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Fj44-2a Ipc
Fj44-2a Ipc
FJ44-2A
LINE MAINTENANCE MANUAL
FJ44-2A
Initial Issue:
Mar 31/97
WI P/N 56210
Revision 17
Page 2
00-Titlepage Blank
LINE MAINTENANCE MANUAL FJ44-2A
SUMMARY OF CHANGES
FJ44-2A Line Maintenance Manual FJ44-2A
P/N 56210
TABLE OF CONTENTS
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
RECORD OF REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INTRODUCTION
STANDARD PRACTICES
ASSEMBLY/DISASSEMBLY MAINTENANCE
PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-00-01
Assembly/Disassembly Maintenance
Practices - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
POWER PLANT
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-00
Engine - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-30
Spinner - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-30-10
Spinner - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Spinner - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
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SECTION
SUBJECT SUBJECT
PAGE
IGNITION
AIR
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SECTION
SUBJECT SUBJECT
PAGE
ENGINE CONTROLS
ENGINE INDICATING
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
OIL
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CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Page x
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RECORD OF REVISIONS
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LINE MAINTENANCE MANUAL FJ44-2A
CHAPTER 00
INTRODUCTION
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
SUBTASK 00-00-00-860-105
A. This manual (P/N 56210) contains maintenance information prepared for the Williams International
FJ44-2A turbofan engine by Williams International.
SUBTASK 00-00-00-860-107
A. The manual is written to A.T.A. Specification No. 100 (Revision 28). The contents are organized
using the three element (six digit) Chapter-Section-Subject number (CH-SE-SU). The first element is
the Chapter, the second element is the Section, and the third element is the Subject.
(1) The chapter number and the first digit of the section number are assigned by the ATA
100 specification. This promotes continuity of contents between the manuals of different
manufacturers.
(2) The second digit of the section number and the subject number are assigned by the
manufacturer to identify the subject component with a unique designation.
(4) This numbering system is adjusted to identify removal/installation of core engine modules. This
allows engine build-up tasks to be grouped together in the manual. In these cases, the Section
number is moved to the third element and "00" is used for the second "middle" element.
B. Contents are further divided within a CH-SE-SU number by topic. Each topic is identified by a
separate range of page numbers. These Page Blocks organize the task information within a Subject.
A full list of topic Page Blocks for this manual are:
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C. This manual is written to conform to the requirements of the Aircraft Maintenance Task Oriented
Support System (A.M.T.O.S.S.). This system is designed to facilitate automated data retrival. Each
Page Block task is divided into Tasks and Subtasks which carry an A.M.T.O.S.S. number in bold
print. A.M.T.O.S.S numbers are an expansion of the ATA 100 CH-SE-SU number and provide a
numerical identity for work requirements. They are assigned as follows:
ELEMENT NUMBER: 1 2 3 4 5
Element 5 Numeric Indentifier - Used to make similarly numbered tasks and subtasks unique
Table 2 Function Codes for A.M.T.O.S.S. Task/Subtask Numbering (Fourth Element - 72-00-00-XXX-000)
Code Description
000 Disassemble (General)
010 Remove Engine
020 Remove Engine Modular Sections
030 Disassemble Engine Modular Sections
040 Disassemble Engine Subassemblies
050 Remove Accessory/Power Plant Components
100 Cleaning (General)
110 Chemical Cleaning
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3. Revisions
SUBTASK 00-00-00-860-108
The List of Effective Page Blocks will list the correct date for each page block within the Chapter.
(1) For CD-ROM, revised text on the CD-ROM 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) on the CD-ROM 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. You may call:
1-248-669-9515 (telefax)
C. If you find an error in this manual or feel that important information has been left out, please copy
and fill out the Technical Publications Customer Feedback Form (Figure 1 Technical Publications
Customer Feedback Form) and return it, along with a marked-up copy of the manual page to:
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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 WI 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:
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The IPC shows the relationship of all parts and assemblies and lists all part numbers.
References to specific parts for maintenance use (found under the Equipment and Materials
listing at the front of each task) are by IPC figure and item number.
B. Special tools are described in the Illustrated Tools and Equipment Catalog.
C. Consumable materials are assigned a MAT number and are listed under Equipment and Materials at
the front of each task. A complete listing of consumable materials is found in 70-10-01, P.B. 201.
6. General
The FJ44-2A is a two-spool, co-rotating, turbofan engine with medium bypass ratio, mixed exhaust, and a
high cycle pressure ratio. The engine can weigh up to 520 pounds dry, depending on configuration
options, and produces 2300 pounds of uninstalled takeoff thrust at sea level flat rated to an ambient
temperature of 72F.
Engine control is provided by an electronic fuel control unit (EFCU) consisting of an airframe mounted,
single channel, electronic control unit (ECU) directly linked to an engine mounted hydromechanical fuel
control unit (FCU). Thrust is managed through power lever input to the FCU which is mounted to the fuel
pump and is driven by the engine gearbox. In the electronic mode, the FCU is controlled by the ECU, while
in the manual mode, the FCU operates with authority independent of the ECU. The ECU utilizes TT2, N1,
N2, ITT and Pamb from sensor inputs to adjust fuel schedules and govern engine operation within limits.
7. Major Components
A. The FJ44-2A internal configuration is comprised of six distinct groups: LP shaft module, fan group,
core module, LP turbine group, accessory gearbox, and the EFCU.
(1) The LP shaft module consists of the LP shaft, the front bearing support, the No. 1 ball bearing,
and No. 1.5 roller bearing, and seal.
(2) The fan group consists of the spinner, the fan rotor, the fan housing and fan stator, the 3-stage
IP compressor, and the three piece 3-stage IP stator.
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(3) 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.
(4) 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.
(5) The fifth group is the accessory gearbox module and engine mounted accessories.
8. General
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Abbreviation Definition
HCL hydrochloric acid
HMU hydromechanical (fuel control) unit
HP high pressure
HPC high pressure compressor
HPT high pressure turbine
hr hour
ID inner diameter
IFCU integrated fuel control unit
Inc incorporated
IP intermediate pressure
IPC Illustrated Parts Catalog
ITT interturbine temperature
LP low pressure
LPT low pressure turbine
max maximum
min minimum
ml milliliters
mm millimeters
MM Maintenance Manual
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
P pressure
PB Page Block
pH hydrogen-ion concentration
PLA power lever angle
P/N part number
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Abbreviation Definition
ppm parts per million
PRESS pressure
psi pounds per square inch
psid pounds per square inch differential
psig pounds per square inch gauge
PT2 total inlet pressure
rpm revolutions per minute
sec second
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
UV ultraviolet
V velocity
WI Williams International, Inc.
C degrees Celsius
F degrees Fahrenheit
% percent
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9. General
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LINE MAINTENANCE MANUAL FJ44-2A
CHAPTER 05
05-10-00 201 Apr 11/08 05-17-00 201 Apr 11/08 05-50-00 201 Apr 11/08
05-12-00 201 Apr 11/08 05-20-00 601 Apr 11/08
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16
and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
This task gives the maximum approved lives for life-limited parts. Do not allow parts to exceed these
approved lives.
CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.
SUBTASK 05-10-00-870-013
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:
B. Full Cycle: Engine start, takeoff power setting, followed by engine shutdown, regardless of duration.
C. Partial Cycle:
(2) Full stop landing without engine shutdown shall be recorded as .50 cycle.
(3) Ground Running: Idle to max continuous thrust shall be recorded as .50 cycle.
(4) Throttle movement associated with low approaches are not counted as cycles.
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SUBTASK 05-10-00-870-014
A. Refer to table below for the component name, part number and approved part life.
SUBTASK 05-10-00-870-015
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 Flight Profile Duty Cycle. It is in
the Owner/Operators 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 Flight Profile Duty Cycle.
(2) The average profile of his operation exceeds the profile shown in Figure 201 Flight Profile
Duty Cycle for the number of times the power setting goes from low to high to low (as in a
touch-and-go).
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SUBTASK 05-10-00-870-016
CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.
A. Time in service, with respect to maintenance time records, means the time from the moment an
aircraft leaves the surface of the runway until it touches it at the next point of landing. Engine
operating hours and flight hours shall be considered the same as aircraft time in service.
SUBTASK 05-10-00-870-017
A. The critical parts, listed in Airworthiness Limitations, 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
components service life as defined in table 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 table 201.
This program applies to those engines which are the fleet leaders in regards to flight cycles. The fleet
leaders are defined as the six engines in the fleet that have the highest number of flight cycles. Fleet
leaders can change over the course of time, depending upon individual engine usage.
For purpose of illustration, the life management inspection intervals for the fan rotor are defined as
2000, 4000, 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, Inc. 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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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 dont exceed their safe service lives (SSL).
2. Life Recording
SUBTASK 05-12-00-870-002
An internal record system must be maintained for each Group A critical part, including a part held
serviceable in stores pending issue to an assembly/engine. As these records are important to
controlling the parts life, they must be accurate and up-to-date.
(1) Record the part serial number and modification standard against the parts total life. Recording
is logged numerically by flight cycles and hours.
(2) For quick location of a particular part, index the part under description and modification
standard (under engine serial number).
(2) Tell the operator and Williams International of the reason for rejection.
(3) Tell Williams International what the parts total running time was in flight cycles and hours.
C. Before refitting a Group A critical part to the engine, calculate its remaining life to determine if the part
will time expire before the engine and/or assembly life. If it will expire, do not use this part.
D. After fitting a Group A critical part into the engine, do the following:
(1) Tell the operator the serial number and life completed in flight cycles and hours.
(2) Include, or tell operator to include, the same information in the records accompanying the
engine or module.
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1. General
This task contains a listing of specific parts/serial numbers which are not approved for use. Refer to the
following:
table 201
2. Unapproved Parts
SUBTASK 05-17-00-870-003
Table 201
Engine Component
Serial Component Serial
Number Part Number Number Description
105269 65502 AU21062 ROTOR, FAN
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task contains procedures for routine and major periodic inspection of the engine at scheduled
intervals. Refer to the following:
table 601
table 602
.
NOTES: 1 The time limits in this schedule are the minimum necessary to keep
an engine in serviceable condition.
SUBTASK 05-20-00-210-013
C. Hourly - Special inspection or maintenance at the engine operating hours interval shown.
E. Check 2 - Inspections at every 300 to 400 engine operating hours, but no more than 150 to 200
engine operating hours after Check 1 was performed.
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SUBTASK 05-20-00-210-014
B. Check 4 - Inspections at every 3500 engine operating hours, but no more than 1750 engine operating
hours after Check 3 was performed.
SUBTASK 05-20-00-210-015
5. Storage Limits
SUBTASK 05-20-00-210-016
NOTE If storage time limits for the following components are exceeded,
contact the component manufacturer.
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SUBTASK 05-20-00-943-017
A. Refer to 70-53-00 P.B. 201 for maintenance and calibration requirements for special tools.
7. Job Set-up
SUBTASK 05-20-00-010-003
(2) Open the cowl doors. Refer to the Aircraft Maintenance Manual.
SUBTASK 05-20-00-210-018
A. Do the inspection checks at the time interval given. Refer to Tables 1 and 2.
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9. Job Close-up
SUBTASK 05-20-00-410-003
(1) Close the cowl doors. Refer to the Aircraft Maintenance Manual.
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1. General
In the interest of ensuring that the safe service lives (SSLs) for engine parts are not degraded by corrosion
or sand ingestion, Williams International recommends that the following policy be followed regarding
water washing of the engine.
2. Desalinization 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). Sea salt contamination from flying in a marine atmosphere
or landing at airports near the ocean may initiate corrosion on metallic 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.
(1) Marine Atmosphere. Operation in a marine atmosphere is defined as operation over salt water
or within 5 miles (8 kilometers) of the ocean.
(2) If the aircraft is operated in a marine atmosphere below 4000 feet for more than 30 minutes,
perform the desalinization rinse procedure at the end of flight operations for the day.
(3) If the aircraft is operated in any of the flight conditions listed below, perform the desalinization
rinse procedure at least once per week:
(a) In a marine atmosphere at altitudes below 4000 feet for less than 30 minutes.
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).
(1) Perform compressor cleaning procedure whenever fan or compressor components appear
dirty. Adjust cleaning interval to suit local operating conditions.
(2) If engine performance has gradually degraded (increase in ITT), perform the compressor
cleaning procedure.
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CHAPTER 70
STANDARD PRACTICES
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70-STANDARD PRACTICES Apr 11/08
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70-00-01 201 Apr 11/08 70-12-00 201 Apr 11/08 70-42-12 801 Apr 11/08
70-01-05 201 Apr 11/08 70-12-04 201 Apr 11/08 70-42-15 601 Apr 11/08
70-01-07 201 Apr 11/08 70-21-00 701 Apr 11/08 70-51-00 201 Apr 11/08
70-01-11 201 Apr 11/08 70-31-01 201 Apr 11/08 70-53-00 201 Apr 11/08
70-02-01 201 Apr 11/08 70-33-01 601 Apr 11/08 70-61-01 201 Apr 11/08
70-10-01 201 Apr 11/08 70-42-11 801 Apr 11/08
Chapter 70
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
Standard maintenance practices for engine maintenance are provided in this task. These practices
are recommended by the engine manufacturer.
SUBTASK 70-00-01-942-001
A. 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
SUBTASK 70-00-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-01-05 201 Temporary Marking of Parts - Maintenance Practices
70-10-01 201 Consumable Materials - Maintenance Practices
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SUBTASK 70-00-01-870-003
A. Use the following general procedures for disassembly and removal of engine and accessory
components.
(1) Examine components for signs of burning, scoring, chafing, evidence of leaks and other
defects when removed from engine. 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.
(2) Cover all ports, and openings, of tubes and assemblies when performing any maintenance
action to prevent contamination.
(3) 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.
(4) 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.
(5) Record thickness and quantity of all shims and spacers removed. Tag with location for
reference during assembly procedures.
(6) 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.
(7) 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.
(8) 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.
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SUBTASK 70-00-01-870-004
A. Use the following general procedures for assembly and installation of engine and accessory
components. Refer to the Consumable Materials Listing 70-10-01, P.B. 201for applicable materials.
(1) 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.
(2) Use protective closures and covers on large openings. Cap open tube ends to prevent
contamination. Do not leave engine unattended without covering.
(3) You must maintain the highest standards of precision shop practices during all stages of
assembly. Close attention to detailed procedures is required.
(4) Support equipment must be cleaned before and after use to prevent any dirt or metal build-up
that may transfer to engine components.
(5) Lube all O-rings and packings with a light coat of engine oil MAT-001 or assembly fluid MAT-011
prior to installation. Lube bearings with engine oil, MAT-001 . The gearbox/interstage gasket is
installed clean and dry (no lubricant required).
(6) 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.
(7) 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.
(8) Do not handle bearings with bare hands. To prevent fingerprint damage, always handle
bearings with plastic-type gloves MAT-072.
(9) 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.
(10) 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.
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1. General
This task defines the acceptable materials for the temporary marking of parts.
SUBTASK 70-01-05-942-001
A. Consumables
Reference Designation
MAT-030 Pencil, Silver
MAT-032 Marker, Broad Line
MAT-033 Marker, Fine Line
SUBTASK 70-01-05-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-10-01 201 Consumable Materials - Maintenance Practices
3. Procedures
SUBTASK 70-01-05-870-001
3 ALL MARKS MADE WITH FELT TIP MARKER MAT-032 OR MAT-033 MUST
BE REMOVED BEFORE PARTS ARE EXPOSED TO TEMPERATURES
ABOVE 400F (204C) OR ARE ASSEMBLED ON ENGINES
A. During maintenance, it may be necessary to mark certain parts to highlight defects or aid in assembly.
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B. Use the materials listed under Consumable Materials (above) for temporary marking of parts. These
are detailed in the Consumable Materials Listing, 70-10-01, P.B. 201.
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1. General
This task provides the standard practices for marking of repaired parts.
Figure 201 Repair Symbols
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 Repair Symbols . The symbols consist of a triangle ()
which encloses an alphabetic code representing the repair process.
D. Method of marking should be the same as was used to originally identify the part:
(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 suppliers
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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1. General
2. Procedures
SUBTASK 70-01-11-870-001
A. Molybdenum disulfide lubricants (Molykote, MAT-008 break down at temperatures above 572 F.
(300 C). They also release sulphur which can cause corrosion and failure of engine parts. Most of
the bolt materials used in the higher temperature zones of the engine can be damaged by sulphur.
B. Never use lubricants that have molybdenum disulfide except in cases where it is specifically called
out in the manual.
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1. General
SUBTASK 70-02-01-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 70-02-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-61-01 201 Storage of Parts that have Shelf Life Limits - Maintenance Practices
3. Identification
SUBTASK 70-02-01-870-002
A. To identify new O-rings, read the part number on the envelope in which they are packed. Each
envelope lists:
(2) Quantity
B. The storage life of an seal ring can be determined by the cure date on the envelope. There is a listing
of storage periods in 70-61-01. The year is divided into quarters as follows:
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The quarter number and the year, isolated by the letter Q, show the cure date. A cure date of
2Q91 shows the cure date to be in the second quarter (April, May, or June) of 1991. The storage
life can be calculated from this date.
C. You can identify the seal ring material by looking up its basic part number (MS number) in the
table below.
PART NUMBER MATERIAL
M25988 Fluorosilicone
M83248 Fluorosilicone
MS9020 Nitrile
MS9021 Nitrile
4. Lubrication
SUBTASK 70-02-01-870-003
A. To prevent seal ring damage and to permit easier assembly of parts, you must lubricate the seal
rings before their installation. The lubricant must be compatible with the engine system in which
a seal ring is installed. Use small quantities of the approved lubricant immediately before the
installation of the part.
(2) All other seal rings - assembly fluid No. 1 MAT-011 or engine oil MAT-001
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.
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.
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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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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This section describes the consumable materials and other shop supplies required to perform the
maintenance in this manual. Each maintenance task contains a listing of consumable materials by name
and MAT-number. The MAT-numbers are listed here, in numerical order, to reference the applicable
specification, part number, or manufacturer.
Specification numbers applying to consumable materials in this list are basic numbers and include all
revisions and amendments.
All warnings and cautions applicable to the products listed here are shown in the text where the product is
used.
2. Consumable Materials
SUBTASK 70-10-01-942-001
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1. General
2. Procedures
SUBTASK 70-12-00-870-001
A. Some materials used in engines can be contaminated through contact with other materials.
(1) When a material is contaminated by a low melting point alloy, it can, at certain temperatures,
become brittle and crack.
(2) Contamination of certain titanium alloy parts by materials used in processing can, if not
thoroughly cleaned, react with the surface at low temperature and form brittle intermetallic
compounds. This happens when the part temperature is raised either through normal engine
operation or by the application of heat during a repair cycle.
3. Cadmium Contamination
SUBTASK 70-12-00-870-002
A. Cadmium contamination of titanium alloy components is normally caused by the transfer of the soft
electroplated cadmium from or by fixtures and hand tools.
B. Although cadmium platings are no longer used on tools and fixtures (thus avoiding direct transfer),
secondary transfer is still possible. This can occur from the use of a tool which was previously in
contact with cadmium plated components or fasteners.
C. Other low melting point alloys to avoid include: lead, zinc, tin, mercury, and silver. Lead hammers or
shop aids are not to be used. A silver pencil must not be used on titanium parts.
D. You must be extremely careful to make sure that you eliminate both the obvious and the less obvious
sources of contamination.
SUBTASK 70-12-00-870-003
A. Materials containing chloride ions (or other halogens) can, if left on the surface of titanium alloy parts,
stress corrode or embrittle the material when heat or load is applied. Chlorides can come from
organic solvents, tap water, and hand contact.
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B. To avoid any problems with these materials, you must strictly follow the instructions issued in this
manual relating to cleaning, inspection, repair, assembly, transportation, and storage.
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1. General
This Standard Practice gives the approved procedures for the following locking techniques:
Wire locking
Self-locking fasteners
2. Wire Locking
SUBTASK 70-12-04-870-003
3. Self-Locking Fasteners
SUBTASK 70-12-04-870-004
A. General
(1) Fasteners with self-locking capability can be used a limited number of times before the
self-locking feature wears out. These fasteners must be checked at installation to make sure
that they have the proper locking torque.
(2) Wear may occur to either the self-locking fastener or to the fastener that is used with it. For
example, a self-locking nut may not meet the minimum torque requirement if the bolt that goes
into it is worn. If a self-locking threaded insert or a self-locking swage nut fails to meet the
minimum torque requirement, check it with a new bolt before replacing.
(1) Self-locking nuts, bolts, and helical coil inserts must meet the torque requirements in the
table below:
FINE THREAD SERIES COARSE THREAD SERIES
Mating Bolt Max Min Mating Bolt Max Min
Thread Size Locking Break-away Thread Size Locking Break-away
Torque* Torque Torque* Torque
.112 -48 NF-2A 3 0.5 .112 -40 NC-2A 3 0.5
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1. General
This chapter describes methods and procedures required for cleaning engine components. Cleaning of
engine components must do the following:
(1) Permit components to be examined for any flaws or dimension loss from abrasion and wear.
SUBTASK 70-21-00-941-001
A. Standard Equipment
Rinse Tank
Spray Booth
Air Compressor,
Ultrasonic Tank
SUBTASK 70-21-00-942-001
B. Consumables
Reference Designation
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-026 Ultrasonic Cleaner, Detergent
MAT-027 Alcohol, Isopropyl
MAT-076 Paper, Litmus
MAT-123 Solvent, Wet Cleaning
SUBTASK 70-21-00-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-10-01 201 Consumable Materials - Maintenance Practices
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3. Cleaning Policy
SUBTASK 70-21-00-870-001
A. These instructions apply to the cleaning of engine components. Refer to the specific cleaning
procedure for each component in the Engine Manual. The instructions must be followed completely.
B. Selection of a cleaning procedure for each part must take the following into consideration.
(1) Cleaning materials selected must consider the nature of the deposits, type of metal, type of
coating, and how clean the part must be to permit correct inspection.
(2) Engine parts operating in relatively low-temperature ranges (i.e., cold section parts) can
usually be cleaned using standardized methods and processes such as dry cleaning solvent
spray washing.
(3) Combustion and turbine "hot section" engine parts may require more extensive cleaning
procedures, involving a series of carefully controlled ultrasonic and alkali baths and water
rinses.
(4) To maintain part durability, the recommended cleaning method must meet the following
requirements:
(a) It must clean part sufficiently to allow correct inspection by recommended method.
(b) Prohibit use of cleaning methods on parts where cleaning agent(s) can get trapped and
not completely removed by the neutralizing process.
(c) The physical attributes of the part must not be altered by the cleaning procedure.
(a) Extensive cleaning is not necessary for parts that dont require crack detection, or
require only magnetic inspection. However, extensive cleaning is required for penetrant
inspected parts.
(b) Leave stains on nickel-cadmium plated parts. They do not impair magnetic particle
inspection. Scrubbing may remove plating.
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NOTE Cleaning materials and solutions specified with each cleaning procedure
are not supplied by Williams International. However, these items are
identified by their trade names or part/specification number in the
listing of Consumable Materials. Other equivalent products under a
different trade name may be used as materials and solutions identified
in this Consumable Materials list are only a representative sample.
Also, use of these products does not constitute an unconditional
approval of, or guarantee of them by Williams International. Cleaning
materials listed in the Unacceptable Cleaning Materials table are
products not permitted for use in cleaning.
Give special attention to specific cleaning instructions and the information listed in this section
concerning the cleaning of certain component materials.
(1) The cleaning solution temperature, strength and part immersion time must be monitored
continuously to avoid part damage.
(2) Ultrasonic cleaning solutions must be tested on a regular basis for maintenance of proper pH
levels. This will avoid possible damage to costly engine parts.
(3) 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.
(4) 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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(5) 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-123, or
isopropyl alcohol MAT-027. Use clean water for final rinse of titanium parts.
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-123.
WARNING CLEANING SOLUTION CAN CAUSE SKIN RASH AND EMIT HARMFUL
VAPORS. WEAR PROTECTIVE CLOTHING, RUBBER GLOVES,
APRON, AND FACE SHIELD/GOGGLES DURING USE. USE IN
WELL-VENTILATED AREAS AWAY FROM OPEN FLAME.
(a) Hand scrub parts with dry cleaning solvent MAT-024 using a soft fiber brush or pad to
remove contaminants.
(b) If any residue remains after cleaning, use a stiff fiber brush to remove residue. Repeat
procedure (a).
(c) Using an Air Compressor,, blow components dry with clean, filtered shop air.
(a) Hand scrub, using a soft fiber brush or pad. Spray, dip, sponge, or ultrasonically clean
parts with wet cleaning solvent MAT-123 to remove contaminants.
1 If surface to be cleaned is vertical or difficult to reach, use the gel form of wet
cleaning solvent.
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(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.
2 Slowly sprinkle caustic ultrasonic cleaner MAT-023 over entire surface. Use 3.5
ounces (99.22 grams) for every one gallon of water.
3 Maintain water level as it will decrease with use. Check pH level with litmus paper
MAT-076 and add more ultrasonic cleaner MAT-023 if necessary to maintain a pH
of 13.
(b) Remove lid from tank, carefully letting condensation on underside of lids drain back
into tank.
(d) Caustic solution, when tested with litmus paper MAT-076 must show a pH of 13. If
necessary, add chemicals to tank to maintain correct pH.
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(e) Heat caustic and rinse tanks between 160 and 200F (71 and 93C).
2 If necessary, clean components with carbon and oil build-up in accordance with
instructions for primary cleaning (paragraph C) before putting in ultrasonic or still tank.
3 Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove
wet cleaning solvent MAT-123 by rinsing part with water.
5 Remove parts from solution and inspect parts for cleanliness. If necessary, use a
fiber brush to remove residue.
6 Turn parts over and put parts back in solution for five to seven minutes.
8 Remove parts from cleaning solution and put in rinse tank for two to three minutes.
9 Remove parts from rinse tank and dry with shop air.
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2 Slowly sprinkle detergent ultrasonic cleaner MAT-026 over entire surface. Follow
package directions for mixing.
3 Maintain water level as it will decrease with use. Check pH level with litmus paper
MAT-076 and add detergent ultrasonic cleaner MAT-026 to maintain a pH of 9.
(b) Remove lid from tank, carefully letting condensation on underside of lids drain back
into tank.
(d) Detergent tank, when tested with litmus paper MAT-076 must show a pH of 9. If
necessary, add chemicals to tank to maintain correct pH.
(e) Heat detergent tank between 130 and 170F (54 and 77C).
2 Clean components with carbon and oil build-up in accordance with instructions for
primary cleaning (paragraph C), before putting in ultrasonic tank.
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3 Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove
wet cleaning solvent MAT-123 by rinsing part with water.
5 Remove parts from solution and inspect parts for cleanliness. If necessary, use a
fiber brush to remove remaining contamination.
6 Turn parts over and put back in solution for five to seven minutes.
8 Remove parts from cleaning solution and put in rinse tank for two to three minutes.
9 Remove parts from rinse tank and dry with shop air.
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1. General
This section provides step-by-step procedural information for correctly screening and processing used
bearings. It covers the cleaning environment, cleaning procedures, packaging and identification.
SUBTASK 70-31-01-941-001
A. Standard Equipment
Ultrasonic Tank
Rinse Tank
Diopter Lighted Magnifying Lens (or 7X Magnification
With Optical Comparison Scale)
Still Soak Tank (Lubricant)
Still Soak Tank (Cleaner)
Still Tank (Fingerprint Remover)
Apron, Chemical Resistant
Magnetometer (Gaussmeter)
Face Shield/goggles
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
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3. Job Set-up
SUBTASK 70-31-01-010-001
A. Do not mix sets of bearings or mix components of separable bearings. Make sure that all bearings
are correctly tagged and identified.
B. Before bearings are cleaned, do an initial visual inspection; refer to TASK 70-31-01-220-801 .
C. There are separate procedures for cleaning contaminated bearings (Subtask 70-31-01-110-001), and
cleaning bearings with carbon/varnish build-up (Subtask 70-31-01-110-002).
E. The following equipment is used for this task: Magnetometer (Gaussmeter), Demagnetizer,
Thermometer (Room Temp. Gauge), Diopter Lighted Magnifying Lens (or 7X Magnification with
Optical Comparison Scale), Rinse Tank, Still Tank (Fingerprint Remover), Still Soak Tank (Cleaner),
Still Soak Tank (Lubricant), Handling Tweezers, Ultrasonic Tank, Apron, Chemical Resistant, Face
shield/goggles.
4. Procedures
SUBTASK 70-31-01-200-001
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(1) Fingerprints
Bearings must not come in contact with bare skin or other moist surfaces. When handling
bearings, you must wear one of the following types of gloves:
(b) Clean cotton gloves MAT-075. Whenever cotton gloves are used, they must be changed
frequently to avoid the possibility of the gloves becoming perspiration soaked.
The majority of bearing defects are the result of contamination from dust, dirt, and metal
particles. Dirt is often made up of many types of diamond-hard particles that break up when
trapped between the rolling elements. As the particles mix with the lubricant, they act as
an abrasive and cause surface damage in the form of indentations, metal displacement,
and premature wear.
Areas of localized stress generate too much friction, causing fatigue flaking of the surface
which occurs at an increased rate, leading to early bearing failure.
The bearing cleaning area is equipped with the standard equipment and materials listed in the
paragraph, Equipment and Materials. The equipment and materials have the following purpose.
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Used to check the effectiveness of the demagnetizing procedure. Remaining magnetism must
not be greater than five (5) gauss during the cleaning procedure.
(2) Demagnetizer
(3) Container
Used to perform initial cleaning of bearings using mineral spirits MAT-020 or dry cleaning
solvent MAT-024 for a time period of five (5) minutes.
(5) Thermometer
Used to protective wrap bearings until they are needed for engine installation.
To protect bearing cleaning personnel from caustic chemicals. Special handling gloves,
apron and face shield.
SUBTASK 70-31-01-100-001
C. Bearing Cleaning
Bearings must be clean before final inspection TASK 70-31-01 P.B. 201, (Subtask 70-31-01-200-002).
You must clean bearings when one or more of the following conditions exist:
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(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.
(4) Bearings with carbon deposits and/or varnish build-up require special cleaning in accordance
with Subtask 70-31-01-110-002.
SUBTASK 70-31-01-110-001
(1) Demagnetize each bearing using demagnitizer. 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. After each major cleaning, the residual magnetism shall be rechecked and
the bearing shall be demagnetized, as necessary.
(a) Support bearing in a container, above any sludge or contamination that may have
collected near the bottom of container.
(b) Put bearing fully into container, containing MAT-020 or (MAT-24) for five (5) minutes
minimum. Occassionally agitate by hand.
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(a) Spray rinse with MAT-020 or MAT-024 in a spray booth, allowing the bearing to rotate
slowly to make sure the part is flushed of contamination.
NOTE Initial spray procedure requires rotating the bearing very slowly
for complete purging of any contamination. Subsequent spray
procedures are designed to remove different chemical solvents from
the bearing, and do not require slow rotation.
(c) Lift bearing above solution level and allow remaining solution to drain off bearing.
(d) Spray rinse bearing with dry cleaning solvent MAT-024 and prevent spinning. Continue
rinsing for 30 to 60 seconds.
Remove bearings from ultrasonic tank and spray rinse bearings with dry cleaning solvent
MAT-024 using the handling tweezers or gloved hands to prevent spinning.
Blow dry bearing using filtered dry air until moisture is removed. Make sure bearing does not
spin while drying.
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Put bearing fully into still tank containing dry cleaning solvent MAT-024 for five (5) minutes.
Remove bearing from still tank and spray rinse with P-D-680, Type II MAT-024 making sure
bearing does not spin. Continue rinsing for 30 to 60 seconds.
Blow dry using filtered dry air until moisture is removed from bearing. Make sure bearing
does not spin when drying.
(10) Inspect
(a) Inspect bearing to determine whether contamination (or carbon deposits) have been
removed.
(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.
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(11) 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).
A record of all bearings and bearing assemblies must be maintained, noting good and/or
rejected bearings.
SUBTASK 70-31-01-110-002
Bearings with carbon deposits and/or varnish buildup require more cleaning, using oakite rustripper
MAT-174.
Put bearing in container containing rustripper solution at 180 to 200F (82 to 93C) for
five (5) minutes.
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(a) Cleaning solution is made by mixing one (1) pound of oakite rustripper MAT-174 with one
(1) gallon of water at 180 to 200F (82 to 93C). Solution must be mixed at least 24
hours before using as a cleaning agent to make sure full cleaning potential is reached.
Mixed solution has a long shelf life and can be stored indefinitely.
Remove bearing from container and put in flowing cold water bath for two minutes.
Put bearing in container containing water 180 to 200F (82 to 93C) for two (2) minutes.
Remove bearing and container from container. Spray rinse bearing with dry cleaning solvent
MAT-024 using gloved hands or tweezers to prevent the bearing from spinning. Continue
rinsing for 30 to 60 seconds.
NOTE The first dry cleaning solvent spray procedure required the bearing to be
rotated slowly to make sure contamination is completely removed. Subsequent
dry cleaning solvent spray procedures are designed to remove chemical
solvents from the bearing and do not require slow rotation.
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 201 Bearing Functional/Non-Functional Surfaces
Figure 202 Inspection of Bearings
Figure 203 Bearing Functional Surfaces Inspection - Center 1/3 of Roller
Figure 204 Bearing Functional Surfaces Inspection - Scratch or Scoring (Center Roller)
Figure 205 Bearing Functional Surfaces Inspection - Outer 1/3 of Roller
Figure 206 Bearing Non-Functional Surfaces Inspection
Figure 207 Bearing Cage Inspection
Figure 208 Bearing Cage Inspection - Continued
Figure 209 Correct Positioning of Radius Stylus
Figure 210 Bearing Brinelling - Contact Zones
Figure 211 Bearing Corrosion
Figure 212 Bearing Rings - Nicks, Dents, and Scratches
Figure 213 Bearing Skidding Damage
Figure 214 Roller End Wear
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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
(1) Check for Damage. Inspect bearings in accordance with visual inspection criteria shown in
Figure 202 Inspection of Bearings. If bearing shows evidence of damage, reject bearing.
There is no need to clean damaged bearings.
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(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
Functional and nonfunctional surfaces of bearings are defined in Figure 201 Bearing
Functional/Non-Functional Surfaces.
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 202 Inspection of Bearings, Figure 203
Bearing Functional Surfaces Inspection - Center 1/3 of Roller, Figure 204 Bearing Functional
Surfaces Inspection - Scratch or Scoring (Center Roller), Figure 205 Bearing Functional
Surfaces Inspection - Outer 1/3 of Roller, Figure 206 Bearing Non-Functional Surfaces
Inspection, Figure 207 Bearing Cage Inspection, Figure 208 Bearing Cage Inspection -
Continued
(b) No. 2 bearings shall be removed from the 1st reduction bevel gear.
(c) No. 3 bearing outer ring and the No. 4 bearing rollers shall be removed from their
assembled housings.
(e) No. 4 bearing inner race shall remain on the 1st LP turbine.
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(f) Main shaft accessory drive bearings shall remain installed in their housings or supports.
(g) Gearbox bearings shall remain installed in the gearbox or installed on their shafts.
(a) Visually inspect all bearings, using 1X magnification, to find any contamination or
carbon/varnish buildup on the bearings. Magnification of 1X is defined as 16-18 in.
distant and illumination must be 100 foot candles (1000 lux) minimum. Used bearings
must be 100 percent screened and processed.
(b) Magnification may be used to measure the size of a defect if the scribe test is not capable
of verifying the size. Magnification is not to be used to find defects, only measure size or
determine classification, (i.e., skidding versus spalling).
(4) Use of a Radius Stylus. The scribe test is conducted once a visual imperfection is found.
No magnification is permitted during the scribe test. If the imperfection is felt during the
scribe test, continue to follow the applicable bearing inspection flow chart. Refer to Figure
209 Correct Positioning of Radius Stylus.
(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.
(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.
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(b) Hold one race stationary and rotate the other race slowly by hand while applying a
load in the thrust direction. The applied load should be enough to ensure that all the
rotating elements are loaded. Note any binding or rough turning. Rough spots should be
oscillated over to distinguish between a defect and the chattering of the cage. If a rough
spot is found, reclean the bearing to insure that it is not contaminated. Up to a total of
four bearing cleanings and subsequent inspections are allowed. Any binding or rough
turning following the completion of this cycle is cause for rejection.
(6) The following equipment is used for inspecting the bearings: Handling Tweezers, Scribe
(Bearing Surface Tester), .040 inch (1.016 mm) Radius Stylus, Magnification (1X).
C. Definitions.
(a) Functional Surfaces. Functional surfaces are all active surfaces of a bearing.
1 Rolling elements. All surfaces except the corners of the rollers. Roller corners at the
point of intersection with the roller profile and roller end are functional.
2 Rings. Raceways and adjacent guide flanges for roller bearings, but not
track-to-guide undercuts or fillet radii.
3 Cage (retainer). Entire pocket (except retention features) and control land surface.
The control land surface is the cage surface that pilots the cage.
(b) Non-Functional Surfaces. Non-functional surfaces are all surfaces other than those
defined as functional.
(2) Non-Separable Bearings. Certain bearings, such as those used for the gearbox, towershaft,
and some mainshaft bearings, cannot be disassembled for detailed component inspection.
These bearings should first be screened by rotational check. The functional, non-functional, and
cage surfaces which are visible should be inspected as defined in the applicable flow charts.
(3) Imperfections
(4) 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 210 Bearing Brinelling - Contact Zones.
(5) 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.
(6) 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 211 Bearing Corrosion.
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(a) 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 212 Bearing Rings - Nicks,
Dents, and Scratches.
(c) Flaking or Blistering of Plating. Flaking, or blistering of silver plating due to inadequate
adhesive bond.
(d) 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.
(e) 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.
(f) 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 480F (221 to 249C) - Very pale yellow through dark yellow
(g) 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 212 Bearing Rings -
Nicks, Dents, and Scratches.
(h) Pits. Small cavities in the surface, free of discoloration around the perimeter, usually dark
at the bottom and generally circular in shape.
(i) Raised Material. Material disturbed such that it has been raised above the surrounding
surface.
(j) Retention Feature Interference. Cage retention feature showing evidence of contact
with the ball or roller during operation.
(k) Rivet Imperfection. Non-uniform view of rivet heads on either side of the cage is an
indication of a process problem.
(l) Roller Banding. Visible band on roller that may or may not have depth.
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(m) 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.
(n) Scratch. A linear depression with a sharp bottom caused by movement of a sharp
object or particle across a surface. Refer to Figure 212 Bearing Rings - Nicks, Dents,
and Scratches.
(o) 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 213 Bearing Skidding Damage.
(p) 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.
(q) Stain. Surface discoloration with surface not broken, including tarnishes other than those
associated with corrosion or heat discoloration.
(r) Wear. Deterioration or surface finish or perceptible removal of material. Refer to Figure
214 Roller End Wear.
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Fig. 204 Bearing Functional Surfaces Inspection - Scratch or Scoring (Center Roller)
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This section defines the accept/reject criteria for surfaces of all mainshaft carbon seals.
Figure 601 Carbon Seal Surface Quality - Inspection Zones
Figure 602 Carbon Seal Inspection - Banded Ring Seal
Figure 603 Carbon Seal Inspection - Circumferential Grooves
2. Definitions
SUBTASK 70-33-01-870-002
B. Seal Face: The surface(s) designed to mate with adjoining surface(s) to seal off fluid or other media
to be retained by the seal.
D. Chips: Discontinuities on the edge resulting from pieces of the material being broken and separated
from the edge.
E. Chip Width: The maximum dimension of a chip measured perpendicular to the edge along the
surfaces forming the edge. Chips have two width dimensions; each one measured along the surface
that forms the edge.
F. Chip Length: The maximum dimension of a chip measured along the edge.
G. Scratch: A random, shallow, linear depression caused by a sharp object (see lay).
H. Lay: The predominate surface pattern caused by the marks of tools used to finish the surface.
I. Crack:. A linear discontinuity resulting from the fracture (rupture) of the material by internal or
external stress.
3. Carbon Face Seal Quality Requirements (No. 1 and No. 2 Carbon Seals)
SUBTASK 70-33-01-870-003
NOTE Carbon face seals and runners should always be replaced together to avoid
excessive wear rates. If either the seal or runner shows coking or wear, both
parts should be replaced with new or relapped parts.
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B. Chips, pits, nicks, dents, and scratches shall be in accordance with table 601.
C. Seal Hang-Up. If the carbon seal is compressed into its metal case and does not extend without
assistance, both runner and seal should be replaced.
D. Coking and Carbon Deposits. Soft deposits that break up easily are not cause for rejection if not
accompanied by seal hang-up or hard deposits. The seal should be cleaned and reused. Hard
deposits on the seal runner that are not easily removed by wiping with a soft cloth are cause for
rejection. Both runner and seal should be replaced.
E. Stringers. Stringers are long, thin formations of coked material. If stringers are soft, easily smeared
and not accompanied by seal hang-up or hard deposits, the seal should be cleaned and reused. If
stringers are hard, gritty or accompanied by seal hang-up or hard material build-up on seal runner,
both seal and runner should be replaced.
4. Banded Ring Carbon Seal Quality Requirements (No. 3 and No. 4 Carbon Seals).
SUBTASK 70-33-01-870-004
A. Inspect banded ring carbon seals per Figure 602 Carbon Seal Inspection - Banded Ring Seal.
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SUBTASK 70-33-01-870-001
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
Seal Face(Except Pits, Dents, Nicks Depth - 0.015 inch Defects 0.005 inch
Edges) (0.381 mm) or 20% of (0.127 mm) width and
section - whichever is less - no limit.Defects
smaller.Width - 0.15 over 0.005 inch (0.127
inch (3.81 mm) or 20% mm) - sum of defect
of dimension across areas not to exceed
surface - whichever is 0.1% of face area.
smaller.
One pit may be up to
0.015 inch (0.381 mm)
x 0.027 inch (0.685
mm) as long as it is
0.030 inch (0.762 mm)
from nearest edge.
Scratches (includes lay) Scratches are
acceptable if they
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.
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Table 601 Carbon Face Seal Surface Quality Requirements FJ44 (Continued)
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
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.
Edges (Seal Face and Chips 0.015 inch (0.381 mm) Chips 0.007 (0.177
O-ring Groove) or 20% of face width - mm) and smaller - no
whichever is smaller. limit. Chips over 0.007
inch wide - the sum of
the chip lengths shall
not exceed 10% of
edge length.
Edges (Other Face) Chips 0.032 inch (0.812 mm) Chips 0.016 (0.406
or 20% of face width - mm) and smaller - no
whichever is smaller. limit. Chips over 0.016
inch wide - the sum of
the chip lengths shall
not exceed 10% of
edge length.
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This repair task must be performed when directed, in the relevant Inspection/Check task (page block 601)
for the part being repaired.
SUBTASK 70-42-11-942-001
A. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-041 Pad, Abrasive
MAT-042 Paper, Abrasive, Silicone Carbide
MAT-043 Stone, Sharpening
3. Instructions
SUBTASK 70-42-11-870-003
A. Parts repaired to these instructions must be restored as near to their original shape and surface
condition as possible. After repair, parts must not exceed the worn dimension limits detailed in the
relevant Inspection/Check task (page block 601).
B. Standard workshop equipment is required to do these repairs. Special tooling is not required.
Consumable materials to perform this task are: MAT-040 Abrasive Cloth, MAT-041 Abrasive Pad,
MAT-042 Silicon Carbide Abrasive Paper, MAT-043 Sharpening Stone.
SUBTASK 70-42-11-350-001
CAUTIONS: 1 YOU MUST NOT USE ALUMINUM OXIDE TYPE WHEELS, STONES, AND
ABRASIVES ON TITANIUM PARTS. USE ONLY SILICON CARBIDE TYPES.
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(1) Remove high spots, burrs and pick-up, and pick-up on threads. Use hand stones and light
hand polishing.
(1) Remove pitting by blending. Use hand stones and light hand polishing.
(1) Remove distortion and dents by blending. Use hand stones and light hand polishing.
D. Repair of Nicks
(1) Remove nick by blending, scalloping, and/or hand polishing to a smooth shape.
(1) Dress, Blend, and polish burned areas. For standards, refer to the relevant Inspection/Check
task (page block 601) 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 (page block 601) 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 (page block 601)
for the part under repair.
SUBTASK 70-42-11-220-001
A. Inspect and Crack Test. Refer to the relevant Inspection/Check task (page block 601) for the part
under repair to determine the method and instruction for inspection and crack test.
SUBTASK 70-42-11-350-002
A. Repair Surface Protection. Refer to 70-42-12, P.B. 801 and/or relevant Repair task (page block
801) for the part under repair.
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1. General
This task must be performed to restore protective coating to surfaces which have been damaged or
repaired.
SUBTASK 70-42-12-942-001
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
MAT-050 Coating, Chemical Conversion (Iridite)
3. Instructions
SUBTASK 70-42-12-870-003
A. Make sure that all damaged/repaired surfaces are blended smoothly and match the surface finish of
the surrounding area.
B. Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl alcohol
MAT-027 to clean.
SUBTASK 70-42-12-870-004
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B. Allow coating to dry for one to five minutes. Wipe off excess coating with a damp cloth.
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1. General
This task covers the penetrant method of inspection for the detection of cracks and other discontinuities
open to the surface.
SUBTASK 70-42-15-942-001
A. Consumables
The penetrant test materials used for inspection per this task shall be as specified in AMS-2644.
SUBTASK 70-42-15-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-21-00 701 Cleaning Methods and Procedures - Cleaning
72-00-00 601 Engine - Cleaning
3. General
SUBTASK 70-42-15-110-001
A. Parts inspected must be clean and free from oil, grease, dirt, cleaning solution, and other
contamination which could prevent adequate penetration of discontinuities or hold penetrant and
cause non-relevant indications. . Clean parts in accordance with the methods specified in Engine
Manual 72-00-00, P.B. 601 and the general requirements of 70-21-00, P.B. 701.
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4. Procedures
SUBTASK 70-42-15-870-003
A. Inspection Process
(1) Materials
The penetrant test materials used for inspection per this task shall be as specified in
AMS-2644, and shall be from one manufacturers 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), D(Note a(Note 4), (b,c)(Note 4
2) 1), d
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3 Developer not required, inspect opposite side surface for evidence of thru leaks
5. Acceptance Criteria
SUBTASK 70-42-15-870-004
A. Parts shall meet the acceptance criteria (class) specified in the detailed inspection instructions.
Acceptance criteria classes are defined in table 601
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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.
(a) The cumulative length of all indications must not be greater than the
max size of indications times the max number of indications specified;
e.g., Class F permitted indication/size mixtures include: 3 at 0.060
inch, 6 at 0.030 inch, 5 at 0.036 inch, etc
B. Parts exhibiting indications may be evaluated using additional non-destructive test methods to
determine the relevancy and severity of the indications.
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
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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.
8. Inspection of Components
SUBTASK 70-42-15-870-010
A. Refer to table 602 requirements which lists the components, their NDI requirement and defect criteria.
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NOTES: 1 2 hour minimum dwell time for HPT disc and blades
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1. General
This task provides information for torque tightening technique. Refer to the following illustration(s):
Figure 201 Typical Torque Sequences and Torque Calculation for the Use of Extensions and Adapters
SUBTASK 70-51-00-941-001
A. Standard Equipment
Hand torque wrench, flexible beam type, 1/4-in. drive
Hand torque wrench, flexible beam type, 3/8-in. drive
Hand torque wrench, screwdriver type, 1/4-in drive
SUBTASK 70-51-00-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-012 Lubricant, Dry Film
3. Information
SUBTASK 70-51-00-870-002
A. A predetermined torque load is applied to nuts, bolts, fittings, and screws to prevent overstressing
and to give optimum security. All threaded fasteners on the engine are tightened to either:
B. Torque values for all threaded fasteners are given at the point of application in the maintenance
manual.
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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 :
B. Lubricate all steel tube nut fittings prior to assembly with MAT-012dry film lubricant and allow to
dry. Do not spray lubricant on inside of tubes.
C. Lubricate all other threaded fasteners with MAT-001engine oil (unless otherwise specified).
D. You must not use any other lubricants unless specifically told otherwise in the specific procedure
in the manual.
E. If you use the wrong lubricant, the mean tensile load, when you apply torque, can increase by 80
percent. This can put severe stress on the fastener.
5. Retightening of Nuts
SUBTASK 70-51-00-870-004
CAUTION IF YOU DO NOT DO THE INSTRUCTIONS THAT FOLLOW, THE RESULT CAN
BE AN INADEQUATE CLAMPING LOAD. IF YOU GO PAST THE CORRECT
TORQUE LOAD IN AN ATTEMPT TO INCREASE THE CLAMPING LOAD, YOU
CAN DAMAGE THE THREADS OF PARTS. THIS MAY NOT BE OBVIOUS AT
FIRST BUT CAN CAUSE FAILURE OF THE JOINT DURING SERVICE.
A. Whenever you must tighten nuts again, do the procedure that follows:
(2) Clean and apply lubricant to the threads and abutment faces.
SUBTASK 70-51-00-870-005
A. When you use close-pitch bolting, and when you must make a seal, no 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.
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(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 Typical Torque Sequences
and Torque Calculation for the Use of Extensions and Adapters for an example of a typical
torque sequence.
SUBTASK 70-51-00-870-006
(1) Standard equipment flexible beam type wrenches include: Hand torque wrench, flexible beam
type, 1/4-in. drive and Hand torque wrench, flexible beam type, 1/4-in. drive.
(2) To get a correct reading, hold the handle lightly with one hand. Pull the handle at right-angles
(90 degrees) to the center-line of the wrench. The handle must be free to move on the
pivot point; this will keep the force or load at the correct point. Do not move the position of
the handle. If you do, this will change the concentration of the force from the pivot point to
another position on the handle.
(3) Use a torque wrench which will show you torque value in the higher range of the scale. This will
make sure that you get the greatest possible accuracy when you look at the scale values.
B. Screwdriver type
(1) Standard equipment screwdriver type wrench includes: Hand torque wrench, screwdriver
type, 1/4-in drive.
(2) To get a correct reading, hold the handle like a screwdriver. Turn the handle smoothly until you
can see the required torque load.
(3) Examine screwdriver-type wrenches for accuracy. When there is no load, make sure that
the pointer shows zero on the scale. If necessary, adjust the wrench in accordance with
manufacturer instructions.
SUBTASK 70-51-00-870-007
A. The use of an adapter on the torque wrench lengthens the effective working arm of the torque wrench,
except when the adapter is used at right angles (90) to the wrench handle. When the adapter is used
in such a manner that it lengthens the arm of the torque wrench, adjust the torque values as follows:
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(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 Typical Torque Sequences and Torque Calculation
for the Use of Extensions and Adapters).
(2) Measure the length of the torque wrench with the adapter attached. This measurement
(dimension B) is taken from the center of the handle to the centerline of the adapter.
(4) Multiply the conversion factor by the torque value given for the nut to get the torque reading
that should be used with the adapter on the wrench.
Dimension A on the torque wrench is 12.5 inches. With an adapter installed, dimension B is 14.3
inches. A + B = 12.5 14.3 = 0.87. This is the conversion factor. Multiply the conversion factor by
the nominal torque.
SUBTASK 70-51-00-870-008
A. Refer to Locking Techniques for Threaded Parts, 70-12-04, P.B. 201, for a description of the proper
use and minimum run-down torques for self-locking fasteners.
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Fig. 201 Typical Torque Sequences and Torque Calculation for the Use of Extensions and Adapters
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206
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Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task describes the maintenance practices required to keep special tools for engines in proper working
condition. Special tools require regular inspection and maintenance to ensure safety of operation and/or
accuracy of measurement.
SUBTASK 70-53-00-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-005 Oil, Penetrating
MAT-041 Pad, Abrasive
3. Procedures
SUBTASK 70-53-00-870-001
(1) Damage: Tools that are cracked, chipped, or otherwise damaged should not be used. Nicks,
burrs, or raised material should be blended smooth. Areas on tools where a protective surface
is removed should be recoated to prevent corrosion.
(2) Wear: Contact surfaces should be inspected for areas of excessive wear that would prevent the
tool from functioning properly. Threaded diameters and contact surfaces should be lubricated
with clean engine oil MAT-001 to reduce friction. Replace tools that are excessively worn.
(3) Cleanliness: All tools are potential sources of engine contamination and should be properly
cleaned before use. Assembly tools must be held to the same standards of cleanliness as
engine parts in the system in which they are used.
(4) Corrosion: Corrosion may impair the function of a tool, shorten its life-span, or weaken it.
Remove corrosion with an abrasive pad MAT-041. All steel tools, including those which have
black oxide coating, should be coated with penetrating oil MAT-005 to inhibit corrosion. In areas
of high humidity, tools should be sealed in plastic bags or stored in rust-inhibiting paper.
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(5) Proper Configuration: Tools which are composed of multiple piece-parts should be checked for
proper assembly and/or configuration. Refer to the Tool/Equipment List Catalog or the detailed
instructions in the Maintenance or Engine Manual.
B. Non-Destructive Inspection (NDI): Tools which are under high stress during operation must be
periodically checked with fluorescent penetrant to detect cracks or weaknesses which would
otherwise be invisible. Perform NDI inspection at intervals indicated in table 201.
C. Calibration: In order to assure accuracy of measurement, service facilities shall maintain a program
for calibrating engine tools. Tools which require periodic calibration are identified in table 201.
Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools
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Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools (Continued)
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task describes the maintenance practices required for storage of parts that have shelf life limits.
2. Shelf Life
SUBTASK 70-61-01-870-002
A. The date which the shelf life of rubber and synthetic rubber parts is calculated is the cure date.
This cure date is shown on the parts and/or on their associated packaging. It is applicable to the
following types of parts:
(2) Cables
(3) Harnesses
B. The cure date is shown as the quarter of the year (given as a single figure) and the year (given as
a double figure) when the part was manufactured. The letter Q separates the single figure and
double figure. For example, 2Q91 is the cure date for a part made in the second quarter of 1991.
The year is divided into quarters as follows:
C. Calculate the age of any part from the end of the quarter in which the part was made. For example, a
part with the cure date 2Q91 would be one year old at the end of the second quarter of 1992,
i.e. 30 June, 1992.
SUBTASK 70-61-01-870-003
A. The method that shows the cure date of uninstalled or separate rubber or synthetic rubber parts is
as follows:
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(1) Individual parts (except seal rings) are stamped or stencilled with a permanent marking fluid of
a contrasting color. The parts are large enough for marks to be made on them. Examples of
these parts are diaphragms and bulkhead seals.
(2) Seal rings (O-rings) and individual parts, which are too small to mark on, are put into identifiable
envelopes. Labels are attached to the part or batch.
(3) The cure date is on all basic envelopes, bags, or packages and all intermediate and/or exterior
containers into which the items are put. Additionally, each envelope, bag, or package shows
the manufacturers name or reference, the Williams International part number, and the batch
number.
4. Storage of Parts
SUBTASK 70-61-01-870-004
A. Keep rubber and synthetic rubber parts in good condition. Look carefully at the storage conditions
in order to get the maximum shelf life. Keep parts in conditions that give the maximum protection
against these effects:
(1) Strain
(3) Ozone
(4) Moisture
B. If parts are supplied in envelopes, plastic bags, or cartons, keep them in this condition until you need
them. Monitor level of stocks to rate of use to prevent excessive storage time. You must remove
parts from the shelf on the basis of age. The cure date shows you how old the part is. Do not let
rubber parts and metals (especially copper) touch each other.
C. Store parts in a relaxed position. They must be free from tension and, wherever possible, in their
normal shape. Do not put too many parts in a vertical stack. This can cause permanent distortion of
the lower layers. Put flexible hoses in straight lengths, wherever possible, as coiling causes tension
in the outside of each coil. It also increases the risk of ozone cracking.
D. Give sufficient ventilation to prevent condensation, but do not let currents of air come into contact
with the stored parts. Keep parts away from sources of ozone. These are:
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E. When you put lip-type seals into storage, make sure that you do not cause damage and distortion to
the edges. Only attach seal rings to ferrules or bobbins immediately before installation into an engine
or unit. Prolonged exposure to light can cause deterioration to the seal rings.
F. Keep temperature within the preferred range of 59 to 70 degrees F (15 to 21 degrees C). The
minimum temperature must be 41 degrees F (5 degrees C) and the maximum must be 100 degrees
F (38 degrees C). The relative air humidity will be 65 percent. Put parts at least 3 feet (1 meter)
from any unscreened source of heat.
G. If you store parts in the recommended conditions in paragraph F, the shelf life of rubber and rubber
synthetic parts is virtually unlimited. In certain cases, examine and monitor the parts at specified
intervals. For this purpose, materials are divided into three groups.
(1) Group A
The customer can receive these up to five years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
two years (see paragraph 4, Inspection of Parts).
(2) Group B
(a) Butyl
The customer can receive these up to seven years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
three years (see paragraph 4, Inspection of Parts).
(c) Nitrile
The customer can receive these up to 10 years from cure date. The ultimate life is 15
years.
(3) Group X
There is no life limit for supply to a customer or for storage. Cure date marks are on
these parts to help monitor stock.
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5. Inspection of Parts
SUBTASK 70-61-01-870-005
A. Examine parts for signs of aging or degradation because of oxidation; this is shown by surface cracks
and deterioration. Bend the part gently and discard it if you see cracks.
B. Do not automatically discard parts because you see a white or colored bloom on their surface. The
layers of blooms help to prevent ageing. They come from the anti-oxidants which are in high-grade
rubber.
C. Examine parts for conditions as follows; discard them if they are faulty:
(4) Chafing of outer coverings and corrosion of, or damage to, end fittings of hose assemblies
and cable harnesses
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CHAPTER 71
POWER PLANT
Page 1
71-POWER PLANT Apr 11/08
Page 2
71-POWER PLANT Blank
LINE MAINTENANCE MANUAL FJ44-2A
71-00-00 101 Apr 11/08 71-00-22 201 Apr 11/08 71-00-32 601 Apr 11/08
71-00-00 201 Apr 11/08 71-00-23 201 Apr 11/08 71-00-40 601 Apr 11/08
71-00-00 401 Apr 11/08 71-00-24 201 Apr 11/08 71-00-50 601 Apr 11/08
71-00-00 501 Apr 11/08 71-00-25 201 Apr 11/08 71-00-52 601 Apr 11/08
71-00-03 701 Apr 11/08 71-00-26 201 Apr 11/08
71-00-21 201 Apr 11/08 71-00-30 601 Apr 11/08
Chapter 71
List of Effective Page Blocks
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Chapter 71
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Use these procedures to isolate specific faults in the engine systems. Refer to the list of troubleshooting
top events and their corresponding troubleshooting trees.
SUBTASK 71-00-00-941-027
A. Standard Equipment
Hi Pot Tester
Jumper Wires
Multimeter (Digital).
Megohm Meter
Borescope
3. Instructions
SUBTASK 71-00-00-810-002
A. Standard equipment for this task includes: Borescope, Hi pot tester, Jumper wires, Megohm meter,
Multimeter (Digital).
The following troubleshooting instructions are provided as an aid in locating the cause of a
malfunction based on the symptoms it produces.
B. The listing of troubleshooting "top events" serves as an index which references malfunction
symptoms to the corresponding troubleshooting tree. The list of top events is arranged in sequence
of normal engine operation:
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SUBTASK 71-00-00-810-003
Figure 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
IDLE MALFUNCTIONS
ACCELERATION MALFUNCTIONS
TAKE-OFF MALFUNCTIONS
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Figure 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
DECELERATION MALFUNCTIONS
SHUTDOWN MALFUNCTIONS
OTHER MALFUNCTIONS
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5. General
This task identifies all possible BIT faults detected by the electronic control unit (ECU) which collects
operating limit exceedence and BIT fault data. A fault is denoted by the EFCU light. This data is
downloaded from the ECU by using an Electronic Maintenance Terminal (EMT).
The individual BIT Fault isolation tasks identify the recommended procedures used to isolate and correct
the problem which caused the BIT Fault to originally occur. When all the fault isolation analysis and
maintenance is completed, the ECU should be cleared of all BIT Faults using the EMT.
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2 Identify the BIT FAULT number and BIT Fault ID displayed on the EMTs Maintenance
Data display. Perform the procedures located in each specific BIT fault task.
4 When a component is in question, turn A/C power off and temporarily replace the
component with a spare to see if the BIT FAULT will clear. This can be done by
only hooking up the component electrically, but not physically mounted. DO NOT
ATTEMPT TO START THE ENGINE IN THIS CONFIGURATION.
6 If needed, refer to FJ44-2A Electrical Interface Schematic, Drawing Part Number 56736
SUBTASK 71-00-00-941-028
A. Standard Equipment
Jumper Wires
Hi Pot Tester
Megohm Meter
Multimeter (digital)
7. Job Set-up
SUBTASK 71-00-00-010-050
A. The following equipment is used for this task: multimeter (digital), megohm meter,hi pot tester,jumper
wires
8. Procedures
SUBTASK 71-00-00-810-004
A. Refer to the table below which identifies the BIT fault numbers, BIT Fault IDs, and their related task.
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B. A description of the BIT fault that occurred can be found by using the EMT. There are two ways
to access this information:
(1) When a BIT fault is identified on the Maintenance Data display (in the EMT software), double
click on the fault name. This calls up a description.
(2) Or, open the computers Windows Explorer program and use this pathway
(C:\EMT\355A5945.ECU\355A5945.HLP ) to find the help file. (The descriptions are located in
this file.) Double click on the 355A5945.HLP file.
Table 101
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28 N1 Counter 71-00-00-811-013
29 N1 Gross Error 71-00-00-811-014
30 N1 Open Input
31 N1 Overspeed 71-00-00-811-015
32 N1 Range High 71-00-00-811-016
33 N1 BIT Internal
34 N2 Counter 71-00-00-811-017
35 N2 Gross Error 71-00-00-811-018
36 N2 Open Input
37 N2 Overspeed 71-00-00-811-019
38 N2 Range High 71-00-00-811-020
39 N2 BIT Internal 71-00-00-811-021
40 N2 Shaft Separation 71-00-00-811-022
41 Pamb HW Range High 71-00-00-811-023
42 Pamb HW Range Low
43 Pamb Range High
44 Pamb Range Low
45 PLA Exc Range 71-00-00-811-024
46 PLA Exc BIT
47 ECU Internal PLA
48 PLA Signal Loss
49 PLA Range Low
50 PLA Range High
51 PMEM Record 71-00-00-811-025
52 RAM
53 ROM
54 Serial Port
55 ARINC Transmit
56 Twin ECU Receive 71-00-00-811-026
57 TT2 HW Range High 71-00-00-811-027
58 TT2 HW Range Low
59 TT2 Open Input
60 TT2 Range Low
61 TT2 Range High
62 TT2 Short
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TASK 71-00-00-811-001 BIT 1 - A/D Conversion Timeout; BIT 2 - AD Ref Range High; BIT 3 -
AD Ref Range Low
9. General
This task contains troubleshooting instructions for the EFCU Bit faults.
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SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
11. Procedures
SUBTASK 71-00-00-811-050
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-002 BIT 4- Accel Bleed Load Open; BIT 5- Accel Bleed Load Short; BIT 6 -
Accel Bleed Internal; BIT 7 - Suspect Accel Bleed Load Open
13. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
15. Procedures
SUBTASK 71-00-00-811-051
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(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(c) If check is outside of limits, replace HMU per 73-21-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-003 BIT 8 - BIT Fault Record; 9 - CJ Range Low; 10 - CJ Range High; 11 -
Discrete Input
17. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
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19. Procedures
SUBTASK 71-00-00-811-052
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-005 BIT 12 - ECU Active Load Open; BIT 13 - ECU Active Load Short; BIT 14 -
ECU Active Load Internal; BIT15 - Suspect ECU Active Load Open
21. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
23. Procedures
SUBTASK 71-00-00-811-053
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(e) If check is within limits, replace ECU per 73-24-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
25. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
27. Procedures
SUBTASK 71-00-00-811-054
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
29. General
This task contains troubleshooting instructions for the EFCU Bit faults. A compressor surge was recorded
(uncommanded N1 deceleration).
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SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
73-24-01 201 Electronic Control Unit - Maintenance Practices
31. Procedures
SUBTASK 71-00-00-811-055
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-009 BIT 18 - Multi-purpose Load Open; BIT 19 - Multi-purpose Load Short;
BIT 20- Multi-purpose Load Internal; BIT 21 Suspect Multi-purpose
Load Open
33. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
35. Procedures
SUBTASK 71-00-00-811-056
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(e) If check is within limits, replace ECU per 73-24-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-011 BIT 22 - HMU Res Range Low; BIT 23 - HMU Res Range High
37. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
39. Procedures
SUBTASK 71-00-00-811-057
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(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(c) If check is outside of limits, replace HMU per 73-21-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-012 BIT 24 - ITT Gross Error; BIT 25 - ITT HW Range High; BIT 26 - ITT
Range Low; BIT 27 - ITT Range High
41. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
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43. Procedures
SUBTASK 71-00-00-811-058
(1) Disconnect Airframe Harness to P7M and P7N. Clear bit fault message
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(c) P7m to P7n = 3.5 to 5.5 ohms P7m to GND, P7n to GND =~10Mohm
(e) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
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(k) N P =~10Mohm
(m) If check is outside of limits, replace probe 77-20-02 P.B. 401 according to its position after
each resistance check of J1A J1M and repeat resistance check.
(n) If resistance check is out of limits from J1N J1U, replace J1 connector 77-20-02 P.B.
401and repeat resistance check.
(o) If check is within limits, replace EFCU Engine Harness 77-40-01 P.B. 401
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
45. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
47. Procedures
SUBTASK 71-00-00-811-059
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
EFFECTIVITY: FJ44-2A
71-00-00
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49. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
51. Procedures
SUBTASK 71-00-00-811-060
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
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(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
53. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
73-24-01 201 Electronic Control Unit - Maintenance Practices
55. Procedures
SUBTASK 71-00-00-811-061
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
57. General
This task contains troubleshooting instructions for the EFCU Bit faults.
EFFECTIVITY: FJ44-2A
71-00-00
Page 119
Apr 11/08
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
59. Procedures
SUBTASK 71-00-00-811-062
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(d) If check is within limits, repair ECU to J7 Airframe Harness per AMM.
(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
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71-00-00
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SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
61. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
63. Procedures
SUBTASK 71-00-00-811-063
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
65. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
EFFECTIVITY: FJ44-2A
71-00-00
Page 121
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67. Procedures
SUBTASK 71-00-00-811-064
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
EFFECTIVITY: FJ44-2A
71-00-00
Page 122
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69. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
73-24-01 201 Electronic Control Unit - Maintenance Practices
71. Procedures
SUBTASK 71-00-00-811-065
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
73. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
EFFECTIVITY: FJ44-2A
71-00-00
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75. Procedures
SUBTASK 71-00-00-811-066
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM..
(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
77. General
This task contains troubleshooting instructions for the EFCU Bit faults.
EFFECTIVITY: FJ44-2A
71-00-00
Page 124
Apr 11/08
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
79. Procedures
SUBTASK 71-00-00-811-067
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
81. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
83. Procedures
SUBTASK 71-00-00-811-068
A. Uncommanded N2 deceleration was recorded. Inspect engine for severed HP shaft, bearing failure,
engine flameout per engine MM. Consult Product Support of Williams International.
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71-00-00
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SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-023 BIT 41 - Pamb HW Range High; BIT 42 - Pamb HW Range Low; BIT 43 -
Pamb Range High; BIT 44 - Pamb Range Low
85. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
87. Procedures
SUBTASK 71-00-00-811-069
A. Inspect Pamb port lines and filters for leakage or blockage. Service per A.M.M.
B. Clear Fault per 73-24-01 P.B. 201. Verify BIT FAULT message is clear. If message is persistent,
replace ECU per 73-24-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-024 BIT 45 - PLA Exc Range; BIT 46 - PLA Exc BIT; BIT 47 - ECU Internal
PLA; BIT 48 - PLA Signal Loss; BIT 49 - PLA Range Low; BIT 50 - PLA
Range High
89. General
This task contains troubleshooting instructions for the EFCU Bit faults.
EFFECTIVITY: FJ44-2A
71-00-00
Page 126
Apr 11/08
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
91. Procedures
SUBTASK 71-00-00-811-070
(h) If check is within limits, replace ECU per 73-24-01 P.B. 401.
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(h) If check is within limits, repair ECU to J7 Airframe Harness per A.M.M..
(g) If check is outside of limits, replace HMU per 73-21-01 P.B. 401.
(h) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-025 BIT 51 - PMEN Record; BIT 52 - RAM; BIT 53 - ROM; BIT 54 - Serial
Port; BIT 55 - ARINC Transmit
93. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
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71-00-00
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95. Procedures
SUBTASK 71-00-00-811-071
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
97. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
99. Procedures
SUBTASK 71-00-00-811-072
100.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
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TASK 71-00-00-811-027 BIT 57 - TT2 HW Range High; BIT 58 - TT2 HW Range Low; BIT 59
- TT2 Open Input; BIT 60 - TT2 Range Low; BIT 61 - TT2 Range High;
BIT 62 - TT2 Short;
101.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
77-22-01 601 EFCU TT2 Sensor - Inspection/Check
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
103.Procedures
SUBTASK 71-00-00-811-073
(1) Check to ensure TT2 heater is OFF (Engine Anti-icing OFF). If ON, turn heater OFF and wait
10 minutes. Clear faults and check for repeat occurrence. Verify TT2 heat is OFF by quickly
touching sensor by hand.
(f) If check is within limits, replace ECU per 73-24-01 P.B. 401.
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(h) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(g) If check is within limits, replace engine harness per 77-40-01 P.B. 401
104.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-028 BIT 63 - TT2 BIT Internal; BIT 64 -VREF 5 Volt Range High
105.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
EFFECTIVITY: FJ44-2A
71-00-00
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107.Procedures
SUBTASK 71-00-00-811-074
108.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
109.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
111. Procedures
SUBTASK 71-00-00-811-075
A. Check A/C electrical power supplied to ECU for low voltage. Repair as required per A/C and clear
fault per 73-24-01, P.B. 201. If voltage is OK, replace ECU per 73-24-01 P.B. 401.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
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113. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
115. Procedures
SUBTASK 71-00-00-811-076
A. Clear Fault per 73-24-01, P.B. 201 and watch for repeat.
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
117. General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2A
71-00-00
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119. Procedures
SUBTASK 71-00-00-811-077
120.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-032 BIT 69 - Wf/P3 Req Load Open; BIT 70 - Wf/P3 Req Load Short; BIT
71 - Wf/P3 Internal
121.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
73-24-01 201 Electronic Control Unit - Maintenance Practices
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
123.Procedures
SUBTASK 71-00-00-811-078
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
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(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(c) If check is outside of limits, replace HMU per 73-24-01 P.B. 401.
(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
124.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
125.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
127.Procedures
SUBTASK 71-00-00-811-079
EFFECTIVITY: FJ44-2A
71-00-00
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128.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
129.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
131.Procedures
SUBTASK 71-00-00-811-080
NOTE Check the following if landing gear was not deployed above 18000 feet.
(e) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(a)
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(b)
(d)
(4)
(a)
(b)
(c)
(d)
132.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-035 BIT 74 - BG Execution Failure; BIT 75 - Init Bad Key Argument; BIT 76 -
BUS Error; BIT 77 - BUS Error Twice in Frame; BIT 78 - ADDR ERR Illegal
Instruction; BIT 79 - BAD Interrupt; BIT 80 - Frame Overrun Exc
133.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
135.Procedures
SUBTASK 71-00-00-811-081
EFFECTIVITY: FJ44-2A
71-00-00
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136.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
137.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
73-24-01 201 Electronic Control Unit - Maintenance Practices
139.Procedures
SUBTASK 71-00-00-811-082
B. Refer to General Operating Procedures 71-00-00, P.B. 501 for maintenance required after
Overspeed/Overtemperature.
140.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
TASK 71-00-00-811-037 BIT 86 - EEPROM Verify Failure; BIT 87 - Exceedence Checksum Fault;
BIT 88 - Dummy Fault
141.General
This task contains troubleshooting instructions for the EFCU Bit faults.
EFFECTIVITY: FJ44-2A
71-00-00
Page 138
Apr 11/08
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
143.Procedures
SUBTASK 71-00-00-811-083
144.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
145.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
147.Procedures
SUBTASK 71-00-00-811-084
EFFECTIVITY: FJ44-2A
71-00-00
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148.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
149.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
151.Procedures
SUBTASK 71-00-00-811-085
C. If BIT FAULT continues to occur and check is positive, replace ECU per 73-24-01 P.B. 401.
152.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
153.General
This task contains troubleshooting instructions for the EFCU Bit faults.
EFFECTIVITY: FJ44-2A
71-00-00
Page 140
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SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
155.Procedures
SUBTASK 71-00-00-811-086
156.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
157.General
This task contains troubleshooting instructions for the EFCU Bit faults.
SUBTASK 71-00-00-945-050
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
73-24-01 401 Electronic Control Unit - Removal/Installation
159.Procedures
SUBTASK 71-00-00-811-087
C. If BIT FAULT continues to occur and check is positive, replace ECU per 73-24-01 P.B. 401.
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160.Job Close-up
SUBTASK 71-00-00-870-050
A. After corrective action is completed, clear all BIT faults. Refer to 73-24-01 P.B. 201.
161.General
This task contains instructions to isolate the source of an overboard fuel leak (engine operating). The
leak may originate in the either fuel pump assembly or the fuel control unit (HMU). This procedure gives
instructions to block the internal drain passage between the two parts and perform a ground run to
identify the source of the leak. As a minimum, this procedure will require removal/installation of the fuel
control unit and replacement of the flange O-rings.
SUBTASK 71-00-00-943-001
A. Special Tools
Reference Designation
TL99521 Shut-Off
SUBTASK 71-00-00-944-002
B. Expendable Parts
IPC Reference
Refer to 73-21-01, P.B. 401 and 73-16-01, P.B. 401 for listing of expendable parts, as applicable.
SUBTASK 71-00-00-945-050
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
163.Job Set-up
SUBTASK 71-00-00-010-001
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(2) Open the circuit breakers to isolate the engine electrical supply.
164.Procedures
SUBTASK 71-00-00-810-050
A. Remove fuel control unit heatshield (if applicable). Refer to 73-21-01, P.B. 401
B. Disconnect the FCU-to-oil cooler tube assembly from the fuel control unit. Refer to 73-21-01, P.B. 401.
C. Loosen three nuts securing the FCU to the fuel pump. Loosen nuts enough to slide TL99521 (or
equivalent) between the FCU and the fuel pump to block off the drain passage between the two
parts. Refer to Figure 148 Overboard Fuel Leak Block Fuel Drain for location. Torque the three
FCU nuts 110 to 123 inch-pounds (12.4 to 13.8 N.m)s .
D. Install/connect the FCU-to-oil cooler tube assembly to the fuel control unit. Refer to 73-21-01,
P.B. 401.
SUBTASK 71-00-00-410-001
SUBTASK 73-21-01-760-001
F. Purge the fuel system and perform an Idle Speed and Leak Check ground run. (71-00-00, P.B. 501).
Check overboard drain during engine operation for fuel leakage.
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SUBTASK 71-00-00-810-003
NOTE Limit for overboard fuel leakage are found in the Idle Speed and
Leak Check ground run task.
(1) If fuel is still leaking from the overboard drain (with internal drain port blocked), the fuel pump is
the source of the leak. Replace the fuel pump if the leak is beyond acceptable limits. Refer to
73-16-01, P.B. 401.
(2) If fuel is not leaking from the overboard drain (with internal drain port blocked), the fuel control
unit is the source of the leak. Replace the fuel control unit. Refer to 73-21-01, P.B. 401.
NOTE The O-rings between the FCU and the fuel pump shall be replaced after
this test is performed, regardless of the outcome, because the tool used
to block the drain passage may have nicked or cut the O-ring.
165.Job Close-up
SUBTASK 71-00-00-410-002
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71-00-00
Page 144
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71-00-00
Page 145
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 146
Apr 11/08
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71-00-00
Page 147
Apr 11/08
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71-00-00
Page 148
Apr 11/08
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71-00-00
Page 149
Apr 11/08
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71-00-00
Page 150
Apr 11/08
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71-00-00
Page 151
Apr 11/08
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Fig. 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
EFFECTIVITY: FJ44-2A
71-00-00
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Fig. 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
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Page 156
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Page 157
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Page 158
Apr 11/08
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Page 159
Apr 11/08
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Page 160
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Fig. 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
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Fig. 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
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1. General
This task provides procedures to change a No. 1 (left hand) engine to a No. 2 (right hand) engine or a No.
2 (right hand) engine to a No. 1 (left hand) engine.
NOTE We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
SUBTASK 71-00-00-943-034
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
SUBTASK 71-00-00-945-034
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
79-33-01 401 Low Oil Level Sensor - Removal/Installation
79-33-11 401 Oil Sight Glass - Removal/Installation
3. Procedures
SUBTASK 71-00-00-570-003
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
oclock positions.
NOTE There is no forward or aft orientation required when installing the rear mount ring.
(3) Install the rear bypass duct; refer to 72-00-71, P.B. 401.
NOTE The engine must be hanging from the engine lifting sling,
08-0119-8000, to do the following task
(4) Move the eight mounting pad hole plugs to the opposite side of the engine. Torque plugs
90-100 inch-pounds (10.1-11.2 N.m).
(5) The dipstick assembly must be installed on the outboard side. Change positions of dipstick
assembly and filler port plug assembly, as required. Refer to 79-31-01, P.B. 401.
(6) If installed, 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) If installed the low oil sensor must be installed on the outboard side. The cover plate blank
must be installed on the inboard side. Change positions of the low oil level sensor and the
cover plate blank. Refer to 79-33-11, P.B. 401 and 79-33-01, P.B. 401.
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1. General
This task provides procedures for removing the engine from the build stand. Refer to the following
illustration(s):
Figure 401 Engine in Build Stand - Removal/Installation
SUBTASK 71-00-00-941-036
A. Standard Equipment
Hoist
SUBTASK 71-00-00-943-036
B. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-2021-0000 Stand, Engine
K-2032 Adapter, Engine Stand
3. Procedures
SUBTASK 71-00-00-010-036
(2) Install engine lifting sling, 08-0119-8000, to hoist. Attach lifting sling to engine lift points on the
rear mount ring and interstage housing bracket.
(3) Adjust position of engine build stand and/or hoist, as required, and raise hoist until there is
equal tension on lifting sling cables.
(4) Remove two detent pins from pivoting support arm yokes on the engine build stand. Retract
the pivoting support arm.
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(5) Remove two detent pins from gear-driven support arm yokes and disengage engine mount
adapters from yokes.
(6) When engine and mount adapters are completely clear of build stand support arms, raise hoist
and/or remove engine build stand.
(7) 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.
B. 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.
5. General
This task provides procedures for installing the engine in the build stand. Refer to the following
illustration(s):
Figure 401 Engine in Build Stand - Removal/Installation
SUBTASK 71-00-00-941-037
A. Standard Equipment
Hoist
SUBTASK 71-00-00-943-037
B. Special Tools
Reference Designation
08-0119-8000 Engine Sling
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7. Job Set-up
SUBTASK 71-00-00-010-040
A. Using a hoist and engine lifting sling, 08-0119-8000, remove engine from aircraft. Refer to the
Aircraft Maintenance Manual.
SUBTASK 71-00-00-010-041
B. Remove two forward engine mounts from two mounting pads on the interstage housing. Remove
plugs from the other two mounting pads. Refer to the Aircraft Maintenance Manual.
8. Procedures
SUBTASK 71-00-00-410-037
(1) Install four engine mount adapters, K-2032, to the four engine mount pads on the interstage
housing. Torque 16 mounting bolts 200 to 245 inch-pounds (22.5 to 27.6 N.m).
(2) Rotate the gear-driven support arm, if necessary, to put it in the vertical position. Lock
rotation crank.
(3) Retract the pivoting support arm to make room for installation of the engine.
(4) Move the engine build stand, 08-2021-0000, into position as shown in Figure 401 Engine in
Build Stand - Removal/Installation. 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.
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Fig. 401 Engine in Build Stand - Removal/Installation 71-00-00
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1. General
This task lists the types of ground running tests that are necessary after engine maintenance. Refer
to the following tables:
table 501
table 502
NOTE The tests which are referred to in this task are found in 71-00-00, P.B. 501.
SUBTASK 71-00-00-945-018
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-00 1301 Engine - Testing
72-60-01 401 Gearbox Magnetic Carbon Seals - Removal/Installation
77-20-02 601 Intermediate Turbine Temperature (ITT) Probe - Inspection/Check
3. Procedures
SUBTASK 71-00-00-760-027
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B. Refer to table below for specific tests that are necessary after engine maintenance or replacement of
the engine, basic engine components, or engine line replaceable units (LRUs). The Oil Consumption
Check is required to evaluate a suspected oil consumption problem.
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3 Any failure of the starter/generator or hydraulic pump that would affect the
gearbox drive shaft requires that the affected magnetic carbon seal be
removed and reseated. Refer to 72-60-01, P.B. 401.
4. General
This task gives operational procedures and limits for the engine. Refer to the following illustration(s):
Figure 501 Danger Areas During Ground Run
Figure 502 Nominal Oil Pressure Operating Band
Figure 503 Overtemperature Limits (Except Starting)
Figure 504 Overtemperature Limits (Starting)
Figure 505 N2 Overspeed Limits
Figure 506 N1 Overspeed Limits
Figure 507 FJ44-2A Start Envelope MANUAL Mode (Estimated)
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3 When you run the engine on the ground, set HP bleed OFF (unless test instructions
specify ON) and use minimal electrical and hydraulic power.
4 When you are doing more than one test, group them, if possible, during the one
engine cycle. This prevents unnecessary operation of the engine.
5 When operating the engine, monitor the engine parameters to make sure
the engine does not go past its operating limits.
6 Operate the thrust levers slowly and smoothly and keep ground running to the
minimum level of power and time required. You should not move the thrust lever
quickly unless you are doing snap acceleration or deceleration tests. This causes the
engine temperature to change quickly which is not good for the life of the engine.
SUBTASK 71-00-00-945-025
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 71-00-00-700-001
(d) To monitor the effect which a replacement unit can have on the operation of a system or
the performance of the engine.
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(a) When you do ground-run tests, look at the areas that are dangerous before you go near
the aircraft. Refer to Figure 501 Danger Areas During Ground Run.
(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.
(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.
CAUTION THE TT2 SENSOR HEATER (ICE PROTECTION - ENGINE) SHOULD NOT
BE SWITCHED ON WHILE THE ENGINE IS NOT RUNNING EXCEPT WHEN
REQUIRED FOR BRIEF FUNCTIONAL CHECK (LESS THAN 10 SECONDS).
DAMAGE TO HEATER WILL RESULT IF IT IS ACTIVATED FOR MORE THAN
10 SECONDS WHILE THE ENGINE IS NOT RUNNING. HEATER MAY ALSO
BECOME HOT ENOUGH TO BECOME AN IGNITION SOURCE.
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1 Keep ground runs to the minimum level of power and time that is necessary
to do the tests.
(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, operate the airframe-supplied
anti-icing system (if available) and TT2 sensor heat per the aircraft operating manual.
(a) Oil Pressure - Engine oil pressure limits are listed under operating limits. For nominal
engine operation, the oil pressures shown in Figure 502 Nominal Oil Pressure Operating
Band apply.
(b) Oil Temperature - Continuous operation at all engine speeds is permitted when engine oil
temperature is between 10 - 135 C (50 - 275 F).
(c) Ground Operation Recommendation - Low and high oil temperatures can occur when
returning to ground idle from extended operation at or near takeoff thrust. Therefore
ground operation at or near takeoff thrust should be limited to avoid oil temperatures rising
above 90 C (194F) or perform a part power cool down prior to returning to ground idle.
(d) Starting under cold weather conditions - When starting a cold soaked engine, high
oil pressure can occur. As oil temperature rises with engine at idle, oil pressure will
decrease. Oil pressure limits are listed in table 503.
(e) Oil Consumption - The maximum permissible oil consumption is 0.023 gal/hr. Operation
in excess of this value will require agreement of Williams International, Inc.
(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 71-00-00-700-002
CAUTIONS: 1 OBEY THE OPERATING LIMITS SPECIFIED IN THE TEXT AND THE
FIGURES WHEN YOU OPERATE THE ENGINE. IF YOU DO NOT, IT WILL
DECREASE THE OPERATING LIFE OF THE ENGINE.
NOTES: 1 The conditions defined herein are the minimum/maximum as noted for
the engine. Other information is supplied for operator convenience. Any
instances of the operating limits being exceeded must be recorded and
reported together with duration and degree of excess. The operator should
take whatever action is necessary, to keep operation within limits. When
operational, the ECU will record any instance which is outside the limits
including duration and magnitude of that instance.
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 periodically download ECU trend data and notify Williams International
if any sudden or gradual changes over time are detected.
(3) Maximum Fuel Leakage - Refer to Idle Speed and Leak Check Run, 71-00-00-760-810.
NOTE Fuel leakage rate is for normal operations. However, after an aborted start,
fuel leakage may exceed 2ml/min. If this occurs, clear fuel from combustor by
motoring the engine. Refer to instructions given under Failure of Engine to Light.
B. Starting Limits:
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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 FJ44-2A Operating Instructions Manual.
THRUST TIME LIMIT ITT TEMP N2 RPM - % N1 RPM - % OIL PRESS OIL TEMP
SETTING (minutes) C psig C
see
Figure 504
START Overtemperature -40 - 135
Limits
(Starting)
IDLE 35 MIN 100
CONTINUOUS -40 - 135 (7)
(gnd & flt) MAX (6)
18,150-
TAKEOFF (1) 820 max 40,700-98.8 45-90 10 - 135
105.2
MAXIMUM 18,150-
(2) 805 max 40,700-98.8 45-90 (3) 10 - 135
CONTINUOUS 105.2
see
Figure 503 see Figure see Figure
Overtemperature 505 N2 506 N1 23 MIN (4)
TRANSIENT 149 (4)
Limits Overspeed Overspeed 100 MAX (5)
(Except Limits Limits
Starting)
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NOTES: 1 When in the ELECTRONIC mode, takeoff thrust is obtained when PLA is in the
takeoff position. Operation above the takeoff PLA position in the ELECTRONIC
mode is not permitted since a reversion to MANUAL (under some flight conditions)
may result in an exceedance of operating limits. Takeoff thrust settings are
defined in the Williams International approved N1 power setting charts in the
applicable engine parts list. Time at takeoff thrust is limited to 5 minutes maximum
and beginning when the thrust lever is advanced for takeoff thrust.
6 Maximum allowable oil pressure is 100 psig for five minutes with oil
pressure returning to normal range.
SUBTASK 71-00-00-700-003
CAUTION DO NOT START THE ENGINE UNTIL YOU HAVE MADE SURE THE
OIL TEMPERATURE OF THE ENGINE IS NOT COLDER THAN MINUS
40 DEGREES C (MINUS 40 DEGREES F.).
(a) Verify battery or ground power supply meets the starter/generator manufacturers
requirements.
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(g) Set bleed air -OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Operating Limits Table above).
(e) Monitor the ITT. ITT may not exceed the limits defined in Figure 504 Overtemperature
Limits (Starting).
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(h) If applicable, at 48% N2 or above, set generator ON, ignition OFF, and fuel boost
pump OFF.
(i) When the engine reaches stable RPM, start is complete. Scan the engine instruments
and warning lamps for normal indications.
SUBTASK 71-00-00-700-004
NOTE Allow engine to remain at ground idle for a minimum of two minutes prior to
shutdown to 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 operating limits table).
SUBTASK 71-00-00-700-005
(3) Set bleed air - OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in operating limits table).
(4) Set engine starter switch - ON, for time duration as specified by starter/generator
manufacturers operation duty cycle limit.
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SUBTASK 71-00-00-700-050
(1) Verify battery or ground power supply meets the starter/generator manufacturers requirements.
(6) Set bleed air OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Operating Limits Table.
NOTES: 1 Expect increased peak ITT temperatures and reduced start envelope before
attempting start. Refer to Figure 507 FJ44-2A Start Envelope MANUAL Mode
(Estimated) to ensure aircraft is within engines MANUAL mode start envelope.
(5) Monitor the ITT. ITT may not exceed the limits defined in Figure 504 Overtemperature Limits
(Starting)
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(6) Advance PLA only if required to improve lightoff and/or acceleration, by engaging start fuel
enrichment.
(7) At 40%, N2 or above, set starter OFF. (Refer to starter generator manufacturer for optimum
starter cutout speed.)
(9) If applicable, at 48% N2 or above, set generator ON, ignition OFF, and fuel boost pump OFF.
(10) When the engine reaches stable RPM, start is complete. Scan the engine instruments and
warning lamps for normal indications.
(11) If applicable, attempt to restore ELECTRONIC mode after MANUAL mode start per paragraph
MANUAL Mode Light ON, in Subtask 71-00-00-700-006. If unsuccessful, continue using
MANUAL mode procedures.
SUBTASK 71-00-00-700-006
(5) Set bleed air - OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in operating limits table).
(6) Set engine starter - ON, for the time duration as specified by starter/generator manufacturers
operation duty cycle limit.
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(4) If ITT does not remain within allowable limits, shut down the engine. Refer to Troubleshooting,
71-00-00, P.B. 101.
C. Compressor Surge
(1) If the ITT increases suddenly or you hear a rumbling, banging, or backfire sound you must:
(1) As soon as practical, advance PLA to restore lost thrust as required or reduce PLA to avoid
extended over thrust duration. Match N1 speed with opposite engine, if practical. Thrust
settings for the MANUAL mode are defined in the Williams International approved N1
powersetting charts in the applicable engine parts list.
(e) If MANUAL light still ON, cycle ELECTRONIC/MANUAL mode switch to MANUAL, then
back to ELECTRONIC.
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(f) If MANUAL light still ON, refer to engine maintenance troubleshooting or continue
operations using MANUAL mode procedures. Any aircraft dispatchibility and/or flight
duration limitations should be specified in the Aircraft Flight Manual.
(1) Whenever an engine fails to start within 10 seconds after moving the power lever to the
idle position:
(c) Continue to motor engine with starter for a minimum of 15 seconds (within manufacturers
operational duty cycle limits) to clear fuel from the combustor.
F. No N1 Speed at 25% N2
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(1) Refer to Troubleshooting. Any aircraft dispatchibility and/or flight duration limitations should
be specified in the Aircraft Flight Manual.
I. Hot Start
(5) Refer to Figure 504 Overtemperature Limits (Starting) for corrective action.
11. 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 508 Idle N2 Speed Check (Electronic Mode)
Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
NOTES: 1 Refer to the Test List matrix in the List of Test Procedures, 71-00-00, P.B. 501,
for a listing of all tests required after replacement or repair of parts.
SUBTASK 71-00-00-945-008
A. Reference Information
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13. Definitions
SUBTASK 71-00-00-760-050
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.
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 0.35 ml per minute, or approximately 7 drops per minute.
NOTE If fuel leakage from drain during engine operation exceeds the allowable
limit, refer to Troubleshooting Task 710000811843.
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.
SUBTASK 71-00-00-010-008
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
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15. Procedures
SUBTASK 71-00-00-760-012
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
A. If maintenance has been performed on the fuel system or if fuel system has been preserved, purge
air from the fuel system.
(3) Install drain hose to oil cooler fitting and direct open end of hose into a bucket.
(4) Disconnect flexible HMU-to-nozzle fuel line from fuel nozzle and cap line.
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(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.
(6) Remove drain hose and install oil cooler-to-fuel manifold tube assembly. Torque tube nuts
135 to 150 inch-pounds (15.2-16.9 N.m.).
(7) Install flexible HMU-to-nozzle fuel line in accordance with 73-10-01, P.B. 401.
B. Set the power lever to the SHUT-OFF position. Motor the engine for 30 seconds, refer to General
Operating Procedures, 71-00-00, P.B. 501.
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
F. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501 .
NOTE The OAT indicator reading must be within 3 C of actual airfield ambient temperature.
H. Observe N2 speed and OAT and compare to Figure 508 Idle N2 Speed Check (Electronic Mode).
(1) FOR FJ44-2A ONLY: Ground idle speed must be within the specified tolerance shown. (Note
that idle speed varies with temperature.)
(2) All other models: Must be at or below the value shown in the figure. (Note that idle speed
varies with temperature.)
(3) If idle speed exceeds limit, shut down engine and refer to Troubleshooting, 71-00-00, P.B. 101.
I. Refer to 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. Slowly advance the power lever to max continuous
speed position 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.
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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.
L. Stop the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
M. Check the engine for signs of leakage. If there are leaks, repair as necessary.
N. If an engine hot section component has been removed/installed since the engine was last run, check
the oil supply and scavenge tube flanges with a borescope to make sure there are no leaks.
O. If there are signs of leaks at the core engine tubes, repair as necessary.
SUBTASK 71-00-00-410-008
17. 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 Vibration Accelerometers - Removal/Installation
Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
NOTES: 1 Refer to the Test List matrix in the LIst of Test Procedures, 71-00-00, P.B. 501,
for a listing of all tests required after replacement or repair of parts.
SUBTASK 71-00-00-941-023
A. Standard Equipment
Vibration Analyzer (ACES Model 1700, 4040, Or
Equivalent)
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SUBTASK 71-00-00-943-023
B. Special Tools
Reference Designation
TL37253 Mount, Engine Vibration
SUBTASK 71-00-00-945-023
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-023
(3) Remove lockwire and remove plug from the engine mount pad hole (upper or lower outboard
side 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 Vibration Accelerometers -
Removal/Installation.
(5) Hook-up vibraton pick-up assembly to vibration analyzer (ACES Model 1700, 4040, or
equivalent) and set unit to record vibration data in accordance with manufacturers instructions.
20. Procedures
SUBTASK 71-00-00-760-033
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WARNINGS: 1 MAKE SURE THAT PEOPLE AT WORK NEAR THE AIRCRAFT KNOW
OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE THAT
PEOPLE ARE NOT KILLED OR BADLY INJURED.
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
(5) Refer to Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
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.
(8) Move the power lever back, at a uniform rate over a period of approximately 90 seconds
(not less than 60 seconds), to idle.
(9) Review the recorded vibration data and compare it with the following limits:
(a) Allowable vibration level - peak (1E HP, Radial) = 1.1 IPS (inch per second).
(b) Allowable vibration level - peak (1E LP, Radial) = 0.37 IPS (inch per second).
(10) Stop the engine or continue with the next ground run test, if applicable. Refer to General
Operating Procedures, 71-00-00, P.B. 501.
(11) If vibration levels exceed limits, refer to Troubleshooting (High vibration with or without noise),
71-00-00, P.B. 101.
(12) If LP vibration levels exceed limits, refer to Trim Balance Procedures, 71-00-00, P.B. 501.
SUBTASK 71-00-00-410-023
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(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.
22. 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 511 Reflective Tape Placement
Figure 512 Trim Balance by Vector Subtraction - Sample Plot
Figure 513 Trim Balance by Vector Subtraction - Sample Plot Procedure
Figure 514 Reducing Data for Final Trim Weight Rotation
NOTE The following are the two methods for trim balancing:
The Vector Subtraction Method: This is the initial method used for trim balancing.
The 3-Weight Method: This is the second method used, if further reduction of
1E LP is required. This method may also be used if phase information (from
the ACES Analyzer) is not available.
SUBTASK 71-00-00-941-020
A. Standard Equipment
Cabling (between Accelerometers And Analyzers)
Vibration Analyzer (ACES Model 1700 Or Equivalent)
Accelerometer (radial UOMP)
Setscrews
Accelerometer Mounting Bracket
SUBTASK 71-00-00-942-020
B. Consumables
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Reference Designation
MAT-033 Marker, Fine Line
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
24. Procedures
SUBTASK 71-00-00-760-030
(1) Install accelerometer (radial UOMP) radially at the upper outboard mount pad (UOMP)
location. Additional accelerometers and/or microphones may be installed as required to
monitor engine response.
(2) Hook up the vibration analyzer (ACES Model 1700 or equivalent), accelerometer mounting
bracket, cabling (between accelerometers and analyzers) and N1 speed light sensor.
B. Setup Procedures:
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(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.
(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 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
511 Reflective Tape Placement.
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the ACES analyzer. Perform a slow decel to idle.
(b) Shutdown engine per General Operating Procedures 71-00-00 P.B. 501, and examine
fan tip shroud for new tip rubs.
NOTE Weight(s) are setscrews, available in various sizes and weights, ranging
from 0.0442 ounces (1.25 grams) to 0.1500 ounces (4.25 grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(a) Remove the spinner and install 1 trim weight in the first hole CW (aft looking forward)
from the 0 degree reference mark. Screw in approximately 1/8 to inch below flush.
NOTE For longer trim balance screws, it is acceptable for the screw to stand
proud of the surface, as long as it is bottomed in the hole.
(b) Reinstall spinner to baseline position. Refer to 72-00-30, P.B. 401 for spinner installation.
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the analyzer. Perform a slow decel to idle.
(b) Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501 and examine
fan tip shroud for new tip rubs.
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(a) If the 1E LP vibration level has not been reduced to acceptable levels, a Third Run is
needed.
(b) Plot data per Figure 512 Trim Balance by Vector Subtraction - Sample Plot and Figure
513 Trim Balance by Vector Subtraction - Sample Plot Procedure.
(a) Move weight. Refer to Figure 513 Trim Balance by Vector Subtraction - Sample Plot
Procedure.
(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 512 Trim Balance by Vector Subtraction - Sample Plot and Figure
513 Trim Balance by Vector Subtraction - Sample Plot Procedure.
(a) Move weight. Refer to Figure 513 Trim Balance by Vector Subtraction - Sample Plot
Procedure.
(b) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the ACES analyzer or equivalent. Perform a slow decel to
idle. Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501.
(c) If this method, (Trim Balance Testing by Vector Subtraction Method), results in vibration
levels that are not sufficiently reduced, do the following:
1 Verify lowest vibration levels (at the speed of interest) were obtained during the
final run.
2 Verify vibrations (at other speeds) were not reached or exceeded the limit.
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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.
(d) If the 1E LP vibration level has not been reduced to acceptable levels, proceed to Trim
Balance by 3-Weight Method.
NOTE Weight(s) are setscrews, available in various sizes and weights (grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(1) Perform an initial run per step C(3). Only the 1E amplitude is needed.
(a) Baseline Weight Location: If this effort is a follow-on to the Vector Subtraction Method,
then the fourth run (of the vector subtraction method) will be the 1st weight run and the
initial run, step C(3) is the initial.
(a) Relocate trim weight 120 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power
(over a 90 second time frame), 1 minute dwell at T.O., followed by a slow decel to
idle (over 90 seconds).
(4) Shut down and examine fan tip shroud for new tip rubs.
(a) Relocate trim weight to 240 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power
(over a 90 second time frame), 1 minute dwell at T.O., followed by a slow decel to
idle (over 90 seconds).
(c) Shutdown and examine fan tip shroud for new tip rubs.
(a) Reduce data. Refer to Figure 514 Reducing Data for Final Trim Weight Rotation.
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(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.
(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.
25. 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. Refer
to the following illustration(s):
Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings
Figure 515 Accel Time Limits - Electronic Mode - WOW Enabled (GRD Idle to 98% T.O. N1)
Figure 516 Accel Time Limits - Electronic Mode - WOW Disabled (Flt Idle to 98% T.O. N1)
Figure 517 Accel Time Limits - Manual Mode - (Idle PLA to 96% T.O. N1)
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NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-941-003
A. Standard Equipment
SUBTASK 71-00-00-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-003
28. Procedures
SUBTASK 71-00-00-760-002
NOTES: 1 An operational check of the EFCU in manual mode is required for Check 1 (5-20-00
P.B. 601). Perform SUBTASK 71-00-00-760-001 to complete this requirement.
2 Before performing the visual check of the acceleration bleed system, refer
to TEST LIST, 71-00-00, P.B. 501 to check if it is required.
A. Engine cowling should be open so an observer can see movement of the bleed valve lever.
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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.
D. Start the engine. Refer to General Operating Procedures, Task 71-00-00, P.B. 501.
F. Accel engine to 84% 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.
G. Determine the outside air temperature (OAT) and refer to Figure 509 N1 Speeds for Ground Checks
at Takeoff Thrust Settings to determine the takeoff thrust N1 speed setting. Note the takeoff thrust N1
speed setting.
H. Slowly advance the power lever from idle to takeoff N1 (maximum PLA) as determined in step G. A
minimum of 20 seconds should elapse during the idle-max transient. Maintain takeoff N1 for three
minutes. Actual N1 speed should be within +2.0% of target speed. If not, refer to Troubleshooting,
71-00-00 P.B. 101.
I. Rapidly (less than 1 second) move the power lever back to the idle position, observing the N2 speed
indicator. Maintain the power lever at idle for a minimum of 1 minute, then rapidly (less than 1
second) advance the power lever from idle to takeoff N1.
J. 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-idle-max transient.
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(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 IDLE position. The engine must
operate normally without flame-out during the entire intermediate-idle decel transient.
(3) Repeat steps (1) and (2) (above) one more time.
(4) Slowly advance the power lever position from 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 IDLE position. The engine must
operate normally without flame-out during the entire intermediate-idle decel transient.
(6) Repeat steps (4) and (5) (above) one more time.
(7) Slowly advance the power lever position from 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 IDLE position. The engine must
operate normally without flame-out during the entire intermediate-idle decel transient.
(9) Repeat steps (7) and (8) (above) one more time.
L. Move PLA to flight idle. Refer to General Operating Procedures, 71-00-00 P.B. 501.
NOTES: 1 The following ELECTRONIC Mode acceleration time check may be performed
from either the Ground Idle or Flight Idle setting.
2 If performing the test from Ground Idle, use Figure 515 Accel Time Limits -
Electronic Mode - WOW Enabled (GRD Idle to 98% T.O. N1). This is the normal
idle setting for ground operation (aircraft WOW switch enabled).
3 If performing the test from Flight Idle, use Figure 516 Accel Time Limits
- Electronic Mode - WOW Disabled (Flt Idle to 98% T.O. N1). The Flight
Idle setting is attained only when the aircraft WOW switch is disabled,
according to the A.M.M. WOW override procedure.
(1) Determine 98% of the takeoff N1 speed setting as determined in step G. Refer to Figure 509
N1 Speeds for Ground Checks at Takeoff Thrust Settings
(2) Set generator OFF and normal bleed OFF. Stabilize at idle for two minutes.
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(3) Using a stop watch, rapidly (less than one second) advance PLA from idle to the takeoff
position and measure the time between initiation of PLA movement and 98% of the takeoff N1
speed setting. Note N1% overshoot/undershoot.
O. Repeat the acceleration and timing procedure at least one more time and average the results to
reduce timing errors.
P. Compare the measured acceleration time with the appropriate Accel Time Limits figure, as noted
in step above, for accel from either Ground or Flight Idle. Acceleration time must be no greater
than the value obtained from the appropriate figure. If acceleration time exceeds limits, refer to
Troubleshooting (Slow Acceleration) 71-00-00 P.B. 101. Retest as required.
SUBTASK 71-00-00-760-001
(4) Start engine in MANUAL Mode per procedures in SUBTASK 71-00-00-700-050 of TASK
71-00-00-760-803.
(5) Run at idle for two minutes. Verify stable engine N2 speed (N2 speed should not fluctuate
more than 2.0%).
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.
(6) To accomplish MANUAL mode acceleration time check, perform the following:
(a) Determine outside air temperature (OAT) and refer to Figure 509 N1 Speeds for Ground
Checks at Takeoff Thrust Settings to determine the takeoff thrust N1 speed setting.
Note the takeoff thrust N1 speed setting.
(b) Slowly accelerate the engine to either full PLA or the N1 speed as specified in the
figure, whichever is less, but do not exceed normal operating limits. Note the PLA
position and N1 speed.
(c) Rapidly decelerate the engine to idle and stabilize for two minutes.
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(d) Using a stopwatch, rapidly accelerate the PLA (less than one second) to the noted
PLA position and measure the time from initiation of PLA movement to 96% of the
noted N1 speed.
(e) Compare the measured acceleration time with Figure 517 Accel Time Limits - Manual
Mode - (Idle PLA to 96% T.O. N1). Acceleration time must be no greater than the value
from the figure. If acceleration time exceeds limits, refer to Troubleshooting (Slow
Acceleration) 71-00-00 P.B. 101. Retest as required.
(7) Reduce PLA to normal takeoff position. Switch the cockpit EFCU mode switch to ELECTRONIC
mode. Verify engine responds within one second. Following a two minute stabilization period,
switch the cockpit EFCU mode switch to MANUAL mode. Verify the engine responds within
one second. Allow the engine to stabilize for two minutes. Verify engine N2 speed does not
fluctuate "hunt" more than 2.0%.
(8) Rapidly decelerate the engine to ground idle. Verify engine deceleration is smooth and
consistent. Following a two minute stabilization period at ground idle, switch the cockpit EFCU
mode switch to ELECTRONIC mode. Verify engine responds within one second. Following a
two minute stabilization period, verify engine N2 speed does not fluctuate more than 1.0%.
SUBTASK 71-00-00-410-003
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.
30. 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 508 Idle N2 Speed Check (Electronic Mode)
Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
Figure 518 ITT Limits for Ground Checks at Takeoff Thrust (Electronic Mode)
Figure 519 N2 Speed Limits for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
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NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-942-014
A. Consumables
Reference Designation
MAT-021 R-MC Cleaner
SUBTASK 71-00-00-945-014
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-31-20 801 Fan Rotor - Repair
SUBTASK 71-00-00-010-014
33. Procedures
SUBTASK 71-00-00-760-023
(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. Remove the HP bleed air tubes from the right and left hand service adapters. Install HP bleed port
cap, to each port. Refer to the Aircraft Maintenance Manual.
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WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
F. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE The OAT indicator reading must be within 1 C of actual airfield ambient temperature.
H. Observe N2 speed and outside air temperature (OAT) and compare to Figure 508 Idle N2 Speed
Check (Electronic Mode).
(1) Idle speed 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.
I. Refer to Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode) to
determine the takeoff thrust N1 speed setting.
NOTE In ELECTRONIC mode, 85 is takeoff thrust. In MANUAL mode, refer to Figure 509
N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode).
J. Slowly advance the power lever to the N1 speed setting (maximum PLA) required for takeoff thrust
and stabilize for two minutes. (N1 speed at maximum PLA should be within +2.0% of target N1
speed. If not, refer to Troubleshooting 71-00-00 P.B. 101).
K. Monitor the engine ITT and refer to Figure 518 ITT Limits for Ground Checks at Takeoff Thrust
(Electronic Mode) 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.
L. Monitor the engine N2 speed and refer to Figure 519 N2 Speed Limits for Ground Checks at Takeoff
Thrust Settings (Electronic Mode) 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.
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N. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
O. Remove the HP bleed port caps from the right and left hand service adapters. Install the HP bleed
tubes, to each port. Refer to the Aircraft Maintenance Manual.
SUBTASK 71-00-00-410-014
35. General
This task monitors and calculates oil consumption. You must do this test as required by Troubleshooting,
71-00-00 P.B. 101.
SUBTASK 71-00-00-942-011
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 71-00-00-945-011
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2A
71-00-00
Page 540
Apr 11/08
37. 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.
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
B. Start the engine and run for five minutes at idle to warm oil. Refer to General Operating Procedures,
71-00-00 P.B. 501.
C. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
NOTE Carefully time engine run time in decimal hours. This information will
be used to calculate oil consumption.
E. Start the engine and run for a minimum of one hour at 85 to 90% N2. Refer to General Operating
Procedures, 71-00-00 P.B. 501. Engine run can be performed on the ground or in flight.
F. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
G. Carefully check the oil level while still warm. Add small measured amounts of oil, and continue
checking level, until oil is at the original recorded level. Record amount of oil added (used).
(1) Convert recorded amount of oil used to gallons. Use one of the following conversion factors, as
required:
EFFECTIVITY: FJ44-2A
71-00-00
Page 541
Apr 11/08
(2) Divide gallons of oil used by engine run time (decimal hours). This is oil consumption in
gallons per hour.
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.
38. 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 508 Idle N2 Speed Check (Electronic Mode)
Figure 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
Figure 518 ITT Limits for Ground Checks at Takeoff Thrust (Electronic Mode)
Figure 519 N2 Speed Limits for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
NOTES: 1 Refer to the Test List matrix, 71-00-00, P.B. 501, for a listing of all tests
required after replacement or repair of parts.
SUBTASK 71-00-00-945-006
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-006
EFFECTIVITY: FJ44-2A
71-00-00
Page 542
Apr 11/08
41. Procedures
SUBTASK 71-00-00-760-004
WARNINGS: 1 MAKE SURE THAT THE PEOPLE AT WORK NEAR THE AIRCRAFT
KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE
THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
C. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE The OAT indicator reading must be within 3 C of actual airfield ambient temperature.
E. Observe N2 speed and outside air temperature (OAT) and compare to Figure 508 Idle N2 Speed
Check (Electronic Mode).
(a) FOR FJ44-2A 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.
F. To determine the takeoff thrust N1 speed setting, refer to Figure 509 N1 Speeds for Ground Checks
at Takeoff Thrust Settings (Electronic Mode).
G. Slowly advance the power lever to the N1 speed setting required for takeoff thrust and stabilize
for two minutes.
EFFECTIVITY: FJ44-2A
71-00-00
Page 543
Apr 11/08
H. Monitor the engine ITT to determine if it is within allowable limits. Refer to Figure 518 ITT Limits
for Ground Checks at Takeoff Thrust (Electronic Mode). 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 519 N2
Speed Limits for Ground Checks at Takeoff Thrust Settings (Electronic Mode). If not, shut-down
engine and refer to Troubleshooting (Overspeed N2, 71-00-00, P.B. 101.
K. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE If the engine did not perform within allowable limits at take-off power, remove the
HP bleed tubes and repeat the ground-run test with the bleed ports capped. If
engine performs within limits with bleed ports capped, troubleshoot aircraft bleed
system in accordance with the Aircraft Maintenance Manual.
SUBTASK 71-00-00-410-006
43. General
This task contains instructions for performing a capped bleed engine run. Refer to the following power
charts included in this task:
Figure 520
Figure 521 FJ44 Climb/Cruise Power Chart
SUBTASK 71-00-00-945-005
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
SUBTASK 71-00-00-010-005
A. To prepare engine for test, remove the cowling. Refer to the Aircraft Maintenance Manual.
EFFECTIVITY: FJ44-2A
71-00-00
Page 544
Apr 11/08
46. Procedures
SUBTASK 77-20-02-760-001
A. Disconnect the aircraft bleed air plumbing from the HP bleed air tubes 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.
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE Make sure that atmospheric conditions are measured at the time
of test and are recorded accurately.
(6) (FOR FJ44-2A ONLY) If in manual mode, determine the takeoff thrust N1 speed setting.
(7) Take data as shown on Figure 520 for Ground Power Check stabilizing three minutes before
recording data at each powersetting.
(8) Return to idle for two-minute cool-down and stop the engine. Refer to General Operating
Procedures, 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
71-00-00
Page 545
Apr 11/08
SUBTASK 71-00-00-410-005
A. Remove HP bleed caps and reconnect aircraft bleed plumbing. Refer to aircraft Maintenance Manual.
EFFECTIVITY: FJ44-2A
71-00-00
Page 546
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 547
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 548
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 549
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 550
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 551
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 552
Apr 11/08
EFFECTIVITY: FJ44-2A
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Page 553
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 554
Apr 11/08
Fig. 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
EFFECTIVITY: FJ44-2A
71-00-00
Page 555
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 556
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 557
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 558
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 560
Apr 11/08
Fig. 515 Accel Time Limits - Electronic Mode - WOW Enabled (GRD Idle to 98% T.O. N1)
EFFECTIVITY: FJ44-2A
71-00-00
Page 561
Apr 11/08
Fig. 516 Accel Time Limits - Electronic Mode - WOW Disabled (Flt Idle to 98% T.O. N1)
EFFECTIVITY: FJ44-2A
71-00-00
Page 562
Apr 11/08
Fig. 517 Accel Time Limits - Manual Mode - (Idle PLA to 96% T.O. N1)
EFFECTIVITY: FJ44-2A
71-00-00
Page 563
Apr 11/08
Fig. 518 ITT Limits for Ground Checks at Takeoff Thrust (Electronic Mode)
EFFECTIVITY: FJ44-2A
71-00-00
Page 564
Apr 11/08
Fig. 519 N2 Speed Limits for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
EFFECTIVITY: FJ44-2A
71-00-00
Page 565
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 566
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-00
Page 567
Apr 11/08
71-00-00
568
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures to clean the power plant with fresh water. Perform this task to remove salt
and other corrosive substances from the engine.
Figure 701 Location of Cleaning Areas
Figure 702 Location of Cleaning Areas
SUBTASK 71-00-03-941-001
A. Standard Equipment
Pressure Washer Spray Equipment (50 To 100 Psi)
SUBTASK 71-00-03-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
05-50-00 201 Recommended Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
3. Procedures
SUBTASK 71-00-03-170-001
NOTE There are two separate cleaning tasks for the power plant. The desalinization rinse is
a water-only wash for removing salt or other corrosive substances from the interior of
the engine. The compressor wash procedure uses approved cleaning fluids to remove
dirt and grime from the gas path and improve compressor efficiency.
A. Desalinization Rinse
(1) If ambient temperature is below freezing and engine has been shut down for more than 30
minutes, engine must be warmed up. Start engine and run at idle for a minimum of five
minutes. Operate engine in accordance with General Operating Instructions Task of 71-00-00,
P.B. 501. Shut down engine.
EFFECTIVITY: FJ44-2A
71-00-03
Page 701
Apr 11/08
NOTE To ensure that fluid reaches the engine core, initial spray cleaning should
be performed with the engine static (not running). Rotation of the fan
(LP spool) forces the flow outwards into the bypass area.
(4) While engine is static (not running), use Pressure Washer Spray Equipment (50 to 100 psi).
Spray 2.5 to 3.5 gallons of clean water (drinking purity) into the engine core. Direct the spray
towards the base of the spinner and the fan blade root area. Spray 360 degrees around.
(5) Have a second person starter-crank the engine in accordance with the duty cycle limits for
the starter-generator in the Aircraft Maintenance Manual. As soon as the fan starts to rotate,
spray 2.5 to 3.5 gallons of clean water into the engine core flowpath. Direct the spray at a
30 degree angle relative to the axial engine center line, in the same direction as the rotor
rotation. Hold the spray nozzle at the appropriate radius to enter the core Figure 702 Location
of Cleaning Areas. To confirm that water has entered the core, observe water dripping from
the engine diffuser drains (aircraft drain mast). If water is not observed, change the direction
of spray and repeat starter crank.
(7) Perform Post-Desalinization Engine Ground Run in accordance with the subtask that follows.
SUBTASK 71-00-03-170-003
EFFECTIVITY: FJ44-2A
71-00-03
Page 702
Apr 11/08
(1) After completing desalinization rinse procedure, start engine and run at idle for a minimum
of five minutes (with bleed air OFF) to ensure that all water is evaporated or blown from the
engine. Operate engine in accordance with General Operating Procedures Task of 71-00-00,
P.B. 501. Shut down engine.
4. General
This task provides procedures to clean the power plant using an approved cleaning fluid. The compressor
wash procedure removes dirt and grime from the gas path to improve compressor efficiency.
Figure 701 Location of Cleaning Areas
Figure 703 Removal of Borescope Plug/IP Bleed Port
NOTES: 1 R-MC MAT-021 is the preferred cleaning fluid. R-MC is a non-flammable, non-toxic,
biodegradable fluid. Also approved for use are the following compressor cleaners:
B&B 3100 MAT-029 and Gas Path Cleaner MAT-031.
SUBTASK 71-00-03-941-001
A. Standard Equipment
Air Compressor
Pressure Washer Spray Equipment (50 To 100 Psi)
SUBTASK 71-00-03-942-001
B. Consumables
Reference Designation
MAT-021 R-MC Cleaner
MAT-029 Cleaner, Compressor
MAT-031 Cleaner, Gas Path
EFFECTIVITY: FJ44-2A
71-00-03
Page 703
Apr 11/08
SUBTASK 71-00-03-943-001
C. Special Tools
Reference Designation
TL99920 Nozzle, Wash, HP Compressor
TL99926 Can, Pressure
SUBTASK 71-00-03-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-50-00 201 Recommended Maintenance - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
6. Job Set-up
SUBTASK 71-00-03-010-001
7. Procedures
SUBTASK 71-00-03-170-002
(3) Open the cowling to access the engine. Refer to the Aircraft Maintenance Manual.
(4) Disconnect (separate) the aircraft bleed piping from the engine bleed fittings.
(5) Cover the aircraft side of the bleed piping with a plastic bag, or equivalent, to prevent entry of
water. Leave piping disconnected so that water can drain from the engine bleed fittings.
EFFECTIVITY: FJ44-2A
71-00-03
Page 704
Apr 11/08
(6) (If engine configuration has a CDP line, perform this step) Remove heatshield, if required, for
access to CDP elbow. Refer to 73-21-01, P.B. 401.
(7) (If engine configuration has a gearbox breather flex hose, perform this step.) Disconnect
the gearbox breather flex hose from the elbow by loosening the hose clamp and pulling off
the aft end of the flex tube. Plug the end of the flex tube and elbow with a suitable plastic
water-tight plug or cap.
(8) (If engine configuration has a CDP line, perform this step) Disconnect CDP air-to-elbow tube
assembly from FCU elbow. Refer to 73-10-01, P.B. 401 .
(1) With engine shut down, wipe readily accessible inlet area, spinner, and fan blades free of all
dirt and grime using a cloth wetted with cleaning fluid MAT-021, MAT-029, or MAT-031.
(2) While engine is static, use Pressure Washer Spray Equipment (50 to 100 psi) and spray
approximately one to two gallons of cleaner MAT-021, MAT-029, or MAT-031 into the engine.
Direct the spray near the spinner and between the fan blades, concentrating on the core of the
engine. Spray 360 degrees around the spinner. Let engine stand five minutes.
(3) Have a second person starter-crank the engine in accordance with the duty cycle limits for
the starter-generator in the Aircraft Maintenance Manual. As soon as the fan starts to rotate,
spray 2.5 to 3.5 gallons of fluid into the engine core. Direct spray near the fan/spinner to
concentrate the cleaner into the core of the engine as shown in Figure 701 Location of
Cleaning Areas. Move spray wand 360 degrees around the spinner to ensure cleaner can
reach all areas of the core.
(4) Spray some cleaner around the remaining inlet area to clean bypass duct flow path. Spray 2.5
to 3.5 gallons of cleaner during this procedure. Repeat starter cranking as necessary to use up
cleaner (no more than two times total). Allow engine to stand 10 minutes.
(5) Repeat steps (2) and (3) using 2.5 to 3.5 gallons of clean water (drinking purity).
EFFECTIVITY: FJ44-2A
71-00-03
Page 705
Apr 11/08
(1) Remove the hex cap from TL99926 spray can and fill the can with 32 ounces (946 ML) of
cleaning fluid MAT-021, MAT-029, or MAT-031. Install hex cap and tighten securely. Using an
Air Compressor, pressurize the can to 120 150 psi.
(2) Remove the borescope plug/IP bleed port from the top of the interstage housing. Refer to
Figure 703 Removal of Borescope Plug/IP Bleed Port.
(3) Install TL99920 wash nozzle into the borescope port at the top of the interstage housing.
Tighten the nozzle securely.
(4) Connect the steel braided hose from TL99926 to the wash nozzle and torque 90 to 100
inch-pounds (10.1 to 11.2 N.m).
(6) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the starter is activated, press
the lever on top of the TL99926 spray can to allow the pressurized cleaning fluid to flow to the
nozzle. Hold the lever until the starter-crank cycle is complete.
(7) Disconnect the steel braided hose from the TL99920 wash nozzle. Remove the hex cap from
TL99926 and fill the can with 32 ounces of clean water (drinking purity). Install hex cap and
tighten securely. Using an Air Compressor, pressurize the can to 120 150 psi.
(8) Connect the steel braided hose from TL99926 to the wash nozzle and torque 90 to 100
inch-pounds (10.1 to 11.2 N.m).
(9) Have a second person starter-crank the engine in accordance with the duty cycle limits for the
starter-generator in the Aircraft Maintenance Manual. As soon as the starter is activated, press
the lever on top of the TL99926 spray can to allow the pressurized cleaning fluid to flow to the
nozzle. Hold the lever until the starter-crank cycle is complete.
(10) Disconnect the steel braided hose from TL99920 wash nozzle. Remove TL99920 wash
nozzle from the borescope port.
(11) Install borescope plug/IP bleed port into interstage housing. Torque the plug assembly 90 to
100 inch-pounds (10.1 to 11.2 N.m)28 to 32 inch-pounds (3.2 to 3.6 N.m).
EFFECTIVITY: FJ44-2A
71-00-03
Page 706
Apr 11/08
(1) If engine is equipped with CDP line, blow out any residual water from the CDP line. Reattach
CDP air-to-elbow tube assembly to FCU. Refer to 73-10-01, P.B. 401.
(2) Remove plastic bag from aircraft bleed piping and reconnect piping to engine bleed fittings.
Refer to the Aircraft Maintenance Manual. If torque was disturbed on HP bleed fittings, torque
fittings 590 to 610 inch-pounds (66.6 to 68.9 N.m).
(3) (If engine configuration has a gearbox breather flex hose, perform this step.) Remove plastic
plug or cap from the gearbox breather tube flex hose. Reconnect the flex hose to the elbow
and tighten the hose clamp.
E. Ensure aircraft bleed system is still set OFF/CLOSED. Run engine at idle for five minutes to ensure
excess cleaning fluid and water is evaporated or blown from the engine and that there are no
bleed leaks. Operate engine in accordance with General Operating Procedures Task of 71-00-00,
P.B. 501. Shut down engine.
8. Job Close-up
SUBTASK 71-00-03-410-001
EFFECTIVITY: FJ44-2A
71-00-03
Page 707
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-03
Page 708
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-03
Page 709
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-03
Page 710
Apr 11/08
1. General
This task provides procedures for the storage of an engine for nine months or more. The engine must be
preserved. Refer to the following illustration(s):
Figure 201 Engine Setup for Preservation
Figure 202 Location of Closures
NOTES: 1 Before preserving, clean the power plant externally (installed or uninstalled).
Refer to 71-00-03, 701, Clean the Power Plant.
2 Engines stored more than nine months require periodic inspection. Refer
to 71-00-24, 201, Storage Inspection.
SUBTASK 71-00-21-942-001
A. Consumables
Reference Designation
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-21-943-001
B. Special Tools
Reference Designation
08-0119-8000 Engine Sling
08-2021-0000 Stand, Engine
SUBTASK 71-00-21-944-001
C. Parts Required
IPC Reference
Subject Fig Item Nomenclature
71-00-25 01 20 Inlet Closure
71-00-25 01 20 Liner
71-00-25 01 30 Closure (5)
EFFECTIVITY: FJ44-2A
71-00-21
Page 201
Apr 11/08
SUBTASK 71-00-21-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 401 Power Plant - Removal/Installation
71-00-03 701 Power Plant Cleaning - Cleaning
71-00-22 201 Preserving Installed Engine for Nine Months or More - Maintenance
Practices
71-00-24 201 Storage Inspection - Maintenance Practices
71-00-25 201 Engine Shipping/Receiving - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2A
71-00-21
Page 202
Apr 11/08
3. Job Set-up
SUBTASK 71-00-21-010-001
A. Preserve the engine fuel system before removing the engine from the aircraft. Refer to 71-00-22,
P.B. 201.
SUBTASK 71-00-21-010-003
B. Remove the engine using engine lifting sling, 08-0119-8000. Refer to Aircraft Maintenance Manual.
4. Procedures
SUBTASK 71-00-21-620-003
(1) With the engine hanging from lifting sling (08-0119-8000) or installed in engine maintenance
stand (08-2021-0000), drain the engine oil. Refer to 72-00-03, P.B 301.
SUBTASK 71-00-21-620-005
(2) If engine is on a sling, remove the eight plugs which are located on the engine mount pads of
the interstage housing. Place them into a cloth bag and attach them near the mount pads.
(3) Using MAT-176 barrier material make a bag to cover the engine. Slip bag over the engine
from the underside.
(4) Cut small openings in the barrier material at each engine mount pad.
(6) Heat seal the top edge of the barrier bag. Cut a small opening along the seam and vacuum the
air from the bag until it is drawn snugly around the engine. Reseal the bag.
(7) To install engine into an engine build stand to store the engine, refer to 71-00-00, P.B 401. To
install engine into a shipping/storage container to store the engine, refer to 71-00-25, P.B. 201.
EFFECTIVITY: FJ44-2A
71-00-21
Page 203
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-21
Page 204
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-21
Page 205
Apr 11/08
71-00-21
206
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for preserving an installed engine for more than nine months. Refer
to the following illustration(s):
Figure 201 Engine Setup for Preservation
SUBTASK 71-00-22-942-002
A. Consumables
Reference Designation
MAT-002 Oil, Preservative
SUBTASK 71-00-22-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-03 701 Power Plant Cleaning - Cleaning
71-00-24 201 Storage Inspection - Maintenance Practices
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Procedures
NOTE This procedure is for the engine which will remain on the aircraft and on the ground
for nine months or more. The engine fuel and oil system must be drained.
SUBTASK 71-00-22-620-004
EFFECTIVITY: FJ44-2A
71-00-22
Page 201
Apr 11/08
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(2) Disconnect the out-going fuel tube attached to the oil cooler.
(3) Disconnect the flex fuel tube from the fuel nozzle. Insert the end of tube into a suitable container.
(4) Remove the aircraft supplied fuel inlet line to the engine fuel pump.
(5) Install a drain tube to the fitting on oil cooler. Insert the opposite end of the tube into an
appropriate container.
(6) Connect the preservation oil supply hose to the inlet port on the engine fuel pump.
(10) Let preserving oil flow into engines fuel pump and out the drain tube which is attached to
the oil cooler.
NOTE Only, MAT-002, MIL-L-6081, grade 1010 oil is approved for preservation
of this engine. Other fluids may damage the fuel system.
(11) Continue flowing preserving oil until you see a clean flow of oil.
(12) Stop motoring the engine and set the power lever to OFF.
EFFECTIVITY: FJ44-2A
71-00-22
Page 202
Apr 11/08
(14) Disconnect the preservation oil tubes from the engine and reinstall the oil cooler to engine
fuel tube. Plug the fuel inlet port on the engine fuel pump. Torque the fuel tube 135 to 150
inch-pounds (15.2 to 16.9 N.m).
(15) Install the flex fuel tube to the fuel nozzle. Torque 70 to 120 inch-pounds (7.9 to 13.5 N.m).
(16) Secure a warning tag to the engine to indicate that engine has been preserved and that it
should not be operated or rotated until it has been depreserved.
(17) Clean all fuel and preservation oil from the engine.
SUBTASK 71-00-22-620-005
SUBTASK 71-00-22-620-006
(1) Secure a warning tag to the aircraft controls to indicate the engine has been preserved and it
should not be operated.
EFFECTIVITY: FJ44-2A
71-00-22
Page 203
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-22
Page 204
Apr 11/08
1. General
This task provides procedures for preserving an installed engine for nine months or less. Refer to the
following illustration(s):
Figure 201 Location of Closures
NOTE Before preserving, clean the engine externally (installed or uninstalled). Refer
to 71-00-03, 701, Power Plant Cleaning.
SUBTASK 71-00-23-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-03 701 Power Plant Cleaning - Cleaning
3. Procedures
SUBTASK 71-00-23-430-001
NOTE This procedure is for an aircraft which will remain on the ground for nine months or less.
The engine fuel system must not be drained or flushed. The fuel which remains in the
engines fuel system is enough to preserve the fuel system for this period of time.
EFFECTIVITY: FJ44-2A
71-00-23
Page 201
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-23
Page 202
Apr 11/08
1. General
Engines which have been preserved must be inspected periodically for signs of corrosion or deterioration
of preservation materials.
SUBTASK 71-00-24-942-001
A. Consumables
Reference Designation
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-24-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-21 201 Preserving Uninstalled Engine - Maintenance Practices
3. Procedures
SUBTASK 71-00-24-550-001
A. Perform the following inspections every six months if engine is on a build stand or in a shipping
container:
(1) Make sure there is no apparent deterioration of the MAT-176 barrier bag sealing the engine. If
the bag is deteriorated, replace the bag and the MAT-175 desiccant bags. Refer to 71-00-21,
P.B. 201.
B. If engine is installed, check every six months to make sure that there is no external sign of corrosion
on the engine.
EFFECTIVITY: FJ44-2A
71-00-24
Page 201
Apr 11/08
71-00-24
202
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides the procedures to prepare the engine for shipping. Refer to the following illustration(s):
Figure 201 Assemble Engine Shipping Mounts and Supports
Figure 202 Location of Closures
Figure 203 Installation of Engine in Container
Figure 204 Container Ready to Ship
SUBTASK 71-00-25-943-005
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
SUBTASK 71-00-25-510-006
B. Parts Required
Refer to table of shipping preparation caps and plugs
SUBTASK 71-00-25-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Procedures
SUBTASK 71-00-25-620-005
B. If needed, the engine may be wiped clean using a general wet cleaner (MAT-202) and a lint free
cloth (MAT-071).
EFFECTIVITY: FJ44-2A
71-00-25
Page 201
Apr 11/08
SUBTASK 71-00-25-510-007
NOTE The engine must be hanging from the engine sling, 08-0119-8000 in order
to install in the shipping container.
C. Prepare the engine and the container for engine installation as follows:
NOTE Make sure that SAE grade 5 bolts are used when assembling
the shipping container.
(1) Assemble two engine shipping mount supports to the shipping mount plates using four screws,
four locknuts and four washers. Torque 90 to 100 foot-pounds (10.1 to 11.2 N.m).
EFFECTIVITY: FJ44-2A
71-00-25
Page 202
Apr 11/08
(3) Place eight plugs from the engine mount pads located on the interstage housing into a cloth
bag and tie near the mount pads.
(4) Install inlet and exhaust closures or secure a liner around the inlet and exhaust openings
with a rubber band.
(5) Cover oil tank sightglass with 200 lb. test cardboard. Tape in place (no masking tape allowed).
(6) Install closure on TT2 sensor. Protective wrap sensor and tie wrap to top of engine.
(7) Install four engine shipping mounts to the engine using 16 screws and 16 washers. Torque
140 to 160 inch-pounds (15.8 to 18.0 N.m).
EFFECTIVITY: FJ44-2A
71-00-25
Page 203
Apr 11/08
(1) After installing closures on ECU, place ECU in anti-static bag. Package ECU in its original
container and ship separately.
(2) Optional method: Place ECU in anti-static bag and re-box ECU in its original shipping box.
Wrap box in polyethylene film and strap to shipping pallet on inside of engine container.
SUBTASK 71-00-25-510-008
(1) Lower the engine into the container and secure it to the engine shipping mount supports using
four screws, four locknuts and four washers. Torque 70 to 90 foot-pounds (94.8 to 121.2 N.m).
(2) Align the upper collar of the shipping container to the lower collar.
(3) Place the engine log book into the polyethylene tube and heat seal both ends.
(5) Install the container sides on the shipping pallet. Install the lid and secure the container
using steel strapping.
SUBTASK 71-00-25-550-003
F. Storage (Stacking) of Engine Containers. FJ44 containers can be stacked two high when empty
(no engine installed).
4. General
This task provides procedures for receiving the engine. Refer to the following illustration(s):
Figure 202 Location of Closures
Figure 203 Installation of Engine in Container
Figure 204 Container Ready to Ship
SUBTASK 71-00-25-943-001
A. Special Tools
Reference Designation
08-0119-8000 Engine Sling
EFFECTIVITY: FJ44-2A
71-00-25
Page 204
Apr 11/08
SUBTASK 71-00-25-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
6. Procedures
SUBTASK 71-00-25-520-001
(1) Remove the container lid by removing the steel strapping and the edge protectors.
(2) Remove the upper collar of the container and the engine log book.
NOTE The engine log book must be kept with the engine.
(3) Install engine lifting sling, 08-0119-8000, to hoist. Attach sling to engine lift points on the rear
mount ring and interstage housing.
(4) Adjust position of hoist as required and raise hoist until there is equal tension on sling cables.
(5) Remove four screws, four locknuts, and four washers which secure the engine mounts to the
container support.
(7) Remove the four engine shipping mounts and store them in the container.
(8) Remove engine inlet and exhaust closures. Store them inside the container
(9) Remove engine shipping mount supports and store inside the container.
(10) Fold the upper collar of the container and store it inside the container.
SUBTASK 71-00-25-520-002
EFFECTIVITY: FJ44-2A
71-00-25
Page 205
Apr 11/08
(1) Visually inspect the container for any obvious damage such as damaged hinges, torn labels,
or other visual damage.
(2) Visually inspect the engine for any obvious damage such as dents in the bypass duct.
SUBTASK 71-00-25-620-001
EFFECTIVITY: FJ44-2A
71-00-25
Page 206
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-25
Page 207
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-25
Page 208
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-25
Page 209
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-25
Page 210
Apr 11/08
1. General
NOTE Engine should be in a condition suitable for motoring with systems connected
and engine accessories installed.
SUBTASK 71-00-26-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Procedures
SUBTASK 71-00-26-630-001
A. Depreservation/purging of the engine fuel system is performed during ground run after engine
installation. Refer to 71-00-00, P.B. 501, Idle Speed and Leak Check Run.
SUBTASK 71-00-26-630-002
EFFECTIVITY: FJ44-2A
71-00-26
Page 201
Apr 11/08
71-00-26
202
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task contains detailed procedures for borescope inspection of the HP and IP compressor sections
and the diffuser inlet vanes. Refer to the following illustration(s):
Figure 601 IP Compressor Blades and Stator Vanes - Borescope Inspection
Figure 602 Borescope Plug
Figure 603 HP and IP Compressor Blades and Diffuser Vanes - Borescope Inspection
Figure 604 HP Compressor Rotor - Inspection
Figure 605 Engine Rotation Tool
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International., Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International., Walled Lake, Michigan, USA for service.
SUBTASK 71-00-30-941-002
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
SUBTASK 71-00-30-943-002
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-30-944-002
C. Expendable Parts
EFFECTIVITY: FJ44-2A
71-00-30
Page 601
Apr 11/08
IPC Reference
Subject Fig. Item Nomenclature
75-35-01 02 131 O-ring
3. Job Set-up
SUBTASK 71-00-30-010-002
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-30-870-001
NOTE A Flexible, steerable fiberscope, 6mm dia x 50 inch long is standard equipment
for borescoping inspection procedures.
SUBTASK 71-00-30-220-002
A. Inspect the IP compressor rotor blades leading edges (stage 1 only). Refer to Figure 601 IP
Compressor Blades and Stator Vanes - Borescope Inspection.
(1) Insert the borescope through the fan blades and fan stator vanes to examine the IP rotor blades
leading edge (area A). Inspect as follows:
B. Inspect the IP stator leading edges (stage 1 only). Refer to Figure 601 IP Compressor Blades and
Stator Vanes - Borescope Inspection.
(1) Insert the borescope through the fan blades, fan stator vanes, and IP rotor blades to examine
the IP stator vanes leading edge (area B). Inspect as follows:
C. Remove the borescope plug assembly and O-ring from the top of the interstage housing. Refer to
Figure 602 Borescope Plug .
D. Inspect IP compressor rotor blades (stage 3 only). Refer to Figure 603 HP and IP Compressor
Blades and Diffuser Vanes - Borescope Inspection.
EFFECTIVITY: FJ44-2A
71-00-30
Page 602
Apr 11/08
(1) Adjust the flexible fiberscope so that it points forward, toward the IP compressor (area C).
Inspect as follows:
E. Inspect the HP compressor rotor. Refer to Figure 603 HP and IP Compressor Blades and Diffuser
Vanes - Borescope Inspection and Figure 604 HP Compressor Rotor - Inspection.
(1) Adjust the flexible fiberscope so that it points aft, toward the HP compressor.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox. Refer to
Figure 605 Engine Rotation Tool
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
(5) With borescope still located between HP compressor rotor blades, look forward in flowpath and
rotate HP rotary group to inspect diffuser vanes (area G) for:
F. With borescope still located between HP compressor rotor blades, turn tip radially outward to inspect
the HP compressor cover. Rotate HP rotary assembly and inspect the compressor cover for:
EFFECTIVITY: FJ44-2A
71-00-30
Page 603
Apr 11/08
(2) Loss of abradable coating in bleed hole Contact Williams International for current
area (area H). limits.
(3) Rub indications in zone outboard and Contact Williams International for current
inboard of bleed holes. limits.
NOTE Craze crack indications in the abradable coating in the area forward
of the bleed holes are acceptable.
H. Withdraw borescope from gas path and insert it through the bleed valve opening. Inspect the
compressor cover bleed holes (area H) for:
(1) Install plug into port on interstage housing bleed port cover.
5. Job Close-up
SUBTASK 71-00-30-410-002
EFFECTIVITY: FJ44-2A
71-00-30
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-30
Page 605
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-30
Page 606
Apr 11/08
Fig. 603 HP and IP Compressor Blades and Diffuser Vanes - Borescope Inspection
EFFECTIVITY: FJ44-2A
71-00-30
Page 607
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-30
Page 608
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-30
Page 609
Apr 11/08
71-00-30
610
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task contains detailed procedures for checking for an internal oil leak with a borescope. Refer
to the following illustration(s):
Figure 601 Internal Oil Leak - Facing Aft - Borescope Inspection
Figure 602 Internal Oil Leak - Side View - Borescope Inspection
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-32-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
3. Job Set-up
SUBTASK 71-00-32-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
71-00-32
Page 601
Apr 11/08
4. Procedures
SUBTASK 71-00-32-220-002
NOTE Visible oil is not cause for engine rejection. The Oil Consumption Check in
71-00-00, P.B. 501 will determine engine acceptability.
(1) Move the borescope through the front case, past the fan and the fan stator vanes. Borescope
should remain in the bypass airflow area and face the bottom (6 oclock) strut in the interstage
housing.
(2) Move the borescope to the right side (facing aft) of the interstage housing 6:00 strut and
inspect for signs of oil leakage. Oil coming from the carbon seal scupper drain on this side of
the strut originates from the No. 2 carbon seal.
(3) Move the borescope to the left side (facing aft) of the interstage housing strut and inspect for
signs of oil leakage. Oil coming from the carbon seal scupper drain on this side of the strut
originates from the No. 1 carbon seal.
(4) Inspect for the following conditions. If oil is visible, perform an Oil Consumption Check in
71-00-00, P.B. 501.
(a) Visible oil puddles are present in the bypass duct, the origin of which are traceable
to the No. 1 or No. 2 scupper drains.
and/or
(b) Oil streams/drops are present on the bypass duct and/or core (i.e. diffuser) which
originate from the No. 1 or No. 2 scupper drains.
and/or
(c) A visible drop of oil is present on the respective scupper drain outlets.
and/or
(5) Inspect the front bypass duct fairing assembly for signs of oil leakage. Oil leaking from this
area means an oil tank cover leak.
EFFECTIVITY: FJ44-2A
71-00-32
Page 602
Apr 11/08
(6) Inspect the oil scavenge and supply tube bosses on the interstage housing/tube connections
for signs of oil leakage.
5. Job Close-up
SUBTASK 71-00-32-410-001
EFFECTIVITY: FJ44-2A
71-00-32
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-32
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-32
Page 605
Apr 11/08
71-00-32
606
Page
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LINE MAINTENANCE MANUAL FJ44-2A
TASK 71-00-40-220-801 Inspect the Combustor, Fuel Slinger, and HP Turbine Blade Leading
Edges with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the combustor, fuel slinger, and HP
turbine blades leading edge. Refer to the following illustration:
Figure 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-40-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
SUBTASK 71-00-40-943-001
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-40-945-001
C. Reference Information
EFFECTIVITY: FJ44-2A
71-00-40
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 71-00-40-010-001
(2) Open the aircraft circuit breakers to isolate engine electrical supply.
4. Procedures
SUBTASK 71-00-40-220-001
A. Remove the two igniter plugs from the service adapters on the front bypass duct. Refer to 74-22-01,
P.B. 401.
(1) Insert the borescope through the right hand igniter port.
(2) Move the borescope forward in the space between the outside of the combustor cover and
the inside of the diffuser.
C. Insert the borescope into the combustor area through either igniter port.
EFFECTIVITY: FJ44-2A
71-00-40
Page 602
Apr 11/08
NOTE If inspection reveals foreign object damage, you must also do a compressor
inspection. Refer to 71-00-30, P.B. 601.
(1) Move the borescope through the HP nozzle vanes and into the area behind the primary plate.
(1) Insert the borescope into the combustion area and inspect the primary plate (area C) for
erosion and cracks. Contact Williams International for current limits.
(2) Inspect combustor cover (area D) for erosion and cracks. Contact Williams International for
current limits.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
G. Inspect the HP turbine nozzle vanes (area F) for cracks and pitting. Evaluate damage as follows:
EFFECTIVITY: FJ44-2A
71-00-40
Page 603
Apr 11/08
(1) Move the borescope around and down between the HP nozzle vanes to point at the HP
turbine blades.
(2) Have someone slowly turn the HP rotary assembly to allow inspection of all the blades.
(3) Inspect the blade roots, leading edges, and blade tips of the 43 blades for any damage, erosion,
cracks, nicks, or any other visual defects. Contact Williams International for current limits.
(2) Locate the combustor cover key (area H) on the HP nozzle. It is radially in-line with the
right-hand igniter port and slightly forward. It locates the large indexing slot on the outside edge
of the combustor cover.
5. Job Close-up
SUBTASK 71-00-40-410-001
EFFECTIVITY: FJ44-2A
71-00-40
Page 604
Apr 11/08
Fig. 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection
EFFECTIVITY: FJ44-2A
71-00-40
Page 605
Apr 11/08
71-00-40
606
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task contains detailed procedures for borescope inspection of the 1st LP turbine rotor blades trailing
edge and the 2nd LP turbine rotor blades leading edge. Refer to the following illustration(s):
Figure 601 Borescope Plug Removal
Figure 602 LP Turbines - Borescope Inspection
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-50-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
SUBTASK 71-00-50-942-001
B. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 71-00-50-944-001
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
EFFECTIVITY: FJ44-2A
71-00-50
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 71-00-50-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-50-870-001
NOTE A Flexible, steerable fiberscope, 6mm dia x 50 inch long is standard equipment
for borescoping inspection procedures.
SUBTASK 71-00-50-220-001
A. Remove fuel drain tube from the rear bypass duct. Refer to the Aircraft Maintenance Manual.
B. Remove two screws, two nuts, and four washers which attach the rear fuel drain adapter to the rear
bypass duct. Remove adapter and O-ring. Refer to Figure 601 Borescope Plug Removal.
C. Using one of the screws removed, install screw into end of tube and remove fuel drain transfer
tube and two O-rings.
D. Insert appropriate hex key (1/4 inch)through the fuel drain port through the rear housing boss.
Remove the borescope plug from the 2nd nozzle case.
E. Insert borescope through the fuel drain port. Move borescope forward and locate the trailing edge of
the 1st LP turbine rotor blades (area A). Inspect blades as follows:
EFFECTIVITY: FJ44-2A
71-00-50
Page 602
Apr 11/08
(1) Slowly rotate the LP rotary assembly and inspect the blade root, trailing edge, and blade tip
platforms of the 70 blades on the 1st LP turbine rotor. Refer to Figure 602 LP Turbines -
Borescope Inspection. Contact Williams International for current limits.
F. Move borescope aft and find the 2nd LP turbine rotor blades (area B). Inspect blades as follows:
(1) Slowly rotate the LP rotary assembly and inspect the blade root, leading edge, and tip platform
of 65 LP turbine rotor blades. Contact Williams International for current limits.
I. Lube two O-rings with assembly fluid (MAT-011) and install on rear fuel drain transfer tube.
K. Install O-ring with assembly fluid and install on rear fuel drain adapter. Attach rear fuel drain adapter
to adapter boss using two screws, four washers, and two nuts. Torque screws 31 to 35 inch-pounds
(3.5 to 3.9 N.m).
SUBTASK 71-00-50-401-001
5. Job Close-up
SUBTASK 71-00-50-410-001
EFFECTIVITY: FJ44-2A
71-00-50
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-50
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-50
Page 605
Apr 11/08
71-00-50
606
Page
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LINE MAINTENANCE MANUAL FJ44-2A
TASK 71-00-52-220-801 Inspect the HP Nozzle/HP Turbine Trailing Edge and 1st LP Turbine
Leading Edge with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the HP nozzle/HP turbine trailing edge
and the 1st LP turbine leading edge. Refer to following illustration:
Figure 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-52-941-001
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
SUBTASK 71-00-52-943-001
B. Special Tools
Reference Designation
TL37244 Tool, Engine Rotation
SUBTASK 71-00-52-945-001
C. Reference Information
EFFECTIVITY: FJ44-2A
71-00-52
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 71-00-52-010-001
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 71-00-52-040-001
A. Remove any one of the six ITT probes from the front bypass duct. Refer to 77-20-02, P.B. 401.
SUBTASK 71-00-52-870-001
NOTE A Flexible, steerable fiberscope, 6mm dia x 50 inch long is standard equipment
for borescoping inspection procedures.
SUBTASK 71-00-52-220-001
B. Insert the borescope through the ITT port and into the core airflow path.
(1) Move the borescope aft, between the 1st LP nozzle vanes, and locate the 1st LP turbine
rotor blades (area A).
(2) Slowly rotate the LP rotary assembly. Inspect the blade root, leading edge, and blade tip
platforms of each of the 70 1st LP turbine rotor blades for any damage, erosion, cracks, nicks,
or any other visual defects. Contact Williams International for current limits.
EFFECTIVITY: FJ44-2A
71-00-52
Page 602
Apr 11/08
(1) Turn the borescope so it is facing forward and locate the HP turbine rotor blades.
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
(3) Inspect the blade root, trailing edge, and blade tip platform of each of the 43 blades (area
B) for any damage, erosion, cracks, nicks, or any other visual defects. Contact Williams
International for current limits.
(1) Move the borescope forward until it passes through the HP turbine rotor blades and the HP
nozzle vanes are visible.
(2) Have someone slowly turn the HP rotary assembly. The HP turbine rotor will carry the
borescope around the engines circumference, allowing inspection of the HP turbine nozzle
vanes.
(3) Inspect the trailing edges of the HP turbine nozzle vanes (area C) for any damage, erosion,
cracks, nicks, or any other visual defects. Contact Williams International for current limits.
SUBTASK 71-00-52-440-001
G. Install ITT probe to front bypass duct. Refer to 77-20-02, P.B. 401.
5. Job Close-up
SUBTASK 71-00-52-410-001
EFFECTIVITY: FJ44-2A
71-00-52
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
71-00-52
Page 604
Apr 11/08
Fig. 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"
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71-00-52
606
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LINE MAINTENANCE MANUAL FJ44-2A
CHAPTER 72
ENGINE
Page 1
72-ENGINE Apr 11/08
Page 2
72-ENGINE Blank
LINE MAINTENANCE MANUAL FJ44-2A
72-00-00 1 Apr 11/08 72-00-71 401 Apr 11/08 72-32-10 801 Apr 11/08
72-00-01 301 Apr 11/08 72-02-00 1 Apr 11/08 72-32-20 601 Apr 11/08
72-00-03 301 Apr 11/08 72-30-10 601 Apr 11/08 72-32-20 801 Apr 11/08
72-00-05 201 Apr 11/08 72-30-10 801 Apr 11/08 72-60-01 401 Apr 11/08
72-00-30 401 Apr 11/08 72-31-15 601 Apr 11/08 72-60-02 401 Apr 11/08
72-00-31 401 Apr 11/08 72-31-20 601 Apr 11/08 72-71-10 601 Apr 11/08
72-00-32 401 Apr 11/08 72-31-20 801 Apr 11/08 72-71-20 601 Apr 11/08
72-00-60 401 Apr 11/08 72-32-10 601 Apr 11/08
Chapter 72
List of Effective Page Blocks
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Chapter 72
List of Effective Page Blocks
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:
2. Description
SUBTASK 72-00-00-860-002
Spinner
Case assembly
(1) The spinner bolts onto the front of the fan rotor. The spinner shape provides a smooth airflow
into the engine. The sharp point prevents accumulation of ice.
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(2) The fan rotor (LP axial compressor) is a 20 blade titanium blisk (blades and disc are integral).
The fan is attached to the LP shaft with one nut. The fan is splined but there is no master
keyway to clock the position.
(3) The fan stator is located directly behind the fan rotor. The stator is keyed into the fan case
assembly. It contains 53 vanes set in an aluminum case and secured and damped with
polyurethane. The ID seal on the rear side seals with the IP compressor.
(4) The IP compressor is a 60 blade titanium blisk. The IP compressor is installed on the LP shaft
and is secured by the installation of the fan and front LP retaining nut.
(5) The IP stator is cast from inconel 718 with integral vanes and case. The case forms the splitter
fairing dividing the LP compressor air into core airflow and bypass airflow. The LP turbines
power both the fan and the IP rotors.
(6) The HP compressor is a centrifugal compressor made from forged and machined titanium. It is
attached to the HP shaft and is powered by a single HP turbine. The HP compressor, along
with the diffuser, increase the pressure of the incoming axial compressor air before combustion.
The compressor is pressed onto the HP shaft and is secured by the installation of the fuel
slinger/seal assembly, HP turbine, and the rear HP nut. These parts are locked together by
curvic couplings on the rear of the HP compressor, front and back of the fuel slinger/seal, and
the front of the HP turbine disc.
(7) The diffuser case assembly is made from inconel 718. The diffuser forward flange bolts to
the interstage housing. The rear flange is the single mounting point for all the hot section
components. In addition to directing HP compressor air flow, the diffuser also houses the fuel
supply tube and fuel manifold which supplies fuel to the fuel slinger/seal assembly. The diffuser
also has two pads on its OD which allow extraction of compressor discharge pressure (CDP)
and HP bleed. The diffuser also contains ports for the igniter plugs and fuel delivery
3. Operation
SUBTASK 72-00-00-860-003
A. The rotation of the compressor and turbine assemblies moves air into the engine. The diameter of
the compressors and stators narrows from front to rear. This increases the pressure and velocity of
the airflow.
B. The airflow goes from the fan (LP compressor) to the IP compressor. The splitter fairing, which is
part of the IP stator, divides the airflow into core air and bypass air. Core air is routed to the HP
compressor and then into the diffuser. The diffused air then enters the combustor section where it is
mixed with fuel and burned. Bypass air is ducted around the core and mixes with the exhaust.
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C. The LP turbines drive the fan and IP compressors. The HP turbine drives the HP compressor.
The LP shaft passes through the HP shaft and connects the LP turbines with the fan and IP
compressor. The HP shaft connects the HP turbine with the HP compressor. Both shafts rotate in
the same direction but not at the same speed. The HP shaft speed is slightly more than twice as
fast as the LP shaft speed.
4. General
The gearbox assembly supplies shaft power and mounting for the engine accessories. It is bolted to the
interstage housing and is located at the bottom of the engine. Refer to the following illustration(s):
Figure 2 Gearbox - Accessory Mounting Pads
Figure 3 Gearbox - Drive Train
5. Description
SUBTASK 72-00-00-860-002
A. The gearbox assembly connects to the interstage housing and is driven off the HP shaft by an
accessory drive shaft. The gearbox provides rotational power to four mount pads for accessories.
These accessories are the starter/generator, the fuel pump, the lube and scavenge pump, and the
hydraulic pump. The shaft drives are oil-wetted. Magnetic/spring loaded carbon seals are provided at
each mount pad except the lube and scavenge pump mount pad. The lube and scavenge pump
mount pad uses internal passages to transfer oil to and from the gearbox assembly.
The starter/generator pad is on the forward end of the gearbox. The oil pump pad is directly aft of
the starter/generator pad. Drive for the starter/generator and oil pump is provided by the same
drive gear. Next to the oil pad is the fuel pump pad. The fuel control is mounted on the back end
of the fuel pump and is driven by the fuel pump drive shaft. The hydraulic pad is also forward and
adjacent to the starter/generator pad.
6. Operation
SUBTASK 72-00-00-860-003
A. The gearbox receives its rotational power from the HP shaft, via an accessory drive shaft. Two
reduction bevel gears, one at the top and one at the bottom of the accessory drive shaft, reduce
the HP shaft rotational speed for accessory operation. The gearbox provides mounting and drive
provisions for the accessories. Oil wetted shafts provide lubrication for accessory shafts. The
gearbox provides internal passages for the engine oil system.
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7. General
The gearbox assembly supplies shaft power and mounting for the engine accessories. It is bolted to the
interstage housing and is located at the bottom of the engine. Refer to the following illustration(s):
Figure 4 Gearbox - Accessory Mounting Pads
Figure 3 Gearbox - Drive Train
8. Description
SUBTASK 72-00-00-860-002
A. The gearbox assembly connects to the interstage housing and is driven off the HP shaft by an
accessory drive shaft. The gearbox provides rotational power to four mount pads for accessories.
These accessories are the starter/generator, fuel control unit (IFCU or FDU), the lube and scavenge
pump, and the hydraulic pump. The shaft drives are oil-wetted. Carbon seals are provided at each
mount pad except the lube and scavenge pump mount pad. The lube and scavenge pump mount
pad uses internal passages to transfer oil to and from the gearbox assembly.
The starter/generator pad is on the forward end of the gearbox. The lube and scavenge pump pad is
directly aft of the starter/generator pad. Drive for the starter/generator and lube and scavenge pump
is provided by the same drive gear. Next to the oil pad is the fuel control unit pad. The hydraulic
pad is also forward and adjacent to the starter/generator pad.
9. Operation
SUBTASK 72-00-00-860-003
A. The gearbox receives its rotational power from the HP shaft, via an accessory drive shaft. Two
reduction bevel gears, one at the top and one at the bottom of the accessory drive shaft, reduce
the HP shaft rotational speed for accessory operation. The gearbox provides mounting and drive
provisions for the accessories. Oil wetted shafts provide lubrication for accessory shafts. The
gearbox provides internal passages for the engine oil system.
10. General
The bypass duct group includes the front bypass duct assembly, the rear bypass duct assembly, and their
related parts. The function of the bypass duct group is to route a part of the air received from the fan
around the core and into the exhaust. The engine air bypass-to-core ratio is 3.31 : 1. The bypass flow
allows operation of high core temperatures and pressure, while decreasing the velocity and temperatures
of the engine exhaust. Refer to the following illustration(s):
Figure 5 Bypass Duct Group
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11. Description
SUBTASK 72-00-00-860-002
A. The front bypass duct assembly is made from sheet aluminum that is formed and seam welded.
Access holes for ITT probes are provided toward the aft flange. Spacers, retainers, plates, and
retaining rings are used to seal the thermocouple bosses. The front duct also houses the service
adapters which supply access ports for fuel, HP bleed air, CDP air, and igniter plugs. A boss is
provided on the front duct for mounting of the fuel nozzle. Fuel drain ports are located at the
bottom of the duct.
B. The rear bypass duct assembly is also made from sheet aluminum that is formed and seam welded.
It also has a fuel drain port located on the bottom side of the duct. The rear duct contains a trip lever
housing and cable attachment as part of the LP trip system that shuts down the engine if the shaft
separates. The rear duct also includes a bracket for external mounting of the start nozzle control
valve. On some engines, a fan bleed port is also provided.
C. The rear mount ring is mounted between the front and rear bypass duct. The rear mount ball socket
changes location depending on which side of the aircraft the engine is mounted on.
12. General
The bypass duct group includes the front bypass duct assembly, the rear bypass duct assembly, and their
related parts. The function of the bypass duct group is to route a part of the air received from the fan around
the core and into the exhaust. The bypass flow allows operation of high core temperatures and pressure,
while decreasing the velocity and temperatures of the engine exhaust. Refer to the following illustration(s):
Figure 6 Bypass Duct Group
13. Description
SUBTASK 72-00-00-860-050
A. The front bypass duct assembly is made from sheet aluminum that is formed and seam welded.
Access holes for ITT probes are provided toward the aft flange. Spacers, retainers, plates,
and retaining rings are used to seal the thermocouple bosses. The front duct also houses the
removable service adapters which supply access ports for fuel, HP bleed air, and igniter plugs. A
boss is provided on the front duct for mounting of the fuel nozzle. Fuel drain ports are located
at the bottom of the duct.
B. The rear bypass duct assembly is also made from sheet aluminum that is formed and seam welded.
It also has a fuel drain port located on the bottom side of the duct. The rear duct contains a trip lever
housing and cable attachment as part of the LP trip system that shuts down the engine if the shaft
separates. The rear duct also includes a bracket for external mounting of the start nozzle control
valve. On some engines, a fan bleed port is also provided.
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C. The rear mount ring is mounted between the front and rear bypass duct. The rear mount ball socket
changes location depending on which side of the aircraft the engine is mounted on.
14. General
These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:
15. Description
SUBTASK 72-00-00-860-005
Spinner
Case assembly
(1) The spinner bolts onto the front of the fan rotor. The spinner shape provides a smooth airflow
into the engine. The sharp point prevents accumulation of ice.
(2) The fan rotor (LP axial compressor) is a 16 blade titanium blisk (blades and disc are integral).
The fan is attached to the LP shaft with one nut. The fan is splined but there is no master
keyway to clock the position.
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(3) The fan stator is located directly behind the fan rotor. The stator is keyed into the fan case
assembly. It contains 41 vanes set in an aluminum case and secured and damped with
polyurethane. The ID seal on the rear side seals with the IP compressor.
(4) The IP compressor rotor is a three stage axial compressor. It consists of three titanium blisks
welded together to form an integral assembly. The IP compressor is installed on the LP shaft
and is secured by the installation of the fan and front LP retaining nut.
(5) The IP stator is comprised of three stages. The 1st and 2nd IP stator stages are integral to the
IP compressor case and forged and machined inconel 718. This stator and case assembly is
divided into three equal circumferential segments that are bolted together to form the complete
assembly. The 3rd stator is a one piece assembly made from forged and machined inconel 718.
All three stages are bolted together to the interstage housing. The IP stator assembly is covered
by an aerodynamic splitter fairing that divides the fan air flow into core and bypass air flows.
(6) The HP compressor is a centrifugal compressor made from forged and machined titanium. It is
attached to the HP shaft and is powered by a single HP turbine. The HP compressor, along
with the diffuser, increase the pressure of the incoming axial compressor air before combustion.
The compressor is pressed onto the HP shaft and is secured by the installation of the fuel
slinger/seal assembly, HP turbine, and the rear HP nut. These parts are locked together by
curvic couplings on the rear of the HP compressor, front and back of the fuel slinger/seal, and
the front of the HP turbine disc.
(7) The diffuser case assembly is made from inconel 718. The diffuser forward flange bolts to
the interstage housing. The rear flange is the single mounting point for all the hot section
components. In addition to directing HP compressor air flow, the diffuser also houses the fuel
supply tube and fuel manifold which supplies fuel to the fuel slinger/seal assembly. The diffuser
also has two pads on its OD which allow extraction of compressor discharge pressure (CDP)
and HP bleed. The diffuser also contains ports for the igniter plugs and fuel delivery
16. Operation
SUBTASK 72-00-00-860-006
A. The rotation of the compressor and turbine assemblies moves air into the engine. The diameter of
the compressors and stators narrows from front to rear. This increases the pressure and velocity of
the airflow.
B. The airflow goes from the fan (LP compressor) to the IP compressor. The splitter fairing, which is
part of the IP stator, divides the airflow into core air and bypass air. Core air is routed to the HP
compressor and then into the diffuser. The diffused air then enters the combustor section where it is
mixed with fuel and burned. Bypass air is ducted around the core and mixes with the exhaust.
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C. The LP turbines drive the fan and IP compressors. The HP turbine drives the HP compressor.
The LP shaft passes through the HP shaft and connects the LP turbines with the fan and IP
compressor. The HP shaft connects the HP turbine with the HP compressor. Both shafts rotate in
the same direction but not at the same speed. The HP shaft speed is slightly more than twice as
fast as the LP shaft speed.
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1. General
This task lists approved fuels and additives for the engine. It is the responsibility of the operator to
ensure that all fuel delivered to the engine meets the requirements of the approved fuel specifications in
all respects.
2. Approved Fuels
SUBTASK 72-00-01-610-008
A. The fuel specifications and additives listed below are based on the results of engine testing. The
fuels and additives listed as approved are not necessarily approved for use in the aircraft. Refer to
the aircraft Operating Instructions.
Grade (type) Specification
Jet A NOTE 1 ASTM-D1655
Jet A1 NOTE 1 ASTM-D1655
JP-5 NOTE 1 MIL-T-5624
JP-8 NOTE 1 MIL-T-83133
Chinese #3 Jet Fuel NOTE 1 & 5 GB 6537-94
TS-1 NOTE 2 C.I.S. GOST # 10227
RT NOTE 2 C.I.S. GOST # 10227
Aviation Gasoline NOTES 3 & 4 ASTM D910 Grade
(Limited Use Only) 100LL
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2 Fluid I (C.I.S. GOST 8313) or Fluid IM (C.I.S. TU-6-10-1458) fuel system icing
inhibitor is required in amounts between 0.1% and 0.3% by volume.
3 Record in engine logbook total amount of run time with aviation gasoline.
If aviation gasoline is used for over 50 hours, the engine(s) must go
through a major periodic inspection.
3. Mixing of Fuels.
SUBTASK 72-00-01-610-009
EFFECTIVITY: FJ44-2A
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TASK 72-00-03-610-801 Service the Engine Using Dipstick Oil Fill Port
1. General
This task contains procedures for checking the oil level, draining, and filling the engine with oil via the
dipstick oil fill port. Do this task as required by scheduled maintenance checks. Refer to the following
illustration(s):
Figure 301 Oil Servicing - Dipstick
Figure 302 Oil Servicing - Oil Drain Fitting
Figure 303 Oil Servicing - Chip Collector Drains
CAUTIONS: 1 DO NOT LET OIL FALL ONTO ENGINE PARTS WHICH ARE NOT USUALLY
IN TOUCH WITH OIL. RUB OFF ANY OIL WHICH FALLS ONTO THE ENGINE.
THE OIL CAN DAMAGE PAINTWORK AND RUBBER PARTS.
SUBTASK 72-00-03-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-071 Cloth, Lint Free
SUBTASK 72-00-03-943-001
B. Special Tools
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Reference Designation
TL37255 Fitting, Oil Drain
SUBTASK 72-00-03-944-001
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-30-01 1 25 O-ring (2)
79-30-01 1 30 O-ring (2)
SUBTASK 72-00-03-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
79-30-01 401 Magnetic Chip Collector - Removal/Installation
3. Job Set-up
SUBTASK 72-00-03-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-00-03-610-001
NOTES: 1 If BP 2380, Exxon 2380, or Mobil Jet II are being drained, Williams International
recommends that only Mobil Jet II is used for servicing. Mobil 254 may be used for
servicing only if Mobil 254 has been used as the replenishing (topping-off) oil for at least
the last 150 flight hours or if Mobil 254 was used for servicing at the last oil change.
A. Drain engine oil (if required) using TL37255 oil drain fitting
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(2) Remove the self-closing plug from the bottom rear of the lube pump (port labeled TANK DRAIN).
(3) Install oil drain fitting, TL37255, to self-closing fitting and drain oil tank oil into a suitable
container.
(4) Lubricate new O-ring with engine oil (MAT-001) and install on self-closing plug.
(6) Remove the self-closing plug from the bottom of the gearbox.
(7) Install oil drain fitting, TL37255, to self-closing fitting and drain gearbox oil into a suitable
container.
(8) Lubricate new O-ring with engine oil and install on self-closing plug.
B. You may also drain engine oil (if required) by removing the gearbox and the lube and scavenge pump
(TANK DRAIN) chip collector fittings. Refer to 79-30-01, P.B. 401.
SUBTASK 72-00-03-610-002
(1) (FJ44-2A Only) Actuate low oil level sensor (if engine is so equipped) in accordance with aircraft
flight manual. If low oil is indicated, check oil with dipstick and service oil system, as required.
(2) Check the oil sight glass (if engine is so equipped), or insert and remove the (oil fill cap)
dipstick from the fill port.
(3) Wipe the oil from the dipstick using a clean, lint-free cloth (MAT-071). Install the dipstick and
then remove it to get an accurate reading of the oil level on the dipstick.
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NOTE Filling the oil tank above the FULL mark on the dipstick or the sight glass will
not harm the engine, but will ultimately result in overflow from the fill port.
(4) You must add oil (MAT-001) if level is at or below the ADD mark on the dipstick or the sight
glass. To avoid overfilling, add oil in increments and check the level after each addition.
NOTE If it appears that the oil is over-full or there is more oil registering than
has been added, smell the oil to detect the possible presence of fuel.
If you smell fuel in the oil, reject the engine.
(5) Inspect the dipstick O-ring for damage and replace, if required. To avoid binding, rotate
dipstick on filler port plug so offset bend faces aft of engine. Install dipstick in fill port and
secure by turning and folding down lever against base portion of cap to lock.
SUBTASK 72-00-03-610-010
SUBTASK 72-00-03-610-005
NOTE Mobil 254 may be used for servicing only if Mobil 254 has been used as the
replenishing (topping-off) oil for at least the last 150 flight hours or if Mobil
254 was used for servicing at the last oil change.
(1) Make sure that magnetic chip collector fittings are properly installed. Refer to 79-30-01,
P.B. 401.
(2) Fill the tank with oil (approximately 3.7 quarts [3.5 liters]).
(3) To avoid binding, rotate the dipstick on the filler port plug so the offset bend faces aft of the
engine. Install the dipstick in the fill port and secure by turning and folding down the lever
against the base portion of the cap to lock. Motor the engine to approximately 14% N2 rpm for
positive oil pressure indication. Refer to 71-00-00, P.B. 501 Engine Operating Instructions.
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(4) When N2 rpm decreases to "0", remove the dipstick and wipe it with a clean, lint-free cloth.
Reinstall and remove it to get an accurate reading of the oil level. If required, add oil to bring
the level up to the FULL mark on the dipstick or sight glass. To avoid overfilling, add oil in
increments and check the level after each addition.
(5) Inspect the dipstick O-ring for damage and replace, if required. To avoid binding, rotate the
dipstick on the filler port plug so the offset bend faces aft of the engine. Install the dipstick
in the fill port and secure by turning and folding down the lever against the base portion
of the cap to lock.
(6) Record amount and type of oil added in the engine logbook.
SUBTASK 72-00-03-610-007
5. Job Close-up
SUBTASK 72-00-03-410-001
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Fig. 303 Oil Servicing - Chip Collector Drains Apr 11/08
1. General
This task contains procedures for changing the oil filter and submitting it to be analyzed as part of the oil
filter analysis program. This program provides the operator and maintenance personnel with valuable
information about engine health. Do this task as directed by periodic maintenance checks or other
maintenance procedures.
SUBTASK 72-00-05-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
NOTE The following is a listing of oil filter analysis kit part numbers:
The oil filter analysis kit sold by Jet-Care International contains a new oil filter/O-rings
and sample bottles.
SUBTASK 72-00-05-944-001
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-21-01 01 20 O-Ring
79-21-01 01 30 Filter, Oil-Disposable
79-21-01 01 40 O-Ring
SUBTASK 72-00-05-945-001
C. Reference Information
EFFECTIVITY: FJ44-2A
72-00-05
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3. Job Set-up
SUBTASK 72-00-05-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-00-05-020-001
A. Remove the oil filter and place it in the container provided with the oil filter analysis kit. Install
a new oil filter. Refer to 79-21-01, P.B. 401.
SUBTASK 72-00-05-510-001
(6) Time (engine operating hours) since last filter sample submitted
(8) Time (engine operating hours) since the last oil filter change
(9) Amount of oil added since the last filter sample submitted
SUBTASK 72-00-05-610-001
C. Service the engine with oil (MAT-001). Refer to 72-00-03, P.B. 301.
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SUBTASK 72-00-05-510-002
5. Job Close-up
SUBTASK 72-00-05-410-001
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72-00-05
204
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LINE MAINTENANCE MANUAL FJ44-2A
SPINNER - REMOVAL/INSTALLATION
1. General
This task covers removal of the spinner from the engine. Refer to the following illustration(s):
Figure 401 Spinner - Removal/Installation
NOTE The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-30-942-001
A. Consumables
Reference Designation
MAT-032 Marker, Broad Line
MAT-033 Marker, Fine Line
SUBTASK 72-00-30-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
3. Job Set-up
SUBTASK 72-00-30-010-001
(2) Open the circuit breakers to isolate the engine electrical system.
4. Procedures
SUBTASK 72-00-30-020-001
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(1) Using MAT-033 or equivalent MAT-032 marker, alignment match-mark the spinner and fan rotor
as a baseline. Put the match mark in line with one of the spinner mount bolts.
(2) Remove six bolts (1-20) and six washers (1-30) which attach the spinner (1-10) to the engine.
(3) After removal of spinner, make an alignment mark on the pilot plate, locking plate, and LP shaft
in-line with the mark on the fan. Use MAT-033 marker (or equivalent).
5. General
This task covers installation of the spinner. Refer to the following illustration(s):
Figure 401 Spinner - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
720030, Fig. 01
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 72-00-30-942-002
A. Consumables
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Reference Designation
MAT-001 Oil, Engine
SUBTASK 72-00-30-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
7. Procedures
SUBTASK 72-00-30-420-001
A. Install Spinner
NOTE The pilot area of the spinner touches the spinner pilot plate
assembly and the fan locking plate when installed. There will be a
gap between the spinner and the fan.
(1) Inspect the pilot area of the spinner for burrs. Remove any burrs in accordance with standard
practices. Refer to 70-42-11, P.B. 801.
(2) Make sure that the LP nut locking plate (1-30, 72-00-31) is installed on the front LP nut and
that all six pilot plate bolt holes are visible.
NOTE Make sure that there is an alignment mark on the spinner. Refer
to spinner removal task.
(3) Insert one bolt (1-20) and washer (1-30) through the spinner and align the spinner with the
spinner pilot plate and with alignment marks made at removal. Install the bolt into one of the
six pilot plate holes, finger tight.
(6) Check for gap between spinner and fan. Gap should be 0.002 inch (0.050 mm).
EFFECTIVITY: FJ44-2A
72-00-30
Page 403
Apr 11/08
8. Job Close-up
SUBTASK 72-00-30-410-002
EFFECTIVITY: FJ44-2A
72-00-30
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-30
Page 405
Apr 11/08
72-00-30
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers removal of the fan rotor from the engine. Refer to the following illustrations:
Figure 401 Fan - Stretch Dimension
Figure 402 Fan - Shaft Stretch Tool
Figure 403 Fan - Pilot Plate Removal
Figure 404 Fan - Removal
NOTE The part callouts in parentheses in the text correspond to the figure-item numbers
used in the illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-31-941-002
A. Standard Equipment
Depth Micrometer
SUBTASK 72-00-31-942-002
B. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 72-00-31-943-002
C. Special Tools
Reference Designation
TL37102 Tool, Shaft Stretch
TL99500 Spanner Tool, LP Shaft Forward Nut
TL99501 Puller Assembly, Spinner Pilot Plate
TL99502 Puller Assembly, Fan
SUBTASK 72-00-31-945-002
D. Reference Information
EFFECTIVITY: FJ44-2A
72-00-31
Page 401
Apr 11/08
3. Job Set-up
SUBTASK 72-00-31-870-002
A. Update life history records for the removed component in the engine log book.
SUBTASK 72-00-31-020-003
4. Procedures
SUBTASK 72-00-31-020-004
(a) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly. Refer to Figure 401 Fan - Stretch Dimension.
(3) Remove the fan retainer nut (1-20) using TL37102 shaft stretch tool as follows (Figure 402
Fan - Shaft Stretch Tool):
(a) Install the TL37102-12 LP shaft adapter on the TL37102-11 rod so that the large threaded
ID of the adapter is located on the end of the rod.
(b) Lubricate threads with MAT-001engine oil and install the rod/adapter to the front of the LP
shaft. After the adapter is hand tight on the LP shaft, back-off one turn.
(d) Install the TL37102-7 hydraulic cylinder over the rod with the piston side facing forward.
(e) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
EFFECTIVITY: FJ44-2A
72-00-31
Page 402
Apr 11/08
(g) Have one person operate the TL37102-19 hydraulic hand pump until the gage indicates
7100 psig and the fan retainer nut can be loosened by rotating it with TL99500 spanner
tool. If nut does not become loose at 7100 psig:
2 Using TL99500, check for nut counterclockwise rotation after each increase in
pressure.
(4) Using a depth micrometer, measure from the front face of the LP shaft to the forward face of
the pilot plate assembly.
(6) Install TL99501 on the pilot plate assembly. Align the puller jaws with the solid portions of the
pilot plate (not the scallops). Remove the pilot plate from the LP shaft. Refer to Figure 403
Fan - Pilot Plate Removal.
(7) Install TL99502 puller on the fan and remove the fan from the LP shaft. Refer to Figure
404 Fan - Removal.
5. General
This task covers installation of the fan rotor on the engine. Refer to the following illustrations:
Figure 402 Fan - Shaft Stretch Tool
Figure 401 Fan - Stretch Dimension
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-31, Fig. 01
EFFECTIVITY: FJ44-2A
72-00-31
Page 403
Apr 11/08
NOTE The part callouts in parentheses in the text correspond to the figure-item numbers
used in the illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-31-941-004
A. Standard Equipment
Depth Micrometer
SUBTASK 72-00-31-942-004
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-013 Magnesium Hydroxide
MAT-017 Lubricant, Rapid GT
SUBTASK 72-00-31-943-004
C. Special Tools
Reference Designation
TL37102 Tool, Shaft Stretch
TL99500 Spanner Tool, LP Shaft Forward Nut
SUBTASK 72-00-31-945-004
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
EFFECTIVITY: FJ44-2A
72-00-31
Page 404
Apr 11/08
7. Job Set-up
SUBTASK 72-00-31-870-005
8. Procedures
SUBTASK 72-00-31-420-005
(1) Install the fan rotor (1-10) on the LP shaft against the IP compressor rotor. Align marks on fan
rotor and LP shaft made at removal.
(2) Install the pilot plate assembly (1-40) with the thick flange against the fan. Make sure that the
locating pin is aligned with the hole in the fan flange.
NOTE You must seat the fan rotor on the LP shaft using TL37102 shaft
stretch tool before installing the LP nut.
(3) Seat the fan rotor using TL37102 shaft stretch tool as follows (Figure 402 Fan - Shaft Stretch
Tool).:
(a) Install the TL37102-12 LP shaft adapter on the TL37102-11 rod so that the large threaded
ID of the adapter is located on the end of the rod.
(b) Lubricate threads with engine oil and install the rod/adapter to the front of the LP shaft.
After the adapter is hand tight on the LP shaft, back-off one turn.
(d) Install the TL37102-7 hydraulic cylinder over the rod with the piston side facing forward.
(e) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
(g) Operate the TL37102-19 hydraulic hand pump until the gauge indicates 7100 psi. This
seats the fan rotor on the LP shaft.
SUBTASK 72-00-31-220-003
EFFECTIVITY: FJ44-2A
72-00-31
Page 405
Apr 11/08
(1) Using a depth micrometer, measure from the front face of the LP shaft to the forward face of
the pilot plate assembly. Refer to Figure 401 Fan - Stretch Dimension.
SUBTASK 72-00-31-420-006
(1) Lubricate the face and threads of the fan retainer nut (1-20) and LP shaft with Rapid GT
lubricant (MAT-017, preferred) or magnesium hydroxide (MAT-013) and install it on LP shaft,
hand tight.
(2) Tighten fan retainer nut using TL37102 shaft stretch tool as follows:
(a) Lubricate threads with engine oil (MAT-001) and install the TL37102 rod/adapter to the
front of the LP shaft. After the adapter is hand tight on the LP shaft, back-off two turns.
(c) Install the TL37102-7 hydraulic cylinder over the rod with the piston side facing forward.
(d) Install the TL37102-13 nut on the rod. After nut is hand tight, back-off 1/2 turn.
(f) Have one person operate the TL37012-19 hydraulic hand pump until the gage indicates
7100 psi. Tighten the fan retainer nut by turning it with TL99500 until finger tight.
(h) To make sure parts are seated properly, operate hand pump again and make sure that
nut is able to be loosened (by hand) at 7100 psi (50 psi). Tighten nut. If gage reading is
above or below limit, remove fan and reinstall until you get a proper reading.
(i) Remove all details of TL37102.
SUBTASK 72-00-31-220-004
(1) Using a depth micrometer, measure from the front face of the LP shaft to the forward face of
the pilot plate assembly.
EFFECTIVITY: FJ44-2A
72-00-31
Page 406
Apr 11/08
(3) Subtract unstretched dimension from stretched dimension to determine shaft stretch. Shaft
stretch must be 0.018 - 0.022 inch (0.457 - 0.558 mm).
9. Job Close-up
SUBTASK 72-00-31-420-007
SUBTASK 72-00-31-420-008
SUBTASK 72-00-31-410-004
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
SUBTASK 72-00-31-760-002
D. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
72-00-31
Page 407
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-31
Page 408
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-31
Page 409
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-31
Page 410
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-31
Page 411
Apr 11/08
72-00-31
412
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers removal of the case and insert and fan stator from the engine. Refer to the following
illustration(s):
Figure 401 Case and Insert Assembly - Removal/Installation
NOTE The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-32-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-32-10 801 Case and Insert Assembly - Repair
74-10-01 401 Igniton Exciter - Removal/Installation
3. Job Set-up
SUBTASK 72-00-32-010-002
(2) Open the circuit breakers to isolate the engine electrical system.
SUBTASK 72-00-32-020-005
SUBTASK 72-00-32-020-006
C. Remove the fan rotor (1-10, 72-00-31). Refer to 72-00-31, P.B. 401.
EFFECTIVITY: FJ44-2A
72-00-32
Page 401
Apr 11/08
SUBTASK 72-00-32-020-007
D. Remove the ignition exciter(s) (1-10, 74-10-01). Refer to 74-10-01, P.B. 401 in the Maintenance
Manual.
4. Procedures
SUBTASK 72-00-32-020-008
(1) Remove 33 nuts (1-60), 33 bolts (1-30 and 1-40), and 60 washers (1-50) from the inlet flange.
Remove the harness clamps, lifting bracket, the oil supply tube clamp bracket, and the forward
ignition exciter bracket from flange.
CAUTION FAN STATOR VANE MAY BE LOOSE AND MAY FALL OUT OF INLET
CASE DURING REMOVAL. USE CARE TO PREVENT DAMAGE.
(2) Carefully remove the case and insert assembly (1-10) from the interstage housing.
(3) Separate the fan stator vane assembly (1-20) by removing it from the aft side of the case
and insert assembly.
(4) Cover front of the interstage housing to prevent dirt from entering the engine.
NOTE If case and insert assembly is to be rejected from the engine, remove the
engine identification plate and transfer it to the new case and insert assembly.
Refer to 72-32-10, P.B. 801, Repair in the Maintenance Manual.
5. General
This task covers installation of the fan stator in the case and insert assembly, and installation of the case
and insert assembly in the engine. Refer to the following illustrations:
Figure 401 Case and Insert Assembly - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-32, Fig. 01
EFFECTIVITY: FJ44-2A
72-00-32
Page 402
Apr 11/08
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 72-00-32-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-009 Petrolatum
SUBTASK 72-00-32-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-32-10 801 Case and Insert Assembly - Repair
74-10-01 401 Igniton Exciter - Removal/Installation
7. Procedures
SUBTASK 72-00-32-420-005
(1) Make sure that the fan stator is correctly installed in the case and insert assembly. Follow the
installation procedure below, depending on the configuration:
EFFECTIVITY: FJ44-2A
72-00-32
Page 403
Apr 11/08
(a) For PN 65788 fan stator vane assembly: Align the wider non-grooved area (on fan stator
OD) with the area (on case and insert ID) where there is a wider gap between the locating
keys. Note that all aluminum key inserts will engage the fan case keys.
(b) For PN 59508 fan stator vane assembly: Note the tooling hole through the fan stator
outer shroud will vary from engine to engine and may be in any orientation for installation.
(2) Apply a thin layer of petrolatum MAT-009 to the shroud for the IP forward labyrinth seal on the
ID of the fan stator. Wipe excess lubricant from the edges of the seal.
(3) Hold stator in place and align and install the case and insert assembly on the interstage housing.
(4) Install the lifting bracket at the forward, 12:00 oclock position on the flange. Secure with three
bolts (1-30), three washers (1-50), and three nuts (1-60).
Harness clamps
(6) Install the oil supply tube clamp bracket (1-70, 79-26-01) on the aft side of the flange. Secure
with one bolt (1-30), one washer (1-50), and one nut (1-60).
8. Job Close-up
SUBTASK 72-00-32-420-006
SUBTASK 72-00-32-420-007
SUBTASK 72-00-32-420-008
SUBTASK 72-00-32-410-004
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
EFFECTIVITY: FJ44-2A
72-00-32
Page 404
Apr 11/08
SUBTASK 72-00-32-760-002
E. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
72-00-32
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-32
Page 406
Apr 11/08
1. General
This task covers removal of the gearbox assembly from the engine. Removal procedures for
gearbox-mounted accessory items are referenced to the appropriate Maintenance Manual page block.
Refer to the following illustration(s):
Figure 401 Gearbox - Removal/Installation
Figure 402 Gearbox - Breather Tube Torque Adapter
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-60-943-001
A. Special Tools
Reference Designation
TL37255 Fitting, Oil Drain
TL37270 Torque Adapter, 3/8"
SUBTASK 72-00-60-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
79-21-01 401 Oil Filter - Removal/Installation
79-22-01 401 Lube Oil Cooler - Removal/Installation
79-24-01 401 Lube and Scavenge Pump - Removal/Installation
EFFECTIVITY: FJ44-2A
72-00-60
Page 401
Apr 11/08
3. Job Set-up
SUBTASK 72-00-60-010-001
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the cowling.
SUBTASK 72-00-60-020-001
(1) Drain oil from the engine using TL37255, oil drain fitting. Refer to 72-00-03, P.B. 301 in
the Maintenance Manual.
(2) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(3) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(4) Remove the gearbox magnetic speed pickup. Refer to 77-12-01, P.B. 401 in the Maintenance
Manual.
(5) Remove the fuel control unit/fuel delivery unit. Refer to 73-21-01, P. B. 401 in the Maintenance
Manual.
(6) Remove the fuel pump from the gearbox, if applicable. Refer to 73-16-01, P.B. 401 in the
Maintenance Manual.
(7) Remove the lube oil cooler from the gearbox. Refer to 79-22-01, P.B. 401 in the Maintenance
Manual.
(8) Remove the lube and scavenge pump from the gearbox. Refer to 79-24-01, P.B. 401 in
the Maintenance Manual.
(9) Remove the oil filter from the gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.
4. Procedures
SUBTASK 72-00-60-020-002
(1) If applicable, disconnect gearbox breather tube discharge plumbing. Refer to the Aircraft
Maintenance Manual.
(2) Remove bolt (1-150) and nut (1-160) which secures breather tube loop clamp (1-170) to
bracket (1-140).
EFFECTIVITY: FJ44-2A
72-00-60
Page 402
Apr 11/08
(3) If applicable, remove screw (1-220) from bracket (1-210) which secures the elbow (1-200) in
the service island. Remove O-ring (1-215) from elbow.
(4) Remove two bolts (1-110) and two washers (1-120) which attach breather tube assembly (1-90)
flange and O-ring (1-130) to gearbox. Use TL37270, as required.
(5) Remove four nuts (1-40), four washers (1-50), two bolts (1-20), and two washers (1-30) which
attach the gearbox to the engine.
(6) Carefully remove the gearbox (1-10), gearbox gasket (1-60) and the accessory drive shaft
(1-70) from the engine.
NOTE Check the accessory drive shaft for wear or damage. If worn or damaged
contact WI Product Support for inspection criteria.
5. General
This task covers installation of the gearbox assembly. Installation procedures for gearbox-mounted
accessory items are referenced to the appropriate Maintenance Manual page block. Refer to the following
illustration(s):
Figure 401 Gearbox - Removal/Installation
Figure 402 Gearbox - Breather Tube Torque Adapter
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-60, Fig. 01
EFFECTIVITY: FJ44-2A
72-00-60
Page 403
Apr 11/08
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
2 During installation, make sure all parts are clean and free from burrs or high metal that
might cause misalignment, interference to mating flanges, or damage to O-rings.
3 Lubricate all threads and contact surfaces of nuts and bolts with clean engine oil
(MAT-001) before installation unless otherwise noted in text.
SUBTASK 72-00-60-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 72-00-60-943-002
B. Special Tools
Reference Designation
TL37270 Torque Adapter, 3/8"
TL99924 Torque Adapter
SUBTASK 72-00-60-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-00-60 01 260 O-ring
EFFECTIVITY: FJ44-2A
72-00-60
Page 404
Apr 11/08
SUBTASK 72-00-60-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
79-21-01 401 Oil Filter - Removal/Installation
79-22-01 401 Lube Oil Cooler - Removal/Installation
79-24-01 401 Lube and Scavenge Pump - Removal/Installation
7. Procedures
SUBTASK 72-00-60-420-001
(1) Make sure that mount pads on interstage housing and gearbox assembly are clean and dry.
(2) The gearbox mounting gasket (1-60) may be re-used if it passes the following criteria:
(a) No evidence of sealing material (rubber) delamination or pull-away from base metal
groove side walls permitted.
(b) Cracks, splits, or other defects which may affect sealing in the rubber component are
not permitted.
(c) Raised metal in the sealing surface areas not permitted. It is permitted to stone raised
metal and touch up anodize per 70-42-12, P.B. 801.
(d) Scratches or defects in the anodize coating may be repaired per 70-42-12, P.B. 801.
(e) Gearbox gasket must be replaced at the compressor zone inspection interval (Check 4).
(3) Install gearbox mounting gasket (1-60) (dry) on gearbox (1-10). Make sure oil passages
and bolt holes are aligned.
EFFECTIVITY: FJ44-2A
72-00-60
Page 405
Apr 11/08
NOTE Check the accessory drive shaft for wear or damage. If worn or damaged
contact WI Product Support for inspection criteria.
(4) Install the accessory drive shaft (1-70) into the gearbox assembly and engage it with reduction
gear.
(5) Align bolt holes and install the gearbox assembly on the interstage housing. Make sure that the
accessory drive shaft engages with the reduction bevel gear in the interstage housing. Attach
gearbox with four washers (1-50), four nuts (1-40), two washers (1-30) and two bolts (1-20).
(6) Torque nuts (1-40) 110 to 123 inch-pounds (12.4 to 13.8 N.m). Use TL99924 torque adapter as
required.
(a) For magnetic carbon seal gearbox configuration, lubricate a new O-ring (1-130) with
assembly fluid (MAT-011) and install on breather tube (1-80) flange.
(b) For spring-loaded carbon seal gearbox configuration, lubricate a new O-ring (1130) with
assembly fluid and install on OD of the installed carbon seal assembly.
(9) Carefully position the breather tube flange on the gearbox housing.
(10) Install two bolts (1-110) and washers (1-120) to attach breather tube (1-80) flange to gearbox.
If fuel pump is installed, use TL37270 torque adapter. Torque screws 49 to 55 inch-pounds
(5.5 to 6.2 N.m).
(11) Install loop clamp to breather tube. Secure loop clamp bracket with one bolt and one nut.
Torque 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(12) Lubricate elbow O-ring with assembly fluid (MAT-011) and install on elbow. Secure breather
tube elbow in service island by attaching with a bracket and screw. Torque 25 to 28
inch-pounds (2.8 to 3.1 N.m).
(13) Connect the breather tube discharge plumbing to the breather tube, if applicable. Refer to
the Aircraft Maintenance Manual.
EFFECTIVITY: FJ44-2A
72-00-60
Page 406
Apr 11/08
8. Job Close-up
SUBTASK 72-00-60-420-002
(1) Install oil filter to gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.
(2) Install the hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
(3) Install the starter/generator to the gearbox. Refer to the Aircraft Maintenance Manual.
(4) Install the lube and scavenge pump to the gearbox. Refer to 79-24-01, P.B. 401 in the
Maintenance Manual.
(5) Install the fuel pump to the gearbox, if applicable. Refer to 73-16-01, P.B. 401 in the
Maintenance Manual.
(6) Install the fuel control unit/fuel delivery unit. Refer to 73-21-01, P.B. 401 in the Maintenance
Manual.
(7) Install the lube oil cooler to the gearbox. Refer to 79-22-01, P.B. 401 in the Maintenance
Manual.
(8) Install the gearbox magnetic speed pickup. Refer to 77-12-01, P.B. 401 in the Maintenance
Manual.
SUBTASK 72-00-60-610-001
B. Service the engine with oil. Refer to 72-00-03, P.B. 301 in the Maintenance Manual.
SUBTASK 72-00-60-410-002
(1) Refer to Aircraft Maintenance Manual (A.M.M.) and install the cowling.
SUBTASK 72-00-60-760-001
D. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
72-00-60
Page 407
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-60
Page 408
Apr 11/08
72-00-60
410
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers removal of the rear bypass duct assembly from the engine. Refer to the following
illustration(s):
Figure 401 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
Figure 402 Rear Bypass Duct - Removal/Installation
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-00-71-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 72-00-71-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and do the following:
EFFECTIVITY: FJ44-2A
72-00-71
Page 401
Apr 11/08
4. Procedures
SUBTASK 72-00-71-020-002
(1) Remove the two screws (280, 76-20-01) and the two washers (20, 76-20-01) which attach the
cover plate (290, 76-20-01) to the LP trip sensor housing. Remove the cover plate.
(2) Measure and record trigger pin end play. Refer to 76-20-01, P.B. 501 in the Maintenance
Manual.
(3) Remove two screws (1-270, 76-20-01), four washers (1-20, 76-20-01), and two nuts
(1-260, 76-20-01) which attach the cable actuator housing (1-240, 76-20-01) to the LP
trip sensor housing. Refer to Figure 401 Rear Bypass Duct - Cable Actuator Housing -
Removal/Installation.
(4) (FJ33 Only) Remove the trip sensor cable from the FDU support boss.
(5) Remove the cable actuator housing by sliding the housing straight forward. Wrap a protective
covering on the open end of the housing to prevent contamination and accidental actuation.
(7) While holding the LP trip lever (1-50, 76-20-01) (through the trip lever housing), push
adjustment spring (1-40, 76-20-01) located on rear housing forward to release the trip lever.
Remove the trip lever through the trip lever housing.
NOTE Trip lever adjustment spring and spring shaft are not normally
removed during engine disassembly.
(8) If trip lever adjustment spring or spring shaft require removal, remove from bracket on rear
case/mixer as follows:
(9) If required, remove drain fitting (160) and O-ring (150) from transfer tube adapter.
(10) Remove two screws (1-90), four washers (1-80), and two nuts (1-70) and remove the external
transfer tube adapter (1-140) from bottom of duct. Refer to Figure 402 Rear Bypass Duct -
Removal/Installation.
(11) Remove the transfer (drain) tube (1-110) from the boss in the duct by installing an 8-32 screw
into the tube end. Remove two O-rings (1-120 and 1-100) from the tube.
(12) Index mark front bypass duct, rear mount ring, and rear bypass duct and brackets for assembly
purposes.
EFFECTIVITY: FJ44-2A
72-00-71
Page 402
Apr 11/08
(13) If applicable, remove the rear mount sleeve (65) from the rear mount ring.
SUBTASK 72-00-71-020-003
(1) Remove 24 screws (1-40), 24 nuts (1-30), washers (1-20), and 10 brackets (1-50) securing the
rear bypass duct to the front bypass duct. Remove the rear bypass duct (1-10) from the engine.
5. General
This task covers installation of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 402 Rear Bypass Duct - Removal/Installation
Figure 401 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
Figure 403 Rear Bypass Duct - Apply RTV to Flanges
Figure 404 Rear Bypass Duct - ITT Bracket Locations
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
NOTES: 1 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
3 Lubricate all threads and contact surfaces of nuts and bolts with clean engine oil
(MAT-001) before installation unless otherwise noted in text.
SUBTASK 72-00-71-942-002
A. Consumables
EFFECTIVITY: FJ44-2A
72-00-71
Page 403
Apr 11/08
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-019 Acetone
MAT-027 Alcohol, Isopropyl
MAT-090 Sealant, RTV 106
MAT-093 Compound Retaining, 620
SUBTASK 72-00-71-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-00-71 01 100 O-ring
72-00-71 01 120 O-ring
72-00-71 01 130 O-ring
72-00-71 01 150 O-ring
76-20-01 01 230 Gasket, cable housing
SUBTASK 72-00-71-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
7. Procedures
SUBTASK 72-00-71-420-001
EFFECTIVITY: FJ44-2A
72-00-71
Page 404
Apr 11/08
(1) Clean the bottom 180 degrees of the flange area mating surfaces of the rear bypass duct,
mount ring, and front bypass duct. Use a cloth soaked with isopropyl alcohol (MAT-027) or
acetone (MAT-019).
(2) Apply RTV sealant MAT-090 to the bottom 180 degrees of the flange mating surfaces of the
rear bypass duct, mount ring, and front bypass duct. See Figure 403 Rear Bypass Duct
- Apply RTV to Flanges.
NOTE RTV sealant must also be applied to the rear flange of the rear
bypass duct and the tailpipe flange.
SUBTASK 72-00-71-420-004
(1) Install the rear mount ring (1-65). Make sure that the uniball mount is located on the inboard
side of the engine.
(2) Install the rear bypass duct assembly (1-10), aligning the index mark made during disassembly.
Attach with 24 screws (1-40), 24 nuts (1-30), 10 brackets (1-50), and 48 washers (1-20).
Torque nuts 25 to 28 inch-pounds. Refer to Figure 404 Rear Bypass Duct - ITT Bracket
Locations for ITT bracket locations.
SUBTASK 72-00-71-420-005
(1) Lube two O-rings (1-120 and 1-100) with assembly fluid (MAT-011) and install on transfer
tube (1-110). Install transfer tube into port. Refer to Figure 402 Rear Bypass Duct -
Removal/Installation.
EFFECTIVITY: FJ44-2A
72-00-71
Page 405
Apr 11/08
(2) Lube new O-ring (1-130) with assembly fluid and install on transfer tube adapter (1-140). Install
transfer tube adapter and attach with two screws (1-90), four washers (1-80), and two nuts
(1-70). Torque 18 to 20 inch-pounds (2.0 to 2.3 N.m)
(3) If drain fitting (160) was removed, lube new O-ring (150) with assembly fluid and install on fitting.
Install drain fitting into transfer tube adapter and torque 60 to 70 inch-pounds (6.8 to 7.9 N.m).
SUBTASK 72-00-71-420-007
D. Install the LP trip lever and related parts as follows (Figure 401 Rear Bypass Duct - Cable Actuator
Housing - Removal/Installation):
(a) Insert the trigger pin through the LP trip sensor housing bushing to check for free travel.
Insert both ends of the pin and slide it all the way to the adjustment screw. Reject trigger
pin if it binds. Remove trigger pin from bushing.
(b) If lever adjustment spring and shaft were removed from the rear case/mixer, install
them as follows:
1 Install the shaft (1-40, 76-20-01) and position on the forward side of the bracket
2 Coat the threads of the bolt (1-10) with retaining compound (MAT-093).
3 Install the washer (1-20) and spring (1-30) on the bolt. Install the bolt into the
shaft from the aft side of the bracket.
(c) Slide the trip lever assembly (1-50, 76-20-01) through the trip sensor housing and the
rear housing strut with the trip lever notch facing forward. Push the adjustment spring
(1-40, 76-20-01) (located on the rear housing) forward to allow trip lever to enter. Release
the adjustment spring when the trip lever notch is aligned with the slot in the adjustment
spring bolt. Move the lever axially to make sure that it does not bind.
(d) Insert the trigger pin (1-100, 76-20-01) through the bushing on the LP trip sensor housing
assembly (part of the rear bypass duct).
(e) Position the trip lever by pulling it radially outward until the pin contacts the top of the trip
lever cup. Look through the witness hole at the bottom of the lever cup to make sure
that the pin is seated properly.
(f) Check to make sure that the trip mechanism has not actuated by pushing on the inner
cable (1-250, 76-20-01) from the fuel control end. If the mechanism is set (not actuated)
the cable should not move.
(g) Adjust the LP trip lever/recalculate trigger pin length (76-20-01, P.B. 501 in the applicable
Maintenance Manual) if any of the following conditions apply:
EFFECTIVITY: FJ44-2A
72-00-71
Page 406
Apr 11/08
1 Trigger pin end play dimension was not acceptable before disassembly.
NOTE If the trigger pin was damaged or lost, the trigger pin dimension must
be recalculated. Refer to 76-20-01, P.B. 501. If trip mechanism was
actuated, mechanism must be reset. Refer to 76-20-01 P.B. 501.
E. Remove protective covering and install cable actuator housing (1-240, 76-20-01) and gasket (1-230,
76-20-01).
F. Attach the housing and gasket with two screws (1-270, 76-20-01), four washers (1-20, 76-20-01),
and two nuts (1-260, 76-20-01). Torque screws 25 to 28 inch-pounds (2.8 to 3.2 N.m) .
G. Install the cover plate (1-290, 76-20-01) to the LP trip sensor housing. Attach the cover plate with
two screws (1-280, 76-20-01) and washers (1-20, 76-20-01). Torque screws 25 to 28 inch-pounds
(2.8 to 3.2 N.m).
8. Job Close-up
SUBTASK 72-00-71-410-002
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and do the following:
NOTE RTV sealant (MAT-090) must be applied to the rear flange of the
rear bypass duct and the tailpipe flange.
SUBTASK 72-00-71-760-001
B. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
72-00-71
Page 407
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-71
Page 408
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-71
Page 409
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-71
Page 410
Apr 11/08
EFFECTIVITY: FJ44-2A
72-00-71
Page 411
Apr 11/08
72-00-71
412
Page
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LINE MAINTENANCE MANUAL FJ44-2A
TASK 72-02-00-860-801 Internal Cooling and Sealing Air System - Description and Operation
1. General
Cooling air is important in maintaining the long life of the core engine parts by keeping them from getting
too hot. Pressurized air is used to seal one area of the engine from another. Intermediate pressure (IP)
compressor air, high pressure (HP) compressor air, and compressor discharge pressure (CDP) air are
used for sealing and cooling engine areas and parts.
SUBTASK 72-02-00-860-002
A. Air Seals
The primary function of the air seals is to prevent air pressure from leaking at different areas of
the engine. Another function of the air seals is to vent cooling air to hot engine parts, mainly the
HP and LP turbine rotors.
Compressor discharge pressure (CDP) air from the diffuser is routed to the heat exchanger where it
is cooled and returned via the 1st LP nozzle to the No. 3 and 4 carbon seals and bearing cavities.
The rest of the CDP air is routed to the LP turbine discs through integral 1st nozzle air tubes.
B. Oil Seals
The No. 3 and No. 4 bearing cavity oil seals receive CDP sealing air through the 1st LP turbine
nozzle.
C. Cooling Air
Cooling air from the HP compressor cools the HP nozzle (hollow) vanes, the HP turbine disc fir trees,
and the fuel slinger/seal assembly.
D. Breather System
Sealing air is mixed with oil in the bearing cavities and is then scavenged back to the gearbox. The
gearbox contains an air/oil separator to remove the air from the oil. After separation, the air is
routed overboard by a breather tube.
EFFECTIVITY: FJ44-2A
72-02-00
Page 1
Apr 11/08
72-02-002
Page
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LINE MAINTENANCE MANUAL FJ44-2A
SPINNER - INSPECTION/CHECK
1. General
This task covers visual inspection of the spinner after it is removed from the engine.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-30, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The
word "reject" means that the part should not be used in its present condition.
If there is no approved repair procedure listed, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-30-10-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-30-10 801 Spinner - Repair
3. Procedures
SUBTASK 72-30-10-220-002
A. Visual Inspection
EFFECTIVITY: FJ44-2A
72-30-10
Page 601
Apr 11/08
(a) Blunted condition within the limits Repair, refer to 72-30-10, P.B. 801
of repair.
(b) Nicks within the limits of repair. Repair, refer to 72-30-10, P.B. 801
(d) Scratches/gouges within the limits Repair, refer to 72-30-10, P.B. 801
of repair
(f) Dents within the limits of repair. Repair, refer to 72-30-10, P.B. 801
EFFECTIVITY: FJ44-2A
72-30-10
Page 602
Apr 11/08
SPINNER - REPAIR
1. General
This task contains procedures for repairing the spinner by blending out damage and restoring the correct
profile of the tip. Do this task if the component inspection/check task indicates that the damage is
repairable. Refer to the following illustration(s):
Figure 801 Spinner - Repair
SUBTASK 72-30-10-941-004
A. Standard Equipment
Handstone
SUBTASK 72-30-10-942-004
B. Consumables
Reference Designation
MAT-050 Coating, Chemical Conversion (Iridite)
SUBTASK 72-30-10-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
70-42-12 801 Local Surface Protection - Repair
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
71-00-00 501 Power Plant - Adjustment/Test
3. Procedures
SUBTASK 72-30-10-350-002
(1) Surface blends must be made to a concave diameter at least 10 times the blend depth. Use
handstone for blending.
EFFECTIVITY: FJ44-2A
72-30-10
Page 801
Apr 11/08
(2) Minor erosion, evidenced by a rough surface and multiple small, shallow pits closely grouped,
is acceptable to a maximum depth of 0 .005 inches. Only light smoothing is necessary to
remove any roughness.
(3) All blends must be touched up with anodic solution (iridite). Refer to 70-42-12, P.B. 801.
B. Blend Limits
(1) The maximum damage allowed is that which can be repaired by grinding the tip to a maximum
radius of:
(2) Machine the spinner tip within the limits of repair (Figure 801 Spinner - Repair). Refer to
70-42-11, P.B. 801.
EFFECTIVITY: FJ44-2A
72-30-10
Page 802
Apr 11/08
(3) Apply anodic solution (iridite) MAT-050 to finished surface. Refer to 70-42-12, P.B.801 .
4. Job Close-up
SUBTASK 72-30-10-350-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
Bird Strike or Foreign Object Ingestion chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2A
72-30-10
Page 803
Apr 11/08
EFFECTIVITY: FJ44-2A
72-30-10
Page 804
Apr 11/08
1. General
This task covers visual inspection of the spinner pilot plate assembly. Refer to the following illustration(s):
Figure 601 Spinner Pilot Plate Assembly - Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-31-15, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The
word "reject" means that the part should not be used in its present condition.
If there is no approved repair procedure listed, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-31-15-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
EFFECTIVITY: FJ44-2A
72-31-15
Page 601
Apr 11/08
3. Procedures
SUBTASK 72-31-15-220-002
A. Visually inspect the spinner pilot plate assy (1-40, 72-00-31) for:
EFFECTIVITY: FJ44-2A
72-31-15
Page 602
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-15
Page 603
Apr 11/08
72-31-15
604
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers visual inspection of the fan rotor. Refer to the following illustration(s):
Figure 601 Fan Blade - Inspection Zones
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-31, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The
word "reject" means that the part should not be used in its present condition.
If there is no approved repair procedure listed, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-31-20-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-30 601 IP and HP Compressors (Borescope) - Inspection/Check
72-31-20 801 Fan Rotor - Repair
EFFECTIVITY: FJ44-2A
72-31-20
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 72-31-20-010-003
B. Clean the fan before inspection. Use compressor cleaner (MAT-021, MAT-029, or MAT-031).
4. Procedures
SUBTASK 72-31-20-220-001
A. Visually inspect fan blades for damage as follows (Figure 601 Fan Blade - Inspection Zones):
(b) Erosion or scratches within limits Repair, refer to 72-31-20, P.B. 801
of repair.
(a) Dents, nicks, or erosion within limits Repair, refer to 72-31-20, P.B. 801
of repair.
(3) Inspect the blade trailing edges (Zones E1 and E2) for:
EFFECTIVITY: FJ44-2A
72-31-20
Page 602
Apr 11/08
NOTE You should inspect the trailing edges by feel. If you feel damage,
or if there is excessive damage on leading edge, remove the fan
for detailed inspection and repair.
(a) Nicks or dents within limits of repair Repair, refer to 72-31-20, P.B. 801
(c) Bend on trailing edge blade tip. Evaluate and repair blade tip in
accordance with Repair Station Instruction
72507. If fan P/N is not covered by repair
instruction, reject fan.
(a) Nicks within the limits of repair Repair, refer to 72-31-20, P.B. 801
(a) Rub indications, build-up, or face Refer to 72-31-20, P.B. 801 for blend
nicks within the limits of repair repair limits
(c) Blue discoloration up to 0.125 inch Accept for FJ44-1 and FJ44-2. Reject
(3.18 mm) depth for FJ44-3.
SUBTASK 72-31-20-220-006
B. Inspect fan blade leading and trailing edges for mid-span deformation. If deformation is evident,
measure and disposition as follows:
(1) Lay a straight edge on the blade at the location of the deformation.
(2) Using gage pins, determine the largest diameter pin that will just fit between the deformed
surface and the straight edge.
EFFECTIVITY: FJ44-2A
72-31-20
Page 603
Apr 11/08
(3) Deflection may be repaired by hot straightening in accordance with Repair Instruction 72680 if
it is within the following requirements:
(b) Hot straightening is not allowed if deflection is inboard of a point that is either 0.250
inches above the rim or 20% of blade span (distance between hub and tip of blade),
whichever is greater.
(c) No more than three locations on a leading or trailing edge may be straightened.
SUBTASK 72-31-20-220-002
C. If fan rotor is removed (per scheduled maintenance requirements) inspect the bore/spline/web face
areas of fan rotor bore for:
(d) Slight deformation of spline leading Remove raised material with hand stone
edge due to assembly damage up to
0.020 inch (0.50 mm) long x 0.002
inch (0.050 mm) deep.
(3) Inspect the forward and aft clamp faces of the bore for:
EFFECTIVITY: FJ44-2A
72-31-20
Page 604
Apr 11/08
(a) Tool mark (nick or dent) up to 0.010 Blend with aluminum oxide cloth to remove
inch (0.25 mm) deep raised material or sharp edges.
(a) Burr on edge from tool contact. Remove raised material with hand stone
and smooth sharp edge with aluminum
oxide cloth. Perform NDI inspection
on repaired area.
SUBTASK 72-31-20-220-005
(1) Measure clearance at 12 oclock position. Max radial tip clearance must be 0.079
inch (2.0 mm)
(2) Measure clearance at 3 and 9 oclock Max radial tip clearance must be 0.067
positions. inch (1.70 mm)
(3) Measure clearance at 6 oclock position. Max radial tip clearance must be 0.055
inch (1.39 mm)
SUBTASK 72-31-20-220-003
E. If fretting is evident on fan spline, it is allowable to add molydisufide coating to LP shaft spline.
Refer to approved Repair Station Instructions.
EFFECTIVITY: FJ44-2A
72-31-20
Page 605
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-20
Page 606
Apr 11/08
1. General
This task contains procedures for repairing the fan rotor by blending and restoring the surface finish to
damaged areas. This task also describes the extent of damage which may be repaired by this method.
Refer to 72-31-20, P.B. 601 for visual inspection criteria. Refer to the following illustration(s):
Figure 801 Tungsten Carbide Rotary Burr
Figure 802 Fan Blade - Inspection Zones
Figure 803 Fan Blade - Blending of Deep Nicks
SUBTASK 72-31-20-941-005
A. Standard Equipment
Tungsten Carbide Rotary Burr
Carborundum Stone
SUBTASK 72-31-20-942-005
B. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-042 Paper, Abrasive, Silicone Carbide
SUBTASK 72-31-20-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
71-00-00 501 Power Plant - Adjustment/Test
72-31-20 601 Fan Rotor - Inspection/Check
EFFECTIVITY: FJ44-2A
72-31-20
Page 801
Apr 11/08
3. Job Set-up
SUBTASK 72-31-20-010-005
4. Procedures
SUBTASK 72-31-20-350-002
EFFECTIVITY: FJ44-2A
72-31-20
Page 802
Apr 11/08
(2) Examine the fan blades with a bright light and 5x magnification to check the amount of damage.
Refer to Figure 802 Fan Blade - Inspection Zones, Figure 803 Fan Blade - Blending of Deep
Nicks, and the table of blend limits to determine the quantity, size, and location of repairable
defects. If defects exceed limits, reject fan.
EFFECTIVITY: FJ44-2A
72-31-20
Page 803
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-20
Page 804
Apr 11/08
2 Total allowable length of Zone C and E1 blends per rotor is limited to:1.5 x
Length of All Zone C Blends + Length of All Zone E1 Blends = 15 Inch Max.
No more than three adjacent blended blades allowed per rotor.
3 For multiple nicks less than 0.050 inch in length x 0.015 inch in depth, in
Zones:B,C,D, and F, light smoothing to remove raised metal is allowed.
(a) Repair damage to blades by blending. Refer to Blend Limits table and Figure 802
Fan Blade - Inspection Zones and Figure 803 Fan Blade - Blending of Deep Nicks
for a definition of reparable areas. Blend in accordance with the following general
requirements:
1 Use tungsten carbide rotary burr and/or carborundum stone for blending.
2 The surface length of all leading and trailing edge blends must be 5 times the
maximum blend depth.
3 Surface blends must be made to a concave diameter 5 times the blend depth.
4 To maintain rotor balance when blending damaged airfoils in the field, equal material
must be removed from the blade closest to 180 degrees opposite the blended blade.
This material should be removed from the same area as the blend. If repair limits
do not allow removing material from the opposite blade, return fan to Authorized
Repair Facility for balancing.
5 All blends made on leading and trailing edges must leave a full radius on the air foil
(see Figure 803 Fan Blade - Blending of Deep Nicks).
(c) If blending installed fan, use vacuum to remove metal particles from inlet case.
(5) Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure
802 Fan Blade - Inspection Zones and Figure 803 Fan Blade - Blending of Deep Nicks.
EFFECTIVITY: FJ44-2A
72-31-20
Page 805
Apr 11/08
5. Job Close-up
SUBTASK 72-31-20-230-003
A. Check repaired areas for cracks using local penetrant inspection. Refer to 70-42-15, P.B. 601 for
non-destructive inspection (NDI) methods. No cracks are allowed.
SUBTASK 72-31-20-350-050
B. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
Bird Strike or Foreign Object Ingestion chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2A
72-31-20
Page 806
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-20
Page 807
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-20
Page 808
Apr 11/08
EFFECTIVITY: FJ44-2A
72-31-20
Page 809
Apr 11/08
72-31-20
810
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers visual inspection of the inlet case and fan shroud insert. Refer to the following illustrations:
Figure 601 Case and Insert Assembly - Inspection
Figure 602 Case and Insert Assembly - Flange and Shroud Inserts
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The
word "reject" means that the part should not be used in its present condition.
If there is no approved repair procedure listed, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-32-20-941-001
A. Standard Equipment
Handstone
SUBTASK 72-32-20-942-001
B. Consumables
EFFECTIVITY: FJ44-2A
72-32-10
Page 601
Apr 11/08
Reference Designation
MAT-040 Cloth, Abrasive
SUBTASK 72-32-10-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-32-10 801 Case and Insert Assembly - Repair
3. Procedures
SUBTASK 72-32-10-220-001
NOTES: 1 If the case and insert assembly is rejected and requires replacement, the engine
identification plate must be removed and installed on the new case and insert
assembly. Refer to 723210, P.B. 801 in the Maintenance Manual.
(a) Corrosion with pitting of ID surface Remove corrosion products with stiff nylon
of nitronic steel case or bristle brush, emery cloth, or scotch
brite pad. Do not use metallic brush.
Alternate method to brush is to use 600
grit aluminum oxide or silicon carbide
paper (MAT-040).
If rust spots remain, clean with 5%
phosphorus acid solution.
Reclean part.
EFFECTIVITY: FJ44-2A
72-32-10
Page 602
Apr 11/08
(4) Inspect the outer surfaces and inner flowpath of the inlet case for:
(c) Wear mark on outer case forward of Blend down to 0.010 inch max depth with
weld up to 0.008 inch (0.20 mm) deep brite boy rubberized stone. Perform local
x 0.170 inch (4.31 mm) wide x 0.666 penetrant inspection on repaired area.
inch (16.9 mm) long.
SUBTASK 72-32-10-220-002
(3) Nicks, gouges, dents up to 0.080 inch Blend to remove raised material or sharp
(2.03 mm) depth corners using handstone.
EFFECTIVITY: FJ44-2A
72-32-10
Page 603
Apr 11/08
(6) Chip indications on fan shroud abradable Blend to remove raised material or sharp
coating are allowed up to 0.080 inch (0.43 edges.
mm) in depth. Damage may extend 1.75
inch (44.5 mm) in diameter, provided
depth limits are maintained. Maximum of
5.8 square inches (147.3 mm) cumulative
in abradable area are allowed. No sharp
edges, cracks, or loose material allowed.
(7) Rub indications or erosion on fan shroud Blend to remove raised material or sharp
abradable coating are allowed up to 0.025 edges.
inch (0.63 mm) deep. Damage may extend
360 degrees in circumference, provided
depth limits are maintained. No sharp
edges, cracks, or loose material allowed.
4. Job Close-up
SUBTASK 72-32-10-220-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
Bird Strike or Foreign Object Ingestion chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2A
72-32-10
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
72-32-10
Page 605
Apr 11/08
Fig. 602 Case and Insert Assembly - Flange and Shroud Inserts
EFFECTIVITY: FJ44-2A
72-32-10
Page 606
Apr 11/08
1. General
This task contains procedures for removing the engine identification plate from the inlet case and installing
it on a new case and insert assembly. Refer to the following illustration(s):
Figure 801 Case and Insert Assembly - Engine Identification Plate - Replace
SUBTASK 72-32-10-942-005
A. Consumables
Reference Designation
MAT-096 Primer, Epoxy
SUBTASK 72-32-10-944-005
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-32-10 1 90 Stud, Grooved (4)
SUBTASK 72-32-10-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-32 401 Case and Insert Assy - Removal/Installation
3. Job Set-up
SUBTASK 72-32-10-020-001
A. Remove the case and insert assembly from the engine and remove the fan stator from the case and
insert. Refer to 72-00-32, P.B. 401.
4. Procedures
SUBTASK 72-32-10-350-002
EFFECTIVITY: FJ44-2A
72-32-10
Page 801
Apr 11/08
(1) Carefully drill and/or punch-out the four grooved studs which hold the identification plate to
the inlet case.
(3) Install identification plate on four mounting holes. Identification plate is to be oriented so that it
can be read, from left to right, when looking at bottom of engine, looking aft.
(4) Coat four grooved studs with epoxy primer MAT-096 and tap into case to secure identification
plate.
5. Job Close-up
SUBTASK 72-32-10-420-001
A. Install fan stator into inlet case and vane. Install the case and vane assembly to the engine. Refer to
72-00-32, P.B. 401.
EFFECTIVITY: FJ44-2A
72-32-10
Page 802
Apr 11/08
Fig. 801 Case and Insert Assembly - Engine Identification Plate - Replace
EFFECTIVITY: FJ44-2A
72-32-10
Page 803
Apr 11/08
72-32-10
804
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers visual inspection of the fan stator. Refer to the following illustration(s):
Figure 601 Fan Stator Vanes - Inspection Zones
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-32, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The
word "reject" means that the part should not be used in its present condition.
If there is no approved repair procedure listed, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-32-20-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-00-32 401 Case and Insert Assy - Removal/Installation
72-32-20 801 Fan Stator - Repair
EFFECTIVITY: FJ44-2A
72-32-20
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 72-32-20-010-001
SUBTASK 72-32-20-020-001
SUBTASK 72-32-20-020-002
SUBTASK 72-32-20-020-003
D. Remove the case and insert assembly. Refer to 720032, P.B. 401. Remove fan stator from
case and insert.
4. Procedures
SUBTASK 72-32-20-220-001
(a) Erosion within limits of repair. Repair, refer to 72-32-20, P.B. 801
(c) Nicks or pits within limits of repair. Repair, refer to 72-32-20, P.B. 801
(2) Inspect the leading and trailing edges of the stator vanes (Zone B for FJ44-1; Zones B and C
for FJ44-2 and FJ44-3):
(a) Nicks or dents within the limits Repair, refer to 72-32-20, P.B. 801
of repair.
EFFECTIVITY: FJ44-2A
72-32-20
Page 602
Apr 11/08
(c) Erosion on leading edge within Repair, refer to 72-32-20, P.B. 801
limits of repair.
NOTE Gouges that penetrate the outer casing are acceptable in one defect area
only. Gouges must not penetrate stiffening ring. Gouges that penetrate an
area where there is no stiffening ring are not acceptable.
(a) Gouges, dents, or holes within the Repair, refer to 72-32-20, P.B. 801
limits of repair
(a) Gouges or dents within the limits Repair, refer to 72-32-20, P.B. 801
of repair
(a) Rips on inner casing metal within the Repair, Refer to 72-32-20, P.B. 801
limits of repair.
EFFECTIVITY: FJ44-2A
72-32-20
Page 603
Apr 11/08
(c) Wear in the outer urethane due to Wear that has gone through the urethane
contact with the fan case anti-rotation with some material loss on the vane is
keys. acceptable. Wear that has gone through
the vane is not acceptable.
SUBTASK 72-32-20-220-001
B. Inspect the forward shoulder of the center body which supports the rubber seal for the fan ID fan. If
damage is present (dents), repair by cold straightening to best possible condition. Any amount of
deflection is acceptable provided that there are no cracks. Visually inspect for cracks after repair.
EFFECTIVITY: FJ44-2A
72-32-20
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
72-32-20
Page 605
Apr 11/08
72-32-20
606
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task contains procedures for repairing the fan stator by blending and restoring the surface finish to
damaged areas or welding. This task also describes the extent of damage which may be repaired by
these methods. Refer to the following illustration(s):
Figure 801 Fan Stator Blades - Inspection Zones
SUBTASK 72-32-20-941-004
A. Standard Equipment
Handstones
5x Magnification
SUBTASK 72-32-20-942-004
B. Consumables
Reference Designation
MAT-040 Cloth, Abrasive
MAT-050 Coating, Chemical Conversion (Iridite)
SUBTASK 72-32-20-945-004
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
71-00-00 501 Power Plant - Adjustment/Test
72-00-30 401 Spinner - Removal/Installation
72-00-31 401 Fan Rotor - Removal/Installation
72-00-32 401 Case and Insert Assy - Removal/Installation
3. Job Set-up
SUBTASK 72-32-20-010-002
EFFECTIVITY: FJ44-2A
72-32-20
Page 801
Apr 11/08
SUBTASK 72-32-20-020-004
SUBTASK 72-32-20-020-005
SUBTASK 72-32-20-020-006
D. Remove the case and insert assembly. Refer to 720032, P.B. 401. Remove fan stator from
case and insert.
4. Procedures
SUBTASK 72-32-20-350-003
NOTE If the inspection task reveals damage to the stator vanes, the vanes can be
dressed and blended, as permitted by the limits in this repair.
(2) Examine the fan stator vanes with a bright light and 5x magnification to check the amount of
damage. Refer to Figure 801 Fan Stator Blades - Inspection Zones and the blend limits
below to determine the quantity, size, and location of repairable defects. If defects exceed
limits, reject fan stator.
SUBTASK 72-32-20-350-005
B. Blend Limits (refer to Figure 801 Fan Stator Blades - Inspection Zones):
EFFECTIVITY: FJ44-2A
72-32-20
Page 802
Apr 11/08
EFFECTIVITY: FJ44-2A
72-32-20
Page 803
Apr 11/08
SUBTASK 72-32-20-350-006
(1) Repair damage to vanes by blending using handstones. Refer to Blend Limits table and Figure
801 Fan Stator Blades - Inspection Zones for maximum repair limits. Blend in accordance with
the following general requirements:
(a) The surface length of all leading and trailing edge blends must be 5 times the maximum
blend depth.
(b) Surface blends must be made to a concave diameter at least 10 times the blend depth.
(c) Corner blends must have a length which is 2.5 times the depth
(d) All blends made on leading and trailing edges must leave a full radius on the air foil (see
Figure 801 Fan Stator Blades - Inspection Zones).
(e) All casing damage should be blended by removing any raised metal and smoothing rough
edges. Dents should be carefully peened back to flush with adjacent casing surface.
D. Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure 801
Fan Stator Blades - Inspection Zones.
EFFECTIVITY: FJ44-2A
72-32-20
Page 804
Apr 11/08
E. Apply anodic solution (iridite) (MAT-050) to repaired areas. Refer to 70-42-12, P.B. 801 in the
Maintenance Manual.
5. Job Close-up
SUBTASK 72-32-20-350-050
A. If there is any possibility of foreign object ingestion, troubleshooting must be performed. Refer to the
Bird Strike or Foreign Object Ingestion chart in Troubleshooting, 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2A
72-32-20
Page 805
Apr 11/08
EFFECTIVITY: FJ44-2A
72-32-20
Page 806
Apr 11/08
1. General
This task covers removal of any of the magnetic carbon seal assemblies from the 8k configuration
gearbox. Refer to the following illustration(s):
Figure 401 Gearbox Magnetic Seals - Magnet Keeper - Removal/Installation
Figure 402 Gearbox Magnetic Seals - Legend
Figure 403 Hydraulic Pump Gearshaft and Adapter - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
3. Job Set-up
SUBTASK 72-60-01-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
72-60-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 72-60-01-050-003
A. Use the procedure that follows to remove magnetic carbon seals from these locations:
(1) Remove the gearbox-mounted accessory which covers the magnetic seal to be replaced (fuel
pump, starter/generator, or hydraulic pump); refer to the applicable procedure listed above.
(2) Remove bolts and washers attaching the adapter to the gearbox housing.
(3) Remove the adapter and O-ring from the gearbox housing.
(4) Remove the seal case (carbon) from the gearshaft. Discard O-rings.
(5) Remove the magnet from the adapter. If magnet keeper is installed to retain the magnet in the
adapter, remove in accordance with the appropriate paragraph, below:
EFFECTIVITY: FJ44-2A
72-60-01
Page 402
Apr 11/08
(a) Hydraulic Pump or Fuel Pump Adapter. To remove the carbon seal magnet from the
hydraulic pump or fuel pump adapters, remove the retaining ring which attaches the
magnet keeper and magnet. Remove the wave spring, magnet keeper, and magnet
from the adapter.
(b) Starter/Generator Adapter. To remove the carbon seal magnet from the adapter, remove
the wave spring and magnet keeper from the adapter bore. Carefully drive the magnet
out of the adapter using the three driver holes provided.
SUBTASK 72-60-01-050-004
B. Use the procedure that follows to remove the aft magnetic carbon seal for the hydraulic pump
gearshaft (breather tube port):
NOTE The hydraulic pump gearshaft must be removed from the gearbox when
reinstalling or replacing the aft magnetic carbon seal.
(1) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove four bolts and washers which attach the hydraulic pump adapter to the gearbox
housing. Remove the adapter and O-ring. Do not remove the magnet portion of the forward
magnetic carbon seal from the adapter.
(3) Carefully remove the hydraulic pump gearshaft from the gearbox.
(4) Carefully remove the forward and aft carbon seal cases from the gearshaft.
EFFECTIVITY: FJ44-2A
72-60-01
Page 403
Apr 11/08
(6) Remove the aft magnet from the gearbox housing breather port. Use a clean, nylon drift if
required.
TASK 72-60-01-050-804 Remove Type 1 Spring-Loaded Carbon Seals from the 8k Gearbox
5. General
This task covers removal of the type 1 spring-loaded carbon seal assemblies from the 8k configuration
gearbox. Refer to the following illustration(s):
Figure 404 Gearbox Carbon Seals Type 1 Spring-Loaded Configuration (8k) Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-01-943-002
A. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-945-050
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
EFFECTIVITY: FJ44-2A
72-60-01
Page 404
Apr 11/08
7. Job Set-up
SUBTASK 72-60-01-010-050
(2) Open the circuit breakers to isolate the engine electrical supply.
8. Procedures
SUBTASK 72-60-01-020-050
A. Use the following procedure to remove spring-loaded carbon seal from the starter/generator location:
(1) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove six bolts (40) and washers (50) attaching the starter/generator adapter (100) to the
gearbox housing. Carefully remove the adapter. Remove O-ring (105) and O-ring (107)
from the adapter.
(3) Remove carbon seal (120) from the starter/generator adapter bore using driver from TL99696
kit, or equivalent.
(4) Remove seal runner (125) from the gearshaft using puller from TL99696 kit, or equivalent.
Hold gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
SUBTASK 72-60-01-020-051
B. Use the following procedure to remove spring-loaded carbon seal from the fuel pump location:
EFFECTIVITY: FJ44-2A
72-60-01
Page 405
Apr 11/08
(1) Remove the fuel control unit from the gearbox. Refer to 73-21-01, P.B. 401
(2) Remove the fuel pump from the gearbox. Refer to 73-16-01, P.B. 401.
(3) Remove two bolts (80) and washers (90) attaching the fuel pump adapter (60) to the gearbox
housing. Carefully remove the adapter. Remove O-ring (65) from the adapter.
(4) Remove the carbon seal (70) from the fuel pump adapter bore using driver from TL99696
kit, or equivalent.
(5) Remove the seal runner (74) from the gearshaft. Use puller from TL99696 kit, or equivalent.
Hold gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
SUBTASK 72-60-01-020-052
C. Use the following procedure to remove spring-loaded carbon seal from the hydraulic pump location:
(1) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove four bolts (40) and washers (50) attaching the hydraulic pump adapter (20) to the
gearbox housing. Carefully remove the adapter. Remove O-ring (25) from the adapter.
NOTE Hydraulic pump gearshaft may come out of gearbox with the adapter.
(3) Remove the hydraulic pump gearshaft from the gearbox housing (or separate it from the
adapter) and place it on a clean surface.
(4) Remove the carbon seal (110) from the hydraulic pump adapter bore using driver from
TL99696 kit, or equivalent.
EFFECTIVITY: FJ44-2A
72-60-01
Page 406
Apr 11/08
(5) Remove the seal runner (115) from the gearshaft. Use puller from the TL99696 kit, or
equivalent.
SUBTASK 72-60-01-020-053
D. Use the following procedure to remove the spring-loaded carbon seal from the aft side of the
hydraulic pump gearshaft (breather tube port):
(1) Remove the breather tube from the gearbox. Refer to 72-00-60, P.B. 401. Make sure that the
breather tube hose is disconnected from the breather tube.
(2) Remove the OD O-ring and the spring-loaded carbon seal (30) from the gearbox housing
breather port.
(3) Remove the hydraulic pump adapter and the hydraulic pump gearshaft in accordance with
Subtask 72-60-010-020-052, above. It is not necessary to remove the hydraulic pump carbon
seal or seal runner, as long as the sealing surfaces are protected from damage and cleaned
before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump gearshaft.
Use puller from TL99696 kit, or equivalent.
(5) Place gearshaft in plastic bag and cover all open gearbox ports to prevent contamination.
TASK 72-60-01-050-806 Remove Type 2 or Type 3 Spring-Loaded Carbon Seals from the 8k
Gearbox
9. General
This task covers removal of the type 2 or type 3 spring-loaded carbon seal assemblies from the 8k
configuration gearbox. Refer to the following illustration(s):
Figure 405 Gearbox Carbon Seals Type 2 or Type 3 Spring-Loaded Configuration (8k)
Removal/Installation
EFFECTIVITY: FJ44-2A
72-60-01
Page 407
Apr 11/08
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-01-943-002
A. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-945-050
B. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
SUBTASK 72-60-01-010-050
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
72-60-01
Page 408
Apr 11/08
12. Procedures
SUBTASK 72-60-01-020-050
A. Use the following procedure to remove spring-loaded carbon seal from the starter/generator location:
(1) Remove the starter/generator from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove six bolts (40) and washers (50) attaching the starter/generator adapter (100) to the
gearbox housing. Carefully remove the adapter. Remove O-ring (105) and O-ring (107)
from the adapter.
(3) Remove wave spring (26) and spring washer (108) from adapter bore.
(4) Remove carbon seal (120) from the starter/generator adapter bore using driver from TL99696
kit, or equivalent.
(5) Remove seal runner (125) from the gearshaft using puller from TL99696 kit, or equivalent.
Hold gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
SUBTASK 72-60-01-020-051
B. Use the following procedure to remove spring-loaded carbon seal from the fuel pump location:
(1) Remove the fuel control unit from the gearbox. Refer to 73-21-01, P.B. 401
(2) Remove the fuel pump from the gearbox. Refer to 73-16-01, P.B. 401.
(3) Remove two bolts (80) and washers (90) attaching the fuel pump adapter (60) to the gearbox
housing. Carefully remove the adapter. Remove O-ring (65) from the adapter.
(4) Remove the carbon seal (70) from the fuel pump adapter bore using driver from TL99696
kit, or equivalent.
EFFECTIVITY: FJ44-2A
72-60-01
Page 409
Apr 11/08
(5) Remove the seal runner (74) from the gearshaft. Use puller from TL99696 kit, or equivalent.
Hold gearshaft in place during removal to prevent dislodging gearshaft/bearing from housing.
SUBTASK 72-60-01-020-052
C. Use the following procedure to remove spring-loaded carbon seal from the hydraulic pump location:
(1) Remove the hydraulic pump from the gearbox. Refer to the Aircraft Maintenance Manual.
(2) Remove four bolts (40) and washers (50) attaching the hydraulic pump adapter (20) to the
gearbox housing. Carefully remove the adapter. Remove O-ring (25) from the adapter.
NOTE Hydraulic pump gearshaft may come out of gearbox with the adapter.
(3) Remove the spring sleeve (29), wave spring (28), and spring washer (27) from the adapter bore
(4) Remove the hydraulic pump gearshaft from the gearbox housing (or separate it from the
adapter) and place it on a clean surface.
(5) Remove the carbon seal (110) from the hydraulic pump adapter bore using driver from
TL99696 kit, or equivalent.
(6) Remove the seal runner (115) from the gearshaft. Use puller from the TL99696 kit, or
equivalent.
SUBTASK 72-60-01-020-053
D. Use the following procedure to remove the spring-loaded carbon seal from the aft side of the
hydraulic pump gearshaft (breather tube port):
(1) Remove the breather tube from the gearbox. Refer to 72-00-60, P.B. 401. Make sure that the
breather tube hose is disconnected from the breather tube.
EFFECTIVITY: FJ44-2A
72-60-01
Page 410
Apr 11/08
(2) Remove the OD O-ring and the spring-loaded carbon seal (30) from the gearbox housing
breather port.
(3) Remove the hydraulic pump adapter and the hydraulic pump gearshaft in accordance with
Subtask 72-60-010-020-052, above. It is not necessary to remove the hydraulic pump carbon
seal or seal runner, as long as the sealing surfaces are protected from damage and cleaned
before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump gearshaft.
Use puller from TL99696 kit, or equivalent.
(5) Place gearshaft in plastic bag and cover all open gearbox ports to prevent contamination.
13. General
This task covers installation of any of the magnetic carbon seals in the 8k configuration gearbox. Refer
to the following illustration(s):
Figure 401 Gearbox Magnetic Seals - Magnet Keeper - Removal/Installation
Figure 402 Gearbox Magnetic Seals - Legend
Figure 406 Typical Magnetic Seal Installation - Assembly
Figure 403 Hydraulic Pump Gearshaft and Adapter - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-01, Fig. 02
EFFECTIVITY: FJ44-2A
72-60-01
Page 411
Apr 11/08
SUBTASK 72-60-01-941-004
A. Standard Equipment
Heat Gun
SUBTASK 72-60-01-942-004
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-944-004
C. Expendable Parts
IPC Reference
Subject Fig Item Nomenclature
72-60-01 02 25 O-Ring
72-60-01 02 32 O-Ring (2)
72-60-01 02 33 O-Ring (2)
72-60-01 02 51 O-Ring
72-60-01 02 65 O-Ring
72-60-01 02 72 O-Ring
72-60-01 02 73 O-Ring
EFFECTIVITY: FJ44-2A
72-60-01
Page 412
Apr 11/08
72-60-01 02 94 O-Ring
72-60-01 02 105 O-Ring
72-60-01 02 107 O-Ring
72-60-01 02 112 O-Ring
72-60-01 02 113 O-Ring
72-60-01 02 130 O-Ring
D. Repair Parts:
IPC Reference
Subject Fig Item Nomenclature
72-60-01 02 30 Magnetic Seal (2)
72-60-01 02 31 Magnetic Seal
72-60-01 02 70 Magnetic Seal
72-60-01 02 110 Magnetic Seal
SUBTASK 72-60-01-945-004
E. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
15. Procedures
SUBTASK 72-60-01-420-002
A. Use the procedure that follows to install magnetic carbon seals to these locations:
EFFECTIVITY: FJ44-2A
72-60-01
Page 413
Apr 11/08
(1) Ensure seal cavity is free of all dirt and foreign material.
(a) When removing seal from packaging, the seal case must be separated from the magnet.
Pull seal case straight away from magnet.
(b) Install a new O-ring into the carbon seal case ID and onto the magnet OD.
(c) Carefully inspect both installed O-rings to make sure that they are not twisted. The
mold lines from the O-ring manufacturing process should not spiral and should be
relatively uniform around the O-ring diameter. Reinstall or manipulate O-rings to make
sure that they are not twisted.
(3) Thoroughly lubricate the installed O-ring on the magnet with a coat of assembly fluid (MAT-011).
Do not clean excess assembly fluid from the magnet before installation. Lubricate the bore of
the adapter with assembly fluid.
(4) Install the magnet portion of the seal into the adapter bore (or starter/generator retainer) with
the highly polished and unmarked surface (mating face) facing up.
(5) Install magnet keepers to hydraulic pump adapter and fuel pump adapter as follows:
(a) Install the magnet keeper into the adapter bore, against the carbon seal magnet.
(c) Install the retaining ring into the adapter groove to retain the magnet keeper.
(d) Clean the mating face of the magnet and the seal case with alcohol (MAT-027) or clean
engine oil (MAT-001) and a lint-free cloth.
EFFECTIVITY: FJ44-2A
72-60-01
Page 414
Apr 11/08
(b) Clean the mating face of the magnet and seal case with alcohol (MAT-027) or clean
engine oil (MAT-001) and a lint-free cloth.
(c) Lubricate the wave spring with assembly fluid (MAT-011) to hold it during installation and
install it over the magnet keeper.
(7) Mate the seal case and the (installed) seal runner magnet as follows:
(a) Thoroughly lubricate the O-ring, which is installed in the seal case, with a coat of
assembly fluid (MAT-011).
(b) Apply one or two drops of clean engine oil to the carbon seal or runner before final
assembly.
(c) Install (mate) the carbon face of the seal case onto the seal runner magnet (which is
installed in the adapter). Make sure that the seal case has its carbon face down and is
centered on the polished magnet seal face.
(8) Prepare the gearshaft (hydraulic pump, starter/generator, or fuel pump) for installation of the
carbon seal/adapter as follows:
NOTE Oil is the solvent for assembly fluid. Oil residue on gearshafts must be
removed to ensure proper lubrication with assembly fluid.
(b) Apply a coat of assembly fluid (MAT-011) to the dry gearshaft. Make sure that the full
diameter and length of gearshaft is coated with assembly fluid.
(9) Lube adapter O-ring(s) with assembly fluid and install on adapter groove.
(10) Install the adapter onto the gearbox, aligning the carbon seal assembly with the gearshaft end.
Using constant pressure, PUSH the adapter into place sliding the carbon seal assembly over
the gearshaft until the bearing is engaged in the adapter bore and the face is seated against
the gearbox. It will take some force to overcome the adapter O-ring press fit.
EFFECTIVITY: FJ44-2A
72-60-01
Page 415
Apr 11/08
(11) Attach the adapter to the gearbox housing with bolts. Use one washer under each bolt.
SUBTASK 72-60-10-420-003
B. Use the procedure that follows to install the aft magnetic carbon seal for the hydraulic pump
gearshaft (breather tube port):
NOTE The (forward) hydraulic pump mount adapter and the hydraulic pump gearshaft
were removed from the gearbox to allow aft carbon seal replacement.
(1) Apply a thin film of assembly fluid to the forward and aft OD surfaces of the hydraulic pump
gearshaft.
CAUTION ACID FROM HUMAN HANDS IS CORROSIVE AND CAN CAUSE BEARINGS
TO FAIL. TO PREVENT CONTAMINATION, WEAR CLEAN PLASTIC
GLOVES (WITHOUT TALC) WHEN HANDLING GEARSHAFT.
(2) Install the hydraulic pump gearshaft by centering it in the housing bore and engaging the aft
bearing pilot diameter. Rotate, as required, to mesh gear teeth.
(3) Prepare the forward seal case for the hydraulic pump gearshaft assembly per SUBTASK
72-60-01-420-002.
(a) Inspect the carbon ring for damage or imperfections in the sealing surface. If the seal
case is rejected, the whole forward magnetic carbon seal assembly (seal case, magnet,
and O-rings) must be replaced.
(4) If the forward magnetic carbon seal assembly was rejected because of its condition, remove
the magnet from the hydraulic pump adapter and install a new magnet and O-ring per
SUBTASK 72-60-01-420-002.
(5) Mate the seal case with the installed magnet and install and secure the hydraulic pump adapter
per SUBTASK 72-60-01-420-002.
(6) Prepare new aft carbon seal assembly for installation as follows:
EFFECTIVITY: FJ44-2A
72-60-01
Page 416
Apr 11/08
(a) When removing seal from its packaging, the seal case must be separated from the
magnet. Pull seal case straight away from the magnet.
(b) Install a new O-ring into the carbon seal case ID and onto the magnet OD.
(c) Carefully inspect both installed O-rings to make sure that they are not twisted. The
mold lines from the O-ring manufacturing process should not spiral and should be
relatively uniform around the O-ring diameter. Reinstall or manipulate O-rings to make
sure they are not twisted.
(d) Lubricate the breather port of the gearbox housing with assembly fluid (MAT-011).
(e) Using alcohol (MAT-027) or clean engine oil (MAT-001) on a clean lint-free cloth, clean
both the carbon ring sealing face of the forward seal case and the highly polished
sealing surface on the magnet.
(f) Apply one or two drops of clean engine oil to the carbon seal or runner before final
assembly.
(g) Carefully mate the carbon seal case and the magnet, making sure that the highly
polished surface of the magnet is against the carbon ring and the two halves are visually
centered, relative to each other.
(h) Thoroughly lubricate the installed O-ring on the magnet and the O-ring on the seal case
ID with a coat of assembly fluid (MAT-011).
(7) With the seal case facing into the gearbox, carefully install the assembled carbon seal
assembly into the breather port seal bore until the magnet is fully seated in the machined
pocket in the gearbox housing. Use constant, uniform pressure while keeping the assembly
perpendicular to the bore. A small, clean plate of aluminum or plastic may be used to push
the assembly into position.
SUBTASK 72-60-01-420-004
EFFECTIVITY: FJ44-2A
72-60-01
Page 417
Apr 11/08
SUBTASK 72-60-01-410-004
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
SUBTASK 72-60-01-760-002
B. Perform engine ground run testing as required by List of Test Procedures. Refer to 71-00-00, P.B. 501.
17. General
This task covers installation of the type 1 spring-loaded carbon seal assemblies into the 8k configuration
gearbox. Refer to the following illustration(s):
Figure 404 Gearbox Carbon Seals Type 1 Spring-Loaded Configuration Removal/Installation
Figure 407 Gearbox Tyep 1 Spring-Loaded Carbon Seal Starter/Generator
Figure 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit
Figure 409 Gearbox Type 1 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
Figure 410 Gearbox Spring-Loaded Carbon Seals (8k) Breather Tube
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-01, Fig. 03
EFFECTIVITY: FJ44-2A
72-60-01
Page 418
Apr 11/08
SUBTASK 72-60-01-942-050
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-943-050
B. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-944-050
C. Expendable Parts
IPC Reference
Subject Fig Item Nomenclature
72-60-01 03 25 O-Ring
72-60-01 03 36 O-Ring
72-60-01 03 65 O-Ring
72-60-01 03 105 O-Ring
72-60-01 03 107 O-Ring
EFFECTIVITY: FJ44-2A
72-60-01
Page 419
Apr 11/08
SUBTASK 72-60-01-945-051
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
19. Procedures
SUBTASK 72-60-01-420-050
A. Use the following procedure to install spring-loaded carbon seal at the starter/generator location.
Refer to Figure 407 Gearbox Tyep 1 Spring-Loaded Carbon Seal Starter/Generator.
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
EFFECTIVITY: FJ44-2A
72-60-01
Page 420
Apr 11/08
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (100) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
(3) Install the seal runner (125) onto the generator gearshaft with the highly polished sealing
surface facing out. Push the seal runner down the shaft until it bottoms against the bearing
inner race. Make sure that O-ring does not roll.
(4) Install the carbon seal (125) into the adapter bore using driver from TL99696 kit, or equivalent.
Make sure that the carbon seal is fully installed in the adapter pocket. Make sure that the
O-ring does not roll.
(5) Apply assembly fluid to O-rings (105) and (107) and install on starter/generator adapter.
(6) Use alcohol (MAT-027) or clean engine oil (MAT-001) and a clean, lint-free cloth to clean any
residual assembly fluid off the mating faces of the carbon seal and the seal runner.
(7) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
(8) Align and install the adapter onto the gearbox. Be careful to lower the adapter evenly.
(9) Install six bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
B. Install the starter-generator to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-051
C. Use the following procedure to Install spring-loaded carbon seal at the fuel pump location. Refer to
Figure 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit.
EFFECTIVITY: FJ44-2A
72-60-01
Page 421
Apr 11/08
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (60) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
(3) Install the seal runner (74) onto the fuel pump gearshaft with the highly polished sealing surface
facing out. Push the seal runner down the shaft until it bottoms against the gearshaft flange.
Make sure O-ring does not roll.
(4) Install carbon seal (70) into seal bore of fuel pump adapter until it bottoms. Use driver from
TL99696 kit, or equivalent. Make sure that the O-ring does not roll.
(5) Apply assembly fluid to O-ring (65) and install on fuel pump adapter.
(6) Use alcohol (MAT-027) or clean engine oil (MAT-001) and a clean, lint-free cloth to clean any
residual assembly fluid off the mating faces of the carbon seal and the seal runner.
(7) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
EFFECTIVITY: FJ44-2A
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Page 422
Apr 11/08
(8) Align bolt holes and carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(9) Install two bolts (80) and washers (90) to secure adapter. Torque bolts 46 to 51 inch-pounds
(5.3 to 5.7 N.m).
D. Install the fuel pump onto the gearbox. Refer to 73-16-01, P.B. 401.
E. Install the fuel control unit onto the gearbox. Refer to 73-21-01, P.B. 401.
SUBTASK 72-60-01-420-052
F. Use the following procedure to install spring-loaded carbon seal at the hydraulic pump location. Refer
to Figure 409 Gearbox Type 1 Spring-Loaded Carbon Seals (8k) Hydraulic Pump.
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (20) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
EFFECTIVITY: FJ44-2A
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Page 423
Apr 11/08
(3) Install the seal runner (115) onto the gearshaft with the highly polished sealing surface facing
out. Push the seal runner down the shaft until it bottoms against the bearing inner race.
Make sure O-ring does not roll.
(4) Insert a piece of shim stock (0.001 - 0.002 inch) into the adapter to cover the drain hole groove
so that the O-ring is not pinched during installation. Allow enough shim stock to protrude so
that it can be removed after seal installation.
(5) Install the carbon seal (110) into the hydraulic pump adapter until it bottoms. Use driver from
TL99696 kit, or equivalent. Make sure that the O-ring does not roll. Remove shim stock.
(6) Apply assembly fluid to O-ring (25). Install O-ring on adapter assembly.
NOTE Make sure that the aft hydraulic pump (breather tube) carbon seal runner is
properly installed before the gearshaft is installed in the gearbox.
(7) Install the hydraulic pump gearshaft by centering it in the housing bore and engaging the aft
bearing pilot diameter. Rotate, as required, to mesh gear teeth.
(8) Use alcohol (MAT-027) or clean engine oil (MAT-001) and a clean, lint-free cloth to clean any
residual assembly fluid off the mating faces of the carbon seal and the seal runner (forward and
aft carbon seal locations).
(9) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
(10) Align bolt hole pattern and install hydraulic pump adapter on gearbox. Use care not to damage
carbon seal during installation.
(11) Install four bolts (40) and washers (50) to secure adapter. Torque bolts 55 to 65 inch-pounds
(6.2 to 7.3 N.m).
G. Install hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-053
H. Use the following procedure to install spring-loaded carbon seal at the aft side of the hydraulic
pump gearshaft (breather tube port). Refer to Figure 410 Gearbox Spring-Loaded Carbon Seals
(8k) Breather Tube.
EFFECTIVITY: FJ44-2A
72-60-01
Page 424
Apr 11/08
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-ring on seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
NOTE The hydraulic pump gearshaft was removed from the gearbox when the carbon
seal runner was removed. The new seal runner should be installed on the aft
end of the gearshaft before the gearshaft is installed in the gearbox.
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Apply a coating of assembly fluid to the breather tube bore of the gearbox housing.
(3) Install the seal runner (32) onto the aft end of the gearshaft. Make sure it is seated and
the O-ring does not roll.
(4) Intstall the hydraulic pump gearshaft and adapter into the gearbox in accordance with Subtask
72-60-01-420-052 (above).
(5) Use engine oil (MAT-001) and a clean, lint-free cloth to clean any residual assembly fluid off the
mating faces of the carbon seal and the seal runner.
(6) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
EFFECTIVITY: FJ44-2A
72-60-01
Page 425
Apr 11/08
(7) Install the carbon seal (30) into the housing bore so that it mates with the seal runner.
(8) Apply assembly fluid to breather tube O-ring (36) and install around OD of installed carbon
seal, flush against breather face. Work the O-ring into the groove between the housing and the
carbon seal.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
SUBTASK 72-60-01-410-050
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
B. Perform ground run testing in accordance with the requirements of the List of Test Procedures.
Refer to 710000, P.B. 501.
TASK 72-60-01-450-806 Install Type 2 or Type 3 Spring-Loaded Carbon Seals in the 8k Gearbox
21. General
This task covers installation of the type 2 or type 3 spring-loaded carbon seal assemblies into the 8k
configuration gearbox. Refer to the following illustration(s):
Figure 405 Gearbox Carbon Seals Type 2 or Type 3 Spring-Loaded Configuration Removal/Installation
Figure 411 Gearbox Type 2 Spring-Loaded Carbon Seal Starter/Generator
Figure 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit
Figure 412 Gearbox Type 2 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
Figure 410 Gearbox Spring-Loaded Carbon Seals (8k) Breather Tube
Figure 413 Wave Spring Proper Winding of Overlap
EFFECTIVITY: FJ44-2A
72-60-01
Page 426
Apr 11/08
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-01, Fig. 04
SUBTASK 72-60-01-942-050
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
SUBTASK 72-60-01-943-050
B. Special Tools
Reference Designation
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-944-050
C. Expendable Parts
IPC Reference
Subject Fig Item Nomenclature
72-60-01 04 25 O-Ring
72-60-01 04 36 O-Ring
72-60-01 04 65 O-Ring
EFFECTIVITY: FJ44-2A
72-60-01
Page 427
Apr 11/08
SUBTASK 72-60-01-945-051
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-60 401 Gearbox Assy - Removal/Installation
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
23. Procedures
SUBTASK 72-60-01-420-050
A. Use the following procedure to install spring-loaded carbon seal at the starter/generator location.
Refer to Figure 411 Gearbox Type 2 Spring-Loaded Carbon Seal Starter/Generator.
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
EFFECTIVITY: FJ44-2A
72-60-01
Page 428
Apr 11/08
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (100) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
(3) Install the seal runner (125) onto the generator gearshaft with the highly polished sealing
surface facing out. Push the seal runner down the shaft until it bottoms against the bearing
inner race. Make sure that O-ring does not roll.
(4) Install the carbon seal (125) into the adapter bore using driver from TL99696 kit, or equivalent.
Make sure that the carbon seal is fully installed in the adapter pocket. Make sure that the
O-ring does not roll.
(5) Apply assembly fluid to O-rings (105) and (107) and install on starter/generator adapter.
EFFECTIVITY: FJ44-2A
72-60-01
Page 429
Apr 11/08
NOTES: 1 Assembly fluid is used to make sure that the spring washer and the wave
spring stay in their proper location during installation to gearbox. Make sure
that surfaces are clean of engine oil before applying assembly fluid.
2 Make sure that the split line of the wave spring is located away
from the adapter plate cooling holes.
3 Make sure that the overlap portion of the wave spring is wound as shown
in Figure 413 Wave Spring Proper Winding of Overlap.
(6) Apply three drops of assembly fluid to the spring washer (108) and install it into the adapter
bore. Apply three drops to the wave spring (26) and install it over the spring washer. The
wave spring snaps in place.
(7) Use engine oil (MAT-001) and a clean, lint-free cloth to clean any residual assembly fluid off the
mating faces of the carbon seal and the seal runner.
(8) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
(9) Align and install the adapter onto the gearbox. Lower the adapter plate, using even hand
pressure, until the wave spring is loaded. The adapter bolts will be used to complete the
seating of the adapter plate onto the housing.
(10) Install six bolts (40) and washers (50) to secure the adapter. Gradually tighten the bolts, in
an opposite-and-opposed pattern, to evenly seat the adapter plate assembly on the housing.
Apply 55 to 65 inch-pounds (6.2 to 7.3 N.m) final torque to the bolts.
B. Install the starter-generator to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-051
C. Use the following procedure to Install spring-loaded carbon seal at the fuel pump location. Refer to
Figure 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit.
EFFECTIVITY: FJ44-2A
72-60-01
Page 430
Apr 11/08
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (60) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
(3) Install the seal runner (74) onto the fuel pump gearshaft with the highly polished sealing surface
facing out. Push the seal runner down the shaft until it bottoms against the gearshaft flange.
Make sure O-ring does not roll.
(4) Install carbon seal (70) into seal bore of fuel pump adapter until it bottoms. Use driver from
TL99696 kit, or equivalent. Make sure that the O-ring does not roll.
(5) Apply assembly fluid to O-ring (65) and install on fuel pump adapter.
(6) Use engine oil (MAT-001) and a clean, lint-free cloth to clean any residual assembly fluid off the
mating faces of the carbon seal and the seal runner.
(7) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
EFFECTIVITY: FJ44-2A
72-60-01
Page 431
Apr 11/08
(8) Align bolt holes and carefully install the adapter on the gearbox. Use care not to damage
carbon seal during installation.
(9) Install two bolts (80) and washers (90) to secure adapter. Torque bolts 46 to 51 inch-pounds
(5.3 to 5.7 N.m).
D. Install the fuel pump onto the gearbox. Refer to 73-16-01, P.B. 401.
E. Install the fuel control unit onto the gearbox. Refer to 73-21-01, P.B. 401.
SUBTASK 72-60-01-420-052
F. Use the following procedure to install spring-loaded carbon seal at the hydraulic pump location. Refer
to Figure 412 Gearbox Type 2 Spring-Loaded Carbon Seals (8k) Hydraulic Pump.
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-rings on both carbon seal and seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
(2) Prepare adapter assembly (20) and gearshaft surface for seal installation, as follows:
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
EFFECTIVITY: FJ44-2A
72-60-01
Page 432
Apr 11/08
(3) Install the seal runner (115) onto the gearshaft with the highly polished sealing surface facing
out. Push the seal runner down the shaft until it bottoms against the bearing inner race.
Make sure O-ring does not roll.
(4) Insert a piece of shim stock (0.001 - 0.002 inch) into the adapter to cover the drain hole groove
so that the O-ring is not pinched during installation. Allow enough shim stock to protrude so
that it can be removed after seal installation.
(5) Install the carbon seal (110) into the hydraulic pump adapter until it bottoms. Use driver from
TL99696 kit, or equivalent. Make sure that the O-ring does not roll. Remove shim stock.
(6) Apply assembly fluid to O-ring (25). Install O-ring on adapter assembly.
NOTE Assembly fluid (MAT-011) is used to retain the spring washer, wave
spring, and spring sleeve in the adapter bore when the adapter is
installed on the gearbox. Make sure that these parts are clean and
free of engine oil before applying assembly fluid.
(7) Apply assembly fluid to spring washer (27) and install it over the carbon seal. The X mark
on the spring washer should face the installer. Apply assembly fluid to wave spring (28) and
install it on top of spring washer.
(8) Apply assembly fluid to spring sleeve (29) and install it over the wave spring. The X mark on
the spring sleeve should face down (towards the wave spring).
NOTE Make sure that the aft hydraulic pump (breather tube) carbon seal runner is
properly installed before the gearshaft is installed in the gearbox.
(9) Install the hydraulic pump gearshaft by centering it in the housing bore and engaging the aft
bearing pilot diameter. Rotate, as required, to mesh gear teeth.
(10) Use engine oil (MAT-001) and a clean, lint-free cloth to clean any residual assembly fluid off the
mating faces of the carbon seal and the seal runner (forward and aft carbon seal locations).
(11) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
EFFECTIVITY: FJ44-2A
72-60-01
Page 433
Apr 11/08
(12) Align bolt hole pattern and install hydraulic pump adapter on gearbox. Use care not to damage
the carbon seal during installation. Lower the adapter plate, using even hand pressure, until
the wave spring is loaded. The adapter bolts will be used to complete the seating of the
adapter plate onto the housing.
(13) Install four bolts (40) and washers (50) to secure adapter. Gradually tighten the bolts, in an
opposite-and-opposed pattern, to evenly seat the adapter plate assembly on the housing.
Apply 55 to 65 inch-pounds (6.2 to 7.3 N.m) final torque to the bolts.
G. Install hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
SUBTASK 72-60-01-420-053
H. Use the following procedure to install spring-loaded carbon seal at the aft side of the hydraulic
pump gearshaft (breather tube port). Refer to Figure 410 Gearbox Spring-Loaded Carbon Seals
(8k) Breather Tube.
(1) Prepare new carbon seal and seal runner for assembly as follows:
NOTE Carbon seals and seal runners should not be replaced individually.
They should always be replaced as a set.
(a) Verify correct carbon seal and runner part number at each installation.
(b) Clean the carbon sealing face of the new carbon seal and highly polished sealing face of
the seal runner. Saturate a lint-free cloth with alcohol (MAT-027) or clean engine oil and
turn the seal, face down on the pad to clean.
(c) Lubricate the O-ring on seal runner with assembly fluid (MAT-011).
(d) Inspect seal and runner O-rings for twists or waves prior to assembly. Straighten installed
O-ring by pushing O-ring against the outboard wall of the O-ring groove. For the seal, the
O-ring should be pushed towards the carbon face side of the O-ring groove. For the seal
runner, the O-ring should be pushed towards the seal face.
EFFECTIVITY: FJ44-2A
72-60-01
Page 434
Apr 11/08
NOTE The hydraulic pump gearshaft was removed from the gearbox when the carbon
seal runner was removed. The new seal runner should be installed on the aft
end of the gearshaft before the gearshaft is installed in the gearbox.
(a) Clean gearshaft surface with alcohol (MAT-027) and a clean, lint-free cloth.
(c) Apply a coating of assembly fluid to the breather tube bore of the gearbox housing.
(3) Install the seal runner (32) onto the aft end of the gearshaft. Make sure it is seated and
the O-ring does not roll.
(4) Intstall the hydraulic pump gearshaft and adapter into the gearbox in accordance with Subtask
72-60-01-420-052 (above).
(5) Use engine oil (MAT-001) and a clean, lint-free cloth to clean any residual assembly fluid off the
mating faces of the carbon seal and the seal runner.
(6) Apply one or two drops of clean engine oil to the carbon seal or runner before final assembly.
(7) Install the carbon seal (30) into the housing bore so that it mates with the seal runner.
(8) Apply assembly fluid to breather tube O-ring (36) and install around OD of installed carbon
seal, flush against breather face. Work the O-ring into the groove between the housing and the
carbon seal.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
SUBTASK 72-60-01-410-050
EFFECTIVITY: FJ44-2A
72-60-01
Page 435
Apr 11/08
(1) Service the engine with oil. Refer to 72-00-03, P.B. 301.
B. Perform ground run testing in accordance with the requirements of the List of Test Procedures.
Refer to 710000, P.B. 501.
EFFECTIVITY: FJ44-2A
72-60-01
Page 436
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 437
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 438
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 439
Apr 11/08
Fig. 404 Gearbox Carbon Seals Type 1 Spring-Loaded Configuration (8k) Removal/Installation
EFFECTIVITY: FJ44-2A
72-60-01
Page 440
Apr 11/08
Fig. 405 Gearbox Carbon Seals Type 2 or Type 3 Spring-Loaded Configuration (8k) Removal/Installation
EFFECTIVITY: FJ44-2A
72-60-01
Page 441
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 442
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 443
Apr 11/08
Fig. 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit
EFFECTIVITY: FJ44-2A
72-60-01
Page 444
Apr 11/08
Fig. 409 Gearbox Type 1 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
EFFECTIVITY: FJ44-2A
72-60-01
Page 445
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 446
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 447
Apr 11/08
Fig. 412 Gearbox Type 2 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
EFFECTIVITY: FJ44-2A
72-60-01
Page 448
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-01
Page 449
Apr 11/08
72-60-01
450
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers removal of the delta P indicator from the gearbox. Refer to the following illustration(s):
Figure 401 Delta P Indicator Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-02-941-001
A. Standard Equipment
Oil Drain Pan
3. Job Set-up
SUBTASK 72-60-02-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 72-60-02-020-001
NOTE If indicator is suspected of leaking, confirm location of leak by wiping off oil and
making sure that the leak repeats. If removal is necessary, note the condition
of the O-rings and the gearbox housing sealing surfaces.
EFFECTIVITY: FJ44-2A
72-60-02
Page 401
Apr 11/08
(1) Cut and remove the lockwire which attaches the delta P indicator to the gearbox.
(2) Place an oil drain pan or other suitable container below the indicator to catch oil.
5. General
This task covers installation of the delta P indicator into the gearbox. Refer to the following illustration(s):
Figure 401 Delta P Indicator Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-60-02, Fig. 01
SUBTASK 72-60-02-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-060 Lockwire, .032
SUBTASK 72-60-02-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
72-60-02 01 30 O-ring
72-60-02 01 40 O-ring
SUBTASK 72-60-02-945-002
C. Reference Information
EFFECTIVITY: FJ44-2A
72-60-02
Page 402
Apr 11/08
7. Procedures
SUBTASK 72-60-02-420-001
(1) Lube O-rings with assembly fluid (MAT-011) and install on delta P indicator.
(2) Wipe threads on delta P indicator with a clean cloth to remove excess oil.
(3) Install delta P indicator in gearbox port. Torque indicator 145 to 155 inch-pounds (16.4
- 16.9 N.m).
8. Job Close-up
SUBTASK 72-60-02-610-001
SUBTASK 72-60-02-410-002
EFFECTIVITY: FJ44-2A
72-60-02
Page 403
Apr 11/08
SUBTASK 72-60-02-760-001
C. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501
NOTE If indicator is suspected of leaking, confirm location of leak by wiping off oil and
making sure that the leak repeats. If removal is necessary, note the condition
of the O-rings and the gearbox housing sealing surfaces.
EFFECTIVITY: FJ44-2A
72-60-02
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
72-60-02
Page 405
Apr 11/08
72-60-02
406
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers visual inspection of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 601 Rear Bypass Duct Assembly - Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-71-10-941-001
A. Standard Equipment
Stylus Probe
SUBTASK 72-71-10-942-001
B. Consumables
Reference Designation
MAT-050 Coating, Chemical Conversion (Iridite)
EFFECTIVITY: FJ44-2A
72-71-10
Page 601
Apr 11/08
SUBTASK 72-71-10-945-001
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-12 801 Local Surface Protection - Repair
72-00-71 401 Rear Bypass Duct Assy - Removal/Installation
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 72-71-10-020-001
A. Remove the rear bypass duct assembly. Refer to 720071, P.B. 401.
4. Procedures
SUBTASK 72-71-10-220-001
A. Visually inspect the rear bypass duct assembly as follows (Figure 601 Rear Bypass Duct Assembly -
Inspection):
NOTE If the rear bypass duct is replaced, a new LP shaft sensor trigger pin
must be installed. Refer to 76-20-01, P.B. 501.
(b) Elongation of bolt holes and Smooth blend to remove raised material
scratches due to bolt contact and sharp edges. Apply chemical
conversion coating (Refer to 70-42-12,
P.B. 801 in the Maintenance Manual).
Perform florescent penetrant inspection to
make sure that there are no cracks.
EFFECTIVITY: FJ44-2A
72-71-10
Page 602
Apr 11/08
(d) Chafing or fretting damage. Damage Blend to remove damage using hand
may be removed as long as a stones. Width of blend to be five (5) times
minimum of 0.040 inch sheet metal the depth. Blended area not to exceed
thickness remains after blending. 1.0 inch (25.4 mm) diameter. Touch-up
Blended areas must be separated blended area with chemical conversion
by at least 3 inches. No more than coating.
5 areas may be blended on any
one duct.
(e) Gouge in sheet metal up to 0.045 inch Repair in accordance with Approved
(1.14 mm) deep x 0.180 inch (4.57 Repair Station Instructions.
mm) long x 0.075 inch (1.90 mm) wide
(3) Inspect duct sheet metal for crack indications along weld seam:
Areas of crazing are acceptable in a band that extends 0.5 inches either side of the axial weld
on the duct wall. This area shall extend for the entire axial length of the duct. No evidence of
crazing is to be allowed outside of this area. Linear indications, up to 0.100 inch in length,
are permissible in this area only. No more than ten indications are permitted throughout the
allowable zone and the minimum distance between adjacent indications shall not be less than
four times the length of the longer of the two indications. No indication shall extend through
the duct wall.
(4) Inspect drain boss, trip sensor housing, and brackets for:
EFFECTIVITY: FJ44-2A
72-71-10
Page 603
Apr 11/08
5. Job Close-up
SUBTASK 72-71-10-420-001
EFFECTIVITY: FJ44-2A
72-71-10
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
72-71-10
Page 605
Apr 11/08
72-71-10
606
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers visual inspection of the rear mounting ring assembly. Refer to the following illustration(s):
Figure 601 Rear Mounting Ring Assembly - Inspection/Check
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
72-00-71, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected.
The word "reject" means that the part should not be used in its present
condition. If there is no approved repair procedure, you should keep the part
for a possible future repair procedure and/or contact Williams International,
Walled Lake, Michigan, USA for service.
4 The part callouts in parentheses in the text correspond to the figure-item numbers
used in the Illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
(CH-SE-SU) number. If parts from a different CH-SE-SU are discussed, that
CH-SE-SU number is also included within parentheses.
SUBTASK 72-71-20-941-001
A. Standard Equipment
Stylus Probe
3. Job Set-up
SUBTASK 72-71-20-020-001
A. Remove the rear bypass duct assembly. Refer to 720071, P.B. 401.
EFFECTIVITY: FJ44-2A
72-71-20
Page 601
Apr 11/08
4. Procedures
SUBTASK 72-71-20-220-001
A. Visually inspect the rear mounting ring assembly (1-60, 72-00-71) as follows (Figure 601 Rear
Mounting Ring Assembly - Inspection/Check):
(1) Loss of black chromate outer coating up to Accept at unscheduled or HSI interval;
75% of part surface area recoat in accordance with approved
Repair Station Instructions at CSI.
SUBTASK 72-71-20-220-002
EFFECTIVITY: FJ44-2A
72-71-20
Page 602
Apr 11/08
5. Job Close-up
SUBTASK 72-71-20-420-001
A. Install the rear bypass duct assembly. Refer to 720071, P.B. 401.
EFFECTIVITY: FJ44-2A
72-71-20
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
72-71-20
Page 604
Apr 11/08
CHAPTER 73
Page 1
73-ENGINE FUEL AND CONTROL Apr 11/08
Page 2
73-ENGINE FUEL AND CONTROL Blank
LINE MAINTENANCE MANUAL FJ44-2A
73-00-00 1 Apr 11/08 73-14-01 401 Apr 11/08 73-23-01 601 Apr 11/08
73-10-01 401 Apr 11/08 73-16-01 401 Apr 11/08 73-24-01 201 Apr 11/08
73-10-01 601 Apr 11/08 73-20-00 1 Apr 11/08 73-24-01 401 Apr 11/08
73-11-01 401 Apr 11/08 73-21-01 401 Apr 11/08 73-25-01 401 Apr 11/08
73-12-01 401 Apr 11/08 73-21-01 601 Apr 11/08 73-27-01 201 Apr 11/08
73-12-01 601 Apr 11/08 73-23-01 401 Apr 11/08
Chapter 73
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 73
List of Effective Page Blocks
Page 2
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
The purpose of the fuel system is to supply metered fuel for combustion in the engine combustion section.
Refer to the following illustration:
Figure 1 Fuel System
2. Description
SUBTASK 73-00-00-860-010
B. The fuel pump is made of aluminum and is mounted to the gearbox. The fuel pump uses two pump
elements in a single housing. One element, at the pump inlet, is a radial flow impeller called the
boost stage. The second element is a gear type, positive displacement pump called the pressure
stage. Both elements are driven by a single gearbox drive coupling.
C. The fuel filter is contained in a stainless steel bowl that is threaded into the pump housing. The filter
is located between the boost pump and the gear pump to protect the gear pump from any fuel tank
contaminants. The fuel filter element is 30 micron.
D. The fuel filter electrical indicator (delta P switch) is installed on the fuel pump. It allows fuel to continue
to flow into the gear pump if the differential pressure between the filter inlet and outlet passages
reaches 10 psid. When 4.5 psid is present, an annuciator light in the cockpit will illuminate, indicating
impending bypass. The lamp will remain illuminated until differential pressure drops below 1.5 psid.
EFFECTIVITY: FJ44-2A
73-00-00
Page 1
Apr 11/08
E. Electronic control unit provides several functions. One principle function is to provide limiting for the
critical parameters: N1, N2, and ITT. The ECU controls N1 at high power and N2 at low power. The
ECU is also responsible for thrust and acceleration scheduling.
F. The engine has a fixed flow, stationary fuel nozzle for improved altitude re-start reliability. This nozzle
provides approximately 9 pph of additional fuel flow, continuously, during all engine operation. The
nozzle receives high pressure (P2) metered fuel from the fuel control unit, via the start nozzle
control valve.
G. The fuel manifold supplies fuel to the fuel slinger in the combustion section. The manifold tube goes
through the front bypass duct by way of the right service island and enters the diffuser case. The
manifold supplies fuel to the under side of the rotating fuel slinger.
H. The fuel slinger is located on the HP shaft between the combustor cover and the primary plate. It is
part of the seal and fuel slinger assembly. Fuel is supplied to the under side of the slinger by the
fuel manifold. The fuel is ejected radially outward into the combustion zone through a series of
holes in the slinger.
I. The lube oil cooler is a fuel/oil heat exchanger mounted on the engine gearbox. It uses fuel from the
fuel control to cool engine oil.
3. Operation
SUBTASK 73-00-00-860-011
A. Fuel enters the fuel pump where it is filtered, pressurized, and moved to the HMU through internal
passages in the pump. Metered fuel leaves the HMU and enters the oil cooler (fuel-oil heat
exchanger), then enters the core engine through the fuel manifold tube. A last chance filter is located
in the manifold tube. The manifold tube follows the contour of the diffuser to a fuel distribution manifold
where the fuel is supplied to the underside of the fuel slinger. The fuel slinger, which rotates with the
HP rotary group, ejects the fuel radially through a series of delivery holes into the combustion zone.
Additional fuel for engine relight is continuously supplied from the HMU to the fuel nozzle where it
is sprayed directly into the combustion zone.
4. Fuel Shutdown
SUBTASK 73-00-00-860-012
A. A fuel shutoff valve, which is controlled by power lever movement, provides the normal means
for engine shutdown.
B. A mechanical LP (N1) shaft separation detection device, mounted on the engine, will detect LP shaft
rearward movement of 0.050 inch (1.27 mm) or greater. This safety device will prevent an LP turbine
rotor overspeed condition, and possible turbine burst, in case of LP shaft separation. It does this by
automatically shutting off fuel flow to the fuel control unit via mechanical linkage.
EFFECTIVITY: FJ44-2A
73-00-00
Page 2
Apr 11/08
EFFECTIVITY: FJ44-2A
73-00-00
Page 3
Apr 11/08
73-00-004
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 401 Fuel Tube Assemblies - Removal/Installation
Figure 402 Fuel Tube Loop Clamps - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2 Use this task to remove any of the external fuel tube assemblies. The tube
assemblies covered by this task are as follows:
SUBTASK 73-10-01-941-005
A. Standard Equipment
Backup Wrench
3. Job Set-up
SUBTASK 73-10-01-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
73-10-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 73-10-01-050-003
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(1) Loosen tube nuts on fuel tube. Use a backup wrench on fittings and/or reducers.
5. General
This task provides procedures for installing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 403 Fuel Tube Assemblies - Removal/Installation
Figure 402 Fuel Tube Loop Clamps - Removal/Installation
Figure 404 Fuel Tube and Cables Interference
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
SUBTASK 73-10-01-942-006
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 73-10-01-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
EFFECTIVITY: FJ44-2A
73-10-01
Page 402
Apr 11/08
7. Procedures
SUBTASK 73-10-01-450-003
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(1) Lubricate tube nut threads and contact surfaces with engine oil MAT-001.
(2) Align and install the fuel tube. Allow a minimum of 0.060-inch (1.524 mm) space between fuel
tubes and other components. Use a back-up wrench on fittings and/or reducers.
(1) Make sure fittings are aligned and torque both ends of the flex tube assembly 70 to 120
inch-pounds (7.9 to 13.5 N.m).
(2) Install loop clamp on fuel tube. Secure loop clamp (and igniter lead loop clamp) onto bracket
with two spacers, screw, and nut. Torque nut 25 to 28 inch-pounds (2.8 to 3.1 N.m).
EFFECTIVITY: FJ44-2A
73-10-01
Page 403
Apr 11/08
8. Job Close-up
SUBTASK 73-10-01-410-006
SUBTASK 73-10-01-760-003
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-10-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
73-10-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
73-10-01
Page 407
Apr 11/08
EFFECTIVITY: FJ44-2A
73-10-01
Page 408
Apr 11/08
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-10-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 73-10-01-945-009
A. Reference Information
CH-SE-SU Pg Block Nomenclature
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
3. Procedures
SUBTASK 73-10-01-220-001
NOTE Any nicks or high metal that are otherwise within acceptable limits should be
repaired in accordance with 70-42-11, P.B. 801.
(1) Damage:
EFFECTIVITY: FJ44-2A
73-10-01
Page 601
Apr 11/08
(3) Nicks:
(4) Galled:
EFFECTIVITY: FJ44-2A
73-10-01
Page 602
Apr 11/08
1. General
This task provides procedures for removing the fuel drain tube assembly. Refer to the following illustration:
Figure 401 Fuel Drain Tube Assemblies - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-11-01-943-003
A. Special Tools
Reference Designation
TL65047 Puller, Drain Tube
3. Job Set-up
SUBTASK 73-11-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
73-11-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 73-11-01-020-003
A. Remove the aircraft fuel drain line from the fuel drain boss at the 6:00 oclock location on the front
bypass duct. Refer to the Aircraft Maintenance Manual.
SUBTASK 73-11-01-020-004
(1) Remove one screw and loop clamp brackets and remove drain plug from the aft drain tube port
of the fuel drain boss on the front bypass duct. Remove O-ring from drain fitting.
(2) Insert a .250-28, 2 to 3-inch bolt (or TL65047) into forward drain tube port on fuel drain boss
and install it into forward drain tube. Remove forward drain tube from fuel drain boss. Remove
O-rings and seal from tube.
(3) Insert the same bolt (or TL65047) into the aft drain tube port on the fuel drain boss and
install it into the aft (short) fuel drain tube. Remove aft drain tube from port. Remove O-ring
and seal from drain tube.
5. General
This task provides procedures for installing the fuel drain tube assembly. Refer to the following illustration:
Figure 401 Fuel Drain Tube Assemblies - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-11-01, Fig. 01
SUBTASK 73-11-01-942-004
A. Consumables
EFFECTIVITY: FJ44-2A
73-11-01
Page 402
Apr 11/08
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-11-01-943-004
B. Special Tools
Reference Designation
TL65047 Puller, Drain Tube
SUBTASK 73-11-01-944-004
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-11-01 01 30 O-ring (2)
73-11-01 01 10 Seal, Drain Tube (2)
73-11-01 01 40 O-ring (2)
SUBTASK 73-11-01-945-004
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-11-01-420-003
(1) Install one drain tube seal on the ball end of both the forward and the aft fuel drain tubes. Make
sure that the spring side of the seal is visible (facing the core of the engine), when installed.
Lubricate two O-rings with MAT-011 assembly fluid and install on the flat end of the forward
and aft fuel drain tubes.
EFFECTIVITY: FJ44-2A
73-11-01
Page 403
Apr 11/08
(2) Install a .250-28, 2 to 3-inch long bolt (or TL65047) into the threaded end of the forward (long)
fuel drain tube. Insert the tube through the forward drain tube port and into the fuel drain
boss on the diffuser. Remove bolt.
(3) Install same bolt (or TL65047) into the threaded end of the aft (short) fuel drain tube. Insert the
tube through the aft drain tube port and into the fuel drain boss on the diffuser. Remove bolt.
(4) Lubricate O-ring with assembly fluid and install on drain plug.
(5) Install drain plug into aft drain tube port. Install screw and loop clamps. Torque screw 25 to
28 inch-pounds (2.8 to 3.1 N.m).
SUBTASK 73-11-01-420-004
B. Install the aircraft fuel drain tube to the fuel drain boss. Refer to the Aircraft Maintenance Manual.
8. Job Close-up
SUBTASK 73-11-01-410-004
SUBTASK 73-11-01-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-11-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
73-11-01
Page 405
Apr 11/08
73-11-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 401 Fuel Nozzle Removal/Installation
Figure 402 Fuel Nozzle Adapter Wrench
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-12-01-942-001
A. Consumables
Reference Designation
MAT-024 Solvent, Dry Cleaning
SUBTASK 73-12-01-943-001
B. Special Tools
Reference Designation
TL37212 or TL37330
TL99517 Socket, Fuel Adapter Nozzle, Slotted
3. Job Set-up
SUBTASK 73-12-01-010-001
EFFECTIVITY: FJ44-2A
73-12-01
Page 401
Apr 11/08
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-12-01-020-001
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(1) Remove the flexible tube assembly from the fuel nozzle.
(2) Loosen the bulkhead nut which holds the fuel nozzle assembly.
(3) Turn the fuel nozzle assembly counter-clockwise and remove from the fuel nozzle adapter
assembly. If necessary, apply dry cleaning solvent (MAT-024) between nozzle and adapter to
loosen carbon deposits. Remove O-ring and bulkhead nut from the fuel nozzle assembly.
NOTE If the fuel nozzle assembly cannot be removed from the adapter due to carbon
build-up, it is allowable to use TL99517, slotted fuel nozzle adapter socket, to
remove the adapter with the nozzle still installed. This requires cutting and
replacement of the seals. Contact Williams International Product Support.
B. Remove fuel nozzle port seals and fuel nozzle adapter assembly, as follows:
(1) Remove retaining ring, fuel nozzle plate seal, and fuel nozzle ring seal from the fuel nozzle port.
EFFECTIVITY: FJ44-2A
73-12-01
Page 402
Apr 11/08
CAUTION TO AVOID BENDING THE ADAPTER, KEEP THE FUEL NOZZLE ADAPTER
WRENCH CENTERED IN THE PORT DURING REMOVAL/INSTALLATION.
(2) Insert fuel nozzle adapter wrench TL37212 or TL37330 into the fuel nozzle port and engage it
onto the slots in the top face of the bearing retainer nut. Loosen nut and remove fuel nozzle
adapter assembly from the fuel nozzle port.
5. General
This task provides procedures for installing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 401 Fuel Nozzle Removal/Installation
Figure 402 Fuel Nozzle Adapter Wrench
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-12-01, Fig. 01
SUBTASK 73-12-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-12-01-943-002
B. Special Tools
Reference Designation
TL37212 Wrench, Fuel Nozzle Adapter
TL37330 Socket, Fuel Nozzle Adapter
TL99517 Socket, Fuel Adapter Nozzle, Slotted
SUBTASK 73-12-01-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-12-01 01 110 O-ring
EFFECTIVITY: FJ44-2A
73-12-01
Page 403
Apr 11/08
SUBTASK 73-12-01-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
73-12-01 501 Fuel Nozzle Assembly - Adjustment/Test
7. Procedures
SUBTASK 73-12-01-420-001
A. You must recalculate the depth setting of the fuel nozzle if any of the following conditions apply:
NOTE If any of the above conditions apply, measure nozzle depth and adjust
by replacing shim. Refer to 73-12-01, P.B. 501.
B. If removed, install the fuel nozzle port seals and fuel nozzle adapter assembly as follows:
CAUTION TO AVOID BENDING THE ADAPTER, KEEP THE FUEL NOZZLE ADAPTER
WRENCH CENTERED IN THE PORT DURING REMOVAL/INSTALLATION.
(1) Install fuel nozzle adapter assembly into fuel nozzle port. Using fuel nozzle adapter wrench
TL37212 TL99517 TL37330 torque bearing retainer nut 300 to 325 inch-pounds (33.9 to
36.7 N.m).
(2) Install fuel nozzle ring seal, fuel nozzle plate seal, and retaining ring.
(2) Lubricate O-ring with assembly fluid (MAT-011) and install on fuel nozzle assembly.
(3) Insert the fuel nozzle assembly into the fuel nozzle adapter and torque nozzle 50 to 54
inch-pounds (5.6 to 6.1 N.m) to initially seat the nozzle. Turn nozzle counter-clockwise one-half
turn to loosen and then re-torque to a final torque nozzle 20 to 24 inch-pounds (2.2 to 2.7 N.m) .
EFFECTIVITY: FJ44-2A
73-12-01
Page 404
Apr 11/08
NOTE When torquing fuel nozzle assembly or bulkhead nut, use a backup wrench
on the fuel nozzle adapter assembly to keep it from turning.
(5) Install the flexible tube assembly to the fuel nozzle. Refer to 73-10-01, P.B. 401.
8. Job Close-up
SUBTASK 73-12-01-410-002
SUBTASK 73-12-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-12-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
73-12-01
Page 406
Apr 11/08
EFFECTIVITY: FJ44-2A
73-12-01
Page 407
Apr 11/08
73-12-01
408
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601 Fuel Nozzle Adapter - Visual Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-12-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 73-12-01-942-004
A. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-024 Solvent, Dry Cleaning
SUBTASK 73-12-01-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
73-12-01 401 Fuel Nozzle Assembly - Removal/Installation
EFFECTIVITY: FJ44-2A
73-12-01
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 73-12-01-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
SUBTASK 73-12-01-020-003
B. Remove the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
4. Procedures
SUBTASK 73-12-01-220-001
A. Visually inspect:
(a) Signs of coking on nozzle (signs of Clean with mineral spirits (MAT-020) or dry
solid carbon or varnish build-up cleaning solvent (MAT-024) and a nylon
which may interfere with the normal brush while blowing 35 psi filtered air
operation of the nozzle). through nozzle.
B. Visually inspect:
EFFECTIVITY: FJ44-2A
73-12-01
Page 602
Apr 11/08
5. Job Close-up
SUBTASK 73-12-01-420-003
A. Install the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
SUBTASK 73-12-01-410-004
6. General
This task provides procedures for checking the fuel nozzle spray pattern. Refer to the following
illustration(s):
Figure 602 Fuel Nozzle Assembly - Spray Pattern Check
SUBTASK 73-12-01-941-005
A. Standard Equipment
Fuel Nozzle Spray Test Equipment
EFFECTIVITY: FJ44-2A
73-12-01
Page 603
Apr 11/08
SUBTASK 73-12-01-942-005
B. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-023 Ultrasonic Cleaner, Caustic
SUBTASK 73-12-01-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
73-12-01 401 Fuel Nozzle Assembly - Removal/Installation
8. Job Set-up
SUBTASK 73-12-01-010-006
(2) Open the circuit breakers to isolate the engine electrical supply.
SUBTASK 73-12-01-020-004
B. Remove the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
9. Procedures
SUBTASK 73-12-01-730-001
A. Check fuel nozzle spray pattern using fuel or mineral spirits MAT-020 as follows:
(1) Connect the fuel nozzle to fuel nozzle spray test equipment.
EFFECTIVITY: FJ44-2A
73-12-01
Page 604
Apr 11/08
(2) Set flow rate on spray test equipment to 100 psig, minimum.
(3) Flow fuel/mineral spirits through the nozzle and observe the spray pattern. Refer to Figure 602
Fuel Nozzle Assembly - Spray Pattern Check.
NOTE If nozzle tip is pointing down, fluid will drain out of the nozzle which
may appear as drips from the nozzle orifice.
(a) The spray pattern should be conical with no visible streaks or voids.
(b) If the spray pattern is not acceptable, refer to ultrasonic cleaning procedure, Subtask
73-12-01-730-002.
(4) Disconnect the fuel nozzle from the fuel nozzle spray test equipment.
SUBTASK 73-12-01-730-002
B. If fuel nozzle fails spray pattern check, ultrasonic clean the fuel nozzle as follows:
(1) Stand nozzle assembly upright in wire basket with elbow down (tip facing up). Secure nozzle to
keep it from tipping over during cleaning.
(2) Immerse in caustic ultrasonic solution MAT-023 for four, six-minute cycles.
(3) Recheck nozzle flow pattern. Reject nozzle if flow pattern does not meet flow requirements.
SUBTASK 73-12-01-420-004
SUBTASK 73-12-01-410-005
EFFECTIVITY: FJ44-2A
73-12-01
Page 605
Apr 11/08
EFFECTIVITY: FJ44-2A
73-12-01
Page 606
Apr 11/08
EFFECTIVITY: FJ44-2A
73-12-01
Page 607
Apr 11/08
EFFECTIVITY: FJ44-2A
73-12-01
Page 608
Apr 11/08
TASK 73-14-01-050-801 Remove the Fuel Filter from the Fuel Pump
1. General
This task provides procedures for removing the fuel filter from the fuel pump. Refer to the following
illustration(s):
Figure 401 Fuel Pump Filter - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
3. Job Set-up
SUBTASK 73-14-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-14-01-020-001
EFFECTIVITY: FJ44-2A
73-14-01
Page 401
Apr 11/08
(2) Remove the filter bowl from the fuel pump housing using wrench on bowl wrench flats. Remove
the filter and O-ring from the fuel pump housing.
NOTE Removal of sharp edges and raise material of the wrench flats of the
filter bowl will ensure hardware in close proximity is not damaged during
installation/removal and personnel are not injured. Rounding of the corners will
not affect functionality of the bowl or inhibit the ability to remove/install.
(3) Inspect and remove sharp edges and raise material on the removal nut feature on the filter bowl.
5. Job Close-up
SUBTASK 73-14-01-410-001
6. General
This task provides procedures for installing the fuel filter on the fuel pump. Refer to the following
illustration(s):
Figure 401 Fuel Pump Filter - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-14-01, Fig. 01
SUBTASK 73-14-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-060 Lockwire, .032
EFFECTIVITY: FJ44-2A
73-14-01
Page 402
Apr 11/08
SUBTASK 73-14-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-14-01 01 30 Filter
73-14-01 01 40 O-Ring
SUBTASK 73-14-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
8. Job Set-up
SUBTASK 73-14-01-010-001
NOTE Removal of sharp edges and raise material of the wrench flats of the filter bowl will
ensure hardware in close proximity is not damaged during installation/removal
and personnel are not injured. Rounding of the corners will not affect functionality
of the bowl or inhibit the ability to remove/install.
A. Inspect and remove sharp edges and raise material on the removal nut feature on the filter bowl.
9. Procedures
SUBTASK 73-14-01-420-001
NOTE Removal of sharp edges and raise material of the wrench flats of the filter bowl will
ensure hardware in close proximity is not damaged during installation/removal
and personnel are not injured. Rounding of the corners will not affect functionality
of the bowl or inhibit the ability to remove/install.
EFFECTIVITY: FJ44-2A
73-14-01
Page 403
Apr 11/08
(1) Lube the filter O-ring with a light coat of assembly fluid (MAT-011) and install the filter on
the fuel pump.
(2) Lube the filter bowl O-ring with assembly fluid and install on the filter bowl.
(3) Install the filter bowl over the filter. Torque the filter bowl 80 to 100 inch-pounds (9.0 to 11.2
N.m).
(4) Install lockwire (MAT-060) to safety the filter bowl to the fuel pump housing.
SUBTASK 73-14-01-410-002
SUBTASK 73-14-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-14-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
73-14-01
Page 405
Apr 11/08
73-14-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the fuel pump assembly. Refer to the following illustration(s):
Figure 401 Fuel Pump - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-16-01-942-001
A. Consumables
Reference Designation
MAT-010 Grease, Aircraft, General Purpose
SUBTASK 73-16-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
3. Job Set-up
SUBTASK 73-16-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply
EFFECTIVITY: FJ44-2A
73-16-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 73-16-01-020-001
A. Remove the fuel control unit (FCU). Refer to 73-21-01, P.B. 401.
SUBTASK 73-16-01-020-002
B. Remove the fuel filter Delta P indicator. Refer to 73-23-01, P.B. 401.
SUBTASK 73-16-01-020-003
(1) Disconnect the fuel-in tube assembly from the fuel pump adapter. Refer to Aircraft Maintenance
Manual (A.M.M.)
(2) Disconnect the drain tube assembly from the fuel pump drain fitting.
(3) Remove three nuts and washers and remove the fuel pump from the gearbox assembly.
(4) Remove the drain fitting and O-ring and the fuel-in adapter and O-ring from the fuel pump
(if required).
SUBTASK 73-16-01-210-001
D. Check drive shafts on gearbox and FCU sides of pump for secure engagement of shaft retaining rings.
E. If gearbox drive shaft pulls out of the fuel pump when fuel pump is removed from gearbox, install
drive shaft as follows:
(1) If removed, press the retaining ring on the drive shaft. Apply grease MAT-010 to the spline with
the retaining ring; spline on gearbox end of the shaft is not to be greased.
(2) Install the drive shaft into the drive gear until the retaining ring snaps into the gear.
F. If FCU drive shaft pulls out of the fuel pump when FCU is removed from the fuel pump, install
drive shaft as follows:
(2) Insert the drive shaft into the fuel pump until it snaps in place.
EFFECTIVITY: FJ44-2A
73-16-01
Page 402
Apr 11/08
G. If fuel pump is to be packaged for shipment, make sure that it contains no residual fuel.
5. General
This task provides procedures for installing the fuel pump assembly. Refer to the following illustration(s):
Figure 401 Fuel Pump - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-16-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 73-16-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-16-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-16-01 01 40 O-Ring
73-16-01 01 50 O-Ring
73-16-01 01 60 O-Ring
SUBTASK 73-16-01-945-002
C. Reference Information
EFFECTIVITY: FJ44-2A
73-16-01
Page 403
Apr 11/08
7. Procedures
SUBTASK 73-16-01-420-001
(1) If drain fitting was removed, lubricate O-ring with assembly fluid (MAT-011) and install on fitting.
Install fitting into drain port on fuel pump and torque 90 to 100 inch-pounds (10.1 to 11.2 N.m).
(2) If fuel-in adapter fitting was removed, install adapter and fitting in accordance with the Aircraft
Maintenance Manual.
(3) Lubricate two O-rings with assembly fluid and install on shaft and mounting flange of the
fuel pump.
(4) Install the fuel pump on the gearbox, aligning the mounting studs with the mounting holes on
the pump. Install three washers and nuts.
(5) Torque nuts 110 to 123 inch-pounds (12.4 to 13.8 N.m). Use TL99924 torque adapter as
required.
(6) Install the fuel-in tube assembly to the fuel pump adapter and install fuel drain line to drain
fitting. Refer to the Aircraft Maintenance Manual.
SUBTASK 73-16-01-420-002
B. Install the fuel filter Delta P indicator. Refer to 73-23-01, P.B. 401.
SUBTASK 73-16-01-420-003
EFFECTIVITY: FJ44-2A
73-16-01
Page 404
Apr 11/08
8. Job Close-up
SUBTASK 73-16-01-410-002
SUBTASK 73-16-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-16-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
73-16-01
Page 406
Apr 11/08
1. General
The electronic fuel control unit (EFCU) is comprised of an engine-mounted hydromechanical control unit
(HMU) and an airframe-mounted electronic control unit (ECU). The EFCU utilizes TT2, N1 N2, ITT, and
Pamb as sensor inputs to adjust fuel schedules and govern engine operation within limits. Refer to the
following illustration(s):
Figure 1 EFCU System - Block Diagram
SUBTASK 73-20-00-860-004
One of the principle functions of the ECU is to provide limiting for critical parameters: N1, N2, and
ITT. The N1 governor limits N1 at high power while the N2 governor limits N2 at low power. The
overspeed function limits both N1 and N2. ITT is held to a start limit during the start and to a fixed
margin above the redline during run. New engine production margins will ensure that the governed
N1 speed will result in max ITT values below the redline. As the engine deteriorates with time, the ITT
margin at max N1 will decrease and may eventually reach the redline limit indicating maintenance
action is necessary. The pilot is responsible to limit ITT, as required.
The ECU is also responsible for thrust and acceleration scheduling through fuel metering commands
to the HMU torque motor. Normal takeoff thrust (in the ELECTRONIC mode) is commanded when the
PLA is at 85(2) and scheduled based on inputs of N1, TT2, Pamb, and three discretes (anti-ice 1,
anti-ice 2, & TT2 heat compensate). Aircraft electrical power is to be provided directly to the anti-ice
heater on the TT2 sensor in response to the pilot initiated anti-ice discrete. The appropriate power
lever stop (preferably mechanical ) for normal takeoff thrust PLA is the responsibility of the airframer.
ELECTRONIC mode operation with the PLA above 90 (or above 75 when above 20000 feet) is not
permitted since a reversion to MANUAL may cause an operating limit to be exceeded.
Maximum continuous/climb thrust is commanded when the PLA is at 72(2). The appropriate
indicator or detent is the responsibility of the airframer.
EFFECTIVITY: FJ44-2A
73-20-00
Page 1
Apr 11/08
Idle (flight or ground) is commanded when the PLA is at 17.5(2). Flight idle versus ground idle
thrust is scheduled based on the aircraft "Weight On Wheels (WOW)" discrete which has: an 8
second built-in delay for ground idle selection, and a 2 second delay for flight idle selection (from
ground idle). Selection of the "idle select" discrete commands ground idle without the 8 second
time delay (when the WOW discrete is closed). The appropriate idle PLA position stop is also the
responsibility of the airframer. Engine acceleration is scheduled as a function of the rate of change of
N2 (N2 DOT), TT2 and ambient pressure (altitude). The ECU also commands the engine HMU to
open the engine acceleration/deceleration bleed valve via mechanical linkage whenever acceleration
or deceleration is commanded above 34,000 rpm N2. Below 34000 rpm N2 the acceleration bleed
valve is kept open under all operating conditions. Engine shutdown is initiated when the PLA passes
down through 11 and is completed at 8. A minimum PLA hard stop at 0 (+0/-2) is provided on the
HMU. The min stop tolerance on the HMU relative to the station line is +20.5/-9.5 (see Installation
Drawing). Note that all the PLA positions and tolerances are measured at the HMU. Rig pin holes are
provided at the idle (17.5) and T.O.(90) PLA positions.
Another discrete initiated by the pilot, commands the ECU to activate either the ELECTRONIC
or MANUAL mode. The ECU sends a status discrete back to the aircraft (pilot) for
ELECTRONIC/MANUAL operation.
When certain ECU BIT checks fail, the ECU will output a maintenance fault discrete to the airframe to
indicate that maintenance may be required.
Engine synchronization is provided by the ECU for twin engine operation. Two airframe discrete
inputs activate synchronization and determine the master/slave engine. Communication between twin
ECUs is through a RS422 serial communication link. When synchronization is commanded, N1 is
synchronized at high power settings (above 40 PLA while on the N1 governor schedule) and N2 is
synchronized at low power settings (while on the N2 governor schedule). The power levers must also
be within 8.5 of each other at or below MC power lever angle. Synchronization authority is limited to
approximately 5.1% N1 and 2.4% N2. Synchronization is disabled above MC power lever angle.
An ARINC 429 serial data output is available between the ECU and the aircraft systems. This serial
stream contains internal EFCU data and EFCU maintenance data. The ARINC output of some
parameters are not available during engine starts. These parameters and data rates are defined in
the Installation Instructions.
The ECU contains a Test Mode Enable Discrete. When closed, it enables communication between
an ECU and ground support equipment via a RS 422 serial data link. This, with a password, enables
downloading of ECU fault records and ECU operating parameters for ECU diagnostics. When the
test mode enable discrete (or circuit) is opened, communication through the link is stopped and
allows RS422 inter-engine communication to resume.
The EFCU system automatically engages self check logic upon ECU power up or engine shutdown.
A maintenance lamp is illuminated when there is an anomaly with the EFCU that may require
maintenance. In addition, the ECU records parameter exceedences. The EFCU records the anomaly
and the exceedences in non-volatile memory that can be downloaded with a maintenance computer.
These parameters are presented in the Installation Instructions and Maintenance Manual.
EFFECTIVITY: FJ44-2A
73-20-00
Page 2
Apr 11/08
The EFCU records N1, N2 and ITT exceedences if they occur along with illuminating the
maintenance lamp.
The HMU receives inputs of compressor discharge pressure (CDP) and N2 directly from the engine
and PLA from the pilot. In the MANUAL mode, the HMU schedules steady state and transient thrust
as a function of N2 speed which is, in turn, a fixed function of PLA. Reversion to MANUAL results
in less thrust on a hot day and more thrust on a cold day compared to the ELECTRONIC mode.
Compressor bleed and power extraction will increase governor droop causing further thrust decreases
in the MANUAL mode. The thrust change due to an ECU reversion can be fully regained by
advancing the PLA beyond the 90airframe supplied stop or reducing PLA below 90. Takeoff power,
max continuous power, and idle speed settings in the MANUAL mode are the pilot responsibility via
charts as a function of N1, TT2, and altitude (Po). Maximum PLA travel in the MANUAL mode is
100(+4/-0) and a hard stop on the HMU is provided to limit maximum travel. In the MANUAL mode
the power lever has a slight self advancing torque not present in the ELECTRONIC mode. Also in the
MANUAL mode, the minimum idle PLA flat is increased slightly to 17.5 (+3.5/-5).
The HMU limiting functions are restricted to N2 and maximum and minimum fuel flow.
In both the MANUAL and ELECTRONIC modes, the LP turbine overspeed due to LP shaft failure is
limited via a mechanical linkage connected to the HMU fuel shutoff valve. This linkage is actuated
by aft movement of the LP turbine rotors in the event of an LP shaft failure, automatically shutting
down the engine.
In the MANUAL mode, the HMU fixes the acceleration bleed valve open and acceleration schedules
are not compensated by TT2. This results in faster acceleration on colder days versus warmer days.
In MANUAL mode, where the acceleration bleed valve is always open, ITT will be slightly increased.
Additional start fuel is available (start enrichment) in the MANUAL mode by advancing the PLA up to
30 to assist in acceleration during MANUAL mode starts (if required).
Synchronization is not available in the manual mode. HMU functions that are active in both the
ELECTRONIC and MANUAL modes are as follows:
Positive mechanical shutoff of the main fuel supply via the PLA.
EFFECTIVITY: FJ44-2A
73-20-00
Page 3
Apr 11/08
EFFECTIVITY: FJ44-2A
73-20-00
Page 4
Apr 11/08
1. General
This task provides procedures for removing the fuel control unit from the engine. Refer to the following
illustration(s):
Figure 401 Fuel Control Unit - Heatshield - Removal/Installation
Figure 402 Fuel Control Unit - Fuel Tubes - Locator View
Figure 403 Fuel Control Unit - Fuel Tubes - Removal/Installation
Figure 404 Fuel Control Unit - Removal/Installation
Figure 405 Fuel Control Unit - Removal/Installation
Figure 406 Fuel Control Unit - Removal/Installation
Figure 407 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
Figure 408 HMU/IFCU Discrepancy Report
NOTES: 1 During removal of parts, group all components together to make assembly easier.
3 In order to enable troubleshooting of the removed FCU, make sure that operating
conditions and engine parameters observed during test are recorded on
Figure 408 HMU/IFCU Discrepancy Report
and returned with the suspect part.
2. Job Set-up
SUBTASK 73-21-01-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
73-21-01
Page 401
Apr 11/08
3. Procedures
SUBTASK 73-21-01-020-003
A. Download bit faults and exceedences from the electronic control unit. After download is complete,
clear bit faults and exceedances from the electronic control unit. Refer to Download Data from ECU,
Maintenance Practices in 73-24-01, P.B. 201.
C. Disconnect the EFCU engine harness electrical connector plug (P2) from the jack (J2) on the left side
of the hydromechanical fuel control unit (HMU). Cap the harness plug and the jack.
D. Remove the throttle control linkage and components as required from the PLA shaft on the bottom of
the HMU. Refer to the Aircraft Maintenance Manual.
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(3) Disconnect the HMU-to-oil cooler (fuel-out) tube from the HMU.
(5) Remove loop clamp from the CDP to HMU tube. Disconnect the CDP to HMU tube from
the HMU.
(6) Loosen the CDP tube at the service adapter and remove.
(7) Disconnect the LP trip sensor cable from the HMU as follows:
(a) Cut the safety wire and disconnect the jam nut which attaches the forward end of the
cable to the HMU.
(b) Remove two screws, four washers, and two nuts which attach the cable actuator housing
to the LP trip sensor housing. Remove the cable actuator housing by pulling it forward
with a hard pull.
(c) Slide the cable assembly straight back to remove from the HMU.
(d) Disconnect the EFCU harness P2 connector plug from the HMU.
EFFECTIVITY: FJ44-2A
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(8) Disconnect the acceleration bleed cable. Remove the roll pin from the cable ball end of the
acceleration bleed cable. Place ring in a protective bag and tag it for later reinstallment.
(a) Insert a 0.125 inch (3.175 mm) rod through the hole in the side of the HMU plunger to
keep it from turning. Loosen the inner cable jam nut on the HMU side of the acceleration
bleed cable assembly and unthread by turning the cable (inner) at the IP bleed boss end.
Remove inner cable jam nut.
(b) Remove the outer cable front jam nut which attaches the (outer) cable assembly to
the HMU. Remove the cable.
(9) Remove three nuts and three washers which attach the HMU to the fuel pump. Remove the
HMU from the fuel pump.
(10) Remove the nipple and O-ring from the WF port on the HMU.
(11) Remove the elbow and O-ring from the P3 port on the HMU.
(12) Remove the nipple and O-ring from the SN port on the HMU.
(13) If HMU is to be packaged for shipment, make sure it contains no residual fuel. Install protective
plugs to all open ports.
(14) Complete the attached discrepancy report Figure 408 HMU/IFCU Discrepancy Reportand
include with removed fuel control unit.
4. General
This task provides procedures for installing the fuel control unit on the engine. Refer to the following
illustration(s):
Figure 401 Fuel Control Unit - Heatshield - Removal/Installation
Figure 402 Fuel Control Unit - Fuel Tubes - Locator View
Figure 403 Fuel Control Unit - Fuel Tubes - Removal/Installation
Figure 404 Fuel Control Unit - Removal/Installation
Figure 405 FCU - Accel Bleed Cable - Adjustment
Figure 406 Fuel Control Unit - LP Trip Cable Adjustment
Figure 407 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
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Page 403
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Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean MAT-001
engine oil before installation unless otherwise indicated in text.
SUBTASK 73-21-01-941-006
A. Standard Equipment
Ohmmeter
SUBTASK 73-21-01-942-006
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-027 Alcohol, Isopropyl
MAT-061 Lockwire, .020
SUBTASK 73-21-01-943-006
C. Special Tools
Reference Designation
TL99924 Torque Adapter
SUBTASK 73-21-01-944-006
D. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-21-01 01 20 O-Ring
73-21-01 01 30 O-Ring
73-21-01 01 35 O-Ring
73-21-01 01 40 O-Ring
73-21-01 01 70 O-Ring
EFFECTIVITY: FJ44-2A
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Page 404
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73-2101 01 85 O-Ring
73-21-01 01 95 O-Ring
SUBTASK 73-21-01-945-006
E. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
77-40-01 601 EFCU Engine Wiring Harness Assembly - Inspection/Check
6. Procedures
SUBTASK 73-21-01-420-003
(1) Before installing HMU on engine, install CDP bracket with screw. Torque 25 to 28 inch-pounds
(2.8 to 3.2 N.m.).
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. CONTAINERS SHOULD BE PLACED
BELOW WORK AREA TO CATCH DRIPPING FUEL.
(2) Connect the LP trip sensor actuator cable to the HMU as follows:
(a) Insert the cable through the support bracket on the HMU and attach the cable with
washer and jam nut.
(b) Push the cable all the way aft so that it is seated in the trip mechanism. Adjust the gap
between the shutoff valve arm and the cable to 0.001 - 0.005 inch (0.025 - 0.127 mm).
(3) Lubricate the O-ring with MAT-011 assembly fluid and install on elbow. Install elbow to the
P3 port on the HMU. Do not torque elbow nut at this time.
(4) Lubricate O-ring with assembly fluid and install on nipple. Install nipple into WF port on HMU.
Torque nipple 58 to 63 inch-pounds (6.5 to 7.1 N.m).
(5) Lubricate O-ring with assembly fluid and install on nipple. Install nipple into SN port on HMU.
Torque nipple 38 to 42 inch-pounds (4.2 to 4.7 N.m).
EFFECTIVITY: FJ44-2A
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(6) Lubricate four O-rings with assembly fluid. Install one O-ring on HMU shaft flange and three on
HMU flange.
(7) Align and install the HMU on the fuel pump. Attach HMU with three washers and nuts. Torque
the nuts 110 to 123 inch-pounds (12.4 to 13.8 N.m). Use TL99924 torque adapter as required.
NOTE It may be necessary to loosen the forward jam nut and rotate the
actuator cable to get the proper alignment when mounting the actuator
housing on the trip sensor housing.
(a) Install cable actuator housing and gasket to the LP trip sensor housing.
(b) Attach the cable actuator housing with two screws, four washers, and two nuts. Torque
nuts 25 to 28 inch-pounds (2.8 to 3.2 N.m).
(c) Torque the cable jam nut 85 to 95 inch-pounds (23.1 to 25.7 N.m) Lockwire jam nuts to
each other using MAT-061 safety wire (0.020).
(8) Install the acceleration bleed cable assembly. Refer to 75-37-01, P.B. 401.
(9) Install an O-ring on CDP to HMU tube assembly and an O-ring on the elbow. Install the
elbow in the HMU and hand tighten nut. Install tube assembly to elbow. Align tube assembly
to service adapter port.
(10) Install retainer with two washers and two screws and torque 25 to 28 inch-pounds (2.8 to 3.1
N.m). Torque elbow jam nut 38 to 42 inch-pounds (4.2 to 4.7 N.m). Torque tube nut 135 to 150
inch-pounds (15.2 to 16.9 N.m).
(11) After installing HMU and connecting CDP to HMU tube, install loop clamp on tube at HMU
bracket location. Orient the loop clamp outboard and forward. Secure loop clamp to bracket
with one bolt and nut.Torque nut 49 to 55 inch pounds (5.5 to 6.2 N.m).
(12) Install the HMU-to-oil cooler tube on the HMU. Torque tube nuts 450 to 500 inch-pounds
(50.8 to 56.4 N.m).
(13) Connect flex tube assembly to nipple in SN port of HMU. Torque tube 70 to 120inch-pounds
(7.9 to 13.5 N.m).
(14) Attach the loose end of the electrical bonding strap as follows:
(a) Prior to installing the bonding strap, inspect for signs of corrosion. Replace strap
if corrosion is present.
EFFECTIVITY: FJ44-2A
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Apr 11/08
(b) Secure loose end of bonding strap to HMU with one bolt. Torque bolt 49 to 55 inch
pounds (5.5 to 6.2 N.m).
(15) Adjust the power lever. Refer to the Aircraft Maintenance Manual.
(16) Install heatshield with five screws. Torque 31 to 35 inch-pounds (3.5 to 3.9 N.m).
(17) Install the throttle control linkage and components. Refer to the Aircraft Maintenance Manual.
(b) Check all used contacts for short to connector case using an ohmmeter. Refer to
77-40-01, P.B. 601.
(19) Connect the EFCU engine harness electrical connector plug (P2) to the jack (J2) on the
left side of the HMU.
7. Job Close-up
SUBTASK 73-21-01-410-006
SUBTASK 73-21-01-760-003
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-21-01
Page 407
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73-21-01
Page 408
Apr 11/08
EFFECTIVITY: FJ44-2A
73-21-01
Page 409
Apr 11/08
EFFECTIVITY: FJ44-2A
73-21-01
Page 410
Apr 11/08
EFFECTIVITY: FJ44-2A
73-21-01
Page 411
Apr 11/08
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73-21-01
Page 412
Apr 11/08
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Page 413
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Fig. 407 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2A
73-21-01
Page 414
Apr 11/08
EFFECTIVITY: FJ44-2A
73-21-01
Page 415
Apr 11/08
73-21-01
416
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for visually inspecting the fuel control unit.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-21-01, Fig. 01
NOTE You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 73-21-01-945-008
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-21-01 401 Fuel Control Unit - Removal/Installation
3. Procedures
SUBTASK 73-21-01-220-002
(2) Loose hose, tube, or linkage connections Tighten. Refer to 73-21-01, P.B. 401
(3) External leakage around mating surfaces, Re-install FCU Refer to 73-21-01, P.B. 401
mounting surfaces, plugs, shafts, or
connections
(1) Edge cracks up to 0.130 inch (3.3 mm) long. Stop-drill crack using 0.0625 inch diameter
drill.
(2) Cracks adjacent to mounting hole up to Weld repair and blend down smooth
0.350 inch (8.89 mm) long.
EFFECTIVITY: FJ44-2A
73-21-01
Page 601
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EFFECTIVITY: FJ44-2A
73-21-01
Page 602
Apr 11/08
1. General
This task provides procedures for removing the fuel filter indicator. Refer to the following illustration(s):
Figure 401 Fuel Filter Indicator - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-23-01-943-001
A. Special Tools
Reference Designation
TL39454 Torque Adapter, Fuel Indicator
3. Job Set-up
SUBTASK 73-23-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
73-23-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 73-23-01-020-001
SUBTASK 73-23-01-050-001
5. General
This task provides procedures for installing the fuel filter indicator. Refer to the following illustration(s):
Figure 401 Fuel Filter Indicator - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-23-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 73-23-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-061 Lockwire, .020
EFFECTIVITY: FJ44-2A
73-23-01
Page 402
Apr 11/08
SUBTASK 73-23-01-943-002
B. Special Tools
Reference Designation
TL39454 Torque Adapter, Fuel Indicator
SUBTASK 73-23-01-944-002
C. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-23-01 01 20 O-Ring
73-23-01 01 30 O-Ring
SUBTASK 73-23-01-945-002
D. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-23-01-420-001
WARNING FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL
THAT CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY.
CLOTHING WITH FUEL CONTAMINATION MUST BE THOROUGHLY
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(1) Lubricate two O-rings with assembly fluid (MAT-011). Install one O-ring at O-ring groove at
bottom of delta P switch, and one O-ring at boss seal flange.
SUBTASK 73-23-01-450-001
B. Using TL39454 torque adapter, torque delta P switch 145 to 155 inch-pounds (16.3 to 17.4 N.m).
EFFECTIVITY: FJ44-2A
73-23-01
Page 403
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SUBTASK 73-23-01-450-003
SUBTASK 73-23-01-450-004
8. Job Close-up
SUBTASK 73-23-01-410-002
SUBTASK 73-23-01-760-001
B. Perform engine testing per the Table Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-23-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
73-23-01
Page 405
Apr 11/08
73-23-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
TASK 73-23-01-220-801 Visually Inspect the Fuel Filter Indicator (Delta P Switch)
1. General
This task covers visual check of the fuel filter indicator. Refer to the following illustration(s):.
Figure 601 Fuel Filter Indicator - Visual Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog: 73-23-01, Fig. 01
SUBTASK 73-23-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
3. Procedures
SUBTASK 73-23-01-020-002
A. Remove the fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
SUBTASK 73-23-01-220-001
TASK 73-23-01-750-801 Perform Resistance Check on Fuel Filter Indicator (Delta P Switch)
4. General
This task performs the resistance check on the fuel filter indicator. Refer to the following illustration(s):
Figure 602 Fuel Filter Indicator - Resistance Check
EFFECTIVITY: FJ44-2A
73-23-01
Page 601
Apr 11/08
SUBTASK 73-23-01-941-004
A. Standard Equipment
Multimeter
SUBTASK 73-23-01-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
73-23-01 401 Fuel Filter Indicator (Delta P Switch) - Removal/Installation
6. Procedures
SUBTASK 73-23-01-750-001
A. Using a multimeter set to "ohms", do an electrical resistance and continuity check as follows:
CONNECTOR PIN CONNECTOR PIN/CASE RESISTANCE LIMIT
A case 10 Mohms minimum (isolation)
B case 10 Mohms minimum (isolation)
A B 10 Mohms minimum (isolation)
B C 2 ohms maximum (continuity)
B. If fuel filter delta P switch does not meet resistance limits, reject.
SUBTASK 73-23-01-420-002
C. Install the fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
EFFECTIVITY: FJ44-2A
73-23-01
Page 602
Apr 11/08
EFFECTIVITY: FJ44-2A
73-23-01
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
73-23-01
Page 604
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1. General
This task provides the EMT hardware requirements and guidance for choosing the appropriate hardware,
procedures for loading the software into the laptop computer, and procedures for downloading data from
the ECU.
The electronic control unit (ECU) collects operating limit exceedence and BIT fault data. This data is
downloaded from the ECU by using an Electronic Maintenance Terminal (EMT). The downloaded data is
stored in Comma Delimited Format.
SUBTASK 73-24-01-941-002
A. Standard Equipment
Laptop Computer
SUBTASK 73-24-01-943-002
B. Special Tools
Reference Designation
TL99516 Cable Assembly, EMT
TL99600 Terminal, Electronic Maint (Software) - Level 1
TL99604 EMT Converter
TL99605 EMT Converter, USB
TL99756 Terminal, Electronic Maintenance (Software)
SUBTASK 73-24-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 101 Power Plant - Fault Isolation
EFFECTIVITY: FJ44-2A
73-24-01
Page 201
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3. Job Setup
SUBTASK 73-24-01-010-001
A. EMT Hardware Requirements: The following table is a list of components required to connect a
Laptop Computer to the TL99516 cable, enabling communication between the engine ECU and the
EMT software.
QTY P/N DESCRIPTION
1 Commercial Laptop Computer with Windows 95, 98, 2000, or XP operating system
2 TL99600 or EMT (Electronic Maintenance Terminal) CD-ROM and ECU CD-ROM
TL99756 Software
1 TL99516 Cable, EMT
1 TL99604 Converter, EMT (serial port)
See NOTES OR
1 TL99605 Converter, EMT, USB
See NOTES
(1) Insert TL99600 or TL99756 EMT CD-ROM and open Windows Explorer to the CD-ROM drive.
(4) After installation is complete, remove the diskette / CD from the laptop. Do not try to run the
program until you install the ECU CD-ROM software or the installation will fail.
(5) Insert the ECU CD-ROM in the drive and open Windows Explorer to the CD-ROM drive.
EFFECTIVITY: FJ44-2A
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(8) After installation is complete, remove the ECU CD-ROM from the laptop. Your EMT software is
now installed. Connection to the engine ECU is now possible.
4. Procedures
SUBTASK 73-24-01-910-002
NOTE The EMT HELP function contains detailed directions for all of the following procedures.
A. Connect the EMT to the aircraft engine maintenance connector port. Refer to Figure 201 EMT -
Connecting to ECU.
NOTE When connecting the maintenance cable to the converter, the choice of using
the LEFT or RIGHT connector is dependent on the enunciator light(s).
Exceedence
BIT Fault
Exceedence
BIT Fault
D. View downloaded data. Refer to the troubleshooting task, EFCU Maintenance Fault Indicator ON, in
71-00-00, P.B. 101, for detailed BIT fault troubleshooting procedures. If needed, contact Customer
Support.
E. If a new or different ECU is being installed, clear BIT and Exceedence data.
F. Troubleshooting
If an error occurs during downloading or a data file cannot be read, notify Customer Support.
EFFECTIVITY: FJ44-2A
73-24-01
Page 203
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EFFECTIVITY: FJ44-2A
73-24-01
Page 204
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1. General
This task provides procedures for removing the Electronic Control Unit. Refer to the following illustration(s):
Figure 401 Electronic Control Unit (ECU) - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 73-24-01-945-005
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-24-01 201 Electronic Control Unit - Maintenance Practices
3. Job Set-up
SUBTASK 73-24-01-010-005
A. Download and clear any BIT Fault or Exceedence data in ECU memory. Refer to 73-24-01, P.B. 201.
(2) Open the circuit breakers to isolate the ECU electrical supply.
(3) Access the aircraft tail cavity. Refer to the Aircraft Maintenance Manual.
4. Procedures
SUBTASK 73-24-01-020-002
B. Remove the ECU to airframe harness connector (P4) from the ECU connector (J4).
D. Remove one screw and remove the electrical bond strap from the ECU.
EFFECTIVITY: FJ44-2A
73-24-01
Page 401
Apr 11/08
E. Remove four bolts from ECU mounts and remove ECU from aircraft.
5. General
This task provides procedures for installing the Electronic Control Unit. Refer to the following illustration(s):
Figure 401 Electronic Control Unit (ECU) - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-24-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean MAT-001
engine oil before installation unless otherwise indicated in text.
SUBTASK 73-24-01-941-006
A. Standard Equipment
Ohmmeter
SUBTASK 73-24-01-942-006
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-027 Alcohol, Isopropyl
MAT-061 Lockwire, .020
SUBTASK 73-24-01-945-006
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
73-24-01 201 Electronic Control Unit - Maintenance Practices
EFFECTIVITY: FJ44-2A
73-24-01
Page 402
Apr 11/08
7. Procedures
SUBTASK 73-24-01-420-002
B. Install electrical bond strap to ECU and secure with one screw. Torque 32 - 35 inch-pounds (3.6 to
3.95 N.m).
(2) Check all used contacts for short to connector case using an ohmmeter.
F. If used, connect ambient pressure line to ECU pressure port. Torque ambient pressure nut and
MAT-061safety wire ( 0.020.
8. Job Close-up
SUBTASK 73-24-01-410-006
B. Verify that BIT Fault and Exceedence data records are clear in ECU memory before operation.
Refer to 73-24-01, P.B. 201.
EFFECTIVITY: FJ44-2A
73-24-01
Page 403
Apr 11/08
SUBTASK 73-24-01-760-002
C. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-24-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
73-24-01
Page 405
Apr 11/08
73-24-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the fuel manifold filter. Do this task as required by periodic
maintenance. Refer to the following illustration(s):
Figure 401 Fuel Manifold Filter - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 73-25-01-941-001
A. Standard Equipment
Ultrasonic Cleaning Equipment
3. Job Set-up
SUBTASK 73-25-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-25-01-020-001
EFFECTIVITY: FJ44-2A
73-25-01
Page 401
Apr 11/08
(2) Remove the fuel filter from the engine service adapter fuel port.
5. General
This tasks provides procedures for installing the fuel manifold filter. Refer to the following illustration(s):
Figure 401 Fuel Manifold Filter - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
73-25-01, Fig. 01
SUBTASK 73-25-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 73-25-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
73-25-01 01 10 Filter, Assembly, Fuel Manifold
73-25-01 01 20 O-ring
EFFECTIVITY: FJ44-2A
73-25-01
Page 402
Apr 11/08
SUBTASK 73-25-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
7. Procedures
SUBTASK 73-25-01-420-001
(1) Lubricate O-ring with assembly fluid (MAT-011) and install on the fuel filter assembly.
(2) Apply a light coat of engine oil (MAT-001) to threads of the fuel filter.
(3) Install the fuel manifold filter into the service adapter fuel port and torque 38 to 42 inch-pounds
(4.2 to 4.7 N.m).
(4) Install the fuel tube assembly. Use backup wrench on filter and torque 135 to 150 inch-pounds
(15.2 to 16.9 N.m).
8. Job Close-up
SUBTASK 73-25-01-410-002
SUBTASK 73-25-01-760-001
B. Perform engine testing per the table Test Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-25-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
73-25-01
Page 404
Apr 11/08
1. General
This task provides procedures for resetting the fuel shutoff valve. Refer to the following illustration(s):
Figure 201 Fuel Control Shut-Off Valve - Reset
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 73-27-01-942-001
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-060 Lockwire, .032
SUBTASK 73-27-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
71-00-50 601 LP Turbines (Borescope) - Inspection/Check
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 73-27-01-010-001
EFFECTIVITY: FJ44-2A
73-27-01
Page 201
Apr 11/08
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 73-27-01-210-001
CAUTION YOU MUST FULLY IDENTIFY THE REASON WHY THE FUEL SHUTOFF VALVE
TRIPPED BEFORE PUTTING THE ENGINE BACK IN SERVICE.
A. Before placing an engine that has had the FCU shutoff valve activated by the LP trip sensor back
into service, do the following:
(1) Refer to 71-00-50, P.B. 601. Inspect the LP shaft end and LP turbines with a borescope. Look
through the port in the rear housing and inspect for:
SUBTASK 73-27-01-830-002
SUBTASK 73-27-01-020-001
C. Remove cable assembly and cable actuator housing. Refer to 76-20-01, P.B. 501.
SUBTASK 73-27-01-830-003
NOTE The shutoff valve arm, when in the open position, holds the reset pin in.
When the shutoff valve is closed, the arm is pushed forward and the pin
comes across to hold it in the closed position.
(1) Push in the reset pin on the FCU. This allows you to move the shutoff valve arm back in the
open position holding the reset button in.
SUBTASK 73-27-01-830-004
E. Reset the LP shaft trip sensor mechanism. Refer to 76-20-01, P.B. 501.
EFFECTIVITY: FJ44-2A
73-27-01
Page 202
Apr 11/08
SUBTASK 73-27-01-420-001
SUBTASK 73-27-01-820-001
SUBTASK 73-27-01-420-002
(1) Insert the cable through the support boss on the FCU and attach cable with two washers
and two jam nuts.
(2) Push the inner cable all the way aft so that it is seated in the trip mechanism. Adjust the
gap between the shutoff valve arm, and the inner cable end, to 0.001 - 0.005 inches (0.025
- 0.127 mm).
(3) Torque jam nuts 75 to 85 inch-pounds (8.47 to 9.6 N.m). Install lockwire (MAT-060) to jam nuts.
5. Job Close-up
SUBTASK 73-27-01-410-001
SUBTASK 73-27-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
73-27-01
Page 203
Apr 11/08
EFFECTIVITY: FJ44-2A
73-27-01
Page 204
Apr 11/08
CHAPTER 74
IGNITION
Page 1
74-IGNITION Apr 11/08
Page 2
74-IGNITION Blank
LINE MAINTENANCE MANUAL FJ44-2A
74-00-00 1 Apr 11/08 74-20-01 401 Apr 11/08 74-22-01 601 Apr 11/08
74-00-10 501 Apr 11/08 74-20-01 601 Apr 11/08 74-22-01 701 Apr 11/08
74-10-01 401 Apr 11/08 74-22-01 401 Apr 11/08
Chapter 74
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 74
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
The ignition system supplies spark to ignite the fuel/air mixture in the combustor. Refer to the following
illustration(s):
Figure 1 Ignition System
2. Description
SUBTASK 74-00-00-860-002
B. The two ignition exciters are high energy, capacitive discharge devices. The parts for each ignition
exciter are contained in a corrosion resistant, case which is sealed against air. Both ignition exciter
cases are mounted to the engine interstage housing. The spark rate is one to six sparks per channel,
per second. The exciters can operate continuously with input voltage ranging from 10 to 30 volts,
3.5 Joules stored energy.
C. The igniter leads are made from a low-loss coaxial cable which is designed for use at 18 to 24 Kv.
The right and left leads are different lengths.
D. The igniter plugs are sealed against air and have precious metal electrodes. The igniter plug case is
made of high temperature, corrosion resistant alloys.
3. Operation
SUBTASK 74-00-00-860-003
A. The ignition switch in the cockpit activates the ignition exciters. The ignition exciters draw current
from the battery and sends current through each igniter lead, independently, at a rate of one to six
sparks per second. The igniter plugs ignite the fuel/air mixture in the combustor. Igniters continue to
fire until the ignition switch is turned off.
EFFECTIVITY: FJ44-2A
74-00-00
Page 1
Apr 11/08
EFFECTIVITY: FJ44-2A
74-00-00
Page 2
Apr 11/08
1. General
SUBTASK 74-00-10-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
74-22-01 401 Igniter Plug - Removal/Installation
3. Job Set-up
SUBTASK 74-00-10-010-001
4. Procedures
SUBTASK 74-00-10-770-001
(1) Switch the ignition system to the ON position. Refer to the Aircraft Maintenance Manual.
(2) Listen for the igniters firing. The igniters may start out firing together or they may start out
alternately firing. In either case, they will drift from one mode to the other. If you can hear both
igniters firing in this way, functional test is complete. If you cannot hear both igniters firing in
this way, one or both of the igniters are malfunctioning.
EFFECTIVITY: FJ44-2A
74-00-10
Page 501
Apr 11/08
(c) Remove igniter leads from igniters. Use a backup wrench on igniter plug flats.
(d) Remove igniter plug nuts and remove igniter plugs from engine.
(e) Install igniter leads to igniter plugs. Use a backup wrench on igniter plug flats.
(f) Let igniters hang down below engine for operational test.
(b) From a distance of at least 10 feet (3 meters), visually make sure that igniters fire
(make a spark).
(d) Replace defective igniters as required. Install igniters in accordance with 74-22-01,
P.B. 401.
EFFECTIVITY: FJ44-2A
74-00-10
Page 502
Apr 11/08
5. Job Close-up
SUBTASK 74-00-10-410-001
EFFECTIVITY: FJ44-2A
74-00-10
Page 503
Apr 11/08
74-00-10
504
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the ignition exciters. Refer to the following illustration(s):
Figure 401 Ignition Exciter - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 74-10-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 74-10-01-050-001
(1) Disconnect the two electrical connectors from the forward side of the two ignition exciters.
(2) Remove lockwire from the igniter lead connectors and disconnect igniter leads from the ignition
exciters. Put protective covers on the cable ends.
(3) Remove four nuts, eight washers, and four bolts from the ignition exciter clamps and brackets.
Remove the two exciter clamps.
EFFECTIVITY: FJ44-2A
74-10-01
Page 401
Apr 11/08
(4) Remove the ignition exciters, put in a protective bag and identify as required.
4. General
This task provides procedures for removing the ignition exciter. Refer to the following illustration(s):
Figure 401 Ignition Exciter - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-10-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 74-10-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 74-10-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
74-00-10 501 Ignition System - Adjustment/Test
6. Procedures
SUBTASK 74-10-01-420-001
(1) Install ignition exciters onto the forward and rear mounting brackets. Locate the igniter leads
toward the aft end of the engine.
(2) Attach the ignition exciters with two clamps, four bolts, eight washers and four nuts. Torque
nuts 2 to 5 inch-pounds (0.22 to 0.56 N.m) above the prevailing run-on torque.
EFFECTIVITY: FJ44-2A
74-10-01
Page 402
Apr 11/08
(3) Remove protective covers from the igniter leads and install the two cables into the two ignition
exciters. Torque each lead 140 to 150 inch-pounds (15.7 to 16.8 N.m). Install lockwire
(MAT-061) to the igniter lead nuts.
(5) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
7. Job Close-up
SUBTASK 74-10-01-410-002
SUBTASK 74-10-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
74-10-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
74-10-01
Page 404
Apr 11/08
1. General
This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401 Igniter Leads - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 74-20-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
3. Job Set-up
SUBTASK 74-20-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 74-20-01-020-001
(1) Remove aircraft power leads from the two ignition exciters.
EFFECTIVITY: FJ44-2A
74-20-01
Page 401
Apr 11/08
(4) Remove fuel tubes, as required, to gain access to the igniter lead clamps. Refer to 73-10-01,
P.B. 401
(5) Remove the screws from the clamps which secure the igniter lead to the brackets. Note that
one of the clamps has a spring screw and is released by turning the screw 90.
(6) Disconnect the igniter lead from the igniter plug. Use a back-up wrench on the igniter plug flats.
Remove the igniter lead.
5. General
This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401 Igniter Leads - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-20-01, Fig. 01
SUBTASK 74-20-01-942-002
A. Consumables
Reference Designation
MAT-061 Lockwire, .020
SUBTASK 74-20-01-945-002
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
74-00-10 501 Ignition System - Adjustment/Test
EFFECTIVITY: FJ44-2A
74-20-01
Page 402
Apr 11/08
7. Procedures
SUBTASK 74-20-01-420-001
(1) If not already installed, install .025-inch spiral wrap to igniter leads. Secure spiral wrap with
nylon strap locks and trim ends of strap locks flush.
SUBTASK 74-20-01-450-003
B. Install the straight end of the igniter lead to the ignition exciter.
SUBTASK 74-20-01-450-002
(2) Install the 90 end of the igniter lead to the igniter plug.
(3) Torque the igniter lead at the ignition exciter end 140 to 150 inch-pounds (15.7 to 16.8 N.m).
(4) Torque the igniter lead at the igniter end 240 to 250 inch-pounds (27.1 to 28.2 N.m).
(5) Lockwire the two igniter lead nuts together with .020 inch lockwire (MAT-061).
(b) Carefully close the clamps on the leads, slotted clamp first.
(c) Align the "T" nut on the clamp screw with the slots in the clamp arm and the clamp base,
then push through and lock into position.
(7) Install other lead clamps and torque clamp bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(8) Install the fuel tubes that were removed for access to the igniter leads. Refer to 73-10-01,
P.B. 401.
(10) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
8. Job Close-up
SUBTASK 74-20-01-410-002
EFFECTIVITY: FJ44-2A
74-20-01
Page 403
Apr 11/08
SUBTASK 74-20-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501..
EFFECTIVITY: FJ44-2A
74-20-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
74-20-01
Page 405
Apr 11/08
74-20-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for visually inspecting the igniter leads.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-20-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 74-20-01-942-003
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
SUBTASK 74-20-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
74-20-01 401 Igniter Lead - Removal/Installation
3. Procedures
SUBTASK 74-20-01-020-002
SUBTASK 74-20-01-220-001
EFFECTIVITY: FJ44-2A
74-20-01
Page 601
Apr 11/08
(g) Missing or damaged spiral wrap Install new spiral wrap. Refer to 74-20-01,
P.B. 401
SUBTASK 74-20-01-420-002
EFFECTIVITY: FJ44-2A
74-20-01
Page 602
Apr 11/08
1. General
This task provides procedures for removing the igniter plugs. Refer to the following illustration(s):
Figure 401 Igniter Plug Removal/Installation
Figure 402 Igniter Adapter Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 74-22-01-942-001
A. Consumables
Reference Designation
MAT-013 Magnesium Hydroxide
3. Job Set-up
SUBTASK 74-22-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 74-22-01-020-001
(1) Disconnect the aircraft electrical leads from the ignition exciters.
(2) Use a back-up wrench on the igniter plug wrench flats and disconnect the igniter lead from the
igniter plug. Put a protective cover on the igniter cable end.
EFFECTIVITY: FJ44-2A
74-22-01
Page 401
Apr 11/08
(3) Remove igniter plug nut and igniter plug from the igniter boss on the service island. If the igniter
plug adapter loosens from the diffuser port during igniter plug nut removal, do the following:
(b) Remove retaining ring, igniter plug ring seal, and igniter plug plate seal.
(c) Remove igniter plug nut, igniter plug, and igniter plug adapter as an assembly from the
engine. The spacer will come out separately.
(d) Separate igniter plug nut from the igniter plug adapter.
(e) Reinstall igniter plug adapter and spacer into igniter boss on the service island. Lubricate
igniter plug adapter threads with MAT-013 and torque 590 to 610 inch-pounds (66.6
to 68.9 N.m).
(4) Remove the internal retaining ring which holds the igniter plug to the igniter plug nut. Separate
the igniter plug from the igniter plug nut.
5. General
This task provides procedures for installing the igniter plugs. Refer to the following illustration(s):
Figure 401 Igniter Plug Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
74-22-01, Fig. 01
SUBTASK 74-22-01-942-002
A. Consumables
Reference Designation
MAT-013 Magnesium Hydroxide
MAT-015 Lubricant, Anti-seize
SUBTASK 74-22-01-945-002
B. Reference Information
EFFECTIVITY: FJ44-2A
74-22-01
Page 402
Apr 11/08
7. Procedures
SUBTASK 74-22-01-420-001
NOTE If HP turbine nozzle and/or primary plate were replaced, igniter shim must
be recalculated. Refer to 74-22-02, P.B. 501.
(1) Insert the igniter plug into the igniter plug nut and install the internal retaining ring. Ensure
retaining ring is installed below the last thread in the igniter plug nut.
(2) Apply magnesium hydroxide MAT-013 or anti-seize lubricant MAT-015 to the igniter plug nut
threads.
(3) Following the angle of the igniter boss, insert the igniter plug and igniter nut into the diffuser
and locate in the hole in the combustor.
NOTE The igniter plug nut will not thread on the boss if the igniter plug is
not located in the combustor primary plate.
(4) Torque the igniter plug nut 300 to 325 inch-pounds (33.8 to 36.7 N.m).
(5) Remove protective covering from the igniter lead and install on the igniter plug. Hold the
igniter plug with a back-up wrench and torque the igniter lead 240 to 250 inch-pounds (27.1
to 28.2 N.m).
(7) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
EFFECTIVITY: FJ44-2A
74-22-01
Page 403
Apr 11/08
8. Job Close-up
SUBTASK 74-22-01-410-002
SUBTASK 74-22-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
C. Indicate in the engine logbook the hours/cycles that igniter was installed.
EFFECTIVITY: FJ44-2A
74-22-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
74-22-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
74-22-01
Page 406
Apr 11/08
1. General
Perform this task at the interval shown in Routine Periodic Inspections, 05-20-00, P.B. 601. Refer to the
following illustration(s):
Figure 601 Igniter Plug - Visual Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog: 74-22-01, Fig. 01.
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 74-22-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
74-22-01 401 Igniter Plug - Removal/Installation
74-22-01 701 Igniter Plug - Cleaning
3. Procedures
SUBTASK 74-22-01-020-002
SUBTASK 74-22-01-220-001
EFFECTIVITY: FJ44-2A
74-22-01
Page 601
Apr 11/08
C. Visually inspect the igniter tip for combustion deposits. Clean, refer to 74-22-01, P.B. 701
NOTE When checking for binding of spherical pivot, make sure that pivot area is
clean and free from anti-seize compound residue.
4. General.
This task covers dimensional inspection of the igniter plugs for erosion or wear. Refer to the following
illustration(s):
Figure 602 Igniter Plug - Erosion Measurement
SUBTASK 74-22-01-941-005
A. Standard Equipment
Depth Micrometer Or Caliper (probe Diameter 0.100
Inch [2.54 Mm] Or Less)
SUBTASK 74-22-01-945-005
B. Reference Information
CH-SE-SU Pg Block Nomenclature
74-22-01 401 Igniter Plug - Removal/Installation
EFFECTIVITY: FJ44-2A
74-22-01
Page 602
Apr 11/08
6. Procedures
SUBTASK 74-22-01-220-003
A. Measure the internal wear groove in the tip using a Depth Micrometer or Caliper (probe diameter
0.100 inch [2.54 mm] or less)as follows:
(1) Measure the distance between the face of the igniter tip and the center electrode. Refer to
Figure 602 Igniter Plug - Erosion Measurement. Check the igniter part number and compare
the dimension with the evaluation criteria in the table below:
IGNITER PART NUMBER ACCEPT REJECT
68032 0.215 inch (5.461 mm) or less Greater than 0.215 inch (5.461 mm)
CH31956 See Note 1
57846
CH31876-6
70161 0.134 inch (3.403 mm) or less Greater than 0.134 inch (3.403 mm)
See Note 1
SUBTASK 74-22-01-420-002
EFFECTIVITY: FJ44-2A
74-22-01
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
74-22-01
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
74-22-01
Page 605
Apr 11/08
74-22-01
606
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
SUBTASK 74-22-01-942-006
A. Consumables
Reference Designation
MAT-020 Mineral Spirits
MAT-028 Alcohol, Methyl, Wood, or Methanol
SUBTASK 74-22-01-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
74-22-01 401 Igniter Plug - Removal/Installation
3. Procedures
SUBTASK 74-22-01-020-003
SUBTASK 74-22-01-120-001
(2) Terminal well may be cleaned with a felt swab saturated in mineral spirits MAT-020 or methyl,
wood, or methanol alcohol MAT-028.
EFFECTIVITY: FJ44-2A
74-22-01
Page 701
Apr 11/08
SUBTASK 74-22-01-420-003
EFFECTIVITY: FJ44-2A
74-22-01
Page 702
Apr 11/08
CHAPTER 75
AIR
Page 1
75-AIR Apr 11/08
Page 2
75-AIR Blank
LINE MAINTENANCE MANUAL FJ44-2A
75-00-00 1 Apr 11/08 75-35-01 401 Apr 11/08 75-37-01 401 Apr 11/08
75-30-01 601 Apr 11/08 75-35-01 501 Apr 11/08
Chapter 75
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 75
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
The FJ44 is a two spool, axial flow, bypass turbofan engine. The bypass ratio is 3.3 : 1. The engine has
three compressors: a low pressure (LP) axial compressor, an intermediate pressure (IP) axial compressor,
and a high pressure (HP) centrifugal compressor. The LP compressor (fan) and IP compressor are driven
by two LP turbines. The HP compressor is driven by a single HP turbine. When the mixture of fuel and
compressed air is ignited in the combustor section, the expanding gases drive the turbines.
SUBTASK 75-00-00-860-005
A. Bypass Principal.
The bypass principal lets part of the air passing through the fan bypass the IP compressor, HP
compressor, combustor section and HP and LP turbines. This permits the engine to use high cyclic
temperatures and pressures and still produce a low jet exhaust velocity. Bypass air also decreases
the velocity and temperature of the exhaust gases. This combination creates high thermal efficiency
and high propulsive efficiency. In addition, the bypass air decreases the noise level and increases
the power/weight ratio for a given engine thrust.
B. Cooling Air
Cooling air comes from the HP compressor at the diffuser flange. It is known as compressor
discharge pressure (CDP). CDP air moves through the 1st LP turbine nozzle to cool the two LP
turbines. Diffused air cools the HP nozzle and the HP turbines.
The acceleration bleed system is operated by the fuel control unit (FCU). The acceleration bleed
cable connects the FCU with a butterfly valve in the interstage housing. The butterfly valve is open at
engine start and is closed by the FCU when the engine reaches 84.7% to 85.2% N2. This allows
unloading of the HP compressor during acceleration.
D. HP Bleed
There are two HP bleed connections for aircraft use. The ports are located at each service island.
The HP bleed ports are capped with a marmon type clamp and cap when not in use. The HP bleed
air is taken from the diffuser boss and moved out through the bypass duct by a short pipe.
EFFECTIVITY: FJ44-2A
75-00-00
Page 1
Apr 11/08
75-00-002
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-37-01, Fig. 02
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
3 You should not discard parts which fail inspection limits and are rejected. The word
"reject" means that the part should not be used in its present condition. Approved
repair procedures for this part are contained in page block 801. If there is no approved
repair procedure listed, you should keep the part for a possible future repair procedure
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 75-30-01-942-001
A. Consumables
Reference Designation
MAT-008 Lubricant, Molybdenum Disulfide
MAT-040 Cloth, Abrasive
MAT-089 Sealant, RTV 103
SUBTASK 75-30-01-945-001
B. Reference Information
CH-SE-SU Pg Block Nomenclature
75-35-01 501 Acceleration Bleed System Lever - Adjustment/Test
EFFECTIVITY: FJ44-2A
75-30-01
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 75-30-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-30-01-220-001
(1) Minor damage to outer cable insulation Repair with adhesive sealant MAT-089
(RTV 103, black)
(2) Shrink tubing pulled away from cable at Apply a shrink tube splice
fuel control side.
(5) Light wear on inner cable Polish the wear out with 400 grit abrasive
cloth MAT-040. Apply molybdenum
disulfide lubricant MAT-008.
(6) Cracked inner cable coating (FJ44 pull-only Strip nylon coating back to a point 2.3
configuration) inches (58.42 mm) back from tip of the
swaged ball. All nylon coating that exhibits
cracks, splits, peeled coating or bare
areas shall be reworked if defects occur
with in this 2.3 inch region.
Apply a 1.90 inch (48.2 mm) long piece of
teflon shrink tube over bare cable. Overlay
end of nylon coating. Shrink tube ends
shall have a smooth transition. Trim to
allow full closure of bleed valve.
SUBTASK 75-30-01-220-002
EFFECTIVITY: FJ44-2A
75-30-01
Page 602
Apr 11/08
5. Job Close-up
SUBTASK 75-30-01-410-001
EFFECTIVITY: FJ44-2A
75-30-01
Page 603
Apr 11/08
Fig. 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection
EFFECTIVITY: FJ44-2A
75-30-01
Page 604
Apr 11/08
1. General
This task provides procedures for removing the acceleration bleed system lever. Refer to the following
illustration(s):
Figure 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 75-35-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 75-35-01-020-002
A. Remove the "pull only" configuration acceleration bleed system lever as follows:
(1) Remove one bolt, cover, and spacer from the acceleration bleed port cover.
(3) Remove the retaining clip or roll pin (depending on the engine configuration) which attaches
the ball end of the cable to the bleed lever.
(4) Remove one screw and nut which attaches the bleed lever to the shaft. Remove the bleed
lever and key from the shaft.
EFFECTIVITY: FJ44-2A
75-35-01
Page 401
Apr 11/08
4. General
This task provides procedures for installing the acceleration bleed system lever. Refer to the following
illustration(s):
Figure 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-35-01, Fig. 02
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001engine oil before installation.
SUBTASK 75-35-01-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 75-35-01-945-004
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
75-35-01 501 Acceleration Bleed System Lever - Adjustment/Test
6. Procedures
SUBTASK 75-35-01-420-002
A. Install the "pull only" configuration acceleration bleed system lever as follows:
(1) Install the spring over the bleed valve shaft and align lower tang over the right-rear bolt hole
of the bleed port cover.
(2) Install washer and bolt into right-rear bolt hole of the bleed port cover. Ensure that the lower
tang of spring is hooked around bolt. Torque bolt 36 to 40 inch-pounds (4.0 to 4.5 N.m).
EFFECTIVITY: FJ44-2A
75-35-01
Page 402
Apr 11/08
(3) Install the woodruff key in the slot in the bleed valve shaft and install the bleed lever on the
shaft, aligning the key slots. Install the screw and the nut which secures the lever on the shaft.
Torque nut 25 to 28 inch-pounds (2.8 to 3.5 N.m).
(4) Hook the upper tang of spring around the bleed lever.
(5) Install the ball end of the acceleration bleed cable in the lever and secure with roll pin or
retaining ring (depending on engine configuration).
(6) Install spacer and cover onto bleed port cover post. Install other end of cover into slot in bleed
cable bracket. Secure cover with one bolt. Torque bolt 36 to 40 inch-pounds (4.0 to 4.5 N.m).
B. Adjust the acceleration bleed system lever. Refer to 75-35-01, P.B. 501.
7. Job Close-up
SUBTASK 75-35-01-410-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches the minimum and
maximum stops during test.
EFFECTIVITY: FJ44-2A
75-35-01
Page 403
Apr 11/08
Fig. 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2A
75-35-01
Page 404
Apr 11/08
1. General
Do this task after a new lever arm is installed. If the cable assembly or fuel control unit were replaced, you
must verify that the maximum and minimum stops are contacted during acceleration and deceleration
test. Refer to the following illustration(s):
Figure 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment
SUBTASK 75-35-01-942-005
A. Consumables
Reference Designation
MAT-061 Lockwire, .020
SUBTASK 75-35-01-945-005
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
3. Job Set-up
SUBTASK 75-35-01-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 75-35-01-820-002
A. Adjust the "pull only" configuration lever arm stop as follows (Figure 501 Acceleration Bleed System
Lever - Pull Only Configuration - Adjustment):
EFFECTIVITY: FJ44-2A
75-35-01
Page 501
Apr 11/08
(2) Remove the retaining ring or roll pin (depending on engine configuration) and remove the
ball end of the bleed cable from the lever.
(3) Remove lockwire, loosen the jam nut and loosen the set screw.
(4) Move and hold the lever counter-clockwise toward the set screw until the bleed valve is
stopped internally. This is the closed position.
(5) Adjust the set screw until it touches the lever arm stop. Continue turning it 1/4 turn. Tighten the
jam nut. Torque the jam nut25 to 28 inch-pounds (2.8 - 3.1 N.m) and install lockwire MAT-061.
(6) Install the bleed cable ball end to the lever and secure with retaining clip.
B. Check adjustment of the bleed cable jam nuts to make sure that bleed valve lever is properly adjusted
in the open position. Refer to 75-37-01, P.B. 401
5. Job Close-up
SUBTASK 75-35-01-410-005
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches both the minimum
and maximum stops during the test.
EFFECTIVITY: FJ44-2A
75-35-01
Page 502
Apr 11/08
Fig. 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment
EFFECTIVITY: FJ44-2A
75-35-01
Page 503
Apr 11/08
75-35-01
504
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 401 Acceleration Bleed System Cable - Adjustment
Figure 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 75-37-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 75-37-01-020-002
(1) Remove one bolt, cover, and spacer from the acceleration bleed port cover.
(2) Drive out the roll pin or retaining ring (depending the engine configuration) which attaches
the ball end of the cable to the bleed lever.
(3) Loosen the bleed cable jam nuts and remove the bleed cable from the bracket.
(4) Remove the loop clamp(s) which attach the cable assembly to the rear bypass duct.
(5) Disconnect the jam nut which attaches the cable assembly (outer sheath) to the fuel control
unit (FCU/FDU) boss.
(6) Loosen the jam nut which attaches the inner cable to the FCU/FDU plunger.
EFFECTIVITY: FJ44-2A
75-37-01
Page 401
Apr 11/08
4. General
This task provides procedures for installing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 401 Acceleration Bleed System Cable - Adjustment
Figure 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
75-37-01, Fig. 02
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001engine oil before installation.
SUBTASK 75-37-01-942-004
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 75-37-01-943-004
B. Special Tools
Reference Designation
TL37220 Torque Adapter, Air Bleed Cable Nut
SUBTASK 75-37-01-944-004
C. Expendable Parts
IPC Reference:
Subject Fig. Item Nomenclature
75-35-01 2 80 Roll Pin
SUBTASK 75-37-01-945-004
D. Reference Information
EFFECTIVITY: FJ44-2A
75-37-01
Page 402
Apr 11/08
6. Procedures
SUBTASK 75-37-01-420-002
(1) Install the threaded end of the acceleration bleed cable assembly on the FCU/FDU by inserting
the cable through the mounting boss on the FCU/FDU connection. One jam nut and washer
should be on the aft side of the boss. Install the other jam nut and washer on forward side of
the boss. Do not tighten jam nuts at this time.
NOTE To install the cable, turn the plunger, rather than the cable.
(2) Install inner cable in FCU/IFCU as follows: Thread the inner cable, with jam nut installed, into
the FCU plunger by turning the plunger until inner cable bottoms in the plunger. Insert a
0.125-inch (3.175 mm) rod through the hole in the plunger to hold it while torquing jam nut.
Using torque adapter TL37220, torque the inner cable jam nut 15 to 20 inch-pounds (1.6 to
2.2 N.m).
(3) Install inner cable in FDU as follows: Thread the inner cable, with jam nut installed, into the
FDU plunger by turning the plunger until inner cable bottoms in the plunger. hold the plunger
with a 7/32 inch open wrench while torquing jam nut. Using torque adapter TL37220, torque
the inner cable jam nut 15 to 20 inch-pounds (1.6 to 2.2 N.m).
(4) Pull the FCU/FDU plunger rod to the full aft position. Adjust the two outer cable jam nuts so
that the threaded end of the outer cable is 0.125 to .250 inch (3.175 to 6.35 mm) from the inner
cable jam nut. Position cable straight back from fuel control unit. This will prevent misalignment
between the FCU/FDU plunger and the cable end. Torque both outer cable jam nuts 25 to
28 inch-pounds (2.8 - 3.2 N.m).
(5) Install ball end of cable to the bleed valve lever and secure with roll pin or retaining ring
(depending on the engine configuration).
(6) Loosen cable jam nuts and install cable in slot on bleed valve cover bracket. Adjust jam nuts as
follows to achieve proper tension on bleed valve lever when it is in the open position:
(a) With jam nuts loose, spring pressure will force the forward stop of the bleed lever against
the adjustment post (bleed valve is in open position).
EFFECTIVITY: FJ44-2A
75-37-01
Page 403
Apr 11/08
(b) Tighten rear jam nut so that cable assembly moves aft and pulls the forward stop of the
bleed lever away from the adjustment post. Gap between the bleed lever and the
adjustment post must be 0.050 to 0.070 inch (1.27 to 1.77 mm).
(7) Install spacer and cover onto bleed port cover post. Install other end of cover into slot in bleed
cable bracket. Secure cover with one bolt. Torque bolt36 to 40 inch-pounds (4.0 to 4.5 N.m) .
(8) Connect the loop clamp(s) at the rear bypass duct flange and torque bolt 49 to 55 inch-pounds
(5.5 to 6.2 N.m).
7. Job Close-up
SUBTASK 75-37-01-410-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches the minimum and
maximum stops during test.
EFFECTIVITY: FJ44-2A
75-37-01
Page 404
Apr 11/08
Fig. 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
EFFECTIVITY: FJ44-2A
75-37-01
Page 406
Apr 11/08
CHAPTER 76
ENGINE CONTROLS
Page 1
76-ENGINE CONTROLS Apr 11/08
Page 2
76-ENGINE CONTROLS Blank
LINE MAINTENANCE MANUAL FJ44-2A
76-00-00 1 Apr 11/08 76-20-01 501 Apr 11/08 76-20-01 601 Apr 11/08
Chapter 76
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 76
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
The speed of the engine is controlled by limiting fuel flow. In the case of an LP shaft separation, the fuel is
shut off to prevent the engine from an overspeed condition.
2. Description
SUBTASK 76-00-00-860-001
Power Lever
B. The power lever is connected to the fuel control unit (FCU) at the power lever input shaft. The
minimum and maximum speed settings are adjusted and set prior to engine installation.
C. The LP shaft trip sensor is connected to the FCU fan/LP shaft separation shutoff valve by a cable that
runs from the LP trip lever housing, located on the rear bypass duct, to the FCU.
3. Operation
SUBTASK 76-00-00-860-003
A. The power lever angle (PLA) setting in the cockpit is mechanically transferred to the FCU by a
cable linkage. The PLA controls the engine speed by limiting the fuel flow from the FCU for any
desired engine speed in the operating range.
B. The LP shaft trip sensor is operated in the event of an LP shaft separation. This event would force
the LP turbines in an aft direction against the LP trip lever. The LP trip lever is connected to a
trigger mechanism on the rear bypass duct. The trigger mechanism, when tripped, pushes the LP
trip sensor cable forward and shuts down the engine by cutting off its fuel. This also prevents an
overspeed condition.
EFFECTIVITY: FJ44-2A
76-00-00
Page 1
Apr 11/08
76-00-002
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Do this task whenever the LP shaft trip sensor has been operated or the trip lever requires adjustment.
Refer to the following illustration(s):
Figure 501 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
Figure 502 LP Shaft Trip Sensor - Disassembly/Assembly
Figure 503 LP Shaft Trip Sensor - Lever Adjustment
Figure 504 LP Shaft Trip Sensor - Cable Adjustment
Figure 505 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge
Figure 506 LP Shaft Trip Sensor Trigger Pin Calculation Measurements
Figure 507 LP Shaft Trigger Pin Dimensions Installed Trigger Pin Dimensions
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 76-20-01-941-001
A. Standard Equipment
Arbor Press
Depth Micrometer
SUBTASK 76-20-01-942-001
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-060 Lockwire, .032
MAT-061 Lockwire, .020
SUBTASK 76-20-01-944-001
C. Expendable Parts
EFFECTIVITY: FJ44-2A
76-20-01
Page 501
Apr 11/08
IPC Reference
Subject Fig. Item Nomenclature
76-20-01 01 230 Gasket, Cable Housing
SUBTASK 76-20-01-945-001
D. Reference Information
CH-SE-SU Pg Block Nomenclature
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
73-27-01 201 Fuel Control Shutoff Valve - Maintenance Practices
3. Job Set-up
SUBTASK 76-20-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
NOTE Do this task whenever the LP shaft trip sensor has been operated or
the trip lever requires adjustment.
SUBTASK 76-20-01-050-001
(1) Remove two screws and washers which attach the housing cover. Remove the housing cover.
(2) Remove two screws, two washers and two nuts which attach the cable actuator housing to the
LP trip sensor housing.
(3) Remove the cable actuator housing by pulling it away from the trip lever housing.
(4) Remove lockwire from cable jam nuts. Remove the jam nut which attaches the forward end of
the LP trip sensor cable to the FCU.
(5) Remove the cable and the cable actuator housing assembly.
SUBTASK 76-20-01-820-001
EFFECTIVITY: FJ44-2A
76-20-01
Page 502
Apr 11/08
NOTES: 1 The coil spring and spring retainer may come out of outer latch.
(1) Remove snap ring from cable actuator housing. Remove outer latch, coil spring, spring
retainer, and inner latch assembly from the cable actuator housing. Do not disassemble
inner latch assembly.
(2) Twist a piece of lockwire MAT-060 around spring feet of outer latch. Insert spring retainer and
coil spring into outer latch. Put outer latch in an arbor press.
(3) Put inner latch assembly on coil spring in outer latch. Compress coil spring with arbor press.
Twist lockwire loop to compress spring feet of outer latch to fit around the center portion
and inside of inner latch. Compress coil spring until spring feet of outer latch are retained
by inner latch.
(4) Remove loaded latch assembly from arbor press. Remove lockwire.
(5) Install latch assembly into cable actuator housing and secure with snap ring.
SUBTASK 76-20-01-820-002
NOTE Do this task after installing the LP trip lever into the rear housing/rear bypass duct.
The adjustment allows for 0.050 to 0.060 inch (1.27 to 1.52 mm) distance between
the end trip lever and the LP shaft aft end with LP shaft thrusted aft.
(a) Thrust the LP rotary group aft by pushing on the fan rotor. Continue to apply pressure
during adjustment.
(b) Insert the trigger pin through the trigger pin bushing in the LP trip sensor housing on the
rear bypass duct. Move the trip lever forward and backward to make sure that it does
not bind. Position the trip lever by pulling it radially outward until the pin contacts the
top of the trip lever cup. Look through the witness hole in the bottom of lever cup to
ensure that pin is seated properly.
EFFECTIVITY: FJ44-2A
76-20-01
Page 503
Apr 11/08
(c) Remove lockwire on adjustment screw jam nut and loosen jam nut. Turn adjustment
screw until it just touches the trip lever. Do not apply any hand pressure to the lever
when making this adjustment.
(d) Index mark the adjustment screw and turn the screw an additional 1-7/8 turns clockwise
past the point of trip lever contact. Make sure that the adjustment screw is centered
on the lever.
NOTE Total adjustment of screw, following trip lever contact, is not to be less
than 1-3/4 turns or greater than 2 turns (including final adjustment). A
1-7/8 initial setting allows 1/8 turn for final adjustment.
(e) Tighten adjustment screw jam nut. Jam nut will be torqued after final adjustment.
SUBTASK 76-20-01-820-003
NOTE Do this procedure whenever the trigger pin that was removed from the engine is
damaged and/or otherwise replaced. Trigger pins are matched to an engine and
their lengths must be recalculated if any of the following apply:
(a) Using depth micrometer, measure from face of trigger pin anvil to housing flange
face. Record this as L1 dimension. See Figure 506 LP Shaft Trip Sensor Trigger
Pin Calculation Measurements.
EFFECTIVITY: FJ44-2A
76-20-01
Page 504
Apr 11/08
NOTE Make sure that the LP trip lever stop is adjusted correctly.
Refer to Subtask 76-20-01-820-002.
1 Use a depth micrometer with a rod which is close to the diameter of the trigger pin.
2 Measure from the end of the trigger pin bushing to the bottom of the lever cup. Make
sure that the lever and pin are correctly positioned. Record as dimension L2.
(c) Measure from trigger pin bushing to trip lever housing and record as dimension L3.
(f) Grind trigger pin 0.003 - 0.007 inch (0.076 - 0.178 mm) shorter than calculated dimension.
(2) After final assembly and adjustment of trip sensor, measure trigger pin movement through the
witness hole at the bottom of the trip lever cup. Trigger pin end play must be 0.003 - 0.007
inch (0.076 - 0.177 mm). Use a set of feeler gauges which have been modified (ground) per
Figure 505 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge
SUBTASK 76-20-01-420-001
(2) Reset FCU shut-off valve, if required. Refer to 73-27-01, P.B. 201.
(3) If actuator cable has been removed from cable actuator housing, install as follows:
NOTE If one of the jam nuts on the actuator cable is a self-locking nut, (MS21083C5),
it should be installed inside the actuator housing.
(a) Remove one jam nut from actuator cable and install threaded outer cable into actuator
housing.
(b) Install jam nut to cable inside actuator housing. Adjust inner jam nut so that three
threads are visible between the end of the outer cable and the jam nut. Tighten outer
jam nut to secure housing and torque 85 to 98 inch-pounds (9.6 to 10.7 N.m). Install
lockwire to jam nut.
(4) Install latch assembly, if not already installed, into cable actuator housing and secure with
snap ring.
EFFECTIVITY: FJ44-2A
76-20-01
Page 505
Apr 11/08
SUBTASK 76-20-01-830-001
(1) Install cable in FCU and, using jam nuts, adjust outer shielding so that inner cable has 0.001
- 0.005 inch (0.127 - 0.025 mm) clearance to the HMU shut-off latch arm (inner cable must
be pushed fully aft for measurement and cable must be straight). Torque nuts 85 to 95
inch-pounds (9.6 to 10.7 N.m). Install lockwire to jam nuts.
SUBTASK 76-20-01-830-003
(1) Install the trigger pin into the bushing of aft LP trip sensor housing. The ground end of the
pin should face the trigger anvil. Make sure that pin is properly seated in the cup of the
lever assembly.
(2) Align and carefully install the cable and actuator housing assembly and gasket on the LP
trip sensor housing.
(3) Attach the housing with two screws, two washers and two nuts. Torque screws 25 to 28
inch-pounds (2.8 to 3.1 N.m).
SUBTASK 76-20-01-210-001
(1) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
(2) Measure trigger pin movement through the witness hole at the bottom of the trip lever cup.
Trigger pin end play must be 0.003 - 0.007 inch (0.076 - 0.177 mm). Use a set of feeler
gauges which have been modified (ground) per Figure 505 LP Shaft Trip Sensor - Trigger
Pin Feeler Gauge
(3) If end play is not within limits, the trip lever adjustment screw may be moved up to 1/8 turn. If
end play is still not within limits, the pin length will have to be modified.
(4) After end play measurement is correct, torque adjustment screw jam nut 85 to 95 inch-pounds
(9.6 to 10.7 N.m). Secure the jam nut with lockwire MAT-061.
(5) Align the bolt holes of the housing cover with the bolt holes on the sensor housing. Attach the
housing cover with two screws and two washers.
EFFECTIVITY: FJ44-2A
76-20-01
Page 506
Apr 11/08
5. Job Close-up
SUBTASK 76-20-01-430-001
EFFECTIVITY: FJ44-2A
76-20-01
Page 507
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 508
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 509
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 510
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 511
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 512
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 513
Apr 11/08
Fig. 507 LP Shaft Trigger Pin Dimensions Installed Trigger Pin Dimensions
EFFECTIVITY: FJ44-2A
76-20-01
Page 514
Apr 11/08
1. General
This task contains procedures for checking that the LP shaft trip sensor system is properly rigged. Refer
to the following illustration(s):
Figure 601 LP Shaft Trip Sensor - Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
76-20-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 76-20-01-941-002
A. Standard Equipment
Flexible, Steerable Fiberscope, 6mm Dia 50 Inch
Long
SUBTASK 76-20-01-942-002
B. Consumables
Reference Designation
MAT-089 Sealant, RTV 103
SUBTASK 76-20-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-71 401 Rear Bypass Duct Assy - Removal/Installation
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
EFFECTIVITY: FJ44-2A
76-20-01
Page 601
Apr 11/08
3. Job Set-up
SUBTASK 76-20-01-010-002
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 76-20-01-220-001
(1) Light damage to cable outer sheathing Repair with MAT-089 (RTV sealant)
B. Inspect trip lever/LP shaft with a borescope (Flexible, steerable fiberscope, 6mm dia 50 inch long)
(1) Insert borescope through the center hole in the aft end of the rear housing tail cone.
(2) Move the borescope forward and inspect the LP trip lever/LP shaft. Inspect the trip lever for
signs that it has contacted the LP shaft (rub mark, fretting). If fretting/rub damage is noted,
remove LP trip lever (72-00-71, P.B. 401). Evaluate trip lever in accordance with inspection
criteria (below). Install trip lever and adjust LP sensor in accordance with 76-20-01, P.B. 501.
(a) LP trip lever fretting/rub damage up to Blend damage smooth with minimal
0.012 inch (0.304 mm) deep. material removal.
5. Job Close-up
SUBTASK 76-20-01-410-002
EFFECTIVITY: FJ44-2A
76-20-01
Page 602
Apr 11/08
6. General
This task checks the trigger pin end play of the LP shaft trip sensor. Refer to the following illustration(s):
Figure 601 LP Shaft Trip Sensor - Inspection
Figure 602 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge
SUBTASK 76-20-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
8. Job Set-up
SUBTASK 76-20-01-010-004
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
9. Procedures
SUBTASK 76-20-01-220-002
(1) Remove the two screws and two washers which attach the trip lever housing cover on the outer
bypass duct. Remove the housing cover.
(2) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
EFFECTIVITY: FJ44-2A
76-20-01
Page 603
Apr 11/08
(3) Measure trigger pin movement through the witness hole at the bottom of the trip lever cup.
Trigger pin end play must be 0.003 - 0.007 inch (0.076 - 0.177 mm). Use a set of feeler gauges
which have been modified (ground) per Figure 602 LP Shaft Trip Sensor - Trigger Pin Feeler
Gauge. If end play is out-of-limits, adjust LP shaft trip sensor. Refer to 76-20-01, P.B. 501.
(4) Install the trip lever housing cover and install two screws and washers. Torque the screws 25 to
28 inch-pounds (2.8 to 3.1 N.m).
SUBTASK 76-20-01-410-003
EFFECTIVITY: FJ44-2A
76-20-01
Page 604
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 605
Apr 11/08
EFFECTIVITY: FJ44-2A
76-20-01
Page 606
Apr 11/08
CHAPTER 77
ENGINE INDICATING
Page 1
77-ENGINE INDICATING Apr 11/08
Page 2
77-ENGINE INDICATING Blank
LINE MAINTENANCE MANUAL FJ44-2A
77-00-00 1 Apr 11/08 77-12-01 601 Apr 11/08 77-22-01 601 Apr 11/08
77-11-01 401 Apr 11/08 77-20-02 401 Apr 11/08 77-40-01 401 Apr 11/08
77-11-01 601 Apr 11/08 77-20-02 601 Apr 11/08 77-40-01 601 Apr 11/08
77-12-01 401 Apr 11/08 77-22-01 401 Apr 11/08
Chapter 77
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 77
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
The engine indicating system monitors the condition of the engines and transmits this information to
the cockpit.
2. Description
SUBTASK 77-00-00-860-006
Fuel filter electrical indicator switch (delta P); refer to 73-23-01, P.B. 401
Oil filter differential pressure (delta P) indicator; refer to 72-60-02, P.B. 401
B. The EFCU engine harness assembly interfaces with the ECU to airframe electrical harness through
the engine P7 connector at the firewall. The EFCU engine harness assembly carries the input/output
signals, power, and discretes for the engine ECU, the engine HMU, and the engine instrumentation.
C. The EFCU TT2 sensor is installed in the airframe inlet duct. It provides ambient temperature to
the EFCU.
D. The gearbox magnetic speed pickup is installed on the gearbox and reads the HP spool speed
through the gearbox. An output frequency of 6741 Hz is produced at maximum HP shaft speed
(100 percent N2).
E. The LP magnetic speed pickup is installed in the interstage housing and measures speed directly
from the LP shaft. The output frequency is 5174 Hz at full rotational speed (100 percent N1).
F. There are six type K ITT probes located in the 1st LP turbine nozzle. All the ITT probes are the same
length. The thermocouple leads are joined and averaged at the electrical connector of the EFCU
engine harness. The averaged temperature is then displayed in the cockpit.
EFFECTIVITY: FJ44-2A
77-00-00
Page 1
Apr 11/08
G. The engine vibration pickup(s) (test equipment) is attached to the interstage housing. It measures
vibration levels and sends this data to the vibration analyzer.
EFFECTIVITY: FJ44-2A
77-00-00
Page 2
Apr 11/08
1. General
This task provides procedures for removing the LP magnetic speed pickup assembly. Refer to the
following illustration(s):
Figure 401 LP Magnetic Speed Pickup - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 77-11-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 77-11-01-020-001
NOTE When reconfiguring the engine for a right or left-hand position, make sure that the pickup
is installed on the outboard side and the plug is installed on the inboard side.
(1) Disconnect the electrical connector (N1 SPEED) from the LP magnetic speed pickup, located
on the interstage housing.
(2) Remove screw from clamp and remove pickup from interstage housing.
EFFECTIVITY: FJ44-2A
77-11-01
Page 401
Apr 11/08
(1) Remove screw from plug and remove plug and O-ring.
4. General
This task provides procedures for installing the LP magnetic speed pickup assembly. Refer to the
following illustration(s):
Figure 401 LP Magnetic Speed Pickup - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-11-01, Fig. 01
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
Refer to Electrical Bonding - Maintenance Practices, 70-03-01, P.B. 201.
SUBTASK 77-11-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 77-11-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-11-01 01 20 O-Ring (2)
SUBTASK 77-11-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
70-03-01 201 Electrical Bonding - Maintenance Practices
71-00-00 501 Power Plant - Adjustment/Test
EFFECTIVITY: FJ44-2A
77-11-01
Page 402
Apr 11/08
6. Procedures
SUBTASK 77-11-01-420-001
(2) Install the LP pickup in the outboard port of interstage housing and attach with clamp and screw.
(1) Lube O-ring with assembly fluid MAT-011 and install on plug.
(2) Install plug in opposite port of interstage housing and install screw.
7. Job Close-up
SUBTASK 77-11-01-410-002
SUBTASK 77-11-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
77-11-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
77-11-01
Page 404
Apr 11/08
1. General
This task covers visual inspection of the LP magnetic speed pickup assembly.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-11-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 77-11-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
77-11-01 401 LP Magnetic Speed Pickup Assembly - Removal/Installation
3. Procedures
SUBTASK 77-11-01-020-002
A. Remove the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
SUBTASK 77-11-01-220-001
EFFECTIVITY: FJ44-2A
77-11-01
Page 601
Apr 11/08
SUBTASK 77-11-01-420-001
C. Install the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
4. General
This task performs a resistance check on the LP magnetic speed pickup assembly (dual channel). Refer
to the following illustration(s):
Figure 601 LP Magnetic Speed Pickup - Resistance Check
SUBTASK 77-11-01-941-005
A. Standard Equipment
Ohmmeter
6. Procedures
SUBTASK 77-11-01-750-002
EFFECTIVITY: FJ44-2A
77-11-01
Page 602
Apr 11/08
(1) Using ohmmeter, check the electrical resistance between pins A and B (A sense). Resistance
should be 540 to 580 ohms . Reject pickup if resistance is outside limits.
(2) Using ohmmeter, check the electrical resistance between pins C and D (B sense). Resistance
should be 535 to 575 ohms . Reject pickup if resistance is outside limits.
(3) Check for shorts between pins A, B, C, D and pickup case. Reject pickup if shorted.
(4) Check resistance between pin F and pickup case. Resistance should be less than 10 ohms.
Reject pickup if resistance is outside limits.
EFFECTIVITY: FJ44-2A
77-11-01
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
77-11-01
Page 604
Apr 11/08
TASK 77-12-01-050-801 Remove the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task provides procedures for removing the gearbox (HP) magnetic speed pickup assembly. Refer
to the following illustration(s):
Figure 401 Gearbox Magnetic Speed Pickup - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 77-12-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 77-12-01-020-001
(1) Disconnect the electrical connector (N2 SPEED) from the gearbox speed pickup, located
on the gearbox housing.
(2) Remove screw and washer and remove pickup from gearbox housing.
TASK 77-12-01-450-801 Install the Gearbox (HP) Magnetic Speed Pickup Assembly
4. General
This task provides procedures for installing the gearbox (HP) magnetic speed pickup assembly. Refer
to the following illustration(s):
Figure 401 Gearbox Magnetic Speed Pickup - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
EFFECTIVITY: FJ44-2A
77-12-01
Page 401
Apr 11/08
77-12-01, Fig. 01
NOTE Make sure that all electrical connectors are clean and free of damage or corrosion.
SUBTASK 77-12-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
SUBTASK 77-12-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-12-01 01 20 O-Ring
SUBTASK 77-12-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
6. Procedures
SUBTASK 77-12-01-420-001
(1) Lube O-ring with assembly fluid MAT-011 and install on pickup.
(2) Install the gearbox pickup on gearbox housing and attach with screw and washer.
7. Job Close-up
SUBTASK 77-12-01-410-002
EFFECTIVITY: FJ44-2A
77-12-01
Page 402
Apr 11/08
SUBTASK 77-12-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
77-12-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
77-12-01
Page 404
Apr 11/08
TASK 77-12-01-220-801 Visually Inspect the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task covers visual inspection of the gearbox (HP) magnetic speed pickup assembly.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-12-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 77-12-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
3. Procedures
SUBTASK 77-12-01-020-002
A. Remove the gearbox (HP) magnetic speed pickup assembly. Refer to 77-12-01, P.B. 401.
SUBTASK 77-12-01-220-001
EFFECTIVITY: FJ44-2A
77-12-01
Page 601
Apr 11/08
SUBTASK 77-12-01-420-002
C. Install the gearbox (HP) magnetic speed pickup assembly. Refer to 77-12-01, P.B. 401.
TASK 77-12-01-750-802 Perform Resistance Check on Gearbox (HP) Magnetic Speed Pickup
Assembly (Dual Channel)
4. General
This task performs a resistance check on the gearbox (HP) magnetic speed pickup assembly (dual
channel). Refer to the following illustration(s):
Figure 601 Gearbox Magnetic Speed Pickup - Resistance Check
SUBTASK 77-12-01-941-005
A. Standard Equipment
Ohmmeter
6. Procedures
SUBTASK 77-12-01-750-002
(1) Using ohmmeter, check the electrical resistance between pins A and B (A sense). Resistance
should be 710 to 880 ohms. Reject pickup if resistance is outside limits.
(2) Using ohmmeter, check the electrical resistance between pins C and D (B sense). Resistance
should be 770 to 950 ohms. Reject pickup if resistance is outside limits.
(3) Check for shorts between pins A, B, C, D and pickup case. Reject pickup if shorted.
(4) Check resistance between pin F and pickup case. Resistance should be less than 10 ohms.
Reject pickup if resistance is outside limits.
EFFECTIVITY: FJ44-2A
77-12-01
Page 602
Apr 11/08
EFFECTIVITY: FJ44-2A
77-12-01
Page 603
Apr 11/08
77-12-01
604
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the ITT probes. Refer to the following illustration(s):
Figure 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration -
Removal/Installation
Figure 402 ITT Probes - Loop Clamp Locations
NOTE During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 77-20-02-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 77-20-02-050-001
(2) Remove lockwire and remove connector nut from J1 connector. Remove connector from
bracket on front bypass duct.
SUBTASK 77-20-02-050-004
EFFECTIVITY: FJ44-2A
77-20-02
Page 401
Apr 11/08
(2) Remove nut which attaches the ITT probe to the low pressure turbine (LPT) nozzle assembly.
Remove probe.
(3) Mark clamp locations. Remove 90 brackets (as required), 10 screws, 10 nuts, and open 10
loop clamps which retain the ITT probe leads.
4. General
This task provides procedures to disassemble ITT probe J1 connector. Refer to the following illustration(s):
Figure 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration -
Removal/Installation
Figure 403 ITT Probe - Connector - Assembly/Disassembly
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 77-20-02-941-010
A. Standard Equipment
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-945-010
B. Reference Information
CH-SE-SU Pg Block Nomenclature
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
6. Procedures
SUBTASK 77-20-02-040-010
A. Remove ITT Probe(s) from the engine. Refer to 77-20-02, P.B. 401.
EFFECTIVITY: FJ44-2A
77-20-02
Page 402
Apr 11/08
(7) Remove the ITT probe chromel (white) wire and the alumel (green) wire from the J1 connector
(bayonet type). Mark the location of each pin and color for proper assembly. Use the
M8196914-02 extraction/insertion tool as required.
7. General
This task provides procedures for assembling the ITT probe J1 connector. Refer to the following
illustration(s):
Figure 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration -
Removal/Installation
Figure 403 ITT Probe - Connector - Assembly/Disassembly
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTES: 1 Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil before installation.
2 Make sure that all electrical connectors are clean and free of damage or corrosion. .
SUBTASK 77-20-02-941-011
A. Standard Equipment
Connector Pliers
Strap Wrench
Connector Holding Tools
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-20-02 01 67 Wrap, Spiral, .250 OD
EFFECTIVITY: FJ44-2A
77-20-02
Page 403
Apr 11/08
SUBTASK 77-20-02-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
77-20-02 601 Intermediate Turbine Temperature (ITT) Probe - Inspection/Check
9. Procedures
SUBTASK 77-20-02-420-001
(3) Install the chromel pin (non-magnetic white wire) into the correct receptacle on the J1
connector. Use the M8196914-02 extraction/insertion tool as required:
NOTE ITT probes, when mounted on engine, are identified by position as they
would be viewed from aft of the engine, looking forward.
EFFECTIVITY: FJ44-2A
77-20-02
Page 404
Apr 11/08
NOTE For reliable assembly of the connector and backshell, it is suggested that
connector holding tools, strap wrench and connector pliers be used.
(b) Place ground ring, adapter, grommet, follower, and strain relief on the cable in sequence
shown. Keep these components at a convenient distance from the end of the cable, so
they will not interfere with subsequent assembly steps.
(c) Extract shield pigtail from individual conductors. Tape pigtails to the bundle.
(e) Move the four-footed ground ring forward near the rear of the backshell. Untie individual
pigtails, and flare back over ground ring to evenly disperse pigtails through the four
quadrants of the ring. Tie or tape pigtails back to bundle, allowing for approx. 1/2
of slack, for subsequent step.
(f) Push ground ring forward and into rear of the backshell. Thread adapter onto the
backshell, providing the shield grounding.
(g) Slide rubber grommet forward into counter bore of adapter. Slide follower onto rear
of grommet.
(h) Engage strain relief with adapter and tighten securely. Tighten strain relief saddles
securely on cable. This will then provide the environmental seal on cable.
(5) Do a resistance check on the J1 harness connector. Refer to 77-20-02, P.B. 601.
(6) Do a continuity check between the ITT connector and case. Refer to 77-20-02, P.B. 601.
10. General
This task provides procedures for installing the ITT probes. Refer to the following illustration(s):
Figure 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration -
Removal/Installation
Figure 402 ITT Probes - Loop Clamp Locations
EFFECTIVITY: FJ44-2A
77-20-02
Page 405
Apr 11/08
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil MAT-001 before installation.
SUBTASK 77-20-02-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 77-20-02-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
77-20-02 01 67 Wrap, Spiral, .250 OD
77-20-02 01 68 Wrap, Spiral, .187 OD
77-20-02 01 69 Tie, Locking Cable
SUBTASK 77-20-02-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
12. Procedures
SUBTASK 77-20-02-450-002
(1) Install the ITT probe through the front bypass duct thermocouple access boss and into the
stud on the 1st LP turbine nozzle assembly. The thermocouple passes through a hole in
the ITT probe mounting flange.
(2) Install nut on stud and torque 25 to 28 inch-pounds (2.8 to 3.1 N.m).
EFFECTIVITY: FJ44-2A
77-20-02
Page 406
Apr 11/08
(3) Carefully fold the ITT probe wire into a bundle (with no sharp bends) so that the bundle will be
secured by as many loop clamps as possible.
(4) Secure 10 loop clamps with screw and nut. Torque 49 to 55 inch-pounds (5.5 to 6.2 N.m).
Install 90 brackets at marked locations on front bypass duct flange.
(a) Install .187 OD spiral wrap to single strands of ITT wire in areas where wire may come in
contact with one of the ITT bosses on the front bypass duct.
(b) Install .250 OD spiral wrap to multiple strands of ITT wire in areas where wire may come
in contact with one of the ITT bosses on the front bypass duct.
(c) Secure ends of spiral wrap with locking cable ties. Cut excess ends of ties off flush.
SUBTASK 77-20-02-450-004
B. Install J1 connector into bracket on front bypass duct. Install connector nut (finger tight) and secure
nut with lockwire MAT-061. Connect the harness to J1 connector.
SUBTASK 77-20-02-410-002
SUBTASK 77-20-02-760-002
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
77-20-02
Page 407
Apr 11/08
Fig. 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
EFFECTIVITY: FJ44-2A
77-20-02
Page 408
Apr 11/08
EFFECTIVITY: FJ44-2A
77-20-02
Page 409
Apr 11/08
EFFECTIVITY: FJ44-2A
77-20-02
Page 410
Apr 11/08
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 77-20-02-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
3. Job Set-up
SUBTASK 77-20-02-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
77-20-02
Page 601
Apr 11/08
4. Procedures
SUBTASK 77-20-02-020-002
SUBTASK 77-20-02-220-001
(3) Small dents up to 0.150 inch (3.81 mm) Blend down raised material
long x 0.010 inch (0.254 mm) deep. Max
quantity is one per probe.
SUBTASK 77-20-02-420-002
5. Job Close-up
SUBTASK 77-20-02-410-004
SUBTASK 77-20-02-760-004
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
6. General
EFFECTIVITY: FJ44-2A
77-20-02
Page 602
Apr 11/08
SUBTASK 77-20-02-943-005
A. Special Tools
Reference Designation
For FJ44-1A: TL37197 ITT Dual Element Probe Test Equipment
For FJ44-1C, FJ44-2A, FJ44-2C: ITT Probe Test Equipment
TL37289
8. Job Set-up
SUBTASK 77-20-02-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
9. Procedures
SUBTASK 77-20-02-210-004
(1) Disconnect the ITT electrical connector from the harness connector.
(2) Connect probes to the data logger for individual temperature read-out, as follows:
NOTE The special tools used for this procedure are included as part of
TL37289, ITT Probe Test Equipment.
(a) Connect TL37288 cable (part of TL37289) to the J1 connector and to the TL37286
temperature indicator (part of TL37289).
(b) Plug the TL37286 temperature indicator into a 100 to 125 VAC, 48 to 400 Hz power
supply.
(c) Check temperature of each ITT thermocouple probe with the TL37286. Each
numbered button on the TL37286 corresponds to each identification number of the
ITT thermocouple probe.
EFFECTIVITY: FJ44-2A
77-20-02
Page 603
Apr 11/08
(3) Display the reading from each of the six probes on the TL37286. Record each reading. The
readings must all range 10 degrees F. (5.5 degrees C) from each other.
(4) Replace any probe that is not within this range. Refer to 77-20-02, P.B 401.
SUBTASK 77-20-02-410-005
11. General
SUBTASK 77-20-02-943-006
A. Special Tools
Reference Designation
For FJ44-1A: TL37197 ITT Dual Element Probe Test Equipment
For FJ44-1C, FJ44-2A, FJ44-2C: ITT Probe Test Equipment
TL37289
SUBTASK 77-20-02-945-006
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
77-20-02 601 Intermediate Turbine Temperature (ITT) Probe - Inspection/Check
EFFECTIVITY: FJ44-2A
77-20-02
Page 604
Apr 11/08
13. Procedures
SUBTASK 77-20-02-210-004
(1) Connect probes to data logger unit TL37289. Refer to (Perform Continuity Check on Installed
Probes), 77-20-01, P.B. 601.
(2) Place the tip of one probe into a glass of ice water. Wait 30 seconds and display the reading on
the data logger. Repeat for each of the six probes and record each reading. The readings
must all range 4 degrees F (2.2 degrees C) from each other.
(3) Replace any probe that is not within this range. Refer to 77-20-02, P.B. 401.
SUBTASK 77-20-02-420-010
SUBTASK 77-20-02-410-010
SUBTASK 77-20-02-760-010
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
15. General
This task performs a resistance check on the assembled J1 connector. Refer to the following illustration(s):
Figure 602 ITT Probes - Mid-Length Configuration - Harness Connector
EFFECTIVITY: FJ44-2A
77-20-02
Page 605
Apr 11/08
SUBTASK 77-20-02-941-008
A. Standard Equipment
Ohmmeter
M8196914-02 Pin Extraction/Insertion Tool
SUBTASK 77-20-02-010-008
(2) Open the circuit breakers to isolate the engine electrical supply.
18. Procedures
SUBTASK 77-20-02-210-008
EFFECTIVITY: FJ44-2A
77-20-02
Page 606
Apr 11/08
SUBTASK 77-20-02-410-008
EFFECTIVITY: FJ44-2A
77-20-02
Page 607
Apr 11/08
EFFECTIVITY: FJ44-2A
77-20-02
Page 608
Apr 11/08
EFFECTIVITY: FJ44-2A
77-20-02
Page 609
Apr 11/08
77-20-02
610
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the EFCU TT2 Sensor. Refer to the following illustration(s):
Figure 401 EFCU TT2 Sensor - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 77-22-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 77-22-01-020-001
(1) Disconnect the EFCU engine harness connector (P8) from the TT2 sensor connector (J8).
(2) Remove two screws holding the TT2 sensor to the airframe.
4. General
This task provides procedures for installing the EFCU TT2 sensor. Refer to the following illustration(s):
Figure 401 EFCU TT2 Sensor - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-22-01, Fig. 01
EFFECTIVITY: FJ44-2A
77-22-01
Page 401
Apr 11/08
SUBTASK 77-22-01-945-002
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
6. Procedures
SUBTASK 77-22-01-420-001
(1) Install two screws holding the TT2 sensor to the airframe. Torque the screws 49 to 55
inch-pounds (5.53 to 6.21 N.m).
(2) Connect the EFCU engine harness connector (P8) to the TT2 sensor connector (J8).
7. Job Close-up
SUBTASK 77-22-01-410-002
SUBTASK 77-22-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
77-22-01
Page 402
Apr 11/08
EFFECTIVITY: FJ44-2A
77-22-01
Page 403
Apr 11/08
77-22-01
404
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-22-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
2. Procedures
SUBTASK 77-22-01-220-001
3. General
SUBTASK 77-22-01-941-003
A. Standard Equipment
EFFECTIVITY: FJ44-2A
77-22-01
Page 601
Apr 11/08
Ohmmeter
SUBTASK 77-22-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
77-40-01 601 EFCU Engine Wiring Harness Assembly - Inspection/Check
5. Procedures
SUBTASK 77-22-01-210-001
CAUTION THE TT2 SENSOR HEATER (ICE PROTECTION - ENGINE) SHOULD NOT
BE SWITCHED ON WHILE THE ENGINE IS NOT RUNNING EXCEPT WHEN
REQUIRED FOR BRIEF FUNCTIONAL CHECK (LESS THAN 10 SECONDS).
DAMAGE TO HEATER WILL RESULT IF IT IS ACTIVATED FOR MORE THAN
10 SECONDS WHILE THE ENGINE IS NOT RUNNING.
(1) Make sure that engine is shut down and that engine and TT2 sensor are cool.
(2) Locate TT2 sensor in engine inlet. Carefully check sensor and verify that it is at ambient
temperature.
(3) While touching sensor and feeling for temperature change, have another person turn ICE
PROTECTION - ENGINE to the ON position for no more than 10 seconds.
EFFECTIVITY: FJ44-2A
77-22-01
Page 602
Apr 11/08
6. General
SUBTASK 77-22-01-941-005
A. Standard Equipment
Ohmmeter
Thermometer
8. Job Set-up
SUBTASK 77-22-01-010-005
9. Procedures
SUBTASK 77-22-02-750-001
A. Perform TT2 sensor element resistance test (TT2 heater OFF) as follows:
(2) Locate TT2 sensor in engine inlet. Carefully check sensor and verify that it is at ambient
temperature.
(4) Use the following procedure to determine if the TT2 sensor is within acceptable limits.
(a) Using a thermometer, measure and record the ambient temperature (in C or F), near
the TT2 sensor. Refer to table 601 and look up the ideal resistance (R ideal) for the
ambient temperature.
EFFECTIVITY: FJ44-2A
77-22-01
Page 603
Apr 11/08
Ambient Air Temperature Ambient Air Temperature Ideal Resistance in Ohms (R Ideal)
Celsius Farenheit
(-40C) (-40F) 422
(-39C) (-38F) 424
(-38C) (-36F) 426
(-37C) (-35F) 428
(-36C) (-33F) 430
(-35C) (-31F) 432
(-34C) (-29F) 434
(-33C) (-27F) 436
(-32C) (-26F) 438
(-31C) (-24F) 440
(-30C) (-22F) 442
(-29C) (-20F) 443
(-28C) (-18F) 445
(-27C) (-17F) 447
(-26C) (-15F) 449
(-25C) (-13F) 451
(-24C) (-11F) 453
(-23C) (-9F) 455
(-22C) (-8F) 457
(-21C) (-6F) 459
(-20C) (-4F) 461
(-19C) (-2F) 463
(-18C) 0F 465
(-17C) 1F 467
(-16C) 3F 469
(-15C) 5F 471
(-14C) 7F 473
EFFECTIVITY: FJ44-2A
77-22-01
Page 604
Apr 11/08
Ambient Air Temperature Ambient Air Temperature Ideal Resistance in Ohms (R Ideal)
Celsius Farenheit
(-13C) 9F 475
(-12C) 10F 477
(-11C) 12F 478
(-10C) 14F 481
(-9C) 16F 482
(-8C) 18F 484
(-7C) 19F 486
(-6C) 21F 488
(-5C) 23F 490
(-4C) 25F 490
(-3C) 27F 494
(-2C) 28F 496
(-1C) 30F 500
0C 32F 500
1C 34F 502
2C 36F 504
3C 37F 506
4C 39F 508
5C 41F 509
6C 43F 512
7C 45F 514
8C 46F 516
9C 48F 518
10C 50F 520
11C 52F 521
12C 54F 523
13C 55F 525
14C 57F 527
EFFECTIVITY: FJ44-2A
77-22-01
Page 605
Apr 11/08
Ambient Air Temperature Ambient Air Temperature Ideal Resistance in Ohms (R Ideal)
Celsius Farenheit
15C 59F 529
16C 61F 531
17C 63F 533
18C 64F 535
19C 66F 537
20C 68F 539
21C 70F 541
22C 72F 543
23C 73F 545
24C 75F 547
25C 77F 549
26C 79F 551
27C 81F 553
28C 82F 555
29C 84F 557
30C 86F 559
31C 88F 560
32C 90F 562
33C 91F 564
34C 93F 566
35C 95F 568
36C 97F 570
37C 99F 572
38C 100F 574
39C 102F 576
40C 104F 578
41C 106F 580
42C 107F 582
EFFECTIVITY: FJ44-2A
77-22-01
Page 606
Apr 11/08
Ambient Air Temperature Ambient Air Temperature Ideal Resistance in Ohms (R Ideal)
Celsius Farenheit
43C 108F 584
44C 109F 586
45C 110F 588
(b) Using an ohmmeter, measure across pins A and B to get R Measured. Record ohms.
(c) If R Measured is within +/-12 ohms of R Ideal, then TT2 sensor element resistance is
acceptable.
EFFECTIVITY: FJ44-2A
77-22-01
Page 607
Apr 11/08
77-22-01
608
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the EFCU engine harness assembly. Refer to the following
illustration(s):
Figure 401 EFCU Engine Harness Assembly - RH/Bottom Views - Removal/Installation
Figure 402 EFCU Engine Harness Assembly - LH View - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 77-40-01-941-001
A. Standard Equipment
Electrical Connector Pliers
PROTECTIVE CAPS OR PLUGS
3. Job Set-up
SUBTASK 77-40-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 77-40-01-020-001
A. Disconnect EFCU engine harness assembly electrical connectors using electrical connector pliers
as follows:
(1) Remove the EFCU connector plug (P1) from jack (J1) on the bulkhead.
(2) Remove the N1 connector plug (P3) from the N1 magnetic speed sensor (J3).
EFFECTIVITY: FJ44-2A
77-40-01
Page 401
Apr 11/08
(3) Remove the TT2 connector plug (P5) from the TT2 inlet temperature sensor (J8).
(4) Remove the ITT connector plug (P4) from the ITT harness connector (J4).
(5) Remove the HMU connector plug (P2) from the HMU jack (J2).
(6) Remove the N2 connector plug (P6) from the N2 magnetic speed sensor (J6).
B. Remove loop clamps and attaching hardware from EFCU engine harness assembly as shown
in figures.
5. General
This task provides procedures for installing the EFCU engine harness assembly. Refer to the following
illustration(s):
Figure 401 EFCU Engine Harness Assembly - RH/Bottom Views - Removal/Installation
Figure 403 EFCU Engine Harness Assembly - LH View - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
MAT-001 engine oil before installation.
SUBTASK 77-40-01-941-002
A. Standard Equipment
Electrical Connector Pliers
Ohmmeter
SUBTASK 77-40-01-942-002
B. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-027 Alcohol, Isopropyl
SUBTASK 77-40-01-945-002
C. Reference Information
EFFECTIVITY: FJ44-2A
77-40-01
Page 402
Apr 11/08
7. Procedures
SUBTASK 77-40-01-420-001
(2) Using an ohmmeter, check all used contacts for short to connector case. Refer to 77-40-01,
P.B. 601.
B. Connect EFCU Engine harness assembly electrical connectors using electrical connector pliers
as follows:
(1) Install the N2 connector plug (P6) to the N2 magnetic speed sensor (J6).
(2) Install the HMU connector plug (P2) to the HMU jack (J2).
(3) Install the ITT connector plug (P4) to the ITT harness connector (J4).
(4) Install the TT2 connector plug (P5) to the TT2 inlet temperature sensor (J8).
(5) Install the N1 connector plug (P3) to the N1 magnetic speed sensor (J3).
(6) Install the EFCU connector plug (P1) to the (J1) jack on the bulkhead.
EFFECTIVITY: FJ44-2A
77-40-01
Page 403
Apr 11/08
NOTE When installing the engine in the airframe, the EFCU engine harness
assembly loop clamps may be loosened as required to allow adjustment
of the harness for clearance purposes.
C. Install loop clamps to EFCU engine harness assembly as shown in figures. Make sure that the
correct size clamp is used at each location. Secure loop clamps to brackets with one screw, nut,
and washer. Torque nuts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
8. Job Close-up
SUBTASK 77-40-01-410-002
SUBTASK 77-40-01-760-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
77-40-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
77-40-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
77-40-01
Page 406
Apr 11/08
EFFECTIVITY: FJ44-2A
77-40-01
Page 407
Apr 11/08
77-40-01
408
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
77-40-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 77-40-01-942-003
A. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
3. Job Set-up
SUBTASK 77-40-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
77-40-01
Page 601
Apr 11/08
4. Procedures
SUBTASK 77-40-01-210-001
A. Perform a visual inspection for missing or bent pins. Reject harness if condition exist.
B. Check harness leads for broken insulation. Reject harness if condition exists.
C. Inspect the safety wire holes of the harness N2 backshell. It is allowed to have one of the three
safety wire holes to be torn through.
5. General
This task performs a resistance check on the EFCU engine harness assembly. Refer to the following
illustration:
Figure 601 EFCU Engine Harness Assembly - Schematic
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 77-40-01-941-005
A. Standard Equipment
Ohmmeter
SUBTASK 77-40-01-942-005
B. Consumables
Reference Designation
MAT-027 Alcohol, Isopropyl
EFFECTIVITY: FJ44-2A
77-40-01
Page 602
Apr 11/08
7. Job Set-up
SUBTASK 77-40-01-010-005
(2) Open the circuit breakers to isolate the engine electrical supply.
8. Procedures
SUBTASK 77-40-01-210-002
A. Using an ohmmeter, do a resistance check between the EFCU engine/airframe connector (P7) and
the HMU connector (P2):
AIRFRAME CONNECTOR PIN (P7) COMPONENT CONNECTOR PIN (P2) RESISTANCE
h L < 10 Ohms
f U < 10 Ohms
N N < 10 Ohms
U A < 10 Ohms
V P < 10 Ohms
W G < 10 Ohms
A T < 10 Ohms
B R < 10 Ohms
C E < 10 Ohms
S C < 10 Ohms
R J < 10 Ohms
(2) Check all used contacts for short between each other.
(3) Reject EFCU engine harness assembly if resistance is not within limits.
EFFECTIVITY: FJ44-2A
77-40-01
Page 603
Apr 11/08
B. Do a resistance check between the EFCU engine/airframe connector (P7) and the TT2 sensor
connector (P8):
AIRFRAME CONNECTOR PIN (P7) COMPONENT CONNECTOR PIN (P8) RESISTANCE
M A < 10 Ohms
K B < 10 Ohms
T C < 10 Ohms
k D < 10 Ohms
i E < 10 Ohms
(2) Check all used contacts for short between each other.
(3) Reject EFCU engine harness assembly if resistance is not within limits.
C. Do a resistance check between the EFCU engine/airframe connector (P7) and the ITT probe
connector (P1):
AIRFRAME CONNECTOR PIN (P7) COMPONENT CONNECTOR PIN (P1) RESISTANCE
G R < 10 Ohms
E S < 10 Ohms
m T < 10 Ohms
n U < 10 Ohms
(1) On connector P1, check for (jumper) continuity between pins A, C, E, G, J, L, N, T, and R.
(2) On connector P1, check for (jumper) continuity between pins B, D, F, H, K, M, P, U and S.
(4) Check all used contacts R to S, and T to U of P1 for short between each other.
(5) Reject EFCU engine harness assembly if resistance is not within limits.
D. Do a resistance check between the EFCU engine/airframe connector (P7) and the N1 speed sensor
connector (P3):
AIRFRAME CONNECTOR PIN (P7) COMPONENT CONNECTOR PIN (P3) RESISTANCE
H A < 10 Ohms
L B < 10 Ohms
t C < 10 Ohms
s D < 10 Ohms
EFFECTIVITY: FJ44-2A
77-40-01
Page 604
Apr 11/08
(2) Check all used contacts for short between each other.
(3) Reject EFCU engine harness assembly if resistance is not within limits.
E. Do a resistance check between the EFCU engine/airframe connector (P7) and the N2 speed sensor
connector (P6):
AIRFRAME CONNECTOR PIN (P7) COMPONENT CONNECTOR PIN (P6) RESISTANCE
J A < 10 Ohms
P B < 10 Ohms
d C < 10 Ohms
e D < 10 Ohms
(2) Check all used contacts for short between each other.
(3) Reject EFCU engine harness assembly if resistance is not within limits.
9. Job Close-up
SUBTASK 77-40-01-410-005
EFFECTIVITY: FJ44-2A
77-40-01
Page 605
Apr 11/08
EFFECTIVITY: FJ44-2A
77-40-01
Page 606
Apr 11/08
CHAPTER 79
OIL
Page 1
79-OIL Apr 11/08
Page 2
79-OIL Blank
LINE MAINTENANCE MANUAL FJ44-2A
79-00-00 1 Apr 11/08 79-24-01 401 Apr 11/08 79-30-01 601 Apr 11/08
79-21-01 401 Apr 11/08 79-25-01 401 Apr 11/08 79-31-01 401 Apr 11/08
79-22-01 401 Apr 11/08 79-25-01 501 Apr 11/08 79-33-01 401 Apr 11/08
79-22-01 501 Apr 11/08 79-26-01 401 Apr 11/08 79-33-01 601 Apr 11/08
79-22-01 601 Apr 11/08 79-30-01 401 Apr 11/08 79-33-11 401 Apr 11/08
Chapter 79
List of Effective Page Blocks
Page 1
Apr 11/08
Chapter 79
List of Effective Page Blocks
Page 2
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
The oil system provides lubrication for the four main shaft bearings, the accessory gearbox bearings,
the gears and the drive splines. The oil tank and oil passages are internal to the engine except for one
external oil line. Refer to the following illustration(s):
Figure 1 Oil System
2. Description
SUBTASK 79-00-00-860-008
The lube and scavenge pump is a positive displacement pump. It includes one pressure element and
two scavenge elements contained in a single housing. The inlet to each element is protected by a
wire mesh screen. All inlet and discharge ports are located on the pump mounting flange face to
make pump replacement easier. A pressure relief valve is located in the pump housing. This valve
will keep approximately 130 - 140 psi pressure rise across the lube element under normal operating
temperatures and flow conditions. The regulator valve also protects against over-pressurization.
C. Oil Filter
The oil filter is a disposable cartridge that is housed in an stainless steel bowl that is threaded into the
gearbox housing. It is connected to the pressure pump outlet through drilled passages in the gearbox.
EFFECTIVITY: FJ44-2A
79-00-00
Page 1
Apr 11/08
An oil filter bypass valve is located in the gearbox housing. When differential pressure across the
oil filter approaches the 25 to 30 psid range, the valve opens. This allows oil to flow to the engine
if the filter element becomes totally blocked.
E. Delta P indicator
A filter differential pressure (delta P) indicator is paralleled with the oil filter and bypass valve. As
the bypass valve approaches its opening pressure, the delta P indicator button extends to indicate
excessive filter contamination. The indicator operates at 15 3 psid. A thermal lockout prevents the
indicator from operating because of high delta P caused by cold oil.
The oil cooler is a fuel/oil heat exchanger and is made of aluminum. The oil cooler is mounted to
the gearbox and transmits the oil in and out through the mounting flange faces. Fuel travels in and
out through external lines.
Oil level is established by the oil sight glass/and or dipstick on the side of the engine interstage
housing. The tank is internally vented to the forward bearing cavity through a 5 psi pressurizing
valve which, in turn, is vented to the bypass duct via the gearbox air-oil separator. The reservoir
vent valve and bypass duct pressure reference ensure sufficient oil tank pressure for efficient pump
operation at all altitudes.
An oil level sight glass and a gravity type oil filler port fitted with an over-center-lock sealed cap are
provided on the outboard side of the engine. The sight gage is marked with two levels: FULL and
ADD. The oil volume between these levels is approximately 1.0 U.S. quart. The quantity of usable oil
is approximately 1.8 quarts at 0 installed pitch angle. The oil tank filler port is designed such that the
oil tank cannot be over-filled even if the oil filler port is over-filled.
The oil pressure regulator is located on the upper right side of the interstage housing, near the right
hand oil fill port. It is set at the factory to monitor the main oil pressure of the internal passage which
carries oil to the gearbox. When regulating oil pressure, the regulator returns oil to the oil tank
through a separate internal passage in the interstage housing.
An optional low oil level sensor is available to provide an electrical go/no-go discrete when the engine
oil level drops below a predetermined level. The switch assembly consists of a double pole single
throw (DPST) reed switch connected to a magnetic float in a stainless steel housing. The switch
assembly is designed to replace the oil sight glass on the side of the engine interstage housing. Due
to normal oil level fluctuations during engine operation, the oil level switch can only be used on the
ground with the engine shutdown.
EFFECTIVITY: FJ44-2A
79-00-00
Page 2
Apr 11/08
3. Operation
SUBTASK 79-00-00-860-009
A. The lube oil from the oil tank passes through the a perforated sheet metal screen at the tank exit,
through a screen and magnetic chip collector at the pump inlet, and then through the lube pump to
the main oil filter and oil cooler. The pressure oil is then taken, via a manifold mounted in the oil
tank, to the top of the tank. At this point, an anti-siphon orifice breaks the siphon between the oil
tank and the bearing cavities during an engine shutdown, preventing flooding. The flow is then split
between the gearbox, front bearings and rear bearings. The pressure regulating valve is located at
this point to maintain a stable lube pressure at the lube jets independent of upstream pressure drops
from the oil filter, oil cooler and lines. The oil for the gearbox passes through a last-chance filter and
lubricates the second reduction gear mesh, the lower towershaft spline, and the generator spline.
The remaining gear meshes, splines, and gearbox bearings are splash-lubricated. The oil from the
front bearings passes through last chance filters to jet lubricate the No. 1 and No. 1.5 bearings and
supplies oil for the No. 1 bearing cage damper. The remainder of the front bearing oil passes through
a last chance filter and lubricates the No. 2 bearing with two jets, an underrace supply and damper
film. The towershaft bearings are also jet-lubricated along with the upper towershaft spline and the
first reduction gear mesh. Another oil jet supplies cooling for the HP tieshaft.The oil for the rear
bearings passes through a last-chance filter and jet-lubricates the No. 3 and 4 bearings and supplies
oil for their dampers. The No. 3 bearing is both under-race and external jet-lubricated.
Two scavenge elements are used to provide independent scavenging of rear bearing cavity and
gearbox sumps. The forward bearing cavity drains down the towershaft annulus into the gearbox
scavenge. A screen and a self-sealing magnetic chip collector are located before each scavenge
pump to remove particles from the oil that are large enough to cause damage. Excess air delivered to
the oil reservoir is vented to the front bearing cavity through a pressurizing valve. The bearing cavities
are vented to the engine bypass duct through a breather air-oil separator located in the gearbox.
EFFECTIVITY: FJ44-2A
79-00-00
Page 3
Apr 11/08
EFFECTIVITY: FJ44-2A
79-00-00
Page 4
Apr 11/08
1. General
This task provides procedures for removing the oil filter. Refer to the following illustration(s):
Figure 401 Oil Filter Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-21-01-942-001
A. Consumables
Reference Designation
MAT-070 Bag, Plastic
3. Job Set-up
SUBTASK 79-21-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
79-21-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 79-21-01-020-001
NOTE The oil filter may need to be examined as part of the oil filter analysis program. It
must be protected from contaminants as soon as it is removed.
A. To remove the oil filter, place a suitable container under oil filter bowl to catch residual oil
(approximately 4 ounces).
B. Cut and remove the lockwire from the oil filter bowl (located next to the filter bowl)
SUBTASK 79-21-01-050-002
C. Remove the oil filter bowl using an 8-point (double square) socket wrench or an open end wrench.
SUBTASK 79-21-01-050-003
D. Remove the oil filter and small O-ring. Place filter in a protective bag (MAT-070) and tag if it is to be
examined as part of the oil filter analysis program.
5. General
This task provides procedures for installing the oil filter. Refer to the following illustration(s):
Figure 401 Oil Filter Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-21-01, Fig. 01
EFFECTIVITY: FJ44-2A
79-21-01
Page 402
Apr 11/08
SUBTASK 79-21-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
MAT-020 Mineral Spirits
MAT-027 Alcohol, Isopropyl
MAT-060 Lockwire, .032
SUBTASK 79-21-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-21-01 01 20 O-Ring
79-21-01 01 30 Filter, Oil, Disposable
79-21-01 01 40 O-Ring
SUBTASK 79-21-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
7. Procedures
SUBTASK 79-21-01-420-001
(1) Make sure that the oil filter has an O-ring installed in its ID.
EFFECTIVITY: FJ44-2A
79-21-01
Page 403
Apr 11/08
(2) Lube O-ring with assembly fluid (MAT-011) and install in the ID of the gearbox/filter bowl flange.
(a) Wipe the threads on the oil filter bowl and the oil filter port with a clean cloth to remove
excess oil.
(b) Lubricate the filter bowl threads with 2 or 3 drops of clean engine oil (MAT-001).
(c) Install filter bowl and torque 80 to 100 inch-pounds (9.0 to 11.2 N.m) using an 8-point
(double square) socket wrench.
NOTE Filter bowl may be safety wired to the adjacent safety wire hole in the
gearbox housing or to the bypass valve spring plug.
SUBTASK 79-21-01-610-001
8. Job Close-up
SUBTASK 79-21-01-410-002
SUBTASK 79-21-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-21-01
Page 404
Apr 11/08
NOTE Filter bowl may show seepage of excess oil after engine running. Clean
the area with isopropyl alcohol (MAT-027) or mineral spirits (MAT-020)
and monitor for signs of oil leakage.
EFFECTIVITY: FJ44-2A
79-21-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
79-21-01
Page 406
Apr 11/08
1. General
This task provides procedures for removing the oil cooler. Refer to the following illustration(s):
Figure 401 Lube Oil Cooler - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 79-22-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 79-22-01-020-001
WARNINGS: 1 FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT AND
OPEN FLAME. FUEL MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL THAT
CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY. CLOTHING WITH
FUEL CONTAMINATION MUST BE THOROUGHLY CLEANED BEFORE BEING
WORN. CONTAINERS SHOULD BE PLACED TO CATCH DRIPPING FUEL.
SUBTASK 79-22-01-050-002
A. Remove oil cooler-to-engine fuel tube assembly from reducer in oil cooler FUEL OUT port.
B. Remove HMU-to-oil cooler fuel tube assembly from reducer in oil cooler FUEL IN port.
EFFECTIVITY: FJ44-2A
79-22-01
Page 401
Apr 11/08
SUBTASK 79-22-01-050-004
C. Remove two reducers and two O-rings from the oil cooler.
D. Disconnect and remove three nuts and three washers which attach the oil cooler to the gearbox.
Remove the oil cooler.
NOTE Oil transfer tubes may remain in the gearbox or the oil cooler.
E. Remove the oil transfer tubes from the oil cooler (or gearbox ports).
4. General
This task provides procedures for installing the oil cooler. Refer to the following illustration(s):
Figure 401 Lube Oil Cooler - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-22-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
engine oil (MAT-001) before installation.
SUBTASK 79-22-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 79-22-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
EFFECTIVITY: FJ44-2A
79-22-01
Page 402
Apr 11/08
SUBTASK 79-22-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
6. Procedures
SUBTASK 79-22-01-420-001
A. Lube four transfer tube O-rings with engine oil and install on two transfer tubes.
B. Install the two transfer tubes in the gearbox oil cooler oil ports.
C. Install the oil cooler, aligning the transfer tubes and the mounting studs. Attach the oil cooler with
three washers and three nuts. Do not tighten nuts at this time.
D. Lube two O-rings with engine oil and install on reducers. Install reducer in FUEL IN and FUEL OUT
ports. Torque reducers 70 to 80 inch-pounds (7.9 to 9.0 N.m).
SUBTASK 79-22-01-450-002
E. Connect the two fuel tubes to the reducers in oil cooler ports. Torque oil cooler-to-engine fuel
tube nuts 135 to 150 inch-pounds (15.2 to 16.9 N.m). Torque HMU-to-oil cooler tube nuts 450 to
500 inch-pounds (50.4 to 56.0 N.m).
EFFECTIVITY: FJ44-2A
79-22-01
Page 403
Apr 11/08
SUBTASK 79-22-01-450-004
F. Torque the three oil cooler mounting nuts 55 to 59 inch-pounds (6.2 to 6.6 N.m).
SUBTASK 79-22-01-610-001
7. Job Close-up
SUBTASK 79-22-01-410-002
SUBTASK 79-22-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-22-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
79-22-01
Page 405
Apr 11/08
79-22-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers pressure testing the lube oil cooler to check for leakage between the fuel and oil circuits.
Do this task as required by troubleshooting or scheduled maintenance.
Figure 501 Lube Oil Cooler - Pressure Test Rig
SUBTASK 79-22-01-941-003
A. Standard Equipment
Pressurization Pump/reservoir
SUBTASK 79-22-01-942-003
B. Consumables
Reference Designation
MAT-002 Oil, Preservative
MAT-003 Fuel, Jet A, Jet A-1, or Jet B
MAT-024 Solvent, Dry Cleaning
SUBTASK 79-22-01-945-003
C. Reference Information
CH-SE-SU Pg Block Nomenclature
79-22-01 401 Lube Oil Cooler - Removal/Installation
3. Procedures
SUBTASK 79-22-01-020-002
A. Remove the lube oil cooler from the engine gearbox. Refer to 79-22-01, P.B. 401. Drain oil/fuel and
install clean plastic caps/plugs to keep contamination from entering the lube oil cooler. Leave
adapter fittings installed in fuel ports.
EFFECTIVITY: FJ44-2A
79-22-01
Page 501
Apr 11/08
SUBTASK 79-22-01-780-001
(1) Service pressurization pump reservoir with one of the approved test fluids listed in table
501 below:
NOTES: 1 Requires flushing of oil cooler after test and filling with fuel or preservative oil.
CAUTION MAKE SURE THAT LUBE OIL CIRCUIT PORTS ARE PLUGGED TO
PREVENT ENTRY OF TEST FLUID OR CONTAMINATION.
(2) Fill fuel circuit of lube oil cooler with test fluid.
(3) Attach outlet tube from pressurization pump to FUEL IN port adapter on the oil cooler. Hold
adapter with a back-up wrench and torque tube nut 450 to 500 inch-pounds (50.4 to 56.0 N.m).
(4) Attach drain tube to FUEL OUT port adapter on oil cooler. Hold adapter with a back-up wrench
and torque tube nut 135 to 150 inch-pounds (15.2 to 16.9 N.m).
EFFECTIVITY: FJ44-2A
79-22-01
Page 502
Apr 11/08
(2) Slowly pressurize pump and watch the flow of fluid into the drain container. Tilt lube oil cooler,
as required, to help air bubbles to escape. Reservice pressurization pump/reservoir with
fluid, as required.
(3) When fluid flow is steady with no air bubbles, remove the drain line from the adapter and install
a cap to plug fuel outlet. Hold adapter with a back-up wrench and torque cap 135 to 150
inch-pounds (15.2 to 16.9 N.m).
(1) Install clean tapered cap plugs into lube IN and OUT ports.
(2) Slowly pressurize pump to 100 psig and check for fluid leaks.
(b) If fluid leaks from lube IN or OUT ports during pressurization, reject lube oil cooler.
(3) Increase pressure to 1200 ( 25) psig and leave system pressurized for 2 minutes.
E. Remove inlet line adapter cap from the lube oil cooler. Drain test fluid from lube oil cooler.
F. If distilled water was used as a test fluid, dry lube oil cooler in a 250 degree F oven for 15 minutes.
Fill fuel circuit with fuel or preservative oil.
G. If solvent or distilled water was used as a test fluid, flush fuel circuit of oil cooler with fuel MAT-003 or
preservative oil MAT-002.
SUBTASK 79-22-01-420-002
H. Install the lube oil cooler to the engine gearbox. Refer to 79-22-01, P.B. 401.
EFFECTIVITY: FJ44-2A
79-22-01
Page 503
Apr 11/08
EFFECTIVITY: FJ44-2A
79-22-01
Page 504
Apr 11/08
1. General
This task covers general visual inspection of the lube oil cooler.
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-22-01, Fig. 01
SUBTASK 79-22-01-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
79-22-01 401 Lube Oil Cooler - Removal/Installation
SUBTASK 79-22-01-942-004
B. Consumables
Reference Designation
MAT-050 Chemical Conversion Coating
3. Procedures
SUBTASK 79-22-01-020-003
SUBTASK 79-22-01-220-001
(2) Nicks on cooler body up to 0.015 inch Blend smooth to remove raised material
(0.38 mm) deep (Does not apply to epoxy and sharp corners. Touch up chemical
coated oil cooler) conversion coating (MAT-050)
EFFECTIVITY: FJ44-2A
79-22-01
Page 601
Apr 11/08
SUBTASK 79-22-01-420-003
EFFECTIVITY: FJ44-2A
79-22-01
Page 602
Apr 11/08
1. General
This task provides procedures for removing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401 Lube and Scavenge Pump - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-24-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
3. Job Set-up
SUBTASK 79-24-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-24-01-020-001
A. Remove the fuel control unit/fuel delivery unit. Refer to 73-21-01, P.B. 401 .
SUBTASK 79-24-01-020-002
EFFECTIVITY: FJ44-2A
79-24-01
Page 401
Apr 11/08
SUBTASK 79-24-01-020-003
(2) Remove four bolts and four washers which attach the lube and scavenge pump to the gearbox
mounting pad.
(3) Remove the lube and scavenge pump and six O-rings from the gearbox mounting pad.
5. General
This task provides procedures for installing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401 Lube and Scavenge Pump - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-24-01, Fig. 01
SUBTASK 79-24-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-011 Assembly Fluid, No. 1
SUBTASK 79-24-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
EFFECTIVITY: FJ44-2A
79-24-01
Page 402
Apr 11/08
79-24-01 01 40 O-Ring
79-24-01 01 50 O-Ring (5)
SUBTASK 79-24-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
73-16-01 401 Fuel Pump - Removal/Installation
73-21-01 401 Fuel Control Unit - Removal/Installation
7. Procedures
SUBTASK 79-24-01-420-001
(1) Lubricate one O-ring with assembly fluid (MAT-011) and install on pump face pilot diameter.
(2) Lubricate five O-rings with assembly fluid and install in ports on the face of the lubrication pump.
(3) Install the lube pump drive shaft into the gearbox. Make sure that the shaft engages the
gearbox drive spline.
(4) Make sure that all the O-rings are in their proper grooves.
(5) Slide the pump until it touches the gearbox pad. Make sure that the screw holes are aligned
with the proper threaded inserts on the gearbox pad.
(6) Install four washers and four bolts. Torque bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
SUBTASK 79-24-01-420-002
SUBTASK 79-24-01-420-003
C. Install the fuel control unit/fuel delivery unit. Refer to 73-21-01, P.B. 401.
SUBTASK 79-24-01-610-001
D. Service the engine with oil (MAT-001). Refer to 72-00-03, P.B. 301.
EFFECTIVITY: FJ44-2A
79-24-01
Page 403
Apr 11/08
8. Job Close-up
SUBTASK 79-24-01-410-002
SUBTASK 79-24-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-24-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
79-24-01
Page 405
Apr 11/08
79-24-01
406
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task provides procedures for removing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 401 Oil Pressure Regulating Valve - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 79-25-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 79-25-01-050-001
(1) Cut and remove lockwire attaching the regulating valve to the interstage housing.
EFFECTIVITY: FJ44-2A
79-25-01
Page 401
Apr 11/08
(2) Remove the regulating valve and two O-rings from the interstage housing.
4. General
This task provides procedures for installing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 401 Oil Pressure Regulating Valve - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-25-01, Fig. 01
SUBTASK 79-25-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 79-25-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-25-01 01 20 O-Ring
79-25-01 01 30 O-Ring
SUBTASK 79-25-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
79-25-01 501 Oil Pressure Regulating Valve - Adjustment/TestOil Pressure Regulating
Valve - Adjustment/Test
EFFECTIVITY: FJ44-2A
79-25-01
Page 402
Apr 11/08
6. Procedures
SUBTASK 79-25-01-420-001
(1) Lubricate two O-rings with engine oil (MAT-001) and install on the regulating valve. Install the
large O-ring at the flange and the small O-ring in the O-ring groove at the regulator tip.
(3) Torque the regulating valve 145 to 155 inch-pounds (16.4 - 16.9 N.m). Install lockwire MAT-061
to secure valve to interstage housing.
SUBTASK 79-25-01-610-001
7. Job Close-up
SUBTASK 79-25-01-410-002
SUBTASK 79-25-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501. If the oil pressure regulating valve is new to the
engine, adjust valve to ensure oil pressure falls within operating band. Refer to 79-25-01, P.B. 501.
EFFECTIVITY: FJ44-2A
79-25-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
79-25-01
Page 404
Apr 11/08
1. General
SUBTASK 79-25-01-942-003
A. Consumables
Reference Designation
MAT-001 Oil, Engine
MAT-019 Acetone
MAT-020 Mineral Spirits
MAT-061 Lockwire, .020
SUBTASK 79-25-01-945-003
B. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
79-25-01 401 Oil Pressure Regulating Valve - Removal/Installation
3. Job Set-up
SUBTASK 79-25-01-010-003
4. Procedures
SUBTASK 79-25-01-820-001
EFFECTIVITY: FJ44-2A
79-25-01
Page 501
Apr 11/08
(2) Start the engine and allow to idle for five minutes. Refer to General Operating Procedures in
71-00-00, P.B. 501. Check main oil temperature. Main oil temperature must be at least 115 F
when adjusting oil pressure. Allow additional idle time, if required.
2 If one turn of adjustment screw yields less than 2 psid in MOP, then the valve
should be repaired in accordance with the overhaul procedure in this task.
(a) Turn the adjustment screw clockwise to increase engine oil pressure.
(b) Turn the adjustment screw counter-clockwise to decrease engine oil pressure.
(5) While holding the adjustment screw, Torque the adjustment locknut 30 to 40 inch-pounds
(3.3 to 4.5 N.m).
(6) Verify correct oil pressure reading per Figure 501 Oil Pressure Regulating Valve - Adjustment.
(7) Shut-down the engine. Refer to General Operating Procedures in71-00-00, P.B. 501.
SUBTASK 79-25-01-870-001
B. If required, overhaul the oil pressure regulating valve (replace internal O-ring seal) as follows:
EFFECTIVITY: FJ44-2A
79-25-01
Page 502
Apr 11/08
(1) Remove the oil pressure regulating valve from the engine. Refer to 79-25-01, P.B. 401.
(2) Remove the jam nut from oil pressure regulating valve.
(4) Remove the internal spring and the poppet from the valve body.
(5) Remove the O-ring from the adjustment screw. Discard the O-ring.
(6) Clean the adjustment screw, internal spring, poppet and valve body. Clean with vapor degrease
or flush with mineral spirits (MAT-020) or acetone (MAT-019).
(7) Lubricate new O-ring (M93248/1-009) with engine oil (MAT-001) and install to adjustment screw.
(10) Adjust jam nut and adjustment screw until no more than 4 threads protrude past jam nut.
(11) Install the oil pressure regulating valve. Refer to 79-25-01, P.B. 401.
(12) Adjust the oil pressure regulating valve in accordance with the adjustment subtask
(79-25-01-820-001).
5. Job Close-up
SUBTASK 79-25-01-410-003
EFFECTIVITY: FJ44-2A
79-25-01
Page 503
Apr 11/08
EFFECTIVITY: FJ44-2A
79-25-01
Page 504
Apr 11/08
1. General
This task provides procedures for removing the oil supply tube. Refer to the following illustration(s):
Figure 401 Oil Supply Tube - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 79-26-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 79-26-01-050-001
(1) Remove bolt and nut from loop clamp(s). Remove loop clamp(s) from oil supply tube assembly.
(2) Remove two screws from oil supply tube flange brackets.
EFFECTIVITY: FJ44-2A
79-26-01
Page 401
Apr 11/08
(3) Remove oil supply tube and two O-rings from interstage housing.
4. General
This task provides procedures for installing the oil supply tube. Refer to the following illustration(s):
Figure 401 Oil Supply Tube - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-26-01, Fig. 01
SUBTASK 79-26-01-942-002
A. Consumables
Reference Designation
MAT-001 Oil, Engine
SUBTASK 79-26-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-26-01 01 20 O-Ring (2)
SUBTASK 79-26-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
EFFECTIVITY: FJ44-2A
79-26-01
Page 402
Apr 11/08
6. Procedures
SUBTASK 79-26-01-420-001
(1) Lubricate two O-rings with engine oil and install on the oil supply tube ends. Install the oil
supply tube into the tube ports in the interstage housing.
(2) Install two screws to the oil supply tube flange brackets. Torque screws 25 to 28 inch-pounds
(2.8 to 3.1 N.m).
(3) Install the loop clamp, bolt, and nut to the flange bracket. Torque nut 49 to 55 inch-pounds
(5.5 to 6.2 N.m). Install loop clamp to sight glass flange (if applicable). Torque bolt 29 to
35 inch-pounds (3.2 to 3.9 N.m).
SUBTASK 79-26-01-610-001
B. Service the engine with oil MAT-001. Refer to 72-00-03, P.B. 301.
7. Job Close-up
SUBTASK 79-26-01-410-002
SUBTASK 79-26-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-26-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
79-26-01
Page 404
Apr 11/08
1. General
This task contains procedures for removal of the chip collector assembly installed in the gearbox housing
and/or either of the chip collectors on the lube and scavenge pump. Refer to the following illustration(s):
Figure 401 Magnetic Chip Collectors - Removal/Installation
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 79-30-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
79-30-01 601 Magnetic Chip Collector - Inspection/Check
3. Job Set-up
SUBTASK 79-30-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-30-01-020-001
NOTE To inspect the magnetic chip collectors for metal particles, only the self-closing
magnetic valve plug need be removed. Refer to 79-30-01, P.B. 601.
SUBTASK 79-30-01-050-001
A. Remove the TANK DRAIN magnetic chip collector from the lube and scavenge pump as follows:
EFFECTIVITY: FJ44-2A
79-30-01
Page 401
Apr 11/08
(2) Remove safety wire from the chip collector fitting at the bottom rear of the lube pump (labeled
TANK DRAIN).
(3) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(4) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
SUBTASK 79-30-01-050-002
B. Remove the SCAV magnetic chip collector from the lube and scavenge pump as follows:
(1) Remove safety wire from the chip collector fitting at the bottom front of the lube pump (labeled
SCAV).
(2) Remove chip collector fitting/self-closing plug assembly and let residual oil drain into a clean
container.
(3) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
C. Remove the magnetic chip collector from the gearbox housing, if engine is so equipped, as follows:
EFFECTIVITY: FJ44-2A
79-30-01
Page 402
Apr 11/08
NOTE If engine is equipped with an electrical oil debris sensor in the gearbox housing
port, rather than a magnetic chip collector, refer to 79-30-02.
(1) Remove safety wire from the chip collector fitting at the bottom of the gearbox housing.
(2) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(3) If required by scheduled maintenance, remove oil screen from gearbox housing, as follows:
5. General
This task contains procedures for installation of the chip collector assembly installed in the gearbox
housing or either of the chip collectors on the lube and scavenge pump.
Figure 401 Magnetic Chip Collectors - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-942-002
A. Consumables
EFFECTIVITY: FJ44-2A
79-30-01
Page 403
Apr 11/08
Reference Designation
MAT-001 Oil, Engine
MAT-061 Lockwire, .020
SUBTASK 79-30-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-30-01 01 60 O-Ring (3)
79-30-01 01 55 O-Ring (3)
79-30-01 01 48 O-Ring (2)
72-60-10 01 440 O-Ring (1)
SUBTASK 79-30-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
7. Procedures
SUBTASK 79-30-01-420-002
A. Install any of the magnetic chip collectors to the lube and scavenge pump or the gearbox as follows:
NOTE If engine is equipped with an electrical oil debris sensor in the gearbox housing
port, rather than a magnetic chip collector, refer to 79-30-02.
(a) Lubricate O-ring with engine oil and install on oil screen.
(c) Install one bolt and one washer. Torque bolt 46 to 51 inch-pounds (5.2 to 5.7 N.m).
EFFECTIVITY: FJ44-2A
79-30-01
Page 404
Apr 11/08
(b) Install oil screen into lube pump housing. Torque oil screen 150 to 250 inch-pounds
(16.9 to 28.2 N.m).
(4) Lubricate new O-ring with engine oil MAT-001 and install on chip collector fitting. Install chip
collector fitting into lube and scavenge pump or gearbox housing. Torque chip collector fittings
50 to 60 inch-pounds (5.6 - 6.7 N.m).
SUBTASK 79-30-01-610-001
8. Job Close-up
SUBTASK 79-30-01-410-002
SUBTASK 79-30-01-790-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-30-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
79-30-01
Page 406
Apr 11/08
1. General
This task contains procedures for checking the magnetic chip collectors. There are chip collectors in
the gearbox and lubrication pump. They detect metal particles in the 1/2 bearing scavenge and the
3/4 bearing scavenge. The magnetic plugs must be visually inspected at specified intervals of engine
operating hours. Refer to the following illustration(s):
Figure 601 Magnetic Chip Collectors - Visual Inspection
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
72-00-05 201 Oil Filter Analysis Program - Maintenance Practices
79-21-01 401 Oil Filter - Removal/Installation
3. Job Set-up
SUBTASK 79-30-01-010-003
(2) Open the circuit breakers to isolate the engine electrical supply.
4. Procedures
SUBTASK 79-30-01-210-001
EFFECTIVITY: FJ44-2A
79-30-01
Page 601
Apr 11/08
NOTE Self-closing magnetic valve plugs do not require tools to remove or install.
(1) Remove the self-closing magnetic valve plug by turning counter-clockwise 1/6 turn.
(b) Small hair-like slivers of steel or fine dust around the magnet. This condition usually
applies to engines which are new/repaired or overhauled with low hours. This condition
would not represent internal failure or impending failure of the engine
(c) Large sized particles. This condition does not always represent internal failure of the
engine since the particles could have originated in the fabrication or build-up of the
engine. Collect particles from the magnet for further analysis. Make sure that sample
is not contaminated during the collection process. Use a clean plastic bag and mark
sample with engine S/N, chip collector location, and date. Photo document particles and
contact a WI representative for further evaluation and disposition.
2 Submit the oil filter element for analysis. Refer to 72-00-05, P.B. 201.
(3) Inspect the O-ring on the magnetic plug and replace if necessary.
(4) Install the magnetic plug into the valve by pushing and turning clockwise until you feel it
lock in place.
(5) Inspect the valve for leaks after installation. No leaks are allowed.
(e) Perform engine testing per the table Tests Required after Maintenance or Component
Replacement (List of Test Procedures) in 71-00-00, P.B. 501.
1 If the engine testing results in almost the same or larger quantity of metal particles,
reject the engine.
EFFECTIVITY: FJ44-2A
79-30-01
Page 602
Apr 11/08
2 If there are no particles on the magnetic plug, examine the plug after the next
flight for metal particles.
SUBTASK 79-30-01-610-002
5. Job Close-up
SUBTASK 79-30-01-410-003
EFFECTIVITY: FJ44-2A
79-30-01
Page 603
Apr 11/08
EFFECTIVITY: FJ44-2A
79-30-01
Page 604
Apr 11/08
1. General
This task covers removal of both the oil filler cap and dipstick assembly and removal of the filler port plug
assembly (if the engine is so equipped). Refer to the following illustration(s):
Figure 401 Oil Filler Cap and Dipstick - Removal/Installation
Figure 402 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation
NOTES: 1 During removal of parts, group all components together to make assembly easier.
2. Job Set-up
SUBTASK 79-31-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
3. Procedures
SUBTASK 79-31-01-020-001
A. Remove the oil filler cap and dipstick assembly by lifting up the locking tab and turning counter
clockwise.
EFFECTIVITY: FJ44-2A
79-31-01
Page 401
Apr 11/08
SUBTASK 79-31-01-020-002
NOTE The filler port plug assembly may be located on the inboard oil filler port,
instead of a oil filler cap and dipstick assembly.
(1) Remove safety wire and loosen (but do not remove) wing nut on plug assembly.
(2) Turn plug assembly and remove from oil fill port.
4. General
This task covers installation of both the oil filler cap and dipstick assembly and installation of the filler
port plug assembly (if the engine is so equipped).
Figure 401 Oil Filler Cap and Dipstick - Removal/Installation
Figure 402 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-31-01, Fig. 01
SUBTASK 79-31-01-942-002
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
MAT-061 Lockwire, .020
SUBTASK 79-31-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
EFFECTIVITY: FJ44-2A
79-31-01
Page 402
Apr 11/08
79-31-01 01 20 O-Ring
79-31-01 01 50 O-Ring
79-31-01 01 60 O-Ring
6. Procedures
SUBTASK 79-31-01-420-001
NOTE The oil filler cap and dipstick assembly must be installed on the
outboard side of the engine.
(1) Inspect the O-ring on the oil filler cap and dipstick assembly for damage. Replace if damaged.
(2) Insert the oil filler cap and dipstick assembly into the oil filler port. To avoid binding, rotate
the dipstick on the filler port plug so the offset bend faces aft of the engine. Lock by turning
clockwise and folding down locking tab.
SUBTASK 79-31-01-420-002
(2) Lube small O-ring with MAT-011 assembly fluid and install on shaft.
(3) Lube large O-ring with assembly fluid and install on cap
(4) Install cap on the shaft and secure with wing nut.
NOTE The filler port plug assembly must be installed on the inboard side of the engine.
(1) Loosen the wing nut on the shaft so that the two tangs on the underside of the cap are just
engaging the slots in the shaft.
(2) Insert the plug assembly into the filler port. Turn cap/shaft assembly to engage lock plate in the
filler port slot. Tighten wing nut.
EFFECTIVITY: FJ44-2A
79-31-01
Page 403
Apr 11/08
7. Job Close-up
SUBTASK 79-31-01-410-002
SUBTASK 79-31-01-450-001
B. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-31-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
79-31-01
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
79-31-01
Page 406
Apr 11/08
1. General
This task covers removal of the low oil level sensor from the interstage housing (if the engine is so
equipped). When configuring the engine for right or left-hand installation, the low oil level sensor must be
installed on the outboard side. The cover plate blank is installed on the inboard side.
Figure 401 Low Oil Level Sensor - Removal/Installation
Figure 402 Low Oil Level Sensor - Torque Pattern
NOTES: 1 During removal of parts, group all components together to make assembly easier.
SUBTASK 79-33-01-945-001
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Job Set-up
SUBTASK 79-33-01-010-001
(2) Open the circuit breakers to isolate the engine electrical supply.
EFFECTIVITY: FJ44-2A
79-33-01
Page 401
Apr 11/08
4. Procedures
SUBTASK 79-33-01-610-001
SUBTASK 79-33-01-020-001
B. Remove the low oil level sensor from the interstage housing as follows:.
CAUTION AFTER REMOVAL OF THE LOW OIL LEVEL SENSOR OR THE BLANKING
PLATE, COVER THE OPEN PORT IN THE INTERSTAGE HOUSING TO
ENSURE THAT NO CONTAMINATION ENTERS THE ENGINE.
(1) Remove the aircraft connector plug from the oil level sensor connector. Refer to the Aircraft
Maintenance Manual.
(2) Remove eight bolts which retain the low oil level sensor. Carefully remove the low oil level
sensor from the interstage housing Cover the port in the interstage housing to prevent
contamination.
5. General
This task covers installation of the low oil level sensor onto the interstage housing (if the engine is so
equipped). When configuring the engine for right or left-hand installation, the low oil level sensor must be
installed on the outboard side. The cover plate blank is installed on the inboard side.
Figure 401 Low Oil Level Sensor - Removal/Installation
Figure 402 Low Oil Level Sensor - Torque Pattern
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-33-01, Fig. 01
SUBTASK 79-33-01-942-002
A. Consumables
EFFECTIVITY: FJ44-2A
79-33-01
Page 402
Apr 11/08
Reference Designation
MAT-001 Oil, Engine
SUBTASK 79-33-01-944-002
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-33-01 01 12 O-Ring (1)
SUBTASK 79-33-01-945-002
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
7. Procedures
SUBTASK 79-33-01-420-001
NOTE Low oil level sensor must be installed on the outboard side of the engine.
A. Install the low oil level sensor onto the interstage housing as follows:
(2) Make sure that the mounting surface on the interstage housing is clean and free of defects.
(3) Install low oil level sensor on interstage housing and secure with eight bolts. Install oil supply
tube loop clamp and secure with lower left-hand bolt. Torque bolts 29 to 35 inch pounds (3.2 to
3.9 N.m), in 7 to 8 inch-pound (0.79 to 0.90 N.m) steps, in the sequence pattern shown on
Figure 402 Low Oil Level Sensor - Torque Pattern.
(4) Install the aircraft harness connector plug to the sensor connector. Refer to the Aircraft
Maintenance Manual.
SUBTASK 79-33-01-610-002
SUBTASK 79-33-01-790-001
C. Perform engine testing per the table Tests Required after Maintenance or Component Replacement
(List of Test Procedures) in 71-00-00 P.B. 501.
EFFECTIVITY: FJ44-2A
79-33-01
Page 403
Apr 11/08
EFFECTIVITY: FJ44-2A
79-33-01
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
79-33-01
Page 405
Apr 11/08
79-33-01
406
Page
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LINE MAINTENANCE MANUAL FJ44-2A
1. General
Parts relating to this maintenance procedure are found in the following figure(s) of the Illustrated Parts
Catalog:
79-33-01, Fig. 01
NOTES: 1 We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
2 You must inspect all parts for damage, corrosion, and wear whether specified in the
text or not. If you find any part to be defective which is not included in the inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
SUBTASK 79-33-01-945-003
A. Reference Information
CH-SE-SU Pg Block Nomenclature
79-33-01 401 Low Oil Level Sensor - Removal/Installation
3. Procedures
SUBTASK 79-33-01-220-001
A. Remove the low oil level sensor. Refer to 79-33-01, P.B. 401.
EFFECTIVITY: FJ44-2A
79-33-01
Page 601
Apr 11/08
C. Install the low oil level sensor. Refer to 79-33-01, P.B. 401.
TASK 79-33-01-770-801 Functionally Check the Installed Low Oil Level Sensor
4. General
This task functionally checks the installed low oil level sensor. Refer to the following illustration(s):
Figure 601 Low Oil Level Sensor - Functional Check
SUBTASK 79-33-01-941-002
A. Standard Equipment
Ohmmeter
6. Procedures
SUBTASK 79-33-01-770-001
A. The low oil sensor contains a coil which provides the capability to self-test the reed switch. This
is accomplished using an ohmmeterand by applying 28 Vdc to pins 3 and 4 on the connector as
shown on the figure. Refer to the Aircraft Flight Manual for instructions for self-test during normal
oil level check.
EFFECTIVITY: FJ44-2A
79-33-01
Page 602
Apr 11/08
EFFECTIVITY: FJ44-2A
79-33-01
Page 603
Apr 11/08
79-33-01
604
Page
Blank
LINE MAINTENANCE MANUAL FJ44-2A
1. General
This task covers removal of both the oil level sight glass and the sight glass cover plate blank from the
interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 401 Interstage Housing Oil Sight Glass - Removal/Installation
SUBTASK 79-33-11-945-004
A. Reference Information
CH-SE-SU Pg Block Nomenclature
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
3. Job Set-up
SUBTASK 79-33-11-010-004
(2) Open the circuit breakers to isolate the engine electrical supply.
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the engine cowling.
SUBTASK 79-33-11-610-001
EFFECTIVITY: FJ44-2A
79-33-11
Page 401
Apr 11/08
4. Procedures
SUBTASK 79-33-11-020-009
A. Remove the oil sight glass from the interstage housing as follows:.
(1) Remove eight bolts which retain cover plate. Remove cover plate, gasket, sight glass, and
O-ring from the interstage housing port. Cover the sight glass port in the interstage housing.
SUBTASK 79-33-11-020-010
B. Remove the cover plate blank from the interstage housing as follows (if engine is so equipped):
(1) Remove eight bolts, oil supply tube loop clamp, and the cover plate heatshield.
(2) Remove the cover plate blank from the interstage housing. Cover the sight glass port in the
interstage housing.
5. General
This task covers installation of both the oil level sight glass and the sight glass cover plate blank onto
the interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 401 Interstage Housing Oil Sight Glass - Removal/Installation
Figure 402 Interstage Housing Oil Sight Glass - Torque Pattern
SUBTASK 79-33-11-942-005
A. Consumables
Reference Designation
MAT-011 Assembly Fluid, No. 1
EFFECTIVITY: FJ44-2A
79-33-11
Page 402
Apr 11/08
SUBTASK 79-33-11-944-005
B. Expendable Parts
IPC Reference
Subject Fig. Item Nomenclature
79-33-11 02 20 O-Ring
79-33-11 02 40 Gasket
SUBTASK 79-33-11-945-005
C. Reference Information
CH-SE-SU Pg Block Nomenclature
71-00-00 501 Power Plant - Adjustment/Test
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
7. Procedures
SUBTASK 79-33-11-420-002
A. Install the oil sight glass onto the interstage housing as follows (Figure 401 Interstage Housing Oil
Sight Glass - Removal/Installation):
NOTE Sight glass must be installed on the outboard side of the engine.
(1) Replace O-ring and gasket. Visually inspect O-ring, gasket, sight glass, and cover plates
for damage prior to installation.
(2) Assemble the sight glass, gasket, and cover plate. Make sure that the chamfer on the cover is
facing out and up and the glass is assembled smooth side out. Lube the O-ring with assembly
fluid (MAT-011) and install on back (grooved) side of glass.
(3) Install assembled sight glass on interstage housing and secure with eight bolts. Install oil
supply tube loop clamp and secure with lower left-hand bolt. Torque bolts 29 to 35 inch pounds
(3.2 to 3.9 N.m), in 7 to 8 inch-pound (0.79 to 0.90 N.m) steps, in the sequence pattern shown
on Figure 402 Interstage Housing Oil Sight Glass - Torque Pattern.
SUBTASK 79-33-11-420-003
B. Install the cover plate blank onto the interstage housing as follows (if engine is so equipped) (Figure
401 Interstage Housing Oil Sight Glass - Removal/Installation):
NOTE Cover plate blank must be installed on the inboard side of the engine.
(1) Inspect the seal on the cover plate blank for damage. If damaged, replace cover plate blank.
EFFECTIVITY: FJ44-2A
79-33-11
Page 403
Apr 11/08
(2) Install the cover plate blank and the cover plate heatshield to the interstage housing.
(3) Install eight bolts and torque to 29 to 35 inch-pounds (3.2 to 3.9 N.m) in the sequence pattern
shown on Figure 402 Interstage Housing Oil Sight Glass - Torque Pattern.
8. Job Close-up
SUBTASK 79-33-11-610-002
NOTE Carefully service oil to prevent oil from getting trapped between cover plate/interstage
or cover plate/sight glass. Small amounts of oil wicked into crevices may give false
indication of leakage (wetness only, no droplets forming) after engine has been run.
SUBTASK 79-33-11-410-005
SUBTASK 79-33-11-760-001
C. Perform engine testing as required by List of Test Procedures in 71-00-00, P.B. 501.
EFFECTIVITY: FJ44-2A
79-33-11
Page 404
Apr 11/08
EFFECTIVITY: FJ44-2A
79-33-11
Page 405
Apr 11/08
EFFECTIVITY: FJ44-2A
79-33-11
Page 406
Apr 11/08
79-33-11
407
Page
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