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FJ44-2C
LINE MAINTENANCE MANUAL
- FJ44-2C

Initial Issue:
Jul 01/00

WI P/N 64135
Revision 42

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

SUMMARY OF CHANGES
FJ44-2C Line Maintenance Manual - FJ44-2C
P/N 64135

TRANSMITTAL LETTER No. 42


Remove Insert CH-SEC- Task Number Task Title
Page Page SUB Description of Change
Block Block
101 101 71-00-00 71-00-00-810-801 Power Plant - Troubleshooting
Revised Starter/Generator and/or Auxiliary
Generator Failure troubleshooting to add sheet 2
inspection photographs and to require leak check
ground run at max continuous power.
101 101 71-00-00 71-00-00-810-801 Power Plant - Troubleshooting
Corrected IP compressor inspection task reference
in engine shock load troubleshooting.
501 501 71-00-00 71-00-00-760-808 List of Test Procedures
Replaced line item for oil filler cap and dipstick with
oil filler port plug assembly.
501 501 71-00-00 71-00-00-760-808 List of Test Procedures
Added Routine Periodic Inspection section to table
of Tests Required after Maintenance or Component
Replacement.
501 501 71-00-00 71-00-00-760-811 Idle Speed and Leak Check Run
Revised limits chart for Ground Idle N2 Speed
Check
501 501 71-00-00 71-00-00-760-811 Idle Speed and Leak Check Run
Clarified instruction to disengage ignition circuit
breaker during fuel purge procedure.
501 501 71-00-00 71-00-00-760-819 Stability/Acceleration Check
Added instruction to adjust fuel control unit
acceleration control to the maximum internal stop.
501 501 71-00-00 71-00-00-760-824 Performance Check
Revised limits chart for Ground Idle N2 Speed
Check.
501 501 71-00-00 71-00-00-760-826 High Power Check
Revised limits chart for Ground Idle N2 Speed
Check.

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

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.

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

TABLE OF CONTENTS

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

RECORD OF REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

INTRODUCTION

MANUAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00-00


Manual Introduction - Description and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

TIME LIMITS/MAINTENANCE CHECKS

AIRWORTHINESS LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-10-00


Airworthiness Limitations - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

SERVICE LIFE TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-12-00


Service Life Tracking - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

UNSERVICEABLE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17-10


Unserviceable Parts - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

SCHEDULED MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . 05-20-00


Scheduled Maintenance Checks -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

RECOMMENDED MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 05-50-00


Recommended Maintenance - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

STANDARD PRACTICES

ASSEMBLY/DISASSEMBLY MAINTENANCE
PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-00-01
Assembly/Disassembly Maintenance
Practices - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

TEMPORARY MARKING OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . 70-01-05


Temporary Marking of Parts - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

MARKING OF REPAIRED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01-07

Page i
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

Marking of Repaired Parts - Maintenance


Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

MISUSE OF MOLYBDENUM DISULFIDE


LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01-11
Misuse of Molybdenum Disulfide Lubricants
- Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

IDENTIFICATION, LUBRICATION, AND FITTING OF


O-RING SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-02-01
Identification, Lubrication, and Fitting of
O-ring Seals - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

ELECTRICAL CONNECTOR MAINTENANCE . . . . . . . . . . . . . . . . . 70-04-01


Electrical Connector Maintenance -
Maintenance Practice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

CONSUMABLE MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-01


Consumable Materials - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

CONTAMINATION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . 70-12-00


Contamination of Engine Components -
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

LOCKING TECHNIQUES FOR THREADED PARTS . . . . . . . . . . . . 70-12-04


Locking Techniques for Threaded Parts -
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

CLEANING METHODS AND PROCEDURES . . . . . . . . . . . . . . . . . . 70-21-00


Cleaning Methods and Procedures -
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701

BALL AND ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-31-01


Ball and Roller Bearing - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

CARBON SEAL SURFACE QUALITY . . . . . . . . . . . . . . . . . . . . . . . . 70-33-01


Carbon Seal Surface Quality -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

REPAIR SURFACES AFFECTED BY MINOR


DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42-11
Repair Surfaces Affected by Minor Damage
- Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

LOCAL SURFACE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42-12


Local Surface Protection - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

Page ii
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

NON-DESTRUCTIVE INSPECTION (NDI) METHODS . . . . . . . . . . . 70-42-15


Non-Destructive Inspection (NDI) Methods
- Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

TORQUE TIGHTENING TECHNIQUE . . . . . . . . . . . . . . . . . . . . . . . . 70-51-00


Torque Tightening Technique - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-53-00


Special Tools - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

STORAGE OF PARTS THAT HAVE SHELF LIFE


LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-61-01
Storage of Parts that have Shelf Life Limits
- Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

POWER PLANT

POWER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-00


Power Plant - Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Power Plant - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Power Plant - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Power Plant - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

POWER PLANT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-03


Power Plant Cleaning - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701

PRESERVING UNINSTALLED ENGINE . . . . . . . . . . . . . . . . . . . . . . 71-00-21


Preserving Uninstalled Engine -
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

PRESERVING INSTALLED ENGINE FOR NINE MONTHS


OR MORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-22
Preserving Installed Engine for Nine
Months or More - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

PRESERVING INSTALLED ENGINE FOR NINE MONTHS


OR LESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-23
Preserving Installed Engine for Nine
Months or Less - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

STORAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-24


Storage Inspection - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

Page iii
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

ENGINE SHIPPING/RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-25


Engine Shipping/Receiving - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

ENGINE DEPRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-26


Engine Depreservation - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

IP AND HP COMPRESSORS (BORESCOPE) . . . . . . . . . . . . . . . . . 71-00-30


IP and HP Compressors (Borescope) -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

INTERNAL OIL LEAK (BORESCOPE) . . . . . . . . . . . . . . . . . . . . . . . 71-00-32


Internal Oil Leak (Borescope) -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

COMBUSTOR, FUEL SLINGER, AND HP TURBINE


BLADES LEADING EDGE (BORESCOPE) . . . . . . . . . . . . . . . . . . . . 71-00-40
Combustor, Fuel Slinger, and HP Turbine
Blades Leading Edge (Borescope) -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

LP TURBINES (BORESCOPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-50


LP Turbines (Borescope) -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

HP NOZZLE/HP TURBINE TRAILING EDGE AND 1ST LP


TURBINES LEADING EDGE (BORESCOPE) . . . . . . . . . . . . . . . . . . 71-00-52
HP Nozzle/HP Turbine Trailing Edge and
1st LP Turbines Leading Edge (Borescope)
- Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

ENGINE

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-00
Engine - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

APPROVED ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-01


Approved Engine Fuel - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

ENGINE SERVICING — OIL


CHANGING/REPLENISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-03
Engine Servicing - Oil
Changing/Replenishing - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

OIL FILTER ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-05

Page iv
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

Oil Filter Analysis Program - Maintenance


Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-30
Spinner - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

FAN ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-31


Fan Rotor - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

CASE AND INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-32


Case and Insert Assy - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-60


Gearbox Assy - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

REAR BYPASS DUCT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-71


Rear Bypass Duct Assy -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

INTERNAL COOLING AND SEALING AIR SYSTEM . . . . . . . . . . . . 72-02-00


Internal Cooling and Sealing Air System -
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-30-10
Spinner - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Spinner - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

SPINNER PILOT PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 72-31-15


Spinner Pilot Plate Assy - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

FAN ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-31-20


Fan Rotor - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Fan Rotor - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

CASE AND INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-32-10


Case and Insert Assembly -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Case and Insert Assembly - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

FAN STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-32-20


Fan Stator - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Fan Stator - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

LP SHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-35-22


LP Shaft Assembly - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

Page v
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

GEARBOX CARBON SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-60-01


Gearbox Carbon Seals -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

OIL FILTER DIFFERENTIAL PRESSURE (DELTA P)


INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-60-02
Oil Filter Differential Pressure (Delta P)
Indicator - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Oil Filter Differential Pressure (Delta P)
Indicator - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

REAR BYPASS DUCT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 72-71-10


Rear Bypass Duct Assy - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

REAR MOUNTING RING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 72-71-20


Rear Mounting Ring Assy -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

ENGINE FUEL AND CONTROL

FUEL SYSTEM (DESCRIPTION AND OPERATION) . . . . . . . . . . . . 73-00-00


Fuel System - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FUEL TUBE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-10-01


Fuel Tube Assemblies -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Fuel Tube Assemblies - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

FUEL DRAIN TUBE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . 73-11-01


Fuel Drain Tube Assemblies -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

FUEL NOZZLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-12-01


Fuel Nozzle Assembly -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Fuel Nozzle Assembly - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

FUEL PUMP FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-14-01


Fuel Pump Filter - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

FUEL CONTROL SYSTEM – DESCRIPTION AND


OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-18-00

Page vi
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

Fuel Control System - Description and


Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

FUEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-18-01


Fuel Control Unit - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Fuel Control Unit - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
Fuel Control Unit - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

FUEL FILTER INDICATOR (DELTA P SWITCH) . . . . . . . . . . . . . . . 73-23-01


Fuel Filter Indicator (Delta P Switch) -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Fuel Filter Indicator (Delta P Switch) -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

FUEL MANIFOLD FILTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-25-01


Fuel Manifold Filter Assy -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

FUEL CONTROL SHUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 73-27-01


Fuel Control Shutoff Valve - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

IGNITION

IGNITION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 74-00-00


Ignition System - Description and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-00-10


Ignition System - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

IGNITION EXCITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-10-01


Igniton Exciter - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

IGNITER LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-20-01


Igniter Lead - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Igniter Lead - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

IGNITER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-22-01


Igniter Plug - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Igniter Plug - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Igniter Plug - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701

AIR

AIR SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-00-00

Page vii
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

Air System - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

ACCELERATION BLEED SYSTEM LINKAGE . . . . . . . . . . . . . . . . . 75-30-01


Acceleration Bleed System Linkage -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

ACCELERATION BLEED SYSTEM LEVER . . . . . . . . . . . . . . . . . . . 75-35-01


Acceleration Bleed System Lever -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Acceleration Bleed System Lever -
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

ACCELERATION BLEED SYSTEM CABLE . . . . . . . . . . . . . . . . . . . 75-37-01


Acceleration Bleed System Cable -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

ENGINE CONTROLS

ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-00-00


Engine Controls - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LP SHAFT TRIP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-20-01


LP Shaft Trip Sensor - Adjustment/Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
LP Shaft Trip Sensor - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

ENGINE INDICATING

ENGINE INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-00-00


Engine Indicating - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

LP MAGNETIC SPEED PICKUP ASSEMBLY . . . . . . . . . . . . . . . . . . 77-11-01


LP Magnetic Speed Pickup Assembly -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
LP Magnetic Speed Pickup Assembly -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

GEARBOX (HP) MAGNETIC SPEED PICKUP


ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-12-01
Gearbox (HP) Magnetic Speed Pickup
Assembly - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Gearbox (HP) Magnetic Speed Pickup
Assembly - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

Page viii
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

INTERMEDIATE TURBINE TEMPERATURE (ITT) . . . . . . . . . . . . . . 77-20-02


Intermediate Turbine Temperature (ITT)
Probe - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Intermediate Turbine Temperature (ITT)
Probe - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

INTERMEDIATE TURBINE TEMPERATURE (ITT) JUMPER


HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-20-04
Intermediate Turbine Temperature (ITT)
Jumper Harness - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Intermediate Turbine Temperature (ITT)
Jumper Harness - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

OIL

OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-00-00


Oil System - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-21-01


Oil Filter - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Oil Filter - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

LUBE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-22-01


Lube Oil Cooler - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Lube Oil Cooler - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
Lube Oil Cooler - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

LUBE AND SCAVENGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-24-01


Lube and Scavenge Pump -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

OIL PRESSURE REGULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . 79-25-01


Oil Pressure Regulating Valve -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Oil Pressure Regulating Valve -
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501

OIL SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-26-01


Oil Supply Tube - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

MAGNETIC CHIP COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-30-01


Magnetic Chip Collector -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Magnetic Chip Collector - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601

Page ix
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE

OIL FILLER CAP AND DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-31-01


Oil Filler Cap and Dipstick -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

OIL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-33-11


Oil Sight Glass - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401

Page x
Table of Contents Dec 12/17

© 2017 Williams International Co., LLC


All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairman’s responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
LINE MAINTENANCE MANUAL - FJ44-2C

RECORD OF REVISIONS

Revision 1 Apr 15/02


Revision 2 Aug 01/04
Revision 3 Oct 30/04
Revision 4 Jan 14/05
Revision 5 Apr 15/05
Revision 6 Aug 19/05
Revision 7 Dec 05/05
Revision 8 Feb 15/06
Revision 9 Jul 05/06
Revision 10 Dec 01/06
Revision 11 Apr 17/07
Revision 12 Sep 04/07
Revision 13 Dec 01/07
Revision 14 Apr 11/08
Revision 15 Aug 12/08
Revision 16 Dec 04/08
Revision 17 Apr 24/09
Revision 18 Dec 2/09
Revision 19 May 20/10
Revision 20 Nov 15/10
Revision 21 Jun 01/10
Revision 22 Dec 02/11
Revision 23 Apr 16/12
Revision 24 Aug 21/12
Revision 25 Dec 04/12
Revision 26 Apr 26/13
Revision 27 Sep 3/13
Revision 28 Dec 6/13
Revision 29 Apr 1/14
Revision 30 Sep 2/14
Revision 31 Dec 18/14
Revision 32 Apr 13/15

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Revision 33 Sep 11/15


Revision 34 Dec 11/15
Revision 35 Mar 18/16
Revision 36 Jun 20/16
Revision 37 Sep 20/16
Revision 38 Dec 16/16
Revision 39 Mar 16/17
Revision 40 Jun 21/17
Revision 41 Sep 22/17
Revision 42 Dec 12/17

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RECORD OF TEMPORARY REVISIONS

None

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CHAPTER 00

INTRODUCTION

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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

00-00-00 1 Dec 12/17

Chapter 00
List of Effective Page Blocks
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MANUAL INTRODUCTION - DESCRIPTION AND OPERATION

TASK 00-00-00-860-801 How to Use this Manual

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.

2. How to Use this Manual

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.

(3) For example, the CH-SE-SU number 72-30-00 is interpreted as follows:

(a) 72 is the Chapter (Engine)

(b) 30 is the Section (Compressor Section)

(c) 00 is the Subject (Description and Operation)

(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.

EXAMPLE: 72-00-55 LP Turbine Module - Removal/Installation

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:

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Table 1 List of Page Blocks (Maintenance Manual)

Description and Operation P.B. 001 - 099


Fault Isolation P.B. 101 - 199
Maintenance Practices P.B. 201 - 299
Servicing P.B. 301 - 399
Removal/Installation P.B. 401 - 499
Adjustment/Test P.B. 501 - 599
Inspection/Check P.B. 601 - 699
Cleaning/Painting P.B. 701 - 799
Repairs P.B. 801 - 899

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:

EXAMPLE: SUBTASK 72-32-20-220-001

ELEMENT NUMBER: 1 2 3 4 5

Element 1 Chapter Number

Element 2 Section Number

Element 3 Subject Number

Element 4 Function Code - Refer to table below.

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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Table 2 Function Codes for A.M.T.O.S.S. Task/Subtask Numbering (Fourth


Element - 72-00-00-XXX-000) (Continued)

050 Remove Accessory/Power Plant Components


100 Cleaning (General)
110 Chemical Cleaning
130 Ultrasonic Cleaning
170 Foam/Water Wash
200 Inspection (General)
210 Check
220 Visual/Dimensional/Grading
230 Penetrant Inspect
250 Eddy Current Inspect
270 Ultrasonic Inspect
280 Radiographic Inspection
290 Phased Array Inspection
300 Repair (General)
320 Machining
350 Miscellaneous Repairs
400 Assemble (General)
410 Install Engine
420 Install Engine Modular Sections
430 Assemble Engine Modular Sections
440 Assemble Engine Subassemblies
450 Install Accessory/Power Plant Components
480 Install Engine Test Equipment
510 Shipping
520 Receiving
550 Storage
600 Test (General)
610 Servicing
620 Preserving

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Table 2 Function Codes for A.M.T.O.S.S. Task/Subtask Numbering (Fourth


Element - 72-00-00-XXX-000) (Continued)

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

A. List of Effective Page Blocks

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.

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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.

4. Observance of Manual Instructions

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:

(1) Aircraft Maintenance Manual (A.M.M.)

(2) Illustrated Parts Catalog (I.P.C.).

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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.

(3) Engine Manual (E.M.)

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.

TASK 00-00-00-860-806 Engine Description

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.

Refer to the following illustration:


Figure 1
Figure 2

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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Fig. 1 FJ44-2C - Right Side View

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Fig. 2 FJ44-2C - Left Side View

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TASK 00-00-00-860-807 List of Abbreviations

8. General

The following is a list of common abbreviations used throughout this manual.


Abbreviation Definition
A.M.M. Aircraft Maintenance Manual
A.M.T.O.S.S. Aircraft Maintenance Task Oriented Support System
ATA Air Transport Association of America
CDP compressor discharge pressure
CH-SE-SU Chapter/Section/Subject number
cm centimeter
CSI Compressor Section Inspection
delta P differential pressure
ECS Environmental Control System (Airframe)
ECU engine control unit
EBK Engine Build Kit
EM Engine Manual
est estimate
etc et cetera
FAA Federal Aviation Administration
FADEC full authority digital engine control
FCU fuel control unit
FDU fuel delivery unit
FOD foreign object damage
FPI fluorescent penetrant inspection
gal gallon
HCL hydrochloric acid
HMU hydromechanical (fuel control) unit
HP high pressure
HPC high pressure compressor
HPT high pressure turbine

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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

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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

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Abbreviation Definition
UV ultraviolet
V velocity
WI Williams International, Inc.
°C degrees Celsius
°F degrees Fahrenheit
% percent

TASK 00-00-00-860-815 FJ44-2C Service Bulletin List

9. General

SERVICE BULLETIN NUMBER INCORPORATION STATUS


FJ44-05-002 Dec 11/15
FJ44-71-002 No Effect
FJ44-72-042 Feb 28/02
FJ44-72-043 Feb 28/02
FJ44-72-047 Feb 28/02
FJ44-72-048 Feb 28/02
FJ44-72-049 Feb 28/02
FJ44-72-051 No Effect
FJ44-72-054 No Effect
FJ44-72-055 No Effect
FJ44-72-058 No Effect
FJ44-72-062 No Effect
FJ44-72-063 No Effect
FJ44-72-064 No Effect
FJ44-72-066 No Effect
FJ44-72-068 No Effect
FJ44-72-070 No Effect
FJ44-72-075 No Effect
FJ44-72-077 No Effect

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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

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FJ44-79-011 No Effect
FJ44-79-012 No Effect
FJ44-79-015 No Effect

TASK 00-00-00-860-829 How to Contact Williams International

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.

2. Send an e-mail to: WIProductSupport@williams-int.com

3. Call Williams International Product Support at 1-800-859-3544 (Continental U.S.) or


1-248-960-2929 (Outside of the Continental U.S.)

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CHAPTER 05

TIME LIMITS/MAINTENANCE CHECKS

05-TIME LIMITS/MAINTENANCE Page 1


CHECKS Dec 12/17

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05-TIME LIMITS/MAINTENANCE Page 2


CHECKS Blank
LINE MAINTENANCE MANUAL - FJ44-2C

LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 05
List of Effective Page Blocks
Page 2
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AIRWORTHINESS LIMITATIONS - MAINTENANCE PRACTICES

TASK 05-10-00-870-803 Airworthiness Limitations

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.

Refer to the following illustration:


Figure 201

CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.

2 IT IS THE OWNER/OPERATOR’S RESPONSIBILITY TO MAKE SURE THAT


THE PARTS DO NOT EXCEED THEIR MAXIMUM APPROVED LIVES. THE
OWNER IS DEFINED AS THE OWNER OF THE AIRCRAFT ON REGISTER
WITH THE FEDERAL AVIATION ADMINISTRATION (FAA) OR ITS EQUIVALENT
OR THE LEGAL OWNER OF THE ENGINE.

2. Flight Cycle Definition.

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:

(1) Touch-and-go landing shall be recorded as .50 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.

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3. Maximum Approved Part Lives

SUBTASK 05-10-00-870-020

A. Refer to table 201 for the component name, part number, and approved part life.

Table 201 Time Limits for Life-Limited Parts

PART DESCRIPTION Service Life Williams


(Flight Cycles) International
Part Number
Fan Rotor 10,000 59482
Fan Rotor 10,000 61967
Fan Rotor 10,000 65502
Fan Rotor 10,000 115572
Fan Rotor 10,000 117809
IP Compressor Rotor 8,000 57401
IP Compressor Rotor 8,000 61968
IP Compressor Rotor 8,000 69986
IP Compressor Rotor 8,000 115552
HP Compressor Rotor 6,000 57672
HP Compressor Rotor 6,000 61964
HP Compressor Rotor 6,000 115564
HP Compressor Rotor 6,000 118376
HP Compressor Rotor 8,000 119048
HP Compressor Rotor 8,000 119049
HP Compressor Rotor 8,000 119050
HP Compressor Rotor 8,000 119051
HP Compressor Rotor 8,000 120475
HP Compressor Rotor 8,000 123508
HP Compressor Rotor 8,000 123509
HP Compressor Rotor 8,000 123510
HP Compressor Rotor 8,000 123511
HP Compressor Rotor 8,000 122729

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Table 201 Time Limits for Life-Limited Parts (Continued)

PART DESCRIPTION Service Life Williams


(Flight Cycles) International
Part Number
HP Turbine Disk 8,000 67093
HP Turbine Disk 8,000 59387
1st LP Turbine Disk 10,000 72037
1st LP Turbine Disk 10,000 55531
2nd LP Turbine Disk 10,000 66993
2nd LP Turbine Disk 10,000 55534

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.

Table 202 Critical Non-Life Limited Parts

PART DESCRIPTION Williams International Part


Number
Fuel Manifold Assembly 121784

4. Flight Profile and Operational Monitoring.

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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5. Operating Hour Monitoring.

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.

2 IT IS THE OWNER/OPERATOR’S RESPONSIBILITY TO MAKE SURE THAT


THE PARTS DO NOT EXCEED THEIR MAXIMUM APPROVED LIVES.
THE OWNER IS DEFINED AS THE OWNER OF THE AIRCRAFT ON
REGISTER WITH THE FEDERAL AVIATION ADMINISTRATION (FAA) OR
ITS EQUIVALENT OR THE LEGAL OWNER OF THE ENGINE.

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.

6. Life Management Program

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.

The life management program works as follows:

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.

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Fig. 201 Flight Profile Duty Cycle

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SERVICE LIFE TRACKING - MAINTENANCE PRACTICES

TASK 05-12-00-870-801 Service Life Tracking

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

CAUTION IT IS MOST IMPORTANT TO MAINTAIN DETAILED LIFE RECORDS


ON ALL LIFE-LIMITED PARTS. THIS IS THE ONLY IDENTIFICATION
OF LIFE COMPLETED BY EACH PART.

A. Records and information are to be supplied by the repair facility as follows:

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.

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UNSERVICEABLE PARTS - MAINTENANCE PRACTICES

TASK 05-17-10-870-802 Unserviceable Parts

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
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SCHEDULED MAINTENANCE CHECKS - INSPECTION/CHECK

TASK 05-20-00-210-804 Scheduled Maintenance Checks

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.

2 You must do the checks in this task at the intervals described.

3 Engine Operating Hours are equivalent to Flight Hours as defined


in Airworthiness Limitations, 05-10-00

2. Intervals – Routine Periodic Inspection

SUBTASK 05-20-00-210-020

NOTES: 1 For Routine Periodic Inspections, refer to table 606.

2 Specified inspection intervals shall not be exceeded by more than


30 engine operating hours.

A. Preflight Check - Inspection procedure performed before each flight.

B. Postflight Check - Inspection procedure performed after each flight.

C. Hourly - Special inspection or maintenance at the engine operating hours interval shown.

D. Check 1 - Inspections at every 300 engine operating hours.

E. Check 2 - Inspections at every 600 engine operating hours, but no more than 300 engine operating
hours after Check 1 was performed.

3. Intervals – Major Periodic Inspections

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.

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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.

Table 601 Determination of Major Periodic Inspection Intervals

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.

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NOTES: 1 For Major Periodic Inspection requirements, refer to Task 05-20-00-210-821


in the Elite Line Maintenance Manual or the Engine Manual.

2 Life limited parts should be reviewed to determine if lives will be


exceeded before the next inspection interval.

3 Specified inspection intervals shall not be exceeded by more


than 50 engine operating hours.

4 Additional checks will be added, as necessary, when engines approach


the end of the intervals listed below.

5 Odd numbered Major Periodic Inspections (Check 3, 5, 7) are Hot Section


Inspections (HSI). Even numbered Major Periodic Inspections (Check 4,
6, 8) are Compressor Section Inspections (CSI).

6 If engine is de-enrolled in TAP or Tap Advantage and has exceeded the


1750 operating hour inspection interval, inspection becomes due immediately
(not to be exceeded by more than 50 operating hours).

Table 602 Service Bulletins Affecting Major Periodic Inspection Intervals

Service Bulletin Number Title

FJ44-72-106 Engine - 2nd Reduction Pinion Bearing Housing - Replace


FJ44-72-126 Engine - HP Shaft - Replace

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.

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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).

4. Time Between Overhaul (TBO)

SUBTASK 05-20-00-210-037

NOTES: 1 Component Operating Hours are equivalent to Flight Hours


accumulated on the component.

2 The intervals shown for TBO of accessories shall not be exceeded by


more than 100 component operating hours.

A. Integrated Fuel Control Unit: 4000 Component Operating Hours

B. Lube and Scavenge Pump: 5000 Component Operating Hours

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.

A. Integrated Fuel Control Unit (IFCU): 10 years

B. Lube and Scavenge Pump: 4 years

6. Equipment and Materials

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

A. Prepare the engine for inspection checks

(1) Install DO NOT OPERATE signs.

(2) Open the cowl doors. Refer to the Aircraft Maintenance Manual.

8. Routine Periodic Inspection Requirements

SUBTASK 05-20-00-210-024

A. Do the inspection checks at the time interval given. Refer to table 606.

Table 606 Routine Periodic Inspections

Nature of Inspection Preflight Check Check 2 Comply with Mech Insp


Hourly 1 Page Block Remarks
or Task
Inspect the engine inlet, fan rotor, fan Preflight Aircraft Flight
tip shroud, fan stator, and 2nd LP Manual
turbine rotor for evidence of foreign
object damage (FOD). Remove any
obstructions.
Inspect engine inlet and exhaust areas Preflight Aircraft Flight
for evidence of oil leakage. If you find Manual
evidence of oil leakage, isolate the
cause and correct.
Check the oil filter differential pressure Preflight Aircraft Flight
(delta P) indicator. If indicator is Manual
extended, refer to troubleshooting.
Check the oil level and add oil as Preflight Subtask
required. 72-00-03-610-002
in
72-00-03 P.B.
301
Check the overboard fuel drain ports Preflight Aircraft Flight
for fuel leakage Manual
Remove oil filter and submit for x x 72-00-05 P.B.
analysis 201

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Table 606 Routine Periodic Inspections (Continued)

Nature of Inspection Preflight Check Check 2 Comply with Mech Insp


Hourly 1 Page Block Remarks
or Task
Install new oil filter. x x 79-21-01 P.B.
401
Visually inspect and clean fuel start x x 73-12-01 P.B.
nozzle and start nozzle adapter 601
NOTE (1)
Check fuel start nozzle spray pattern x x 73-12-01 P.B.
NOTE (1) 601
Change FCU filter x x 73-14-01 P.B.
401
Remove and visually inspect the x x 74-22-01 P.B.
igniter plugs 601
NOTE (1)
Dimensionally inspect the igniter plugs x x 74-22-01 P.B.
NOTE (1) 601
Remove and inspect magnetic chip x x 79-30-01 P.B.
collectors 601
Do an operational test on the x x 74-00-10 P.B.
ignition system after inspection and 501
reinstallation of the igniter plugs
Clean fan rotor and physically inspect x Subtask
for defects (feel with fingers) 72-31-20-220-001
in
72-31-20 P.B.
601
Visually inspect the installed spinner x 72-30-10, P.B.
601
Change oil x 72-00-03 P.B.
301

Inspect acceleration bleed system x 75-30-01 P.B.


601

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Table 606 Routine Periodic Inspections (Continued)

Nature of Inspection Preflight Check Check 2 Comply with Mech Insp


Hourly 1 Page Block Remarks
or Task
(Rental Engines Only) Replace x 73-10-01, P.B.
FCU-to-fuel union fuel tube assembly 401
and fuel union-to-manifold fuel tube
assembly
NOTES: (1) If parts are replaced/exchanged with new or certified-serviceable
parts, inspection tasks do not need to be accomplished.

9. Job Close-up

SUBTASK 05-20-00-410-004

A. Put the engine back to normal

(1) Close the cowl doors. Refer to the Aircraft Maintenance Manual.

(2) Remove DO NOT OPERATE signs.

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RECOMMENDED MAINTENANCE - MAINTENANCE PRACTICES

TASK 05-50-00-870-801 Power Plant Wash Guidelines

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.

(b) In a sandy environment.

(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

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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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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ASSEMBLY/DISASSEMBLY MAINTENANCE PRACTICES - MAINTENANCE PRACTICES

TASK 70-00-01-870-801 Assembly/Disassembly Maintenance Practices

1. General

Standard maintenance practices for engine maintenance are provided in this task. These practices
are recommended by the engine manufacturer.

CAUTIONS: 1 TO AVOID DAMAGE TO PARTS, THESE HANDLING INSTRUCTIONS


MUST BE FOLLOWED:

2 USE HAND PROTECTION FOR HEAVY, LARGE OR DIFFICULT TO MANEUVER


PARTS. AVOID WEARING RINGS OR BRACELETS WHILE HANDLING PARTS.

3 PLACE PARTS ON A FLAT, RESILIENT SURFACE.

4 KEEP PARTS SEPARATED.

5 PICK PARTS STRAIGHT UP AND PLACE STRAIGHT DOWN. AVOID


ANY WEIGHT ON BLADE TIPS.

2. Equipment and Materials

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

3. Standard Disassembly 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.

4. Standard Assembly Practices

SUBTASK 70-00-01-870-004

CAUTION DUE TO PHYSICAL SIMILARITY, SOME ENGINE PARTS CAN BE ASSEMBLED


INTO THE WRONG LOCATION, RESULTING IN A POSSIBLE FAILURE. TO
PREVENT THIS, CHECK EACH PART CAREFULLY FOR CORRECT USE.

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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TEMPORARY MARKING OF PARTS - MAINTENANCE PRACTICES

TASK 70-01-05-870-801 Temporary Marking of Parts

1. General

This task defines the acceptable materials for the temporary marking of parts.

2. Equipment and Materials

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

CAUTIONS: 1 A SILVER PENCIL, MAT-030, MUST NOT BE USED ON TITANIUM PARTS.

2 CHINA CLAY BASED PENCILS (CHINAGRAPH PENCILS) MUST NOT BE


USED. GRAPHITE PENCILS CAUSE CARBON PENETRATION AT HIGH
TEMPERATURES AND MUST NOT BE USED. MARKS ACCIDENTALLY
MADE BY GRAPHITE PENCILS MUST BE COMPLETELY REMOVED
BEFORE HEAT TREATMENT OR ASSEMBLY.

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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MARKING OF REPAIRED PARTS - MAINTENANCE PRACTICES

TASK 70-01-07-870-801 Marking of Repaired Parts

1. General

This task provides the standard practices for marking of repaired parts.
Figure 201

2. Equipment and Materials

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.

C. Repair symbols are to be marked in two places:

(1) Next to the part number identification


(2) Adjacent to the repaired area (if practical - refer to specific repair instructions).

D. Refer to specific repair instructions for method of marking.

(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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Fig. 201 Repair Symbols

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MISUSE OF MOLYBDENUM DISULFIDE LUBRICANTS - MAINTENANCE PRACTICES

TASK 70-01-11-870-801 Misuse of Molybdenum Disulfide Lubricants

1. General

This task provides information on the misuse of molybdenum disulfide lubricants.

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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IDENTIFICATION, LUBRICATION, AND FITTING OF O-RING SEALS - MAINTENANCE PRACTICES

TASK 70-02-01-870-801 Identification, Lubrication, and Fitting of O-ring Seals

1. General

This task provides information on O-ring seals.

2. Equipment and Materials

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:

(1) Description of part

(2) Quantity

(3) Engine manufacturer’s part number

(4) Cure date

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:

1st quarter - January, February, March

2nd quarter - April, May, June

3rd quarter - July, August, September

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4th quarter - October, November, December

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.

B. The lubricants to be used for seal rings are as follows:

(1) Seal rings in fuel system - assembly fluid No. 1 MAT-011.

(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.

C. Use new seal rings when you assemble units or parts.

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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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ELECTRICAL CONNECTOR MAINTENANCE - MAINTENANCE PRACTICE

TASK 70-04-01-870-801 Electrical Connector Maintenance

1. General

This task provides maintenance practices for electrical connectors on components and harnesses.

2. Equipment and Materials

SUBTASK 70-04-01-942-001

A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl

3. Procedures

SUBTASK 70-04-01-870-001

A. Before Disconnecting Connectors:

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:

CAUTION WHEN HANDLING DISCONNECTED CONNECTORS, AVOID TOUCHING


THE MATING SURFACES OF THE CONNECTOR (PINS OR SOCKETS).
AVOID CONTACTING THE MATING FACE OF THE CONNECTOR AGAINST
OTHER PARTS, ESPECIALLY HARD SURFACES.

(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.

C. Connector Visual Inspection:

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NOTE Visual inspection and, if necessary, cleaning should be done


every time a connection is made.

(1) Examine the connectors for obvious defects or damage such as badly worn plating or deformed
threads.

(2) Check for bent, broken, recessed, or misaligned contacts.

(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.

(3) Do not use abrasives to clean connectors.

(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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CONSUMABLE MATERIALS - MAINTENANCE PRACTICES

TASK 70-10-01-870-801 Consumable Materials List

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

Table 201 Consumable Materials

Reference Nomenclature Specification/Part Number/Manuf.


MAT-001 Oil, Engine Refer to list of approved engine oils
(72-00-03, P.B. 301)
MAT-002 Oil, Preservative MIL-PRF-6081, Grade 1010
MAT-003 Fuel, Jet A Fuel, Jet A-1 or Jet B Refer to list of approved engine fuels
and additives (72-00-01, P.B. 301).
MIL-PRF-8188
Corrosion-Preventative, Aircraft
Turbine Engine, Synthetic Base
Rustlick #606
ITW ROCOL North America, 3624
West Lake Avenue, Glenview, IL
MAT-004 Oil, Corrosion Preventive 60026
LPS RUST INHIBITOR #3
LPS Laboratories 4647 Hugh Howell
Rd., Tucker, GA 30084
RUST BAN 392
Exxon Company, P.O. Box 2180,
Houston, TX 77001

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


BOESHIELD T-9
PMS Products Inc., 76 Veterans Drive
#110, Holland, MI 49423
MIL-PRF-16173
Corrosion Preventative Compound,
Solvent Cutback, Cold-Application
MIL-PRF-6085 Lubricating Oil
Instrument, Aircraft, Low Volatility
MIL-PRF-32033 Preservative Oil
Lubricating Oil, General Purpose
MAT-005 Oil, Penetrating WD-40
WD-40 Company
San Diego, CA 92110 USA
MAT-007 Steel Strapping 1-1/4, 3/4, or 1/2 inch width
MAT-008 Lubricant, Molybdenum Disulfide Molykote, G-n Paste
Dow Corning Corporation
Midland, MI 48686-0994 USA
MAT-009 Petrolatum VV-P-236 or equivalent
MAT-010 Grease, Aircraft, General Purpose MIL-PRF-81322
MAT-011 Assembly Fluid, No. 1 Ultrachem, Inc.
900 Centerpoint Blvd.
New Castle, DE 19720 USA
MAT-012 Lubricant, Dry Film Dow Corning (R) 321
MAT-013 Magnesium Hydroxide A-A-51924 (Equivalent of A-A-51924
= mixture of 405 mg per teaspoon of
magnesium hydroxide and 5 ml of
purified water.)
MAT-013 Magnesium Hydroxide Milk of Magnesia, Non-Flavored
MAT-014 Lubricant, Boron Nitride 36-206
BN Aerosol Lubricoat
Product of:
Zyp Coating Inc.
120 Valley Court, Oak Ridge TN,
37383

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-015 Lubricant, Anti-seize NSN-165
Never-Seez Pure Nickel Special
Bostik
Boston Street
Middleton, MA 01949
Telephone: 508-777-0100
MAT-016 Lubricant, Silicone Based 36-202
SUPER O LUBE
PRODUCT OF: PARKER SEAL CO.
2360 PALUMBO DR. LEXINGTON,
KY 40512-1751
MAT-017 Lubricant, Rapid GT Lubcon Turbon Lubrication, INC.
Lubricant Consult GmbH
Gutenbergstrasse 13
D-63477 Maintal
GERMANY
MAT-018 Petroleum Distillates Garosolve A 100
MAT-019 Acetone Commercial Grade
MAT-020 Mineral Spirits MIL-PRF-680, Type 1
Shell 145-EC
SHELLSOL D40
MAT-021 R-MC Cleaner Part No. 4072 (concentrate)
Part No. 4070 (pre-mixed, R-MC
G-21)
ECT Inc.
155 S. Limerick Rd.
Limerick, PA 19468
Telephone 610-239-5120
MAT-022 Nitric Acid (HNO3)
MAT-023 Ultrasonic Cleaner, Caustic Chem Crest 270
Metalterj 4340
Metal Medic 7055
MAT-024 Solvent, Dry Cleaning MIL-PRF-680, Type II
MAT-025 Solvent, Remover AMS 2644

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-026 Ultrasonic Cleaner, Detergent Chem Crest 135
Chem Crest 250
Metal Medic 7565AR (Max 7%
concentration)
MAT-027 Alcohol, Isopropyl
MAT-028 Alcohol, Methyl, Wood, or Methanol
MAT-029 Alkaline Cleaner, HDL-202 HDL-202
Dysol Inc. – 2901 Shamrock Ave. –
Ft. Worth, TX 76107
Phone 1-817-335-1826
csr-na@socomore.com
MAT-030 Pencil, Silver Berol Verithin, No. 753
MAT-031 Gas Path Cleaner Cleaners that meet MIL-PRF-85704
Type II or III (as listed in
QPL-85704–QPD):
B&B TC-100N-3 B&B Tritech, Inc
Turco 6783-50 Elf Atochem, N.A.
Turco 6783-10 Elf Atochem, N.A
EZE 206MS Calgon Corp
EZE 206RU Calgon Corp
ZOK-27 ZOK Inc.
ZOK-MX ZOK Inc
Techniclean GT Castrol Industrial
NA,Inc
MA 109C JAD Chemical Co.
MA 110 JAD Chemical Co.
ARDROX 6367 (TURBOCLEAN2)
MA 112C JAD Chemical Co.
ARDROX 6375 Chemtall Oakite

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-032 Marker, Broad Line Magic Marker, brand (blue, red, or
black)
Binney and Smith, Inc.
Easton, PA 18044-0431
Mighty Marks 7000-Red
Peter Castell Corp.
Lewisburg, TN 37091
Dykem High Purity 44 (Medium Tip)
— Tex Action Marker; white, black, or
red. ITW Dymon.
MAT-033 Marker, Fine Line Sharpie Fine Point Marker (red)
Vis-a-Vis Fine Line Marker (blue)
Sanford Corp.
Bellwood, Illinois 60104
Dykem High Purity (Fine) — Tex
Action Marker; white, black, or red.
ITW Dymon.
MAT-037 Fluid, Calibration MIL-PRF-7024E, Type II
MAT-040 Cloth, Abrasive ANSI B74.18
MAT-041 Pad, Abrasive A-A-58054
MAT-042 Paper, Abrasive, Silicone Carbide ANSI B74.18
MAT-043 Stone, Sharpening A-A-3068
MAT-044 Stone, Arkansas HF43-Hard
MAT-045 Stone, Rubberized Bright-Boy, Fine
Cratex ST 70
ALO 800
MAT-050 (Iridite) Chemical Conversion Materials MIL-DTL-81706; 14-2 or
for Coating Aluminum and Aluminum MIL-DTL-5541
Alloys

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-052 Polyurethane Topcoat, Color Anodize 16570 Gloss Dark Blue (WI Material
Repair Code 38-401)
16568 Gloss Blue (WI-Material Code
38-402)
16569 Gloss Light Blue (WI-Material
Code 38-403)
APS Fox Valley/LIC
2120 West Nordale Drive Appleton,
WI 54941
MAT-055 Epoxy Paint, Ceasefire CEASEFIRE™ Epoxy Paint, Part A,
White
Product of:
Cote~L Industries
1542 Jefferson St.
Teaneck, NJ, 07666
MAT-056 Epoxy Hardener, Ceasefire CEASEFIRE™ Epoxy Hardener, Part
B
Product of:
Cote~L Industries
1542 Jefferson St.
Teaneck, NJ, 07666
MAT-058 Hydraulic Fluid Refer to Aircraft Maintenance Manual
for compatible specification
MAT-060 Lockwire, .032 MS20995-C32
MAT-061 Lockwire, .020 MS20995-C20
MS20995-NC20

MAT-063 Safety Cable, .022 .022 Cable AS3510-0118C


and
Ferrule AS3510-01F

MAT-070 Bag, Plastic PPP-B-26


Use polypropylene bags to store
bearings or other parts wet with engine
oil.
MAT-071 Cloth, Lint Free CCC-F-46

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-072 Gloves, Plastic (Lint free) Disposable MIL-G-36593, MIL-DTL-32066
Rubber Vinyl
MAT-073 Brush, Wire H-B-178
MAT-075 Gloves, Cotton
MAT-076 Paper, Litmus MS36253
MAT-077 Swab, Cotton Commercial
MAT-078 Gloves, Thermal Protective
MAT-079 Crocus Cloth, Non-metallic
MAT-080 Liquid Nitrogen, Refrigerated Airco
MAT-081 Penetrants/Emulsifiers AMS 2644, QPL-AMS2644-QPD
MAT-082 Developers AMS 2644, QPL-AMS2644-QPD
MAT-083 Powder, Fluorescent, Dry Magnaglo 14A
MAT-084 Fluid, MPI Suspension Medium A-A-59230
(corrosion inhibitor, wetting &
defoaming agents)
MAT-085 Petroleum Distillate, Light Blend 380 (AMS 3160 or 3161)
MAT-086 Magnaflux/Magnaglo Carrier II
MAT-087 Sealant, RTV 159
MAT-088 Sealant, RTV 157 (gray)
MAT-089 Sealant, RTV 103 (black)
MAT-090 Sealant, RTV MIL-A-46106, Group III, Type I
Recommended Products:
RTV 106, General Electric Co.
Dow Corning 736, Dow Corning Corp.
MAT-091 Compound, Retaining Loctite 242
MAT-092 Compound, Retaining Loctite 404 or Permabond 910
MAT-093 Compound, Retaining Loctite 620
MAT-094 Compound, Retaining Loctite 601 or 609
MAT-095 Compound, Retaining Loctite 262 or 271

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-096 Primer, Epoxy MIL-PRF-23377
MIL-PRF-85582
MIL-DTL-0053022
MAT-097 Sealant, RTV RTV 162
MIL-A-46146, Group 1, Type 1
MAT-098 Sealant, Adhesive M46146-21AGN
Dow Corning 3145 RTV, Gray
MAT-099 Compound, Retaining Loctite 222
MAT-100 Leak Tec 372E
MAT-101 Primer, Silicone PR-1200 Dow Corning
MAT-102 RTV 3120 Silicone Rubber Base and (BASE) RTV 3120 A-A-56023, Type
Catalyst I Silicone Rubber
(CATALYST) Type S Catalyst for RTV
3120
MAT-110 Seal, Impregnation MIL-I-17563
PSM-10 or Resinol RTC
Loctite Corp.
705 Mountain Rd
Newington, CT 06111
MAT-111 Compound, Threadlock Loctite 290
MAT-120 Polish Paste, Flitz Flitz Metal Plastic Fiberglass Polish
Paste
Flitz International, Ltd. 821 Mohr
Avenue Waterford, WI 53185-4257
USA
MAT-121 Coating, Protective, Xzilon 3 X20-18 Xzilon 3
Granitize Aviation – 11022 Vulcan St.
South Gate, CA 90280 USA
MAT-170 Material, Barrier MIL-PRF-121, Type I
MAT-173 Bag, Sealable, Polyethylene PPP-B-26
MAT-175 Bag, Desiccant MIL-D-3464, Type I, 8-unit bag
MAT-176 Bag, Barrier MIL-PRF-131, Class 3
MAT-200 Shim Stock .001 - .010

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Table 201 Consumable Materials (Continued)

Reference Nomenclature Specification/Part Number/Manuf.


MAT-201 Tape, Reflective P/N 2169.020 (1/2 inch wide)
Schenck Trebel
535 Acorn Street
Deer Park, N. Y. 11729
MAT-202 Cleaner, General Wet Simple Green
Sunshine Makers, Inc
15922 Pacific Coast Highway
Huntington Harbor CA 92649
Ph: 800–228–0709
MAT-203 Marking Paste, Machinist, Blue Dykem Hi-Spot Blue No. 107
P/N 83307
ITW Dymon
Ph: 800–443–9536
MAT-204 Powder, Gear Marking, Yellow Powder, Gear Marking, Yellow No. 10
O/N 326568
Prescott and Company (Canada)

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THIS PAGE LEFT INTENTIONALLY BLANK

70-10-01
210
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

CONTAMINATION OF ENGINE COMPONENTS - MAINTENANCE PRACTICES

TASK 70-12-00-870-801 Contamination of Engine Components

1. General

This task provides information on the types of contamination of engine components.

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.

4. Chlorinated Solvents (or other Halogens)

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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LOCKING TECHNIQUES FOR THREADED PARTS - MAINTENANCE PRACTICES

TASK 70-12-04-870-801 Locking Techniques for Threaded Parts

1. General

This Standard Practice gives the approved procedures for the following locking techniques:

Wire locking

Self-locking fasteners

NOTE A threaded fastener which is correctly torqued is extended, and in this


condition, is self-locked. The function of a locking device is to keep the locking
properties, even if the load on the bolt decreases.

2. Wire Locking

SUBTASK 70-12-04-870-003

A. Install lockwire in accordance with MS33540.

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.

B. Torque Check for Reuse of Self-Locking Fasteners

(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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.138 -40 NF-2A 6 1.0 .125 -40 NC-2A 4 1


.164 -36 NF-2A 9 1.5 .138 -32 NC-2A 6 1.0
.190 -32 UNF-3A 13 2 .164 -32 NC-2A 9 1.5
.250 -28 UNF-3A 30 3.5 .190 -24 UNC-3A 13 2.0
.3125-24 UNF-3A 60 6.5 .250 -20 UNC-3A 30 4.5
.375 -24 UNF-3A 80 9.5 .3125-18 UNC-3A 60 7.5
Torque is measured in inch-pounds at room temp, lubricated with engine oil
* Installation or Removal

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CLEANING METHODS AND PROCEDURES - CLEANING

TASK 70-21-00-870-801 Cleaning Methods and Procedures

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.

(2) Remove deposits that inhibit correct part functioning.

2. Equipment and Materials

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.

WARNING MANY CLEANING SOLUTIONS AND THEIR COMPONENTS ARE HARMFUL


TO SKIN, EYES AND CLOTHING. WEAR CHEMICAL RESISTANT CLOTHING,
APRON, GLOVES AND FACE SHIELD/GOGGLES TO PROTECT SKIN
AND EYES. MAKE SURE THERE IS ADEQUATE VENTILATION AS
SOME SOLUTIONS EMIT HARMFUL VAPORS.

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.

(5) Avoid unnecessary cleaning of parts:

(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.

CAUTION DO NOT USE ABRASIVE MATERIALS OR SCRUB CLEAN


DIFFUSED NICKEL-CADMIUM PLATED SURFACES.

(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.

(c) The following table contains Unacceptable Cleaning Materials:


ACIDS SOLVENTS
CHLORINATED OTHER SOLVENTS
HYDROCARBONS
Nitric acid red fuming Perchlorthylene Methel Ethyl Ketone (MEK)
HCL Acid in concentrations greater Trichloroethane (1,1,1) Tolulene
than 5%
Trichloroethylene Ethanol
Trichlorotrifluoroethane Methanol
Freon

C. Important Cleaning Information

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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CAUTION DO NOT WIRE BRUSH TITANIUM PARTS.

(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.

(1) Dry Cleaning

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).

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.

(c) Using an Air Compressor,, blow components dry with clean, filtered shop air.

(2) Wet Cleaning

(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.

EFFECTIVITY: FJ44-2C
70-21-00
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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.

WARNING DO NOT OPERATE CAUSTIC TANK WITHOUT ADEQUATE VENTILATION.


CLEANING SOLUTIONS CAN DAMAGE SKIN AND EYES. WEAR
CHEMICAL RESISTANT PROTECTIVE CLOTHING, APRON, GLOVES,
AND FACE SHIELD TO PROTECT SKIN AND EYES.

CAUTIONS: 1 DO NOT PUT ALUMINUM, OR MAGNESIUM, INTO THE CAUSTIC TANK.

2 DO NOT USE ULTRASONIC CLEANING OR ULTRASONIC AGITATION


FOR ALUMINUM PARTS OR PARTS WITH THERMAL SPRAY COATINGS.

(1) Clean parts in ultrasonic tanks as follows:

CAUTION DO NOT STACK PARTS ON TOP OF EACH OTHER OR DAMAGE


COULD RESULT. DO NOT LET PARTS TOUCH EACH OTHER
OR SIDE WALLS OF ULTRASONIC CLEANER.

(a) Remove all caps and fittings.

WARNING CLEANING SOLUTIONS 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.

(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.

EFFECTIVITY: FJ44-2C
70-21-00
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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.

(c) Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove wet
cleaning solvent MAT-202 by rinsing part with water.

(d) Put parts in tank for five to seven minutes minimum.

(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.

EFFECTIVITY: FJ44-2C
70-21-00
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BALL AND ROLLER BEARING - MAINTENANCE PRACTICES

TASK 70-31-01-110-801 Ball and Roller Bearing Cleaning

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

2. Equipment and Materials

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

EFFECTIVITY: FJ44-2C
70-31-01
Page 201
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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).

D. Bearings cleaned as part of a scheduled or unscheduled maintenance activity must be recorded in


the engine log book and/or Repair Station Records.

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

A. Cleaning Area and Handling

CAUTION NO SMOKING, EATING, OR DRINKING IN THE BEARING CLEANING AREA.


KEEP THIS AREA CLEAN. MATERIALS NOT NECESSARY TO PERMIT
BEARING CLEANING MUST NOT BE INTRODUCED TO THE ROOM.
LEAD (GRAPHITE) PENCILS ARE NOT PERMITTED IN THE BEARING
AREA/ROOM DUE TO THEIR CONTAMINATING PROPERTIES

NOTE Success of bearing cleaning requires maintenance of a clean environment.


The area/room, equipment and chemicals must be pure. Bearing cleaning
personnel must follow the procedures given to effectively clean bearings.

(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:

(a) Plastic (powder-free, nitrile) gloves MAT-072.

(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.

(2) Unwanted Matter

EFFECTIVITY: FJ44-2C
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Rolling elements on bearings are manufactured to exceptionally close tolerances to provide


precise positioning during engine operation. These tolerances, coupled with high unit stresses
occurring between the rolling elements and races, make bearings particularly susceptible to
almost any form of contamination. You must take every precaution to prevent any form of
contamination from entering the bearing at all points of the handling process.

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.

B. Cleaning Area Equipment and Materials

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.

(1) Magnetometer (Gaussmeter)

Used to check the effectiveness of the demagnetizing procedure.

(2) Demagnetizer

Used to remove remaining magnetism in a bearing.

(3) Soak Tanks

Used to perform initial cleaning of bearings using mineral spirits.

(4) Handling Gloves

Used to handle bearings while protecting them against acid contamination.

(5) Protective Clothing

Handling gloves, apron and face shield are used to protect bearing cleaning personnel from
caustic chemicals.

EFFECTIVITY: FJ44-2C
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SUBTASK 70-31-01-100-001

WARNING MANY OF THE CHEMICALS USED IN BEARING CLEANING ARE TOXIC


AND CORROSIVE TO HUMAN SKIN AND MUCOUS MEMBRANES. WEAR A
CHEMICAL RESISTANT PROTECTIVE APRON, CLEAN VINYL GLOVES AND A
FACE SHIELD WHEN WORKING WITH OR NEAR THESE MATERIALS.

CAUTION DO NOT SPIN BEARINGS DURING THE CLEANING AND DRYING


PROCEDURES. SPINNING THE RACE AND ROLLING ELEMENTS CAN
CAUSE DAMAGE FROM SKIDDING. ALWAYS HOLD THE INNER AND
OUTER RACES OF NONSEPARABLE BEARINGS IN A MANNER THAT
WILL PREVENT VIBRATIONS AND/OR SPINNING.

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:

(1) Bearing looks like it has contamination.

(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

D. Contaminated Bearing Cleaning

(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.

WARNING DISPOSE OF ALL USED SOLVENTS AND SOLUTIONS IN A FIREPROOF


CONTAINER TO BE LATER EMPTIED INTO A SCRAP LIQUID CONTAINER
FOR DISPOSAL IN ACCORDANCE WITH LOCAL REGULATIONS.

CAUTION DO NOT STORE BEARINGS OR ALLOW BEARINGS TO SET IDLE BETWEEN


SUBSEQUENT STEPS WITHOUT PROTECTIVE LUBRICATION MAT-001.

(2) Soak/Stir Clean

(a) Support bearing in a soak tank, above any sludge or contamination that may have
collected near the bottom of container.

EFFECTIVITY: FJ44-2C
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WARNING CLEANING SOLUTIONS CAN CAUSE SKIN RASH AND EMIT


HARMFUL VAPORS. USE IN WELL-VENTILATED AREAS AWAY FROM
OPEN FLAME. WEAR PROTECTIVE CLOTHING, RUBBER GLOVES,
APRON, AND FACE SHIELD/GOGGLES DURING USE.

(b) Put bearing fully into soak tank, containing MAT-020 or MAT-024 for five (5) minutes
minimum. Occassionally agitate by hand.

(3) Rinse

Remove bearing and 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.

(b) Continue rinse for 30 to 60 seconds.

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.

(4) Additional Soak/Rinse Cycles:

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.

(5) Dry Bearing

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.

CAUTION BEARING SURFACES MUST BE KEPT FREE OF UNWANTED


MATERIAL CONTAMINATION DURING INSPECTION. ALL
PERSONNEL MUST WEAR GLOVES WHEN TOUCHING BEARINGS
TO PREVENT FINGERPRINT DAMAGE.

(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.

(d) Inspect bearing per TASK 70-31-01-220-801.

(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).

(8) Remove bearing and make sure no rotational roughness is present.

(9) Preserve and Package

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.

NOTE Bearings assemblies are manufactured as a complete set. If one ball


bearing or race track is rejected, you must also reject the remaining
part or parts of that bearing assembly.

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Fig. 201 Hard Particle Dent (Top) and a Soft Particle Dent (Bottom) Can Both Be Damaging

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TASK 70-31-01-220-801 Ball and Roller Bearing Inspection

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

6. Equipment and Materials

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

A. Initial Visual Inspection

EFFECTIVITY: FJ44-2C
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CAUTIONS: 1 BEARINGS CAN BE DAMAGED BY ANY UNWANTED MATERIAL


CONTAMINATION DURING INSPECTION. TO PREVENT DAMAGE,
BEARINGS MUST BE KEPT AWAY FROM ALL CONTAMINANTS AND LINT
FREE PLASTIC GLOVES MAT-072 MUST BE WORN WHEN HANDLING
BEARINGS. THIS WILL REDUCE THE POSSIBILITY OF PUTTING FINGER
PRINT ACID ON THE BEARINGS, WHICH CAN CAUSE CORROSION.

2 DO NOT HAVE WOOD FIBER PAPER OR LEAD PENCILS IN


THE BEARING CLEANING/INSPECTION AREA; THEY HAVE
CONTAMINATING PROPERTIES.

(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.

NOTE Normal carbon/varnish buildup can appear as discolorations and give


false indications of cracked and damaged conditions.

(2) Group bearings together in containers correctly identified for processing.

CAUTION DO NOT MIX MATCHED BEARING SETS OR MIXED COMPONENTS


OF SEPARABLE 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

B. Bearing Inspection After Cleaning

CAUTION BEARING DAMAGE FROM UNWANTED MATERIAL CONTAMINATION


CAN OCCUR DURING INSPECTION. TO PREVENT DAMAGE, BEARINGS
MUST BE KEPT AWAY FROM ALL CONTAMINANTS AND INSPECTOR
MUST WEAR GLOVES WHEN HANDLING BEARINGS.

NOTE Cleaned bearings must be inspected again to see if carbon deposits


have been removed and visual contamination has been eliminated.
They also must be inspected and accepted before being returned to
the supply cycle or re-installed in the engine.

(1) Bearing Inspection Flow Charts.

Functional and nonfunctional surfaces of bearings are defined in Figure 202.

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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

(2) Level of Disassembly. When inspection is required, ensure the following:

(a) No. 1 bearings shall be removed from their housings.

(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.

(d) No. 3 bearing rollers shall be removed from the HP turbine.

(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.

(3) Visual Inspection

(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.

(1) Surfaces. Refer to Figure 202.

(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.

(b) Brinelling (False). False brinelling is characterized by frosty indentations on rolling


elements or raceways. It is generated by a fretting corrosion wear mechanism. This is
usually caused by continuous non-rotational vibrations.

(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.

(e) Extruded Material. Silver extruding from cage functional surfaces.

(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

From 490° to 510°F (254° to 266°C) - Yellow-brown through spotted yellow-brown

From 520° to 550°F (271° to 288°C) - Brown-purple through dark purple

From 560° to 570°F (293° to 299°C) - Full blue to dark blue

From 570°F (299°C) and up - Black

(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. 202 Bearing Functional/Non-Functional Surfaces

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Fig. 203 Inspection of Bearings

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Fig. 204 Bearing Functional Surfaces Inspection - Center 1/3 of Roller

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Fig. 205 Bearing Functional Surfaces Inspection - Scratch or Scoring (Center Roller)

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Fig. 206 Bearing Functional Surfaces Inspection - Outer 1/3 of Roller

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Fig. 207 Bearing Non-Functional Surfaces Inspection

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Fig. 208 Bearing Cage Inspection

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Fig. 209 Bearing Cage Inspection - Continued

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Fig. 210 Correct Positioning of Radius Stylus

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Fig. 211 Bearing Brinelling - Contact Zones

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Fig. 212 Bearing Corrosion

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Fig. 213 Bearing Rings - Nicks, Dents, and Scratches

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Fig. 214 Bearing Skidding Damage

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Fig. 215 Roller End Wear

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CARBON SEAL SURFACE QUALITY - INSPECTION/CHECK

TASK 70-33-01-870-801 Carbon Seal Surface Quality

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

A. Refer to Figure 601.

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.

C. Edge: A feature (line) formed at the intersection of two surface planes.

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.

A. Cracks are not acceptable in any surface of the part.

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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

A. Inspect banded ring carbon seals per Figure 602.

5. Carbon Face Seal Surface Quality Requirements

SUBTASK 70-33-01-870-001

Table 601 Carbon Face Seal Surface Quality Requirements — FJ44

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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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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Fig. 601 Carbon Seal Surface Quality - Inspection Zones

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Fig. 602 Carbon Seal Inspection - Banded Ring Seal

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Fig. 603 Carbon Seal Inspection - Circumferential Grooves

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REPAIR SURFACES AFFECTED BY MINOR DAMAGE - REPAIR

TASK 70-42-11-870-801 Repair Surfaces Affected by Minor Damage

1. General

This repair task must be performed when directed, in the relevant Inspection/Check task for the part
being repaired.

2. Equipment and Materials

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.

4. Repair Minor Damage

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.

2 IF YOU USE MECHANICAL CUTTERS, MAKE LIGHT CUTS TO PREVENT


OVERHEATING OF THE TITANIUM PART. DO NOT GRIND.

A. Repair of Scores, Galling, Burrs, Pick-up and Fretting

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(1) Remove high spots, burrs and pick-up, and pick-up on threads. Use hand stones and light
hand polishing.

B. Repair of Pitting, Stripping, and Rubbing Marks

(1) Remove pitting by blending. Use hand stones and light hand polishing.

C. Repair of Distortion and Dents

(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.

E. Repair of Burned Areas

(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.

5. Inspect Repaired Area

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.

6. Apply Surface Protection to Repaired Area

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.

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LOCAL SURFACE PROTECTION - REPAIR

TASK 70-42-12-870-801 Local Surface Protection

1. General

This task must be performed to restore protective coating to surfaces which have been damaged or
repaired.

2. Equipment and Materials

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.

WARNING ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A


COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND
KEEP AWAY FROM HEAT, SPARKS, OR FLAME.

B. Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl alcohol
MAT-027 to clean.

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4. Anodized Aluminum Cases

SUBTASK 70-42-12-870-004

WARNING MAT-050 CHEMICAL COATING MAY BE HARMFUL TO EYES, SKIN, AND


LUNGS. MAY CAUSE PERMANENT DAMAGE AND SKIN BURNS. WEAR EYE
PROTECTION AND PROTECTIVE CLOTHING WHILE MIXING AND USING
COATING MATERIAL. MIX ONLY SMALL AMOUNTS AND AVOID PROLONGED
BREATHING OF FUMES. USE IN WELL VENTILATED AREA.

A. If liquid Iridite MAT-050 is used, apply it as follows:

(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).

B. If Alodine 1132 pen is used (MAT-050) , apply it as follows:

(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).

(4) Allow the coating to dry thoroughly.

(5) Do not wipe up excess.

C. Blue topcoat (MAT-052) may be applied to repaired areas as follows:

(1) Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl
alcohol MAT-027 to clean.

WARNING MAT-050 CHEMICAL COATING OR TOPCOAT MAT-052 MAY BE HARMFUL


TO EYES, SKIN, AND LUNGS. MAY CAUSE PERMANENT DAMAGE
AND SKIN BURNS. WEAR EYE PROTECTION AND PROTECTIVE
CLOTHING WHILE MIXING AND USING COATING MATERIAL. MIX
ONLY SMALL AMOUNTS AND AVOID PROLONGED BREATHING
OF FUMES. USE IN WELL VENTILATED AREA.

(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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(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.

(c) Allow surface to fully dry before applying topcoat.

(4) Mask off areas of part which do not require application of topcoat.

(5) Mix topcoat (MAT-052) in accordance with the manufacturer’s instructions.

(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.

5. Non-Anodized Polished Aluminum Surfaces

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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NON-DESTRUCTIVE INSPECTION (NDI) METHODS - INSPECTION/CHECK

TASK 70-42-15-870-801 Fluorescent Penetrant Inspection

1. General

This task covers the penetrant method of inspection for the detection of cracks and other discontinuities
open to the surface.

2. Equipment and Materials

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

(1) Industry Specification ASTM E 1417

(2) Industry Specification AMS 2644

(3) Industry Specification NAS-410

3. General

NOTES: 1 These instructions are to be used as a supplement to regular visual


inspection procedures, not a replacement.

2 Inspectors shall be qualified and certified as specified in NAS-410.

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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NOTES: 1 Aqueous or water soluble developers cannot be used with water


washable (method A) penetrants

2 Method D penetrants are mandatory for inspecting rotating or highly stressed


parts (except fan rotor at Line Maintenance Facilities).

3 Developer not required, inspect opposite side surface for evidence of thru leaks

4 Form “a” developer only.

5 Dwell time for lipophilic emulsifiers shall be 1 minute maximum unless


otherwise agreed to in the fixed process.

6 Method C penetrant is allowed only for inspecting the fan rotor


at Line Maintenance Facilities.

7 Use developers a, c, or d only when using Method C.

Methods Developer Type Sensitivity Level


A - Water Wash a - Dry Powder I - Fluorescent Dye 2 - Medium
B - Post Emulsifier b - Water Soluble II - Visible Dye 3 - High
(Lipophilic) c - Water 4 - Ultra-High
C - Solvent Suspendable
Removable d - Non-Aqueous
D - Post Emulsifier
(Hydrophilic)

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

Table 601 Fluorescent Penetrant Limits — FJ44

Class Max Size Any Max. Size Max. No. of Dist.


Linear Indication Rounded Indications per
(Inch) Indication (Inch) Square or Linear
(Notes 2 & 3) Inch
AA None Allowed None Allowed - -
A None Allowed 0.010 7 Note 5
B None Allowed 0.030 5 Note 1

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Table 601 Fluorescent Penetrant Limits — FJ44 (Continued)

Class Max Size Any Max. Size Max. No. of Dist.


Linear Indication Rounded Indications per
(Inch) Indication (Inch) Square or Linear
(Notes 2 & 3) Inch
C None Allowed 0.060 3 Note 1
D 0.010 0.010 7 Note 1
E 0.030 0.030 5 Note 1
F 0.060 0.060 3, (Note 4) Note 1
G 0.120 0.120 2, (Note 4) Note 1

NOTES: 1 Indications to be separated by a minimum of 4 times the largest dimension


of the largest indication being considered (edge to edge).

2 A linear indication is defined as an indication whose length is


5 times its width, minimum.

3 The following defects are not allowed for Class AA through C:


cracks, laps, laminations, seams, tears, cold shuts, forging bursts,
intruded scale, pipes and corrosion pits.

4 The maximum number of indications above can be greater under


the following conditions:

(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) The requirements of Note 1 are maintained.

5 Indications to be separated by a minimum of 1 times the largest dimension


of the largest indication being considered (edge to edge).

6 A tightly spaced group of defects (usually consisting of porosity or microshrinkage)


must be considered as a cluster and treated as a single defect.

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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6. Quality Assurance Provisions

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

Details of applying developer (if used)

Part number and inspection class, as applicable

Cleaning method after inspection

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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TORQUE TIGHTENING TECHNIQUE - MAINTENANCE PRACTICES

TASK 70-51-00-870-801 Torque Tightening Technique

1. General

This task provides information for torque tightening technique. Refer to the following illustration(s):
Figure 201

2. Equipment and Materials

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:

(1) A special load for a particular application, or

(2) A standard torque for the size of the thread

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 :

(1) Friction at the screw head

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(2) The mating faces of the assembly parts

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:

(1) Remove the nuts.

(2) Clean and apply lubricant to the threads and abutment faces.

(3) Install the nuts again.

(4) Torque the nuts to the specified torque load.

6. Torque Tightening Sequence - Close-Pitch Bolting

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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7. Hand Torque Wrenches

SUBTASK 70-51-00-870-006

A. Flexible Beam Type

(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.

(4) Before you use the wrench, set it to zero.

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.

8. Use of Torque Adapters and Extensions.

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.

(3) Divide dimension A by dimension B to get the conversion factor.

(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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B. Example - Torque Value Conversion:

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.

9. Locking Torque for Self-Locking Fasteners.

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

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SPECIAL TOOLS - MAINTENANCE PRACTICES

TASK 70-53-00-870-801 Maintenance and Calibration of Special Tools

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.

2. Equipment and Materials

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

A. Visual Inspection: Each time a tool is used it should be checked for:

(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

TOOL TOOL NAME REQUIREMENT INTERVAL NOTES


NUMBER
TL37102-4 Gauge, Hydraulic Pump Calibrate Pressure 6 Months
Gauge
TL37102-76 Gauge, Pressure Calibrate Pressure 6 Months
Gauge
TL37102-11, Stretch Tooling details NDI Inspect 24 Months Inspect for cracks
TL37102-12, Visual check prior using visible
TL37102-13, to each usage dye (spray can)
TL37102-29, penetrant.
TL37102-62,
TL37102-64,
TL217317-13,
TL217317-14,
TL235628, Oil Tank Pressure Test Calibrate Pressure 6 months
TL217323 Fixture Gauge
TL37114-2 Puller, 1st and 2nd LP NDI Inspect Puller 24 Months Inspect for cracks
Turbines Legs (3) using visible
Visual check prior dye (spray can)
to each useage penetrant.
TL37281 Gauge, Gearbox Calibrate Dial 6 months
Backlash Indicator
TL65023 Gauge, HP Compressor Calibrate Dial 6 months
Rotor Face Clearance Indicator
TL99967 Test Box, Delta P Calibrate Pressure 12 months
Pressure Sensor Gauge

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Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools (Continued)

TOOL TOOL NAME REQUIREMENT INTERVAL NOTES


NUMBER
TL-110118 Test Block, Indicator, Calibrate Pressure 6 months
Delta P, Oil Filter and Gauge
Fuel Filter
TL-115142 Checker, Low Oil Level Return to Williams 12 months
Sensor International for
Calibration

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STORAGE OF PARTS THAT HAVE SHELF LIFE LIMITS - MAINTENANCE PRACTICES

TASK 70-61-01-870-801 Storage of Parts that have Shelf Life Limits

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:

(1) Rubber or synthetic rubber

(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:

(1) January, February, March

(2) April, May, June

(3) July, August, September

(4) October, November, December

NOTE On some parts, the month of manufacture is shown in brackets


after the cure date, e.g. 2Q91 (May).

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.

3. Cure Date Marking

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

(2) Direct Sunlight

(3) Ozone

(4) Moisture

(5) Excessive circulation of air

(6) Extremes of temperature

(7) Physical damage

(8) Contamination by fuel, oil, grease, or solvents

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:

(1) Mercury vapor lamps

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(2) Electrical machinery

(3) Excessive exposure to outdoor air

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

(a) Natural rubber

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

(b) Neoprene (Chloroprene)

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

(a) Silicone, Fluorosilicone, and Fluorocarbon (Viton)

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:

(1) Permanent distortion, flats, and other obvious defects

(2) Tackiness or surface hardening or softening

(3) Blistering, peeling, or cracks when material is extended or flexed

(4) Chafing of outer coverings and corrosion of, or damage to, end fittings of hose assemblies
and cable harnesses

(5) Corrosion of metal elements in bonded rubber to metal assemblies

(6) Obstruction of the bore (flexible hoses)

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CHAPTER 71

POWER PLANT

Page 1
71-POWER PLANT Dec 12/17

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Page 2
71-POWER PLANT Blank
LINE MAINTENANCE MANUAL - FJ44-2C

LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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

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List of Effective Page Blocks
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Chapter 71
List of Effective Page Blocks
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POWER PLANT - FAULT ISOLATION

TASK 71-00-00-810-801 Power Plant - Troubleshooting

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.

2. Equipment and Materials

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:

(1) Starting Malfunctions

(2) Idle Malfunctions

(3) Acceleration Malfunctions

(4) Take-Off Malfunctions

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(5) Maximum Continuous Malfunctions

(6) Deceleration Malfunctions

(7) Shutdown Malfunctions

(8) Other Malfunctions

4. TROUBLESHOOTING TOP EVENTS

SUBTASK 71-00-00-810-007

STARTING MALFUNCTIONS (START INITIATED)

Figure 101

Figure 102

Figure 103

Figure 104

STARTING MALFUNCTIONS (POWER LEVER MOVED TO IDLE; NO LIGHT OFF)

Figure 105

Figure 106

STARTING MALFUNCTIONS (ENGINE LIGHTS OFF)

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

MAXIMUM CONTINUOUS MALFUNCTIONS

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. 101 No N2 Indication on Instrumentation (Starter Rotates)

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Fig. 102 Engine Will Not Start (2 sheets)

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Fig. 102 Engine Will Not Start (2 sheets)

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Fig. 103 No Oil Pressure Indication (2 sheets)

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Fig. 103 No Oil Pressure Indication (2 sheets)

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Fig. 104 High Oil Pressure on Start

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Fig. 105 Low/No Sound of Igniter(s) Firing (2 sheets)

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Fig. 105 Low/No Sound of Igniter(s) Firing (2 sheets)

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Fig. 106 No/Low Fuel Flow Indication


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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. 108 No ITT Indication

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Fig. 109 Engine Hot Start (3 sheets)

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Fig. 109 Engine Hot Start (3 sheets)

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Fig. 109 Engine Hot Start (3 sheets)

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Fig. 110 No N1 Speed Indication

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Fig. 111 High N2 Indication at Idle

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Fig. 112 Low Oil Pressure (2 sheets)

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Fig. 112 Low Oil Pressure (2 sheets)

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Fig. 113 Engine Flameout (2 sheets)

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Fig. 113 Engine Flameout (2 sheets)

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Fig. 114 No Acceleration Above Idle

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Fig. 115 Slow Acceleration (2 sheets)

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Fig. 115 Slow Acceleration (2 sheets)

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Fig. 116 Low Fuel Pressure

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Fig. 117 High ITT

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Fig. 118 Bleed Odor Troubleshooting (2 Sheets)

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Fig. 118 Bleed Odor Troubleshooting (2 Sheets)

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Fig. 119 Overspeed N2

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EFFECTIVITY: FJ44-2C Fig. 120 Engine Surge (3 sheets)


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Fig. 120 Engine Surge (3 sheets)

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Fig. 120 Engine Surge (3 sheets)

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Fig. 121 N1/N2/ITT Indications Erratic (Max Continuous Operation) (2 sheets)

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Fig. 121 N1/N2/ITT Indications Erratic (Max Continuous Operation) (2 sheets)

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Fig. 122 High Oil Pressure (Max Continuous Operation) (2 sheets)

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Fig. 122 High Oil Pressure (Max Continuous Operation) (2 sheets)

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Fig. 123 High Oil Temperature

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Fig. 124 Lightning Strike Troubleshooting and Inspection (2 sheets)

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Fig. 124 Lightning Strike Troubleshooting and Inspection (2 sheets)

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Fig. 125 Low Oil Pressure at Altitude - Normal on Ground

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Fig. 126 Engine Flameout (Deceleration)


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Fig. 127 Failure to Shutdown

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Fig. 128 Short or Noisy Engine Rundown (2 sheets)


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Fig. 128 Short or Noisy Engine Rundown (2 sheets)

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 129 Fuel Filter Delta P Lamp Lit

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Fig. 130 High Vibration With or Without Noise (2 sheets)

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Fig. 130 High Vibration With or Without Noise (2 sheets)

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Fig. 131 High Oil Consumption/Oil Leak


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Fig. 132 Fuel Leak/Increased Fuel Consumption

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Fig. 133 Oil Discoloration

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Fig. 134 Engine Shock Load (Hard Landing) (2 sheets)

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Fig. 134 Engine Shock Load (Hard Landing) (2 sheets)

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EFFECTIVITY: FJ44-2C
Fig. 135 Oil Filter Delta P Indicator Extended
71-00-00
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Fig. 136 Suspect N1 or N2 Speed Pickup(s)

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Fig. 137 High Oil Consumption/Oil Leak (3 sheets)

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Fig. 137 High Oil Consumption/Oil Leak (3 sheets)

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Fig. 137 High Oil Consumption/Oil Leak (3 sheets)


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 138 Bird Strike/Foreign Object Ingestion (2 sheets)

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Fig. 138 Bird Strike/Foreign Object Ingestion (2 sheets)

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Fig. 139 ITT Split Between Engines (2 sheets)

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Fig. 139 ITT Split Between Engines (2 sheets)

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Fig. 140 Throttle Lever Movement is Rough/Binding/Sticks

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Fig. 141 Debris in Fuel Filter Bowl

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Fig. 142 Volcanic Ash Exposure (Engine Not Operated)

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Fig. 143 Volcanic Ash Ingestion (Engine Operated)

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Fig. 144 Starter/Generator and/or Auxiliary Generator Failure

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Fig. 144 Starter/Generator and/or Auxiliary Generator Failure

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Fig. 145 Hydraulic Pump Failure

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LINE MAINTENANCE MANUAL - FJ44-2C

POWER PLANT - MAINTENANCE PRACTICES

TASK 71-00-00-870-803 Configure Engine For Right or Left-Hand Use

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.

2. Equipment and Materials

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.

WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY


CAREFUL AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

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
71-00-00
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LINE MAINTENANCE MANUAL - FJ44-2C

POWER PLANT - REMOVAL/INSTALLATION

TASK 71-00-00-010-801 Remove the Engine from Build Stand

1. General

This task provides procedures for removing the engine from the build stand. Refer to the following
illustration(s):
Figure 401
Figure 402

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual before beginning work.

2. Equipment and Materials

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
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LINE MAINTENANCE MANUAL - FJ44-2C

3. Procedures

SUBTASK 71-00-00-010-041

WARNING HANGING LOADS CAN INJURE OR KILL YOU. BE EXTREMELY CAREFUL


AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

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.

A. Connect engine lifting sling 08-0119-8000 ,08-0147C4000 to engine as follows:

(1) Adjust lift sling for length and/or center-of-gravity to match engine model/type. Tighten bolts
securely. Refer to Figure 401.

(2) Connect engine lifting sling to engine lift points:

CAUTION VERIFY THAT ALL DETENT PINS ARE SECURELY INSERTED


AND LOCKED IN PLACE WHEN USING THE ENGINE
SLING AND BUILD STAND.

(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:

EFFECTIVITY: FJ44-2C
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LINE MAINTENANCE MANUAL - FJ44-2C

WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY


CAREFUL AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

(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.

EFFECTIVITY: FJ44-2C
71-00-00
Page 403
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Engine Lifting Sling – Removal/Installation

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LINE MAINTENANCE MANUAL - FJ44-2C

EFFECTIVITY: FJ44-2C
Fig. 402 Engine in Build Stand - Removal/Installation 71-00-00
Page 405
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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 71-00-00-410-801 Install the Engine in Build Stand

5. General

This task provides procedures for installing the engine in the build stand. Refer to the following
illustration(s):
Figure 403
Figure 404

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual before beginning work.

6. Equipment and Materials

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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LINE MAINTENANCE MANUAL - FJ44-2C

7. Job Set-up

SUBTASK 71-00-00-010-040

WARNING HANGING LOADS CAN INJURE OR KILL YOU. BE EXTREMELY CAREFUL


AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

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.

A. Connect engine lifting sling 08-0119-800008-0147C4000 to engine as follows:

(1) Adjust lift sling for length and/or center-of-gravity to match engine model/type. Tighten bolts
securely. Refer to Figure 403.

(2) Connect engine lifting sling to engine lift points:

(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.

CAUTION MAKE SURE ALL DETENT PINS ARE SECURELY INSERTED


AND LOCKED IN PLACE WHEN USING THE ENGINE
SLING AND BUILD STAND.

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.

EFFECTIVITY: FJ44-2C
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8. Procedures

SUBTASK 71-00-00-410-037

A. Install engine to engine build stand as follows:

(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.

CAUTION WHEN ENGINE IS SERVICED WITH OIL, DO NOT ROTATE TO THE


EXTREME "NOSE UP" OR "NOSE DOWN" POSITION. THIS MAY CAUSE
OIL WETTING BEHIND THE COMPRESSOR COVER.

(6) Remove engine lifting sling from the engine by removing detent pins.

EFFECTIVITY: FJ44-2C
71-00-00
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Fig. 403 Engine Lifting Sling – Removal/Installation

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EFFECTIVITY: FJ44-2C
Fig. 404 Engine in Build Stand - Removal/Installation 71-00-00
Page 410
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POWER PLANT - ADJUSTMENT/TEST

TASK 71-00-00-760-808 List of Test Procedures

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

2. Equipment and Materials

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

A. Refer to the List of Test Procedures in the table below.

Table 501 List of Test Procedures

TASK NAME REASON


71-00-00-760-811 Idle Speed and Leak Check To check the engines performance at
Run idle and make sure that there are no
leaks in the fuel, oil, or air systems.

EFFECTIVITY: FJ44-2C
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Table 501 List of Test Procedures (Continued)

71-00-00-760-815 Vibration Survey To check the level of vibration and the


source.
71-00-00-760-819 Stability/Acceleration Check To make sure that the acceleration and
time is correct and that the engine does
not flame-out during deceleration.
71-00-00-760-824 Performance Check To make sure that the engine
performance is within limits.
71-00-00-760-827 Oil Consumption Check To monitor and calculate oil
consumption.
71-00-00-760-826 High Power Check To make sure that the engine performs
correctly at high power.
71-00-00-760-828 Capped Bleed Engine Run To troubleshoot an ITT split between
engines.

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.

NOTE Do the tests in the order shown.

Table 502 Tests Required after Maintenance or Component Replacement

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
ROUTINE PERIODIC INSPECTION:
Check 1 Inspection X
NOTE 5 NOTE 9
Check 2 Inspection X
NOTE 5 NOTE 9
ENGINE INSTALLATION OR MAJOR PERIODIC INSPECTION:
Major Periodic Inspection X X X X
(Engine installed in aircraft) NOTE 1
Major Periodic Inspection( Perform engine acceptance test procedure (ATP).
(Engine installed in test cell) Refer to 72-00-00, P.B. 1301 in the Engine Manual.
NOTE 1

EFFECTIVITY: FJ44-2C
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Page 502
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Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
Engine Installation X
(New engine or engine which NOTE 1
has undergone acceptance test
procedure since last installation or
maintenance)
Engine Installation X X
(Rental Engine) NOTE 1
Engine Installation X As required by maintenance performed
(Engine which has not undergone NOTE 1 on individual parts (see below)
acceptance test procedure since last
installation or maintenance.)
BASIC ENGINE COMPONENT REPLACEMENT:
Spinner Repaired X
or New
Fan Rotor Remove/ X
Install
Repaired X X X
or New
Case and Insert Assy Remove/ X
and/or Fan Stator Install
Repaired X X
or New
Magnetic Chip Collector Replacement X
Assy NOTE 4
IP Compressor Rotor Remove/ X
Install
Repaired X X X
or New
IP Compressor Stator Remove/ X
Install
Repaired X X
or New

EFFECTIVITY: FJ44-2C
71-00-00
Page 503
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Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
No 1. Carbon Seal Any Maint. X X
NOTE 1
Combustor Covey Assy Remove/ X X X X
Install
New X X X X
Fuel Slinger Remove/ X X X X
Install
New X X X X
Balance Piston Seal Remove/ X X X X
Install
New X X X X
HP Turbine Combustor Remove/ X X X X
Assy Install
Repaired X X X X
or New
HP Turbine Rotor Remove/ X X X X
Install
Repaired X X X X
or New
No. 3 Roller Bearing Any Maint. X X X
1st LP Turbine Nozzle Remove/ X X X
Install
Repaired X X X X
or New
No. 4 Roller Bearing Any Maint. X X X
No. 3 Carbon Seal Any Maint. X X X
No. 4 Carbon Seal Any Maint. X X X

EFFECTIVITY: FJ44-2C
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Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
LP Turbine Module Remove/ X X
Install
Disassy/ X X X
Assy
Repaired X X X
or New
Rear Housing Assy Remove/ X X
Install
Repaired X X X
or New
Front Bypass Duct Assy Any Maint. X X X
NOTE 2
Rear Bypass Duct Assy Any Maint. X
ENGINE ACCESSORIES/LRU REPLACEMENT:
Fuel Tube Assembly Any Maint. X
NOTE 9
Fuel Nozzle Assembly Any Maint. X
NOTE 9
Fuel Fuel Filter Any Maint. X
NOTE 9
Integrated Fuel Control Remove/ X X X
Unit (IFCU) Install NOTE 9
Repaired
or New
Adjust X X
Fuel Filter Electrical Any Maint. X
Indicator (Delta P) NOTE 9
Fuel Manifold FIlter Any Maint. X
Assy NOTE 9
Gearbox Assy Remove/ X X X
Install NOTE 1

EFFECTIVITY: FJ44-2C
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Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
Gearbox Carbon Seal Any Maint. X
NOTE 1
Gearbox Filter Delta P Any Maint. X
Indicator NOTE 9
Ignition Exciter Any Maint.
NOTE 5
Igniter Lead Any Maint.
NOTE 5
Igniter Plug Any Maint.
NOTE 5
Oil Filler Port Plug Any Maint. X
Assembly NOTE 1
Oil Sight Glass Any Maint. X
(Interstage Housing) NOTE 9
Acceleration Bleed Any Maint X X
System NOTE 2
LP Magnetic Speed Any Maint. X X
Pickup Assy NOTE 9
Gearbox (HP) Magnetic Any Maint. X X
Speed Assy NOTE 9
ITT Probe Any Maint. X X
NOTE 3 NOTE 9
ITT Jumper Harness Any Maint. X
NOTE 9
Starter/Generator Any Maint. X Refer to Aircraft Maintenance Manual
NOTE 6 NOTE 1
Hydraulic Pump Any Maint. X Refer to Aircraft Maintenance Manual
NOTE 6 NOTE 1
Oil Filter Any Maint. X
NOTE 9
Lube Oil Cooler Any Maint. X
NOTE 1

EFFECTIVITY: FJ44-2C
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Page 506
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Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Component Maint. Idle/Leak Vibe Stability Perform High


Action Check Survey Accel Check Power
Check Check
Lube and Scavenge Any Maint. X X
Pump NOTE 1
Note 7
Oil Pressure Regulating Any Maint. X X
Valve NOTE 9
Note 7
Oil Supply Tube Any Maint. X
NOTE 9
Fuel Flow Transmitter NOTE 8

EFFECTIVITY: FJ44-2C
71-00-00
Page 507
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NOTES: 1 Leak Check at max continuous is required. Refer to 71-00-00, P.B.


501, Idle Speed and Leak Check Run.

2 Visual/functional check of acceleration bleed system is required. Refer


to 71-00-00, P.B. 501, Stability/Acceleration Check.

3 As an alternate means of compliance after ITT probe replacement, perform


Continuity Check and Resistance Check tasks. Refer to 77-20-02, P.B. 601.

4 Leak Check is required only if the complete Magnetic Chip Collector


Assembly is replaced.

5 Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501

6 If the starter/generator or hydraulic pump is rejected for failure, you must


perform maintenance specified in the corresponding troubleshooting
tree (Refer to 71–00–00, P.B. 101).

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.

9 Leak check at Intermediate Power is required. Refer to 71-00-00,


P.B. 501, Idle Speed and Leak Check Run.

TASK 71-00-00-760-804 General Operating Procedures

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

EFFECTIVITY: FJ44-2C
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NOTES: 1 Refer to this task before all ground running.

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.

5. Equipment and Materials

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

A. Ground Running Tests - General Procedures

(1) Reason for ground running tests

(a) To make sure that the engine is correctly installed.

(b) When told of a defect on the engine, to find that defect.

(c) To make sure an adjustment is done correctly.

EFFECTIVITY: FJ44-2C
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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.

(e) To check for leaks.

(2) Safety precautions

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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING


(COATS, JACKETS, CAPS AND SCARVES) NEAR THE
ENGINE WHILE IT OPERATES. MAKE SURE THAT THE
HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE


GROUND CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF
FOREIGN OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR
A DECREASED 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.

WARNING MAKE SURE THERE IS SOMEONE IN THE COCKPIT AT ALL


TIMES DURING ENGINE OPERATON.

(3) Engine Handling

(a) Power Control

1 Keep ground runs to the minimum level of power and time that is necessary to do
the tests.

EFFECTIVITY: FJ44-2C
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CAUTION DO NOT MOVE THE THRUST LEVERS FORWARD AND BACK


QUICKLY UNLESS YOU ARE DOING ACCELERATION/DECELERATION
TESTS. FAST MOVEMENT OF THE THRUST LEVERS CAUSES
THE ENGINE TEMPERATURE TO CHANGE QUICKLY WHICH IS
NOT GOOD FOR THE LIFE OF THE ENGINE.

(4) Ground Running in Icing Conditions

(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.

(5) Oil System Characteristics:

(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.

(6) Windmilling on Ground.

(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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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.

2 WHEN YOU MONITOR A LIMIT, MAKE SURE THE RELATED


AIRCRAFT INSTRUMENT IS NOT DEFECTIVE OR INACCURATE.
THIS WILL PREVENT FALSE MONITORING.

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.

3 Airflow disturbances across engine intake, particularly during gusty or


crosswind conditions, may result in RPM fluctuations. This is normal at
high power settings during static or low speed operations.

A. Fuel System Limits:

(1) Minimum Fuel Temperature - Refer to 72-00-01, P.B. 301.

(2) Maximum Fuel Temperature - Refer to 72-00-01, P.B. 301.

(3) Maximum Fuel Leakage - Refer to 71-00-00, P.B. 501.

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:

(1) Maximum Tailwind Component - Refer to Aircraft Operating Instructions (1)

(2) Maximum Crosswind Component - Refer to Aircraft Operating Instructions (1)

(3) Time Between Starts - 30 Seconds

(4) Time to Light-Off (2) - 10 seconds (3)

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NOTES: 1 Higher minimum throttle up speeds may be required if tailwind


component exceeds 5 knots.

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.

C. Operating Limits: Refer to table 503

Table 503 FJ44-2C Operating Limits

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.

3 Minimum oil pressure is 45 psig when operating at or above 80% N2;


35 psig when operating below 80% N2.

4 When operating below 80% N2 for up to 5 minutes maximum.

5 When operating at or above 80% N2 for up to 5 minutes maximum.

6 Maximum allowable oil pressure is 100 psig for up to five minutes maximum.

7 The engine should not be operated above 80% N2 until oil


temperature is above 10°C.

8 Max bleed extraction during start is limited to equivalent flow through


a 0.222 square inch sharp edge orifice.

8. Normal Operating Procedures

SUBTASK 71-00-00-700-009

A. Engine Pre-Start

(1) Verify battery or ground power supply meets the starter/generator manufacturer’s requirements.

CAUTION IF GROUND POWER SUPPLY IS USED, MAXIMUM CURRENT


IS TO BE LIMITED TO 1100 AMPS.

(2) Set SYNC - OFF.

(3) Set generator -OFF (or NORMAL position if controlled by GCU)

(4) Set bleed air -OFF. (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Table 2-1))

(5) If applicable, set idle select - GROUND.

(6) Set power lever - SHUT OFF.

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B. Engine Start

NOTE Follow starter manufacturer’s operational duty cycle limits.

(1) Set engine starter switch - ON.

CAUTION DO NOT TURN ON ENGINE IGNITION UNTIL POSITIVE HP


(N2) ROTATION IS NOTED.

(2) Set ignition switch - ON.

(3) Set fuel boost pumps - ON (and motive flow OFF).

NOTE If tailwind or crosswind component exceeds 5 knots, use 12% N2 as minimum


N2 speed prior to moving power lever to start. A GPU may be required.

(4) At a minimum of 8% N2, move power lever to IDLE position.

(5) Monitor ITT. ITT may not exceed the limits defined in Figure 506

CAUTIONS: 1 AT 25% N2, ENSURE POSITIVE N1 INDICATION. IF NO N1


INDICATION IS PRESENT, ABORT START.

2 IF ENGINE MAINTENANCE HAS BEEN PERFORMED, AIR IN FUEL


LINES MAY CAUSE A HOT START. ENSURE PROPER PURGING
PROCEDURES HAVE BEEN ACCOMPLISHED PRIOR TO ATTEMPTING
A START. BE PREPARED TO ABORT START.

(6) Between 40% N2 and idle, set starter - OFF. Refer to starter-generator manufacturer for
optimum starter cut-out speed.

(7) Check oil pressure indication.

CAUTION IF OIL PRESSURE IS OUTSIDE THE LIMITS IDENTIFIED IN


TABLE 503, SHUT DOWN ENGINE.

(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

(1) Set ignition switch - OFF.

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(2) Set the power lever - IDLE.

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)

(4) Set power lever - SHUT OFF.

(5) Set boost pumps - OFF

SUBTASK 71-00-00-700-011

D. Motoring the Engine

(1) Set power lever - SHUT OFF.

(2) Set ignition switch - OFF.

(3) Set bleed air - OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in table 503

NOTE Starter damage may occur if motoring is prolonged. Consult starter/generator


manufacturer’s operational duty cycle limits for proper motoring time.

(4) Set engine starter switch - ON, for time duration as specified by starter/generator
manufacturer’s operation duty cycle limit.

(5) Set engine starter switch - OFF.

9. Abnormal Operating Procedures

SUBTASK 71-00-00-700-012

A. Failure of Engine to Light.

Whenever an engine fails to start within 10 seconds after moving the power lever to the idle position:

(1) Set power lever - SHUT OFF.

(a) Set ignition switch - OFF.

(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

(1) Set power lever - SHUT OFF.

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(2) Set ignition switch - OFF.

(3) Starter - OFF.

(4) Set fuel pumps - OFF.

C. Oil Pressure After Start (Exceeding limits in table 503)

(1) Set power lever - SHUT OFF.

(2) Set ignition switch - OFF.

(3) Starter - OFF.

(4) Set fuel pumps - OFF.

(5) Refer to Troubleshooting, 71-00-00, P.B. 101.

D. Hot Start (ITT exceeds levels in Figure 506

(1) Set power lever - OFF.

(2) Set ignition switch - OFF.

(3) Set fuel pumps - OFF.

(4) Motor engine as required.

(5) Refer to Figure 506 for corrective action.

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Fig. 501 Danger Areas During Ground Run

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Fig. 502 Nominal Oil Pressure Operating Band

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Fig. 503 Overtemperature Limits (Continuous Operation)

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Fig. 504 Overtemperature Limits (Takeoff)

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Fig. 505 Overtemperature Limits (Takeoff – One Engine Inoperative)

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Fig. 506 Overtemperature Limits (Starting)

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Fig. 507 N2 Overspeed Limits

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Fig. 508 N1 Overspeed Limits

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TASK 71-00-00-760-811 Idle Speed and Leak Check Run

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.

2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for


engine operation instructions.

11. Equipment and Materials

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.

E. Absorbent materials may not be used for the detection of leaks.

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.

13. Job Set-up

SUBTASK 71-00-00-010-009

A. Position the aircraft into the wind.

B. Remove the cowling. Refer to the Aircraft Maintenance Manual.

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.

C. Put the aircraft booster pumps on.

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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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND


CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.

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:

(1) Disengage the ignition circuit breaker.

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.

TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(2) Loosen the two loop clamps securing the fuel line tubes together. Disconnect the Fuel Union to
Manifold tube at both ends.

NOTE The flowmeter fitting will be a union fitting if no flowmeter is installed.

(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.

C. Check all external fuel and oil tubes for leaks.

D. Repair leaks as necessary.

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.

E. Reconnect the ignition circuit breakers

F. Start the engine to ground idle. Refer to General Operating Procedures, 71-00-00, P.B. 501.

G. Run the engine at idle for at least two minutes

NOTE The OAT indicator reading must be within ±3° C of actual airfield ambient temperature.

H. Observe N2 speed and OAT and compare to Figure 509.

(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.

P. Repeat steps I through R after corrective action.

Q. Inspect the magnetic chip collectors. Refer to 79-30-01, P.B. 601.

R. If there are no leaks, proceed to Job Close-up.

15. Job Close-up

SUBTASK 71-00-00-410-009

A. Install the cowling. Refer to the Aircraft Maintenance Manual.

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EFFECTIVITY: FJ44-2C
71-00-00
Page 531
Fig. 509 Ground Idle N2 Speed Check
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TASK 71-00-00-760-815 Vibration Survey

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.

2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for


engine operation instructions.

17. Equipment and Materials

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

18. Job Set-up

SUBTASK 71-00-00-010-024

A. Install vibration measuring equipment

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(1) Point the nose of the aircraft into the wind.

(2) Remove the cowling. Refer to the Aircraft Maintenance Manual.

(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.

(4) Install vibration pick-up assembly to TL37253 vibration mount.

(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

A. Do the vibration survey

(1) Set generator - OFF.

(2) Set bleed air - OFF.

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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING


(COATS, JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE
WHILE IT OPERATES. MAKE SURE THAT THE HOODS
ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE


GROUND CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF
FOREIGN OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR
A DECREASED PERFORMANCE OF THE ENGINE.

(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.

(4) Let the engine stabilize at idle for two minutes.

(5) Refer toFigure 511 to determine the takeoff N1 speed setting.

(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.

(7) Hold the engine at takeoff speed for a minimum of 2 minutes.

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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).

NOTE The vibration limits displayed by test equipment do not necessarily


reflect the engine manual limits.

(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..

20. Job Close-up

SUBTASK 71-00-00-410-024

A. Remove the vibration measuring equipment

(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.

(4) Install the cowling. Refer to the Aircraft Maintenance Manual.

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Fig. 510 Vibration Accelerometers - Removal/Installation

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Fig. 511 N1 Speeds for Ground Checks at Takeoff Settings

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TASK 71-00-00-760-825 Trim Balance Procedures

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

CAUTION TRIM BALANCE PROCEDURES ARE ONLY USED IF LP VIBRATION LEVELS


EXCEED LIMITS (HIGH VIBRATION WITH OR WITHOUT NOISE).

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.

22. Equipment and Materials

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

EFFECTIVITY: FJ44-2C
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MAT-096 Primer, Epoxy


MAT-201 Tape, Reflective

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

A. Install test equipment.

(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.

CAUTION THE SENSOR MUST BE ATTACHED SO THAT INGESTION


DURING TESTING WILL BE AVOIDED.

(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.

EFFECTIVITY: FJ44-2C
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LINE MAINTENANCE MANUAL - FJ44-2C

(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.

C. Trim Balance Testing by Vector Subtraction Method

NOTE If testing is performed on an aircraft, the engine not being balanced


is to be OFF or at idle.

(1) Initial Run

(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.

(2) Trial Weight Location

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.

(3) Second Run

(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.

(4) Vector Plotting/Subtraction Procedures

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(a) If the 1E LP vibration level has not been reduced to acceptable levels, a Third Run is
needed.

(b) Plot data per Figure 513 and Figure 514.

(5) Third Run

(a) Move weight. Refer to Figure 514.

(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.

(e) Plot data per Figure 513 and Figure 514.

(6) Fourth Run

(a) Move weight. Refer to Figure 514.

(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.

CAUTION TRIM BALANCING IS DONE TO REDUCE VIBRATIONS AT ONE


SPECIFIC SPEED DURING THE SLOW TRANSIENT ACCELERATION.
CAUTION MUST BE USED TO ENSURE THAT VIBRATION LEVELS (AT
SPEEDS OTHER THAN THE ONE OF ORIGINAL INTEREST) DO NOT
INCREASE BEYOND LIMITS AS A RESULT OF THE TRIM BALANCING.

(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.

D. Trim Balance Testing 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.

(2) First Weight Location: Put trial weight in any hole.

(3) Weight Rotation:

(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.

(5) Weight Rotation:

(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.

(6) Final Trim Weight Rotation:

(a) Reduce data. Refer to Figure 515.

(b) Install trim weight at optimum calculated clock angle.

(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.

(7) Reduce data to quantify change in 1E LP vibration.

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CAUTION TRIM BALANCING IS DONE TO REDUCE VIBRATIONS AT ONE SPECIFIC


SPEED DURING THE SLOW TRANSIENT ACCELERATION. CAUTION
MUST BE USED TO ENSURE THAT VIBRATION LEVELS (AT SPEEDS
OTHER THAN THE ONE OF ORIGINAL INTEREST) DO NOT INCREASE
BEYOND LIMITS AS A RESULT OF THE TRIM BALANCING.

(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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Fig. 512 Reflective Tape Placement

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Fig. 513 Trim Balance by Vector Subtraction - Sample Plot

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Fig. 514 Trim Balance by Vector Subtraction - Sample Plot Procedure


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Fig. 515 Reducing Data for Final Trim Weight Rotation

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TASK 71-00-00-760-819 Stability/Acceleration Check

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.

2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for


engine operation instructions.

25. Equipment and Materials

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

26. Job Set-up

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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CAUTIONS: 1 ENGINE MUST BE SHUT DOWN PRIOR TO PERFORMING IFCU


ACCELERATION SCHEDULE ADJUSTMENT PROCEDURES. ENGINE
MUST NOT BE RUNNING WHILE MAKING ADJUSTMENT.

2 DO NOT LOOSEN THE IFCU JAM NUT. ADJUSTMENT


TO THE RECESSED HEX-HEAD SCREW IS TO BE MADE
WITHOUT LOOSENING THE JAM NUT.

3 DO NOT USE EXCESSIVE FORCE WHEN TURNING ADJUSTMENT


SCREW. IT IS POSSIBLE THAT ADJUSTMENT SCREW IS
ALREADY ADJUSTED TO THE MAXIMUM. FORCING THE
ADJUSTMENT SCREW COULD CAUSE INTERNAL DAMAGE TO
THE IFCU. TO DETERMINE APPROPRIATE FORCE, TURN SCREW
COUNTER-CLOCKWISE ONE HALF TURN AND THEN TURN IT
CLOCKWISE TO THE ORIGINAL POSITION.

(1) Turn internal hex adjustment screw up to 1½ turns clockwise, or until the screw reaches the
internal stop, whichever is less.

NOTE Increasing fuel flow (clockwise rotation) is limited by an internal


stop on the adjustment screw. It may not be possible to make
any further clockwise adjustment.

(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

A. Point the nose of the aircraft into the wind.

B. Set generator - OFF

C. Set normal bleed - OFF

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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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND


CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.

D. Start the engine. Refer to General Operating Procedures,71-00-00, P.B. 501 .

CAUTION IF DURING TEST, ANY OF THE FOLLOWING WARNING LIGHTS ILLUMINATE,


REFER TO THE ABNORMAL PROCEDURES SECTION OF THE AIRCRAFT
MANUAL: (1) ANTI-ICE (WING); (2) AIR DUCT OVERHEAT; (3) BLEED
AIR OVERHEAT; (4) WINDSHIELD AIR OVERHEAT.

E. Run the engine at ground idle for at least two minutes.

NOTE Visual check of the acceleration bleed system is required. Refer to


TEST LIST, 71-00-00, P.B. 501.

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.

I. Maintain takeoff N1 for three minutes.

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.

L. Perform intermediate-ground idle snap decel checks as follows:

(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.

N. Move the power lever to achieve 64.3% N2 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.

28. Job Close-up

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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Fig. 517 N1 Speeds for Ground Checks at Takeoff Settings

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TASK 71-00-00-760-824 Performance Check

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.

2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for


engine operation instructions.

30. Equipment and Materials

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

31. Job Set-up

SUBTASK 71-00-00-010-015

A. Remove the cowling. Refer to the Aircraft Maintenance Manual.

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32. Procedures

SUBTASK 71-00-00-760-024

A. Inspect the fan rotor and the bypass area as follows:

(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.

B. Point the nose of the aircraft into the wind.

C. Set generator - OFF.

D. Set bleed air - OFF.

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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND


CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.

E. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.

F. Run the engine at idle for at least two minutes.

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.

H. Refer to Figure 519 to determine the takeoff thrust N1 speed setting.

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.

L. Move power lever to ground IDLE position.

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.

33. Job Close-up

SUBTASK 71-00-00-410-015

A. Install the engine cowling. Refer to the Aircraft Maintenance Manual.

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Fig. 518 Ground Idle N2 Speed Check
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Fig. 519 N1 Speeds for Ground Checks at Takeoff Settings

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Fig. 520 ITT Limits for Ground Checks at Takeoff Settings


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Fig. 521 N2 Speed Limits for Ground Checks at Takeoff Settings

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71-00-00
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Fig. 522 HP Bleed Air Port Locations

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TASK 71-00-00-760-827 Oil Consumption Check

34. General

This task monitors and calculates oil consumption. You must do this test as required by Troubleshooting,
71-00-00 P.B. 101.

NOTE Refer to General Operating Procedures, 71-00-00 P.B. 501 , for


engine operation instructions.

35. Equipment and Materials

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
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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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND


CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.

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.

D. Check and carefully record the oil level.

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).

H. Calculate oil consumption as follows:

(1) Convert recorded amount of oil used to gallons. Use one of the following conversion factors, as
required:

(a) To convert quarts to gallons, multiply by 0.25.

(b) To convert fluid ounces to gallons, multipy by 0.0078.

(c) To convert cubic inches to gallons, multiply by 0.0043.

(d) To convert liters to gallons, multiply by 0.264

(e) To convert milliliters to gallons, multiply by 0.000264.

(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
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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.

TASK 71-00-00-760-826 High Power Check

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.

2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for


engine operation instructions.

38. Equipment and Materials

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

39. Job Set-up

SUBTASK 71-00-00-010-006

A. Remove the engine cowling. Refer to the Aircraft Maintenance Manual.

B. Point the nose of the aircraft into the wind.

EFFECTIVITY: FJ44-2C
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Page 564
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40. Procedures

SUBTASK 71-00-00-760-004

A. Set generator - OFF.

B. Set bleed air - OFF.

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.

2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND


CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.

NOTE For FJ44-2C, references to idle mean ground idle.

C. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.

D. Run the engine at idle for at least two minutes.

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.

(1) Idle speed:

NOTE Note that idle speed varies with temperature.

(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

F. To determine the takeoff thrust N1 speed setting, refer to Figure 524.

EFFECTIVITY: FJ44-2C
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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.

J. Move power lever to IDLE position.

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.

41. Job Close-up

SUBTASK 71-00-00-410-006

A. Install the engine cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
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Page 566
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EFFECTIVITY: FJ44-2C
71-00-00
Page 567
Fig. 523 Ground Idle N2 Speed Check
Dec 12/17

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Fig. 524 N1 Speeds for Ground Checks at Takeoff Settings

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Fig. 525 ITT Limits for Ground Checks at Takeoff Settings


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Page 569
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Fig. 526 N2 Speed Limits for Ground Checks at Takeoff Settings

EFFECTIVITY: FJ44-2C
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TASK 71-00-00-760-828 Capped Bleed Run

42. General

This task contains instructions for performing a capped bleed engine run. Refer to the following
illustration(s):
Figure 527
Figure 528

43. Equipment and Materials

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

44. Job Set-up

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.

B. Perform baseline ground run. UseFigure 527.

(1) Point the nose of the aircraft into the wind.

(2) Set generator - OFF.

EFFECTIVITY: FJ44-2C
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WARNINGS: 1 ENSURE PEOPLE WORKING NEAR AIRCRAFT ARE AWARE


OF DANGEROUS AREAS. THIS PRECAUTION IS TO PREVENT
LOSS OF LIFE OR SERIOUS INJURY.

2 ENSURE PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,


JACKETS, CAPS, AND SCARVES) WHILE ENGINE IS OPERATING.
ENSURE HOODS ON PARKAS ARE NOT LOOSE.

CAUTION ENSURE NO MATERIAL OR EQUIPMENT ON THE GROUND CAN GO INTO


THE ENGINE AIR INTAKE. INGESTION OF FOREIGN OBJECTS CAUSES
DAMAGE TO ENGINE AND/OR A DECREASED PERFORMANCE.

(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.

(4) Let the engine stabilize at idle for two minutes.

(5) Determine the takeoff thrust N1 speed setting.

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.

(9) Send data recorded on Figure 527 to Williams International.

46. Job Close-up

SUBTASK 71-00-00-410-005

A. Remove HP bleed caps.

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.

C. Reconnect aircraft bleed plumbing. Refer to Aircraft Maintenance Manual.

D. Install cowling. Refer to Aircraft Maintenance Manual.

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Fig. 527 FJ44 Ground Power Chart

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Fig. 528 HP Bleed Air Port Locations

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POWER PLANT CLEANING - CLEANING

TASK 71-00-03-170-801 Clean the Power Plant – Water Rinse

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

NOTE Perform engine cleaning at intervals recommended in Recommended


Maintenance, 05-50-00, P.B. 201.

2. Equipment and Materials

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.

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71-00-03
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(2) Set engine bleed air OFF/CLOSED.

(3) Set ignition OFF.

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.

CAUTIONS: 1 TO PREVENT DAMAGE TO FAN, KEEP THE END OF THE


NOZZLE OUTSIDE OF THE INLET LIP.

2 DO NOT SPRAY INTO THE ENGINE EXHAUST DUCT FROM


THE REAR. IF FLUID IS SPRAYED INTO THE EXHAUST DUCT,
IT WILL ENTER THE GEARBOX BREATHER VENT AND CAUSE
CONTAMINATION OF THE ENGINE OIL SYSTEM.

(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.

WARNING TO PREVENT INJURY OR DAMAGE, MAKE SURE THAT


PEOPLE AND EQUIPMENT ARE CLEAR OF THE FAN BLADES
DURING STARTER CRANKING

(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.

(6) Repeat starter-crank rinse (one time).

(7) Perform Post-Rinse Engine Ground Run in accordance with the subtask that follows.

SUBTASK 71-00-03-170-003

B. Post-Rinse Engine Ground Run

EFFECTIVITY: FJ44-2C
71-00-03
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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.

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71-00-03
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Fig. 701 Location of Cleaning Areas

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Fig. 702 Location of Cleaning Areas

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TASK 71-00-03-170-803 Clean the Power Plant – Compressor Wash

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.

2 Perform engine cleaning at intervals recommended in Recommended


Maintenance, 05-50-00, P.B. 201.

5. Equipment and Materials

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
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Dec 12/17

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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

A. Remove the engine cowling. Refer to the Aircraft Maintenance Manual.

7. Procedures

SUBTASK 71-00-03-170-002

A. Prepare the Engine for Compressor Wash:

(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.

CAUTION TO ENSURE THAT CLEANING FLUIDS DO NOT ENTER FCU/FDU


OR AIRCRAFT BLEED SYSTEM, REMOVE CDP LINE FROM
FCU ELBOW (IF ENGINE CONFIGURATION HAS A CDP LINE).
SET AIRCRAFT BLEED OFF/CLOSED.

(2) Set engine bleed air OFF/CLOSED.

(3) Set ignition OFF.

(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.

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73-18-01, P.B. 401.

(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 .

B. Wash the Fan and Bypass Area:

WARNING SPINNER TIP IS EXTREMELY SHARP. COVER THE TIP DURING


MAINTENANCE TO PREVENT INJURY.

NOTE If cleaning fluid is purchased as concentrate, mix it per


manufacturer’s instructions.

(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.

WARNING TO PREVENT INJURY OR DAMAGE, MAKE SURE THAT


PEOPLE AND EQUIPMENT ARE CLEAR OF THE FAN BLADES
DURING STARTER CRANKING

(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).

C. Wash the Compressor Core:

(1) Equipment and tools for washing the compressor core:


Pressure Washer Tank (50-150 psi, 2.5 gallons minimum volume)
Hose for Connecting Pressure Washer Tank to –4 AN Male Fitting on HP Compressor Wash Nozzle

EFFECTIVITY: FJ44-2C
71-00-03
Page 708
Dec 12/17

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M83248/1-904 O-ring for HP Compressor Wash Nozzle and Borescope Port Plug
TL109739 or TL99920 HP Compressor Wash Nozzle

NOTE TL99926 ("Can, Pressure") is still acceptable for use, although no


longer manufactured by Williams International.

(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).

(6) Set Ignition OFF.

WARNING TO PREVENT INJURY OR DAMAGE, MAKE SURE THAT


PEOPLE AND EQUIPMENT ARE CLEAR OF THE FAN BLADES
DURING STARTER CRANKING

CAUTION DO NOT SPRAY INTO THE ENGINE EXHAUST DUCT FROM


THE REAR. IF FLUID IS SPRAYED INTO THE EXHAUST DUCT,
IT WILL ENTER THE GEARBOX BREATHER VENT AND CAUSE
CONTAMINATION OF THE ENGINE OIL SYSTEM.

(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

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WARNING TO PREVENT INJURY OR DAMAGE, MAKE SURE THAT


PEOPLE AND EQUIPMENT ARE CLEAR OF THE FAN BLADES
DURING STARTER CRANKING

(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) .

D. Prepare the Engine for Ground Run

(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

A. Install engine cowling. Refer to Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
71-00-03
Page 710
Dec 12/17

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Fig. 703 Location of Cleaning Areas

EFFECTIVITY: FJ44-2C
71-00-03
Page 711
Dec 12/17

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Fig. 704 HP Compressor Wash Nozzle – Removal/Installation

EFFECTIVITY: FJ44-2C
71-00-03
Page 712
Dec 12/17

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PRESERVING UNINSTALLED ENGINE - MAINTENANCE PRACTICES

TASK 71-00-21-620-801 Uninstalled Engine Preservation

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.

2. Equipment and Materials

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

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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

WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY CAREFUL


AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

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

A. Drain oil system as follows:

(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.

(2) Tag the engine "NO OIL INSTALLED".

NOTE Residual engine oil is sufficient to preserve the oil system.

SUBTASK 71-00-21-620-005

B. Perform the following steps to preserve the engine:

(1) Install all closures on the engine.

(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

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(4) Cut small openings in the barrier material at each engine mount pad.

(5) Insert three desiccant bags MAT-175 around engine.

(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

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Fig. 201 Engine Setup for Preservation

EFFECTIVITY: FJ44-2C
71-00-21
Page 204
Dec 12/17

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Fig. 202 Location of Closures

EFFECTIVITY: FJ44-2C
71-00-21
Page 205
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

71-00-21
206
Page
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PRESERVING INSTALLED ENGINE FOR NINE MONTHS OR MORE - MAINTENANCE PRACTICES

TASK 71-00-22-620-803 Installed Engine Preservation - More than Nine Months

1. General

This task provides procedures for preserving an installed engine for more than nine months. Refer
to the following illustration(s):
Figure 201

NOTES: 1 Before preserving, clean the power plant externally (installed or


uninstalled). Refer to 70-21-00, 701.

2 Engines stored more than six months require periodic inspection. Refer to 71-00-24, 201.

2. Equipment and Materials

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

A. Preserve the engine’s fuel system as follows:

EFFECTIVITY: FJ44-2C
71-00-22
Page 201
Dec 12/17

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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) Turn off fuel supply to engine.

(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.

(8) Turn off engine ignition system.

CAUTION STAY WITHIN THE STARTER/GENERATOR DUTY CYCLE LIMITS


WHEN MOTORING THE ENGINE.

(9) Adjust the power lever to idle.

(10) Motor the engine to 10% N2 speed (approx. 4000 RPM).

WARNING PRESERVATION OIL IS COMBUSTIBLE AND MUST BE KEPT FROM


OPEN FLAME OR EXCESSIVE HEAT. AVOID PROLONGED OR
REPEATED SKIN CONTACT WHICH MAY CAUSE SKIN IRRITATION.
REMOVE CONTAMINATED CLOTHING. WIPE MATERIAL FROM SKIN
AND WASH THOROUGHLY WITH SOAP AND WATER.

(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

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(14) Let all residual oil drain from the system.

(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

B. Drain oil system as follows:

(1) Drain the engine oil. Refer to 72-00-03, P.B. 301.

(2) Tag the engine "NO OIL INSTALLED".

NOTE Residual engine oil is sufficient to preserve the oil system.

SUBTASK 71-00-22-620-009

C. Perform the final protective procedures as follows:

(1) Secure a warning tag to the aircraft controls to indicate the engine has been preserved and
it should not be operated.

(2) Install closures to the aircraft inlet and exhaust areas.

EFFECTIVITY: FJ44-2C
71-00-22
Page 203
Dec 12/17

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Fig. 201 Engine Setup for Preservation

EFFECTIVITY: FJ44-2C
71-00-22
Page 204
Dec 12/17

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PRESERVING INSTALLED ENGINE FOR NINE MONTHS OR LESS - MAINTENANCE PRACTICES

TASK 71-00-23-620-804 Installed Engine Preservation - Nine Months or Less

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.

2. Equipment and Materials

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.

A. Turn off fuel supply to the engine.

B. Inspect engine to ensure the inlet area is clean and dry.

C. Install inlet and exhaust closures on the engine.

EFFECTIVITY: FJ44-2C
71-00-23
Page 201
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

71-00-23
202
Page
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STORAGE INSPECTION - MAINTENANCE PRACTICES

TASK 71-00-24-550-801 Storage Inspection

1. General

Engines which have been preserved must be inspected periodically for signs of corrosion or deterioration
of preservation materials.

2. Equipment and 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

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(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

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ENGINE SHIPPING/RECEIVING - MAINTENANCE PRACTICES

TASK 71-00-25-510-804 Engine Shipping

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

2. Equipment and Materials

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

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3. Procedures

SUBTASK 71-00-25-620-006

A. Prior to engine removal, determine engine preservation steps.

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.

B. Drain oil system as follows:

(1) Drain the engine oil. Refer to 72-00-03, P.B. 301.

(2) Tag the engine "NO OIL INSTALLED".

NOTE Residual engine oil is sufficient to preserve the oil system.

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:

CAUTION TO PREVENT DAMAGE TO THE ENGINE, MAKE SURE ALL SCREWS,


NUTS, WASHERS ON EACH SIDE ARE INSTALLED. A MISSING ITEM CAN
CAUSE THE ENGINE TO SHIFT, CAUSING SEVERE DAMAGE.

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).

(2) Install all caps and plugs on the engine.

EFFECTIVITY: FJ44-2C
71-00-25
Page 202
Dec 12/17

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Shipping Preparation – Caps and Plugs


Location Qty Description Size/Dimensions
Drain Port, Rear Bypass 1 Cap, Threaded -4 size
Duct
Front Bypass Duct, Fuel 1 Cap, Threaded -4 size
Drain Fitting
Fuel Control Unit, Motive 1 Plug, Threaded -6 size
Flow Port
Fuel Control Unit, Motive 1 O-Ring MIL-R-83248/1–906
Flow Port
Fuel Control Unit, TT2 2 Plastic Cap, Un-Threaded 0.750 ID x 0.75 long
Ports
Fuel Filter Delta P 1 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Indicator Connector
Fuel Pump, Fuel Inlet 1 Plug, Threaded -8 size
Fuel Pump, Fuel Inlet 1 O-Ring MIL-R-83248/1–908
Fuel Pump/FDU, Drain 1 Cap, Threaded -4 size
Port
Gearbox, Oil Pressure 1 Plug, Threaded -4 size
Port
Gearbox, Oil Pressure 1 O-Ring MIL-R-83248/1–904
Port
Gearbox, Oil 1 Plug, Threaded 1/2-20 thread
Temperature Port
Gearbox, Oil 1 O-Ring MIL-R-83248/1–905
Temperature Port
Gearbox, 2 Plexi-Glass Cover WI P/N 50728 or equivalent. Refer
Starter/Generator/Hydraulic to Figure 206.
Pump
Gearbox, 8 Nut, Studs 5/16-24 Hex Nut
Starter/Generator
/Hydraulic Pump
HP Bleed Port 2 Flange Cover, Soft Plastic 2.0 ID
HP Magnetic Speed 1 Plastic Cap, Un-Threaded 0.437 ID x 0.50 long
Pickup Connector
IFCU Connector 1 Cap, Threaded -6 size

EFFECTIVITY: FJ44-2C
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IFCU Fuel Pressure Port 1 Plug, Threaded -4 size


Ignition Exciter, 2 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Connector
Inlet/Exhaust Opening 2 Plastic Drum Liner 10 mil, 37 x 40 x 74 circum
Inlet/Exhaust Opening 2 Large Rubber Band 14 x .25 x .125
Jumper Harness 1 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Connector
LP Magnetic Speed 1 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Pickup Connector

(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

F. Install the engine into the shipping container as follows:

CAUTION TO PREVENT DAMAGE TO THE ENGINE, MAKE SURE ALL SCREWS,


NUTS, WASHERS ON EACH SIDE ARE INSTALLED. A MISSING ITEM CAN
CAUSE THE ENGINE TO SHIFT, CAUSING SEVERE DAMAGE.

(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:

(a) Place the engine logbook in a suitable container for protection.

(b) Secure logbook inside the container.

(c) Assemble lid assembly as shown in Figure 204

EFFECTIVITY: FJ44-2C
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(d) Secure container lid on container using keylock fasteners.

(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:

(a) Place the engine logbook in a suitable container for protection.

(b) Secure logbook inside the container.

(c) Assemble lid assembly as shown in Figure 205.

(d) Secure container lid on container using clips.

(e) If banding is required for shipment, use edge protectors and do not over-tighten banding.

(4) Assemble and secure metal engine container as follows:

(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.

(c) Secure logbook inside the container.

(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
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Fig. 201 Metal Container – Assemble Engine Shipping Mounts and Supports

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Fig. 202 Location of Closures

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Fig. 203 Metal Container Ready to Ship

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Fig. 204 Plastic Container – Assembly of Container Lid

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Fig. 205 Plastic Container – Hinged Panel

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Fig. 206 Gearbox Accessory Pads – Protective Shipping Covers

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TASK 71-00-25-520-801 Engine Receiving

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

5. Equipment and Materials

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

A. Prepare to remove the engine from the shipping/storage container as follows:

NOTE Two people are required for the following procedure.

(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
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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.

WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY


CAREFUL AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.

(6) Raise engine until clear of container.

(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.

(e) Place the lid on 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

(c) Secure the top of the lid assembly on the container.

(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
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(b) Fold container sides and secure as shown in Figure 212.

(c) Secure lid assembly top on container.

SUBTASK 71-00-25-520-002

B. Perform an acceptance check of the engine and container as follows:

(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

C. If required, service oil system . Refer to 72-00-03, P.B. 301.

EFFECTIVITY: FJ44-2C
71-00-25
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Fig. 207 Location of Closures

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Fig. 208 Installation of Engine in Container

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Fig. 209 Metal Container Ready to Ship

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Page 217
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Fig. 210 Plastic Engine Container – Storage of Engine Mounts


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Fig. 211 Plastic Engine Container – Break Down of Lid for Return Shipment

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Fig. 212 Plastic Engine Container – Hinged Panel

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Page 220
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ENGINE DEPRESERVATION - MAINTENANCE PRACTICES

TASK 71-00-26-630-801 Depreserve the Engine

1. General

This task provides procedures for depreserving the engine.

NOTE Engine should be in a condition suitable for motoring with systems connected
and engine accessories installed.

2. Equipment and Materials

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

B. As required, replenish the oil system. Refer to 72-00-03, P.B. 301.

EFFECTIVITY: FJ44-2C
71-00-26
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THIS PAGE LEFT INTENTIONALLY BLANK

71-00-26
202
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

IP AND HP COMPRESSORS (BORESCOPE) - INSPECTION/CHECK

TASK 71-00-30-220-802 Inspect the HP and IP Compressors with a Borescope

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.

2. Equipment and Materials

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

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IPC Reference
Subject Fig. Item Nomenclature
75-35-01 02 131 O-ring

3. Job Set-up

SUBTASK 71-00-30-010-002

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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.

A. Remove the starter/generator. Refer to the Aircraft Maintenance Manual.

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:

(a) Foreign object damage (FOD) Reject

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:

(a) FOD Reject

D. Remove the borescope plug assembly and O-ring from the top of the interstage housing. Refer
to Figure 602 .

E. Inspect IP compressor rotor blades (stage 3 only). Refer to Figure 603.

(1) Adjust the flexible fiberscope so that it points forward, toward the IP compressor (area C).
Inspect as follows:

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(a) FOD Reject

F. Inspect the HP compressor rotor. Refer to Figure 603 and Figure 604.

NOTE The HP compressor is in the same flowpath downstream of the IP compressor.

(1) Adjust the flexible fiberscope so that it points aft, toward the HP compressor.

NOTE A second person is required to turn the HP rotary assembly


during borescope inspection.

(2) Rotate the HP rotary group for inspection as follows:

(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.

(3) Inspect the following areas of the HP compressor rotor:

(a) Blade roots (qty 32)

(b) Main blade (area D) leading edges (qty 8)

(c) Long splitter blades (area E) leading edges (qty 8)

(d) Short splitter blades (area F) leading edges (qty 16)

(4) Inspect HP compressor rotor as follows:

(a) Cracks or FOD Reject

(5) Position the borescope between HP compressor rotor blades and rotate HP rotary group to
inspect diffuser vanes (area G) for:

(a) FOD Reject

(b) Buildup of material on vanes Reject

CAUTION TO PREVENT DAMAGE TO BORESCOPE OR ENGINE, ALLOW THE


STRAIGHTEST LINE POSSIBLE FOR REMOVAL FROM ENGINE.

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:

(1) Missing segments between holes Reject

(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
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(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.

H. Rotate HP compressor in reverse direction to allow removal of borescope.

I. Withdraw borescope from gas path and insert it through the bleed valve opening. Inspect the
compressor cover bleed holes (area H) for:

(1) Missing segments between bleed holes Reject

(2) Cracks (any amount) Reject

J. Inspect compressor cover for:

(1) Other damage or cracks. Reject

K. Inspect the compressor bleed valve (area J) for

(1) Fretting or galling where the valve meets Accept as long as valve movement is not
the case restricted.

(2) Missing or damaged bushing (6 o’clock Reject


position)

L. Install borescope plug assembly into interstage housing.

(1) Install plug into port on interstage housing bleed port cover.

(2) Torque plug assembly 90 to 100 inch-pounds (10.1 to 11.2 N.m).

5. Job Close-up

SUBTASK 71-00-30-410-002

A. Put the engine back to normal

(1) Install the starter/generator. Refer to the Aircraft Maintenance Manual.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
71-00-30
Page 604
Dec 12/17

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Fig. 601 IP Compressor Blades and Stator Vanes - Borescope Inspection

EFFECTIVITY: FJ44-2C
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Page 605
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Fig. 602 Borescope Plug

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Page 606
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Fig. 603 HP and IP Compressor Blades and Diffuser Vanes - Borescope Inspection

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71-00-30
Page 607
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Fig. 604 HP Compressor Rotor - Inspection

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Fig. 605 Engine Rotation Tool

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Page 609
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71-00-30
610
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LINE MAINTENANCE MANUAL - FJ44-2C

INTERNAL OIL LEAK (BORESCOPE) - INSPECTION/CHECK

TASK 71-00-32-220-801 Check for an Internal Oil Leak with a Borescope

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.

2. Equipment and Materials

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

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
71-00-32
Page 601
Dec 12/17

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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.

A. Inspect for an oil leak with the borescope

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

NOTE A wetted/damp surface located around the scupper holes is acceptable.

(d) A wetted/damp surface located around the scupper holes.

(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

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(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
71-00-32
Page 603
Dec 12/17

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Fig. 601 Internal Oil Leak - Facing Aft - Borescope Inspection

EFFECTIVITY: FJ44-2C
71-00-32
Page 604
Dec 12/17

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Fig. 602 Internal Oil Leak - Side View - Borescope Inspection

EFFECTIVITY: FJ44-2C
71-00-32
Page 605
Dec 12/17

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606
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LINE MAINTENANCE MANUAL - FJ44-2C

COMBUSTOR, FUEL SLINGER, AND HP TURBINE BLADES LEADING EDGE


(BORESCOPE) - INSPECTION/CHECK

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.

2. Equipment and Materials

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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

CH-SE-SU Pg Block Nomenclature


71-00-30 601 IP and HP Compressors (Borescope) - Inspection/Check
74-22-01 401 Igniter Plug - Removal/Installation

3. Job Set-up

SUBTASK 71-00-40-010-001

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

(4) Remove the starter/generator. Refer to the Aircraft Maintenance Manual.

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.

B. Inspect the fuel manifold supply tube (area A) as follows:

(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.

(3) Check the fuel manifold tube for:

(a) Signs of leakage (carbon, residue) Reject

(b) Signs of overtemperature Reject

(4) Remove the borescope.

C. Insert the borescope into the combustor area through either igniter port.

EFFECTIVITY: FJ44-2C
71-00-40
Page 602
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

NOTE If inspection reveals foreign object damage, you must also do a compressor
inspection. Refer to 71-00-30, P.B. 601.

D. Inspect the TOBI nozzle (area B) as follows:

(1) Move the borescope through the HP nozzle vanes and into the area behind the primary plate.

(2) Looking aft, inspect the TOBI nozzle (area B) for:

(a) Loose rivets Reject

(b) Separation of weld joint Reject

E. Inspect the combustor as follows:

(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.

(3) Inspect the combustor cover (area D) for:

(a) Signs of cracks, erosion or burn Reject


through

(b) Deformed shape caused by warpage Reject

(c) Cracks between inner row of dilution Reject


holes and adjacent effusion holes

F. Inspect Fuel Slinger

NOTE A second person is required to turn the HP rotary assembly


during borescope inspection.

(1) Rotate the HP rotary assembly for inspection as follows:

(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.

(2) Inspect the fuel slinger (area E) for:

(a) Clogged fuel delivery holes or slots Reject

G. Inspect the HP turbine nozzle vanes (area F) for cracks and pitting. Evaluate damage as follows:

(1) Cracks on leading edge of vanes Reject

(2) Pits that can be detected by borescope Reject

EFFECTIVITY: FJ44-2C
71-00-40
Page 603
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

H. Inspect HP turbine blades leading edges (area G) as follows:

CAUTION TO AVOID DAMAGE TO THE BORESCOPE OR THE ENGINE, DO NOT


ALLOW BORESCOPE TO CONTACT THE HP TURBINE ROTOR BLADES.

(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.

I. Carefully remove the borescope from the igniter port.

J. Inspect the combustor cover key as follows:

(1) Insert the borescope into the right-hand igniter port.

(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.

(3) Inspect the combustor cover key for:

(a) Cracks Reject

(b) Missing Reject

K. Install the igniter plugs. Refer to 74-22-01, P.B. 401.

5. Job Close-up

SUBTASK 71-00-40-410-001

A. Put the engine back to normal

(1) Install the starter/generator. Refer to the Aircraft Maintenance Manual.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
71-00-40
Page 604
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection

EFFECTIVITY: FJ44-2C
71-00-40
Page 605
Dec 12/17

© 2017 Williams International Co., LLC


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71-00-40
606
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LINE MAINTENANCE MANUAL - FJ44-2C

LP TURBINES (BORESCOPE) - INSPECTION/CHECK

TASK 71-00-50-220-801 Inspect the LP Turbines with a Borescope

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.

2. Equipment and Materials

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

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72-00-71 01 100 O-ring


72-00-71 01 120 O-ring
72-00-71 01 130 O-ring

3. Job Set-up

SUBTASK 71-00-50-010-001

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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

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WARNING BE CAREFUL TO PREVENT INJURY TO FINGERS AND HANDS


WHEN YOU TURN THE LP ROTARY ASSEMBLY.

CAUTION TO PREVENT DAMAGE TO THE FAN, DO NOT USE METAL TOOLS OR


SIMILAR HARD OBJECTS TO TURN THE LP ROTARY ASSEMBLY.

NOTE Clicking sound originating from rotation of No. 1 bearing is acceptable.

(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.

G. Carefully remove borescope from fuel drain port.

H. Install plug and torque 85 to 95 inch-pounds (9.6 to 10.7 N.m).

I. Lube two O-rings with assembly fluid (MAT-011) and install on rear fuel drain transfer tube.

J. Install transfer tube in port.

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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
71-00-50
Page 603
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 601 Borescope Plug Removal

EFFECTIVITY: FJ44-2C
71-00-50
Page 604
Dec 12/17

© 2017 Williams International Co., LLC


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Fig. 602 LP Turbines - Borescope Inspection

EFFECTIVITY: FJ44-2C
71-00-50
Page 605
Dec 12/17

© 2017 Williams International Co., LLC


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71-00-50
606
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HP NOZZLE/HP TURBINE TRAILING EDGE AND 1ST LP TURBINES LEADING EDGE


(BORESCOPE) - INSPECTION/CHECK

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.

2. Equipment and Materials

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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

CH-SE-SU Pg Block Nomenclature


77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation

3. Job Set-up

SUBTASK 71-00-52-010-001

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

(4) Remove the starter/generator. Refer to the Aircraft Maintenance Manual.

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.

D. Inspect 1st LP Turbine Rotor Blades

(1) Move the borescope aft, between the 1st LP nozzle vanes, and locate the 1st LP turbine
rotor blades (area A).

WARNING BE CAREFUL TO PREVENT INJURY TO FINGERS AND HANDS


WHEN YOU TURN THE LP ROTARY ASSEMBLY.

CAUTION TO PREVENT DAMAGE TO THE FAN, DO NOT USE METAL TOOLS OR


SIMILAR HARD OBJECTS TO TURN THE LP ROTARY ASSEMBLY.

(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.

E. Inspect HP Turbine Rotor Blades

EFFECTIVITY: FJ44-2C
71-00-52
Page 602
Dec 12/17

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(1) Turn the borescope so it is facing forward and locate the HP turbine rotor blades.

NOTE A second person is required to turn the HP rotary assembly


during borescope inspection

(2) Rotate the HP rotary assembly for inspection as follows:

(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.

F. Inspect HP Turbine Nozzle Vanes

(1) Move the borescope forward until it passes through the HP turbine rotor blades and the HP
nozzle vanes are visible.

CAUTION TO AVOID DAMAGE TO THE BORESCOPE OR THE ENGINE, DO NOT


ALLOW BORESCOPE TO CONTACT THE HP TURBINE NOZZLE VANES.

(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.

G. Carefully remove borescope from engine.

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

A. Put the engine back to normal

(1) Install the starter/generator. Refer to the Aircraft Maintenance Manual.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close the aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
71-00-52
Page 603
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"

EFFECTIVITY: FJ44-2C
71-00-52
Page 604
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER 72

ENGINE

Page 1
72-ENGINE Dec 12/17

© 2017 Williams International Co., LLC


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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 72
List of Effective Page Blocks
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ENGINE - DESCRIPTION AND OPERATION

TASK 72-00-00-860-807 Gearbox Assembly (4k Configuration) - Description and Operation

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.

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Fig. 1 Gearbox - Accessory Mounting Pads

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Fig. 2 Gearbox - Drive Train

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TASK 72-00-00-860-808 Bypass Duct Group - Description and Operation

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.

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Fig. 3 Bypass Duct Group

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TASK 72-00-00-860-811 Compressor System - Description and Operation

6. General

The engine has three compressor stages:

Low pressure (LP) compressor stage

Intermediate pressure (IP) compressor stage

High pressure (HP) compressor stage

These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:

Sealing air for oil and labyrinth seals

Cooling air for LP and HP turbine discs

7. Description

SUBTASK 72-00-00-860-005

A. The main parts of the compressor system are:

Spinner

Fan rotor (LP axial compressor)

Fan stator (LP compressor axial stator)

Case assembly

IP compressor rotor (axial)

IP compressor stator (axial)

HP compressor rotor (centrifugal)

Diffuser 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.

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(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.

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72-00-008
Page
Blank
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APPROVED ENGINE FUEL - SERVICING

TASK 72-00-01-610-804 Approved Engine Fuels

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

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NOTES: 1 MIL-DTL-27686 or MIL-DTL-85470 fuel system icing inhibitor is allowed in


amounts between 0.10% and 0.15% by volume, except JP-5. Allowable
concentration for JP-5 is 0.15% and 0.20% by volume.

Dupont Stadis 450 anti-static additive or equivalent is permitted to bring fuel


up to 300 conductive units but not to exceed 1 part per million.

SOHIO Biobor JF biocide additive is approved at a concentration not to


exceed 20 ppm (270 ppm total additive) of elemental boron.

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 T1301 (SH0396-92) fuel system icing inhibitor is allowed in amounts


between 0.10% and 0.15% by volume

3. Mixing of Fuels.

SUBTASK 72-00-01-610-007

A. Mixing of approved fuels is permissible.

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ENGINE SERVICING - OIL CHANGING/REPLENISHING - SERVICING

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

WARNINGS: 1 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

2 TO AVOID BURNS, ALLOW TIME AFTER ENGINE OPERATION FOR THE


OIL SYSTEM COMPONENTS AND TUBES TO COOL.

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.

3 DO NOT PUT USED OIL BACK INTO THE SYSTEM.

2. Equipment and Materials

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

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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

A. Prepare to service engine with oil

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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

(1) Vent oil tank by removing oil fill cap (dipstick).

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(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.

(5) Remove oil drain tube and install 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.

(9) Remove oil drain tube and install self-closing plug.

(10) Tag the engine "NO OIL INSTALLED".

SUBTASK 72-00-03-610-002

B. Check the engine oil level and add oil as required.

(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.

WARNING TO AVOID SUDDEN PRESSURE RELEASE FROM THE OIL TANK,


WAIT AT LEAST FIVE (5) MINUTES AFTER ENGINE SHUTDOWN
BEFORE REMOVING OIL FILL CAP/DIPSTICK.

(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.

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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.

(6) Record amount and type of oil added in engine logbook.

SUBTASK 72-00-03-610-004

C. Approved engine lubricating oils are listed below:


Approved Brand (Note 2) Specification
Mobil Jet II (Note 1) MIL-PRF-23699
Mobil 254 MIL-PRF-23699

NOTES: 1 Mobil Jet II is the preferred oil.

2 Mixing of approved oils is permissible when replenishing (topping


off) oil due to normal consumption.

SUBTASK 72-00-03-610-005

D. Oil servicing of dry engine

NOTES: 1 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.

(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.

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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

E. Check oil drain fittings for leaks.

5. Job Close-up

SUBTASK 72-00-03-410-001

A. Put the Engine Back to Normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE and NO OIL INSTALLED signs.

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Fig. 301 Oil Servicing - Dipstick


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Fig. 302 Oil Servicing - Oil Drain Fitting

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Fig. 303 Oil Servicing - Proper Installation of Oil Fill Cap/Dipstick

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OIL FILTER ANALYSIS PROGRAM - MAINTENANCE PRACTICES

TASK 72-00-05-870-801 Submit Oil Filter for Analysis

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.

2. Equipment and Materials

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

A. Prepare to Access Engine

(1) Install DO NOT OPERATE signs.

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(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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

B. Identify the oil filter with the following:

(1) Engine model number and serial number

(2) Aircraft number

(3) Date of oil filter sample

(4) Total engine run hours

(5) Oil filter hours (in engine operating hours)

(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

ATTN: Product Support

2280 E. West Maple Rd.

Walled Lake, MI, 48390

EFFECTIVITY: FJ44-2C
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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

A. Put the engine back to normal.

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
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72-00-05
204
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SPINNER - REMOVAL/INSTALLATION

TASK 72-00-30-020-801 Remove the Spinner

1. General

This task covers removal of the spinner from the engine. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

2. Equipment and Materials

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

A. Prepare to Disassemble the Engine

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical system.

EFFECTIVITY: FJ44-2C
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4. Procedures

SUBTASK 72-00-30-020-001

A. Remove Spinner Bolts

WARNING SPINNER TIP IS EXTREMELY SHARP AND SHOULD BE COVERED


BEFORE MAINTENANCE TO PREVENT INJURY. A REUSEABLE
COVER CAN BE MADE BY DIPPING THE SPINNER TIP IN
PLASTIC OR LATEX COATING MATERIAL.

CAUTION ONLY USE APPROVED MARKER. DO NOT SCRIBE A MARK


WHICH REMOVES/DISPLACES METAL.

NOTE During removal, the spinner is alignment match-marked in case trim


balancing is needed. Trim balancing is needed if LP vibration levels exceed
limits (high vibration with or without noise). Trim balance procedures
are in 71-00-00, P.B. 501 in the Maintenance Manual.

(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).

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Fig. 401 Spinner - Removal/Installation

EFFECTIVITY: FJ44-2C
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TASK 72-00-30-420-801 Install the Spinner

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

6. Equipment and Materials

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
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70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair


71-00-00 501 Power Plant - Adjustment/Test

7. Procedures

SUBTASK 72-00-30-420-001

WARNING USE EPOXY PRIMER (MAT-096) WITH ADEQUATE VENTILATION AND


AVOID CONTACT WITH SKIN OR EYES.

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

WARNING SPINNER TIP IS EXTREMELY SHARP AND SHOULD BE COVERED BEFORE


MAINTENANCE TO PREVENT INJURY. A REUSABLE COVER CAN BE MADE
BY DIPPING THE SPINNER TIP IN PLASTIC OR LATEX COATING MATERIAL.

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.

NOTE Make sure that there is an alignment mark on the spinner.


Refer to spinner removal task.

(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.

(4) Install the remaining five bolts and washers.

(5) Torque bolts 49 to 55 inch-pounds (5.5 - 6.2 N.m).

(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

A. Put the Engine Back to Normal

(1) Close aircraft circuit breakers.

(2) Remove DO NOT OPERATE signs.

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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Fig. 402 Spinner - Removal/Installation

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72-00-30
408
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FAN ROTOR - REMOVAL/INSTALLATION

TASK 72-00-31-020-802 Remove the Fan Rotor

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

2. Equipment and Materials

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
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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

B. Remove the spinner. Refer to 72-00-30, P.B. 401.

4. Procedures

SUBTASK 72-00-31-020-004

A. Remove the Fan Rotor

(1) Remove the fan locking plate (1-30).

(2) Measure the LP shaft stretch (stretched condition):

(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.

(b) Record as "stretched dimension".

(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
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(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.

NOTE Check the functional contact surface of the LP pusher for


wear or deformation. Reject pusher if contact surface flatness
deviates 0.005 inch (0.13 mm) or greater.

(c) Install TL37102-61 LP pusher over the rod.

(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.

(f) Install the TL37102-14 cap on the hydraulic cylinder.

CAUTION DO NOT EXCEED 7800 PSIG WHEN PUMPING HYDRAULIC


CYLINDER. EXCESSIVE PRESSURE WILL DAMAGE THE LP
SHAFT. IF MORE THAN 7800 PSIG IS REQUIRED TO LOOSEN NUT,
CONTACT WILLIAMS INTERNATIONAL CUSTOMER SUPPORT.

NOTE Two people are needed to remove the LP nut.

(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:

1 Increase the pressure in 50 psig increments.

2 Check for nut counterclockwise rotation after each increase in pressure.

3 Do not exceed 7800 psig.

4 Record pressure at which nut became loose.

(h) Release pump pressure and remove all details of stretch tooling.

(i) Remove the fan retainer nut

(4) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly.

(5) Record measurement as unstretched dimension.

(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
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(7) Install TL99502 puller on the fan and remove the fan from the LP shaft. Refer to Figure 404.

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Fig. 401 Fan - Stretch Dimension

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Fig. 402 Fan - Shaft Stretch Tool

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Fig. 403 Fan - Pilot Plate Removal

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Fig. 404 Fan - Removal

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TASK 72-00-31-420-802 Install the Fan Rotor

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

6. Equipment and Materials

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

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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

A. Install the Fan Rotor

(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
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NOTE Check the functional contact surface of the LP pusher for


wear or deformation. Reject pusher if contact surface flatness
deviates 0.005 inch (0.13 mm) or greater.

(c) Install TL37102-61 LP pusher over the rod.

(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.

(f) Install the TL37102-14 cap on the hydraulic cylinder.

CAUTION DO NOT EXCEED SPECIFIED PRESSURE WHEN PUMPING


HYDRAULIC CYLINDER. EXCESSIVE PRESSURE WILL
DAMAGE THE LP SHAFT.

(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

B. Measure the LP Shaft Stretch (Unstretched Condition)

(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.

(2) Record as unstretched dimension.

SUBTASK 72-00-31-420-006

C. Install Fan Retainer Nut

NOTE Magnesium hydroxide (MAT-013) must be dry before the fan


retainer nut is installed.

(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.

(b) Install TL37102-61 LP pusher over the rod.

EFFECTIVITY: FJ44-2C
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(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.

(e) Install the TL37102-14 cap on the hydraulic cylinder.

CAUTION DO NOT EXCEED SPECIFIED PRESSURE WHEN PUMPING


HYDRAULIC CYLINDER. EXCESSIVE PRESSURE WILL
DAMAGE THE LP SHAFT.

NOTE Two people are needed to install the LP nut.

(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.

(g) Release pump pressure.

(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.

(i) Remove all details of stretch tooling.

SUBTASK 72-00-31-220-004

D. Measure the LP Shaft Stretch (Stretched Condition)

(1) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly.

(2) Record as stretched dimension.

NOTE If shaft stretch dimension is below acceptable range, it is allowable to


repeat shaft stretch procedure and increase pump pressure, in 50 psi
increments, to an allowable maximum of 7500 psi.

(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
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SUBTASK 72-00-31-420-008

B. Install the spinner. Refer to 72-00-30, P.B. 401.

SUBTASK 72-00-31-410-004

C. Put the Engine Back to Normal

(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.

(2) Close aircraft circuit breakers

(3) Remove DO NOT OPERATE signs.

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
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Fig. 405 Fan - Shaft Stretch Tool

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Fig. 406 Fan - Stretch Dimension

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72-00-31
416
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CASE AND INSERT ASSY - REMOVAL/INSTALLATION

TASK 72-00-32-020-802 Remove the Case and Insert Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

2. Equipment and Materials

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

A. Prepare to Disassemble the Engine

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical system.

SUBTASK 72-00-32-020-005

B. Remove the spinner (1-10, 72-00-30). Refer to 72-00-30, P.B. 401.

EFFECTIVITY: FJ44-2C
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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

A. Remove the case and insert assembly as follows:

NOTE Mark location of all brackets before removal.

(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
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Fig. 401 Case and Insert Assembly - Removal/Installation

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TASK 72-00-32-420-802 Install the Case and Insert Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

6. Equipment and Materials

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
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Page 404
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71-00-00 501 Power Plant - Adjustment/Test


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

7. Procedures

SUBTASK 72-00-32-420-005

A. Install case and insert assembly as follows:

NOTE If case and insert assembly is replaced, transfer engine identification


plate to the new case and insert assembly. Refer to 72-32-10, P.B.
801, Repair in the Maintenance Manual.

(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).

(5) Install the following:

Forward ignition exciter bracket on the aft side of the flange

Harness clamps

Remaining bolts, washers, and nuts

(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).

(7) Torque nuts 25 to 28 inch-pounds (2.8 to 3.1 N.m).

EFFECTIVITY: FJ44-2C
72-00-32
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8. Job Close-up

SUBTASK 72-00-32-420-006

A. Install the ignition exciter(s). Refer to 74-10-01, P.B. 401.

SUBTASK 72-00-32-420-007

B. Install the fan rotor. Refer to 72-00-31, P.B. 401.

SUBTASK 72-00-32-420-008

C. Install the spinner. Refer to 72-00-30, P.B. 401.

SUBTASK 72-00-32-410-004

D. Put the Engine Back to Normal

(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.

(2) Close aircraft circuit breakers

(3) Remove DO NOT OPERATE signs.

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
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Fig. 402 Case and Insert Assembly - Removal/Installation

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Page 407
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72-00-32
408
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GEARBOX ASSY - REMOVAL/INSTALLATION

TASK 72-00-60-020-801 Remove the Gearbox Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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
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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

3. Job Set-up

SUBTASK 72-00-60-010-001

A. Prepare to Disassemble the Engine.

(1) Install DO NOT OPERATE signs.

(2) Open circuit breakers to isolate the engine electrical supply.

(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the cowling.

SUBTASK 72-00-60-020-001

B. Remove Gearbox Accessories

(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
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(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

A. Remove Gearbox Breather Tube – Flexible Configuration

(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.

CAUTION IF GEARBOX HAS SPRING-LOADED CONFIGURATION CARBON


SEALS, USE CAUTION WHEN REMOVING THE BREATHER TUBE.
THE BREATHER PORT CARBON SEAL IS NOT RETAINED WHEN THE
BREATHER TUBE ASSEMBLY IS REMOVED. MAKE SURE THAT THE
CARBON SEAL DOES NOT FALL OUT. YOU MAY INSTALL SHIPPING
COVER TP-216022 OR TEMPORARILY RE-INSTALL THE BREATHER
TUBE AS REQUIRED TO RETAIN CARBON SEAL.

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

B. Remove Gearbox Assembly

(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
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CAUTION THE ACCESSORY DRIVE SHAFT IS NOT SECURED AND MAY


BE DAMAGED IF DROPPED. REMOVE THE ACCESSORY DRIVE
SHAFT FROM THE INTERSTAGE HOUSING OR THE GEARBOX
ASSEMBLY BEFORE IT DROPS.

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.

(4) Put gearbox in a clean plastic bag to protect from contamination.

EFFECTIVITY: FJ44-2C
72-00-60
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Fig. 401 Gearbox - Removal/Installation - Flexible Breather Tube Configuration

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TASK 72-00-60-420-801 Install the Gearbox Assembly

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

CAUTION IF A NEW PART NUMBER GEARBOX IS INSTALLED ON THE ENGINE, REFER


TO THE ILLUSTRATED PARTS CATALOG (IPC) OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

6. Equipment and Materials

SUBTASK 72-00-60-942-002

A. Consumables

EFFECTIVITY: FJ44-2C
72-00-60
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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
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Dec 12/17

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7. Procedures

SUBTASK 72-00-60-420-002

A. Install Gearbox Assembly

(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.

(7) Torque bolts (1-20) 49 to 55 inch-pounds (5.5 to 6.2 N.m).

SUBTASK 72-00-60-420-006

B. Install Breather Tube – Flexible Breather Tube Configuration

EFFECTIVITY: FJ44-2C
72-00-60
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CAUTION IF GEARBOX HAS SPRING-LOADED CONFIGURATION CARBON SEALS,


USE CAUTION WHEN REMOVING THE SHIPPING COVER FROM THE
BREATHER PORT. THE BREATHER PORT CARBON SEAL IS NOT
RETAINED WHEN THE SHIPPING COVER IS REMOVED. MAKE SURE
THAT THE CARBON SEAL DOES NOT FALL OUT.

(1) Install breather tube O-ring (1-130) as follows:

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.

CAUTION USE CARE NOT TO PINCH O-RING DURING INSTALLATION


OF BREATHER TUBE FLANGE.

(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).

NOTE If hose portion of breather tube is disassembled from either end,


reassemble by lubricating ends with assembly fluid (MAT-011). Torque
hose clamp 16 to 18 inch-pounds (1.8 to 2.0 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

A. Install Gearbox Accessories

EFFECTIVITY: FJ44-2C
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(1) Install oil filter to gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.

CAUTION HYDRAULIC PUMP SPLINE SHOULD BE CLEAN AND DRY WHEN


INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANT.

(2) Install the hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.

CAUTION STARTER/GENERATOR SPLINE SHOULD BE CLEAN AND DRY WHEN


INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANT.

(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

C. Put Engine Back to Normal

(1) Refer to Aircraft Maintenance Manual (A.M.M.) and install the cowling.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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Page 410
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Fig. 402 Gearbox - Removal/Installation - Flexible Breather Tube Configuration

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REAR BYPASS DUCT ASSY - REMOVAL/INSTALLATION

TASK 72-00-71-020-801 Remove the Rear Bypass Duct Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare to Disassemble the Engine

(1) Install DO NOT OPERATE signs.

(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:

(a) Remove the cowling.

(b) Remove the tailpipe.

EFFECTIVITY: FJ44-2C
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4. Procedures

SUBTASK 72-00-71-020-002

A. Remove Rear Bypass Duct and Related Parts

(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.

(6) Remove trigger pin (1-100, 76-20-01) from housing.

(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:

(a) Remove bolt (1-10, 76-20-01) and washer (1–20).

(b) Remove spring (1-30) and lever spring shaft (1-40).

(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
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SUBTASK 72-00-71-020-003

B. Remove Rear Bypass Duct attaching hardware

(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.

(2) Remove the rear mount ring (1-60).

(3) Clean RTV from flange mating surfaces (if present).

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
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Fig. 401 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation

EFFECTIVITY: FJ44-2C
72-00-71
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Fig. 402 Rear Bypass Duct - Removal/Installation

EFFECTIVITY: FJ44-2C
72-00-71
Page 405
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TASK 72-00-71-420-801 Install the Rear Bypass Duct Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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 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.

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.

6. Equipment and Materials

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
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MAT-027 Alcohol, Isopropyl


MAT-090 Sealant, RTV 106
MAT-093 Compound Retaining, 620

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

A. Apply RTV to mounting flange

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WARNINGS: 1 ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A


COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND
KEEP AWAY FROM HEAT, SPARKS, OR FLAME.

2 ACETONE IS A CLEAR LIQUID WHICH IS FLAMMABLE AND


COMBUSTIBLE. IT IS SUGGESTED THAT A SOURCE OF CLEAN WATER
BE AVAILABLE IN WORK AREA FOR FLUSHING EYES AND SKIN. WEAR
CHEMICAL PROTECTIVE GOGGLES, GLOVES, AND CLOTHING TO
PREVENT SKIN CONTACT. AVOID BREATHING VAPORS AND MAKE
SURE ADEQUATE VENTILATION IS AVAILABLE OR USE A RESPIRATOR.
CONSUMPTION OF ACETONE MAY BE HAZARDOUS TO YOUR HEALTH.

(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

B. Mount rear bypass duct

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.

(3) Install rear mount sleeve on rear mount ring.

SUBTASK 72-00-71-420-005

C. Install transfer tube and drain fitting

(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
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(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):

(1) Install and adjust the trigger pin

(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.

4 Torque the bolt 25 to 28 inch-pounds (2.8 to 3.2 N.m).

(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
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(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.

2 Trip lever adjustment screw has been disturbed

3 Trip lever, rear housing, or rear bypass duct were replaced.

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

A. Put the Engine Back to Normal

(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.

NOTE RTV sealant (MAT-090) must be applied to the rear flange of


the rear bypass duct and the tailpipe flange.

(b) Install the tailpipe.

(c) Install the cowling.

(2) Close Aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
72-00-71
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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.

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Fig. 403 Rear Bypass Duct - Removal/Installation

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Fig. 404 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation

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Fig. 405 Rear Bypass Duct - Apply RTV to Flanges

EFFECTIVITY: FJ44-2C
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Fig. 406 Rear Bypass Duct - ITT Bracket Locations

EFFECTIVITY: FJ44-2C
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INTERNAL COOLING AND SEALING AIR SYSTEM - DESCRIPTION AND OPERATION

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.

2. Description and Operation

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
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72-02-002
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SPINNER - INSPECTION/CHECK

TASK 72-30-10-220-801 Visually Inspect the Spinner

1. General

This task covers visual inspection of the spinner.

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.

2. Equipment and Materials

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

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(1) Inspect the spinner tip for:

(a) Blunted condition within the limits of Repair, refer to 72-30-10, P.B. 801
repair.

(b) Blunted condition greater than the Reject


limits of repair

(2) Inspect the spinner surface for:

(a) Minor erosion, evidenced by a rough Remove roughness by lightly smoothing


surface and multiple small, shallow with handstone.
pits closely grouped (.005 inch max
depth).

(b) Nicks within the limits of repair. Repair, refer to 72-30-10, P.B. 801

(c) Nicks greater than the limits of repair Reject

(d) Scratches/gouges within the limits of Repair, refer to 72-30-10, P.B. 801
repair

(e) Scratches/gouges greater than the Reject


limits of repair.

(f) Dents within the limits of repair. Repair, refer to 72-30-10, P.B. 801

(g) Dents greater than the limits of repair Reject

WARNING USE EPOXY PRIMER (MAT-096) WITH ADEQUATE VENTILATION


AND AVOID CONTACT WITH SKIN OR EYES.

(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

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SPINNER - REPAIR

TASK 72-30-10-350-801 Blend Repair the Spinner

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

2. Equipment and Materials

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

A. General Blend Requirements

(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

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(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

Table 801 Blend Limits – FJ44

MAX DAMAGE SIZE MAX NUMBER OF BLENDS


Minor erosion See General Blend Requirements
0.015 inch deep face nicks Total area of nicks not to exceed 0.625 square inches
Scratches or gouges up to: Total area of scratches/gouges not to exceed 0.5
0.015 inch deep by 0.1 inch wide by 0.1 inch long; or square inches
0.005 inch deep by 0.010 inch wide by 0.5 inch long;
or
0.007 inch deep by 0.020 inch wide by 0.5 inch long.
0.10 inch deep dents; 0.5 inch max diameter Five dents maximum
Dents or nicks on spinner aft edge up to 0.050 inch Max quantity of 5 defects per part.
(1.27 mm) from edge face Surface length and radius of blends must be 3 times
the max blend depth.
Repaired areas checked using local penetrant
inspection. Refer to 70-42-15, P.B 601 for NDI
methods. No cracks allowed.

C. Repair blunted spinner tip as follows:

(1) The maximum damage allowed is that which can be repaired by grinding the tip to a maximum
radius of:

(a) FJ44-1 Series: 0.050 inch (1.27 mm)

(b) FJ44-2 Series: 0.080 inch (2.03 mm)

(c) FJ44-3 Series and FJ44-1AP: 0.080 inch (2.03 mm)

(d) FJ44-4 Series: 0.088 inch (2.23 mm)

(e) FJ33 Series: 0.064 inch (1.62 mm)

(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

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WARNING CHEMICAL CONVERSION SOLUTION IS TOXIC TO SKIN, EYES,


AND LUNGS. YOU MUST WEAR SKIN AND EYE PROTECTION.
AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL
VENTILATION IS USUALLY SUFFICIENT.

(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

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Fig. 801 Spinner - Repair

EFFECTIVITY: FJ44-2C
72-30-10
Page 804
Dec 12/17

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SPINNER PILOT PLATE ASSY - INSPECTION/CHECK

TASK 72-31-15-220-801 Visually Inspect the Spinner Pilot Plate Assembly

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.

2. Equipment and Materials

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

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3. Procedures

SUBTASK 72-31-15-220-002

A. Visually inspect the spinner pilot plate assy (1-40, 72-00-31) for:

(1) Burrs on pilot diameter Repair, refer to 70-42-11, P.B. 801

(2) Missing or damaged shank nuts or inserts, Reject.


depending on configuration

(3) Loose or missing roll pin Reject.

EFFECTIVITY: FJ44-2C
72-31-15
Page 602
Dec 12/17

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Fig. 601 Spinner Pilot Plate Assembly - Inspection

EFFECTIVITY: FJ44-2C
72-31-15
Page 603
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

72-31-15
604
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

FAN ROTOR - INSPECTION/CHECK

TASK 72-31-20-220-801 Visually Inspect the Fan Rotor

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.

2. Equipment and Materials

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

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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

WARNING SPINNER TIP IS EXTREMELY SHARP. USE CAUTION WHEN WORKING


AROUND SPINNER TO AVOID INJURY.

1. If you find damage to fan that indicates foreign object damage,


you must do a borescope inspection of the compressor
section. Refer to 71-00-30, P.B. 601.

2. If periodic inspection requirements require physical inspection


of fan rotor, all accessible surfaces must be closely examined
by touch and/or close visual inspection.

A. Prepare to inspect the Fan Rotor

(1) Install DO NOT OPERATE signs.

(2) Open circuit breakers to isolate the engine electrical supply.

(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.

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).

B. Visually inspect fan blades for damage as follows (Figure 601):

(1) Inspect the blade leading edges (Zones B, C, and D) for:

(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

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(b) Dents or nicks greater than limits of Reject


repair.

(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

(b) Nicks or dents greater than limits of Reject


repair

(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

(c) Nicks in zone F greater than limits of Reject


repair

(4) Inspect fan rotor tip (Zone D2) for:

(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

(b) Rub indication or damage greater Reject


than limits of repair

(c) Blue discoloration up to 0.125 inch Accept


(3.18 mm) depth

EFFECTIVITY: FJ44-2C
72-31-20
Page 603
Dec 12/17

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(d) Blue discoloration greater than 0.125 Reject


inch (3.18 mm) depth

(5) Area between blades

(a) Smooth machine tool marks on fan Accept


hub between blades up to 0.003 inch
(0.076 mm) deep

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:

(a) Deflection measures 0.070 inch (1.778 mm) or less.

(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:

(1) Inspect the splines for:

(a) Cracks, chips, gouges Reject

(b) Fretting indications (material transfer) Accept


which cannot be felt with a 0.060 inch
diameter stylus.

(c) Fretting indications (material transfer) Reject


which can be felt with a 0.060 inch
diameter stylus.

(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

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(2) Inspect the bore for:

(a) Cracks, chips, gouges, dents Reject

(b) Scratches on pilot diameters Accept

(c) Fretting indications (material transfer) Reject


which can be felt with a 0.060 inch
diameter stylus.

(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:

(a) Fretting Reject

(b) Wear Reject

(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.

(4) Inspect the webface of the rotor for:

(a) Cracks, nicks, gouges Reject

(5) Inspect the spinner clearance area of the rotor for:


(a) Tool mark (nick or dent) up to 0.010 Blend with aluminum oxide cloth to remove
inch (0.25 mm) deep raised material or sharp edges.

(6) Inspect the puller shoulder area of the rotor for:

(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

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(1) Light build-up of material Hand stone or polish with silicone carbide
or aluminum oxide 180 grit paper to
remove build-up.

(2) Straw color or excessive build-up of material Reject

SUBTASK 72-31-20-220-005

F. Measure fan rotor tip clearance as follows:

NOTE Measure tip clearance at the blade leading edge only.

(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

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Fig. 601 Fan Blade Edge Blending - Inspection Zones

EFFECTIVITY: FJ44-2C
72-31-20
Page 607
Dec 12/17

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Fig. 602 Fan Blade Surfaces – FJ44-2A and FJ44-2C – Inspection Zones

EFFECTIVITY: FJ44-2C
72-31-20
Page 608
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

FAN ROTOR - REPAIR

TASK 72-31-20-350-802 Blend Repair the Fan Rotor

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

2. Equipment and Materials

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

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3. Job Set-up

SUBTASK 72-31-20-010-005

WARNING SPINNER TIP IS EXTREMELY SHARP. USE CAUTION WHEN WORKING


AROUND SPINNER TO AVOID INJURY.

A. Prepare to Blend Repair the Fan Rotor

(1) Install DO NOT OPERATE signs.


(2) Open circuit breakers to isolate the engine electrical supply.

(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 72-31-20-350-002

A. Repair the Fan Rotor

(1) Clean the fan blades before blending or inspection.

EFFECTIVITY: FJ44-2C
72-31-20
Page 802
Dec 12/17

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CAUTIONS: 1 THE FAN IS MADE OF TITANIUM. DO NOT GRIND. USE


HAND BLENDING ONLY.

2 BE EXTREMELY CAREFUL WHEN BLENDING BLADES TO MAKE


SURE THAT TITANIUM IS NOT OVERHEATED (TOO HOT TO TOUCH).
OVERHEATING RESULTS IN A BLUE DISCOLORATION AND THE BLADE
IS EASILY CRACKED. IF THE FAN IS OVERHEATED, AS EVIDENCED
BY BLUE DISCOLORATION, RETURN THE FAN TO WILLIAMS
INTERNATIONAL FOR EVALUATION. REFER TO VISUAL INSPECTION
TASK FOR ALLOWABLE LIMITS FOR BLUE DISCOLORATION ON
THE TIP OF THE FAN BLADES. IF NECESSARY, SMOOTH ANY
MATERIAL THAT HAS DISPLACED ONTO THE PRESSURE SIDE OF
THE BLADE. USE 180 GRIT ALUMINUM OXIDE (MAT-040) OR SILICON
CARBIDE (MAT-042) CLOTH TO FINISH BLEND THE BLADES TO
REMOVE ANY NICKS, SHARP EDGES, OR TOOL MARKS.

3 IF BLENDING IS PERFORMED ON INSTALLED FAN ROTOR, DO


NOT ALLOW ANY REMOVED MATERIAL OR FOREIGN OBJECTS TO
ENTER COMPRESSOR GAS PATH WHEN BLENDING BLADES. ENGINE
WILL BE DAMAGED IF IT IS OPERATED WITH BLENDING DEBRIS
OR OTHER FOREIGN OBJECTS IN THE GAS PATH. USE VACUUM
EQUIPMENT TO ENSURE THAT ALL DEBRIS IS REMOVED.

4 FAN REPAIRS ALLOWED PER THE MANUAL MAY CAUSE


UNACCEPTABLE ACOUSTICAL EFFECTS (NOISE). IF SUCH
A CHARACTERISTIC IS INTRODUCED CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT FOR FURTHER DIRECTION.

(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.

(3) Blend Limits:


ZONE MAX BLENDABLE DAMAGE SIZE ALLOWABLE EXTENT OF BLEND
A No damage allowed. If there is a minor Light smoothing to remove any
scratch (<0.001 inch deep), polish roughness on the leading edge. No
to remove scratch. It is acceptable blending allowed.
to have minor erosion, evidenced
by rough leading edges (minute
serrations) and multiple small shallow
pits closely grouped.
B 0.060 inch deep dents and nicks. Total edge blending in Zone B not to
exceed 1 inch per blade. See Notes
1 and 3.

EFFECTIVITY: FJ44-2C
72-31-20
Page 803
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ZONE MAX BLENDABLE DAMAGE SIZE ALLOWABLE EXTENT OF BLEND


C 0.100 inch deep dents and nicks. Total edge blending in Zone C not to
exceed 1.5 inch per blade. See Notes
2 and 3.
D Not to exceed the zone dimensions Dimension "M" not to exceed 0.25
shown in Figure 801 inch per blade. Dimension "N" not to
exceed 1.0 inch per blade. See Note
1 and 3.

D2 (1) Blade-thickness grooves or (1) Smooth blend to remove sharp


scratches not to exceed 0.016 inch edges and raised material.
(0.40 mm) in depth. Three blades may (2) Blend for cosmetic acceptability
be blended up to 0.025 inch (0.63 mm) per general blend instructions.
deep. (3) Remove with MAT-040 or MAT-042
(2) Face nicks to 0.020 inch (0.50 abrasive paper using light pressure.
mm), 4 total per blade
(3) Aluminum metal build-up
E1 0.10 inch deep dents and nicks Total edge blending in Zone E1 not to
exceed 1.75 inch per blade. See Note
2.
E2 0.10 inch deep dents and nicks Total edge blending in Zone E2 not to
exceed 2.25 inch per blade. See Note
1.
F 0.020 inch deep face nicks. Five per side unless some are
back-to-back, then six total. See Note
3.

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.

(4) Remove blade damage as follows:

EFFECTIVITY: FJ44-2C
72-31-20
Page 804
Dec 12/17

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(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:

1 Use carborundum stone for blending.

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).

(b) Polish scored surfaces with aluminum oxide cloth.

(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

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Fig. 801 Fan Blade Edge Blending – Inspection Zones

EFFECTIVITY: FJ44-2C
72-31-20
Page 806
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Fig. 802 Fan Blade - Blending of Deep Edge Nicks

EFFECTIVITY: FJ44-2C
72-31-20
Page 807
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Fig. 803 Fan Blade Surfaces – FJ44-2A and FJ44-2C – Inspection Zones

EFFECTIVITY: FJ44-2C
72-31-20
Page 808
Dec 12/17

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CASE AND INSERT ASSEMBLY - INSPECTION/CHECK

TASK 72-32-10-220-801 Visually Inspect the Case and Insert Assembly

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:

72-00-32, Fig. 01 and 72-32-10, 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.

2. Equipment and Materials

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

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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

A. Visually inspect case as follows:

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.

(1) Inspect case surface for:

CAUTION DO NOT CONTACT ALUMINUM INSERT WITH ACID SOLUTION.

(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.

(2) Inspect the forward flange insert for:

(a) Bends or distortion Reject

(b) Wear/fretting with material transfer Reject


that is detectable by a 0.060 inch
diameter stylus

(c) Wear/fretting less than previous step Accept

EFFECTIVITY: FJ44-2C
72-32-10
Page 602
Dec 12/17

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(d) Loose or missing rivet Replace in accordance with approved


Repair Station instructions.

(3) Inspect the rear flange of the inlet case for:

(a) Bends or distortion Reject

(b) Wear/fretting with material transfer Reject


that is detectable by a 0.060 inch
diameter stylus

(c) Wear/fretting less than previous step Accept

(4) Inspect the outer surfaces and inner flowpath of the inlet case for:

(a) Nicks, gouges, dents; 0.030 inch Accept


(0.762 mm) deep x 0.25 (6.35 mm)
length and width; must be separated
by 2 inches (50.8 mm); 5 total

(b) Nicks, gouges, dents greater than Reject


previous step

(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.

B. Inspect the fan shroud insert for:

(1) Corrosion Clean with scotch brite pad. If pitting


remains, use a stiff nylon or bristle brush.
Do no use a metallic brush. It is also
allowable to use 600 grit aluminum oxide or
silicon carbide paper. Touch-up chemical
conversion coating in accordance with
70-42-12, P.B. 801 in the Maintenance
Manual.

(2) Bends or distortion Reject.


FJ44-1A Only: Return to Williams
International Repair Station for repair per
67804.

EFFECTIVITY: FJ44-2C
72-32-10
Page 603
Dec 12/17

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(3) Loose or missing rivets Replace in accordance with approved


Repair Station instructions.

(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.

(5) Nicks, gouges, dents greater than previous Reject.


step
FJ44-1A Only: Return to Williams
International Repair Station for repair per
67804.

(6) Visible cracks Blend to remove cracks using length and


width to depth ratio of 5 to 1.

(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.

(9) Chipping or damage to abradable greater Reject.


than previous steps
FJ44–1A Only: Return to Williams
International Repair Station for repair per
67804.

(10) Blistering or craze cracking of the abradable. Accept

SUBTASK 72-32-10-220-004

C. Inspect the fan shroud insert seal lands (ribs) for:

(1) Nicks from FOD Only 3 ribs can be affected.

EFFECTIVITY: FJ44-2C
72-32-10
Page 604
Dec 12/17

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Total length in one area must be less than


1.5 inch (38.1 mm).
Maximum depth is 0.050 inch (1.27 mm).
Total length from multiple area must be
less than 2.0 inch (50.8 mm).
Blend to a 5:1 ratio and perform penetrant
inspection for final approval.

SUBTASK 72-32-10-220-005

D. Inspect the fan shroud insert seal lands (ribs) for:

(1) Bends in ribs Bends in ribs up to a 2-inch circumferential


span are acceptable in up to four locations
(any ribs) provided the bend is such that an
0.080 inch pin gauge can still fit behind it.

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

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Fig. 601 Case and Insert Assembly - Inspection

EFFECTIVITY: FJ44-2C
72-32-10
Page 606
Dec 12/17

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Fig. 602 Case and Insert Assembly - Flange and Shroud Inserts

EFFECTIVITY: FJ44-2C
72-32-10
Page 607
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

72-32-10
608
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

CASE AND INSERT ASSEMBLY - REPAIR

TASK 72-32-10-350-801 Replace the Engine Identification Plate

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

2. Equipment and Materials

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

A. Replace the engine identification plate as follows:

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.

(3) Remove the engine identification plate.

(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

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(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

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Fig. 801 Case and Insert Assembly - Engine Identification Plate - Replace

EFFECTIVITY: FJ44-2C
72-32-10
Page 803
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

72-32-10
804
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

FAN STATOR - INSPECTION/CHECK

TASK 72-32-20-220-801 Visually Inspect the Fan Stator

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.

2. Equipment and Materials

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

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3. Job Set-up

SUBTASK 72-32-20-010-001

A. Prepare to inspect the fan stator:

(1) Install DO NOT OPERATE signs.

(2) Open circuit breakers to isolate the engine electrical supply.

(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.

SUBTASK 72-32-20-020-001

B. Remove the spinner. Refer to 72–00–30, P.B. 401.

SUBTASK 72-32-20-020-002

C. Remove the fan rotor. Refer to 72–00–31, P.B. 401.

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. Inspect the Fan Stator

(1) Inspect stator vane face surfaces (Zone A) for:

(a) Erosion within limits of repair. Repair, refer to 72-32-20, P.B. 801

(b) Erosion greater than previous step. Reject

(c) Nicks or pits within limits of repair. Repair, refer to 72-32-20, P.B. 801

(d) Nicks or pits greater than previous Reject


step

(e) Pitting on vane surfaces from Accept


corrosion that is less than 0.008 inch
(0.20 mm) deep.

(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

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(b) Nicks or dents greater than previous Reject


step.

(c) Erosion on leading edge within limits Repair, refer to 72-32-20, P.B. 801
of repair.

(d) Deflection (bending) of leading edge Maximum size of deflection is 0.110


from FOD. inch (2.794 mm). Straighten to best
condition using soft jaw pliers. Perform
fluorescent penetrant inspection on vanes
in accordance with Task 72-32-20-230-801
for final acceptance.

(3) Inspect the outer casing of the fan stator for:

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

(b) Gouges, dents, or holes greater than Reject


previous step.

(4) Inspect the inner casing of the fan stator for:

(a) Gouges or dents within the limits of Repair, refer to 72-32-20, P.B. 801
repair

(b) Gouges or dents greater than Reject


previous step

(5) Inspect the forward lip seal for:

(a) Rips on inner casing metal within the Repair, Refer to 72-32-20, P.B. 801
limits of repair.

(b) Damage greater than previous step Reject

(c) Damage to rubber material Repair in accordance with Repair


Instruction 123252.

(6) Inspect the center IP laby seal for:

(a) Assembly damage (cut) on aft edge of Accept


rubber material. Max circumference
of damaged area 180° max depth
0.005 inch (0.127 mm).

EFFECTIVITY: FJ44-2C
72-32-20
Page 603
Dec 12/17

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(b) Voids in rubber material up to max Accept


depth of 0.120 inch (3.04 mm) and
max diameter of 0.205 inch (5.20
mm). No voids breaking into side of
rubber. Minimum distance between
voids 0.40 inch (10.16 mm).

(c) (FJ44–1 Only) Grooves from laby seal Accept


rub or assembly damage up to 0.030
inch (0.76 mm) deep.

(d) Damage or voids greater than Repair in accordance with Repair


previous steps Instruction 123252.

(7) Inspect the urethane material which secures the vanes:

(a) Local discoloration and/or deformation Accept


(swelling) up to 0.060 inch (1.524
mm) in a 1 to 2 inch area on the
inner diameter. Vanes are not loose.
Half or more of the vane tip or hub
is incased in urethane that has not
become discolored.

(b) Damage, swelling, or discoloration of Reject


urethane greater than previous step.

(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.

(8) Inspect the aft lip seal for:

(a) Damage to rubber material Repair in accordance with Repair


Instruction 123252.

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

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Fig. 601 Fan Stator Vanes - Inspection Zones

EFFECTIVITY: FJ44-2C
72-32-20
Page 605
Dec 12/17

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72-32-20
606
Page
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LINE MAINTENANCE MANUAL - FJ44-2C

FAN STATOR - REPAIR

TASK 72-32-20-350-801 Blend Repair the Fan Stator

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

2. Equipment and Materials

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

A. Prepare to inspect the fan stator:

EFFECTIVITY: FJ44-2C
72-32-20
Page 801
Dec 12/17

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(1) Install DO NOT OPERATE signs.

(2) Open circuit breakers to isolate the engine electrical supply.

(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.

SUBTASK 72-32-20-020-004

B. Remove the spinner. Refer to 72–00–30, P.B. 401.

SUBTASK 72-32-20-020-005

C. Remove the fan rotor. Refer to 72–00–31, P.B. 401.

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

A. Blend Repair the Fan Stator Vanes

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.

(1) Clean the fan stator vanes.

(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

B. Blend Limits (refer to Figure 801):

EFFECTIVITY: FJ44-2C
72-32-20
Page 802
Dec 12/17

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NOTE If damage exceeds limits, refer to weld repair criteria.

ZONE MAX DAMAGE SIZE MAX NUMBER OF BLENDS


Minor Erosion Minor erosion, evidenced by rough
leading edge (minute serrations) and
multiple small shallow pits closely
grouped, is acceptable to a max depth
of 0.005 inches. Only light smoothing
A is necessary to remove roughness on
leading edge.
0.010 inch deep face nicks Three per side unless back-to-back,
then four total
0.030 inch deep pit One per vane
0.08 inch dents (local bends) Two per vane
0.008 inch deep face nicks Two per side unless back-to-back,
B then two total.
Upper 50% 0.12 inch leading/trailing edge nicks Four per vane; Max total blending in
of Vane Zone B not to exceed 4 inch length
Erosion on leading edge up to 0.025 Smooth raised material while
inch deep maintaining leading edge contour.
C 0.060 inch max blend depth provided No more than 2 blends per vane
Lower 50% adjacent vane is blended less than leading edge.
of Vane 0.040 inch No more than 6 blends total (all
surfaces) per vane.
No more than 12 blended vanes per
part.
Blend depth less than 0.010 inch
should not be counted in the above
criteria. Any number of blends at this
depth on any number of vanes is
acceptable.
0.25 inch by 0.25 inch gouges No limit
0.50 inch diameter dents 10 Maximum
Outer Casing
Forward edge only: 0.150 deep by 3.0 4 separate blend areas separated by
inch long (circumferential) 2.0 inches circumferential length.

EFFECTIVITY: FJ44-2C
72-32-20
Page 803
Dec 12/17

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ZONE MAX DAMAGE SIZE MAX NUMBER OF BLENDS


0.10 inch by 0.10 inch gouges No limit
Inner Casing
0.15 inch diameter dents 10 Maximum
Forward Lip 0.100 inch by 0.100 inch metal rips Two per part. Blend 3 times longer
Seal Inner than the depth of blend. Some rubber
Casing may be removed (minimize removal).
Radius sharp edges smoothly

SUBTASK 72-32-20-350-006

C. Remove damage as follows:

(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.

(f) Polish scored surfaces with aluminum oxide cloth (MAT-040).

D. Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure 801.

WARNING ANODIC SOLUTION (IRIDITE) MAT-050 IS TOXIC TO SKIN, EYES,


AND LUNGS. YOU MUST WEAR SKIN AND EYE PROTECTION.
AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL
VENTILATION IS USUALLY SUFFICIENT.

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

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Fig. 801 Fan Stator Vanes - Inspection Zones

EFFECTIVITY: FJ44-2C
72-32-20
Page 805
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72-32-20
806
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LINE MAINTENANCE MANUAL - FJ44-2C

LP SHAFT ASSEMBLY - INSPECTION/CHECK

TASK 72-35-22-220-803 Dimensionally Inspect the LP Shaft Forward End (Run-Out)

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.

2. Equipment and Materials

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

A. Prepare to inspect the LP shaft

(1) Install DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
72-35-22
Page 601
Dec 12/17

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(2) Open circuit breakers to isolate the engine electrical supply.

(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.

SUBTASK 72-35-22-020-007

B. Remove the spinner. Refer to 72-00-30, P.B. 401.

4. Procedures

SUBTASK 72-35-22-220-006

A. Take a run-out measurement on the ID of the LP shaft using a Dial indicator:

(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

B. Remove the fan rotor. Refer to 72-00-31, P.B. 401.

SUBTASK 72-35-22-220-007

C. Take a run-out measurement on the OD of the LP shaft

(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

B. Install the spinner. Refer to 72-00-30, P.B. 401.

SUBTASK 72-35-22-410-001

C. Put the engine back to normal

EFFECTIVITY: FJ44-2C
72-35-22
Page 602
Dec 12/17

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(1) Install the cowl. Refer to the Aircraft Maintenance Manual

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
72-35-22
Page 603
Dec 12/17

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72-35-22
604
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GEARBOX CARBON SEALS - REMOVAL/INSTALLATION

TASK 72-60-01-050-803 Remove Magnetic Carbon Seals from the Gearbox

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

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CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH ALTERNATE REMOVAL/INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG AND MAKE SURE THAT YOU IDENTIFY THE
CORRECT CONFIGURATION AND ARE WORKING TO THE CORRECT TASK

THIS TASK COVERS THE MAGNETIC CONFIGURATION.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX WHEN NOT IN USE. MAKE SURE TOOLS,
WORKKSPACE, AND FINGERS ARE CLEAN DURING MAINTENANCE. WEAR
POWDER-FREE LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

3 IF GEARBOX CARBON SEALS ARE CHANGED TO A DIFFERENT


CONFIGURATION, THE GEARBOX BREATHER TUBE MAY ALSO NEED TO BE
CHANGED. REFER TO THE APPLICABLE SERVICE BULLETIN, ILLUSTRATED
PARTS CATALOG (72–00–60), OR CONTACT WILLIAMS INTERNATIONAL
PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER TUBE IS A
COMPATIBLE CONFIGURATION. INSTALLING THE WRONG CONFIGURATION
COULD RESULT IN A SUDDEN LOSS OF OIL.

4 ACID FROM HUMAN HANDS IS CORROSIVE AND CAN CAUSE


BEARINGS TO FAIL. AVOID SKIN CONTACT WITH GEARBOX BEARINGS
WHEN REMOVING CARBON SEALS.

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

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3. Job Set-up

SUBTASK 72-60-01-010-006

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

(4) Drain the engine oil. Refer to 72-00-03, P.B. 301.

4. Procedures

SUBTASK 72-60-01-020-005

WARNINGS: 1 MAINTENANCE SHOULD NOT BE PERFORMED ON GEARBOXES OF BOTH


ENGINES FOR THE SAME AIRCRAFT SIMULTANEOUSLY. IMPROPER
ASSEMBLY OF GEARBOX CARBON SEALS CAN RESULT IN A SUDDEN
LOSS OF ENGINE OIL. FOLLOW ASSEMBLY INSTRUCTIONS AND
REFER TO ILLUSTRATED PARTS CATALOG OR APPLICABLE SERVICE
BULLETIN TO MAKE SURE CORRECT PART NUMBERS ARE USED.
ENGINE MUST BE GROUND TESTED FOR LEAKS AT MAX CONTINUOUS
POWER FOR 10 MINUTES FOLLOWING CARBON SEAL MAINTENANCE.
ENGINE SHOULD ALSO BE FLIGHT TESTED BEFORE PERFORMING
GEARBOX MAINTENANCE ON THE OPPOSITE ENGINE.

2 ENGINE OIL IS TOXIC TO THE SKIN. WEAR PROTECTIVE CLOTHING


WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE SKIN
MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

(3) Remove adapter from gearbox housing.

(4) Remove and discard both the adapter O-ring and the O-ring on face of gearbox housing.

(5) Remove seal case (carbon) (115) from gearshaft.

(6) Remove magnet from starter/generator adapter:

EFFECTIVITY: FJ44-2C
72-60-01
Page 403
Dec 12/17

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(a) Remove the magnet keeper from the adapter bore.

(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.

CAUTION HOLD GEARSHAFT FORWARD WHILE REMOVING ADAPTER AND


FUEL PUMP CARBON SEAL. THIS WILL KEEP THE GEARSHAFT
FROM BECOMING DISLODGED.

(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.

(4) Remove and discard adapter O-ring.

(5) Remove seal case (carbon) (75) from gearshaft.

(6) Remove magnet from fuel pump adapter:

(a) Remove the retaining ring (23) from the adapter bore.

(b) Remove the wave spring (22).

(c) Remove the magnet keeper (61).

(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

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CAUTION WHEN REPLACING EITHER THE FORWARD OR AFT HYDRAULIC PUMP


MAGNETIC CARBON SEAL, IT IS NECESSARY TO REPLACE BOTH
SEALS WITH NEW PARTS. REPLACING ONLY THE FORWARD SEAL CAN
DISLODGE THE AFT SEAL AND CAUSE A MAJOR OIL LEAK.

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.

(3) Remove adapter from gearbox housing

NOTE Hydraulic pump gearshaft may come out of the gearbox with the adapter.

(4) Remove and discard adapter O-ring.

(5) Remove magnet from hydraulic pump adapter:

(a) Remove the magnet keeper (96).

(b) Carefully, evenly drive the magnet (114) out of the adapter by hand (no hammer).

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT


TO PREVENT BEARING CONTAMINATION.

(6) Carefully remove hydraulic pump gearshaft from gearbox.

(7) Remove forward and aft carbon seal cases (35 and 115) from gearshaft.

(8) Remove the breather tube. Refer to 72-00-60, P.B. 401.

CAUTION TO PROTECT THE SEAL BORE IN THE GEARBOX HOUSING FROM


DAMAGE, DO NOT USE METAL TOOLS TO REMOVE THE AFT
MAGNET. MAKE SURE THAT ALL TOOLS ARE CLEAN.

(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

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EFFECTIVITY: FJ44-2C
Fig. 401 Gearbox Magnetic Seals - Removal/Installation 72-60-01
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Fig. 402 Gearbox - Carbon Seal Locations

EFFECTIVITY: FJ44-2C
72-60-01
Page 407
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Fig. 403 Gearbox - Hydraulic Pump/Breather Port Carbon Seal Locations

EFFECTIVITY: FJ44-2C
72-60-01
Page 408
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Fig. 404 Gearbox - FCU Carbon Seal Location

EFFECTIVITY: FJ44-2C
72-60-01
Page 409
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Fig. 405 Gearbox - Starter/Generator Carbon Seal Location

EFFECTIVITY: FJ44-2C
72-60-01
Page 410
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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

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WARNING MAINTENANCE SHOULD NOT BE PERFORMED ON GEARBOXES OF BOTH


ENGINES FOR THE SAME AIRCRAFT SIMULTANEOUSLY. IMPROPER ASSEMBLY
OF GEARBOX CARBON SEALS CAN RESULT IN A SUDDEN LOSS OF ENGINE
OIL. FOLLOW ASSEMBLY INSTRUCTIONS AND REFER TO ILLUSTRATED PARTS
CATALOG OR APPLICABLE SERVICE BULLETIN TO MAKE SURE CORRECT PART
NUMBERS ARE USED. ENGINE MUST BE GROUND TESTED FOR LEAKS AT MAX
CONTINUOUS POWER. ENGINE SHOULD ALSO BE FLIGHT TESTED BEFORE
PERFORMING GEARBOX MAINTENANCE ON THE OPPOSITE ENGINE.

CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH ALTERNATE REMOVAL/INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG AND MAKE SURE THAT YOU IDENTIFY THE
CORRECT CONFIGURATION AND ARE WORKING TO THE CORRECT TASK

THIS TASK COVERS THE TYPE 1 SPRING-LOADED CONFIGURATION


WITH NON-MAGNETIC SEAL RUNNERS.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX WHEN NOT IN USE. MAKE SURE TOOLS
AND FINGERS ARE CLEAN DURING MAINTENANCE. WEAR POWDER-FREE
LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

6. Equipment and Materials

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

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LINE MAINTENANCE MANUAL - FJ44-2C

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
72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation

7. Job Set-up

SUBTASK 72-60-01-010-053

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

8. Procedures

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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

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CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

(7) Cover open ports in gearbox to prevent contamination.

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.

(4) Remove O-ring (65) from the adapter.

(5) Remove the carbon seal (70) from the fuel pump adapter bore using driver TL99696-10 from
the kit.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

(8) Cover open ports in gearbox to prevent contamination

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

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(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.

(3) Remove O-ring (25) from the adapter.

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT


TO PREVENT BEARING CONTAMINATION.

(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.

(7) Cover open ports in gearbox to prevent contamination

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.

NOTE In order to remove/install the breather port carbon seal assembly, it is


necessary to remove the hydraulic pump gearshaft from the gearbox.

(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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 406 Gearbox Carbon Seals – Type 1 Spring-Loaded Configuration (4k)– Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 416
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

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.

Refer to the following illustration(s):


Figure 407
Figure 408

EFFECTIVITY: FJ44-2C
72-60-01
Page 417
Dec 12/17

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WARNING MAINTENANCE SHOULD NOT BE PERFORMED ON GEARBOXES OF BOTH


ENGINES FOR THE SAME AIRCRAFT SIMULTANEOUSLY. IMPROPER ASSEMBLY
OF GEARBOX CARBON SEALS CAN RESULT IN A SUDDEN LOSS OF ENGINE
OIL. FOLLOW ASSEMBLY INSTRUCTIONS AND REFER TO ILLUSTRATED PARTS
CATALOG OR APPLICABLE SERVICE BULLETIN TO MAKE SURE CORRECT PART
NUMBERS ARE USED. ENGINE MUST BE GROUND TESTED FOR LEAKS AT MAX
CONTINUOUS POWER. ENGINE SHOULD ALSO BE FLIGHT TESTED BEFORE
PERFORMING GEARBOX MAINTENANCE ON THE OPPOSITE ENGINE.

CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH ALTERNATE REMOVAL/INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG AND MAKE SURE THAT YOU IDENTIFY THE
CORRECT CONFIGURATION AND ARE WORKING TO THE CORRECT TASK

THIS TASK COVERS THE TYPE 2 OR TYPE 3 SPRING-LOADED CONFIGURATION.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX WHEN NOT IN USE. MAKE SURE TOOLS
AND FINGERS ARE CLEAN DURING MAINTENANCE. WEAR POWDER-FREE
LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

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.

10. Equipment and Materials

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

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LINE MAINTENANCE MANUAL - FJ44-2C

70-00-01 201 Assembly/Disassembly Maintenance Practices - Maintenance Practices


72-00-60 401 Gearbox Assy - Removal/Installation
73-18-01 401 Fuel Control Unit - Removal/Installation

11. Job Set-up

SUBTASK 72-60-01-010-053

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

12. Procedures

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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

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LINE MAINTENANCE MANUAL - FJ44-2C

(8) Inspect the inner diameter of gearshaft for damage; photograph and submit any evidence of
damage to WIProductSupport@williams-int.com.

(9) Cover open ports in gearbox to prevent contamination

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.

(4) Remove O-ring (65) from the adapter.

(5) Remove the carbon seal (70) from the fuel adapter bore using driver TL99696-10 from kit.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

(8) Cover open ports in gearbox to prevent contamination

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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT


TO PREVENT BEARING CONTAMINATION.

(3) Carefully remove the adapter.

EFFECTIVITY: FJ44-2C
72-60-01
Page 420
Dec 12/17

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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.

(4) Remove O-ring (25) from the adapter.

(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.

(9) Cover open ports in gearbox to prevent contamination.

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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT


TO PREVENT BEARING CONTAMINATION.

NOTE In order to remove/install the breather port carbon seal assembly, it is


necessary to remove the hydraulic pump gearshaft from the gearbox.

(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

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Fig. 407 Gearbox Carbon Seals – Type 2 Spring-Loaded Configuration (4k) – Removal/Installation
EFFECTIVITY: FJ44-2C
72-60-01
Page 422
Dec 12/17

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Fig. 408 Gearbox — Type 3 Spring-Loaded Carbon Seals (4k) — Removal/Installation


EFFECTIVITY: FJ44-2C
72-60-01
Page 423
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TASK 72-60-01-450-803 Install Magnetic Carbon Seals in Gearbox

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
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Page 424
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CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH ALTERNATE REMOVAL/INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG AND MAKE SURE THAT YOU IDENTIFY THE
CORRECT CONFIGURATION AND ARE WORKING TO THE CORRECT TASK

THIS TASK COVERS THE MAGNETIC CONFIGURATION.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX WHEN NOT IN USE. MAKE SURE TOOLS,
WORKSPACE, AND FINGERS ARE CLEAN DURING MAINTENANCE. WEAR
POWDER-FREE LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

3 IF GEARBOX CARBON SEALS ARE CHANGED TO A DIFFERENT


CONFIGURATION, THE GEARBOX BREATHER TUBE MAY NEED TO BE
CHANGED TOO. REFER TO THE APPLICABLE SERVICE BULLETIN, THE
ILLUSTRATED PARTS CATALOG (72-00-60), OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.

4 DO NOT REMOVE SEAL FROM PACKAGE UNTIL READY TO INSTALL


IT. TO PREVENT DAMAGE TO MATING FACES, DO NOT SLIDE SEAL
CASE ACROSS MAGNET. AVOID PLACING MAGNET IN AREA WHERE
SMALL METAL CHIPS MAY BE ATTRACTED TO IT.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual, before beginning work.

14. Equipment and Materials

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

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72-60-01 02 33 O-Ring (2)


72-60-01 02 65 O-Ring
72-60-01 02 72 O-Ring
72-60-01 02 73 O-Ring
72-60-01 02 105 O-Ring
72-60-01 02 107 O-Ring
72-60-01 02 112 O-Ring
72-60-01 02 113 O-Ring

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

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LINE MAINTENANCE MANUAL - FJ44-2C

15. Procedures

SUBTASK 72-60-01-420-005

WARNINGS: 1 IMPROPER ASSEMBLY OF GEARBOX CARBON SEALS CAN


RESULT IN A SUDDEN LOSS OF ENGINE OIL. CAREFULLY FOLLOW
ASSEMBLY INSTRUCTIONS AND REFER TO ILLUSTRATED PARTS
CATALOG OR APPLICABLE SERVICE BULLETIN TO MAKE SURE
CORRECT PART NUMBERS ARE USED.

2 ENGINE MUST BE GROUND TESTED FOR LEAKS AT MAX


CONTINUOUS POWER FOR 10 MINUTES FOLLOWING GEARBOX
CARBON SEAL REPLACEMENTS.

3 ENGINE SHOULD BE FLIGHT TESTED BEFORE PERFORMING GEARBOX


MAINTENANCE ON THE OPPOSITE ENGINE.

4 ENGINE OIL IS TOXIC TO THE SKIN. WEAR PROTECTIVE CLOTHING


WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE SKIN
MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

A. STARTER/GENERATOR. Use the procedure that follows to install magnetic carbon seals to the
starter/generator location:

(1) Prepare starter/generator adapter (100) for seal installation as follows:

(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).

(e) Inspect O-rings for twists or waves. Straighten O-rings as required.

(3) Assemble starter/generator adapter as follows:

EFFECTIVITY: FJ44-2C
72-60-01
Page 427
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LINE MAINTENANCE MANUAL - FJ44-2C

(a) Lubricate adapter bore with assembly fluid.

(b) Install magnet into adapter bore with the highly polished and umarked surface (mating
face) facing up. Verify magnet is seated.

WARNING WEAR THERMAL PROTECTIVE GLOVES WHEN HANDLING


HEATED OR CHILLED COMPONENTS.

(c) Chill the magnet keeper on dry ice prior to installation.

(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.

CAUTION IT IS IMPERATIVE THAT ALL ASSEMBLY FLUID BE REMOVED FROM


THE MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

(4) Prepare the gearshaft for carbon seal/adapter installation as follows:

(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.

CAUTION WHEN INSTALLING THE ASSEMBLED ADAPTER/CARBON SEAL


OVER THE GEARSHAFT, DO NOT REVERSE THE INSTALLATION
DIRECTION (I.E., PULL). THIS MAY CAUSE THE O-RING TO
ROLL AND UNSEAT THE CARBON SEAL.

NOTE Because of assembly tolerances, it may be necessary to hear the


bearing pocket in the starter/generator adapter with a heat gun
for 1 to 2 minutes before installing the adapter.

(5) Install adapter onto the gearbox as follows:

EFFECTIVITY: FJ44-2C
72-60-01
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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.

CAUTION DO NOT STRIKE THE ADAPTER PLATE OR APPLY


UNEVEN PRESSURE WHEN INSTALLING THE ADAPTER
PLATE ONTO THE GEARBOX.

NOTE If it is necessary to remove the adapter/carbon seal assembly, you


must remove the seal case and magnet and repeat all procedures
for inspecting, lubricating, and installing the carbon seal.

(6) Attach adapter to gearbox housing with bolts. Use on washer under each bolt.

(7) Torque bolts 55 to 65 inch-pounds (6.2 to 7.3 N.m).

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.

(3) Assemble fuel pump adapter as follows:

(a) Lubricate adapter bore with assembly fluid (MAT-011).

EFFECTIVITY: FJ44-2C
72-60-01
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(b) Install magnet into adapter bore with highly polished and unmarked surface (mating face)
facing up. Verify the magnet is seated.

(c) Install magnet keeper (61) against the magnet.

(d) Install wave spring (22) onto the magnet keeper.

(e) Install retaining ring (23) into adapter groove.

(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.

CAUTION IT IS IMPERATIVE THAT ALL ASSEMBLY FLUID BE REMOVED FROM


THE MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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:

(a) Wipe gearshaft to remove oil residue.

(b) Apply a light coating of assembly fluid to the gearshaft outer diameter.

CAUTION WHEN INSTALLING THE ASSEMBLED ADAPTER/CARBON SEAL


OVER THE GEARSHAFT, DO NOT REVERSE THE INSTALLATION
DIRECTION (I.E., PULL). THIS MAY CAUSE THE O-RING TO
ROLL AND UNSEAT THE CARBON SEAL.

(5) Install the adapter onto the gearbox as follows:

NOTE Maintain constant pressure on the adapter, holding it tightly against


the gearbox housing, until bolts are installed.

(a) Align the adapter/carbon seal assembly with the gearshaft end.

EFFECTIVITY: FJ44-2C
72-60-01
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CAUTION DO NOT STRIKE THE ADAPTER PLATE OR APPLY UNEVEN


PRESSURE WHEN INSTALLING IT ONTO THE GEARBOX.
THIS CAN DAMAGE THE BEARING.

(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.

NOTE If it is necessary to remove the adapter/carbon seal assembly, you


must remove the seal case and magnet and repeat all the procedures
for inspecting, lubricating, and installing the carbon seal.

(6) Attach the adapter to the gearbox housing with bolts. Use one washer under each bolt.

(7) Torque bolts 55 to 65 inch-pounds (6.2 to 7.3 N.m).

SUBTASK 72-60-01-420-007

CAUTION WHEN REPLACING EITHER THE FORWARD OR AFT HYDRAULIC PUMP


MAGNETIC CARBON SEAL, IT IS NECESSARY TO REPLACE BOTH SEALS
WITH NEW PARTS. REPLACING ONLY THE FORWARD SEAL CAN DISLODGE
THE AFT SEAL AND CAUSE A MAJOR OIL LEAK.

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.

(1) Prepare gearshaft as follows:

(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.

(b) Lubricate adapter bore with assembly fluid.

(4) Prepare new magnetic carbon seal (110) for installation as follows:

EFFECTIVITY: FJ44-2C
72-60-01
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(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.

(5) Assemble hydraulic pump as follows:

(a) Install magnet into adapter bore with the highly polished and unmarked surface (mating
face) facing up. Verify the magnet is seated.

WARNING WEAR THERMAL PROTECTIVE GLOVES WHEN HANDLING


HEATED OR CHILLED COMPONENTS.

(b) Chill the magnet keeper on dry ice prior to installation.

(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.

CAUTION IT IS IMPERATIVE THAT ALL ASSEMBLY FLUID BE REMOVED FROM


THE MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

(6) Install adapter onto the gearbox as follows:

NOTE Maintain constant pressure on the adapter, holding it tightly against


the gearbox housing, until bolts are installed.

(a) Align the adapter/carbon seal assembly with the gearshaft end.

EFFECTIVITY: FJ44-2C
72-60-01
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CAUTION DO NOT STRIKE THE ADAPTER PLATE OR APPLY UNEVEN


PRESSURE WHEN INSTALLING IT ONTO THE GEARBOX.
THIS CAN DAMAGE THE BEARING.

WHEN INSTALLING THE ASSEMBLED ADAPTER/CARBON SEAL


OVER THE GEARSHAFT, DO NOT REVERSE THE INSTALLATION
DIRECTION (I.E., PULL). THIS MAY CAUSE THE O-RING TO
ROLL AND UNSEAT THE CARBON SEAL.

(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.

NOTE If it is necessary to remove the adapter/carbon seal assembly, you


must remove the seal case and magnet and repeat all the procedures
for inspecting, lubricating, and installing the carbon seal.

(7) Attach adapter to gearbox housing with bolts. Use one washer under each bolt.

(8) Torque bolts 55 to 65 inch-pounds (6.2 to 7.3 N.m).

(9) Assemble breather tube carbon seal (30) 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 (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.

CAUTION IT IS IMPERATIVE THAT ALL ASSEMBLY FLUID BE REMOVED FROM


THE MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(g) Apply two or three drops of clean engine oil to the carbon seal or magnet.

EFFECTIVITY: FJ44-2C
72-60-01
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(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

CAUTION WHEN INSTALLING THE STARTER/GENERATOR, DO NOT ALLOW THE


SPLINE TO STRIKE THE GEARSHAFT AND DO NOT LET THE STARTER
GENERATOR "HANG" UNSUPPORTED ON THE STUDS BEFORE BEING
SECURED. THE WEIGHT OF THE STARTER GENERATOR CAN EASILY
UNSEAT THE CARBON SEAL, CAUSING AN OIL LEAK.

D. Install the gearbox-mounted accessories; refer to applicable procedures referenced above.


Installation instructions for the gearbox breather tube are found in 72-00-60, P.B. 401.

16. Job Close-up

SUBTASK 72-60-01-410-007

A. Put the engine back to normal

(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close the aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

SUBTASK 72-60-01-760-003

CAUTION LEAK CHECK GROUND RUN MUST BE PERFORMED AT MAX CONTINUOUS


POWER FOR 10 MINUTES AFTER GEARBOX CARBON SEAL MAINTENANCE.

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
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EFFECTIVITY: FJ44-2C
Fig. 409 Gearbox Magnetic Seals - Removal/Installation 72-60-01
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Fig. 410 Gearbox - Carbon Seal Locations

EFFECTIVITY: FJ44-2C
72-60-01
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Fig. 411 Gearbox - Hydraulic Pump/Breather Port Carbon Seal Locations

EFFECTIVITY: FJ44-2C
72-60-01
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Fig. 412 Gearbox - FCU Carbon Seal Location

EFFECTIVITY: FJ44-2C
72-60-01
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Fig. 413 Gearbox - Starter/Generator Carbon Seal Location

EFFECTIVITY: FJ44-2C
72-60-01
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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 72-60-01-450-805 Install Type 1 Spring-Loaded Carbon Seals in the 4k Gearbox

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
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CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH DIFFERENT REMOVAL / INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG TO IDENTIFY THE CONFIGURATION YOU ARE
WORKING WITH AND THEN WORK TO THE CORRESPONDING TASK.

THIS TASK COVERS THE TYPE 1 SPRING-LOADED CONFIGURATION

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX. ENSURE TOOLS, WORK SURFACES, AND
FINGERS ARE CLEAN DURING MAINTENANCE. WEAR POWDER-FREE
LATEX, NITRILE OR NEOPRENE GLOVES FOR THIS TASK.

3 IF GEARBOX CARBON SEALS ARE CHANGED TO A DIFFERENT


CONFIGURATION, THE GEARBOX BREATHER TUBE MAY NEED TO BE
CHANGED TOO. REFER TO THE APPLICABLE SERVICE BULLETIN, THE
ILLUSTRATED PARTS CATALOG (72-00-60), OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual, before beginning work.

18. Equipment and Materials

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
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LINE MAINTENANCE MANUAL - FJ44-2C

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
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19. Procedures

SUBTASK 72-60-01-420-050

WARNINGS: 1 IMPROPER ASSEMBLY OF GEARBOX CARBON SEALS CAN


RESULT IN A SUDDEN LOSS OF ENGINE OIL. CAREFULLY FOLLOW
ASSEMBLY INSTRUCTIONS AND REFER TO ILLUSTRATED PARTS
CATALOG OR APPLICABLE SERVICE BULLETIN TO VERIFY
CORRECT PART NUMBERS ARE USED.

2 ENGINE MUST BE GROUND RUN FOR LEAKS AT MAX CONTINUOUS


POWER FOLLOWING GEARBOX CARBON SEAL REPLACEMENTS.

3 ENGINE SHOULD BE FLIGHT TESTED BEFORE PERFORMING GEARBOX


MAINTENANCE ON THE OPPOSITE ENGINE.

4 ENGINE OIL IS TOXIC TO THE SKIN. WEAR PROTECTIVE CLOTHING


WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE SKIN
MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 415.

(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
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(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.

(b) Lubricate seal bore of the adapter with assembly fluid.

(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.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(4) Apply assembly fluid to new O-ring (105) and install on adapter.

(5) Prepare gearshaft for seal runner installation as follows:

(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEAT DAMAGE TO THE CARBON SEAL.

(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
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CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE


WHEN INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX.

(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).

CAUTION STARTER/GENERATOR SPLINE-SHAFT SHOULD BE CLEAN AND DRY WHEN


INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANTS. REPLACE
SPLINE-SHAFT O-RING PER THE AIRCRAFT MAINTENANCE MANUAL.

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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 415.

(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.

(2) Prepare adapter assembly (60) for seal installation as follows:

(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.

(b) Lubricate seal bore of adapter with assembly fluid.

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72-60-01
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(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.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION.

(4) Apply assembly fluid to new O-ring (65) and install on adapter.

(5) Prepare gearshaft for seal runner installation as follows:

(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE


WHEN INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX.

(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
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(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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 415.

(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.

(2) Prepare adapter assembly (20) for seal installation as follows:

(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.

(b) Lubricate seal bore of adapter with assembly fluid.

(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 TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(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.

(6) Prepare gearshaft for seal runner installation as follows:

EFFECTIVITY: FJ44-2C
72-60-01
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(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE


WHEN INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX.

(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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 415.

(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

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(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT.


MAKE SURE THAT ALL WORK SURFACES ARE CLEAN.

(2) Prepare gearshaft surface for seal installation, as follows:

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(6) Apply approximately three drops of fresh engine oil (MAT-001) to the carbon seal or runner.

EFFECTIVITY: FJ44-2C
72-60-01
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(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.

CAUTION BE CAREFUL NOT TO PINCH THE O-RING DURING INSTALLATION


OF BREATHER TUBE.

NOTE Breather tube should be disconnected from the flexible breather


hose to allow for proper installation.

(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.

20. Job Close-up

SUBTASK 72-60-01-410-050

A. Put the engine back to normal

(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close the aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

CAUTION LEAK CHECK GROUND RUN MUST BE PERFORMED AT MAX CONTINUOUS


POWER AFTER GEARBOX CARBON SEAL MAINTENANCE.

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
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Fig. 414 Gearbox – Type 1 Spring-Loaded Carbon Seals (4k) – Removal/Installation


EFFECTIVITY: FJ44-2C
72-60-01
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Fig. 415 Gearbox – Seal Runners – Sealing Surface Identification

EFFECTIVITY: FJ44-2C
72-60-01
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TASK 72-60-01-450-807 Install Type 2 Spring-Loaded Carbon Seals in the 4k Gearbox

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.

Refer to the following illustration(s):


Figure 416
Figure 417
Figure 418
Figure 419
Figure 420
Figure 421
Figure 422
Figure 423

Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:

72-60-01, Fig. 04.

EFFECTIVITY: FJ44-2C
72-60-01
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CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH DIFFERING REMOVAL / INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG TO IDENTIFY THE CONFIGURATION YOU ARE
WORKING WITH AND THEN WORK TO THE CORRESPONDING TASK.

THIS TASK COVERS THE TYPE 2 SPRING-LOADED CONFIGURATION.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX. ENSURE TOOLS, WORK SURFACES, AND
FINGERS ARE CLEAN DURING MAINTENANCE. WEAR POWDER-FREE
LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

3 IF GEARBOX CARBON SEALS ARE CHANGED TO A DIFFERENT


CONFIGURATION, THE GEARBOX BREATHER TUBE MAY NEED TO BE
CHANGED TOO. REFER TO THE APPLICABLE SERVICE BULLETIN, THE
ILLUSTRATED PARTS CATALOG (72-00-60), OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual, before beginning work.

22. Equipment and Materials

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
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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
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23. Procedures

WARNINGS: 1 IMPROPER ASSEMBLY OF GEARBOX CARBON SEALS CAN RESULT


IN A SUDDEN LOSS OF ENGINE OIL AND/OR DAMAGE TO ENGINE
HARDWARE. CAREFULLY FOLLOW ASSEMBLY INSTRUCTIONS AND REFER
TO ILLUSTRATED PARTS CATALOG OR APPLICABLE SERVICE BULLETIN
TO VERIFY CORRECT PART NUMBERS ARE USED.

2 ENGINE MUST BE GROUND RUN FOR LEAKS AT MAX CONTINUOUS POWER


FOLLOWING GEARBOX CARBON SEAL REPLACEMENTS.

3 ENGINE SHOULD BE FLIGHT TESTED BEFORE PERFORMING GEARBOX


MAINTENANCE ON THE OPPOSITE ENGINE.

4 ENGINE OIL IS TOXIC TO THE SKIN. WEAR PROTECTIVE CLOTHING


WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE SKIN
MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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

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(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.

(b) Lubricate seal bore of the adapter with assembly fluid.

(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.

CAUTIONS: 1 TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

2 WHEN INSTALLING SPRING WASHER (108), 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.

2 Make sure that the overlap portion of the wave spring is


wound as shown in Figure 418

(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.

(7) Prepare gearshaft for seal runner installation as follows:

EFFECTIVITY: FJ44-2C
72-60-01
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(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEAT DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE WHEN


INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX. THIS CAN
CAUSE THE WAVE SPRING TO DISLODGE AND DAMAGE THE BEARING.

(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).

CAUTION STARTER/GENERATOR SPLINE-SHAFT SHOULD BE CLEAN AND DRY WHEN


INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANTS. REPLACE
SPLINE-SHAFT O-RING PER THE AIRCRAFT MAINTENANCE MANUAL.

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
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NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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.

(2) Prepare adapter assembly (60) for seal installation, as follows:

(a) Clean adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.

(b) Lubricate seal bore of the adapter with assembly fluid.

(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.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(4) Apply assembly fluid to new O-ring (65) and install on adapter.

(5) Prepare gearshaft for seal runner installation as follows:

(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.

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72-60-01
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CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE


WHEN INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX.

(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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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.

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(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.

(2) Prepare adapter assembly (20) for seal installation as follows:

(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.

(b) Lubricate seal bore of adapter with assembly fluid.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(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.

2 Make sure that the overlap portion of the wave spring is


wound as shown in Figure 418

(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
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(6) Apply assembly fluid to new O-ring (25) and install on adapter.

(7) Prepare gearshaft for seal runner installation as follows:

(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE WHEN


INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX. THIS CAN
CAUSE THE WAVE SPRING TO DISLODGE AND DAMAGE THE BEARING.

(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:

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72-60-01
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NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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.

(2) Prepare gearshaft surface for seal installation, as follows:

(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
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CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION BE CAREFUL NOT TO PINCH THE BREATHER TUBE O-RING


DURING INSTALLATION OF BREATHER TUBE.

NOTE Breather tube should be disconnected from the flexible breather


hose to allow for proper installation.

(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.

24. Job Close-up

SUBTASK 72-60-01-410-050

A. Put the engine back to normal

(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close the aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

CAUTION LEAK CHECK GROUND RUN MUST BE PERFORMED AT MAX CONTINUOUS


POWER AFTER GEARBOX CARBON SEAL MAINTENANCE.

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
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Fig. 416 Gearbox – Type 2 Spring-Loaded Carbon Seals (4k) – Removal/Installation


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Fig. 417 Gearbox – Seal Runners – Identification of Sealing Surfaces

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Fig. 418 Wave Spring – Proper Winding of Overlap

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Fig. 419 Properly Assembled Type 2 Starter/Generator Adapter, 4k Gearbox

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Fig. 420 Properly Assembled Type 2 Starter/Generator Adapter, 4k Gearbox — Detail

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Fig. 421 Type 2 Wave Spring - Starter/Generator Adapter and Hydraulic Pump Adapter, 4k Gearbox

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Fig. 422 Properly Assembled Type 2 Hydraulic Pump Adapter, 4k Gearbox

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Fig. 423 Properly Assembled Type 2 Hydraulic Pump Adapter, 4k Gearbox— Detail

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TASK 72-60-01-450-811 Install Type 3 Spring-Loaded Configuration Carbon Seals in the 4k


Gearbox

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.

Refer to the following illustration(s):


Figure 424
Figure 425
Figure 426
Figure 427
Figure 428
Figure 429
Figure 430
Figure 431

Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:

72-60-01, Fig. 05.

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CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS


WITH DIFFERING REMOVAL / INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG TO IDENTIFY THE CONFIGURATION YOU ARE
WORKING WITH AND THEN WORK TO THE CORRESPONDING TASK.

THIS TASK COVERS THE TYPE 3 SPRING-LOADED CONFIGURATION.

2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL


OPEN PORTS IN THE GEARBOX. ENSURE TOOLS, WORK SURFACES, AND
FINGERS ARE CLEAN DURING MAINTENANCE. WEAR POWDER-FREE
LATEX, NITRILE, OR NEOPRENE GLOVES FOR THIS TASK.

3 IF GEARBOX CARBON SEALS ARE CHANGED TO A DIFFERENT


CONFIGURATION, THE GEARBOX BREATHER TUBE MAY NEED TO BE
CHANGED TOO. REFER TO THE APPLICABLE SERVICE BULLETIN, THE
ILLUSTRATED PARTS CATALOG (72-00-60), OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual, before beginning work.

26. Equipment and Materials

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
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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
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27. Procedures

WARNINGS: 1 IMPROPER ASSEMBLY OF GEARBOX CARBON SEALS CAN RESULT


IN A SUDDEN LOSS OF ENGINE OIL AND/OR DAMAGE TO ENGINE
HARDWARE. CAREFULLY FOLLOW ASSEMBLY INSTRUCTIONS AND REFER
TO ILLUSTRATED PARTS CATALOG OR APPLICABLE SERVICE BULLETIN
TO VERIFY CORRECT PART NUMBERS ARE USED.

2 ENGINE MUST BE GROUND RUN FOR LEAKS AT MAX CONTINUOUS POWER


FOLLOWING GEARBOX CARBON SEAL REPLACEMENTS.

3 ENGINE SHOULD BE FLIGHT TESTED BEFORE PERFORMING GEARBOX


MAINTENANCE ON THE OPPOSITE ENGINE.

4 ENGINE OIL IS TOXIC TO THE SKIN. WEAR PROTECTIVE CLOTHING


WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE SKIN
MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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
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(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.

(b) Lubricate seal bore of the adapter with assembly fluid.

(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.

CAUTIONS: 1 TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

2 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.

2 Make sure that the overlap portion of the wave spring is


wound as shown in Figure 426

(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.

(7) Prepare gearshaft for seal runner installation as follows:

EFFECTIVITY: FJ44-2C
72-60-01
Page 477
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE
TO REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL
RESULT IN OVERHEAT DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE WHEN


INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX. THIS CAN
CAUSE THE WAVE SPRING TO DISLODGE AND DAMAGE THE BEARING.

(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).

CAUTION STARTER/GENERATOR SPLINE-SHAFT SHOULD BE CLEAN AND DRY WHEN


INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANTS. REPLACE
SPLINE-SHAFT O-RING PER THE AIRCRAFT MAINTENANCE MANUAL.

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

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NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 425.

(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.

(2) Prepare adapter assembly (60) for seal installation, as follows:

(a) Clean adapter bore and face with alcohol (MAT-027) and a clean, lint-free cloth.

(b) Lubricate seal bore of the adapter with assembly fluid.

(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.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(4) Apply assembly fluid to new O-ring (65) and install on adapter.

(5) Prepare gearshaft for seal runner installation as follows:

(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

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CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE


WHEN INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX.

(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.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 417.

(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

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(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.

(2) Prepare adapter assembly (20) for seal installation as follows:

(a) Clean the adapter bore and face with alcohol and a clean, lint-free cloth.

(b) Lubricate seal bore of adapter with assembly fluid.

CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON


SURFACE DURING INSTALLATION

(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.

2 Make sure that the overlap portion of the wave spring is


wound as shown in Figure 418

(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

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(6) Apply assembly fluid to new O-ring (25) and install on adapter.

(7) Prepare gearshaft for seal runner installation as follows:

(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.

CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT


BEARING CONTAMINATION.

(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.

CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION DO NOT STRIKE ADAPTER PLATE OR APPLY UN-EVEN PRESSURE WHEN


INSTALLING THE ADAPTER PLATE ONTO THE GEARBOX. THIS CAN
CAUSE THE WAVE SPRING TO DISLODGE AND DAMAGE THE BEARING.

(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

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NOTES: 1 Carbon seals and seal runners must not be replaced individually.
They must always be replaced as a set.

2 Seal runners have either an etched-pattern sealing surface or a


highly-polished sealing surface. See Figure 425.

(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.

(2) Prepare gearshaft surface for seal installation, as follows:

(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

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CAUTION IT IS IMPERATIVE ALL ASSEMBLY FLUID IS REMOVED FROM THE


MATING FACES OF THE CARBON SEAL AND RUNNER. FAILURE TO
REMOVE ALL ASSEMBLY FLUID FROM THE SEAL FACES WILL RESULT
IN OVERHEATING DAMAGE TO THE CARBON SEAL.

(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.

CAUTION BE CAREFUL NOT TO PINCH THE BREATHER TUBE O-RING


DURING INSTALLATION OF BREATHER TUBE.

NOTE Breather tube should be disconnected from the flexible breather


hose to allow for proper installation.

(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.

28. Job Close-up

SUBTASK 72-60-01-410-052

A. Put the engine back to normal

(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.

(2) Install the cowling. Refer to the Aircraft Maintenance Manual.

(3) Close the aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

CAUTION LEAK CHECK GROUND RUN MUST BE PERFORMED AT MAX CONTINUOUS


POWER AFTER GEARBOX CARBON SEAL MAINTENANCE.

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

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Fig. 424 Gearbox — Type 3 Spring-Loaded Carbon Seals (4k) — Removal/Installation


EFFECTIVITY: FJ44-2C
72-60-01
Page 485
Dec 12/17

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Fig. 425 Gearbox — Seal Runners — Identification of Sealing Surfaces

EFFECTIVITY: FJ44-2C
72-60-01
Page 486
Dec 12/17

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Fig. 426 Wave Spring — Proper Winding of Overlap

EFFECTIVITY: FJ44-2C
72-60-01
Page 487
Dec 12/17

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Fig. 427 Properly Assembled Type 3 Starter/Generator Adapter, 4k Gearbox

EFFECTIVITY: FJ44-2C
72-60-01
Page 488
Dec 12/17

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Fig. 428 Properly Assembled Type 3 Starter/Generator Adapter, 4k Gearbox — Detail

EFFECTIVITY: FJ44-2C
72-60-01
Page 489
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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

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Fig. 430 Properly Assembled Type 3 Hydraulic Pump Adapter, 4k Gearbox

EFFECTIVITY: FJ44-2C
72-60-01
Page 491
Dec 12/17

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Fig. 431 Properly Assembled Type 3 Hydraulic Pump Adapter, 4k Gearbox — Detail

EFFECTIVITY: FJ44-2C
72-60-01
Page 492
Dec 12/17

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OIL FILTER DIFFERENTIAL PRESSURE (DELTA P) INDICATOR - REMOVAL/INSTALLATION

TASK 72-60-02-050-801 Remove the Oil Filter Delta P Indicator

1. General

This task covers removal of the oil filter delta P indicator from the gearbox. Refer to the following
illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201


in the Maintenance Manual, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

SUBTASK 72-60-02-941-001

A. Standard Equipment
Oil Drain Pan

3. Job Set-up

SUBTASK 72-60-02-010-001

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
72-60-02
Page 401
Dec 12/17

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4. Procedures

SUBTASK 72-60-02-020-001

WARNING ENGINE OIL (SYNTHETIC) (MAT-001) IS TOXIC TO THE SKIN. WEAR


PROTECTIVE CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT
CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN
IF EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

A. Remove oil filter delta P Indicator

(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.

(3) Remove delta P indicator from gearbox port.

(4) Remove two O-rings from delta P indicator.

EFFECTIVITY: FJ44-2C
72-60-02
Page 402
Dec 12/17

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Fig. 401 Oil Filter Delta P Indicator – Removal/Installation

EFFECTIVITY: FJ44-2C
72-60-02
Page 403
Dec 12/17

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TASK 72-60-02-450-801 Install the Oil Filter Delta P Indicator

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

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN OIL


FILTER. TO PREVENT CONTAMINATION OF THE OIL SYSTEM, MAKE
SURE THAT PORTS AND COMPONENT MATING SURFACES ARE KEPT
EXTREMELY CLEAN DURING MAINTENANCE.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B. 201 in


the Maintenance Manual, before beginning work.

6. Equipment and Materials

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
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Page 404
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71-00-00 501 Power Plant - Adjustment/Test


72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing

7. Procedures

SUBTASK 72-60-02-420-001

A. Install oil filter delta P indicator

WARNING ENGINE OIL (SYNTHETIC) (MAT-001) IS TOXIC TO THE SKIN.


WEAR PROTECTIVE CLOTHING WHILE HANDLING ENGINE OIL.
ANY OIL THAT CONTACTS THE SKIN MUST BE WASHED OFF
IMMEDIATELY. OIL MAY BURN IF EXPOSED TO FLAME. HANDLE
ONLY WITH ADEQUATE VENTILATION.

CAUTION EXCESS OIL USED TO INSTALL COMPONENTS MAY GIVE A


FALSE INDICATION OF A LEAK.

(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

A. Service the engine with oil. Refer to 72-00-03, P.B. 301.

SUBTASK 72-60-02-410-002

B. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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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
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Fig. 402 Oil Filter Delta P Indicator – Removal/Installation

EFFECTIVITY: FJ44-2C
72-60-02
Page 407
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72-60-02
408
Page
Blank
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OIL FILTER DIFFERENTIAL PRESSURE (DELTA P) INDICATOR - INSPECTION/CHECK

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

2. Equipment and Materials

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.

C. If the red indicator pin on the indicator is extended, push to reset.

EFFECTIVITY: FJ44-2C
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Page 601
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D. Prepare test fixture for use as follows:

(1) Completely close the air inlet valve before connecting to air source.

(2) Completely open the air exit flow control valve.

(3) Regulate air pressure at source to 0 psi

(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).

(3) Verify that pressure on the gauge is 0 psi

WARNING HIGH TEMPERATURES WILL BURN SKIN. WEAR PROTECTIVE


GLOVES WHEN HANDLING HEATED PARTS.

CAUTION DO NOT EXCEED 250° F (121° C)

(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.

F. Test Normal Mode, as follows:

(1) Regulate air pressure at source to between 20 and 100 psi.

(2) Using the inlet valve and flow control valve, slowly increase pressure to 11 psi.

(3) Verify the red indicating pin does not extend.

G. Test Bypass Mode, as follows:

(1) Regulate pressure at source to between 20 and 100 psi.

WARNING HIGH TEMPERATURES WILL BURN SKIN. WEAR PROTECTIVE


GLOVES WHEN HANDLING HEATED PARTS.

(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.

NOTE A Stopwatch or Clock is required to time the following steps.

(3) Using the inlet valve and flow control valve, slowly increase pressure to 18 psi and then start
the stopwatch.

EFFECTIVITY: FJ44-2C
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(4) The red indicating pin should extend within 5 seconds after 18 psi is reached.

(5) Reduce pressure to zero, ensure the indicator remains extended.

(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:

Normal Mode Test

Bypass Mode Test

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
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Fig. 601 Functional Test – Oil Filter Mechanical Delta P Indicator

EFFECTIVITY: FJ44-2C
72-60-02
Page 604
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REAR BYPASS DUCT ASSY - INSPECTION/CHECK

TASK 72-71-10-220-801 Visually Inspect the Rear Bypass Duct Assembly

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.

2. Equipment and Materials

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
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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

A. Visually inspect the rear bypass duct assembly as follows:

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.

(1) Inspect the mounting flanges for:

(a) Distortion Reject

(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.

(c) Damage to mounting holes Reject

(d) Missing, loose, or damaged rivets Reject


(e) Fretting (material transfer) which Accept
cannot be felt with a 0.060 inch
diameter stylus probe

(f) Fretting greater than previous step Reject

(2) Inspect all duct sheet metal surfaces for:

(a) Dents up to 0.200 inch (5 mm) deep Accept

EFFECTIVITY: FJ44-2C
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Page 602
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(b) Dents greater than previous step Reject

(c) Scratches and nicks up to 0.030 inch Accept


(0.762 mm) deep; max of 20 per duct

NOTE Touch-up scratches and nicks with chemical conversion coating


(MAT-050). Refer to 70-42-12, P.B. 801.

(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:

(a) Cracks Reject

(b) Damage to sealing surfaces Reject

(c) Loose, missing, or damaged rivets Reject

(d) Fretting Reject

(e) Thread Damage Reject

5. Job Close-up

SUBTASK 72-71-10-420-001

A. Install the rear bypass duct. Refer to 72-00-71, P.B. 401.

EFFECTIVITY: FJ44-2C
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Fig. 601 Rear Bypass Duct Assembly - Inspection

EFFECTIVITY: FJ44-2C
72-71-10
Page 604
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REAR MOUNTING RING ASSY - INSPECTION/CHECK

TASK 72-71-20-220-801 Visually Inspect the Rear Mounting Ring Assembly

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.

2. Equipment and Materials

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

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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) Inspect mounting ring for cracks or other Reject


damage

(2) Inspect mounting ring for corrosion Reject

B. Inspect mounting ring for loss of coating/plating:

(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.

C. Inspect the mounting flanges for:

(1) Distortion Reject

(2) Damage to mounting holes Reject

(3) Fretting (material transfer) which cannot be Accept


felt with a 0.060 inch diameter stylus probe

(4) Fretting greater than previous step Reject

D. Inspect monoball for:

(1) Excessive resistance when rotated. Bearing Reject


must move freely under a maximum torque
of 30 inch-pounds (3.3 N.m). Torque wrench
reading to be 26 inch-pounds (2.9 N.m) max
if a 1-inch extension tool is used.

(2) Axial movement of ball in housing up to Accept


0.003 inch (0.076 mm).

(3) Axial movement of ball in housing greater Reject


than previous step.

SUBTASK 72-71-20-220-002

E. If applicable, inspect the rear mount sleeve (1-65, 72-00-71) as follows:

(1) Visually inspect rear mount for:

EFFECTIVITY: FJ44-2C
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Page 602
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(a) Tears or missing sections Reject

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
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Fig. 601 Rear Mounting Ring Assembly - Inspection/Check

EFFECTIVITY: FJ44-2C
72-71-20
Page 604
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CHAPTER 73

ENGINE FUEL AND CONTROL

Page 1
73-ENGINE FUEL AND CONTROL Dec 12/17

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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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

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Chapter 73
List of Effective Page Blocks
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FUEL SYSTEM - DESCRIPTION AND OPERATION

TASK 73-00-00-860-804 Fuel System (FJ44-2C) - Description and Operation

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

A. The fuel system is made up of the following parts:

(1) Fuel filter

(2) Fuel filter bypass valve

(3) Integrated uel control unit (IFCU)

(4) Fuel manifold

(5) Fuel slinger

(6) Lube oil cooler

(7) Fuel Nozzle

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.

D. Integrated fuel control unit; refer to 73-18-00, P.B. 1.

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

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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

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Fig. 1 Fuel System

EFFECTIVITY: FJ44-2C
73-00-00
Page 3
Dec 12/17

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73-00-004
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

FUEL TUBE ASSEMBLIES - REMOVAL/INSTALLATION

TASK 73-10-01-050-804 Remove Fuel Tube Assemblies

1. General

This task provides procedures for removing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 401
Figure 402

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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:

• Fuel heater tube assembly

• FCU to fuel heater tube assembly

• Fuel union to manifold tube assembly

• FCU to fuel union tube assembly

• CDP tube assembly

• Flex tube assembly (FCU to fuel nozzle)

2. Equipment and Materials

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

A. Prepare the engine for part replacement

EFFECTIVITY: FJ44-2C
73-10-01
Page 401
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WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Close the aircraft fuel shutoff valve.

(4) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-10-01-050-004

A. Remove any of the engine fuel tubes 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 THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.

CAUTION USE A BACK-UP WRENCH ON ADAPTERS/FITTINGS WHEN


REMOVING TUBE NUTS.

(1) Loosen tube nuts on fuel tube. Use a backup wrench on fittings and/or reducers.

(2) Disconnect and remove fuel tube.

EFFECTIVITY: FJ44-2C
73-10-01
Page 402
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Fig. 401 Fuel Tube Assemblies - Removal/Installation

EFFECTIVITY: FJ44-2C
73-10-01
Page 403
Dec 12/17

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Fig. 402 Fuel Tube Loop Clamps - Removal/Installation

EFFECTIVITY: FJ44-2C
73-10-01
Page 404
Dec 12/17

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TASK 73-10-01-450-804 Install Fuel Tube Assemblies

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:

73-10-01, Fig. 01, 73-10-01, Fig. 02

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

A. Install any of the rigid engine fuel tubes as follows:

EFFECTIVITY: FJ44-2C
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Page 405
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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.

CAUTION TUBES SHALL NOT BE SPRUNG INTO POSITION.

(2) Re-bending of tubing at assembly to achieve alignment and/or minimum clearances shall be
permissible provided that re-bending does not:

(a) Result in dents, scratches or other defects.

(b) Result in flattening or reduction of tube diameter.

(c) Result in a variation of the as-received configuration greater than 0.100 inch (2.54 mm).

NOTE Re-bending or adjusting of tubing while assembled on engine is not permitted.

(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.

CAUTIONS: 1 USE A BACK-UP WRENCH ON ADAPTERS/FITTINGS WHEN


TORQUING TUBE NUTS. EXCESSIVE TORQUE MAY DAMAGE
PORTS AND/OR FUEL TUBES.

2 ALWAYS TORQUE THE TUBE NUTS ON BOTH ENDS OF THE FUEL


TUBE, EVEN IF ONLY ONE END WAS PREVIOUSLY DISCONNECTED.

(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.

(5) Verify clearance in step A (2).

EFFECTIVITY: FJ44-2C
73-10-01
Page 406
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Table 401 Torque Values for Tube Assemblies

Tube Tube Torque inch-pounds (N.m)


CDP tube (to elbow at P3 port) 90 -100 (10.2 to 11.3). elbow jam nut 60 - 80 (6.8 to
9.0).
Fuel heater tube assy 270 - 300 (30.5 to 33.9)
FCU to fuel heater tube assy 270 - 300 (30.5 to 33.9)
FCU to union (flowmeter) tube (to fitting in WF 450 - 500 (50.8 to 56.5)
port)
Fuel union (flowmeter) to manifold tube 450 - 500 (50.8 to 56.5)
Flex tube, FCU to Fuel Nozzle 135 - 190 (15.2 - 21.4)

Table 402 Clamp Procedures and Torques

Clamp Location Procedure Torque inch-pounds


(N.m)
2 clamps on FCU to union tube At rear mount ring, attach 1 bracket 49 - 55 (5.5 - 6.2)
with clamps oriented outboard using
bolts and nuts.
1 clamp on FCU to union tube (side Connect the two clamps tube-to-tube 49 - 55 (5.5 - 6.2)
by side, adjacent to the duct butterfly using a bolt and nut. (Attach clamps
clamp) between the tubes next to the HP
1 clamp on union to service ilsand bleed.)
1 clamp on CDP tube Attach to the remaining clamp on the 49 - 55 (5.5 - 6.2)
fuel tube, using a bolt and nut. (Attach
clamp to each other just forward of the
duct butterfly clamp.)
2 clamps on Fuel heater tubes 49 - 55 (5.5 - 6.2)
1 clamp on Flex tube 49 - 55 (5.5 - 6.2)

B. Install the flex tube assembly as follows:

(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

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8. Job Close-up

SUBTASK 73-10-01-410-008

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 403 Fuel Tube Assemblies - Removal/Installation

EFFECTIVITY: FJ44-2C
73-10-01
Page 409
Dec 12/17

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Fig. 404 Fuel Tube Loop Clamps - Removal/Installation

EFFECTIVITY: FJ44-2C
73-10-01
Page 410
Dec 12/17

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FUEL TUBE ASSEMBLIES - INSPECTION/CHECK

TASK 73-10-01-220-801 Visually Inspect Fuel Tube Assemblies

1. General

This task covers visual inspection of the fuel tube assemblies.

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.

2. Equipment and Materials

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.

A. Examine the tube surface for:

(1) Damage:

(a) Obvious excessive damage Reject

(b) Dents located less than 0.005-inch. Reject


(0.127 mm) from tube end fittings

(2) Smooth bottom dents:

EFFECTIVITY: FJ44-2C
73-10-01
Page 601
Dec 12/17

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(a) The area of any dent is not more than Accept


0.125 sq. inch. (3.18 sq. mm)

(b) The depth of any dent is not more Accept


than 0.015-inch (0.38 mm).

(c) Dents greater than previous two steps Reject

(3) Nicks:

(a) Nicks less than 0.005-inch (0.127 Reject


mm) from the tube end fitting

(b) Nicks that are round bottomed and Accept


are not more than 0.004-inch (0.10
mm) deep with all burrs removed

(c) Nicks greater than limits in previous Reject


step

(4) Galled:

(a) Galled less than 0.005-inch (0.127 Reject


mm) from the tube end fittings

(b) Galled on the tube surface not more Accept


than 0.005-inch (0.127 mm)

(c) Galled greater than limits in previous Reject


step

B. Examine the attachment flanges and end fittings for:

(1) Visual damage:

(a) Crack Reject

(b) Galled Reject

(c) Loose Reject

(d) Worn Reject

EFFECTIVITY: FJ44-2C
73-10-01
Page 602
Dec 12/17

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FUEL DRAIN TUBE ASSEMBLIES - REMOVAL/INSTALLATION

TASK 73-11-01-050-802 Remove Fuel Drain Tube Assemblies

1. General

This task provides procedures for removing the fuel drain tube assembly. Refer to the following illustration:
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

EFFECTIVITY: FJ44-2C
73-11-01
Page 401
Dec 12/17

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(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-11-01-020-003

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.

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

B. Remove fuel drain tubes as follows:

(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

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Fig. 401 Fuel Drain Tube Assemblies - Removal/Installation

EFFECTIVITY: FJ44-2C
73-11-01
Page 403
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 73-11-01-450-802 Install Fuel Drain Tube Assemblies

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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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

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.

A. Install the drain tubes as follows:

(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

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8. Job Close-up

SUBTASK 73-11-01-410-004

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Fuel Drain Tube Assemblies - Removal/Installation

EFFECTIVITY: FJ44-2C
73-11-01
Page 407
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

73-11-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

FUEL NOZZLE ASSEMBLY - REMOVAL/INSTALLATION

TASK 73-12-01-050-801 Remove the Fuel Nozzle Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

Table 401 Fuel Nozzle Adapter Removal/Installation Tool Options

Engine Model Tool Number Description


Application
FJ44-1 TL37212 Socket, Fuel Nozzle Adapter
FJ44-2 NOTE: Revision C and later is preferred
FJ44-3
FJ44-1 TL37330 Socket, Fuel Nozzle Adapter
FJ44-2
FJ44-3

EFFECTIVITY: FJ44-2C
73-12-01
Page 401
Dec 12/17

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Table 401 Fuel Nozzle Adapter Removal/Installation Tool Options (Continued)

FJ44-1 TL99517 Socket, Fuel Nozzle Adapter, Slotted


FJ44-2
FJ44-3
FJ44-1 TL-114226 Socket, Fuel Nozzle Adapter, Slotted
FJ44-2 NOTE: For FJ44-3AP 111000-202 engine. Socket is
FJ44-3 shorter and has a flat to clear diverter valve bleed tube.
FJ44-4 TL-217346 Socket, Fuel Nozzle Adapter
FJ44-4 TL-109571 Socket, Fuel Nozzle Adapter, Slotted
FJ33 TL99681 Socket, Fuel Nozzle Adapter, Slotted

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

A. Prepare the engine for part replacement

WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

CAUTION DO NOT BEND START NOZZLE ADAPTER DURING REMOVAL.


REMOVE AIRCRAFT BLEED PLUMBING, AS REQUIRED, TO PROVIDE
CLEARANCE FOR REMOVAL OF ADAPTER.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-12-01-020-001

A. Remove fuel nozzle assembly as follows:

EFFECTIVITY: FJ44-2C
73-12-01
Page 402
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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:

CAUTION DO NOT BEND FUEL NOZZLE ADAPTER DURING REMOVAL.


REMOVE AIRCRAFT BLEED PLUMBING, AS REQUIRED, TO PROVIDE
CLEARANCE FOR REMOVAL OF ADAPTER.

(1) Remove retaining ring, fuel nozzle plate seal, and fuel nozzle ring seal from the fuel nozzle port.

CAUTION TO AVOID BENDING OR DENTING THE FUEL NOZZLE ADAPTER,


KEEP THE FUEL NOZZLE ADAPTER WRENCH CENTERED IN
THE PORT DURING REMOVAL/INSTALLATION. THIS WILL KEEP
IT FROM SLIPPING OFF THE RETAINING NUT.

(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

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Fig. 401 Fuel Nozzle – Removal/Installation

EFFECTIVITY: FJ44-2C
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Page 404
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Fig. 402 Fuel Nozzle – Adapter Wrench

EFFECTIVITY: FJ44-2C
73-12-01
Page 405
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Fig. 403 Fuel Nozzle Adapter — Slotted Socket

EFFECTIVITY: FJ44-2C
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Page 406
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Fig. 404 Fuel Nozzle Adapter - Visual Inspection for Damage to Mid-Span (Zone D)

EFFECTIVITY: FJ44-2C
73-12-01
Page 407
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TASK 73-12-01-450-801 Install the Fuel Nozzle Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

6. Equipment and Materials

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

Table 402 Fuel Nozzle Adapter Removal/Installation Tool Options

Engine Model Tool Number Description


Application
FJ44-1 TL37212 Wrench, Fuel Nozzle Adapter
FJ44-2 NOTE: Revision C and later is preferred
FJ44-3
FJ44-1 TL37330 Socket, Fuel Nozzle Adapter
FJ44-2
FJ44-3

EFFECTIVITY: FJ44-2C
73-12-01
Page 408
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Table 402 Fuel Nozzle Adapter Removal/Installation Tool Options (Continued)

FJ44-1 TL99517 Socket, Fuel Nozzle Adapter, Slotted


FJ44-2
FJ44-3
FJ44-1 TL-114226 Socket, Fuel Nozzle Adapter, Slotted
FJ44-2 NOTE: For FJ44-3AP 111000-202 engine. Socket is shorter and
FJ44-3 has a flat to clear diverter valve bleed tube.
FJ44-4 TL-217346 Socket, Fuel Nozzle Adapter
FJ44-4 TL-109571 Socket, Fuel Nozzle Adapter, Slotted
FJ33 TL99681 Socket, Fuel Nozzle Adapter, Slotted

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

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CAUTION TO AVOID BENDING OR DENTING THE FUEL NOZZLE ADAPTER,


KEEP THE FUEL NOZZLE ADAPTER WRENCH CENTERED IN
THE PORT DURING REMOVAL/INSTALLATION. THIS WILL KEEP
IT FROM SLIPPING OFF THE RETAINING NUT.

(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.

B. Install fuel nozzle assembly as follows:

(1) Install bulkhead nut on fuel nozzle assembly.

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.

(4) Torque bulkhead nut 38 to 42 inch-pounds (4.2 to 4.7 N.m) .

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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Fig. 405 Fuel Nozzle – Removal/Installation

EFFECTIVITY: FJ44-2C
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Page 411
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Fig. 406 Fuel Nozzle – Adapter Wrench

EFFECTIVITY: FJ44-2C
73-12-01
Page 412
Dec 12/17

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FUEL NOZZLE ASSEMBLY - INSPECTION/CHECK

TASK 73-12-01-220-801 Visually Inspect the Fuel Nozzle Assembly

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.

2. Equipment and Materials

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

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CH-SE-SU Pg Block Nomenclature


73-12-01 401 Fuel Nozzle Assembly - Removal/Installation

3. Job Set-up

SUBTASK 73-12-01-010-004

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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:

(1) Fuel nozzle for:

CAUTION BE CAREFUL NOT TO INTRODUCE DIRT OR FOREIGN OBJECTS


INTO THE NOZZLE FLOWPATH WHILE CLEANING.

(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.

(b) Bent or dented shaft Replace

(c) Missing or damaged spring ring Replace


Figure 601

EFFECTIVITY: FJ44-2C
73-12-01
Page 602
Dec 12/17

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(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.

(e) Damage to threads beyond previous Reject


step

B. Visually inspect:

(1) Fuel nozzle adapter for:

(a) Thread damage to adapter inlet port Reject


or adapter nut Figure 602

(b) Uniball mount binding or damaged Reject


Figure 602

(c) Dents in Zone A which are less than Accept


0.032 inch (0.812 mm) deep by 0.25
dia. inch (6.35 mm) Figure 602

(d) Dents in Zone A greater than previous Reject


step Figure 602

(e) Fretting wear in Zone B resulting in Reject


a 0.533 inch (13.5 mm) diameter or
less. When measuring for fretting
wear in Zone B, take measurement
at area of widest OD on adapter tip.
Figure 602

(f) Fretting wear in Zone C resulting in Reject


a 0.476 inch (12.0 mm) diameter or
less. Figure 602

(g) Coking Clean with mineral spirits (MAT-020) or


dry cleaning solvent (MAT-024) and an
abrasive pad or stainless steel or fiber
brush. Ultrasonic cleaning with MAT-023
is also acceptable. You may also use
Alkaline Cleaner HDL-202 (MAT-029) for
ultrasonic or primary cleaning.

(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

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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

B. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
73-12-01
Page 604
Dec 12/17

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Fig. 601 Fuel Nozzle – Visual Inspection

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Page 605
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Fig. 602 Fuel Nozzle Adapter - Visual Inspection

EFFECTIVITY: FJ44-2C
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Page 606
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TASK 73-12-01-730-801 Check Fuel Nozzle Spray Pattern

6. General

This task provides procedures for checking the fuel nozzle spray pattern. Refer to the following
illustration(s):
Figure 603

7. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
73-12-01
Page 607
Dec 12/17

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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

Mineral Spirits – MAT-020

Petroleum Distillates – MAT-018

Dry Cleaning Solvent – MAT-024

Calibration Fluid – MAT-037

(1) Connect the fuel nozzle to fuel nozzle spray test equipment.

WARNINGS: 1 FUEL/PETROLEUM SOLVENTS ARE HIGHLY FLAMMABLE.


IT MUST BE KEPT AWAY FROM HEAT AND OPEN FLAME.
FUEL/PETROLEUM SOLVENTS MAY ALSO CAUSE SKIN
IRRITATION. ANY FUEL/PETROLEUM SOLVENT THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. CLOTHING
WITH FUEL/PETROLEUM SOLVENT CONTAMINATION MUST BE
THOROUGHLY CLEANED BEFORE BEING WORN. A CONTAINER
SHOULD BE PLACED UNDERNEATH WORK AREA TO CATCH
DRIPPING FUEL/PETROLEUM SOLVENT.

2 CALIBRATION FLUID IS A COMBUSTIBLE FLUID AND VAPOR. IT MAY


AFFECT THE CENTRAL NERVOUS SYSTEM CAUSING DIZZINESS,
HEADACHE OR NAUSEA. IT MAY BE HARMFUL IF INHALED OR
SWALLOWED. PROLONGED OR REPEATED CONTACT MAY DRY
THE SKIN AND CAUSE IRRITATION AND BURNS.

3 A FACE SHIELD IS REQUIRED DURING SPRAY PATTERN CHECK


DUE TO POSSIBLE FUEL/PETROLEUM SOLVENT MIST.

(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
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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.

B. If fuel nozzle fails spray pattern check:

(1) Ultrasonically clean the fuel nozzle using caustic ultrasonic solution (MAT-023), mineral spirits
(MAT-020), or dry cleaning solvent (MAT-024).

(2) Alternate: Clean per Repair Station Instruction 207097.

(3) Recheck nozzle flow pattern. Reject nozzle if flow pattern does not meet flow requirements.

SUBTASK 73-12-01-420-004

C. Install the fuel nozzle assembly. Refer to 73-12-01, P.B. 401.

10. Job Close-up

SUBTASK 73-12-01-410-005

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
73-12-01
Page 609
Dec 12/17

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Fig. 603 Fuel Nozzle Assembly - Spray Pattern Check

EFFECTIVITY: FJ44-2C
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Page 610
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FUEL PUMP FILTER - REMOVAL/INSTALLATION

TASK 73-14-01-050-802 Remove the Fuel Filter from the IFCU

1. General

This task provides procedures for removing the fuel filter from the fuel pump. Refer to the following
illustration:
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

(4) Close aircraft fuel shut-off valve.

EFFECTIVITY: FJ44-2C
73-14-01
Page 401
Dec 12/17

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4. Procedures

SUBTASK 73-14-01-020-002

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.

A. Remove the filter as follows:

(1) Cut lockwire on the filter bowl.

(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
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Page 403
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Fig. 401 Fuel Filter - Removal/Installation
LINE MAINTENANCE MANUAL - FJ44-2C

TASK 73-14-01-450-802 Install the Fuel Filter on the IFCU

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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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

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.

A. Install the filter as follows:

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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
73-14-01
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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.

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73-14-01
Page 407
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Fig. 402 Fuel Filter - Removal/Installation
LINE MAINTENANCE MANUAL - FJ44-2C

THIS PAGE LEFT INTENTIONALLY BLANK

73-14-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

FUEL CONTROL SYSTEM - DESCRIPTION AND OPERATION

TASK 73-18-00-860-801 Fuel Control Unit - Description and Operation

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.

(1) Metering valve

(2) Fan/LP shaft separation lever

(3) Pressure and shutoff valve

(4) Acceleration and deceleration schedules

(5) Motive flow valve

(6) HP relief valve

(7) TT2 bias of max N2

(8) Thrust lever angle input shaft

(9) Acceleration bleed valve control

(10) Start nozzle fuel supply

(11) Integral fuel pump

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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.

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FUEL CONTROL UNIT - REMOVAL/INSTALLATION

TASK 73-18-01-050-801 Remove the Integrated Fuel Control Unit

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

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.

2. Equipment and Materials

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
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Page 401
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3. Job Set-up

SUBTASK 73-18-01-010-001

A. Prepare the engine for part replacement

WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Close the aircraft fuel shutoff valve.

(4) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-18-01-020-001

A. Remove the drain tubes. Refer to the Aircraft Maintenance Manual.

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.

C. Remove the FCU 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 THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.

(1) Remove the following tubes, leaving clamps attached to tubes:

• Fuel Heater to FCU Tube

• FCU to Fuel Heater Tube

(2) Disconnect the following tubes from FCU, removing clamps as needed:

• CDP Tube from the 90 degree elbow

• FCU to Union Tube

• Flex Tube

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(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.

CAUTION USE CARE NOT TO BEND STRAIGHT SECTIONS OF BLEED CABLE.

(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.

(8) Loosen fittings.

(9) Remove FCU from gearbox:

(a) Removing three nuts and three washers securing FCU to the gearbox. Use TL-111884
wrench (optional).

(b) Remove FCU.

(10) (If not removed) Remove fittings/O-rings from the following ports of FCU:

• WF

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• SN

• P3

• FUEL IN and FUEL OUT

• 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.

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EFFECTIVITY: FJ44-2C
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Fig. 401 IFCU - Removal/Installation Page 405
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Fig. 402 Fuel Tube Assemblies - Removal/Installation

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Fig. 403 Fuel Tube Loop Clamps- Removal/Installation

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Fig. 404 FCU - Accel Bleed Cable - Adjustment

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Fig. 405 FCU - LP Trip Sensor Cable - Adjustment

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Fig. 406 HMU/IFCU – Discrepancy Report

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TASK 73-18-01-450-801 Install the Integrated Fuel Control Unit

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 Lubricate all threads and contact surfaces of nuts and bolts with clean MAT-001engine
oil before installation unless otherwise indicated in text.

6. Equipment and Materials

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)

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TL37220 Torque Adapter, Air Bleed Cable Nut


TL99924 Torque Adapter

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

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7. Procedures

SUBTASK 73-18-01-420-001

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. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.

A. Lubricate O-rings with MAT-011assembly fluid and install on fittings and/or locations as identified in
table 401. Torque fittings.

Table 401

Fittings and/or Locations Requiring Lubricated Torque inch-pounds (N.m)


O-rings)
Fuel control drive spline
Fuel control boss
nipple in WF port 275 to 300 (31 to 33.9)
CDP elbow in P3 port (nut installed on elbow) torqued later
unions in heater in/heater out ports 150 to 160 (16.9 to 18)
nipple in SN port 90 to 100 (10.2 to 11.3)
union in drain port 90 to 100 (10.2 to 11.3)

B. If T2 sensor plug on IFCU appears to be loose, torque as follows Figure 409:

(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

(3) Torque plug 30 to 40 inch-pounds (3.39 to 4.53 N.m).

(4) Reinstall lockwire Figure 409

C. Install fuel filter delta P switch. Refer to 73-23-01, P.B. 401.

EFFECTIVITY: FJ44-2C
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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.

CAUTION ALWAYS ROTATE THE GEARBOX IN THE DIRECTION SHOWN BY THE


ARROW MARKED ON THE ARM OF THE ALIGNMENT TOOL.

(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.)

F. Connect the LP trip sensor actuator cable to the FCU as follows:

(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
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NOTES: 1 FCU PLA lever needs to be at or above IDLE position.

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.

G. Install tubes and torque per table 402.

Table 402

Tube Tube Torque inch-pounds (N.m)


CDP tube (to elbow at P3 port) 90 -100 (10.2 to 11.3)
elbow jam nut 60 - 80 (6.8 to 9.0)
Fuel heater to FCU tube 270 - 300 (30.5 to 33.9)
FCU to fuel heater tube 270 - 300 (30.5 to 33.9)
FCU to union tube (to fitting in WF port) 450 - 500 (50.8 to 56.5)
Flex tube (to fitting in SN port) 135 - 150 (15.2 - 16.9)

H. Install the acceleration bleed cable assembly. Refer to 75-37-01, P.B. 401.

I. Install clamps (if removed) per table 403.

Table 403

Clamp Location Procedure Torque inch-pounds


(N.m)
2 clamps on FCU to union tube At rear mount ring, attach 49 - 55 (5.5 - 6.2)
1 bracket with clamps
oriented outboard using
bolts and nuts.
1 clamp on FCU to union tube (side by side, Connect the two clamps 49 - 55 (5.5 - 6.2)
adjacent to the duct butterfly clamp)1 clamp tube-to-tube using a bolt
on union to service ilsand and nut. (Attach clamps
between the tubes next to
the HP bleed.)

EFFECTIVITY: FJ44-2C
73-18-01
Page 415
Dec 12/17

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Table 403 (Continued)

Clamp Location Procedure Torque inch-pounds


(N.m)
1 clamp on CDP tube Attach to the remaining 49 - 55 (5.5 - 6.2)
clamp on the fuel tube,
using a bolt and nut.
(Attach clamp to each
other just forward of the
duct butterfly clamp.)
2 clamps on Fuel heater tubes 49 - 55 (5.5 - 6.2)
1 clamp on Flex tube 49 - 55 (5.5 - 6.2)

J. Adjust the power lever. Refer to the Aircraft Maintenance Manual.

K. Install the throttle control linkage and components. Refer to the Aircraft Maintenance Manual.

L. Install drain tubes. Refer to the Aircraft Maintenance Manual.

8. Job Close-up

SUBTASK 73-18-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Open the aircraft fuel shutoff valve

(3) Close aircraft circuit breakers.

(4) Remove DO NOT OPERATE signs.

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
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EFFECTIVITY: FJ44-2C
73-18-01
Fig. 407 IFCU - Removal/Installation Page 417
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Fig. 408 IFCU - Spline Alignment Tool

EFFECTIVITY: FJ44-2C
73-18-01
Page 418
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Fig. 409 IFCU - T2 Sensor Plug

EFFECTIVITY: FJ44-2C
73-18-01
Page 419
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Fig. 410 Fuel Tube Assemblies - Removal/Installation

EFFECTIVITY: FJ44-2C
73-18-01
Page 420
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Fig. 411 Fuel Tube Loop Clamps - Removal/Installation

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73-18-01
Page 421
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Fig. 412 FCU - Accel Bleed Cable - Adjustment

EFFECTIVITY: FJ44-2C
73-18-01
Page 422
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Fig. 413 FCU - LP Trip Sensor Cable - Adjustment

EFFECTIVITY: FJ44-2C
73-18-01
Page 423
Dec 12/17

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Fig. 414 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
73-18-01
Page 424
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FUEL CONTROL UNIT - ADJUSTMENT/TEST

TASK 73-18-01-820-801 Adjust the FCU Acceleration Control

1. General

Do this procedure, as directed by Troubleshooting, to change engine acceleration time. Refer to the
following illustration(s):
Figure 501

2. Equipment and Materials

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

A. Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-18-01-820-001

A. Prior to adjusting acceleration schedule:

(1) Measure acceleration times. Refer to the 71-00-00, P.B. 501.

B. Adjust FCU acceleration schedule as follows:

EFFECTIVITY: FJ44-2C
73-18-01
Page 501
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CAUTION ENGINE MUST BE SHUT DOWN PRIOR TO PERFORMING


ADJUSTMENT PROCEDURES. ENGINE MUST NOT BE RUNNING
WHILE MAKING ADJUSTMENT.

(1) Remove lockwire from end of threaded sleeve or clean out torque paint from recessed hex as
required.

(2) Adjust acceleration control as follows:

NOTE To increase engine surge margin, acceleration rate should be reduced.

(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.

(b) Re-installMAT-061 lockwire to protect adjustment or re-apply torque paint to recessed


hex to protect adjustment.

SUBTASK 73-18-01-790-001

C. After adjusting acceleration schedule, perform the following:

(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.

D. Record this adjustment in the engine log book.

5. Job Close-up

SUBTASK 73-18-01-410-003

A. Install the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
73-18-01
Page 502
Dec 12/17

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Fig. 501 IFCU - Acceleration Control - Adjustment

EFFECTIVITY: FJ44-2C
73-18-01
Page 503
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73-18-01
504
Page
Blank
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FUEL CONTROL UNIT - INSPECTION/CHECK

TASK 73-18-01-220-801 Visually Inspect the Fuel Control Unit

1. General

This task inspects the fuel control unit.

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.

2. Equipment and Materials

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

A. Visually check the fuel control unit for:

(1) Broken/removed lockwire or seals Reject

(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

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73-18-01
602
Page
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FUEL FILTER INDICATOR (DELTA P SWITCH) - REMOVAL/INSTALLATION

TASK 73-23-01-050-801 Remove the Fuel Filter Indicator (Delta P Switch)

1. General

This task provides procedures for removing the fuel filter indicator. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

EFFECTIVITY: FJ44-2C
73-23-01
Page 401
Dec 12/17

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WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 73-23-01-020-001

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.

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN FUEL


FILTER. TO AVOID CONTAMINATION/DAMAGE TO THE FUEL CONTROL/FDU,
MAKE SURE THAT PORTS AND COMPONENT MATING SURFACES ARE
KEPT EXTREMELY CLEAN DURING MAINTENANCE.

A. Remove the delta P switch as follows:

(1) Disconnect electrical connector from the delta P switch.

(2) Cut and remove lockwire from the delta P switch.

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

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EFFECTIVITY: FJ44-2C
73-23-01
Page 403
Dec 12/17

Fig. 401 ©Fuel 2017Filter


Williams International
Indicator Co., LLC
- Removal/Installation
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TASK 73-23-01-450-801 Install the Fuel Filter Indicator (Delta P Switch)

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

6. Equipment and Materials

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

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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

A. Install the delta P switch 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 THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN


FUEL FILTER. TO AVOID CONTAMINATION/DAMAGE TO THE FUEL
CONTROL/FDU, MAKE SURE THAT PORTS AND COMPONENT MATING
SURFACES ARE KEPT EXTREMELY CLEAN DURING MAINTENANCE.

(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.

(2) Install delta P switch into port.

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

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SUBTASK 73-23-01-450-003

C. Install lockwire (MAT-061) to safety delta P switch to fuel pump/FCU.

SUBTASK 73-23-01-450-004

D. Install electrical connector to delta P switch; refer to Aircraft Maintenance Manual.

8. Job Close-up

SUBTASK 73-23-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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EFFECTIVITY: FJ44-2C
73-23-01
Page 407
Dec 12/17

Fig. 402 ©Fuel 2017Filter


Williams International
Indicator Co., LLC
- Removal/Installation
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73-23-01
408
Page
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FUEL FILTER INDICATOR (DELTA P SWITCH) - INSPECTION/CHECK

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.

2. Equipment and Materials

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

B. Visually inspect the fuel filter delta P switch for:

(1) Bent, broken, or missing connector pins Reject

(2) Thread damage or rounded wrench flats Reject

(3) Damage to O-ring groove Reject

(4) Scorch or burn marks Reject. Contact Williams International


Product Support

EFFECTIVITY: FJ44-2C
73-23-01
Page 601
Dec 12/17

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Fig. 601 Fuel Filter Indicator - Visual Inspection

EFFECTIVITY: FJ44-2C
73-23-01
Page 602
Dec 12/17

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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.

5. Equipment and Materials

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

NOTE TL99967 is an acceptable alternate tool for performing functional


check of fuel delta P indicator.

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

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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.

C. Prepare test fixture for use as follows Figure 603:

(1) Completely close the air inlet valve before connecting to air source.

(2) Completely open the air exit flow control valve.

(3) Regulate air pressure at source to 0 psi

(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).

(3) Verify that pressure on the gauge is 0 psi

E. Test Normal Mode, as follows:

(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).

F. Test Bypass Mode, as follows:

(1) Regulate pressure at source to between 5 and 100 psi.

NOTE A Stopwatch or Clock is required to time the following steps

(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

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(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).

G. Test Return to Normal Mode, as follows:

NOTE Tester should still be connected to pins A and C with 4.5 psi of pressure applied.

(1) Reset the stopwatch.

(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:

Normal Mode Test

Bypass Mode Test

Return to Normal Mode Test.

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
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Fig. 602 Fuel Filter Indicator

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73-23-01
Page 606
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Fig. 603 Functional Test – Fuel Filter Indicator

EFFECTIVITY: FJ44-2C
73-23-01
Page 607
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73-23-01
608
Page
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FUEL MANIFOLD FILTER ASSY - REMOVAL/INSTALLATION

TASK 73-25-01-050-801 Remove the Fuel Manifold Filter

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL


LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
73-25-01
Page 401
Dec 12/17

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4. Procedures

SUBTASK 73-25-01-020-001

A. Remove Fuel Manifold Filter

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.

(1) Disconnect and remove the fuel tube.

(2) Remove the fuel filter from the engine service adapter fuel port.

NOTE The filter element is reusable if contaminants can be removed


without damage to the filter assembly.

B. Clean the filter using ultrasonic cleaning equipment.

EFFECTIVITY: FJ44-2C
73-25-01
Page 402
Dec 12/17

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Fig. 401 Fuel Manifold Filter - Removal/Installation

EFFECTIVITY: FJ44-2C
73-25-01
Page 403
Dec 12/17

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TASK 73-25-01-450-801 Install the Fuel Manifold Filter

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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7. Procedures

SUBTASK 73-25-01-420-001

A. Install Fuel Manifold Filter

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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Fig. 402 Fuel Manifold Filter - Removal/Installation

EFFECTIVITY: FJ44-2C
73-25-01
Page 406
Dec 12/17

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FUEL CONTROL SHUTOFF VALVE - MAINTENANCE PRACTICES

TASK 73-27-01-830-802 Reset the Fuel Shutoff Valve

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.

2. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
73-27-01
Page 201
Dec 12/17

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(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the Cowling. Refer to the Aircraft Maintenance Manual.

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:

(a) Signs that rotating parts have rubbed stationary parts.

(b) Sign that LP shaft has touched LP trip lever.

(2) Inspect the inlet for foreign object damage.

(3) Contact Williams International, Commerce Twp, Michigan, USA.

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

C. Reset the FCU fuel shutoff valve as follows:

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

E. Install cable and actuator housing. Refer to 76-20-01, P.B. 501.

EFFECTIVITY: FJ44-2C
73-27-01
Page 202
Dec 12/17

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SUBTASK 73-27-01-820-002

F. Adjust the LP trip lever. Refer to 76-20-01, P.B. 501.

SUBTASK 73-27-01-420-004

G. Install Cable on FCU.

(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.

NOTES: 1 FCU PLA lever needs to be at or above IDLE position.

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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 201 Fuel Contol Shut-Off Valve - Reset

EFFECTIVITY: FJ44-2C
73-27-01
Page 204
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER 74

IGNITION

Page 1
74-IGNITION Dec 12/17

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Page 2
74-IGNITION Blank
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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 74
List of Effective Page Blocks
Page 2
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IGNITION SYSTEM - DESCRIPTION AND OPERATION

TASK 74-00-00-860-801 Ignition System - Description and Operation

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

A. The ignition system is made up of the following parts:

Ignition Exciters (2)

Igniter Leads (2)

Igniter Plugs (2)

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
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Fig. 1 Ignition System

EFFECTIVITY: FJ44-2C
74-00-00
Page 2
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IGNITION SYSTEM - ADJUSTMENT/TEST

TASK 74-00-10-770-801 Do an Operational Test on the Ignition System

1. General

Do this task at the interval shown under periodic inspections.

2. Equipment and Materials

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

A. Prepare for ignition test

(1) Install DO NOT OPERATE signs.

(2) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 74-00-10-770-001

A. Do an audible check on the igniters

(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.

B. Identify Malfunctioning Igniter

EFFECTIVITY: FJ44-2C
74-00-10
Page 501
Dec 12/17

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WARNINGS: 1 IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY


CIRCUITS. REMOVE INPUT POWER PRIOR TO HANDLING
EXCITER, HIGH TENSION LEAD, OR PLUG.

2 IGNITION SYSTEM OUTPUT VOLTAGE IS DANGEROUSLY HIGH.


PERFORM IGNITION SPARK CHECK OUTDOORS, IN AN ATMOSPHERE
FREE OF EXPLOSIVE OR FLAMMABLE GASES OR LIQUIDS.

(1) Remove two igniters as follows:

(a) Disconnect main electrical supply from ignition exciter.

(b) Wait at least two minutes before beginning work.

(c) Remove igniter leads from igniters. Use a backup wrench on igniter plug flats.

CAUTION PLUG IGNITER PORTS TO KEEP FOREIGN OBJECTS


FROM ENTERING THE ENGINE.

(d) Remove igniter plug nuts and remove igniter plugs from engine.

CAUTION TO PREVENT DAMAGE TO IGNITER LEAD TERMINAL, DO NOT SPIN


IGNITER PLUG WHEN INSTALLING LEAD. HOLD IGNITER PLUG
WITH BACKUP WRENCH AND TIGHTEN IGNITER LEAD NUT.

(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.

(2) Visually check that igniters fire:

(a) Connect main electrical connector to ignition exciter.

WARNING DO NOT STAND NEXT TO IGNITER WHEN CHECKING TO SEE IF


IGNITERS FIRE. YOU SHOULD BE AT LEAST 10 FEET (3 METERS)
FROM IGNITER TIP AT ALL TIMES DURING 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

A. Put the engine back to normal

EFFECTIVITY: FJ44-2C
74-00-10
Page 502
Dec 12/17

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(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
74-00-10
Page 503
Dec 12/17

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74-00-10
504
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

IGNITON EXCITER - REMOVAL/INSTALLATION

TASK 74-10-01-050-801 Remove the Ignition Exciters

1. General

This task provides procedures for removing the ignition exciters. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 74-10-01-050-001

A. Remove the Ignition Exciters

EFFECTIVITY: FJ44-2C
74-10-01
Page 401
Dec 12/17

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WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY


CIRCUITS. REMOVE INPUT POWER PRIOR TO HANDLING
EXCITER, HIGH TENSION LEAD, OR PLUG.

(1) Disconnect the two electrical connectors from the forward side of the two ignition exciters.

(2) Wait at least two minutes before continuing work.

(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

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Fig. 401 Ignition Exciter - Removal/Installation

EFFECTIVITY: FJ44-2C
74-10-01
Page 403
Dec 12/17

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TASK 74-10-01-450-801 Install the Ignition Exciters

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

6. Equipment and Materials

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

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7. Procedures

SUBTASK 74-10-01-420-001

A. Install the Ignition Exciters

(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.

NOTE Prior to connecting igniter leads or installing electrical connectors to


the exciters, verify that all electrical interface points are clean, show
no signs of corrosion, and are free of debris.

(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.

(4) Install the electrical connectors to the ignition exciters.

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Ignition Exciter - Removal/Installation

EFFECTIVITY: FJ44-2C
74-10-01
Page 406
Dec 12/17

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IGNITER LEAD - REMOVAL/INSTALLATION

TASK 74-20-01-050-801 Remove the Igniter Leads

1. General

This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 74-20-01-020-001

A. Remove either of the two igniter leads as follows:

WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY CIRCUITS.


REMOVE INPUT POWER PRIOR TO HANDLING EXCITER, LEAD, OR PLUG.

(1) Remove aircraft power leads from the two ignition exciters.

EFFECTIVITY: FJ44-2C
74-20-01
Page 401
Dec 12/17

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(2) Wait at least two minutes before continuing work.

(3) Remove lockwire from the igniter lead connector nuts.

(4) Disconnect the igniter lead from each ignition exciter.

WARNING 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.

(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

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Fig. 401 Igniter Leads - Removal/Installation

EFFECTIVITY: FJ44-2C
74-20-01
Page 403
Dec 12/17

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TASK 74-20-01-450-801 Install the Igniter Leads

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

A. Install spiral wrap to igniter lead:

(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

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SUBTASK 74-20-01-450-003

WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY CIRCUITS.


REMOVE INPUT POWER PRIOR TO HANDLING EXCITER, LEAD, OR PLUG.

B. Install the straight end of the igniter lead to the ignition exciter.

SUBTASK 74-20-01-450-002

C. Install igniter lead:

WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY CIRCUITS.


REMOVE INPUT POWER PRIOR TO HANDLING EXCITER, LEAD, OR PLUG.

NOTE Prior to connecting igniter leads, verify that all electrical interface points
are clean, show no signs of corrosion, and are free of debris.

(1) Route the lead and install the cable clamps.

(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).

(6) Install igniter leads in the dual clamp assembly as follows

(a) Install leads in clamp assembly. Do not cross the leads.

(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.

(d) Torque clamp screw 49 to 55 inch-pounds (5.5 to 6.2 N.m).

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.

(9) Install two aircraft power leads to the ignition exciters.

(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

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8. Job Close-up

SUBTASK 74-20-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Igniter Leads - Removal/Installation

EFFECTIVITY: FJ44-2C
74-20-01
Page 407
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

74-20-01
408
Page
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LINE MAINTENANCE MANUAL - FJ44-2C

IGNITER LEAD - INSPECTION/CHECK

TASK 74-20-01-220-801 Visually Inspect the Igniter Leads

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.

2. Equipment and Materials

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

A. Remove igniter leads. Refer to 74-20-01, P.B. 401.

SUBTASK 74-20-01-220-001

B. Inspect Igniter Leads

(1) Inspect igniter lead cables for:

EFFECTIVITY: FJ44-2C
74-20-01
Page 601
Dec 12/17

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WARNING ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A


COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND
KEEP AWAY FROM HEAT, SPARKS, OR FLAME.

(a) Carbon deposits - no damage Clean with isopropyl alcohol (MAT-027)


and a soft brush

(b) Carbon deposits with damage Reject


(burned)

(c) Chafed Reject

(d) Frayed Reject

(e) Kinked Reject

(f) Severed Reject

(g) Missing or damaged spiral wrap Install new spiral wrap. Refer to 74-20-01,
P.B. 401

(2) Inspect the two connectors for:

(a) Stripped threads Reject

(b) Cross threaded Reject

(c) Rounded wrench flats Reject

(d) Cracked elbow Reject

(e) Kinked elbow Reject

(f) Corrosion Reject

SUBTASK 74-20-01-420-002

C. Install igniter leads. Refer to 74-20-01, P.B. 401.

EFFECTIVITY: FJ44-2C
74-20-01
Page 602
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IGNITER PLUG - REMOVAL/INSTALLATION

TASK 74-22-01-050-801 Remove the Igniter Plugs

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
74-22-01
Page 401
Dec 12/17

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4. Procedures

SUBTASK 74-22-01-020-001

A. Remove either of the two igniter plugs as follows:

WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY


CIRCUITS. REMOVE INPUT POWER PRIOR TO HANDLING
EXCITER, HIGH TENSION LEAD, OR PLUG.

CAUTION DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY LEAD TO


INTERNAL DAMAGE NOT VISUALLY DETECTABLE. REJECT ANY IGNITER
PLUG THAT IS DROPPED OR IS TORQUED BEYOND MANUAL LIMITS.

(1) Disconnect the aircraft electrical leads from the ignition exciters.

(2) Wait at least two minutes before continuing work.

(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.

CAUTION PLUG THE IGNITER PORTS TO PREVENT FOREIGN OBJECTS


FROM ENTERING THE ENGINE.

(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:

(a) If applicable, remove safety wire from adapter/diffuser.

(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.

B. Visually check the igniter plugs:

(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

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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

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Fig. 401 Igniter Plug – Removal/Installation

EFFECTIVITY: FJ44-2C
74-22-01
Page 404
Dec 12/17

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Fig. 402 Igniter Adapter– Removal/Installation

EFFECTIVITY: FJ44-2C
74-22-01
Page 405
Dec 12/17

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Fig. 403 Igniter Plug – Visual Inspection for Fretting in Zone C

EFFECTIVITY: FJ44-2C
74-22-01
Page 406
Dec 12/17

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Fig. 404 4-Pole Igniter Plug – Visual Inspection for Missing Electrode

EFFECTIVITY: FJ44-2C
74-22-01
Page 407
Dec 12/17

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TASK 74-22-01-450-801 Install the Igniter Plugs

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

A. Install igniter plug as follows:

EFFECTIVITY: FJ44-2C
74-22-01
Page 408
Dec 12/17

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CAUTIONS: 1 DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY


LEAD TO INTERNAL DAMAGE NOT VISUALLY DETECTABLE.
REJECT ANY IGNITER PLUG THAT IS DROPPED OR IS
TORQUED BEYOND MANUAL LIMITS.

2 IMPROPER INSTALLATION OF RETAINING RING WILL RESULT IN


DAMAGE TO ENGINE. THE RETAINING RING MUST BE INSTALLED
BELOW THE LAST THREAD IN THE IGNITER PLUG NUT.

3 GRASP IGNITER PLUG AND TEST FOR TRANSVERSE OR AXIAL


MOVEMENT. A PROPERLY SEATED IGNITER PLUG WILL HAVE NO
RELATIVE MOTION. AXIAL MOVEMENT OF PLUG WILL RESULT IN
ENGINE DAMAGE FROM IGNITER PLUG MOVEMENT.

(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).

(6) Connect the aircraft electrical connectors to the ignition exciters.

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
74-22-01
Page 409
Dec 12/17

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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

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Fig. 405 Igniter Plug – Removal/Installation

EFFECTIVITY: FJ44-2C
74-22-01
Page 411
Dec 12/17

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74-22-01
412
Page
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LINE MAINTENANCE MANUAL - FJ44-2C

IGNITER PLUG - INSPECTION/CHECK

TASK 74-22-01-220-801 Visually Inspect the Igniter Plugs

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.

2. Equipment and Materials

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

CAUTION DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY LEAD TO INTERNAL


DAMAGE NOT VISUALLY DETECTABLE. REJECT ANY IGNITER PLUG THAT
IS DROPPED OR IS TORQUED BEYOND MANUAL LIMITS.

A. Remove igniter plug(s). Refer to 74-22-01, P.B. 401.

EFFECTIVITY: FJ44-2C
74-22-01
Page 601
Dec 12/17

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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.

C. Inspect igniter plug exterior shell for:

(1) Cracks or chips Reject

(2) Swelling or distortion Reject

(3) Fretting or chafing wear in Zone A resulting Accept


in a local shell diameter of 0.450 inch (11.4
mm) or greater

(4) Fretting or chafing wear in Zone B resulting Accept


in a local shell diameter of 0.500 inch (12.7
mm) or greater

(5) Fretting or chafing wear in Zone A or B Reject


resulting in local shell diameters less than
previous two steps

(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.

(1) Rattling noise detected Reject

E. Visually inspect the igniter tip for:

(1) Combustion deposits Clean, refer to 74-22-01, P.B. 701

(2) Cracked ceramic Reject

F. Inspect igniter connector for:

(1) Cracked ceramic Reject

(2) Carbon deposits Reject

EFFECTIVITY: FJ44-2C
74-22-01
Page 602
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NOTE When checking for binding of spherical pivot, make sure that pivot area is
clean and free from anti-seize compound residue.

G. Check spherical pivot for proper movement. If binding is apparent, reject.

EFFECTIVITY: FJ44-2C
74-22-01
Page 603
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 601 Igniter Plug - Visual Inspection

EFFECTIVITY: FJ44-2C
74-22-01
Page 604
Dec 12/17

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Fig. 602 4-Pole Igniter Plug - Visual Inspection for Missing Electrode

EFFECTIVITY: FJ44-2C
74-22-01
Page 605
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TASK 74-22-01-220-802 Dimensionally Inspect Igniter Plugs - Tip Gap Diameter

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

5. Equipment and Materials

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

6. Dimensional Inspection Requirements by Part Number

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

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7. Procedures

SUBTASK 74-22-01-220-002

CAUTIONS: 1 DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY LEAD TO


INTERNAL DAMAGE NOT VISUALLY DETECTABLE. REJECT ANY IGNITER
PLUG THAT IS DROPPED OR IS TORQUED BEYOND MANUAL LIMITS.

2 IF IGNITER(S) ARE REJECTED FOR EXCEEDING EROSION LIMITS AT


ROUTINE PERIODIC INSPECTION INTERVAL, REVIEW FLIGHT OPERATION
PRACTICES TO ENSURE THAT IGNITION SYSTEM IS NOT BEING
OPERATED EXCESSIVELY. REFER TO THE AIRCRAFT FLIGHT MANUAL
FOR PROCEDURES FOR OPERATING IGNITION SYSTEM.

A. Using caliper, measure the electrode tip for:

(1) Electrical erosion of tip gap up to 0.230 inch Accept


(5.84 mm) max diameter measured at end
face

(2) Electrical erosion of tip gap greater than Reject


above

EFFECTIVITY: FJ44-2C
74-22-01
Page 607
Dec 12/17

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Fig. 603 Igniter Plug - Erosion Measurement

EFFECTIVITY: FJ44-2C
74-22-01
Page 608
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TASK 74-22-01-220-803 Dimensionally Inspect Igniter Plugs - Electrode Depth

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

9. Equipment and Materials

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

10. Dimensional Inspection Requirements by Part Number

SUBTASK 74-22-01-220-001

CAUTION DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY LEAD TO INTERNAL


DAMAGE NOT VISUALLY DETECTABLE. REJECT ANY IGNITER PLUG THAT
IS DROPPED OR IS TORQUED BEYOND MANUAL LIMITS.

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

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LINE MAINTENANCE MANUAL - FJ44-2C

IGNITER PART NUMBER Electrode Depth Inspection Tip Gap Diameter Inspection

70161 See procedures below Refer to 74-22-01-220-802


57846 See procedures below Not applicable
68032
78214
114220

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:

CAUTION IF IGNITER(S) ARE REJECTED FOR EXCEEDING EROSION LIMITS


AT ROUTINE PERIODIC INSPECTION INTERVAL, REVIEW FLIGHT
OPERATION PRACTICES TO ENSURE THAT IGNITION SYSTEM IS NOT
BEING OPERATED EXCESSIVELY. REFER TO THE AIRCRAFT FLIGHT
MANUAL FOR PROCEDURES FOR OPERATING IGNITION SYSTEM.

(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

NOTE Continue to use igniter plug if measurement is at acceptable limits. An igniter


plug at acceptable limits will last until the next engine inspection.

SUBTASK 74-22-01-420-002

B. Install Igniter plug(s). Refer to 74-22-01, P.B. 401.

EFFECTIVITY: FJ44-2C
74-22-01
Page 610
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 604 Igniter Plug - Erosion Measurement

EFFECTIVITY: FJ44-2C
74-22-01
Page 611
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

74-22-01
612
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

IGNITER PLUG - CLEANING

TASK 74-22-01-110-801 Clean the Igniter Plugs

1. General

Perform this task as indicated by visual inspection.

2. Equipment and Materials

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

A. Remove igniter plug(s). Refer to 74-22-01, P.B. 401.

SUBTASK 74-22-01-120-001

B. Clean igniter plug(s) as follows:

CAUTION DROPPING OR OVER-TORQUING THE IGNITER PLUG MAY LEAD TO


INTERNAL DAMAGE NOT VISUALLY DETECTABLE. REJECT ANY IGNITER
PLUG THAT IS DROPPED OR IS TORQUED BEYOND MANUAL LIMITS.

(1) Wipe combustion deposits from exterior with a lint-free cloth.

EFFECTIVITY: FJ44-2C
74-22-01
Page 701
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

CAUTION DO NOT DISTURB THE COMBUSTION DEPOSITS IN THE GAP


AREA. IF GAP AREA DEPOSITS MUST BE REMOVED FOR CLOSER
INSPECTION, REMOVE DEPOSITS WITH A WOODEN SCRAPER.
DO NOT TOUCH THE SEMI-CONDUCTOR SURFACE DEPOSITS IN
THE GAP AREA; THEY AID PLUG OPERATION.

(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

C. Install igniter plug(s). Refer to 74-22-01, P.B. 401.

EFFECTIVITY: FJ44-2C
74-22-01
Page 702
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

CHAPTER 75

AIR

Page 1
75-AIR Dec 12/17

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Page 2
75-AIR Blank
LINE MAINTENANCE MANUAL - FJ44-2C

LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 75
List of Effective Page Blocks
Page 2
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AIR SYSTEM - DESCRIPTION AND OPERATION

TASK 75-00-00-860-804 Air System - Description and Operation

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.

2. Description and Operation

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.

C. Acceleration Bleed System

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

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75-00-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

ACCELERATION BLEED SYSTEM LINKAGE - INSPECTION/CHECK

TASK 75-30-01-220-801 Visually Inspect the Acceleration Bleed System Linkage

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.

2. Equipment and Materials

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

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3. Job Set-up

SUBTASK 75-30-01-010-001

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 75-30-01-220-001

A. Inspect the cable assembly for:

(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.

(3) Damage to outer cable metal sheathing Reject

(4) Bends Reject

(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

B. Inspect the P/N 56301 cable assembly for:

(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

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SUBTASK 75-30-01-220-002

C. Inspect other acceleration bleed system parts as follows:

(1) Inspect all jam nuts for tightness. Tighten if needed.

(2) Inspect brackets for tightness. Tighten if needed.

(3) Inspect IP bleed valve lever for cracks. Reject

NOTE If the lever is replaced, you must adjust it after installation.


Refer to 75-35-01, P.B. 501.

5. Job Close-up

SUBTASK 75-30-01-410-001

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
75-30-01
Page 603
Dec 12/17

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Fig. 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection

EFFECTIVITY: FJ44-2C
75-30-01
Page 604
Dec 12/17

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ACCELERATION BLEED SYSTEM LEVER - REMOVAL/INSTALLATION

TASK 75-35-01-050-802 Remove the Acceleration Bleed System Lever

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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.

(2) Remove the spring tang from the bleed lever.

EFFECTIVITY: FJ44-2C
75-35-01
Page 401
Dec 12/17

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(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.

(7) Remove the spring from the bleed port cover.

SUBTASK 75-35-01-050-003

B. Remove the IP bleed port cover as follows. Refer to Figure 402.

(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

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Fig. 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
75-35-01
Page 403
Dec 12/17

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Fig. 402 IP Bleed Cover - Removal/Installation

EFFECTIVITY: FJ44-2C
75-35-01
Page 404
Dec 12/17

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TASK 75-35-01-450-802 Install the Acceleration Bleed System Lever

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001engine oil before installation.

6. Equipment and Materials

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
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Page 405
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7. Procedures

SUBTASK 75-35-01-450-003

A. Install the IP bleed cover as follows. Refer to Figure 403.

(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).

(c) Install retaining ring.

(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
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8. Job Close-up

SUBTASK 75-35-01-410-004

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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Fig. 403 IP Bleed Cover - Removal/Installation

EFFECTIVITY: FJ44-2C
75-35-01
Page 408
Dec 12/17

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Fig. 404 Acceleration Bleed System Lever - Removal/Installation

EFFECTIVITY: FJ44-2C
75-35-01
Page 409
Dec 12/17

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Fig. 405 Acceleration Bleed System Cable - Headed Pin – Safety Wire Method

EFFECTIVITY: FJ44-2C
75-35-01
Page 410
Dec 12/17

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ACCELERATION BLEED SYSTEM LEVER - ADJUSTMENT/TEST

TASK 75-35-01-820-801 Adjust the Acceleration Bleed Lever

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

2. Equipment and Materials

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

A. Prepare the engine for adjustment

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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
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(1) Disconnect the spring tang from the lever.

(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.

(7) Install the spring tang on the lever.

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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment

EFFECTIVITY: FJ44-2C
75-35-01
Page 503
Dec 12/17

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75-35-01
504
Page
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ACCELERATION BLEED SYSTEM CABLE - REMOVAL/INSTALLATION

TASK 75-37-01-050-802 Remove the Acceleration Bleed System Cable

1. General

This task provides procedures for removing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 401
Figure 402

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft.

4. Procedures

SUBTASK 75-37-01-020-002

A. Remove the "pull only" configuration acceleration bleed cable as follows

(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
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(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.

(7) Disconnect the outer sheath from the FCU/FDU boss.

(8) Disconnect the inner cable from the FCU/FDU plunger

CAUTION GRIPPING THE FCU/FDU PLUNGER WITH PLIERS OR OTHER


TOOL WILL DAMAGE THE COATED (IF APPLICABLE) SURFACE
OF THE ROD AND CAUSE FUEL LEAKS.

(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

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EFFECTIVITY: FJ44-2CFig. 401 Acceleration Bleed System Cable - Adjustment


75-37-01
Page 403
Dec 12/17

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Fig. 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
75-37-01
Page 404
Dec 12/17

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TASK 75-37-01-450-802 Install the Acceleration Bleed System Cable

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001 engine oil before installation.

6. Equipment and Materials

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

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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

A. Install the "pull only" acceleration bleed system cable as follows:

(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.

CAUTION GRIPPING THE FCU/FDU PLUNGER WITH PLIERS OR OTHER


TOOL WILL DAMAGE THE COATED (IF APPLICABLE) SURFACE
OF THE ROD AND CAUSE FUEL LEAKS.

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
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(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).

(c) Install retaining ring.

(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) .

(c) Torque jam nuts 85 to 95 inch-pounds (9.6 to 10.7 N.m) .

(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).

NOTE Loop clamp configurations may be different depending on bleed


cable part number. Please refer to the applicable Illustrated
Parts Catalog, section 75-37-01.

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
75-37-01
Page 407
Dec 12/17

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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

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EFFECTIVITY: FJ44-2CFig. 403 Acceleration Bleed System Cable - Adjustment


75-37-01
Page 409
Dec 12/17

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Fig. 404 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
75-37-01
Page 410
Dec 12/17

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Fig. 405 Acceleration Bleed System Cable - Headed Pin – Safety Wire Method

EFFECTIVITY: FJ44-2C
75-37-01
Page 411
Dec 12/17

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Fig. 406 Acceleration Bleed Cable – Attaching Parts

EFFECTIVITY: FJ44-2C
75-37-01
Page 412
Dec 12/17

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CHAPTER 76

ENGINE CONTROLS

Page 1
76-ENGINE CONTROLS Dec 12/17

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Page 2
76-ENGINE CONTROLS Blank
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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 76
List of Effective Page Blocks
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ENGINE CONTROLS - DESCRIPTION AND OPERATION

TASK 76-00-00-860-801 Engine Controls - Description and Operation

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

A. The engine control system contains the following parts:

Power Lever

LP Shaft Trip Sensor

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

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76-00-002
Page
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LP SHAFT TRIP SENSOR - ADJUSTMENT/TEST

TASK 76-20-01-830-801 Adjust (Reset) the LP Shaft Trip Sensor

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.

2. Equipment and Materials

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
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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

A. Prepare the engine for maintenance

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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

A. Remove the cable actuator housing as follows:

(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

B. Reset the LP Trip Sensor Housing Mechanism

EFFECTIVITY: FJ44-2C
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WARNING SPRING LOADED ASSEMBLY MAY DISCHARGE AND CAUSE INJURY.


FOLLOW DIRECTIONS CAREFULLY AND WEAR SAFETY GOGGLES.

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

C. Adjust LP Trip Lever

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.

(1) Perform initial trip lever adjustment as follows:

NOTE The following task requires two people.

(a) Thrust the LP rotary group aft by pushing on the fan rotor. Continue to apply pressure
during adjustment.

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(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

D. Recalculate Trigger Pin Dimension.

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:

• Replaced rear housing.

• Lost, damaged or replaced trigger pin

• Replaced trip lever

• Replaced rear bypass duct

(1) Recalculate trigger pin dimension (length) as follows:

WARNING WHEN MEASURING L1, DO NOT PUT FORCE AGAINST THE


ANVIL. THIS CAN TRIGGER SPRING LOADED DEVICE AND
CAUSE INJURY. WEAR SAFETY GOGGLES.

(a) Using depth micrometer, measure from face of trigger pin anvil to housing flange face.
Record this as L1 dimension. See Figure 506.

(b) Measure L2 dimension as follows:

EFFECTIVITY: FJ44-2C
76-20-01
Page 504
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CAUTION WHEN MEASURING L2 AND L3, MAKE SURE THAT YOU


MAINTAIN THE SAME RELATIVE POSITIONING OF THE
MICROMETER ON THE BUSHING.

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.

(d) Measure thickness of gasket.

(e) Calculate as follows: L1 + L2 - L3 + gasket thickness = Trigger pin dimension (length).

(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

E. Install the cable actuator housing as follows:

(1) Recalculate trigger pin dimension as required. Refer to Subtask 76-20-01-820-003.

(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
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SUBTASK 76-20-01-830-002

F. Install cable as follows:

(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.

NOTES: 1 FCU PLA lever needs to be at or above IDLE position.

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

G. Final installation as follows:

(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

H. Inspect Trigger Pin End Play/Final Trip Lever Adjustment.

CAUTION DO NOT APPLY EXCESSIVE FORCE IN THE FORWARD DIRECTION


WHEN POSITIONING PIN FOR END PLAY MEASUREMENT. THIS
MAY TRIGGER SPRING-LOADED ASSEMBLY.

(1) Gently move the pin all the way forward to seat it in the anvil for end play measurement.

EFFECTIVITY: FJ44-2C
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(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.

(6) Torque the screws 26 to 29 inch-pounds (2.9 to 3.2 N.m).

5. Job Close-up

SUBTASK 76-20-01-430-001

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
76-20-01
Page 507
Dec 12/17

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Fig. 501 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation

EFFECTIVITY: FJ44-2C
76-20-01
Page 508
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Fig. 502 LP Shaft Trip Sensor - Disassembly/Assembly

EFFECTIVITY: FJ44-2C
76-20-01
Page 509
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Fig. 503 LP Shaft Trip Sensor - Lever Adjustment

EFFECTIVITY: FJ44-2C
76-20-01
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Fig. 504 LP Shaft Trip Sensor - Cable Adjustment

EFFECTIVITY: FJ44-2C
76-20-01
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Fig. 505 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge

EFFECTIVITY: FJ44-2C
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Fig. 506 LP Shaft Trip Sensor – Trigger Pin Calculation Measurements

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Fig. 507 LP Shaft Trigger Pin Dimensions – Installed Trigger Pin Dimensions

EFFECTIVITY: FJ44-2C
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LP SHAFT TRIP SENSOR - INSPECTION/CHECK

TASK 76-20-01-220-801 Visually Inspect the LP Shaft Trip Sensor System

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.

2. Equipment and Materials

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
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3. Job Set-up

SUBTASK 76-20-01-010-002

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 76-20-01-220-001

A. Visually inspect LP trip sensor cable for:

(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.

(b) Damage greater than above Reject

5. Job Close-up

SUBTASK 76-20-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
76-20-01
Page 602
Dec 12/17

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Fig. 601 LP Shaft Trip Sensor - Inspection

EFFECTIVITY: FJ44-2C
76-20-01
Page 603
Dec 12/17

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TASK 76-20-01-220-802 Check the Trigger Pin End Play

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

7. Equipment and Materials

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

A. Make the engine ready for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the aircraft circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

9. Procedures

SUBTASK 76-20-01-220-002

A. Check the trigger pin end play

(1) Remove the two screws and two washers which attach the trip lever housing cover on the
outer bypass duct. Remove the housing cover.

CAUTION USE ONLY LIGHT PRESSURE ON TRIGGER PIN WHEN


CHECKING END PLAY. USE OF TOO MUCH PRESSURE COULD
DISCHARGE THE TRIGGER MECHANISM.

(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

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(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).

10. Job Close-up

SUBTASK 76-20-01-410-003

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
76-20-01
Page 605
Dec 12/17

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Fig. 602 LP Shaft Trip Sensor - Inspection

EFFECTIVITY: FJ44-2C
76-20-01
Page 606
Dec 12/17

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Fig. 603 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge

EFFECTIVITY: FJ44-2C
76-20-01
Page 607
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

76-20-01
608
Page
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CHAPTER 77

ENGINE INDICATING

Page 1
77-ENGINE INDICATING Dec 12/17

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77-ENGINE INDICATING Blank
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LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 77
List of Effective Page Blocks
Page 2
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ENGINE INDICATING - DESCRIPTION AND OPERATION

TASK 77-00-00-860-804 Engine Indicating - Description and Operation

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

A. The indicating system is made up of the following parts:

Gearbox magnetic speed pickup assembly (HP)

LP magnetic speed pickup assembly

Interstage turbine temperature (ITT) probe (6)

Engine vibration pickup (test equipment)

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

Magnetic chip collectors; refer to 79-30-01, 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

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THIS PAGE LEFT INTENTIONALLY BLANK

77-00-002
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

LP MAGNETIC SPEED PICKUP ASSEMBLY - REMOVAL/INSTALLATION

TASK 77-11-01-050-801 Remove the LP Magnetic Speed Pickup Assembly

1. General

This task provides procedures for removing the LP magnetic speed pickup assembly. Refer to the
following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
77-11-01
Page 401
Dec 12/17

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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.

A. Remove the LP magnetic speed pickup assembly

(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.

B. Remove pickup port plug (if required for engine reconfiguration)

(1) Remove screw from plug and remove plug and O-ring.

EFFECTIVITY: FJ44-2C
77-11-01
Page 402
Dec 12/17

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Fig. 401 LP Magnetic Speed Pickup - Removal/Installation

EFFECTIVITY: FJ44-2C
77-11-01
Page 403
Dec 12/17

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TASK 77-11-01-450-801 Install the LP Magnetic Speed Pickup Assembly

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

3 This part must undergo major periodic inspection. If a serviceable, used


LP magnetic speed pickup 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.

6. Equipment and Materials

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

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LINE MAINTENANCE MANUAL - FJ44-2C

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 77-11-01-420-001

A. Install the LP magnetic speed pickup assembly

(1) Lube O-ring with assembly fluid MAT-011and install on pickup.

(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.

CAUTION BE SURE TO OBSERVE ALL TORQUES WHEN INSTALLING THE LP


SPEED PICKUP AND PLUG. FAILURE TO PROPERLY TORQUE THE
LP SPEED PICKUP SCREW AND PLUG SCREW COULD RESULT IN
THE LOSS OF OIL DURING ENGINE OPERATION.

(3) Torque the screw 31 to 35 inch-pounds (3.5 to 3.9 N.m).

CAUTIONS: 1 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

2 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE


THAT THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE
HARNESS PLUG AND VISUALLY INSPECT THE CONNECTOR JACK TO
MAKE SURE THAT THE RED BAND IS FULLY COVERED BY THE PLUG.

(4) Install harness connector plug (N1 SPEED) to pick-up assembly.

B. Install pickup port plug (if removed).

(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

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CAUTION BE SURE TO OBSERVE ALL TORQUES WHEN INSTALLING THE LP


SPEED PICKUP AND PLUG. FAILURE TO PROPERLY TORQUE THE
LP SPEED PICKUP SCREW AND PLUG SCREW COULD RESULT IN
THE LOSS OF OIL DURING ENGINE OPERATION.

(3) Torque the screw 31 to 35 inch-pounds (3.5 to 3.9 N.m).

8. Job Close-up

SUBTASK 77-11-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 LP Magnetic Speed Pickup - Removal/Installation

EFFECTIVITY: FJ44-2C
77-11-01
Page 407
Dec 12/17

© 2017 Williams International Co., LLC


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THIS PAGE LEFT INTENTIONALLY BLANK

77-11-01
408
Page
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LINE MAINTENANCE MANUAL - FJ44-2C

LP MAGNETIC SPEED PICKUP ASSEMBLY - INSPECTION/CHECK

TASK 77-11-01-220-801 Visually Inspect the LP Magnetic Speed Pickup Assembly

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.

2. Equipment and Materials

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

B. Inspect LP Magnetic Speed Pickup Assembly

(1) Inspect pickup connector for:

(a) Bent or missing pins, cracks Reject

EFFECTIVITY: FJ44-2C
77-11-01
Page 601
Dec 12/17

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(2) Inspect pickup shaft for:

(a) Cracks, chips, or bends Reject

(3) Inspect tip of pickup for:

(a) Damage or signs of contact with LP Reject


shaft

(4) Inspect pickup shaft for nicks:

(a) Nicks without sharp edges up to Accept


0.0015 inch (0.038 mm) deep

(b) Nicks greater than previous step Reject

(5) Inspect pickup shaft for wear:

(a) Light fretting and scratches to 0.007 Accept


inch (0.18 mm) deep in worn areas up
to 0.5 inch (12.7 mm) diameter. Five
areas maximum.

(b) Fretting and scratches greater than Reject


previous step

SUBTASK 77-11-01-420-001

C. Install the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.

TASK 77-11-01-750-801 Perform Resistance Check on LP Magnetic Speed Pickup Assembly


(Single Channel)

4. General

This task performs a resistance check on the LP magnetic speed pickup assembly (single channel).

5. Equipment and Materials

SUBTASK 77-11-01-941-004

A. Standard Equipment
Ohmmeter

EFFECTIVITY: FJ44-2C
77-11-01
Page 602
Dec 12/17

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6. Procedures

SUBTASK 77-11-01-750-001

CAUTIONS: 1 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

2 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE THAT


THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE HARNESS
PLUG AND VISUALLY INSPECT THE CONNECTOR JACK TO MAKE SURE
THAT THE RED BAND IS FULLY COVERED BY THE PLUG.

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

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77-11-01
604
Page
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LINE MAINTENANCE MANUAL - FJ44-2C

GEARBOX (HP) MAGNETIC SPEED PICKUP ASSEMBLY - REMOVAL/INSTALLATION

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
77-12-01
Page 401
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

4. Procedures

SUBTASK 77-12-01-020-001

A. Remove the gearbox (HP) magnetic speed pickup

(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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Gearbox Magnetic Speed Pickup - Removal/Installation


EFFECTIVITY: FJ44-2C
77-12-01
Page 403
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

3 This part must undergo major periodic inspection. If a serviceable, used


gearbox magnetic speed pickup 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.

6. Equipment and Materials

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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

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 77-12-01-420-001

A. Install the gearbox (HP) magnetic speed pickup

(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.

(3) Torque the screw 31 to 35 inch-pounds (3.5 to 3.9 N.m).

CAUTIONS: 1 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

2 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE


THAT THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE
HARNESS PLUG AND VISUALLY INSPECT THE CONNECTOR JACK TO
MAKE SURE THAT THE RED BAND IS FULLY COVERED BY THE PLUG.

(4) Install electrical connector plug (N2 SPEED) to pickup jack.

8. Job Close-up

SUBTASK 77-12-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 Gearbox Magnetic Speed Pickup - Removal/Installation


EFFECTIVITY: FJ44-2C
77-12-01
Page 406
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

GEARBOX (HP) MAGNETIC SPEED PICKUP ASSEMBLY - INSPECTION/CHECK

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.

2. Equipment and Materials

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

B. Inspect HP Magnetic Speed Pickup Assembly

(1) Inspect pickup connector for bent or missing Reject


pins, cracks.

EFFECTIVITY: FJ44-2C
77-12-01
Page 601
Dec 12/17

© 2017 Williams International Co., LLC


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(2) Inspect pickup case for cracks, chips, nicks Reject


or bends

(3) Inspect tip of pickup for damage or signs of Reject


contact with gearshaft.

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).

5. Equipment and Materials

SUBTASK 77-12-01-941-004

A. Standard Equipment
Ohmmeter

6. Procedures

SUBTASK 77-12-01-750-001

CAUTIONS: 1 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

2 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE THAT


THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE HARNESS
PLUG AND VISUALLY INSPECT THE CONNECTOR JACK TO MAKE SURE
THAT THE RED BAND IS FULLY COVERED BY THE PLUG.

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

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

INTERMEDIATE TURBINE TEMPERATURE (ITT) PROBE - REMOVAL/INSTALLATION

TASK 77-20-02-050-801 Remove the ITT Probes

1. General

This task provides procedures for removing the ITT probes. Refer to the following illustration(s):
Figure 401
Figure 402

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
77-20-02
Page 401
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

4. Procedures

SUBTASK 77-20-02-050-001

A. Remove J1 connector from the harness as follows:

(1) Disconnect J1 connector from the harness.

(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.

B. Remove ITT Probe(s)

(1) Remove the following from the probe:

(a) Thermocouple retaining ring

(b) Thermocouple seal retainer

(c) Thermocouple seal plate

(d) Thermocouple seal spacer

(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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
77-20-02
Page 403
Dec 12/17

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Fig. 402 ITT Probes - Loop Clamp Locations

EFFECTIVITY: FJ44-2C
77-20-02
Page 404
Dec 12/17

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TASK 77-20-02-040-801 Disassemble ITT Probe J1 Connector

5. General

This task provides procedures to disassemble ITT probe J1 connector. Refer to the following illustration(s):
Figure 403
Figure 404

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

6. Equipment and Materials

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.

B. Remove probe from backshell and J1 connector as follows:

(1) Loosen saddle clamp of the strain relief.

(2) Unscrew strain relief from adapter.

(3) Slide grommet and follower back.

EFFECTIVITY: FJ44-2C
77-20-02
Page 405
Dec 12/17

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(4) Remove adapter from backshell.

(5) Move ground ring back and separate braids.

(6) Remove backshell from connector.

(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

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Fig. 403 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
77-20-02
Page 407
Dec 12/17

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Fig. 404 ITT Probe - Connector - Assembly/Disassembly

EFFECTIVITY: FJ44-2C
77-20-02
Page 408
Dec 12/17

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TASK 77-20-02-440-801 Assemble ITT Probe J1 Connector

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:

, , 77-20-02, Fig. 01 77-20-02, Fig. 02

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

9. Equipment and Materials

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

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10. Procedures

SUBTASK 77-20-02-420-001

A. Assemble ITT Probe J1 Connector:

(1) Install the following parts on the thermocouple:

(a) Thermocouple seal retainer

(b) Thermocouple seal plate

(c) Thermocouple seal spacer

(d) Thermocouple retaining ring

(2) Thread thermocouple cable through the backshell.

(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.

2 The contact is locked in place when the retaining mechanism clicks


and the contact lead can be pulled until taut.

(a) IN-leads are chromel (white), RETURN-leads are alumel (green).

(b) Insert pins in the J1 connector in the following order:

1 No. 6, left upper IN to pin A, RETURN to pin B.

2 No. 5, left middle IN to C, RETURN to pin D.

3 No. 4, left lower IN to pin E, RETURN to pin F.

4 No. 3, right lower IN to pin G, RETURN to pin H.

5 No. 2, right middle IN to pin J, RETURN to pin K.

6 No. 1, right upper IN to pin L, RETURN to pin M.

7 FOR LONG/SHORT CONFIGURATION ONLY: Verify the following jumpers: N to


R (yellow); P to S (red).

8 FOR MID-LENGTH CONFIGURATION ONLY: Verify the following jumpers: N to R to


T (3 yellow wires); P to S to U (3 red wires).

(4) Assemble backshell as follows:

EFFECTIVITY: FJ44-2C
77-20-02
Page 410
Dec 12/17

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NOTE For reliable assembly of the connector and backshell, it is suggested that
connector holding tools, strap wrench and connector pliers be used.

(a) Ensure O-ring is on the connector.

(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

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Fig. 405 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
77-20-02
Page 412
Dec 12/17

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Fig. 406 ITT Probe - Connector - Assembly/Disassembly

EFFECTIVITY: FJ44-2C
77-20-02
Page 413
Dec 12/17

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TASK 77-20-02-450-801 Install the ITT Probes

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:

77-20-02, Fig. 01 77-20-02, Fig. 02

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

12. Equipment and Materials

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

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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

13. Procedures

SUBTASK 77-20-02-450-002

A. Install ITT Probe(s)

(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.

(5) If removed, install teflon spiral wrap to ITT harness as follows:

(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

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SUBTASK 77-20-02-450-004

CAUTIONS: 1 CHECK CONNECTORS FOR DEBRIS AND/OR CORROSION


PRIOR TO MATING.

2 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

3 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE


THAT THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE
HARNESS PLUG AND VISUALLY INSPECT THE CONNECTOR JACK
TO MAKE SURE THAT THEY ARE FULLY MATED.

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.

14. Job Close-up

SUBTASK 77-20-02-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 407 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation

EFFECTIVITY: FJ44-2C
77-20-02
Page 417
Dec 12/17

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Fig. 408 ITT Probes - Loop Clamp Locations

EFFECTIVITY: FJ44-2C
77-20-02
Page 418
Dec 12/17

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INTERMEDIATE TURBINE TEMPERATURE (ITT) PROBE - INSPECTION/CHECK

TASK 77-20-02-220-801 Visually Inspect ITT Probes

1. General

This task visually inspects the ITT probes.

Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:

77-20-02, Fig. 01 77-20-02, 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 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.

2. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
77-20-02
Page 601
Dec 12/17

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4. Procedures

SUBTASK 77-20-02-020-002

A. Remove the ITT probes. Refer to 77-20-02, P.B. 401.

SUBTASK 77-20-02-220-001

B. Inspect removed ITT probe(s) for:

(1) Obvious excessive damage Reject

(2) Cracks, chips, or other damage Reject

(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.

(4) Damage to O-rings located on the connector Reject


or backshell

SUBTASK 77-20-02-420-002

C. Install the ITT probes. Refer to 77-20-02, P.B. 401.

5. Job Close-up

SUBTASK 77-20-02-410-004

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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.

TASK 77-20-02-750-801 Perform Temperature Check on Installed ITT Probes

6. General

This task performs a temperature check on installed ITT probes.


Figure 601

EFFECTIVITY: FJ44-2C
77-20-02
Page 602
Dec 12/17

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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.

7. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

9. Procedures

SUBTASK 77-20-02-210-003

A. Disconnect the ITT harness connector from the harness plug.

NOTE Engine must be cold (ambient) for inspection of installed probes.

B. Using Type K Thermocouple Meter and Thermocouple Adapter as defined in Figure 601, perform the
following checks on each ITT probe.

C. Room Temperature Check on Removed Probe(s)

(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

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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.

CAUTIONS: 1 CHECK CONNECTORS FOR DEBRIS AND/OR CORROSION


PRIOR TO MATING.

2 IF YOU FEEL RESISTANCE WHEN HAND-TIGHTENING CONNECTORS,


REMOVE THE CONNECTOR AND INSPECT FOR BENT PINS.

3 ELECTRICAL CONNECTORS MUST BE INSPECTED TO MAKE SURE


THAT THEY ARE FULLY MATED AFTER INSTALLATION. TIGHTEN THE
HARNESS PLUG AND VISUALLY INSPECT THE CONNECTOR JACK
TO MAKE SURE THAT THEY ARE FULLY MATED.

D. Connect the ITT harness connector to the harness plug.

10. Job Close-up

SUBTASK 77-20-02-410-005

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
77-20-02
Page 604
Dec 12/17

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Fig. 601 ITT Probes - Temperature Check

EFFECTIVITY: FJ44-2C
77-20-02
Page 605
Dec 12/17

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TASK 77-20-02-750-802 Perform Temperature Check on Removed ITT Probes

11. General

This task performs a temperature check on removed ITT probes.


Figure 602

12. Equipment and Materials

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.

B. Room Temperature Check on Removed Probe(s)

(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

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(4) Remove and replace any probe(s) which are outside the allowable range.

C. Ice Water Temperature Check on Removed Probe(s)

(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

D. Install the ITT probes. Refer to 77-20-02, P.B. 401.

14. Job Close-up

SUBTASK 77-20-02-410-010

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 602 ITT Probes - Temperature Check

EFFECTIVITY: FJ44-2C
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Page 608
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TASK 77-20-02-750-804 Perform Resistance Check on Assembled J1 Connector

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.

16. Equipment and Materials

SUBTASK 77-20-02-941-008

A. Standard Equipment
Ohmmeter

17. Job Set-up

SUBTASK 77-20-02-010-008

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

18. Procedures

SUBTASK 77-20-02-210-008

A. Using an ohmmeter do a resistance check on the J1 harness connector as follows. Probe


temperature to be 55 to 90 degrees F:
COMPONENT CONNECTOR CONNECTOR PIN RESISTANCE
PIN
A B 2.0 to 5.3 Ohms
C D 2.0 to 5.3 Ohms
E F 2.0 to 5.3 Ohms
G H 2.0 to 5.3 Ohms
J K 2.0 to 5.3 Ohms
L M 2.0 to 5.3 Ohms

EFFECTIVITY: FJ44-2C
77-20-02
Page 609
Dec 12/17

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COMPONENT CONNECTOR CONNECTOR PIN RESISTANCE


PIN
N R Less than 1.0 Ohm
N T Less than 1.0 Ohm
R T Less than 1.0 Ohm
P S Less than 1.0 Ohm
P U Less than 1.0 Ohm
S U Less than 1.0 Ohm

B. Do a continuity check between the ITT connector and case as follows:


Case J1-A Open
Case J1-C Open
Case J1-E Open
Case J1-G Open
Case J1-J Open
Case J1-L Open
Case J1-N Open
Case J1-P Open
J1 Case Engine Case Less than 1.0 Ohm

19. Job Close-up

SUBTASK 77-20-02-410-008

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
77-20-02
Page 610
Dec 12/17

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Fig. 603 ITT Probes - Mid-Length Configuration - Harness Connector

EFFECTIVITY: FJ44-2C
77-20-02
Page 611
Dec 12/17

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TASK 77-20-02-750-805 Perform Resistance Check on Removed ITT Probes

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.

21. Equipment and Materials

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.

C. Using an ohmmeter, check the resistance on each ITT probe as follows:

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

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(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.

23. Job Close-up

SUBTASK 77-20-02-410-008

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 604 ITT Probes - Resistance Check of Removed Probe

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Page 614
Dec 12/17

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INTERMEDIATE TURBINE TEMPERATURE (ITT) JUMPER HARNESS - REMOVAL/INSTALLATION

TASK 77-20-04-050-801 Remove ITT Jumper Harness

1. General

This task provides procedures for removing the ITT jumper harness. Refer to the following illustration:
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

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.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 77-20-04-020-001

A. Remove ITT jumper harness

(1) Remove aircraft ITT harness from J2 harness connector.

EFFECTIVITY: FJ44-2C
77-20-04
Page 401
Dec 12/17

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(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.

(4) Remove the P1 plug/jumper harness from the J1 connector.

EFFECTIVITY: FJ44-2C
77-20-04
Page 402
Dec 12/17

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Fig. 401 ITT Jumper Harness - Removal/Installation

EFFECTIVITY: FJ44-2C
77-20-04
Page 403
Dec 12/17

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TASK 77-20-04-450-801 Install the ITT Jumper Harness

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.

3 Check connectors for debris and/or corrosion prior to mating.

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.

6. Equipment and Materials

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

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7. Procedures

SUBTASK 77-20-04-420-001

A. Install ITT Jumper harness

(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).

(4) Install .020 inch lockwire MAT-061 to bulkhead nut.

(5) Perform resistance check to installed jumper harness. Refer to 77-20-04, P.B. 601.

(6) Install aircraft ITT harness to J2 connector.

8. Job Close-up

SUBTASK 77-20-04-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 ITT Jumper Harness - Removal/Installation

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77-20-04
Page 406
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INTERMEDIATE TURBINE TEMPERATURE (ITT) JUMPER HARNESS - INSPECTION/CHECK

TASK 77-20-04-220-801 Visually inspect the ITT Jumper Harness

1. General

This task covers visual inspection of the ITT jumper harness.

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.

2. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
77-20-04
Page 601
Dec 12/17

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4. Procedures

SUBTASK 77-20-04-220-001

A. Visually inspect ITT jumper harness for:

(1) Broken or stripped connector Reject

(2) Damaged insulation Reject

5. Job Close-up

SUBTASK 77-20-04-410-003

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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.

TASK 77-20-04-750-801 Perform Resistance Check on Installed ITT Jumper Harness

6. General

This task performs a resistance check for the ITT jumper harness. Refer to the following illustration:
Figure 601

NOTES: 1 Check connectors for debris and/or corrosion prior to mating.

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.

7. Equipment and Materials

SUBTASK 77-20-04-941-004

A. Standard Equipment
Ohmmeter

EFFECTIVITY: FJ44-2C
77-20-04
Page 602
Dec 12/17

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8. Job Set-up

SUBTASK 77-20-04-010-004

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

9. Procedures

SUBTASK 77-20-04-750-001

A. Using an ohmmeter, do a resistance check on installed ITT jumper harness:

(1) Disconnect the aircraft ITT harness from the jumper harness J2 connector.

(2) Make the following resistance checks:


COMPONENT CONNECTOR PIN RESISTANCE
CONNECTOR PIN
J2-A P1-R Less than 1.0 Ohm
J2-B P1-S Less than 1.0 Ohm
P1-A P1-C Less than 1.0 Ohm
P1-A P1-E Less than 1.0 Ohm
P1-A P1-G Less than 1.0 Ohm
P1-A P1-J Less than 1.0 Ohm
P1-A P1-L Less than 1.0 Ohm
P1-A P1-N Less than 1.0 Ohm
P1-A P1-B Open Circuit
P1-A P1-R Open Circuit
P1-A P1-S Open Circuit
P1-A Case Open Circuit
P1-B P1-D Less than 1.0 Ohm
P1-B P1-F Less than 1.0 Ohm
P1-B P1-H Less than 1.0 Ohm
P1-B P1-K Less than 1.0 Ohm

EFFECTIVITY: FJ44-2C
77-20-04
Page 603
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P1-B P1-M Less than 1.0 Ohm


P1-B P1-P Less than 1.0 Ohm
P1-B P1-C Open Circuit
P1-B P1-R Open Circuit
P1-B P1-S Open Circuit
P1-B Case Open Circuit
P1 Case J2 Case Less than 1.0 Ohm
J2 Case Engine Case Less than 1.0 Ohm

(3) Reject ITT jumper harness if resistance values do not meet limits.

10. Job Close-up

SUBTASK 77-20-04-410-004

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
77-20-04
Page 604
Dec 12/17

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Fig. 601 ITT Jumper Harness - Schematic

EFFECTIVITY: FJ44-2C
77-20-04
Page 605
Dec 12/17

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THIS PAGE LEFT INTENTIONALLY BLANK

77-20-04
606
Page
Blank
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CHAPTER 79

OIL

Page 1
79-OIL Dec 12/17

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Page 2
79-OIL Blank
LINE MAINTENANCE MANUAL - FJ44-2C

LIST OF EFFECTIVE PAGE BLOCKS

Chapter Chapter Chapter


Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date

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
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Chapter 79
List of Effective Page Blocks
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OIL SYSTEM - DESCRIPTION AND OPERATION

TASK 79-00-00-860-804 Oil System - Description and Operation

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

A. The oil system is made up of the following parts:

(1) Lube and scavenge pump

(2) Oil filter

(3) Oil filter bypass valve

(4) Filter differential pressure (delta P) indicator

(5) Lube oil cooler

(6) Reservoir (oil tank)

(7) Oil pressure regulator

(8) Magnetic chip collectors

B. Lube and Scavenge Pump

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.

D. Oil filter bypass

EFFECTIVITY: FJ44-2C
79-00-00
Page 1
Dec 12/17

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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.

F. Lube oil cooler

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.

G. Oil reservoir (oil tank)

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.

H. Oil pressure regulator

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

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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

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Fig. 1 Oil System

EFFECTIVITY: FJ44-2C
79-00-00
Page 4
Dec 12/17

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OIL FILTER - REMOVAL/INSTALLATION

TASK 79-21-01-050-801 Remove the Oil Filter

1. General

This task provides procedures for removing the oil filter. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-21-01
Page 401
Dec 12/17

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4. Procedures

SUBTASK 79-21-01-020-001

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

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.

E. Remove the O-ring from the gearbox/filter bowl flange.

EFFECTIVITY: FJ44-2C
79-21-01
Page 402
Dec 12/17

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Fig. 401 Oil Filter – Removal/Installation

EFFECTIVITY: FJ44-2C
79-21-01
Page 403
Dec 12/17

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TASK 79-21-01-450-801 Install the Oil Filter

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

CAUTION DURING MAINTENANCE, OIL SYSTEM CONTAMINANTS COULD POSSIBLY


BE INTRODUCED DOWNSTREAM OF THE MAIN OIL FILTER. TO PREVENT
CONTAMINATION OF THE OIL SYSTEM, MAKE SURE THAT PORTS AND
COMPONENT MATING SURFACES ARE KEPT EXTREMELY CLEAN.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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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

A. Install the oil filter as follows:

(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.

WARNING FAILURE TO ENSURE CLEANLINESS OF THE OIL FILTER ID CAN RESULT


IN BLOCKAGE OF THE OIL SUPPLY TO THE ENGINE BEARINGS.

(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.

(5) Install the oil filter on the gearbox.

(6) Install the filter bowl on the gearbox as follows:

CAUTION EXCESS OIL USED TO INSTALL FILTER/FILTER BOWL MAY


GIVE A FALSE INDICATION OF A LEAK.

(a) Lubricate the filter bowl threads with 2 or 3 drops of clean engine oil (MAT-001).

CAUTION TO AVOID DAMAGE TO FLAME ARREST COATING (IF APPLICABLE),


DO NOT USE AN OPEN END WRENCH ON SQUARE DRIVE
WRENCH FEATURE OF OIL FILTER BOWL. USE AN 8-POINT
(DOUBLE SQUARE) SOCKET WRENCH.

(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.

(c) Clean excess oil with mineral spirits (MAT-020).

EFFECTIVITY: FJ44-2C
79-21-01
Page 405
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

NOTE Filter bowl may be safety wired to the adjacent safety wire hole in the
gearbox housing or to the bypass valve spring plug.

(7) Install lockwire (MAT-060) to safety filter bowl.

SUBTASK 79-21-01-610-001

B. Service the oil system. Refer to 72-00-03, P.B. 301.

8. Job Close-up

SUBTASK 79-21-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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
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Fig. 402 Oil Filter – Removal/Installation

EFFECTIVITY: FJ44-2C
79-21-01
Page 407
Dec 12/17

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79-21-01
408
Page
Blank
LINE MAINTENANCE MANUAL - FJ44-2C

OIL FILTER - INSPECTION/CHECK

TASK 79-21-01-220-801 Visually Inspect the Oil Filter Bowl

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

A. Visually inspect the oil filter bowl for:

(1) Thread damage Reject

(2) Dents, distortion, or other damage Reject

(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

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Fig. 601 Oil Filter Bowl - Inspection/Check

EFFECTIVITY: FJ44-2C
79-21-01
Page 602
Dec 12/17

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LUBE OIL COOLER - REMOVAL/INSTALLATION

TASK 79-22-01-050-801 Remove the Lube Oil Cooler

1. General

This task provides procedures for removing the oil cooler. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-22-01
Page 401
Dec 12/17

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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.

2 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY . OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

SUBTASK 79-22-01-050-003

A. Remove the two fuel tubes (from oil cooler to FCU/FDU).

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

E. Oil Cooler Handling Guidelines:

(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

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Fig. 401 Lube Oil Cooler - Removal/Installation

EFFECTIVITY: FJ44-2C
79-22-01
Page 403
Dec 12/17

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TASK 79-22-01-450-801 Install the Lube Oil Cooler

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

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN OIL


FILTER. TO PREVENT CONTAMINATION OF THE OIL SYSTEM, MAKE
SURE THAT PORTS AND COMPONENT MATING SURFACES ARE KEPT
EXTREMELY CLEAN DURING MAINTENANCE.

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.

6. Equipment and Materials

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

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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
73-10-01 401 Fuel Tube Assemblies - Removal/Installation

7. Procedures

SUBTASK 79-22-01-870-001

A. Oil Cooler Handling Guidelines:

(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

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.

2 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY . OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

B. Lube four transfer tube O-rings with Assembly Fluid (MAT-011) and install on two transfer tubes.

C. Clean outside diameter of transfer tubes to remove any residual oil.

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

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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

CAUTION TO PREVENT DAMAGE TO OIL COOLER PORTS, USE A BACKUP WRENCH


ON REDUCERS WHEN TORQUING TUBE NUTS.

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

I. Service the oil system. Refer to 72-00-03, P.B. 301.

8. Job Close-up

SUBTASK 79-22-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Lube Oil Cooler - Removal/Installation

EFFECTIVITY: FJ44-2C
79-22-01
Page 407
Dec 12/17

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79-22-01
408
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LINE MAINTENANCE MANUAL - FJ44-2C

LUBE OIL COOLER - ADJUSTMENT/TEST

TASK 79-22-01-780-801 Pressure Test the Lube Oil Cooler

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

2. Equipment and Materials

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

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN OIL


FILTER. TO PREVENT CONTAMINATION OF THE OIL SYSTEM, MAKE
SURE THAT PORTS AND COMPONENT MATING SURFACES ARE KEPT
EXTREMELY CLEAN DURING MAINTENANCE.

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

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SUBTASK 79-22-01-780-001

B. Prepare lube oil cooler for testing as follows:

WARNING FUEL/DRY CLEANING SOLVENT ARE HIGHLY FLAMMABLE AND MUST BE


KEPT AWAY FROM HEAT AND OPEN FLAME. FUEL/MINERAL SPIRITS
MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL MINERAL SPIRITS
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL/MINERAL SPIRITS CONTAMINATION MUST
BE THOROUGHLY CLEANED BEFORE BEING WORN.

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:

Table 501 Approved Test Fluids

Nomenclature Reference/Spec. Notes


Fuel, Jet A MAT-003
Oil, Preservative MAT-002
Solvent, Dry Cleaning MAT-024 See Note (1), below
Water, Distilled Commercial See Note (2), below
NOTE: Do not mix test fluids

NOTES: 1 Requires flushing of oil cooler after test and filling with fuel or preservative oil.

2 Requires drying of oil cooler after test

(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).

C. Purge air from lube oil cooler as follows:

(1) Route drain tube to a suitable container.

EFFECTIVITY: FJ44-2C
79-22-01
Page 502
Dec 12/17

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WARNING FACE SHIELD/PROTECTIVE CLOTHING ARE REQUIRED TO BE WORN


DURING PURGING AND PRESSURIZATION CHECK.

(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).

D. Perform pressurization check as follows:

WARNING FACE SHIELD/PROTECTIVE CLOTHING ARE REQUIRED TO BE WORN


DURING PURGING AND PRESSURIZATION CHECK.

(1) Install clean tapered cap plugs into lube IN and OUT ports.

(2) Slowly pressurize pump to 100 psig and check for fluid leaks.

(a) Fix connection leaks as required.

(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.

NOTE Correction for pump system leakage is allowed.

(4) If pressure holds, accept oil cooler.

(5) If pressure decays, reject oil cooler.

(6) Release pressure on pump.

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
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Fig. 501 Lube Oil Cooler - Pressure Test Rig

EFFECTIVITY: FJ44-2C
79-22-01
Page 504
Dec 12/17

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LUBE OIL COOLER - INSPECTION/CHECK

TASK 79-22-01-220-801 Visually Inspect the Lube Oil Cooler

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

2. Equipment and Materials

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

A. Remove the lube oil cooler. Refer to 79-22-01, P.B. 401.

SUBTASK 79-22-01-870-001

B. Oil Cooler Handling Guidelines:

(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

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NOTE Failure to follow these guidelines may result in internal corrosion of oil cooler.

SUBTASK 79-22-01-220-001

C. Visually inspect the lube oil cooler for:

(1) Cracks Reject

(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)

(3) Distortion of flange mating surface Reject

(4) Damage to threaded ports Reject

(5) Damage to O-ring grooves Reject

SUBTASK 79-22-01-420-003

D. Install the lube oil cooler. Refer to 79-22-01, P.B. 401.

EFFECTIVITY: FJ44-2C
79-22-01
Page 602
Dec 12/17

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LUBE AND SCAVENGE PUMP - REMOVAL/INSTALLATION

TASK 79-24-01-050-801 Remove the Lube and Scavenge Pump

1. General

This task provides procedures for removing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

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

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SUBTASK 79-24-01-020-003

B. Remove the lube and scavenge pump as follows:

(1) If applicable to engine configuration, remove sensor harness connector from oil debris sensor.

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(2) Drain engine oil tank. Refer to 72-00-03, P.B. 301.

(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
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Fig. 401 Lube and Scavenge Pump - Removal/Installation

EFFECTIVITY: FJ44-2C
79-24-01
Page 403
Dec 12/17

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TASK 79-24-01-450-801 Install the Lube and Scavenge Pump

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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7. Procedures

SUBTASK 79-24-01-420-001

A. Install the lube and scavenge pump as follows:

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Lube and Scavenge Pump - Removal/Installation

EFFECTIVITY: FJ44-2C
79-24-01
Page 406
Dec 12/17

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OIL PRESSURE REGULATING VALVE - REMOVAL/INSTALLATION

TASK 79-25-01-050-801 Remove the Oil Pressure Regulating Valve

1. General

This task provides procedures for removing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 79-25-01-050-001

A. Remove the oil pressure regulating valve as follows:

EFFECTIVITY: FJ44-2C
79-25-01
Page 401
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WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(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

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Fig. 401 Oil Pressure Regulating Valve - Removal/Installation

EFFECTIVITY: FJ44-2C
79-25-01
Page 403
Dec 12/17

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TASK 79-25-01-450-801 Install the Oil Pressure Regulating Valve

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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7. Procedures

SUBTASK 79-25-01-420-001

A. Install the oil pressure regulating valve as follows:

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(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.

(2) Install the regulating valve into the interstage housing.

(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

B. Service the engine with oil. Refer to 72-00-03, P.B. 301.

8. Job Close-up

SUBTASK 79-25-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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Fig. 402 Oil Pressure Regulating Valve - Removal/Installation

EFFECTIVITY: FJ44-2C
79-25-01
Page 406
Dec 12/17

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OIL PRESSURE REGULATING VALVE - ADJUSTMENT/TEST

TASK 79-25-01-820-801 Adjust the Oil Pressure Regulating Valve

1. General

Do this procedure to increase or decrease engine oil pressure.


Figure 501

2. Equipment and Materials

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

A. Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 79-25-01-820-001

A. To adjust oil pressure:

(1) Remove lockwire from the regulating valve adjustment locknut.

EFFECTIVITY: FJ44-2C
79-25-01
Page 501
Dec 12/17

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(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.

(3) Loosen the regulating valve adjustment locknut.

CAUTION TO PREVENT INTERNAL LEAKAGE FROM RELIEF VALVE, MAKE SURE


THAT THE MAXIMUM EXTENSION OF THE ADJUSTMENT SCREW FROM
THE OUTBOARD FACE OF THE JAM NUT DOES NOT EXCEED:

0.136 INCH (3.45 MM) OR 4 THREADS FOR P/N 50485

0.220 INCH (5.58 MM) OR 6.5 THREADS FOR P/N 77795

IF LEAKAGE PERSISTS OR IF THE ADJUSTMENT SCREW IS EXTENDED


PAST THESE LIMITS, THE VALVE SHOULD BE UPGRADED TO
LATEST CONFIGURATION OR REPAIRED IN ACCORDANCE WITH
THE OVERHAUL PROCEDURE IN THIS TASK.

(4) Using a flat-tip screwdriver adjust the adjustment screw as follows:

NOTES: 1 It may be necessary to hold the adjustment locknut while turning


adjustment screw. One full turn of the screw will yield approximately
5 - 8 psid change in pressure.

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).

NOTE If oil pressure regulator is leaking externally, repair in accordance


with the overhaul subtask in this task.

(6) Verify correct oil pressure reading per Figure 501.

(7) Shut-down the engine. Refer to General Operating Procedures in71-00-00, P.B. 501.

(8) Install .020 lockwire, MAT-061, to regulating valve adjustment locknut.

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
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(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.

CAUTION BE CAREFUL NOT TO LOSE THE INTERNAL SPRING OR POPPET


WHILE REMOVING ADJUSTMENT SCREW.

(3) Remove the adjustment screw.

(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.

(8) Reassemble poppet, spring, and adjustment screw to valve body.

(9) Install jam nut 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

A. Install the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-25-01
Page 503
Dec 12/17

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Fig. 501 Oil Pressure Regulating Valve - Adjustment

EFFECTIVITY: FJ44-2C
79-25-01
Page 504
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

OIL SUPPLY TUBE - REMOVAL/INSTALLATION

TASK 79-26-01-050-801 Remove the Oil Supply Tube

1. General

This task provides procedures for removing the oil supply tube. Refer to the following illustration(s):
Figure 401

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

4. Procedures

SUBTASK 79-26-01-050-001

A. Remove the oil supply tube as follows:

EFFECTIVITY: FJ44-2C
79-26-01
Page 401
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Oil Supply Tube - Removal/Installation

EFFECTIVITY: FJ44-2C
79-26-01
Page 403
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 79-26-01-450-801 Install the Oil Supply Tube

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

CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN OIL


FILTER. TO PREVENT CONTAMINATION OF THE OIL SYSTEM, MAKE
SURE THAT PORTS AND COMPONENT MATING SURFACES ARE KEPT
EXTREMELY CLEAN DURING MAINTENANCE.

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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LINE MAINTENANCE MANUAL - FJ44-2C

7. Procedures

SUBTASK 79-26-01-420-001

A. Install the oil supply tube:

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(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

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 Oil Supply Tube - Removal/Installation

EFFECTIVITY: FJ44-2C
79-26-01
Page 406
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

MAGNETIC CHIP COLLECTOR - REMOVAL/INSTALLATION

TASK 79-30-01-050-801 Remove the Magnetic Chip Collector(s)

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-30-01
Page 401
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

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:

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

CAUTION HOLD A LARGE, CLEAN CONTAINER (FOR APPROXIMATELY 4 QUARTS


(4 LITERS) BELOW TANK DRAIN PORT. OIL WILL IMMEDIATELY DRAIN
WHEN THE TANK DRAIN CHIP COLLECTOR FITTING IS REMOVED.

(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:

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(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

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LINE MAINTENANCE MANUAL - FJ44-2C

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.

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

CAUTION HOLD A LARGE, CLEAN CONTAINER (FOR APPROXIMATELY 4 QUARTS (4


LITERS) BELOW GEARBOX PORT. OIL WILL IMMEDIATELY DRAIN FROM
GEARBOX WHEN THE CHIP COLLECTOR FITTING IS REMOVED.

(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:

(a) Remove one bolt and one washer,

(b) Remove oil screen from gearbox housing.

(c) Remove O-ring from oil screen.

D. Tag engine "NO OIL INSTALLED".

EFFECTIVITY: FJ44-2C
79-30-01
Page 403
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Magnetic Chip Collectors - Removal/Installation

EFFECTIVITY: FJ44-2C
79-30-01
Page 404
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 79-30-01-450-801 Install the Magnetic Chip Collector(s)

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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

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LINE MAINTENANCE MANUAL - FJ44-2C

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.

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(1) If removed, install oil screen to gearbox housing as follows:

(a) Lubricate O-ring with engine oil and install on oil screen.

(b) Install O-ring in gearbox housing.

(c) Install one bolt and one washer. Torque bolt 46 to 51 inch-pounds (5.2 to 5.7 N.m) .

(2) If removed, install oil screen to lube pump housing as follows:

(a) Lubricate O-ring with engine oil and install on O-ring.

(b) Install oil screen into lube pump housing. Torque oil screen 150 to 250 inch-pounds
(16.9 to 28.2 N.m).

(3) Remove self-closing magnetic plug from chip collector fitting.

(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).

(5) Install safety wire MAT-061 to chip collector fitting.

(6) Install self-closing magnetic plug to chip collector fitting.

SUBTASK 79-30-01-610-001

B. Service the engine with oil. Refer to 72-00-03, P.B. 301.

8. Job Close-up

SUBTASK 79-30-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-30-01
Page 406
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

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

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 Magnetic Chip Collectors - Removal/Installation

EFFECTIVITY: FJ44-2C
79-30-01
Page 408
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

MAGNETIC CHIP COLLECTOR - INSPECTION/CHECK

TASK 79-30-01-220-801 Visually Inspect the Magnetic Chip Collectors

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

2. Equipment and Materials

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

A. Prepare the engine for inspection

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-30-01
Page 601
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

4. Procedures

SUBTASK 79-30-01-210-001

A. Check the magnetic chip collectors as follows:

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.

(2) Inspect magnetic plug for metal particles:

(a) No metallic particles. Engine is acceptable for use.

(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.

1 Remove the oil filter element. Refer to 79-21-01, P.B. 401.

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.

CAUTION MAKE SURE THAT THE MAGNET IS CLEAN AND FREE OF


CONTAMINATION BEFORE INSTALLING IT INTO THE ENGINE.

(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.

(6) If unsure of examination results:

(a) Drain the oil system

(b) Clean and install the magnetic chip detectors

(c) Install the new oil filter element

(d) Fill the oil system

EFFECTIVITY: FJ44-2C
79-30-01
Page 602
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

(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.

(f) Examine the magnetic plug after engine testing.

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

B. Service the engine with oil. Refer to 72-00-03, P.B. 301.

5. Job Close-up

SUBTASK 79-30-01-410-003

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
79-30-01
Page 603
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 601 Magnetic Chip Collectors - Visual Inspection

EFFECTIVITY: FJ44-2C
79-30-01
Page 604
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

OIL FILLER CAP AND DIPSTICK - REMOVAL/INSTALLATION

TASK 79-31-01-050-801 Remove the Oil Filler Cap and Dipstick

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

NOTES: 1 Review Assembly/Disassembly Maintenance Practices, 70-00-01,


P.B. 201, before beginning work.

2 During removal of parts, group all components together to make assembly easier.

3 Discard all O-rings and gaskets during disassembly.

2. Equipment and Materials

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

A. Prepare the engine for part replacement

(1) Install DO NOT OPERATE signs.

(2) Open the circuit breakers to isolate the engine electrical supply.

(3) Remove the cowling. Refer to the Aircraft Maintenance Manual.

EFFECTIVITY: FJ44-2C
79-31-01
Page 401
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

4. Procedures

SUBTASK 79-31-01-020-001

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

CAUTION AFTER REMOVAL OF CAP/DIPSTICK ASSEMBLY OR FILLER PORT


PLUG, COVER OIL FILLER PORT TO ENSURE THAT CONTAMINATION
DOES NOT ENTER THE ENGINE.

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.

B. Remove the filler port plug assembly as follows:

(1) Remove safety wire and loosen (but do not remove) wing nut on plug assembly.

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

(2) Turn plug assembly and remove from oil fill port.

EFFECTIVITY: FJ44-2C
79-31-01
Page 402
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Oil Filler Cap and Dipstick - Removal/Installation

EFFECTIVITY: FJ44-2C
79-31-01
Page 403
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation

EFFECTIVITY: FJ44-2C
79-31-01
Page 404
Dec 12/17

© 2017 Williams International Co., LLC


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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 79-31-01-450-801 Install the Oil Filler Cap and Dipstick

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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
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LINE MAINTENANCE MANUAL - FJ44-2C

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.

A. Install the oil filler cap and dipstick assembly as follows:

(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

B. Assemble the filler port plug assembly (if necessary) as follows:

(1) Install lockplate on shaft and secure with nut.

(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.

C. Install the filler port plug assembly as follows:

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.

(3) Using MAT-061, lockwire wing nut to plug assembly cap.

8. Job Close-up

SUBTASK 79-31-01-410-002

A. Put the engine back to normal

(1) Install the cowling. Refer to the Aircraft Maintenance Manual.

(2) Close the aircraft circuit breakers.

(3) Remove DO NOT OPERATE signs.

EFFECTIVITY: FJ44-2C
79-31-01
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LINE MAINTENANCE MANUAL - FJ44-2C

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
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 403 Oil Filler Cap and Dipstick - Removal/Installation

EFFECTIVITY: FJ44-2C
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 404 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation

EFFECTIVITY: FJ44-2C
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 405 Oil Filler Port/Dipstick - Proper Installation

EFFECTIVITY: FJ44-2C
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LINE MAINTENANCE MANUAL - FJ44-2C

OIL SIGHT GLASS - REMOVAL/INSTALLATION

TASK 79-33-11-050-801 Remove the Oil Sight Glass

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

2. Equipment and Materials

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

A. Prepare to Disassemble the Engine

(1) Install DO NOT OPERATE signs.

(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

WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE


CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.

B. Drain engine oil. Refer to 72-00-03, P.B. 301.

EFFECTIVITY: FJ44-2C
79-33-11
Page 401
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LINE MAINTENANCE MANUAL - FJ44-2C

4. Procedures

SUBTASK 79-33-11-020-009

A. Remove the oil sight glass from the interstage housing as follows:.

CAUTIONS: 1 AFTER REMOVAL OF THE SIGHT GLASS OR THE BLANKING PLATE,


COVER SIGHT GLASS PORT IN THE INTERSTAGE HOUSING TO
ENSURE THAT NO CONTAMINATION ENTERS THE ENGINE.

2 USE CARE WHEN HANDLING THE SIGHT GLASS TO MAKE


SURE THAT IT DOES NOT FALL AND BREAK.

(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
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 401 Interstage Housing Oil Sight Glass - Removal/Installation

EFFECTIVITY: FJ44-2C
79-33-11
Page 403
Dec 12/17

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LINE MAINTENANCE MANUAL - FJ44-2C

TASK 79-33-11-450-801 Install the Oil Sight Glass

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

NOTE Review Assembly/Disassembly Maintenance Practices, 70-00-01, P.B.


201, before beginning work.

6. Equipment and Materials

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
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LINE MAINTENANCE MANUAL - FJ44-2C

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.

A. Service engine with oil. Refer to 72-00-03, P.B. 301.

EFFECTIVITY: FJ44-2C
79-33-11
Page 405
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LINE MAINTENANCE MANUAL - FJ44-2C

SUBTASK 79-33-11-410-005

B. Put the Engine Back to Normal

(1) Close aircraft circuit breakers.

(2) Remove DO NOT OPERATE signs.

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
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 402 Interstage Housing Oil Sight Glass - Removal/Installation

EFFECTIVITY: FJ44-2C
79-33-11
Page 407
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LINE MAINTENANCE MANUAL - FJ44-2C

Fig. 403 Interstage Housing Oil Sight Glass - Torque Pattern

EFFECTIVITY: FJ44-2C
79-33-11
Page 408
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