C_CHECK_Appendix_J.pdf

09/01/2012 71-00-02_601

TDC # 00603

SPARE ENGINE – “C” CHECK

1. General

A. AN INSPECTOR IS REQUIRED TO COMPLETE THIS TASK.

B. Whenever an engine is removed for any reason and is to be held as a part-time spare, or is removed from one airplane and installed on another, the work outline in this subject must be accomplished to place the engine in serviceable status. Record airplane TSO on NON-Routine work Card, this work consist of items normally done on the engine at every “C” check and must be accomplished prior to installing the engine.

This will allow installation of the engine on the airplane at any time periods.

C. If the engine was removed for a reported malfunction, the cause of malfunction must also be corrected before the engine is considered serviceable.

D. If the engine involved is owned by NASA and is being returned after have been used on another aircraft, additional servicing may be required to prevent oil contamination. (Ref, 71-00-99/201).

E. Non-routine forms for uncompleted work and for special test requirements must remain with the engine. Any deferred work must be entered in aircraft flight log upon engine installation.

F. Refer to the latest SOFIA procedures for authority to deviate from this procedure.

2. Special Tools and Materials A. Special Tools

(1) Dispenser

(2) Torque Wrench – to 700 inch-pounds

(3) Tap – Igniter Plug Boss

(4) Holder – Filter, PN 600-0100-005-0005

(5) Wrench, Duro Torque Indicator – 1/4 inch drive

(6) Burton Jet Light, PN 2127 or

(7) EverReady Commander Flashlight, PN3112

(8) Grease – Gun and Nozzle

(9) Rigging Pin, 3/16 inch diameter, 1 inch long

(10) Warning Streamer

(11) Universal Socket extension

(12) Eyeball Extender

(13) Right Angle Viewer

(14) Rig Pin 5/16 inch diameter x 2 inch long

(15) Volt-ohm meter, 0-50 volts DC

(16) Test Equipment-TE65B90229

B. Materials

(1) Filter – Paper Cone

(2) Oil – Engine Mobil Jet II

(3) Solvent, (Aliphatic Hydrocarbon MIL-PRF-680-TYPE 1)

WARNING: FLAMMABLE

(4) Oil – Engine (Turbine Engine and Accessories Oil) Mobil Jet II

(a) Quart Containers

(b) 5 Gallon Containers

(5) Lubricant, Moly Kote - G-R Riprid - Paste

(6) Grease, High Heat Mica- Lube - BG-A718 or Silver Goop

(7) Grease, Krytox 240 AC or Com 3003-2

(8) Cloth, (CL511) Rymple Cloth CL 511

(9) Acid Brush, (BR796)

(10) For Main Oil Screen Installation:

(a) Screen – Main Oil

(b) Packing – Screen Cover, PN M83248/1-234

(11) Gearbox Magnetic Plug Installation:

(a) Packing – Magnetic Plugs (Aft on main gearbox and No. 3 and No. 4 bearings), PN M83248/1-11 (3 each)

(b) Packing – Magnetic Plug (Angle gearbox), PN M83248/1-012

(1 each)

(12) Fuel Heater Plug Installation:

(a) Gasket – Fuel Heater Plug, PN 281-0338-9974 (1 each)

(13) Flow Divider Replacement

(a) Resistor Assembly, PN 72799 (JT9D-7 only)

(14) Starter Plugs(s) Installation:

(a) Packing – Drain Plug, PN M83248/1-111 (1 each)

(b) Packing – Filler Plug, PN M83248/1-011

(c) Fill Plug, PN MS9015-03

(d) Stand Pipe, PN 753330-1

(e) Packing – Stand Pipe Cap, PN M83248/1-007

(15) Igniter Plugs Replacement:

(a) Igniter Plug,

(b) Keywasher, PN 672237 (As Required)

(16) CSD Filter and Plug(s) Installation:

(a) Element, PN 57880

(b) Packing – Marking Plug, PN M832/1-902 (1 each)

(c) Grease, PN Unirex-S2 or Acryloid HF820 (bags or packets)

(17) Engine Mount

(a) Molybdenum Disulfide, D5330NS 12oz. Aerosol can, replacing (LUB4503-2SC)

(18) Fan Reverser Drive Unit Plug(s) Installation:

(a) Packing – Motor Bearing Fill Plug, PN 3-5S455-7 (1 each)

(b) Packing – Gearbox Fill Plug, PN 3-9U6S455-7

(c) Packing – Magnetic Plug, PN M83248/1-902 (1 each)

(19) Pad – Scotch Brite, PN PA135S (Fine Grade)

C. Referenced Procedures

(1) MM 24-11-01/401, Constant Speed Drive – Removal/Installation –

Check

(2) MM 24-11-01/601, Constant Speed Drive – Inspection/Check

(3) MM 24-11-04/401, CSD Charge Filter – Removal/Installation

(4) MM 24-11-05/401, CSD Scavenge Filter – Removal/Installation

(5) MM 24-11-08/601, CSD Quad Ring – Torque Check

(6) MM 24-11-13/401, Input Flange, CSD - Removal/Installation

(7) MM 71-00-00/401, Power Plant - Removal/Installation

(8) MM 71-00-59/201, Power Plant – Test Requirements

(9) MM 71-00-94/201, Engine Work Control Record – Description/Use

(10) MM 71-00-96/201, Spare Engine – Receiving and Storage

(11) MM 71-00-99/201, Leased Engine Service

(12) MM 71-11-01/201, Nose Cowl – Inspection/Repair

(13) MM 72-00-95/601, Engine Boroscope – Inspection/Check

(14) MM 72-00-98/601, Compressor Blades, Disc and Vanes –

Inspection/Check

(15) MM 72-00-99/601, Turbine Blades and Vanes – Inspection/Check

(Limits)

(16) MM 72-31-99/301, Fan Rotor Blades – Servicing (Lubrication)

(17) MM 72-53-00/601, Exhaust Case, Exhaust Plug Mounting Flange –

Inspection/Check

(18) MM 72-61-17/401, Main Oil Pump – Removal/Installation

(19) MM 72-61-99/601, N2 Tachometer drive Shaft Bearing

(20) MM 73-14-01/401, Fuel Heater – Removal/Installation

(21) MM 74-21-02/401, Plug Igniter – Removal/Installation

(22) MM 75-24-00/201, Turbine Cooling System – Troubleshooting/Test

(23) MM 78-31-00/201, Fan thrust Reverser – Manual Operation

(24) MM 80-11-01/401, Engine Starter – Removal/Installation

(25) MM 75-32-04/601 Valve, Three-Way Solenoid – Check

(26) MM 73-11-01/401 Fuel Pump QAD Ring Replacement

(27) AD 96-03-01, Airworthiness Directive

3. Access for Nose Cowl Inspection A. Remove Nose Cowl access plates shown in Figure 201 if cowl is installed.

4. Engine Inspection

NOTE: Following items 5.A. through 5.L. to be accomplished by an inspector. All inspections will be GENERAL unless otherwise specified.

INSPECTOR:

A. INSPECTION NOSE COWL AND ENGINE INLET

(1) INSPECT FOLLOWING FOR GENERAL CONDITION, SECURITY,

CRACK, DAMAGE AND ANY OTHER IRREGULARITIES.

(a) FIXED-LIP NOSE COWL (IF INSTALLED)

1) NOSE COWL OUTER AND INNER (INLET) SURFACES.

2) INTERNAL STRUCTURE AND INSTALLATIONS,

INCLUDING BALLAST WEIGHT (IF INSTALLED) AS

VISIBLE THROUGH REMOVED ACCESS PLATES.

(b) FAN BLADES

1) INSPECT ALL FAN BLADES FOR EVIDENCE OF TIGHT

(LOCKED) SHROUDS. ENSURE BLADES ARE FREE TO

MOVE ON THE SHROUD FACE.

2) VISUALLY INSPECT MID-SPAN SHROUDS FOR

EVIDENCE OF CRACKS OR DAMAGE (INTENSIFIED

INSPECTION): IF ANY AREA IS SUSPECTED OF BEING

CRACKED, DYE-PENETRATE CHECK SUSPECTED

AREA(S).

3) VISUALLY INSPECT REMAINING AREA OF FAN BLADES

FOR CONDITION AND DAMAGE, PARTICULARLY

BETWEEN THE INBOARD MID-SPAN SHROUD AND THE

BLADE ROOT AT LEADING AND TRAILING EDGES. USE

STRONG LIGHTS AND MIRRORS, FINGERTIPS AND

FINGERNAILS AS NECESSARY TO DETECT DAMAGE.

NOTE: DAMAGE GREATER THAN .005 DEEP BELOW THE

LINER SHROUD ON THE BLADE LEADING OR TRAILING

EDGES SHALL EDDY CURRENT CHECKED PER 72-31-

02/801. BLADES FOUND WITH OR WITHOUT CRACKS

SHALL BE BLENDED PER AUTHORIZED REPAIRS AND

INSPECTION LIMITS IN 72-31-02/601 (REF. AD NOTE

76-24-03).

(c) SECOND-STAGE COMPRESSOR BLADES

1) USING APPROVED LIGHT (REF. 2.A.), INSPECT

SECOND-STAGE BLADES BY SHINING LIGHT THROUGH

FIRST-STAGE BLADES AND INLET GUIDE VANES.

INSPECT BLADES FOR EVIDENCE OF CRACKS, FAILURE

AND/OR DOWNSTREAM DAMAGE.

(d) INLET CASE, FAN EXIT GUIDE VANES DUCTS, STRUTS AND

PRESSURE PROBES.

INSPECTOR:

B. INSPECT FAN REVERSER

(1) INSPECT FOLLOWING VISIBLE STRUCTURE, COMPONENTS AND

ACESSORIES FOR GENERAL CONDITION, SECURITY, CRACKS,

DAMAGE AND ANT OTHER IRREGULARITIES.

(a) TRANSLATING SLEEVE AND CASCADE VANES.

(b) BLOCKER DOORS AND LINKS.

(c) FORWARD SUPPORT RING, TRACKS, CARRIAGES WITH

LOCKOUT MECHANISM (IF INSTALLED), AND LINKS

(d) FAN REVERSER BALLSCREWS AND GEARBOXES.

(e) FLEXIBLE DRIVE SHAFTS.

(f) PNEUMATIC DRIVE UNIT AND SOLENOID S/O VALVE (IF

INSTALLED).

(g) BLOCKER VALVE: SEQUENCE ACTUATOR (IF INSTALLED)

AND DIRECTIONAL CONTROL VALVE.

(h) FAN REVERSER POSITION SWITCHES AND WIRING.

INSPECTOR:

C. INSPECT ENGINE CASES, COMPONENTS AND ACCESSORIES

(1) INSPECT FOLLOWING SYSTEMS AND COMPONENTS (INCLUDING

VALVES, CONTROLS, DUCTING, PLUMBING, ELECTRICAL LEADS

AND CONNECTORS AND LINKAGE) FOR GENERAL CONDITIONS,

SECURITY, CRACKS, DAMAGE AND ANY OTHER IRREGULARITIES.

(a) THRUST FRAME AND COWLING SUPPORT RAILS.

(b) REVERSING SYSTEM.

(c) FUEL SYSTEM

1) CHECK TT2 SENSOR LINES FOR CLEARANCE AND

CHAFING FROM THE FUEL PUMP CONNECTIONS TO

PYLON CONNECTION FITTINGS.

a) MAXIMUM DEPTH OF CHAFING - .005 INCH.

b) IF LINE(S) CHAFED WITHIN TOLERANCE, WORN

AREA MUST BE BLENDED AND SHARP EDGES

REMOVED.

c) IF LINE(S) CHAFED DEEPER THAN .005 INCH, MUST BE REPLACED AND TT2 SENSOR SYSTEM

MUST BE BLED AND PRESSURE-CHECKED.

(d) OIL SYSTEM

(e) HYDRAULIC SYSTEM

(f) PNEUMATIC SYSTEM

(g) ENGINE BLEED AIR AND ANTI-ICE SYSTEMS.

(h) FIRE DETECTORS.

(i) ENGINE DRAIN SYSTEM.

(j) IGNITION SYSTEM

(k) ENGINE CONTROLS.

1) INSPECT EVC ACTUATOR LINES (FUEL AND HYDRAULIC)

FOR WEAR DUE TO INTERFERENCE BETWEEN LINES.

WITHOUT REMOVING TUBES, CHECK TUBES FOR WEAR

AT THE CLAMPING ATTACHMENT POINTS.

a) WEAR IN EXCESS OF .005 INCH IS CAUSE FOR

LINE REPLACEMENT.

(l) ENGINE INDICATING SYSTEM.

(m) ENGINE CASES AND GEARBOXES

1) INSPECT MAIN AND ANGLE GEARBOXES MOUNT

BEARINGS FOR EXTERNAL EVIDENCE OF WEAR AND

MOUNT PINS FOR BROKEN TABS.

a) MAIN GEARBOX MOUNT BEARINGS SHOWING

DISCOLORATION OR OTHER VISUAL INDICATION

OF WEAR MUST BE REPLACED.

b) MAIN GEARBOX MOUNT PINS BROKEN TABS MUST

BE REPLACED.

c) INDICATION OF WORN ANGLE GEARBOX FRONT

MOUNTS MAY BE CONFIRMED BY MOVING FRONT

OF GEARBOX UP AND DOWN, MOVEMENT MUST

NOT EXCEED .015 INCH.

(n) BIFURCATION DUCT, DIAPHRAGM HOUSING AND RACEWAY.

(o) EXHAUST PLUG.

INSPECTOR:

D. INSPECT ENGINE WIRING (INTENSIFIED INSPECTION)

(1) INSPECT ALL ENGINE WIRING, WIRING SUPPORTS AND

ASSOCIATED CONNECTOR MOUNTED ON ENGINE AND IN SLOT

SEAL AREA. NOTE CONDITION OF CHAFE PROTECTION WHERE

WIRE BUNDLES MAY RUB SLOT SEAL.

INSPECTOR:

E. VISUAL CHECK ENGINE EXTERNAL CONDITION PER FIGURE 215.

INSPECTOR:

F. INSPECT SIXTH-STAGE TURBINE BLADES AND VANES FOR STRUCTURAL

FAILURE AND DAMAGE FROM FOREIGN MATERIAL PASSING THROUGH

ENGINE (INTENSIFIED INSPECTION). REF. 72-00-99/601 FOR

INSPECTION LIMITS.

G. INSPECT EXHAUST PLUG MOUNTING FLANGE OF EXHAUST CASE (REF

FIGURE 206).

(1) USING TOOL [EYE BALL EXTENDER] EQUIPPED WITH A RIGHT

ANGLE VIEWER, INSPECT FOR 360°, EXHAUST CASE FLANGE FOR

CRACKS.

NOTE: ALTERNATE TOOLS, (EXAMPLE: A WOODEN DOWEL WITH A

MIRROR ATTACHED) MAY BE USED PROVIDED IT IS CAPABLE OF

OBSERVING THE DISCREPANCIES AS SPECIFIED IN THE

INSPECTION LIMITS.

REFERENCE 72-53-00/601 FOR INSPECTION LIMITS.

H. REVIEW ALL ENGINE RELATED PAPERWORK AND COMPLETE

SERVICEABLE TAG.

I. COMPLETE TRANSACTION IN NAMIS OF A TIME CONTROLLED

COMPONENT.

INSPECTOR:

J. REPORT ENGINE SERVICEABLE AND “OPEN ITEM AND CALL-OUT” STATUS

IN NAMIS

INSPECTOR:

K. SOFIA AIRCRAFT MAINTENACE MANAGER OR CREW CHIEF VERIFY THE

SERVICEABLE TAG IS COMPLETE ANS ATTACHED TO THE ENGINE.

5. Oil system Static Leak Check A. Check Oil System For Leaks

(1) Connect Kit TE65B90229 to engine overboard breather with adapter.

(2) Install O-ring M83248/1/121 and gearbox crank pad if previously removed. Torque bolt 65-75 inch pounds and safety.

(3) Remove cap from tee fitting on right side of accessory case and connect air pressure gauge to tee fitting.

(4) Close flow control valve and connect test hose to air supply. Start cart air supply is preferred if 1½ inch air line is not available.

(5) Check that oil tank filler cap is secured.

(6) Turn on air supply.

(7) Adjust regulator valve to obtain 50 PSIG.

(8) Carefully open flow control valve. Adjust valve to maintain 5-10

PSIG breather pressure. If pressure cannot be obtained notify Crew Chief and determine causes.

CAUTION: DO NOT EXCEED 10 PSIG ON BREATHER PRESSURE

GAUGE.

NOTE: Adjustment of regulator valve may be required to maintain input pressure at 50 PSIG.

(9) Using leak check solution, check external oil system for leaks.

Particular attention must be given to the following items:

(a) Check #3 bearing scavenge line diffuser case at 6 o’clock position,

(b) Check main gearbox front cover parting surface.

(c) Check #3 bearing pressure tube connection at diffuser case at 5 o’clock position.

(d) Check breather tube under radiation shield at 3 o’clock position

(e) Check #4 bearing scavenge tube condition at aft side of gearbox,

(f) Check drain cluster for gearbox carbon seal leakage.

(g) Check oil tank seam, joints and oil cap.

(h) Check hydraulic drive pad.

(i) Check generator blast tube.

(j) Check horizontal drive shaft housing from angle gearbox to main gearbox.

(10) Close flow control valve.

(11) Shut off air supply and remove test equipment.

(12) Install cap on tee fitting on right side of accessory case. Torque cap 65-75 inch pounds.

(13) Initiate non-routine write-ups for any discrepancies found during leak check.

6. Oil System Service

A. Main Oil Screen

(1) Place container with paper cone filter under oil screen to catch oil drainage,

(2) Remove oil screen cover and screen assembly. Discard cover packing.

(3) Holding screen over paper cone filter, wash screen assembly with

SOL3001-1 and spray gun. Blow screen dry with air,

(4) Check paper cone filter carefully for metal particles.

(a) Use magnet if necessary, as metal is sometimes coated with carbon.

(b) If metal is found, contact SOFIA Aircraft Maintenance Manager or Crew Chief

(5) Discard screen assembly.

(6) Obtain serviceable screen assembly from stock.

(7) Lubricate new packing with MOBIL JET II and install on screen cover.

(8) Install screen assembly and cover in gearbox. Tighten cover nuts to 50-85 inch pounds and safety.

B. Gearbox Magnetic Plugs

(1) Remove three (3) each magnetic plugs from main accessory gearbox and check for metal.

(2) Remove one (1) each magnetic plug from angle gearbox and check for metal.

(3) If found, take corrective action necessary NOTE: If metal is found in main accessory gearbox magnetic plug, main oil pump must be removed and checked for bearing failure, (ref, 72-61-17/401 and N2 tachometer drive shaft bearing must be checked for failure, (Ref 72-61-99/6010.

(4) Wash plugs in SOL3001-1.

(5) Reinstall magnetic plugs, Torque plugs to 10-20 inch pounds and safety.

INSPECTOR: MAIN OIL SCREEN AND GEARBOX MAGNETIC PLUGS SECURE

7. Fuel Heater Check A. Check Fuel Heater for Leaks

(1) Remove drain plug from bottom of heater.

(2) Check for presence of fuel. If found, fuel heater must be replaced, Replace fuel heater per 72-14-01/401.

(3) If no leak indicated, reinstall drain plug with new gasket. Tighten and lockwire plug.

INSPECTOR: DRAIN PLUG

8. Flow Divider replacement A. Remove Flow Divider

(1) Install serviceable flow divider on bracket with attached bolts.

(2) Tighten and safety bolts.

(3) Connect input, output and vent tubes at flow divider.

(4) Tighten and safety tube nuts.

INSPECTOR: DRAIN PLUG

9. Starter Services A. Uninstalled QEC Only

(1) Place container with new paper cone filter under starter to catch oil drainage.

(2) Remove starter drain plug and oil fill plug or standpipe cap using downward pressure and counterclockwise rotation.

NOTE: If there is less than 125 ccs (4.3 ounces) of oil in starter, replace starter. (Ref. 80-11-01/401 for starter replacement).

(3) Check magnetic plug and paper cone filter for metal.

(4) Reinstall drain plug using new packing. Tighten plug to 10-25 inch-pounds and safety.

(5) Fill starter with MOBIL JET II until appears at filler neck or if standpipe installed, fill to standpipe.

(6) Install new lubricated (MOBIL JET II) packing on plug or standpipe cap.

(7) Secure filler plug 10-25 inch-pounds and safety or, if standpipe installed, replace cap using downward pressure and clockwise rotation.

INSPECTOR: DRAIN PLUG

10. Ignition System Service A. Replace engine igniter plugs and check high voltage contact tips on each end of both igniter leads and at both exciter boxes for signs of arcing, pitting, flashover and corrosion.

WARNING: HIGH VOLTAGE. AFTER DISCONNECTING IGNITER

LEADS SHORT TO GROUND.

(1) Disconnect and check igniter leads at igniter, and exciter boxes.

(a) Open heatshield clamps; remove heat shields.

(b) Disconnect igniter leads from igniter plugs.

(c) Check igniter leads for the following:

1) Hard, brittle and/or cracked insulation on the conductor wires and rubber bushings, paying particular attention to area under compressor spring.

2) Arcing and/or carbon tracking around high tension lead ceramics and on contact tip.

(d) If any of the preceding conditions are found replace leads and/or exciter.

(2) Hold igniter plug boss with applicable wrench to prevent loosening and remove igniter plugs.

NOTE: If igniter plug removals are difficult, soak threaded area with

Solvent-Petroleum (PMC 9001 AMS 3160), local purchase.

Work igniters and resoak, Ref 74-21-02/401 if igniter plug boss repair/replace required.

(a) Check keywasher for condition, if damaged replaced replace with new keywasher.

(b) If keywashers are replaced, do not bend tabs around boss until igniter plug installed.

(c) Install dust caps on igniter plug ports.

B. Install igniter plug

(1) Remove dust caps from plug posrts.

(2) If required, clean threads in plug boss, using TAP 1SF1649.

(3) Lubricant, High Heat Mica-Lube-BG-A718 or Silver Goop.

CAUTION: IF PLUG IS DROPPED, OR IF THREADS ARE DAMAGE,

ATTACH SERVICABLE TAG TO BAGGED PLUG, GIVING

DETAILS AND RETURN TO STORES.

IF PLUG CONTACTS COMBUSTION LINER, LINER MAY BE

CUT BACK TO 1/16 INCH FOR 180° TO PROVIDE

CLEARANCE.

(4) Place keywasher on plug (if removed from boss), install plugs, torque to 300-360 inch-pounds. Bend keywasher tabs around boss.

(5) Reinstall igniter plug leads.

(a) Clean ignition lead contact tips to a shinny condition using

SCOTCH BRITE.

(b) Clean high tension lead ceramic insulators and rubber bushings with clean cloth and solvent (MIL-PRF-680-TYPE 1).

(c) Without touching insulators with fingers, use a clean acid brush and apply a thin film of KRYTOX 240 AC to the face of the rubber bushings.

CAUTION: KEEP GREASE AND FINGERS OFF THE CERAMIC

INSULATOR.

(d) Connect leads to plugs. Tighten coupling nuts.

CAUTION: - ENSURE LEAD DOES NOT TWIST DURING

TIGHTENING.

ENSURE HEATSHIELD SKIRTS AT PLUGS DO NOT

BLOCK COOLING AIR HOLES IN LEAD.

(e) Install heat shields, close and tighten clamps.

INSPECTOR: INGNITER PLUGS AND CABLE LEADS SECURE.

NOTE: Ignition System Test accomplish during engine operation checks and service per 71-00-00/401.

11. CSD Service A. Magnetic Plug Check (Ref 24-11-01/601)

(1) Remove magnetic plug, check for contamination. If excessive metal found, replace CSD. (24-11-01/401).

NOTES: - Cleanliness and contamination prevention is an absolute necessary during CSD Check and Service.

- Do not remove drain plug surrounding magnetic plug.

- Do not clean magnetic plug. Cleaning plug delays repair of a failing CSD.

(2) Install magnetic plug with new packing. Tighten finger tight and safety plug.

B. Delta-P Indicator (Ref Figure 209)

(1) Check charge filter Delta-P (bypass) indicator.

(a) If indicator is popped, replace filter element. (24-11-04/401).

C. Retorque CSD QAD Assembly

(1) Attempt to lift aft end of CSD. (CSD weights 95 pounds).

NOTE: If CSD moves, CSD must be supported during retorquing to avoid a false torque reading on the thread wear “step” of the worn QAD plate. (Ref, 24-11-01/401 for part numbers of cradle and CSD lift assembly).

(2) Center QAD ring by tapping with a soft faced drift or hammer on the ring outer diameter.

(3) Retorque tension (torque) bolt to 144-180 inch-pounds

(4) Repeat tapping and torquing until 144-180 inch-pounds is retained after tapping (i.e. no further torque bolt rotation is achieved).

(5) Check that QAD gap has not gone below 3/8 minimum allowable gap.

NOTE: If gap goes below minimum limit before the proper torque is obtained, replace the QAD assembly and CSD input flange.

(Ref 24-11-08/601 and 24-11-13/401).

(6) Safety wire using double twist method.

(7) Remove cradle and lift assembly (if used).

(8) Attempt to lift aft end of CSD (CSD weights 95 pounds). If CSD moves relative to engine, CSD and QAD assembly must be replaced because of excessive wear. (Ref 24-11-01/401 and 24-11- 08/601).

D. Scavenge Filter Service (Ref Figure 209) (Ref. 24-11-05/401)

(1) Place 2 gallons container directly below CSD.

(2) Depress center of CSD overfill boss fitting to relieve internal pressure, or loosen gravity fill port plug.

(3) Remove four retaining screws on filter cap. Retain screws and washers for reinstallation.

(4) Pull on scavenge filter cap and remove filter cap, filter cartridge and three O-ring from filter housing; discard O-ring.

CAUTION: DO NOT USE A SCREWDRIVER TO PRY APART OR THE

CASTING MAY BE DAMAGED.

NOTE: A soft faced mallet may be used to tap lightly during removal of filter cap.

(5) Lubricate O-ring with UNIREX S-2.

NOTE: O-rings are included with element assembly.

CAUTION: ENGINE OIL IS NOT AN ACCEPTABLE SUBSTITUTE FOR

UNIREX-S2 OR EQUIVILANT. OIL DOES NOT MAKE O-

RING SLIPPERY ENOUGH TO PREVENT CUTTING THEM

ON INSTALLATION.

(6) Install TWO O-RING INTO GROOVES ON FILTER CAP.

(7) Install O-ring into filter cartridge.

(8) Slide cartridge over center part of the filter cap.

(9) Insert and push filter assembly into filter housing with twisting motion and secure without screws and washers; tighten screws to a final torque of 48 to 53 inch-pounds.

CAUTION: DO NOT ATTEMPT TO DRAW FILTER ASSEMBLY INTO

TRANSMISSION HOUSING BY TIGHTENING SCREWS.

THE FILTER CAP OR THE MOUNTING PAD MAY BE

DAMAGE. IF PROBLEM IS ENCOUNTERED PUT MORE

UNIREX S-2 ON THE CAP O-RINGS.

(10) Reset pressure differential indicator if tripped.

E. Check oil condition and accomplish oil service.

(1) Check CSD oil condition; if excessively dark (red or brown in color), cloudy or smells “burnt”, Ref 24-11-01/601 for required action.

(2) If CSD is serviceable, check oil level at sight gauge (Ref. Figure

202).

(a) If level is more than ¼ inch below fill area and there is a previous report of oil loss, replace CSD.

(b) If CSD is serviceable, service oil system, as necessary.

1) Depressurize CSD to removing pressure cap and depressing overfill fitting check valve.

2) Fill CSD to area between silver bands with MOBIL JET II through fill fitting.

3) Wait at least five minutes and re-service.

INSPECTOR: CSD MAGNETIC PLUG, FILTER COVERS, AND QAD SECURE.

12. Fan Reverser Drive Unit Service

NOTE: Reversing type pneumatic Drive unit does not have oil servicing provisions.

A. Magnetic Plug (if applicable)

(1) Remove magnetic plug and check for metal.

(a) If excessive metal is found, replace pneumatic drive unit.

(2) Reinstall magnetic plug. Tighten plug to 10-25 inch-pounds and secure with lockwire. Use new packing.

B. Oil service (if applicable)

(1) Remove motor bearing and gearbox oil fill plugs. (LH and RH sides).

(2) Fill reservoirs with MOBIL JET II to top mark on dripsticks.

(3) Reinstall fill plugs and tighten to 25-35 inch-pounds (lockwire not required). Use new packings

INSPECTOR: MAGNETIC AND FILTER PLUGS.

13. Engine Mount Check (On Uninstalled QEC Only) A. Check both forward and aft mounts for general conditions with special attention to engine/pylon attach hardware for scoring or thread damage, B. Check self-locking torque of engine/pylon attach nuts. Replace any outside limits of 117-900 inch-pounds.

C. Check for freedom of motion of aft mount spherical bearings. (Ref Figure

204).

D. Check Forward Mount bolt migration per 71-21-02/601 (AD 97-10-05).

This check applies only to bolts secured with self locking nuts.

E. Aft Mount Tangential Link Upper Bolt Nut Torque Check – This Check does

NOT apply to mounts incorporating a tangential link Upper bolt retainer.

INSPECTOR: VISUAL CHECK: SECURITY, SAFETY AND CONDITION.

14. Engine Borescope Check A. Borescope hot section per 72-00-95/601. (Uninstalled QEC only).

INSPECTOR: ASSURE BOROSCOPE PLUGS ARE ALL INSTALLED.

15. Install Engine Condition Actuator A. Check Condition Actuator. Replacement (Per 76-11-04/401) with “0” TSO condition actuator is required.

Record Condition Actuator Part Number ________ ON __________OFF

B. Fuel condition control actuator operation check is accomplished during engine operational checks and service per 71-00-00/401.

16. Fuel Pump Mount Check A. Check QAD ring area foe evidence of wear (“sludge”) between the Main

Gearbox and the QAD ring. If there is movement between the Main Gearbox and the QAD ring, the Fuel Pump/Fuel Control unit must be removed to Retorque the QAD ring to the Main Gearbox.

B. Retorque Fuel Pump QAD ring using the “tap and torque” method tap the exposed sections of the QAD ring using a soft drift and hard face hammer until torque lock bolt to 160-170 inch-pounds, Repeat the “tap and torque” until torque is constant (no more rotation of the bolt at set torque after tapping).

(1) Check for 0.010 – 0.26 inch gap between the face of the clamp ring and face of the fuel pump.

(2) Safety QAD lock bolt.

17. Miscellaneous Check and Service A. Check RABS Switch Installation.

NOTE: RABS switch is mounted on upper right hand 3.5 bleed valve.

Reverser must be stowed for this check.

(1) Alignment of roller to roller or bumper to bumper must be within + 0.015 inch to ensure simultaneous actuation of switches. Adjust by moving switches either forward or aft within limits of hole clearances.

(2) Measure gap two places between cam and rollers or bumpers when in undeflected position. Maximum height is 1.650 inches. Gap between cam and rollers or bumpers must be within 0.125-0.250 inch.

B. If dimension between switch rollers or bumpers and cam is not within limits specified, check switch rollers or bumpers and cam for wear;

replace parts as required. Remove rig pin.

C. Close applicable T/R SEQ & BLEED circuit breaker on P12 panel.

D. Connect RABS switch connecting rod to control cam; check rod length and adjust if necessary per 78-34-08.

(1) Operation check of bleed system solenoid valves after engine is installed, per 78-34-08/501.

E. Check Pneumatic Pressure Relief Valve

(1) Check movement of valve.

(a) Visually check that no foreign object jam the valve piston to prevent movement.

(b) Grasp relief valve piston with both hands through slots in valve housing.

(c) Pull piston away from its seat slightly to check that it is free to move. If the piston will not move, the valve must be replaced.

NOTE: It required only slight movement to verify that piston is not seized or misaligned.

F. Check thrust reverser Stow Switch (Ref. Figure 210)

(1) Check stow switch assembly for proper switch to striker plate contact.

(2) Check switch arm for deformation.

(3) Check spring for bending and wear at the switch roller surface contact area.

(4) Check spring bumper for wear, thickness must be greater than .200 inch.

(5) Check that the stow switch strike plate (lip), if present, does not protrude forward more than .100 inch. If striker plate protrudes forward more than .100 inch have it cut back to .100 inch or less.

G. Clean Strut Drain

(1) Blow air through strut line to ensure that it is not restricted.

Located at lower center of cluster and is the largest tube.

H. Lubricate Fan Reverser Components

(1) Lubricate fan reverser ballscrew actuator nuts (4 each) with zerk gun containing BMS 3-33.

(2) Wipe excess grease from areas after lubrication.

I. Reinstall nose cowl access plates if cowl is installed.

INSPECTOR: NOSE COWL ACCESS PLATES SECURE.

J. Lubricate all fan blade shroud hard face surface with Moly Kote - G-R Riprid-Paste

K. Check the N1 Wire Harness condition:

(1) Check for wire harness chafes and/or fluid contamination at all locations from the N1 fan case pick-up to the DisP Firewall disconnect. No wear or contamination is allowed. Repair or replace the harness per MM 77-31-98/401.

L. Protect Engine

(1) Cover and seal following with cardboard or paper and tape and/or moldable paper

(a) 3.5 Bleed Valve Ducts

(b) Breather outlet duct and engine drains.

(c) Generator cooling air exhaust duct.

(d) Engine to pylon main pneumatic duct.

(e) Air, hydraulic and fuel lines.

(f) Electrical plugs.

(2) Cover engine with cover.

(3) Store engine in a protected area and attach to it the spare Engine

Work Control Record form and any other pertinent records.

ACCESS PLATE REMOVAL FOR NOSE COWL INTERNAL C CHECK INSPECTION

Figure 201

OFF-WING (ONLY) CONSTAND SPEED DRIVE OIL SERVICING

Figure 202

Reverser Actuated Bleed Switch Clearance Check

Figure 203

ENGINE MOUNTS

Figure 204

FLOW DIVIDER INSTALLATION

Figure 205

EXHAUST CASE

Figure 206

NOTE: Keep insulator (3) free from all contaminants.

Apply grease Krytox 240 AC to the face of the rubber bushing (4).

EXPLODED VIEW OF LEAD TERMINAL TYPICAL BOTH ENDS

Figure 207

CSD FILTER SERVICING

Figure 208