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COPY NO.

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
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

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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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.

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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.

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LINE MAINTENANCE MANUAL - FJ44-2C

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.

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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.

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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.

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71-00-00
Page 567
Fig. 523 Ground Idle N2 Speed Check
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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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Fig. 526 N2 Speed Limits for Ground Checks at Takeoff Settings

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LINE MAINTENANCE MANUAL - FJ44-2C

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.

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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.<