Fj44-2a Ipc

COPY NO.
FJ44-2A
LINE MAINTENANCE MANUAL
FJ44-2A
Initial Issue:
Mar 31/97
WI P/N 56210
Revision 17
2008 Williams International Co., LLC

All rights reserved. This copyright protected document may be reproduced for your internal use only.
NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairmans responsibility to review all
applicable service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
THIS PAGE LEFT INTENTIONALLY BLANK
Page 2
00-Titlepage Blank
LINE MAINTENANCE MANUAL FJ44-2A
SUMMARY OF CHANGES
FJ44-2A Line Maintenance Manual FJ44-2A
P/N 56210
TRANSMITTAL LETTER No. 17

Remove Insert CH-SEC- Task Number Task Title
Page Page SUB Description of Change
Block Block
201 05-17-00 05-17-00-870-803 Listing of Unapproved Parts
New Task
601 601 05-20-00 05-20-00-210-803 Scheduled Maintenance Checks
Removed requirement to pressure test oil cooler
assembly at Check 4.
201 201 70-10-01 70-10-01-870-801 Consumable Materials List
Added a general wet cleaner to the consumable
materials list.
101 101 71-00-00 71-00-00-810-803 Power Plant - Troubleshooting
Revised troubleshooting for Oil Smell in
Cabin/Bleed Odor.
501 501 71-00-00 71-00-00-760-807 List of Test Procedures
Add High Power Test to list of tests when any
maintenance if performed on the fuel pump.
201 201 71-00-25 71-00-25-510-803 Engine Shipping
Added a step to reference a general cleaner if
engine needs to be wiped clean.
401 401 72-00-31 72-00-31-420-802 Install the Fan Rotor
Delete unnecessary step in Job Setup.
801 801 72-30-10 72-30-10-350-801 Blend Repair the Spinner
Added a step to use the troubleshooting chart for
foreign object ingestion, if there is any possibility an
occurrence took place.
601 601 72-31-20 72-31-20-220-801 Visually Inspect the Fan Rotor
Revised fan blade diagram to clarify inspection
zones.
801 801 72-31-20 72-31-20-350-802 Blend Repair the Fan Rotor
Revised fan blade diagram to clarify inspection
zones.

NOTE: When printed, this selection may not include all relevant data. It is the mechanic/repairmans responsibility to review all applicable
service information documents in depth to ensure they understand all the specific requirements for the operation concerned.
801 801 72-31-20 72-31-20-350-802 Blend Repair the Fan Rotor

601 601 72-32-10 72-32-10-220-801 Visually Inspect the Case and Insert Assembly
601 601 72-32-20 72-32-20-220-801 Visually Inspect the Fan Stator
Added criteria for wear through the outer wall
urethane from contact with fan case keys.
801 801 72-32-20 72-32-20-350-801 Blend Repair the Fan Stator
401 401 72-60-01 72-60-01-050-802 Remove Magnetic Carbon Seals from Gearbox
Corrected caution that defines gearbox
configuration.
401 401 72-60-01 72-60-01-450-802 Install Magnetic Carbon Seals in Gearbox
Added Warning describing importance of proper
assembly of gearbox seals and highlighting test
requirements after maintenance.
401 401 72-60-01 72-60-01-450-804 Install Type 1 Spring-Loaded Carbon Seals in the
8k Gearbox
401 401 72-60-01 72-60-01-450-806 Install Type 2 or Type 3 Spring-Loaded Carbon
Seals in the 8k Gearbox
401 401 73-21-01 73-21-01-450-803 Install the Fuel Control Unit
Referenced the install task of the Accel Bleed
System Cable.

TABLE OF CONTENTS
CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
RECORD OF REVISIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
RECORD OF TEMPORARY REVISIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
INTRODUCTION
MANUAL INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00-00-00

Manual Introduction - Description and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
TIME LIMITS/MAINTENANCE CHECKS
AIRWORTHINESS LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-10-00

Airworthiness Limitations - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
SERVICE LIFE TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-12-00

Service Life Tracking - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
UNAPPROVED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17-00

Unapproved Parts - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
SCHEDULED MAINTENANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . 05-20-00

Scheduled Maintenance Checks -
Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
RECOMMENDED MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . 05-50-00

Recommended Maintenance -
Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
STANDARD PRACTICES
ASSEMBLY/DISASSEMBLY MAINTENANCE
PRACTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-00-01
Assembly/Disassembly Maintenance
Practices - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
TEMPORARY MARKING OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . 70-01-05

Temporary Marking of Parts - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
MARKING OF REPAIRED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01-07
Page i
Table of Contents Apr 11/08

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Marking of Repaired Parts - Maintenance

Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
MISUSE OF MOLYBDENUM DISULFIDE

LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-01-11
Misuse of Molybdenum Disulfide Lubricants
- Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
IDENTIFICATION, LUBRICATION, AND FITTING OF

O-RING SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-02-01
Identification, Lubrication, and Fitting of
O-ring Seals - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
CONSUMABLE MATERIALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-10-01

Consumable Materials - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
CONTAMINATION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . 70-12-00

Contamination of Engine Components -
LOCKING TECHNIQUES FOR THREADED PARTS . . . . . . . . . . . . 70-12-04

Locking Techniques for Threaded Parts -
CLEANING METHODS AND PROCEDURES . . . . . . . . . . . . . . . . . . 70-21-00

Cleaning Methods and Procedures -
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
BALL AND ROLLER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-31-01

Ball and Roller Bearing - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
CARBON SEAL SURFACE QUALITY . . . . . . . . . . . . . . . . . . . . . . . . 70-33-01

Carbon Seal Surface Quality -
REPAIR SURFACES AFFECTED BY MINOR

DAMAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42-11
Repair Surfaces Affected by Minor Damage
- Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
LOCAL SURFACE PROTECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-42-12

Local Surface Protection - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
NON-DESTRUCTIVE INSPECTION (NDI) METHODS . . . . . . . . . . . 70-42-15

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

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
TORQUE TIGHTENING TECHNIQUE . . . . . . . . . . . . . . . . . . . . . . . . 70-51-00

Torque Tightening Technique -
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-53-00

Special Tools - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
STORAGE OF PARTS THAT HAVE SHELF LIFE
LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70-61-01
Storage of Parts that have Shelf Life Limits
- Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
POWER PLANT
POWER PLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-00

Power Plant - Fault Isolation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Power Plant - Maintenance Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Power Plant - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Power Plant - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
POWER PLANT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-03

Power Plant Cleaning - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
PRESERVING UNINSTALLED ENGINE . . . . . . . . . . . . . . . . . . . . . . 71-00-21

Preserving Uninstalled Engine -
PRESERVING INSTALLED ENGINE FOR NINE MONTHS

OR MORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-22
Preserving Installed Engine for Nine
Months or More - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
PRESERVING INSTALLED ENGINE FOR NINE MONTHS

OR LESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-23
Preserving Installed Engine for Nine
Months or Less - Maintenance Practices
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
STORAGE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-24
Storage Inspection - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
ENGINE SHIPPING/RECEIVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-25

Engine Shipping/Receiving - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
ENGINE DEPRESERVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-26
Page iii

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Engine Depreservation - Maintenance

Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
IP AND HP COMPRESSORS (BORESCOPE) . . . . . . . . . . . . . . . . . 71-00-30

IP and HP Compressors (Borescope) -
INTERNAL OIL LEAK (BORESCOPE) . . . . . . . . . . . . . . . . . . . . . . . 71-00-32

Internal Oil Leak (Borescope) -
COMBUSTOR, FUEL SLINGER, AND HP TURBINE

BLADES LEADING EDGE (BORESCOPE) . . . . . . . . . . . . . . . . . . . . 71-00-40
Combustor, Fuel Slinger, and HP Turbine
Blades Leading Edge (Borescope) -
LP TURBINES (BORESCOPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-00-50

LP Turbines (Borescope) -
HP NOZZLE/HP TURBINE TRAILING EDGE AND 1ST LP

TURBINES LEADING EDGE (BORESCOPE) . . . . . . . . . . . . . . . . . . 71-00-52
HP Nozzle/HP Turbine Trailing Edge and
1st LP Turbines Leading Edge (Borescope)
- Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-00
Engine - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
APPROVED ENGINE FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-01

Approved Engine Fuel - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
ENGINE SERVICING OIL

CHANGING/REPLENISHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-03
Engine Servicing - Oil
Changing/Replenishing - Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
OIL FILTER ANALYSIS PROGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-05

Oil Filter Analysis Program - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-30
Spinner - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
FAN ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-31
Page iv

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Fan Rotor - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
CASE AND INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-32

Case and Insert Assy - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
GEARBOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-60

Gearbox Assy - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
REAR BYPASS DUCT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 72-00-71

Rear Bypass Duct Assy -
Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
INTERNAL COOLING AND SEALING AIR SYSTEM . . . . . . . . . . . . 72-02-00

Internal Cooling and Sealing Air System -
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
SPINNER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-30-10
Spinner - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Spinner - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
SPINNER PILOT PLATE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 72-31-15

Spinner Pilot Plate Assy - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
FAN ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-31-20

Fan Rotor - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Fan Rotor - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
CASE AND INSERT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-32-10

Case and Insert Assembly -
Case and Insert Assembly - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
FAN STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-32-20

Fan Stator - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Fan Stator - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801
GEARBOX CARBON SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-60-01

Gearbox Carbon Seals -
FILTER DIFFERENTIAL PRESSURE (DELTA P)

INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72-60-02
Filter Differential Pressure (Delta P)
Indicator - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
REAR BYPASS DUCT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 72-71-10
Page v

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Rear Bypass Duct Assy - Inspection/Check

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
REAR MOUNTING RING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 72-71-20

Rear Mounting Ring Assy -
ENGINE FUEL AND CONTROL
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-00-00

Fuel System - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FUEL TUBE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-10-01

Fuel Tube Assemblies -
Fuel Tube Assemblies - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
FUEL DRAIN TUBE ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . 73-11-01

Fuel Drain Tube Assemblies -
FUEL NOZZLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-12-01

Fuel Nozzle Assembly -
Fuel Nozzle Assembly - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
FUEL PUMP FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-14-01
Fuel Pump Filter - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
FUEL PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-16-01

Fuel Pump - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
FUEL CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-20-00

Fuel Control System - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
FUEL CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-21-01
Fuel Control Unit - Removal/Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Fuel Control Unit - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
FUEL FILTER INDICATOR (DELTA P SWITCH) . . . . . . . . . . . . . . . 73-23-01

Fuel Filter Indicator (Delta P Switch) -
Page vi

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Fuel Filter Indicator (Delta P Switch) -

ELECTRONIC CONTROL UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-24-01

Electronic Control Unit - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Electronic Control Unit -
FUEL MANIFOLD FILTER ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73-25-01

Fuel Manifold Filter Assy -
FUEL CONTROL SHUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 73-27-01

Fuel Control Shutoff Valve - Maintenance
Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
IGNITION
IGNITION SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 74-00-00

Ignition System - Description and
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-00-10

Ignition System - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
IGNITION EXCITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-10-01

Igniton Exciter - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
IGNITER LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-20-01

Igniter Lead - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Igniter Lead - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
IGNITER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74-22-01

Igniter Plug - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Igniter Plug - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Igniter Plug - Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .701
AIR
AIR SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75-00-00

Air System - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
ACCELERATION BLEED SYSTEM LINKAGE . . . . . . . . . . . . . . . . . 75-30-01

Acceleration Bleed System Linkage -
ACCELERATION BLEED SYSTEM LEVER . . . . . . . . . . . . . . . . . . . 75-35-01
Page vii

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Acceleration Bleed System Lever -

Acceleration Bleed System Lever -
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
ACCELERATION BLEED SYSTEM CABLE . . . . . . . . . . . . . . . . . . . 75-37-01

Acceleration Bleed System Cable -
ENGINE CONTROLS
ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-00-00

Engine Controls - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LP SHAFT TRIP SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76-20-01

LP Shaft Trip Sensor - Adjustment/Test
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
LP Shaft Trip Sensor - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
ENGINE INDICATING
ENGINE INDICATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-00-00

Engine Indicating - Description and
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
LP MAGNETIC SPEED PICKUP ASSEMBLY . . . . . . . . . . . . . . . . . . 77-11-01

LP Magnetic Speed Pickup Assembly -
LP Magnetic Speed Pickup Assembly -
GEARBOX (HP) MAGNETIC SPEED PICKUP

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-12-01
Gearbox (HP) Magnetic Speed Pickup
Assembly - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Gearbox (HP) Magnetic Speed Pickup
Assembly - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
INTERMEDIATE TURBINE TEMPERATURE (ITT) . . . . . . . . . . . . . . 77-20-02

Intermediate Turbine Temperature (ITT)
Probe - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Intermediate Turbine Temperature (ITT)
Probe - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
EFCU TT2 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77-22-02
Page viii

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
EFCU TT2 Sensor - Removal/Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
EFCU TT2 Sensor - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
EFCU ENGINE WIRING HARNESS ASSEMBLY . . . . . . . . . . . . . . . 77-40-01

EFCU Engine Wiring Harness Assembly -
EFCU Engine Wiring Harness Assembly -
OIL
OIL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-00-00

Oil System - Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-21-01

Oil Filter - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
LUBE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-22-01

Lube Oil Cooler - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Lube Oil Cooler - Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
Lube Oil Cooler - Inspection/Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
LUBE AND SCAVENGE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-24-01

Lube and Scavenge Pump -
OIL PRESSURE REGULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . 79-25-01

Oil Pressure Regulating Valve -
Oil Pressure Regulating Valve -
Adjustment/Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .501
OIL SUPPLY TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-26-01

Oil Supply Tube - Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
MAGNETIC CHIP COLLECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-30-01

Magnetic Chip Collector -
Magnetic Chip Collector - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
OIL FILLER CAP AND DIPSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-31-01

Oil Filler Cap and Dipstick -
LOW OIL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-33-01
Page ix

CHAPTER
SECTION
SUBJECT SUBJECT
PAGE
Low Oil Level Sensor - Removal/Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Low Oil Level Sensor - Inspection/Check
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
OIL SIGHT GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79-33-11

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

RECORD OF REVISIONS
Revision 1 Aug 21/00

Revision 2 Mar 20/01
Revision 3 Jun 15/01
Revision 4 Mar 01/03
Revision 6 Oct 30/04
Revision 7 Jan 14/05
Revision 8 Apr 15/05
Revision 10 Dec 05/05
Revision 11 Feb 15/06
Revision 12 Jul 05/06
Revision 15 Sep 04/07
Page 1
Apr 11/08

Page 2
Blank
RECORD OF TEMPORARY REVISIONS
None
Page 1
Apr 11/08

Page 2
Blank
CHAPTER 00
INTRODUCTION
Page 1
00-INTRODUCTION Apr 11/08

Page 2
00-INTRODUCTION Blank
LIST OF EFFECTIVE PAGE BLOCKS
Chapter Chapter Chapter

Section Page Section Page Section Page
Subject Block Date Subject Block Date Subject Block Date
00-00-00 1 Apr 11/08
Chapter 00
List of Effective Page Blocks
Page 1
Apr 11/08

Chapter 00
Page 2
Blank
MANUAL INTRODUCTION - DESCRIPTION AND OPERATION
TASK 00-00-00-860-801 How to Use this Manual
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.
2. How to Use this Manual
SUBTASK 00-00-00-860-107
A. The manual is written to A.T.A. Specification No. 100 (Revision 28). The contents are organized
using the three element (six digit) Chapter-Section-Subject number (CH-SE-SU). The first element is
the Chapter, the second element is the Section, and the third element is the Subject.
(1) The chapter number and the first digit of the section number are assigned by the ATA
100 specification. This promotes continuity of contents between the manuals of different
manufacturers.
(2) The second digit of the section number and the subject number are assigned by the
manufacturer to identify the subject component with a unique designation.
(3) For example, the CH-SE-SU number 72-30-00 is interpreted as follows:
(a) 72 is the Chapter (Engine)
(b) 30 is the Section (Compressor Section)
(c) 00 is the Subject (Description and Operation)
(4) This numbering system is adjusted to identify removal/installation of core engine modules. This
allows engine build-up tasks to be grouped together in the manual. In these cases, the Section
number is moved to the third element and "00" is used for the second "middle" element.
EXAMPLE: 72-00-55 LP Turbine Module - Removal/Installation
B. Contents are further divided within a CH-SE-SU number by topic. Each topic is identified by a
separate range of page numbers. These Page Blocks organize the task information within a Subject.
A full list of topic Page Blocks for this manual are:
Table 1 List of Page Blocks (Maintenance Manual)
Description and Operation P.B. 001 - 099

Fault Isolation P.B. 101 - 199
EFFECTIVITY: FJ44-2A
00-00-00
Page 1
Apr 11/08

Table 1 List of Page Blocks (Maintenance Manual) (Continued)
Maintenance Practices P.B. 201 - 299

Servicing P.B. 301 - 399
Removal/Installation P.B. 401 - 499
Adjustment/Test P.B. 501 - 599
Inspection/Check P.B. 601 - 699
Cleaning/Painting P.B. 701 - 799
Repairs P.B. 801 - 899
C. This manual is written to conform to the requirements of the Aircraft Maintenance Task Oriented
Support System (A.M.T.O.S.S.). This system is designed to facilitate automated data 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:
EXAMPLE: SUBTASK 72-32-20-220-001
ELEMENT NUMBER: 1 2 3 4 5
Element 1 Chapter Number
Element 2 Section Number
Element 3 Subject Number
Element 4 Function Code - Refer to table below.
Element 5 Numeric Indentifier - Used to make similarly numbered tasks and subtasks unique
Table 2 Function Codes for A.M.T.O.S.S. Task/Subtask Numbering (Fourth Element - 72-00-00-XXX-000)
Code Description
000 Disassemble (General)
010 Remove Engine
020 Remove Engine Modular Sections
030 Disassemble Engine Modular Sections
040 Disassemble Engine Subassemblies
050 Remove Accessory/Power Plant Components
100 Cleaning (General)
110 Chemical Cleaning
00-00-00
Page 2
Apr 11/08

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

Element - 72-00-00-XXX-000) (Continued)
130 Ultrasonic Cleaning

170 Foam/Water Wash
200 Inspection (General)
210 Check
220 Visual/Dimensional/Grading
230 Penetrant Inspect
250 Eddy Current Inspect
270 Ultrasonic Inspect
300 Repair (General)
320 Machining
350 Miscellaneous Repairs
400 Assemble (General)
410 Install Engine
420 Install Engine Modular Sections
430 Assemble Engine Modular Sections
440 Assemble Engine Subassemblies
450 Install Accessory/Power Plant Components
480 Install Engine Test Equipment
510 Shipping
520 Receiving
550 Storage
600 Test (General
610 Servicing
620 Preserving
630 Depreserving
730 Fuel Flow Testing
750 Electrical Testing
760 Engine Testing
770 Accessory Testing
00-00-00
Page 3
Apr 11/08

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

Element - 72-00-00-XXX-000) (Continued)
780 Pressure Check

810 Fault Isolation
820 Adjust/Align/Calibrate
830 Rigging
860 Description and Operation
870 Maintenance Practices
940 Balance
941 Standard Equipment
942 Consumables
943 Special Tools
944 Expendable Parts
945 Reference Information
3. Revisions
SUBTASK 00-00-00-860-108
A. List of Effective Page Blocks
The List of Effective Page Blocks will list the correct date for each page block within the Chapter.
(1) For CD-ROM, 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:
1-800-859-FJ44 (3544) (toll-free within CONUS)
1-248-960-2929 (outside CONUS)
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:
00-00-00
Page 4
Apr 11/08

Williams International, Inc.
2280 W. Maple Rd.
P.0. Box 200
Walled Lake, MI 48390-0200
Att: Product Support
4. Observance of Manual Instructions
SUBTASK 00-00-00-860-109
A. The instructions for maintenance and maintenance practices of the engine contained in this manual,
particularly those related to removal, installation, and repair of critical (life-limited) parts, have been
written to keep parts in serviceable condition during their service lives.
B. Instructions are written to permit, wherever possible, the use of standard shop practices when doing
tasks. However, where instructions are specific as to means and method, it is important that you
do not use alternate methods unless alternatives are agreed upon with Williams International Even
minor deviations from manual instructions may require careful evaluation to avoid abuse, which
may not be detectable by routine inspection.
C. Where changes to the specified instructions or standards are required and cannot be approved at
the originating source under the terms of approval granted by the appropriate regulatory authority,
then details of the required technical variance should be submitted to Williams International for
consideration.
D. To comply with the certification and recording requirements involved in revisions or amendments to
manual instructions, Williams International in approving a submission, will provide to the originating
source a Technical Variance document and covering Temporary Revision as proof of approval.
E. It is the responsibility of the originating source to record and preserve these documents in a manner
and locality which complies with appropriate regulatory authority requirements.
F. These instructions are written to return engines and hardware to service when used in normal
operations. Aircraft accidents/incidents induce additional investigation requirements which are not
covered in these instructions. For 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:
(1) Aircraft Maintenance Manual (A.M.M.)
00-00-00
Page 5
Apr 11/08

(2) Illustrated Parts Catalog (I.P.C.).
The IPC shows the relationship of all parts and assemblies and lists all part numbers.
References to specific parts for maintenance use (found under the Equipment and Materials
listing at the front of each task) are by IPC figure and item number.
(3) Engine Manual (E.M.)
B. 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.
TASK 00-00-00-860-805 Engine Description
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.
Refer to the following illustration:

Figure 2 FJ44-2A - Left Side View
Figure 3 FJ44-2A -Right Side View
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.
00-00-00
Page 6
Apr 11/08

(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.
(6) The sixth group is the airframe mounted ECU.
TASK 00-00-00-860-807 List of Abbreviations
8. General
The following is a list of common abbreviations used throughout this manual.

Abbreviation Definition
A.M.M. Aircraft Maintenance Manual
A.M.T.O.S.S. Aircraft Maintenance Task Oriented Support System
ATA Air Transport Association of America
CDP compressor discharge pressure
CH-SE-SU Chapter/Section/Subject number
cm centimeter
delta P differential pressure
EBK Engine Build Kit
ECS Environmental Control System (Airframe)
EM Engine Manual
est estimate
etc et cetera
FAA Federal Aviation Administration
FADEC full authority digital electronic control
FCU fuel control unit (hydromechanical)
FOD Foreign Object Damage
gal gallon
00-00-00
Page 7
Apr 11/08

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
00-00-00
Page 8
Apr 11/08

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
00-00-00
Page 9
Apr 11/08

TASK 00-00-00-860-814 FJ44-2A Service Bulletin List
9. General
SERVICE BULLETIN NUMBER INCORPORATION STATUS

FJ44-72-040 No effect
FJ44-72-042 Incorporated
FJ44-72-045 No Effect
00-00-00
Page 10
Apr 11/08

Fig. 1 Technical Publications Customer Feedback Form
00-00-00
Page 11
Apr 11/08

Fig. 2 FJ44-2A - Left Side View
00-00-00
Page 12
Apr 11/08

Fig. 3 FJ44-2A -Right Side View
00-00-00
Page 13
Apr 11/08

00-00-0014
Page
Blank
CHAPTER 05
TIME LIMITS/MAINTENANCE CHECKS
05-TIME LIMITS/MAINTENANCE Page 1

CHECKS Apr 11/08

05-TIME LIMITS/MAINTENANCE Page 2

CHECKS Blank

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
Chapter 05
Page 1
Apr 11/08

Chapter 05
Page 2
Blank
AIRWORTHINESS LIMITATIONS - MAINTENANCE PRACTICES
TASK 05-10-00-870-802 Airworthiness Limitations
1. General
The Airworthiness Limitations section is FAA approved and specifies maintenance required under 43.16
and 91.403 of the Federal Aviation Regulations unless an alternative program has been FAA approved.
This task gives the maximum approved lives for life-limited parts. Do not allow parts to exceed these
approved lives.

Figure 201 Flight Profile Duty Cycle
CAUTIONS: 1 LIFE-LIMITED PARTS MAY REACH THEIR MAXIMUM APPROVED LIFE LIMITS
BEFORE OR BETWEEN SCHEDULED ENGINE/PART REMOVALS.
2 IT IS THE OWNER/OPERATORS RESPONSIBILITY TO MAKE SURE THAT

THE PARTS DO NOT EXCEED THEIR MAXIMUM APPROVED LIVES. THE
OWNER IS DEFINED AS THE OWNER OF THE AIRCRAFT ON REGISTER
WITH THE FEDERAL AVIATION ADMINISTRATION (FAA) OR ITS EQUIVALENT
OR THE LEGAL OWNER OF THE ENGINE.
2. Flight Cycle Definition.
SUBTASK 05-10-00-870-013
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:
(1) Touch-and-go landing shall be recorded as .50 cycle.
(2) Full stop landing without engine shutdown shall be recorded as .50 cycle.
(3) Ground Running: Idle to max continuous thrust shall be recorded as .50 cycle.
(4) Throttle movement associated with low approaches are not counted as cycles.
05-10-00
Page 201
Apr 11/08

3. Maximum Approved Part Lives
SUBTASK 05-10-00-870-014
A. Refer to table below for the component name, part number and approved part life.
Table 201 Time Limits for Life-Limited Parts
PART DESCRIPTION Service Life (Flight Williams

Cycles) International
Part Number
Fan Rotor 6,000 59482
Fan Rotor 6,000 61967
Fan Rotor 6,000 65502
IP Compressor Rotor 8,000 57401
HP Compressor Rotor 6,000 57672
HP Compressor Rotor 6,000 61964
HP Turbine Disk 8,000 67093
HP Turbine Disk 8,000 59387
1st LP Turbine Disk 10,000 72037
1st LP Turbine Disk 6,000 55531
2nd LP Turbine Disk 10,000 66993
2nd LP Turbine Disk 5,000 55534
4. Flight Profile and Operational Monitoring.
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).
05-10-00
Page 202
Apr 11/08

5. Operating Hour Monitoring.
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.
2 IT IS THE OWNER/OPERATORS RESPONSIBILITY TO MAKE SURE THAT

THE PARTS DO NOT EXCEED THEIR MAXIMUM APPROVED LIVES.
THE OWNER IS DEFINED AS THE OWNER OF THE AIRCRAFT ON
REGISTER WITH THE FEDERAL AVIATION ADMINISTRATION (FAA) OR
ITS EQUIVALENT OR THE LEGAL OWNER OF THE ENGINE.
A. Time in service, with respect to maintenance time records, means the time from the moment an
aircraft leaves the surface of the runway until it touches it at the next point of landing. Engine
operating hours and flight hours shall be considered the same as aircraft time in service.
6. Life Management Program
SUBTASK 05-10-00-870-017
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.
The life management program works as follows:
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.
05-10-00
Page 203
Apr 11/08

Fig. 201 Flight Profile Duty Cycle
05-10-00
Page 204
Apr 11/08

SERVICE LIFE TRACKING - MAINTENANCE PRACTICES
TASK 05-12-00-870-801 Service Life Tracking
1. General
Since critical parts cannot be practicably marked to track service history or life, a record system must be
kept to ensure that they dont exceed their safe service lives (SSL).
2. Life Recording
SUBTASK 05-12-00-870-002
CAUTION IT IS MOST IMPORTANT TO MAINTAIN DETAILED LIFE RECORDS ON

ALL GROUP A CRITICAL PARTS. THIS IS THE ONLY IDENTIFICATION
OF LIFE COMPLETED BY EACH PART.
A. Records and information are to be supplied by the repair facility as follows:
An internal record system must be maintained for 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).
B. When a Group A critical part is rejected, do the following:
(1) Record it.
(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.
(3) Send the same information to Williams International.
05-12-00
Page 201
Apr 11/08

05-12-00
202
Page
Blank
UNAPPROVED PARTS - MAINTENANCE PRACTICES
TASK 05-17-00-870-803 Listing of Unapproved Parts
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
WARNING THE FOLLOWING COMPONENT PART NUMBERS/SERIAL NUMBERS MUST

NOT BE USED. THESE ENGINES/PARTS HAVE BEEN INVOLVED IN AN
ACCIDENT OR SCRAPPED AND NOT RETURNED TO SERVICE.
Table 201
Engine Component
Serial Component Serial
Number Part Number Number Description
105269 65502 AU21062 ROTOR, FAN
05-17-00
Page 201
Apr 11/08

05-17-00
202
Page
Blank
SCHEDULED MAINTENANCE CHECKS - INSPECTION/CHECK
TASK 05-20-00-210-803 Scheduled Maintenance Checks
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.
2 You must do the checks in this task at the intervals described.
3 Engine Operating Hours are equivalent to Flight Hours as defined in

Airworthiness Limitations, 05-10-00.
2. Intervals Routine Periodic Inspection
SUBTASK 05-20-00-210-013
NOTES: 1 For Routine Periodic Inspections, refer to table 601.
2 Specified inspection intervals shall not be exceeded by more than

30 engine operating hours.
A. Preflight Check - Inspection procedure performed before each flight.
B. Postflight Check - Inspection procedure performed after each flight.
C. Hourly - Special inspection or maintenance at the engine operating hours interval shown.
D. Check 1 - Inspections at every 150 to 200 engine operating hours.
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.
05-20-00
Page 601
Apr 11/08

3. Intervals Major Periodic Inspection Intervals.
SUBTASK 05-20-00-210-014
NOTES: 1 For Major Periodic Inspections, refer to table 602.
2 Life limited parts should be reviewed to determine if lives will be exceeded

before the next inspection interval.
3 Specified inspection intervals shall not be exceeded by more than

100 engine operating hours.
A. Check 3 - Inspections at every 1750 engine operating hours.
B. Check 4 - Inspections at every 3500 engine operating hours, but no more than 1750 engine operating
hours after Check 3 was performed.
4. Time Between Overhaul (TBO)
SUBTASK 05-20-00-210-015
NOTES: 1 Component Operating Hours are equivalent to Flight Hours accumulated

on the component.
2 The intervals shown for TBO of accessories shall not be exceeded by

more than 100 Component Operating Hours.
A. Fuel Control Unit: 3500 Component Operating Hours
B. Lube and Scavenge Pump: 3500 Component Operating Hours
C. Fuel Pump: 3500 Component Operating Hours
D. Electronic Control Unit: 3500 Component Operating Hours
5. Storage Limits
SUBTASK 05-20-00-210-016
NOTE If storage time limits for the following components are exceeded,
contact the component manufacturer.
A. Fuel Control Unit: 10 years
B. Fuel Pump: 4 years
C. Lube and Scavenge Pump: 4 years
05-20-00
Page 602
Apr 11/08

D. Electronic Control Unit: 10 years
6. Equipment and Materials
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
A. Prepare the engine for inspection checks
(1) Install DO NOT OPERATE signs.
(2) Open the cowl doors. Refer to the Aircraft Maintenance Manual.
8. Inspections Routine Periodic and Major Periodic
SUBTASK 05-20-00-210-018
A. Do the inspection checks at the time interval given. Refer to Tables 1 and 2.
Table 601 Routine Periodic Inspections
Nature of Inspection Preflight Check 1 Check 2 Comply with

Hourly
Inspect the engine inlet, fan rotor, fan tip Preflight Aircraft Flight Manual
shroud, fan stator, and 2nd LP turbine rotor
for evidence of foreign object damage
(FOD). Remove any obstructions.
Inspect engine inlet and exhaust areas Preflight Aircraft Flight Manual
for evidence of oil leakage. If you find
evidence of oil leakage, isolate the cause
and correct.
Check the oil filter differential pressure Preflight Aircraft Flight Manual
(delta P) indicator. If indicator is extended,
refer to troubleshooting.
Check the oil level and add oil as required Preflight Subtask
72-00-03-610-002 in
72-00-03 P.B. 301
Check maintenance fault indicator Preflight Aircraft Flight Manual
Postflight
05-20-00
Page 603
Apr 11/08

Table 601 Routine Periodic Inspections (Continued)
Nature of Inspection Preflight Check 1 Check 2 Comply with

Hourly
Check the overboard fuel drain ports for Preflight A.M.M.
fuel leakage
Perform an operational check of the EFCU x Subtask
in manual mode 71-00-00-760-001
71-00-00-760-818
Remove oil filter and submit for analysis x x 72-00-05 P.B. 201
Install new oil filter x x 79-21-01 P.B. 401
Visually inspect and clean fuel start nozzle x x 73-12-01 P.B. 601
and start nozzle adapter
Check fuel start nozzle spray pattern x x 73-12-01 P.B. 601
Change fuel pump filter x 73-14-01 P.B. 401
Remove and visually inspect the igniter x x 74-22-01 P.B. 601
plugs
Dimensionally inspect the igniter plugs x x 74-22-01 P.B. 601
Do an operational test on the ignition x x 74-00-10 P.B. 501
system
Remove and inspect magnetic chip x x 79-30-01 P.B. 601
collectors
Inspect TT2 sensor heater element x x 77-22-01 P.B. 601
(functional check)
Physically inspect fan rotor for damage x Subtask
and cleanliness 72-31-20-220-001 in
72-31-20 P.B. 601
Change oil x 72-00-03 P.B. 301
Inspect acceleration bleed system x 75-30-01 P.B. 601
Perform resistance and continuity check x 73-23-01 P.B. 601
on fuel filter electrical (delta P) indicator
05-20-00
Page 604
Apr 11/08

Table 602 Major Periodic Inspections
Nature of Inspection Check 3 Check 4 Comply with

Take an oil filter analysis program sample x x 72-00-05, P.B. 201
after acceptance testing
Change oil (If maintenance is performed x x 72-00-03, P.B. 301
on wing)
Flush oil tank by pouring one quart of (new) x 79-30-01 P.B. 401
engine oil through the oil fill port and letting
it drain from the tank drain port (while
screen is removed). Reinstall oil screens.
Rear bypass duct - Remove and visually x 72-71-10 P.B. 601
inspect.
Front bypass duct - Visually inspect. x EM72-70-10 P.B. 801
Rear mount ring - Remove and visually x 72-71-20 P.B. 601
inspect.
Rear housing - Remove and visually x EM72-56-10 P.B. 801
inspect.
LP turbine module - Remove and visually x EM72-55-10 P.B. 801
inspect assembled module (interface
inspection only).
1st LP turbine nozzle group - Remove x EM72-53-10 P.B. 801
and visually inspect assembled module
(interface inspection only).
HP turbine rotor - Remove and visually x EM72-51-10 P.B. 801

inspect assembled rotor (interface
inspection only).
HP turbine rotor Dimensionally inspect x x EM 72-51-15-220-804
blade tip diameter
HP turbine combustor assembly/seal and x EM72-45-10 P.B. 801
fuel slinger assembly/balance piston seal EM72-47-10 P.B. 801
- Remove assembled group from engine
and visually inspect (interface inspection
only).
05-20-00
Page 605
Apr 11/08

Table 602 Major Periodic Inspections (Continued)

Combustor cover - Remove and visually x EM72-40-10 P.B. 801
inspect.
HP Shaft - Visually inspect aft end. x EM72-37-22 P.B. 801
Fuel Manifold - Visually inspect. x EM72-39-16 P.B. 801
Fuel Manifold Filter - Clean x 73-25-01 P.B. 401
Remove oil screens from the three x x 79-30-01 P.B. 401
magnetic chip collector ports. Clean oil
screens. Reinstall oil screens.
LP magnetic speed pickup - Remove and x x Subtask
inspect (visual inspection only). 77-11-01-220-001 in
77-11-01-220-801
Gearbox magnetic speed pickup (HP) - x x Subtask
Remove and inspect (visual inspection 77-12-01-220-001 in
only). 77-12-01-220-801
Inspect the fuel drain tubes to make sure x x 73-11-01 P.B. 401
they are open.
HP turbine rotor metallic seal ring - inspect x x EM72-00-51 P.B. 301
for installation of metallic seal ring.
Fuel Control Unit - Determine operating X X Refer to Paragraph Time Between
hours since new (or since last overhaul). Overhaul (TBO)
If overhaul will be due before next Subtask
engine Major Periodic Inspection, 05-20-00-210-015
perform overhaul in accordance with
manufacturers requirements.
Lube and Scavenge Pump - Determine X X Refer to Paragraph Time Between
operating hours since new (or since last Overhaul (TBO)
overhaul). If overhaul will be due before Subtask
next engine Major Periodic Inspection, 05-20-00-210-015
Fuel Pump - Determine operating hours X X Refer to Paragraph Time Between
since new (or since last overhaul). Overhaul (TBO)
If overhaul will be due before next Subtask
engine Major Periodic Inspection, 05-20-00-210-015
05-20-00
Page 606
Apr 11/08


Electronic Control Unit (ECU) - Determine X X Refer to Paragraph Time Between
operating hours since new (or since last Overhaul (TBO)
overhaul). If overhaul will be due before Subtask
next engine Major Periodic Inspection, 05-20-00-210-015
Fuel Manifold - Inspect (Visual/NDI) x EM72-39-16-220-801
EM72-39-16-230-801
Fuel Slinger - Inspect x EM72-45-10 P.B. 801
(Visual/Dimensional/NDI)
Balance Piston Seal - Inspect x EM72-45-10 P.B. 801
Fan rotor - Inspect (Visual/NDI). x 72-31-20-220-801
EM72-31-20-230-801
EM72-31-20-250-801
Spinner - Inspect x 72-30-10-220-801
(Visual/Dimensional/NDI). EM72-30-10 P.B. 801
Pilot plate assembly - Inspect x 72-31-15-220-801
Spinner bolts - Replace. x EM72-00-30 P.B. 401
Fan stator - Inspect x EM 72-32-20 P.B. 801
(Visual/NDI/Dimensional).
Inlet case - Inspect x 72-32-10-220-801
Inlet case flange bolts - Replace. x EM72-00-32 P.B. 401
IP compressor rotor - Inspect (Visual/NDI). x EM72-34-20 P.B. 801
IP compressor stator (stage 1-2) inspect x EM72-33-10 P.B. 801
(Visual/NDI)
IP compressor stator (stage 3)- Inspect x EM72-36-20 P.B. 801
(Visual/NDI).
IP fairing group - Inspect. x EM72-33-12 P.B. 801
LP shaft/No. 1 bearing group - Inspect. x EM72-35-20, P.B. 801
No. 1 bearing carrier assembly - Inspect. x EM72-35-24 P.B. 801
05-20-00
Page 607
Apr 11/08


1.5 bearing group - Inspect. x EM72-35-30 P.B. 801
Front bearing housing assembly - Inspect. x EM72-35-40 P.B. 801
Interstage housing group - Inspect (NDI). x EM72-37-10 P.B. 801
Interstage housing - Inspect (Visual/NDI). x EM72-37-12 P.B. 801
Interstage housing assembly Replace oil x EM 72-37-12, P.B. 901
tank check valve
Oil manifold - Inspect (Visual/NDI) x EM72-37-18 P.B. 801
LP shaft - Inspect (Visual/NDI). x EM72-35-22 P.B. 801
No. 1 ball bearing - Inspect. x EM72-35-26 P.B. 801
No. 2 ball bearing - Replace x EM72-37-10 P.B. 1001
No.1.5 bearing - Inspect. x EM72-35-30 P.B. 801
Ball bearing, 1st reduction bevel gear - x EM72-37-10 P.B. 501
Replace.
1st reduction bevel gear support - Inspect x EM72-37-16 P.B. 801
HP compressor cover - x EM72-37-17 P.B. 801
Inspect(Visual/NDI).
HP rotary group - Inspect. x EM72-37-20 P.B. 801
HP shaft - Inspect (Visual/NDI). x EM72-37-22 P.B. 801
HP compressor rotor - Inspect (Visual/NDI). x EM72-37-24 P.B. 801
Diffuser assembly - Inspect (Visual/NDI). x EM72-39-14 P.B. 801
Diffuser-to-interstage bolts - Replace. x EM72-00-39 P.B. 401
Combustor cover - Inspect (Visual/NDI) x EM72-40-10 P.B. 801
HP turbine combustor assembly - Inspect x EM72-47-10 P.B. 801
Primary plate - Inspect (Visual/NDI) x EM72-47-10 P.B. 801
HP turbine rotor group - Inspect (Visual) x EM72-51-10 P.B. 801
HP turbine rotor disk - Inspect (Visual/NDI) x EM72-51-15 P.B. 801
HP turbine rotor blades - Inspect x EM72-51-15 P.B. 801
(Visual/Dimensional/NDI).
HP retaining nut - Replace. x EM72-00-51 P.B. 401
05-20-00
Page 608
Apr 11/08


1st LP turbine nozzle group - Inspect. x EM72-53-10 P.B. 801
1st LP turbine nozzle - Inspect (NDI). x EM72-53-12 P.B. 801
1st LP turbine disk - Inspect (Visual/NDI). x EM72-55-31 P.B. 801
1st LP turbine blades - Inspect x EM72-55-31 P.B. 801
(Visual/NDI).
2nd LP turbine disk - Inspect (Visual/NDI). x EM72-55-33 P.B. 801
2nd LP turbine blades - Inspect x EM72-55-33 P.B. 801
(Visual/NDI).
LP turbine module - Inspect (Visual/NDI). x EM72-55-10 P.B. 801
LP turbine retaining bolts and nuts - x EM72-55-10 P.B. 1001
Replace.
2nd LP nozzle - Inspect x EM72-55-20 P.B. 801
(Visual/Dimensional/NDI).
Rear housing group - Inspect (Visual/NDI). x EM72-56-10 P.B. 801
Rear housing assembly- Inspect (NDI). x EM72-56-12 P.B. 801
Rear bypass duct - Inspect x 72-71-10-220-801
EM72-71-10 P.B. 801
Rear mount ring - Inspect. x 72-71-20-220-801
EM72-71-20 P.B. 801
Front bypass duct - Inspect x EM72-70-10 P.B. 801
Gearbox assembly - Disassemble/Inspect x EM72-60-10 P.B. 801
- Replace Gasket
LP shaft separation system - Functional x
check.
9. Job Close-up
SUBTASK 05-20-00-410-003
A. Put the engine back to normal
(1) Close the cowl doors. Refer to the Aircraft Maintenance Manual.
(2) Remove DO NOT OPERATE signs.
05-20-00
Page 609
Apr 11/08

05-20-00
610
Page
Blank
RECOMMENDED MAINTENANCE - MAINTENANCE PRACTICES
TASK 05-50-00-870-801 Power Plant Water Wash Policy
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.
(b) Smog laden or sandy environment.
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.
05-50-00
Page 201
Apr 11/08

05-50-00
202
Page
Blank
CHAPTER 70
STANDARD PRACTICES
Page 1
70-STANDARD PRACTICES Apr 11/08

Page 2
70-STANDARD PRACTICES Blank

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
Page 1
Apr 11/08

Chapter 70
Page 2
Blank
ASSEMBLY/DISASSEMBLY MAINTENANCE PRACTICES - MAINTENANCE PRACTICES
TASK 70-00-01-870-801 Assembly/Disassembly Maintenance Practices
1. General
Standard maintenance practices for engine maintenance are provided in this task. These practices
are recommended by the engine manufacturer.
CAUTIONS: 1 TO AVOID DAMAGE TO PARTS, THESE HANDLING INSTRUCTIONS

MUST BE FOLLOWED:
2 USE HAND PROTECTION FOR HEAVY, LARGE OR DIFFICULT TO MANEUVER

PARTS. AVOID WEARING RINGS OR BRACELETS WHILE HANDLING PARTS.
3 PLACE PARTS ON A FLAT, RESILIENT SURFACE.
4 KEEP PARTS SEPARATED.
5 PICK PARTS STRAIGHT UP AND PLACE STRAIGHT DOWN. AVOID

ANY WEIGHT ON BLADE TIPS.
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
70-00-01
Page 201
Apr 11/08

3. Standard Dissassembly Practices
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.
70-00-01
Page 202
Apr 11/08

4. Standard Assembly Practices
SUBTASK 70-00-01-870-004
CAUTION DUE TO PHYSICAL SIMILARITY, SOME ENGINE PARTS CAN BE ASSEMBLED

INTO THE WRONG LOCATION, RESULTING IN A POSSIBLE FAILURE. TO
PREVENT THIS, CHECK EACH PART CAREFULLY FOR CORRECT USE.
A. Use the following general procedures for assembly and installation of engine and accessory
components. Refer to the Consumable Materials Listing 70-10-01, P.B. 201for applicable materials.
(1) 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.
70-00-01
Page 203
Apr 11/08

70-00-01
204
Page
Blank
TEMPORARY MARKING OF PARTS - MAINTENANCE PRACTICES
TASK 70-01-05-870-801 Temporary Marking of Parts
1. General
This task defines the acceptable materials for the temporary marking of parts.
SUBTASK 70-01-05-942-001
A. Consumables
MAT-030 Pencil, Silver
MAT-032 Marker, Broad Line
MAT-033 Marker, Fine Line
SUBTASK 70-01-05-945-001
3. Procedures
SUBTASK 70-01-05-870-001
CAUTIONS: 1 A SILVER PENCIL, MAT-030, MUST NOT BE USED ON TITANIUM PARTS.
2 CHINA CLAY BASED PENCILS (CHINAGRAPH PENCILS) MUST NOT BE

USED. GRAPHITE PENCILS CAUSE CARBON PENETRATION AT HIGH
TEMPERATURES AND MUST NOT BE USED. MARKS ACCIDENTALLY
MADE BY GRAPHITE PENCILS MUST BE COMPLETELY REMOVED
BEFORE HEAT TREATMENT OR ASSEMBLY.
3 ALL MARKS MADE WITH FELT TIP MARKER MAT-032 OR MAT-033 MUST
BE REMOVED BEFORE PARTS ARE EXPOSED TO TEMPERATURES
ABOVE 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.
70-01-05
Page 201
Apr 11/08

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.
70-01-05
Page 202
Apr 11/08

MARKING OF REPAIRED PARTS - MAINTENANCE PRACTICES
TASK 70-01-07-870-801 Marking of Repaired Parts
1. General
This task provides the standard practices for marking of repaired parts.
Figure 201 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
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.
C. Repair symbols are to be marked in two places:
(1) Next to the part number identification

(2) Adjacent to the repaired area (if practical - refer to specific repair instructions).
D. 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.
70-01-07
Page 201
Apr 11/08

(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.
70-01-07
Page 202
Apr 11/08

Fig. 201 Repair Symbols

70-01-07
Page 203
Apr 11/08

70-01-07
204
Page
Blank
MISUSE OF MOLYBDENUM DISULFIDE LUBRICANTS - MAINTENANCE PRACTICES
TASK 70-01-11-870-801 Misuse of Molybdenum Disulfide Lubricants
1. General
This task provides information on the misuse of molybdenum disulfide lubricants.
2. Procedures
SUBTASK 70-01-11-870-001
A. Molybdenum disulfide lubricants (Molykote, MAT-008 break down at temperatures above 572 F.
(300 C). They also release sulphur which can cause corrosion and failure of engine parts. Most of
the bolt materials used in the higher temperature zones of the engine can be damaged by sulphur.
B. Never use lubricants that have molybdenum disulfide except in cases where it is specifically called
out in the manual.
70-01-11
Page 201
Apr 11/08

70-01-11
202
Page
Blank
IDENTIFICATION, LUBRICATION, AND FITTING OF O-RING SEALS - MAINTENANCE PRACTICES
TASK 70-02-01-870-801 Identification, Lubrication, and Fitting of O-ring Seals
1. General
This task provides information on O-ring seals.
SUBTASK 70-02-01-942-001
A. Consumables
MAT-001 Oil, Engine
SUBTASK 70-02-01-945-001
70-61-01 201 Storage of Parts that have Shelf Life Limits - Maintenance Practices
3. Identification
SUBTASK 70-02-01-870-002
A. To identify new O-rings, read the part number on the envelope in which they are packed. Each
envelope lists:
(1) Description of part
(2) Quantity
(3) Engine manufacturers part number
(4) Cure date
B. The storage life of an seal ring can be determined by the cure date on the envelope. There is a listing
of storage periods in 70-61-01. The year is divided into quarters as follows:
1st quarter - January, February, March
2nd quarter - April, May, June
3rd quarter - July, August, September
70-02-01
Page 201
Apr 11/08

4th quarter - October, November, December
The quarter number and the year, isolated by the letter Q, show the cure date. A cure date of
2Q91 shows the cure date to be in the second quarter (April, May, or June) of 1991. The storage
life can be calculated from this date.
C. You can identify the seal ring material by looking up its basic part number (MS number) in the
table below.
PART NUMBER MATERIAL
M25988 Fluorosilicone
M83248 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.
B. The lubricants to be used for seal rings are as follows:
(1) Seal rings in fuel system - assembly fluid No. 1 MAT-011
(2) All other seal rings - assembly fluid No. 1 MAT-011 or engine oil MAT-001
5. Installation
SUBTASK 70-02-01-870-004
A. Check the shelf life (refer to 70-61-01, P.B. 201) the condition of the seals. Ensure there are no flat
spots, cuts, or other damage.
B. Make sure that grooves and mating faces, to which the seal rings are to be installed, are clean,
smooth, and free from damage. When installed, make sure that the seal rings are not twisted and
are correctly seated in the grooves.
C. Use new seal rings when you assemble units or parts.
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.
70-02-01
Page 202
Apr 11/08

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.
70-02-01
Page 203
Apr 11/08

70-02-01
204
Page
Blank
CONSUMABLE MATERIALS - MAINTENANCE PRACTICES
TASK 70-10-01-870-801 Consumable Materials List
1. General
This section describes the consumable materials and other shop supplies required to perform the
maintenance 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
Table 201 Consumable Materials
Reference Nomenclature Specification/Part Number/Manuf.

MAT-001 Oil, Engine Refer to list of approved engine oils
(72-00-03, P.B. 301)
MAT-002 Oil, Preservative MIL-L-6081, Grade 1010
MAT-003 Fuel, Jet A Fuel, Jet A-1 or Jet B ASTM-D-1655
MIL-T-5624 Grade JP-4; JP-5
or MIL-T-83133 Grade JP-8
MAT-004 Oil, Corrosion Preventive MIL-C-8188
MAT-005 Oil, Penetrating WD-40
WD-40 Company
San Diego, CA 92110 USA
MAT-007 Steel Strapping 11/4, 3/4, or 1/2 inch width
MAT-008 Lubricant, Molybdenum Disulfide Molykote, G-n Paste
Dow Corning Corporation
Midland, MI 48686-0994 USA
MAT-009 Petrolatum VV-P-236A or equivalent
MAT-010 Grease, Aircraft, General Purpose MIL-G-81322
70-10-01
Page 201
Apr 11/08

Table 201 Consumable Materials (Continued)

MAT-011 Assembly Fluid, No. 1 Ultrachem, Inc.
900 Centerpoint Blvd.
New Castle, DE 19720 USA
MAT-012 Lubricant, Dry Film Dow Corning (R) 321
MAT-013 Magnesium Hydroxide A-A-51924A (Equivalent of
A-A-51924A = mixture of 405mg
per teaspoon of magnesium hydroxide
and 5 ml of purified water.)
MAT-013 Magnesium Hydroxide Milk of Magnesia, Non-Flavored
MAT-015 Lubricant, Anti-seize NSN-165
Bostik
Boston Street
Middleton, MA 01949
Telephone: 508-777-0100
MAT-017 Lubricant, Rapid GT Lubcon Turbon Lubrication, INC.
Lubricant Consult GmbH
Gutenbergstrasse 13
D-63477 Maintal
GERMANY
MAT-019 Acetone Commercial Grade
MAT-020 Mineral Spirits TT-T-291; Shell 145-EC
MAT-021 R-MC Cleaner Part No. 4072 (concentrate)
Part No. 4070 (pre-mixed, R-MC
G-21)
ECT Inc.
155 S. Limerick Rd.
Limerick, PA 19468
Telephone 610-239-5120
MAT-022 Nitric Acid (HNO3)
MAT-023 Ultrasonic Cleaner, Caustic Chem Crest 270
MAT-024 Solvent, Dry Cleaning P-D-680, Type II
MAT-025 Solvent, Remover MIL-I-25135
MAT-026 Ultrasonic Cleaner, Detergent Chem Crest 135 or 250
MAT-027 Alcohol, Isopropyl
70-10-01
Page 202
Apr 11/08


MAT-028 Alcohol, Methyl, Wood, or Methanol
MAT-029 Compressor Cleaner B&B 3100
MIL-C-85704B, Type 1
B&B Tritech, Inc.
P.O. Box 660776 Miami, FL
33266-07766
Telephone: 305-888-5247
MAT-030 Pencil, Silver Berol Verithin, No. 753
MAT-031 Gas Path Cleaner B&P TC-100N-3 B&P Tritech, Inc
Turco 6783-50 Elf Atochem, N.A.
Turco 6783-10 Elf Atochem, N.A
EZE 206MS Calgon Corp
EZE 206RU Calgon Corp
ZOK-27 ZOK Inc.
ZOK-MX ZOK Inc
Techniclean GT Castrol Industrial
NA,Inc
MA 109C JAD Chemical Co.
MA 110 JAD Chemical Co.
ARDROX 6367 (TURBOCLEAN2)
MAT-032 Marker, Broad Line Magic Marker, brand (blue, red, or
black)
Binney and Smith, Inc.
Easton, PA 18044-0431
Mighty Marks 7000-Red
Peter Castell Corp.
Lewisburg, TN 37091
Dykem High Purity 44 (Medium Tip)
Tex Action Marker; white, black, or
red. ITW Dymon.
MAT-033 Marker, Fine Line Sharpie Fine Point Marker (red)
Vis-a-Vis Fine Line Marker (blue)
Sanford Corp.
Bellwood, Illinois 60104
Dykem High Purity (Fine) Tex
Action Marker; white, black, or red.
ITW Dymon.
MAT-040 Cloth, Abrasive P-C-458C
70-10-01
Page 203
Apr 11/08


MAT-041 Pad, Abrasive MIL-A-9962A
MAT-042 Paper, Abrasive, Silicone Carbide P-P-101E
MAT-043 Stone, Sharpening SS-S-736C
MAT-044 Stone, Arkansas HF43-Hard
MAT-045 Stone, Rubberized Bright-Boy, Fine
Cratex ST 70
ALO 800
MAT-050 (Iridite) Chemical Conversion Materials MIL-C-81706; 14-2 or MIL-C-5541
for Coating Aluminum and Aluminum
Alloys
MAT-060 Lockwire, .032 MS20995-C32
MAT-061 Lockwire, .020 MS20995-C20
MAT-070 Bag, Plastic PPP-B-26
MAT-071 Cloth, Lint Free CCC-F-46
MAT-072 Gloves, Plastic (Lint free) Disposable MIL-G-36593 ZZ-G-381
Rubber Vinyl
MAT-073 Brush, Wire H-B-178
MAT-075 Gloves, Cotton
MAT-076 Paper, Litmus MS-36253B
MAT-077 Swab, Cotton Commercial
MAT-078 Gloves, Thermal Protective
MAT-079 Crocus Cloth, Non-metallic
MAT-080 Liquid Nitrogen, Refrigerated Airco
MAT-081 Penetrants/Emulsifiers MIL-I-25135, QPL-25135-15
MAT-082 Developers MIL-I-25135, QPL-25135-15
MAT-083 Powder, Fluorescent, Dry Magnaflow 14A
MAT-084 Fluid, MPI Suspension Medium DOD-F-87935
(corrosion inhibitor, wetting &
defoaming agents)
MAT-085 Petroleum Distillate, Light Blend 380 (AMS 3160 or 3161)
MAT-086 Magnaflux/Magnaglo Carrier II
70-10-01
Page 204
Apr 11/08


MAT-087 Sealant, RTV 159
MAT-088 Sealant, RTV 157 (gray)
MAT-089 Sealant, RTV 103 (black)
MAT-090 Sealant, RTV MIL-A-46106, Group III, Type I
Recommended Products:
RTV 106, General Electric Co.
Dow Corning 736, Dow Corning Corp.
MAT-091 Compound, Retaining Loctite 242
MAT-092 Compound, Retaining Loctite 404 or Permabond 910
MAT-093 Compound, Retaining Loctite 620
MAT-094 Compound, Retaining Loctite 601 or 609
MAT-095 Compound, Retaining Loctite 262 or 271
MAT-096 Primer, Epoxy MIL-P-23377
MIL-P-85582
MIL-P-53022
MAT-097 Sealant, RTV RTV 162
MIL-A-46146, Group 1, Type 1
MAT-100 Leak Tec 372E
MAT-110 Seal, Impregnation MIL-I-6869
PSM-10 or Resinol RTC
Loctite Corp.
705 Mountain Rd
Newington, CT 06111
MAT-122 Fingerprint Remover MIL-C-15074-C
MAT-123 Solvent, Wet Cleaning Mirachem 100
MAT-170 Material, Barrier MIL-B-121E, Grade A, Type I, Class I
MAT-173 Bag, Sealable, Polyethylene PPP-B-26
MAT-174 Rustripper Oakite
MAT-175 Bag, Desiccant MIL-D-3464, Type I, 8-unit bag
MAT-176 Bag, Barrier MIL-B-131, Type I, Class III
MAT-200 Shim Stock .001 - .010
70-10-01
Page 205
Apr 11/08


MAT-201 Tape, Reflective P/N 2169.020 (1/2 inch wide)
Schenck Trebel
535 Acorn Street
Deer Park, N. Y. 11729
MAT-202 Cleaner, General Wet Simple Green
Sunshine Makers, Inc
15922 Pacific Coast Highway
Huntington Harbor CA 92649
Ph: 8002280709
70-10-01
Page 206
Apr 11/08

CONTAMINATION OF ENGINE COMPONENTS - MAINTENANCE PRACTICES
TASK 70-12-00-870-801 Contamination of Engine Components
1. General
This task provides information on the types of contamination of engine components.
2. Procedures
SUBTASK 70-12-00-870-001
A. Some materials used in engines can be contaminated through contact with other materials.
(1) When a material is contaminated by a low melting point alloy, it can, at certain temperatures,
become brittle and crack.
(2) Contamination of certain titanium alloy parts by materials used in processing can, if not
thoroughly cleaned, react with the surface at low temperature and form brittle intermetallic
compounds. This happens when the part temperature is raised either through normal engine
operation or by the application of heat during a repair cycle.
3. Cadmium Contamination
SUBTASK 70-12-00-870-002
A. Cadmium contamination of titanium alloy components is normally caused by the transfer of the soft
electroplated cadmium from or by fixtures and hand tools.
B. Although cadmium platings are no longer used on tools and fixtures (thus avoiding direct transfer),
secondary transfer is still possible. This can occur from the use of a tool which was previously in
contact with cadmium plated components or fasteners.
C. Other low melting point alloys to avoid include: lead, zinc, tin, mercury, and silver. Lead hammers or
shop aids are not to be used. A silver pencil must not be used on titanium parts.
D. You must be extremely careful to make sure that you eliminate both the obvious and the less obvious
sources of contamination.
4. Chlorinated Solvents (or other Halogens)
SUBTASK 70-12-00-870-003
A. Materials containing chloride ions (or other halogens) can, if left on the surface of titanium alloy parts,
stress corrode or embrittle the material when heat or load is applied. Chlorides can come from
organic solvents, tap water, and hand contact.
70-12-00
Page 201
Apr 11/08

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.
70-12-00
Page 202
Apr 11/08

LOCKING TECHNIQUES FOR THREADED PARTS - MAINTENANCE PRACTICES
TASK 70-12-04-870-801 Locking Techniques for Threaded Parts
1. General
This Standard Practice gives the approved procedures for the following locking techniques:
Wire locking
Self-locking fasteners
NOTE A threaded fastener which is correctly torqued is extended, and in this

condition, is self-locked. The function of a locking device is to keep the locking
properties, even if the load on the bolt decreases.
2. Wire Locking
SUBTASK 70-12-04-870-003
A. Install lockwire in accordance with MS33540.
3. Self-Locking Fasteners
SUBTASK 70-12-04-870-004
A. General
(1) Fasteners with self-locking capability can be used a limited number of times before the
self-locking feature wears out. These fasteners must be checked at installation to make sure
that they have the proper locking torque.
(2) Wear may occur to either the self-locking fastener or to the fastener that is used with it. For
example, a self-locking nut may not meet the minimum torque requirement if the bolt that goes
into it is worn. If a self-locking threaded insert or a self-locking swage nut fails to meet the
minimum torque requirement, check it with a new bolt before replacing.
B. Torque Check for Reuse of Self-Locking Fasteners
(1) Self-locking nuts, bolts, and helical coil inserts must meet the torque requirements in the
table below:
FINE THREAD SERIES COARSE THREAD SERIES
Mating Bolt Max Min Mating Bolt Max Min
Thread Size Locking Break-away Thread Size Locking Break-away
Torque* Torque Torque* Torque
.112 -48 NF-2A 3 0.5 .112 -40 NC-2A 3 0.5
70-12-04
Page 201
Apr 11/08

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

.164 -36 NF-2A 9 1.5 .138 -32 NC-2A 6 1.0
.190 -32 UNF-3A 13 2 .164 -32 NC-2A 9 1.5
.250 -28 UNF-3A 30 3.5 .190 -24 UNC-3A 13 2.0
.3125-24 UNF-3A 60 6.5 .250 -20 UNC-3A 30 4.5
.375 -24 UNF-3A 80 9.5 .3125-18 UNC-3A 60 7.5
Torque is measured in inch-pounds at room temp, lubricated with engine oil
* Installation or Removal
70-12-04
Page 202
Apr 11/08

CLEANING METHODS AND PROCEDURES - CLEANING
TASK 70-21-00-870-801 Cleaning Methods and Procedures
1. General
This chapter describes methods and procedures required for cleaning engine components. Cleaning of
engine components must do the following:
(1) Permit components to be examined for any flaws or dimension loss from abrasion and wear.
(2) Remove deposits that inhibit correct part functioning.
SUBTASK 70-21-00-941-001
Rinse Tank
Spray Booth
Air Compressor,
Ultrasonic Tank
SUBTASK 70-21-00-942-001
B. Consumables
MAT-023 Ultrasonic Cleaner, Caustic
MAT-024 Solvent, Dry Cleaning
MAT-026 Ultrasonic Cleaner, Detergent
MAT-076 Paper, Litmus
MAT-123 Solvent, Wet Cleaning
SUBTASK 70-21-00-945-001
C. Reference Information
70-21-00
Page 701
Apr 11/08

3. Cleaning Policy
SUBTASK 70-21-00-870-001
A. These instructions apply to the cleaning of engine components. Refer to the specific cleaning
procedure for each component in the Engine Manual. The instructions must be followed completely.
WARNING MANY CLEANING SOLUTIONS AND THEIR COMPONENTS ARE HARMFUL

TO SKIN, EYES AND CLOTHING. WEAR CHEMICAL RESISTANT CLOTHING,
APRON, GLOVES AND FACE SHIELD/GOGGLES TO PROTECT SKIN
AND EYES. MAKE SURE THERE IS ADEQUATE VENTILATION AS
SOME SOLUTIONS EMIT HARMFUL VAPORS.
B. Selection of a cleaning procedure for each part must take the following into consideration.
(1) Cleaning materials selected must consider the nature of the deposits, type of metal, type of
coating, and how clean the part must be to permit correct inspection.
(2) Engine parts operating in relatively low-temperature ranges (i.e., cold section parts) can
usually be cleaned using standardized methods and processes such as dry cleaning solvent
spray washing.
(3) Combustion and turbine "hot section" engine parts may require more extensive cleaning
procedures, involving a series of carefully controlled ultrasonic and alkali baths and water
rinses.
(4) To maintain part durability, the recommended cleaning method must meet the following
requirements:
(a) It must clean part sufficiently to allow correct inspection by recommended method.
(b) Prohibit use of cleaning methods on parts where cleaning agent(s) can get trapped and
not completely removed by the neutralizing process.
(c) The physical attributes of the part must not be altered by the cleaning procedure.
(5) Avoid unnecessary cleaning of parts:
(a) Extensive cleaning is not necessary for parts that dont require crack detection, or
require only magnetic inspection. However, extensive cleaning is required for penetrant
inspected parts.
CAUTION DO NOT USE ABRASIVE MATERIALS OR SCRUB CLEAN DIFFUSED

NICKEL-CADMIUM PLATED SURFACES.
(b) Leave stains on nickel-cadmium plated parts. They do not impair magnetic particle
inspection. Scrubbing may remove plating.
70-21-00
Page 702
Apr 11/08

NOTE Cleaning materials and solutions specified with each cleaning procedure
are not supplied by Williams International. However, these items are
identified by their trade names or part/specification number in the
listing of Consumable Materials. Other equivalent products under a
different trade name may be used as materials and solutions identified
in this Consumable Materials list are only a representative sample.
Also, use of these products does not constitute an unconditional
approval of, or guarantee of them by Williams International. Cleaning
materials listed in the Unacceptable Cleaning Materials table are
products not permitted for use in cleaning.
(c) The following table contains Unacceptable Cleaning Materials:

ACIDS SOLVENTS
CHLORINATED OTHER SOLVENTS
HYDROCARBONS
Nitric acid red fuming Perchlorthylene Methel Ethyl Ketone (MEK)
HCL Acid in concentrations greater Trichloroethane (1,1,1) Tolulene
than 5%
Trichloroethylene Ethanol
Trichlorotrifluoroethane Methanol
Freon
C. Important Cleaning Information
Give special attention to specific cleaning instructions and the information listed in this section
concerning the cleaning of certain component materials.
(1) The cleaning solution temperature, strength and part immersion time must be monitored
continuously to avoid part damage.
(2) Ultrasonic cleaning solutions must be tested on a regular basis for maintenance of proper 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.
70-21-00
Page 703
Apr 11/08

CAUTION DO NOT WIRE BRUSH TITANIUM PARTS.
(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.
(1) Dry Cleaning
WARNING CLEANING SOLUTION CAN CAUSE SKIN RASH AND EMIT HARMFUL
VAPORS. WEAR PROTECTIVE CLOTHING, RUBBER GLOVES,
APRON, AND FACE SHIELD/GOGGLES DURING USE. USE IN
WELL-VENTILATED AREAS AWAY FROM OPEN FLAME.
(a) Hand scrub parts with dry cleaning solvent MAT-024 using a soft fiber brush or pad to
remove contaminants.
(b) If any residue remains after cleaning, use a stiff fiber brush to remove residue. Repeat
procedure (a).
WARNING USE APPROVED PERSONNEL PROTECTIVE EQUIPMENT

(GOGGLES/FACE SHIELD). WHEN USING COMPRESSED AIR,
NOZZLE AIR PRESSURE MUST BE RESTRICTED TO LESS THAN 30
PSI TO PROVIDE PROTECTION FROM FLYING PARTICLES. DO NOT
DIRECT AIRFLOW TOWARD SELF OR OTHER PERSONNEL.
(c) Using an Air Compressor,, blow components dry with clean, filtered shop air.
(2) Wet Cleaning
(a) Hand scrub, using a soft fiber brush or pad. Spray, dip, sponge, or ultrasonically clean
parts with wet cleaning solvent MAT-123 to remove contaminants.
1 If surface to be cleaned is vertical or difficult to reach, use the gel form of wet
cleaning solvent.
70-21-00
Page 704
Apr 11/08

(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.
CAUTION DO NOT PUT ALUMINUM, TITANIUM, OR MAGNESIUM INTO

THE CAUSTIC TANK.
(1) Caustic Solution Procedure
(a) Prepare caustic solution as follows:
WARNING WHEN ULTRASONIC CLEANER IS ADDED TO WATER, A

CHEMICAL REACTION OCCURS CAUSING HEAT. DO NOT POUR
CLEANER IN ULTRASONIC TANK ALL AT ONCE. WEAR APRON,
FACE SHIELD, AND RUBBER GLOVES WHEN MIXING SOLUTION.
1 Turn on ultrasonic generator for five minutes to de-gas 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.
WARNING DO NOT OPERATE CAUSTIC TANK WITHOUT ADEQUATE

VENTILATION. CLEANING SOLUTIONS CAN DAMAGE SKIN AND
EYES. WEAR CHEMICAL RESISTANT PROTECTIVE CLOTHING,
APRON, GLOVES, AND FACE SHIELD TO PROTECT SKIN AND EYES.
(b) Remove lid from tank, carefully letting condensation on underside of lids drain back
into tank.
(c) If necessary, add water to fill mark on each 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.
70-21-00
Page 705
Apr 11/08

(e) Heat caustic and rinse tanks between 160 and 200F (71 and 93C).
(f) Clean part as follows:
CAUTION DO NOT STACK PARTS ON TOP OF EACH OTHER OR DAMAGE

COULD RESULT. DO NOT LET PARTS TOUCH EACH OTHER
OR SIDE WALLS OF ULTRASONIC CLEANER.
1 Remove all caps and fittings.
WARNING CLEANING SOLUTIONS CAN CAUSE SKIN RASH AND EMIT

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

(GOGGLES/FACE SHIELD) WHEN USING COMPRESSED
AIR; NOZZLE AIR PRESSURE MUST BE RESTRICTED TO
LESS THAN 30 PSI TO PROVIDE PROTECTION FROM
FLYING PARTICLES. DO NOT DIRECT AIRFLOW TOWARD
SELF OR OTHER PERSONNEL.
3 Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove
wet cleaning solvent MAT-123 by rinsing part with water.
4 Put parts in tank for five to seven minutes minimum.
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.
7 Repeat cycle as many times as necessary to clean.
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.
(2) Detergent Solution
(a) Prepare detergent solution as follows:
70-21-00
Page 706
Apr 11/08

WARNING WHEN ULTRASONIC CLEANER IS ADDED TO WATER, A

CHEMICAL REACTION TAKES PLACE CAUSING HEAT.
DO NOT POUR CLEANER IN ULTRASONIC TANK ALL
AT ONCE. WEAR APRON, FACE SHIELD, AND RUBBER
GLOVES WHEN MIXING SOLUTION.
1 Turn on ultrasonic generator for five minutes to de-gas water.
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.
WARNING CLEANING SOLUTIONS CAN DAMAGE SKIN AND EYES. WEAR

CHEMICAL RESISTANT PROTECTIVE CLOTHING, APRON, GLOVES,
AND FACE SHIELD TO PROTECT SKIN AND EYES.
(b) Remove lid from tank, carefully letting condensation on underside of lids drain back
into tank.
(c) If necessary, add water to fill mark on each 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).
(f) Clean parts as follows:
CAUTION DO NOT STACK PARTS ON TOP OF EACH OTHER OR DAMAGE

COULD RESULT. DO NOT LET PARTS TOUCH EACH OTHER
OR SIDE WALLS OF ULTRASONIC CLEANER.
1 Remove all caps and fittings.

HARMFUL VAPORS. WEAR PROTECTIVE CLOTHING, RUBBER
GLOVES, APRON, AND FACE SHIELD/GOGGLES DURING USE.
USE IN WELL-VENTILATED AREAS AWAY FROM OPEN FLAME.
2 Clean components with carbon and oil build-up in accordance with instructions for
primary cleaning (paragraph C), before putting in ultrasonic tank.
70-21-00
Page 707
Apr 11/08


(GOGGLES/FACE SHIELD) WHEN USING COMPRESSED
AIR; NOZZLE AIR PRESSURE MUST BE RESTRICTED TO
LESS THAN 30 PSI TO PROVIDE PROTECTION FROM
FLYING PARTICLES. DO NOT DIRECT AIRFLOW TOWARD
SELF OR OTHER PERSONNEL.
3 Remove remaining dry cleaning solvent MAT-024 using filtered shop air. Remove
wet cleaning solvent MAT-123 by rinsing part with water.
4 Put parts in tank for five to seven minutes minimum.
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.
7 Repeat cycle as many times as necessary to clean.
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.
70-21-00
Page 708
Apr 11/08

BALL AND ROLLER BEARING - MAINTENANCE PRACTICES
TASK 70-31-01-110-801 Ball and Roller Bearing Cleaning
1. General
This section provides step-by-step procedural information for correctly screening and processing used
bearings. It covers the cleaning environment, cleaning procedures, packaging and identification.
SUBTASK 70-31-01-941-001
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
MAT-001 Oil, Engine
MAT-020 Mineral Spirits
70-31-01
Page 201
Apr 11/08

MAT-075 Gloves, Cotton

MAT-078 Gloves, Thermal Protective
MAT-122 Remover, Fingerprint
MAT-170 Material, Barrier
MAT-174 Rustripper
3. Job Set-up
SUBTASK 70-31-01-010-001
A. Do not mix sets of bearings or mix components of separable bearings. Make sure that all bearings
are correctly tagged and identified.
B. Before bearings are cleaned, do an initial visual inspection; refer to TASK 70-31-01-220-801 .
C. There are separate procedures for cleaning contaminated bearings (Subtask 70-31-01-110-001), and
cleaning bearings with carbon/varnish build-up (Subtask 70-31-01-110-002).
D. Bearings cleaned as part of a scheduled or unscheduled maintenance activity must be recorded in

the engine log book.
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
A. Cleaning Area and Handling
70-31-01
Page 202
Apr 11/08

WARNING BEARING CLEANING ROOM TEMPERATURE MUST STAY BELOW 70F

(21C) DUE TO FINGERPRINT REMOVERS FLASH POINT OF 102F
(39C). ALWAYS WEAR GLOVES WHEN HANDLING BEARINGS.
CAUTION NO SMOKING, EATING, OR DRINKING IN THE BEARING CLEANING AREA.

KEEP THIS AREA CLEAN. MATERIALS NOT NECESSARY TO PERMIT
BEARING CLEANING MUST NOT BE INTRODUCED TO THE ROOM.
LEAD (GRAPHITE) PENCILS ARE NOT PERMITTED IN THE BEARING
AREA/ROOM DUE TO THEIR CONTAMINATING PROPERTIES
NOTE Success of bearing cleaning requires maintenance of a clean environment.

The area/room, equipment and chemicals must be pure. Bearing cleaning
personnel must follow the procedures given to effectively clean bearings.
(1) Fingerprints
Bearings must not come in contact with bare skin or other moist surfaces. When handling
bearings, you must wear one of the following types of gloves:
(a) Plastic (synthetic rubber/vinyl) gloves MAT-072.
(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.
(2) Unwanted Matter
Rolling elements on bearings are manufactured to exceptionally close tolerances to provide

precise positioning during engine operation. These tolerances, coupled with high unit stresses
occurring between the rolling elements and races, make bearings particularly susceptible to
almost any form of contamination. You must take every precaution to prevent any form of
contamination from entering the bearing at all points of the handling process.
The majority of bearing defects are the result of contamination from dust, dirt, and metal
particles. 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.
B. Cleaning Area Equipment and Materials
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.
(1) Magnetometer (Gaussmeter)
70-31-01
Page 203
Apr 11/08

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
Used to remove remaining magnetism in a bearing.
(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.
(4) Handling Gloves
Used to handle bearings while protecting them against acid contamination.
(5) Thermometer
Used to monitor bearing cleaning area/room temperatures.
(6) Barrier Paper (MAT-170) and Dispenser
Used to protective wrap bearings until they are needed for engine installation.
(7) 7 Power, (13) Diopter Lighted Magnifying Lens
Used to inspect bearings for very small defects.
(8) Protective Clothing
To protect bearing cleaning personnel from caustic chemicals. Special handling gloves,
apron and face shield.
SUBTASK 70-31-01-100-001
WARNING MANY OF THE CHEMICALS USED IN BEARING CLEANING ARE TOXIC

AND CORROSIVE TO HUMAN SKIN AND MUCOUS MEMBRANES. WEAR A
CHEMICAL RESISTANT PROTECTIVE APRON, CLEAN VINYL GLOVES AND A
FACE SHIELD WHEN WORKING WITH OR NEAR THESE MATERIALS.
CAUTION DO NOT SPIN BEARINGS DURING THE CLEANING AND DRYING

PROCEDURES. SPINNING THE RACE AND ROLLING ELEMENTS CAN
CAUSE DAMAGE FROM SKIDDING. ALWAYS HOLD THE INNER AND
OUTER RACES OF NONSEPARABLE BEARINGS IN A MANNER THAT
WILL PREVENT VIBRATIONS AND/OR SPINNING.
C. Bearing Cleaning
Bearings must be clean before final inspection TASK 70-31-01 P.B. 201, (Subtask 70-31-01-200-002).
You must clean bearings when one or more of the following conditions exist:
70-31-01
Page 204
Apr 11/08

(1) Bearing looks like it has contamination.
(2) Bearing turns rough or binds when one race is held stable and the other race is turned slowly
by hand while applying a load in the thrust direction.
(3) There was a mechanical failure of the engine. This may have caused contamination in the
bearing with chips or other unwanted material.
CAUTION CAUTION: USE CARE WHEN CLEANING BEARINGS WITH RUSTRIPPER.

IT IS A HIGHLY CAUSTIC SUBSTANCE, WHICH CAN CAUSE GALVANIC
CORROSION (ETCHING) OF THE BEARINGS.
(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
D. Contaminated Bearing Cleaning
(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.
WARNING DISPOSE OF ALL USED SOLVENTS AND SOLUTIONS IN A FIREPROOF

CONTAINER TO BE LATER EMPTIED INTO A SCRAP LIQUID CONTAINER
FOR DISPOSAL IN ACCORDANCE WITH LOCAL REGULATIONS.
CAUTION DO NOT STORE BEARINGS OR ALLOW BEARINGS TO SET

IDLE BETWEEN SUBSEQUENT STEPS WITHOUT PROTECTIVE
LUBRICATION MAT-001.
(2) First Soak/Stir Clean
(a) Support bearing in a container, above any sludge or contamination that may have
collected near the bottom of container.

HARMFUL VAPORS. USE IN WELL-VENTILATED AREAS AWAY FROM
OPEN FLAME. WEAR PROTECTIVE CLOTHING, RUBBER GLOVES,
APRON, AND FACE SHIELD/GOGGLES DURING USE.
(b) Put bearing fully into container, containing MAT-020 or (MAT-24) for five (5) minutes
minimum. Occassionally agitate by hand.
(3) First Spray Rinse
70-31-01
Page 205
Apr 11/08

Remove bearing and spray rinse.
(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.
(b) Continue spray rinse for 30 to 60 seconds.
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.
(4) Fingerprint Remover
Place bearing in soak tank containing fingerprint remover, MAT-122.
(a) Allow to soak for two (2) minutes minimum.
(b) Vertically agitate bearing in solution for 30 seconds.
(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.
(5) Second Spray Rinse
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.

(GOGGLES/FACE SHIELD, WHEN USING COMPRESSED AIR. AIR
PRESSURE IS RESTRICTED TO LESS THAN 30 PSI. PROVIDE
PROTECTION FROM FLYING PARTICLES. DO NOT DIRECT
AIRFLOW TOWARD SELF OR OTHERS.
(6) First Dry
Blow dry bearing using filtered dry air until moisture is removed. Make sure bearing does not
spin while drying.
70-31-01
Page 206
Apr 11/08

CAUTIONS: 1 MAKE SURE BEARING IS DRY BEFORE IMMERSING IN FINGERPRINT

REMOVER. IF BEARING HAS ANY MOISTURE, A WHITE FILM WILL
DEVELOP ON IT WHILE IN FINGERPRINT REMOVER. IF THIS OCCURS,
BEARING MUST BE CLEANED AGAIN WITH DRY CLEANING SOLVENT
MAT-024 AND RE-DIPPED IN FINGERPRINT REMOVER.
2 FAILURE TO SOAK BEARING IN DRY CLEANING SOLVENT

MAT-024, MAY RESULT IN DISCOLORATION. IF BEARING
BECOMES DISCOLORED, CONDITION OF BEARING MAY
BE DIFFICULT TO INTERPRET.
(7) Second Soak Clean
Put bearing fully into still tank containing dry cleaning solvent MAT-024 for five (5) minutes.
(8) Third Spray Rinse
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.

(GOGGLES/FACE SHIELD) WHEN USING COMPRESSED AIR. AIR
PRESSURE IS RESTRICTED TO LESS THAN 30 PSI. PROVIDE
PROTECTION FROM FLYING PARTICLES. DO NOT DIRECT
AIRFLOW TOWARD SELF OR OTHERS.
(9) Second Dry
Blow dry using filtered dry air until moisture is removed from bearing. Make sure bearing
does not spin when drying.
CAUTION BEARING SURFACES MUST BE KEPT FREE OF UNWANTED

MATERIAL CONTAMINATION DURING INSPECTION. ALL
PERSONNEL MUST WEAR GLOVES WHEN TOUCHING BEARINGS
TO PREVENT FINGERPRINT DAMAGE.
(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.
(d) Inspect bearing per TASK 70-31-01-220-801.
70-31-01
Page 207
Apr 11/08

(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).
(12) Remove bearing and make sure no rotational roughness is present.
(13) Preserve and Package
Preserve and package bearing in accordance with SUBTASK 70-31-01-200-003.
(14) Bearing Log
A record of all bearings and bearing assemblies must be maintained, noting good and/or
rejected bearings.
NOTE Bearings assemblies are manufactured as a complete set. If one ball

bearing or race track is rejected, you must also reject the remaining
part or parts of that bearing assembly.
SUBTASK 70-31-01-110-002
E. Carbon/Varnish Buildup Bearing Cleaning
Bearings with carbon deposits and/or varnish buildup require more cleaning, using oakite rustripper
MAT-174.
(1) Do procedures in Contaminated Bearing Cleaning (Subtask 70-31-01-110-002), steps D(1)-(3).
WARNING RUSTRIPPER SOLUTION IS HIGHLY CAUSTIC. AVOID CONTACT

WITH SKIN BY WEARING PROTECTIVE FACE SHIELD, GLOVES,
APRONS, ETC. TO AVOID BURNS OR FROSTBITE, WEAR
THERMAL PROTECTIVE GLOVES MAT-078, WHEN HANDLING
HEATED OR CHILLED COMPONENTS.
CAUTION AS RUSTSTRIPPER IS A HIGHLY CAUSTIC SUBSTANCE, EXPOSING

BEARINGS FOR MORE THAN THE FIVE MINUTE TIME LIMIT CAN
CAUSE GALVANIC CORROSION (ETCHING) OF BEARINGS.
(2) Ruststripper Soaking
Put bearing in container containing rustripper solution at 180 to 200F (82 to 93C) for
five (5) minutes.
70-31-01
Page 208
Apr 11/08

(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.
(3) Cold Rinse
Remove bearing from container and put in flowing cold water bath for two minutes.
(4) Hot Rinse
Put bearing in container containing water 180 to 200F (82 to 93C) for two (2) minutes.
(5) Second Spray Rinse
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.
(6) Continue bearing cleaning procedures in Contaminated Bearing Cleaning ((Subtask

70-31-01-110-001), steps D(8)-(14).
TASK 70-31-01-220-801 Ball and Roller Bearing Inspection
5. General
This task provides step-by-step procedural information for initial inspection and final inspection of ball and
roller bearings. Refer to the following illustrations:
Figure 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
70-31-01
Page 209
Apr 11/08

SUBTASK 70-31-01-941-002
Magnification (1X)
.040 Inch (1.016 Mm) Radius Stylus
Scribe (Bearing Surface Tester)
Handling Tweezers
SUBTASK 70-31-01-942-002
B. Consumables
7. Procedures
SUBTASK 70-31-01-210-001
A. Initial Visual Inspection
CAUTIONS: 1 BEARINGS CAN BE DAMAGED BY ANY UNWANTED MATERIAL

CONTAMINATION DURING INSPECTION. TO PREVENT DAMAGE,
BEARINGS MUST BE KEPT AWAY FROM ALL CONTAMINANTS
AND LINT FREE PLASTIC GLOVES MAT-072 MUST BE WORN
WHEN HANDLING BEARINGS. THIS WILL REDUCE THE
POSSIBILITY OF PUTTING FINGER PRINT ACID ON THE BEARINGS,
WHICH CAN CAUSE CORROSION.
2 DO NOT HAVE WOOD FIBER PAPER OR LEAD PENCILS IN

THE BEARING CLEANING/INSPECTION AREA; THEY HAVE
CONTAMINATING PROPERTIES.
(1) Check for Damage. Inspect bearings in accordance with visual inspection criteria shown in
Figure 202 Inspection of Bearings. If bearing shows evidence of damage, reject bearing.
There is no need to clean damaged bearings.
NOTE Normal carbon/varnish buildup can appear as discolorations and give

false indications of cracked and damaged conditions.
(2) Group bearings together in containers correctly identified for processing.
70-31-01
Page 210
Apr 11/08

CAUTION DO NOT MIX MATCHED BEARING SETS OR MIXED COMPONENTS

OF SEPARABLE BEARINGS.
(3) All bearings that have passed initial visual inspection must be cleaned in accordance with
TASK 70-31-01-110-801 (if TASK determines cleaning is necessary). Clean bearings with
carbon/varnish build-up per Subtask 70-31-01-110-002.
SUBTASK 70-31-01-200-002
B. Bearing Inspection After Cleaning
CAUTION BEARING DAMAGE FROM UNWANTED MATERIAL CONTAMINATION

CAN OCCUR DURING INSPECTION. TO PREVENT DAMAGE, BEARINGS
MUST BE KEPT AWAY FROM ALL CONTAMINANTS AND INSPECTOR
MUST WEAR GLOVES WHEN HANDLING BEARINGS.
NOTE Cleaned bearings must be inspected again to see if carbon deposits

have been removed and visual contamination has been eliminated.
They also must be inspected and accepted before being returned to
the supply cycle or re-installed in the engine.
(1) Bearing Inspection Flow Charts.
Functional and nonfunctional surfaces of bearings are defined in Figure 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
(2) Level of Disassembly. When inspection is required, ensure the following:
(a) No. 1 bearings shall be removed from their housings.
(b) No. 2 bearings shall be removed from the 1st reduction bevel gear.
(c) No. 3 bearing outer ring and the No. 4 bearing rollers shall be removed from their
assembled housings.
(d) No. 3 bearing rollers shall be removed from the HP turbine.
(e) No. 4 bearing inner race shall remain on the 1st LP turbine.
70-31-01
Page 211
Apr 11/08

(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.
(3) Visual Inspection
(a) Visually inspect all bearings, using 1X magnification, to find any contamination or
carbon/varnish buildup on the bearings. Magnification of 1X is defined as 16-18 in.
distant and illumination must be 100 foot candles (1000 lux) minimum. Used bearings
must be 100 percent screened and processed.
(b) Magnification may be used to measure the size of a defect if the scribe test is not capable
of verifying the size. Magnification is not to be used to find defects, only measure size or
determine classification, (i.e., skidding versus spalling).
(4) Use of a Radius Stylus. The scribe test is conducted once a visual imperfection is found.
No magnification is permitted during the scribe test. If the imperfection is felt during the
scribe test, continue to follow the applicable bearing inspection flow chart. Refer to Figure
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.
70-31-01
Page 212
Apr 11/08

(b) Hold one race stationary and rotate the other race slowly by hand while applying a
load in the thrust direction. The applied load should be enough to ensure that all the
rotating elements are loaded. Note any binding or rough turning. Rough spots should be
oscillated over to distinguish between a defect and the chattering of the cage. If a rough
spot is found, reclean the bearing to insure that it is not contaminated. Up to a total of
four bearing cleanings and subsequent inspections are allowed. Any binding or rough
turning following the completion of this cycle is cause for rejection.
(6) The following equipment is used for inspecting the bearings: Handling Tweezers, Scribe
(Bearing Surface Tester), .040 inch (1.016 mm) Radius Stylus, Magnification (1X).
C. Definitions.
(1) Surfaces. Refer to Figure 201 Bearing Functional/Non-Functional Surfaces.
(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.
70-31-01
Page 213
Apr 11/08

(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.
(b) Extruded Material. Silver extruding from cage functional surfaces.
(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
From 490 to 510F (254 to 266C) - Yellow-brown through spotted yellow-brown
From 520 to 550F (271 to 288C) - Brown-purple through dark purple
From 560 to 570F (293 to 299C) - Full blue to dark blue
From 570F (299C) and up - Black
(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.
70-31-01
Page 214
Apr 11/08

(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.
70-31-01
Page 215
Apr 11/08

Fig. 201 Bearing Functional/Non-Functional Surfaces
70-31-01
Page 216
Apr 11/08

Fig. 202 Inspection of Bearings
70-31-01
Page 217
Apr 11/08

Fig. 203 Bearing Functional Surfaces Inspection - Center 1/3 of Roller

70-31-01
Page 218
Apr 11/08

Fig. 204 Bearing Functional Surfaces Inspection - Scratch or Scoring (Center Roller)
70-31-01
Page 219
Apr 11/08

Fig. 205 Bearing Functional Surfaces Inspection - Outer 1/3 of Roller
70-31-01
Page 220
Apr 11/08

Fig. 206 Bearing Non-Functional Surfaces Inspection

70-31-01
Page 221
Apr 11/08

Fig. 207 Bearing Cage Inspection

70-31-01
Page 222
Apr 11/08

Fig. 208 Bearing Cage Inspection - Continued
70-31-01
Page 223
Apr 11/08

Fig. 209 Correct Positioning of Radius Stylus
70-31-01
Page 224
Apr 11/08

Fig. 210 Bearing Brinelling - Contact Zones
70-31-01
Page 225
Apr 11/08

Fig. 211 Bearing Corrosion
70-31-01
Page 226
Apr 11/08

Fig. 212 Bearing Rings - Nicks, Dents, and Scratches
70-31-01
Page 227
Apr 11/08

Fig. 213 Bearing Skidding Damage
70-31-01
Page 228
Apr 11/08

Fig. 214 Roller End Wear
70-31-01
Page 229
Apr 11/08

70-31-01
230
Page
Blank
CARBON SEAL SURFACE QUALITY - INSPECTION/CHECK
TASK 70-33-01-870-801 Carbon Seal Surface Quality
1. General
This section defines the accept/reject criteria for surfaces of all mainshaft carbon seals.
Figure 601 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
A. Refer to Figure 601 Carbon Seal Surface Quality - Inspection Zones.
B. Seal Face: The surface(s) designed to mate with adjoining surface(s) to seal off fluid or other media
to be retained by the seal.
C. Edge: A feature (line) formed at the intersection of two surface planes.
D. Chips: Discontinuities on the edge resulting from pieces of the material being broken and separated
from the edge.
E. Chip Width: The maximum dimension of a chip measured perpendicular to the edge along the
surfaces forming the edge. Chips have two width dimensions; each one measured along the surface
that forms the edge.
F. Chip Length: The maximum dimension of a chip measured along the edge.
G. Scratch: A random, shallow, linear depression caused by a sharp object (see lay).
H. Lay: The predominate surface pattern caused by the marks of tools used to finish the surface.
I. Crack:. A linear discontinuity resulting from the fracture (rupture) of the material by internal or
external stress.
3. Carbon Face Seal Quality Requirements (No. 1 and No. 2 Carbon Seals)
SUBTASK 70-33-01-870-003
NOTE Carbon face seals and runners should always be replaced together to avoid
excessive wear rates. If either the seal or runner shows coking or wear, both
parts should be replaced with new or relapped parts.
A. Cracks are not acceptable in any surface of the part.
70-33-01
Page 601
Apr 11/08

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.
70-33-01
Page 602
Apr 11/08

5. Carbon Face Seal Surface Quality Requirements
SUBTASK 70-33-01-870-001
Table 601 Carbon Face Seal Surface Quality Requirements FJ44
FEATURE IMPERFECTIONS
Type Size Quantity (Max)
Seal Face(Except Pits, Dents, Nicks Depth - 0.015 inch Defects 0.005 inch
Edges) (0.381 mm) or 20% of (0.127 mm) width and
section - whichever is less - no limit.Defects
smaller.Width - 0.15 over 0.005 inch (0.127
inch (3.81 mm) or 20% mm) - sum of defect
of dimension across areas not to exceed
surface - whichever is 0.1% of face area.
smaller.
One pit may be up to
0.015 inch (0.381 mm)
x 0.027 inch (0.685
mm) as long as it is
0.030 inch (0.762 mm)
from nearest edge.
Scratches (includes lay) Scratches are
acceptable if they
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.
70-33-01
Page 603
Apr 11/08

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.
70-33-01
Page 604
Apr 11/08

Fig. 601 Carbon Seal Surface Quality - Inspection Zones
70-33-01
Page 605
Apr 11/08

Fig. 602 Carbon Seal Inspection - Banded Ring Seal
70-33-01
Page 606
Apr 11/08

Fig. 603 Carbon Seal Inspection - Circumferential Grooves
70-33-01
Page 607
Apr 11/08

70-33-01
608
Page
Blank
REPAIR SURFACES AFFECTED BY MINOR DAMAGE - REPAIR
TASK 70-42-11-870-801 Repair Surfaces Affected by Minor Damage
1. General
This repair task must be performed when directed, in the relevant Inspection/Check task (page block 601)
for the part being repaired.
SUBTASK 70-42-11-942-001
A. Consumables
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.
4. Repair Minor Damage
SUBTASK 70-42-11-350-001
CAUTIONS: 1 YOU MUST NOT USE ALUMINUM OXIDE TYPE WHEELS, STONES, AND
ABRASIVES ON TITANIUM PARTS. USE ONLY SILICON CARBIDE TYPES.
2 IF YOU USE MECHANICAL CUTTERS, MAKE LIGHT CUTS TO PREVENT

OVERHEATING OF THE TITANIUM PART. DO NOT GRIND.
A. Repair of Scores, Galling, Burrs, Pick-up and Fretting
70-42-11
Page 801
Apr 11/08

(1) Remove high spots, burrs and pick-up, and pick-up on threads. Use hand stones and light
hand polishing.
B. Repair of Pitting, Stripping, and Rubbing Marks
(1) Remove pitting by blending. Use hand stones and light hand polishing.
C. Repair of Distortion and Dents
(1) Remove distortion and dents by blending. Use hand stones and light hand polishing.
D. Repair of Nicks
(1) Remove nick by blending, scalloping, and/or hand polishing to a smooth shape.
E. Repair of Burned Areas
(1) Dress, Blend, and polish burned areas. For standards, refer to the relevant Inspection/Check
task (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.
5. Inspect Repaired Area
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.
6. Apply Surface Protection to Repaired Area
SUBTASK 70-42-11-350-002
A. Repair Surface Protection. Refer to 70-42-12, P.B. 801 and/or relevant Repair task (page block
801) for the part under repair.
70-42-11
Page 802
Apr 11/08

LOCAL SURFACE PROTECTION - REPAIR
TASK 70-42-12-870-801 Local Surface Protection
1. General
This task must be performed to restore protective coating to surfaces which have been damaged or
repaired.
SUBTASK 70-42-12-942-001
A. Consumables
3. Instructions
SUBTASK 70-42-12-870-003
A. Make sure that all damaged/repaired surfaces are blended smoothly and match the surface finish of
the surrounding area.
WARNING ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A

COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND KEEP
AWAY FROM HEAT, SPARKS, OR FLAME.
B. Make sure that all damaged/repaired surfaces are clean and dry. Swab area with isopropyl alcohol
MAT-027 to clean.
4. Anodized Aluminum Cases
SUBTASK 70-42-12-870-004
WARNING MAT-050 CHEMICAL COATING MAY BE HARMFUL TO EYES, SKIN, AND

LUNGS. MAY CAUSE PERMANENT DAMAGE AND SKIN BURNS. WEAR EYE
PROTECTION AND PROTECTIVE CLOTHING WHILE MIXING AND USING
COATING MATERIAL. MIX ONLY SMALL AMOUNTS AND AVOID PROLONGED
BREATHING OF FUMES. USE IN WELL VENTILATED AREA.
A. Apply touch-up chemical coating MAT-050 to damaged/repaired area. Overlapping of touch-up

coating to base coating is allowed.
70-42-12
Page 801
Apr 11/08

B. Allow coating to dry for one to five minutes. Wipe off excess coating with a damp cloth.
70-42-12
Page 802
Apr 11/08

NON-DESTRUCTIVE INSPECTION (NDI) METHODS - INSPECTION/CHECK
TASK 70-42-15-870-801 Fluorescent Penetrant Inspection
1. General
This task covers the penetrant method of inspection for the detection of cracks and other discontinuities
open to the surface.
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
70-21-00 701 Cleaning Methods and Procedures - Cleaning
72-00-00 601 Engine - Cleaning
(1) Industry Specification ASTM E 1417
(2) Industry Specification AMS 2644
(3) Industry Specification NAS-410
3. General
NOTES: 1 These instructions are to be used as a supplement to regular visual

inspection procedures, not a replacement.
2 Inspectors shall be qualified and certified as specified in NAS-410.
SUBTASK 70-42-15-110-001
A. Parts inspected must be clean and free from oil, grease, dirt, cleaning solution, and other
contamination which could prevent adequate penetration of discontinuities or hold penetrant and
cause non-relevant indications. . Clean parts in accordance with the methods specified in Engine
Manual 72-00-00, P.B. 601 and the general requirements of 70-21-00, P.B. 701.
70-42-15
Page 601
Apr 11/08

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
I A, B(Note 5), D(Note a, (b,c)(Note1) 3 or 4
2)
SUBTASK 70-42-15-230-004
I A, B(Note 5), D(Note a(Note 4), (b,c)(Note 4
2) 1), d
70-42-15
Page 602
Apr 11/08

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

washable (method A) penetrants
2 Method D penetrants are mandatory for inspecting rotating or highly stressed

parts (except fan rotor at Line Maintenance Facilities).
3 Developer not required, inspect opposite side surface for evidence of thru leaks
4 Form a developer only.
5 Dwell time for lipophilic emulsifiers shall be 1 minute maximum unless

otherwise agreed to in the fixed process.
6 Method C penetrant is allowed only for inspecting the fan rotor

at Line Maintenance Facilities.
7 Use developers a, c, or d only when using Method C.
Methods Developer Type Sensitivity Level

A - Water Wash a - Dry Powder I - Fluorescent Dye 2 - Medium
B - Post Emulsifier b - Water Soluble II - Visible Dye 3 - High
(Lipophilic) c - Water 4 - Ultra-High
C - Solvent Suspendable
Removable d - Non-Aqueous
D - Post Emulsifier
(Hydrophilic)
5. Acceptance Criteria
SUBTASK 70-42-15-870-004
A. Parts shall meet the acceptance criteria (class) specified in the detailed inspection instructions.
Acceptance criteria classes are defined in table 601
70-42-15
Page 603
Apr 11/08

Table 601 Fluorescent Penetrant Limits FJ44
Class Max Size Any Max. Size Max. No. of Dist.

Linear Indication Rounded Indications per
(Inch) Indication (Inch) Square or Linear
(Notes 2 & 3) Inch
AA None Allowed None Allowed - -
A None Allowed 0.010 7 Note 5
B None Allowed 0.030 5 Note 1
C None Allowed 0.060 3 Note 1
D 0.010 0.010 7 Note 1
E 0.030 0.030 5 Note 1
F 0.060 0.060 3, (Note 4) Note 1
G 0.120 0.120 2, (Note 4) Note 1
70-42-15
Page 604
Apr 11/08

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

of the largest indication being considered (edge to edge).
2 A linear indication is defined as an indication whose length is 5

times its width, minimum.
3 The following defects are not allowed for Class AA through C: cracks,
laps, laminations, seams, tears, cold shuts, forging bursts, intruded
scale, pipes and corrosion pits.
4 The maximum number of indications above can be greater under

the following conditions:
(a) The cumulative length of all indications must not be greater than the
max size of indications times the max number of indications specified;
e.g., Class F permitted indication/size mixtures include: 3 at 0.060
inch, 6 at 0.030 inch, 5 at 0.036 inch, etc
(b) The requirements of Note 1 are maintained.
5 Indications to be separated by a minimum of 1 times the largest dimension

of the largest indication being considered (edge to edge).
6 A tightly spaced group of defects (usually consisting of porosity or microshrinkage)

must be considered as a cluster and treated as a single defect.
B. Parts exhibiting indications may be evaluated using additional non-destructive test methods to
determine the relevancy and severity of the indications.
6. Quality Assurance Provisions
SUBTASK 70-42-15-870-005
A. Inspection Process
The inspecting activity shall establish an inspection process defining, as a minimum, the following:
Brand name, type and group designation of penetrant and developer (if used)
Surface preparation
Dwell time
Wash method
Details of applying developer (if used)
Part number and inspection class, as applicable
70-42-15
Page 605
Apr 11/08

Cleaning method after inspection
B. Process Controls
The inspecting activity shall be responsible for conducting process control tests per ASTM E 1417.
7. Notes
SUBTASK 70-42-15-870-006
A. Nonrelevant Indications
All indications revealed by liquid penetrant inspection do not necessarily represent detrimental
defects since nonrelevant indications are sometimes encountered. They may be caused by rough
areas or by insufficient rinsing following penetrant applications. Nonrelevant indications can be wiped
off without reappearing and not show the brilliance of true indications. Regard any indication which is
believed to be nonrelevant as unacceptable until the indication is either eliminated by surface
conditioning or it is evaluated by other nondestructive means and demonstrated to be nonrelevant.
B. Relevant Indications
Relevant indications are those which result from mechanical discontinuities. Linear indications are
those indications in which the length is more than five times the width. Linear indications can be
caused by such discontinuities as cracks, laps, laminations, seams, tears, etc. Rounded indications
are indications which are circular or ellipticalo with the length less than five times the width. Cracks,
seams, laps, and cold shuts appear as lines. Porosity is revealed by round spots. Growing or
bleeding spots are indicative of subsurface cavities. For estimating the extent of a defect, it is helpful
to examine under white light preferably with 10x (area) magnification.
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.
Table 602 Table Of Requirements For Components
NAME NDI REQUIREMENT DEFECT CRITERIA

Fan Rotor Refer to SUBTASK See Note 7
70-42-15-230-004
IP Compressor Rotor Refer to SUBTASK Class B
70-42-15-230-004
LP Shaft Refer to SUBTASK Class AA
70-42-15-230-004
70-42-15
Page 606
Apr 11/08

Table 602 Table Of Requirements For Components (Continued)
HP Compressor Rotor Refer to SUBTASK Note 6

70-42-15-230-004
HP Shaft Refer to SUBTASK Class AA
70-42-15-230-004
HP Turbine Rotor Disk Refer to SUBTASK Class E
70-42-15-230-004 Note 1
HP Turbine Rotor Blades Refer to SUBTASK Class E
72-42-15-230-004 Note 1
1st LP Turbine Rotor Refer to SUBTASK Class B
70-42-15-230-004
2nd LP Turbine Rotor Refer to SUBTASK Class B
70-42-15-230-004
Balance Piston Refer to SUBTASK Class B
70-42-15-230-004
Combustor Cover Assy Refer to SUBTASK Class E
70-42-15-230-001
Primary Plate Refer to SUBTASK Class E
70-42-15-230-001 Note 5
Interstage Housing Refer to SUBTASK Class E
70-42-15-230-001 Note 2
IPC Stator Stg 1 and Stg 2 Refer to SUBTASK Class E
70-42-15-230-001
IPC Stator Stg 3 Refer to SUBTASK Class E
70-42-15-230-001
Rear Case/Mixer Refer to SUBTASK Class E
70-42-15-230-001 Note 3
Fan Stator Refer to SUBTASK Class E
70-42-15-230-001
Compressor Cover Refer to SUBTASK Class E
70-42-15-230-001
Rear Housing Refer to SUBTASK Class E
70-42-15-230-001 Note 4
HPT Combustor Assy Refer to SUBTASK Class E
70-42-15-230-001
70-42-15
Page 607
Apr 11/08

Table 602 Table Of Requirements For Components (Continued)
Fuel Manifold Refer to SUBTASK Class E

70-42-15-230-001
Diffuser Refer to SUBTASK Class E
70-42-15-230-001
Oil Manifold Refer to SUBTASK Class E
70-42-15-230-001
Fuel Slinger Refer to SUBTASK Class E
70-42-15-230-001
2nd LP Turbine Nozzle Refer to SUBTASK Class E
70-42-15-230-003
1st LP Turbine Nozzle Refer to SUBTASK Class E
70-42-15-230-003
Case/Insert Assy Refer to SUBTASK Class E
70-42-15-230-003
Rear Mount Ring Refer to SUBTASK Class E
70-42-15-230-003
NOTES: 1 2 hour minimum dwell time for HPT disc and blades
2 Local area strut fillet radii only
3 Weld joints only
4 Local area struts only
5 Inner support weld
6 Minimum 2 hour penetrant dwell time. Backwall and bore class

A. All other areas class B.
7 Four hour dwell time.
70-42-15
Page 608
Apr 11/08

TORQUE TIGHTENING TECHNIQUE - MAINTENANCE PRACTICES
TASK 70-51-00-870-801 Torque Tightening Technique
1. General
This task provides information for torque tightening technique. Refer to the following illustration(s):
Figure 201 Typical Torque Sequences and Torque Calculation for the Use of Extensions and Adapters
2. Equipments and Materials
SUBTASK 70-51-00-941-001
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
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:
(1) A special load for a particular application, or
(2) A standard torque for the size of the thread
B. Torque values for all threaded fasteners are given at the point of application in the maintenance
manual.
70-51-00
Page 201
Apr 11/08

4. Lubrication
SUBTASK 70-51-00-870-003
A. You must apply lubricant to the threads on parts to get the correct torque load at assembly. This
lubrication is necessary because most of the applied torque is absorbed by :
(1) Friction at the screw head
(2) The mating faces of the assembly parts
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:
(1) Remove the nuts.
(2) Clean and apply lubricant to the threads and abutment faces.
(3) Install the nuts again.
(4) Torque the nuts to the specified torque load.
6. Torque Tightening Sequence - Close-Pitch Bolting
SUBTASK 70-51-00-870-005
A. When you use close-pitch bolting, and when you must make a seal, 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.
70-51-00
Page 202
Apr 11/08

(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.
7. Hand Torque Wrenches
SUBTASK 70-51-00-870-006
A. Flexible Beam Type
(1) Standard equipment flexible beam type wrenches include: Hand torque wrench, flexible beam
type, 1/4-in. drive and Hand torque wrench, flexible beam type, 1/4-in. drive.
(2) To get a correct reading, hold the handle lightly with one hand. Pull the handle at right-angles
(90 degrees) to the center-line of the wrench. The handle must be free to move on the
pivot point; this will keep the force or load at the correct point. Do not move the position of
the handle. If you do, this will change the concentration of the force from the pivot point to
another position on the handle.
(3) Use a torque wrench which will show you torque value in the higher range of the scale. This will
make sure that you get the greatest possible accuracy when you look at the scale values.
(4) Before you use the wrench, set it to zero.
B. Screwdriver type
(1) Standard equipment screwdriver type wrench includes: Hand torque wrench, screwdriver
type, 1/4-in drive.
(2) To get a correct reading, hold the handle like a screwdriver. Turn the handle smoothly until you
can see the required torque load.
(3) Examine screwdriver-type wrenches for accuracy. When there is no load, make sure that
the pointer shows zero on the scale. If necessary, adjust the wrench in accordance with
manufacturer instructions.
8. Use of Torque Adapters and Extensions.
SUBTASK 70-51-00-870-007
A. The use of an adapter on the torque wrench lengthens the effective working arm of the torque wrench,
except when the adapter is used at right angles (90) to the wrench handle. When the adapter is used
in such a manner that it lengthens the arm of the torque wrench, adjust the torque values as follows:
70-51-00
Page 203
Apr 11/08

(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.
(3) Divide dimension A by dimension B to get the conversion factor.
(4) Multiply the conversion factor by the torque value given for the nut to get the torque reading
that should be used with the adapter on the wrench.
B. Example - Torque Value Conversion:
Dimension A on the torque wrench is 12.5 inches. With an adapter installed, dimension B is 14.3
inches. A + B = 12.5 14.3 = 0.87. This is the conversion factor. Multiply the conversion factor by
the nominal torque.
9. Locking Torque for Self-Locking Fasteners.
SUBTASK 70-51-00-870-008
A. Refer to Locking Techniques for Threaded Parts, 70-12-04, P.B. 201, for a description of the proper
use and minimum run-down torques for self-locking fasteners.
70-51-00
Page 204
Apr 11/08

Fig. 201 Typical Torque Sequences and Torque Calculation for the Use of Extensions and Adapters
70-51-00
Page 205
Apr 11/08

70-51-00
206
Page
Blank
SPECIAL TOOLS - MAINTENANCE PRACTICES
TASK 70-53-00-870-801 Maintenance and Calibration of Special Tools
1. General
This task describes the maintenance practices required to keep special tools for engines in proper working
condition. Special tools require regular inspection and maintenance to ensure safety of operation and/or
accuracy of measurement.
SUBTASK 70-53-00-942-001
A. Consumables
MAT-001 Oil, Engine
MAT-005 Oil, Penetrating
MAT-041 Pad, Abrasive
3. Procedures
SUBTASK 70-53-00-870-001
A. Visual Inspection: Each time a tool is used it should be checked for:
(1) Damage: Tools that are cracked, chipped, or otherwise damaged should not be used. Nicks,
burrs, or raised material should be blended smooth. Areas on tools where a protective surface
is removed should be recoated to prevent corrosion.
(2) Wear: Contact surfaces should be inspected for areas of excessive wear that would prevent the
tool from functioning properly. Threaded diameters and contact surfaces should be lubricated
with clean engine oil MAT-001 to reduce friction. Replace tools that are excessively worn.
(3) Cleanliness: All tools are potential sources of engine contamination and should be properly
cleaned before use. Assembly tools must be held to the same standards of cleanliness as
engine parts in the system in which they are used.
(4) Corrosion: Corrosion may impair the function of a tool, shorten its life-span, or weaken it.
Remove corrosion with an abrasive pad MAT-041. All steel tools, including those which have
black oxide coating, should be coated with penetrating oil MAT-005 to inhibit corrosion. In areas
of high humidity, tools should be sealed in plastic bags or stored in rust-inhibiting paper.
70-53-00
Page 201
Apr 11/08

(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
TOOL TOOL NAME REQUIREMENT INTERVAL NOTES

NUMBER
TL37102-3 Hydraulic Hand Functional Check 6 Months Pressurize hydraulic
Pump(Pressure Relief cylinder and check for
Valve) relief valve actuation.
Valve must actuate at
5950 - 6300 psig.
TL37102-4 Gauge, Hydraulic Pump Calibrate Pressure 6 Months
Gauge
TL37102-11 Rod NDI Inspect 6 Months Inspect for cracks
TL37102-12 LP Shaft Adapter Visual check prior using visible dye
TL37102-13 Nut to each useage (spray can) penetrant.
TL37102-10 HP Shaft Adapter
TL37102-19 Hydraulic Hand Pump Functional Check 6 Months Pressurize hydraulic
(Pressure Relief Valve) cylinder and check for
relief valve actuation.
Valve must actuate at
7250-7550 psig.
TL37110 Oil Tank Pressure Test Calibrate Pressure 6 months
Fixture Gauge
TL37114-2 Puller, 1st and 2nd LP NDI Inspect Puller 6 months Inspect for cracks
Turbines Legs (3) using visible dye
Visual check prior (spray can) penetrant.
to each useage
70-53-00
Page 202
Apr 11/08

Table 201 Maintenance And Calibration Requirements For All FJ44 Special Tools (Continued)
TOOL TOOL NAME REQUIREMENT INTERVAL NOTES

NUMBER
TL37256 ITT Dual Element Probe Calibrate 6 months Calibrate at 1450
Harness NDI Inspect 12months or 5 F for type K
50 engine thermocouples
uses Inspect for cracks
on the ends of the
probes which protrude
into the engine. Use
visible dye (spray
can) penetrant,
method A, class AA
requirements.
TL37258 ITT Data Logger Calibrate Calibrate in
Assembly accordance with
manufacturers
instructions.
TL37289 Temperature Indicator Calibrate Calibrate in
Assembly (TL37286) accordance with
manufacturers
instructions.
TL37261 Temperature Indicator Calibrate Calibrate in
Assembly accordance with
manufacturers
instructions.
TL37275 Data Logger, ITT Dual Calibrate 6 months Calibrate in
Element Probe accordance with
manufacturers
instructions
TL37281 Gauge, Gearbox Calibrate Dial 6 months
Backlash Indicator
TL37314 Gauge, HP Turbine Calibrate Dial 6 months
Measurement Indicator
TL65023 Gauge, HP Compressor Calibrate Dial 6 months
Rotor Face Clearance Indicator
TL65123 Gauge, Igniter and Fuel Calibrate Dial 6 months
Nozzle Spacer Indicator
70-53-00
Page 203
Apr 11/08

70-53-00
204
Page
Blank
STORAGE OF PARTS THAT HAVE SHELF LIFE LIMITS - MAINTENANCE PRACTICES
TASK 70-61-01-870-801 Storage of Parts that have Shelf Life Limits
1. General
This task describes the maintenance practices required for storage of parts that have shelf life limits.
2. Shelf Life
SUBTASK 70-61-01-870-002
A. The date which the shelf life of rubber and synthetic rubber parts is calculated is the cure date.
This cure date is shown on the parts and/or on their associated packaging. It is applicable to the
following types of parts:
(1) Rubber or synthetic rubber
(2) Cables
(3) Harnesses
B. The cure date is shown as the quarter of the year (given as a single figure) and the year (given as
a double figure) when the part was manufactured. The letter Q separates the single figure and
double figure. For example, 2Q91 is the cure date for a part made in the second quarter of 1991.
The year is divided into quarters as follows:
(1) January, February, March
(2) April, May, June
(3) July, August, September
(4) October, November, December
NOTE On some parts, the month of manufacture is shown in brackets

after the cure date, e.g. 2Q91 (May).
C. Calculate the age of any part from the end of the quarter in which the part was made. For example, a
part with the cure date 2Q91 would be one year old at the end of the second quarter of 1992,
i.e. 30 June, 1992.
3. Cure Date Marking
SUBTASK 70-61-01-870-003
A. The method that shows the cure date of uninstalled or separate rubber or synthetic rubber parts is
as follows:
70-61-01
Page 201
Apr 11/08

(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
(2) Direct Sunlight
(3) Ozone
(4) Moisture
(5) Excessive circulation of air
(6) Extremes of temperature
(7) Physical damage
(8) Contamination by fuel, oil, grease, or solvents
B. If parts are supplied in envelopes, plastic bags, or cartons, keep them in this condition until you need
them. Monitor level of stocks to rate of use to prevent excessive storage time. You must remove
parts from the shelf on the basis of age. The cure date shows you how old the part is. Do not let
rubber parts and metals (especially copper) touch each other.
C. Store parts in a relaxed position. They must be free from tension and, wherever possible, in their
normal shape. Do not put too many parts in a vertical stack. This can cause permanent distortion of
the lower layers. Put flexible hoses in straight lengths, wherever possible, as coiling causes tension
in the outside of each coil. It also increases the risk of ozone cracking.
D. Give sufficient ventilation to prevent condensation, but do not let currents of air come into contact
with the stored parts. Keep parts away from sources of ozone. These are:
(1) Mercury vapor lamps
70-61-01
Page 202
Apr 11/08

(2) Electrical machinery
(3) Excessive exposure to outdoor air
E. When you put lip-type seals into storage, make sure that you do not cause damage and distortion to
the edges. Only attach seal rings to ferrules or bobbins immediately before installation into an engine
or unit. Prolonged exposure to light can cause deterioration to the seal rings.
F. Keep temperature within the preferred range of 59 to 70 degrees F (15 to 21 degrees C). The
minimum temperature must be 41 degrees F (5 degrees C) and the maximum must be 100 degrees
F (38 degrees C). The relative air humidity will be 65 percent. Put parts at least 3 feet (1 meter)
from any unscreened source of heat.
G. If you store parts in the recommended conditions in paragraph F, the shelf life of rubber and rubber
synthetic parts is virtually unlimited. In certain cases, examine and monitor the parts at specified
intervals. For this purpose, materials are divided into three groups.
(1) Group A
(a) Natural rubber
The customer can receive these up to five years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
two years (see paragraph 4, Inspection of Parts).
(2) Group B
(a) Butyl
(b) Neoprene (Chloroprene)
The customer can receive these up to seven years after the cure date. The subsequent
shelf life is unlimited, provided you examine a sample of the oldest stock at least every
three years (see paragraph 4, Inspection of Parts).
(c) Nitrile
The customer can receive these up to 10 years from cure date. The ultimate life is 15
years.
(3) Group X
(a) Silicone, Fluorosilicone, and Fluorocarbon (Viton)
There is no life limit for supply to a customer or for storage. Cure date marks are on
these parts to help monitor stock.
70-61-01
Page 203
Apr 11/08

5. Inspection of Parts
SUBTASK 70-61-01-870-005
A. Examine parts for signs of aging or degradation because of oxidation; this is shown by surface cracks
and deterioration. Bend the part gently and discard it if you see cracks.
B. Do not automatically discard parts because you see a white or colored bloom on their surface. The
layers of blooms help to prevent ageing. They come from the anti-oxidants which are in high-grade
rubber.
C. Examine parts for conditions as follows; discard them if they are faulty:
(1) Permanent distortion, flats, and other obvious defects
(2) Tackiness or surface hardening or softening
(3) Blistering, peeling, or cracks when material is extended or flexed
(4) Chafing of outer coverings and corrosion of, or damage to, end fittings of hose assemblies
and cable harnesses
(5) Corrosion of metal elements in bonded rubber to metal assemblies
(6) Obstruction of the bore (flexible hoses)
70-61-01
Page 204
Apr 11/08

CHAPTER 71
POWER PLANT
Page 1
71-POWER PLANT Apr 11/08

Page 2
71-POWER PLANT Blank

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
Page 1
Apr 11/08

Chapter 71
Page 2
Blank
POWER PLANT - FAULT ISOLATION
TASK 71-00-00-810-803 Power Plant - Troubleshooting
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
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:
(1) Starting Malfunctions
(2) Idle Malfunctions
(3) Acceleration Malfunctions
(4) Take-Off Malfunctions
(5) Maximum Continuous Malfunctions
(6) Deceleration Malfunctions
71-00-00
Page 101
Apr 11/08

(7) Shutdown Malfunctions
(8) Other Malfunctions
4. Troubleshooting Top Events
SUBTASK 71-00-00-810-003
STARTING MALFUNCTIONS (START INITIATED)
Figure 101 No N2 Indication on Instrumentation (Starter Rotates)
Figure 102 Engine Will Not Start (2 sheets)
Figure 103 No Oil Pressure Indication (2 sheets)
Figure 104 High Oil Pressure on Start
STARTING MALFUNCTIONS (POWER LEVER MOVED TO IDLE; NO LIGHT OFF)
Figure 105 Low/No Sound of Igniter(s) Firing (2 sheets)
Figure 106 No/Low Fuel Flow Indication
STARTING MALFUNCTIONS (ENGINE LIGHTS OFF)
Figure 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
Figure 108 No ITT Indication
Figure 109 Engine Hot Start (3 sheets)
Figure 110 No N1 Speed Indication
IDLE MALFUNCTIONS
Figure 111 High N2 Indication at Idle
Figure 112 Low Oil Pressure (2 sheets)
Figure 113 Engine Flameout
Figure 114 Fuel Leaking from Overboard Drain (Engine Operating)
ACCELERATION MALFUNCTIONS
Figure 115 No Acceleration Above Idle
Figure 116 Slow Acceleration (2 sheets)
TAKE-OFF MALFUNCTIONS
Figure 117 High ITT (2 sheets)
71-00-00
Page 102
Apr 11/08

Figure 118 Low N1 Indication at Takeoff Power Setting
Figure 119 Bleed Odor Troubleshooting (2 Sheets)
Figure 120 Overspeed N2
Figure 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
Figure 122 Overspeed N1
MAXIMUM CONTINUOUS MALFUNCTIONS
Figure 123 Engine Surge (3 sheets)
Figure 124 N1/N2/ITT Indications Erratic (Max Continuous Operation) (2 sheets)
Figure 125 High Oil Pressure (Max Continuous Operation) (2 sheets)
Figure 126 High Oil Temperature
Figure 127 Lightning Strike Troubleshooting and Inspection (2 sheets)
Figure 128 Volcanic Ash Ingestion (2 sheets)
Figure 129 Low Oil Pressure at Altitude - Normal on Ground
DECELERATION MALFUNCTIONS
Figure 130 Engine Flameout (Deceleration)
Figure 131 Slow Engine Deceleration
SHUTDOWN MALFUNCTIONS
Figure 132 Failure to Shutdown
Figure 133 Short or Noisy Engine Rundown (2 sheets)
OTHER MALFUNCTIONS
Figure 134 Fuel Filter Delta P Lamp Lit
Figure 135 High Vibration With or Without Noise (2 sheets)
Figure 136 High Oil Consumption/Leak
Figure 137 Fuel Leak/Increased Fuel Consumption
Figure 138 Oil Discoloration
Figure 139 Engine Shock Load (Hard Landing) (2 sheets)
Figure 140 Oil Filter Delta P Indicator Extended
71-00-00
Page 103
Apr 11/08

Figure 141 Suspect N1 or N2 Speed Pickup(s)
Figure 142 High Oil Consumption (3 sheets)
Figure 143 Bird Strike/Foreign Object Ingestion (2 sheets)
Figure 144 ITT Split Between Engines (2 sheets)
Figure 145 Engine Switches to Manual Mode Automatically
Figure 146 Throttle Lever Movement is Rough/Binding/Sticks
Figure 147 Engines will not synchronize
TASK 71-00-00-810-805 EFCU Maintenance Fault Indicator ON
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.
71-00-00
Page 104
Apr 11/08

NOTES: 1 Refer to 73-24-01 P.B. 201 to download the BIT FAULTS.
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.
3 Multiple BIT FAULTS displayed on the EMT can be introduced by multiple

problems, such as loose connectors on the ECU or engine Harnesses. When
multiple faults exist, check all connectors first. If multiple faults still exist,
troubleshoot the most recent BIT FAULT first.
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.
5 After maintenance action is complete, the BIT FAULTS must be

cleared per 73-24-01 P.B. 201.
6 If needed, refer to FJ44-2A Electrical Interface Schematic, Drawing Part Number 56736
SUBTASK 71-00-00-941-028
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.
71-00-00
Page 105
Apr 11/08

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
Bit Fault Numbers / Bit Fault IDs and Related Task

BIT # BIT FAULT ID TASK
1 A/D Conversion Timeout 71-00-00-811-001
2 AD Ref Range High
3 AD Ref Range Low
4 Accel Bleed Load Open 71-00-00-811-002
5 Accel Bleed Load Short
6 Accel Bleed Internal
7 Suspect Accel Bleed Load Open
8 BIT Fault Record 71-00-00-811-003
9 CJ Range Low
10 CJ Range High
11 Discrete Input
12 ECU Active Load Open 71-00-00-811-005
13 ECU Active Load Short
14 ECU Active Internal
15 Suspect ECU Active Load Open
16 EEPROM Trim Checksum 71-00-00-811-007
17 Engine Surge 71-00-00-811-008
18 Multi-purpose Load Open 71-00-00-811-009
19 Multi-purpose Load Short
20 Multi-purpose Load Internal
21 Suspect Multi-purpose Load Open
22 HMU Res Range Low 71-00-00-811-011
23 HMU Res Range High
24 ITT Gross Error 71-00-00-811-012
25 ITT HW Range High
26 ITT Range Low
27 ITT Range High
71-00-00
Page 106
Apr 11/08

Table 101 (Continued)
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
71-00-00
Page 107
Apr 11/08

Table 101 (Continued)
63 TT2 BIT Internal 71-00-00-811-028

64 VREF 5 Volt Range High
65 Watchdog Excess Trips Shutdown 71-00-00-811-029
66 Watchdog Unexpected Trip 71-00-00-811-030
67 Watchdog Timer 71-00-00-811-031
68 WDG Output Disable
69 Wf/P3 Req Load Open 71-00-00-811-032
70 Wf/P3 Req Load Short
71 Wf/P3 Internal
72 Wf/P3 Disable 71-00-00-811-033
73 WOW Stuck Grounded 71-00-00-811-034
74 BG Execution Failure 71-00-00-811-035
75 Init Bad Key Argument
76 BUS Error
77 BUS Error Twice in Frame
78 ADDR ERR Illegal Instruction
79 BAD Interrupt
80 Frame Overrun Exc
81 N1 Exceedence Occurred 71-00-00-811-036
82 N2 Exceedence Occurred
83 ITT Exceedence Occurred
84 APR Occurred
85 Download Required
86 EEPROM Verify Failure 71-00-00-811-037
87 Exceedence Checksum
88 Dummy Fault
89 Switchover Occurred 71-00-00-811-038
90 ECU Running Engine 71-00-00-811-039
91 Fault Switchover 71-00-00-811-040
92 Power Cycle While Running 71-00-00-811-041
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.
71-00-00
Page 108
Apr 11/08

SUBTASK 71-00-00-945-050
A. Reference Information
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
A. Replace ECU per 73-24-01 P.B. 401.
12. 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 71-00-00-811-002 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
SUBTASK 71-00-00-945-050
73-21-01 401 Fuel Control Unit - Removal/Installation
15. Procedures
SUBTASK 71-00-00-811-051
A. Troubleshoot fault as follows:
71-00-00
Page 109
Apr 11/08

(1) Check ECU connector:
(a) P4W to P4A = 34.5 +/-2 ohms
(b) P4W to GND, P4A to GND =~10Mohm
(c) If check is outside of limits, go to step (2).
(d) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(2) Check EFCU Engine Harness connector:
(a) P7W to P7A = 34.5 +/-2 ohms
(b) P7W to GND, P7A to GND =~10Mohm
(c) If check is within limits, repair P4 to J7 Airframe Harness.
(d) If check is outside of limits, go to step (3).
(3) Check HMU connector:
(a) J2G to J2T = 34.5 +/-2 ohms
(b) J2G to GND, J2T to GND =~10Mohm
(c) If check is outside of limits, replace HMU per 73-21-01 P.B. 401.
(d) If check is within limits, replace Engine Harness.
16. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-003 BIT 8 - BIT Fault Record; 9 - CJ Range Low; 10 - CJ Range High; 11 -
Discrete Input
17. General
SUBTASK 71-00-00-945-050
71-00-00
Page 110
Apr 11/08


19. Procedures
SUBTASK 71-00-00-811-052
20. Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
23. Procedures
SUBTASK 71-00-00-811-053
(a) P20E to P20Z = 240 to 2000 ohms
(b) P20E to GND, P20Z to GND = ~10Mohm
71-00-00
Page 111
Apr 11/08

(c) If check is outside of limits, refer to A.M.M.
(d) Clear Fault per 73-24-01 P.B. 201.
(e) If check is within limits, replace ECU per 73-24-01 P.B. 401.
24. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-007 BIT 16 - EEPROM Trim Checksum
25. General
SUBTASK 71-00-00-945-050
27. Procedures
SUBTASK 71-00-00-811-054
28. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-008 BIT 17 - Engine Surge
29. General
This task contains troubleshooting instructions for the EFCU Bit faults. A compressor surge was recorded
(uncommanded N1 deceleration).
71-00-00
Page 112
Apr 11/08

SUBTASK 71-00-00-945-050
71-00-00 101 Power Plant - Fault Isolation
31. Procedures
SUBTASK 71-00-00-811-055
A. Refer to Engine Surge Troubleshooting chart in 71-00-00 P.B. 101.
32. Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
35. Procedures
SUBTASK 71-00-00-811-056
71-00-00
Page 113
Apr 11/08

(a) P20D to P20C = 240 to 2000 ohms
(b) P20D to GND, P20C to GND = ~10Mohm
(c) If check is outside of limits, refer to A.M.M.
(d) Clear Fault per 73-24-01 P.B. 201.
36. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-011 BIT 22 - HMU Res Range Low; BIT 23 - HMU Res Range High
37. General
SUBTASK 71-00-00-945-050
39. Procedures
SUBTASK 71-00-00-811-057
(a) P4S to P4R = 150 to 10.05K ohms
(b) P4S to GND, P4R to GND =~10Mohm
71-00-00
Page 114
Apr 11/08

(a) P7S to P7R = 150 to 10.05K ohms
(b) P7S to GND, P7R to GND =~10Mohm
(d) If check is within limits, repair P4 to J7 Airframe Harness.
(3) Check HMU:
(a) J2C to J2J = 150 to 10.05K ohms
(b) J2C to GND, J2J to GND =~10Mohm
(d) If check is within limits, replace Engine Harness.
40. Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
77-20-02 401 Intermediate Turbine Temperature (ITT) Probe - Removal/Installation
77-40-01 401 EFCU Engine Wiring Harness Assembly - Removal/Installation
71-00-00
Page 115
Apr 11/08

43. Procedures
SUBTASK 71-00-00-811-058
(1) Disconnect Airframe Harness to P7M and P7N. Clear bit fault message
(a) If BIT FAULT is clear, refer to A.M.M.
(b) If BIT fault is persistant, continue check of ECU to J7 Airframe Harness.
(2) Check ECU to J7 Airframe Harness connector:
(a) P4G to P4E = 8 to 10 ohms
(b) P4G to GND, P4E to GND =~10Mohm
(3) Check Engine Harness:
(a) P7G to P7E = 3.5 to 5.5 ohms
(b) P7G to GND, P7E to GND =~10Mohm
(c) P7m to P7n = 3.5 to 5.5 ohms P7m to GND, P7n to GND =~10Mohm
(d) If check is outside of limits, go to step (4).
(e) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(4) Do a resistance check on J1 connector:
(a) A B = 2.5 .5 ohms probe 6
(b) C D = 2.5 .5 ohms probe 5
(c) E F = 2.5 .5 ohms probe 4
(d) G H = 2.5 .5 ohms probe 3
(e) J K = 2.5 .5 ohms probe 2
(f) L M = 2.5 .5 ohms probe 1
(g) N R = 0.5 .3 ohms
(h) N T = 0.5 .3 ohms
(i) P S = 0.5 .3 ohms
71-00-00
Page 116
Apr 11/08

(j) P U = 0.5 .3 ohms
(k) N P =~10Mohm
(l) J1A through J1U to GND = 10 Mohm
(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
44. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-013 BIT 28 - N1 Counter
45. General
SUBTASK 71-00-00-945-050
47. Procedures
SUBTASK 71-00-00-811-059
48. Job Close-up
SUBTASK 71-00-00-870-050
71-00-00
Page 117
Apr 11/08

TASK 71-00-00-811-014 BIT 29 - N1 Gross Error; BIT 30- N1 Open Input
49. General
SUBTASK 71-00-00-945-050
51. Procedures
SUBTASK 71-00-00-811-060
(a) P4H to P4L = 555 +/-20 ohms
(b) P4H to GND, P4L to GND =~10Mohm
(a) P7H to P7L = 555 +/-20 ohms
(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(3) Check N1 pickup connector:
(a) J3B to J3A = 555 +/-20 ohms
(b) J3B to GND, J3A to GND =~10Mohm
71-00-00
Page 118
Apr 11/08

(c) If check is outside of limits, replace N1 pickup.
(d) If check is within limits, replace engine harness per 77-40-01 P.B. 401.
52. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-015 BIT 31 - N1 Overspeed
53. General
SUBTASK 71-00-00-945-050
55. Procedures
SUBTASK 71-00-00-811-061
A. Refer to Overspeed N1 Chart in Troubleshooting 71-00-00, P.B. 101.
56. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-016 BIT 32 - N1 Range High; BIT 33 - N1 BIT Internal
57. General
71-00-00
Page 119
Apr 11/08

SUBTASK 71-00-00-945-050
59. Procedures
SUBTASK 71-00-00-811-062
(a) P4H to P4L = 555 +/-20 ohms
(a) P7H to P7L = 555 +/-20 ohms
(d) If check is within limits, repair ECU to J7 Airframe Harness per AMM.
(a) J3B to J3A = 555 +/-20 ohms
(b) J3B to GND, J3A to GND =~10Mohm
71-00-00
Page 120
Apr 11/08

60. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-017 BIT 34 - N2 Counter
61. General
SUBTASK 71-00-00-945-050
63. Procedures
SUBTASK 71-00-00-811-063
64. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-018 BIT 35 - N2 Gross Error; BIT 36 - N2 Open Input
65. General
SUBTASK 71-00-00-945-050
71-00-00
Page 121
Apr 11/08


67. Procedures
SUBTASK 71-00-00-811-064
(a) P4J to P4P = 795 +/-85 ohms
(b) P4J to GND, P4P to GND =~10Mohm
(a) P7J to P7P = 795 +/-85 ohms
(a) J6A to J6B = 795 +/-85 ohms
(b) J6A to GND, J6B to GND =~10Mohm
68. Job Close-up
SUBTASK 71-00-00-870-050
71-00-00
Page 122
Apr 11/08

TASK 71-00-00-811-019 BIT 37 - N2 Overspeed
69. General
SUBTASK 71-00-00-945-050
71. Procedures
SUBTASK 71-00-00-811-065
A. Refer to Overspeed N2 Chart in Troubleshooting 71-00-00, P.B. 101.
72. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-020 BIT 38 N2 Range High
73. General
SUBTASK 71-00-00-945-050
71-00-00
Page 123
Apr 11/08

75. Procedures
SUBTASK 71-00-00-811-066
(a) P4J to P4P = 795 +/-85 ohms
(a) P7J to P7P = 795 +/-85 ohms
(d) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM..
(a) J6A to J6B = 795 +/-85 ohms
(b) J6A to GND, J6B to GND =~10Mohm
76. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-021 BIT 39 - N2 BIT Internal
77. General
71-00-00
Page 124
Apr 11/08

SUBTASK 71-00-00-945-050
79. Procedures
SUBTASK 71-00-00-811-067
80. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-022 BIT 40 - N2 Shaft Separation
81. General
SUBTASK 71-00-00-945-050
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.
71-00-00
Page 125
Apr 11/08

84. Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
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.
88. Job Close-up
SUBTASK 71-00-00-870-050
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
71-00-00
Page 126
Apr 11/08

SUBTASK 71-00-00-945-050
91. Procedures
SUBTASK 71-00-00-811-070
(1) Check ECU to J7 Airframe Harness:
(a) P4U to P4V = 165 +/-33 ohms
(b) P4U to P4N = 165 +/-33 ohms
(c) P4h to P4f = 175 +/-35 ohms
(d) P4U to GND, P4V to GND,
(e) P4N to GND, P4h to GND,
(f) P4f to GND =~10Mohm
(g) If check is outside of limits, go to step (2).
(h) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(2) Check EFCU Engine Harness:
(a) P7U to P7V = 165 +/-33 ohms
(b) P7U to P7N = 165 +/-33 ohms
(c) P7h to P7f = 175 +/-35 ohms
(d) P7U to GND, P7V to GND,
(e) P7N to GND, P7h to GND,
(f) P7f to GND =~10Mohm
71-00-00
Page 127
Apr 11/08

(h) If check is within limits, repair ECU to J7 Airframe Harness per A.M.M..
(3) Check HMU connector::
(a) J2A to J2P = 165 +/-33 ohms
(b) J2A to J2N = 165 +/-33 ohms
(c) J2L to J2U = 175 +/-35 ohms
(d) J2A to GND, J2P to GND,
(e) J2N to GND, J2L to GND,
(f) J2U to GND =~10Mohm
(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.
92. Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
71-00-00
Page 128
Apr 11/08

95. Procedures
SUBTASK 71-00-00-811-071
96. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-026 BIT 56 - Twin ECU Receive
97. General
SUBTASK 71-00-00-945-050
99. Procedures
SUBTASK 71-00-00-811-072
A. During synchronization, a momentary or permanent loss of communication between ECUs was

recorded. Engine is acceptable as is.
100.Job Close-up
SUBTASK 71-00-00-870-050
71-00-00
Page 129
Apr 11/08

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
102.Equipment and Materials
SUBTASK 71-00-00-945-050
77-22-01 601 EFCU TT2 Sensor - Inspection/Check
103.Procedures
SUBTASK 71-00-00-811-073
WARNING AN ANTI-ICED SENSOR COULD BURN SKIN.
(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.
(2) Check ECU to J7 Airframe Harness:
(a) P4M to P4K = see 77-22-01, P.B. 601
(b) P4K to P4T = 1.5 0.5 ohms
(c) P4M to GND, P4K to GND
(d) P4T to GND =~10Mohm
(e) If check is outside of limits, go to step (3).
(f) If check is within limits, replace ECU per 73-24-01 P.B. 401.
(3) Check EFCU Engine Harness:
71-00-00
Page 130
Apr 11/08

(a) P7k to P7i = 8.5 2 ohms
(b) P7k to GND, P7i to GND =~10Mohm
(c) P7M to P7K = see 77-22-01 P.B. 601
(d) P7K to P7T = 1.0 0.5 ohms
(e) P7M to GND, P7K to GND,
(f) P7T to GND =~10Mohm
(h) If check is within limits, repair ECU to J7 Airframe Harness per aircraft MM.
(4) Check TT2 sensor:
(a) J8A to J8B = see 77-22-01 P.B. 601
(b) J8B to J8C = 0.5 0.3 ohms
(c) J8D to J8E = 8.5 2 ohms
(d) J8A to GND, J8B to GND, J8C to GND,
(e) J8D to GND, J8E to GND =~10Mohm
(f) If check is outside of limits, replace TT2 sensor.
(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
TASK 71-00-00-811-028 BIT 63 - TT2 BIT Internal; BIT 64 -VREF 5 Volt Range High
105.General
SUBTASK 71-00-00-945-050
71-00-00
Page 131
Apr 11/08


107.Procedures
SUBTASK 71-00-00-811-074
108.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-029 BIT 65 - Watchdog Excess Trips Shutdown
109.General
SUBTASK 71-00-00-945-050
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.
112. Job Close-up
SUBTASK 71-00-00-870-050
71-00-00
Page 132
Apr 11/08

TASK 71-00-00-811-030 BIT 66 - Watchdog Unexpected Trip
113. General
SUBTASK 71-00-00-945-050
115. Procedures
SUBTASK 71-00-00-811-076
A. Clear Fault per 73-24-01, P.B. 201 and watch for repeat.
116. Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-031 BIT 67 - Watchdog Timer; BIT 68 - WDG Output Disable
117. General
SUBTASK 71-00-00-945-050
71-00-00
Page 133
Apr 11/08

119. Procedures
SUBTASK 71-00-00-811-077
120.Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
123.Procedures
SUBTASK 71-00-00-811-078
(a) P4B to P4C = 75 6 ohms
(b) P4B to GND, P4C to GND =~10Mohm
71-00-00
Page 134
Apr 11/08

(a) P7B to P7C = 75 6 ohms
(b) P7B to GND, P7C to GND =~10Mohm
(3) Check HMU connector:
(a) J2R to J2E = 75 6 ohms
(b) J2R to GND, J2E to GND =~10Mohm
124.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-033 BIT 72 - Wf/P3 Disable
125.General
SUBTASK 71-00-00-945-050
127.Procedures
SUBTASK 71-00-00-811-079
71-00-00
Page 135
Apr 11/08

128.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-034 BIT 73 - WOW Stuck Grounded
129.General
SUBTASK 71-00-00-945-050
131.Procedures
SUBTASK 71-00-00-811-080
NOTE Check the following if landing gear was not deployed above 18000 feet.
(1) Check WOW switch per A.M.M.
(a) P20p to P20T=<100 ohms with gear down and locked
(b) P20p to P20T = >100 Mohms with gear stowed
(c) P20p to GND, P20T to GND~10Mohm
(d) If check is outside of limits, refer to A.M.M.
(a)
71-00-00
Page 136
Apr 11/08

(b)
(d)
(4)
(a)
(b)
(c)
(d)
132.Job Close-up
SUBTASK 71-00-00-870-050
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
SUBTASK 71-00-00-945-050
135.Procedures
SUBTASK 71-00-00-811-081
71-00-00
Page 137
Apr 11/08

136.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-036 BIT 81 - N1 Exceedence Occurred; BIT 82 - N2 Exceedence Occurred;

BIT 83 - ITT Exceedence Occurred; BIT 84 - APR Occurred; BIT 85 -
Download Required
137.General
SUBTASK 71-00-00-945-050
71-00-00 501 Power Plant - Adjustment/Test
139.Procedures
SUBTASK 71-00-00-811-082
A. Download data per 73-24-01, P.B. 201.
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
TASK 71-00-00-811-037 BIT 86 - EEPROM Verify Failure; BIT 87 - Exceedence Checksum Fault;
BIT 88 - Dummy Fault
141.General
71-00-00
Page 138
Apr 11/08

SUBTASK 71-00-00-945-050
143.Procedures
SUBTASK 71-00-00-811-083
144.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-038 BIT 89 - Switchover Occurred
145.General
SUBTASK 71-00-00-945-050
147.Procedures
SUBTASK 71-00-00-811-084
A. Determine cause of switchover, and refer to indicated BIT number..
71-00-00
Page 139
Apr 11/08

148.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-039 BIT 90 - ECU Running Engine
149.General
SUBTASK 71-00-00-945-050
151.Procedures
SUBTASK 71-00-00-811-085
A. Verify aircraft power at this location and refer to A.M.M.
B. P20A (28 volt positive) to P20B (28 volt return)
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
TASK 71-00-00-811-040 BIT 91 - Fault Switchover
153.General
71-00-00
Page 140
Apr 11/08

SUBTASK 71-00-00-945-050
155.Procedures
SUBTASK 71-00-00-811-086
A. Refer to associated BIT fault.
156.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-041 BIT 91 - Power Cycle While Running
157.General
SUBTASK 71-00-00-945-050
159.Procedures
SUBTASK 71-00-00-811-087
A. Verify aircraft power at this location and refer to A.M.M.
B. P20A (28 volt positive) to P20B (28 volt return)
C. If BIT FAULT continues to occur and check is positive, replace ECU per 73-24-01 P.B. 401.
71-00-00
Page 141
Apr 11/08

160.Job Close-up
SUBTASK 71-00-00-870-050
TASK 71-00-00-811-843 Overboard Fuel Leak Troubleshooting
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
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
73-16-01 401 Fuel Pump - Removal/Installation
163.Job Set-up
SUBTASK 71-00-00-010-001
A. Prepare the engine for fuel system maintenance
71-00-00
Page 142
Apr 11/08

WARNING TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL

LINES, OPEN OR CYCLE ANY AIRCRAFT ISOLATION VALVES PRIOR
TO ENGINE FUEL SYSTEM MAINTENANCE.
(2) Open the circuit breakers to isolate the engine electrical supply.
(3) Close the aircraft fuel shutoff valve.
(4) Remove the cowling. Refer to the Aircraft Maintenance Manual.
164.Procedures
SUBTASK 71-00-00-810-050
A. Remove fuel control unit heatshield (if applicable). Refer to 73-21-01, P.B. 401
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.
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
E. Prepare the engine for running.
(1) Open the aircraft fuel shutoff valve
(2) Close aircraft circuit breakers.
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.
71-00-00
Page 143
Apr 11/08

SUBTASK 71-00-00-810-003
G. Evaluate ground run leak check as follows:
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
(1) Install the cowling. Refer to the Aircraft Maintenance Manual.
71-00-00
Page 144
Apr 11/08

Fig. 101 No N2 Indication on Instrumentation (Starter Rotates)
71-00-00
Page 145
Apr 11/08

Fig. 102 Engine Will Not Start (2 sheets)
71-00-00
Page 146
Apr 11/08

Fig. 102 Engine Will Not Start (2 sheets)
71-00-00
Page 147
Apr 11/08

Fig. 103 No Oil Pressure Indication (2 sheets)
71-00-00
Page 148
Apr 11/08

Fig. 103 No Oil Pressure Indication (2 sheets)
71-00-00
Page 149
Apr 11/08

Fig. 104 High Oil Pressure on Start
71-00-00
Page 150
Apr 11/08

Fig. 105 Low/No Sound of Igniter(s) Firing (2 sheets)
71-00-00
Page 151
Apr 11/08

Fig. 105 Low/No Sound of Igniter(s) Firing (2 sheets)
71-00-00
Page 152
Apr 11/08

Fig. 106 No/Low Fuel Flow Indication

71-00-00
Page 153
Apr 11/08

Fig. 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
71-00-00
Page 154
Apr 11/08

Fig. 107 No/Slow Acceleration (Hung Start) 42% 20 Sec After Light (2 sheets)
71-00-00
Page 155
Apr 11/08

Fig. 108 No ITT Indication
71-00-00
Page 156
Apr 11/08

Fig. 109 Engine Hot Start (3 sheets)
71-00-00
Page 157
Apr 11/08

71-00-00
Page 158
Apr 11/08

71-00-00
Page 159
Apr 11/08

Fig. 110 No N1 Speed Indication
71-00-00
Page 160
Apr 11/08

Fig. 111 High N2 Indication at Idle
71-00-00
Page 161
Apr 11/08

Fig. 112 Low Oil Pressure (2 sheets)
71-00-00
Page 162
Apr 11/08

Fig. 112 Low Oil Pressure (2 sheets)
71-00-00
Page 163
Apr 11/08

Fig. 113 Engine Flameout

71-00-00
Page 164
Apr 11/08

Fig. 114 Fuel Leaking from Overboard Drain (Engine Operating)
71-00-00
Page 165
Apr 11/08

Fig. 115 No Acceleration Above Idle
71-00-00
Page 166
Apr 11/08

Fig. 116 Slow Acceleration (2 sheets)
71-00-00
Page 167
Apr 11/08

Fig. 116 Slow Acceleration (2 sheets)
71-00-00
Page 168
Apr 11/08

Fig. 117 High ITT (2 sheets)
71-00-00
Page 169
Apr 11/08

Fig. 117 High ITT (2 sheets)
71-00-00
Page 170
Apr 11/08

Fig. 118 Low N1 Indication at Takeoff Power Setting
71-00-00
Page 171
Apr 11/08

Fig. 119 Bleed Odor Troubleshooting (2 Sheets)
71-00-00
Page 172
Apr 11/08

Fig. 119 Bleed Odor Troubleshooting (2 Sheets)
71-00-00
Page 173
Apr 11/08

Fig. 120 Overspeed N2
71-00-00
Page 174
Apr 11/08

Fig. 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
71-00-00
Page 175
Apr 11/08

Fig. 121 ITT at Max Limit Prior to Achieving Takeoff N1 Speed (2 sheets)
71-00-00
Page 176
Apr 11/08

Fig. 122 Overspeed N1
71-00-00
Page 177
Apr 11/08

EFFECTIVITY: FJ44-2A Fig. 123 Engine Surge (3 sheets)

71-00-00
Page 178
Apr 11/08

Fig. 123 Engine Surge (3 sheets)
71-00-00
Page 179
Apr 11/08

Fig. 123 Engine Surge (3 sheets)
71-00-00
Page 180
Apr 11/08

Fig. 124 N1/N2/ITT Indications Erratic (Max Continuous Operation) (2 sheets)
71-00-00
Page 181
Apr 11/08

Fig. 124 N1/N2/ITT Indications Erratic (Max Continuous Operation) (2 sheets)
71-00-00
Page 182
Apr 11/08

Fig. 125 High Oil Pressure (Max Continuous Operation) (2 sheets)
71-00-00
Page 183
Apr 11/08

Fig. 125 High Oil Pressure (Max Continuous Operation) (2 sheets)
71-00-00
Page 184
Apr 11/08

Fig. 126 High Oil Temperature
71-00-00
Page 185
Apr 11/08

Fig. 127 Lightning Strike Troubleshooting and Inspection (2 sheets)
71-00-00
Page 186
Apr 11/08

Fig. 127 Lightning Strike Troubleshooting and Inspection (2 sheets)
71-00-00
Page 187
Apr 11/08

Fig. 128 Volcanic Ash Ingestion (2 sheets)
71-00-00
Page 188
Apr 11/08

Fig. 128 Volcanic Ash Ingestion (2 sheets)
71-00-00
Page 189
Apr 11/08

Fig. 129 Low Oil Pressure at Altitude - Normal on Ground
71-00-00
Page 190
Apr 11/08

Fig. 130 Engine Flameout (Deceleration)
71-00-00
Page 191
Apr 11/08

Fig. 131 Slow Engine Deceleration
71-00-00
Page 192
Apr 11/08

Fig. 132 Failure to Shutdown
71-00-00
Page 193
Apr 11/08

Fig. 133 Short or Noisy Engine Rundown (2 sheets)
71-00-00
Page 194
Apr 11/08

Fig. 133 Short or Noisy Engine Rundown (2 sheets)
71-00-00
Page 195
Apr 11/08

Fig. 134 Fuel Filter Delta P Lamp Lit
71-00-00
Page 196
Apr 11/08

Fig. 135 High Vibration With or Without Noise (2 sheets)
71-00-00
Page 197
Apr 11/08

Fig. 135 High Vibration With or Without Noise (2 sheets)
71-00-00
Page 198
Apr 11/08

Fig. 136 High Oil Consumption/Leak
71-00-00
Page 199
Apr 11/08

Fig. 137 Fuel Leak/Increased Fuel Consumption
71-00-00
Page 200
Apr 11/08

Fig. 138 Oil Discoloration
71-00-00
Page 201
Apr 11/08

Fig. 139 Engine Shock Load (Hard Landing) (2 sheets)
71-00-00
Page 202
Apr 11/08

Fig. 139 Engine Shock Load (Hard Landing) (2 sheets)
71-00-00
Page 203
Apr 11/08

Fig. 140 Oil Filter Delta P Indicator Extended
71-00-00
Page 204
Apr 11/08

Fig. 141 Suspect N1 or N2 Speed Pickup(s)
71-00-00
Page 205
Apr 11/08

Fig. 142 High Oil Consumption (3 sheets)
71-00-00
Page 206
Apr 11/08

71-00-00
Page 207
Apr 11/08

71-00-00
Page 208
Apr 11/08

EFFECTIVITY: FJ44-2AFig. 143 Bird Strike/Foreign Object Ingestion (2 sheets)

71-00-00
Page 209
Apr 11/08

Fig. 143 Bird Strike/Foreign Object Ingestion (2 sheets)
71-00-00
Page 210
Apr 11/08

Fig. 144 ITT Split Between Engines (2 sheets)
71-00-00
Page 211
Apr 11/08

Fig. 144 ITT Split Between Engines (2 sheets)
71-00-00
Page 212
Apr 11/08

Fig. 145 Engine Switches to Manual Mode Automatically
71-00-00
Page 213
Apr 11/08

Fig. 146 Throttle Lever Movement is Rough/Binding/Sticks
71-00-00
Page 214
Apr 11/08

Fig. 147 Engines will not synchronize
71-00-00
Page 215
Apr 11/08

Fig. 148 Overboard Fuel Leak Block Fuel Drain
71-00-00
Page 216
Apr 11/08

POWER PLANT - MAINTENANCE PRACTICES
TASK 71-00-00-870-802 Configure Engine For Right or Left-Hand Use
1. General
This task provides procedures to change a No. 1 (left hand) engine to a No. 2 (right hand) engine or a No.
2 (right hand) engine to a No. 1 (left hand) engine.
NOTE We identify locations of all parts of the engine as if installed in an aircraft, viewed
from the rear. All radial locations are numbered counting clockwise. Number one
(1) is always at the top (12 oclock position) on the centerline.
SUBTASK 71-00-00-943-034
A. Special Tools
08-0119-8000 Engine Sling
SUBTASK 71-00-00-945-034
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:
71-00-00
Page 201
Apr 11/08

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

CAREFUL AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.
NOTE The engine must be hanging from the engine lifting sling,
08-0119-8000, to do the following task
(4) Move the eight mounting pad hole plugs to the opposite side of the engine. Torque plugs
90-100 inch-pounds (10.1-11.2 N.m).
(5) The dipstick assembly must be installed on the outboard side. Change positions of dipstick
assembly and filler port plug assembly, as required. Refer to 79-31-01, P.B. 401.
(6) 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.
71-00-00
Page 202
Apr 11/08

POWER PLANT - REMOVAL/INSTALLATION
TASK 71-00-00-010-801 Remove the Engine from Build Stand
1. General
This task provides procedures for removing the engine from the build stand. Refer to the following
illustration(s):
Figure 401 Engine in Build Stand - Removal/Installation
SUBTASK 71-00-00-941-036
Hoist
SUBTASK 71-00-00-943-036
B. Special Tools
08-2021-0000 Stand, Engine
K-2032 Adapter, Engine Stand
3. Procedures
SUBTASK 71-00-00-010-036
A. Remove engine from 08-2021-0000 engine stand as follows:
(1) Place engine installed in engine build stand under hoist.
(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.
71-00-00
Page 401
Apr 11/08

(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.
TASK 71-00-00-410-801 Install the Engine in Build Stand
5. General
This task provides procedures for installing the engine in the build stand. Refer to the following
illustration(s):
Figure 401 Engine in Build Stand - Removal/Installation
SUBTASK 71-00-00-941-037
Hoist
SUBTASK 71-00-00-943-037
B. Special Tools
71-00-00
Page 402
Apr 11/08


K-2032 Adapter, Engine Stand
7. Job Set-up
SUBTASK 71-00-00-010-040
WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY CAREFUL

AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.
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
A. Install engine to engine build stand as follows:
(1) Install four engine mount adapters, K-2032, to the four engine mount pads on the interstage
housing. Torque 16 mounting bolts 200 to 245 inch-pounds (22.5 to 27.6 N.m).
(2) Rotate the gear-driven support arm, if necessary, to put it in the vertical position. Lock
rotation crank.
(3) Retract the pivoting support arm to make room for installation of the engine.
(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.
CAUTION WHEN ENGINE IS SERVICED WITH OIL, DO NOT ROTATE TO THE

EXTREME "NOSE UP" OR "NOSE DOWN" POSITION. THIS MAY CAUSE
OIL WETTING BEHIND THE COMPRESSOR COVER.
(6) Remove engine lifting sling, 08-0119-8000.
71-00-00
Page 403
Apr 11/08

Fig. 401 Engine in Build Stand - Removal/Installation 71-00-00
Page 404
Apr 11/08

POWER PLANT - ADJUSTMENT/TEST
TASK 71-00-00-760-807 List of Test Procedures
1. General
This task lists the types of ground running tests that are necessary after engine maintenance. Refer
to the following tables:
table 501
table 502
NOTE The tests which are referred to in this task are found in 71-00-00, P.B. 501.
SUBTASK 71-00-00-945-018
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
A. Refer to the List of Test Procedures table below.
Table 501 List of Test Procedures
TASK NAME REASON

71-00-00-760-810 Idle Speed and Leak Check To check the engines performance at
Run idle and make sure that there are no
leaks in the fuel, oil, or air systems.
71-00-00-760-814 Vibration Survey To check the level of vibration and the
source.
71-00-00-760-818 Stability/Acceleration Check To make sure that the acceleration and
time is correct and that the engine does
not flame-out during deceleration.
71-00-00
Page 501
Apr 11/08

Table 501 List of Test Procedures (Continued)
TASK NAME REASON

71-00-00-760-823 Performance Check To make sure that the engine
performance is within limits.
71-00-00-760-827 Oil Consumption Check To aid in troubleshooting of oil
consumption.
71-00-00-760-826 High Power Check To make sure that the engine performs
correctly at high power.
71-00-00-760-828 Capped Bleed Engine Run To record engine data when engine is
isolated from aircraft bleed system.
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.
NOTE Do the tests in the order shown.
Table 502 Tests Required after Maintenance or Component Replacement
Component Maint. Idle/Leak Vibe Stability Perform High

Action Check Survey Accel Check Power
Check Check
ENGINE INSTALLATION OR MAJOR PERIODIC INSPECTION:
Major Periodic Inspection (Check 3) X X X X
(Engine installed in aircraft) NOTE 1 NOTE 2
NOTE 3
Major Periodic Inspection (Check 3) Perform engine acceptance test procedure (ATP).
(Engine installed in test cell) Refer to 72-00-00, P.B. 1301 in the Engine Manual.
NOTE 1
Engine Installation X
(New engine or engine which NOTE 1
has undergone acceptance test
procedure since last installation or
maintenance)
Engine Installation X X
(Rental Engine) NOTE 1
71-00-00
Page 502
Apr 11/08

Table 502 Tests Required after Maintenance or Component Replacement (Continued)

Check Check
Engine Installation X As required by maintenance performed
(Engine which has not undergone NOTE 1 on individual parts (see below)
acceptance test procedure since last
installation or maintenance.)
BASIC ENGINE COMPONENT REPLACEMENT:
Fan Rotor Remove/ X
Install
Repaired X X X
or New
Case and Insert Remove/ X
Assyand/or Fan Stator Install
Repaired X X
or New
Magnetic Chip Collector Replacement X
Assy NOTE 5
IP Compressor Rotor Remove/ X
Install
Repaired X X X
or New
No. 1 Carbon Seal Any Maint. X X
NOTE 1
Combustor Cover Assy Remove/ X X X X
Install
New X X X X
Fuel Slinger Remove/ X X X X
Install
New X X X X
Balance Piston Seal Remove/ X X X X
Install
New X X X X
71-00-00
Page 503
Apr 11/08


Check Check
HP Turbine Combustor Remove/ X X X X
Assy Install
Repaired X X X X
or New
HP Turbine Rotor Remove/ X X X X
Install
Repaired X X X X
or New
No. 3 Roller Bearing Any Maint. X X X
1st LP Turbine Nozzle Remove/ X X X
Assy Install
Repaired X X X X
or New
No. 4 Roller Bearing Any Maint X X X
No. 3 Carbon Seal Any Maint. X X X
No. 4 Carbon Seal Any Maint. X X X
LP Turbine Module Remove/ X X
Install
Disassy/ X X X
Assy
Repaired X X X
or New
Rear Housing Assy Remove/ X X
Install
Repaired X X X
or New
Front Bypass Duct Assy Any Maint. X X X X
NOTE 2
Rear Bypass Duct Assy Any Maint X
ENGINE ACCESSORIES/LRU REPLACEMENT:
Fuel Tube Assembly Any Maint. X
71-00-00
Page 504
Apr 11/08


Check Check
Fuel Nozzle Assembly Any Maint. X
Fuel Pump Filter Any Maint. X
Fuel Pump Any Maint. X X X
NOTE 1 NOTE 2
Hydromechanical Fuel Remove/ X X X
Control Unit (HMU) Install NOTE 2
Repaired
or New
Electronic Control Unit Any Maint. X

(ECU)
Fuel Filter Electrical Any Maint. X

Indicator (Delta P)
Fuel Manifold Filter Any Maint. X
Assy
Gearbox Assy Remove/ X X X
Install NOTE 1
Gearbox Carbon Seal Any Maint. X
NOTE 1
Gearbox Filter Delta P Any Maint. X
Indicator
Ignition Exciter Any Maint. X
Igniter Lead Any Maint. X
Igniter Plug Any Maint. X
Oil Sight Glass Any Maint. X
(Interstage Housing)
Acceleration Bleed Any Maint X X
System NOTE 2
LP Magnetic Speed Any Maint. X X
Pickup Assy
71-00-00
Page 505
Apr 11/08


Check Check
Gearbox (HP) Magnetic Any Maint. X X
Speed Assy
ITT Probe Any Maint. X X
NOTE 4
Starter/Generator Any Maint. X Refer to Aircraft Maintenance Manual
NOTE 1 NOTE 3
NOTE 6
Hydraulic Pump Any Maint. X Refer to Aircraft Maintenance Manual
NOTE 1 NOTE 3
Oil Filter Any Maint. X
Lube Oil Cooler Any Maint. X
Lube and Scavenge Any Maint. X X
Pump NOTE 1
Oil Pressure Regulating Any Maint. X X
Valve
Oil Supply Tube Any Maint. X
TT2 Sensor Any Maint. X
EFCU Engine Harness Any Maint. X
Assembly
71-00-00
Page 506
Apr 11/08

NOTES: 1 Leak check at max continuous power is required. Refer to 71-00-00,

P.B. 501, Idle Speed and Leak Check Run.
2 Visual/functional check of acceleration bleed system is required. Refer to

71-00-00, P.B. 501, Stability/Acceleration Check.
3 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 As an alternate means of compliance after ITT probe replacement, perform

Continuity Check and Resistance Check tasks. Refer to 77-20-02, P.B. 601.
5 Leak Check is required only if the complete Magnetic Chip

Collector Assembly is replaced.
6 If the Starter/Generator has been subjected to a short circuit or other failure

that could have resulted in an electrical discharge through the drive shaft into
the engine, troubleshoot the engine in accordance with the Lightning Strike
Troubleshooting and Inspection fault tree (Ref 71-00-00, P.B. 101).
TASK 71-00-00-760-803 General Operating Procedures
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)
71-00-00
Page 507
Apr 11/08

NOTES: 1 Refer to this task before all ground running .
2 Use this task in conjunction with the manufacturers operating instructions

for the FJ44-2A engine.
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
72-00-01 301 Approved Engine Fuel - Servicing
6. Procedures
SUBTASK 71-00-00-700-001
A. Ground Running Tests - General Procedures
(1) Reason for ground running tests
(a) To make sure that the engine is correctly installed.
(b) When told of a defect on the engine, to find that defect.
(c) To make sure an adjustment is done correctly.
(d) To monitor the effect which a replacement unit can have on the operation of a system or
the performance of the engine.
71-00-00
Page 508
Apr 11/08

(e) To check for leaks.
(2) Safety precautions
WARNINGS: 1 MAKE SURE THAT PEOPLE AT WORK NEAR THE AIRCRAFT

KNOW OF THE AREAS THAT ARE DANGEROUS. THIS MAKES
SURE THAT PEOPLE ARE NOT KILLED OR BADLY INJURED.
2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING

(COATS, JACKETS, CAPS AND SCARVES) NEAR THE
ENGINE WHILE IT OPERATES. MAKE SURE THAT THE
HOODS ON PARKAS ARE NOT LOOSE.
CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE

GROUND CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF
FOREIGN OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR
A DECREASED PERFORMANCE OF THE ENGINE.
(a) When you do ground-run tests, look at the areas that are dangerous before you go near
the aircraft. Refer to Figure 501 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.
WARNING MAKE SURE THERE IS SOMEONE IN THE COCKPIT AT ALL

TIMES DURING ENGINE OPERATON.
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.
(3) Engine Handling
(a) Power Control
71-00-00
Page 509
Apr 11/08

1 Keep ground runs to the minimum level of power and time that is necessary
to do the tests.
CAUTION DO NOT MOVE THE THRUST LEVERS FORWARD AND BACK

QUICKLY UNLESS YOU ARE DOING ACCELERATION/DECELERATION
TESTS. FAST MOVEMENT OF THE THRUST LEVERS CAUSES THE
ENGINE TEMPERATURE TO CHANGE QUICKLY WHICH IS NOT
GOOD FOR THE LIFE OF THE ENGINE.
(4) Ground Running in Icing Conditions
(a) Icing can be expected to occur when visible moisture is present such as cloud or fog with
low visibility, rain, snow, sleet, ice crystals, or with standing water, ice or snow present on
the ground. If icing conditions exist or are anticipated, operate the airframe-supplied
anti-icing system (if available) and TT2 sensor heat per the aircraft operating manual.
(5) Oil System Characteristics:
(a) Oil Pressure - Engine oil pressure limits are listed under operating limits. For nominal
engine operation, the oil pressures shown in Figure 502 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.
(6) Windmilling on Ground.
(a) It is highly recommended that while the aircraft is unattended, the inlet and exhaust
covers are installed to prevent windmilling.
71-00-00
Page 510
Apr 11/08

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.
2 WHEN YOU MONITOR A LIMIT, MAKE SURE THE RELATED AIRCRAFT

INSTRUMENT IS NOT DEFECTIVE OR INACCURATE. THIS WILL
PREVENT FALSE MONITORING.
NOTES: 1 The conditions defined herein are the minimum/maximum as noted for
the engine. Other information is supplied for operator convenience. Any
instances of the operating limits being exceeded must be recorded and
reported together with duration and degree of excess. The operator should
take whatever action is necessary, to keep operation within limits. 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 Airflow disturbances across engine intake, particularly during gusty or

crosswind conditions, may result in RPM fluctuations. This is normal at
high power settings during static or low speed operations.
A. Fuel System Limits:
(1) Minimum Fuel Temperature - Refer to 72-00-01, P.B. 301.
(2) Maximum Fuel Temperature - Refer to 72-00-01, P.B. 301.
(3) Maximum Fuel Leakage - Refer to 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:
(1) Maximum Tailwind Component - 25 knots, estimated (1)
(2) Maximum Crosswind Component - 25 knots, estimated (1)
71-00-00
Page 511
Apr 11/08

(3) Time Between Starts - 30 Seconds
(4) Time to Light-Off (2) - 10 seconds (3)
NOTES: 1 Higher minimum throttle up speeds may be required if tailwind

component exceeds 5 knots.
2 Time to light-off is defined as the time after the power lever is moved
from SHUTOFF to START position until light-off is indicated.
3 For ground start only. For in-flight windmill and starter assisted starts,
refer to FJ44-2A Operating Instructions Manual.
C. Operating Limits: Refer to table below.
Table 503 FJ44-2A Operating Limits
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)
71-00-00
Page 512
Apr 11/08

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.
2 When in the ELECTRONIC mode, max continuous thrust is obtained when

the PLA is in the max continuous thrust position. Max continuous thrust
settings are defined in the Williams International approved N1 Power
setting charts in the applicable engine parts list. Continuous operation is
acceptable provided engine limits are not exceeded.
3 Minimum oil pressure is 45 psig when operating at or above 80% N2;

35 psig when operating below 80% N2.
4 When operating below 80% N2 for up to 5 minutes maximum.
5 When operating above 80% N2 for up to 5 minutes maximum.
6 Maximum allowable oil pressure is 100 psig for five minutes with oil
pressure returning to normal range.
7 The engine should not be operated above 80% N2 until oil

temperature is above 10C.
8 Max bleed extraction during start is limited to equivalent flow through

a 0.222 square inch sharp edge orifice.
8. Normal Operating Procedures
SUBTASK 71-00-00-700-003
A. Starting the Engine (ELECTRONIC MODE)
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.).
(1) Perform engine pre-start checks as follows:
(a) Verify battery or ground power supply meets the starter/generator manufacturers
requirements.
71-00-00
Page 513
Apr 11/08

CAUTION IF GROUND POWER SUPPLY IS USED, MAXIMUM CURRENT

IS TO BE LIMITED TO 1100 AMPS.
(b) Set EFCU mode switch ELECTRONIC
(c) Verify EFCU power ON and MANUAL mode light OFF.
(d) Verify maintenance indicator lamp-OFF.
(e) Set SYNC - OFF.
(f) Set generator -OFF (or NORMAL position if controlled by GCU).
(g) Set bleed air -OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Operating Limits Table above).
(h) Set power lever - SHUT OFF.
(2) Start engine as follows:
NOTE Follow starter manufacturers operational duty cycle limits.
(a) Set engine starter switch - ON.
(b) Set fuel boost pumps - ON.
CAUTION DO NOT TURN ON ENGINE IGNITION SWITCH UNTIL POSITIVE

HP (N2) ROTATION IS NOTED.
(c) Set ignition switch - ON.
NOTE If tailwind or crosswind component exceeds 5 knots, use 12%

N2 as minimum N2 speed prior to moving power lever to
start. A GPU may be required.
(d) At a minimum of 8% N2, move power lever to IDLE position.
(e) Monitor the ITT. ITT may not exceed the limits defined in Figure 504 Overtemperature
Limits (Starting).
CAUTION AT 25% N2, ENSURE POSITIVE N1 INDICATION. IF NO N1

INDICATION IS PRESENT, ABORT START.
(f) At 40% N2 or above, set starter - OFF.
NOTE Refer to starter-generator manufacturer for optimum starter cutout speed.
(g) Check oil pressure indication.
71-00-00
Page 514
Apr 11/08

CAUTION IF OIL PRESSURE IS OUTSIDE THE LIMITS DEFINED IN

TABLE 503, SHUT DOWN ENGINE.
(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
B. Shutting Down the Engine
(1) Set ignition switch - OFF.
(2) Set the power lever - IDLE.
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).
(4) Set power lever - SHUT OFF.
(5) Set fuel boost pumps - OFF
SUBTASK 71-00-00-700-005
C. Motoring the Engine
NOTE Starter damage may occur if motoring is prolonged. Consult starter/generator

manufacturers operational duty cycle limits for proper motoring time.
(4) Set engine starter switch - ON, for time duration as specified by starter/generator
manufacturers operation duty cycle limit.
(5) Set engine starter switch - OFF.
71-00-00
Page 515
Apr 11/08

9. MANUAL Mode Start Procedures
SUBTASK 71-00-00-700-050
A. MANUAL Mode: Engine Pre-Start
(1) Verify battery or ground power supply meets the starter/generator manufacturers requirements.
CAUTION IF GROUND POWER SUPPLY IS USED, MAXIMUM CURRENT

IS TO BE LIMITED TO 1100 AMPS.
(2) Set EFCU mode switch MANUAL.
(3) Verify MANUAL mode light ON.
(4) Set SYNC OFF
(5) Set generator OFF (or NORMAL position if controlled by GCU)
(6) Set bleed air OFF (or NORMAL position if controlled by bleed air extraction is within start
limits defined in Operating Limits Table.
B. MANUAL Mode: Engine Start
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.
2 Follow starter manufacturers operational duty cycle limits.
(1) Set engine starter switch ON.
(2) Set fuel boost pumps ON.
CAUTION DO NOT TURN ON ENGINE IGNITION SWITCH UNTIL POSITIVE

HP (N2) ROTATION IS NOTED.
(3) Set ignition switch - ON.
NOTE If tailwind or crosswind component exceeds 5 knots, use 12% N2 as minimum

N2 speed prior to moving power lever to start. A GPU may be required.
(4) At a minimum of 8% N2, move power lever to IDLE position.
(5) Monitor the ITT. ITT may not exceed the limits defined in Figure 504 Overtemperature Limits
(Starting)
71-00-00
Page 516
Apr 11/08

CAUTION AT 25% N2, ENSURE POSITIVE N1 INDICATION. IF NO NI

INDICATION, ABORT START.
(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.)
(8) Check oil pressure indication.
CAUTION IF OIL PRESSURE IS OUTSIDE THE LIMITS IDENTIFIED IN TABLE

TABLE 503, SHUT DOWN ENGINE.
(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.
NOTE If performing an Operational Check of the EFCU in the MANUAL

Mode, the following step is not applicable.
(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.
10. Abnormal Operating Procedures
SUBTASK 71-00-00-700-006
A. Ground Engine Fire/Fire Out of Tail pipe
(1) Determine engine affected.
(4) Set fuel supply - OFF.
(6) Set engine starter - ON, for the time duration as specified by starter/generator manufacturers
operation duty cycle limit.
(7) Set engine starter - OFF.
(8) Determine cause of fire.
71-00-00
Page 517
Apr 11/08

B. Procedure if the engine becomes too hot during ground run
CAUTION DO NOT USE THE FIRE EXTINGUISHING SYSTEM IN THE

AIRCRAFT IF YOU HAVE A WARNING INDICATION THAT THE
ENGINE IS TOO HOT INTERNALLY.
(1) Retard power lever until ITT is within allowable limits.
(2) Monitor ITT.
(3) Record ITT exceedance in engine log book.
(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:
(a) Close the power lever.

(b) Stop the engine.
(c) Find the cause. Refer to Troubleshooting, 71-00-00, P.B. 101.
D. MANUAL Mode Light ON.
CAUTION MAY REQUIRE ADDITIONAL PILOT ACTION TO REMOVE A MECHANICAL

STOP PRIOR TO ADVANCING PLA BEYOND TAKEOFF POSITION.
(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.
(2) When practical, attempt to restore ELECTRONIC mode.
(a) Reduce PLA below the takeoff position.
CAUTION DO NOT ATTEMPT TO RESTORE ELECTRONIC MODE WITH

PLA ABOVE THE TAKEOFF POSITION.
(b) Turn SYNC OFF.
(c) Verify ECU power is ON with circuit breaker IN.
(d) Verify ELECTRONIC mode is selected ON.
(e) If MANUAL light still ON, cycle ELECTRONIC/MANUAL mode switch to MANUAL, then
back to ELECTRONIC.
71-00-00
Page 518
Apr 11/08

CAUTION DURING MANUAL MODE OPERATION, IDLE SPEED MAY NEED TO

BE INCREASED TO PROVIDE ADEQUATE HP BLEED, GENERATOR
OUTPUT, ETC. IF INCREASED IDLE SPEEDS ARE REQUIRED BY
THE AIRCRAFT, THEY SHOULD BE SPECIFIED IN THE AIRCRAFT
FLIGHT MANUAL. ALSO NORMAL AUTOMATIC MAXIMUM
POWER SETTING, AUTOMATIC N1 OVERSPEED LIMITING, AND
AUTOMATIC ITT LIMITING ARE DISABLED.
(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.
E. Failure of Engine to Light.
(1) Whenever an engine fails to start within 10 seconds after moving the power lever to the
idle position:
(a) Set power lever - SHUT OFF.
(b) Set ignition switch - OFF.
(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.
(d) Allow N2 RPM to reach zero before attempting a restart.
F. No N1 Speed at 25% N2
(3) Set fuel boost pumps - OFF.
(4) Starter - OFF.
G. Low Oil Pressure After Start (outside limits in table 503)
(4) Starter - OFF.
(5) Refer to Troubleshooting, 71-00-00, P.B. 101.
H. EFCU Maintenance Indicator Lamp ON.
71-00-00
Page 519
Apr 11/08

(1) Refer to Troubleshooting. Any aircraft dispatchibility and/or flight duration limitations should
be specified in the Aircraft Flight Manual.
(2) If MANUAL mode light is ON, utilize MANUAL mode procedures.
(3) If MANUAL mode light is OFF, utilize ELECTRONIC mode procedures.
CAUTION EFCU OPERATING IN A DEGRADED MODE. AUTOMATIC ITT

LIMITING MAY BE DISABLED.
I. Hot Start
CAUTION DO NOT USE THE FIRE EXTINGUISHING SYSTEM IN THE

AIRCRAFT IF YOU HAVE A WARNING INDICATION THAT THE
ENGINE IS TOO HOT INTERNALLY.
(1) Set power lever - OFF.
(4) Motor engine as required.
(5) Refer to Figure 504 Overtemperature Limits (Starting) for corrective action.
TASK 71-00-00-760-810 Idle Speed and Leak Check Run
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.
2 Refer to General Operating Procedures, 71-00-00, P.B. 501, for

engine operation instructions.
SUBTASK 71-00-00-945-008
71-00-00
Page 520
Apr 11/08


71-00-00 843
73-10-01 401 Fuel Tube Assemblies - Removal/Installation
79-30-01 601 Magnetic Chip Collector - Inspection/Check
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.
E. Absorbent materials may not be used for the detection of leaks.
14. Job Set-up
SUBTASK 71-00-00-010-008
A. Position the aircraft into the wind.
B. Remove the cowling. Refer to the Aircraft Maintenance Manual.
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
C. Put the aircraft booster pumps on.
71-00-00
Page 521
Apr 11/08

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

JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE WHILE IT OPERATES.
MAKE SURE THAT THE HOODS ON PARKAS ARE NOT LOOSE.
CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE GROUND

CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF FOREIGN
OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR A DECREASED
PERFORMANCE OF THE ENGINE.
A. If maintenance has been performed on the fuel system or if fuel system has been preserved, purge
air from the fuel system.
(1) Disconnect the ignition circuit breakers.
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 BELOW WORK AREA TO CATCH DRIPPING FUEL.
TO PREVENT POSSIBLE FUEL SPRAY FROM PRESSURIZED FUEL

2 PRESERVATION OIL IS COMBUSTIBLE AND MUST BE KEPT FROM

OPEN FLAME OR EXCESSIVE HEAT. AVOID PROLONGED OR
REPEATED SKIN CONTACT WHICH MAY CAUSE SKIN IRRITATION.
REMOVE CONTAMINATED CLOTHING. WIPE MATERIAL FROM SKIN
AND WASH THOROUGHLY WITH SOAP AND WATER.
(2) Disconnect oil cooler-to-fuel manifold tube assembly.
(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.
71-00-00
Page 522
Apr 11/08

(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.
C. Check all external fuel and oil tubes for leaks.
D. Repair leaks as necessary.
NOTE Visually inspect all engine surfaces to make sure that they are clean and free
of fuel or oil residue prior to running. Clean surfaces as required.
E. Reconnect the ignition circuit breakers
F. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501 .
G. Run the engine at idle for at least two minutes
NOTE The OAT indicator reading must be within 3 C of actual airfield ambient temperature.
H. Observe N2 speed and OAT and compare to Figure 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.
71-00-00
Page 523
Apr 11/08

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.
P. Repeat steps I through R after corrective action.
Q. Inspect the magnetic chip collectors. Refer to 79-30-01, P.B. 601.
R. If there are no leaks, proceed to Job Close-up.
16. Job Close-up
SUBTASK 71-00-00-410-008
A. Install the cowling. Refer to the Aircraft Maintenance Manual.
TASK 71-00-00-760-814 Vibration Survey
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
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
Vibration Analyzer (ACES Model 1700, 4040, Or
Equivalent)
71-00-00
Page 524
Apr 11/08

SUBTASK 71-00-00-943-023
B. Special Tools
TL37253 Mount, Engine Vibration
SUBTASK 71-00-00-945-023
19. Job Set-up
SUBTASK 71-00-00-010-023
A. Install vibration measuring equipment
(1) Point the nose of the aircraft into the wind.
(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.
(4) Install vibration pick-up assembly to TL37253 vibration mount.
(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
A. Do the vibration survey
(1) Set generator - OFF.
(2) Set bleed air - OFF.
71-00-00
Page 525
Apr 11/08

WARNINGS: 1 MAKE SURE THAT PEOPLE AT WORK NEAR THE AIRCRAFT KNOW
OF THE AREAS THAT ARE DANGEROUS. THIS MAKES SURE THAT
PEOPLE ARE NOT KILLED OR BADLY INJURED.
2 MAKE SURE THAT PEOPLE DO NOT WEAR LOOSE CLOTHING

(COATS, JACKETS, CAPS, AND SCARVES) NEAR THE ENGINE
WHILE IT OPERATES. MAKE SURE THAT THE HOODS ON
PARKAS ARE NOT LOOSE.
CAUTION MAKE SURE THAT NO MATERIAL OR EQUIPMENT ON THE

GROUND CAN GO INTO THE ENGINE AIR INTAKE. INGESTION OF
FOREIGN OBJECTS CAUSES DAMAGE TO THE ENGINE AND/OR
A DECREASED PERFORMANCE OF THE ENGINE.
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
(4) Let the engine stabilize at idle for two minutes.
(5) Refer 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.
(7) Hold the engine at takeoff speed for a minimum of 2 minutes.
(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.
21. Job Close-up
SUBTASK 71-00-00-410-023
A. Remove the vibration measuring equipment
71-00-00
Page 526
Apr 11/08

(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.
TASK 71-00-00-760-825 Trim Balance Procedures
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
CAUTION TRIM BALANCE PROCEDURES ARE ONLY USED IF LP VIBRATION LEVELS

EXCEED LIMITS (HIGH VIBRATION WITH OR WITHOUT NOISE).
NOTE The following are the two methods for trim balancing:
The Vector Subtraction Method: This is the initial method used for trim balancing.
The 3-Weight Method: This is the second method used, if further reduction of
1E LP is required. This method may also be used if phase information (from
the ACES Analyzer) is not available.
SUBTASK 71-00-00-941-020
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
71-00-00
Page 527
Apr 11/08

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
72-00-30 401 Spinner - Removal/Installation
24. Procedures
SUBTASK 71-00-00-760-030
A. Install test equipment.
(1) Install accelerometer (radial UOMP) radially at the upper outboard mount pad (UOMP)
location. Additional accelerometers and/or microphones may be installed as required to
monitor engine response.
CAUTION THE SENSOR MUST BE ATTACHED SO THAT INGESTION

DURING TESTING WILL BE AVOIDED.
(2) Hook up the vibration analyzer (ACES Model 1700 or equivalent), accelerometer mounting
bracket, cabling (between accelerometers and analyzers) and N1 speed light sensor.
B. Setup Procedures:
71-00-00
Page 528
Apr 11/08

(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.
C. Trim Balance Testing by Vector Subtraction Method
NOTE If testing is performed on an aircraft, the engine not being balanced

is to be OFF or at idle.
(1) Initial Run
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
then a 1 minute dwell at T.O. After the 1 minute dwell at T.O., take initial run data. Record
1E amplitude and phase from the ACES analyzer. Perform a slow decel to idle.
(b) Shutdown engine per General Operating Procedures 71-00-00 P.B. 501, and examine
fan tip shroud for new tip rubs.
(2) Trial Weight Location
NOTE Weight(s) are setscrews, available in various sizes and weights, ranging
from 0.0442 ounces (1.25 grams) to 0.1500 ounces (4.25 grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(a) Remove the spinner and install 1 trim weight in the first hole CW (aft looking forward)
from the 0 degree reference mark. Screw in approximately 1/8 to inch below flush.
NOTE For longer trim balance screws, it is acceptable for the screw to stand
proud of the surface, as long as it is bottomed in the hole.
(b) Reinstall spinner to baseline position. Refer to 72-00-30, P.B. 401 for spinner installation.
(3) Second Run
(a) After a 2 minute (min.) warm-up at idle, perform a slow accel from idle to Takeoff power,
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
71-00-00
Page 529
Apr 11/08

(4) Vector Plotting/Subtraction Procedures
(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.
(5) Third Run
(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,
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
(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.
(6) Fourth Run
(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,
1E amplitude and phase from the ACES analyzer or equivalent. Perform a slow decel to
idle. Shutdown engine per General Operating Procedures, 71-00-00 P.B. 501.
CAUTION TRIM BALANCING IS DONE TO REDUCE VIBRATIONS AT ONE

SPECIFIC SPEED DURING THE SLOW TRANSIENT ACCELERATION.
CAUTION MUST BE USED TO ENSURE THAT VIBRATION LEVELS (AT
SPEEDS OTHER THAN THE ONE OF ORIGINAL INTEREST) DO NOT
INCREASE BEYOND LIMITS AS A RESULT OF THE TRIM BALANCING.
(c) If this method, (Trim Balance Testing by Vector Subtraction Method), results in vibration
levels that are not sufficiently reduced, do the following:
1 Verify lowest vibration levels (at the speed of interest) were obtained during the
final run.
2 Verify vibrations (at other speeds) were not reached or exceeded the limit.
71-00-00
Page 530
Apr 11/08

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.
D. Trim Balance Testing by 3-Weight Method
NOTE Weight(s) are setscrews, available in various sizes and weights (grams). They
are installed using MAT-096. If the weight(s) are moved to new location(s),
clean off the uncured adhesive from the hole and weight.
(1) Perform an initial run per step C(3). Only the 1E amplitude is needed.
(a) Baseline Weight Location: If this effort is a follow-on to the Vector Subtraction Method,
then the fourth run (of the vector subtraction method) will be the 1st weight run and the
initial run, step C(3) is the initial.
(2) First Weight Location: Put trial weight in any hole.
(3) Weight Rotation:
(a) Relocate trim weight 120 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power
(over a 90 second time frame), 1 minute dwell at T.O., followed by a slow decel to
idle (over 90 seconds).
(4) Shut down and examine fan tip shroud for new tip rubs.
(5) Weight Rotation:
(a) Relocate trim weight to 240 degrees CW (aft looking forward) from step (2) above.
(b) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power
(c) Shutdown and examine fan tip shroud for new tip rubs.
(6) Final Trim Weight Rotation:
(a) Reduce data. Refer to Figure 514 Reducing Data for Final Trim Weight Rotation.
(b) Install trim weight at optimum calculated clock angle.
71-00-00
Page 531
Apr 11/08

(c) Repeat the 2 minute (min.) warm-up at idle, slow accel from idle to Takeoff power
(d) Shutdown and examine fan tip shroud for new tip rubs.
(7) Reduce data to quantify change in 1E LP vibration.
CAUTION TRIM BALANCING IS DONE TO REDUCE VIBRATIONS AT ONE SPECIFIC

SPEED DURING THE SLOW TRANSIENT ACCELERATION. CAUTION
MUST BE USED TO ENSURE THAT VIBRATION LEVELS (AT SPEEDS
OTHER THAN THE ONE OF ORIGINAL INTEREST) DO NOT INCREASE
BEYOND LIMITS AS A RESULT OF THE TRIM BALANCING.
(8) If this method, (Trim Balance Testing by 3-Weight Method), results in vibration levels that are
not sufficiently reduced, do the following:
(a) Verify lowest vibration levels (at the speed of interest) were obtained during the final run.
(b) Verify vibrations (at other speeds) were not reached or exceeded the limit.
(9) If above verifications apply, one additional weight may be used in the location adjacent to the
weight that is already installed. The procedures must be repeated to verify that vibration levels
at all speeds are satisfactory. No more than two weights may be used.
TASK 71-00-00-760-818 Stability/Acceleration Check
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)
71-00-00
Page 532
Apr 11/08

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
SUBTASK 71-00-00-945-003
05-20-00 601 Scheduled Maintenance Checks - Inspection/Check
27. Job Set-up
SUBTASK 71-00-00-010-003
A. Point the nose of the aircraft into the wind.
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.
B. Set generator - ON and configure aircraft for normal load extraction.
C. Set normal bleed - ON.
71-00-00
Page 533
Apr 11/08



D. Start the engine. Refer to General Operating Procedures, Task 71-00-00, P.B. 501.
CAUTION IF DURING TEST, ANY OF THE FOLLOWING WARNING LIGHTS ILLUMINATE,

REFER TO THE ABNORMAL PROCEDURES SECTION OF THE AIRCRAFT
MANUAL: (1) ANTI-ICE (WING); (2) AIR DUCT OVERHEAT; (3) BLEED
AIR OVERHEAT; (4) WINDSHIELD AIR OVERHEAT.
E. Run the engine at idle for at least two minutes.
NOTE Visual check of the acceleration bleed system is required. Refer to

TEST LIST, 71-00-00, P.B. 501 .
F. Accel engine 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.
K. Perform intermediate-idle snap decel checks as follows:
71-00-00
Page 534
Apr 11/08

(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.
(7) Slowly advance the power lever position from IDLE to 68% N2 and maintain this position for a
minimum of 30 seconds.
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.
CAUTION TO PREVENT DAMAGE TO THE ENGINE, STEP H MUST BE COMPLETED

SUCCESSFULLY PRIOR TO PERFORMING THE ACCELERATION
TIME TEST IN THE NEXT STEP.
M. Perform ELECTRONIC Mode acceleration time check as follows:
(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.
71-00-00
Page 535
Apr 11/08

(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.
N. Return PLA to the idle position.
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
Q. EFCU Operational Check of MANUAL Mode:
(2) Set generator OFF.
(3) Set normal bleed OFF.
(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.
CAUTION TO PREVENT DAMAGE TO ENGINE, DO NOT EXCEED TAKEOFF

N1 SPEED AS DETERMINED FROM THE FIGURE.
(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.
71-00-00
Page 536
Apr 11/08

(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.
CAUTION DO NOT ATTEMPT TO RESTORE ELECTRONIC MODE WITH

PLA ABOVE THE TAKEOFF POSITION.
(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%.
(9) Perform Job Close-up below.
29. Job Close-up
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.
TASK 71-00-00-760-823 Performance Check
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 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)
71-00-00
Page 537
Apr 11/08


SUBTASK 71-00-00-942-014
A. Consumables
MAT-021 R-MC Cleaner
SUBTASK 71-00-00-945-014
72-31-20 801 Fan Rotor - Repair
32. Job Set-up
SUBTASK 71-00-00-010-014
A. Remove the cowling. Refer to the Aircraft Maintenance Manual.
33. Procedures
SUBTASK 71-00-00-760-023
A. Inspect the fan rotor and the bypass area as follows:
(1) Make sure the fan rotor is clean. Clean as required using MAT-021.
(2) Inspect fan rotor for damage and repair as required. Refer to 72-31-20, P.B. 801.
(3) Visually inspect bypass area for debris or other blockage. Remove any blockage.
B. 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.
C. Point the nose of the aircraft into the wind.
71-00-00
Page 538
Apr 11/08

D. Set generator - OFF.
E. Set bleed air - OFF.


F. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
G. Run the engine at idle for at least two minutes.
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.
71-00-00
Page 539
Apr 11/08

M. Move power lever to IDLE position.
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.
34. Job Close-up
SUBTASK 71-00-00-410-014
A. Install the engine cowling. Refer to the Aircraft Maintenance Manual.
TASK 71-00-00-760-827 Oil Consumption Check
35. General
This task monitors and calculates oil consumption. You must do this test as required by Troubleshooting,
71-00-00 P.B. 101.
NOTE Refer to General Operating Procedures, 71-00-00 P.B. 501 , for

SUBTASK 71-00-00-942-011
A. Consumables
MAT-001 Oil, Engine
SUBTASK 71-00-00-945-011
72-00-03 301 Engine Servicing - Oil Changing/Replenishing - Servicing
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.


B. Start the engine and run for five minutes at idle to warm oil. Refer to General Operating Procedures,
71-00-00 P.B. 501.
C. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
D. Check and carefully record the oil level.
NOTE Carefully time engine run time in decimal hours. This information will
be used to calculate oil consumption.
E. Start the engine and run for a minimum of one hour at 85 to 90% N2. Refer to General Operating
Procedures, 71-00-00 P.B. 501. Engine run can be performed on the ground or in flight.
F. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00 P.B. 501.
G. Carefully check the oil level while still warm. Add small measured amounts of oil, and continue
checking level, until oil is at the original recorded level. Record amount of oil added (used).
H. Calculate oil consumption as follows:
(1) Convert recorded amount of oil used to gallons. Use one of the following conversion factors, as
required:
(a) To convert quarts to gallons, multiply by 0.25.
(b) To convert fluid ounces to gallons, multipy by 0.0078.
(c) To convert cubic inches to gallons, multiply by 0.0043.
71-00-00
Page 541
Apr 11/08

(d) To convert liters to gallons, multiply by 0.264
(e) To convert milliliters to gallons, multiply by 0.000264.
(2) Divide gallons of oil used by engine run time (decimal hours). This is oil consumption in
gallons per hour.
SUBTASK 71-00-00-760-021
I. The maximum allowable limit for oil consumption is 0.023 gallons (or 2.94 ounces) per hour. If oil
consumption exceeds this limit, reject engine.
TASK 71-00-00-760-826 High Power Check
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
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)

SUBTASK 71-00-00-945-006
40. Job Set-up
SUBTASK 71-00-00-010-006
A. Remove the engine cowling. Refer to the Aircraft Maintenance Manual.
B. Point the nose of the aircraft into the wind.
71-00-00
Page 542
Apr 11/08

41. Procedures
SUBTASK 71-00-00-760-004
A. Set generator - OFF.
B. Set bleed air - OFF.


NOTE For FJ44-2C, references to idle mean ground idle.
C. Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
D. Run the engine at idle for at least two minutes.
E. Observe N2 speed and outside air temperature (OAT) and compare to Figure 508 Idle N2 Speed
Check (Electronic Mode).
(1) Idle speed:
NOTE Note that idle speed varies with temperature.
(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.
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.
J. Move power lever to IDLE position.
K. Shut-Down the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
NOTE If the engine did not perform within allowable limits at take-off power, remove the
HP bleed tubes and repeat the ground-run test with the bleed ports capped. If
engine performs within limits with bleed ports capped, troubleshoot aircraft bleed
system in accordance with the Aircraft Maintenance Manual.
42. Job Close-up
SUBTASK 71-00-00-410-006
A. Install the engine cowling. Refer to the Aircraft Maintenance Manual.
TASK 71-00-00-760-828 Capped Bleed Run
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
45. Job Set-up
SUBTASK 71-00-00-010-005
A. To prepare engine for test, remove the cowling. Refer to the Aircraft Maintenance Manual.
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.
B. Perform baseline ground run. Use Figure 520 .
(2) Set generator - OFF.
WARNINGS: 1 ENSURE PEOPLE WORKING NEAR AIRCRAFT ARE AWARE

OF DANGEROUS AREAS. THIS PRECAUTION IS TO PREVENT
LOSS OF LIFE OR SERIOUS INJURY.
2 ENSURE PEOPLE DO NOT WEAR LOOSE CLOTHING (COATS,

JACKETS, CAPS, AND SCARVES) WHILE ENGINE IS OPERATING.
ENSURE HOODS ON PARKAS ARE NOT LOOSE.
CAUTION ENSURE NO MATERIAL OR EQUIPMENT ON THE GROUND CAN GO INTO

THE ENGINE AIR INTAKE. INGESTION OF FOREIGN OBJECTS CAUSES
DAMAGE TO ENGINE AND/OR A DECREASED PERFORMANCE.
(3) Start the engine. Refer to General Operating Procedures, 71-00-00, P.B. 501.
(4) Let the engine stabilize at idle for two minutes.
(5) Determine the takeoff thrust N1 speed setting.
NOTE Make sure that atmospheric conditions are measured at the time
of test and are recorded accurately.
(6) (FOR FJ44-2A ONLY) If in manual mode, determine the takeoff thrust N1 speed setting.
(7) Take data as shown on Figure 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.
(9) Send data recorded on Figure 520 to Williams International.
71-00-00
Page 545
Apr 11/08

47. Job Close-up
SUBTASK 71-00-00-410-005
A. Remove HP bleed caps and reconnect aircraft bleed plumbing. Refer to aircraft Maintenance Manual.
B. Install cowling. Refer to Aircraft Maintenance Manual.
71-00-00
Page 546
Apr 11/08

Fig. 501 Danger Areas During Ground Run
71-00-00
Page 547
Apr 11/08

Fig. 502 Nominal Oil Pressure Operating Band
71-00-00
Page 548
Apr 11/08

Fig. 503 Overtemperature Limits (Except Starting)
71-00-00
Page 549
Apr 11/08

Fig. 504 Overtemperature Limits (Starting)
71-00-00
Page 550
Apr 11/08

Fig. 505 N2 Overspeed Limits
71-00-00
Page 551
Apr 11/08

Fig. 506 N1 Overspeed Limits
71-00-00
Page 552
Apr 11/08

Fig. 507 FJ44-2A Start Envelope MANUAL Mode (Estimated)
71-00-00
Page 553
Apr 11/08

Fig. 508 Idle N2 Speed Check (Electronic Mode)
71-00-00
Page 554
Apr 11/08

Fig. 509 N1 Speeds for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
71-00-00
Page 555
Apr 11/08

Fig. 510 Vibration Accelerometers - Removal/Installation
71-00-00
Page 556
Apr 11/08

Fig. 511 Reflective Tape Placement
71-00-00
Page 557
Apr 11/08

Fig. 512 Trim Balance by Vector Subtraction - Sample Plot
71-00-00
Page 558
Apr 11/08

Fig. 513 Trim Balance by Vector Subtraction - Sample Plot Procedure

71-00-00
Page 559
Apr 11/08

Fig. 514 Reducing Data for Final Trim Weight Rotation
71-00-00
Page 560
Apr 11/08

Fig. 515 Accel Time Limits - Electronic Mode - WOW Enabled (GRD Idle to 98% T.O. N1)
71-00-00
Page 561
Apr 11/08

Fig. 516 Accel Time Limits - Electronic Mode - WOW Disabled (Flt Idle to 98% T.O. N1)
71-00-00
Page 562
Apr 11/08

Fig. 517 Accel Time Limits - Manual Mode - (Idle PLA to 96% T.O. N1)
71-00-00
Page 563
Apr 11/08

Fig. 518 ITT Limits for Ground Checks at Takeoff Thrust (Electronic Mode)
71-00-00
Page 564
Apr 11/08

Fig. 519 N2 Speed Limits for Ground Checks at Takeoff Thrust Settings (Electronic Mode)
71-00-00
Page 565
Apr 11/08

Fig. 520 FJ44 Ground Power Chart
71-00-00
Page 566
Apr 11/08

Fig. 521 FJ44 Climb/Cruise Power Chart
71-00-00
Page 567
Apr 11/08

71-00-00
568
Page
Blank
POWER PLANT CLEANING - CLEANING
TASK 71-00-03-170-801 Clean the Power Plant Desalinization Rinse
1. General
This task provides procedures to clean the power plant with fresh water. Perform this task to remove salt
and other corrosive substances from the engine.
Figure 701 Location of Cleaning Areas
NOTE Perform engine cleaning at intervals recommended in Recommended

Maintenance, 05-50-00, P.B. 201.
SUBTASK 71-00-03-941-001
Pressure Washer Spray Equipment (50 To 100 Psi)
SUBTASK 71-00-03-945-001
05-50-00 201 Recommended Maintenance - Maintenance Practices
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.
71-00-03
Page 701
Apr 11/08

(2) Set engine bleed air OFF/CLOSED.
(3) Set ignition OFF.
NOTE To ensure that fluid reaches the engine core, initial spray cleaning should
be performed with the engine static (not running). Rotation of the fan
(LP spool) forces the flow outwards into the bypass area.
CAUTION TO PREVENT DAMAGE TO FAN, KEEP THE END OF THE

NOZZLE OUTSIDE OF THE INLET LIP.
(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.
WARNING TO PREVENT INJURY OR DAMAGE, MAKE SURE THAT

PEOPLE AND EQUIPMENT ARE CLEAR OF THE FAN BLADES
DURING STARTER CRANKING
(5) Have a second person starter-crank the engine in accordance with the duty cycle limits for
the starter-generator in the Aircraft Maintenance Manual. As soon as the fan starts to rotate,
spray 2.5 to 3.5 gallons of clean water into the engine core flowpath. Direct the spray at a
30 degree angle relative to the axial engine center line, in the same direction as the rotor
rotation. Hold the spray nozzle at the appropriate radius to enter the core Figure 702 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.
(6) Repeat starter-crank rinse (one time).
(7) Perform Post-Desalinization Engine Ground Run in accordance with the subtask that follows.
SUBTASK 71-00-03-170-003
B. Post-Desalinization Engine Ground Run
71-00-03
Page 702
Apr 11/08

NOTE Please reference the Aircraft Maintenance Manual (AMM) for

post-desalinization engine run procedures. Operate engine in accordance
with General Operating Procedures,71-00-00, P.B. 501. Shut down engine.
If the AMM does not contain post-desalinization engine run procedures,
run the engine in accordance with the following step.
(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,
TASK 71-00-03-170-803 Clean the Power Plant Compressor Wash
4. General
This task provides procedures to clean the power plant using an approved cleaning fluid. The compressor
wash procedure removes dirt and grime from the gas path to improve compressor efficiency.
Figure 703 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.
2 Perform engine cleaning at intervals recommended in Recommended

Maintenance, 05-50-00, P.B. 201.
SUBTASK 71-00-03-941-001
Air Compressor
Pressure Washer Spray Equipment (50 To 100 Psi)
SUBTASK 71-00-03-942-001
B. Consumables
MAT-021 R-MC Cleaner
MAT-029 Cleaner, Compressor
MAT-031 Cleaner, Gas Path
71-00-03
Page 703
Apr 11/08

SUBTASK 71-00-03-943-001
C. Special Tools
TL99920 Nozzle, Wash, HP Compressor
TL99926 Can, Pressure
SUBTASK 71-00-03-945-001
05-50-00 201 Recommended Maintenance - Maintenance Practices
6. Job Set-up
SUBTASK 71-00-03-010-001
A. Remove the engine cowling. Refer to the Aircraft Maintenance Manual.
7. Procedures
SUBTASK 71-00-03-170-002
A. Prepare the Engine for Compressor Wash:
CAUTION TO ENSURE THAT CLEANING FLUIDS DO NOT ENTER FCU/FDU

OR AIRCRAFT BLEED SYSTEM, REMOVE CDP LINE FROM
FCU ELBOW (IF ENGINE CONFIGURATION HAS A CDP LINE).
SET AIRCRAFT BLEED OFF/CLOSED.
(1) Set engine bleed air OFF/CLOSED.
(2) Set ignition OFF.
(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.
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 .
B. Wash the Fan and Bypass Area:
WARNING SPINNER TIP IS EXTREMELY SHARP. COVER THE TIP DURING

MAINTENANCE TO PREVENT INJURY.
NOTE If cleaning fluid is purchased as concentrate, mix it per

manufacturers instructions.
(1) With engine shut down, wipe readily accessible inlet area, spinner, and fan blades free of all
dirt and grime using a cloth wetted with 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).
C. Wash the Compressor Core:
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).
(5) Set Ignition OFF.

(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

(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).
D. Prepare the Engine for Ground Run
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,
8. Job Close-up
SUBTASK 71-00-03-410-001
A. Install engine cowling. Refer to Aircraft Maintenance Manual.
71-00-03
Page 707
Apr 11/08

Fig. 701 Location of Cleaning Areas
71-00-03
Page 708
Apr 11/08

Fig. 702 Location of Cleaning Areas
71-00-03
Page 709
Apr 11/08

Fig. 703 Removal of Borescope Plug/IP Bleed Port
71-00-03
Page 710
Apr 11/08

PRESERVING UNINSTALLED ENGINE - MAINTENANCE PRACTICES
TASK 71-00-21-620-801 Uninstalled Engine Preservation
1. General
This task provides procedures for the storage of an engine for nine months or more. The engine must be
preserved. Refer to the following illustration(s):
Figure 201 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
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-21-943-001
B. Special Tools
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)
71-00-21
Page 201
Apr 11/08

71-00-25 01 40 Closure (2)

71-00-25 01 50 Closure (2)
71-00-25 01 60 Closure (2)
71-00-25 01 65 Closure (2)
71-00-25 01 70 Tag, Caution Ident
71-00-25 01 80 Exhaust Closure
71-00-25 01 80 Liner
71-00-25 01 90 Tag, Caution Ident
71-00-25 01 100 Cloth Bag
71-00-25 01 110 Plug with O-ring
71-00-25 01 120 Closure (2)
71-00-25 01 130 Plug with O-ring
71-00-25 01 140 Tag, Caution (Fuel System)
71-00-25 01 150 Shipping Cover, Hyd Pump Pad
71-00-25 01 160 Nut, Wing
71-00-25 01 165 Plug, Threaded (For FJ44-1A only)
71-00-25 01 170 Shipping Cover, Generator/Starter Pad
71-00-25 01 180 Nut, Wing
SUBTASK 71-00-21-945-001
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
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
WARNING HANGING LOADS COULD KILL OR INJURE YOU. BE EXTREMELY CAREFUL

AROUND HANGING LOADS AND OVERHEAD EQUIPMENT.
B. Remove the engine using engine lifting sling, 08-0119-8000. Refer to Aircraft Maintenance Manual.
4. Procedures
SUBTASK 71-00-21-620-003
A. Drain oil system as follows:
(1) With the engine hanging from lifting sling (08-0119-8000) or installed in engine maintenance
stand (08-2021-0000), drain the engine oil. Refer to 72-00-03, P.B 301.
(2) Tag the engine "NO OIL INSTALLED".
NOTE Residual engine oil is sufficient to preserve the oil system.
SUBTASK 71-00-21-620-005
B. Perform the following steps to preserve the engine:
(1) Install all closures on the engine.
(2) If engine is on a sling, remove the eight plugs which are located on the engine mount pads of
the interstage housing. 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.
(5) Insert three desiccant bags MAT-175 around engine.
(6) Heat seal the top edge of the barrier bag. Cut a small opening along the seam and vacuum the
air from the bag until it is drawn snugly around the engine. Reseal the bag.
(7) To install engine into an engine build stand to store the engine, refer to 71-00-00, P.B 401. To
install engine into a shipping/storage container to store the engine, refer to 71-00-25, P.B. 201.
71-00-21
Page 203
Apr 11/08

Fig. 201 Engine Setup for Preservation
71-00-21
Page 204
Apr 11/08

Fig. 202 Location of Closures
71-00-21
Page 205
Apr 11/08

71-00-21
206
Page
Blank
PRESERVING INSTALLED ENGINE FOR NINE MONTHS OR MORE - MAINTENANCE PRACTICES
TASK 71-00-22-620-802 Installed Engine Preservation - More than Nine Months
1. General
This task provides procedures for preserving an installed engine for more than nine months. Refer
Figure 201 Engine Setup for Preservation
NOTES: 1 Before preserving, clean the power plant externally (installed or

uninstalled). Refer to 71-00-03, 701.
2 Engines stored more than nine months require periodic inspection.

Refer to 71-00-24, 201.
SUBTASK 71-00-22-942-002
A. Consumables
MAT-002 Oil, Preservative
SUBTASK 71-00-22-945-002
71-00-24 201 Storage Inspection - Maintenance Practices
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
A. Preserve the engines fuel system as follows:
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.
CLEANED BEFORE BEING WORN. A CONTAINER SHOULD BE PLACED
UNDERNEATH WORK AREA TO CATCH DRIPPING FUEL.
(1) Turn off fuel supply to engine.
(2) Disconnect the 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.
(7) Turn off engine ignition system.
CAUTION STAY WITHIN THE STARTER/GENERATOR DUTY CYCLE LIMITS

WHEN MOTORING THE ENGINE.
(8) Adjust the power lever to idle.
(9) Motor the engine to 10% N2 speed (approx. 4000 rpm).
WARNING PRESERVATION OIL IS COMBUSTIBLE AND MUST BE KEPT FROM

OPEN FLAME OR EXCESSIVE HEAT. AVOID PROLONGED OR
REPEATED SKIN CONTACT WHICH MAY CAUSE SKIN IRRITATION.
REMOVE CONTAMINATED CLOTHING. WIPE MATERIAL FROM SKIN
AND WASH THOROUGHLY WITH SOAP AND WATER.
(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.
(13) Let all residual oil drain from the system.
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
(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
B. Drain oil system as follows:
(1) Drain the engine oil. Refer to 72-00-03, P.B. 301.
SUBTASK 71-00-22-620-006
C. Perform the final protective procedures as follows:
(1) Secure a warning tag to the aircraft controls to indicate the engine has been preserved and it
should not be operated.
(2) Install closures to the aircraft inlet and exhaust areas.
71-00-22
Page 203
Apr 11/08

Fig. 201 Engine Setup for Preservation
71-00-22
Page 204
Apr 11/08

PRESERVING INSTALLED ENGINE FOR NINE MONTHS OR LESS - MAINTENANCE PRACTICES
TASK 71-00-23-620-804 Installed Engine Preservation - Nine Months or Less
1. General
This task provides procedures for preserving an installed engine for nine months or less. Refer to the
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
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.
A. Turn off fuel supply to the engine.
B. Inspect engine to ensure the inlet area is clean and dry.
C. Install all closures on the engine.
71-00-23
Page 201
Apr 11/08

71-00-23
Page 202
Apr 11/08

STORAGE INSPECTION - MAINTENANCE PRACTICES
TASK 71-00-24-550-801 Storage Inspection
1. General
Engines which have been preserved must be inspected periodically for signs of corrosion or deterioration
of preservation materials.
SUBTASK 71-00-24-942-001
A. Consumables
MAT-175 Bag, Desiccant
MAT-176 Bag, Barrier
SUBTASK 71-00-24-945-001
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.
71-00-24
Page 201
Apr 11/08

71-00-24
202
Page
Blank
ENGINE SHIPPING/RECEIVING - MAINTENANCE PRACTICES
TASK 71-00-25-510-803 Engine Shipping
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 203 Installation of Engine in Container
Figure 204 Container Ready to Ship
SUBTASK 71-00-25-943-005
A. Special Tools
SUBTASK 71-00-25-510-006
B. Parts Required
Refer to table of shipping preparation caps and plugs
SUBTASK 71-00-25-945-005
3. Procedures
SUBTASK 71-00-25-620-005
A. Drain oil system as follows:
B. If needed, the engine may be wiped clean using a general wet cleaner (MAT-202) and a lint free
cloth (MAT-071).
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:
CAUTION TO PREVENT DAMAGE TO THE ENGINE, MAKE SURE ALL SCREWS,

NUTS, WASHERS ON EACH SIDE ARE INSTALLED. A MISSING ITEM CAN
CAUSE THE ENGINE TO SHIFT, CAUSING SEVERE DAMAGE.
NOTE Make sure that SAE grade 5 bolts are used when assembling
the shipping container.
(1) 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).
(2) Install all caps and plugs on the engine.

Shipping Preparation Caps and Plugs
Location Qty Description Size/Dimensions
EFCU Harness, Airframe 1 Plastic Cap, Un-Threaded 1.625 ID x 1.5 long
Connector
EFCU Harness, TT2 1 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Connector
Fuel Control Unit, Motive 1 Plug, Threaded -6 size
Flow Port
Fuel Control Unit, Motive 1 O-Ring MIL-R-83248/1906
Flow Port
Fuel Filter Delta P 1 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Indicator Connector
Drain Port, Rear Bypass 1 Cap, Threaded -4 size
Duct
Front Bypass Duct, Fuel 1 Cap, Threaded -4 size
Drain Fitting
Fuel Pump, Fuel Inlet 1 Plug, Threaded -8 size
Fuel Pump, Fuel Inlet 1 O-Ring MIL-R-83248/1908
Fuel Pump/FDU, Drain 1 Cap, Threaded -4 size
Port
71-00-25
Page 202
Apr 11/08

Gearbox, Hydraulic 1 Plexi-Glass Cover WI P/N 50727

Pump
Gearbox, Hydraulic 4 Nut, Hydraulic Pump Studs 1/4-28 Hex Nut
Pump
Gearbox, Oil Pressure 1 Plug, Threaded -4 size
Port
Gearbox, Oil Pressure 1 O-Ring MIL-R-83248/1904
Port
Gearbox, Oil 1 Plug, Threaded 1/2-20 thread
Temperature Port
Gearbox, Oil 1 O-Ring MIL-R-83248/1905
Temperature Port
Gearbox, 1 Plexi-Glass Cover WI P/N 50728
Starter/Generator
Gearbox, 4 Nut, Starter/Gen Studs 5/16-24 Hex Nut
Starter/Generator
HP Bleed Port 2 Flange Cover, Soft Plastic 2.0 ID
Ignition Exciter, 2 Plastic Cap, Un-Threaded 0.625 ID x 0.75 long
Connector
Inlet/Exhaust Opening 2 Plastic Drum Liner 10 mil, 37 x 40 x 74 circum
Inlet/Exhaust Opening 2 Large Rubber Band 14 x .25 x .125
Oil Level Sensor 1 Plastic Cap, Un-threaded 0.625 ID x 0.75 long
Connector
TT2 Sensor Connector 1 Plastic Cap, Un-Threaded 0.750 ID x 2.25 long
(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).
D. ECU Shipping Methods
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
E. Install the engine into the shipping container as follows:
CAUTION TO PREVENT DAMAGE TO THE ENGINE, MAKE SURE ALL SCREWS,

NUTS, WASHERS ON EACH SIDE ARE INSTALLED. A MISSING ITEM CAN
CAUSE THE ENGINE TO SHIFT, CAUSING SEVERE DAMAGE.
(1) Lower the engine into the container and secure it to the engine shipping mount supports using
four 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.
(4) Tape log book to inside of container
(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).
TASK 71-00-25-520-801 Engine Receiving
4. General
This task provides procedures for receiving the engine. Refer to the following illustration(s):
Figure 203 Installation of Engine in Container
Figure 204 Container Ready to Ship
SUBTASK 71-00-25-943-001
A. Special Tools
71-00-25
Page 204
Apr 11/08

SUBTASK 71-00-25-945-001
6. Procedures
SUBTASK 71-00-25-520-001
A. Prepare to remove the engine from the shipping/storage container as follows:
NOTE Two people are required for the following procedure.
(1) Remove the container lid by removing the steel strapping and the edge protectors.
(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.

(6) Raise engine until clear of container.
(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.
(11) Place the lid on the container.
SUBTASK 71-00-25-520-002
B. Perform an acceptance check of the engine and container as follows:
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
C. If required, service oil system . Refer to 72-00-03, P.B. 301.
71-00-25
Page 206
Apr 11/08

Fig. 201 Assemble Engine Shipping Mounts and Supports
71-00-25
Page 207
Apr 11/08

71-00-25
Page 208
Apr 11/08

Fig. 203 Installation of Engine in Container
71-00-25
Page 209
Apr 11/08

Fig. 204 Container Ready to Ship
71-00-25
Page 210
Apr 11/08

ENGINE DEPRESERVATION - MAINTENANCE PRACTICES
TASK 71-00-26-630-801 Depreserve the Engine
1. General
This task provides procedures for depreserving the engine.
NOTE Engine should be in a condition suitable for motoring with systems connected
and engine accessories installed.
SUBTASK 71-00-26-945-001
3. Procedures
SUBTASK 71-00-26-630-001
A. Depreservation/purging of the engine fuel system is performed during ground run after engine
installation. Refer to 71-00-00, P.B. 501, Idle Speed and Leak Check Run.
SUBTASK 71-00-26-630-002
B. As required, replenish the oil system. Refer to 72-00-03, P.B. 301.
71-00-26
Page 201
Apr 11/08

71-00-26
202
Page
Blank
IP AND HP COMPRESSORS (BORESCOPE) - INSPECTION/CHECK
TASK 71-00-30-220-802 Inspect the HP and IP Compressors with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the HP and IP compressor sections
and the diffuser inlet vanes. Refer to the following illustration(s):
Figure 601 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
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
Flexible, Steerable Fiberscope, 6mm Dia X 50 Inch
Long
SUBTASK 71-00-30-943-002
B. Special Tools
TL37244 Tool, Engine Rotation
SUBTASK 71-00-30-944-002
C. Expendable Parts
71-00-30
Page 601
Apr 11/08

IPC Reference
75-35-01 02 131 O-ring
3. Job Set-up
SUBTASK 71-00-30-010-002
A. Make the engine ready for inspection
(2) Open the aircraft circuit breakers to isolate the engine electrical supply.
(4) Remove the starter/generator. Refer to the Aircraft Maintenance Manual.
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:
(a) Foreign object damage (FOD) Reject
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:
(a) FOD Reject
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.
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:
(a) FOD Reject
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.
NOTE The HP compressor is in the same flowpath downstream of the IP compressor.
(1) Adjust the flexible fiberscope so that it points aft, toward the HP compressor.
NOTE A second person is required to turn the HP rotary assembly

during borescope inspection.
(2) Rotate the HP rotary group for inspection as follows:
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox. Refer to
Figure 605 Engine Rotation Tool
(b) Slowly turn the tool clockwise. This will rotate the HP rotary assembly for inspection.
(3) Inspect the following areas of the HP compressor rotor:
(a) Blade roots (qty 32)
(b) Main blade (area D) leading edges (qty 8)
(c) Long splitter vanes (area E) leading edges (qty 8)
(d) Short splitter vanes (area F) leading edges (qty 16)
(4) Inspect HP compressor rotor as follows:
(a) Cracks or FOD Reject
(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:
(a) FOD Reject
(b) Buildup of material on vanes Reject
CAUTION TO PREVENT DAMAGE TO BORESCOPE OR ENGINE, ALLOW THE

STRAIGHTEST LINE POSSIBLE FOR REMOVAL FROM ENGINE.
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:
(1) Missing segments between holes Reject
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.
G. Rotate HP compressor in reverse direction to allow removal of borescope.
H. Withdraw borescope from gas path and insert it through the bleed valve opening. Inspect the
compressor cover bleed holes (area H) for:
(1) Missing segments between bleed holes Reject
(2) Cracks (any amount) Reject
I. Inspect compressor cover for:
(1) Other damage or cracks. Reject
J. Inspect the compressor bleed valve (area J) for
(1) Fretting where the valve meets the case Reject
K. Install borescope plug assembly into interstage housing.
(1) Install plug into port on interstage housing bleed port cover.
(2) Torque plug assembly 90 to 100 inch-pounds (10.1 to 11.2 N.m).
5. Job Close-up
SUBTASK 71-00-30-410-002
(1) Install the starter/generator. Refer to the Aircraft Maintenance Manual.
71-00-30
Page 604
Apr 11/08

Fig. 601 IP Compressor Blades and Stator Vanes - Borescope Inspection
71-00-30
Page 605
Apr 11/08

Fig. 602 Borescope Plug
71-00-30
Page 606
Apr 11/08

Fig. 603 HP and IP Compressor Blades and Diffuser Vanes - Borescope Inspection
71-00-30
Page 607
Apr 11/08

Fig. 604 HP Compressor Rotor - Inspection
71-00-30
Page 608
Apr 11/08

Fig. 605 Engine Rotation Tool
71-00-30
Page 609
Apr 11/08

71-00-30
610
Page
Blank
INTERNAL OIL LEAK (BORESCOPE) - INSPECTION/CHECK
TASK 71-00-32-220-801 Check for an Internal Oil Leak with a Borescope
1. General
This task contains detailed procedures for checking for an internal oil leak with a borescope. Refer
Figure 601 Internal Oil Leak - Facing Aft - Borescope Inspection
Figure 602 Internal Oil Leak - Side View - Borescope Inspection
procedure, notify Williams International, Walled Lake, Michigan, USA.
and/or contact Williams International, Walled Lake, Michigan, USA for service.
SUBTASK 71-00-32-941-001
Long
3. Job Set-up
SUBTASK 71-00-32-010-001
71-00-32
Page 601
Apr 11/08

4. Procedures
SUBTASK 71-00-32-220-002
NOTE A Flexible, steerable fiberscope, 6mm dia x 50 inch long is standard

equipment for borescoping inspection procedures.
A. Inspect for an oil leak with the borescope
NOTE Visible oil is not cause for engine rejection. The Oil Consumption Check in
71-00-00, P.B. 501 will determine engine acceptability.
(1) Move the borescope through the front case, past the fan and the fan stator vanes. Borescope
should remain in the bypass airflow area and face the bottom (6 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
NOTE A wetted/damp surface located around the scupper holes is acceptable.
(d) A wetted/damp surface located around the scupper holes.
(5) Inspect the front bypass duct fairing assembly for signs of oil leakage. Oil leaking from this
area means an oil tank cover leak.
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
71-00-32
Page 603
Apr 11/08

Fig. 601 Internal Oil Leak - Facing Aft - Borescope Inspection
71-00-32
Page 604
Apr 11/08

Fig. 602 Internal Oil Leak - Side View - Borescope Inspection
71-00-32
Page 605
Apr 11/08

71-00-32
606
Page
Blank
COMBUSTOR, FUEL SLINGER, AND HP TURBINE BLADES LEADING EDGE

(BORESCOPE) - INSPECTION/CHECK
TASK 71-00-40-220-801 Inspect the Combustor, Fuel Slinger, and HP Turbine Blade Leading
Edges with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the combustor, fuel slinger, and HP
turbine blades leading edge. Refer to the following illustration:
Figure 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection
SUBTASK 71-00-40-941-001
Long
SUBTASK 71-00-40-943-001
B. Special Tools
SUBTASK 71-00-40-945-001
71-00-40
Page 601
Apr 11/08


71-00-30 601 IP and HP Compressors (Borescope) - Inspection/Check
74-22-01 401 Igniter Plug - Removal/Installation
3. Job Set-up
SUBTASK 71-00-40-010-001
(2) Open the aircraft circuit breakers to isolate engine electrical supply.
4. Procedures
SUBTASK 71-00-40-220-001
NOTE A Flexible, steerable fiberscope, 6mm dia x 50 inch long is standard

equipment for borescoping inspection procedures.
A. Remove the two igniter plugs from the service adapters on the front bypass duct. Refer to 74-22-01,
P.B. 401.
B. Inspect the fuel manifold supply tube (area A) as follows:
(1) Insert the borescope through the right hand igniter port.
(2) Move the borescope forward in the space between the outside of the combustor cover and
the inside of the diffuser.
(3) Check the fuel manifold tube for:
(a) Signs of leakage (carbon, residue) Reject
(b) Signs of overtemperature Reject
(4) Remove the borescope.
C. Insert the borescope into the combustor area through either igniter port.
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.
D. Inspect the TOBI nozzle (area B) as follows:
(1) Move the borescope through the HP nozzle vanes and into the area behind the primary plate.
(2) Looking aft, inspect the TOBI nozzle (area B) for:
(a) Loose rivets Reject
(b) Separation of weld joint Reject
E. Inspect the combustor as follows:
(1) Insert the borescope into the combustion area and inspect the primary plate (area C) for
erosion and cracks. Contact Williams International for current limits.
(2) Inspect combustor cover (area D) for erosion and cracks. Contact Williams International for
current limits.
(3) Inspect the combustor cover (area D) for:
(a) Signs of cracks, erosion or burn Reject

through
(b) Deformed shape caused by warpage Reject
(c) Cracks between inner row of dilution Reject

holes and adjacent effusion holes
F. Inspect Fuel Slinger
NOTE A second person is required to turn the HP rotary assembly during

borescope inspection.
(1) Rotate the HP rotary assembly for inspection as follows:
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(2) Inspect the fuel slinger (area E) for:
(a) Clogged fuel delivery holes or slots Reject
G. Inspect the HP turbine nozzle vanes (area F) for cracks and pitting. Evaluate damage as follows:
(1) Cracks on leading edge of vanes Reject
(2) Pits that can be detected by borescope Reject
71-00-40
Page 603
Apr 11/08

H. Inspect HP turbine blades leading edges (area G) as follows:
CAUTION TO AVOID DAMAGE TO THE BORESCOPE OR THE ENGINE, DO NOT

ALLOW BORESCOPE TO CONTACT THE HP TURBINE ROTOR BLADES.
(1) Move the borescope around and down between the HP nozzle vanes to point at the HP
turbine blades.
(2) Have someone slowly turn the HP rotary assembly to allow inspection of all the blades.
(3) Inspect the blade roots, leading edges, and blade tips of the 43 blades for any damage, erosion,
cracks, nicks, or any other visual defects. Contact Williams International for current limits.
I. Carefully remove the borescope from the igniter port.
J. Inspect the combustor cover key as follows:
(1) Insert the borescope into the right-hand igniter port.
(2) Locate the combustor cover key (area H) on the HP nozzle. It is radially in-line with the
right-hand igniter port and slightly forward. It locates the large indexing slot on the outside edge
of the combustor cover.
(3) Inspect the combustor cover key for:
(a) Cracks Reject
(b) Missing Reject
K. Install the igniter plugs. Refer to 74-22-01, P.B. 401.
5. Job Close-up
SUBTASK 71-00-40-410-001
71-00-40
Page 604
Apr 11/08

Fig. 601 Combustor, Fuel Slinger, HP Turbine Leading Edge - Borescope Inspection
71-00-40
Page 605
Apr 11/08

71-00-40
606
Page
Blank
LP TURBINES (BORESCOPE) - INSPECTION/CHECK
TASK 71-00-50-220-801 Inspect the LP Turbines with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the 1st LP turbine rotor blades trailing
edge and the 2nd LP turbine rotor blades leading edge. Refer to the following illustration(s):
Figure 601 Borescope Plug Removal
Figure 602 LP Turbines - Borescope Inspection
SUBTASK 71-00-50-941-001
Long
SUBTASK 71-00-50-942-001
B. Consumables
SUBTASK 71-00-50-944-001
C. Expendable Parts
IPC Reference
71-00-50
Page 601
Apr 11/08

72-00-71 01 100 O-ring

72-00-71 01 120 O-ring
72-00-71 01 130 O-ring
3. Job Set-up
SUBTASK 71-00-50-010-001
4. Procedures
SUBTASK 71-00-50-870-001
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:
71-00-50
Page 602
Apr 11/08

WARNING BE CAREFUL TO PREVENT INJURY TO FINGERS AND HANDS

WHEN YOU TURN THE LP ROTARY ASSEMBLY.
CAUTION TO PREVENT DAMAGE TO THE FAN, DO NOT USE METAL TOOLS OR

SIMILAR HARD OBJECTS TO TURN THE LP ROTARY ASSEMBLY.
NOTE Clicking sound originating from rotation of No. 1 bearing is acceptable.
(1) Slowly rotate the LP rotary assembly and inspect the blade root, trailing edge, and blade tip
platforms of the 70 blades on the 1st LP turbine rotor. Refer to Figure 602 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.
G. Carefully remove borescope from fuel drain port.
H. Install plug and torque 85 to 95 inch-pounds (9.6 to 10.7 N.m).
I. Lube two O-rings with assembly fluid (MAT-011) and install on rear fuel drain transfer tube.
J. Install transfer tube in port.
K. Install O-ring with assembly fluid and install on rear fuel drain adapter. Attach rear fuel drain adapter
to adapter boss using two screws, four washers, and two nuts. Torque screws 31 to 35 inch-pounds
(3.5 to 3.9 N.m).
SUBTASK 71-00-50-401-001
5. Job Close-up
SUBTASK 71-00-50-410-001
(2) Close the aircraft circuit breakers.
71-00-50
Page 603
Apr 11/08

Fig. 601 Borescope Plug Removal
71-00-50
Page 604
Apr 11/08

Fig. 602 LP Turbines - Borescope Inspection
71-00-50
Page 605
Apr 11/08

71-00-50
606
Page
Blank
HP NOZZLE/HP TURBINE TRAILING EDGE AND 1ST LP TURBINES LEADING EDGE

(BORESCOPE) - INSPECTION/CHECK
TASK 71-00-52-220-801 Inspect the HP Nozzle/HP Turbine Trailing Edge and 1st LP Turbine
Leading Edge with a Borescope
1. General
This task contains detailed procedures for borescope inspection of the HP nozzle/HP turbine trailing edge
and the 1st LP turbine leading edge. Refer to following illustration:
Figure 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"
SUBTASK 71-00-52-941-001
Long
SUBTASK 71-00-52-943-001
B. Special Tools
SUBTASK 71-00-52-945-001
71-00-52
Page 601
Apr 11/08


3. Job Set-up
SUBTASK 71-00-52-010-001
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
SUBTASK 71-00-52-220-001
B. Insert the borescope through the ITT port and into the core airflow path.
C. Inspect 1st LP Turbine Rotor Blades
(1) Move the borescope aft, between the 1st LP nozzle vanes, and locate the 1st LP turbine
rotor blades (area A).
WARNING BE CAREFUL TO PREVENT INJURY TO FINGERS AND HANDS

WHEN YOU TURN THE LP ROTARY ASSEMBLY.
CAUTION TO PREVENT DAMAGE TO THE FAN, DO NOT USE METAL TOOLS OR

SIMILAR HARD OBJECTS TO TURN THE LP ROTARY ASSEMBLY.
(2) Slowly rotate the LP rotary assembly. Inspect the blade root, leading edge, and blade tip
platforms of each of the 70 1st LP turbine rotor blades for any damage, erosion, cracks, nicks,
or any other visual defects. Contact Williams International for current limits.
71-00-52
Page 602
Apr 11/08

D. Inspect HP Turbine Rotor Blades
(1) Turn the borescope so it is facing forward and locate the HP turbine rotor blades.
NOTE A second person is required to turn the HP rotary assembly

during borescope inspection
(2) Rotate the HP rotary assembly for inspection as follows:
(a) Insert engine rotation tool, TL37244, into starter/generator spline in gearbox.
(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.
E. Inspect HP Turbine Nozzle Vanes
(1) Move the borescope forward until it passes through the HP turbine rotor blades and the HP
nozzle vanes are visible.
CAUTION TO AVOID DAMAGE TO THE BORESCOPE OR THE ENGINE, DO NOT

ALLOW BORESCOPE TO CONTACT THE HP TURBINE NOZZLE VANES.
(2) Have someone slowly turn the HP rotary assembly. The HP turbine rotor will carry the
borescope around the 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.
F. Carefully remove borescope from engine.
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
71-00-52
Page 603
Apr 11/08

71-00-52
Page 604
Apr 11/08

Fig. 601 "HP Nozzle, HP Turbine, and 1st LP Turbine - Borescope Inspection"
71-00-52
Page 605
Apr 11/08

71-00-52
606
Page
Blank
CHAPTER 72
ENGINE
Page 1
72-ENGINE Apr 11/08

Page 2
72-ENGINE Blank

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
Page 1
Apr 11/08

Chapter 72
Page 2
Blank
ENGINE - DESCRIPTION AND OPERATION
TASK 72-00-00-860-805 Compressor System - Description and Operation
1. General
The engine has three compressor stages:

Figure 1 Compressor System
Low pressure (LP) compressor stage
Intermediate pressure (IP) compressor stage
High pressure (HP) compressor stage
These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:
Sealing air for oil and labyrinth seals
Cooling air for LP and HP turbine discs
The compressor rotors are located in front of the compressor stators.
2. Description
SUBTASK 72-00-00-860-002
A. The main parts of the compressor system are:
Spinner
Fan rotor (LP axial compressor)
Fan stator (LP compressor axial stator)
Case assembly
IP compressor rotor (axial)
IP compressor stator (axial)
HP compressor rotor (centrifugal)
Diffuser case assembly
(1) The spinner bolts onto the front of the fan rotor. The spinner shape provides a smooth airflow
into the engine. The sharp point prevents accumulation of ice.
72-00-00
Page 1
Apr 11/08

(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.
72-00-00
Page 2
Apr 11/08

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.
TASK 72-00-00-860-806 Gearbox Assembly (8k Configuration) - Description and Operation
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.
72-00-00
Page 3
Apr 11/08

TASK 72-00-00-860-807 Gearbox Assembly (4k Configuration) - Description and Operation
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.
TASK 72-00-00-860-808 Bypass Duct Group - Description and Operation
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
72-00-00
Page 4
Apr 11/08

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.
TASK 72-00-00-860-810 Bypass Duct Group - Description and Operation
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.
72-00-00
Page 5
Apr 11/08

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.
TASK 72-00-00-860-811 Compressor System - Description and Operation
14. General
The engine has three compressor stages:
Low pressure (LP) compressor stage
Intermediate pressure (IP) compressor stage
High pressure (HP) compressor stage
These stages supply compressed air for combustion. Some other functions of the air supplied by the
compressor section are:
Sealing air for oil and labyrinth seals
Cooling air for LP and HP turbine discs
15. Description
SUBTASK 72-00-00-860-005
A. The main parts of the compressor system are:
Spinner
Fan rotor (LP axial compressor)
Fan stator (LP compressor axial stator)
Case assembly
IP compressor rotor (axial)
IP compressor stator (axial)
HP compressor rotor (centrifugal)
Diffuser case assembly
(1) The spinner bolts onto the front of the fan rotor. The spinner shape provides a smooth airflow
into the engine. The sharp point prevents accumulation of ice.
(2) The fan rotor (LP axial compressor) is a 16 blade titanium blisk (blades and disc are integral).
The fan is attached to the LP shaft with one nut. The fan is splined but there is no master
keyway to clock the position.
72-00-00
Page 6
Apr 11/08

(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.
72-00-00
Page 7
Apr 11/08

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.
72-00-00
Page 8
Apr 11/08

Fig. 1 Compressor System
72-00-00
Page 9
Apr 11/08

Fig. 2 Gearbox - Accessory Mounting Pads
72-00-00
Page 10
Apr 11/08

Fig. 3 Gearbox - Drive Train
72-00-00
Page 11
Apr 11/08

Fig. 4 Gearbox - Accessory Mounting Pads
72-00-00
Page 12
Apr 11/08

Fig. 5 Bypass Duct Group
72-00-00
Page 13
Apr 11/08

Fig. 6 Bypass Duct Group
72-00-00
Page 14
Apr 11/08

APPROVED ENGINE FUEL - SERVICING
TASK 72-00-01-610-803 Approved Engine Fuels
1. General
This task lists approved fuels and additives for the engine. It is the responsibility of the operator to
ensure that all fuel delivered to the engine meets the requirements of the approved fuel specifications in
all respects.
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
72-00-01
Page 301
Apr 11/08

NOTES: 1 MIL-I-27686 or MIL-I-85470 fuel system icing inhibitor is required in amounts

between 0.10% and 0.15% by volume, when fuel temperature is below 32F.
Minimum fuel icing inhibitor content during refueling is 0.10% by volume.
Dupont Stadis 450 anti-static additive or equivalent is permitted to bring fuel

upto 300 conductive units but not to exceed 1 part per million.
SOHIO Biobor JF biocide additive is approved at a concentration not to

exceed 20 ppm (270 ppm total additive) of elemental boron.
2 Fluid I (C.I.S. GOST 8313) or Fluid IM (C.I.S. TU-6-10-1458) fuel system icing
inhibitor is 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.
4 The upper altitude/temperature for use of aviation gasoline is limited by

the airframe. Refer to the aircraft Operating Instructions.
5 T1301 (SH0396-92) fuel system icing inhibitor is allowed in amounts

between 0.10% and 0.15% by volume.
3. Mixing of Fuels.
SUBTASK 72-00-01-610-009
A. Mixing of approved fuels is permissible.
72-00-01
Page 302
Apr 11/08

ENGINE SERVICING - OIL CHANGING/REPLENISHING - SERVICING
TASK 72-00-03-610-801 Service the Engine Using Dipstick Oil Fill Port
1. General
This task contains procedures for checking the oil level, draining, and filling the engine with oil via the
dipstick oil fill port. Do this task as required by scheduled maintenance checks. Refer to the following
illustration(s):
Figure 301 Oil Servicing - Dipstick
Figure 302 Oil Servicing - Oil Drain Fitting
Figure 303 Oil Servicing - Chip Collector Drains
WARNINGS: 1 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE

CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS THE
SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED
TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.
2 TO AVOID BURNS, ALLOW TIME AFTER ENGINE OPERATION FOR THE

OIL SYSTEM COMPONENTS AND TUBES TO COOL.
CAUTIONS: 1 DO NOT LET OIL FALL ONTO ENGINE PARTS WHICH ARE NOT USUALLY
IN TOUCH WITH OIL. RUB OFF ANY OIL WHICH FALLS ONTO THE ENGINE.
THE OIL CAN DAMAGE PAINTWORK AND RUBBER PARTS.
2 USE ONLY CLEAN CONTAINERS AND EQUIPMENT. THE OIL WILL

BREAKDOWN IF MIXED WITH ANY ALKALINE FLUID.
3 DO NOT PUT USED OIL BACK INTO THE SYSTEM.
SUBTASK 72-00-03-942-001
A. Consumables
MAT-001 Oil, Engine
MAT-071 Cloth, Lint Free
SUBTASK 72-00-03-943-001
B. Special Tools
72-00-03
Page 301
Apr 11/08

TL37255 Fitting, Oil Drain
SUBTASK 72-00-03-944-001
C. Expendable Parts
IPC Reference
79-30-01 1 25 O-ring (2)
79-30-01 1 30 O-ring (2)
SUBTASK 72-00-03-945-001
79-30-01 401 Magnetic Chip Collector - Removal/Installation
3. Job Set-up
SUBTASK 72-00-03-010-001
A. Prepare to service engine with oil
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.
2 Two alternate methods for draining oil are described below.
A. Drain engine oil (if required) using TL37255 oil drain fitting
72-00-03
Page 302
Apr 11/08

(1) Vent oil tank by removing oil fill cap (dipstick).
(2) Remove the self-closing plug from the bottom rear of the lube pump (port labeled TANK DRAIN).
(3) Install oil drain fitting, TL37255, to self-closing fitting and drain oil tank oil into a suitable
container.
(4) Lubricate new O-ring with engine oil (MAT-001) and install on self-closing plug.
(5) Remove oil drain tube and install self-closing plug.
(6) Remove the self-closing plug from the bottom of the gearbox.
(7) Install oil drain fitting, TL37255, to self-closing fitting and drain gearbox oil into a suitable
container.
(8) Lubricate new O-ring with engine oil and install on self-closing plug.
(9) Remove oil drain tube and install self-closing plug.
CAUTION HOLD A LARGE, CLEAN CONTAINER (FOR APPROXIMATELY 4 QUARTS

(4 LITERS) BELOW OIL DRAIN PORT. OIL WILL IMMEDIATELY DRAIN
WHEN THE CHIP COLLECTOR FITTING IS REMOVED.
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
C. Check the engine oil level and add oil as required.
(1) (FJ44-2A Only) Actuate low oil level sensor (if engine is so equipped) in accordance with aircraft
flight manual. If low oil is indicated, check oil with dipstick and service oil system, as required.
WARNING TO AVOID SUDDEN PRESSURE RELEASE FROM THE OIL TANK,

WAIT AT LEAST FIVE (5) MINUTES AFTER ENGINE SHUTDOWN
BEFORE REMOVING OIL FILL CAP/DIPSTICK.
(2) Check the oil sight glass (if engine is so equipped), or insert and remove the (oil fill cap)
dipstick from the fill port.
(3) Wipe the oil from the dipstick using a clean, lint-free cloth (MAT-071). Install the dipstick and
then remove it to get an accurate reading of the oil level on the dipstick.
72-00-03
Page 303
Apr 11/08

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.
(6) Record amount and type of oil added in engine logbook.
SUBTASK 72-00-03-610-010
D. Approved engine lubricating oils are listed below:

Approved Brand (Note 2) Specification
Mobil Jet II (Note 1) MIL-L-23699
Mobil 254 MIL-L-23699
NOTES: 1 Mobil Jet II is the preferred oil.
2 Mixing of approved oils is permissible when servicing oil due

to normal consumption.
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.
E. Oil servicing of dry engine
(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.
72-00-03
Page 304
Apr 11/08

(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
F. Check oil drain fittings for leaks.
5. Job Close-up
SUBTASK 72-00-03-410-001
A. Put the Engine Back to Normal
(3) Remove DO NOT OPERATE and NO OIL INSTALLED signs.
72-00-03
Page 305
Apr 11/08

Fig. 301 Oil Servicing - Dipstick

72-00-03
Page 306
Apr 11/08

Fig. 302 Oil Servicing - Oil Drain Fitting
72-00-03
Page 307
Apr 11/08

72-00-03
Page 308
Fig. 303 Oil Servicing - Chip Collector Drains Apr 11/08

OIL FILTER ANALYSIS PROGRAM - MAINTENANCE PRACTICES
TASK 72-00-05-870-801 Submit Oil Filter for Analysis
1. General
This task contains procedures for changing the oil filter and submitting it to be analyzed as part of the oil
filter analysis program. This program provides the operator and maintenance personnel with valuable
information about engine health. Do this task as directed by periodic maintenance checks or other
maintenance procedures.
SUBTASK 72-00-05-942-001
A. Consumables
MAT-001 Oil, Engine
NOTE The following is a listing of oil filter analysis kit part numbers:
GA-0F-TAP-NO (Aviation Laboratories, New Orleans)
JCL FJ44 (Jet Care International)
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
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
72-00-05
Page 201
Apr 11/08


79-21-01 401 Oil Filter - Removal/Installation
3. Job Set-up
SUBTASK 72-00-05-010-001
A. Prepare to Access Engine
4. Procedures
SUBTASK 72-00-05-020-001
A. Remove the oil filter and place it in the container provided with the oil filter analysis kit. Install
a new oil filter. Refer to 79-21-01, P.B. 401.
SUBTASK 72-00-05-510-001
B. Identify the oil filter with the following:
(1) Engine model number and serial number
(2) Aircraft number
(3) Date of oil filter sample
(4) Oil Brand and type
(5) Total engine run hours
(6) Time (engine operating hours) since last filter sample submitted
(7) Time (engine operating hours) since last oil change
(8) Time (engine operating hours) since the last oil filter change
(9) Amount of oil added since the last filter sample submitted
(10) Your return address and phone number
SUBTASK 72-00-05-610-001
C. Service the engine with oil (MAT-001). Refer to 72-00-03, P.B. 301.
72-00-05
Page 202
Apr 11/08

SUBTASK 72-00-05-510-002
D. Send the oil filter to one of the following approved laboratories:

Aviation Laboratories, Inc.
910 Maria St.
Kenner, LA 70062 USA
Jet-Care International
3 Saddle Road
Cedar Knolls, NJ 07927 USA
Spectro Oil Analysis Company, Ltd.
Palace Gate High Street
Odiham Hook, Hampshire, UK RG29 1NP
Spectro Oil AG
Rinaustrasse 452,
CH-4303 Kaiseraughst
Switzerland
5. Job Close-up
SUBTASK 72-00-05-410-001
A. Put the engine back to normal.
72-00-05
Page 203
Apr 11/08

72-00-05
204
Page
Blank
SPINNER - REMOVAL/INSTALLATION
TASK 72-00-30-020-801 Remove the Spinner
1. General
This task covers removal of the spinner from the engine. Refer to the following illustration(s):
Figure 401 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
MAT-032 Marker, Broad Line
SUBTASK 72-00-30-945-001
3. Job Set-up
SUBTASK 72-00-30-010-001
A. Prepare to Disassemble the Engine
(2) Open the circuit breakers to isolate the engine electrical system.
4. Procedures
SUBTASK 72-00-30-020-001
A. Remove Spinner Bolts
72-00-30
Page 401
Apr 11/08

WARNING SPINNER TIP IS EXTREMELY SHARP AND SHOULD BE COVERED

BEFORE MAINTENANCE TO PREVENT INJURY. A REUSEABLE
COVER CAN BE MADE BY DIPPING THE SPINNER TIP IN PLASTIC
OR LATEX COATING MATERIAL.
CAUTION ONLY USE APPROVED MARKER. DO NOT SCRIBE A MARK

WHICH REMOVES/DISPLACES METAL.
NOTE During removal, the spinner is alignment match-marked in case trim

balancing is needed. Trim balancing is needed if LP vibration levels exceed
limits (high vibration with or without noise). Trim balance procedures are
in 71-00-00, P.B. 501 in the Maintenance Manual.
(1) Using MAT-033 or equivalent MAT-032 marker, alignment match-mark the spinner and fan rotor
as a baseline. Put the match mark in line with one of the spinner mount bolts.
(2) Remove six bolts (1-20) and six washers (1-30) which attach the spinner (1-10) to the engine.
(3) After removal of spinner, make an alignment mark on the pilot plate, locking plate, and LP shaft
in-line with the mark on the fan. Use MAT-033 marker (or equivalent).
TASK 72-00-30-420-801 Install the Spinner
5. General
This task covers installation of the spinner. Refer to the following illustration(s):
Figure 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
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
72-00-30
Page 402
Apr 11/08

MAT-001 Oil, Engine
SUBTASK 72-00-30-945-002
70-42-11 801 Repair Surfaces Affected by Minor Damage - Repair
7. Procedures
SUBTASK 72-00-30-420-001
A. Install Spinner
WARNING SPINNER TIP IS EXTREMELY SHARP AND SHOULD BE COVERED

BEFORE MAINTENANCE TO PREVENT INJURY. A REUSEABLE
COVER CAN BE MADE BY DIPPING THE SPINNER TIP IN PLASTIC
OR LATEX COATING MATERIAL.
NOTE The pilot area of the spinner touches the spinner pilot plate
assembly and the fan locking plate when installed. There will be a
gap between the spinner and the fan.
(1) Inspect the pilot area of the spinner for burrs. Remove any burrs in accordance with standard
practices. Refer to 70-42-11, P.B. 801.
(2) Make sure that the LP nut locking plate (1-30, 72-00-31) is installed on the front LP nut and
that all six pilot plate bolt holes are visible.
NOTE Make sure that there is an alignment mark on the spinner. Refer
to spinner removal task.
(3) Insert one bolt (1-20) and washer (1-30) through the spinner and align the spinner with the
spinner pilot plate and with alignment marks made at removal. Install the bolt into one of the
six pilot plate holes, finger tight.
(4) Install the remaining five bolts and washers.
(5) Torque bolts 49 to 55 inch-pounds (5.5 - 6.2 N.m).
(6) Check for gap between spinner and fan. Gap should be 0.002 inch (0.050 mm).
72-00-30
Page 403
Apr 11/08

8. Job Close-up
SUBTASK 72-00-30-410-002
72-00-30
Page 404
Apr 11/08

Fig. 401 Spinner - Removal/Installation
72-00-30
Page 405
Apr 11/08

72-00-30
406
Page
Blank
FAN ROTOR - REMOVAL/INSTALLATION
TASK 72-00-31-020-802 Remove the Fan Rotor
1. General
This task covers removal of the fan rotor from the engine. Refer to the following illustrations:
Figure 401 Fan - Stretch Dimension
Figure 402 Fan - Shaft Stretch Tool
Figure 403 Fan - Pilot Plate Removal
Figure 404 Fan - Removal
used in the illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
SUBTASK 72-00-31-941-002
Depth Micrometer
SUBTASK 72-00-31-942-002
B. Consumables
MAT-001 Oil, Engine
SUBTASK 72-00-31-943-002
C. Special Tools
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
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
B. Remove the spinner. Refer to 72-00-30, P.B. 401.
4. Procedures
SUBTASK 72-00-31-020-004
A. Remove the Fan Rotor
(1) Remove the fan locking plate (1-30).
(2) Measure the LP shaft stretch (stretched condition):
(a) Using a depth micrometer, measure from the front face of the LP shaft to the forward face
of the pilot plate assembly. Refer to Figure 401 Fan - Stretch Dimension.
(b) Record as "stretched 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.
(c) Install TL37102-9 LP pusher over the rod.
(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.
(f) Install the TL37102-14 cap on the hydraulic cylinder.
72-00-31
Page 402
Apr 11/08

CAUTION DO NOT EXCEED 7800 PSIG WHEN PUMPING HYDRAULIC

CYLINDER. EXCESSIVE PRESSURE WILL DAMAGE THE LP
SHAFT. IF MORE THAN 7100 PSIG IS REQUIRED TO LOOSEN
NUT, CONTACT W-R CUSTOMER SUPPORT.
NOTE Two people are needed to remove the LP nut.
(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:
1 Increase the pressure in 50 psig increments.
2 Using TL99500, check for nut counterclockwise rotation after each increase in
pressure.
3 Do not exceed 7800 psig.
4 Record pressure at which nut became loose.
(h) Release pump pressure and remove all details of TL37102.
(i) Remove the fan retainer nut
(4) Using a depth micrometer, measure from the front face of the LP shaft to the forward face of
the pilot plate assembly.
(5) Record measurement as unstretched dimension.
(6) Install TL99501 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.
TASK 72-00-31-420-802 Install the Fan Rotor
5. General
This task covers installation of the fan rotor on the engine. Refer to the following illustrations:
Figure 402 Fan - Shaft Stretch Tool
Figure 401 Fan - Stretch Dimension
Catalog:
72-00-31, Fig. 01
72-00-31
Page 403
Apr 11/08

used in the illustrated Parts Catalog (IPC) for this particular Chapter-Section-Subject
SUBTASK 72-00-31-941-004
Depth Micrometer
SUBTASK 72-00-31-942-004
B. Consumables
MAT-001 Oil, Engine
MAT-013 Magnesium Hydroxide
MAT-017 Lubricant, Rapid GT
SUBTASK 72-00-31-943-004
C. Special Tools
TL37102 Tool, Shaft Stretch
TL99500 Spanner Tool, LP Shaft Forward Nut
SUBTASK 72-00-31-945-004
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
A. Install the Fan Rotor
(1) Install the fan rotor (1-10) on the LP shaft against the IP compressor rotor. Align marks on fan
rotor and LP shaft made at removal.
(2) Install the pilot plate assembly (1-40) with the thick flange against the fan. Make sure that the
locating pin is aligned with the hole in the fan flange.
NOTE You must seat the fan rotor on the LP shaft using 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.
(c) Install TL37102-9 LP pusher over the rod.
(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.
(f) Install the TL37102-14 cap on the hydraulic cylinder.
CAUTION DO NOT EXCEED SPECIFIED PRESSURE WHEN PUMPING

HYDRAULIC CYLINDER. EXCESSIVE PRESSURE WILL
DAMAGE THE LP SHAFT.
(g) Operate the TL37102-19 hydraulic hand pump until the gauge indicates 7100 psi. This
seats the fan rotor on the LP shaft.
(h) Release pump pressure and remove all details of TL37102.
SUBTASK 72-00-31-220-003
B. Measure the LP Shaft Stretch (Unstretched Condition)
72-00-31
Page 405
Apr 11/08

the pilot plate assembly. Refer to Figure 401 Fan - Stretch Dimension.
(2) Record as unstretched dimension.
SUBTASK 72-00-31-420-006
C. Install Fan Retainer Nut
(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.
(b) Install TL37102-9 LP pusher over the rod.
(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.
(e) Install the TL37102-14 cap on the hydraulic cylinder.
CAUTION DO NOT EXCEED SPECIFIED PRESSURE WHEN PUMPING

HYDRAULIC CYLINDER. EXCESSIVE PRESSURE WILL
DAMAGE THE LP SHAFT.
NOTE Two people are needed to install the LP nut.
(f) 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.
(g) Release pump pressure.
(h) To make sure parts are seated properly, operate hand pump again and make sure that
nut is able to be loosened (by hand) at 7100 psi (50 psi). Tighten nut. If gage reading is
above or below limit, remove fan and reinstall until you get a proper reading.
(i) Remove all details of TL37102.
SUBTASK 72-00-31-220-004
D. Measure the LP Shaft Stretch (Stretched Condition)
the pilot plate assembly.
(2) Record as stretched dimension.
72-00-31
Page 406
Apr 11/08

NOTE If shaft stretch dimension is below acceptable range, it is allowable to

repeat shaft stretch procedure and increase pump pressure, in 50 psi
increments, to an allowable maximum of 7500 psi.
(3) Subtract unstretched dimension from stretched dimension to determine shaft stretch. Shaft
stretch must be 0.018 - 0.022 inch (0.457 - 0.558 mm).
9. Job Close-up
SUBTASK 72-00-31-420-007
A. Install the fan locking plate (1-30).
SUBTASK 72-00-31-420-008
B. Install the spinner. Refer to 72-00-30, P.B. 401.
SUBTASK 72-00-31-410-004
C. Put the Engine Back to Normal
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
(2) Close aircraft circuit breakers
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.
72-00-31
Page 407
Apr 11/08

Fig. 401 Fan - Stretch Dimension
72-00-31
Page 408
Apr 11/08

Fig. 402 Fan - Shaft Stretch Tool
72-00-31
Page 409
Apr 11/08

Fig. 403 Fan - Pilot Plate Removal
72-00-31
Page 410
Apr 11/08

Fig. 404 Fan - Removal
72-00-31
Page 411
Apr 11/08

72-00-31
412
Page
Blank
CASE AND INSERT ASSY - REMOVAL/INSTALLATION
TASK 72-00-32-020-802 Remove the Case and Insert Assembly
1. General
This task covers removal of the case and insert and fan stator from the engine. Refer to the following
illustration(s):
Figure 401 Case and Insert Assembly - Removal/Installation
SUBTASK 72-00-32-945-002
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
B. Remove the spinner (1-10, 72-00-30). Refer to 72-00-30, P.B. 401.
SUBTASK 72-00-32-020-006
C. Remove the fan rotor (1-10, 72-00-31). Refer to 72-00-31, P.B. 401.
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
A. Remove the case and insert assembly as follows:
NOTE Mark location of all brackets before removal.
(1) Remove 33 nuts (1-60), 33 bolts (1-30 and 1-40), and 60 washers (1-50) from the inlet flange.
Remove the harness clamps, lifting bracket, the oil supply tube clamp bracket, and the forward
ignition exciter bracket from flange.
CAUTION FAN STATOR VANE MAY BE LOOSE AND MAY FALL OUT OF INLET
CASE DURING REMOVAL. USE CARE TO PREVENT DAMAGE.
(2) Carefully remove the case and insert assembly (1-10) from the interstage housing.
(3) Separate the fan stator vane assembly (1-20) by removing it from the aft side of the case
and insert assembly.
(4) Cover front of the interstage housing to prevent dirt from entering the engine.
NOTE If case and insert assembly is to be rejected from the engine, remove the
engine identification plate and transfer it to the new case and insert assembly.
Refer to 72-32-10, P.B. 801, Repair in the Maintenance Manual.
TASK 72-00-32-420-802 Install the Case and Insert Assembly
5. General
This task covers installation of the fan stator in the case and insert assembly, and installation of the case
and insert assembly in the engine. Refer to the following illustrations:
Figure 401 Case and Insert Assembly - Removal/Installation
Catalog:
72-00-32, Fig. 01
72-00-32
Page 402
Apr 11/08

SUBTASK 72-00-32-942-004
A. Consumables
MAT-001 Oil, Engine
MAT-009 Petrolatum
SUBTASK 72-00-32-945-004
74-10-01 401 Igniton Exciter - Removal/Installation
7. Procedures
SUBTASK 72-00-32-420-005
A. Install case and insert assembly as follows:
NOTE If case and insert assembly is replaced, transfer engine identification

plate to the new case and insert assembly. Refer to 72-32-10, P.B.
801, Repair in the Maintenance Manual.
(1) Make sure that the fan stator is correctly installed in the case and insert assembly. Follow the
installation procedure below, depending on the configuration:
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).
(5) Install the following:
Forward ignition exciter bracket on the aft side of the flange
Harness clamps
Remaining bolts, washers, and nuts
(6) Install the oil supply tube clamp bracket (1-70, 79-26-01) on the aft side of the flange. Secure
with one bolt (1-30), one washer (1-50), and one nut (1-60).
(7) Torque nuts 25 to 28 inch-pounds (2.8 to 3.1 N.m).
8. Job Close-up
SUBTASK 72-00-32-420-006
A. Install the ignition exciter(s). Refer to 74-10-01, P.B. 401.
SUBTASK 72-00-32-420-007
B. Install the fan rotor. Refer to 72-00-31, P.B. 401.
SUBTASK 72-00-32-420-008
C. Install the spinner. Refer to 72-00-30, P.B. 401.
SUBTASK 72-00-32-410-004
D. Put the Engine Back to Normal
(1) Refer to the Aircraft Maintenance Manual (A.M.M.) and Install the engine cowling.
(2) Close aircraft circuit breakers
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.
72-00-32
Page 405
Apr 11/08

Fig. 401 Case and Insert Assembly - Removal/Installation
72-00-32
Page 406
Apr 11/08

GEARBOX ASSY - REMOVAL/INSTALLATION
TASK 72-00-60-020-801 Remove the Gearbox Assembly
1. General
This task covers removal of the gearbox assembly from the engine. Removal procedures for
gearbox-mounted accessory items are referenced to the appropriate Maintenance Manual page block.
Refer to the following illustration(s):
Figure 401 Gearbox - Removal/Installation
Figure 402 Gearbox - Breather Tube Torque Adapter
2 Discard all O-rings and gaskets during disassembly.
SUBTASK 72-00-60-943-001
A. Special Tools
TL37255 Fitting, Oil Drain
TL37270 Torque Adapter, 3/8"
SUBTASK 72-00-60-945-001
77-12-01 401 Gearbox (HP) Magnetic Speed Pickup Assembly - Removal/Installation
79-22-01 401 Lube Oil Cooler - Removal/Installation
79-24-01 401 Lube and Scavenge Pump - Removal/Installation
72-00-60
Page 401
Apr 11/08

3. Job Set-up
SUBTASK 72-00-60-010-001
A. Prepare to Disassemble the Engine.
(2) Open circuit breakers to isolate the engine electrical supply.
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the cowling.
SUBTASK 72-00-60-020-001
B. Remove Gearbox Accessories
(1) Drain oil from the engine using TL37255, oil drain fitting. Refer to 72-00-03, P.B. 301 in
the Maintenance Manual.
(2) 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
A. Remove Gearbox Assembly
(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).
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.
CAUTION THE ACCESSORY DRIVE SHAFT IS NOT SECURED AND MAY

BE DAMAGED IF DROPPED. REMOVE THE ACCESSORY DRIVE
SHAFT FROM THE INTERSTAGE HOUSING OR THE GEARBOX
ASSEMBLY BEFORE IT DROPS.
(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.
TASK 72-00-60-420-801 Install the Gearbox Assembly
5. General
This task covers installation of the gearbox assembly. Installation procedures for gearbox-mounted
accessory items are referenced to the appropriate Maintenance Manual page block. Refer to the following
illustration(s):
Figure 401 Gearbox - Removal/Installation
Figure 402 Gearbox - Breather Tube Torque Adapter
Catalog:
72-00-60, Fig. 01
72-00-60
Page 403
Apr 11/08

CAUTION IF A NEW PART NUMBER GEARBOX IS INSTALLED ON THE ENGINE, REFER

TO THE ILLUSTRATED PARTS CATALOG (IPC) OR CONTACT WILLIAMS
INTERNATIONAL PRODUCT SUPPORT TO MAKE SURE THAT THE BREATHER
TUBE IS A COMPATIBLE CONFIGURATION. INSTALLING THE WRONG
CONFIGURATION COULD RESULT IN A SUDDEN LOSS OF OIL.
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
MAT-001 Oil, Engine
SUBTASK 72-00-60-943-002
B. Special Tools
TL37270 Torque Adapter, 3/8"
TL99924 Torque Adapter
SUBTASK 72-00-60-944-002
C. Expendable Parts
IPC Reference
72-00-60 01 260 O-ring
72-00-60
Page 404
Apr 11/08

SUBTASK 72-00-60-945-002
70-42-12 801 Local Surface Protection - Repair
79-24-01 401 Lube and Scavenge Pump - Removal/Installation
7. Procedures
SUBTASK 72-00-60-420-001
A. Install Gearbox Assembly
(1) Make sure that mount pads on interstage housing and gearbox assembly are clean and dry.
(2) The gearbox mounting gasket (1-60) may be re-used if it passes the following criteria:
(a) No evidence of sealing material (rubber) delamination or pull-away from base metal
groove side walls permitted.
(b) Cracks, splits, or other defects which may affect sealing in the rubber component are
not permitted.
(c) Raised metal in the sealing surface areas not permitted. It is permitted to stone raised
metal and touch up anodize per 70-42-12, P.B. 801.
(d) Scratches or defects in the anodize coating may be repaired per 70-42-12, P.B. 801.
(e) Gearbox gasket must be replaced at the compressor zone inspection interval (Check 4).
(3) Install gearbox mounting gasket (1-60) (dry) on gearbox (1-10). Make sure oil passages
and bolt holes are aligned.
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.
(7) Torque bolts (1-20) 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(8) Install breather tube O-ring (1130) as follows:
(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.
CAUTION USE CARE NOT TO PINCH O-RING DURING INSTALLATION

OF BREATHER TUBE FLANGE.
(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).
NOTE If hose portion of breather tube is disassembled from either end,

reassemble by lubricating ends with assembly fluid (MAT-011). Torque
hose clamp 16 to 18 inch-pounds (1.8 to 2.0 N.m).
(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
(13) Connect the breather tube discharge plumbing to the breather tube, if applicable. Refer to
the Aircraft Maintenance Manual.
72-00-60
Page 406
Apr 11/08

8. Job Close-up
SUBTASK 72-00-60-420-002
A. Install Gearbox Accessories
(1) Install oil filter to gearbox. Refer to 79-21-01, P.B. 401 in the Maintenance Manual.
CAUTION HYDRAULIC PUMP SPLINE SHOULD BE CLEAN AND DRY WHEN

INSTALLED. DO NOT USE GREASE OR OTHER LUBRICANT.
(2) Install the hydraulic pump to the gearbox. Refer to the Aircraft Maintenance Manual.
CAUTION STARTER/GENERATOR SPLINE SHOULD BE CLEAN AND DRY WHEN

(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
C. Put Engine Back to Normal
(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.
72-00-60
Page 407
Apr 11/08

Fig. 401 Gearbox - Removal/Installation
72-00-60
Page 408
Apr 11/08

Fig. 402 Gearbox - Breather Tube Torque Adapter

72-00-60
Page 409
Apr 11/08

72-00-60
410
Page
Blank
REAR BYPASS DUCT ASSY - REMOVAL/INSTALLATION
TASK 72-00-71-020-801 Remove the Rear Bypass Duct Assembly
1. General
This task covers removal of the rear bypass duct assembly from the engine. Refer to the following
illustration(s):
Figure 401 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
Figure 402 Rear Bypass Duct - Removal/Installation
SUBTASK 72-00-71-945-001
76-20-01 501 LP Shaft Trip Sensor - Adjustment/Test
3. Job Set-up
SUBTASK 72-00-71-010-001
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and do the following:
(a) Remove the cowling.
(b) Remove the tailpipe.
72-00-71
Page 401
Apr 11/08

4. Procedures
SUBTASK 72-00-71-020-002
A. Remove Rear Bypass Duct and Related Parts
(1) Remove the two screws (280, 76-20-01) and the two washers (20, 76-20-01) which attach the
cover plate (290, 76-20-01) to the LP trip sensor housing. Remove the cover plate.
(2) Measure and record trigger pin end play. Refer to 76-20-01, P.B. 501 in the Maintenance
Manual.
(3) Remove two screws (1-270, 76-20-01), four washers (1-20, 76-20-01), and two nuts
(1-260, 76-20-01) which attach the cable actuator housing (1-240, 76-20-01) to the LP
trip sensor housing. Refer to Figure 401 Rear Bypass Duct - Cable Actuator Housing -
(4) (FJ33 Only) Remove the trip sensor cable from the FDU support boss.
(5) Remove the cable actuator housing by sliding the housing straight forward. Wrap a protective
covering on the open end of the housing to prevent contamination and accidental actuation.
(6) Remove trigger pin (1-100, 76-20-01) from housing.
(7) While holding the LP trip lever (1-50, 76-20-01) (through the trip lever housing), push
adjustment spring (1-40, 76-20-01) located on rear housing forward to release the trip lever.
Remove the trip lever through the trip lever housing.
NOTE Trip lever adjustment spring and spring shaft are not normally
removed during engine disassembly.
(8) If trip lever adjustment spring or spring shaft require removal, remove from bracket on rear
case/mixer as follows:
(a) Remove bolt (1-10, 76-20-01) and washer (120).
(b) Remove spring (1-30) and lever spring shaft (1-40).
(9) If required, remove drain fitting (160) and O-ring (150) from transfer tube adapter.
(10) Remove two screws (1-90), four washers (1-80), and two nuts (1-70) and remove the external
transfer tube adapter (1-140) from bottom of duct. Refer to Figure 402 Rear Bypass Duct -
(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.
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
B. Remove Rear Bypass Duct attaching hardware
(1) Remove 24 screws (1-40), 24 nuts (1-30), washers (1-20), and 10 brackets (1-50) securing the
rear bypass duct to the front bypass duct. Remove the rear bypass duct (1-10) from the engine.
(2) Remove the rear mount ring (1-60).
(3) Clean RTV from flange mating surfaces (if present).
TASK 72-00-71-420-801 Install the Rear Bypass Duct Assembly
5. General
This task covers installation of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 402 Rear Bypass Duct - Removal/Installation
Figure 403 Rear Bypass Duct - Apply RTV to Flanges
Figure 404 Rear Bypass Duct - ITT Bracket Locations
Catalog:
72-00-71, Fig. 01
2 We identify locations of all parts of the engine as if installed in an aircraft, viewed

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
72-00-71
Page 403
Apr 11/08

MAT-001 Oil, Engine
MAT-019 Acetone
MAT-093 Compound Retaining, 620
SUBTASK 72-00-71-944-002
B. Expendable Parts
IPC Reference
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
7. Procedures
SUBTASK 72-00-71-420-001
A. Apply RTV to mounting flange
72-00-71
Page 404
Apr 11/08

WARNINGS: 1 ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A

COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND
KEEP AWAY FROM HEAT, SPARKS, OR FLAME.
2 ACETONE IS A CLEAR LIQUID WHICH IS FLAMMABLE AND

COMBUSTIBLE. IT IS SUGGESTED THAT A SOURCE OF CLEAN
WATER BE AVAILABLE IN WORK AREA FOR FLUSHING EYES AND
SKIN. WEAR CHEMICAL PROTECTIVE GOGGLES, GLOVES, AND
CLOTHING TO PREVENT SKIN CONTACT. AVOID BREATHING
VAPORS AND MAKE SURE ADEQUATE VENTILATION IS AVAILABLE
OR USE A RESPIRATOR. CONSUMPTION OF ACETONE MAY
BE HAZARDOUS TO YOUR HEALTH.
(1) Clean the bottom 180 degrees of the flange area mating surfaces of the rear bypass duct,
mount ring, and front bypass duct. Use a cloth soaked with isopropyl alcohol (MAT-027) or
acetone (MAT-019).
(2) Apply RTV sealant MAT-090 to the bottom 180 degrees of the flange mating surfaces of the
rear bypass duct, mount ring, and front bypass duct. See Figure 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
B. Mount rear bypass duct
(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.
(3) Install rear mount sleeve on rear mount ring.
SUBTASK 72-00-71-420-005
C. Install transfer tube and drain fitting
(1) Lube two O-rings (1-120 and 1-100) with assembly fluid (MAT-011) and install on transfer
tube (1-110). Install transfer tube into port. Refer to Figure 402 Rear Bypass Duct -
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):
(1) Install and adjust the trigger pin
(a) Insert the trigger pin through the LP trip sensor housing bushing to check for free travel.
Insert both ends of the pin and slide it all the way to the adjustment screw. Reject trigger
pin if it binds. Remove trigger pin from bushing.
(b) If lever adjustment spring and shaft were removed from the rear case/mixer, install
them as follows:
1 Install the shaft (1-40, 76-20-01) and position on the forward side of the bracket
2 Coat the threads of the bolt (1-10) with retaining compound (MAT-093).
3 Install the washer (1-20) and spring (1-30) on the bolt. Install the bolt into the
shaft from the aft side of the bracket.
4 Torque the bolt 25 to 28 inch-pounds (2.8 to 3.2 N.m).
(c) Slide the trip lever assembly (1-50, 76-20-01) through the trip sensor housing and the
rear housing strut with the trip lever notch facing forward. Push the adjustment spring
(1-40, 76-20-01) (located on the rear housing) forward to allow trip lever to enter. Release
the adjustment spring when the trip lever notch is aligned with the slot in the adjustment
spring bolt. Move the lever axially to make sure that it does not bind.
(d) Insert the trigger pin (1-100, 76-20-01) through the bushing on the LP trip sensor housing
assembly (part of the rear bypass duct).
(e) Position the trip lever by pulling it radially outward until the pin contacts the top of the trip
lever cup. Look through the witness hole at the bottom of the lever cup to make sure
that the pin is seated properly.
(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:
72-00-71
Page 406
Apr 11/08

1 Trigger pin end play dimension was not acceptable before disassembly.
2 Trip lever adjustment screw has been disturbed
3 Trip lever, rear housing, or rear bypass duct were replaced.
NOTE If the trigger pin was damaged or lost, the trigger pin dimension must
be recalculated. Refer to 76-20-01, P.B. 501. If trip mechanism was
actuated, mechanism must be reset. Refer to 76-20-01 P.B. 501.
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.
(a) Install the tailpipe.
(b) Install the cowling.
(2) Close Aircraft circuit breakers.
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.
72-00-71
Page 407
Apr 11/08

Fig. 401 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
72-00-71
Page 408
Apr 11/08

Fig. 402 Rear Bypass Duct - Removal/Installation
72-00-71
Page 409
Apr 11/08

Fig. 403 Rear Bypass Duct - Apply RTV to Flanges
72-00-71
Page 410
Apr 11/08

Fig. 404 Rear Bypass Duct - ITT Bracket Locations
72-00-71
Page 411
Apr 11/08

72-00-71
412
Page
Blank
INTERNAL COOLING AND SEALING AIR SYSTEM - DESCRIPTION AND OPERATION
TASK 72-02-00-860-801 Internal Cooling and Sealing Air System - Description and Operation
1. General
Cooling air is important in maintaining the long life of the core engine parts by keeping them from getting
too hot. Pressurized air is used to seal one area of the engine from another. Intermediate pressure (IP)
compressor air, high pressure (HP) compressor air, and compressor discharge pressure (CDP) air are
used for sealing and cooling engine areas and parts.
2. Description and Operation
SUBTASK 72-02-00-860-002
A. Air Seals
The primary function of the air seals is to prevent air pressure from leaking at different areas of
the engine. Another function of the air seals is to vent cooling air to hot engine parts, mainly the
HP and LP turbine rotors.
Compressor discharge pressure (CDP) air from the diffuser is routed to the heat exchanger where it
is cooled and returned via the 1st LP nozzle to the No. 3 and 4 carbon seals and bearing cavities.
The rest of the CDP air is routed to the LP turbine discs through integral 1st nozzle air tubes.
B. Oil Seals
The No. 3 and No. 4 bearing cavity oil seals receive CDP sealing air through the 1st LP turbine
nozzle.
C. Cooling Air
Cooling air from the HP compressor cools the HP nozzle (hollow) vanes, the HP turbine disc fir trees,
and the fuel slinger/seal assembly.
D. Breather System
Sealing air is mixed with oil in the bearing cavities and is then scavenged back to the gearbox. The
gearbox contains an air/oil separator to remove the air from the oil. After separation, the air is
routed overboard by a breather tube.
72-02-00
Page 1
Apr 11/08

72-02-002
Page
Blank
SPINNER - INSPECTION/CHECK
TASK 72-30-10-220-801 Visually Inspect the Spinner
1. General
This task covers visual inspection of the spinner after it is removed from the engine.
Catalog:
72-00-30, Fig. 01
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
SUBTASK 72-30-10-945-003
72-30-10 801 Spinner - Repair
3. Procedures
SUBTASK 72-30-10-220-002
A. Visual Inspection
72-30-10
Page 601
Apr 11/08

(1) Inspect the spinner tip for:
(a) Blunted condition within the limits Repair, refer to 72-30-10, P.B. 801
of repair.
(b) Blunted condition greater than the Reject

limits of repair
(2) Inspect the spinner surface for:
(a) Minor erosion, evidenced by a Remove roughness by lightly smoothing.

rough surface and multiple small,
shallow pits closely grouped (.005
inch max depth).
(b) Nicks within the limits of repair. Repair, refer to 72-30-10, P.B. 801
(c) Nicks greater than the limits of repair Reject
(d) Scratches/gouges within the limits Repair, refer to 72-30-10, P.B. 801
of repair
(e) Scratches/gouges greater than the Reject

limits of repair.
(f) Dents within the limits of repair. Repair, refer to 72-30-10, P.B. 801
(g) Dents greater than the limits of repair Reject
72-30-10
Page 602
Apr 11/08

SPINNER - REPAIR
TASK 72-30-10-350-801 Blend Repair the Spinner
1. General
This task contains procedures for repairing the spinner by blending out damage and restoring the correct
profile of the tip. Do this task if the component inspection/check task indicates that the damage is
repairable. Refer to the following illustration(s):
Figure 801 Spinner - Repair
SUBTASK 72-30-10-941-004
Handstone
SUBTASK 72-30-10-942-004
B. Consumables
SUBTASK 72-30-10-945-004
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
3. Procedures
SUBTASK 72-30-10-350-002
A. General Blend Requirements
(1) Surface blends must be made to a concave diameter at least 10 times the blend depth. Use
handstone for blending.
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
Table 801 Blend Limits FJ44
MAX DAMAGE SIZE MAX NUMBER OF BLENDS

Minor erosion See General Blend Requirements
0.015 inch deep face nicks Total area of nicks not to exceed 0.625 square inches
Scratches or gouges up to: Total area of scratches/gouges not to exceed 0.5
0.015 inch deep by 0.1 inch wide by 0.1 inch long; or square inches
0.005 inch deep by 0.010 inch wide by 0.5 inch long;
or
0.007 inch deep by 0.020 inch wide by 0.5 inch long.
0.10 inch deep dents; 0.5 inch max diameter Five dents maximum
Dents or nicks on spinner aft edge up to 0.050 inch Max quantity of 5 defects per part.
(1.27 mm) from edge face Surface length and radius of blends must be 3 times
the max blend depth.
Repaired areas checked using local penetrant
inspection. Refer to 70-42-15, P.B 601 for NDI
methods. No cracks allowed.
C. Repair blunted spinner tip as follows:
(1) The maximum damage allowed is that which can be repaired by grinding the tip to a maximum
radius of:
(a) FJ44-1 Series: 0.050 inch (1.27 mm)
(b) FJ44-2 Series: 0.080 inch (2.03 mm)
(c) FJ44-3 Series and FJ44-1AP: 0.080 inch (2.03 mm)
(d) FJ33 Series: 0.064 inch (1.62 mm)
(2) Machine the spinner tip within the limits of repair (Figure 801 Spinner - Repair). Refer to
70-42-11, P.B. 801.
72-30-10
Page 802
Apr 11/08

WARNING ANODIC SOLUTION (IRIDITE) IS TOXIC TO SKIN, EYES, AND

LUNGS. YOU MUST WEAR SKIN AND EYE PROTECTION. AVOID
REPEATED OR PROLONGED CONTACT. GOOD GENERAL
VENTILATION IS USUALLY SUFFICIENT.
(3) Apply 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.
72-30-10
Page 803
Apr 11/08

Fig. 801 Spinner - Repair
72-30-10
Page 804
Apr 11/08

SPINNER PILOT PLATE ASSY - INSPECTION/CHECK
TASK 72-31-15-220-801 Visually Inspect the Spinner Pilot Plate Assembly
1. General
This task covers visual inspection of the spinner pilot plate assembly. Refer to the following illustration(s):
Figure 601 Spinner Pilot Plate Assembly - Inspection
Catalog:
72-31-15, Fig. 01
SUBTASK 72-31-15-945-001
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:
(1) Burrs on pilot diameter Repair, refer to 70-42-11, P.B. 801
(2) Missing or damaged shank nuts Reject.
(3) Loose or missing roll pin Reject.
72-31-15
Page 602
Apr 11/08

Fig. 601 Spinner Pilot Plate Assembly - Inspection
72-31-15
Page 603
Apr 11/08

72-31-15
604
Page
Blank
FAN ROTOR - INSPECTION/CHECK
TASK 72-31-20-220-801 Visually Inspect the Fan Rotor
1. General
This task covers visual inspection of the fan rotor. Refer to the following illustration(s):
Figure 601 Fan Blade - Inspection Zones
Catalog:
72-00-31, Fig. 01
SUBTASK 72-31-20-945-003
71-00-30 601 IP and HP Compressors (Borescope) - Inspection/Check
72-31-20 801 Fan Rotor - Repair
72-31-20
Page 601
Apr 11/08

3. Job Set-up
SUBTASK 72-31-20-010-003
WARNING SPINNER TIP IS EXTREMELY SHARP. USE CAUTION WHEN WORKING

AROUND SPINNER TO AVOID INJURY.
1. If you find damage to fan that indicates foreign object damage,

you must do a borescope inspection of the compressor section.
Refer to 710030, P.B. 601.
2. If periodic inspection requirements require physical inspection

of fan rotor, all accessible surfaces must be closely examined
by touch and/or close visual inspection.
A. Prepare to inspect the Fan Rotor
(3) Remove the cowl. Refer to the Aircraft Maintenance Manual.
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):
(1) Inspect the blade roots (Zone A) for:
(a) Cracks, nicks, gouges, or other Reject

damage
(b) Erosion or scratches within limits Repair, refer to 72-31-20, P.B. 801
of repair.
(c) Erosion greater than limits of repair Reject
(2) Inspect the blade leading edges (Zones B, C, and D) for:
(a) Dents, nicks, or erosion within limits Repair, refer to 72-31-20, P.B. 801
of repair.
(b) Dents or nicks greater than limits Reject

of repair.
(3) Inspect the blade trailing edges (Zones E1 and E2) for:
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
(b) Nicks or dents greater than limits Reject

of repair
(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.
(4) Inspect the blade face surfaces (Zone F) for:
(a) Nicks within the limits of repair Repair, refer to 72-31-20, P.B. 801
(b) Nicks greater than limits of repair Reject
(5) Inspect fan rotor tip (Zone D2) for:
(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
(b) Rub indication or damage greater Reject

than limits of repair
(c) Blue discoloration up to 0.125 inch Accept for FJ44-1 and FJ44-2. Reject
(3.18 mm) depth for FJ44-3.
(d) Blue discoloration greater than 0.125 Reject

inch (3.18 mm) depth
(6) Area between blades
(a) Smooth machine tool marks on fan Accept

hub between blades up to 0.003 inch
(0.076 mm) deep
SUBTASK 72-31-20-220-006
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.
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:
(a) Deflection measures 0.070 inch (1.778 mm) or less.
(b) Hot straightening is not allowed if deflection is inboard of a point that is either 0.250
inches above the rim or 20% of blade span (distance between hub and tip of blade),
whichever is greater.
(c) No more than three locations on a leading or trailing edge may be straightened.
SUBTASK 72-31-20-220-002
C. If fan rotor is removed (per scheduled maintenance requirements) inspect the bore/spline/web face
areas of fan rotor bore for:
(1) Inspect the splines for:
(a) Cracks, chips, gouges Reject
(b) Fretting indications (material transfer) Accept

which cannot be felt with a 0.060 inch
diameter stylus.
(c) Fretting indications (material transfer) Reject

which can be felt with a 0.060 inch
diameter stylus.
(d) Slight deformation of spline leading Remove raised material with hand stone
edge due to assembly damage up to
0.020 inch (0.50 mm) long x 0.002
inch (0.050 mm) deep.
(2) Inspect the bore for:
(a) Cracks, chips, gouges, dents Reject
(b) Scratches on pilot diameters Accept
(c) Fretting indications (material transfer) Reject

which can be felt with a 0.060 inch
diameter stylus.
(3) Inspect the forward and aft clamp faces of the bore for:
(a) Fretting Reject
(b) Wear Reject
(4) Inspect the webface of the rotor for:
72-31-20
Page 604
Apr 11/08

(a) Cracks, nicks, gouges Reject
(5) Inspect the spinner clearance area of the rotor for:
(a) Tool mark (nick or dent) up to 0.010 Blend with aluminum oxide cloth to remove
inch (0.25 mm) deep raised material or sharp edges.
(6) Inspect the puller shoulder area of the rotor for:
(a) Burr on edge from tool contact. Remove raised material with hand stone
and smooth sharp edge with aluminum
oxide cloth. Perform NDI inspection
on repaired area.
SUBTASK 72-31-20-220-005
D. Measure fan rotor tip clearance as follows:
NOTE Measure tip clearance at the blade leading edge only.
(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.
72-31-20
Page 605
Apr 11/08

Fig. 601 Fan Blade - Inspection Zones
72-31-20
Page 606
Apr 11/08

FAN ROTOR - REPAIR
TASK 72-31-20-350-802 Blend Repair the Fan Rotor
1. General
This task contains procedures for repairing the fan rotor by blending and restoring the surface finish to
damaged areas. This task also describes the extent of damage which may be repaired by this method.
Refer to 72-31-20, P.B. 601 for visual inspection criteria. Refer to the following illustration(s):
Figure 801 Tungsten Carbide Rotary Burr
Figure 802 Fan Blade - Inspection Zones
Figure 803 Fan Blade - Blending of Deep Nicks
SUBTASK 72-31-20-941-005
Tungsten Carbide Rotary Burr
Carborundum Stone
SUBTASK 72-31-20-942-005
B. Consumables
MAT-042 Paper, Abrasive, Silicone Carbide
SUBTASK 72-31-20-945-005
70-42-15 601 Non-Destructive Inspection (NDI) Methods - Inspection/Check
72-31-20 601 Fan Rotor - Inspection/Check
72-31-20
Page 801
Apr 11/08

3. Job Set-up
SUBTASK 72-31-20-010-005
WARNING SPINNER TIP IS EXTREMELY SHARP. USE CAUTION WHEN WORKING

AROUND SPINNER TO AVOID INJURY.
A. Prepare to Blend Repair the Fan Rotor
4. Procedures
SUBTASK 72-31-20-350-002
A. Repair the Fan Rotor
(1) Clean the fan blades before blending or inspection.
72-31-20
Page 802
Apr 11/08

CAUTIONS: 1 THE FAN IS MADE OF TITANIUM. DO NOT GRIND. USE A CLEAN

TUNGSTEN CARBIDE ROTARY BURR (SEE FIGURE 801 TUNGSTEN
CARBIDE ROTARY BURR). PLACE RUBBER BLOCK BETWEEN
THE BLADE TO BE REPAIRED AND AN ADJACENT BLADE TO
DAMPEN VIBRATION AND ADD SUPPORT.
2 BE EXTREMELY CAREFUL WHEN BLENDING BLADES TO MAKE

SURE THAT TITANIUM IS NOT OVERHEATED (TOO HOT TO TOUCH).
OVERHEATING RESULTS IN A BLUE DISCOLORATION AND THE BLADE
IS EASILY CRACKED. IF THE FAN IS OVERHEATED, AS EVIDENCED
BY BLUE DISCOLORATION, RETURN THE FAN TO WILLIAMS
INTERNATIONAL FOR EVALUATION. REFER TO VISUAL INSPECTION
TASK FOR ALLOWABLE LIMITS FOR BLUE DISCOLORATION ON THE
TIP OF THE FAN BLADES. IF NECESSARY, SMOOTH ANY MATERIAL
THAT HAS DISPLACED ONTO THE PRESSURE SIDE OF THE BLADE.
USE 180 GRIT ALUMINUM OXIDE (MAT-040) OR SILICON CARBIDE
(MAT-042) CLOTH TO FINISH BLEND THE BLADES TO REMOVE
ANY NICKS, SHARP EDGES, OR TOOL MARKS.
3 IF BLENDING IS PERFORMED ON INSTALLED FAN ROTOR, DO NOT

ALLOW ANY REMOVED MATERIAL OR FOREIGN OBJECTS TO ENTER
COMPRESSOR GAS PATH WHEN BLENDING BLADES. ENGINE
WILL BE DAMAGED IF IT IS OPERATED WITH BLENDING DEBRIS
OR OTHER FOREIGN OBJECTS IN THE GAS PATH. USE VACUUM
EQUIPMENT TO ENSURE THAT ALL DEBRIS IS REMOVED.
4 FAN REPAIRS ALLOWED PER THE MANUAL MAY CAUSE

UNACCEPTABLE ACOUSTICAL EFFECTS (NOISE). IF SUCH
A CHARACTERISTIC IS INTRODUCED REPLACEMENT OF
THE FAN WILL BE REQUIRED.
(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.
(3) Blend Limits:
72-31-20
Page 803
Apr 11/08

ZONE MAX BLENDABLE DAMAGE SIZE ALLOWABLE EXTENT OF BLEND

A No damage allowed. If there is a minor Light smoothing to remove any
scratch (<0.001 inch deep), polish roughness on the leading edge. No
to remove scratch. It is acceptable blending allowed.
to have minor erosion, evidenced
by rough leading edges (minute
serrations) and multiple small shallow
pits closely grouped.
B 0.060 inch deep dents and nicks. Total edge blending in Zone B not to
exceed 1 inch per blade. See Notes
1 and 3.
C 0.100 inch deep dents and nicks. Total edge blending in Zone C not to
exceed 1.5 inch per blade. See Notes
2 and 3.
D Not to exceed the zone dimensions Dimension "M" not to exceed 0.25
shown in Figure 802 Fan Blade - inch per blade. Dimension "N" not to
Inspection Zones exceed 1.0 inch per blade. See Note
1 and 3.
D2 (1) Blade-thickness grooves or (1) Smooth blend to remove sharp

scratches not to exceed 0.016 inch edges and raised material.
(0.40 mm) in depth. Three blades may (2) Blend for cosmetic acceptability
be blended up to 0.025 inch (0.63 mm) per general blend instructions.
deep. (3) Remove with MAT-040 or MAT-042
(2) Face nicks to 0.020 inch (0.50 abrasive paper using light pressure.
mm), 4 total per blade
(3) Aluminum metal build-up
E1 0.10 inch deep dents and nicks Total edge blending in Zone E1 not to
exceed 1.75 inch per blade. See Note
2.
E2 0.10 inch deep dents and nicks Total edge blending in Zone E2 not to
exceed 2.25 inch per blade. See Note
1.
72-31-20
Page 804
Apr 11/08

ZONE MAX BLENDABLE DAMAGE SIZE ALLOWABLE EXTENT OF BLEND

F 0.020 inch deep face nicks. Five per side unless some are
back-to-back, then six total. See Note
3.
NOTES: 1 Total number of Zones B, D, or E2 blends per rotor not to exceed

8 of each kind. No more than four adjacent blended blades
of any of these types per rotor.
2 Total allowable length of Zone C and E1 blends per rotor is limited to:1.5 x
Length of All Zone C Blends + Length of All Zone E1 Blends = 15 Inch Max.
No more than three adjacent blended blades allowed per rotor.
3 For multiple nicks less than 0.050 inch in length x 0.015 inch in depth, in
Zones:B,C,D, and F, light smoothing to remove raised metal is allowed.
(4) Remove blade damage as follows:
(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).
(b) Polish scored surfaces with aluminum oxide cloth.
(c) If blending installed fan, use vacuum to remove metal particles from inlet case.
(5) Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure
802 Fan Blade - Inspection Zones and Figure 803 Fan Blade - Blending of Deep Nicks.
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
72-31-20
Page 806
Apr 11/08

Fig. 801 Tungsten Carbide Rotary Burr
72-31-20
Page 807
Apr 11/08

Fig. 802 Fan Blade - Inspection Zones
72-31-20
Page 808
Apr 11/08

Fig. 803 Fan Blade - Blending of Deep Nicks
72-31-20
Page 809
Apr 11/08

72-31-20
810
Page
Blank
CASE AND INSERT ASSEMBLY - INSPECTION/CHECK
TASK 72-32-10-220-801 Visually Inspect the Case and Insert Assembly
1. General
This task covers visual inspection of the inlet case and fan shroud insert. Refer to the following illustrations:
Figure 601 Case and Insert Assembly - Inspection
Figure 602 Case and Insert Assembly - Flange and Shroud Inserts
Catalog:
72-00-32, Fig. 01 and 72-32-10, Fig. 01
SUBTASK 72-32-20-941-001
Handstone
SUBTASK 72-32-20-942-001
B. Consumables
72-32-10
Page 601
Apr 11/08

SUBTASK 72-32-10-945-001
3. Procedures
SUBTASK 72-32-10-220-001
A. Visually inspect case as follows:
NOTES: 1 If the case and insert assembly is rejected and requires replacement, the engine
identification plate must be removed and installed on the new case and insert
assembly. Refer to 723210, P.B. 801 in the Maintenance Manual.
(1) Inspect case surface for:
CAUTION DO NOT CONTACT ALUMINUM INSERT WITH ACID SOLUTION.
(a) Corrosion with pitting of ID surface 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.
(2) Inspect the forward flange insert for:
(a) Bends or distortion Reject
(b) Wear/fretting with material transfer Reject

that is detectable by a 0.060 inch
diameter stylus
(c) Wear/fretting less than previous step Accept
72-32-10
Page 602
Apr 11/08

(d) Loose or missing rivet Replace in accordance with approved

Repair Station instructions.
(3) Inspect the rear flange of the inlet case for:
(a) Bends or distortion Reject
(b) Wear/fretting with material transfer Reject

that is detectable by a 0.060 inch
diameter stylus
(c) Wear/fretting less than previous step Accept
(4) Inspect the outer surfaces and inner flowpath of the inlet case for:
(a) Nicks, gouges, dents; 0.030 inch Accept

(0.762 mm) deep x 0.25 (6.35 mm)
length and width; must be separated
by 2 inches (50.8 mm); 5 total
(b) Nicks, gouges, dents greater than Reject

previous step
(c) Wear mark on outer case forward of Blend down to 0.010 inch max depth with
weld up to 0.008 inch (0.20 mm) deep brite boy rubberized stone. Perform local
x 0.170 inch (4.31 mm) wide x 0.666 penetrant inspection on repaired area.
inch (16.9 mm) long.
SUBTASK 72-32-10-220-002
B. Inspect the fan shroud insert for:
(1) Bends or distortion Reject
(2) Loose or missing rivets Replace in accordance with approved

Repair Station instructions.
(3) Nicks, gouges, dents up to 0.080 inch Blend to remove raised material or sharp
(2.03 mm) depth corners using handstone.
(4) Nicks, gouges, dents greater than previous Reject

step
(5) Visible cracks Blend to remove cracks using length and

width to depth ratio of 5 to 1.
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.
(8) Chipping or damage to abradable greater Reject

than previous steps
(9) Blistering or craze cracking of the Accept

abradable.
4. Job Close-up
SUBTASK 72-32-10-220-050
72-32-10
Page 604
Apr 11/08

Fig. 601 Case and Insert Assembly - Inspection
72-32-10
Page 605
Apr 11/08

Fig. 602 Case and Insert Assembly - Flange and Shroud Inserts
72-32-10
Page 606
Apr 11/08

CASE AND INSERT ASSEMBLY - REPAIR
TASK 72-32-10-350-801 Replace the Engine Identification Plate
1. General
This task contains procedures for removing the engine identification plate from the inlet case and installing
it on a new case and insert assembly. Refer to the following illustration(s):
Figure 801 Case and Insert Assembly - Engine Identification Plate - Replace
SUBTASK 72-32-10-942-005
A. Consumables
MAT-096 Primer, Epoxy
SUBTASK 72-32-10-944-005
B. Expendable Parts
IPC Reference
72-32-10 1 90 Stud, Grooved (4)
SUBTASK 72-32-10-945-005
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
A. Replace the engine identification plate as follows:
72-32-10
Page 801
Apr 11/08

CAUTION USE CARE NOT TO DEFORM MOUNTING HOLES IN INLET CASE.
(1) Carefully drill and/or punch-out the four grooved studs which hold the identification plate to
the inlet case.
(2) Remove the engine identification plate.
(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.
72-32-10
Page 802
Apr 11/08

Fig. 801 Case and Insert Assembly - Engine Identification Plate - Replace
72-32-10
Page 803
Apr 11/08

72-32-10
804
Page
Blank
FAN STATOR - INSPECTION/CHECK
TASK 72-32-20-220-801 Visually Inspect the Fan Stator
1. General
This task covers visual inspection of the fan stator. Refer to the following illustration(s):
Figure 601 Fan Stator Vanes - Inspection Zones
Catalog:
72-00-32, Fig. 01
SUBTASK 72-32-20-945-001
72-32-20 801 Fan Stator - Repair
72-32-20
Page 601
Apr 11/08

3. Job Set-up
SUBTASK 72-32-20-010-001
A. Prepare to inspect the fan stator:
SUBTASK 72-32-20-020-001
B. Remove the spinner. Refer to 720030, P.B. 401.
SUBTASK 72-32-20-020-002
C. Remove the fan rotor. Refer to 720031, P.B. 401.
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. Inspect the Fan Stator
(1) Inspect stator vane face surfaces (Zone A) for:
(a) Erosion within limits of repair. Repair, refer to 72-32-20, P.B. 801
(b) Erosion greater than previous step. Reject
(c) Nicks or pits within limits of repair. Repair, refer to 72-32-20, P.B. 801
(d) Nicks or pits greater than previous Reject

step
(e) Pitting on vane surfaces from Accept

corrosion that is less than 0.008 inch
(0.20 mm) deep.
(2) Inspect the leading and trailing edges of the stator vanes (Zone B for FJ44-1; 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.
72-32-20
Page 602
Apr 11/08

(b) Nicks or dents greater than previous Reject

step.
(c) Erosion on leading edge within Repair, refer to 72-32-20, P.B. 801
limits of repair.
(d) Deflection (bending) of leading edge Maximum size of deflection is 0.110

from FOD. inch (2.794 mm). Straighten to best
condition using soft jaw pliers. Perform
fluorescent penetrant inspection on vanes
in accordance with Task 72-32-20-230-801
for final acceptance.
(3) Inspect the outer casing of the fan stator for:
NOTE Gouges that penetrate the outer casing are acceptable in one defect area
only. Gouges must not penetrate stiffening ring. Gouges that penetrate an
area where there is no stiffening ring are not acceptable.
(a) Gouges, dents, or holes within the Repair, refer to 72-32-20, P.B. 801
limits of repair
(b) Gouges, dents, or holes greater than Reject

previous step.
(4) Inspect the inner casing of the fan stator for:
(a) Gouges or dents within the limits Repair, refer to 72-32-20, P.B. 801
of repair
(b) Gouges or dents greater than Reject

previous step
(5) Inspect the forward lip seal for:
(a) Rips on inner casing metal within the Repair, Refer to 72-32-20, P.B. 801
limits of repair.
(b) Damage greater than previous step Reject
(6) Inspect the center IP laby seal for:
(a) Assembly damage (cut) on aft edge of Accept

rubber material. Max circumference
of damaged area 180 max depth
0.005 inch (0.127 mm).
72-32-20
Page 603
Apr 11/08

(b) Voids in rubber material up to max Accept

depth of 0.120 inch (3.04 mm) and
max diameter of 0.205 inch (5.20
mm). No voids breaking into side of
rubber. Minimum distance between
voids 0.40 inch (10.16 mm).
(c) (FJ441 Only) Grooves from laby Accept

seal rub or assembly damage up to
0.030 inch (0.76 mm) deep.
(d) Damage or voids greater than Reject

previous steps
(7) Inspect the urethane material which secures the vanes:
(a) Local discoloration and/or Accept

deformation (swelling) up to 0.060
inch (1.524 mm) in a 1 to 2 inch area
on the inner diameter. Vanes are not
loose. Half or more of the vane tip or
hub is incased in urethane that has
not become discolored.
(b) Damage, swelling, or discoloration of Reject

urethane greater than previous step.
(c) Wear in the outer urethane due to Wear that has gone through the urethane
contact with the fan case anti-rotation with some material loss on the vane is
keys. acceptable. Wear that has gone through
the vane is not acceptable.
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.
72-32-20
Page 604
Apr 11/08

Fig. 601 Fan Stator Vanes - Inspection Zones
72-32-20
Page 605
Apr 11/08

72-32-20
606
Page
Blank
FAN STATOR - REPAIR
TASK 72-32-20-350-801 Blend Repair the Fan Stator
1. General
This task contains procedures for repairing the fan stator by blending and restoring the surface finish to
damaged areas or welding. This task also describes the extent of damage which may be repaired by
these methods. Refer to the following illustration(s):
Figure 801 Fan Stator Blades - Inspection Zones
SUBTASK 72-32-20-941-004
Handstones
5x Magnification
SUBTASK 72-32-20-942-004
B. Consumables
SUBTASK 72-32-20-945-004
3. Job Set-up
SUBTASK 72-32-20-010-002
A. Prepare to inspect the fan stator:
72-32-20
Page 801
Apr 11/08

SUBTASK 72-32-20-020-004
B. Remove the spinner. Refer to 720030, P.B. 401.
SUBTASK 72-32-20-020-005
C. Remove the fan rotor. Refer to 720031, P.B. 401.
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
A. Blend Repair the Fan Stator Vanes
NOTE If the inspection task reveals damage to the stator vanes, the vanes can be
dressed and blended, as permitted by the limits in this repair.
(1) Clean the fan stator vanes.
(2) Examine the fan stator vanes with a bright light and 5x magnification to check the amount of
damage. Refer to Figure 801 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):
72-32-20
Page 802
Apr 11/08

NOTE If damage exceeds limits, refer to weld repair criteria.
ZONE MAX DAMAGE SIZE MAX NUMBER OF BLENDS

Minor Erosion Minor erosion, evidenced by rough
leading edge (minute serrations) and
multiple small shallow pits closely
grouped, is acceptable to a max depth
of 0.005 inches. Only light smoothing
A is necessary to remove roughness on
leading edge.
0.010 inch deep face nicks Three per side unless back-to-back,
then four total
0.030 inch deep pit One per vane
0.08 inch dents (local bends) Two per vane
0.008 inch deep face nicks Two per side unless back-to-back,
B then two total.
Upper 50% 0.12 inch leading/trailing edge nicks Four per vane; Max total blending in
of Vane Zone B not to exceed 4 inch length
Erosion on leading edge up to 0.025 Smooth raised material while
inch deep maintaining leading edge contour.
C 0.060 inch max blend depth provided No more than 2 blends per vane
Lower 50% adjacent vane is blended less than leading edge.
of Vane 0.040 inch No more than 6 blends total (all
surfaces) per vane.
No more than 12 blended vanes per
part.
Blend depth less than 0.010 inch
should not be counted in the above
criteria. Any number of blends at this
depth on any number of vanes is
acceptable.
72-32-20
Page 803
Apr 11/08

ZONE MAX DAMAGE SIZE MAX NUMBER OF BLENDS

0.25 inch by 0.25 inch gouges No limit
0.50 inch diameter dents 10 Maximum
0.25 inch diameter holes 10 Maximum - Holes in outer casing
may be weld repaired and finished
Outer Casing flush with the adjacent casing surface.
Refer to applicable Repair Station
Planning.
Forward edge only: 0.150 deep by 3.0 4 separate blend areas separated by
inch long (circumferential) 2.0 inches circumferential length.
0.10 inch by 0.10 inch gouges No limit
Inner Casing
0.15 inch diameter dents 10 Maximum
Forward Lip 0.100 inch by 0.100 inch metal rips Two per part. Blend 3 times longer
Seal Inner than the depth of blend. Some rubber
Casing may be removed (minimize removal).
Radius sharp edges smoothly
SUBTASK 72-32-20-350-006
C. Remove damage as follows:
(1) Repair damage to vanes by blending using handstones. Refer to Blend Limits table and Figure
801 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.
(f) Polish scored surfaces with aluminum oxide cloth (MAT-040).
D. Visually inspect the repaired areas. Make sure they conform to the limits and contours in Figure 801
Fan Stator Blades - Inspection Zones.
72-32-20
Page 804
Apr 11/08

WARNING ANODIC SOLUTION (IRIDITE) MAT-050 IS TOXIC TO SKIN, EYES,

AND LUNGS. YOU MUST WEAR SKIN AND EYE PROTECTION.
AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL
VENTILATION IS USUALLY SUFFICIENT.
E. Apply anodic solution (iridite) (MAT-050) to repaired areas. Refer to 70-42-12, P.B. 801 in the
Maintenance Manual.
5. Job Close-up
SUBTASK 72-32-20-350-050
72-32-20
Page 805
Apr 11/08

Fig. 801 Fan Stator Blades - Inspection Zones
72-32-20
Page 806
Apr 11/08

GEARBOX CARBON SEALS - REMOVAL/INSTALLATION
TASK 72-60-01-050-802 Remove Magnetic Carbon Seals from Gearbox
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
CAUTIONS: 1 THERE ARE DIFFERENT CONFIGURATIONS OF GEARBOX CARBON SEALS

WITH ALTERNATE REMOVAL/INSTALLATION INSTRUCTIONS. REFER TO THE
ILLUSTRATED PARTS CATALOG AND MAKE SURE THAT YOU IDENTIFY THE
CORRECT CONFIGURATION AND ARE WORKING TO THE CORRECT TASK
THIS TASK COVERS THE CONFIGURATION WITH MAGNETIC SEAL RUNNERS.
2 TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER ALL

OPEN PORTS IN THE GEARBOX WHEN NOT IN USE. MAKE SURE TOOLS
AND FINGERS ARE CLEAN DURING MAINTENANCE.
NOTE During removal of parts, group all components together to make assembly easier.
SUBTASK 72-60-01-945-003
72-00-60 401 Gearbox Assy - Removal/Installation
3. Job Set-up
SUBTASK 72-60-01-010-004
A. Prepare the engine for part replacement
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:
Hydraulic pump mount (AMM)
Starter/generator mount (AMM)
Fuel pump mount (73-16-01, P.B. 401)
WARNING ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE

CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT CONTACTS
THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
EXPOSED TO FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.
(1) Remove 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.
CAUTIONS: 1 DO NOT TOUCH GEARBOX BEARINGS WHEN REMOVING

CARBON SEALS.
2 WHEN REMOVING FUEL PUMP CARBON SEAL, HOLD GEARSHAFT

FORWARD WHILE REMOVING CARBON SEAL. THIS WILL KEEP
BEARING FROM MOVING AND BECOMING MISALIGNED.
3 TO PREVENT DAMAGE TO MATING FACES DO NOT SLIDE

SEAL CASE ACROSS MAGNET. AVOID PLACING MAGNET IN
AREA WHERE SMALL METAL CHIPS MAY BE ATTRACTED TO IT.
KEEP THE MAGNET AND CASE PORTIONS OF THE MAGNETIC
CARBON SEAL TOGETHER AFTER DISASSEMBLY. HANDLE SEAL
ASSEMBLY CAREFULLY TO PREVENT DAMAGE.
(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:
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):
CAUTION TO PREVENT CONTAMINATION, PLACE PROTECTIVE COVERS OVER

ALL OPEN PORTS IN THE GEARBOX WHEN NOT IN USE.
NOTE The hydraulic pump gearshaft must be removed from the gearbox when
reinstalling or replacing the aft magnetic carbon seal.
(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.
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.
STORE GEARSHAFT IN A CLEAN PLASTIC BAG.
(3) Carefully remove the hydraulic pump gearshaft from the gearbox.
(4) Carefully remove the forward and aft carbon seal cases from the gearshaft.
CAUTION TO PROTECT THE SEAL BORE IN THE GEARBOX HOUSING FROM

DAMAGE, DO NOT USE METAL TOOLS TO REMOVE THE AFT MAGNET.
MAKE SURE THAT ALL TOOLS ARE CLEAN.
(5) Remove the breather tube. Refer to 72-00-60, P.B. 401.
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
Figure 404 Gearbox Carbon Seals Type 1 Spring-Loaded Configuration (8k) Removal/Installation

THIS TASK COVERS THE TYPE 1 SPRING-LOADED CONFIGURATION

WITH NON-MAGNETIC SEAL RUNNERS.

SUBTASK 72-60-01-943-002
A. Special Tools
TL99696 Kit, Gearbox Seal Installation/Removal
SUBTASK 72-60-01-945-050
72-60-01
Page 404
Apr 11/08

7. Job Set-up
SUBTASK 72-60-01-010-050
8. Procedures
SUBTASK 72-60-01-020-050
A. Use the following procedure to remove spring-loaded carbon seal from the starter/generator location:

(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.
CAUTION WEAR CLEAN, LINT-FREE GLOVES TO PREVENT BEARING

CONTAMINATION.
(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.
(5) Cover open ports in gearbox to prevent contamination
SUBTASK 72-60-01-020-051
B. Use the following procedure to remove spring-loaded carbon seal from the fuel pump location:
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.

CONTAMINATION.
(5) Remove the seal runner (74) from the gearshaft. Use puller from TL99696 kit, or equivalent.
SUBTASK 72-60-01-020-052
C. Use the following procedure to remove spring-loaded carbon seal from the hydraulic pump location:

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT

TO PREVENT BEARING CONTAMINATION.
(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.
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.
NOTE In order to remove/install the breather port carbon seal assembly, it is

necessary to remove the hydraulic pump gearshaft from the gearbox.
(3) Remove the hydraulic pump adapter and the hydraulic pump gearshaft in accordance with
Subtask 72-60-010-020-052, above. It is not necessary to remove the hydraulic pump carbon
seal or seal runner, as long as the sealing surfaces are protected from damage and cleaned
before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump gearshaft.
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
72-60-01
Page 407
Apr 11/08


THIS TASK COVERS THE TYPE 2 OR TYPE 3 SPRING-LOADED CONFIGURATION

WITH NON-MAGNETIC SEAL RUNNERS.

SUBTASK 72-60-01-943-002
A. Special Tools
SUBTASK 72-60-01-945-050
11. Job Set-up
SUBTASK 72-60-01-010-050
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:

(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.

CONTAMINATION.
(5) Remove seal runner (125) from the gearshaft using puller from TL99696 kit, or equivalent.
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.
72-60-01
Page 409
Apr 11/08


CONTAMINATION.
(5) Remove the seal runner (74) from the gearshaft. Use puller from TL99696 kit, or equivalent.
SUBTASK 72-60-01-020-052
C. Use the following procedure to remove spring-loaded carbon seal from the hydraulic pump location:

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT

TO PREVENT BEARING CONTAMINATION.
(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.
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.
NOTE In order to remove/install the breather port carbon seal assembly, it is

necessary to remove the hydraulic pump gearshaft from the gearbox.
(3) Remove the hydraulic pump adapter and the hydraulic pump gearshaft in accordance with
Subtask 72-60-010-020-052, above. It is not necessary to remove the hydraulic pump carbon
seal or seal runner, as long as the sealing surfaces are protected from damage and cleaned
before final installation.
(4) Remove the breather tube seal runner (32) from the aft end of the hydraulic pump gearshaft.
Use puller from TL99696 kit, or equivalent.
(5) Place gearshaft in plastic bag and cover all open gearbox ports to prevent contamination.
TASK 72-60-01-450-802 Install Magnetic Carbon Seals in Gearbox
13. General
This task covers installation of any of the magnetic carbon seals in the 8k configuration gearbox. Refer
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
Catalog:
72-60-01, Fig. 02
72-60-01
Page 411
Apr 11/08


THIS TASK COVERS THE SPRING-LOADED CONFIGURATION WITH

NON-MAGNETIC SEAL RUNNERS.

SUBTASK 72-60-01-941-004
Heat Gun
SUBTASK 72-60-01-942-004
B. Consumables
MAT-001 Oil, Engine
SUBTASK 72-60-01-944-004
C. Expendable Parts
IPC Reference
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
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
72-60-01 02 30 Magnetic Seal (2)
72-60-01 02 31 Magnetic Seal
SUBTASK 72-60-01-945-004
E. Reference Information
15. Procedures
SUBTASK 72-60-01-420-002
WARNING IMPROPER ASSEMBLY OF GEARBOX CARBON SEALS CAN RESULT IN

A SUDDEN LOSS OF ENGINE OIL. FOLLOW ASSEMBLY INSTRUCTIONS
AND REFER TO ILLUSTRATED PARTS CATALOG OR APPLICABLE SERVICE
BULLETIN TO MAKE SURE CORRECT PART NUMBERS ARE USED. ENGINE
MUST BE GROUND TESTED FOR LEAKS AT MAX CONTINUOUS POWER.
ENGINE SHOULD ALSO BE FLIGHT TESTED BEFORE PERFORMING
GEARBOX MAINTENANCE ON THE OPPOSITE ENGINE.
A. Use the procedure that follows to install magnetic carbon seals to these locations:
72-60-01
Page 413
Apr 11/08

Hydraulic pump mount (AMM)
Starter/generator mount (AMM)
Fuel pump mount (73-16-01, P.B. 401)
WARNING ENGINE OIL (SYNTHETIC) (MAT-001) IS TOXIC TO THE SKIN.

WEAR PROTECTIVE CLOTHING WHILE HANDLING ENGINE OIL.
ANY OIL THAT CONTACTS THE SKIN MUST BE WASHED OFF
IMMEDIATELY. OIL MAY BURN IF EXPOSED TO FLAME. HANDLE
ONLY WITH ADEQUATE VENTILATION.
(1) Ensure seal cavity is free of all dirt and foreign material.
(2) Prepare magnetic carbon seal for installation as follows:
CAUTION DO NOT REMOVE SEAL FROM PACKAGE UNTIL READY TO INSTALL

IT. TO PREVENT DAMAGE TO MATING FACES DO NOT SLIDE SEAL
CASE ACROSS MAGNET. AVOID PLACING MAGNET IN AREA
WHERE SMALL METAL CHIPS MAY BE ATTRACTED TO IT.
(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.
(b) Install the wave spring over the magnet keeper.
(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.
72-60-01
Page 414
Apr 11/08

(6) Install the magnet keeper to starter/generator adapter as follows:
(a) Install the magnet keeper against the magnet.
(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.
(a) Wipe gearshaft to remove oil residue.
(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.
CAUTION WHEN INSTALLING THE ASSEMBLED ADAPTER/CARBON SEAL

OVER THE GEARSHAFT, DO NOT REVERSE THE INSTALLATION
DIRECTION (PULL). THIS MAY CAUSE THE O-RING TO ROLL
AND UNSEAT THE CARBON SEAL.
NOTE Because of assembly tolerances, it may be necessary to heat the

bearing pocket in starter/generator adapter with a heat gun for 2 to
5 minutes before installation of the adapter.
(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.
72-60-01
Page 415
Apr 11/08

NOTE If it is necessary to remove the adapter/carbon seal assembly, you must

remove the seal case and magnet and repeat all the procedures for
inspecting, lubricating, and installing the carbon seal.
(11) Attach the adapter to the gearbox housing with bolts. Use one washer under each bolt.
(12) Torque bolts 55 to 65 inch-pounds (6.2 to 7.3 N.m).
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.
(b) Replace carbon seal O-rings when reinstalling seal.
(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:
72-60-01
Page 416
Apr 11/08

CAUTION DO NOT REMOVE SEAL FROM PACKAGE UNTIL READY TO INSTALL

IT. TO PREVENT DAMAGE TO MATING FACES, DO NOT SLIDE
SEAL CASE ACROSS MAGNET. AVOID PLACING MAGNET IN AREA
WHERE SMALL METAL CHIPS MAY BE ATTRACTED TO IT.
(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
CAUTION WHEN INSTALLING THE STARTER/GENERATOR, DO NOT ALLOW THE

SPLINE TO STRIKE THE GEARSHAFT AND DO NOT LET THE STARTER
GENERATOR "HANG" UNSUPPORTED ON THE STUDS BEFORE BEING
SECURED. THE WEIGHT OF THE STARTER GENERATOR CAN EASILY
UNSEAT THE CARBON SEAL, CAUSING AN OIL LEAK.
C. Install the gearbox-mounted accessories; refer to applicable procedures referenced above.

Installation instructions for the gearbox breather tube are found in 72-00-60, P.B. 401.
72-60-01
Page 417
Apr 11/08

16. Job Close-up
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.
TASK 72-60-01-450-804 Install Type 1 Spring-Loaded Carbon Seals in the 8k Gearbox
17. General
This task covers installation of the type 1 spring-loaded carbon seal assemblies into the 8k configuration
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
Catalog:
72-60-01, Fig. 03
72-60-01
Page 418
Apr 11/08


THIS TASK COVERS THE CONFIGURATION WITH TYPE 1 SPRING-LOADED

NON-MAGNETIC SEAL RUNNERS.

SUBTASK 72-60-01-942-050
A. Consumables
MAT-001 Oil, Engine
SUBTASK 72-60-01-943-050
B. Special Tools
SUBTASK 72-60-01-944-050
C. Expendable Parts
IPC Reference
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
72-60-01
Page 419
Apr 11/08

SUBTASK 72-60-01-945-051
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).
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.
(b) Apply a coating of assembly fluid to the gearshaft.
(c) Make sure that the seal bore of the adapter assembly is clean and free of debris.
(d) Lubricate seal bore of the adapter with assembly fluid.
(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.
CAUTION TO AVOID SEAL DAMAGE, DO NOT PUSH ON THE CARBON

SURFACE DURING INSTALLATION
(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.
72-60-01
Page 421
Apr 11/08


(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.
residual assembly fluid off the mating faces of the carbon seal and the seal runner.
72-60-01
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.

72-60-01
Page 423
Apr 11/08

CAUTION HYDRAULIC PUMP GEARSHAFT SHOULD BE REMOVED FROM THE

GEARBOX FOR CARBON SEAL INSTALLATION. MAKE SURE THAT
ALL WORK SURFACES ARE CLEAN AND WEAR CLEAN, LINT-FREE
GLOVES TO PREVENT CONTAMINATION.
(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.
(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.
residual assembly fluid off the mating faces of the carbon seal and the seal runner (forward and
aft carbon seal locations).
(10) Align bolt hole pattern and install hydraulic pump adapter on gearbox. Use care not to damage
(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.
72-60-01
Page 424
Apr 11/08


(c) Lubricate the O-ring on seal runner with assembly fluid (MAT-011).
CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT.

MAKE SURE THAT ALL WORK SURFACES ARE CLEAN.
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.
(2) Prepare gearshaft surface for seal installation, as follows:
(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.
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.
CAUTION BE CAREFUL NOT TO PINCH THE BREATHER TUBE O-RING

DURING INSTALLATION OF BREATHER TUBE.
NOTE Breather tube should be disconnected from breather tube hose

to allow for proper installation.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
20. Job Close-up
SUBTASK 72-60-01-410-050
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
72-60-01
Page 426
Apr 11/08

Catalog:
72-60-01, Fig. 04

THIS TASK COVERS THE CONFIGURATION WITH TYPE 2 OR TYPE 3

SPRING-LOADED NON-MAGNETIC SEAL RUNNERS.

SUBTASK 72-60-01-942-050
A. Consumables
MAT-001 Oil, Engine
SUBTASK 72-60-01-943-050
B. Special Tools
SUBTASK 72-60-01-944-050
C. Expendable Parts
IPC Reference
72-60-01 04 25 O-Ring
72-60-01 04 36 O-Ring
72-60-01 04 65 O-Ring
72-60-01
Page 427
Apr 11/08

72-60-01 04 105 O-Ring

72-60-01 04 107 O-Ring
SUBTASK 72-60-01-945-051
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.

72-60-01
Page 428
Apr 11/08

(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.
72-60-01
Page 429
Apr 11/08

CAUTION WHEN INSTALLING SPRING WASHER (108), MAKE SURE THAT

CORRECT PART NUMBER IS USED. THIS WASHER IS SIMILAR TO
THE HYDRAULIC PAD SPRING WASHER (27).
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.
CAUTION DO NOT STRIKE THE ADAPTER PLATE OR APPLY UN-EVEN

PRESSURE WHEN INSTALLING THE ADAPTER PLATE SUB-ASSEMBLY
ONTO THE GEARBOX. THIS CAN CAUSE THE WAVE SPRING TO
DISLODGE AND DAMAGE THE BEARING.
(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.
72-60-01
Page 430
Apr 11/08


(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.

(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.
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
(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.

72-60-01
Page 432
Apr 11/08

CAUTION HYDRAULIC PUMP GEARSHAFT SHOULD BE REMOVED FROM THE

GEARBOX FOR CARBON SEAL INSTALLATION. MAKE SURE THAT
ALL WORK SURFACES ARE CLEAN AND WEAR CLEAN, LINT-FREE
GLOVES TO PREVENT CONTAMINATION.
(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.
(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.
CAUTION WHEN INSTALLING SPRING WASHER (27), MAKE SURE THAT

CORRECT PART NUMBER IS USED. THIS WASHER IS SIMILAR TO
THE STARTER/GENERATOR SPRING WASHER (108).
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.
mating faces of the carbon seal and the seal runner (forward and aft carbon seal locations).
72-60-01
Page 433
Apr 11/08

CAUTION DO NOT STRIKE THE ADAPTER PLATE OR APPLY UN-EVEN

PRESSURE WHEN INSTALLING THE ADAPTER PLATE SUB-ASSEMBLY
ONTO THE GEARBOX. THIS CAN CAUSE THE WAVE SPRING TO
DISLODGE AND DAMAGE THE BEARING.
(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.

(c) Lubricate the O-ring on seal runner with assembly fluid (MAT-011).
72-60-01
Page 434
Apr 11/08

CAUTION WEAR CLEAN, LINT-FREE GLOVES WHEN HANDLING GEARSHAFT.

MAKE SURE THAT ALL WORK SURFACES ARE CLEAN.
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.
(2) Prepare gearshaft surface for seal installation, as follows:
(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).
(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.
CAUTION BE CAREFUL NOT TO PINCH THE BREATHER TUBE O-RING

DURING INSTALLATION OF BREATHER TUBE.
NOTE Breather tube should be disconnected from breather tube hose

to allow for proper installation.
(9) Carefully install breather tube over carbon seal and align bolt holes with gearbox housing.
Install two bolts and torque 49 to 51 inch-pounds (5.5 to 5.7 N.m).
(10) Install breather tube hose to breather tube. Refer to 72-00-60, P.B. 401.
24. Job Close-up
SUBTASK 72-60-01-410-050
72-60-01
Page 435
Apr 11/08

B. Perform ground run testing in accordance with the requirements of the List of Test Procedures.
Refer to 710000, P.B. 501.
72-60-01
Page 436
Apr 11/08

Fig. 401 Gearbox Magnetic Seals - Magnet Keeper - Removal/Installation
72-60-01
Page 437
Apr 11/08

Fig. 402 Gearbox Magnetic Seals - Legend
72-60-01
Page 438
Apr 11/08

Fig. 403 Hydraulic Pump Gearshaft and Adapter - Removal/Installation
72-60-01
Page 439
Apr 11/08

Fig. 404 Gearbox Carbon Seals Type 1 Spring-Loaded Configuration (8k) Removal/Installation
72-60-01
Page 440
Apr 11/08

Fig. 405 Gearbox Carbon Seals Type 2 or Type 3 Spring-Loaded Configuration (8k) Removal/Installation
72-60-01
Page 441
Apr 11/08

Fig. 406 Typical Magnetic Seal Installation - Assembly
72-60-01
Page 442
Apr 11/08

Fig. 407 Gearbox Tyep 1 Spring-Loaded Carbon Seal Starter/Generator
72-60-01
Page 443
Apr 11/08

Fig. 408 Gearbox Spring-Loaded Carbon Seals Fuel Pump/Fuel Delivery Unit
72-60-01
Page 444
Apr 11/08

Fig. 409 Gearbox Type 1 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
72-60-01
Page 445
Apr 11/08

Fig. 410 Gearbox Spring-Loaded Carbon Seals (8k) Breather Tube
72-60-01
Page 446
Apr 11/08

Fig. 411 Gearbox Type 2 Spring-Loaded Carbon Seal Starter/Generator
72-60-01
Page 447
Apr 11/08

Fig. 412 Gearbox Type 2 Spring-Loaded Carbon Seals (8k) Hydraulic Pump
72-60-01
Page 448
Apr 11/08

Fig. 413 Wave Spring Proper Winding of Overlap
72-60-01
Page 449
Apr 11/08

72-60-01
450
Page
Blank
FILTER DIFFERENTIAL PRESSURE (DELTA P) INDICATOR - REMOVAL/INSTALLATION
TASK 72-60-02-050-801 Remove the Delta P Indicator
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
Oil Drain Pan
3. Job Set-up
SUBTASK 72-60-02-010-001
4. Procedures
SUBTASK 72-60-02-020-001
WARNING ENGINE OIL (SYNTHETIC) (MAT-001) IS TOXIC TO THE SKIN. WEAR

PROTECTIVE CLOTHING WHILE HANDLING ENGINE OIL. ANY OIL THAT
CONTACTS THE SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF
NOTE If indicator is suspected of leaking, confirm location of leak by wiping off oil and
making sure that the leak repeats. If removal is necessary, note the condition
of the O-rings and the gearbox housing sealing surfaces.
A. Remove delta P Indicator
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.
(3) Remove delta P indicator from gearbox port.
(4) Remove two O-rings from delta P indicator.
TASK 72-60-02-450-801 Install the Delta P Indicator
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
Catalog:
72-60-02, Fig. 01
CAUTION THIS COMPONENT IS LOCATED DOWNSTREAM OF THE MAIN OIL

FILTER. TO PREVENT CONTAMINATION OF THE OIL SYSTEM, MAKE
SURE THAT PORTS AND COMPONENT MATING SURFACES ARE KEPT
EXTREMELY CLEAN DURING MAINTENANCE.
SUBTASK 72-60-02-942-002
A. Consumables
MAT-060 Lockwire, .032
SUBTASK 72-60-02-944-002
B. Expendable Parts
IPC Reference
72-60-02 01 30 O-ring
72-60-02 01 40 O-ring
SUBTASK 72-60-02-945-002
72-60-02
Page 402
Apr 11/08


7. Procedures
SUBTASK 72-60-02-420-001
A. Install delta P indicator
WARNING ENGINE OIL (SYNTHETIC) (MAT-001) IS TOXIC TO THE SKIN.

WEAR PROTECTIVE CLOTHING WHILE HANDLING ENGINE OIL.
ANY OIL THAT CONTACTS THE SKIN MUST BE WASHED OFF
IMMEDIATELY. OIL MAY BURN IF EXPOSED TO FLAME. HANDLE
ONLY WITH ADEQUATE VENTILATION.
CAUTION EXCESS OIL USED TO INSTALL COMPONENTS MAY GIVE A

FALSE INDICATION OF A LEAK.
(1) Lube O-rings with assembly fluid (MAT-011) and install on delta P indicator.
(2) Wipe threads on delta P indicator with a clean cloth to remove excess oil.
(3) Install delta P indicator in gearbox port. Torque indicator 145 to 155 inch-pounds (16.4
- 16.9 N.m).
(4) Install lockwire (MAT-060) to delta P indicator.
8. Job Close-up
SUBTASK 72-60-02-610-001
A. Service the engine with oil. Refer to 72-00-03, P.B. 301.
SUBTASK 72-60-02-410-002
B. Put the engine back to normal
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.
72-60-02
Page 404
Apr 11/08

Fig. 401 Delta P Indicator Removal/Installation
72-60-02
Page 405
Apr 11/08

72-60-02
406
Page
Blank
REAR BYPASS DUCT ASSY - INSPECTION/CHECK
TASK 72-71-10-220-801 Visually Inspect the Rear Bypass Duct Assembly
1. General
This task covers visual inspection of the rear bypass duct assembly. Refer to the following illustration(s):
Figure 601 Rear Bypass Duct Assembly - Inspection
Catalog:
72-00-71, Fig. 01
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
SUBTASK 72-71-10-941-001
Stylus Probe
SUBTASK 72-71-10-942-001
B. Consumables
72-71-10
Page 601
Apr 11/08

SUBTASK 72-71-10-945-001
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.
(1) Inspect the mounting flanges for:
(a) Distortion Reject
(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.
(c) Damage to mounting holes Reject
(d) Missing, loose, or damaged rivets Reject
(e) Fretting (material transfer) which Accept

cannot be felt with a 0.060 inch
diameter stylus probe
(f) Fretting greater than previous step Reject
(2) Inspect all duct sheet metal surfaces for:
72-71-10
Page 602
Apr 11/08

(a) Dents up to 0.200 inch (2 mm) deep Accept
(b) Dents greater than previous step Reject
(c) Scratches and nicks up to 0.030 inch Accept

(0.762 mm) deep; max of 20 per duct
NOTE Touch-up scratches and nicks with chemical conversion coating

(MAT-050). Refer to 70-42-12, P.B. 801.
(d) Chafing or fretting damage. Damage Blend to remove damage using hand
may be removed as long as a stones. Width of blend to be five (5) 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:
(a) Cracks Reject
(b) Damage to sealing surfaces Reject
(c) Loose, missing, or damaged rivets Reject
(d) Fretting Reject
(e) Thread Damage Reject
72-71-10
Page 603
Apr 11/08

5. Job Close-up
SUBTASK 72-71-10-420-001
A. Install the rear bypass duct. Refer to 720071, P.B. 401.
72-71-10
Page 604
Apr 11/08

Fig. 601 Rear Bypass Duct Assembly - Inspection
72-71-10
Page 605
Apr 11/08

72-71-10
606
Page
Blank
REAR MOUNTING RING ASSY - INSPECTION/CHECK
TASK 72-71-20-220-801 Visually Inspect the Rear Mounting Ring Assembly
1. General
This task covers visual inspection of the rear mounting ring assembly. Refer to the following illustration(s):
Figure 601 Rear Mounting Ring Assembly - Inspection/Check
Catalog:
72-00-71, Fig. 01
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
SUBTASK 72-71-20-941-001
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.
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) Inspect mounting ring for cracks or other Reject

damage
(2) Inspect mounting ring for corrosion Reject
B. Inspect mounting ring for loss of coating/plating:
(1) Loss of black chromate outer coating up to Accept at unscheduled or HSI interval;
75% of part surface area recoat in accordance with approved
Repair Station Instructions at CSI.
(2) Loss (flaking) of Ni-Cad plating Recoat in accordance with approved

Repair Station Instructions.
C. Inspect the mounting flanges for:
(1) Distortion Reject
(2) Damage to mounting holes Reject
(3) Fretting (material transfer) which cannot be Accept

felt with a 0.060 inch diameter stylus probe
(4) Fretting greater than previous step Reject
D. Inspect monoball for:
(1) Excessive resistance when rotated. Bearing Reject

must move freely under a maximum torque
of 30 inch-pounds (3.3 N.m). Torque
wrench reading to be 26 inch-pounds (2.9
N.m) max if a 1-inch extension tool is used.
(2) Axial movement of ball in housing up to Accept

0.003 inch (0.076 mm).
(3) Axial movement of ball in housing greater Reject

than previous step.
SUBTASK 72-71-20-220-002
E. If applicable, inspect the rear mount sleeve (1-65, 72-00-71) as follows:
(1) Visually inspect rear mount for:
72-71-20
Page 602
Apr 11/08

(a) Tears or missing sections Reject
5. Job Close-up
SUBTASK 72-71-20-420-001
A. Install the rear bypass duct assembly. Refer to 720071, P.B. 401.
72-71-20
Page 603
Apr 11/08

Fig. 601 Rear Mounting Ring Assembly - Inspection/Check
72-71-20
Page 604
Apr 11/08

CHAPTER 73
ENGINE FUEL AND CONTROL
Page 1
73-ENGINE FUEL AND CONTROL Apr 11/08

Page 2
73-ENGINE FUEL AND CONTROL Blank

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
Page 1
Apr 11/08

Chapter 73
Page 2
Blank
FUEL SYSTEM - DESCRIPTION AND OPERATION
TASK 73-00-00-860-803 Fuel System (FJ44-2A) - Description and Operation
1. General
The purpose of the fuel system is to supply metered fuel for combustion in the engine combustion section.
Figure 1 Fuel System
2. Description
SUBTASK 73-00-00-860-010
A. The fuel system is made up of the following parts:
(1) Fuel pump
(2) Fuel filter
(3) Fuel filter bypass valve
(4) Electronic control unit ECU)
(5) Fuel manifold
(6) Fuel slinger
(7) Lube oil cooler
(8) Hydromechanical control unit
(9) Fuel Nozzle
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.
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.
73-00-00
Page 2
Apr 11/08

Fig. 1 Fuel System
73-00-00
Page 3
Apr 11/08

73-00-004
Page
Blank
FUEL TUBE ASSEMBLIES - REMOVAL/INSTALLATION
TASK 73-10-01-050-803 Remove Fuel Tube Assemblies
1. General
This task provides procedures for removing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 401 Fuel Tube Assemblies - Removal/Installation
Figure 402 Fuel Tube Loop Clamps - Removal/Installation
2 Use this task to remove any of the external fuel tube assemblies. The tube
assemblies covered by this task are as follows:
HMU-to-oil cooler tube assembly
Oil cooler-to-engine tube assembly
CDP to HMU tube assembly
Flex tube assembly
SUBTASK 73-10-01-941-005
Backup Wrench
3. Job Set-up
SUBTASK 73-10-01-010-005

73-10-01
Page 401
Apr 11/08

4. Procedures
SUBTASK 73-10-01-050-003
A. Remove any of the engine fuel tubes as follows:
(1) Loosen tube nuts on fuel tube. Use a backup wrench on fittings and/or reducers.
(2) Disconnect and remove fuel tube.
TASK 73-10-01-450-803 Install Fuel Tube Assemblies
5. General
This task provides procedures for installing an external fuel tube assembly. Refer to the following
illustration(s):
Figure 403 Fuel Tube Assemblies - Removal/Installation
Figure 402 Fuel Tube Loop Clamps - Removal/Installation
Figure 404 Fuel Tube and Cables Interference
Catalog:
73-10-01, Fig. 01, 73-10-01, Fig. 02
SUBTASK 73-10-01-942-006
A. Consumables
MAT-001 Oil, Engine
SUBTASK 73-10-01-945-006
73-10-01
Page 402
Apr 11/08

7. Procedures
SUBTASK 73-10-01-450-003
A. Install any of the rigid engine fuel tubes as follows:
(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.
(3) Verify clearance in step A (2).
B. Install the flex tube assembly as follows:
(1) Make sure fittings are aligned and torque both ends of the flex tube assembly 70 to 120
(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).
Table 401 Torque Values for Tube Assemblies
Tube Tube Torque inch-pounds (N.m)

Oil Cooler to Fuel Manifold Tube Assy 135 - 150 (15.2 - 16.9)
item 10 on Figure
CDP to HMU Tube Assy 90 -100 (10.2 to 11.3)
item 14 on Figure elbow jam nut 60 - 80 (6.8 to 9.0)
Union to Oil Cooler Tube Assy 450 - 500 (50.8 to 56.5)
item 20 on Figure
Valve to Nozzle Flex Valve Assy 135 - 190 (15.2 - 21.4)
item 55 on Figure
HMU to Oil Cooler Tube Assy 450 - 500 (50.8 to 56.5)
item 60 on Figure
73-10-01
Page 403
Apr 11/08

Table 402 Clamp Procedures and Torques
Clamp Location Procedure Torque

inch-pounds
(N.m)
2 clamps on FCU to union tube At rear mount ring, attach 1 49 - 55
bracket with clamps oriented (5.5 - 6.2)
outboard using bolts and nuts.
1 clamp on FCU to union tube (side by side, Connect the two clamps 49 - 55
adjacent to the duct butterfly clamp)1 clamp tube-to-tube using a bolt and (5.5 - 6.2)
on union to service ilsand nut. (Attach clamps between
the tubes next to the HP
bleed.)
1 clamp on CDP tube Attach to the remaining clamp 49 - 55
on the fuel tube, using a bolt (5.5 - 6.2)
and nut. (Attach clamp to each
other just forward of the duct
butterfly clamp.)
2 clamps on Fuel heater tubes 49 - 55
(5.5 - 6.2)
1 clamp on Flex tube 49 - 55
(5.5 - 6.2)
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.
73-10-01
Page 404
Apr 11/08

Fig. 401 Fuel Tube Assemblies - Removal/Installation
73-10-01
Page 405
Apr 11/08

EFFECTIVITY: FJ44-2AFig. 402 Fuel Tube Loop Clamps - Removal/Installation

73-10-01
Page 406
Apr 11/08

Fig. 403 Fuel Tube Assemblies - Removal/Installation
73-10-01
Page 407
Apr 11/08

Fig. 404 Fuel Tube and Cables Interference
73-10-01
Page 408
Apr 11/08

FUEL TUBE ASSEMBLIES - INSPECTION/CHECK
TASK 73-10-01-220-801 Visually Inspect Fuel Tube Assemblies
1. General
This task covers visual inspection of the fuel tube assemblies.
Catalog:
73-10-01, Fig. 01
SUBTASK 73-10-01-945-009
3. Procedures
SUBTASK 73-10-01-220-001
NOTE Any nicks or high metal that are otherwise within acceptable limits should be
repaired in accordance with 70-42-11, P.B. 801.
A. Examine the tube surface for:
(1) Damage:
(a) Obvious excessive damage Reject
(b) Dents located less than 0.005-inch. Reject

(0.127 mm) from tube end fittings
(2) Smooth bottom dents:
73-10-01
Page 601
Apr 11/08

(a) The area of any dent is not more than Accept

0.125 sq. inch. (3.18 sq. mm)
(b) The depth of any dent is not more Accept

than 0.015-inch (0.38 mm).
(c) Dents greater than previous two steps Reject
(3) Nicks:
(a) Nicks less than 0.005-inch (0.127 Reject

mm) from the tube end fitting
(b) Nicks that are round bottomed and Accept

are not more than 0.004-inch (0.10
mm) deep with all burrs removed
(c) Nicks greater than limits in previous Reject

step
(4) Galled:
(a) Galled less than 0.005-inch (0.127 Reject

mm) from the tube end fittings
(b) Galled on the tube surface not more Accept

than 0.005-inch (0.127 mm)
(c) Galled greater than limits in previous Reject

step
B. Examine the attachment flanges and end fittings for:
(1) Visual damage:
(a) Crack Reject
(b) Galled Reject
(c) Loose Reject
(d) Worn Reject
73-10-01
Page 602
Apr 11/08

FUEL DRAIN TUBE ASSEMBLIES - REMOVAL/INSTALLATION
TASK 73-11-01-050-802 Remove Fuel Drain Tube Assemblies
1. General
This task provides procedures for removing the fuel drain tube assembly. Refer to the following illustration:
Figure 401 Fuel Drain Tube Assemblies - Removal/Installation
SUBTASK 73-11-01-943-003
A. Special Tools
TL65047 Puller, Drain Tube
3. Job Set-up
SUBTASK 73-11-01-010-003
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
B. Remove fuel drain tubes as follows:
(1) Remove one screw and loop clamp brackets and remove drain plug from the aft drain tube port
of the fuel drain boss on the front bypass duct. Remove O-ring from drain fitting.
(2) 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.
TASK 73-11-01-450-802 Install Fuel Drain Tube Assemblies
5. General
This task provides procedures for installing the fuel drain tube assembly. Refer to the following illustration:
Figure 401 Fuel Drain Tube Assemblies - Removal/Installation
Catalog:
73-11-01, Fig. 01
SUBTASK 73-11-01-942-004
A. Consumables
73-11-01
Page 402
Apr 11/08

SUBTASK 73-11-01-943-004
B. Special Tools
TL65047 Puller, Drain Tube
SUBTASK 73-11-01-944-004
C. Expendable Parts
IPC Reference
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
7. Procedures
SUBTASK 73-11-01-420-003

A. Install the drain tubes as follows:
(1) Install one drain tube seal on the ball end of both the forward and the aft fuel drain tubes. Make
sure that the spring side of the seal is visible (facing the core of the engine), when installed.
Lubricate two O-rings with MAT-011 assembly fluid and install on the flat end of the forward
and aft fuel drain tubes.
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
73-11-01
Page 404
Apr 11/08

Fig. 401 Fuel Drain Tube Assemblies - Removal/Installation
73-11-01
Page 405
Apr 11/08

73-11-01
406
Page
Blank
FUEL NOZZLE ASSEMBLY - REMOVAL/INSTALLATION
TASK 73-12-01-050-801 Remove the Fuel Nozzle Assembly
1. General
This task provides procedures for removing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 401 Fuel Nozzle Removal/Installation
Figure 402 Fuel Nozzle Adapter Wrench
SUBTASK 73-12-01-942-001
A. Consumables
SUBTASK 73-12-01-943-001
B. Special Tools
TL37212 or TL37330
TL99517 Socket, Fuel Adapter Nozzle, Slotted
3. Job Set-up
SUBTASK 73-12-01-010-001

CAUTION DO NOT BEND START NOZZLE ADAPTER DURING REMOVAL.

REMOVE AIRCRAFT BLEED PLUMBING, AS REQUIRED, TO PROVIDE
CLEARANCE FOR REMOVAL OF ADAPTER.
73-12-01
Page 401
Apr 11/08

4. Procedures
SUBTASK 73-12-01-020-001
A. Remove fuel nozzle assembly as follows:
(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:
CAUTION DO NOT BEND FUEL NOZZLE ADAPTER DURING REMOVAL.

REMOVE AIRCRAFT BLEED PLUMBING, AS REQUIRED, TO PROVIDE
CLEARANCE FOR REMOVAL OF ADAPTER.
(1) Remove retaining ring, fuel nozzle plate seal, and fuel nozzle ring seal from the fuel nozzle port.
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.
TASK 73-12-01-450-801 Install the Fuel Nozzle Assembly
5. General
This task provides procedures for installing the fuel nozzle assembly. Refer to the following illustration(s):
Figure 401 Fuel Nozzle Removal/Installation
Figure 402 Fuel Nozzle Adapter Wrench
Catalog:
73-12-01, Fig. 01
SUBTASK 73-12-01-942-002
A. Consumables
SUBTASK 73-12-01-943-002
B. Special Tools
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
73-12-01 01 110 O-ring
73-12-01
Page 403
Apr 11/08

SUBTASK 73-12-01-945-002
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:
(1) HP turbine combustor assembly was replaced
(2) Primary plate was replaced
(3) HP turbine nozzle was replaced
(4) Diffuser was replaced
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.
C. Install fuel nozzle assembly as follows:
(1) Install bulkhead nut on fuel nozzle assembly.
(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) .
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.
(4) Torque bulkhead nut 38 to 42 inch-pounds (4.2 to 4.7 N.m) .
(5) Install the flexible tube assembly to the fuel nozzle. Refer to 73-10-01, P.B. 401.
8. Job Close-up
SUBTASK 73-12-01-410-002
SUBTASK 73-12-01-760-001
73-12-01
Page 405
Apr 11/08

Fig. 401 Fuel Nozzle Removal/Installation
73-12-01
Page 406
Apr 11/08

Fig. 402 Fuel Nozzle Adapter Wrench
73-12-01
Page 407
Apr 11/08

73-12-01
408
Page
Blank
FUEL NOZZLE ASSEMBLY - INSPECTION/CHECK
TASK 73-12-01-220-801 Visually Inspect the Fuel Nozzle Assembly
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601 Fuel Nozzle Adapter - Visual Inspection
Catalog:
73-12-01, Fig. 01
SUBTASK 73-12-01-942-004
A. Consumables
SUBTASK 73-12-01-945-004
73-12-01 401 Fuel Nozzle Assembly - Removal/Installation
73-12-01
Page 601
Apr 11/08

3. Job Set-up
SUBTASK 73-12-01-010-004
A. Prepare the engine for inspection
(1) Install DO NOT OPERATE signs
SUBTASK 73-12-01-020-003
B. Remove the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
4. Procedures
SUBTASK 73-12-01-220-001
A. Visually inspect:
(1) Fuel nozzle for:
CAUTION BE CAREFUL NOT TO INTRODUCE DIRT OR FOREIGN OBJECTS

INTO THE NOZZLE FLOWPATH WHILE CLEANING.
(a) Signs of coking on nozzle (signs 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) Bent or dented shaft Replace
(c) Missing or damaged spring ring Replace
(d) Damaged threads Replace
B. Visually inspect:
(1) Fuel nozzle adapter for:
(a) Thread damage to adapter inlet port Reject

or adapter nut.
(b) Uniball mount binding or damaged Reject
(c) Dents in zone A which are less than Accept

0.032 inch (0.812 mm) deep by 0.25
dia. inch (6.35 mm)
73-12-01
Page 602
Apr 11/08

(d) Dents in zone A greater than previous Reject

step
(e) Fretting wear in zone B resulting in a Reject

0.533 inch (13.5 mm) diameter or
less. When measuring for fretting
wear in Zone B, take measurement at
area of widest OD on adapter tip.
(f) Fretting wear in zone C resulting in a Reject

0.476 inch (12.0 mm) diameter or
less.
(g) Coking Clean with mineral spirits (MAT-020) or
dry cleaning solvent (MAT-024) and an
abrasive pad or stainless steel or fiber
brush.
5. Job Close-up
SUBTASK 73-12-01-420-003
A. Install the fuel nozzle assembly and fuel nozzle adapter. Refer to 73-12-01, P.B. 401.
SUBTASK 73-12-01-410-004
B. Put the engine back to normal
TASK 73-12-01-730-801 Check Fuel Nozzle Spray Pattern
6. General
This task provides procedures for checking the fuel nozzle spray pattern. Refer to the following
illustration(s):
Figure 602 Fuel Nozzle Assembly - Spray Pattern Check
SUBTASK 73-12-01-941-005
Fuel Nozzle Spray Test Equipment
73-12-01
Page 603
Apr 11/08

SUBTASK 73-12-01-942-005
B. Consumables
MAT-023 Ultrasonic Cleaner, Caustic
SUBTASK 73-12-01-945-005
73-12-01 401 Fuel Nozzle Assembly - Removal/Installation
8. Job Set-up
SUBTASK 73-12-01-010-006
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.
73-12-01
Page 604
Apr 11/08

WARNINGS: 1 FUEL/MINERAL SPIRITS ARE HIGHLY FLAMMABLE. IT MUST BE KEPT

AWAY FROM HEAT AND OPEN FLAME. FUEL/MINERAL SPIRITS
MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL/MINERAL SPIRITS
CLOTHING WITH FUEL/MINERAL SPIRITS CONTAMINATION
MUST BE THOROUGHLY CLEANED BEFORE BEING WORN. A
CONTAINER SHOULD BE PLACED UNDERNEATH WORK AREA TO
CATCH DRIPPING FUEL/MINERAL SPIRITS.
2 A FACE SHIELD IS REQUIRED DURING SPRAY PATTERN CHECK

DUE TO POSSIBLE FUEL/MINERAL SPIRITS MIST.
(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
C. Install the fuel nozzle assembly. Refer to 73-12-01, P.B. 401.
10. Job Close-up
SUBTASK 73-12-01-410-005
73-12-01
Page 605
Apr 11/08

73-12-01
Page 606
Apr 11/08

Fig. 601 Fuel Nozzle Adapter - Visual Inspection
73-12-01
Page 607
Apr 11/08

Fig. 602 Fuel Nozzle Assembly - Spray Pattern Check
73-12-01
Page 608
Apr 11/08

FUEL PUMP FILTER - REMOVAL/INSTALLATION
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
3. Job Set-up
SUBTASK 73-14-01-010-001

(4) Close aircraft fuel shut-off valve.
4. Procedures
SUBTASK 73-14-01-020-001

A. Remove the filter as follows:
73-14-01
Page 401
Apr 11/08

(1) Cut lockwire on the filter bowl.
(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
TASK 73-14-01-450-801 Install the Fuel Filter on the Fuel Pump
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
Catalog:
73-14-01, Fig. 01
SUBTASK 73-14-01-942-002
A. Consumables
73-14-01
Page 402
Apr 11/08

SUBTASK 73-14-01-944-002
B. Expendable Parts
IPC Reference
73-14-01 01 30 Filter
73-14-01 01 40 O-Ring
SUBTASK 73-14-01-945-002
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.
A. Install the filter as follows:
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.
10. Job Close-up
SUBTASK 73-14-01-410-002
SUBTASK 73-14-01-760-001
73-14-01
Page 404
Apr 11/08

Fig. 401 Fuel Pump Filter - Removal/Installation
73-14-01
Page 405
Apr 11/08

73-14-01
406
Page
Blank
FUEL PUMP - REMOVAL/INSTALLATION
TASK 73-16-01-050-801 Remove the Fuel Pump Assembly
1. General
This task provides procedures for removing the fuel pump assembly. Refer to the following illustration(s):
Figure 401 Fuel Pump - Removal/Installation
SUBTASK 73-16-01-942-001
A. Consumables
MAT-010 Grease, Aircraft, General Purpose
SUBTASK 73-16-01-945-001
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
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
C. Remove the fuel pump as follows:
(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:
(1) Install a new retaining clip to the FCU drive shaft.
(2) Insert the drive shaft into the fuel pump until it snaps in place.
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.
TASK 73-16-01-450-801 Install the Fuel Pump Assembly
5. General
This task provides procedures for installing the fuel pump assembly. Refer to the following illustration(s):
Figure 401 Fuel Pump - Removal/Installation
Catalog:
73-16-01, Fig. 01
NOTE Lubricate all threads and contact surfaces of nuts and bolts with clean
SUBTASK 73-16-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 73-16-01-944-002
B. Expendable Parts
IPC Reference
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
73-16-01
Page 403
Apr 11/08


7. Procedures
SUBTASK 73-16-01-420-001

A. Install the fuel pump as follows:
(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
C. Install the fuel control unit. Refer to 73-21-01, P.B. 401.
73-16-01
Page 404
Apr 11/08

8. Job Close-up
SUBTASK 73-16-01-410-002
(2) Open the aircraft fuel shutoff valve.
SUBTASK 73-16-01-760-001
73-16-01
Page 405
Apr 11/08

Fig. 401 Fuel Pump - Removal/Installation
73-16-01
Page 406
Apr 11/08

FUEL CONTROL SYSTEM - DESCRIPTION AND OPERATION
TASK 73-20-00-860-803 Fuel Control System - Description and Operation
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
Figure 1 EFCU System - Block Diagram
SUBTASK 73-20-00-860-004
A. Electronic Control Unit (ELECTRONIC Mode)
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.
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.
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.
B. Hydromechanical Unit (MANUAL Mode):
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:
LP shaft failure/N1 overspeed protection feature
Supply of pressurized fuel to the start nozzle
Supply of excess metered fuel to the motive flow port.
Maximum fuel flow limit (indirectly limits CDP).
Positive mechanical shutoff of the main fuel supply via the PLA.
Gross N2 overspeed protection.
Surge/flame out stability.
73-20-00
Page 3
Apr 11/08

Fig. 1 EFCU System - Block Diagram
73-20-00
Page 4
Apr 11/08

FUEL CONTROL UNIT - REMOVAL/INSTALLATION
TASK 73-21-01-050-803 Remove the Fuel Control Unit
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 407 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
Figure 408 HMU/IFCU Discrepancy Report
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

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.
B. Remove the drain tubes. Refer to the Aircraft Maintenance Manual.
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.
E. Remove the HMU as follows:
(1) Remove the heatshield by removing five screws.
(2) Disconnect the electrical bonding strap from the HMU.
(3) Disconnect the HMU-to-oil cooler (fuel-out) tube from the HMU.
(4) Disconnect the flex tube assembly 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.
73-21-01
Page 402
Apr 11/08

(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.
CAUTION GRIPPING THE HMU PLUNGER WITH PLIERS OR OTHER

TOOL WILL DAMAGE THE COATED SURFACE OF THE
ROD AND CAUSE FUEL LEAKS.
(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.
CAUTION USE CARE NOT TO BEND STRAIGHT SECTIONS OF BLEED CABLE.
(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.
TASK 73-21-01-450-803 Install the 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 405 FCU - Accel Bleed Cable - Adjustment
Figure 406 Fuel Control Unit - LP Trip Cable Adjustment
73-21-01
Page 403
Apr 11/08

Catalog:
73-21-01, Fig. 01 and 73-21-01, Fig. 02
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
Ohmmeter
SUBTASK 73-21-01-942-006
B. Consumables
MAT-001 Oil, Engine
SUBTASK 73-21-01-943-006
C. Special Tools
TL99924 Torque Adapter
SUBTASK 73-21-01-944-006
D. Expendable Parts
IPC Reference
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
73-21-01
Page 404
Apr 11/08

73-2101 01 85 O-Ring
73-21-01 01 95 O-Ring
SUBTASK 73-21-01-945-006
E. Reference Information
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
A. Install the HMU as follows:
(1) Before installing HMU on engine, install CDP bracket with screw. Torque 25 to 28 inch-pounds
(2.8 to 3.2 N.m.).
(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).
73-21-01
Page 405
Apr 11/08

(6) Lubricate four O-rings with assembly fluid. Install one O-ring on HMU shaft flange and three on
HMU flange.
CAUTION DRIVE SPLINE TEETH MUST BE CORRECTLY ENGAGED BEFORE

MATING THE HMU AND THE FUEL PUMP. THE PUMP SHAFT MUST BE
INDEXED BY GEARBOX ROTATION. DO NOT USE THE FUEL PUMP
STUDS TO DRAW THE HMU/FUEL PUMP TOGETHER.
(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
(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.
73-21-01
Page 406
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.
CAUTION USE OF UNAUTHORIZED CLEANING AGENTS ON THE HARNESS

CONNECTORS WILL LEAVE CHLORIDE DEPOSITS WHICH CAUSE
CORROSION BETWEEN THE PIN AND THE RECEPTACLE. IF CONNECTOR
CONTACTS REQUIRE CLEANING, ONLY ALCOHOL MAT-027 IS ALLOWED.
(18) Prior to connecting the EFCU engine harness:
(a) Perform visual inspection of harness for missing or bent pins.
(b) Check all used contacts for short to connector case using an ohmmeter. Refer to
77-40-01, P.B. 601.
(c) Reject the harness if either of the above conditions exist.
(19) Connect the EFCU engine harness electrical connector plug (P2) to the jack (J2) on the
left side of the HMU.
(20) Install drain tubes. Refer to the Aircraft Maintenance Manual.
7. Job Close-up
SUBTASK 73-21-01-410-006
SUBTASK 73-21-01-760-003
73-21-01
Page 407
Apr 11/08

Fig. 401 Fuel Control Unit - Heatshield - Removal/Installation
73-21-01
Page 408
Apr 11/08

Fig. 402 Fuel Control Unit - Fuel Tubes - Locator View
73-21-01
Page 409
Apr 11/08

Fig. 403 Fuel Control Unit - Fuel Tubes - Removal/Installation
73-21-01
Page 410
Apr 11/08

Fig. 404 Fuel Control Unit - Removal/Installation
73-21-01
Page 411
Apr 11/08

73-21-01
Page 412
Apr 11/08

73-21-01
Page 413
Apr 11/08

Fig. 407 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
73-21-01
Page 414
Apr 11/08

Fig. 408 HMU/IFCU Discrepancy Report
73-21-01
Page 415
Apr 11/08

73-21-01
416
Page
Blank
FUEL CONTROL UNIT - INSPECTION/CHECK
TASK 73-21-01-220-801 Visually Inspect the Fuel Control Unit
1. General
This task provides procedures for visually inspecting the fuel control unit.
Catalog:
73-21-01, Fig. 01
NOTE You must inspect all parts for damage, corrosion, and wear whether specified in the
SUBTASK 73-21-01-945-008
3. Procedures
SUBTASK 73-21-01-220-002
A. Visually check the fuel control unit for:
(1) Broken/removed lockwire or seals Reject
(2) Loose hose, tube, or linkage connections Tighten. Refer to 73-21-01, 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
B. Inspect the heatshield for:
(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.
73-21-01
Page 601
Apr 11/08

(3) Damage greater than previous steps. Reject
73-21-01
Page 602
Apr 11/08

FUEL FILTER INDICATOR (DELTA P SWITCH) - REMOVAL/INSTALLATION
TASK 73-23-01-050-801 Remove the Fuel Filter Indicator (Delta P Switch)
1. General
This task provides procedures for removing the fuel filter indicator. Refer to the following illustration(s):
Figure 401 Fuel Filter Indicator - Removal/Installation
SUBTASK 73-23-01-943-001
A. Special Tools
TL39454 Torque Adapter, Fuel Indicator
3. Job Set-up
SUBTASK 73-23-01-010-001

73-23-01
Page 401
Apr 11/08

4. Procedures
SUBTASK 73-23-01-020-001

A. Remove the delta P switch as follows:
(1) Disconnect electrical connector from the delta P switch.
(2) Cut and remove lockwire from the delta P switch.
SUBTASK 73-23-01-050-001
B. Using TL39454 torque adapter, remove the delta P switch.
TASK 73-23-01-450-801 Install the Fuel Filter Indicator (Delta P Switch)
5. General
This task provides procedures for installing the fuel filter indicator. Refer to the following illustration(s):
Figure 401 Fuel Filter Indicator - Removal/Installation
Catalog:
73-23-01, Fig. 01
SUBTASK 73-23-01-942-002
A. Consumables
MAT-001 Oil, Engine
73-23-01
Page 402
Apr 11/08

SUBTASK 73-23-01-943-002
B. Special Tools
TL39454 Torque Adapter, Fuel Indicator
SUBTASK 73-23-01-944-002
C. Expendable Parts
IPC Reference
73-23-01 01 20 O-Ring
73-23-01 01 30 O-Ring
SUBTASK 73-23-01-945-002
7. Procedures
SUBTASK 73-23-01-420-001
A. Install the delta P switch as follows:
(1) Lubricate two O-rings with assembly fluid (MAT-011). Install one O-ring at O-ring groove at
bottom of delta P switch, and one O-ring at boss seal flange.
(2) Install delta P switch into port.
SUBTASK 73-23-01-450-001
B. Using TL39454 torque adapter, torque delta P switch 145 to 155 inch-pounds (16.3 to 17.4 N.m).
73-23-01
Page 403
Apr 11/08

SUBTASK 73-23-01-450-003
C. Install lockwire (MAT-061) to safety delta P switch to fuel pump/FCU.
SUBTASK 73-23-01-450-004
D. Install electrical connector to delta P switch; refer to Aircraft Maintenance Manual.
8. Job Close-up
SUBTASK 73-23-01-410-002
SUBTASK 73-23-01-760-001
B. Perform engine testing per the Table Required after Maintenance or Component Replacement
73-23-01
Page 404
Apr 11/08

Fig. 401 Fuel Filter Indicator - Removal/Installation
73-23-01
Page 405
Apr 11/08

73-23-01
406
Page
Blank
FUEL FILTER INDICATOR (DELTA P SWITCH) - INSPECTION/CHECK
TASK 73-23-01-220-801 Visually Inspect the Fuel Filter Indicator (Delta P Switch)
1. General
This task covers visual check of the fuel filter indicator. Refer to the following illustration(s):.
Figure 601 Fuel Filter Indicator - Visual Inspection
Catalog: 73-23-01, Fig. 01
SUBTASK 73-23-01-945-003
3. Procedures
SUBTASK 73-23-01-020-002
A. Remove the fuel filter delta P switch. Refer to 73-23-01, P.B. 401.
SUBTASK 73-23-01-220-001
B. Visually inspect the fuel filter delta P switch for:
(1) Bent, broken, or missing connector pins Reject
(2) Thread damage or rounded wrench flats Reject
(3) Damage to O-ring groove Reject
(4) Scorch or burn marks Reject. Contact Williams International

Customer Support
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
73-23-01
Page 601
Apr 11/08

SUBTASK 73-23-01-941-004
Multimeter
SUBTASK 73-23-01-945-004
6. Procedures
SUBTASK 73-23-01-750-001
NOTES: 1 Electrical check may be performed on installed switch. Fuel system

must be at ambient pressure during check.
2 The following procedure is to verify pins A and B are isolated from

each other and from the case.
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.
73-23-01
Page 602
Apr 11/08

Fig. 601 Fuel Filter Indicator - Visual Inspection
73-23-01
Page 603
Apr 11/08

Fig. 602 Fuel Filter Indicator - Resistance Check
73-23-01
Page 604
Apr 11/08

ELECTRONIC CONTROL UNIT - MAINTENANCE PRACTICES
TASK 73-24-01-870-802 Download Data from the Electronic Control Unit
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
Laptop Computer
SUBTASK 73-24-01-943-002
B. Special Tools
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
73-24-01
Page 201
Apr 11/08

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
NOTES: 1 Depending on the type of computer, choose either a USB or a Serial

Port converter. Two choices for the EMT converter are offered to
accommodate all types of laptop computers.
2 If using an older laptop computer which is NOT equipped with powered

USB ports, the TL99604 EMT converter will be required. The TL99604 EMT
converter will connect to the computers serial port.
3 If using a newer laptop computer which is equipped with powered USB

ports, the TL99605 should be used. The TL99605 EMT converter will
connect to any powered USB port in the computer.
B. Procedures for Loading Software into Laptop
NOTE There are two CD-ROMs to install: EMT and ECU.
(1) Insert TL99600 or TL99756 EMT CD-ROM and open Windows Explorer to the CD-ROM drive.
(2) Double click on the setup.exe file.
(3) Follow the install instructions and accept all defaults.
(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.
73-24-01
Page 202
Apr 11/08

(6) Double click on the setup.exe file.
(7) Follow the default instructions and accept all defaults
(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).
B. Download the following files when a BIT fault is indicated:
Exceedence
BIT Fault
C. Clear the following files in the ECU:
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.
73-24-01
Page 203
Apr 11/08

Fig. 201 EMT - Connecting to ECU
73-24-01
Page 204
Apr 11/08

ELECTRONIC CONTROL UNIT - REMOVAL/INSTALLATION
TASK 73-24-01-050-802 Remove the Electronic Control Unit
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
SUBTASK 73-24-01-945-005
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.
B. Prepare the engine for part replacement
(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
A. Remove safety wire from the ECU connector jacks.
B. Remove the ECU to airframe harness connector (P4) from the ECU connector (J4).
C. Remove the airframe harness connector from the ECU connector(J20).
D. Remove one screw and remove the electrical bond strap from the ECU.
73-24-01
Page 401
Apr 11/08

E. Remove four bolts from ECU mounts and remove ECU from aircraft.
TASK 73-24-01-450-802 Install the Electronic Control Unit
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
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
Ohmmeter
SUBTASK 73-24-01-942-006
B. Consumables
MAT-001 Oil, Engine
SUBTASK 73-24-01-945-006
73-24-01
Page 402
Apr 11/08

7. Procedures
SUBTASK 73-24-01-420-002
CAUTION MAKE SURE THE SHIPPING COVER OF THE AMBIENT PRESSURE

PORT IS REMOVED. FAILURE TO REMOVE COVER COULD CAUSE
THE ENGINE CONDITIONS OF OVERTHRUST OR OVERTEMPERATURE
WHICH COULD LEAD TO DAMAGE.
A. Install ECU on aircraft bulkhead and secure with four bolts.
B. Install electrical bond strap to ECU and secure with one screw. Torque 32 - 35 inch-pounds (3.6 to
3.95 N.m).

CONNECTORS WILL LEAVE CHLORIDE DEPOSITS WHICH CAUSE CORROSION
BETWEEN THE PIN AND THE RECEPTACLE. IF CONNECTOR CONTACTS
REQUIRE CLEANING, ONLY ALCOHOL MAT-027 IS ALLOWED.
C. Prior to connecting the harness:
(1) Perform visual inspection of harness for missing or bent pins.
(2) Check all used contacts for short to connector case using an ohmmeter.
(3) Reject the harness if either of the above conditions exist.
D. Install airframe harness connector to ECU connector (J20).
E. Install ECU to airframe harness connector (P4) to ECU (J4).
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.
73-24-01
Page 403
Apr 11/08

SUBTASK 73-24-01-760-002
73-24-01
Page 404
Apr 11/08

Fig. 401 Electronic Control Unit (ECU) - Removal/Installation
73-24-01
Page 405
Apr 11/08

73-24-01
406
Page
Blank
FUEL MANIFOLD FILTER ASSY - REMOVAL/INSTALLATION
TASK 73-25-01-050-801 Remove the Fuel Manifold Filter
1. General
This task provides procedures for removing the fuel manifold filter. Do this task as required by periodic
maintenance. Refer to the following illustration(s):
Figure 401 Fuel Manifold Filter - Removal/Installation
SUBTASK 73-25-01-941-001
Ultrasonic Cleaning Equipment
3. Job Set-up
SUBTASK 73-25-01-010-001

4. Procedures
SUBTASK 73-25-01-020-001
A. Remove Fuel Manifold Filter
73-25-01
Page 401
Apr 11/08


THOROUGHLY CLEANED BEFORE BEING WORN.
(1) Disconnect and remove the fuel tube.
(2) Remove the fuel filter from the engine service adapter fuel port.
NOTE The filter element is reusable if contaminants can be removed

without damage to the filter assembly.
B. Clean the filter using ultrasonic cleaning equipment.
TASK 73-25-01-450-801 Install the Fuel Manifold Filter
5. General
This tasks provides procedures for installing the fuel manifold filter. Refer to the following illustration(s):
Figure 401 Fuel Manifold Filter - Removal/Installation
Catalog:
73-25-01, Fig. 01
SUBTASK 73-25-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 73-25-01-944-002
B. Expendable Parts
IPC Reference
73-25-01 01 10 Filter, Assembly, Fuel Manifold
73-25-01 01 20 O-ring
73-25-01
Page 402
Apr 11/08

SUBTASK 73-25-01-945-002
7. Procedures
SUBTASK 73-25-01-420-001
A. Install Fuel Manifold Filter
(1) Lubricate O-ring with assembly fluid (MAT-011) and install on the fuel filter assembly.
(2) Apply a light coat of engine oil (MAT-001) to threads of the fuel filter.
(3) Install the fuel manifold filter into the service adapter fuel port and torque 38 to 42 inch-pounds
(4.2 to 4.7 N.m).
(4) Install the fuel tube assembly. 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
73-25-01
Page 403
Apr 11/08

Fig. 401 Fuel Manifold Filter - Removal/Installation
73-25-01
Page 404
Apr 11/08

FUEL CONTROL SHUTOFF VALVE - MAINTENANCE PRACTICES
TASK 73-27-01-830-801 Reset the Fuel Shutoff Valve
1. General
This task provides procedures for resetting the fuel shutoff valve. Refer to the following illustration(s):
Figure 201 Fuel Control Shut-Off Valve - Reset
SUBTASK 73-27-01-942-001
A. Consumables
MAT-001 Oil, Engine
SUBTASK 73-27-01-945-001
71-00-50 601 LP Turbines (Borescope) - Inspection/Check
3. Job Set-up
SUBTASK 73-27-01-010-001
73-27-01
Page 201
Apr 11/08

(3) Remove the Cowling. Refer to the Aircraft Maintenance Manual.
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:
(a) Signs that rotating parts have rubbed stationary parts.
(b) Sign that LP shaft has touched LP trip lever.
(2) Inspect the inlet for foreign object damage.
SUBTASK 73-27-01-830-002
B. Contact Williams International, Walled Lake, Michigan, USA.
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
D. Reset the FCU fuel shutoff valve as follows:
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.
73-27-01
Page 202
Apr 11/08

SUBTASK 73-27-01-420-001
F. Install cable and actuator housing. Refer to 76-20-01, P.B. 501.
SUBTASK 73-27-01-820-001
G. Adjust the LP trip lever. Refer to 76-20-01, P.B. 501.
SUBTASK 73-27-01-420-002
H. Install Cable on FCU.
(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
73-27-01
Page 203
Apr 11/08

Fig. 201 Fuel Control Shut-Off Valve - Reset
73-27-01
Page 204
Apr 11/08

CHAPTER 74
IGNITION
Page 1
74-IGNITION Apr 11/08

Page 2
74-IGNITION Blank

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
Page 1
Apr 11/08

Chapter 74
Page 2
Blank
IGNITION SYSTEM - DESCRIPTION AND OPERATION
TASK 74-00-00-860-801 Ignition System - Description and Operation
1. General
The ignition system supplies spark to ignite the fuel/air mixture in the combustor. Refer to the following
illustration(s):
Figure 1 Ignition System
2. Description
SUBTASK 74-00-00-860-002
A. The ignition system is made up of the following parts:
Ignition Exciters (2)
Igniter Leads (2)
Igniter Plugs (2)
B. The two ignition exciters are high energy, capacitive discharge devices. The parts for each ignition
exciter are contained in a corrosion resistant, case which is sealed against air. Both ignition exciter
cases are mounted to the engine interstage housing. The spark rate is one to six sparks per channel,
per second. The exciters can operate continuously with input voltage ranging from 10 to 30 volts,
3.5 Joules stored energy.
C. The igniter leads are made from a low-loss coaxial cable which is designed for use at 18 to 24 Kv.
The right and left leads are different lengths.
D. The igniter plugs are sealed against air and have precious metal electrodes. The igniter plug case is
made of high temperature, corrosion resistant alloys.
3. Operation
SUBTASK 74-00-00-860-003
A. The ignition switch in the cockpit activates the ignition exciters. The ignition exciters draw current
from the battery and sends current through each igniter lead, independently, at a rate of one to six
sparks per second. The igniter plugs ignite the fuel/air mixture in the combustor. Igniters continue to
fire until the ignition switch is turned off.
74-00-00
Page 1
Apr 11/08

Fig. 1 Ignition System
74-00-00
Page 2
Apr 11/08

IGNITION SYSTEM - ADJUSTMENT/TEST
TASK 74-00-10-770-801 Do an Operational Test on the Ignition System
1. General
Do this task at the interval shown under periodic inspections.
SUBTASK 74-00-10-945-001
3. Job Set-up
SUBTASK 74-00-10-010-001
A. Prepare for ignition test
4. Procedures
SUBTASK 74-00-10-770-001
A. Do an audible check on the igniters
(1) Switch the ignition system to the ON position. Refer to the Aircraft Maintenance Manual.
(2) Listen for the igniters firing. The igniters may start out firing together or they may start out
alternately firing. In either case, they will drift from one mode to the other. If you can hear both
igniters firing in this way, functional test is complete. If you cannot hear both igniters firing in
this way, one or both of the igniters are malfunctioning.
B. Identify Malfunctioning Igniter
74-00-10
Page 501
Apr 11/08

WARNINGS: 1 IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY

CIRCUITS. REMOVE INPUT POWER PRIOR TO HANDLING
EXCITER, HIGH TENSION LEAD, OR PLUG.
2 IGNITION SYSTEM OUTPUT VOLTAGE IS DANGEROUSLY HIGH. DO

IGNITION SPARK CHECK OUTDOORS, IN AN ATMOSPHERE FREE
OF EXPLOSIVE OR FLAMMABLE GASES OR LIQUIDS.
(1) Remove two igniters as follows:
(a) Disconnect main electrical supply from ignition exciter.
(b) Wait at least two minutes before beginning work.
(c) Remove igniter leads from igniters. Use a backup wrench on igniter plug flats.
CAUTION PLUG IGNITER PORTS TO KEEP FOREIGN OBJECTS

FROM ENTERING THE ENGINE.
(d) Remove igniter plug nuts and remove igniter plugs from engine.
CAUTION TO PREVENT DAMAGE TO IGNITER LEAD TERMINAL, DO NOT SPIN

IGNITER PLUG WHEN INSTALLING LEAD. HOLD IGNITER PLUG
WITH BACKUP WRENCH AND TIGHTEN IGNITER LEAD NUT.
(e) Install igniter leads to igniter plugs. Use a backup wrench on igniter plug flats.
(f) Let igniters hang down below engine for operational test.
(2) Visually check that igniters fire:
(a) Connect main electrical connector to ignition exciter.
WARNING DO NOT STAND NEXT TO IGNITER WHEN CHECKING TO SEE IF

IGNITERS FIRE. YOU SHOULD BE AT LEAST 10 FEET (3 METERS)
FROM IGNITER TIP AT ALL TIMES DURING TEST.
(b) From a distance of at least 10 feet (3 meters), visually make sure that igniters fire
(make a spark).
(c) Disconnect main electrical connector from ignition exciter.
(d) Replace defective igniters as required. Install igniters in accordance with 74-22-01,
P.B. 401.
74-00-10
Page 502
Apr 11/08

5. Job Close-up
SUBTASK 74-00-10-410-001
74-00-10
Page 503
Apr 11/08

74-00-10
504
Page
Blank
IGNITON EXCITER - REMOVAL/INSTALLATION
TASK 74-10-01-050-801 Remove the Ignition Exciters
1. General
This task provides procedures for removing the ignition exciters. Refer to the following illustration(s):
Figure 401 Ignition Exciter - Removal/Installation
2. Job Set-up
SUBTASK 74-10-01-010-001
3. Procedures
SUBTASK 74-10-01-050-001
A. Remove the Ignition Exciters
WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY

(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.
74-10-01
Page 401
Apr 11/08

(4) Remove the ignition exciters, put in a protective bag and identify as required.
TASK 74-10-01-450-801 Install the Ignition Exciters
4. General
This task provides procedures for removing the ignition exciter. Refer to the following illustration(s):
Figure 401 Ignition Exciter - Removal/Installation
Catalog:
74-10-01, Fig. 01
SUBTASK 74-10-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 74-10-01-945-002
74-00-10 501 Ignition System - Adjustment/Test
6. Procedures
SUBTASK 74-10-01-420-001
A. Install the Ignition Exciters
(1) Install ignition exciters onto the forward and rear mounting brackets. Locate the igniter leads
toward the aft end of the engine.
(2) Attach the ignition exciters with two clamps, four bolts, eight washers and four nuts. Torque
nuts 2 to 5 inch-pounds (0.22 to 0.56 N.m) above the prevailing run-on torque.
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.
(4) Install the electrical connectors to the ignition exciters.
(5) Do an operational test on the ignition system. Refer to 74-00-10, P.B. 501.
7. Job Close-up
SUBTASK 74-10-01-410-002
SUBTASK 74-10-01-760-001
74-10-01
Page 403
Apr 11/08

Fig. 401 Ignition Exciter - Removal/Installation
74-10-01
Page 404
Apr 11/08

IGNITER LEAD - REMOVAL/INSTALLATION
TASK 74-20-01-050-801 Remove the Igniter Leads
1. General
This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401 Igniter Leads - Removal/Installation
SUBTASK 74-20-01-945-001
3. Job Set-up
SUBTASK 74-20-01-010-001
4. Procedures
SUBTASK 74-20-01-020-001
A. Remove either of the two igniter leads as follows:
WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY CIRCUITS.

REMOVE INPUT POWER PRIOR TO HANDLING EXCITER, LEAD, OR PLUG.
(1) Remove aircraft power leads from the two ignition exciters.
(2) Remove lockwire from the igniter lead connector nuts.
(3) Disconnect the igniter lead from each ignition exciter.
74-20-01
Page 401
Apr 11/08

WARNING WARNING: FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY

FROM HEAT AND OPEN FLAME. FUEL MAY ALSO CAUSE SKIN
IRRITATION. ANY FUEL THAT CONTACTS THE SKIN MUST BE WASHED
OFF IMMEDIATELY. CLOTHING WITH FUEL CONTAMINATION MUST
BE THOROUGHLY CLEANED BEFORE BEING WORN.
(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.
TASK 74-20-01-450-801 Install the Igniter Leads
5. General
This task provides procedures for removing the igniter leads. Refer to the following illustration(s):
Figure 401 Igniter Leads - Removal/Installation
Catalog:
74-20-01, Fig. 01
SUBTASK 74-20-01-942-002
A. Consumables
SUBTASK 74-20-01-945-002
74-20-01
Page 402
Apr 11/08

7. Procedures
SUBTASK 74-20-01-420-001
A. Install spiral wrap to igniter lead:
(1) If not already installed, install .025-inch spiral wrap to igniter leads. Secure spiral wrap with
nylon strap locks and trim ends of strap locks flush.
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
C. Install igniter lead:
(1) Route the lead and install the cable clamps.
(2) Install the 90 end of the igniter lead to the igniter plug.
(3) Torque the igniter lead at the ignition exciter end 140 to 150 inch-pounds (15.7 to 16.8 N.m).
(4) Torque the igniter lead at the igniter end 240 to 250 inch-pounds (27.1 to 28.2 N.m).
(5) Lockwire the two igniter lead nuts together with .020 inch lockwire (MAT-061).
(6) Install igniter leads in the dual clamp assembly as follows:
(a) Install leads in clamp assembly. Do not cross the leads.
(b) Carefully close the clamps on the leads, slotted clamp first.
(c) Align the "T" nut on the clamp screw with the slots in the clamp arm and the clamp base,
then push through and lock into position.
(d) Torque clamp screw 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(7) Install other lead clamps and torque clamp bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
(8) Install the fuel tubes that were removed for access to the igniter leads. Refer to 73-10-01,
P.B. 401.
(9) Install two aircraft power leads to the ignition exciters.
8. Job Close-up
SUBTASK 74-20-01-410-002
74-20-01
Page 403
Apr 11/08

SUBTASK 74-20-01-760-001
(List of Test Procedures) in 71-00-00, P.B. 501..
74-20-01
Page 404
Apr 11/08

Fig. 401 Igniter Leads - Removal/Installation
74-20-01
Page 405
Apr 11/08

74-20-01
406
Page
Blank
IGNITER LEAD - INSPECTION/CHECK
TASK 74-20-01-220-801 Visually Inspect the Igniter Leads
1. General
This task provides procedures for visually inspecting the igniter leads.
Catalog:
74-20-01, Fig. 01
SUBTASK 74-20-01-942-003
A. Consumables
SUBTASK 74-20-01-945-003
74-20-01 401 Igniter Lead - Removal/Installation
3. Procedures
SUBTASK 74-20-01-020-002
A. Remove igniter leads. Refer to 74-20-01, P.B. 401.
SUBTASK 74-20-01-220-001
B. Inspect Igniter Leads
(1) Inspect igniter lead cables for:
74-20-01
Page 601
Apr 11/08

WARNING ISOPROPYL ALCOHOL IS MILDLY TOXIC AND BURNS WITH A

COLORLESS FLAME. AVOID INGESTION OR EYE CONTACT AND
KEEP AWAY FROM HEAT, SPARKS, OR FLAME.
(a) Carbon deposits - no damage Clean with isopropyl alcohol (MAT-027)

and a soft brush
(b) Carbon deposits with damage Reject

(burned)
(c) Chafed Reject
(d) Frayed Reject
(e) Kinked Reject
(f) Severed Reject
(g) Missing or damaged spiral wrap Install new spiral wrap. Refer to 74-20-01,
P.B. 401
(2) Inspect the two connectors for:
(a) Stripped threads Reject
(b) Cross threaded Reject
(c) Rounded wrench flats Reject
(d) Cracked elbow Reject
(e) Kinked elbow Reject
(f) Corrosion Reject
SUBTASK 74-20-01-420-002
C. Install igniter leads. Refer to 74-20-01, P.B. 401.
74-20-01
Page 602
Apr 11/08

IGNITER PLUG - REMOVAL/INSTALLATION
TASK 74-22-01-050-801 Remove the Igniter Plugs
1. General
This task provides procedures for removing the igniter plugs. Refer to the following illustration(s):
Figure 401 Igniter Plug Removal/Installation
Figure 402 Igniter Adapter Removal/Installation
SUBTASK 74-22-01-942-001
A. Consumables
3. Job Set-up
SUBTASK 74-22-01-010-001
4. Procedures
SUBTASK 74-22-01-020-001
A. Remove either of the two igniter plugs as follows:
WARNING IGNITION EXCITER CONTAINS HIGH VOLTAGE, HIGH ENERGY

(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.
74-22-01
Page 401
Apr 11/08

CAUTION PLUG THE IGNITER PORTS TO PREVENT FOREIGN OBJECTS

FROM ENTERING THE ENGINE.
(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:
(a) If applicable, remove safety wire from adapter/diffuser.
(b) Remove retaining ring, igniter plug ring seal, and igniter plug plate seal.
(c) Remove igniter plug nut, igniter plug, and igniter plug adapter as an assembly from the
engine. The spacer will come out separately.
(d) Separate igniter plug nut from the igniter plug adapter.
(e) Reinstall igniter plug adapter and spacer into igniter boss on the service island. Lubricate
igniter plug adapter threads with MAT-013 and torque 590 to 610 inch-pounds (66.6
to 68.9 N.m).
(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.
TASK 74-22-01-450-801 Install the Igniter Plugs
5. General
This task provides procedures for installing the igniter plugs. Refer to the following illustration(s):
Figure 401 Igniter Plug Removal/Installation
Catalog:
74-22-01, Fig. 01
SUBTASK 74-22-01-942-002
A. Consumables
MAT-015 Lubricant, Anti-seize
SUBTASK 74-22-01-945-002
74-22-01
Page 402
Apr 11/08


74-22-02 501 Igniter Plug Spacer - Maintenance Practices
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.
A. Install igniter plug as follows:
CAUTIONS: 1 IMPROPER INSTALLATION OF RETAINING RING WILL RESULT IN

DAMAGE TO ENGINE. THE RETAINING RING MUST BE INSTALLED
BELOW THE LAST THREAD IN THE IGNITER PLUG NUT.
2 GRASP IGNITER PLUG AND TEST FOR TRANSVERSE OR AXIAL

MOVEMENT. A PROPERLY SEATED IGNITER PLUG WILL HAVE NO
RELATIVE MOTION. AXIAL MOVEMENT OF PLUG WILL RESULT IN
ENGINE DAMAGE FROM IGNITER PLUG MOVEMENT.
(1) Insert the igniter plug into the igniter plug nut and install the internal retaining ring. Ensure
retaining ring is installed below the last thread in the igniter plug nut.
(2) Apply magnesium hydroxide MAT-013 or anti-seize lubricant MAT-015 to the igniter plug nut
threads.
(3) Following the angle of the igniter boss, insert the igniter plug and igniter nut into the diffuser
and locate in the hole in the combustor.
NOTE The igniter plug nut will not thread on the boss if the igniter plug is
not located in the combustor primary plate.
(4) Torque the igniter plug nut 300 to 325 inch-pounds (33.8 to 36.7 N.m).
(5) Remove protective covering from the igniter lead and install on the igniter plug. Hold the
igniter plug with a back-up wrench and torque the igniter lead 240 to 250 inch-pounds (27.1
to 28.2 N.m).
(6) Connect the aircraft electrical connectors to the ignition exciters.
74-22-01
Page 403
Apr 11/08

8. Job Close-up
SUBTASK 74-22-01-410-002
SUBTASK 74-22-01-760-001
C. Indicate in the engine logbook the hours/cycles that igniter was installed.
74-22-01
Page 404
Apr 11/08

Fig. 401 Igniter Plug Removal/Installation
74-22-01
Page 405
Apr 11/08

Fig. 402 Igniter Adapter Removal/Installation
74-22-01
Page 406
Apr 11/08

IGNITER PLUG - INSPECTION/CHECK
TASK 74-22-01-220-801 Visually Inspect the Igniter Plugs
1. General
Perform this task at the interval shown in Routine Periodic Inspections, 05-20-00, P.B. 601. Refer to the
Figure 601 Igniter Plug - Visual Inspection
Catalog: 74-22-01, Fig. 01.
SUBTASK 74-22-01-945-003
74-22-01 701 Igniter Plug - Cleaning
3. Procedures
SUBTASK 74-22-01-020-002
A. Remove igniter plug(s). Refer to 74-22-01, P.B. 401.
SUBTASK 74-22-01-220-001
B. Inspect igniter plug exterior shell for:
(1) Cracks or chips Reject
(2) Swelling or distortion Reject
74-22-01
Page 601
Apr 11/08

(3) Fretting or chafing wear in Zone A resulting Accept

in a local shell diameter of 0.450 inch (11.4
mm) or greater
(4) Fretting or chafing wear in Zone B resulting Accept

in a local shell diameter of 0.500 inch (12.7
mm) or greater
(5) Fretting or chafing wear resulting in local Reject

shell diameters less than previous two steps
C. Visually inspect the igniter tip for combustion deposits. Clean, refer to 74-22-01, P.B. 701
D. Inspect igniter connector for:
(1) Cracked ceramic Reject
(2) Carbon deposits Reject
NOTE When checking for binding of spherical pivot, make sure that pivot area is
clean and free from anti-seize compound residue.
E. Check spherical pivot for proper movement. If binding is apparent, reject.
TASK 74-22-01-220-803 Dimensionally Inspect Igniter Plugs
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
Depth Micrometer Or Caliper (probe Diameter 0.100
Inch [2.54 Mm] Or Less)
SUBTASK 74-22-01-945-005
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:
CAUTION IF IGNITER(S) ARE REJECTED FOR EXCEEDING EROSION LIMITS

AT 150 HOURS OF OPERATING TIME, REVIEW FLIGHT OPERATION
PRACTICES TO ENSURE THAT IGNITION SYSTEM IS NOT BEING
OPERATED EXCESSIVELY. REFER TO THE AIRCRAFT FLIGHT MANUAL
FOR PROCEDURES FOR OPERATING IGNITION SYSTEM.
(1) Measure the distance between the face of the igniter tip and the center electrode. Refer to
Figure 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
NOTES: 1 Continue to use igniter plug if measurement is at acceptable limits. An

igniter plug at acceptable limits will last until the next engine inspection.
2 Refer to task 74-22-01-220-802 for inspection method for igniter plug

P/N 55396 or CH31876-1 (if applicable to engine model).
SUBTASK 74-22-01-420-002
B. Install Igniter plug(s). Refer to 74-22-01, P.B. 401.
74-22-01
Page 603
Apr 11/08

Fig. 601 Igniter Plug - Visual Inspection
74-22-01
Page 604
Apr 11/08

Fig. 602 Igniter Plug - Erosion Measurement
74-22-01
Page 605
Apr 11/08

74-22-01
606
Page
Blank
IGNITER PLUG - CLEANING
TASK 74-22-01-110-801 Clean the Igniter Plugs
1. General
Perform this task as indicated by visual inspection.
SUBTASK 74-22-01-942-006
A. Consumables
MAT-028 Alcohol, Methyl, Wood, or Methanol
SUBTASK 74-22-01-945-006
3. Procedures
SUBTASK 74-22-01-020-003
A. Remove igniter plug(s). Refer to 74-22-01, P.B. 401.
SUBTASK 74-22-01-120-001
B. Clean igniter plug(s) as follows:
(1) Wipe combustion deposits from exterior with a lint-free cloth.
CAUTION DO NOT DISTURB THE COMBUSTION DEPOSITS IN THE GAP

AREA. IF GAP AREA DEPOSITS MUST BE REMOVED FOR CLOSER
INSPECTION, REMOVE DEPOSITS WITH A WOODEN SCRAPER.
DO NOT TOUCH THE SEMI-CONDUCTOR SURFACE DEPOSITS IN
THE GAP AREA; THEY AID PLUG OPERATION.
(2) Terminal well may be cleaned with a felt swab saturated in mineral spirits MAT-020 or methyl,
wood, or methanol alcohol MAT-028.
74-22-01
Page 701
Apr 11/08

SUBTASK 74-22-01-420-003
C. Install igniter plug(s). Refer to 74-22-01, P.B. 401.
74-22-01
Page 702
Apr 11/08

CHAPTER 75
AIR
Page 1
75-AIR Apr 11/08

Page 2
75-AIR Blank

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
Page 1
Apr 11/08

Chapter 75
Page 2
Blank
AIR SYSTEM - DESCRIPTION AND OPERATION
TASK 75-00-00-860-803 Air System - Description and Operation
1. General
The FJ44 is a two spool, axial flow, bypass turbofan engine. The bypass ratio is 3.3 : 1. The engine has
three compressors: a low pressure (LP) axial compressor, an intermediate pressure (IP) axial compressor,
and a high pressure (HP) centrifugal compressor. The LP compressor (fan) and IP compressor are driven
by two LP turbines. The HP compressor is driven by a single HP turbine. When the mixture of fuel and
compressed air is ignited in the combustor section, the expanding gases drive the turbines.
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.
C. Acceleration Bleed System
The acceleration bleed system is operated by the fuel control unit (FCU). The acceleration bleed
cable connects the FCU with a butterfly valve in the interstage housing. The butterfly valve is open at
engine start and is closed by the FCU when the engine reaches 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.
75-00-00
Page 1
Apr 11/08

75-00-002
Page
Blank
ACCELERATION BLEED SYSTEM LINKAGE - INSPECTION/CHECK
TASK 75-30-01-220-801 Visually Inspect the Acceleration Bleed System Linkage
1. General
Do this task at the interval shown under periodic inspections. Refer to the following illustration(s):
Figure 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection
Catalog:
75-37-01, Fig. 02
SUBTASK 75-30-01-942-001
A. Consumables
MAT-008 Lubricant, Molybdenum Disulfide
SUBTASK 75-30-01-945-001
75-35-01 501 Acceleration Bleed System Lever - Adjustment/Test
75-30-01
Page 601
Apr 11/08

3. Job Set-up
SUBTASK 75-30-01-010-001
4. Procedures
SUBTASK 75-30-01-220-001
A. Inspect the cable assembly for:
(1) Minor damage to outer cable insulation Repair with adhesive sealant MAT-089
(RTV 103, black)
(2) Shrink tubing pulled away from cable at Apply a shrink tube splice
fuel control side.
(3) Damage to outer cable metal sheathing Reject
(4) Bends Reject
(5) Light wear on inner cable Polish the wear out with 400 grit abrasive
cloth MAT-040. Apply molybdenum
disulfide lubricant MAT-008.
(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
B. Inspect other acceleration bleed system parts as follows:
(1) Inspect all jam nuts for tightness. Tighten if needed.
75-30-01
Page 602
Apr 11/08

(2) Inspect brackets for tightness. Tighten if needed.
(3) Inspect IP bleed valve lever for cracks. Reject
NOTE If the lever is replaced, you must adjust it after installation.

Refer to 75-35-01, P.B. 501.
5. Job Close-up
SUBTASK 75-30-01-410-001
75-30-01
Page 603
Apr 11/08

Fig. 601 Acceleration Bleed System Linkage - Pull Only Configuration - Visual Inspection
75-30-01
Page 604
Apr 11/08

ACCELERATION BLEED SYSTEM LEVER - REMOVAL/INSTALLATION
TASK 75-35-01-050-802 Remove the Acceleration Bleed System Lever
1. General
This task provides procedures for removing the acceleration bleed system lever. Refer to the following
illustration(s):
2. Job Set-up
SUBTASK 75-35-01-010-003
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.
(2) Remove the spring tang from the bleed lever.
(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.
75-35-01
Page 401
Apr 11/08

(5) Remove the spring from the bleed port cover.
TASK 75-35-01-450-802 Install the Acceleration Bleed System Lever
4. General
This task provides procedures for installing the acceleration bleed system lever. Refer to the following
illustration(s):
Catalog:
75-35-01, Fig. 02
MAT-001engine oil before installation.
SUBTASK 75-35-01-942-004
A. Consumables
MAT-001 Oil, Engine
SUBTASK 75-35-01-945-004
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).
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
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches the minimum and
maximum stops during test.
75-35-01
Page 403
Apr 11/08

Fig. 401 Acceleration Bleed System Lever - Pull Only Configuration - Removal/Installation
75-35-01
Page 404
Apr 11/08

ACCELERATION BLEED SYSTEM LEVER - ADJUSTMENT/TEST
TASK 75-35-01-820-801 Adjust the Acceleration Bleed Lever
1. General
Do this task after a new lever arm is installed. If the cable assembly or fuel control unit were replaced, you
must verify that the maximum and minimum stops are contacted during acceleration and deceleration
test. Refer to the following illustration(s):
Figure 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment
SUBTASK 75-35-01-942-005
A. Consumables
SUBTASK 75-35-01-945-005
75-37-01 401 Acceleration Bleed System Cable - Removal/Installation
3. Job Set-up
SUBTASK 75-35-01-010-005
A. Prepare the engine for adjustment
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):
75-35-01
Page 501
Apr 11/08

(1) Disconnect the spring tang from the lever.
(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.
(7) Install the spring tang on the lever.
B. Check adjustment of the bleed cable jam nuts to make sure that bleed valve lever is properly adjusted
in the open position. Refer to 75-37-01, P.B. 401
5. Job Close-up
SUBTASK 75-35-01-410-005
(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.
75-35-01
Page 502
Apr 11/08

Fig. 501 Acceleration Bleed System Lever - Pull Only Configuration - Adjustment
75-35-01
Page 503
Apr 11/08

75-35-01
504
Page
Blank
ACCELERATION BLEED SYSTEM CABLE - REMOVAL/INSTALLATION
TASK 75-37-01-050-802 Remove the Acceleration Bleed System Cable
1. General
This task provides procedures for removing the acceleration bleed system cable. Refer to the following
illustration(s):
Figure 401 Acceleration Bleed System Cable - Adjustment
Figure 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
2. Job Set-up
SUBTASK 75-37-01-010-003
3. Procedures
SUBTASK 75-37-01-020-002
A. Remove the "pull only" configuration acceleration bleed cable as follows:
(1) Remove one bolt, cover, and spacer from the acceleration bleed port cover.
(2) 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.
(7) Disconnect the outer sheath from the FCU/FDU boss.
75-37-01
Page 401
Apr 11/08

(8) Disconnect the inner cable from the FCU/FDU plunger
TASK 75-37-01-450-802 Install the Acceleration Bleed System Cable
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
Catalog:
75-37-01, Fig. 02
MAT-001engine oil before installation.
SUBTASK 75-37-01-942-004
A. Consumables
MAT-001 Oil, Engine
SUBTASK 75-37-01-943-004
B. Special Tools
TL37220 Torque Adapter, Air Bleed Cable Nut
SUBTASK 75-37-01-944-004
C. Expendable Parts
IPC Reference:
75-35-01 2 80 Roll Pin
SUBTASK 75-37-01-945-004
75-37-01
Page 402
Apr 11/08


6. Procedures
SUBTASK 75-37-01-420-002
A. Install the "pull only" acceleration bleed system cable as follows:
(1) Install the threaded end of the acceleration bleed cable assembly on the FCU/FDU by inserting
the cable through the mounting boss on the FCU/FDU connection. One jam nut and washer
should be on the aft side of the boss. Install the other jam nut and washer on forward side of
the boss. Do not tighten jam nuts at this time.
CAUTION GRIPPING THE FCU/FDU PLUNGER WITH PLIERS OR OTHER

TOOL WILL DAMAGE THE COATED (IF APPLICABLE) SURFACE
OF THE ROD AND CAUSE FUEL LEAKS.
NOTE To install the cable, turn the plunger, rather than the cable.
(2) Install inner cable in 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).
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).
(c) Torque jam nuts 25 to 28 inch-pounds (2.8 to 3.1 N.m) .
(7) Install spacer and cover onto bleed port cover post. Install other end of cover into slot in bleed
cable bracket. Secure cover with one bolt. Torque bolt36 to 40 inch-pounds (4.0 to 4.5 N.m) .
NOTE Loop clamp configurations may be different depending on bleed

cable part number. Please refer to the applicable Illustrated
Parts Catalog, section 75-37-01.
(8) Connect the loop clamp(s) at the rear bypass duct flange and torque bolt 49 to 55 inch-pounds
(5.5 to 6.2 N.m).
7. Job Close-up
SUBTASK 75-37-01-410-004
(List of Test Procedures) in 71-00-00, P.B. 501. Verify that the lever touches the minimum and
maximum stops during test.
75-37-01
Page 404
Apr 11/08

EFFECTIVITY: FJ44-2AFig. 401 Acceleration Bleed System Cable - Adjustment

75-37-01
Page 405
Apr 11/08

Fig. 402 Acceleration Bleed System Cable - Pull Only Configuration - Removal/Installation
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

76-00-00 1 Apr 11/08 76-20-01 501 Apr 11/08 76-20-01 601 Apr 11/08
Chapter 76
Page 1
Apr 11/08

Chapter 76
Page 2
Blank
ENGINE CONTROLS - DESCRIPTION AND OPERATION
TASK 76-00-00-860-801 Engine Controls - Description and Operation
1. General
The speed of the engine is controlled by limiting fuel flow. In the case of an LP shaft separation, the fuel is
shut off to prevent the engine from an overspeed condition.
2. Description
SUBTASK 76-00-00-860-001
A. The engine control system contains the following parts:
Power Lever
LP Shaft Trip Sensor
B. The power lever is connected to the fuel control unit (FCU) at the power lever input shaft. The
minimum and maximum speed settings are adjusted and set prior to engine installation.
C. The LP shaft trip sensor is connected to the FCU fan/LP shaft separation shutoff valve by a cable that
runs from the LP trip lever housing, located on the rear bypass duct, to the FCU.
3. Operation
SUBTASK 76-00-00-860-003
A. The power lever angle (PLA) setting in the cockpit is mechanically transferred to the FCU by a
cable linkage. The PLA controls the engine speed by limiting the fuel flow from the FCU for any
desired engine speed in the operating range.
B. The LP shaft trip sensor is operated in the event of an LP shaft separation. This event would force
the LP turbines in an aft direction against the LP trip lever. The LP trip lever is connected to a
trigger mechanism on the rear bypass duct. The trigger mechanism, when tripped, pushes the LP
trip sensor cable forward and shuts down the engine by cutting off its fuel. This also prevents an
overspeed condition.
76-00-00
Page 1
Apr 11/08

76-00-002
Page
Blank
LP SHAFT TRIP SENSOR - ADJUSTMENT/TEST
TASK 76-20-01-830-801 Adjust (Reset) the LP Shaft Trip Sensor
1. General
Do this task whenever the LP shaft trip sensor has been operated or the trip lever requires adjustment.
Refer to the following illustration(s):
Figure 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
SUBTASK 76-20-01-941-001
Arbor Press
Depth Micrometer
SUBTASK 76-20-01-942-001
B. Consumables
MAT-001 Oil, Engine
SUBTASK 76-20-01-944-001
C. Expendable Parts
76-20-01
Page 501
Apr 11/08

IPC Reference
76-20-01 01 230 Gasket, Cable Housing
SUBTASK 76-20-01-945-001
73-27-01 201 Fuel Control Shutoff Valve - Maintenance Practices
3. Job Set-up
SUBTASK 76-20-01-010-001
A. Prepare the engine for maintenance
4. Procedures
NOTE Do this task whenever the LP shaft trip sensor has been operated or
the trip lever requires adjustment.
SUBTASK 76-20-01-050-001
A. Remove the cable actuator housing as follows:
(1) Remove two screws and washers which attach the housing cover. Remove the housing cover.
(2) Remove two screws, two washers and two nuts which attach the cable actuator housing to the
LP trip sensor housing.
(3) Remove the cable actuator housing by pulling it away from the trip lever housing.
(4) Remove lockwire from cable jam nuts. Remove the jam nut which attaches the forward end of
the LP trip sensor cable to the FCU.
(5) Remove the cable and the cable actuator housing assembly.
SUBTASK 76-20-01-820-001
B. Reset the LP Trip Sensor Housing Mechanism
76-20-01
Page 502
Apr 11/08

WARNING SPRING LOADED ASSEMBLY MAY DISCHARGE AND CAUSE INJURY.

FOLLOW DIRECTIONS CAREFULLY AND WEAR SAFETY GOGGLES.
NOTES: 1 The coil spring and spring retainer may come out of outer latch.
2 FOR FJ44-1A ONLY: If required by the major periodic inspection

requirements (5-20-00, P.B. 601), discard coil spring P/N 45487
and replace with P/N 54901.
(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
C. Adjust LP Trip Lever
NOTE Do this task after installing the LP trip lever into the rear housing/rear bypass duct.
The adjustment allows for 0.050 to 0.060 inch (1.27 to 1.52 mm) distance between
the end trip lever and the LP shaft aft end with LP shaft thrusted aft.
(1) Perform initial trip lever adjustment as follows:
NOTE The following task requires two people.
(a) Thrust the LP rotary group aft by pushing on the fan rotor. Continue to apply pressure
during adjustment.
(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.
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
D. Recalculate Trigger Pin Dimension.
NOTE Do this procedure whenever the trigger pin that was removed from the engine is
damaged and/or otherwise replaced. Trigger pins are matched to an engine and
their lengths must be recalculated if any of the following apply:
Replaced rear housing.
Lost, damaged or replaced trigger pin
Replaced trip lever
Replaced rear bypass duct
(1) Recalculate trigger pin dimension (length) as follows:
WARNING WHEN MEASURING L1, DO NOT PUT FORCE AGAINST THE

ANVIL. THIS CAN TRIGGER SPRING LOADED DEVICE AND
CAUSE INJURY. WEAR SAFETY GOGGLES.
(a) Using depth micrometer, measure from face of trigger pin anvil to housing flange
face. Record this as L1 dimension. See Figure 506 LP Shaft Trip Sensor Trigger
Pin Calculation Measurements.
(b) Measure L2 dimension as follows:
76-20-01
Page 504
Apr 11/08

CAUTION WHEN MEASURING L2 AND L3, MAKE SURE THAT YOU

MAINTAIN THE SAME RELATIVE POSITIONING OF THE
MICROMETER ON THE BUSHING.
NOTE Make sure that the LP trip lever stop is adjusted correctly.
Refer to Subtask 76-20-01-820-002.
1 Use a depth micrometer with a rod which is close to the diameter of the trigger pin.
2 Measure from the end of the trigger pin bushing to the bottom of the lever cup. Make
sure that the lever and pin are correctly positioned. Record as dimension L2.
(c) Measure from trigger pin bushing to trip lever housing and record as dimension L3.
(d) Measure thickness of gasket.
(e) Calculate as follows: L1 + L2 - L3 + gasket thickness = Trigger pin dimension (length).
(f) Grind trigger pin 0.003 - 0.007 inch (0.076 - 0.178 mm) shorter than calculated dimension.
(2) After final assembly and adjustment of trip sensor, measure trigger pin movement through the
witness hole at the bottom of the trip lever cup. Trigger pin end play must be 0.003 - 0.007
inch (0.076 - 0.177 mm). Use a set of feeler gauges which have been modified (ground) per
SUBTASK 76-20-01-420-001
E. Install the cable actuator housing as follows:
(1) Recalculate trigger pin dimension as required. Refer to Subtask 76-20-01-820-003.
(2) Reset FCU shut-off valve, if required. Refer to 73-27-01, P.B. 201.
(3) If actuator cable has been removed from cable actuator housing, install as follows:
NOTE 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.
76-20-01
Page 505
Apr 11/08

SUBTASK 76-20-01-830-001
F. Install cable as follows:
(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
G. Final installation as follows:
(1) Install the trigger pin into the bushing of aft LP trip sensor housing. The ground end of the
pin should face the trigger anvil. Make sure that pin is properly seated in the cup of the
lever assembly.
(2) Align and carefully install the cable and actuator housing assembly and gasket on the LP
trip sensor housing.
(3) Attach the housing with two screws, two washers and two nuts. Torque screws 25 to 28
SUBTASK 76-20-01-210-001
H. Inspect Trigger Pin End Play/Final Trip Lever Adjustment.
CAUTION DO NOT APPLY EXCESSIVE FORCE IN THE FORWARD DIRECTION

WHEN POSITIONING PIN FOR END PLAY MEASUREMENT. THIS
MAY TRIGGER SPRING-LOADED ASSEMBLY.
(1) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
(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.
(6) Torque the screws 26 to 29 inch-pounds (2.9 to 3.2 N.m).
76-20-01
Page 506
Apr 11/08

5. Job Close-up
SUBTASK 76-20-01-430-001
76-20-01
Page 507
Apr 11/08

Fig. 501 Rear Bypass Duct - Cable Actuator Housing - Removal/Installation
76-20-01
Page 508
Apr 11/08

Fig. 502 LP Shaft Trip Sensor - Disassembly/Assembly
76-20-01
Page 509
Apr 11/08

Fig. 503 LP Shaft Trip Sensor - Lever Adjustment
76-20-01
Page 510
Apr 11/08

Fig. 504 LP Shaft Trip Sensor - Cable Adjustment
76-20-01
Page 511
Apr 11/08

Fig. 505 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge
76-20-01
Page 512
Apr 11/08

Fig. 506 LP Shaft Trip Sensor Trigger Pin Calculation Measurements
76-20-01
Page 513
Apr 11/08

Fig. 507 LP Shaft Trigger Pin Dimensions Installed Trigger Pin Dimensions
76-20-01
Page 514
Apr 11/08

LP SHAFT TRIP SENSOR - INSPECTION/CHECK
TASK 76-20-01-220-801 Visually Inspect the LP Shaft Trip Sensor System
1. General
This task contains procedures for checking that the LP shaft trip sensor system is properly rigged. Refer
Figure 601 LP Shaft Trip Sensor - Inspection
Catalog:
76-20-01, Fig. 01
SUBTASK 76-20-01-941-002
Flexible, Steerable Fiberscope, 6mm Dia 50 Inch
Long
SUBTASK 76-20-01-942-002
B. Consumables
SUBTASK 76-20-01-945-002
76-20-01
Page 601
Apr 11/08

3. Job Set-up
SUBTASK 76-20-01-010-002
4. Procedures
SUBTASK 76-20-01-220-001
A. Visually inspect LP trip sensor cable for:
(1) Light damage to cable outer sheathing Repair with MAT-089 (RTV sealant)
B. Inspect trip lever/LP shaft with a borescope (Flexible, steerable fiberscope, 6mm dia 50 inch long)
(1) Insert borescope through the center hole in the aft end of the rear housing tail cone.
(2) Move the borescope forward and inspect the LP trip lever/LP shaft. Inspect the trip lever for
signs that it has contacted the LP shaft (rub mark, fretting). If fretting/rub damage is noted,
remove LP trip lever (72-00-71, P.B. 401). Evaluate trip lever in accordance with inspection
criteria (below). Install trip lever and adjust LP sensor in accordance with 76-20-01, P.B. 501.
(a) LP trip lever fretting/rub damage up to Blend damage smooth with minimal
0.012 inch (0.304 mm) deep. material removal.
(b) Damage greater than above Reject
5. Job Close-up
SUBTASK 76-20-01-410-002
76-20-01
Page 602
Apr 11/08

TASK 76-20-01-220-802 Check the Trigger Pin End Play
6. General
This task checks the trigger pin end play of the LP shaft trip sensor. Refer to the following illustration(s):
Figure 601 LP Shaft Trip Sensor - Inspection
SUBTASK 76-20-01-945-003
8. Job Set-up
SUBTASK 76-20-01-010-004
9. Procedures
SUBTASK 76-20-01-220-002
A. Check the trigger pin end play
(1) Remove the two screws and two washers which attach the trip lever housing cover on the outer
bypass duct. Remove the housing cover.
CAUTION USE ONLY LIGHT PRESSURE ON TRIGGER PIN WHEN CHECKING

END PLAY. USE OF TOO MUCH PRESSURE COULD DISCHARGE
THE TRIGGER MECHANISM.
(2) Gently move the pin all the way forward to seat it in the anvil for end play measurement.
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
10. Job Close-up
SUBTASK 76-20-01-410-003
76-20-01
Page 604
Apr 11/08

Fig. 601 LP Shaft Trip Sensor - Inspection
76-20-01
Page 605
Apr 11/08

Fig. 602 LP Shaft Trip Sensor - Trigger Pin Feeler Gauge
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

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
Page 1
Apr 11/08

Chapter 77
Page 2
Blank
ENGINE INDICATING - DESCRIPTION AND OPERATION
TASK 77-00-00-860-803 Engine Indicating - Description and Operation
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
A. The indicating system is made up of the following parts:
EFCU engine harness assembly
EFCU TT2 sensor
Gearbox magnetic speed pickup assembly (HP)
LP magnetic speed pickup assembly
Interstage turbine temperature (ITT) probe (6)
Engine vibration pickup (test equipment)
Fuel filter electrical indicator switch (delta P); refer to 73-23-01, P.B. 401
Oil filter differential pressure (delta P) indicator; refer to 72-60-02, P.B. 401
Magnetic chip collectors; refer to 79-30-01, P.B. 401
B. The 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.
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.
77-00-00
Page 2
Apr 11/08

LP MAGNETIC SPEED PICKUP ASSEMBLY - REMOVAL/INSTALLATION
TASK 77-11-01-050-801 Remove the LP Magnetic Speed Pickup Assembly
1. General
This task provides procedures for removing the LP magnetic speed pickup assembly. Refer to the
Figure 401 LP Magnetic Speed Pickup - Removal/Installation
2. Job Set-up
SUBTASK 77-11-01-010-001
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.
A. Remove the LP magnetic speed pickup assembly
(1) Disconnect the electrical connector (N1 SPEED) from the LP magnetic speed pickup, located
on the interstage housing.
(2) Remove screw from clamp and remove pickup from interstage housing.
B. Remove pickup port plug (if required for engine reconfiguration)
77-11-01
Page 401
Apr 11/08

(1) Remove screw from plug and remove plug and O-ring.
TASK 77-11-01-450-801 Install the LP Magnetic Speed Pickup Assembly
4. General
This task provides procedures for installing the LP magnetic speed pickup assembly. Refer to the
Figure 401 LP Magnetic Speed Pickup - Removal/Installation
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
SUBTASK 77-11-01-944-002
B. Expendable Parts
IPC Reference
77-11-01 01 20 O-Ring (2)
SUBTASK 77-11-01-945-002
70-03-01 201 Electrical Bonding - Maintenance Practices
77-11-01
Page 402
Apr 11/08

6. Procedures
SUBTASK 77-11-01-420-001
A. Install the LP magnetic speed pickup assembly
(1) Lube O-ring with assembly fluid MAT-011and install on pickup.
(2) Install the LP pickup in the outboard port of interstage housing and attach with clamp and screw.
(3) Torque the screw 31 to 35 inch-pounds (3.5 to 3.9 N.m).
(4) Install harness connector plug (N1 SPEED) to pick-up assembly
B. Install pickup port plug (if removed)
(1) Lube O-ring with assembly fluid MAT-011 and install on plug.
(2) Install plug in opposite port of interstage housing and install screw.
7. Job Close-up
SUBTASK 77-11-01-410-002
SUBTASK 77-11-01-760-001
(List of Test Procedures) in71-00-00, P.B. 501.
77-11-01
Page 403
Apr 11/08

Fig. 401 LP Magnetic Speed Pickup - Removal/Installation
77-11-01
Page 404
Apr 11/08

LP MAGNETIC SPEED PICKUP ASSEMBLY - INSPECTION/CHECK
TASK 77-11-01-220-801 Visually Inspect the LP Magnetic Speed Pickup Assembly
1. General
This task covers visual inspection of the LP magnetic speed pickup assembly.
Catalog:
77-11-01, Fig. 01
SUBTASK 77-11-01-945-003
77-11-01 401 LP Magnetic Speed Pickup Assembly - Removal/Installation
3. Procedures
SUBTASK 77-11-01-020-002
A. Remove the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
SUBTASK 77-11-01-220-001
B. Inspect LP Magnetic Speed Pickup Assembly
(1) Inspect pickup connector for:
(a) Bent or missing pins, cracks Reject
(2) Inspect pickup shaft for:
(a) Cracks, chips, or bends Reject
77-11-01
Page 601
Apr 11/08

(3) Inspect tip of pickup for:
(a) Damage or signs of contact with Reject

LP shaft
(4) Inspect pickup shaft for nicks:
(a) Nicks without sharp edges up to Accept

0.0015 inch (0.038 mm) deep
(b) Nicks greater than previous step Reject
(5) Inspect pickup shaft for wear:
(a) Light fretting and scratches to 0.007 Accept

inch (0.18 mm) deep in worn areas
up to 0.5 inch (12.7 mm) diameter.
Five areas maximum.
(b) Fretting and scratches greater than Reject

previous step
SUBTASK 77-11-01-420-001
C. Install the LP magnetic speed pickup assembly. Refer to 77-11-01, P.B. 401.
TASK 77-11-01-750-802 Perform Resistance Check on LP Magnetic Speed Pickup Assembly

(Dual Channel)
4. General
This task performs a resistance check on the LP magnetic speed pickup assembly (dual channel). Refer
Figure 601 LP Magnetic Speed Pickup - Resistance Check
SUBTASK 77-11-01-941-005
Ohmmeter
6. Procedures
SUBTASK 77-11-01-750-002
A. Perform resistance check as follows.
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.
77-11-01
Page 603
Apr 11/08

Fig. 601 LP Magnetic Speed Pickup - Resistance Check
77-11-01
Page 604
Apr 11/08

GEARBOX (HP) MAGNETIC SPEED PICKUP ASSEMBLY - REMOVAL/INSTALLATION
TASK 77-12-01-050-801 Remove the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task provides procedures for removing the gearbox (HP) magnetic speed pickup assembly. Refer
Figure 401 Gearbox Magnetic Speed Pickup - Removal/Installation
2. Job Set-up
SUBTASK 77-12-01-010-001
3. Procedures
SUBTASK 77-12-01-020-001
A. Remove the gearbox (HP) magnetic speed pickup
(1) Disconnect the electrical connector (N2 SPEED) from the gearbox speed pickup, located
on the gearbox housing.
(2) Remove screw and washer and remove pickup 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
Figure 401 Gearbox Magnetic Speed Pickup - Removal/Installation
Catalog:
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
SUBTASK 77-12-01-944-002
B. Expendable Parts
IPC Reference
77-12-01 01 20 O-Ring
SUBTASK 77-12-01-945-002
6. Procedures
SUBTASK 77-12-01-420-001
A. Install the gearbox (HP) magnetic speed pickup
(1) Lube O-ring with assembly fluid MAT-011 and install on pickup.
(2) Install the gearbox pickup on gearbox housing and attach with screw and washer.
(4) Install electrical connector plug (N2 SPEED) to pickup jack.
7. Job Close-up
SUBTASK 77-12-01-410-002
77-12-01
Page 402
Apr 11/08

SUBTASK 77-12-01-790-001
77-12-01
Page 403
Apr 11/08

Fig. 401 Gearbox Magnetic Speed Pickup - Removal/Installation
77-12-01
Page 404
Apr 11/08

GEARBOX (HP) MAGNETIC SPEED PICKUP ASSEMBLY - INSPECTION/CHECK
TASK 77-12-01-220-801 Visually Inspect the Gearbox (HP) Magnetic Speed Pickup Assembly
1. General
This task covers visual inspection of the gearbox (HP) magnetic speed pickup assembly.
Catalog:
77-12-01, Fig. 01
SUBTASK 77-12-01-945-003
3. Procedures
SUBTASK 77-12-01-020-002
A. Remove the gearbox (HP) magnetic speed pickup assembly. Refer to 77-12-01, P.B. 401.
SUBTASK 77-12-01-220-001
B. Inspect HP Magnetic Speed Pickup Assembly
(1) Inspect pickup connector for bent or Reject

missing pins, cracks.
(2) Inspect pickup case for cracks, chips, Reject

nicks or bends
(3) Inspect tip of pickup for damage or signs Reject

of contact with gearshaft.
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
Ohmmeter
6. Procedures
SUBTASK 77-12-01-750-002
A. Perform resistance check as follows.
(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.
77-12-01
Page 602
Apr 11/08

Fig. 601 Gearbox Magnetic Speed Pickup - Resistance Check
77-12-01
Page 603
Apr 11/08

77-12-01
604
Page
Blank
INTERMEDIATE TURBINE TEMPERATURE (ITT) PROBE - REMOVAL/INSTALLATION
TASK 77-20-02-050-801 Remove the ITT Probes
1. General
This task provides procedures for removing the ITT probes. Refer to the following illustration(s):
Figure 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration -
Figure 402 ITT Probes - Loop Clamp Locations
2. Job Set-up
SUBTASK 77-20-02-010-001
3. Procedures
SUBTASK 77-20-02-050-001
A. Remove J1 connector from the harness as follows:
(1) Disconnect J1 connector from the harness.
(2) Remove lockwire and remove connector nut from J1 connector. Remove connector from
bracket on front bypass duct.
SUBTASK 77-20-02-050-004
B. Remove ITT Probe(s)
(1) Remove the following from the probe:
(a) Thermocouple retaining ring
(b) Thermocouple seal retainer
(c) Thermocouple seal plate
(d) Thermocouple seal spacer
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.
TASK 77-20-02-040-801 Disassemble ITT Probe J1 Connector
4. General
This task provides procedures to disassemble ITT probe J1 connector. Refer to the following illustration(s):
Figure 403 ITT Probe - Connector - Assembly/Disassembly
SUBTASK 77-20-02-941-010
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-945-010
6. Procedures
SUBTASK 77-20-02-040-010
A. Remove ITT Probe(s) from the engine. Refer to 77-20-02, P.B. 401.
B. Remove probe from backshell and J1 connector as follows:
(1) Loosen saddle clamp of the strain relief.
(2) Unscrew strain relief from adapter.
(3) Slide grommet and follower back.
(4) Remove adapter from backshell.
(5) Move ground ring back and separate braids.
77-20-02
Page 402
Apr 11/08

(6) Remove backshell from connector.
(7) Remove the ITT probe chromel (white) wire and the alumel (green) wire from the J1 connector
(bayonet type). Mark the location of each pin and color for proper assembly. Use the
M8196914-02 extraction/insertion tool as required.
TASK 77-20-02-440-801 Assemble ITT Probe J1 Connector
7. General
This task provides procedures for assembling the ITT probe J1 connector. Refer to the following
illustration(s):
Figure 403 ITT Probe - Connector - Assembly/Disassembly
Catalog:
, , 77-20-02, Fig. 01 77-20-02, Fig. 02
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
Connector Pliers
Strap Wrench
Connector Holding Tools
M8196914-02 Extraction/insertion Tool
SUBTASK 77-20-02-944-002
B. Expendable Parts
IPC Reference
77-20-02 01 67 Wrap, Spiral, .250 OD
77-20-02
Page 403
Apr 11/08

77-20-02 01 68 Wrap, Spiral, .187 OD

77-20-02 01 69 Tie, Locking Cable
SUBTASK 77-20-02-945-002
9. Procedures
SUBTASK 77-20-02-420-001
A. Assemble ITT Probe J1 Connector:
(1) Install the following parts on the thermocouple:
(a) Thermocouple seal retainer
(b) Thermocouple seal plate
(c) Thermocouple seal spacer
(d) Thermocouple retaining ring
(2) Thread thermocouple cable through the backshell.
(3) Install the chromel pin (non-magnetic white wire) into the correct receptacle on the J1
connector. Use the M8196914-02 extraction/insertion tool as required:
NOTE ITT probes, when mounted on engine, are identified by position as they
would be viewed from aft of the engine, looking forward.
(a) IN-leads are chromel (white), RETURN-leads are alumel (green).
(b) Insert pins in the J1 connector in the following order:
1 No. 6, left upper IN to pin A, RETURN to pin B.
2 No. 5, left middle IN to C, RETURN to pin D.
3 No. 4, left lower IN to pin E, RETURN to pin F.
4 No. 3, right lower IN to pin G, RETURN to pin H.
5 No. 2, right middle IN to pin J, RETURN to pin K.
6 No. 1, right upper IN to pin L, RETURN to pin M.
77-20-02
Page 404
Apr 11/08

7 FOR LONG/SHORT CONFIGURATION ONLY: Verify the following jumpers: N to R

(yellow); P to S (red).
8 FOR MID-LENGTH CONFIGURATION ONLY: Verify the following jumpers: N to R to

T (3 yellow wires); P to S to U (3 red wires).
(4) Assemble backshell as follows:
NOTE For reliable assembly of the connector and backshell, it is suggested that
connector holding tools, strap wrench and connector pliers be used.
(a) Assemble backshell to connector.
(b) Place ground ring, adapter, grommet, follower, and strain relief on the cable in sequence
shown. Keep these components at a convenient distance from the end of the cable, so
they will not interfere with subsequent assembly steps.
(c) Extract shield pigtail from individual conductors. Tape pigtails to the bundle.
(d) Slide backshell forward to connector, and tighten securely
(e) Move the four-footed ground ring forward near the rear of the backshell. Untie individual
pigtails, and flare back over ground ring to evenly disperse pigtails through the four
quadrants of the ring. Tie or tape pigtails back to bundle, allowing for approx. 1/2
of slack, for subsequent step.
(f) Push ground ring forward and into rear of the backshell. 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.
TASK 77-20-02-450-801 Install the ITT Probes
10. General
This task provides procedures for installing the ITT probes. Refer to the following illustration(s):
Figure 402 ITT Probes - Loop Clamp Locations
77-20-02
Page 405
Apr 11/08

Catalog:
77-20-02, Fig. 01 77-20-02, Fig. 02
engine oil MAT-001 before installation.
SUBTASK 77-20-02-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 77-20-02-944-002
B. Expendable Parts
IPC Reference
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
12. Procedures
SUBTASK 77-20-02-450-002
A. Install ITT Probe(s)
(1) Install the ITT probe through the front bypass duct thermocouple access boss and into the
stud on the 1st LP turbine nozzle assembly. The thermocouple passes through a hole in
the ITT probe mounting flange.
(2) Install nut on stud and torque 25 to 28 inch-pounds (2.8 to 3.1 N.m).
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.
(5) If removed, install teflon spiral wrap to ITT harness as follows:
(a) Install .187 OD spiral wrap to single strands of ITT wire in areas where wire may come in
contact with one of the ITT bosses on the front bypass duct.
(b) Install .250 OD spiral wrap to multiple strands of ITT wire in areas where wire may come
in contact with one of the ITT bosses on the front bypass duct.
(c) Secure ends of spiral wrap with locking cable ties. Cut excess ends of ties off flush.
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.
13. Job Close-up
SUBTASK 77-20-02-410-002
SUBTASK 77-20-02-760-002
77-20-02
Page 407
Apr 11/08

Fig. 401 Intermediate Turbine Temperature (ITT) Probes - Mid-Length Configuration - Removal/Installation
77-20-02
Page 408
Apr 11/08

Fig. 402 ITT Probes - Loop Clamp Locations
77-20-02
Page 409
Apr 11/08

Fig. 403 ITT Probe - Connector - Assembly/Disassembly
77-20-02
Page 410
Apr 11/08

INTERMEDIATE TURBINE TEMPERATURE (ITT) PROBE - INSPECTION/CHECK
TASK 77-20-02-220-801 Visually Inspect ITT Probes
1. General
This task visually inspects the ITT probes.
Catalog:
77-20-02, Fig. 01 77-20-02, Fig. 02
SUBTASK 77-20-02-945-004
3. Job Set-up
SUBTASK 77-20-02-010-004
77-20-02
Page 601
Apr 11/08

4. Procedures
SUBTASK 77-20-02-020-002
A. Remove the ITT probes. Refer to 77-20-02, P.B. 401.
SUBTASK 77-20-02-220-001
B. Inspect removed ITT probe(s) for:
(1) Obvious excessive damage Reject
(2) Cracks, chips, or other damage Reject
(3) Small dents up to 0.150 inch (3.81 mm) Blend down raised material
long x 0.010 inch (0.254 mm) deep. Max
quantity is one per probe.
SUBTASK 77-20-02-420-002
C. Install the ITT probes. Refer to 77-20-02, P.B. 401.
5. Job Close-up
SUBTASK 77-20-02-410-004
SUBTASK 77-20-02-760-004
TASK 77-20-02-750-801 Perform Continuity Check on Installed ITT Probes
6. General
This task performs a continuity check on installed ITT probes.

Figure 601 ITT Probes - Continuity Check
77-20-02
Page 602
Apr 11/08

SUBTASK 77-20-02-943-005
A. Special Tools
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
9. Procedures
SUBTASK 77-20-02-210-004
A. Do a continuity check on installed ITT probes
NOTE Engine must be cold (ambient) for inspection of installed probes.
(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.
77-20-02
Page 603
Apr 11/08

NOTE Usually, if a thermocouple is malfunctioning, the temperature reading

will be much higher or much lower than the others.
(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.
10. Job Close-up
SUBTASK 77-20-02-410-005
TASK 77-20-02-750-802 Perform Continuity Check on Removed ITT Probes
11. General
This task performs a continuity check on removed ITT probes.

Figure 601 ITT Probes - Continuity Check
SUBTASK 77-20-02-943-006
A. Special Tools
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
77-20-02
Page 604
Apr 11/08

13. Procedures
SUBTASK 77-20-02-210-004
A. Do a Continuity Check on Removed Probe(s)
(1) Connect probes to data logger unit TL37289. Refer to (Perform Continuity Check on Installed
Probes), 77-20-01, P.B. 601.
NOTE Usually, if a probe is malfunctioning, the temperature reading will be much

higher or much lower than the others. The temperature indication from the
removed probe should be close to the ambient temperature
(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
B. Install the ITT probes. Refer to 77-20-02, P.B. 401.
14. Job Close-up
SUBTASK 77-20-02-410-010
SUBTASK 77-20-02-760-010
TASK 77-20-02-750-804 Perform Resistance Check on Assembled J1 Connector
15. General
This task performs a resistance check on the assembled J1 connector. Refer to the following illustration(s):
Figure 602 ITT Probes - Mid-Length Configuration - Harness Connector
77-20-02
Page 605
Apr 11/08

SUBTASK 77-20-02-941-008
Ohmmeter
M8196914-02 Pin Extraction/Insertion Tool
17. Job Set-up
SUBTASK 77-20-02-010-008
18. Procedures
SUBTASK 77-20-02-210-008
A. Using an ohmmeter and M8196914-02 Pin Extraction/Insertion Tool, do a resistance check on

the J1 harness connector as follows:
COMPONENT CONNECTOR CONNECTOR PIN RESISTANCE
PIN
A B Less than 10.0 Ohms
C D Less than 10.0 Ohms
E F Less than 10.0 Ohms
G H Less than 10.0 Ohms
J K Less than 10.0 Ohms
L M Less than 10.0 Ohms
N R Less than 1.0 Ohm
N T Less than 1.0 Ohm
R T Less than 1.0 Ohm
P S Less than 1.0 Ohm
P U Less than 1.0 Ohm
S U Less than 1.0 Ohm
77-20-02
Page 606
Apr 11/08

B. Do a continuity check between the ITT connector and case as follows:

Case J1-A Open
Case J1-C Open
Case J1-E Open
Case J1-G Open
Case J1-J Open
Case J1-L Open
Case J1-N Open
Case J1-P Open
J1 Case Engine Case Less than 1.0 Ohm
19. Job Close-up
SUBTASK 77-20-02-410-008
77-20-02
Page 607
Apr 11/08

Fig. 601 ITT Probes - Continuity Check
77-20-02
Page 608
Apr 11/08

Fig. 602 ITT Probes - Mid-Length Configuration - Harness Connector
77-20-02
Page 609
Apr 11/08

77-20-02
610
Page
Blank
EFCU TT2 SENSOR - REMOVAL/INSTALLATION
TASK 77-22-01-050-801 Remove the EFCU TT2 Sensor
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
2. Job Set-up
SUBTASK 77-22-01-010-001
3. Procedures
SUBTASK 77-22-01-020-001
A. Remove the EFCU TT2 sensor:
(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.
TASK 77-22-01-450-801 Install the EFCU TT2 Sensor
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
Catalog:
77-22-01, Fig. 01
77-22-01
Page 401
Apr 11/08

SUBTASK 77-22-01-945-002
6. Procedures
SUBTASK 77-22-01-420-001
A. Install the EFCU TT2 sensor:
(1) Install two screws holding the TT2 sensor to the airframe. Torque the screws 49 to 55
(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
77-22-01
Page 402
Apr 11/08

Fig. 401 EFCU TT2 Sensor - Removal/Installation
77-22-01
Page 403
Apr 11/08

77-22-01
404
Page
Blank
EFCU TT2 SENSOR - INSPECTION/CHECK
TASK 77-22-01-220-801 Visually Inspect the EFCU TT2 Sensor
1. General
This task visually inspects the EFCU TT2 sensor.
Catalog:
77-22-01, Fig. 01
2. Procedures
SUBTASK 77-22-01-220-001
WARNING CONTAINS COPPER-BERYLLIUM (DO NOT BLEND OR REPAIR). SPENT

PRODUCTS MUSTS BE LABELED, MANAGED AND DISPOSED OF, PER
FEDERAL, STATE AND LOCAL REQUIREMENTS. THIS MATERIAL IS NOT
CLASSIFIED A HAZARDOUS WASTE UNDER FEDERAL LAW.
A. Inspect EFCU TT2 sensor:
(1) Inspect connector for bent or missing Reject

pins, cracks
TASK 77-22-01-210-801 Perform Functional Check on TT2 Sensor Heater
3. General
This task performs a functional check on the TT2 sensor heater.
SUBTASK 77-22-01-941-003
77-22-01
Page 601
Apr 11/08

Ohmmeter
SUBTASK 77-22-01-945-003
5. Procedures
SUBTASK 77-22-01-210-001
WARNING DO NOT TOUCH TT2 SENSOR IF HEATER HAS BEEN SWITCHED

ON FOR MORE THAN 10 SECONDS. SENSOR COULD BECOME HOT
ENOUGH TO CAUSE BURNS OR BECOME AN IGNITION SOURCE AND
DAMAGE TO SENSOR HEATER WILL RESULT.
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.
NOTE Functional check of TT2 sensor requires two people to perform.
A. Perform functional check on TT2 sensor heater as follows:
(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.
(a) If sensor temperature increases - ACCEPT
(b) If sensor temperature does not increase:
1 Disconnect TT2 sensor plug from EFCU harness.
2 Using ohmmeter, measure across pins D and E. Record ohmns.
3 If resistance reading is within 3 to 8 ohmns, the sensor heater is acceptable, but

inspection of the harness is required. Refer to inspection of the EFCU engine
harness, 77-40-01, P.B. 601. If harness proves acceptable, continue troubleshooting
using the A.M.M.
77-22-01
Page 602
Apr 11/08

TASK 77-22-01-750-801 Perform TT2 Sensor Element Resistance Check
6. General
The task covers resistance checks for the TT2 sensor.
SUBTASK 77-22-01-941-005
Ohmmeter
Thermometer
8. Job Set-up
SUBTASK 77-22-01-010-005
A. Make sure that engine and TT2 sensor are cool.
9. Procedures
SUBTASK 77-22-02-750-001
A. Perform TT2 sensor element resistance test (TT2 heater OFF) as follows:
(1) Pull ECU circuit breaker.
(2) Locate TT2 sensor in engine inlet. Carefully check sensor and verify that it is at ambient
temperature.
(3) Disconnect EFCU engine harness connector from TT2 sensor.
CAUTION DO NOT HOLD TT2 SENSOR IN YOUR HAND. THIS WILL

AFFECT THE RESISTANCE READING.
(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.
77-22-01
Page 603
Apr 11/08

Table 601 Ideal Resistance in Ohms
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
77-22-01
Page 604
Apr 11/08

Table 601 Ideal Resistance in Ohms (Continued)
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
77-22-01
Page 605
Apr 11/08

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
77-22-01
Page 606
Apr 11/08

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.
(d) Reject TT2 sensor if out of limits
77-22-01
Page 607
Apr 11/08

77-22-01
608
Page
Blank
EFCU ENGINE WIRING HARNESS ASSEMBLY - REMOVAL/INSTALLATION
TASK 77-40-01-050-801 Remove the EFCU Engine Harness Assembly
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
SUBTASK 77-40-01-941-001
Electrical Connector Pliers
PROTECTIVE CAPS OR PLUGS
3. Job Set-up
SUBTASK 77-40-01-010-001
4. Procedures
SUBTASK 77-40-01-020-001
A. Disconnect EFCU engine harness assembly electrical connectors using electrical connector pliers
as follows:
CAUTION TO AVOID DAMAGE OR CONTAMINATION, INSTALL PROTECTIVE CAPS

OR PLUGS TO ALL CONNECTOR JACKS OR PLUGS AFTER REMOVAL.
(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).
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.
TASK 77-40-01-450-801 Install the EFCU Engine Harness Assembly
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
Catalog:
77-40-01, Fig. 01 77-40-01, Fig. 02
MAT-001 engine oil before installation.
SUBTASK 77-40-01-941-002
Electrical Connector Pliers
Ohmmeter
SUBTASK 77-40-01-942-002
B. Consumables
MAT-001 Oil, Engine
SUBTASK 77-40-01-945-002
77-40-01
Page 402
Apr 11/08


71-00-00 201 Power Plant - Maintenance Practices
7. Procedures
SUBTASK 77-40-01-420-001

A. Prior to connecting the EFCU engine harness:
(1) Perform visual inspection of harness for missing or bent pins.
(2) Using an ohmmeter, check all used contacts for short to connector case. Refer to 77-40-01,
P.B. 601.
(3) Reject the harness if either of the above conditions exist.
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.
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.
There may be a requirement to relocate harness loop clamps and reroute

the harness to accomodate left or right-hand engine installations. Refer to
Configuration Maintenance Practices, 71-00-00, P.B. 201 for instructions.
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
77-40-01
Page 404
Apr 11/08

Fig. 401 EFCU Engine Harness Assembly - RH/Bottom Views - Removal/Installation
77-40-01
Page 405
Apr 11/08

Fig. 402 EFCU Engine Harness Assembly - LH View - Removal/Installation
77-40-01
Page 406
Apr 11/08

Fig. 403 EFCU Engine Harness Assembly - LH View - Removal/Installation
77-40-01
Page 407
Apr 11/08

77-40-01
408
Page
Blank
EFCU ENGINE WIRING HARNESS ASSEMBLY - INSPECTION/CHECK
TASK 77-40-01-220-801 Visually Inspect the EFCU Engine Harness Assembly
1. General
This task visually inspects the EFCU engine harness assembly.
Catalog:
77-40-01, Fig. 01
SUBTASK 77-40-01-942-003
A. Consumables
3. Job Set-up
SUBTASK 77-40-01-010-003
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.
TASK 77-40-01-750-802 Perform Resistance Check on EFCU Engine Harness Assembly
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
SUBTASK 77-40-01-941-005
Ohmmeter
SUBTASK 77-40-01-942-005
B. Consumables
77-40-01
Page 602
Apr 11/08

7. Job Set-up
SUBTASK 77-40-01-010-005
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
(1) Check all used contacts for short to connector case.
(2) Check all used contacts for short between each other.
(3) Reject EFCU engine harness assembly if resistance is not within limits.
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):
M A < 10 Ohms
K B < 10 Ohms
T C < 10 Ohms
k D < 10 Ohms
i E < 10 Ohms
C. Do a resistance check between the EFCU engine/airframe connector (P7) and the ITT probe
connector (P1):
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.
D. Do a resistance check between the EFCU engine/airframe connector (P7) and the N1 speed sensor
connector (P3):
H A < 10 Ohms
L B < 10 Ohms
t C < 10 Ohms
s D < 10 Ohms
77-40-01
Page 604
Apr 11/08

E. Do a resistance check between the EFCU engine/airframe connector (P7) and the N2 speed sensor
connector (P6):
J A < 10 Ohms
P B < 10 Ohms
d C < 10 Ohms
e D < 10 Ohms
9. Job Close-up
SUBTASK 77-40-01-410-005
77-40-01
Page 605
Apr 11/08

Fig. 601 EFCU Engine Harness Assembly - Schematic
77-40-01
Page 606
Apr 11/08

CHAPTER 79
OIL
Page 1
79-OIL Apr 11/08

Page 2
79-OIL Blank

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
Page 1
Apr 11/08

Chapter 79
Page 2
Blank
OIL SYSTEM - DESCRIPTION AND OPERATION
TASK 79-00-00-860-803 Oil System - Description and Operation
1. General
The oil system provides lubrication for the four main shaft bearings, the accessory gearbox bearings,
the gears and the drive splines. 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
A. The oil system is made up of the following parts:
(1) Lube and scavenge pump
(2) Oil filter
(3) Oil filter bypass valve
(4) Filter differential pressure (delta P) indicator
(5) Lube oil cooler
(6) Reservoir (oil tank)
(7) Oil pressure regulator
(8) Magnetic chip collectors
B. Lube and Scavenge Pump
The lube and scavenge pump is a positive displacement pump. It includes one pressure element and
two scavenge elements contained in a single housing. The inlet to each element is protected by a
wire mesh screen. All inlet and discharge ports are located on the pump mounting flange face to
make pump replacement easier. A pressure relief valve is located in the pump housing. This valve
will keep approximately 130 - 140 psi pressure rise across the lube element under normal operating
temperatures and flow conditions. The regulator valve also protects against over-pressurization.
C. Oil Filter
The oil filter is a disposable cartridge that is housed in an stainless steel bowl that is threaded into the
gearbox housing. It is connected to the pressure pump outlet through drilled passages in the gearbox.
D. Oil filter bypass
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.
F. Lube oil cooler
The oil cooler is a fuel/oil heat exchanger and is made of aluminum. The oil cooler is mounted to
the gearbox and transmits the oil in and out through the mounting flange faces. Fuel travels in and
out through external lines.
G. Oil reservoir (oil tank)
Oil level is established by the oil sight glass/and or dipstick on the side of the engine interstage
housing. The tank is internally vented to the forward bearing cavity through a 5 psi pressurizing
valve which, in turn, is vented to the bypass duct via the gearbox air-oil separator. The reservoir
vent valve and bypass duct pressure reference ensure sufficient oil tank pressure for efficient pump
operation at all altitudes.
An oil level sight glass and a gravity type oil filler port fitted with an over-center-lock sealed cap are
provided on the outboard side of the engine. The sight gage is marked with two levels: FULL and
ADD. The oil volume between these levels is approximately 1.0 U.S. quart. The quantity of usable oil
is approximately 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.
H. Oil Pressure Regulator
The oil pressure regulator is located on the upper right side of the interstage housing, near the right
hand oil fill port. It is set at the factory to monitor the main oil pressure of the internal passage which
carries oil to the gearbox. When regulating oil pressure, the regulator returns oil to the oil tank
through a separate internal passage in the interstage housing.
I. Low Oil Level Sensor
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.
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.
79-00-00
Page 3
Apr 11/08

Fig. 1 Oil System
79-00-00
Page 4
Apr 11/08

OIL FILTER - REMOVAL/INSTALLATION
TASK 79-21-01-050-801 Remove the Oil Filter
1. General
This task provides procedures for removing the oil filter. Refer to the following illustration(s):
Figure 401 Oil Filter Removal/Installation
SUBTASK 79-21-01-942-001
A. Consumables
MAT-070 Bag, Plastic
3. Job Set-up
SUBTASK 79-21-01-010-001
79-21-01
Page 401
Apr 11/08

4. Procedures
SUBTASK 79-21-01-020-001

SKIN MUST BE WASHED OFF IMMEDIATELY. OIL MAY BURN IF EXPOSED TO
FLAME. HANDLE ONLY WITH ADEQUATE VENTILATION.
NOTE The oil filter may need to be examined as part of the oil filter analysis program. It
must be protected from contaminants as soon as it is removed.
A. To remove the oil filter, place a suitable container under oil filter bowl to catch residual oil
(approximately 4 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.
E. Remove the O-ring from the gearbox/filter bowl flange.
TASK 79-21-01-450-801 Install the Oil Filter
5. General
This task provides procedures for installing the oil filter. Refer to the following illustration(s):
Figure 401 Oil Filter Removal/Installation
Catalog:
79-21-01, Fig. 01
79-21-01
Page 402
Apr 11/08

CAUTION DURING MAINTENANCE, OIL SYSTEM CONTAMINANTS COULD POSSIBLY

BE INTRODUCED DOWNSTREAM OF THE MAIN OIL FILTER. TO PREVENT
CONTAMINATION OF THE OIL SYSTEM, MAKE SURE THAT PORTS AND
COMPONENT MATING SURFACES ARE KEPT EXTREMELY CLEAN.
SUBTASK 79-21-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 79-21-01-944-002
B. Expendable Parts
IPC Reference
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
7. Procedures
SUBTASK 79-21-01-420-001
A. Install the oil filter as follows:
(1) Make sure that the oil filter has an O-ring installed in its ID.
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.
(3) Install the oil filter on the gearbox.
(4) Install the filter bowl on the gearbox as follows:
(a) Wipe the threads on the oil filter bowl and the oil filter port with a clean cloth to remove
excess oil.
CAUTION EXCESS OIL USED TO INSTALL FILTER/FILTER BOWL MAY

GIVE A FALSE INDICATION OF A LEAK.
(b) Lubricate the filter bowl threads with 2 or 3 drops of clean engine oil (MAT-001).
CAUTION TO AVOID DAMAGE TO FLAME ARREST COATING (IF APPLICABLE),

DO NOT USE AN OPEN END WRENCH ON SQUARE DRIVE
WRENCH FEATURE OF OIL FILTER BOWL. USE AN 8-POINT
(DOUBLE SQUARE) SOCKET WRENCH.
(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.
(d) Clean excess oil with mineral spirits (MAT-020).
NOTE Filter bowl may be safety wired to the adjacent safety wire hole in the
gearbox housing or to the bypass valve spring plug.
(5) Install lockwire (MAT-060) to safety filter bowl.
SUBTASK 79-21-01-610-001
B. Service the oil system. Refer to 72-00-03, P.B. 301.
8. Job Close-up
SUBTASK 79-21-01-410-002
SUBTASK 79-21-01-790-001
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.
79-21-01
Page 405
Apr 11/08

Fig. 401 Oil Filter Removal/Installation
79-21-01
Page 406
Apr 11/08

LUBE OIL COOLER - REMOVAL/INSTALLATION
TASK 79-22-01-050-801 Remove the Lube Oil Cooler
1. General
This task provides procedures for removing the oil cooler. Refer to the following illustration(s):
Figure 401 Lube Oil Cooler - Removal/Installation
2. Job Set-up
SUBTASK 79-22-01-010-001
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.
2 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE

SKIN MUST BE WASHED OFF IMMEDIATELY . OIL MAY BURN IF EXPOSED
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.
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).
TASK 79-22-01-450-801 Install the Lube Oil Cooler
4. General
This task provides procedures for installing the oil cooler. Refer to the following illustration(s):
Figure 401 Lube Oil Cooler - Removal/Installation
Catalog:
79-22-01, Fig. 01

SUBTASK 79-22-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 79-22-01-944-002
B. Expendable Parts
IPC Reference
79-22-01
Page 402
Apr 11/08

79-22-01 01 40 O-Ring (2)

79-22-01 01 70 O-Ring (4)
SUBTASK 79-22-01-945-002
6. Procedures
SUBTASK 79-22-01-420-001
WARNINGS: 1 FUEL IS HIGHLY FLAMMABLE. IT MUST BE KEPT AWAY FROM HEAT

THOROUGHLY CLEANED BEFORE BEING WORN. CONTAINERS
SHOULD BE PLACED TO CATCH DRIPPING FUEL.
2 ENGINE OIL (SYNTHETIC) IS TOXIC TO THE SKIN. WEAR PROTECTIVE

SKIN MUST BE WASHED OFF IMMEDIATELY . OIL MAY BURN IF EXPOSED
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
CAUTION TO PREVENT DAMAGE TO OIL COOLER PORTS, USE A BACKUP WRENCH

ON REDUCERS WHEN TORQUING TUBE NUTS.
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
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
G. Service the oil system. Refer to 72-00-03, P.B. 301.
7. Job Close-up
SUBTASK 79-22-01-410-002
SUBTASK 79-22-01-790-001
79-22-01
Page 404
Apr 11/08

Fig. 401 Lube Oil Cooler - Removal/Installation
79-22-01
Page 405
Apr 11/08

79-22-01
406
Page
Blank
LUBE OIL COOLER - ADJUSTMENT/TEST
TASK 79-22-01-780-801 Pressure Test the Lube Oil Cooler
1. General
This task covers pressure testing the lube oil cooler to check for leakage between the fuel and oil circuits.
Do this task as required by troubleshooting or scheduled maintenance.
Figure 501 Lube Oil Cooler - Pressure Test Rig
SUBTASK 79-22-01-941-003
Pressurization Pump/reservoir
SUBTASK 79-22-01-942-003
B. Consumables
MAT-002 Oil, Preservative
MAT-003 Fuel, Jet A, Jet A-1, or Jet B
SUBTASK 79-22-01-945-003
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.
79-22-01
Page 501
Apr 11/08

SUBTASK 79-22-01-780-001
B. Prepare lube oil cooler for testing as follows:
WARNING FUEL/DRY CLEANING SOLVENT ARE HIGHLY FLAMMABLE AND MUST BE

KEPT AWAY FROM HEAT AND OPEN FLAME. FUEL/MINERAL SPIRITS
MAY ALSO CAUSE SKIN IRRITATION. ANY FUEL MINERAL SPIRITS
CLOTHING WITH FUEL/MINERAL SPIRITS CONTAMINATION MUST
BE THOROUGHLY CLEANED BEFORE BEING WORN.
(1) Service pressurization pump reservoir with one of the approved test fluids listed in table
501 below:
Table 501 Approved Test Fluids
Nomenclature Reference/Spec. Notes

Fuel, Jet A MAT-003
Oil, Preservative MAT-002
Solvent, Dry Cleaning MAT-024 See Note (1), below
Water, Distilled Commercial See Note (2), below
NOTE: Do not mix test fluids
NOTES: 1 Requires flushing of oil cooler after test and filling with fuel or preservative oil.
2 Requires drying of oil cooler after test
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).
C. Purge air from lube oil cooler as follows:
(1) Route drain tube to a suitable container.
79-22-01
Page 502
Apr 11/08

WARNING FACE SHIELD/PROTECTIVE CLOTHING ARE REQUIRED TO BE WORN

DURING PURGING AND PRESSURIZATION CHECK.
(2) Slowly pressurize pump and watch the flow of fluid into the drain container. Tilt lube oil cooler,
as required, to help air bubbles to escape. Reservice pressurization pump/reservoir with
fluid, as required.
(3) When fluid flow is steady with no air bubbles, remove the drain line from the adapter and install
a cap to plug fuel outlet. Hold adapter with a back-up wrench and torque cap 135 to 150
D. Perform pressurization check as follows:
WARNING FACE SHIELD/PROTECTIVE CLOTHING ARE REQUIRED TO BE WORN

DURING PURGING AND PRESSURIZATION CHECK.
(1) Install clean tapered cap plugs into lube IN and OUT ports.
(2) Slowly pressurize pump to 100 psig and check for fluid leaks.
(a) Fix connection leaks as required.
(b) If fluid leaks from lube IN or OUT ports during pressurization, reject lube oil cooler.
(3) Increase pressure to 1200 ( 25) psig and leave system pressurized for 2 minutes.
NOTE Correction for pump system leakage is allowed.
(4) If pressure holds, accept oil cooler.
(5) If pressure decays, reject oil cooler.
(6) Release pressure on pump.
E. Remove inlet line adapter cap from the lube oil cooler. Drain test fluid from lube oil cooler.
F. If distilled water was used as a test fluid, dry lube oil cooler in a 250 degree F oven for 15 minutes.
Fill fuel circuit with fuel or preservative oil.
G. If solvent or distilled water was used as a test fluid, flush fuel circuit of oil cooler with fuel MAT-003 or
preservative oil MAT-002.
SUBTASK 79-22-01-420-002
H. Install the lube oil cooler to the engine gearbox. Refer to 79-22-01, P.B. 401.
79-22-01
Page 503
Apr 11/08

Fig. 501 Lube Oil Cooler - Pressure Test Rig
79-22-01
Page 504
Apr 11/08

LUBE OIL COOLER - INSPECTION/CHECK
TASK 79-22-01-220-801 Visually Inspect the Lube Oil Cooler
1. General
This task covers general visual inspection of the lube oil cooler.
Catalog:
79-22-01, Fig. 01
SUBTASK 79-22-01-945-004
SUBTASK 79-22-01-942-004
B. Consumables
MAT-050 Chemical Conversion Coating
3. Procedures
SUBTASK 79-22-01-020-003
A. Remove the lube oil cooler. Refer to 79-22-01, P.B. 401.
SUBTASK 79-22-01-220-001
B. Visually inspect the lube oil cooler for:
(1) Cracks Reject
(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)
(3) Distortion of flange mating surface Reject
(4) Damage to threaded ports Reject
79-22-01
Page 601
Apr 11/08

(5) Damage to O-ring grooves Reject
SUBTASK 79-22-01-420-003
C. Install the lube oil cooler. Refer to 79-22-01, P.B. 401.
79-22-01
Page 602
Apr 11/08

LUBE AND SCAVENGE PUMP - REMOVAL/INSTALLATION
TASK 79-24-01-050-801 Remove the Lube and Scavenge Pump
1. General
This task provides procedures for removing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401 Lube and Scavenge Pump - Removal/Installation
SUBTASK 79-24-01-945-001
3. Job Set-up
SUBTASK 79-24-01-010-001
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
B. Remove the fuel pump assembly. Refer to 73-16-01, P.B. 401.
79-24-01
Page 401
Apr 11/08

SUBTASK 79-24-01-020-003
C. Remove the lube and scavenge pump as follows:

(1) Drain engine oil tank. Refer to 72-00-03, P.B. 301.
(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.
TASK 79-24-01-450-801 Install the Lube and Scavenge Pump
5. General
This task provides procedures for installing the lube and scavenge pump. Refer to the following
illustration(s):
Figure 401 Lube and Scavenge Pump - Removal/Installation
Catalog:
79-24-01, Fig. 01
SUBTASK 79-24-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 79-24-01-944-002
B. Expendable Parts
IPC Reference
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
7. Procedures
SUBTASK 79-24-01-420-001
A. Install the lube and scavenge pump as follows:
(1) Lubricate one O-ring with assembly fluid (MAT-011) and install on pump face pilot diameter.
(2) Lubricate five O-rings with assembly fluid and install in ports on the face of the lubrication pump.
(3) Install the lube pump drive shaft into the gearbox. Make sure that the shaft engages the
gearbox drive spline.
(4) Make sure that all the O-rings are in their proper grooves.
(5) Slide the pump until it touches the gearbox pad. Make sure that the screw holes are aligned
with the proper threaded inserts on the gearbox pad.
(6) Install four washers and four bolts. Torque bolts 49 to 55 inch-pounds (5.5 to 6.2 N.m).
SUBTASK 79-24-01-420-002
B. Install the fuel pump assembly. Refer to 73-16-01, P.B. 401.
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.
79-24-01
Page 403
Apr 11/08

8. Job Close-up
SUBTASK 79-24-01-410-002
SUBTASK 79-24-01-790-001
79-24-01
Page 404
Apr 11/08

Fig. 401 Lube and Scavenge Pump - Removal/Installation
79-24-01
Page 405
Apr 11/08

79-24-01
406
Page
Blank
OIL PRESSURE REGULATING VALVE - REMOVAL/INSTALLATION
TASK 79-25-01-050-801 Remove the Oil Pressure Regulating Valve
1. General
This task provides procedures for removing the oil pressure regulating valve. Refer to the following
illustration(s):
Figure 401 Oil Pressure Regulating Valve - Removal/Installation
2. Job Set-up
SUBTASK 79-25-01-010-001
3. Procedures
SUBTASK 79-25-01-050-001
A. Remove the oil pressure regulating valve as follows:

(1) Cut and remove lockwire attaching the regulating valve to the interstage housing.
79-25-01
Page 401
Apr 11/08

(2) Remove the regulating valve and two O-rings from the interstage housing.
TASK 79-25-01-450-801 Install the Oil Pressure Regulating Valve
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
Catalog:
79-25-01, Fig. 01
SUBTASK 79-25-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 79-25-01-944-002
B. Expendable Parts
IPC Reference
79-25-01 01 20 O-Ring
79-25-01 01 30 O-Ring
SUBTASK 79-25-01-945-002
79-25-01 501 Oil Pressure Regulating Valve - Adjustment/TestOil Pressure Regulating
Valve - Adjustment/Test
79-25-01
Page 402
Apr 11/08

6. Procedures
SUBTASK 79-25-01-420-001
A. Install the oil pressure regulating valve as follows:

(1) Lubricate two O-rings with engine oil (MAT-001) and install on the regulating valve. Install the
large O-ring at the flange and the small O-ring in the O-ring groove at the regulator tip.
(2) Install the regulating valve into the interstage housing.
(3) Torque the regulating valve 145 to 155 inch-pounds (16.4 - 16.9 N.m). Install lockwire MAT-061
to secure valve to interstage housing.
SUBTASK 79-25-01-610-001
B. Service the engine with oil. Refer to 72-00-03, P.B. 301.
7. Job Close-up
SUBTASK 79-25-01-410-002
SUBTASK 79-25-01-790-001
(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.
79-25-01
Page 403
Apr 11/08

Fig. 401 Oil Pressure Regulating Valve - Removal/Installation
79-25-01
Page 404
Apr 11/08

OIL PRESSURE REGULATING VALVE - ADJUSTMENT/TEST
TASK 79-25-01-820-801 Adjust the Oil Pressure Regulating Valve
1. General
Do this procedure, as directed by Troubleshooting, to increase or decrease engine oil pressure.

Figure 501 Oil Pressure Regulating Valve - Adjustment
SUBTASK 79-25-01-942-003
A. Consumables
MAT-001 Oil, Engine
MAT-019 Acetone
SUBTASK 79-25-01-945-003
79-25-01 401 Oil Pressure Regulating Valve - Removal/Installation
3. Job Set-up
SUBTASK 79-25-01-010-003
A. Remove the cowling. Refer to the Aircraft Maintenance Manual.
4. Procedures
SUBTASK 79-25-01-820-001
A. To adjust oil pressure:
(1) Remove lockwire from the regulating valve adjustment locknut.
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.
(3) Loosen the regulating valve adjustment locknut.
CAUTION TO PREVENT INTERNAL LEAKAGE FROM RELIEF VALVE, MAKE SURE

THAT THE MAXIMUM EXTENSION OF THE ADJUSTMENT SCREW FROM
THE OUTBOARD FACE OF THE JAM NUT DOES NOT EXCEED:
0.136 INCH (3.45 MM) OR 4 THREADS FOR P/N 50485
0.220 INCH (5.58 MM) OR 6.5 THREADS FOR P/N 77795
IF LEAKAGE PERSISTS OR IF THE ADJUSTMENT SCREW IS EXTENDED

PAST THESE LIMITS, THE VALVE SHOULD BE UPGRADED TO
LATEST CONFIGURATION OR REPAIRED IN ACCORDANCE WITH
THE OVERHAUL PROCEDURE IN THIS TASK.
(4) Using a flat-tip screwdriver adjust the adjustment screw as follows:
NOTES: 1 It may be necessary to hold the adjustment locknut while turning

adjustment screw. One full turn of the screw will yield approximately
5 - 8 psid change in pressure.
2 If one turn of adjustment screw yields less than 2 psid in MOP, then the valve
should be repaired in accordance with the overhaul procedure in this task.
(a) Turn the adjustment screw clockwise to increase engine oil pressure.
(b) Turn the adjustment screw counter-clockwise to decrease engine oil pressure.
(5) While holding the adjustment screw, Torque the adjustment locknut 30 to 40 inch-pounds
(3.3 to 4.5 N.m).
NOTE If oil pressure regulator is leaking externally, repair in accordance

with the overhaul subtask in this task.
(6) Verify correct oil pressure reading per Figure 501 Oil Pressure Regulating Valve - Adjustment.
(7) Shut-down the engine. Refer to General Operating Procedures in71-00-00, P.B. 501.
(8) Install .020 lockwire, MAT-061, to regulating valve adjustment locknut.
SUBTASK 79-25-01-870-001
B. If required, overhaul the oil pressure regulating valve (replace internal O-ring seal) as follows:
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.
CAUTION BE CAREFUL NOT TO LOSE THE INTERNAL SPRING OR POPPET

WHILE REMOVING ADJUSTMENT SCREW.
(3) Remove the adjustment screw.
(4) Remove the internal spring and the poppet from the valve body.
(5) Remove the O-ring from the adjustment screw. Discard the O-ring.
(6) Clean the adjustment screw, internal spring, poppet and valve body. Clean with vapor degrease
or flush with mineral spirits (MAT-020) or acetone (MAT-019).
(7) Lubricate new O-ring (M93248/1-009) with engine oil (MAT-001) and install to adjustment screw.
(8) Reassemble poppet, spring, and adjustment screw to valve body.
(9) Install jam nut to adjustment screw.
(10) Adjust jam nut and adjustment screw until no more than 4 threads protrude past jam nut.
(11) Install the oil pressure regulating valve. Refer to 79-25-01, P.B. 401.
(12) Adjust the oil pressure regulating valve in accordance with the adjustment subtask
(79-25-01-820-001).
5. Job Close-up
SUBTASK 79-25-01-410-003
A. Install the cowling. Refer to the Aircraft Maintenance Manual.
79-25-01
Page 503
Apr 11/08

Fig. 501 Oil Pressure Regulating Valve - Adjustment
79-25-01
Page 504
Apr 11/08

OIL SUPPLY TUBE - REMOVAL/INSTALLATION
TASK 79-26-01-050-801 Remove the Oil Supply Tube
1. General
This task provides procedures for removing the oil supply tube. Refer to the following illustration(s):
Figure 401 Oil Supply Tube - Removal/Installation
2. Job Set-up
SUBTASK 79-26-01-010-001
3. Procedures
SUBTASK 79-26-01-050-001
A. Remove the oil supply tube as follows:

(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.
79-26-01
Page 401
Apr 11/08

(3) Remove oil supply tube and two O-rings from interstage housing.
TASK 79-26-01-450-801 Install the Oil Supply Tube
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
Catalog:
79-26-01, Fig. 01

SUBTASK 79-26-01-942-002
A. Consumables
MAT-001 Oil, Engine
SUBTASK 79-26-01-944-002
B. Expendable Parts
IPC Reference
79-26-01 01 20 O-Ring (2)
SUBTASK 79-26-01-945-002
79-26-01
Page 402
Apr 11/08

6. Procedures
SUBTASK 79-26-01-420-001
A. Install the oil supply tube:

(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
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
79-26-01
Page 403
Apr 11/08

Fig. 401 Oil Supply Tube - Removal/Installation
79-26-01
Page 404
Apr 11/08

MAGNETIC CHIP COLLECTOR - REMOVAL/INSTALLATION
TASK 79-30-01-050-801 Remove the Magnetic Chip Collectors
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
SUBTASK 79-30-01-945-001
79-30-01 601 Magnetic Chip Collector - Inspection/Check
3. Job Set-up
SUBTASK 79-30-01-010-001
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:
79-30-01
Page 401
Apr 11/08


CAUTION HOLD A LARGE, CLEAN CONTAINER (FOR APPROXIMATELY 4 QUARTS

(4 LITERS) BELOW TANK DRAIN PORT. OIL WILL IMMEDIATELY DRAIN
WHEN THE TANK DRAIN CHIP COLLECTOR FITTING IS REMOVED.
(1) Vent oil tank by removing oil fill cap (dipstick).
(2) Remove safety wire from the chip collector fitting at the bottom rear of the lube pump (labeled
TANK DRAIN).
(3) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(4) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
SUBTASK 79-30-01-050-002
B. Remove the SCAV magnetic chip collector from the lube and scavenge pump as follows:

(1) Remove safety wire from the chip collector fitting at the bottom front of the lube pump (labeled
SCAV).
(2) Remove chip collector fitting/self-closing plug assembly and let residual oil drain into a clean
container.
(3) If required by scheduled maintenance, remove the oil screen from the lube pump housing.
Remove O-ring from oil screen.
C. Remove the magnetic chip collector from the gearbox housing, if engine is so equipped, as follows:
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.

CAUTION HOLD A LARGE, CLEAN CONTAINER (FOR APPROXIMATELY 4 QUARTS (4

LITERS) BELOW GEARBOX PORT. OIL WILL IMMEDIATELY DRAIN FROM
GEARBOX WHEN THE CHIP COLLECTOR FITTING IS REMOVED.
(1) Remove safety wire from the chip collector fitting at the bottom of the gearbox housing.
(2) Remove chip collector fitting/self-closing plug assembly and let oil drain into clean container.
(3) If required by scheduled maintenance, remove oil screen from gearbox housing, as follows:
(a) Remove one bolt and one washer,
(b) Remove oil screen from gearbox housing.
(c) Remove O-ring from oil screen.
D. Tag engine "NO OIL INSTALLED".
TASK 79-30-01-450-801 Install the Magnetic Chip Collectors
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
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-942-002
A. Consumables
79-30-01
Page 403
Apr 11/08

MAT-001 Oil, Engine
SUBTASK 79-30-01-944-002
B. Expendable Parts
IPC Reference
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
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.

(1) If removed, install oil screen to gearbox housing as follows:
(a) Lubricate O-ring with engine oil and install on oil screen.
(b) Install O-ring in gearbox housing.
(c) Install one bolt and one washer. Torque bolt 46 to 51 inch-pounds (5.2 to 5.7 N.m).
79-30-01
Page 404
Apr 11/08

(2) If removed, install oil screen to lube pump housing as follows:
(a) Lubricate O-ring with engine oil and install on O-ring.
(b) Install oil screen into lube pump housing. Torque oil screen 150 to 250 inch-pounds
(16.9 to 28.2 N.m).
(3) Remove self-closing magnetic plug from chip collector fitting.
(4) Lubricate new O-ring with engine oil MAT-001 and install on chip collector fitting. Install chip
collector fitting into lube and scavenge pump or gearbox housing. Torque chip collector fittings
50 to 60 inch-pounds (5.6 - 6.7 N.m).
(5) Install safety wire MAT-061 to chip collector fitting.
(6) Install self-closing magnetic plug to chip collector fitting.
SUBTASK 79-30-01-610-001
8. Job Close-up
SUBTASK 79-30-01-410-002
SUBTASK 79-30-01-790-001
79-30-01
Page 405
Apr 11/08

Fig. 401 Magnetic Chip Collectors - Removal/Installation
79-30-01
Page 406
Apr 11/08

MAGNETIC CHIP COLLECTOR - INSPECTION/CHECK
TASK 79-30-01-220-801 Visually Inspect the Magnetic Chip Collectors
1. General
This task contains procedures for checking the magnetic chip collectors. 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
Catalog:
79-30-01, Fig. 01
SUBTASK 79-30-01-945-003
72-00-05 201 Oil Filter Analysis Program - Maintenance Practices
3. Job Set-up
SUBTASK 79-30-01-010-003
4. Procedures
SUBTASK 79-30-01-210-001
A. Check the magnetic chip collectors as follows:
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.
(2) Inspect magnetic plug for metal particles:
(a) No metallic particles. Engine is acceptable for use.
(b) Small hair-like slivers of steel or fine dust around the magnet. This condition usually
applies to engines which are new/repaired or overhauled with low hours. This condition
would not represent internal failure or impending failure of the engine
(c) Large sized particles. This condition does not always represent internal failure of the
engine since the particles could have originated in the fabrication or build-up of the
engine. Collect particles from the magnet for further analysis. Make sure that sample
is not contaminated during the collection process. Use a clean plastic bag and mark
sample with engine S/N, chip collector location, and date. Photo document particles and
contact a WI representative for further evaluation and disposition.
1 Remove the oil filter element. Refer to 79-21-01, P.B. 401.
2 Submit the oil filter element for analysis. Refer to 72-00-05, P.B. 201.
(3) Inspect the O-ring on the magnetic plug and replace if necessary.
CAUTION MAKE SURE THAT THE MAGNET IS CLEAN AND FREE OF

CONTAMINATION BEFORE INSTALLING IT INTO THE ENGINE.
(4) Install the magnetic plug into the valve by pushing and turning clockwise until you feel it
lock in place.
(5) Inspect the valve for leaks after installation. No leaks are allowed.
(6) If unsure of examination results:
(a) Drain the oil system
(b) Clean and install the magnetic chip detectors
(c) Install the new oil filter element
(d) Fill the oil system
(e) Perform engine testing per the table Tests Required after Maintenance or Component
Replacement (List of Test Procedures) in 71-00-00, P.B. 501.
(f) Examine the magnetic plug after engine testing.
1 If the engine testing results in almost the same or larger quantity of metal particles,
reject the engine.
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
79-30-01
Page 603
Apr 11/08

Fig. 601 Magnetic Chip Collectors - Visual Inspection
79-30-01
Page 604
Apr 11/08

OIL FILLER CAP AND DIPSTICK - REMOVAL/INSTALLATION
TASK 79-31-01-050-801 Remove the Oil Filler Cap and Dipstick
1. General
This task covers removal of both the oil filler cap and dipstick assembly and removal of the filler port plug
assembly (if the engine is so equipped). Refer to the following illustration(s):
Figure 401 Oil Filler Cap and Dipstick - Removal/Installation
Figure 402 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation
2. Job Set-up
SUBTASK 79-31-01-010-001
3. Procedures
SUBTASK 79-31-01-020-001

CAUTION AFTER REMOVAL OF CAP/DIPSTICK ASSEMBLY OR FILLER PORT

PLUG, COVER OIL FILLER PORT TO ENSURE THAT CONTAMINATION
DOES NOT ENTER THE ENGINE.
A. Remove the oil filler cap and dipstick assembly by lifting up the locking tab and turning counter
clockwise.
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.
B. Remove the filler port plug assembly as follows:
(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.
TASK 79-31-01-450-801 Install the Oil Filler Cap and Dipstick
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
Catalog:
79-31-01, Fig. 01
SUBTASK 79-31-01-942-002
A. Consumables
SUBTASK 79-31-01-944-002
B. Expendable Parts
IPC Reference
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.
A. Install the oil filler cap and dipstick assembly as follows:
(1) Inspect the O-ring on the oil filler cap and dipstick assembly for damage. Replace if damaged.
(2) Insert the oil filler cap and dipstick assembly into the oil filler port. To avoid binding, rotate
the dipstick on the filler port plug so the offset bend faces aft of the engine. Lock by turning
clockwise and folding down locking tab.
SUBTASK 79-31-01-420-002
B. Assemble the filler port plug assembly (if necessary) as follows:
(1) Install lockplate on shaft and secure with nut.
(2) Lube small O-ring with MAT-011 assembly fluid and install on shaft.
(3) Lube large O-ring with assembly fluid and install on cap
(4) Install cap on the shaft and secure with wing nut.
C. Install the filler port plug assembly as follows:
NOTE The filler port plug assembly must be installed on the inboard side of the engine.
(1) Loosen the wing nut on the shaft so that the two tangs on the underside of the cap are just
engaging the slots in the shaft.
(2) Insert the plug assembly into the filler port. Turn cap/shaft assembly to engage lock plate in the
filler port slot. Tighten wing nut.
(3) Using MAT-061, lockwire wing nut to plug assembly cap.
79-31-01
Page 403
Apr 11/08

7. Job Close-up
SUBTASK 79-31-01-410-002
SUBTASK 79-31-01-450-001
79-31-01
Page 404
Apr 11/08

Fig. 401 Oil Filler Cap and Dipstick - Removal/Installation
79-31-01
Page 405
Apr 11/08

Fig. 402 Oil Filler Port Dipstick/Filler Port Plug - Removal/Installation
79-31-01
Page 406
Apr 11/08

LOW OIL LEVEL SENSOR - REMOVAL/INSTALLATION
TASK 79-33-01-050-801 Remove the Low Oil Level Sensor
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
SUBTASK 79-33-01-945-001
3. Job Set-up
SUBTASK 79-33-01-010-001
79-33-01
Page 401
Apr 11/08

4. Procedures
SUBTASK 79-33-01-610-001

A. Drain engine oil. Refer to 72-00-03, P.B. 301.
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.
TASK 79-33-01-450-801 Install the Low Oil Level Sensor
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
Catalog:
79-33-01, Fig. 01
SUBTASK 79-33-01-942-002
A. Consumables
79-33-01
Page 402
Apr 11/08

MAT-001 Oil, Engine
SUBTASK 79-33-01-944-002
B. Expendable Parts
IPC Reference
79-33-01 01 12 O-Ring (1)
SUBTASK 79-33-01-945-002
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:
(1) Lube the sensor O-ring with engine oil MAT-001.
(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
B. Service engine with oil. Refer to 72-00-03, P.B. 301.
SUBTASK 79-33-01-790-001
(List of Test Procedures) in 71-00-00 P.B. 501.
79-33-01
Page 403
Apr 11/08

Fig. 401 Low Oil Level Sensor - Removal/Installation
79-33-01
Page 404
Apr 11/08

Fig. 402 Low Oil Level Sensor - Torque Pattern
79-33-01
Page 405
Apr 11/08

79-33-01
406
Page
Blank
LOW OIL LEVEL SENSOR - INSPECTION/CHECK
TASK 79-33-01-220-801 Visually Inspect the Low Oil Level Sensor
1. General
This task visually inspects the low oil level sensor.
Catalog:
79-33-01, Fig. 01
SUBTASK 79-33-01-945-003
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.
B. Visually inspect low oil level sensor:
(1) Inspect sensor body for cracks or other Reject

damage
(2) Inspect connector for bent or missing pins, Reject
(3) Inspect O-ring for cracks, nicks or other Reject

damage
(4) Inspect sensor float for surface craze Accept

cracking
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
Ohmmeter
6. Procedures
SUBTASK 79-33-01-770-001
CAUTION ONLY APPLY 28 VDC POWER TO TEST COIL FOR A MAXIMUM OF

30 SECONDS IN A 5 MINUTE INTERVAL.
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.
79-33-01
Page 602
Apr 11/08

Fig. 601 Low Oil Level Sensor - Functional Check
79-33-01
Page 603
Apr 11/08

79-33-01
604
Page
Blank
OIL SIGHT GLASS - REMOVAL/INSTALLATION
TASK 79-33-11-050-801 Remove the Oil Sight Glass
1. General
This task covers removal of both the oil level sight glass and the sight glass cover plate blank from the
interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 401 Interstage Housing Oil Sight Glass - Removal/Installation
SUBTASK 79-33-11-945-004
3. Job Set-up
SUBTASK 79-33-11-010-004
(3) Refer to the Aircraft Maintenance Manual (A.M.M.) and remove the engine cowling.
SUBTASK 79-33-11-610-001

B. Drain engine oil. Refer to 72-00-03, P.B. 301.
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:.
CAUTIONS: 1 AFTER REMOVAL OF THE SIGHT GLASS OR THE BLANKING PLATE,

COVER SIGHT GLASS PORT IN THE INTERSTAGE HOUSING TO
ENSURE THAT NO CONTAMINATION ENTERS THE ENGINE.
2 USE CARE WHEN HANDLING THE SIGHT GLASS TO MAKE

SURE THAT IT DOES NOT FALL AND BREAK.
(1) Remove eight bolts which retain cover plate. Remove cover plate, gasket, sight glass, and
O-ring from the interstage housing port. Cover the sight glass port in the interstage housing.
SUBTASK 79-33-11-020-010
B. Remove the cover plate blank from the interstage housing as follows (if engine is so equipped):
(1) Remove eight bolts, oil supply tube loop clamp, and the cover plate heatshield.
(2) Remove the cover plate blank from the interstage housing. Cover the sight glass port in the
interstage housing.
TASK 79-33-11-450-801 Install the Oil Sight Glass
5. General
This task covers installation of both the oil level sight glass and the sight glass cover plate blank onto
the interstage housing (if the engine is so equipped). When configuring the engine for right or left-hand
installation, the sight glass must be installed on the outboard side. The cover plate blank is installed on the
inboard side. Some engine models are equipped with sight glasses on both sides and some have oil level
sensors. Refer to the applicable IPC.
Figure 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
79-33-11
Page 402
Apr 11/08

SUBTASK 79-33-11-944-005
B. Expendable Parts
IPC Reference
79-33-11 02 20 O-Ring
79-33-11 02 40 Gasket
SUBTASK 79-33-11-945-005
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.
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.
A. Service engine with oil. Refer to 72-00-03, P.B. 301.
SUBTASK 79-33-11-410-005
B. Put the Engine Back to Normal
SUBTASK 79-33-11-760-001
C. Perform engine testing as required by List of Test Procedures in 71-00-00, P.B. 501.
79-33-11
Page 404
Apr 11/08

Fig. 401 Interstage Housing Oil Sight Glass - Removal/Installation
79-33-11
Page 405
Apr 11/08

Fig. 402 Interstage Housing Oil Sight Glass - Torque Pattern
79-33-11
Page 406
Apr 11/08

79-33-11
407
Page
Blank

Fj44-2a Ipc

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Fj44-2a Ipc

Încărcat de

Drepturi de autor:

Formate disponibile

COPY NO.

2008 Williams International Co., LLC

TRANSMITTAL LETTER No. 17

2008 Williams International Co., LLC

801 801 72-31-20 72-31-20-350-802 Blend Repair the Fan Rotor

2008 Williams International Co., LLC

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

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

TIME LIMITS/MAINTENANCE CHECKS

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

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

UNAPPROVED PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05-17-00

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

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

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

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

2008 Williams International Co., LLC

Marking of Repaired Parts - Maintenance

MISUSE OF MOLYBDENUM DISULFIDE

IDENTIFICATION, LUBRICATION, AND FITTING OF

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

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

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

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

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

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

REPAIR SURFACES AFFECTED BY MINOR

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

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

2008 Williams International Co., LLC

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

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

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

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

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

PRESERVING INSTALLED ENGINE FOR NINE MONTHS

PRESERVING INSTALLED ENGINE FOR NINE MONTHS

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

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

2008 Williams International Co., LLC

Engine Depreservation - Maintenance

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

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

COMBUSTOR, FUEL SLINGER, AND HP TURBINE

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

HP NOZZLE/HP TURBINE TRAILING EDGE AND 1ST LP

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

ENGINE SERVICING OIL

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

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

2008 Williams International Co., LLC

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

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

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

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

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

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

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

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

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

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

FILTER DIFFERENTIAL PRESSURE (DELTA P)

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