt, cover, and spacer from the acceleration bleed port cover.
EFFECTIVITY: FJ44-2C
75-35-01
Page 401
Dec 12/17
(3) If applicable, remove MAT-061 lockwire or MAT-063 safety cable and ferrule from the headed
pin in the bleed lever.
(4) Remove the retaining clip, roll pin, or headed pin (depending on engine configuration) which
attaches the ball end of the bleed valve cable assembly to the bleed lever.
(5) Remove one screw and nut which attaches the bleed lever to the shaft. Remove the bleed
lever and key from the shaft.
(6) Remove bolt and washer from right-rear of bleed port cover.
SUBTASK 75-35-01-050-003
(1) Remove the borescope plug from the port on the IP bleed cover. Remove the O-ring from
the borescope plug.
(2) Remove three bolts and three washers from IP bleed cover and remove cover. Clean sealant
from mating faces of cover and interstage housing.
EFFECTIVITY: FJ44-2C
75-35-01
Page 402
Dec 12/17
Fig. 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
75-35-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
75-35-01
Page 404
Dec 12/17
5. General
This task provides procedures for installing the IP bleed port cover and the acceleration bleed system
lever. Refer to the following illustration(s):
Figure 403
Figure 404
Figure 405
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-35-01, Fig. 02
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001engine oil before installation.
SUBTASK 75-35-01-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
MAT-063 Safety Cable, .022 and Ferrule
MAT-090 Sealant, RTV 106
SUBTASK 75-35-01-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
75-35-01 501 Acceleration Bleed System Lever - Adjustment/Test
EFFECTIVITY: FJ44-2C
75-35-01
Page 405
Dec 12/17
7. Procedures
SUBTASK 75-35-01-450-003
(1) Lube preformed packing with engine oil (MAT-001) and install on upper end of the bleed valve
shaft.
(2) Apply a thin film of RTV sealant (MAT-090) to the bottom of the IP bleed port cover. Install the
cover, over the bleed valve shaft, onto the interstage housing.
(3) Install three bolts and three washers to attach the cover. Torque bolts 36 to 40 inch-pounds
(4.0 to 4.5 N.m).
(4) Lube O-ring with engine oil (MAT-001) and install on borescope plug. Install borescope plug in
IP bleed cover port. Torque borescope plug 90 to 100 inch-pounds (10.1 to 11.2 N.m).
SUBTASK 75-35-01-420-002
B. Install the acceleration bleed system lever as follows. Refer to Figure 404:
(1) Install the spring over the bleed valve shaft and align lower tang over the right-rear bolt hole of
the bleed port cover.
(2) Install washer and bolt into right-rear bolt hole of the bleed port cover. Ensure that the lower
tang of spring is hooked around bolt. Torque bolt 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(3) Install the woodruff key in the slot in the bleed valve shaft and install the bleed lever on the
shaft, aligning the key slots. Install the screw and the nut which secures the lever on the shaft.
Torque nut 31 to 35 inch-pounds (3.5 to 3.9 N.m).
(4) Hook the upper tang of spring around the bleed lever.
(5) Install ball end of cable to the bleed valve lever. Secure cable by one of the following means,
as applicable to engine configuration (check IPC, 75-35-01):
(a) Install headed pin and secure with MAT-061 safety wire or MAT-063 safety cable and
ferrules. Refer to Figure 405 for safety wire method.
(b) Install new roll pin (verifying tight fit of pin upon insertion).
(6) Install spacer and cover onto bleed port cover post. Install other end of cover into slot in bleed
cable bracket. Secure cover with one bolt. Torque bolt 49 to 55 inch-pounds (5.5 to 6.2 N.m).
C. Adjust the acceleration bleed system lever. Refer to 75-35-01, P.B. 501.
EFFECTIVITY: FJ44-2C
75-35-01
Page 406
Dec 12/17
8. Job Close-up
SUBTASK 75-35-01-410-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches the minimum and
maximum stops during test.
EFFECTIVITY: FJ44-2C
75-35-01
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
75-35-01
Page 408
Dec 12/17
EFFECTIVITY: FJ44-2C
75-35-01
Page 409
Dec 12/17
Fig. 405 Acceleration Bleed System Cable - Headed Pin – Safety Wire Method
EFFECTIVITY: FJ44-2C
75-35-01
Page 410
Dec 12/17
1. General
Do this task after a new lever arm is installed. If the cable assembly or fuel control unit were replaced, you
must verify that the maximum and minimum stops are contacted during acceleration and deceleration
test. Refer to the following illustration(s):
Figure 501
SUBTASK 75-35-01-942-005
A. Consumables
Reference Designation
MAT-061 Lockwire, .020
MAT-063 Safety Cable, .022 and Ferrule
SUBTASK 75-35-01-945-005
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
3. Job Set-up
SUBTASK 75-35-01-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-35-01-820-002
A. Adjust the "pull only" configuration lever arm stop as follows (Figure 501):
EFFECTIVITY: FJ44-2C
75-35-01
Page 501
Dec 12/17
(2) Remove the retaining ring, roll pin or headed pin (depending on engine configuration) and
remove the ball end of the bleed cable from the lever.
(3) Remove lockwire, loosen the jam nut and loosen the set screw.
(4) Move and hold the lever counter-clockwise toward the set screw until the bleed valve is stopped
internally. This is the closed position.
(5) Adjust the set screw until it touches the lever arm stop. Continue turning it 1/3 turn. Tighten the
jam nut. Torque the jam nut25 to 28 inch-pounds (2.8 - 3.1 N.m) and install lockwire MAT-061.
(6) Install the bleed cable ball end to the lever and secure with retaining clip, roll pin, or headed pin
as applicable to engine configuration. Secure headed pin with MAT-061 lockwire or MAT-063
safety cable and ferrule.
B. Check adjustment of the bleed cable jam nuts to make sure that bleed valve lever is properly adjusted
in the open position. Refer to 75-37-01, P.B. 401
5. Job Close-up
SUBTASK 75-35-01-410-005
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches both the minimum
and maximum stops during the test.
EFFECTIVITY: FJ44-2C
75-35-01
Page 502
Dec 12/17
Fig. 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment
EFFECTIVITY: FJ44-2C
75-35-01
Page 503
Dec 12/17
75-35-01
504
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 401
Figure 402
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 75-37-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 75-37-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-37-01-020-002
(1) Remove one bolt, cover, and spacer from the acceleration bleed port cover.
(2) Remove headed pin, or drive out the roll pin or retaining ring (depending the engine
configuration) which attaches the ball end of the cable to the bleed lever. Discard roll pin.
EFFECTIVITY: FJ44-2C
75-37-01
Page 401
Dec 12/17
(3) Loosen the bleed cable jam nuts and remove the bleed cable from the bracket.
(4) Remove the loop clamp(s) which attach the cable assembly to the rear bypass duct.
(5) Disconnect the jam nut which attaches the cable assembly (outer sheath) to the fuel control
unit (FCU/FDU) boss.
(6) Loosen the jam nut which attaches the inner cable to the FCU/FDU plunger.
(9) Insert a 0.125 inch (3.175 mm) rod through the hole in the plunger to hold it while loosening
jam nut. Disconnect the inner cable from the FCU/FDU plunger.
EFFECTIVITY: FJ44-2C
75-37-01
Page 402
Dec 12/17
Fig. 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
75-37-01
Page 404
Dec 12/17
5. General
This task provides procedures for installing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 403
Figure 404
Figure 405
Figure 406
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-37-01, Fig. 02
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001 engine oil before installation.
SUBTASK 75-37-01-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
MAT-063 Safety Cable, .022 and Ferrule
SUBTASK 75-37-01-943-004
B. Special Tools
Reference Designation
TL37220 Torque Adapter, Air Bleed Cable Nut
SUBTASK 75-37-01-944-004
C. Expendable Parts
EFFECTIVITY: FJ44-2C
75-37-01
Page 405
Dec 12/17
IPC Reference:
Subject Fig. Item Nomenclature
75-35-01 2 80 Roll Pin
SUBTASK 75-37-01-945-004
D. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 75-37-01-420-003
NOTE Route the acceleration bleed cable under the long ignition lead.
SUBTASK 75-37-01-420-002
(1) Install the threaded end of the acceleration bleed cable assembly on the FCU/FDU by inserting
the cable through the mounting boss on the FCU/FDU connection. One jam nut and washer
should be on the aft side of the boss. Install the other jam nut and washer on forward side of
the boss. Do not tighten jam nuts at this time.
NOTE To install the cable, turn the plunger, rather than the cable.
(2) Install inner cable in HMU/IFCU as follows: Thread the inner cable, with jam nut installed, into
the plunger by turning the plunger until inner cable bottoms in the plunger. Insert a 0.125-inch
(3.175 mm) rod through the hole in the plunger to hold it while torquing jam nut. Using torque
adapter TL37220, torque the inner cable jam nut 15 to 20 inch-pounds (1.6 to 2.2 N.m).
(3) Install inner cable in FDU as follows: Thread the inner cable, with jam nut installed, into the
FDU plunger by turning the plunger until inner cable bottoms in the plunger. hold the plunger
with a 7/32 inch open wrench while torquing jam nut. Using torque adapter TL37220, torque
the inner cable jam nut 16 to 19 inch-pounds (1.8 to 2.1 N.m).
EFFECTIVITY: FJ44-2C
75-37-01
Page 406
Dec 12/17
(4) Pull the plunger rod to the full aft position. Adjust the two outer cable jam nuts so that the
threaded end of the outer cable is 0.125 to .250 inch (3.175 to 6.35 mm) from the inner cable
jam nut. Position cable straight back from fuel control unit. This will prevent misalignment
between the plunger and the cable end. Torque both outer cable jam nuts 85 to 95 inch-pounds
(9.6 - 10.7 N.m).
(5) Install ball end of cable to the bleed valve lever. Secure cable by one of the following means,
as applicable to engine configuration (check IPC, 75-35-01):
(a) Install headed pin and secure with MAT-061 safety wire or MAT-063 safety cable and
ferrules. Refer to Figure 405 for safety wire method.
(b) Install new roll pin (verifying tight fit of pin upon insertion).
(6) Loosen cable jam nuts and install cable in slot on bleed valve cover bracket. Adjust jam nuts as
follows to achieve proper tension on bleed valve lever when it is in the open position:
(a) With jam nuts loose, spring pressure will force the forward stop of the bleed lever against
the adjustment post (bleed valve is in open position).
(b) Tighten rear jam nut so that cable assembly moves aft and pulls the forward stop of
the bleed lever away from the adjustment post. Gap between the bleed lever and the
adjustment post must be 0.050 to 0.070 inch (1.27 to 1.77 mm) .
(7) Install spacer and cover onto bleed port cover post. Install other end of cover into slot in bleed
cable bracket. Secure cover with one bolt. Torque bolt 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(8) Connect the loop clamp(s) at the rear bypass duct flange and torque bolt 49 to 55 inch-pounds
(5.5 to 6.2 N.m).
8. Job Close-up
SUBTASK 75-37-01-410-004
EFFECTIVITY: FJ44-2C
75-37-01
Page 407
Dec 12/17
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever reaches the minimum and
maximum stops during test.
EFFECTIVITY: FJ44-2C
75-37-01
Page 408
Dec 12/17
Fig. 404 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
75-37-01
Page 410
Dec 12/17
Fig. 405 Acceleration Bleed System Cable - Headed Pin – Safety Wire Method
EFFECTIVITY: FJ44-2C
75-37-01
Page 411
Dec 12/17
EFFECTIVITY: FJ44-2C
75-37-01
Page 412
Dec 12/17
CHAPTER 76
ENGINE CONTROLS
Page 1
76-ENGINE CONTROLS Dec 12/17
Page 2
76-ENGINE CONTROLS Blank
LINE MAINTENANCE MANUAL - FJ44-2C
76-00-00 1 Dec 12/17 76-20-01 501 Dec 12/17 76-20-01 601 Dec 12/17
Chapter 76
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 76
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The speed of the engine is controlled by limiting fuel flow. In the case of an LP shaft separation, the fuel is
shut off to prevent the engine from an overspeed condition.
2. Description
SUBTASK 76-00-00-860-001
Power Lever
B. The power lever is connected to the fuel control unit (FCU) at the power lever input shaft. The
minimum and maximum speed settings are adjusted and set prior to engine installation.
C. The LP shaft trip sensor is connected to the FCU fan/LP shaft separation shutoff valve by a cable that
runs from the LP trip lever housing, located on the rear bypass duct, to the FCU.
3. Operation
SUBTASK 76-00-00-860-003
A. The power lever angle (PLA) setting in the cockpit is mechanically transferred to the FCU by a cable
linkage. The PLA controls the engine speed by limiting the fuel flow from the FCU for any desired
engine speed in the operating range.
B. The LP shaft trip sensor is operated in the event of an LP shaft separation. This event would force
the LP turbines in an aft direction against the LP trip lever. The LP trip lever is connected to a
trigger mechanism on the rear bypass duct. The trigger mechanism, when tripped, pushes the LP
trip sensor cable forward and shuts down the engine by cutting off its fuel. This also prevents an
overspeed condition.
EFFECTIVITY: FJ44-2C
76-00-00
Page 1
Dec 12/17
76-00-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
Do this task whenever the LP shaft trip sensor has been operated or the trip lever requires adjustment.
Refer to the following illustration(s):
Figure 501
Figure 502
Figure 503
Figure 504
Figure 505
Figure 506
Figure 507
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 76-20-01-941-001
A. Standard Equipment
Arbor Press
Depth Micrometer
SUBTASK 76-20-01-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-060 Lockwire, .032
MAT-061 Lockwire, .020
SUBTASK 76-20-01-944-001
C. Expendable Parts
EFFECTIVITY: FJ44-2C
76-20-01
Page 501
Dec 12/17
IPC Reference
Subject Fig. Item Nomenclature
76-20-01 01 230 Gasket, Cable Housing
SUBTASK 76-20-01-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
73-27-01 201 Fuel Control Shutoff Valve - Maintenance Practices
3. Job Set-up
SUBTASK 76-20-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
NOTE Do this task whenever the LP shaft trip sensor has been operated or
the trip lever requires adjustment.
SUBTASK 76-20-01-050-001
(1) Remove two screws and washers which attach the housing cover. Remove the housing cover.
(2) Remove two screws, two washers and two nuts which attach the cable actuator housing to
the LP trip sensor housing.
(3) Remove the cable actuator housing by pulling it away from the trip lever housing.
(4) Remove lockwire from cable jam nuts. Remove the jam nut which attaches the forward end of
the LP trip sensor cable to the fuel control unit.
(5) Remove the cable and the cable actuator housing assembly.
SUBTASK 76-20-01-820-001
EFFECTIVITY: FJ44-2C
76-20-01
Page 502
Dec 12/17
NOTE The coil spring and spring retainer may come out of outer latch.
(1) Remove snap ring from cable actuator housing. Remove outer latch, coil spring, spring
retainer, and inner latch assembly from the cable actuator housing. Do not disassemble inner
latch assembly. If inner latch assembly was disassembled, assemble as follows:
(a) Insert trigger anvil into inner latch. Align hole in anvil with hitch slot in latch and install
spring pin through anvil and latch
(b) Install trigger latch ring (cup end first) over latch and against spring pin.
(c) Insert compression spring over latch. Install retainer over latch. Secure retainer with
external retaining ring.
(2) Twist a piece of lockwire MAT-060 around spring feet of outer latch. Insert spring retainer and
coil spring into outer latch. Put outer latch in an arbor press.
(3) Put inner latch assembly on coil spring in outer latch. Compress coil spring with arbor press.
Twist lockwire loop to compress spring feet of outer latch to fit around the center portion and
inside of inner latch. Compress coil spring until spring feet of outer latch are retained by inner
latch.
(4) Remove loaded latch assembly from arbor press. Remove lockwire.
(5) Install latch assembly into cable actuator housing and secure with snap ring.
SUBTASK 76-20-01-820-002
NOTE Do this task after installing the LP trip lever into the rear housing/rear bypass duct.
The adjustment allows for 0.050 to 0.060 inch (1.27 to 1.52 mm) distance between
the end trip lever and the LP shaft aft end with LP shaft thrusted aft.
(a) Thrust the LP rotary group aft by pushing on the fan rotor. Continue to apply pressure
during adjustment.
EFFECTIVITY: FJ44-2C
76-20-01
Page 503
Dec 12/17
(b) Insert the trigger pin through the trigger pin bushing in the LP trip sensor housing on the
rear bypass duct. Move the trip lever forward and backward to make sure that it does not
bind. Position the trip lever by pulling it radially outward until the pin contacts the top of
the trip lever cup. Look through the witness hole in the bottom of lever cup to ensure
that pin is seated properly.
(c) Remove lockwire on adjustment screw jam nut and loosen jam nut. Turn adjustment
screw until it just touches the trip lever. Do not apply any hand pressure to the lever when
making this adjustment.
(d) Index mark the adjustment screw and turn the screw an additional 1-7/8 turns clockwise
past the point of trip lever contact. Make sure that the adjustment screw is centered on
the lever.
NOTE Total adjustment of screw, following trip lever contact, is not to be less
than 1-3/4 turns or greater than 2 turns (including final adjustment).
A 1-7/8 initial setting allows ± 1/8 turn for final adjustment.
(e) Tighten adjustment screw jam nut. Jam nut will be torqued after final adjustment.
SUBTASK 76-20-01-820-003
NOTE Do this procedure whenever the trigger pin that was removed from the engine
is damaged and/or otherwise replaced. Trigger pins are matched to an engine
and their lengths must be recalculated if any of the following apply:
(a) Using depth micrometer, measure from face of trigger pin anvil to housing flange face.
Record this as L1 dimension. See Figure 506.
EFFECTIVITY: FJ44-2C
76-20-01
Page 504
Dec 12/17
NOTE Make sure that the LP trip lever stop is adjusted correctly.
Refer to Subtask 76-20-01-820-002.
1 Use a depth micrometer with a rod which is close to the diameter of the trigger pin.
2 Measure from the end of the trigger pin bushing to the bottom of the lever cup. Make
sure that the lever and pin are correctly positioned. Record as dimension L2.
(c) Measure from trigger pin bushing to trip lever housing and record as dimension L3.
(f) Grind trigger pin 0.003 - 0.007 inch (0.076 - 0.178 mm) shorter than calculated dimension.
(2) After final assembly and adjustment of trip sensor, measure trigger pin movement through the
witness hole at the bottom of the trip lever cup. Trigger pin end play must be 0.003 - 0.007
inch (0.076 - 0.177 mm). Use a set of feeler gauges which have been modified (ground)
per Figure 505
SUBTASK 76-20-01-420-001
(2) Reset FCU shut-off valve, if required. Refer to 73-27-01, P.B. 201.
(3) If actuator cable has been removed from cable actuator housing, install as follows:
NOTE One of the jam nuts on the actuator cable is a self-locking nut, (MS21083C5),
it should be installed inside the actuator housing.
(a) Remove one jam nut from actuator cable and install threaded outer cable into actuator
housing.
(b) Install jam nut to cable inside actuator housing. Adjust inner jam nut so that three threads
are visible between the end of the outer cable and the jam nut. Tighten outer jam nut to
secure housing and torque 85 to 95 inch-pounds (9.6 to 10.7 N.m). Install lockwire to
jam nut.
(4) Install latch assembly, if not already installed, into cable actuator housing and secure with
snap ring.
EFFECTIVITY: FJ44-2C
76-20-01
Page 505
Dec 12/17
SUBTASK 76-20-01-830-002
(1) Connect the LP trip sensor actuator cable to the FCU as follows:
(a) Ensure the FCU end of cable has two nuts and two washers installed.
(b) Space the washers and nuts approximately one-quarter inch apart to allow the threaded
portion of the cable to slip through the slot in the FCU support boss.
(c) Finger tighten the nuts to secure the cable in the FCU support boss.
2 The actuator plunger in the FCU must be pulled out and held
against its stop while the cable gap is being set.
(d) Push the cable all the way aft so that it is seated in the trip mechanism. Adjust the gap
between the shutoff plunger (in FCU) and the cable to 0.001 - 0.005 inch (0.025 - 0.127
mm).
(e) Torque the jam nut 85 to 95 inch-pounds (23.1 to 25.7 N.m) Lockwire jam nuts to each
other.
SUBTASK 76-20-01-830-003
(1) Install the trigger pin into the bushing of aft LP trip sensor housing. The ground end of the pin
should face the trigger anvil. Make sure that pin is properly seated in the cup of the lever
assembly.
(2) Align and carefully install the cable and actuator housing assembly and gasket on the LP
trip sensor housing.
(3) Attach the housing with two screws, two washers and two nuts. Torque screws 25 to 28
inch-pounds (2.8 to 3.1 N.m).
SUBTASK 76-20-01-210-001
(1) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
EFFECTIVITY: FJ44-2C
76-20-01
Page 506
Dec 12/17
(2) Measure trigger pin movement through the witness hole at the bottom of the trip lever cup.
Trigger pin end play must be 0.003 - 0.007 inch (0.076 - 0.177 mm). Use a set of feeler gauges
which have been modified (ground) per Figure 505
(3) If end play is not within limits, the trip lever adjustment screw may be moved up to ± 1/8 turn. If
end play is still not within limits, the pin length will have to be modified.
(4) After end play measurement is correct, torque adjustment screw jam nut 85 to 95 inch-pounds
(9.6 to 10.7 N.m). Secure the jam nut with lockwire MAT-061.
(5) Align the bolt holes of the housing cover with the bolt holes on the sensor housing. Attach the
housing cover with two screws and two washers.
5. Job Close-up
SUBTASK 76-20-01-430-001
EFFECTIVITY: FJ44-2C
76-20-01
Page 507
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 508
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 509
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 510
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 511
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 512
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 513
Dec 12/17
Fig. 507 LP Shaft Trigger Pin Dimensions – Installed Trigger Pin Dimensions
EFFECTIVITY: FJ44-2C
76-20-01
Page 514
Dec 12/17
1. General
This task contains procedures for checking that the LP shaft trip sensor system is properly rigged. Refer
to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
76-20-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 76-20-01-941-002
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia × 50 Inch
Long
SUBTASK 76-20-01-942-002
B. Consumables
Reference Designation
MAT-089 Sealant, RTV 103
SUBTASK 76-20-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-71 401 Rear Bypass Duct Assy - Removal/Installation
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
EFFECTIVITY: FJ44-2C
76-20-01
Page 601
Dec 12/17
3. Job Set-up
SUBTASK 76-20-01-010-002
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 76-20-01-220-001
(1) Light damage to cable outer sheathing Repair with MAT-089 (RTV sealant)
(2) Shrink tubing pulled away from cable at fuel Apply an AMS-3636 shrink tube splice or
control side. equivalent. Other sizes and colors may be
used as appropriate.
B. Inspect trip lever/LP shaft with a borescope (Flexible, steerable fiberscope, 6mm dia × 50 inch long)
(1) Insert borescope through the center hole in the aft end of the rear housing tail cone.
(2) Move the borescope forward and inspect the LP trip lever/LP shaft. Inspect the trip lever for
signs that it has contacted the LP shaft (rub mark, fretting). If fretting/rub damage is noted,
remove LP trip lever (72-00-71, P.B. 401). Evaluate trip lever in accordance with inspection
criteria (below). Install trip lever and adjust LP sensor in accordance with 76-20-01, P.B. 501.
(a) LP trip lever fretting/rub damage up to Blend damage smooth with minimal
0.012 inch (0.304 mm) deep. material removal.
5. Job Close-up
SUBTASK 76-20-01-410-002
EFFECTIVITY: FJ44-2C
76-20-01
Page 602
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 603
Dec 12/17
6. General
This task checks the trigger pin end play of the LP shaft trip sensor. Refer to the following illustration(s):
Figure 602
Figure 603
SUBTASK 76-20-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
8. Job Set-up
SUBTASK 76-20-01-010-004
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
9. Procedures
SUBTASK 76-20-01-220-002
(1) Remove the two screws and two washers which attach the trip lever housing cover on the
outer bypass duct. Remove the housing cover.
(2) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
EFFECTIVITY: FJ44-2C
76-20-01
Page 604
Dec 12/17
(3) Measure trigger pin movement through the witness hole at the bottom of the trip lever cup.
Trigger pin end play must be 0.003 - 0.007 inch (0.076 - 0.177 mm). Use a set of feeler gauges
which have been modified (ground) per Figure 603. If end play is out-of-limits, adjust LP
shaft trip sensor. Refer to 76-20-01, P.B. 501.
(4) Install the trip lever housing cover and install two screws and washers. Torque the screws 31 to
35 inch-pounds (3.5 to 4.0 N.m).
SUBTASK 76-20-01-410-003
EFFECTIVITY: FJ44-2C
76-20-01
Page 605
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 606
Dec 12/17
EFFECTIVITY: FJ44-2C
76-20-01
Page 607
Dec 12/17
76-20-01
608
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
CHAPTER 77
ENGINE INDICATING
Page 1
77-ENGINE INDICATING Dec 12/17
Page 2
77-ENGINE INDICATING Blank
LINE MAINTENANCE MANUAL - FJ44-2C
77-00-00 1 Dec 12/17 77-12-01 401 Dec 12/17 77-20-02 601 Dec 12/17
77-11-01 401 Dec 12/17 77-12-01 601 Dec 12/17 77-20-04 401 Dec 12/17
77-11-01 601 Dec 12/17 77-20-02 401 Dec 12/17 77-20-04 601 Dec 12/17
Chapter 77
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 77
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
A. The engine indicating system monitors the condition of the engines and transmits this information to
the cockpit.
2. Description
SUBTASK 77-00-00-860-008
Fuel filter electrical indicator switch (delta P); refer to 73-23-01, P.B. 401
Oil filter differential pressure (delta P) indicator; refer to 72-60-02, P.B. 401
B. The gearbox magnetic speed pickup is installed on the gearbox and reads the HP spool speed
through the gearbox. An output frequency of 6741 Hz is produced at maximum HP shaft speed
(100 percent N2).
C. The LP magnetic speed pickup is installed in the interstage housing and measures speed directly
from the LP shaft. The output frequency is 5174 Hz at full rotational speed (100 percent N1).
D. There are six type K ITT probes located in the 1st LP turbine nozzle. All the ITT probes are the same
length. The thermocouple leads are joined and averaged at the electrical connector of the jumper
harness. The averaged temperature is then displayed in the cockpit.
E. The engine vibration pickup(s) (test equipment) is attached to the interstage housing. It measures
vibration levels and sends this data to the vibration analyzer.
EFFECTIVITY: FJ44-2C
77-00-00
Page 1
Dec 12/17
77-00-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task provides procedures for removing the LP magnetic speed pickup assembly. Refer to the
following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
4 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-11-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 77-11-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
77-11-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 77-11-01-020-001
NOTE When reconfiguring the engine for a right or left-hand position, make sure that the pickup
is installed on the outboard side and the plug is installed on the inboard side.
For single-engine aircraft, pickup is installed in the LH side and plug is installed in the
RH side.
(1) Disconnect the electrical connector (N1 SPEED) from the LP magnetic speed pickup, located
on the interstage housing.
(2) Remove screw from clamp and remove pickup and O-ring from interstage housing.
(1) Remove screw from plug and remove plug and O-ring.
EFFECTIVITY: FJ44-2C
77-11-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
77-11-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the LP magnetic speed pickup assembly. Refer to the
following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-11-01, Fig. 01
2 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-11-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 77-11-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-11-01 01 20 O-Ring (2)
SUBTASK 77-11-01-945-002
C. Reference Information
EFFECTIVITY: FJ44-2C
77-11-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 77-11-01-420-001
(2) Install the LP pickup in the outboard port of interstage housing and attach with clamp and
screw. For single-engine aircraft, pickup is installed in the LH side.
(1) Lube O-ring with assembly fluid MAT-011 and install on plug.
(2) Install plug in opposite port of interstage housing and install screw.
EFFECTIVITY: FJ44-2C
77-11-01
Page 405
Dec 12/17
8. Job Close-up
SUBTASK 77-11-01-410-002
SUBTASK 77-11-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-11-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
77-11-01
Page 407
Dec 12/17
77-11-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers visual inspection of the LP magnetic speed pickup assembly.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-11-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-11-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
77-11-01 401 LP Magnetic Speed Pickup Assembly - Removal/Installation
3. Procedures
SUBTASK 77-11-01-020-002
A. Remove the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
SUBTASK 77-11-01-220-001
EFFECTIVITY: FJ44-2C
77-11-01
Page 601
Dec 12/17
SUBTASK 77-11-01-420-001
C. Install the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
4. General
This task performs a resistance check on the LP magnetic speed pickup assembly (single channel).
SUBTASK 77-11-01-941-004
A. Standard Equipment
Ohmmeter
EFFECTIVITY: FJ44-2C
77-11-01
Page 602
Dec 12/17
6. Procedures
SUBTASK 77-11-01-750-001
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
A. Using an ohmmeter at room temperature, check the electrical resistance between the two pins
adjacent to the connector master keyway (pins A and C). Resistance must be between 425 - 575
ohms. Reject pickup if resistance is outside limits.
B. Check for shorts between the pins (A and C) and pickup case. Reject pickup if shorted.
EFFECTIVITY: FJ44-2C
77-11-01
Page 603
Dec 12/17
77-11-01
604
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
TASK 77-12-01-050-801 Remove the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task provides procedures for removing the gearbox (HP) magnetic speed pickup assembly. Refer
to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
4 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-12-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 77-12-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
77-12-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 77-12-01-020-001
(1) Disconnect the electrical connector (N2 SPEED) from the gearbox speed pickup, located
on the gearbox housing.
(2) Remove screw and washer and remove pickup and O-ring from gearbox housing.
EFFECTIVITY: FJ44-2C
77-12-01
Page 402
Dec 12/17
TASK 77-12-01-450-801 Install the Gearbox (HP) Magnetic Speed Pickup Assembly
5. General
This task provides procedures for installing the gearbox (HP) magnetic speed pickup assembly. Refer
to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-12-01, Fig. 01
2 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-12-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 77-12-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-12-01 01 20 O-Ring
SUBTASK 77-12-01-945-002
C. Reference Information
EFFECTIVITY: FJ44-2C
77-12-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 77-12-01-420-001
(1) Lube O-ring with assembly fluid MAT-011 and install on pickup.
(2) Install the gearbox pickup on gearbox housing and attach with screw and washer.
8. Job Close-up
SUBTASK 77-12-01-410-002
SUBTASK 77-12-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-12-01
Page 405
Dec 12/17
TASK 77-12-01-220-801 Visually Inspect the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task covers visual inspection of the gearbox (HP) magnetic speed pickup assembly.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-12-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-12-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
3. Procedures
SUBTASK 77-12-01-020-002
A. Remove the gearbox (HP) magnetic speed pickup assembly. Refer to 77-12-01, P.B. 401.
SUBTASK 77-12-01-220-001
EFFECTIVITY: FJ44-2C
77-12-01
Page 601
Dec 12/17
SUBTASK 77-12-01-420-002
C. Install the gearbox (HP) magnetic speed pickup assembly. Refer to 77-12-01, P.B. 401.
TASK 77-12-01-750-801 Perform Resistance Check on Gearbox (HP) Magnetic Speed Pickup
Assembly (Single Channel)
4. General
This task performs a resistance check on the gearbox (HP) magnetic speed pickup assembly (single
channel).
SUBTASK 77-12-01-941-004
A. Standard Equipment
Ohmmeter
6. Procedures
SUBTASK 77-12-01-750-001
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
A. Using an ohmmeter at room temperature, check the electrical resistance between the two pins
adjacent to the connector master keyway (pins A and C). Resistance must be between 637 and 863
ohms. Reject pickup if resistance is outside limits.
EFFECTIVITY: FJ44-2C
77-12-01
Page 602
Dec 12/17
1. General
This task provides procedures for removing the ITT probes. Refer to the following illustration(s):
Figure 401
Figure 402
2 During removal of parts, group all components together to make assembly easier.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-942-003
A. Consumables
Reference Designation
MAT-005 Oil, Penetrating
SUBTASK 77-20-02-945-010
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 77-20-02-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
77-20-02
Page 401
Dec 12/17
4. Procedures
SUBTASK 77-20-02-050-001
(2) Remove lockwire and remove connector nut from J1 connector. Remove connector from
bracket on front bypass duct.
SUBTASK 77-20-02-050-004
NOTE MAT-005 penetrating oil can be applied to assist in the disassembly of seized ITT probes.
(2) Remove nut which attaches the ITT probe to the low pressure turbine (LPT) nozzle assembly.
Remove probe.
(3) Mark clamp locations. Remove 90° brackets (as required), 10 screws, 10 nuts, and open 10
loop clamps which retain the ITT probe leads.
EFFECTIVITY: FJ44-2C
77-20-02
Page 402
Dec 12/17
Fig. 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
77-20-02
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 404
Dec 12/17
5. General
This task provides procedures to disassemble ITT probe J1 connector. Refer to the following illustration(s):
Figure 403
Figure 404
2 During removal of parts, group all components together to make assembly easier.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-941-010
A. Standard Equipment
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-945-010
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
7. Procedures
SUBTASK 77-20-02-040-010
A. Remove ITT Probe(s) from the engine. Refer to 77-20-02, P.B. 401.
EFFECTIVITY: FJ44-2C
77-20-02
Page 405
Dec 12/17
(7) Remove the ITT probe chromel (white) wire and the alumel (green) wire from the J1 connector
(bayonet type). Mark the location of each pin and color for proper assembly. Use the
M8196914-02 extraction/insertion tool as required.
EFFECTIVITY: FJ44-2C
77-20-02
Page 406
Dec 12/17
Fig. 403 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
77-20-02
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 408
Dec 12/17
8. General
This task provides procedures for assembling the ITT probe J1 connector. Refer to the following
illustration(s):
Figure 405
Figure 406
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
2 Lubricate all threads and contact surfaces of nuts and bolts with
clean engine oil before installation.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-941-011
A. Standard Equipment
Connector Pliers
Strap Wrench
Connector Holding Tools
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
77-20-02 601 Intermediate Turbine Temperature (ITT) Probe - Inspection/Check
EFFECTIVITY: FJ44-2C
77-20-02
Page 409
Dec 12/17
10. Procedures
SUBTASK 77-20-02-420-001
(3) Install the chromel pin (non-magnetic white wire) into the correct receptacle on the J1
connector. Use the M8196914-02 extraction/insertion tool as required:
NOTES: 1 ITT probes, when mounted on engine, are identified by position as they
would be viewed from aft of the engine, looking forward.
EFFECTIVITY: FJ44-2C
77-20-02
Page 410
Dec 12/17
NOTE For reliable assembly of the connector and backshell, it is suggested that
connector holding tools, strap wrench and connector pliers be used.
(b) Place ground ring, adapter, grommet, follower, and strain relief on the cable in sequence
shown. Keep these components at a convenient distance from the end of the cable, so
they will not interfere with subsequent assembly steps.
(c) Extract shield pigtail from individual conductor’s. Tape pigtails to the bundle.
CAUTION MAKE SURE THAT THE TEETH ARE FULLY ENGAGED BETWEEN
THE CONNECTOR AND THE BACKSHELL BEFORE TIGHTENING.
(d) Ensure O-ring is inside the forward portion of backshell, and slide backshell forward to
connector, and tighten securely
(e) Move the four-footed ground ring forward near the rear of the backshell. Untie individual
pigtails, and flare back over ground ring to evenly disperse pigtails through the four
quadrants of the ring. Tie or tape pigtails back to bundle, allowing for approx. 1/2 of
slack, for subsequent step.
(f) Push ground ring forward and into rear of the backshell. Ensure O-ring is on backshell
and thread adapter onto the backshell over the O-ring, providing the shield grounding.
(g) Slide rubber grommet forward into counter bore of adapter. Slide follower onto rear of
grommet.
(h) Engage strain relief with adapter and tighten securely. Tighten strain relief saddles
securely on cable. This will then provide the environmental seal on cable.
(5) Do a resistance check on the J1 harness connector. Refer to 77-20-02, P.B. 601.
(6) Do a continuity check between the ITT connector and case. Refer to 77-20-02, P.B. 601.
EFFECTIVITY: FJ44-2C
77-20-02
Page 411
Dec 12/17
Fig. 405 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
77-20-02
Page 412
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 413
Dec 12/17
11. General
This task provides procedures for installing the ITT probes. Refer to the following illustration(s):
Figure 407
Figure 408
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil MAT-001 before installation.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 77-20-02-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-20-02 01 67 Wrap, Spiral, .250 OD
77-20-02 01 68 Wrap, Spiral, .187 OD
77-20-02 01 69 Tie, Locking Cable
SUBTASK 77-20-02-945-002
C. Reference Information
EFFECTIVITY: FJ44-2C
77-20-02
Page 414
Dec 12/17
13. Procedures
SUBTASK 77-20-02-450-002
(1) Install the ITT probe through the front bypass duct thermocouple access boss and into the
stud on the 1st LP turbine nozzle assembly. The thermocouple passes through a hole in the
ITT probe mounting flange.
(2) Install nut on stud and torque 31 to 35 inch-pounds (3.5 to 3.9 N.m).
(3) Carefully fold the ITT probe wire into a bundle (with no sharp bends) so that the bundle will be
secured by as many loop clamps as possible.
(4) Secure 10 loop clamps with screw and nut. Torque 49 to 55 inch-pounds (5.5 to 6.2 N.m).
Install 90° brackets at marked locations on front bypass duct flange.
(a) Install .187 OD spiral wrap to single strands of ITT wire in areas where wire may come in
contact with one of the ITT bosses on the front bypass duct.
(b) Install .250 OD spiral wrap to multiple strands of ITT wire in areas where wire may come
in contact with one of the ITT bosses on the front bypass duct.
(c) Secure ends of spiral wrap with locking cable ties. Cut excess ends of ties off flush.
EFFECTIVITY: FJ44-2C
77-20-02
Page 415
Dec 12/17
SUBTASK 77-20-02-450-004
B. Install J1 connector into bracket on front bypass duct. Install connector nut (finger tight) and secure
nut with lockwire MAT-061. Connect the harness to J1 connector.
SUBTASK 77-20-02-410-002
SUBTASK 77-20-02-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-20-02
Page 416
Dec 12/17
Fig. 407 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
EFFECTIVITY: FJ44-2C
77-20-02
Page 417
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 418
Dec 12/17
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
3. Job Set-up
SUBTASK 77-20-02-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
77-20-02
Page 601
Dec 12/17
4. Procedures
SUBTASK 77-20-02-020-002
SUBTASK 77-20-02-220-001
(3) Small dents up to 0.150 inch (3.81 mm) Blend down raised material
long x 0.010 inch (0.254 mm) deep. Max
quantity is one per probe.
SUBTASK 77-20-02-420-002
5. Job Close-up
SUBTASK 77-20-02-410-004
SUBTASK 77-20-02-760-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
6. General
EFFECTIVITY: FJ44-2C
77-20-02
Page 602
Dec 12/17
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-941-005
A. Standard Equipment
Thermocouple Adapter
Type K Thermocouple Meter
8. Job Set-up
SUBTASK 77-20-02-020-001
NOTE For the purpose of adjusting an ITT split, short probes may replace mid-length probes,
or be used in conjunction with mid-length probes. Replacement of a mid-length probe
with a short probe can result in an increase of +2.5° C to +3° C for each probe replaced.
SUBTASK 77-20-02-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
9. Procedures
SUBTASK 77-20-02-210-003
B. Using Type K Thermocouple Meter and Thermocouple Adapter as defined in Figure 601, perform the
following checks on each ITT probe.
(1) To find the ambient room temperature, touch the two pins of the thermocouple adapter together
and record the measurement.
EFFECTIVITY: FJ44-2C
77-20-02
Page 603
Dec 12/17
NOTE Do not allow any heat/cold sources to touch the pins as this will give an
invalid measurement. Hold only by the insulation.
(2) Refer to Figure 601 and identify the pin combination on the ITT probe connector and match
the polarity to the thermocouple wires. If testing a single probe, refer to the wire color to
determine polarity.
(3) Measure and record temperature for each probe in the connector. Probe(s) must be within
±5 degrees Fahrenheit of room temperature.
(4) Remove and replace any probe(s) which are outside the allowable range.
SUBTASK 77-20-02-410-005
EFFECTIVITY: FJ44-2C
77-20-02
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 605
Dec 12/17
11. General
SUBTASK 77-20-02-941-006
A. Standard Equipment
Thermocouple Adapter
Type K Thermocouple Meter
Ice Water
SUBTASK 77-20-02-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
13. Procedures
SUBTASK 77-20-02-210-004
A. Using Type K Thermocouple Meter and Thermocouple Adapter as defined in Figure 602, perform the
following checks on each ITT probe.
(1) To find the ambient room temperature, touch the two pins of the thermocouple adapter together
and record the measurement.
NOTE Do not allow any heat/cold sources to touch the pins as this will give an
invalid measurement. Hold only by the insulation.
(2) Refer to Figure 602 and identify the pin combination on the ITT probe connector and match
the polarity to the thermocouple wires. If testing a single probe, refer to the wire color to
determine polarity.
(3) Measure and record temperature for each probe in the connector. Probe(s) must be within
±5 degrees Fahrenheit of room temperature.
EFFECTIVITY: FJ44-2C
77-20-02
Page 606
Dec 12/17
(4) Remove and replace any probe(s) which are outside the allowable range.
(1) To find the temperature of the Ice Water, touch the two pins of the thermocouple adapter
together and immerse in the ice water. Record the measurement.
NOTE Do not allow any heat/cold sources to touch the pins as this will give an
invalid measurement. Hold only by the insulation.
(2) Place probes in ice water. Wait 30 seconds until the probes have properly acclimated to the
environment.
(3) Refer to Figure 602 and identify the pin combination on the ITT probe connector and match
the polarity to the thermocouple wires. If testing a single probe, refer to the wire color to
determine polarity.
(4) Measure and record temperature for each probe in the connector. Probe(s) must be within ±5
degrees Fahrenheit of ice water temperature.
(5) Remove and replace any probe(s) which are outside the allowable range.
SUBTASK 77-20-02-420-010
SUBTASK 77-20-02-410-010
SUBTASK 77-20-02-760-010
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-20-02
Page 607
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 608
Dec 12/17
15. General
This task performs a resistance check on the assembled J1 connector. Refer to the following illustration(s):
Figure 603
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-941-008
A. Standard Equipment
Ohmmeter
SUBTASK 77-20-02-010-008
(2) Open the circuit breakers to isolate the engine electrical supply.
18. Procedures
SUBTASK 77-20-02-210-008
EFFECTIVITY: FJ44-2C
77-20-02
Page 609
Dec 12/17
SUBTASK 77-20-02-410-008
EFFECTIVITY: FJ44-2C
77-20-02
Page 610
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 611
Dec 12/17
20. General
This task performs a resistance check on individual ITT probe(s) which have been removed from the
harness connector. Refer to the following illustration(s):
Figure 604
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-02-941-008
A. Standard Equipment
Ohmmeter
SUBTASK 77-20-02-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
22. Procedures
SUBTASK 77-20-02-210-008
A. This resistance check task is applicable to ITT probes which have been removed from the ITT harness
connector. Refer to 77-20-02, P.B. 401 for removal and disassembly tasks for the ITT J1 connector.
B. ITT probe must be at an ambient temperature range of 55 to 90 degrees F (12.8 to 32.2 degrees
C) to perform this resistance check.
NOTE Make sure that the inner and outer EMI shielding braid material does
not touch the probe wire connector pins.
(1) Check resistance between the green and the white wires. Resistance must be 2.0 to 5.3 Ohms.
EFFECTIVITY: FJ44-2C
77-20-02
Page 612
Dec 12/17
(2) Check resistance between the green wire and the outer EMI braid. Make sure that circuit is
open.
(3) Check resistance between the white wire and the outer EMI braid. Make sure that circuit is
open.
SUBTASK 77-20-02-420-010
D. Assemble and install the ITT probes. Refer to 77-20-02, P.B. 401.
SUBTASK 77-20-02-410-008
SUBTASK 77-20-02-760-010
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-20-02
Page 613
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-02
Page 614
Dec 12/17
1. General
This task provides procedures for removing the ITT jumper harness. Refer to the following illustration:
Figure 401
2 During removal of parts, group all components together to make assembly easier.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-04-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
3. Job Set-up
SUBTASK 77-20-04-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 77-20-04-020-001
EFFECTIVITY: FJ44-2C
77-20-04
Page 401
Dec 12/17
(2) Remove lockwire from bulkhead nut on J2 connector. Remove bulkhead nut and remove
J2 connector from flange-mounted bracket.
(3) Remove two nuts, two washers, and two screws from ITT jumper harness clamp. Remove
clamp.
EFFECTIVITY: FJ44-2C
77-20-04
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-04
Page 403
Dec 12/17
5. General
This task provides procedures for installing the ITT jumper harness. Refer to the following illustration:
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-20-04, Fig. 01
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
4 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-04-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 77-20-04-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
77-20-04 601 Intermediate Turbine Temperature (ITT) Jumper Harness -
Inspection/Check
EFFECTIVITY: FJ44-2C
77-20-04
Page 404
Dec 12/17
7. Procedures
SUBTASK 77-20-04-420-001
(1) Install the ITT jumper harness P1 plug to the ITT probe J1 connector
(2) Install ITT jumper harness clamp, two screws, two washers, and two nuts to secure ITT jumper
harness to bracket on front bypass duct. Torque nuts 25 to 28 inch-pounds (2.8 to 3.1 N.m).
(3) Install jumper harness J2 connector through flange-mounted bracket. Install bulkhead nut and
torque 10 to 20 inch-pounds (1.1 to 2.2 N.m).
(5) Perform resistance check to installed jumper harness. Refer to 77-20-04, P.B. 601.
8. Job Close-up
SUBTASK 77-20-04-410-002
SUBTASK 77-20-04-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
77-20-04
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-04
Page 406
Dec 12/17
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-20-04, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 o’clock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Commerce Twp, Michigan, USA.
3 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-04-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-04-01 201 Electrical Connector Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
3. Job Set-up
SUBTASK 77-20-04-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
77-20-04
Page 601
Dec 12/17
4. Procedures
SUBTASK 77-20-04-220-001
5. Job Close-up
SUBTASK 77-20-04-410-003
SUBTASK 77-20-04-760-003
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
6. General
This task performs a resistance check for the ITT jumper harness. Refer to the following illustration:
Figure 601
2 Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Connector Maintenance, 70-04-01, P.B. 201.
SUBTASK 77-20-04-941-004
A. Standard Equipment
Ohmmeter
EFFECTIVITY: FJ44-2C
77-20-04
Page 602
Dec 12/17
8. Job Set-up
SUBTASK 77-20-04-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
9. Procedures
SUBTASK 77-20-04-750-001
(1) Disconnect the aircraft ITT harness from the jumper harness J2 connector.
EFFECTIVITY: FJ44-2C
77-20-04
Page 603
Dec 12/17
(3) Reject ITT jumper harness if resistance values do not meet limits.
SUBTASK 77-20-04-410-004
EFFECTIVITY: FJ44-2C
77-20-04
Page 604
Dec 12/17
EFFECTIVITY: FJ44-2C
77-20-04
Page 605
Dec 12/17
77-20-04
606
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
CHAPTER 79
OIL
Page 1
79-OIL Dec 12/17
Page 2
79-OIL Blank
LINE MAINTENANCE MANUAL - FJ44-2C
79-00-00 1 Dec 12/17 79-22-01 601 Dec 12/17 79-30-01 401 Dec 12/17
79-21-01 401 Dec 12/17 79-24-01 401 Dec 12/17 79-30-01 601 Dec 12/17
79-21-01 601 Dec 12/17 79-25-01 401 Dec 12/17 79-31-01 401 Dec 12/17
79-22-01 401 Dec 12/17 79-25-01 501 Dec 12/17 79-33-11 401 Dec 12/17
79-22-01 501 Dec 12/17 79-26-01 401 Dec 12/17
Chapter 79
List of Effective Page Blocks
Page 1
Dec 12/17
Chapter 79
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
The oil system provides lubrication for the four main shaft bearings, the accessory gearbox bearings, the
gears and the drive splines. Refer to the following illustration(s):
Figure 1
The oil tank and oil passages are internal to the engine except for one external oil line.
2. Description
SUBTASK 79-00-00-860-011
The lube and scavenge pump is a positive displacement pump. It includes one pressure element and
two scavenge elements contained in a single housing. The inlet to each element is protected by a
wire mesh screen. All inlet and discharge ports are located on the pump mounting flange face to
make pump replacement easier. A pressure relief valve is located in the pump housing. This valve
will keep approximately 130 - 140 psi pressure rise across the lube element under normal operating
temperatures and flow conditions. The regulator valve also protects against over-pressurization.
C. Oil Filter
The oil filter is a disposable cartridge that is housed in an stainless steel bowl that is threaded into the
gearbox housing. It is connected to the pressure pump outlet through drilled passages in the gearbox.
EFFECTIVITY: FJ44-2C
79-00-00
Page 1
Dec 12/17
An oil filter bypass valve is located in the gearbox housing. When differential pressure across the
oil filter approaches the 25 to 30 psid range, the valve opens. This allows oil to flow to the engine
if the filter element becomes totally blocked.
E. Delta P indicator
A filter differential pressure (delta P) indicator is paralleled with the oil filter and bypass valve. As
the bypass valve approaches its opening pressure, the delta P indicator button extends to indicate
excessive filter contamination. The indicator operates at 15 ±3 psid. A thermal lockout prevents the
indicator from operating because of high delta P caused by cold oil.
The oil cooler is a fuel/oil heat exchanger and is made of aluminum. The oil cooler is mounted to
the gearbox and transmits the oil in and out through the mounting flange faces. Fuel travels in and
out through external lines.
Oil level is established by the oil sight glass/and or dipstick on the side of the engine interstage
housing. The tank is internally vented to the forward bearing cavity through a 5 psi pressurizing
valve which, in turn, is vented to the bypass duct via the gearbox air-oil separator. The reservoir
vent valve and bypass duct pressure reference ensure sufficient oil tank pressure for efficient pump
operation at all altitudes.
An oil level sight glass and a gravity type oil filler port fitted with an over-center-lock sealed cap are
provided on the outboard side of the engine. The sight gage is marked with two levels: FULL and
ADD. The oil volume between these levels is approximately 1.0 U.S. quart. The quantity of usable oil
is approximately 2 quarts at 0° installed pitch angle. The oil tank filler port is designed such that the
oil tank cannot be over-filled even if the oil filler port is over-filled.
The oil pressure regulator is located on the upper right side of the interstage housing, near the right
hand oil fill port. It is set at the factory to monitor the main oil pressure of the internal passage which
carries oil to the gearbox. When regulating oil pressure, the regulator returns oil to the oil tank
through a separate internal passage in the interstage housing.
EFFECTIVITY: FJ44-2C
79-00-00
Page 2
Dec 12/17
3. Operation
SUBTASK 79-00-00-860-012
A. The lube oil from the oil tank passes through the a perforated sheet metal screen at the tank exit,
through a screen and magnetic chip collector at the pump inlet, and then through the lube pump
to the main oil filter and oil cooler. The pressure oil is then taken, via a manifold mounted in the oil
tank, to the top of the tank. At this point, an anti-siphon orifice breaks the siphon between the oil
tank and the bearing cavities during an engine shutdown, preventing flooding. The flow is then split
between the gearbox, front bearings and rear bearings. The pressure regulating valve is located at
this point to maintain a stable lube pressure at the lube jets independent of upstream pressure drops
from the oil filter, oil cooler and lines. The oil for the gearbox passes through a last-chance filter and
lubricates the second reduction gear mesh, the lower towershaft spline, and the generator spline.
The remaining gear meshes, splines, and gearbox bearings are splash-lubricated. The oil from the
front bearings passes through last chance filters to jet lubricate the No. 1 and No. 1.5 bearings and
supplies oil for the No. 1 bearing cage damper. The remainder of the front bearing oil passes through
a last chance filter and lubricates the No. 2 bearing with two jets, an underrace supply and damper
film. The towershaft bearings are also jet-lubricated along with the upper towershaft spline and the
first reduction gear mesh. Another oil jet supplies cooling for the HP tieshaft.The oil for the rear
bearings passes through a last-chance filter and jet-lubricates the No. 3 and 4 bearings and supplies
oil for their dampers. The No. 3 bearing is both under-race and external jet-lubricated.
Two scavenge elements are used to provide independent scavenging of rear bearing cavity and
gearbox sumps. The forward bearing cavity drains down the towershaft annulus into the gearbox
scavenge. A screen and a self-sealing magnetic chip collector are located before each scavenge
pump to remove particles from the oil that are large enough to cause damage. Excess air delivered to
the oil reservoir is vented to the front bearing cavity through a pressurizing valve. The bearing cavities
are vented to the engine bypass duct through a breather air-oil separator located in the gearbox.
EFFECTIVITY: FJ44-2C
79-00-00
Page 3
Dec 12/17
EFFECTIVITY: FJ44-2C
79-00-00
Page 4
Dec 12/17
1. General
This task provides procedures for removing the oil filter. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-21-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-05 201 Oil Filter Analysis Program - Maintenance Practices
3. Job Set-up
SUBTASK 79-21-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
79-21-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 79-21-01-020-001
NOTE The oil filter may need to be examined as part of the oil filter analysis program. It
must be protected from contaminants as soon as it is removed.
A. To remove the oil filter, place a suitable container under oil filter bowl to catch residual oil
(approximately 4 fluid ounces).
B. Cut and remove the lockwire from the oil filter bowl (located next to the filter bowl)
SUBTASK 79-21-01-050-002
C. Remove the oil filter bowl using an 8-point (double square) socket wrench or an open end wrench.
SUBTASK 79-21-01-050-003
NOTE The kit for the Oil Filter Analysis program includes an oil filter, O-rings,
freight, analysis, and evaluation.
D. Remove the oil filter and small O-ring. Place filter in the container provided with the Oil Filter Analysis
Kit if it is to be examined as part of the oil filter analysis program. Follow instructions found in the Oil
Filter Analysis Program page block for submitting the oil filter (72–00–05, P.B. 201).
CAUTION USE CAUTION WHEN REMOVING O-RING FROM THE GEARBOX HOUSING.
USE A NON-METALLIC PICK TO AVOID SCRATCHING THE O-RING GROOVE.
EFFECTIVITY: FJ44-2C
79-21-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-21-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the oil filter. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-21-01, Fig. 01
SUBTASK 79-21-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-020 Mineral Spirits
MAT-027 Alcohol, Isopropyl
MAT-060 Lockwire, .032
SUBTASK 79-21-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-21-01 01 20 O-Ring
79-21-01 01 30 Filter, Oil, Disposable
79-21-01 01 40 O-Ring
EFFECTIVITY: FJ44-2C
79-21-01
Page 404
Dec 12/17
SUBTASK 79-21-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
7. Procedures
SUBTASK 79-21-01-420-001
(1) Make sure that the oil filter has an O-ring installed in its ID.
(2) Lube O-ring with assembly fluid (MAT-011) and install in the ID of the gearbox/filter bowl flange.
(3) Inspect the ID of the oil filter for cleanliness. Make sure none of the plastic packaging remains
inside or outside the filter.
(4) Wipe the threads on the oil filter bowl and the oil filter port with a clean cloth to remove excess
oil.
(a) Lubricate the filter bowl threads with 2 or 3 drops of clean engine oil (MAT-001).
(b) Install filter bowl and torque 80 to 100 inch-pounds (9.0 to 11.2 N.m) using an 8-point
(double square) socket wrench.
EFFECTIVITY: FJ44-2C
79-21-01
Page 405
Dec 12/17
NOTE Filter bowl may be safety wired to the adjacent safety wire hole in the
gearbox housing or to the bypass valve spring plug.
SUBTASK 79-21-01-610-001
8. Job Close-up
SUBTASK 79-21-01-410-002
SUBTASK 79-21-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
NOTE Filter bowl may show seepage of excess oil after engine running. Clean
the area with isopropyl alcohol (MAT-027) or mineral spirits (MAT-020)
and monitor for signs of oil leakage.
EFFECTIVITY: FJ44-2C
79-21-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
79-21-01
Page 407
Dec 12/17
79-21-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers visual inspection of the oil filter bowl. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-21-01, Fig. 01
2. Procedures
SUBTASK 79-21-01-220-004
(3) Rounding or damage to wrenching feature Blend to remove raised material and sharp
edges.
EFFECTIVITY: FJ44-2C
79-21-01
Page 601
Dec 12/17
EFFECTIVITY: FJ44-2C
79-21-01
Page 602
Dec 12/17
1. General
This task provides procedures for removing the oil cooler. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-22-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 79-22-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
79-22-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 79-22-01-020-001
WARNINGS: 1 FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL THAT
CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY. CLOTHING WITH
FUEL CONTAMINATION MUST BE THOROUGHLY CLEANED BEFORE BEING
WORN. CONTAINERS SHOULD BE PLACED TO CATCH DRIPPING FUEL.
SUBTASK 79-22-01-050-003
SUBTASK 79-22-01-050-003
B. Remove two fittings and two O-rings from the oil cooler.
SUBTASK 79-22-01-050-004
C. Disconnect and remove three nuts and three washers which attach the oil cooler to the gearbox.
Remove the oil cooler.
NOTE Oil transfer tubes may remain in the gearbox or the oil cooler.
D. Remove the oil transfer tubes from the oil cooler (or gearbox ports).
SUBTASK 79-22-01-870-001
(1) Lube oil coolers are not to be uncapped until immediately before installation to the engine and
are not to be flushed at any time prior to installation.
(2) When oil cooler is removed from the engine it is to be capped (both fuel and oil ports) and
placed in a plastic bag. If a Ziplock® or equivalent bag is not available, then oil cooler may be
placed in a plastic bag and sealed with a non-metallic tie. The use of open bags folded-over is
not acceptable.
NOTE Failure to follow these guidelines may result in internal corrosion of oil cooler.
EFFECTIVITY: FJ44-2C
79-22-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-22-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the oil cooler. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-22-01, Fig. 01
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 79-22-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 79-22-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-22-01 01 40 O-Ring (2)
79-22-01 01 70 O-Ring (4)
SUBTASK 79-22-01-945-002
C. Reference Information
EFFECTIVITY: FJ44-2C
79-22-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 79-22-01-870-001
(1) Lube oil coolers are not to be uncapped until immediately before installation to the engine and
are not to be flushed at any time prior to installation.
(2) When oil cooler is removed from the engine it is to be capped (both fuel and oil ports) and
placed in a plastic bag. If a Ziplock® or equivalent bag is not available, then oil cooler may be
placed in a plastic bag and sealed with a non-metallic tie. The use of open bags folded-over is
not acceptable.
NOTE Failure to follow these guidelines may result in internal corrosion of oil cooler.
SUBTASK 79-22-01-420-001
B. Lube four transfer tube O-rings with Assembly Fluid (MAT-011) and install on two transfer tubes.
D. Install the two transfer tubes in the gearbox oil cooler oil ports.
E. Install the oil cooler, aligning the transfer tubes and the mounting studs. Attach the oil cooler with
three washers and three nuts. Do not tighten nuts at this time.
EFFECTIVITY: FJ44-2C
79-22-01
Page 405
Dec 12/17
SUBTASK 79-22-01-450-006
F. Lube two O-rings with engine oil and install on fittings. Install fitting in FUEL IN and FUEL OUT ports.
Torque fittings 70 to 80 inch-pounds (7.9 to 9.0 N.m).
SUBTASK 79-22-01-450-003
G. Connect and torque the two fuel tubes to the oil cooler ports in accordance with 73-10-01, P.B. 401.
SUBTASK 79-22-01-450-004
H. Torque the three oil cooler mounting nuts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
SUBTASK 79-22-01-610-001
8. Job Close-up
SUBTASK 79-22-01-410-002
SUBTASK 79-22-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-22-01
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
79-22-01
Page 407
Dec 12/17
79-22-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C
1. General
This task covers pressure testing the lube oil cooler to check for leakage between the fuel and oil circuits.
Do this task as required by troubleshooting or scheduled maintenance.
Figure 501
SUBTASK 79-22-01-941-003
A. Standard Equipment
Pressurization Pump/reservoir
SUBTASK 79-22-01-942-003
B. Consumables
Reference Designation
MAT-002 Oil, Preservative
MAT-003 Fuel, Jet A, Jet A-1, or Jet B
MAT-024 Solvent, Dry Cleaning
SUBTASK 79-22-01-945-003
C. Reference Information
CH-SE-SU Pg Block Nomenclature
79-22-01 401 Lube Oil Cooler - Removal/Installation
3. Procedures
SUBTASK 79-22-01-020-002
A. Remove the lube oil cooler from the engine gearbox. Refer to 79-22-01, P.B. 401. Drain oil/fuel
and install clean plastic caps/plugs to keep contamination from entering the lube oil cooler. Leave
adapter fittings installed in fuel ports.
EFFECTIVITY: FJ44-2C
79-22-01
Page 501
Dec 12/17
SUBTASK 79-22-01-780-001
CAUTION MAKE SURE THAT LUBE OIL CIRCUIT PORTS ARE PLUGGED TO
PREVENT ENTRY OF TEST FLUID OR CONTAMINATION.
(1) Service pressurization pump reservoir with one of the approved test fluids listed in table 501
below:
NOTES: 1 Requires flushing of oil cooler after test and filling with fuel or preservative oil.
(2) Fill fuel circuit of lube oil cooler with test fluid.
(3) Attach outlet tube from pressurization pump to FUEL IN port adapter on the oil cooler. Hold
adapter with a back-up wrench and torque tube nut 270 to 300 inch-pounds (30.5 to 33.9 N.m).
(4) Attach drain tube to FUEL OUT port adapter on oil cooler. Hold adapter with a back-up wrench
and torque tube nut 135 to 150 inch-pounds (15.2 to 16.9 N.m).
EFFECTIVITY: FJ44-2C
79-22-01
Page 502
Dec 12/17
(2) Slowly pressurize pump and watch the flow of fluid into the drain container. Tilt lube oil cooler,
as required, to help air bubbles to escape. Reservice pressurization pump/reservoir with
fluid, as required.
(3) When fluid flow is steady with no air bubbles, remove the drain line from the adapter and
install a cap to plug fuel outlet. Hold adapter with a back-up wrench and torque cap 135 to
150 inch-pounds (15.2 to 16.9 N.m).
(1) Install clean tapered cap plugs into lube IN and OUT ports.
(2) Slowly pressurize pump to 100 psig and check for fluid leaks.
(b) If fluid leaks from lube IN or OUT ports during pressurization, reject lube oil cooler.
(3) Increase pressure to 1200 (± 25) psig and leave system pressurized for 2 minutes.
E. Remove inlet line adapter cap from the lube oil cooler. Drain test fluid from lube oil cooler.
F. If distilled water was used as a test fluid, dry lube oil cooler in a 250 degree F oven for 15 minutes.
Fill fuel circuit with fuel or preservative oil.
G. If solvent or distilled water was used as a test fluid, flush fuel circuit of oil cooler with fuel MAT-003
or preservative oil MAT-002.
SUBTASK 79-22-01-420-002
H. Install the lube oil cooler to the engine gearbox. Refer to 79-22-01, P.B. 401.
EFFECTIVITY: FJ44-2C
79-22-01
Page 503
Dec 12/17
EFFECTIVITY: FJ44-2C
79-22-01
Page 504
Dec 12/17
1. General
This task covers general visual inspection of the lube oil cooler.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-22-01, Fig. 01
SUBTASK 79-22-01-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
79-22-01 401 Lube Oil Cooler - Removal/Installation
SUBTASK 79-22-01-942-004
B. Consumables
Reference Designation
MAT-050 Coating, Chemical Conversion (Iridite)
3. Procedures
SUBTASK 79-22-01-020-003
SUBTASK 79-22-01-870-001
(1) Lube oil coolers are not to be uncapped until immediately before installation to the engine and
are not to be flushed at any time prior to installation.
(2) When oil cooler is removed from the engine it is to be capped (both fuel and oil ports) and
placed in a plastic bag. If a Ziplock® or equivalent bag is not available, then oil cooler may be
placed in a plastic bag and sealed with a non-metallic tie. The use of open bags folded-over is
not acceptable.
EFFECTIVITY: FJ44-2C
79-22-01
Page 601
Dec 12/17
NOTE Failure to follow these guidelines may result in internal corrosion of oil cooler.
SUBTASK 79-22-01-220-001
(2) Nicks on cooler body up to 0.025 inch (0.64 Blend smooth to remove raised material
mm) deep (Does not apply to epoxy coated and sharp corners. Touch up chemical
oil cooler) conversion coating (MAT-050)
SUBTASK 79-22-01-420-003
EFFECTIVITY: FJ44-2C
79-22-01
Page 602
Dec 12/17
1. General
This task provides procedures for removing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-24-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-18-01 401 Fuel Control Unit - Removal/Installation
3. Job Set-up
SUBTASK 79-24-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-24-01-020-001
A. Remove the fuel control unit/fuel delivery unit. Refer to 73-18-01, P.B. 401 .
EFFECTIVITY: FJ44-2C
79-24-01
Page 401
Dec 12/17
SUBTASK 79-24-01-020-003
(1) If applicable to engine configuration, remove sensor harness connector from oil debris sensor.
(3) Remove four bolts and four washers which attach the lube and scavenge pump to the gearbox
mounting pad.
(4) Remove the lube and scavenge pump and six O-rings from the gearbox mounting pad.
EFFECTIVITY: FJ44-2C
79-24-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-24-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-24-01, Fig. 01
SUBTASK 79-24-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 79-24-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-24-01 01 40 O-Ring
79-24-01 01 50 O-Ring (5)
SUBTASK 79-24-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-18-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2C
79-24-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 79-24-01-420-001
(1) Lubricate one O-ring with assembly fluid (MAT-011) and install on pump face pilot diameter.
(2) Lubricate five O-rings with assembly fluid and install in ports on the face of the lubrication pump.
(3) Install the lube pump drive shaft into the gearbox. Make sure that the shaft engages the
gearbox drive spline.
(4) Make sure that all the O-rings are in their proper grooves.
(5) Slide the pump until it touches the gearbox pad. Make sure that the screw holes are aligned
with the proper threaded inserts on the gearbox pad.
(6) Install four washers and four bolts. Torque bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(7) If applicable to engine configuration, install sensor harness connector to oil debris sensor.
SUBTASK 79-24-01-420-003
B. Install the fuel control unit/fuel delivery unit. Refer to 73-18-01, P.B. 401.
SUBTASK 79-24-01-610-001
C. Service the engine with oil (MAT-001). Refer to 72-00-03, P.B. 301.
8. Job Close-up
SUBTASK 79-24-01-410-002
SUBTASK 79-24-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-24-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
79-24-01
Page 406
Dec 12/17
1. General
This task provides procedures for removing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-25-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 79-25-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-25-01-050-001
EFFECTIVITY: FJ44-2C
79-25-01
Page 401
Dec 12/17
(1) Cut and remove lockwire attaching the regulating valve to the interstage housing.
(2) Remove the regulating valve and two O-rings from the interstage housing.
EFFECTIVITY: FJ44-2C
79-25-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-25-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-25-01, Fig. 01
SUBTASK 79-25-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 79-25-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-25-01 01 20 O-Ring
79-25-01 01 30 O-Ring
SUBTASK 79-25-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
79-25-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 79-25-01-420-001
(1) Lubricate two O-rings with engine oil (MAT-001) and install on the regulating valve. Install the
large O-ring at the flange and the small O-ring in the O-ring groove at the regulator tip.
(3) Torque the regulating valve 145 to 155 inch-pounds (16.4 - 16.9 N.m). Install lockwire MAT-061
to secure valve to interstage housing.
SUBTASK 79-25-01-610-001
8. Job Close-up
SUBTASK 79-25-01-410-002
SUBTASK 79-25-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-25-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
79-25-01
Page 406
Dec 12/17
1. General
SUBTASK 79-25-01-942-003
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-019 Acetone
MAT-020 Mineral Spirits
MAT-061 Lockwire, .020
SUBTASK 79-25-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
79-25-01 401 Oil Pressure Regulating Valve - Removal/Installation
3. Job Set-up
SUBTASK 79-25-01-010-003
4. Procedures
SUBTASK 79-25-01-820-001
EFFECTIVITY: FJ44-2C
79-25-01
Page 501
Dec 12/17
(2) Start the engine and allow to idle for five minutes. Refer to General Operating Procedures in
71-00-00, P.B. 501. Check main oil temperature. Main oil temperature must be at least 115° F
when adjusting oil pressure. Allow additional idle time, if required.
2 If one turn of adjustment screw yields less than 2 psid in MOP, then the valve
should be repaired in accordance with the overhaul procedure in this task.
(a) Turn the adjustment screw clockwise to increase engine oil pressure.
(b) Turn the adjustment screw counter-clockwise to decrease engine oil pressure.
(5) While holding the adjustment screw, Torque the adjustment locknut 28 to 32 inch-pounds
(3.2 to 3.6 N.m).
(7) Shut-down the engine. Refer to General Operating Procedures in71-00-00, P.B. 501.
SUBTASK 79-25-01-870-001
B. If required, overhaul the oil pressure regulating valve (replace internal O-ring seal) as follows:
EFFECTIVITY: FJ44-2C
79-25-01
Page 502
Dec 12/17
(1) Remove the oil pressure regulating valve from the engine. Refer to 79-25-01, P.B. 401.
(2) Remove the jam nut from oil pressure regulating valve.
(4) Remove the internal spring and the poppet from the valve body.
(5) Remove the O-ring from the adjustment screw. Discard the O-ring.
(6) Clean the adjustment screw, internal spring, poppet and valve body. Clean with vapor degrease
or flush with mineral spirits (MAT-020) or acetone (MAT-019).
(7) Lubricate new O-ring (M83248/1-009) with engine oil (MAT-001) and install to adjustment screw.
(10) Adjust jam nut and adjustment screw until no more than 4 threads protrude past jam nut.
(11) Install the oil pressure regulating valve. Refer to 79-25-01, P.B. 401.
(12) Adjust the oil pressure regulating valve in accordance with the adjustment subtask
(79-25-01-820-001).
5. Job Close-up
SUBTASK 79-25-01-410-003
EFFECTIVITY: FJ44-2C
79-25-01
Page 503
Dec 12/17
EFFECTIVITY: FJ44-2C
79-25-01
Page 504
Dec 12/17
1. General
This task provides procedures for removing the oil supply tube. Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-26-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 79-26-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-26-01-050-001
EFFECTIVITY: FJ44-2C
79-26-01
Page 401
Dec 12/17
(1) Remove bolt and nut from loop clamp(s). Remove loop clamp(s) from oil supply tube assembly.
(2) Remove two screws from oil supply tube flange brackets.
(3) Remove oil supply tube and two O-rings from interstage housing.
EFFECTIVITY: FJ44-2C
79-26-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-26-01
Page 403
Dec 12/17
5. General
This task provides procedures for installing the oil supply tube. Refer to the following illustration(s):
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-26-01, Fig. 01
SUBTASK 79-26-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 79-26-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-26-01 01 20 O-Ring (2)
SUBTASK 79-26-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
79-26-01
Page 404
Dec 12/17
7. Procedures
SUBTASK 79-26-01-420-001
(1) Lubricate two O-rings with engine oil and install on the oil supply tube ends. Install the oil
supply tube into the tube ports in the interstage housing.
(2) Install two screws to the oil supply tube flange brackets. Torque screws 31 to 35 inch-pounds
(3.5 to 4.0 N.m).
(3) Install the loop clamp, bolt, and nut to the flange bracket. Torque nut 49 to 55 inch-pounds
(5.5 to 6.2 N.m). Install loop clamp to sight glass flange (if applicable). Torque bolt 29 to
35 inch-pounds (3.2 to 3.9 N.m).
SUBTASK 79-26-01-610-001
B. Service the engine with oil MAT-001. Refer to 72-00-03, P.B. 301.
8. Job Close-up
SUBTASK 79-26-01-410-002
SUBTASK 79-26-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-26-01
Page 405
Dec 12/17
EFFECTIVITY: FJ44-2C
79-26-01
Page 406
Dec 12/17
1. General
This task contains procedures for removal of the chip collector assembly installed in the gearbox housing
and/or either of the chip collectors on the lube and scavenge pump as applicable to engine configuration.
Refer to the following illustration(s):
Figure 401
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-30-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
79-30-01 601 Magnetic Chip Collector - Inspection/Check
3. Job Set-up
SUBTASK 79-30-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
79-30-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 79-30-01-020-001
NOTE To inspect the magnetic chip collectors for metal particles, only the self-closing
magnetic valve plug need be removed. Refer to 79-30-01, P.B. 601.
SUBTASK 79-30-01-050-001
A. Remove the TANK DRAIN magnetic chip collector (if applicable) from the lube and scavenge pump
as follows:
(1) Vent oil tank by removing oil fill cap (or dipstick).
(2) Remove safety wire from the chip collector fitting at the bottom rear of the lube pump (labeled
TANK DRAIN).
(3) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(4) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
SUBTASK 79-30-01-050-002
B. Remove the SCAV magnetic chip collector from the lube and scavenge pump as follows:
(1) Remove safety wire from the chip collector fitting at the bottom front of the lube pump (labeled
SCAV).
(2) Remove chip collector fitting/self-closing plug assembly and let residual oil drain into a clean
container.
(3) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
EFFECTIVITY: FJ44-2C
79-30-01
Page 402
Dec 12/17
C. Remove the magnetic chip collector from the gearbox housing, if engine is so equipped, as follows:
NOTE If engine is equipped with an electrical oil debris sensor in the gearbox housing
port, rather than a magnetic chip collector, refer to 79-30-02.
(1) Remove safety wire from the chip collector fitting at the bottom of the gearbox housing.
(2) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(3) If required by scheduled maintenance, remove oil screen from gearbox housing, as follows:
EFFECTIVITY: FJ44-2C
79-30-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
79-30-01
Page 404
Dec 12/17
5. General
This task contains procedures for installation of the chip collector assembly installed in the gearbox housing
or either/both of the chip collectors on the lube and scavenge pump, as applicable to engine configuration.
Figure 402
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 79-30-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-30-01 01 60 O-Ring (3)
79-30-01 01 55 O-Ring (3)
79-30-01 01 48 O-Ring (2)
SUBTASK 79-30-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
79-30-01
Page 405
Dec 12/17
7. Procedures
SUBTASK 79-30-01-420-002
A. Install any of the magnetic chip collectors to the lube and scavenge pump or the gearbox as follows:
NOTE If engine is equipped with an electrical oil debris sensor in the gearbox housing
port, rather than a magnetic chip collector, refer to 79-30-02.
(a) Lubricate O-ring with engine oil and install on oil screen.
(c) Install one bolt and one washer. Torque bolt 46 to 51 inch-pounds (5.2 to 5.7 N.m) .
(b) Install oil screen into lube pump housing. Torque oil screen 150 to 250 inch-pounds
(16.9 to 28.2 N.m).
(4) Lubricate new O-ring with engine oil MAT-001 and install on chip collector fitting. Install chip
collector fitting into lube and scavenge pump or gearbox housing. Torque chip collector fittings
50 to 60 inch-pounds (5.6 - 6.7 N.m).
SUBTASK 79-30-01-610-001
8. Job Close-up
SUBTASK 79-30-01-410-002
EFFECTIVITY: FJ44-2C
79-30-01
Page 406
Dec 12/17
SUBTASK 79-30-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-30-01
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
79-30-01
Page 408
Dec 12/17
1. General
This task contains procedures for checking the magnetic chip collectors and/or magnetic plug on the oil
debris sensors. There are chip collectors in the gearbox and/or the lube and scavenge pump, depending
on engine configuration. They detect metal particles in the 1/2 bearing scavenge and the 3/4 bearing
scavenge. The magnetic plugs must be visually inspected at specified intervals of engine operating
hours. Refer to the following illustration(s):
Figure 601
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-05 201 Oil Filter Analysis Program - Maintenance Practices
79-21-01 401 Oil Filter - Removal/Installation
3. Job Set-up
SUBTASK 79-30-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
79-30-01
Page 601
Dec 12/17
4. Procedures
SUBTASK 79-30-01-210-001
NOTE Self-closing magnetic valve plugs do not require tools to remove or install.
(1) Remove the self-closing magnetic valve plug by turning counter-clockwise 1/6 turn.
(b) Small hair-like slivers of steel or fine dust around the magnet. This condition usually
applies to engines which are new/repaired or overhauled with low hours. This condition
would not represent internal failure or impending failure of the engine
(c) Large sized particles. This condition does not always represent internal failure of the
engine since the particles could have originated in the fabrication or build-up of the
engine. Collect particles from the magnet for further analysis. Make sure that sample is
not contaminated during the collection process. Use a clean plastic bag and mark sample
with engine S/N, chip collector location, and date. Photo document particles and contact
a Williams International representative for further evaluation and disposition.
2 Submit the oil filter element for analysis. Refer to 72-00-05, P.B. 201.
(3) Inspect the O-ring on the magnetic plug and replace if necessary.
(4) Install the magnetic plug into the valve by pushing and turning clockwise until you feel it lock in
place.
(5) Inspect the valve for leaks after installation. No leaks are allowed.
EFFECTIVITY: FJ44-2C
79-30-01
Page 602
Dec 12/17
(e) Perform engine testing per the table Tests Required after Maintenance or Component
Replacement (List of Test Procedures) in 71-00-00, P.B. 501.
1 If the engine testing results in almost the same or larger quantity of metal particles,
reject the engine.
2 If there are no particles on the magnetic plug, examine the plug after the next flight
for metal particles.
SUBTASK 79-30-01-610-002
5. Job Close-up
SUBTASK 79-30-01-410-003
EFFECTIVITY: FJ44-2C
79-30-01
Page 603
Dec 12/17
EFFECTIVITY: FJ44-2C
79-30-01
Page 604
Dec 12/17
1. General
This task covers removal of both the oil filler cap and dipstick assembly and removal of the filler port plug
assembly (if the engine is so equipped). Refer to the following illustration(s):
Figure 401
Figure 402
2 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-31-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
3. Job Set-up
SUBTASK 79-31-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2C
79-31-01
Page 401
Dec 12/17
4. Procedures
SUBTASK 79-31-01-020-001
A. Remove the oil filler cap and dipstick assembly by lifting up the locking tab and turning counter
clockwise.
SUBTASK 79-31-01-020-002
NOTE The filler port plug assembly may be located on the inboard oil filler port,
instead of a oil filler cap and dipstick assembly.
(1) Remove safety wire and loosen (but do not remove) wing nut on plug assembly.
(2) Turn plug assembly and remove from oil fill port.
EFFECTIVITY: FJ44-2C
79-31-01
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-31-01
Page 403
Dec 12/17
EFFECTIVITY: FJ44-2C
79-31-01
Page 404
Dec 12/17
5. General
This task covers installation of both the oil filler cap and dipstick assembly and installation of the filler
port plug assembly (if the engine is so equipped).
Figure 403
Figure 404
Figure 405
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-31-01, Fig. 01
SUBTASK 79-31-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-061 Lockwire, .020
SUBTASK 79-31-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-31-01 01 20 O-Ring
79-31-01 01 50 O-Ring
79-31-01 01 60 O-Ring
SUBTASK 79-31-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
EFFECTIVITY: FJ44-2C
79-31-01
Page 405
Dec 12/17
7. Procedures
SUBTASK 79-31-01-420-001
NOTE The oil filler cap and dipstick assembly must be installed on the
outboard side of the engine.
(1) Inspect the O-ring on the oil filler cap and dipstick assembly for damage. Replace if damaged.
(2) Insert the oil filler cap and dipstick assembly into the oil filler port. To avoid binding, rotate
the dipstick on the filler port plug so the offset bend faces aft of the engine. Lock by turning
clockwise and folding down locking tab. Refer to Figure 405.
SUBTASK 79-31-01-420-002
(2) Lube small O-ring with MAT-011 assembly fluid and install on shaft.
(3) Lube large O-ring with assembly fluid and install on cap
(4) Install cap on the shaft and secure with wing nut.
NOTE The filler port plug assembly must be installed on the inboard side of the engine.
(1) Loosen the wing nut on the shaft so that the two tangs on the underside of the cap are just
engaging the slots in the shaft.
(2) Insert the plug assembly into the filler port. Turn cap/shaft assembly to engage lock plate in
the filler port slot. Tighten wing nut.
8. Job Close-up
SUBTASK 79-31-01-410-002
EFFECTIVITY: FJ44-2C
79-31-01
Page 406
Dec 12/17
SUBTASK 79-31-01-450-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-31-01
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
79-31-01
Page 408
Dec 12/17
EFFECTIVITY: FJ44-2C
79-31-01
Page 409
Dec 12/17
EFFECTIVITY: FJ44-2C
79-31-01
Page 410
Dec 12/17
1. General
This task covers removal of both the oil level sight glass and the sight glass cover plate blank from the
interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 401
SUBTASK 79-33-11-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Job Set-up
SUBTASK 79-33-11-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the engine cowling.
SUBTASK 79-33-11-610-001
EFFECTIVITY: FJ44-2C
79-33-11
Page 401
Dec 12/17
4. Procedures
SUBTASK 79-33-11-020-009
A. Remove the oil sight glass from the interstage housing as follows:.
(1) Remove eight bolts which retain cover plate. Remove cover plate, gasket, sight glass, and
O-ring from the interstage housing port. Cover the sight glass port in the interstage housing.
SUBTASK 79-33-11-020-010
B. Remove the cover plate blank from the interstage housing as follows (if engine is so equipped):
(1) Remove eight bolts, oil supply tube loop clamp, and the cover plate heatshield.
(2) Remove the cover plate blank from the interstage housing. Cover the sight glass port in the
interstage housing.
EFFECTIVITY: FJ44-2C
79-33-11
Page 402
Dec 12/17
EFFECTIVITY: FJ44-2C
79-33-11
Page 403
Dec 12/17
5. General
This task covers installation of both the oil level sight glass and the sight glass cover plate blank onto
the interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 402
Figure 403
SUBTASK 79-33-11-942-005
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 79-33-11-944-005
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-33-11 02 20 O-Ring
79-33-11 02 40 Gasket
SUBTASK 79-33-11-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2C
79-33-11
Page 404
Dec 12/17
7. Procedures
SUBTASK 79-33-11-420-002
A. Install the oil sight glass onto the interstage housing as follows (Figure 402):
NOTE Sight glass must be installed on the outboard side of the engine.
(1) Replace O-ring and gasket. Visually inspect O-ring, gasket, sight glass, and cover plates for
damage prior to installation.
(2) Assemble the sight glass, gasket, and cover plate. Make sure that the chamfer on the cover is
facing out and up and the glass is assembled smooth side out. Lube the O-ring with assembly
fluid (MAT-011) and install on back (grooved) side of glass.
(3) Install assembled sight glass on interstage housing and secure with eight bolts. Install oil
supply tube loop clamp and secure with lower left-hand bolt. Torque bolts 29 to 35 inch pounds
(3.2 to 3.9 N.m), in 7 to 8 inch-pound (0.79 to 0.90 N.m) steps, in the sequence pattern shown
on Figure 403.
SUBTASK 79-33-11-420-003
B. Install the cover plate blank onto the interstage housing as follows (if engine is so equipped) (Figure
402):
NOTE Cover plate blank must be installed on the inboard side of the engine.
(1) Inspect the seal on the cover plate blank for damage. If damaged, replace cover plate blank.
(2) Install the cover plate blank and the cover plate heatshield to the interstage housing. Make
sure that the gasket side of the plate is facing in towards the interstage housing and the
chamfer is facing out.
(3) Install eight bolts and torque to 29 to 35 inch-pounds (3.2 to 3.9 N.m) in the sequence pattern
shown on Figure 403.
8. Job Close-up
SUBTASK 79-33-11-610-002
NOTE Carefully service oil to prevent oil from getting trapped between cover plate/interstage
or cover plate/sight glass. Small amounts of oil wicked into crevices may give false
indication of leakage (wetness only, no droplets forming) after engine has been run.
EFFECTIVITY: FJ44-2C
79-33-11
Page 405
Dec 12/17
SUBTASK 79-33-11-410-005
SUBTASK 79-33-11-760-001
C. Perform engine testing as required by List of Test Procedures in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2C
79-33-11
Page 406
Dec 12/17
EFFECTIVITY: FJ44-2C
79-33-11
Page 407
Dec 12/17
EFFECTIVITY: FJ44-2C
79-33-11
Page 408
Dec 12/17
79-33-11
409
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