REVISION NO. 02 Apr 01/09 Pages which have been revised are

Transcription

TRENT 700
SERIES ENGINES
__________
HIGHLIGHTS
REVISION NO. 02 Apr 01/09
Pages which have been revised are outlined below, together with the Highlights of the
Revision
-------------------------------------------------------------------------------------CH/SE/SU C
REASON FOR CHANGE
EFFECTIVITY
PAGES
-------------------------------------------------------------------------------------CHAPTER 70
__________
L.E.P. 1- 4 Revised to Reflect this revision indicating
new,revised, and/or deleted pages
70-12-02
CORRECTION/ADDITION/AMPLIFICATION
205- 206, ADDED REFERENCE FOR CLEANING METHOD.
211- 213
ALL
70-20-03
202- 203,
206- 207
CORRECTION/ADDITION/AMPLIFICATION
ADDED REFERENCE FOR CLEANING METHOD.
ALL
70-30-00
11- 12
TECHNICAL CORRECTIONS
ADDED OMAT 2-72.
ALL
70-HIGHLIGHTS Page
REVISION NO. 02
AFL
1 of
1
Apr 01/09
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
STANDARD PRACTICES - ENGINES
LIST OF EFFECTIVE PAGES
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N, R or D indicates pages which are New, Revised or Deleted respectively
Remove and insert the affected pages and complete the Record of Revisions and
the Record of Temporary Revisions as necessary
CH/SE/SU
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Oct01/08
Oct01/08
Oct01/08
CH/SE/SU
70-71-14
70-71-14
70-71-14
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-20
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-21
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-24
70-71-26
70-71-26
70-71-26
70-71-26
70-71-26
70-71-27
70-71-27
70-71-28
70-71-28
C
PAGE
3
4
5
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7
8
9
10
11
12
13
14
15
16
17
18
1
2
3
4
5
6
7
8
9
10
1
2
3
4
5
6
7
8
9
10
11
1
2
3
4
5
1
2
201
202
DATE
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
CH/SE/SU
70-71-28
70-71-28
70-71-28
70-71-28
70-71-29
70-71-29
70-71-29
70-71-29
70-71-29
70-71-29
70-71-29
70-71-40
70-71-40
70-71-40
70-71-40
70-71-41
70-71-41
70-71-41
70-71-41
70-71-41
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
70-71-42
C
PAGE
203
204
205
206
201
202
203
204
205
206
207
201
202
203
204
201
202
203
204
205
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
DATE
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
Oct01/08
70-L.E.P. Page
4
Apr 01/09
AFL
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
STANDARD PRACTICES - ENGINE - GENERAL
_____________________________________
DESCRIPTION AND OPERATION
General
List of FRS (Repair Scheme) used
in AMM.
CONTAMINATION CAUSED BY LOW MELTING
POINT ALLOYS
General
Contamination Caused by Cadmium
Plated Tools
IDENTIFICATION OF SELF-LOCKING NUTS
General
Identification of 12-Point
Self-Locking Nuts
PART CONDITION TERMINOLOGY
General
The Types of Damage to Metal
Parts
The Condition of Metal Parts
Types of Damage to Composite
Materials
PART CONDITION TERMINOLOGY
MAINTENANCE PRACTICES
Part Condition Terminology
CLASSIFICATION AND IDENTIFICATION OF
DANGEROUS SUBSTANCE
General
Dangerous Materials Definitions
FLIGHT PROFILES AND OPERATIONAL
MONITORING - GROUP A PART
General
Preparation of Flight
Profile/Data
Monitoring of the Operational
Flight Data
Definition of a Flight Cycle
MISUSE OF MOLYBDENUM DISULPHIDE
LUBRICANTS
General
IDENTIFICATION, LUBRICATION AND
________
CH/SE/SU
70-00-00
C
_
PAGE ___________
____
EFFECTIVITY
1
1
1
ALL
ALL
ALL
1
1
1
ALL
ALL
ALL
1
1
1
ALL
ALL
ALL
1
1
1
ALL
ALL
ALL
38
41
ALL
ALL
201
201
ALL
ALL
1
1
1
ALL
ALL
ALL
1
1
1
ALL
ALL
ALL
6
ALL
6
ALL
1
1
ALL
ALL
70-00-01
70-00-05
70-01-02
70-01-02
70-01-07
70-01-10
70-01-11
70-02-01
70-CONTENTS
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
FITTING OF FLEXIBLE SEALING RINGS
Identification, Lubrication and
Fitting of Flexible Seal Rings
APPROVED ENGINE OILS
General
System Description
List of Approved Engine Oils,
refer to SB 12-F139.
List of Approved IDG Lubricating
Oils
List of Approved Pneumatic
Starter Lubricating Oils
CH/SE/SU
________
ENGINE WELDING RESTRICTIONS
Engine Welding Restrictions
REMOVAL / INSTALLATION OF RIGID TUBES
Removal of Rigid Tubes and
Flexible Hose Assemblies
Installation of Rigid Tubes and
Flexible Hose Assemblies
REMOVAL/INSTALLATION OF VEE BAND
COUPLING CLAMPS
Removal of Vee-Band
Coupling-Clamps
Installation of Vee-Band
Coupling-Clamps
LOCKING TECHNIQUES FOR THREADED PARTS
Locking Techniques - Double - Lock
Single - Hole Keywasher
Locking Techniques - Ring Nut and
Cupwasher
Locking Techniques - Split Cotter
Pin
Locking Techniques - Wire locking
Locking Techniques - Safety Cable
Locking Techniques - Pinion Wire
Plug
MAINTENANCE PROCESSES - STRIPPING AND
CLEANING
70-12-00
C
_
PAGE ___________
____
EFFECTIVITY
201
201
ALL
ALL
1
1
1
1
ALL
ALL
ALL
ALL
1
ALL
2
ALL
201
201
ALL
ALL
201
201
ALL
ALL
207
ALL
201
201
ALL
ALL
205
ALL
201
201
ALL
ALL
204
ALL
206
ALL
208
213
224
ALL
ALL
ALL
201
ALL
70-02-02
70-12-01
70-12-02
70-12-04
70-20-01
70-CONTENTS
AFL
Page 2
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
List of maintenance Processes Stripping and Cleaning
Non-Aqueous Liquid Degreasing Maintenance Process 101
Abrasive Blasting for Cleaning Maintenance Process 104
Swab Etching of Titanium Alloys Maintenance Process 133
MAINTENANCE PROCESSES - INSPECTION
List of Maintenance Processes Inspection
Post-Emulsified Fluorescent
Penetrant Inspection with
Water-Based (Hydrophilic)
Penetrant Removers - Maintenance
Process 210
Water-washable Fluorescent
Penetrant Inspection - Maintenance
Process 213
MAINTENANCE PROCESSES - SURFACE
PROTECTION
List of Maintenance Processes Surface Protection
Application of Chromate Conversion
Coating to Aluminium - Maintenance
Process 330
Application of Two-Pack Epoxy
Finish (Skydrol Resistant) Maintenance Process 323
Application of Adhesive Bonding,
Sealing and Filling Agents Maintenance Process 707
CH/SE/SU
________
_________________
LIST
OF MATERIALS
General
Abbreviations and Equivalents
Standard Wire Gauge (British
Imperial)
List of Consumable Products
Suppliers Names and Addresses
REPAIR SURFACES AFFECTED BY MINOR
DAMAGE
70-30-00
C
_
____ ___________
PAGE
EFFECTIVITY
201 ALL
202
ALL
206
ALL
209
ALL
201
201
ALL
ALL
202
ALL
209
ALL
201
201
ALL
ALL
202
ALL
206
ALL
210
ALL
1
1
1
2
ALL
ALL
ALL
ALL
3
32
ALL
ALL
201
ALL
70-20-02
70-20-03
70-42-11
70-CONTENTS
AFL
Page 3
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
Repair Surfaces Affected by Minor
Damage - FRS3253
PROTECT LOCALLY DAMAGED ENAMELLED
SURFACE
Protect Locally Damaged Surfaces
of Aluminium Cases
REPAIR THREADED HOLES BY FITTING WIRE
THREAD INSERTS
Repair Threaded Holes by the
installation of the Wirethread
Inserts (FRS3002)
ACCEPTABLE CRACKS - STOP DRILLING
Stop Drilling of Acceptable Cracks
- FRS3255
REPLACE DAMAGE OR LOOSE CAPTIVE NUTS
Replace Damaged or Loose Captive
Nuts - FRS3035
REPLACEMENT OF STUD FASTENERS
Replace Stud Fasteners (Camlocs) FRS3210
SEAL EXPOSED FIBERS ON FIBER
REINFORCED COMPOSITES
Seal the Exposed Fibers on Fiber
Reinforced Composites - FRS3254
RIVETS
Remove and Install the Cherrymax
and Cherrylock Blind Rivets FRS7058
CONNECTION OF ELECTRICAL PLUGS
Connection of Electrical Plugs
(Types ESC10 and ESC11)
CH/SE/SU
________
TORQUE TIGHTENING TECHNIQUE
Torque Tightening Techniques
Torque Stripe Technique
GENERAL VISUAL INSPECTION OF ATTACHING
PARTS
70-51-00
C
_
____ ___________
PAGE
EFFECTIVITY
201 ALL
70-42-12
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
220
ALL
ALL
ALL
70-42-13
70-42-16
70-42-19
70-42-21
70-42-22
70-42-28
70-50-02
70-51-02
70-CONTENTS
AFL
Page 4
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
General Visual Inspection of
Attaching Parts
STORAGE OF FLEXIBLE RINGS, HOSES AND
RUBBER COMPONENTS
General
Storage (Shelf) Life
Cure Date Identification
Storage of Parts
Inspection of Parts
CH/SE/SU
________
POWER PLANT WIRING STANDARD PRACTICES ATA INDEX
General
POWER PLANT WIRING - GENERAL
General
Characteristics
Conditions
Detail Parts
VENDOR CODES, NAMES AND ADRESSES
General
CONNECTOR/INSERT ARRANGEMENT
General
Series Connectors
Specifications
Key-Ways
WIRE HARNESS LACING PROCEDURE
General
Harness Tie
Standard equipement
Consumable Material
Procedure
General Lacing Procedure
Harness Break-Out Support Ties
(Breakouts Other Than 90
Degrees)
Harness Break-Out Support Ties
(90 Degree Break-Outs)
CONNECTOR AND BACKSHELL REPLACEMENT
PROCEDURE
70-71-00
C
_
____ ___________
PAGE
EFFECTIVITY
201 ALL
201 ALL
70-61-01
1
1
1
1
3
5
ALL
ALL
ALL
ALL
ALL
ALL
1
1
ALL
ALL
1
1
1
1
2
ALL
ALL
ALL
ALL
ALL
1
1
ALL
ALL
1
1
1
1
1
ALL
ALL
ALL
ALL
ALL
1
1
1
1
1
2
2
2
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
5
ALL
70-71-01
70-71-02
70-71-12
70-71-14
70-71-20
70-CONTENTS
AFL
Page 5
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
_______
SUBJECT
Connector and Backshell
Replacement Procedure
General
Standard Equipment
Consumable Material
Procedure
Backshell Removal
Contacts Removal
Replace the Connector or
Backshell
Install the Contact
Do a Contact Retention Check
Attach the Backshell Body to the
Connector
Do the Electrical Checks
Connect the Connectors
Test
CONTACT REPLACEMENT PROCEDURE
General Replacement Procedure
General
Standard Equipment
Consumable Materials
Procedure
Repair
Test
SHIELDED WIRE REPLACEMENT PROCEDURE
Shielded Cable Replacement
Procedure
General
Standard Equipment
Consumable Material
Procedure
Replace the Cable
Test
TERMINAL TAG REPLACEMENT PROCEDURE
Terminal Tag Replacement Procedure
General
Standard Equipment
Procedure
Removal
Installation
CH/SE/SU
________
C
_
____ ___________
PAGE
EFFECTIVITY
1 ALL
1 ALL
1
2
3
3
3
5
7
ALL
ALL
ALL
ALL
ALL
ALL
ALL
8
9
11
ALL
ALL
ALL
16
17
18
ALL
ALL
ALL
1
1
1
2
3
3
3
10
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
1
1
ALL
ALL
1
2
2
3
3
11
ALL
ALL
ALL
ALL
ALL
ALL
1
1
1
1
2
2
2
2
ALL
ALL
ALL
ALL
ALL
ALL
ALL
ALL
70-71-21
70-71-24
70-71-26
70-CONTENTS
AFL
Page 6
Oct 01/08
TRENT 700
SERIES ENGINES
CHAPTER 70
__________
TABLE OF CONTENTS
_________________
SUBJECT
_______
Check
Ground Wire Installation.
Test
DISCONNECT AND HARNESS IDENTIFICATION
MARKER REPAIR PROCEDURE
Disconnect and Harness
Identification Marker Repair
Procedure
General
Standard Equipement
Consumable Material
Procedure
CABLE OUTER JACKET REPAIR
Cable Outer Jaket Repair
CABLE BRAIDED SCHIELD REPAIR
Temporary Tape Repair of the Cable
Braided Schield
HARNESS TEMPORARY REPAIR (OVERTIE A NEW
CABLE)
Harness Temporary Repair (Overtie
a New Cable)
HARNESS TYING
Harness Tying
HARNESS TEMPORARY REPAIR (CABLE
SPLICE)
Harness Temporary Repair (Cable
Splice), FRS J180
CH/SE/SU
________
C
_
____ ___________
PAGE
EFFECTIVITY
4 ALL
4 ALL
5 ALL
70-71-27
1
1
ALL
ALL
1
1
2
2
ALL
ALL
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
201
201
ALL
ALL
70-71-28
70-71-29
70-71-40
70-71-41
70-71-42
70-CONTENTS
AFL
Page 7
Oct 01/08
TRENT 700
SERIES ENGINES
STANDARD PRACTICES - ENGINE - GENERAL - DESCRIPTION AND OPERATION
_________________________________________________________________
1. General
_______
A. List of FRS (Repair Scheme) used in AMM.
------------------------------------------------------------------------------FRS No.
TITLE
CH-SE-SU
PAGE
BLOCK
------------------------------------------------------------------------------FRS 3002
Repair Threaded Holes by the installation
70-42-13
201
of Wirethread Inserts
FRS 3035
Replace Damage or Loose Captive Nuts
70-42-19
201
FRS 3253
Repair Surfaces Affected by Minor Damage
70-42-11
201
FRS 3254
Seal the Exposed Fibers on Fiber
Reinforced Composites
70-42-22
201
FRS 3255
Stop Drilling of Acceptable Cracks
70-42-16
201
FRS A024
LPC Fan Blades Repair Damage by Dressing,
Scalloping and/or Cropping
72-31-41
601
FRS J028
Electronic Unit Protection Box - Cover Replace Seal
75-21-41
801
EFF :
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70-00-00
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
CONTAMINATION CAUSED BY LOW MELTING POINT ALLOYS - DESCRIPTION AND OPERATION
____________________________________________________________________________
1. _______
General
An alloy which melts at a low temperature can at some temperatures melt and
go in to another material. This can cause contamination of the material
which subsequently becomes brittle and cracks occur.
A. Contamination Caused by Cadmium Plated Tools
It is possible for particles of cadmium to move from a cadmium plated
tool to the surface of an engine component. This can cause the failure of
a titanium component during some conditions of operation.
The failure is caused at some temperatures by the effect of the cadmium
with the titanium. The titanium becomes brittle and cracks occur.
Do not use a tool or item of equipment which has been cadmium plated on
the engine or its components.
EFF :
ALL
70-00-01
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
IDENTIFICATION OF SELF-LOCKING NUTS - DESCRIPTION AND OPERATION
_______________________________________________________________
1. _______
General
(Ref. Fig. 001)
There are two types of 12-point self-locking nut for low and high
temperature use: The two types of nut are geometrically equivalent but can
be identified as given below.
A. Identification of 12-Point Self-Locking Nuts
Nuts which must be used in the hotter engine locations (which operate at
temperatures of 230 to 650 deg.C (446 to 1202 deg.F)) are not magnetic
and are silver plated. They have a flange which is not fully knurled.
Nuts which are specified for use in the colder engine locations (which
operate at temperatures of not more than 230 deg.C (446 deg.F)) are
magnetic and cadmium plated. They have a layer of molybdenum disulphide
(which is black) and a flange which is not knurled.
Identification of low temperature and high temperature nuts which have
been used before can only be done with a magnet.
Make sure that only the correct type of nut (as specified in the Power
Plant Illustrated Parts Catalog) is installed. Do not think that all low
temperature type nuts are installed in the colder engine locations. High
temperature type nuts are frequently installed in the colder engine
locations.
EFF :
ALL
70-00-05
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
Identification of Self - Locking Nuts
Figure 001
EFF :
ALL
70-00-05
AFL
Page 2
Oct 01/08
TRENT 700
SERIES ENGINES
PART CONDITION TERMINOLOGY - DESCRIPTION AND OPERATION
______________________________________________________
1. _______
General
This chapter gives names to specified types of damage. This is to prevent
errors which can occur when different names are used for the same type of
damage. Always use the correct name for the specified type of damage or
condition when an inspection is made on a component.
(Ref. Fig. 001, 002, 003, 004, 005, 006, 007, 008, 009, 010, 011, 012, 013,
014, 015, 016, 017, 018, 019, 020, 021, 022, 023, 024, 025, 026, 027, 028,
029, 030, 031)
A. The Types of Damage to Metal Parts
------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Arced
Flashed-over
The effects that can be seen (burned
or fused metal) of an unwanted
electrical discharge between two
electrical connections.
Battered
Damaged by impacts
Is damage caused to a part when it is
constantly hit
Bent
Creased, folded,
kinked, leaning
Is angular change from the initial
shape or contour. Usually the cause is
a lateral force
Binding
Sticking, tight
Is decreased movement such as a
tightened condition which results from
very hot or very cold temperatures
or an unwanted particle between
surfaces
Bowed
-
A curve which changes the surfaces
usual shape or contour. Usually the
cause is heat or a lateral force
Brinelled
-
Circular surface damage on bearing
races. Usually the cause is constant
shock loads given to the bearing
False Brinelling :
Roller bearings : It is seen as axial
lines across the roller track which
are surface blemishes. This is
EFF :
ALL
70-01-02
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
Battered
Figure 001
EFF :
ALL
70-01-02
AFL
Page 2
Oct 01/08
TRENT 700
SERIES ENGINES
Bent
Figure 002
EFF :
ALL
70-01-02
AFL
Page 3
Oct 01/08
TRENT 700
SERIES ENGINES
Bowed UD 70010200V10101
Figure 003
EFF :
ALL
70-01-02
AFL
Page 4
Oct 01/08
TRENT 700
SERIES ENGINES
Brinelled
Figure 004
EFF :
ALL
70-01-02
AFL
Page 5
Oct 01/08
TRENT 700
SERIES ENGINES
Broken
Figure 005
EFF :
ALL
70-01-02
AFL
Page 6
Oct 01/08
TRENT 700
SERIES ENGINES
Bulged
Figure 006
EFF :
ALL
70-01-02
AFL
Page 7
Oct 01/08
TRENT 700
SERIES ENGINES
Burned
Figure 007
EFF :
ALL
70-01-02
AFL
Page 8
Oct 01/08
TRENT 700
SERIES ENGINES
Carboned
Figure 008
EFF :
ALL
70-01-02
AFL
Page 9
Oct 01/08
TRENT 700
SERIES ENGINES
Collapsed
Figure 009
EFF :
ALL
70-01-02
AFL
Page 10
Oct 01/08
TRENT 700
SERIES ENGINES
Cracked
Figure 010
EFF :
ALL
70-01-02
AFL
Page 11
Oct 01/08
TRENT 700
SERIES ENGINES
Curled
Figure 011
EFF :
ALL
70-01-02
AFL
Page 12
Oct 01/08
TRENT 700
SERIES ENGINES
Dented
Figure 012
EFF :
ALL
70-01-02
AFL
Page 13
Oct 01/08
TRENT 700
SERIES ENGINES
Deposits
Figure 013
EFF :
ALL
70-01-02
AFL
Page 14
Oct 01/08
TRENT 700
SERIES ENGINES
Disintigrated
Figure 014
EFF :
ALL
70-01-02
AFL
Page 15
Oct 01/08
TRENT 700
SERIES ENGINES
Distorted
Figure 015
EFF :
ALL
70-01-02
AFL
Page 16
Oct 01/08
TRENT 700
SERIES ENGINES
Galled
Figure 016
EFF :
ALL
70-01-02
AFL
Page 17
Oct 01/08
TRENT 700
SERIES ENGINES
Gouge
Figure 017
EFF :
ALL
70-01-02
AFL
Page 18
Oct 01/08
TRENT 700
SERIES ENGINES
Nicked
Figure 018
EFF :
ALL
70-01-02
AFL
Page 19
Oct 01/08
TRENT 700
SERIES ENGINES
Overheated
Figure 019
EFF :
ALL
70-01-02
AFL
Page 20
Oct 01/08
TRENT 700
SERIES ENGINES
Peeled
Figure 020
EFF :
ALL
70-01-02
AFL
Page 21
Oct 01/08
TRENT 700
SERIES ENGINES
Pick-up
Figure 021
EFF :
ALL
70-01-02
AFL
Page 22
Oct 01/08
TRENT 700
SERIES ENGINES
Pitted
Figure 022
EFF :
ALL
70-01-02
AFL
Page 23
Oct 01/08
TRENT 700
SERIES ENGINES
Porous
Figure 023
EFF :
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Rolled-over
Figure 024
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Ruptured
Figure 025
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Scored
Figure 026
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Scratch
Figure 027
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Sheared
Figure 028
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Skidding
Figure 029
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Spalled
Figure 030
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Torn
Figure 031
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------permitted.
Ball bearings : Are two marks
related to each ball that can be seen
on the ball track which are surface
blemishes. This is permitted
Brittle
Perished
Is a change in the elasticity of the
material
Broken
Fractured
The separation of a part by force, into
two or more pieces
Bulged
Ballooned, swollen
Internal and external local distortion.
Usually the cause is too much heat or
differences in pressure
Burned
Charred
A complete structural failure of
the material because of very hot
temperatures
Burrs
-
Rough edges or sharp projections on
the surface of a material
Carboned
Carbon covered,
carbon tracked,
coked
A quantity of carbon particles
collected on the surface of a
material
Chafed
Scraped, scuffed
Friction wear damage. Usually the
cause is two parts that rub together
with a small amount of movement
Checkered
Crazed
Surface cracks. Usually the cause
is heat.
Chipped
-
Material broken off the edge, corner
or surface. Usually caused when a
material is hit.
Collapsed
Crushed
The surface is pulled below its
initial contour. Usually the cause
is large differences in pressure
Corroded
Rusted, oxidation,
etched,
Slow deterioration of the material
because of a chemical effect. Usually
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------sulphidation
seen as oxide particles on the surface
Cracked
-
A linear opening that can easily be
seen and which can cause the material
to break. (Special fluorescent or
magnetic penetrants are not necessary)
Crossed
-
Material damage to a part, for example,
crossed thread. Alternatively a part
incorrectly assembled, for example,
crossed wires
Curled
-
A rounded fold in the material such as
a blade tip that has rubbed against
the engine casing
Dented
-
Damage to the surface of a part when
it is hit with an object. The
material is distorted but not removed
Deposits
Metalized
Particles of material collected on
a part from a different part or
material
Disengaged
Separated, loose
This occurs only to parts that are
usually permanently attached to each
other
Disintegrated
Shattered
Completely broken in pieces
Distorted
Buckled, depressed
twisted, warped
Is damage that changes the initial
shape or contour of a material.
Usually caused when the material is
hit, made hot or has structural
stresses applied
Eccentric
Non-concentric
Occurs when a part has the point about
which it turns moved off center
Eroded
-
The flow of fluids or gases cause the
material to wear : Heat or grit makes
this occur more quickly
Extruded
-
Plastic deformation because of high
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------pressure between parts
Feathered edge
-
The edge of the material is made
thinner
Flattened out
-
Permanent damage more than the
tolerance limits. Usually caused
when the material is compressed
Frayed
-
Worn (rubbed) into strips
Fretted
Galled, spiked
Damage caused when two materials are
rubbed together at high pressure
Fused
-
When two materials become attached
to each other. Usually the cause is
heat, friction or current flow
Galled
Fretted, spiked
rubbed together at high pressure
Glazed
-
This is seen as a hard glossy surface
because of heat, varnish, incorrect
loads or when the surface is rubbed
Gouge
-
At large rough cut of large depth with
the removal of some material, caused
because a sharp object has hit the
part
Grooved
Furrowed, fluted
A smooth rounded score, because of
wear, with rounded corners and smooth
on the groove bottom
Indications
-
Small cracks or other small defects
that cannot be seen without
fluorescent or magnetic penetrants
Melted
-
Distortion to the initial shape or
contour because of heat friction or
pressure
Nicked
-
A small cut on the surface or edge of
a part caused when the part is hit
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------with an object
Overheated
Heat discolored,
The part has become too hot. Usually
heated excessively, seen as a change in color or condition
hot spot
Part missing
Lost
Related only to a detail that is
usually permanently attached
Peeled
Blistered, flaked,
exfoliated
Is when the surface finish (coating,
plating) breaks away
Peened
-
A group of very small dents caused
when the part is hit many times
Pick-up
-
The material from one surface becomes
attached to a different surface.
Usually caused when two surfaces are
rubbed together without sufficient
lubricant
Pierced
Hole in the part
The part has a hole made in it
Pitted
-
Small irregular shaped holes in the
surface of a material. Usually
caused because of corrosion or
electrical discharge
Plugged
Clogged,
obstructed,
restricted
passage
The flow is decreased or prevented
because of blockage
Porous
Pock-marked,
perforated weld
Small empty spaces in the material
usually found in welds and materials
that are cast
Rippled
Impact damage
sustained
typically after
a bird strike
The Fan Blade will have
ripples/undulations typically running
along the length of the fan blade
(in radial direction when installed in
an engine)
Rolled over
Lipped, turned
The edges of the part become rounded
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------metal
Rough
-
When the operation (not the surface)
is not smooth
Rubbed
Abraded
To move with pressure or friction.
Ruptured
Blown, burst,
split
The surface of the part is broken open
because of an internal stress or force
Scored
-
A scratch or scratches of large depth
(with some removal of the material)
made with a sharp object during the
operation of the part
Scratch
-
A small surface cut with not much depth
made with a sharp object or particle.
Material is not usually removed
Seized
Frozen, jammed,
stuck
Movement between the parts is stopped
because the clearance is not
sufficient. Caused because of heat
or unwanted particles
Sheared
Cut
Is when two surfaces move in relation
to each other along the same axis in
opposite directions. This will cause
the details that hold the two surfaces
together to break
Skidding
-
Is surface damage to balls, rollers
and races of bearings. It is seen as
an intermittent matt silver effect on
the surface and occurs because of
intermittent loads during use
Sludged
Gummed
Very small particles of unwanted
material collected in one location
Softened
Perished
Below the specified elasticity
Spalled
Plucked
A rough broken area on the surface of
a material. Usually caused because of
surface cracks or inclusions when a
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------load is put on the surface
Spinning
Damage caused when a bearing race is
turned too much
Stretched
Growth
The part is made larger as a result of
conditions of operation
Stripped
-
The removal of material by force.
Usually related to threads and
insulation
Torn
-
The material is pulled apart
Untwisted
Unwound
An unsatisfactory decrease in the
angular adjustment. The part tries
to become straight
Worn excessively
-
The material of the part is erroded
away because of operation or use
Wrecked
-
The damage is too bad for continued
use
B. The Condition of Metal Parts
------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Acceptable
OK
Satisfactory for continued use
Not inspected
-
Class of part
too low
-
The nozzle guide vane class is the
angular deviation between the airfoil
chord and the buttresses
Class of part
too high
-
chord and the buttresses
Clearance above
maximum
-
Unsatisfactory tolerances have
collected. (Not because of wear)
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Clearance above
minimum
collected. (Not because of wear)
Clearance end
too much
-
-
Compression or
tension below
minimum
-
Compression or tension load is lower
than specified
Compression or
tension above
maximum
-
Compression or tension load is higher
than specified
Damaged during
transit
-
-
Deterioration
in storage
-
-
Dimension below
minimum
-
Below the engineering drawing
dimension or other specified
dimension
Dimension above
maximum
-
Above the engineering drawing
dimension or other specified
dimension
Emission low
-
Is the low output of electrical tubes:
it shows an unsatisfactory tube
Finish not to
specification
-
Is the condition of the surface
finish : not surface damage
Frequency out
of limits
-
The frequency of vibrations of a part
are above permitted limits
Hardness below
limits
-
Found with Rockwell, Brinell or
alternative hardness tests
Hardness above
limits
-
alternative hardness tests
Magnetism low
-
Low or no magnetism of permanently
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------magnetized parts
Mis-matched
-
A condition caused because of the
incorrect relation of parts
Mis-positioned
Mis-aligned,
reversed, cocked
The incorrect installation of a part
which results in damage to the part
or related parts
Obsolete
Superseded
The part is not in use
Out of balance
-
The weight is not equally symmetrical
around the axis. This condition is to
be examined if there is no apparent
damage
Out of round
Elongated
The diameters of the part are not
constant
Out a square
-
The related surfaces are not at the
specified right angle
Part removed
pending
investigation
-
A part removed as a precaution until
an investigation is done and a
technical decision is made on its
condition
Received
disassembled
-
-
Resistance high
-
High electrical resistance in an
electrical circuit that causes
incorrect circuit operation
Resistance low
-
Low electrical resistance in an
electrical circuit that causes
incorrect circuit operation
Tension or
compression
below minimum
-
Tension or compression load is lower
than is specified
Tension or
compression
-
Tension or compression load is higher
than is specified
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------above maximum
Time expiration
Part retired
The part is not used because of a
time limit
Voltage erratic
-
Caused because of the intermittent
or irregular flow of current
Voltage - none
(circuit shorted
or grounded)
-
Caused because of an unwanted current
path to ground or between leads of
circuits that are usually at a
different voltage
Voltage - none
(circuit open)
-
Caused because an electrical circuit
is not complete because of a break
between electrical connections
C. Types of Damage to Composite Materials
(Ref. Fig. 032, 033, 034, 035, 036, 037, 038, 039, 040, 041, 042, 043)
(1) Unbond (or disbond)
The separation of two bonded surfaces. There are two types of unbond
as follows:
(a) Adhesive failure
This is failure at the joint between the bonded surface and the
adhesive. The adhesive stays on one of the surfaces.
For honeycomb structures, adhesive failure can be divided into
two types.
- failure at the joint between the adhesive and the surface layer
or the honeycomb. Adhesive stays on the honeycomb but not on
the related position on the surface layer.
NOTE : The adhesive will stay on the surface layer at the
____
locations related to the honeycomb cells.
- Failure at the joint between the adhesive and the honeycomb.
The adhesive stays on the surface layer but not on the
honeycomb. This is usually known as pull out.
(b) Cohesive failure
This is failure in the adhesive material. The adhesive stays on
each surface.
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Unbond
Figure 032
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Unbond
Figure 033
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Unbond (Adhesive failure)
Figure 034
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Unbond (Cohesive failure)
Figure 035
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Delaminated
Figure 036
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Cracked/Split
Figure 037
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Fretted
Figure 038
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Eroded and Cavities
Figure 039
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Impact damage
Figure 040
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Torn fibers
Figure 041
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Blistered
Figure 042
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Scorched
Figure 043
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NOTE : Unbond which occurs in composites can also occur in
____
honeycomb structures with metal perforate and
non-perforate surface layers.
(2) Delaminated
This is the separation of layers in a composite laminate.
(3) Cracked or split
A crack or split through a composite laminate is seen as a small
opening in the composite surface layer or the complete composite
thickness. It is usually caused when the material is hit or because
of distortion.
NOTE : Cracks can occur in locations that are filled or have large
____
quantities of resin. These are only surface defects and must
be correctly identified from cracks in the composite laminate.
(4) Fretted
This is seen as a rubbed surface with the protection removed from the
fibers. This can result in broken fibers.
(5) Eroded
This is seen as the removal of the surface resin layer caused because
of the effects of weather. When the protection is removed from the
fibers it can make the surface rough. It is possible for the fibers
to become eroded.
(6) Cavity
This is an empty space that occurs usually in the surface layers with
a large quantity of resin or infilled locations.
(7) Impact damage
There are two groups of impact damage:
(a) Sharp object
Usually a split or a crack, possibly with related delamination
near the damage.
(b) Blunt object
Usually delamination of the layers with a possible related split,
crack or unbond. Damage usually extends out of the immediate
location of the damage.
NOTE : In honeycomb sandwich structures, impact damage could
____
include other types of damage to the honeycomb.
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(8) Torn fibers
Strips of lifted surface fibers, pulled and peeled along the fiber
length. Damage is frequently made larger because of the air flow
until the fiber breaks.
(9) Fire or heat damage
This can cause one or all of the conditions that follow:
(a) Blistered
This is bubbles on the surface caused because of local
delamination below the surface layer.
(b) Scorched
This is seen as a change in color of the surface layer.
(c) Resin degradation
This is deterioration of the resin of a composite laminate, at
the surface and also internally, which results in delamination
and loose fibers.
(10) Fluid diffusion
This is fluid leakage through a composite material that has high
porosity.
This is usually related to wet lay up assemblies.
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RIPPLED
Figure 044
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PART CONDITION TERMINOLOGY - MAINTENANCE PRACTICES
__________________________________________________
TASK 70-01-02-910-802
Part Condition Terminology
1. __________________
Reason for the Job
This Chapter, Section, Subject gives names to specified types of damage.
This is to prevent errors which can occur when different names are used for
the same type of damage. Always use the correct name for the specified type
of damage or condition when an inspection is made on a component.
2. ______________________
Job Set-up Information
A. Referenced Information
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-01-02-991-045
70-01-02-991-046
70-01-02-991-047
70-01-02-991-048
70-01-02-991-049
70-01-02-991-050
70-01-02-991-051
70-01-02-991-052
70-01-02-991-053
70-01-02-991-054
70-01-02-991-055
70-01-02-991-056
70-01-02-991-057
70-01-02-991-058
70-01-02-991-059
70-01-02-991-060
70-01-02-991-061
70-01-02-991-062
70-01-02-991-063
70-01-02-991-064
70-01-02-991-065
70-01-02-991-066
70-01-02-991-067
70-01-02-991-088
70-01-02-991-069
70-01-02-991-070
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
201
202
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-01-02-991-071
70-01-02-991-072
70-01-02-991-073
70-01-02-991-074
70-01-02-991-075
70-01-02-991-076
70-01-02-991-077
70-01-02-991-078
70-01-02-991-079
70-01-02-991-080
70-01-02-991-081
70-01-02-991-082
70-01-02-991-083
70-01-02-991-084
70-01-02-991-085
70-01-02-991-086
70-01-02-991-087
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
227
228
229
230
231
232
233
234
235
236
237
238
239
240
241
242
243
3. __________
Job Set-up
Subtask 70-01-02-869-051
A. Not applicable.
4. Procedure
_________
Subtask 70-01-02-918-053
A. The Types of Damage o Metal Parts
------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Arced
Flashed-over
The effects that can be seen (burned or
fused metal) of an unwanted electrical
discharge between two electrical
connections.
Battered
Damaged by impacts
Is damage caused to a part when it is
constantly hit.
(Ref. Fig. 201/TASK 70-01-02-991-045)
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Battered
Figure 201/TASK 70-01-02-991-045
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Bent
Creased, folded,
Is angular change from the initial shape
kinked, leaning
or contour. Usually the cause is a
lateral force.
(Ref. Fig. 202/TASK 70-01-02-991-046)
Binding
Sticking, tight
Is decreased movement such as a
tightened condition which results from
ve or very cold temperatures or an
unwanted particle between surfaces.
Bowed
A curve which changes the surfaces usual
shape or contour. Usually the cause is
heat or a lateral force.
(Ref. Fig. 203/TASK 70-01-02-991-047)
Brinelled
Circular surface damage on bearing
races. Usually the cause is constant sh
loads given to the bearing.
(Ref. Fig. 204/TASK 70-01-02-991-048)
False Brinelling
Roller bearings: It is seen as axial
lines across the roller track which are
surface blemishes. This is permitted.
Ball bearings: Are two marks related to
each ball that can be seen on the ball
track which are surface blemishes. This
is permitted.
Brittle
Perished
Is a change in the elasticity of the
material.
Broken
Fractured
The separation of a part by force, into
two or more pieces.
(Ref. Fig. 205/TASK 70-01-02-991-049)
Bulged
Ballooned, swollen
Internal and external local distortion.
Usually the cause is too much he
differences in pressure. Ref. Fig. 2XX/
TASK 70010299100600)KFM0
(Ref. Fig. 206/TASK 70-01-02-991-050)
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Bent
Figure 202/TASK 70-01-02-991-046
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Bowed
Figure 203/TASK 70-01-02-991-047
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Brinelled
Figure 204/TASK 70-01-02-991-048
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Broken
Figure 205/TASK 70-01-02-991-049
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Bulged
Figure 206/TASK 70-01-02-991-050
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Burned
Charred
A complete structural failure of the
material because of very hot
temperatures.
(Ref. Fig. 207/TASK 70-01-02-991-051)
Burrs
Carboned
Rough edges or sharp projections on the
surface of a material.
Carbon covered,
carbon tracked,
A quantity of carbon particles collected
on the surface of a material. Ref.
(Ref. Fig. 208/TASK 70-01-02-991-052)
coked
Chafed
Scraped, scuffed
Friction wear damage. Usually the cause
is two parts that rub together with a
small amount of movement.
Checkered
Crazed
Surface cracks. Usually the cause is
heat.
Chipped
Material broken off the edge, corner or
surface. Usually caused when a material
is hit.
Collapsed
Crushed
The surface is pulled below its initial
contour. Usually the cause is large
differences in pressure.
(Ref. Fig. 209/TASK 70-01-02-991-053)
Corroded
Rusted, oxidation,
etched,
sulphidation
Slow deterioration of the material
because of a chemical effect. Usually
seen as oxide particles on the surface.
Cracked
A linear opening that can easily be seen
and which can cause the material to
break. (Special fluorescent or magnetic
penetrants are not necessary).
(Ref. Fig. 210/TASK 70-01-02-991-054)
Crossed
Material damage to a part, for example,
crossed thread. Alternatively a part
incorrectly assembled, for example,
crossed wires.
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Burned
Figure 207/TASK 70-01-02-991-051
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Carboned
Figure 208/TASK 70-01-02-991-052
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Collapsed
Figure 209/TASK 70-01-02-991-053
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Cracked
Figure 210/TASK 70-01-02-991-054
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Curled
A rounded fold in the material such as a
blade tip that has rubbed against the
engine casing.
(Ref. Fig. 211/TASK 70-01-02-991-055)
Dented
Damage to the surface of a part when it
is hit with an object. The material is
distorted but not removed.
(Ref. Fig. 212/TASK 70-01-02-991-056)
Deposits
Metalized
Particles of material collected on a
part from a different part or material.
(Ref. Fig. 213/TASK 70-01-02-991-057)
Disengaged
Separated, loose
This occurs only to parts that are
usually permanently attached to each
other.
Disintegrated
Shattered
Completely broken in pieces.
(Ref. Fig. 214/TASK 70-01-02-991-058)
Distorted
Buckled, depressed
twisted, warped
Is damage that changes the initial shape
or contour of a material.
Usually caused when the material is hit,
made hot or has structural stresses
applied.
(Ref. Fig. 215/TASK 70-01-02-991-059)
Eccentric
Non-concentric
Occurs when a part has the point about
which it turns moved off center.
Eroded
The flow of fluids or gases cause the
material to wear: heat or grit makes
this occur more quickly.
Extruded
Plastic deformation because of high
pressure between parts.
Feathered edge
The edge of the material is made
thinner.
Flattened out
Permanent damage more than the tolerance
limits. Usually caused when the material
is compressed.
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Curled
Figure 211/TASK 70-01-02-991-055
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Dented
Figure 212/TASK 70-01-02-991-056
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Deposits
Figure 213/TASK 70-01-02-991-057
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Disintigrated
Figure 214/TASK 70-01-02-991-058
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Distorted
Figure 215/TASK 70-01-02-991-059
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Frayed
Worn (rubbed) into strips.
Fretted
Galled, spiked
Fused
Galled
rubbed together at high pressure. Ref.
(Ref. Fig. 216/TASK 70-01-02-991-060)
When two materials become attached to
each other. Usually the cause is
heat,friction or current flow.
Fretted, spiked
rubbed together at high pressure.
(Ref. Fig. 216/TASK 70-01-02-991-060)
Glazed
This is seen as a hard glossy surface
because of heat, varnish, incorrect
loads or when the surface is rubbed.
Gouge
A large rough cut of large depth with
the removal of some material, caused
because a sharp object has hit the part.
(Ref. Fig. 217/TASK 70-01-02-991-061)
Grooved
Furrowed, fluted
A smooth rounded score, because of wear,
with rounded corners and smooth on the
groove bottom.
Indications
Small cracks or other small defects that
cannot be seen without fluorescent or
magnetic penetrants.
Melted
Distortion to the initial shape or
contour because of heat friction or
pressure.
Nicked
A small cut on the surface or edge of a
part caused when the part is hit with an
object.
(Ref. Fig. 218/TASK 70-01-02-991-062)
Overheated
Heat discolored,
heated excessively,
The part has become too hot. Usually
seen as a change in color or condition.
(Ref. Fig. 219/TASK 70-01-02-991-063)
hot spot
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Galled
Figure 216/TASK 70-01-02-991-060
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Gouge
Figure 217/TASK 70-01-02-991-061
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Nicked
Figure 218/TASK 70-01-02-991-062
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Overheated
Figure 219/TASK 70-01-02-991-063
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Part missing
Lost
Related only to a detail that is usually
permanently attached.
Peeled
Blistered, flaked,
exfoliated
Is when the surface finish (coating,
plating) breaks away.
(Ref. Fig. 220/TASK 70-01-02-991-064)
Peened
A group of very small dents caused when
the part is hit many times.
Pick-up
The material from one surface becomes
attached to a different surface.
Usually caused when two surfaces are
rubbed together without sufficient
lubricant.
(Ref. Fig. 221/TASK 70-01-02-991-065)
Pierced
Hole in the part
Pitted
The part has a hole made in it.
Small irregular shaped holes in the
surface of a material. Usually caused
because of corrosion or electrical
discharge.
(Ref. Fig. 222/TASK 70-01-02-991-066)
Plugged
Clogged,
obstructed,
restricted passage
The flow is decreased or prevented
because of blockage.
Porous
Pock-marked,
perforated weld
Small empty spaces in the material
usually found in welds and materials
that are cast.
(Ref. Fig. 223/TASK 70-01-02-991-067)
Rippled
Impact damage
sustained typically
after a bird strike
The fan blade will have
ripples/undulations typically running
along the length of the fan blade (in a
radial direction when installed in an
engine).
(Ref. Fig. 224/TASK 70-01-02-991-088)
Rolled over
Lipped, turned
The edges of the part become rounded.
(Ref. Fig. 201/TASK 70-01-02-991-045)
metal
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Peeled
Figure 220/TASK 70-01-02-991-064
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Pick-up
Figure 221/TASK 70-01-02-991-065
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Pitted
Figure 222/TASK 70-01-02-991-066
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Porous
Figure 223/TASK 70-01-02-991-067
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Rippled
Figure 224/TASK 70-01-02-991-088
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Rough
When the operation (not the surface) is
not smooth.
Rubbed
Abraded
To move with pressure or friction
against a different surface. Such as
compressor rub.
Ruptured
Blown, burst, split
The surface of the part is broken open
because of an internal stress or force.
(Ref. Fig. 225/TASK 70-01-02-991-069)
Scored
A scratch or scratches of large depth
(with some removal of the material) made
with a sharp object during the operation
of the part. (Ref. Fig. 2XX/ TASK
(Ref. Fig. 226/TASK 70-01-02-991-070)
Scratch
A small surface cut with not much depth
made with a sharp object or particle.
Material is not usually removed. (Ref.
Fig. 2XX/ TASK 70010299102700)LCM0
(Ref. Fig. 227/TASK 70-01-02-991-071)
Seized
Frozen, jammed,
stuck
Movement between the parts is stopped
because the clearance is not sufficient.
Caused because of heat or unwanted
particles.
Sheared
Cut
Is when two surfaces move in relation to
each other along the same axis in
opposite directions. This will cause the
details that hold the two surfaces
together to break.
(Ref. Fig. 228/TASK 70-01-02-991-072)
Skidding
Sludged
Is surface damage to balls, rollers and
races of bearings. It is seen as an
intermittent matt silver effect on the
surface and occurs because of
intermittent loads during use.
(Ref. Fig. 229/TASK 70-01-02-991-073)
Gummed
Very small particles of unwanted
material collected in one location.
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Ruptured
Figure 225/TASK 70-01-02-991-069
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Scored
Figure 226/TASK 70-01-02-991-070
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Scratch
Figure 227/TASK 70-01-02-991-071
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Sheared
Figure 228/TASK 70-01-02-991-072
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Skidding
Figure 229/TASK 70-01-02-991-073
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Softened
Perished
Below the specified elasticity.
Spalled
Plucked
Spinning
Stretched
A rough broken area on the surface of a
material. Usually caused because of
surface cracks or inclusions when a load
is put on the surface. (Ref. Fig. 2XX/
(Ref. Fig. 230/TASK 70-01-02-991-074)
Damage caused when a bearing race is
turned too much.
Growth
The part is made larger as a result of
conditions of operation.
Stripped
The removal of material by force.
Usually related to threads and
insulation.
Torn
The material is pulled apart.
(Ref. Fig. 231/TASK 70-01-02-991-075)
Untwisted
Unwound
An unsatisfactory decrease in the
angular adjustment. The part tries to
become straight.
Worn
excessively
The material of the part is eroded away
because of operation or use.
Wrecked
The damage is too bad for continued use.
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Spalled
Figure 230/TASK 70-01-02-991-074
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Torn
Figure 231/TASK 70-01-02-991-075
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Subtask 70-01-02-918-054
B. The Condition of Metal Parts
------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Acceptable
OK
Satisfactory for continued use.
Not inspected
Class of part
too low
chord and the buttresses.
Class of part
too high
chord and the buttresses.
Clearance above
maximum
collected. (Not because of wear).
Clearance above
minimum
collected. (Not because of wear).
Clearance end
too much
Compression or
tension below
minimum
Compression or tension load is lower
than specified.
Compression or
tension above
maximum
Compression or tension load is higher
than specified.
Damaged during
transit
Deterioration
in storage
Dimension below
minimum
Below the engineering drawing dimension
or other specified dimension.
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Dimension above
Above the engineering drawing dimension
maximum
or other specified dimension.
Emission low
Is the low output of electrical tubes:
it shows an unsatisfactory tube.
Finish not to
specification
Is the condition of the surface finish:
not surface damage.
Frequency out
of limits
The frequency of vibrations of a part
are above permitted limits.
Hardness below
limits
alternative hardness tests.
Hardness above
limits
alternative hardness tests.
Magnetism low
Low or no magnetism of permanently
magnetized parts.
Mismatched
A condition caused because of the
incorrect relation of parts.
Mis-positioned
Misaligned,
reversed, cocked
The incorrect installation of a part
which results in damage to the part or
related parts.
Obsolete
Superseded
The part is not in use.
Out of balance
Out of round
The weight is not equally symmetrical
around the axis. This condition is to be
examined if there is no apparent damage.
Elongated
The diameters of the part are not
constant.
Out of square
The related surfaces are not at the
specified right angle.
Part removed
pending
investigation
A part removed as a precaution until an
investigation is done and a technical
decision is made on its condition.
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------------------------------------------------------------------------------TYPE OF DAMAGE
RELATED DATA
RELATED CONDITION
------------------------------------------------------------------------------Received
disassembled
Resistance high
High electrical resistance in an
electrical circuit that causes incorrect
circuit operation.
Resistance low
Low electrical resistance in an
electrical circuit that causes incorrect
circuit operation.
Tension or
compression
below minimum
Tension or compression load is lower
than is specified.
Tension or
compression
above maximum
Tension or compression load is higher
than is specified.
Time expiration
Part retired
The part is not used because of a time
limit.
Voltage erratic
Caused because of the intermittent or
irregular flow of current.
Voltage - none
(circuit
shorted or
grounded)
Caused because of an unwanted current
path to ground or between leads of
circuits that are usually at a different
voltage.
Voltage - none
(circuit open)
Caused because an electrical circuit is
not complete because of a break be
electrical connections.
Subtask 70-01-02-918-055
C. Types of Damage to Composite Materials
(1) Unbond (or Disbond)
(Ref. Fig. 232/TASK 70-01-02-991-076)
This is the separation of two bonded surfaces. There are two types of
unbond as follows:
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Unbond
Figure 232/TASK 70-01-02-991-076
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(a) Adhesive failure
This is failure at the joint between the bonded surface and the
adhesive. The adhesive stays on one of the surfaces.
For honeycomb structures, adhesive failure can be divided into
two types.
1
_
Failure at the joint between the adhesive and the surface
layer of the honeycomb. Adhesive stays on the honeycomb but
not on the related position on the surface layer
(Ref. Fig. 233/TASK 70-01-02-991-077, 234/TASK 70-01-02-991078)
NOTE : The adhesive will stay on the surface layer at the
____
locations related to the honeycomb cells.
2
_
Failure at the joint between the adhesive and the honeycomb.
The adhesive stays on the surface layer but not on the
honeycomb. This is usually known as pull out.
(Ref. Fig. 233/TASK 70-01-02-991-077)
(b) Cohesive failure
This is failure in the adhesive material. The adhesive stays on
each surface.
(Ref. Fig. 235/TASK 70-01-02-991-079)
NOTE : Unbond which occurs in composites can also occur in
____
honeycomb structures with metal perforate and
non-perforate surface layers.
(2) Delaminated
This is the separation of layers in a composite laminate.
(Ref. Fig. 236/TASK 70-01-02-991-080)
(3) Crack or split
A crack or split through a composite laminate is seen as a small
opening in the composite surface layer or the complete composite
thickness. It is usually caused when the material is hit or because
of distortion.
(Ref. Fig. 237/TASK 70-01-02-991-081)
NOTE : Cracks can occur in locations that are filled or have large
____
quantities of resin. These are only surface defects and must
be correctly identified from cracks in the composite laminate.
(Ref. Fig. 238/TASK 70-01-02-991-082)
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Honeycomb
Figure 233/TASK 70-01-02-991-077
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Unbond (Adhesive failure)
Figure 234/TASK 70-01-02-991-078
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Unbond (Cohesive failure)
Figure 235/TASK 70-01-02-991-079
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Delaminated
Figure 236/TASK 70-01-02-991-080
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Cracked/Split
Figure 237/TASK 70-01-02-991-081
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Eroded and Cavities
Figure 238/TASK 70-01-02-991-082
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(4) Fretted
This is seen as a rubbed surface with the protection removed from the
fibers. This can result in broken fibers.
(Ref. Fig. 239/TASK 70-01-02-991-083)
(5) Eroded
This is seen as the removal of the surface resin layer caused because
of the effects of weather. When the protection is removed from the
fibers it can make the surface rough. It is possible for the fibers
to become eroded.
(Ref. Fig. 238/TASK 70-01-02-991-082)
(6) Cavity
This is an empty space that occurs usually in the surface layers with
a large quantity of resin or infilled locations.
(Ref. Fig. 238/TASK 70-01-02-991-082)
(7) Impact damage
There are two groups of impact damage:
(a) Sharp object
Usually a split or a crack, possibly with related delamination
near the damage.
(Ref. Fig. 239/TASK 70-01-02-991-083)
(b) Blunt object
Usually delamination of the layers with a possible related split,
crack or unbond. Damage usually extends out of the immediate
location of the damage.
(Ref. Fig. 240/TASK 70-01-02-991-084)
NOTE : In honeycomb sandwich structures, impact damage could
____
include other types of damage to the honeycomb.
(8) Torn fibers
Strips of lifted surface fibers, pulled and peeled along the fiber
length.Damage is frequently made larger because of the air flow until
the fiber breaks.
(Ref. Fig. 241/TASK 70-01-02-991-085)
(9) Fire and heat damage
This can cause one or all of the conditions that follow:
(a) Blistered
This is bubbles on the surface caused because of local
delamination below the surface layer.
(Ref. Fig. 242/TASK 70-01-02-991-086)
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Fretted
Figure 239/TASK 70-01-02-991-083
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Impact damage
Figure 240/TASK 70-01-02-991-084
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Torn fibers
Figure 241/TASK 70-01-02-991-085
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Blistered
Figure 242/TASK 70-01-02-991-086
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(b) Scorched
This is seen as a change in color of the surface layer.
(c) Resin degradation
This is deterioration of the resin of a composite laminate, at
the surface and also internally, which results in delamination
and loose fibers.
(Ref. Fig. 243/TASK 70-01-02-991-087)
(10) Fluid diffusion
This is fluid leakage through a composite material that has high
porosity. This is usually related to wet lay up assemblies.
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Scorched
Figure 243/TASK 70-01-02-991-087
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Rolled-over
Figure 244/TASK 70-01-02-991-068
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CLASSIFICATION AND IDENTIFICATION OF DANGEROUS SUBSTANCE
________________________________________________________
_________________________
1. _______
General
(Ref. Fig. 001)
This standard practice gives data on the international warning symbols
(pictograms) used to identify materials which are in the dangerous materials
group. These materials can be chemical elements and their compounds as they
occur in their natural condition, or as made commercially (which includes
additives or solutions).
The pictograms (does not include the asbestos warning label) can be seen on
the outer surface of the containers. They are black on an orange-yellow
background. A description of the warning symbol is written below each
pictogram.
The asbestos warning label can be seen attached to an item or its packet to
show that it contains asbestos. These labels are black and white.
A. Dangerous Materials Definitions
The paragraphs that follow give the descriptions used below each
pictogram.
(1) Explosive
(a) A material which can cause an explosion because of the effects of
flame, shock or friction.
(2) Oxidising
(a) Materials which give an exothermic reaction if they touch with
other materials because of oxidation.
(3) Extremely flammable
(a) Liquid materials which have a flash point (the point at which it
burns without an external cause) lower than 0 deg.C (32 deg.F).
And a boiling point lower than or equal to 35 deg.C (95 deg.F).
(4) Highly flammable
(a) Materials which become hot and go on fire in ambient air
temperature conditions with no applied energy.
(b) Solid materials which go on fire it they touch an ignition source
for only a short time. And which will continue to burn after
removal of that source (this does not include paper, rags etc).
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Identification of Dangerous Materials
Figure 001
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(c) Liquid materials which have a flash point below 21 deg.C (70
deg.F).
(d) Gases which are flammable in air at usual pressure.
(e) Materials which make highly flammable gas if they touch water or
moist air.
(5) Flammable
(a) Liquid materials which have a flash point of between 21 and 55
deg.C (70 and 131 deg.F).
(6) Very toxic
(a) Materials which if drunk, breathed in or touched so that they go
through your skin can be very dangerous to your health. And can
kill you.
(7) Toxic
(a) Materials which if drunk, breathed in or touched so that they go
through your skin can be dangerous to your health. And can kill
you.
(8) Corrosive
(a) Materials which can cause damage to the surface of a metal. And
can cause damage to your body tissues if you touch them.
(9) Harmful
(a) Materials which if drunk, breathed in, or touched so that they go
through your skin can be a risk to your health.
(10) Irritant
(a) Materials that are not corrosive which if touched or breathed in,
immediately, frequently or for a long time can cause inflammation
of the skin or mucous membranes.
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FLIGHT PROFILES AND OPERATIONAL MONITORING - GROUP A PART
___________________________________________________________
_________________________
1. _______
General
The failure of a primary engine part, which turns, can cause a dangerous
engine condition. Such critical parts are given the name GROUP A PARTS. A
mandatory life limit, which must not be ignored, is specified for each of
them. These lives are written into Chapter 5 of the Time Limits Manual.
Cyclic life limits are calculated by Rolls-Royce in relation to stress
cycles. These limits are then changed into equivalent flight cycles that
relate to a rate at which the fatigue life is used. This is calculated from
the datum flight profile.
(Ref. Fig. 001)
This is a frequency-based average calculation, designed to give an optimum
safe operating life.
A. Preparation of Flight Profile/Data
(Ref. Fig. 001)
(1) It is very important for each Operator to prepare and analyse their
operational flight profile/data. Differences between the Operators
data and the datum flight profile
(Ref. Fig. 001)
could make it necessary to change the specified time limits for the
group A parts.
(2) The Operator must make sure their recorded operational flight data
covers all areas in which it could exceed the datum flight profile.
(Ref. Fig. 001)
The recommended minimum number of analysis points necessary to
demonstrate compliance are given below:
(a) Maximum shaft speeds (N1, N2, N3) during Take-off
(b) Maximum shaft speeds (N1, N2, N3) during Climb
(c) Number of throttle movements on descent.
1
_
Confirmation is required that no significant throttle
movements occur during the first 5 minutes of a typical
descent phase. A significant throttle movement is defined as
one that exceeds the datum flight profile value for the start
of descent.
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Datum Flight Profile
Figure 001 (SHEET 1)
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Datum Flight Profile
Figure 001 (SHEET 2)
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(d) Ambient temperature (TAT) during Take-off (deg. C)
1
_
The ambient temperature (TAT) at Take-off must be recorded as
backup information (for possible use in the event of an
exceedance of the datum flight profile).
(3) The operator should be aware that the minimum number of points covers
a limited range of the datum flight profile. If the operator has
concerns regarding their compliance, it is recommended that in order
to provide a more detailed flight profile, the points detailed below
should be monitored:
(a) Maximum shaft speeds (N1, N2, N3) during Take-off
(b) Maximum shaft speeds (N1, N2, N3) during Climb
(c) shaft speeds (N1, N2, N3) at the star of Cruise.
1
_
These should be the settled speeds after the throttles have
been retarded from climb.
(d) Shaft speeds (N1, N2, N3) at the end of Cruise. These should be
the speeds before the throttles are retarded for descent.
(e) Shaft speeds (N1, N2, N3) at the start of Descent. These should
be the Settled speeds after the throttles have been retarded from
Cruise and at the start of descent.
(f) Shaft speeds (N1, N2, N3) at the end of Descent These should be
the Speeds before the throttles are advanced for the Approach.
(g) Ambient temperature (TAT) during Take-off (deg.C)
1
_
The ambient temperature (TAT) at take-off must be recorded as
backup information (for possible use in the event of an
exceedance of the datum flight profile).
(4) Use of COMPASS data
(a) It is acceptable for an Operator to submit COMPASS Take-off and
Climb data to support the flight profile-monitoring requirement.
However, this data must be used in conjunction with at least the
minimum of Descent data as detailed in para 1.A.(2) and any other
data the Operator chooses to monitor, in order for compliance to
be demonstrated.
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(b) It should be noted that in the event of an exceedance, Digital
Flight Data Recorder (DFDR) data may be required to generate a
more detailed understanding of the flight profile.
(5) Construction of operational flight profile/data
(a) If each engine in the Operators fleet is exposed to different
route types during an annual period, we recommend that the
Operator produces an average operational flight profile/data.
This must be fully representative of their fleet, the routes
flown, route frequencies and times of year.
(b) This representative operational flight profile must be
constructed from the minimum points specified in paras (c) or
(d) that follow:
(c) Minimum points (Option 1)
1
_
Average maximum shaft speeds during Take-off
2
_
Average maximum shaft speeds during Climb
3
_
Average significant throttle movements during Descent.
4
_
Average ambient temperature (TAT) at take-off. This is not for
comparison, but backup information for use in the event of an
exceedance of the datum flight profile.
(d) Minimum points (Option 2)
1
_
Average maximum shaft speeds during Take-off
2
_
Average maximum shaft speeds during Climb
3
_
Average shaft speeds at the start of Cruise
4
_
Average shaft speeds at the end of Cruise
5
_
Average shaft speeds at the start of Descent
6
_
Average shaft speeds at the end of Descent
7
_
Average ambient temperature (TAT) at Take-off. This is not for
comparison, but backup information for use in the event of an
exceedance of the datum flight profile.
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NOTE : If the Operator uses dedicated aircraft on individual
____
routes (thus not exposing the engine to two different
route operating conditions), we recommend that an
individual operational flight profile/data is produced
for each route.
B. Monitoring of the Operational Flight Data
(1) Operators must, during the first six months of operation, establish
compliance with the datum flight profile. They must contact
Rolls-Royce in the event of an exceedance. After the initial six
month monitoring period, compliance with the datum flight profile
must be reassessed one year after EIS, and then at yearly intervals.
A compliance report with supporting data must be sent to Rolls-Royce.
NOTE : Compliance with the datum flight profile can only be confirmed
____
after one full years operation, to permit the consideration
of seasonal variations. Therefore, if an Operator thinks they
are in exceedance of the datum flight profile after six
months, he must contact Rolls-Royce. But he must continue to
monitor engine operation.
C. Definition of a Flight Cycle
(1) Usual flight
(a) A usual take-off through to landing which agrees with the datum
flight profile for the engine type is specified as one flight
cycle.
(2) Pilot training flights
(a) The initial take-off and the last landing is specified as one
flight cycle.
(b) Each touch-and-go or overshoot is specified as:
1
_
One fifth of a flight cycle for the LP compressor blade.
2
_
One fifth of a flight cycle for each disk.
3
_
One flight cycle for the compressor and turbine shafts that
follow:
- the LP compressor rotor shaft
- the LP turbine rotor shaft
- the IP rear shaft
- the IP turbine rotor shaft.
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4
_
One fifth of a flight cycle for each of the remaining
compressor and turbine shafts.
(c) Example:
One training flight that includes one overshoot and four
touch-and-goes is the equivalent of:
- two flight cycles for the LP compressor blade
- two flight cycles for each disk
- six flight cycles for each shaft specified in para.
1.C.(2)(b)3_
- two flight cycles for each of the remaining shafts.
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MISUSE OF MOLYBDENUM DISULPHIDE LUBRICANTS - DESCRIPTION AND OPERATION
______________________________________________________________________
1. _______
General
Molybdenum disulfide lubricants will decompose at temperatures higher than
300 deg.C (572 deg.F) and release sulfur. Sulfur can cause stress corrosion
and failure of the lubricated engine part.
Most of the bolt materials used in the higher temperature areas of the
engine can be damaged by the sulfur release. Thus you must only use
lubricants which contain molybdenum disulfide on parts where it is specified
in the maintenance manual.
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IDENTIFICATION, LUBRICATION AND FITTING OF FLEXIBLE SEALING RINGS
_________________________________________________________________
_____________________
TASK 70-02-01-910-801
Identification, Lubrication and Fitting of Flexible Seal Rings
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
A. Fixtures, Tools, Test and Support Equipment
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
correct pilot and sleeve assembling tool
B. Consumable Materials
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1011
Material No.
OMat 1069
Material No.
OMat 1071
Material No. 02-003
*
engine lubricating oil (Ref. 70-30-00)
*
assembly fluid (Ref. 70-30-00)
*
assembly oil (Ref. 70-30-00)
F
NSA 307110
TYPE 4
NO LONGER AVAILABLE (Ref. 20-31-00)
C. Referenced Information
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-02-01-991-001
Fig. 201
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3. __________
Job Set-up
Subtask 70-02-01-869-050
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-02-01-991-001)
Subtask 70-02-01-918-050
A. Identification of Flexible Seal Rings.
(1) Flexible seal rings are identified with the part number on the
envelope in which the rings are contained. Each envelope is
identified with the minimum data as follows:
(a) The description of the part.
(b) The quantity.
(c) The engine manufacturers part number.
(d) The cure date.
(2) The storage life of a seal ring is calculated from the cure date
which is written on the envelope.
(3) The seal ring material is identified with the color of the ring
material: or the color identification on the outer diameter of the
ring.
(4) A table of color codes in relation to material codes and materials is
included in this task.
Subtask 70-02-01-918-051
B. Lubricants used for flexible seal rings.
(1) The lubricant used on a flexible seal ring must be satisfactory for
the system in which it is installed. The recommended lubricants are:
(a) For seal rings in oil systems - use engine lubricating oil
(Material No. OMat 1011) or assembly fluid (Material No. OMat
1069).
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Seal Ring Identificaion
Figure 201/TASK 70-02-01-991-001
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(b) For seal rings in fuel systems - use engine lubricating oil
(Material No. OMat 1011) or assembly fluid (Material No. OMat
1069).
(c) For silicone rubber seals with the material code SE/DTA or WAF in
air systems - Use engine lubricating oil (Material No. OMat
1011).
(d) For silicone rubber seals with a material code other than SE/DTA
or WAF in air systems - Usually kept dry but you can use assembly
oil (Material No. OMat 1071) if you think it is necessary.
(e) For fluorocarbon seals in air systems - use engine lubricating
oil (Material No. OMat 1011) or assembly fluid (Material No. OMat
1069).
(f) For seal rings in magnetic chip detectors - use engine
lubricating oil (Material No. OMat 1011) or assembly fluid
(Material No. OMat 1069).
(g) For seal rings in hydraulic system - use HYDRAULIC FLUIDS
(Material No. 02-003).
(2) The recommended lubricant must be applied to the ring in small
quantities immediately before you install the unit or part. This
makes sure that the ring cannot become soaked with the lubricant and
thus become too large. If the ring does become soaked with lubricant
it can be damaged when you install the unit or part.
Subtask 70-02-01-918-052
C. Installation of flexible seal rings:
(1) Use new seal rings for assembly of units or parts.
(2) Make sure that the storage life and the condition of the seal ring
are satisfactory.
(3) Make sure that the grooves and the mating faces (to which the seal
rings are to be installed) are clean, smooth and not damaged.
(4) Make sure that installed seal rings are not twisted and are correctly
installed in the grooves.
(5) Do not install the seal rings to an engine part which is hot. This
can make the rings become larger and thus easy to damage.
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(6) Use the correct pilot and sleeve assembling tool when you install the
seal rings to a ferrule with two grooves. This will prevent damage to
the rings during their installation.
(7) Install the seal rings in their locations without a lubricant: This
does not include those made from SE/DTA or WAF materials which are
less flexible. The rings with the material code SE/DTA or WAF can be
lubricated with a small quantity of the recommended lubricant.
(8) Lubricate the seal rings immediately before you install the unit or
part. Use a small quantity of the recommended lubricant. Although it
is recommended that you apply slightly more lubricant rings made from
SE/DTA or WAF materials. This will make the parts sealed with these
less flexible rings much easier to install.
(9) Use a straight push to install the ferrules and tubes into their
mating connectors: This will prevent twisted or damaged seal rings.
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APPROVED ENGINE OILS - DESCRIPTION AND OPERATION
________________________________________________
1. _______
General
When you service
list of approved
When you service
applicable lists
the engine oil system, you must refer to SB 12-F139 for the
engine oils.
the IDG or pneumatic starter you must refer to the
of approved oils that follow.
2. __________________
System Description
A. List of Approved Engine Oils, refer to SB 12-F139.
(1) You must do the selection of ONE of the approved oils for engine
servicing. Then, use that oil for subsequent servicing.
(2) You must only mix the approved oils if it becomes operationally
necessary.
B. List of Approved IDG Lubricating Oils
NOTE : The oils in the list that follows are applicable for the IDG oil
____
system. When you service the engine oil system or the pneumatic
starter, you must refer to the applicable lists of approved oils.
(1) The list is as follows:
(a) Aero Shell Turbine Oil 390 (NOTE 2)
(b) Aero Shell/Royco Turbine Oil 500 (NOTE 3)
(c) Aero Shell/Royco Turbine Oil 555 (NOTE 1)
(d) Aero Shell/Royco Turbine Oil 560 (NOTE 1)
(e) Castrol 5000 (NOTE 3)
(f) BP Turbo Oil 2197 (formerly Exxon Turbo Oil 2197 (NOTE 3))
(g) BP Turbo Oil 2389 (formerly Exxon Turbo Oil 2389 (NOTE 3))
(h) BP Turbo Oil 25 (formerly Exxon Turbo Oil 25 (NOTE 3))
(i) BP Turbo Oil 2380 (formerly Exxon Turbo Oil 2380 (NOTE 3))
(j) Mobil Jet Oil II (NOTE 3)
(k) Mobil Jet Oil 254 (NOTE 3)
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(l) Mobil Jet Oil 291 (NOTE 3)
NOTE 1: You must not use this oil frequently. Write to Hamilton Sundstrand and
get written approval to use this oil. When you write to Hamilton
Sundstrand, you must include applications and number of units that will
be used.
NOTE 2: Nominal viscosity at 99 deg.C (210 deg.F) is 3 centistokes. This agrees
with the conditions of MIL-PRF-7808. It is approved for unit start-up
operation at -53.8 deg.C (-65 deg.F) minimum.
NOTE 3: Nominal viscosity at 99 deg.C (210 deg.F) is 5 centistokes. This
agrees with the conditions of MIL-PRF-23699. It is approved for unit
start-up operation at -40 deg.C (-40 deg.F).
(2) You must only make the selection of ONE of the above approved oils
for IDG servicing. You must then continue to use that oil for each
subsequent servicing.
necessary.
C. List of Approved Pneumatic Starter Lubricating Oils
NOTE : The oils in the list that follows are applicable for the pneumatic
____
starter oil system. When you service the engine oil system or the
IDG, you must refer to the applicable lists of approved oils.
(1) The list is as follows:
(a) Aeroshell Turbine Oil 500 (Royco Turbine Oil 500)
(b) Aeroshell Turbine Oil 555 (Royco Turbine Oil 555)
(c) Aeroshell Turbine Oil 560 (Royco Turbine Oil 560)
(d) BP Turbo oil 2380 (formerly Exxon Turbine Oil 2380)
(e) Mobil Jet Oil II
(f) Mobil Jet Oil 254
(g) Mobil Jet Oil 291
(2) Pneumatic Starters Post SB 80-D207: You can also use BP Turbo Oil
2197.
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(3) You must only make the selection of ONE of the above approved oils
for pneumatic starter servicing. You must then continue to use that
oil for each subsequent servicing.
necessary.
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ENGINE WELDING RESTRICTIONS - MAINTENANCE PRACTICES
___________________________________________________
TASK 70-12-00-300-802
Engine Welding Restrictions
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
Not Applicable
3. __________
Job Set-up
Subtask 70-12-00-860-051
A. Not applicable.
4. Procedure
_________
Subtask 70-12-00-310-051
A. Welding repair on engine
WARNING : THE AIRCRAFT AND ENGINE MANUFACTURERS RECOMMEND THAT YOU DO NOT
_______
WELD ENGINE COMPONENTS WHEN THE ENGINE IS INSTALLED ON THE
AIRFRAME.
ALL THE WELD REPAIRS GIVEN BY THE ENGINE MANUFACTURER ARE FOR
ENGINES OR COMPONENTS IN A WORKSHOP.
THERE IS A FIRE RISK IF YOU WELD ON AN INSTALLED ENGINE BECAUSE
OF THE FLAMMABLE LIQUIDS IN THIS AREA.
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REMOVAL / INSTALLATION OF RIGID TUBES - MAINTENANCE PRACTICES
_____________________________________________________________
TASK 70-12-01-000-802
Removal of Rigid Tubes and Flexible Hose Assemblies
1. __________________
Reason for the Job
This procedure gives the necessary steps for correct removal of rigid tube
and flexible hose assemblies. These steps are not specially related to the
tube material. Thus, the steps are applicable if the tube is made from
stainless steel, nickel based alloy, or titanium alloy.
It is important that you use this procedure for all rigid tubes and flexible
hose assemblies. This is to prevent:
- Damage caused by incorrect handling
- Damage caused by contact with adjacent tubes and/ or adjacent engine
surfaces.
NOTE : DAMAGE CAN OCCUR IF FLEXIBLE HOSES ARE TWISTED OR SUBJECT TO
____
EXCESSIVE BENDING. MAKE SURE FLEXIBLE HOSE ASSEMBLIES ARE
APPRORIATELY HELD WHEN LOOSENING OR TIGHTENING CONNECTORS TO PREVENT
THEM TWISTING.
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-01-991-003
Fig. 201
3. __________
Job Set-up
Subtask 70-12-01-917-053
A. Make sure that the pressure has been released from the applicable
system(s).
Subtask 70-12-01-680-051
B. Make sure that the fluid has been drained from the applicable system(s),
where possible.
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4. Procedure
_________
(Ref. Fig. 201/TASK 70-12-01-991-003)
Subtask 70-12-01-917-054
A. General
(1) When you remove a tube, make sure that you do not apply forces that
will permanently change its shape.
(2) Make sure that blanking caps are installed to the joint faces as soon
as possible. This is to prevent damage to the joint faces and to keep
the tube clear from contamination.
NOTE : It is equally important that the mating connectors on the
____
engine component are also given protection.
(3) Make sure that the blanking caps are of the correct type. They must
only be installed externally. Also, it must not be possible for the
caps to stay in position when the tube is installed. An
unsatisfactory cap can go into the tube. If this occurs, and it is
not seen before installation, it can cause a blockage.
(4) It is recommended that you use a type of cap that is red in color.
This will help you to identify the caps and thus make it easier to
make sure that they are removed during the related procedure. When
the tubes are not installed to the engine, give them satisfactory
protection from surfaces that can cause damage. Also, do not put them
in a position that could change their shape. This is very important
during their movement to a different location. If they are not moved
carefully, you can cause damage and/or change their shape.
(5) When the tubes are not installed to the engine, give them
satisfactory protection from surfaces that can cause damage. Also, do
not put them in a position that could change their shape. This is
very important during their movement to a different location. If they
are not moved carefully, you can cause damage and/or change their
shape.
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the Blanking Caps
Figure 201/TASK 70-12-01-991-003
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Subtask 70-12-01-020-052
B. Removal of tubes with bolted flanges
NOTE : It is not recommended that more than one tube is removed, at a
____
time, unless the related procedure tells you differently.
(1) Loosen the related clip assemblies.
(2) Cut, remove and discard the material that safeties the tube
connectors.
(3) Loosen the bolts at each end flange. If necessary, let the fluid
drain into an applicable container.
CAUTION : DAMAGE CAN OCCUR IF FLEXIBLE HOSES ARE TWISTED OR SUBJECT
_______
TO EXCESSIVE BENDING. MAKE SURE FLEXIBLE HOSE ASSEMBLIES
ARE APPRORIATELY HELD WHEN LOOSENING OR TIGHTENING
CONNECTORS TO PREVENT THEM TWISTING.
NOTE : If a tube has a connection at its center, loosen the center
____
connection first. When you do this, make sure that the tube
wall does not become distorted.
(4) Remove the bolts from the related clip positions. Keep the parts of
each clip assembly together for the installation Task.
CAUTION : YOU MUST IDENTIFY THE BOLTS WHEN YOU REMOVE THEM FROM EACH
_______
END FLANGE (IT IS IMPORTANT TO INSTALL THE BOLTS BACK TO
THE SAME END FLANGE). IF YOU DO NOT INSTALL THE CORRECT
BOLTS TO A CONNECTION, FUEL LEAKAGE CAN OCCUR.
(5) Remove the bolts from each end flange and carefully remove the tube
from the engine. Identify the bolts with their related tube end
flange and keep them together with the tube. Make sure that you do
not cause damage to the joint faces.
(6) If applicable, remove the seals from the positions specified in the
related procedure.
(7) Put the applicable blanking caps on to the joint faces.
NOTE : Do this step as soon as possible for maximum protection from
____
damage and contamination.
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Subtask 70-12-01-020-053
C. Removal of tubes with single nut conical sealing joints
NOTE : It is not recommended that more than one tube is removed, at a
____
time, unless the related procedure tells you differently.
(1) Loosen the related clip assemblies.
(2) Cut, remove and discard the material that safeties the tube
connectors.
CAUTION : YOU MUST USE TWO WRENCHES WHEN YOU LOOSEN/TIGHTEN THE TUBE
_______
CONNECTOR(S). USE ONE WRENCH TO HOLD THE MATING TUBE/
ADAPTER SO THAT IT CANNOT TURN. THEN USE THE OTHER WRENCH
TO TURN THE TUBE CONNECTOR. IF YOU DO NOT DO THIS, THE TUBE
CAN BE DAMAGED.
(3) Loosen the tube connectors at each end of the tube. If necessary, let
the fluid drain into an applicable container.
NOTE : If a tube has a connection at its center, loosen the center
____
wall does not become distorted.
(4) Remove the bolts from the related clip positions. Keep the parts of
each clip assembly together for the installation Task.
(5) Disconnect the tube connectors and carefully remove the tube. Make
sure that you do not cause damage to the joint faces.
(6) If applicable, remove the related seal(s) from the positions
specified in the related procedure.
(7) Put the applicable blanking caps on to the tube connectors
NOTE : Do this step as soon as possible for maximum protection from
____
damage and contamination.
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5. Close-up
________
Subtask 70-12-01-210-052
A. Inspection after tube removal
CAUTION : YOU MUST NOT USE HAND TOOLS TO REPAIR A SCRATCH. THIS WILL NOT
_______
REPAIR THE PART, BUT WILL CAUSE LEAKAGE TO OCCUR.
(1) Visually examine the joint faces, the external surfaces and the
internal surfaces (where possible) of the tube(s). Make sure that
there is no damage.
(a) If nicks, scores, corrosion, dents or other damage is found,
refer to the related inspection/check procedure for the
applicable damage limits.
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TASK 70-12-01-400-802
Installation of Rigid Tubes and Flexible Hose Assemblies
1. __________________
Reason for the Job
This procedure gives the necessary steps for correct installation of rigid
tube and flexible hose assemblies. These steps are not specially related to
the tube material. Thus, the steps are applicable if the tube is made from
stainless steel, nickel based alloy, or titanium alloy.
It is important that you use this procedure for all rigid tubes and flexible
hose assemblies. This is to prevent:
- Damage caused by incorrect handling
- Damage caused by contact with adjacent tubes and/or adjacent engine
surfaces
- Unwanted stress caused by incorrectly aligned tube end fittings
- Unwanted stress caused by the force applied to try to attach clips to an
incorrectly aligned tube.
NOTE : DAMAGE CAN OCCUR IF FLEXIBLE HOSES ARE TWISTED OR SUBJECT TO
____
APPRORIATELY HELD WHEN LOOSENING OR TIGHTENING CONNECTORS TO PREVENT
THEM TWISTING.
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-51-00-910-802
70-12-01-991-003
70-12-01-991-005
Fig. 201
Fig. 202
3. __________
Job Set-up
Subtask 70-12-01-917-055
A. Not applicable.
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4. Procedure
_________
(Ref. Fig. 201/TASK 70-12-01-991-003, 202/TASK 70-12-01-991-005)
Subtask 70-12-01-917-056
A. General
(1) When the tubes are not installed to the engine, give them
satisfactory protection from surfaces that can cause damage. Also, do
not put them in a position that could change their shape. This is
very important during their movement to a different location. If they
are not moved carefully, you can cause damage and/or change their
shape.
(2) When you install a tube, make sure that you do not apply forces that
will permanently change its shape.
(3) If you install a replacement tube, make sure that it agrees fully
with the build standard of the engine.
(4) Make sure that blanking caps are installed to the joint faces until
immediately before the tube is installed. This is to prevent damage
to the joint faces and to keep the tube clear from contamination.
NOTE : It is equally important that the mating connectors on the
____
engine component are also given protection.
(5) Make sure that the blanking caps are of the correct type. They must
only be installed externally. Also, it must not be possible for the
caps to stay in position when the tube is installed. An
unsatisfactory cap can go into the tube. If this occurs, and it is
not seen before installation, it can cause a blockage.
(6) It is recommended that you use a type of cap that is red in color.
This will help you to identify the caps and thus make it easier to
make sure that they are removed during the related procedure.
(7) If clip assemblies hold a tube, it is important that they are
installed correctly. The correct sequence of steps is as follows:
- The tube end connectors are loosely attached to their mating
connectors on the engine
- The clip assemblies are then loosely assembled at their specified
locations
- The tube end connections are then fully torqued
- The clip assemblies are then fully torqued.
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(8) If it will give you better access to install a tube, you can loosen
the parts that attach the component. But this is only permitted if:
- There are no other tubes that are tightly attached to the component
- The installed tube(s) will not be pulled out of position and become
stressed when the parts that attach the component are fully
tightened
- Bolts that are part of the component are not loosened/removed to
give better access to install the tube.
(9) If the shape of the tube is incorrect, you must not apply force
(while it is installed or removed from the engine) to make it the
correct shape. A tube that is the incorrect shape must be rejected.
Subtask 70-12-01-210-053
B. Inspection before tube installation
CAUTION : YOU MUST NOT USE HAND TOOLS TO REPAIR A SCRATCH. THIS WILL NOT
_______
REPAIR THE PART, BUT WILL CAUSE LEAKAGE TO OCCUR.
(1) Visually examine the joint faces, the external surfaces and the
internal surfaces (where possible) of the tube(s). Make sure that
there is no damage, dirt, grease, grit or other unwanted material.
(a) If nicks, scores, corrosion, dents or other damage is found,
refer to the related inspection/check procedure for the
applicable damage limits.
Subtask 70-12-01-420-052
C. Installation of tubes with bolted flanges
CAUTION : YOU MUST NOT APPLY FORCE TO THE TUBE TO TRY TO ALIGN THE TUBE
_______
ENDS. IF YOU APPLY FORCE, YOU CAN CAUSE TOO MUCH STRESS IN THE
TUBE. THIS CAN CAUSE ITS FAILURE.
CAUTION : YOU MUST NOT LET THE CLIP ASSEMBLIES PULL THE TUBE INTO
_______
POSITION AS THEY ARE TIGHTENED. THIS CAN CAUSE TOO MUCH STRESS
IN THE TUBE AND CAN CAUSE ITS FAILURE.
CAUTION : DAMAGE CAN OCCUR IF FLEXIBLE HOSES ARE TWISTED OR SUBJECT TO
_______
APPRORIATELY HELD WHEN LOOSENING OR TIGHTENING CONNECTORS TO
PREVENT THEM TWISTING.
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Installation of Rigid Tubes
Figure 202/TASK 70-12-01-991-005- 12 (SHEET 1)
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Installation of Rigid Tubes
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(1) applicable seals as specified in the related procedure. Make sure
that you use the correct lubricant.
NOTE : Make sure that you do this step immediately before the tube is
____
installed. This is to make sure that the blanking caps stay in
position on the tube and thus give the longest possible
protection from contamination.
(2) Put the tube assembly into approximately the correct location on the
engine. Make sure that no damage occurs to the mating surfaces.
NOTE : It is not recommended that you put more than one tube into
____
position, at a time, unless the related procedure tells you
differently.
(3) Installation of bolts to the tube end flange
CAUTION : YOU MUST INSTALL THE CORRECT BOLTS TO THE TUBE END FLANGE.
_______
USE THE BOLTS THAT YOU IDENTIFIED DURING THE TUBE REMOVAL
PROCEDURE. IF YOU DO NOT INSTALL THE CORRECT BOLTS TO A
CONNECTION, FUEL LEAKAGE CAN OCCUR.
(a) Align one of the end flanges with its mating connector and
loosely install the related bolts. Make sure that the related
seal stays in the correct position on the tube. Then tighten the
bolts sufficiently to hold the seal.
CAUTION : DAMAGE CAN
_______
SUBJECT TO
ASSEMBLIES
TIGHTENING
OCCUR IF FLEXIBLE HOSES ARE TWISTED OR
EXCESSIVE BENDING. MAKE SURE FLEXIBLE HOSE
ARE APPRORIATELY HELD WHEN LOOSENING OR
CONNECTORS TO PREVENT THEM TWISTING.
CAUTION : MAKE SURE FLEXIBLE HOSES ARE IN A RELAXED STATE POST
_______
INSTALLATION.
NOTE : If a bolt goes into a self-locking device, it is important
____
that you do a check of the minimum locking torque
(Ref. TASK 70-51-00-910-802).
(4) Carefully align and engage the other end flange with its mating
connector. Make sure that:
- The related seal stays in the correct position on the tube
- The joint mating faces touch each other fully
- The bolt holes are satisfactorily aligned
- The tube does not touch the adjacent parts/surfaces.
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(a) If applicable, find the cause of the unsatisfactory condition and
repair/ replace as necessary.
(5) Loosely install the related bolts.
CAUTION : YOU MUST INSTALL THE CORRECT BOLTS TO THE TUBE END FLANGE.
_______
USE THE BOLTS THAT YOU IDENTIFIED DURING THE TUBE REMOVAL
PROCEDURE. IF YOU DO NOT INSTALL THE CORRECT BOLTS TO A
CONNECTION, FUEL LEAKAGE CAN OCCUR.
____
that you do a check of the minimum locking torque (Ref. TASK
70-51-00-910-802).
(a) If the bolts cannot be installed easily (or they cause the tube
to become twisted), find the cause and repair/replace as
necessary.
(6) Loosely assemble the related clip assemblies at the positions
identified in the related procedure.
(7) TORQUE the bolts, at each end flange, to the torque load value
specified in the related procedure. Do this equally, in increments,
until the bolts are fully torqued.
NOTE : If a tube has a connection at its center, tighten the center
____
wall does not become distorted. Then tighten the two end
flange connections.
(8) TORQUE the bolt/nut, at each of the related clip positions, to the
torque load value specified in the related procedure.
____
70-51-00-910-802).
NOTE : It is important that the bolts/nuts are tightened equally, in
____
increments, until the bolts are fully torqued. This is to keep
the stresses in the tube to a minimum. You must be specially
careful to keep connections satisfactorily aligned where they
are not held near to the connection.
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(9) At each related clip position, do the clearance check that follows:
(a) Make sure that there is a minimum clearance of 1.3 mm (0.0511
in.) between the tube and the adjacent tubes/surfaces for a
distance of 25 mm (0.9842 in.) from the clip assembly center.
(b) If the clearance is not sufficient, find the cause and
repair/replace as necessary.
Subtask 70-12-01-420-053
D. Installation of tubes with single nut conical sealing joints
CAUTION : YOU MUST NOT APPLY FORCE TO THE TUBE TO TRY TO ALIGN THE TUBE
_______
ENDS. IF YOU APPLY FORCE, YOU CAN CAUSE TOO MUCH STRESS IN THE
TUBE. THIS CAN CAUSE ITS FAILURE.
CAUTION : YOU MUST USE TWO WRENCHES WHEN YOU LOOSEN/TIGHTEN THE TUBE
_______
CONNECTOR(S). USE ONE WRENCH TO HOLD THE MATING TUBE/ ADAPTER
SO THAT IT CANNOT TURN. THEN USE THE OTHER WRENCH TO TURN THE
TUBE CONNECTOR. IF YOU DO NOT DO THIS, THE TUBE CAN BE DAMAGED.
CAUTION : YOU MUST NOT LET THE CLIP ASSEMBLIES PULL THE TUBE INTO
_______
POSITION AS THEY ARE TIGHTENED. THIS CAN CAUSE TOO MUCH STRESS
IN THE TUBE AND CAN CAUSE ITS FAILURE.
(1) If applicable, install the related seal(s) as specified in the
related procedure. Make sure that you use the correct lubricant.
NOTE : Make sure that you do this step immediately before the tube is
____
installed. This is to make sure that the blanking caps stay in
position on the tube and thus give the longest possible
protection from contamination.
(2) Put the tube assembly into approximately the correct location on the
engine. Make sure that no damage occurs to the connector threads or
joint faces.
NOTE : It is not recommended that you put more than one tube into
____
position, at a time, unless the related procedure tells you
differently.
(3) Engage one of the end ferrules in its conical mating connector. If
applicable, make sure that the related seal is in the correct
position. Then carefully engage the tube connector on to its mating
threads and tighten it with your fingers. Make sure that the tube is
at right angles to the end face of the tube connector.
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(4) Carefully align and engage the other end ferrule in its conical
mating connector. If applicable, make sure that the related seal is
in the correct position. Then carefully engage the tube connector on
to its mating threads and tighten it with your fingers. Make sure
that the tube is at right angles to the end face of the tube
connector. Also, make sure that the tube does not touch the adjacent
part/surfaces.
(a) If applicable, find the cause of the unsatisfactory condition and
repair/ replace as necessary.
(5) Loosely assemble the related clip assemblies at the positions
identified in the related procedure.
(6) TORQUE the tube connectors, at each end of the tube, to the torque
load value specified in the related procedure. Make sure that you
obey the instructions for tube connections (Union nuts, tube and hose
connections) to bed-in the connections correctly (Ref. TASK 70-51-00910-802).
NOTE : If a tube has a connection at its center, tighten the center
____
wall does not become distorted. Then tighten the two end
flange connections.
(7) TORQUE the bolt/nut, at each of the related clip positions, to the
torque load value specified in the related procedure.
____
70-51-00-910-802).
NOTE : It is important that the bolts/nuts are tightened equally, in
____
increments, until the bolts are fully torqued. This is to keep
the stresses in the tube to a minimum. You must be specially
careful to keep connections satisfactorily aligned where they
are not held near to the connection.
(8) At each related clip position, do the clearance check that follows:
(a) Make sure that there is a minimum clearance of 1.3 mm (0.0511
in.) between the tube and the adjacent tubes/surfaces for a
distance of 25 mm (0.9842 in.) from the clip assembly center.
(b) If the clearance is not sufficient, find the cause and
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(9) Safety the tube connectors with the material specified in the related
procedure.
5. Close-up
________
Subtask 70-12-01-917-057
A. Do a check of the installed tube(s) for satisfactory clearance
(1) Make sure that there is a minimum clearance of 5 mm (0.1968 in.)
between the tube assemblies and the adjacent tubes/surfaces. Make
sure that you have also done the related minimum clearance check at
each clip position as specified in paras 4.C.(9) and 4.D.(8).
(a) If the clearance is not sufficient, find the cause and
Subtask 70-12-01-790-051
B. Do a leak check of the applicable system(s) as specified in the related
procedure.
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REMOVAL/INSTALLATION OF VEE BAND COUPLING CLAMPS - MAINTENANCE PRACTICES
________________________________________________________________________
TASK 70-12-02-000-801
Removal of Vee-Band Coupling-Clamps
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-02-991-001
70-12-02-991-002
Fig. 201
Fig. 202
3. __________
Job Set-up
Subtask 70-12-02-869-050
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-12-02-991-001, 202/TASK 70-12-02-991-002)
Subtask 70-12-02-020-050
A. Removal of Vee-Band Coupling-Clamps.
(1) Remove the Pressure Science coupling clamp.
(a) Loosen the nut (3) until the top of the nut is level with the top
of the eye-bolt (6).
(b) Move the fail-safe link (5) along the bolt (6) in the direction
of arrow X. When the saddle washer (4) is clear of the top
half-clamp (1) lug, pull the link (5) (in the direction of arrow
Y) to disengage the link from the pins (2).
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Pressure Science Coupling Clamp
Figure 201/TASK 70-12-02-991-001
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Avica/Porter Coupling Clamps
Figure 202/TASK 70-12-02-991-002
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(c) Move the top half-clamp (1) and bottom half-clamp (7) apart to
release the clamp from the Vee flanges.
NOTE : If the clamp is tight on the Vee flanges you can lightly
____
hit the half-clamp lug ends with a soft faced mallet to
help removal.
(2) Remove the Avica coupling clamp.
(a) Loosen the nuts (3) equally until the top of each nut is level
with the top of its related bolt (6).
(b) Look at the top half-clamp (1) ends and find the lug with the
slot.
(c) Move the fail-safe link (5), which is adjacent to the lug with
the slot, in the direction of arrow X. When the saddle washer (4)
is clear of the lug, pull the link (5) (in the direction of arrow
Y) to disengage the link from the pins (2).
(3) Move the top half-clamp (1) and bottom half-clamp (7) apart to
release the clamp from the Vee flanges.
NOTE : If the clamp is tight on the Vee flanges you can lightly hit
____
the half-clamp lug ends with a soft faced mallet to help
removal.
(4) Remove the porter coupling clamp.
(a) Remove the nut (1) from the T-bolt (2).
(b) Release the fail-safe device: Push the strap end tongue (5)
through the strap end (4) square hole.
(c) Move the trunnion (3) off the T-bolt (2) to open and release the
clamp from the Vee flanges.
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TASK 70-12-02-400-801
Installation of Vee-Band Coupling-Clamps
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
lint-free cloth
non-metallic scraper
small clean brush
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
Material No.
OMat 1011
Material No.
OMat 102
Material No.
OMat 102A
Material No.
OMat 4-62
Material No.
OMat 7-124
Material No.
OMat 7-84
*
*
white spirit (Ref. 70-30-00)
*
solvent (Ref. 70-30-00)
*
thixotropic dry film lubricant (Ref. 70-30-00)
*
potassium silicate solution (Ref. 70-30-00)
*
yellow marking paint (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
R
70-20-01-100-802
70-51-00-910-802
70-12-02-991-001
70-12-02-991-002
70-12-02-991-003
70-12-02-991-004
Non-Aqueous Liquid Degreasing - Maintenance Process
101
Fig. 201
Fig. 202
Fig. 203
Fig. 204
3. __________
Job Set-up
Subtask 70-12-02-869-051
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-12-02-991-001, 202/TASK 70-12-02-991-002, 203/TASK
70-12-02-991-003, 204/TASK 70-12-02-991-004)
Subtask 70-12-02-210-050
A. Do a visual inspection of the coupling clamp, the mating Vee flanges and
the E-seals:
WARNING : YOU MUST NOT GET THE CLEANING FLUID ON YOUR SKIN, IN YOUR MOUTH
_______
OR IN YOUR EYES. YOU MUST USE APPLICABLE GLOVES, EYE PROTECTION
AND A FACE MASK. USE THE FLUID IN AN AREA THAT HAS A GOOD FLOW
OF AIR. DO NOT BREATHE THE FUMES FROM THE FLUID. IF YOU GET THE
CLEANING FLUID ON YOUR SKIN, IN YOUR MOUTH OR YOUR EYES, FLUSH
IT AWAY WITH WATER. GET MEDICAL AID IF YOU GET FLUID IN YOUR
MOUTH OR EYES. KEEP CLEANING FLUID AWAY FROM SPARKS, FLAME AND
HEAT. CLEANING FLUID IS A POISONOUS FLAMMABLE SOLVENT WHICH CAN
CAUSE INJURY AND/OR DAMAGE.
(1) Clean the coupling clamp and the Vee flanges: This must be done with
a clean lint-free cloth which has been made moist with white spirit
(Material No. OMat 102) or solvent (Material No. OMat 102A).
(2) Dry the parts with a clean dry lint-free cloth.
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Painted Marks on Avica Clamps
Figure 203/TASK 70-12-02-991-003
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Duct Joint with E-Type Seal
Figure 204/TASK 70-12-02-991-004
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(3) Examine the clamp and the Vee flanges for corrosion, distortion,
cracks, scores and burrs.
(a) If damage is found, replace the parts as necessary.
CAUTION : YOU MUST USE THE SCRAPER CAREFULLY TO PREVENT DAMAGE TO
_______
THE SURFACES OF THE FLANGES.
(4) If E-seals were installed, do the steps that follow:
(a) Examine the Vee flanges for silver plating particles.
1
_
If particles are found, remove them with the non-metallic
scraper.
(b) Examine the silver plating on the E-seal.
1
_
If more than 30 percent of the plating has gone, reject the
seal.
(5) Examine the dry film lubricant on the internal Vee faces of the clamp
(where applicable) for wear or damage.
(a) If the lubricant is worn or damaged, apply with the brush a thin
layer of thixotropic dry film lubricant (Material No. OMat 4-62).
(6) On clamps which are not dry film lubricated: Apply a thin layer of
clean engine lubricating oil (Material No. OMat 1011) to the internal
Vee faces of the clamp.
Subtask 70-12-02-420-050
B. If applicable, install the E-seal:
(1) Install the E-seal to the male Vee flange: Make sure that the outer
leg of the seal comes out more than the end face of the male Vee
flange.
(a) If the outer leg does not come out more than the end face of the
flange, reject the seal.
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Subtask 70-12-02-420-051
C. Installation of Vee-Band Coupling-Clamps.
(1) Install the Pressure Science coupling clamp.
(a) Lubricate the threads of the eye-bolt (6) with clean engine
lubricating oil (Material No. OMat 1011).
(b) Do a check of the in-built (locking) torque of the self-locking
nut (3) on the coupling clamp (Ref. TASK 70-51-00-910-802).
- if the torque is not as specified, replace the nut.
(c) Make sure the mating Vee flanges are correctly aligned, then
loosely install the clamp on the flanges: Use light hand pressure
to close the top half-clamp (1) and bottom half-clamp (7) around
the Vee flanges.
(d) Extend the fail-safe link (5) until it touches the bottom of the
nut (3) (with the top of the nut level with the top of the
eye-bolt): Then push the link in the opposite direction to arrow
Y and engage the pins (2) in the link side slots.
(e) Put the clamp into the best position for access to the nut (3):
Make sure the clamp will not touch adjacent parts or structures
as it is tightened.
(f) Tighten the nut (3) in small increments to approximately 70
percent of the torque load specified in the applicable task.
(g) Ligthly hit with a soft-faced mallet around the outer surface of
the clamp to equally apply the tension.
(h) Tighten the nut (3) in small increments to the full torque load
value specified in the applicable task.
(2) Install the Avica coupling clamp.
(a) Lubricate the threads of the bolt (6) with clean engine
lubricating oil (Material No. OMat 1011).
nuts (3) on the coupling clamp (Ref. TASK 70-51-00-910-802).
1
_
If the torque is not as specified, replace the nut.
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loosely install the clamp on the flanges: Use light hand pressure
to close the top half-clamp (1) and bottom half-clamp (7) around
the Vee flanges.
(d) Extend the fail-safe link (5) until it touches the bottom of the
nut (3) (with the top of the nut level with the top of the bolt):
Then push the link in the opposite direction to arrow Y and
engage the pins (2) in the link side slots.
(e) Put the clamp into the best position for access to the nuts (3):
when it is tightened.
(f) Tighten the nuts (3) equally in small increments to approximately
70 percent of the torque load value specified in the applicable
task.
(g) Lightly hit with a soft-faced mallet around the outer surface of
(h) Tighten the nuts (3) equally in small increments to the full
torque load value specified in the applicable task.
(i) Paint a mark linearly across each nut (3) and fail-safe link (5)
to give a visual indication that the nuts are correctly torqued.
WARNING : YOU MUST NOT GET THE CLEANING FLUID ON YOUR SKIN, IN
_______
YOUR MOUTH OR IN YOUR EYES. YOU MUST USE APPLICABLE
GLOVES, EYE PROTECTION AND A FACE MASK. USE THE FLUID
IN AN AREA THAT HAS A GOOD FLOW OF AIR. DO NOT BREATHE
THE FUMES FROM THE FLUID. IF YOU GET THE CLEANING FLUID
ON YOUR SKIN, IN YOUR MOUTH OR YOUR EYES, FLUSH IT AWAY
WITH WATER. GET MEDICAL AID IF YOU GET FLUID IN YOUR
MOUTH OR EYES. KEEP CLEANING FLUID AWAY FROM SPARKS,
FLAME AND HEAT. CLEANING FLUID IS A POISONOUS FLAMMABLE
SOLVENT WHICH CAN CAUSE INJURY AND/OR DAMAGE.
1
_
Remove the grease from the areas of the nuts (3) and links (5)
which are to be painted: (Ref. TASK 70-20-01-100-802).
R
2
_
Clean the areas again: This must be done with a clean lintfree cloth which has been made moist with potassium silicate
solution (Material No. OMat 7-124).
R
3
_
Let the surfaces air dry.
R
R
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R
4
_
Apply with a small clean brush the yellow marking paint
(Material No. OMat 7-84) to the areas given in
(Ref. Fig. 203/TASK 70-12-02-991-003)
(3) Install the Porter coupling clamp.
(a) Lubricate the threads of the T-bolt (2) with engine lubricating
oil (Material No. OMat 1011).
nut (1) on the coupling clamp (Ref. TASK 70-51-00-910-802).
1
_
If the torque is not as specified, replace the nut.
(with the nut (1) removed) loosely install the clamp on the
flanges.
(d) Push the T-bolt (2) through the trunnion (3) and loosely install
the nut (1).
(e) Put the clamp into the best position for access to the nut (1):
when it is tightened.
(f) Make sure the strap end tongue (5) is correctly aligned with the
square hole in the opposite strap end (4).
(g) Tighten the nut (1) in small increments to approximately 70
percent of the torque load value specified in the applicable
task.
(h) Lightly hit with a soft-faced mallet around the outer surface of
CAUTION : YOU MUST NOT APPLY MORE THAN THE SPECIFIED TORQUE LOAD
_______
VALUE TO TRY AND ENGAGE THE STRAP END TONGUE. IF YOU
APPLY A HIGHER TORQUE LOAD THE CLAMP WILL BE TOO
STRESSED WHICH WILL CAUSE CLAMP FAILURE.
(i) Tighten the nut (1) in small increments to the full torque load
value specified in the applicable task: Make sure that the tongue
(5) fully engages in the strap end (4) square hole before the
full torque load is applied.
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1
_
If the tongue (5) does not fully engage before the full torque
load is applied, remove the clamp: Then examine the parts to
find the cause and repair or replace as necessary.
(j) Loosen the nut (1) approximately two turns: Make sure the tongue
(5) stays fully engaged on the strap end (4) square hole.
(k) Tighten the nut (1) to the full torque load value specified in
the applicable task: You must not change the position of the
clamp when you tighten the nut.
(l) Do steps (10) and (11) one more time.
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LOCKING TECHNIQUES FOR THREADED PARTS - MAINTENANCE PRACTICES
_____________________________________________________________
TASK 70-12-04-910-801
Locking Techniques - Double - Lock Single - Hole Keywasher
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-04-991-001
Fig. 201
3. __________
Job Set-up
Subtask 70-12-04-869-050
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-12-04-991-001)
Subtask 70-12-04-910-050
A. Installation of the Double-Lock Single-Hole Keywasher.
(1) The keywasher is assembled on the threaded component with the key
engaged in the location hole or slot (Ref. View A).
(2) The fishtail locking keys are set to an angular position when the
keywasher is made. This preformed angle (Ref View B) must not be
changed until after the fastener has been fully tightened. If the
locking keys are bent before the fastener is tightened, the keywasher
will become irregular in shape. When the fastener is then tightened,
the torque applied will possibly not be sufficient to make the
keywasher flat again. And fatigue damage to the fastener will occur.
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Installation of Double-Lock Single-Hole Keywashers
Figure 201/TASK 70-12-04-991-001
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(3) After the fastener has been tightened, the locking keys are bent so
they are against the fastener (Ref. View C). You must be careful not
to make scores in the component during this operation.
(4) After the locking keys have been bent into position, they must be
examined for precision. Their condition must agree with the dimension
specified in View A.
(5) A used keywasher must be discarded after removal. A new keywasher
must always be used for assembly.
(6) Power wrenches must be used on fasteners where keywashers are used,
as damage can be caused.
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TASK 70-12-04-910-802
Locking Techniques - Ring Nut and Cupwasher
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-04-991-002
Fig. 202
3. __________
Job Set-up
Subtask 70-12-04-869-051
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 202/TASK 70-12-04-991-002)
Subtask 70-12-04-910-051
A. Installation of the Ring Nut and Cupwasher.
(1) The cupwasher is assembled with the ring nut. The ring nut has a
number of locking scallops in its outer edge.
(2) The cupwasher is put on the shaft so that the rim is away from the
component. And with the cupwasher keys engage in the slots in the
shaft. The keys make sure that the cupwasher cannot turn.
(3) After the ring nut has been tightened, the rim of the cupwasher is
peened into two of the locking scallops. This must be done with a
spherical nose tool. The locking scallops that are used must be
opposite each other.
(4) The cupwasher must not be peened into the slots used for spannering
the ring nut.
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Installation of Ring Nut and Cupwasher
Figure 202/TASK 70-12-04-991-002
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TASK 70-12-04-910-803
Locking Techniques - Split Cotter Pin
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-51-00-910-802
70-12-04-991-003
Fig. 203
3. __________
Job Set-up
Subtask 70-12-04-869-052
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 203/TASK 70-12-04-991-003)
Subtask 70-12-04-910-052
A. Installation of the Split Cotter Pin
(1) When a split cotter pin is to be installed, the nut must be tightened
as given in (Ref. TASK 70-51-00-910-802).
(2) The cotter pin is assembled to the bolt and nut with the pin head
engaged in the nut slot. The prongs are then bent into the correct
position (Ref. View A).
(3) If the nut is installed on a component which turns, the cotter pin
must be assembled in the specified position (Ref. View B).
(4) A used cotter pin must be discarded after removal. A new cotter pin
must always be used for assembly.
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Installation of Split Cotter Pins
Figure 203/TASK 70-12-04-991-003
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TASK 70-12-04-910-804
Locking Techniques - Wire locking
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-04-991-004
70-12-04-991-005
Fig. 204
Fig. 205
3. __________
Job Set-up
Subtask 70-12-04-869-053
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 204/TASK 70-12-04-991-004, 205/TASK 70-12-04-991-005)
Subtask 70-12-04-910-053
A. Installation of Lockwire
(1) Safety cable is to be used as an alternative to lockwire when this
specification is referred to in the procedure.
(2) The maximum lockwire span between tension points is 3 in. (76.1998
mm) unless specified in the applicable task.
(3) The maximum number of items that can be safetied together (with
double-twist wire) are those that can be locked with a 12 in.
(304.7994 mm) length of wire.
(4) The maximum number of items that can be safetied together (with
single wire) are those that can be locked with a 24 in. (0.6095 m)
length of wire.
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Installation of Lockwire
Figure 204/TASK 70-12-04-991-004
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Procedure to Wind Lockwire Around the Component
Figure 205/TASK 70-12-04-991-005
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(5) The usual procedure to install lockwire is to use a length of wire
which is bent (into equal lengths) and then twisted together. Each
twist is made when the wires are twisted through an arc of 180 deg
(180.0000 deg) (which is equivalent to half of one full turn). The
number of twists that must occur in each 1 in. (25.3999 mm) of wire
is related to the diameter of the wire. Use the wire diameters that
follow as an aid to the number of turns necessary for the different
diameter wires:
(a) If 0.02 in. (0.5079 mm) diameter wire is twisted correctly, there
will be 10 to 13 twists in each 1 in. (25.3999 mm) of wire.
(b) If 0.031 in. (0.7873 mm) diameter wire is twisted correctly,
there will be 6 to 12 twists in each 1 in. (25.3999 mm) of wire.
(6) Always be careful when you twist the lockwire to make sure the wire
is in tension: But not stressed too much. Light damage caused by the
approved type of lockwire pliers can be accepted. The surfaces of
approved lockwire pliers which hold the wire must have rounded edges
to prevent too much damage to the wire.
(7) The lockwire must be installed so that it cannot become chafed or
damaged by vibration.
(8) Where a tube adaptor is used, the tube connector must be safetied to
the component and not to the adaptor (Ref. View J).
(9) Used lockwire must be discarded after removal. New lockwire must
always be used for assembly.
(10) Where the lockwire is wound around the component to the locked.
(11) When you safety items with lockwire, use the procedure that follows:
(a) Do a check of the items to be safetied to make sure they are
correctly torqued.
(b) Put the lockwire through the hole in the first item, then bend
the wire around the head of that item. For clockwise threads the
lockwire must be installed so that it will pull the item in a
clockwise direction.
For counterclockwise threads, it must pull the item in a
counterclockwise direction. The wire around the head must also be
below the strand which comes out of the wire locking hole: This
helps to keep the wire around the head in position when the wires
are twisted together.
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(c) Apply tension to the two strands of wire and
twist: Make sure the loop of wire around the
the head and is not loose. Continue to twist
until the twisted length is near to the hole
make the first
head stays around
the strands of wire
in the second item.
(d) Put the highest of the two strands (in the last twist) through
the hole in the second item: Then bend the lowest strand around
the head of that item. If there are more than two items to be
safetied, do step (3) again.
(e) Make sure each length of twisted wire between items is twisted to
not less than 0.125 in. (3.1749 mm) from the lockwire holes.
(f) When the last item is to be safetied: Put the highest of the two
strands (in the last twist) through the hole in that item. Then
bend the lowest strand around the head, apply tension to the two
strands and make one twist. Continue to twist the strands of wire
to make an end-piece that has a minimum of six twists.
(g) Cut and remove the unwanted lockwire. Always discard the unwanted
lockwire so that it cannot cause damage.
(h) Bend the end-piece to make sure it cannot become caught: Make
sure the loop of wire around the head stays around the head and
does not become loose.
NOTE : Short end-pieces are necessary to prevent fatigue failures
____
because of vibration.
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TASK 70-12-04-910-806
Locking Techniques - Safety Cable
CAUTION : YOU MUST ONLY USE THE SAFETY CABLE
_______
SPECIFIED IN THIS PROCEDURE. THESE
APPROVED FOR CABLE INSTALLATION ON
DIFFERENT TOOLS THERE IS A RISK OF
PARTS CAN BE RELEASED.
INSTALLATION TOOLS WHICH ARE
ARE THE ONLY TOOLS WHICH ARE
ROLLS-ROYCE ENGINES. IF YOU USE
CABLE FAILURE, AND THE RELATED
1. __________________
Reason for the Job
Safety cable is to be used as an alternative to lockwire when this
specification is referred to in the procedure. This includes those
procedures where lockwire is shown on the illustrations. Lockwire must only
be used if it is not possible to get access to install the safety cable.
The safety cable must be 18-8 stainless steel AMS5689 with a diameter of
0.032 in. (0,89 mm) or 0.02 in. (0,58 mm). The 0.02 in. (0,58 mm) diameter
cable must only be used where specified for parts with small safety holes.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
No specific
No specific
No specific
No specific
No specific
No specific
M203 installation tool (3in. tool nose) 0.020in.
(0,58mm) diameter cable
SCT-TB1 test block
SCT203 installation tool (3in. tool nose) 0.020in.
SCT323 installation tool (3in. tool nose) 0.032in.
Torque Wrench : range 0 to 150 lbf.in (0 to 2 m.daN)
TB-101 test block
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
Omat 2-142
Material No.
Omat 2-143
*
safety cable 0.032in. (0,89mm) diameter
(Ref. 70-30-00)
*
safety cable 0.02in. (0,58mm) diameter
(Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-04-991-004
70-12-04-991-005
70-12-04-991-007
Fig. 204
Fig. 205
Fig. 206
3. __________
Job Set-up
Subtask 70-12-04-911-050
A. If necessary, do the calibration of the installation tool as follows:
NOTE : You must do the calibration of the safety cable installation tools
____
at regular intervals. The local engineering authority must make
the decision as to how frequently the calibration must be done.
This decision must be directly related to how frequently the tools
are used.
NOTE : The maximum time interval between each calibration must be no
____
longer than 3 months. Accurate records must be kept for each tool
to show when the last calibration was done.
(1) The crimp check
(a) Use the installation tool identified for calibration and install
the applicable safety cable 0.032in. (0,89mm) diameter (Material
No. Omat 2-142) or safety cable 0.02in. (0,58mm) diameter
(Material No. Omat 2-143) to the test block. Use the applicable
SCT-TB1 test block or TB-101 test block.
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(b) Install a calibrated Torque Wrench : range 0 to 150 lbf.in (0 to2
m.daN) to the test block.
(c) Slowly turn the torque wrench in a counterclockwise direction to
apply tension to the cable. Stop when the load shown on the
torque wrench is at the applicable value:
Cable diameter
Minimum pull-off load
0.032 in. (0,89 mm)
70 lbf
Cable diameter
Minimum pull-off load
0.020 in. (0,58 mm)
30 lbf
NOTE : Read the torque wrench lbf.in indication directly as lbf.
____
1
_
While the load is applied, look for movement of the ferrule
which was installed at the free end of the cable.
(d) If movement of the ferrule occurs, adjust the tool crimp value in
line with the manufacturers instructions. Then remove and discard
the cable from the test block, and do steps (1) (a) thru (c)
again.
(e) If the ferrule stays in position on the cable, the tool crimp
value is satisfactory.
(f) Remove and discard the used safety cable from the test block.
(2) The cable tension check
(a) Use the installation tool identified for calibration and install
the applicable safety cable 0.032in. (0,89mm) diameter (Material
No. Omat 2-142) or safety cable 0.02in. (0,58mm) diameter
(Material No. Omat 2-143) to the test block. Use the applicable
SCT-TB1 test block or TB-101 test block.
(b) Push the safety cable in the direction of the back of the test
block. Use light finger pressure at the center of the cable.
1
_
Examine the cable to see if the cable touches the back of the
block.
(c) If the cable touches the back of the block, adjust the tool
tensioning device in line with the manufacturers instructions.
Then remove and discard the cable from the block and do steps (a)
and (b) again.
(d) If the cable does not touch the back of the block, the tool
tensioning device is satisfactory.
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(3) Write the date of the calibration in the applicable tool record.
4. Procedure
_________
Subtask 70-12-04-911-051
A. The Procedure to install the Safety Cable
(Ref. Fig. 206/TASK 70-12-04-991-007)
(1) Do a check of the parts to be safetied.
(a) Make sure the parts are correctly torqued.
(b) Make sure the safety holes in adjacent parts are approximately
aligned in relation to each other. For right-handed thread
examples, refer to the equivalent lockwire standards
(Ref. Fig. 204/TASK 70-12-04-991-004)
1
_
If the holes are not aligned, release the related part(s) and
torque the part(s) to the specified torque load value again.
You must not apply a higher or lower torque value than the
value specified for the part(s), to try to align the part(s)
2
_
If the safety holes in adjacent parts cannot be satisfactorily
aligned, you must install a replacement part where necessary.
(2) Install the safety cable through the parts
NOTE : The routing of the safety cable is the same as the routing
____
specified for locking
(Ref. Fig. 204/TASK 70-12-04-991-004, 205/TASK 70-12-04-991-005)
(a) Make the selection of the applicable length of safety cable
0.032in. (0,89mm) diameter (Material No. Omat 2-142) or safety
cable 0.02in. (0,58mm) diameter (Material No. Omat 2-143). No
more than three fasteners are to be safetied together with one
length of safety cable. The maximum length of safety cable
between tension points is 3 in. (76.1998 mm) unless specified
differently.
(b) Put the free end of the safety cable through the safety hole in
the first part. Pull the cable through the hole until the end
fitting is against the part.
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1
_
Make sure the routing of the cable is in correct direction.
The cable must pull in a counterclockwise direction for
left-handed thread parts, or a clockwise direction for righthanded thread parts.
(c) Put the free end of the cable through the safety hole in the
second part. Pull the cable through the hole. Keep the cable as
straight as possible when you pull it through the hole.
(d) If applicable, put the free end of the cable through the safety
hole in the third part. Pull the cable through the hole. Keep the
cable as straight as possible when you pull it through the hole.
(3) Install the ferrule to the free end of the safety cable
(a) For Daniels Manufacturing Corporation (DMC) SCT323 installation
tool (3in. tool nose) 0.032in. (0,89mm) diameter cable and SCT203
installation tool (3in. tool nose) 0.020in. (0,58mm) diameter
cable:
If necessary, push on the end of the tool nose and turn the nose
to a different position
NOTE : There are four positions available to give good access
____
Release the nose and make sure it locks in position.
NOTE : If the nose does not lock in position, turn the nose
____
slightly until it correctly engages.
(b) Make sure the routing of the cable is correct.
(c) Make sure the lengths of cable between tension points are not
longer than 3 in. (76.1998 mm) unless specified differently.
(d) Put the free end of the cable through the ferrule in the ferrule
cartridge.
(e) Pull the safety cable through the ferrule.
(f) Put the free end of the cable through the tool nose of the
installation tool. Make sure the large hole of the tool nose is
on the same side as the ferrule.
(g) Hold the free end of the cable and pull the ferrule cartridge
away to release the ferrule.
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Installation of Safety Cable
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(4) Crimp the ferrule in position on the safety cable
(a) Move the installation tool along the cable until the tool nose is
near the part. Make sure the ferrule goes into the large hole in
the tool nose. If the ferrule will not go into the hole, do the
procedure that follows:
1
_
Remove the installation tool from the cable.
2
_
Push the handles completely together, then release the handles
to fully open the installation tool.
3
_
Do steps (4)(a) and (b) again.
(b) For Daniels Manufacturing Corporation (DMC) SCT323 installation
tool (3in. tool nose) 0.032in. (0,89mm) diameter cable and SCT203
cable:
- Push the cable into the tensioning device cable entrance.
- Continue to push the cable into the entrance until the free end
comes out at the bottom of the tool.
- Pull the cable through from the bottom of the tool until you
feel a resistance to movement.
- Open and close the tool handle continuously to remove the slack
from the cable. Let the handle open fully each time before you
close it.
- When all the slack is removed from the cable, use short strokes
of the handle until the tool nose lightly touches the part.
- Release the handle to the fully open position.
- Fully close the handle to crimp the ferrule and automatically
cut away the unwanted cable in one operation.
NOTE : Make sure you hold the tool stable and perpendicular to
____
the cable during the final operation. It is also important
that you use a full stroke of the handle, to apply the
correct tension.
- Release the handle to the fully open position and remove the
tool from the ferrule.
1
_
Push the pawl release knob to release the unwanted cable from
the tensioning device and discard the cable.
(c) For Bergen Cables M303 installation tool (3in. tool nose)
0.032in. (0,89mm) diameter cable, M305 installation tool (5in.
tool nose) 0.032in. (0,89mm) diameter cable, M307 installation
tool (7in. tool nose) 0.032in. (0,89mm) diameter cable and M203
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cable:
Pull the cable in a clockwise direction into the cable securing
groove in the tensioning device.
Turn the tensioning device in a clockwise direction (shown by the
arrows) to apply the correct tension to the cable. Make sure the
tool nose lightly touches the part when the cable is fully
tensioned.
NOTE : The correct tension is applied when you hear a clicking
____
sound constantly from the tensioning device.
Operate the handle from fully open to fully closed to crimp the
ferrule, and automatically cut away the unwanted cable.
NOTE : Make sure you hold the tool stable and perpendicular to
____
the cable during the final operation. It is also important
that you use a full stroke of the handle, to apply the
correct tension.
Release the handle to the fully open position and remove the tool
from the ferrule.
1
_
Pull the unwanted cable from the tensioning device and discard
it.
(5) Inspect the installed safety cable
(a) Examine the cable for nicks, frays, kinks or other damage
1
_
Nicks, frays, kinks or other damage are not acceptable.
(b) Examine the cable routing
1
_
Make sure the cable cannot become chafed, fatigued by
vibration, or stressed more than the tension applied during
installation.
2
_
If the routing is unsatisfactory, replace the cable.
(c) Apply light finger pressure in the middle of the cable between
two safetied parts. If the cable feels loose, do a dimension
check to find if the cable is serviceable as follows:
1
_
If two parts are safetied together, measure the distance
between each of the parts.
(Ref. Fig. 206/TASK 70-12-04-991-007)
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Record the distance as dimension A.
2
_
If three parts are safetied together, measure the distance
between each of the parts.
(Ref. Fig. 206/TASK 70-12-04-991-007)
Add the two distances together (Dimensions D and E) and record
the result as dimension A.
3
_
Apply light finger pressure in the middle of the cable between
two safetied parts. Measure the distance the safety cable
moves laterally. Record this distance as dimension C.
4
_
Compare the recorded dimensions with the acceptable limits
given below:
Dimension A
Dimension B
Dimension
20,0 mm
6,0 mm
3,0 mm
Dimension A
Dimension B
Dimension
40,0 mm
8,0 mm
4,0 mm
Dimension A
Dimension B
Dimension
60,0 mm
9,0 mm
4,5 mm
Dimension A
Dimension B
Dimension
80,0 mm
10,0 mm
5,0 mm
Dimension A
Dimension B
Dimension
100,0 mm
11,0 mm
5,5 mm
Dimension A
Dimension B
Dimension
120,0 mm
12,0 mm
6,0 mm
Dimension A
Dimension B
Dimension
140,0 mm
14,0 mm
7,0 mm
Dimension A
Dimension B
Dimension
160,0 mm
16,0 mm
8,0 mm
C
C
C
C
C
C
C
5
_
If the cable is not in the acceptable limits given, remove the
installed cable and install a new safety cable.
6
_
Used safety cable must be carefully discarded after removal.
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TASK 70-12-04-910-805
Locking Techniques - Pinion Wire Plug
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-12-04-991-006
Fig. 207
3. __________
Job Set-up
Subtask 70-12-04-869-054
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 207/TASK 70-12-04-991-006)
Subtask 70-12-04-910-054
A. Installation of Pinion Wire Plugs:
(1) Pinion wire plugs which are assembled in aluminium components must be
locked as follows:
(a) Use a punch and make metal from the adjacent area go into the two
serrations of the plug.
(2) Pinion wire plugs which are assembled in magnesium components must be
locked as follows:
(a) Install a cupwasher with the plug. After the plug has been
tightened, the rim of the cupwasher is peened. This must be done
with a spherical nose tool.
NOTE : There is only sufficient clearance between the plug and a
____
magnesium component for a cupwasher to be installed.
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Installation of Pinion Wire Plugs
Figure 207/TASK 70-12-04-991-006
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MAINTENANCE PROCESSES - STRIPPING AND CLEANING - MAINTENANCE PRACTICES
______________________________________________________________________
TASK 70-20-01-100-801
List of maintenance Processes - Stripping and Cleaning
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
Not Applicable
3. __________
Job Set-up
Subtask 70-20-01-869-050
A. Not applicable.
4. Procedure
_________
Subtask 70-20-01-160-050
A. This TASK identifies the maintenance processes which are referred to for
stripping and cleaning. These are:
70200110080200 Non-Aqueous Liquid Degreasing - Maintenance Process 101
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TASK 70-20-01-100-802
Non-Aqueous Liquid Degreasing - Maintenance Process 101
WARNING : YOU MUST FIND AND OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA FOR
_______
THE MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE
THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO THIS, AN INJURY
OR ENVIRONMENTAL DAMAGE CAN OCCUR.
1. __________________
Reason for the Job
This procedure gives three methods that can be used to clean the parts.
These are:
- Swab or clean locally with the approved solvent (Method 1).
- Immerse the part fully in the approved solvent (Method 2).
- Apply the approved solvent with a spray (Method 3).
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
applicable container
squeeze bottle
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1-257
Material No.
OMat 1-260
Material No.
OMat 1-40
Material No.
OMat 101
Material No.
OMat 102
Material No.
OMat 135
Material No.
OMat 150
*
Cleaning solvent (Ref. 70-30-00)
*
Odourless kerosine (Ref. 70-30-00)
*
Isopropyl alcohol (Ref. 70-30-00)
*
Kerosine (Ref. 70-30-00)
*
White spirit (Ref. 70-30-00)
*
Methyl ethyl ketone (Ref. 70-30-00)
*
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 2-101
Acetone (Ref. 70-30-00)
*
absorbent lint-free cloth (Ref. 70-30-00)
3. __________
Job Set-up
Subtask 70-20-01-869-051
A. Not applicable.
4. Procedure
_________
Subtask 70-20-01-110-050
A. Swab or clean locally with the approved solvent (Method 1)
CAUTION : YOU MUST NOT SOAK THE CLOTHS DIRECTLY IN THE BULK STORAGE
_______
CONTAINER. IF YOU DO, YOU WILL CAUSE CONTAMINATION OF THE BULK
OF THE LIQUID.
(1) Apply the solvent to the area to be cleaned. Use a clean absorbent
lint-free cloth (Material No. OMat 2-101) made moist with one of
these solvents:
- Methyl ethyl ketone (Material No. OMat 135)
- Acetone (Material No. OMat 150)
- Isopropyl alcohol (Material No. OMat 1-40)
- Cleaning solvent (Material No. OMat 1-257).
NOTE : Alternatively, you can use the wipes that are soaked in the
____
Cleaning solvent (Material No. OMat 1-257).
(2) Discard the used absorbent lint-free cloth (Material No. OMat 2-101).
(3) Do the steps (1) and (2) again until the area is clean and free from
grease.
(4) Let the part become dry.
NOTE : You can use a clean dry absorbent lint-free cloth (Material
____
No. OMat 2-101) or a clean oil-free air blast to remove the
remaining solvent from the surface. This will help to dry the
part.
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Subtask 70-20-01-110-058
B. Immerse the part fully in the approved solvent (Method 2)
NOTE : The solvent must be in a container that can be shaken.
____
(1) Put the part fully into one of these solvents in an applicable
container:
- Kerosine (Material No. OMat 101)
- White spirit (Material No. OMat 102)
- Cleaning solvent (Material No. OMat 1-257).
(2) Carefully shake the container to move the solvent around the part.
(3) Remove the part from the container.
(4) If the part is not sufficiently clean, do the steps (1) thru (3)
again.
(5) Flush the part with clean solvent to remove all signs of grease and
oil.
CAUTION : YOU MUST MAKE SURE THAT THE PART IS FULLY DRY BEFORE IT IS
_______
INSTALLED TO THE ENGINE. IF SOME REMAINING SOLVENT IS
TRAPPED IN THE PART, IT CAN CAUSE CORROSION INTERNALLY.
THIS CAN CAUSE THE FAILURE OF THE PART.
____
remaining solvent from the surfaces. This will help to dry the
part.
(a) If the part has internal pockets or passageways, let it become
dry for a minimum time of one hour. You can use a clean oil-free
air blast to help to dry the part internally.
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Subtask 70-20-01-110-059
C. Apply the approved solvent with a spray (Method 3)
NOTE : You can use a squeeze bottle or applicable equipment to do this
____
procedure.
(1) Apply the solvent to the area as a spray. Use one of these solvents:
- Kerosine (Material No. OMat 101)
- White spirit (Material No. OMat 102)
- Cleaning solvent (Material No. OMat 1-257)
- Odourless kerosine (Material No. OMat 1-260).
NOTE : It is important that the spray is not atomized. The squeeze
____
bottle must have a nozzle that supplies the solvent as a low
pressure jet. Where the solvent is sent through the equipment
again, there must be a last flush of clean solvent to remove
all contamination.
CAUTION : YOU MUST MAKE SURE THAT THE PART IS FULLY DRY BEFORE IT IS
_______
INSTALLED TO THE ENGINE. IF SOME REMAINING SOLVENT IS
TRAPPED IN THE PART, IT CAN CAUSE CORROSION INTERNALLY.
THIS CAN CAUSE THE FAILURE OF THE PART.
____
remaining solvent from the surfaces. This will help to dry the
part.
(a) If the part has internal pockets or passageways, let it become
dry for a minimum time of one hour. You can use a clean oil-free
air blast to help to dry the part internally.
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TASK 70-20-01-100-808
Abrasive Blasting for Cleaning - Maintenance Process 104
_______
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
abrasive blasting equipment
soft brush
vacuum cleaner
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1249
Material No.
OMat 230
*
polythene sheet (Ref. 70-30-00)
*
tape adhesive (masking) (Ref. 70-30-00)
3. __________
Job Set-up
Subtask 70-20-01-869-053
A. Not applicable.
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4. Procedure
_________
Subtask 70-20-01-160-051
A. Consumable Materials Information
NOTE : Where a letter is used after an OMat number, then you must only
____
use that specified alternative material.
NOTE : Where an asterisk is used after an OMat number, then you must not
____
use the alternatives.
Subtask 70-20-01-120-050
B. General
CAUTION : YOU MUST NOT USE THIS ABRASIVE BLASTING PROCESS UNLESS IT IS
_______
DIRECTLY SPECIFIED IN THE MAINTENANCE MANUAL. IF YOU DO NOT
OBEY THIS INSTRUCTION, THE PART(S) CAN BE DAMAGED.
CAUTION : YOU MUST NOT USE ABRASIVE BLASTING ON FINE LIMIT DIAMETERS,
_______
CURVIC COUPLINGS, BLADE AND DISC RETENTION FEATURES, BLADE
AIR-COOLING PASSAGES AND STUDS UNLESS DIRECTLY SPECIFIED IN THE
MAINTENANCE MANUAL. IF YOU DO NOT OBEY THIS INSTRUCTION, THE
PART(S) CAN BE DAMAGED.
CAUTION : YOU MUST REMOVE ALL OF THE GRIT FROM THE CLEANED PARTS. ALSO,
_______
YOU MUST EXAMINE THE PARTS FULLY TO MAKE SURE THAT ALL OF THE
GRIT HAS BEEN REMOVED. THIS IS VERY IMPORTANT WHEN YOU HAVE
CLEANED OIL SYSTEM RELATED PARTS. IF YOU DO NOT OBEY THIS
INSTRUCTION, THE PART(S) CAN BE DAMAGED.
(1) This process uses non-metallic (inorganic) abrasives to clean engine
parts or to prepare them for other procedures. The maintenance manual
procedure that directly refers to this process will specify:
- the type of blasting necessary
- the applicable abrasive material
- the grit size of the material
- the air pressure that must be used
- special instructions if necessary.
(2) The abrasive must be changed when more than 20-percent by weight of
the material goes through the finest sieve size of that material.
NOTE : It is recommended that you use blasting equipment that
____
includes a re-grading system. This will make sure that you do
not get material that is finer than 20-percent by weight.
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Subtask 70-20-01-120-051
C. Dry Non-Metallic (Inorganic) Abrasive Blasting
(1) Initially remove dirt and grease from the repair area as specified in
the related Maintenance Manual procedure.
(2) Use tape adhesive (masking) (Material No. OMat 230) and polythene
sheet (Material No. OMat 1249), and give protection to the areas that
are not to be blasted.
CAUTION : YOU MUST NOT USE AN AIR PRESSURE OF MORE THAN 40 PSI (280
_______
KPA) TO APPLY THE ABRASIVE. HIGHER PRESSURES CAN CAUSE
DAMAGE TO THE PARTS.
(3) Use abrasive blasting equipment and supply the abrasive to the
applicable area for the minimum time necessary to clean the area. Use
an air pressure of 20 psi (1.3789 bar) to 40 psi (2.7579 bar).
NOTE : The Maintenance Manual repairs can tell you to use air
____
pressures as low as 15 psi (1.0342 bar) , or as high as 80 psi
(5.5158 bar). These pressures are directly related to the
specified component, the material and condition, the component
section/thickness and the permitted material that you can
remove. Thus, use the limit specified in the repair if it is
different from the air pressure values given above.
(4) Remove all signs of abrasive grit and dust. Use a dry blast of air,
or a soft brush and a vacuum cleaner.
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TASK 70-20-01-100-803
Swab Etching of Titanium Alloys - Maintenance Process 133
1. __________________
Reason for the Job
This task gives the procedure to prepare titanium parts for inspection.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
cotton wool swab(s)
demineralised water
polythene container of more than 1 l (0.26 USgal)
capacity
tongs
tweezers
No specific
No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 119
Material No.
OMat 125
Material No.
OMat 150
Material No.
OMat 172
Material No.
OMat 172A
*
sodium carbonate (Na2CO3) (Ref. 70-30-00)
*
nitric acid (HNO3) (Ref. 70-30-00)
*
acetone (CH3) 2CO (Ref. 70-30-00)
*
hydrofluoric acid (30 percent) (Ref. 70-30-00)
*
hydrofluoric acid (40 percent) (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
101
3. __________
Job Set-up
Subtask 70-20-01-110-051
A. Prepare the Etch Solution
WARNING : DO NOT GET ACIDS ON YOUR SKIN OR IN YOUR EYES. ACIDS CAN CAUSE
_______
INJURY. TO PREVENT INJURY, USE PROTECTIVE CLOTHES, GLOVES AND
GOGGLES.
IF YOU GET ACID ON YOUR SKIN, FLUSH WITH LARGE QUANTITIES OF
CLEAN WATER. THEN APPLY BURN JELLY.
CAUTION : USE A POLYTHENE OR CHEMICALLY-RESISTANT CONTAINER FOR THE ETCH
_______
SOLUTIONS.
(1) Make a solution of nitric acid (HNO3) (Material No. OMat 125), 200
g/l (26.69 oz/USgal), and hydrofluoric acid (30 percent) (Material
No. OMat 172) or hydrofluoric acid (40 percent) (Material No. OMat
172A), 50 g/l (5.71 oz/USgal).
(2) To make 1 l (0.2641 USgal) of the solution:
(a) Put 0.5 l (0.1320 USgal) of demineralised water into a polythene
container of more than 1 l (0.26 USgal) capacity.
(b) Add 0.2 l (0.0528 USgal) of nitric acid (HNO3) (Material No. OMat
125) and stir.
(c) Add 0.15 l (0.0396 USgal) of hydrofluoric acid (30 percent)
(Material No. OMat 172) or 0.11 l (0.0290 USgal) of hydrofluoric
acid (40 percent) (Material No. OMat 172A).
(d) Add demineralised water to make up 1 l (0.2641 USgal) of the
solution.
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4. Procedure
_________
Subtask 70-20-01-110-052
A. Prepare the Titanium Parts
(1) Cold liquid degrease the surface (Ref. TASK 70-20-01-100-802).
(2) Swab etch the surface:
(a) Use tongs or tweezers to put a cotton wool swab(s) into the etch
solution. To remove unwanted solution, lightly press the cotton
wool swab(s) against the side of the container.
(b) Apply the etch solution to the titanium surface with the cotton
wool swab(s). Keep a film of solution on the surface between 20
and 30 seconds, until the surface becomes slightly grey in color.
(3) Clean the surface with cotton wool swab(s) and cold water to remove
the acid solution.
(4) Neutralize the surface with sodium carbonate (Na2CO3) (Material No.
OMat 119) at 70 g/l (9.31 oz/USgal). Swab wash the surface two times.
(5) Clean the surface with cotton wool swab(s) and cold water to remove
the neutralizer.
(6) Swab wash the surface with acetone (CH3) 2CO (Material No. OMat 150)
and let it dry in the air.
(7) Discard the used materials, clean the container with cold water.
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MAINTENANCE PROCESSES - INSPECTION - MAINTENANCE PRACTICES
__________________________________________________________
TASK 70-20-02-200-801
List of Maintenance Processes - Inspection
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-02-230-803
70-20-02-230-804
Post-Emulsified Fluorescent Penetrant Inspection with
Water-Based (Hydrophilic) Penetrant Removers Maintenance Process 210
Water-washable Fluorescent Penetrant Inspection Maintenance Process 213
3. __________
Job Set-up
Subtask 70-20-02-869-050
A. Not applicable.
4. Procedure
_________
Subtask 70-20-02-869-051
A. List of Maintenance Processes: This task identifies the maintenance
processes which are referred to for inspection. These are: (Ref. TASK 7020-02-230-803) and (Ref. TASK 70-20-02-230-804).
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TASK 70-20-02-230-803
Post-Emulsified Fluorescent Penetrant Inspection with Water-Based (Hydrophilic)
Penetrant Removers - Maintenance Process 210
_______
CAUTION : THESE PROCEDURES MUST BE DONE BY PERSONS WHO ARE APPROVED BY THE
_______
APPLICABLE AUTHORITY. PERSONS WHO ARE NOT APPROVED CAN POSSIBLY GET
AN INCORRECT RESULT WHICH CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
1. __________________
Reason for the Job
Defects which are open to the surface can be found by fluorescent penetrant
inspection. This procedure is non-destructive and uses materials which are
of a medium, high or ultra high sensitivity. The medium or high sensitivity
materials must be used unless the applicable inspection task tells you to
use the ultra high sensitivity materials specially.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
clean lint-free cloth
lint-free cloth
magnifying glass (X10 magnification)
paper tissues
portable ultra-violet lamp
small brush
ultra-violet lamp monitor
TAM (PSM-5) test panel
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMAT 101
Material No.
OMAT 606
Material No.
OMAT 616
Material No.
OMAT 617
Material No.
OMAT 621
Material No.
OMAT 650
Material No.
OMAT 651
Material No.
OMAT 652
*
kerosine (Ref. 70-30-00)
*
developer powder (Ref. 70-30-00)
*
solvent penetrant remover (Ref. 70-30-00)
*
aerosol developer (Ref. 70-30-00)
*
fluorescent penetrant remover (Ref. 70-30-00)
*
fluorescent penetrant (Ref. 70-30-00)
*
*
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
101
3. __________
Job Set-up
Subtask 70-20-02-720-051
A. Prepare the ultra-violet lamp monitor for the inspection.
WARNING : YOU MUST NOT USE THE ULTRA-VIOLET LAMP IF THE ELEMENT IS OPEN
_______
BECAUSE OF DAMAGED OR BROKEN GLASS, OR IF THE FILTER IS
CRACKED, BROKEN OR DEFECTIVE. IF YOU USE THE LAMP IN THIS
CONDITION YOUR EYES WILL BE DAMAGED.
(1) Examine the ultra-violet lamp monitor to make sure it is serviceable:
then set the lamp to the ON position.
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(2) Let the lamp become warm for approximately 20 minutes so that it is
in a stabilized condition.
(3) Do a check of the light intensity:
NOTE : The lamp can be checked for light intensity when it is used or
____
each 3 months.
(a) Hold the lamp at a distance of 15 in. (0.3809 m) above the lamp
monitor: make sure there is a minimum light intensity of 1000
microwatts per square centimeter.
Subtask 70-20-02-210-051
B. Prepare the TAM (PSM-5) test panel for the inspection:
(1) Remove the test panel from the storage container of approved
degreaser.
(2) Dry the test panel with a clean lint-free cloth or paper tissues.
(3) Visually examine the test panel below the portable ultra-violet lamp:
make sure there are no penetrant indications remaining from the last
time that the panel was used.
(a) If remaining indications are found, do the steps to clean the
test panel (given at the end of the procedure).
4. Procedure
_________
Subtask 70-20-02-230-051
A. Do the penetrant inspection:
CAUTION : YOU MUST USE THE MANUFACTURERS FULL SYSTEM OF MATERIALS. IF
_______
YOU DO NOT DO THIS YOU CAN GET AN UNSATISFACTORY RESULT.
NOTE : For accurate results, the inspection area must be cleaned
____
sufficiently before the penetrant is applied. Contamination in a
defect will decrease or prevent the flow of the penetrant into the
defect and thus cause incorrect indications. Also surface
contamination can hold the penetrant on the surface and thus cause
incorrect indications.
(1) Clean the inspection area (Ref. TASK 70-20-01-100-802): let the
cleaning fluid stay on the area for sufficient time to dissolve the
surface deposits.
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(2) If necessary, do step (1) again until all of the surface deposits
have been removed.
(3) Let the inspection area dry for a minimum time of 10 minutes.
NOTE : This is to make sure that all of the degreaser has gone before
____
the fluorescent penetrant is applied.
(4) Apply the fluorescent penetrant (Material No. OMAT 650) or
fluorescent penetrant (Material No. OMAT 651) or fluorescent
penetrant (Material No. OMAT 652) with a small brush or spray to the
inspection area: Also apply the same penetrant to the area of the TAM
(PSM-5) test panel. Let the penetrant stay on the area for a minimum
time of 10 minutes: but not more than the maximum time of 1 hour.
CAUTION : THIS OPERATION IS CRITICAL AND PENETRANT REMOVER TIME MUST
_______
BE KEPT TO A MINIMUM. IF THE REMOVER STAYS ON THE SURFACE
FOR TOO MUCH TIME YOU CAN POSSIBLY GET AN INCORRECT RESULT.
THIS CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
NOTE : Only use the fluorescent penetrant (Material No. OMAT 652) if
____
it is specified in the related inspection task.
(5) Remove the penetrant from the surface of the part and the TAM (PSM-5)
test panel with a lint-free cloth or paper tissues. Then do procedure
A or procedure B as follows:
(a) Procedure A
1
_
Add the fluorescent penetrant remover (Material No. OMAT 621)
to water until you get a solution which contains 5 to 20
percent by volume of the remover.
2
_
Make a clean lint-free cloth or paper tissues moist with the
remover in solution.
3
_
Wipe across the inspection area and the test panel where the
penetrant was applied: only do two to three wipes with the
moist cloth or tissue.
4
_
Wipe the inspection area and the test panel: use a clean lintfree cloth or paper tissues made moist with clean water.
5
_
Examine the inspection area and the test panel with a portable
ultra-violet lamp in low light: make sure all the surface
penetrant has been removed sufficiently to give a satisfactory
background.
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6
_
If necessary, do steps 2_ thru 5_ again until you get a
satisfactory background.
7
_
Dry the inspection area and the test panel with a dry lintfree cloth or paper tissues.
(b) Procedure B
1
_
Make a clean lint-free cloth or paper tissues moist with
solvent penetrant remover (Material No. OMAT 616). Or with one
of the approved non-aqueous liquid degreasers (Ref. TASK 7020-01-100-802).
2
_
3
_
background.
4
_
5
_
Let the surface of the part and the test panel become dry.
NOTE : The solvent will evaporate quickly.
____
(6) Apply the developer powder (Material No. OMAT 606) with a blow
dispenser or by dusting the inspection area and the TAM (PSM-5) test
panel. Alternatively use the aerosol developer (Material No. OMAT
617). Let the developer powder stay on the area for a minimum time of
10 minutes: But not more than the maximum time of 3 hours.
(a) Remove unwanted powder with a clean dry compressed air supply up
to a maximum pressure of 10 psi (0.6894 bar): Keep the air supply
nozzle at least 12 in. (304.7994 mm) away from the part.
NOTE : The velocity of the air at the surface of the component
____
must only be sufficient to remove the unwanted powder.
(7) Visually examine the inspection area below the portable ultra-violet
lamp for crack indications.
(a) If crack indications are found, use the magnifying glass (X10
magnification) to make sure there is a defect.
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(b) If crack indications can be seen at X10 magnification, visually
examine the area below white light: Use the magnifying glass (X15
magnification) and magnifying glass (X30 magnification) to make
sure there is a defect.
(8) Visually examine the TAM (PSM-5) test panel below the portable ultraviolet lamp for crack indications. Make sure there is the correct
number of known indications as follows:
(a) If fluorescent penetrant (Material No. OMAT 650) (Medium
sensitivity) was applied, look for three indications in view.
(b) If fluorescent penetrant (Material No. OMAT 651) (High
sensitivity) was applied, look for four indications in view.
(c) If fluorescent penetrant (Material No. OMAT 652) (Ultra-high
sensitivity) was applied, look for five indications in view.
NOTE : You can accept the test result if you find one less
____
indication than that given for the related material.
1
_
If the number of crack indications found is less than that
specified above, do the steps to clean the test panel (given
at the end of this procedure): Then on the test panel only, do
the full penetrant inspection again, but with all new
materials.
NOTE : A second unsatisfactory result on the test panel shows
____
that the panel, materials and/or procedure are
unsatisfactory.
You must find the cause of the unsatisfactory result,
then do the full penetrant inspection of the part and
test panel again.
(9) Remove the remaining developer powder with a clean dry air blast:
Make sure that oil and air-ways are not blocked with powder.
Subtask 70-20-02-110-051
B. Clean the TAM (PSM-5) test panel.
(1) Clean the test panel with clean water or kerosine (Material No. OMAT
101) to remove the developer powder.
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(3) Soak the test panel in one of the approved non-aqueous liquid
degreasers (Ref. TASK 70-20-01-100-802) for a minimum time of 15
minutes.
(4) Visually examine the test panel below the portable ultra-violet lamp
for penetrant indications.
(a) If penetrant indications are found, do steps (1) thru (4) one
more time.
(5) If penetrant indications are remaining after the above procedure was
done again, continue as follows:
(a) Add the fluorescent penetrant remover (Material No. OMAT 621) to
water until you get a solution which contains 5 to 20 percent by
volume of the remover.
(b) Soak the test panel in the remover solution at a temperature of
80 deg.C (176.00 deg.F) to 90 deg.C (194.00 deg.F) for 15 minutes
(or until clean).
(c) Flush the test panel with clean hot water at a temperature of 80
deg.C (176.00 deg.F) to 90 deg.C (194.00 deg.F).
(d) Dry the test panel with a clean lint-free cloth or paper tissues.
5. Close-up
________
Subtask 70-20-02-942-051
A. Remove the equipment and materials from the work area.
(1) Set the ultra-violet lamp monitor to the OFF position.
(2) Let the ultra-violet lamp become cold: Then put the lamp into the
applicable container for storage to make sure it does not become
damaged.
(3) Remove all the tools and materials from the work area.
(4) Put the TAM (PSM-5) test panel into storage in a sealed container
full of one of the approved non-aqueous liquid degreasers (Ref. TASK
70-20-01-100-802).
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TASK 70-20-02-230-804
Water-washable Fluorescent Penetrant Inspection - Maintenance Process 213
_______
CAUTION : THESE PROCEDURES MUST BE DONE BY PERSONS WHO ARE APPROVED BY THE
_______
APPLICABLE AUTHORITY. PERSONS WHO ARE NOT APPROVED CAN POSSIBLY GET
AN INCORRECT RESULT WHICH CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
1. __________________
Reason for the Job
Defects which are open to the surface can be found by fluorescent penetrant
inspection. This procedure is non-destructive and uses materials which are
of a medium or high sensitivity. The medium sensitivity materials must be
used unless the applicable inspection task tells you to use the high
sensitivity materials specially.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
lint-free cloth
paper tissues
portable ultra-violet lamp
small brush
ultra-violet lamp monitor
TAM (PSM-5) test panel
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMAT 101
Material No.
OMAT 606
Material No.
OMAT 616
Material No.
OMAT 617
Material No.
OMAT 621
Material No.
OMAT 632
Material No.
OMAT 653
*
*
developer powder (Ref. 70-30-00)
*
solvent penetrant remover (Ref. 70-30-00)
*
aerosol developer (Ref. 70-30-00)
*
fluorescent penetrant remover (Ref. 70-30-00)
*
*
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
101
3. __________
Job Set-up
Subtask 70-20-02-720-052
A. Prepare the ultra-violet lamp monitor for the inspection.
WARNING : YOU MUST NOT USE THE ULTRA-VIOLET LAMP IF THE ELEMENT IS OPEN
_______
BECAUSE OF DAMAGED OR BROKEN GLASS, OR IF THE FILTER IS
CRACKED, BROKEN OR DEFECTIVE. IF YOU USE THE LAMP IN THIS
CONDITION YOUR EYES WILL BE DAMAGED.
(1) Examine the ultra-violet lamp monitor to make sure it is serviceable:
then set the lamp to the ON position.
(2) Let the lamp become warm for approximately 20 minutes so that it is
in a stabilized condition.
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(3) Do a check of the light intensity:
NOTE : The lamp can be checked for light intensity when it is used or
____
each 3 months.
(a) Hold the lamp at a distance of 15 in. (0.3809 m) above the lamp
monitor: make sure there is a minimum light intensity of 1000
microwatts per square centimeter.
Subtask 70-20-02-210-052
B. Prepare the TAM (PSM-5) test panel for the inspection:
(1) Remove the test panel from the storage container of approved
degreaser.
(3) Visually examine the test panel below the portable ultra-violet lamp:
make sure there are no penetrant indications remaining from the last
time that the panel was used.
(a) If remaining indications are found, do the steps to clean the
test panel (given at the end of the procedure).
4. Procedure
_________
Subtask 70-20-02-230-052
A. Do the penetrant inspection:
CAUTION : YOU MUST USE THE MANUFACTURERS FULL SYSTEM OF MATERIALS. IF
_______
YOU DO NOT DO THIS YOU CAN GET AN UNSATISFACTORY RESULT.
NOTE : For accurate results, the inspection area must be cleaned
____
sufficiently before the penetrant is applied. Contamination in a
defect will decrease or prevent the flow of the penetrant into the
defect and thus cause incorrect indications. Also surface
contamination can hold the penetrant on the surface and thus cause
incorrect indications.
(1) Clean the inspection area (Ref. TASK 70-20-01-100-802): Let the
cleaning fluid stay on the area for sufficient time to dissolve the
surface deposits.
(2) If necessary, do step (1) again until all of the surface deposits
have been removed.
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(3) Let the inspection area dry for a minimum time of 10 minutes.
NOTE : This is to make sure that all of the degreaser has gone before
____
the fluorescent penetrant is applied.
(4) Apply the fluorescent penetrant (Material No. OMAT 653) or
fluorescent penetrant (Material No. OMAT 632) with a small brush or
spray to the inspection area: Also apply the same penetrant to the
area of the TAM (PSM-5) test panel. Let the penetrant stay on the
area for a minimum time of 10 minutes: but not more than the maximum
time of 1 hour.
CAUTION : THIS OPERATION IS CRITICAL AND PENETRANT REMOVER TIME MUST
_______
BE KEPT TO A MINIMUM. IF THE REMOVER STAYS ON THE SURFACE
FOR TOO MUCH TIME YOU CAN POSSIBLY GET AN INCORRECT RESULT.
THIS CAN SUBSEQUENTLY CAUSE COMPONENT FAILURE.
NOTE : Only use the fluorescent penetrant (Material No. OMAT 632) if
____
it is specified in the related inspection task.
(5) Remove the penetrant from the surface of the part and the TAM (PSM-5)
test panel with a lint-free cloth or paper tissues. Then do procedure
A or procedure B as follows:
(a) Procedure A
1
_
Make a clean lint-free cloth or paper tissues moist with clean
water.
2
_
3
_
background.
4
_
5
_
Dry the inspection area and the test panel with a dry lintfree cloth or paper tissues.
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(b) Procedure B
1
_
Make a clean lint-free cloth or paper tissues moist with
solvent penetrant remover (Material No. OMAT 616). Or with one
of the approved non-aqueous liquid degreasers (Ref. TASK 7020-01-100-802).
2
_
3
_
background.
4
_
5
_
Let the surface of the part and the test panel become dry.
NOTE : The solvent will evaporate quickly.
____
(6) Apply the developer powder (Material No. OMAT 606) with a blow
dispenser or by dusting the inspection area and the TAM (PSM-5) test
panel. Alternatively use the aerosol developer (Material No. OMAT
617). Let the developer powder stay on the area for a minimum time of
10 minutes: But not more than the maximum time of 3 hours.
(a) Remove unwanted powder with a clean dry compressed air supply up
to a maximum pressure of 10 psi (0.6894 bar): Keep the air supply
nozzle at least 12 in. (304.7994 mm) away from the part.
NOTE : The velocity of the air at the surface of the component
____
must only be sufficient to remove the unwanted powder.
(7) Visually examine the inspection area below the portable ultra-violet
lamp for crack indications.
(a) If crack indications are found, use the magnifying glass (X10
magnification) to make sure there is a defect.
(b) If crack indications can be seen at X10 magnification, visually
examine the area below white light: Use the magnifying glass (X15
magnification) and magnifying glass (X30 magnification) to make
sure there is a defect.
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(8) Visually examine the TAM (PSM-5) test panel below the portable ultraviolet lamp for crack indications. Make sure there is the correct
number of known indications as follows:
(a) If fluorescent penetrant (Material No. OMAT 653) (Medium
sensitivity) was applied, look for three indications in view.
(b) If fluorescent penetrant (Material No. OMAT 632) (High
sensitivity) was applied, look for four indications in view.
NOTE : You can accept the test result if you find one less
____
indication than that given for the related material.
1
_
If the number of crack indications found is less than that
specified above, do the steps to clean the test panel (given
at the end of this procedure): Then on the test panel only, do
the full penetrant inspection again, but with all new
materials.
NOTE : A second unsatisfactory result on the test panel shows
____
that the panel, materials and/or procedure are
unsatisfactory.
You must find the cause of the unsatisfactory result,
then do the full penetrant inspection of the part and
test panel again.
(9) Remove the remaining developer powder with a clean dry air blast:
Make sure that oil and air-ways are not blocked with powder.
Subtask 70-20-02-110-052
B. Clean the TAM (PSM-5) test panel:
(1) Clean the test panel with clean water or kerosine (Material No. OMAT
101) to remove the developer powder.
(3) Soak the test panel in one of the approved non-aqueous liquid
degreasers (Ref. TASK 70-20-01-100-802) for a minimum time of 15
minutes.
(4) Visually examine the test panel below the portable ultra-violet lamp
for penetrant indications.
(a) If penetrant indications are found, do steps (1) thru (4) one
more time.
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(5) If penetrant indications are remaining after the above procedure was
done again, continue as follows:
(a) Add the fluorescent penetrant remover (Material No. OMAT 621) to
water until you get a solution which contains 5 to 20 percent by
volume of the remover.
(b) Soak the test panel in the remover solution at a temperature of
80 deg.C (176.00 deg.F) to 90 deg.C (194.00 deg.F) for 15 minutes
(or until clean).
(c) Flush the test panel with clean hot water at a temperature of 80
(d) Dry the test panel with a clean lint-free cloth or paper tissues.
5. Close-up
________
Subtask 70-20-02-942-052
A. Remove the equipment and materials from the work area.
(1) Set the ultra-violet lamp monitor to the OFF position.
(2) Let the ultra-violet lamp become cold: Then put the lamp into the
applicable container for storage to make sure it does not become
damaged.
(3) Remove all the tools and materials from the work area.
(4) Put the TAM (PSM-5) test panel into storage in a sealed container
full of one of the approved non-aqueous liquid degreasers (Ref. TASK
70-20-01-100-802).
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MAINTENANCE PROCESSES - SURFACE PROTECTION - MAINTENANCE PRACTICES
__________________________________________________________________
TASK 70-20-03-300-801
List of Maintenance Processes - Surface Protection
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-03-300-802
70-20-03-300-803
70-20-03-300-804
Application of Chromate Conversion Coating to
Aluminium - Maintenance Process 330
Application of Two-Pack Epoxy Finish (Skydrol
Resistant) - Maintenance Process 323
Application of Adhesive Bonding, Sealing and Filling
Agents - Maintenance Process 707
3. __________
Job Set-up
Subtask 70-20-03-869-050
A. Not applicable.
4. Procedure
_________
Subtask 70-20-03-380-050
A. This TASK identifies the maintenance processes which are referred to for
surface protection. There are:
Maintenance Process 330 (Ref. TASK 70-20-03-300-802).
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TASK 70-20-03-300-802
Application of Chromate Conversion Coating to Aluminium - Maintenance Process
330
_______
1. __________________
Reason for the Job
To prevent corrosion, local surface protection must be applied to aluminium
surfaces that have damage.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
specific
specific
specific
specific
lint-free cloths
polyethylene container
small brush
stainless steel container
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------R
R
R
Material No.
OMat 117
Material No.
OMat 117D
Material No.
OMat 135
Material No.
OMat 140
Material No.
OMat 2-7
Material No.
OMat 7-176
*
phosphoric acid (H3P04) (Ref. 70-30-00)
*
chromate conversion coating (brush application)
(Ref. 70-30-00)
*
methyl ethyl ketone (Ref. 70-30-00)
*
iso propyl alcohol (Ref. 70-30-00)
*
wetting agent (Ref. 70-30-00)
*
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------acetone (Ref. 70-30-00)
3. __________
Job Set-up
Subtask 70-20-03-869-051
A. Not applicable.
4. Procedure
_________
Subtask 70-20-03-380-051
A. Apply the Chromate Conversion Coating
(1) Clean the repair surface
WARNING : YOU MUST NOT GET THE DEGREASER ON YOUR SKIN OR IN YOUR
_______
EYES. THE DEGREASER IS HARMFUL. USE AN APRON, APPLICABLE
GLOVES AND EYE PROTECTION. IF YOU GET THE DEGREASER ON YOUR
SKIN, REMOVE IT WITH SOAP AND WATER. REMOVE CLOTHING IF
CONTAMINATION HAS OCCURRED. IF YOU GET THE DEGREASER IN
YOUR EYES, FLUSH THEM WITH ISOTONIC SALINE OR WATER FOR 15
MINUTES MINIMUM. IMMEDIATELY GET MEDICAL AID. IF THE
DEGREASER GOES THROUGH YOUR SKIN THERE CAN BE A HEALTH
RISK.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE DEGREASER OR GET IT
_______
IN YOUR MOUTH. THE DEGREASER IS HARMFUL. USE THE APPROVED
FACE MASK. ALSO USE THE DEGREASER IN AN AREA THAT HAS A
GOOD FLOW OF AIR. IF YOU GET THE DEGREASER IN YOUR MOUTH,
FLUSH WITH WATER. IMMEDIATELY GET MEDICAL AID. IF THE
DEGREASER IS BREATHED IN OR DRUNK THERE CAN BE A HEALTH
RISK.
R
R
(a) Use a small brush and apply iso propyl alcohol (Material No. OMat
140) or methyl ethyl ketone (Material No. OMat 135) or acetone
(Material No. OMat 7-176) to remove all grease from the repair
surface.
(b) Add the wetting agent (Material No. OMat 2-7) to water to make a
solution that is one percent by volume. Keep the solution in the
stainless steel container at a temperature between 15 deg.C
(59.00 deg.F) and 25 deg.C (77.00 deg.F).
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(c) Use a small brush and apply the wetting agent (Material No. OMat
2-7) solution to clean the repair surface.
(d) Flush the repair surface with clean, cold water.
(2) Etch the repair surface
WARNING : YOU MUST NOT GET THE PHOSPHORIC ACID SOLUTION ON YOUR SKIN
_______
OR IN YOUR EYES. THE SOLUTION IS CORROSIVE. USE AN APRON,
APPLICABLE GLOVES AND EYE PROTECTION. IF YOU GET THE
SOLUTION ON YOUR SKIN, REMOVE IT WITH SOAP AND WATER.
REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED. IF YOU GET
THE SOLUTION IN YOUR EYES, FLUSH THEM WITH ISOTONIC SALINE
OR WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET MEDICAL
AID. IF THE SOLUTION TOUCHES YOU IT CAN CAUSE DAMAGE TO
YOUR BODY TISSUES.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE PHOSPHORIC ACID
_______
SOLUTION OR GET IT IN YOUR MOUTH. THE SOLUTION IS
CORROSIVE. USE THE APPROVED FACE MASK. ALSO USE THE
SOLUTION IN AN AREA THAT HAS A GOOD FLOW OF AIR. IF YOU GET
THE SOLUTION IN YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY
GET MEDICAL AID. IF THE SOLUTION IS BREATHED IN OR DRUNK IT
CAN CAUSE DAMAGE TO YOUR BODY TISSUES.
(a) Add 0.33 l (0.0871 USgal) of the phosphoric acid (H3P04)
(Material No. OMat 117) to 0.67 l (0.1769 USgal) of water. Keep
the solution in a polyethylene container at a temperature between
15 deg.C (59.00 deg.F) and 25 deg.C (77.00 deg.F).
(b) Use a small brush and apply the phosphoric acid (H3P04) (Material
No. OMat 117) solution to etch the repair surface.
(c) Flush the repair surface with clean, cold water.
(3) Apply the chromate conversion coating
WARNING : YOU MUST NOT GET THE CHROMATE CONVERSION COATING SOLUTION
_______
ON YOUR SKIN OR IN YOUR EYES. THE SOLUTION IS CORROSIVE.
USE AN APRON, APPLICABLE GLOVES AND EYE PROTECTION. IF YOU
GET THE SOLUTION ON YOUR SKIN, REMOVE IT WITH SOAP AND
WATER. REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED. IF
YOU GET THE SOLUTION IN YOUR EYES, FLUSH THEM WITH ISOTONIC
SALINE OR WATER FOR 15 MINUTES MINIMUM. IMMEDIATELY GET
MEDICAL AID. IF THE SOLUTION TOUCHES YOU IT CAN CAUSE
DAMAGE TO YOUR BODY TISSUES.
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WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE CHROMATE CONVERSION
_______
COATING SOLUTION OR GET IT IN YOUR MOUTH. THE SOLUTION IS
(a) Mix equal volumes of chromate conversion coating (brush
application) (Material No. OMat 117D) solution parts A and B in a
polyethylene container. Make only sufficient solution for the
area to be treated and use the solution immediately.
WARNING : YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE
_______
SOAKED WITH THE CHROMATE CONVERSION COATING SOLUTION
BECOME DRY. THE SOLUTION IS OXIDISING. IF THEY BECOME
DRY THERE IS A RISK OF FIRE (WITHOUT AN EXTERNAL
CAUSE).
1
_
Use a small brush and apply the chromate conversion coating
(brush application) (Material No. OMat 117D) solution to the
repair surface. Monitor the effect of the solution on the
surface. When the surface shows and irridescent gold to light
golden-brown color, the conversion is complete.
NOTE : The conversion will usually be complete in 2 to 7
____
minutes.
2
_
Flush the repair surface with clean, cold water.
3
_
Dry the repair surface with clean, lint-free cloths or with
warm air.
4
_
Safety discard the materials used in the chromate conversion
procedure:
- Flush the chromate solution from the materials with cold
water, collect the used water in a container
- Put the used materials in sealed plastic bags. Identify the
bags with a label that shows TOXIC CHROME WASTE
- Discard the water, the toxic chrome waste and the unwanted
chromate solution: refer to local safety regulations.
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TASK 70-20-03-300-803
Application of Two-Pack Epoxy Finish (Skydrol Resistant) - Maintenance Process
323
1. __________________
Reason for the Job
To prevent deterioration local surface protection must be applied to painted
surfaces that have damage.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
clean plastic container
small brush
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1-176
*
acetone (Ref. 70-30-00)
Material No.
OMat 135
Material No.
OMat 140
Material No.
OMat 2-40
Material No.
OMat 5-63
Material No.
OMat 776
Material No.
OMat 793
Material No.
OMat 799
*
methyl ethyl ketone (Ref. 70-30-00)
*
iso propyl alcohol (Ref. 70-30-00)
*
adhesive tape heat resistant (Ref. 70-30-00)
*
aluminium oxide abrasive paper (Ref. 70-30-00)
*
two-pack epoxy primer and catalyst (Ref. 70-30-00)
*
thinners (Ref. 70-30-00)
*
two-pack epoxy finish and catalyst (Ref. 70-30-00)
R
R
R
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3. __________
Job Set-up
Subtask 70-20-03-869-052
A. Not applicable.
4. Procedure
_________
Subtask 70-20-03-370-050
A. Apply the Two-Pack Epoxy Finish
WARNING : YOU MUST FIND AND OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA
_______
FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO
MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO
THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
(1) Prepare the surface
(a) Use the aluminium oxide abrasive paper (Material No. OMat 5-63)
to make the damaged area smooth and to remove the adjacent gloss
finish.
WARNING : YOU MUST NOT GET THE DEGREASER ON YOUR SKIN OR IN YOUR
_______
EYES. THE DEGREASER IS HARMFUL. USE AN APRON,
DEGREASER ON YOUR SKIN, REMOVE IT WITH SOAP AND WATER.
REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED. IF YOU
GET THE DEGREASER IN YOUR EYES, FLUSH THEM WITH
ISOTONIC SALINE OR WATER FOR 15 MINUTES MINIMUM.
IMMEDIATELY GET MEDICAL AID. IF THE DEGREASER GOES
THROUGH YOUR SKIN THERE CAN BE A HEALTH RISK.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE DEGREASER OR
_______
GET IT IN YOUR MOUTH. THE DEGREASER IS HARMFUL. USE THE
APPROVED FACE MASK. ALSO USE THE DEGREASER IN AN AREA
THAT HAS A GOOD FLOW OF AIR. IF YOU GET THE DEGREASER
IN YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY GET
MEDICAL AID. IF THE DEGREASER IS BREATHED IN OR DRUNK
THERE CAN BE A HEALTH RISK.
R
R
1
_
Use a small brush and apply iso propyl alcohol (Material No.
OMat 140) or methyl ethyl ketone (Material No. OMat 135) or
acetone (Material No. OMat 1-176) to remove all grease from
the repair surface.
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2
_
Use the adhesive tape heat resistant (Material No. OMat 2-40)
to give protection to adjacent surfaces.
(2) Apply the two-pack epoxy primer
(a) Mix together equal volumes of the two-pack epoxy primer and
catalyst (Material No. OMat 776). Leave the mixture in the clean
plastic container for 30 minutes before you use it.
NOTE : The mixture has a pot life of eight hours, material not
____
used in this time must be discarded.
(b) Use a small brush to apply one layer of the primer to the repair
surface. Let the primer dry for at least one hour, at a minimun
temperature of 16 deg.C (60.80 deg.F).
(c) If necessary, apply a second layer of the primer. Let the primer
dry in the air for at least four hours at a minimun temperature
of 16 deg.C (60.80 deg.F).
(3) Apply the two-pack epoxy finish
WARNING : YOU MUST KEEP THE EPOXY FINISH AWAY FROM SPARKS, FLAMES AND
_______
HEAT. THE EPOXY FINISH IS FLAMMABLE AND CAN CAUSE A FIRE.
WARNING : YOU MUST NOT GET THE EPOXY FINISH ON YOUR SKIN OR IN YOUR
_______
EYES. THE EPOXY FINISH IS HARMFUL. USE AN APRON, APPLICABLE
GLOVES AND EYE PROTECTION. IF YOU GET THE EPOXY FINISH ON
YOUR SKIN, REMOVE IT WITH SOAP AND WATER. REMOVE CLOTHING
IF CONTAMINATION HAS OCCURRED. IF YOU GET THE EPOXY FINISH
IN YOUR EYES, FLUSH THEM WITH ISOTONIC SALINE OR WATER FOR
15 MINUTES MINIMUM. IMMEDIATELY GET MEDICAL AID. IF THE
EPOXY FINISH GOES THROUGH YOUR SKIN, THERE CAN BE A HEALTH
RISK.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE EPOXY FINISH OR GET
_______
IT IN YOUR MOUTH. THE EPOXY FINISH IS HARMFUL. USE THE
APPROVED FACE MASK. ALSO USE THE EPOXY FINISH IN AN AREA
THAT HAS A GOOD FLOW OF AIR. IF YOU GET THE EPOXY FINISH IN
YOUR MOUTH, FLUSH WITH WATER. IMMEDIATELY GET MEDICAL AID.
IF THE EPOXY FINISH IS BREATHED IN OR DRUNK THERE CAN BE A
HEALTH RISK.
(a) Mix together equal volumes of the two-pack epoxy finish and
catalyst (Material No. OMat 799). Add sufficient thinners
(Material No. OMat 793) to get the correct viscosity for brush
application.
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NOTE : The mixture has a pot life of eight hours, material not
____
used in this time must be discarded.
(b) Use a small brush to apply one layer of the finish to the repair
surface. Let the finish dry in the air for at least one hour, at
a minimun temperature of 16 deg.C (60.80 deg.F).
(c) If necessary, apply a second layer of the finish. Let the finish
dry in the air for at least four hours, at a minimun temperature
of 16 deg.C (60.80 deg.F).
(d) Remove and discard the adhesive tape.
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TASK 70-20-03-300-804
Application of Adhesive Bonding, Sealing and Filling Agents - Maintenance
Process 707
_______
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
cloth
comb
container
distilled water
dry oil-free compressed air supply
palette knife
precision scales
pressure gun
small trowel
soft-hair brush
spatula
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 145
Material No.
OMat 150
Material No.
OMat 2-65
Material No.
OMat 8-52
Material No.
OMat 874
Material No.
OMat 874B
Material No.
OMat 874C
Material No.
OMat 874D
*
abrasive medium (Ref. 70-30-00)
*
acetone (Ref. 70-30-00)
*
Stainless steel wire 0.006 thickness (Ref. 70-30-00)
*
adhesive (Ref. 70-30-00)
*
filler (Ref. 70-30-00)
*
*
*
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
70-20-03-300-802
70-20-03-991-001
101
Application of Chromate Conversion Coating to
Aluminium - Maintenance Process 330
Fig. 201
3. __________
Job Set-up
Subtask 70-20-03-869-053
A. Not applicable.
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4. Procedure
_________
Subtask 70-20-03-340-050
A. General
(1) The usual types of adhesive/sealant are epoxy resins, acrylic
adhesives, cyanocrylate adhesives, silicone adhesive sealants and
polysulphide adhesive sealants.
(2) Some adhesives are one-part systems, thus it is not necessary to mix
them. Some adhesives are supplied in measured kits (such as Sem-kits
or blister packs). Although the kits supply accurately measured
quantities, it is equally important that their materials are mixed
together fully, as with independently measured materials. Some
materials, for example epoxy resins, are supplied as two parts that
must be accurately measured and mixed before they are used.
(3) You must keep the adhesives in a cool dry environment when in
storage. The applicable storage temperature must be as specified by
the manufacturer. Some materials can be kept in storage at room
temperature. Some materials must be kept in a refrigerator at 4 deg.C
(39.20 deg.F). Some materials must be kept in a freezer at minus 18
deg.C (64.40 deg.F).
(4) The paragraphs that follow give general data for:
- Standard Equipment and Consumable Materials
- Epoxy Resins.
(5) Standard Equipment and Consumable Materials.
(a) Spatula.
1
_
Use a spatula to put the resin/hardener into the applicable
container(s). Also, use a spatula to mix the resin/hardener
together. The typical type of spatula that is used is a wooden
tongue depressor. It is important that you use a different
spatula for each different resin material to prevent
contamination.
NOTE : Make sure that the spatulas are kept in dry storage
____
conditions, as wood can absorb moisture.
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(b) Container.
CAUTION : YOU MUST NOT USE WAXED OR COATED CONTAINERS. THE
_______
COATING CAN DISSOLVE AND CAUSE THE CONTAMINATION OF THE
MATERIAL.
1
_
A container is necessary to contain the resin when it is
measured and mixed. The recommended containers are made of
transparent High Density Polyethylene (HDPE) with a height to
diameter ratio of one. A radius in the bottom of the container
helps to make sure that material is not caught in the bottom
that is not mixed. The transparent sides of the container let
you see that the resin is mixed fully. Alternatively, paper
that is not coated or clean metal containers can be used.
(c) Shallow tray.
1
_
A shallow tray can be used for larger quantities of the mixed
resin. This will prevent the build-up of heat and thus help to
give a pot-life of maximum length. The tray must be made of
the same material as the container above, or can have a top
layer of Mylar or Nylon film.
(d) Precision scales.
1
_
Precision scales are necessary to weigh the resin/hardener.
The scales must be electronic, triple beam or equal arm with
one beam. The accuracy of the scales must be better than 1
percent of the smallest quantity to be weighed. For example,
if the quantity to be weighed is 10 g (0.35 oz), then the
accuracy of the scales must be 0.1 g (0.00 oz).Spring scales
must not be used.
NOTE : Scales with a Tare selection can help you to weigh-out
____
the resin/hardener more accurately. The Tare selection
lets you set the scale to zero after each item
(container, material) is weighed. Thus each item can be
weighed independently.
(e) Heating devices.
1
_
Some adhesives can be cured at increased temperatures. This
can be done with infrared heaters, hot air guns, air
re-circulatory ovens or heater blankets. If the repair does
not specify the equipment (but gives the instruction that the
cure time for the material can be decreased by heat), make the
selection of the applicable heating device. The device must be
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calibrated and it must supply a constant heat at the bond
line. The device must also be approved for the repair location
and conditions.
(f) Clamping devices.
1
_
It is necessary to clamp many assemblies in the correct
position while the adhesive cures. This can be done with
weights, clamps or tape. The method that is used must not
cause damage to the component. Tape must be approved and be
applicable for the temperature of the repair area. The
clamp(s) must not be bonded to the component and must be
removed when the adhesive has cured.
(g) Gap setting.
1
_
When it is necessary to set the adhesive line thickness, this
can be done with:
- Component design, for example pips on the surface of the
bond
- Stainless steel wire 0.006 thickness (Material No. OMat 265), for example
- Tool fixtures
- Supported adhesive.
(6) Epoxy resins.
(a) Epoxy resins are used to bond composites, honeycomb and metal.
They have a good resistance to fluids, which gets better with the
grades that are cured by heat. As a general rule, grades that are
cured by heat can be applied in higher temperature areas than
those cured at room temperature. The highest temperature
materials will operate continuously at temperatures of 200 deg.C
(392.00 deg.F).
(b) Many types of epoxy resins are available. There are one and two
part pastes, one-part powders, unsupported and supported films.
In general, they are brittle materials and grades that are cured
by heat are more brittle than those cured at room temperature.
But there are stronger and more peel resistant types.
(c) Epoxy resins become hard as a result of a chemical reaction at
specified temperatures in relation to their type. The chemical
type of the hardener has the primary effect on the properties of
the material.
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(d) Refer to the manufacturers data if the data that follows is not
specified in the related repair procedure:
- The ratio of the resin/hardener mixture
- The recommended temperatures to apply the material
- The pot life/gel time
- The cure cycle.
(e) Mix.
WARNING : YOU MUST NOT MIX MORE THAN THE MANUFACTURERS
_______
RECOMMENDED QUANTITIES OF EPOXY RESINS OR FILLERS AT A
TIME. IF THE QUANTITY IS TOO LARGE, THERE CAN BE A
DANGEROUS BUILD-UP OF HEAT. THIS CAN CAUSE AN INJURY OR
DAMAGE TO COMPONENTS.
1
_
The cure cycle starts as soon as the resin and the hardener
are mixed. This cycle is an exothermic reaction that causes
heat to occur in the mixture. If the heat cannot be released
to the environment, the increased temperature of the mixture
can cause the pot life to be very short. There can also be a
dangerous build-up of heat. If the heat can be released to the
environment, then the pot life can be sufficiently longer.
Thus there is a relation between the mass of the resin and the
area of the applied mixture.
(f) Make sure that you do a check of the shelf life of the resin and
the hardener. Do not use the resin/hardener if its shelf life has
expired.
(g) Make sure that the related surfaces of the component are fully
prepared before you mix the resin/hardener.
(h) Do not mix too much of the material such that its pot life has
expired before it has all been applied. The recommended quantity
of each mixture is approximately 250 g (8.81 oz). If large
quantities of the mixture are necessary, keep the weighed
resin/hardener in storage until immediately before it must be
mixed.
(i) Make sure that the resin/hardener is at room temperature before
you open the containers. This will prevent the condensation of
moisture on the resin/hardener. Also, make sure that you close
the containers immediately after the necessary quantities have
been weighed-out. If the containers stay open, the resin/hardener
can absorb moisture, which can prevent the correct cure.
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(j) Use a different spatula for each different resin material to
prevent contamination.
(k) Weigh the resin in a container that is of sufficient dimensions
to hold the two parts of the material while they are mixed. If
the material is to be mixed immediately, then weigh the hardener
in the same container. If not, then weigh the hardener in a
different container. Make sure that you use the correct ratio of
the two parts as specified by the manufacturer.
(l) Mix the material with a spatula for a minimum time period of 3
minutes, or until the mixture has a constant color and texture.
Use the longest of the time periods to make sure that the
material is fully mixed. Stir the mixture slowly to keep as much
air as possible out of the mixture. Make sure that material on
the sides of the container is included in the mixture.
(m) Use the mixed resin immediately. To get the best pot-life for the
mixture, put the resin into a shallow tray or on to a film. This
will prevent the build-up of heat and thus help to give a
pot-life of maximum length.
Subtask 70-20-03-340-051
B. Apply the filler (Material No. OMat 874), filler (Material No. OMat
874B), filler (Material No. OMat 874C) and filler (Material No. OMat
874D)
(1) Prepare the filler (Material No. OMat 874) and filler (Material No.
OMat 874B).
NOTE : The filler (Material No. OMat 874) and filler (Material No.
____
OMat 874B) is a two-part low density compounds. Part A is a
white heavy consistency paste. Part B is a blue or black heavy
consistency paste.
(a) Use the precision scales to weigh 94 parts of part A and 100
parts of part B.
(b) Fully mix the materials by kneading until you get a constant
color without streaks.
NOTE : The mixed filler can only be used for approximately one
____
hour at 22 deg.C (71.60 deg.F). After this time period,
the remaining mixture must be discarded.
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(2) Prepare the filler (Material No. OMat 874C).
NOTE : The filler (Material No. OMat 874C) is a two-part low-density
____
compound. Part A is a white heavy- consistency paste. Part B
is a blue or black heavy-consistency paste.
parts of part B.
NOTE : The mixed filler can only be used for approximately one
____
hour at 22 deg.C (71.60 deg.F). After this time period,
(3) Prepare the filler (Material No. OMat 874D).
NOTE : The filler (Material No. OMat 874D) is a two-part low-density
____
compound that cures quickly.
NOTE : This filler can be used for small repairs as an alternative to
____
the slower types of the same material. Do not mix more than
can be applied before the pot life has expired.
parts of part B.
NOTE : The mixed filler can only be used for approximately 5
____
minutes at 22 deg.C (71.60 deg.F). After this time period,
(4) Apply the filler (Material No. OMat 874), filler (Material No. OMat
874B), filler (Material No. OMat 874C) and filler (Material No. OMat
874D).
(a) Use a spatula, palette knife, small trowel or pressure gun to
apply the filler.
NOTE : If the filler is tacky (thus you cannot get a smooth
____
air-washed surface), it is permitted to make the tool
moist with a small quantity of cold water. This will help
you to make the surface layer smooth. Be careful not to
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use too much water as this can cause the filler to become
too soft.
(b) Carefully use the edge of a tool blade to remove unwanted filler,
as soon as it is hard to the touch.
(5) Cure the filler (Material No. OMat 874), filler (Material No. OMat
874B) and filler (Material No. OMat 874C) for the applicable time, at
the related temperature.
(Ref. Fig. 201/TASK 70-20-03-991-001)
NOTE : The minimum cure time is 30 minutes.
____
NOTE : The filler will not cure below 12 deg.C (53.60 deg.F).
____
(6) Cure the filler (Material No. OMat 874D) for 2 hours at a room
temperature of 23 deg.C (73.40 deg.F).
Subtask 70-20-03-340-052
C. Apply the adhesive (Material No. OMat 8-52)
CAUTION : YOU MUST BOND THE PART(S) TOGETHER AS QUICKLY AS POSSIBLE AFTER
_______
YOU PREPARE THE SURFACES. THE MAXIMUM TIME PERIOD IN WHICH TO
BOND THE PARTS IS 8 HOURS. IF YOU TRY TO BOND THE PARTS AFTER
THIS TIME PERIOD, YOU WILL GET AN UNSATISFACTORY BOND AND
DAMAGE CAN OCCUR.
CAUTION : YOU MUST NOT TOUCH THE PREPARED SURFACES WITH YOUR HANDS OR
_______
CAUSE OTHER CONTAMINATION OF THE SURFACES. A DIRTY SURFACE CAN
CAUSE AN UNSATISFACTORY BOND AND DAMAGE CAN OCCUR.
(1) Prepare the applicable surfaces of the Aluminium, Titanium, Stainless
Steel or Nickel Base Parts.
(a) Initially remove the dirt and grease from the applicable surfaces
(Ref. TASK 70-20-01-100-802).
(b) Prepare the applicable surfaces with the abrasive medium
(Material No. OMat 145) (Ref. TASK 70-20-01-100-802).
Alternatively, use aluminium oxide, silicon carbide or garnet
paper (Grit size 60-180) to prepare the surfaces.
NOTE : Use the abrasive on the applicable surfaces for the
____
minimum time necessary to clean them. Use a dry oil-free
compressed air supply.
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Cure Times at Specified Temperatures
Figure 201/TASK 70-20-03-991-001
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NOTE : You can apply the chromate conversion coating to aluminium
____
components (Ref. TASK 70-20-03-300-802).
(c) Clean the applicable surfaces again (Ref. TASK 70-20-01-100-802).
(d) Do a water break test of the applicable surfaces to make sure
they are sufficiently clean.
1
_
Use a clean soft-hair brush to quickly apply a continuous
layer of distilled water to the surfaces.
2
_
Look for breaks in the layer of distilled water.
3
_
If breaks occur in 30 seconds or less, clean the applicable
surfaces again, then do the water break test again. Continue
to clean the surfaces until this test gives a continuous layer
of distilled water for more than 30 seconds.
4
_
Use a clean cloth made moist with clean acetone (Material No.
OMat 150) and remove the break test fluid.
5
_
Let the applicable surfaces become dry.
NOTE : Make sure that you do not touch the cleaned surfaces
____
with your hands before the adhesive is applied.
(2) Prepare the adhesive (Material No. OMat 8-52).
NOTE : The adhesive (Material No. OMat 8-52) is a two-part epoxy
____
resin base general adhesive which can be used at temperatures
up to 120 deg.C (248.00 deg.F). Part A of the adhesive is a
grey paste. Part B of the adhesive is an amber liquid. The
adhesive can also be used as a liquid shim.
NOTE : Make sure you read the general instructions given in para. 4.
____
A. before you do this procedure.
(a) Stir the Part A of the adhesive (the grey paste) fully before you
remove it from its container.
(b) Use the precision scales to weigh 100 parts of part A (the grey
paste) and 33 parts of part B (the amber liquid).
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(c) Mix the Parts A and B of the adhesive together fully.
NOTE : The mixed adhesive can only be used for approximately one
____
hour at 22 deg.C (71.60 deg.F). After this time period the
remaining mixture must be discarded.
(3) Apply the adhesive (Material No. OMat 8-52).
(a) Use a spatula, palette knife and comb to apply the adhesive
(Material No. OMat 8-52). Make the thickness of the adhesive
approximately 0.005 in. (0.1269 mm) to 0.024 in. (0.6095 mm).
NOTE : The thinner the layer of adhesive, the better the result.
____
But you will get a satisfactory bond with a thickness of
up to 0.04 in. (1.0159 mm).
(4) Cure the adhesive (Material No. OMat 8-52) for the applicable time,
at the related temperature.
(Ref. Fig. 201/TASK 70-20-03-991-001)
NOTE : The minimum cure time is 1 hour.
____
NOTE : The adhesive will not cure below 12 deg.C (53.60 deg.F).
____
NOTE : Make sure that you monitor the temperature at the bond line
____
with thermocouples (or available method) if you apply heat to
decrease the cure time.
(5) Do a visual inspection of the bond line.
NOTE : The repair can tell you to do more inspections than those
____
specified below.
(a) If you cannot see a continuous line of adhesive along the full
bond line, reject it.
(b) If there are cracks or delamination in the adhesive or the bonded
material, reject it.
(c) If there is a failure of the bond at the adhesive layer to bonded
material interface, reject it.
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LIST OF MATERIALS - DESCRIPTION AND OPERATION
_____________________________________________
1. General
_______
WARNING: BEFORE YOU USE A MATERIAL REFERRED TO IN THIS PUBLICATION, YOU MUST
KNOW ALL OF THE APPLICABLE PRECAUTIONS.
- USE THE MATERIAL SAFELY
- KEEP THE MATERIAL SAFELY
- DISCARD THE MATERIAL SAFELY.
READ THE SAFELY DATA SHEETS FROM THE MANUFACTURER OR THE SUPPLIER OF
THE MATERIAL TO LEARN THE RECOMMENDED PRECAUTIONS.
This page block gives all the consumable materials that are necessary for
the maintenance of the engine.
The list is divided into two parts:
- A materials list which lists the consumable materials by section. The
sections are:
Section 1 - Processing and Cleaning Materials
Section 2 - Processing Sundries and General Stores
Section 3 - Welding, Brazing and Metal Spraying
Section 4 - Greases, Jointings and Anti-Seize Compounds
Section 5 - Polishing and Dressing
Section 6 - Crack Detecting
Section 7 - Paints, Varnishes, Thinners and Non-Metallic Coatings
Section 8 - Bonding Agents, Adhesives, Fillers and Sealers
Section 9 - Not applicable
Section 10 - Oils and Fluids
Section 11 - Not applicable
Section 12 - Packing
- A list of Suppliers Names and Addresses which are in Supplier Code
alphanumeric order.
Alternative materials are shown with an alpha suffix attached to the
consumable material item number and can be used unless the maintenance
procedure tells you differently.
Orders to Rolls-Royce plc for materials, must only be related to materials
for which Rolls-Royce are given as the only supplier. But, aid will be given
if problems occur with the supply of consumable materials from other
sources.
If you need more data about consumable materials you must read the Overhaul
Materials Manual (OMat).
A. Abbreviations and Equivalents
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Af.
AMS
As.
A.S.T.M.
Aus.
B.S.
DERD
dia.
D.T.D.
Eu.
in.
mm.
MSRR
NA.
SA.
S.W.G.
UK.
-
African
American Material Specification
Asian
American Society for Testing Materials
Australian
British Standard
Directorate of Engineering, Research and Development
diameter
Directorate of Technical Development
European
inch
millimetre = 0.038 inches
Rolls-Royce Material Specification
North American
South American
Standard Wire Gauge (British Imperial)
United Kingdom
B. Standard Wire Gauge (British Imperial)
06 S.W.G. = 0.1920 in.
07 S.W.G. = 0.1760 in.
08 S.W.G. = 0.1600 in.
09 S.W.G. = 0.1440 in.
10 S.W.G. = 0.1280 in.
11 S.W.G. = 0.1160 in.
12 S.W.G. = 0.1040 in.
13 S.W.G. = 0.0920 in.
14 S.W.G. = 0.0800 in.
15 S.W.G. = 0.0720 in.
16 S.W.G. = 0.0640 in.
17 S.W.G. = 0.0560 in.
18 S.W.G. = 0.0480 in.
19 S.W.G. = 0.0400 in.
20 S.W.G. = 0.0360 in.
21 S.W.G. = 0.0320 in.
22 S.W.G. = 0.0280 in.
23 S.W.G. = 0.0240 in.
24 S.W.G. = 0.0220 in.
25 S.W.G. = 0.0200 in.
26 S.W.G. = 0.0180 in.
27 S.W.G. = 0.0164 in.
28 S.W.G. = 0.0148 in.
29 S.W.G. = 0.0136 in.
30 S.W.G. = 0.0124 in.
31 S.W.G. = 0.0116 in.
32 S.W.G. = 0.0108 in.
33 S.W.G. = 0.0100 in.
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34 S.W.G.
35 S.W.G.
36 S.W.G.
37 S.W.G.
38 S.W.G.
39 S.W.G.
40 S.W.G.
41 S.W.G.
42 S.W.G.
43 S.W.G.
44 S.W.G.
45 S.W.G.
46 S.W.G.
47 S.W.G.
48 S.W.G.
49 S.W.G.
50 S.W.G.
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
0.0092
0.0084
0.0076
0.0068
0.0060
0.0052
0.0048
0.0044
0.0040
0.0036
0.0032
0.0028
0.0024
0.0020
0.0016
0.0012
0.0010
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
in.
C. List of Consumable Products
(1) Section 1 - Processing and cleaning chemicals
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 101 Kerosine
Commercial grade
(D.Eng.RD 2494)
(MIL-T-5624 type
JP5)
Local purchase Aus. 1
OMat
101A
Safrasol
As.21
OMat 102 White spirit
B.S.245 P-D-680
TY1 or TY11
UK.10, 47, 261, 363
NA.36 or local purchase
OMat
102A
Solvent
Stoddard solvent
Type 1 to
A.S.T.M.D484
UK.10
NA.36, 138 or local purchase
OMat
102B
Solvent
Safranor
As.21
Kerosine
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------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 117 Phosphoric acid
S.G. 1.65 (0-0-670 UK.10
H3PO4
C1 1)
NA.36
OMat 135 Methyl ethyl
ketone (M.E.K.)
CH3C0 C2 H5
Technical
Grade
UK.40
UK.10
UK.209
UK.261
NA.2
NA.216
Local Purchase
OMat 145 Abrasive
medium
Aluminium oxide
60-80 mesh
CSS.12
FEPA 42-GB or
ANSI B74-12
UK.40
UK.10
UK.128
NA.61
NA.95
OMat 146 Abrasive
medium
Aluminium oxide
120-220 mesh
CSS.12
FEPA 32-GB
ANSI B74-12
120 grade
(A-A-1045T1)
UK.40
UK.10
UK.196
UK.27
UK.128
NA.61
NA.95
OMat 147 Abrasive
medium
Aluminium oxide
140-400 mesh
CSS.12
FEPA 42-GB
ANSI B74-12
220 Grade
(A-A-1045T1)
UK.40
UK.10
UK.196
UK.27
UK.128
NA.61
NA.95
OMat 150 Acetone (CH3) 2CO
Commercial grade
O-A-51
UK.10, 40, 209, 261,
OMat
175D
Part A Alocrom
1200 MP0004 Part B
Alocrom 1200
MP0005
UK.10, 272, 363,
NA.16
Chromate
conversion coating
for aluminum
(Brushing type)
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------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------(MIL-C-81706) type
C1A)
OMat 184 Abrasive
medium
Aluminium oxide
20 grade
CSS.12
FEPA 42-GB
ANSI B74-12
UK.40
UK.10
UK.128
NA.61
NA.95
OMat
1-21
Deleted - Use OMat
1/257, Desoclean
45 or OMat 150,
Acetone or
OMat 140, Iso
Propyl Alcohol
OMat
1-21A
Product no longer
supplied
Genklene LV.
OMat
1-21B
1.1.1
trichloroethylene
(Inhibited and
stabilized)
Triklone N
B.A.580:1963
Fed.Spec.1956
O-T-634a Type 2
UK.10, 47
OMat
1-21C
1.1.1
trichloroethane
(Inhibited and
stabilized)
Baltane
CF/Mecloran D
B.S.4487
MIL-T-81533A
UK.280
OMat
1-21D
1.1.1
trichloroethane
(Inhibited and
stabilized)
Tri-ethane (R)
MIL-T-81533A
UK.163
NA.129
OMat
1-21E
1.1.1
trichloroethane
(Inhibited and
stabilized)
Vulcan 1.1.1
NA.40
OMat
1-24
Primary cleaner
Ardrox 6025
DTD 5507B
UK.2
NA.127, 179
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------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
1-24A
Primary cleaner
Diversy 1255
UK.10, 236
NA.140
OMat
1-24B
Primary cleaner
Turco 5948-A
UK.126
NA.119
Eu.33, 34, 35
Aus.7
OMat
1-24C
Primary cleaner
Ardrox 631
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
1-24D
Primary cleaner
Ardrox 632
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
1-24E
Primary cleaner
Stripalene 275
UK.16, 272
NA.186
OMat
1-24F
Primary cleaner
Ardrox 6333
UK.2
NA.127, 179
Eu.28
AS.1, 9
SA.10
Af.11
Aus.1
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------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Primary cleaner
SAXIN P3
UK.272
1-24G
OMat
1-24H
Primary cleaner
Blue Gold
Industrial
Cleaner
NA.72
OMat
1-24J
Primary cleaner
Cee-Bee
A-7X7
UK.89
NA.52
OMat
1-24K
Primary cleaner
Turco 5948DPM
UK.126
NA.119
Eu.33, 34, 35
Aus.7
OMat
1-24L
Primary cleaner
Blue Gold
Spray Wash
NA.72
OMat
1-24M
Primary cleaner
Turco Liquid
Sprayeze-LT
UK.126
NA.119
Eu.33, 34, 35
Aus.7
OMat
1-24N
Primary cleaner
ED-306LF
NA.199
OMat
1-40
Iso propyl Alcohol
GPR BDH 29694
UK 10, 40, 209
OMat
1-119
Isopropanol (CH3)
2CHOH
(propan-2-ol)
Analar grade
BDH10224
UK.10, 209, 261
OMat
1-144
Filter paper
Whatman 541
UK.10, 209 or local purchase
OMat
1-176
Acetone
(CH3)2CO
Analar
BDH 10003
UK.10, 209, 261
NA.216 or local
purchase
EFF :
ALL
70-30-00
AFL
Page 7
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Cleaning solvent
Desoclean 45
UK.40
1-257
P-D-680 TY1
UK.163
NA.129
OMat
1-257A
Cleaning solvent
Desoclean 20
UK.163
NA.129
OMat
1-257B
Cleaning solvent
Applied 8-300
UK.142
OMat
1-257C
Cleaning solvent
Applied 8-000
UK.142
OMat
1-257D
Cleaning solvent
Ardrox 5548
UK.2
NA.127, 179 Eu.28 As.1, 9
SA.10 Af.11 Aus.1
OMat
1-257E
Cleaning solvent
MS38
UK.31
OMat
1-257F
Cleaning solvent
MS56
UK.31
OMat
1-257G
Cleaning solvent
Lotoxane
UK.32
As.2, As.3, As.6, Eu.17,
Eu.18, Eu.19, Eu.20
OMat
1-257H
Cleaning solvent
Lotoxane Fast
UK.32
As.2, As.3, As.6, Eu.17,
Eu.18, Eu.19, Eu.20
OMat
1-257J
Cleaning solvent
Primaclean 3650
UK.53
NA.27, 218 SA.8 As.18, 19
EU.42 Aus.8
OMat
1-260
Odourless Kerosine
Odourless Kerosine
DOD-F-87935
UK.13 or local purchase
OMat
1-260B
Odourless Kerosine
Safraker
As.21
EFF :
ALL
70-30-00
AFL
Page 8
Oct 01/08
TRENT 700
SERIES ENGINES
(2) Section 2 - Processing sundries and general stores
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 230 Adhesive tape
(Masking)
Zinc oxide
AT142
UK.10, 40 or
local purchase
OMat 237 Tape Adhesive
general purpose
paper
Scotch 202 Premium
grade
(A-A-883 Ty I)
UK.40
UK.10
UK.108
NA.70
OMat
237A
Tape Adhesive
Paper Masking
Scotch 213
UK.40
UK.10
UK.108
NA.2
NA.70
Aus.16
OMat
237B
Tape Adhesive
Paper Masking
Scotch 214
UK.40
UK.10
UK.108
NA.2
NA.70
Aus.16
OMat
237C
Tape Adhesive
Paper Masking
Scotch 232
UK.40
UK.10
UK.108
NA.2
NA.70
Aus.16
OMat
237D
Tape Adhesive
Paper Masking
Scotch 233
UK.40
UK.10
UK.108
NA.2
NA.70
Aus.16
OMat
237E
Tape Adhesive
Paper Masking
Scotch 236
UK.40
UK.10
EFF :
ALL
70-30-00
AFL
Page 9
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------UK.108
NA.2
NA.70
Aus.16
OMat 238 Lockwire
Staybrite DTD189A
(0.028 to 0.031
in. dia.)
UK.10, 245
NA.138
OMat
238A
Lockwire
MS9226-03 (0.025
in. dia.)
NA.30
OMat
238B
Lockwire
Pt No.5019006 AMS
5689 ASTM A-580
Type 321 condition
A (0.025 in. dia.)
NA.85
OMat 249 Modelling clay
Plasticine
A-A-51006
UK.10 or local purchase
NA.28
OMat 256 Adhesive tape
(P.T.F.E)
Scotch No 61
(brown)
UK.10, 108
NA.70, 2
OMat 261 Temporary marker
pencil/crayon
Berol Verithin
(hard type)
NA.28
OMat
261A
Temporary marker
pencil/crayon
Steadtler Mars
Ominchrom (medium
type)
UK.10, 171
NA.28
OMat
261B
Temporary marker
pencil/crayon
Style No.705 No
Blot Ink pencil
UK.10, 356
NA.116
OMat
261C
Temporary marker
pencil/crayon
All-Stabilo 8008
UK.10, 101
Eu.24
OMat
261D
Temporary marker
pencil/crayon
Staonal 222
UK.10
OMat
262A
Temporary marker
felt/fiber tip
Soft chalk
UK.10, 153
EFF :
ALL
70-30-00
AFL
Page 10
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Temporary marker
Staedtler
UK.171
262B
felt/fiber tip
Lumocolour 318
NA.28
OMat
262C
Temporary marker
felt/fiber tip
Staedtler
Panocolour 303
UK.171
NA.28
OMat
262D
Temporary marker
felt/fiber tip
Berol push start
valve marker
UK.10, 172 NA.105
OMat
262J
Temporary marker
felt/fiber tip
Berol wet wipe board writer
UK.10, 172 NA.105
OMat
262K
Temporary marker
felt/fiber tip
Pentel - felt or
fiber pen
UK.10, 173
NA.17
As.4
OMat
262M
Temporary marker
felt/fiber tip
Platignum Instant marker
UK.10
OMat
262N
Temporary marker
felt/fiber tip
Vari line marker
UK.10
OMat
262Q
Temporary marker
felt/fiber tip
Sharpie marker
UK.10
OMat
262S
Temporary marker
felt/fiber tip
Art line 30, 50,
70, 100 or 700
As.5
OMat
262T
Temporary marker
felt/fiber tip
Marks-A-Lot
NA.28
OMat 274 Lacing tape
T085
transparent
Silicone polyester
1602
UK.40, 10, 22
OMat 293 Tying cord
Fiber glass
(Electrical)
Scotch No.69
UK.10, 108
OMat 2-7 Wetting agent
Libranone 140
UK.10, 91
OMat
2-7A
Divoplus V5
UK.236
NA.140
Wetting agent
EFF :
ALL
70-30-00
R AFL
Page 11
Apr 01/09
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Spiral binding
Spiratemp 2P
UK.10, 61
2-18
R
R
R
R
OMat
2-18A
Tape
Rapidon MA2520/40
UK.10, 51
OMat
2-40
Adhesive tape
paper heat res.
masking tape
Sellotape 2595 or
3M HT214
UK.10, 22 NA.70
OMat
2-47
Cleaning pads
Lint-free pads
(protective mask
refill)
Local purchase
OMat
2-67
Disposable
cleaning tissues
Kimwipes No. 7105
UK.240
OMat
2-72
Lockwire
Staybrite
DTD 189A
20 S.W.G
0.036 in.
UK.40
UK.245
UK.10
OMat
2-88
Adhesive tape
polyester, clear
Scapa
1602 or 1610
BS3924
UK.40, 10, 22
OMat
2-88A
Cellulose tape
(clear)
OMat
2-101
Absorbent cloth
lint free
Superstrong
Soft - 917
MIL-C-24671A
UK.242 or
local purchase
OMat
2-115
Adhesive tape
3M-Y436 (Speed
Tape)
UK.108
NA.70
NA.2
OMat
2-125
Lockwire
DTD189 AMS5689
AS44725-2
MS20995C32 0,8 mm
dia.
UK.285 NA.85
UK.40, 10, 22
EFF :
ALL
70-30-00
AFL
Page 12
Apr 01/09
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Safety cable
Dia. 0.032in.
UK.74, 85 NA.107, 113 Eu.27
2-142
AS63237 - Cable
AS63239 - Ferrule
OMat
2-143
Safety cable
Dia. 0.020in.
AS63236 - Cable
AS63238 - Ferrule
UK.74, 85 NA.107, 113 Eu.27
(3) Section 4 - Greases, jointings and anti-seize compounds
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 402 Petroleum jelly
DEF.STAN 91-38
Grade PX-7
(VV-P-236)
Nato code NS743
Silkolene 77S
(yellow-soft)
UK.10, 243
OMat 418 Silicone grease
DEF.STAN59-10/2
(MS.4) MIL-S-8660
AMEND.1 (DC4)
AMS3087 NATO S-736
UK.10, 53
NA.27, 218
Aus.8
As.18, 19
Eu.42
SA.8
Jointing Renolit 762
compound
UK. 40, 10, 243,
261
NA.2
Local
OMat
4-21A
Sundstrand
PN.730691-1 5cc
PN.730691-2 1 lb
Anti-frettage
compound
(Molybdenum
disulphide)
UK.10
NA.73
EFF :
ALL
70-30-00
AFL
Page 13
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Anti-seize
Bostik Never Seez
UK.10, 83 NA.19, 2
4-23
compound, pure
NS-165 NSN-16A
nickel special
MSRR 9409
OMat
4-24
Thread Sealer
Sauereisen Cement
Insa-Lute
N⁰.1
UK.40
NA.68
Local
OMat
4-46
Jointing compound
DTD.900/4586
Hylomar PL32
(Light)
UK.7, 10, 261
NA.2
OMat
4-47
Jointing compound
DTD.900/4586
Hylomar PL32
(Medium)
UK.7, 10, 261
NA.2
OMat
4-50
Lubricant paste
Molykote G rapid
plus
UK.10, 53
NA.27, 218
Eu.42
As.18, 19
SA.8
Aus.8
OMat
4-51
Bonded Lubricant
Dow Corning 321R
UK.10, 53
NA.27, 218
As.18, 19
Aus.8
OMat
4-52
Dry film
anti-scuffing
spray
Rocol A.S.
UK.10, 52, 6
NA.2, 102
As.8
Aus.14
OMat
4-62
Hight temperature
anti-seize
compound
Rocol ASC251
MSRR4008
UK.10, 52,6 NA.2, 124
As.8
Aus.12
SA.1
OMat
4-67
Lubricant
Rocol Dry PTFE
Spray
UK.6, 10, 52
NA.2, 124
As.8
EFF :
ALL
70-30-00
AFL
Page 14
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------R
Aus.14 GT
R
R
R
OMat
4-70
Dry Film Lubricant
PL 470
Paint Rapid
Relubrication
System
UK.40
UK.261
NA.2
R
R
OMat
4-71
Rapid
Relubrication
System Trent 700
UK.40
(4) Section 5 - Polishing and dressing
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 582 Scotch-brite
Type S.7448
ultrafine (grey)
(MIL-A.9962A type
III grade
AAA) (CSS 222)
UK.10
UK.40
UK.108
OMat
5-33
Waterproof silicon
carbide
Grit size 320
A-A-1047
UK.10, 29
OMat
5-35
Waterproof silicon
carbide
Grit size 240
A-A-1047
NA.95
OMat
5-39
Waterproof silicon
carbide
Grit size 120
A-A-1047A
UK.29, 40, 161
NA.95
OMat
5-41
Waterproof silicon
carbide
Grit size 80
A-A-1047
UK.40, 29
NA.95
LOCAL
OMat
5-43
Emery paper
(standard)
00 ELN 251
UK.10, 196
EFF :
ALL
70-30-00
AFL
Page 15
Jan 01/09
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Aluminium oxide
Grade 150
UK.10, 20, 161 NA.95
5-63
abrasive paper
Grit size A-A-1048
OMat
5-64
Aluminium oxide
abrasive paper
Grade 120
Grit size
UK.10, 29, 40, 161
NA.95
OMat
5-93
Garnet paper
Grit size 180
Grade 5/0
(A-A-1201 Class 2)
UK.40, 10, 29
NA.95
OMat
5-96
Garnet paper
Grit size 100
Grade 2/0
(A-A-1201
Class 2)
UK.10, 29, 161
NA.95
UK.40
OMat
5-97
Garnet paper
Grit size 80
Grade 0
(A-A-1201
Class 2)
UK.10, 29, 161
NA.95
OMat
5-98
Garnet paper
Grit size 60
Grade 1/2
(A-A-1201
Class 2)
UK.10, 29, 161
NA.95
OMat
5-100
Garnet paper
Grit size 40
Grade 1 1/2
(A-A-1201A Class
2)
UK.40, 10
NA.136
EFF :
ALL
70-30-00
R AFL
Page 16
Jan 01/09
TRENT 700
SERIES ENGINES
(5) Section 6 - Crack Detecting
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 606 Developer,
powder
Magnaflux ZP-4B
MIL-I-25135
UK.10, 87
NA.20 or
local purchase
OMat
606A
Developer,
powder
Ardrox 9D4A
MIL-I-25135
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
606B
Developer,
powder
Britemor PD3
or PD4
MIL-I-25135
UK.10, 71
NA.99, 214
As.14, 15
Af.10
Aus.5
OMat
606C
Developer,
powder
Met-L-Check
D72A
MIL-I-25135
NA.63
Eu.21 or
local purchase
OMat
606D
Developer,
powder
Turco DD2A
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7, 28
Aus.13
OMat
606E
Developer,
powder
F-5D/1
MIL-I-25135
As.16
OMat
606H
Developer,
powder
Dubl-Check
D90G
MIL-I-25135
NA.171 or
local purchase
Ardrox No.9
PR50
DTD 929
UK.2
NA.127, 179
Eu.28
OMat 616 Solvent
penetrant
remover
EFF :
ALL
70-30-00
AFL
Page 17
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------(MIL-I-25135
As.1, 9
Class 2)
SA.10
Af.11
Aus.1
OMat
616A
Solvent
penetrant
remover
Turco Dy-Check
Remover
DTD 929
UK.10, 126
NA.119
Eu.33, 34, 35
Aus.7, 13
AS.28
OMat
616C
Solvent
penetrant
remover
Magnaflux SKC-S
UK.10, 87
NA.20 or
local purchase
OMat 617 Developer,
non-aqueous
aerosol
Ardrox No.9D6F
or 9D1B
MIL-I-25135
form A
DTD 929
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
617A
Developer,
non-aqueous
aerosol
Turco NAD
Developer
DTD 929
UK.10, 126
NA.119
Eu.33, 34, 35
Aus.7
OMat
617B
Developer,
non-aqueous
aerosol
Magnaflux ZP-9E
MIL-I-25135
form d type 1
UK.10, 87
NA.20 or
local purchase
OMat
621A
Fluorescent
penetrant
remover
(hydrophilic)
Ardrox 9 PR12
MIL-I-25135C
DTD 929
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
EFF :
ALL
70-30-00
AFL
Page 18
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Fluorescent
Met-L-Check
NA.63
621B
penetrant
E-58D
Eu.21
remover
MIL-I-25135
(hydrophilic)
OMat
621E
Fluorescent
penetrant
remover
(hydrophilic)
Turco E41k
MIL-I-25135
UK.126
NA.119
EU.33, 34, 35
Aus.7, 13
AS.28, 29
OMat
621F
Fluorescent
penetrant
remover
(hydrophilic)
Zyglo ZR10A
or ZR10B
MIL-I-25135
UK.10, 87
NA.20 or
local purchase
OMat
621H
Fluorescent
penetrant
remover
(hydrophilic)
H91 or H91A
UK.10, 71
NA.99, 214
As.14, 15
Af.10
Aus.5
OMat
621J
Fluorescent
penetrant
remover
(hydrophilic)
Emulsifier
F-6E-W/1
MIL-I-25135
As.16
OMat
621L
Fluorescent
penetrant
remover
(hydrophilic)
Dubl-Check
ER 83A
NA.171 or
local purchase
Ardrox 970/P25
DTD 929
MIL-I-25135C
(1.A.3.)
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat 632 Fluorescent
penetrant,
high sensitivity
water washable
EFF :
ALL
70-30-00
AFL
Page 19
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Fluorescent
Sherwin HM607
NA.171 or
632B
penetrant,
MIL-I-25135
local purchase
high sensitivity
(1.A.3.)
water washable
OMat
632C
Fluorescent
penetrant,
high sensitivity
water washable
Zyglo ZL55 or
ZL67
MIL-I-25135
(1.A.3.)
UK.10, 87
NA.20 or
local purchase
OMat
632D
Fluorescent
penetrant,
high sensitivity
water washable
Turco WP170LS
or WP170LSBD
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7
OMat
632E
Fluorescent
penetrant,
high sensitivity
water washable
Britemor 446
UK.10, 71
NA.99, 214
As.14, 15
Af.10
Aus.5
OMat
632F
Fluorescent
penetrant,
high sensitivity
water washable
F-4A-C/1
MIL-I-25135
(1.A.3)
As.16
OMat
632G
Fluorescent
penetrant,
high sensitivity
water washable
Met-L-Chek
FP-903
MIL-I-25135
(1.A.3)
NA.63
Eu.21
OMat 641 Surface inspection
fluid
NML21
MSRR 9015
UK.10, 261
NA.2
penetrant,
medium sensitivity
post-emulsified
Zyglo ZL-2C
MIL-I-25135
(1.D.2)
UK.10, 87
NA.20 or
local purchase
OMat
650A
Ardrox 985-P12
MIL-I-25135
UK.2
NA.127, 179
Fluorescent
penetrant,
EFF :
ALL
70-30-00
AFL
Page 20
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------medium sensitivity (1.D.2)
Eu.28
post-emulsified
As.1, 9
SA.10
Af.11
Aus.1
OMat
650B
Fluorescent
penetrant,
medium sensitivity
post-emulsified
Met-L-Chek
FP-93A (M)
MIL-I-25135
(1.D.2)
NA.63
Eu.21 or
local purchase
OMat
650C
Fluorescent
penetrant,
medium sensitivity
post-emulsified
F-5L-SP/1
MIL-I-25135
(1.D.2)
As.16
OMat
650D
Fluorescent
penetrant,
medium sensitivity
post-emulsified
Britemor 555
MIL-I-25135
(1.D.2)
UK.10, 71
NA.99, 214
As.14, 15
Af.10
Aus.5
OMat
650E
Fluorescent
penetrant,
medium sensitivity
post-emulsified
Turco P-31H1
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7
penetrant,
high sensitivity
post-emulsified
Zyglo ZL27A
or ZL22D
MIL-I-25135
(1.D.3)
UK.10, 87
NA.20 or
local purchase
OMat
651A
Ardrox 985-P13
MIL-I-25135
(1.D.3)
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
Fluorescent
penetrant,
high sensitivity
post-emulsified
EFF :
ALL
70-30-00
AFL
Page 21
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Fluorescent
Britemor 600
UK.10, 71
651B
penetrant,
MIL-I-25135
NA.99, 214
high sensitivity
(1.D.3)
As.14, 15
post-emulsified
Af.10
Aus.5
OMat
651C
Fluorescent
penetrant,
high sensitivity
post-emulsified
F-6A-1
MIL-I-25135
(1.D.3)
As.16
OMat
651D
Fluorescent
penetrant,
high sensitivity
post-emulsified
Met-L-Check
FP-95A (M)
MIL-I-25135
(1.D.3)
NA.63
Eu.21 or
local purchase
OMat
651E
Fluorescent
penetrant,
high sensitivity
post-emulsified
Turco P-41H1
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7
OMat
651F
Fluorescent
penetrant,
high sensitivity
post-emulsified
Sherwin RC65
MIL-I-25135
(1.D.3)
NA.171 or
local purchase
penetrant,
ultra high
sensitivity
post-emulsified
Ardrox 985-P14
MIL-I-25135
(1.D.4)
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
Af.11
Aus.1
OMat
652A
Zyglo ZL37
MIL-I-25135
(1.D.4)
UK.10, 87
NA.10 or
local purchase
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
EFF :
ALL
70-30-00
AFL
Page 22
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Fluorescent
Britemor 668
UK.10, 71
652B
penetrant,
MIL-I-25135
NA.99, 214
ultra high
(1.D.4)
As.14, 15
sensitivity
Af.10
post-emulsified
Aus.5
OMat
652C
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
F-6A-SP/1
MIL-I-25135
(1.D.4)
As.16
OMat
652D
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
Dbul-Check
RC77
MIL-I-25135
(1.D.4)
NA.171 or
local purchase
OMat
652E
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
Met-L-Check
FP-97A (M)
MIL-I-25135
(1.D.4)
NA.63
Eu.21 or
local purchase
OMat
652F
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
Turco P-60H (M)
or P-60_H2
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7, 28
Aus.13
OMat
652G
Fluorescent
penetrant,
ultra high
sensitivity
post-emulsified
Sherwin RC77
MIL-I-25135
(1.D.4)
NA.171 or
local purchase
Ardrox 970/P23
and 970/P24
MIL-I-25135
(1.A.2)
UK.2
NA.127, 179
Eu.28
As.1, 9
SA.10
penetrant,
medium sensitivity
water washable
EFF :
ALL
70-30-00
AFL
Page 23
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------Af.11
Aus.1
OMat
653A
Fluorescent
penetrant,
medium sensitivity
water washable
Zyglo ZL17D
and ZL60C
MIL-I-25135
(1.A.2)
UK.10, 87
NA.20 or
local purchase
OMat
653B
Fluorescent
penetrant,
medium sensitivity
water washable
Turco WP100M
or WP100H or
WP100LSBD
MIL-I-25135
UK.10, 126
NA.119
Eu.33, 34, 35
As.7, 28
Aus.13
OMat
653C
Fluorescent
penetrant,
medium sensitivity
water washable
Britemor 4455
MIL-I-25135
(1.A.2)
UK.10, 71
NA.99, 214
As.14, 15
Af.10
Aus.5
OMat
653D
Fluorescent
penetrant,
medium sensitivity
water washable
F-4A-B/1
MIL-I-25135
(1.A.2)
As.16
OMat
653E
Fluorescent
penetrant,
medium sensitivity
water washable
Met-L-Check
FP-92B (M)
MIL-I-25135
(1.A.2)
NA.63
Eu.21
OMat
653F
Fluorescent
penetrant,
medium sensitivity
water washable
Sherwin HM406
or HM3A
MIL-I-25135
(1.A.2)
NA.171 or
local purchase
EFF :
ALL
70-30-00
AFL
Page 24
Oct 01/08
TRENT 700
SERIES ENGINES
(6) Section 7 - Paints, varnishes, thinners and non-metallic coatings
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 766 Two-pack epoxy
primer and
catalyst
(Strontium
chromate)
Base component PR
143R
Catalyst ACT 149R
MIL-P-23377
UK.10, 163 NA.129
OMat 788 Two-Pack Epoxy
Finish Black and
Catalyst
Base EC78/801
Black
Catalyst ACT65
UK.40, UK.10, UK.163,
NA.129
OMat
788A
Two-Pack Epoxy
Finish Black and
Catalyst
IP9064/9000 +
IP9064/CAT.
UK.40, UK.261
NA.2
OMat
788B
Two-Pack Epoxy
Finish Black and
Catalyst
IP2/9000 +
IP2/CAT.
UK.40, UK.261
NA.2
OMat 793 Thinners, for
two-pack epoxy
finishes
T17
UK.10, 163 NA.129
OMat 799 Two-pack epoxy
finish yellow
and catalyst
BSC381: No356
Base EC75R/356
Catalyst ACT65R
UK.10, 163 NA.129
OMat
7-35A
Air drying
touch-up enamel,
aircraft grey
B.S.C.693
IP 9170
UK.261
NA.2
OMat
7-84
Yellow marking
paint, water based
PL168A
UK.10, 261
NA.2
OMat
7-124
Potassium silicate
solution
No.66 grade
Wt.Ratio 2:2.1 (Si
02/K20)
UK.10, 134, 261
NA.2
EFF :
ALL
70-30-00
AFL
Page 25
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Potassium silicate Kasil 33 Wt.Ratio
7-124A
solution
2:2.1 (Si 02/K20)
OMat
7-197
Thinners
Diestone D
Local
OMat
7-229
Inspection Marking
Lacquer
Torque Seal F925
UK.10
UK.40
NA.267
(7) Section 8 - Bonding Agents, Adhesives, Fillers and Sealers
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat 805 Resin
Araldite
SV.409
UK.38, 261, 273 NA.89, 2
OMat 806 Hardener
Versamid
polyamide 140
UK.10, 261, 328
NA.37, 153 or
Local purchase
OMat 872 Cold curing
silicone compound
(While)
Silcoset 152
UK.10, 175, 261 NA.2
OMat
872A
Cold curing
silicone compound
(Red)
RTV106 MIL-A-46106
AFS 1755
UK.10, 190
NA.108, 125
OMat
872D
Bonding agent
RTV159 AFS 1756
UK.10, 190
NA.108, 125
OMat
872E
Cold curing
silicone rubber
(black)
Ambersil 1008A
UK.10, 175
EFF :
ALL
70-30-00
AFL
Page 26
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Cold curing
Silastic 732
UK.10, 53
872F
silicone rubber
NA.27, 218
SA.8
As.18, 19
Eu.42
Aus.8
OMat 874 Filler
Two-pack
EC3524B/A
Part A & B
MSRR 1001
(Injection and
spatula
application.)
UK.40, UK.10, UK.108
NA.70, NA.2
OMat
874A
Filler
Two-pack
OMat
874B
Filler
Two-pack
EC3524B/A AF
MSRR 1002
Spatula
application only.
UK.40, UK.10, UK.108
NA.70
OMat
874C
Filler
Two-pack
Epocast 1637
MSRR 1001
UK.40, UK.38
NA.89
OMat
874D
Filler
Two-pack
EC 3534 B/A
UK.40, UK.10, UK.108
NA.70
Eu.47
OMat
8-52
Epoxy Paste
Adhesive
Hysol EA934NA
(2-part)
MSRR9328
MMM-A-132
Type 1, Class A
Alternative
OMat 8/154
UK.40, 332, 10
Eu.38
NA.164, NA.2
OMat
8-66
Locking Compound
Loctite 222
NATO 8030-99
-224-8425
AFS 1737A
DTD 900/6003C
MIL-S-46163A
Type 2
UK.40,10,124,261
NA.80,88,2
SA.5
Af.6
As.10,11
Aus.2
EFF :
ALL
70-30-00
R AFL
Page 27
Jan 01/09
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Deleted
8-66A
R
R
R
R
R
R
R
OMat
8-66B
Locking Compound
Permabond A011
UK.40,10,277
NA.168,219
OMat
8-66C
Locking Compound
Permabond A123
UK.40,10,277
NA.168,219
OMat
8-68
Locking Compound
Loctite 242
NATO 8030-99
-224-8707
MIL-S-46163
8-18 Nm
Type 2, Grade N
AFS 1737A
UK.40,10,124
NA.80,88
SA.5
AS.5,10,11
OMat
8-77A
Retaining compound
Loctite 648
UK.10,40,124,261
NA.2,88
AS.10,11
AUS.2
SA.5
AF.6
OMat
8-107
Sealant
Two part
polysulphide
PR 1436G B1/2
dichromate cat
MIL-S-81733
UK.40, 10, 163
NA.87
OMat
8-107A
Sealant
Two part
polysulphide
PR 1436G B2
dichromate cat
MIL-S-81733
UK.40, 10, 163
NA.87
OMat
8-107B
Sealant
Two part
polysulphide
PR 1436G B4
dichromate cat
MIL-S-81733
UK.40, 10, 163
NA.87
OMat
8-107C
Sealant
Two part
polysulphide
P/S870B-1/2
MIL-S-81733
UK.40, 163
NA.87
OMat
8-107D
Sealant
Two part
polysulphide
P/S 870B-2
UK.40, 163
NA.87
EFF :
ALL
70-30-00
AFL
Page 28
Jan 01/09
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Polysulphide
PR1422B-2
UK.10, 40, 163
8-136
Compound
Two pack mix
NA.87
Base and
accelerator
DTD 900/4868
dichromate cat
OMat
8-173
Adhesive/sealant
Q4-2817
NA 27, 218, 2
OMat
8-176
Sealing Compound
Mastinox D40
Eu.4
(8) Section 10 - Oils and fluids
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
1001A
Penetrating oil
Plus-gas
UK.10, 29 or
Local purchase
OMat
1001B
Penetrating oil
Freeway 8-46
UK.10, 142
OMat
1011
Engine lubricating
oil (synthetic)
As given in
Chapter
70-02-02(0)
OMat
1024A
Mineral oil
Aeroshell
turbine oil
No.2 or ROYCO
481
MIL-L-6081
GRADE 1010
NATO 0-133
UK.13
NA.10
NA.44
SA.7
AF.8
AUS.6
EFF :
ALL
70-30-00
AFL
Page 29
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
Mineral oil
Avrex M Turbo
NA.100
1024C
201/1010
MIL-L-6081
GRADE 1010
NATO 0-133
OMat
1024D
Mineral oil
Castrol Aero
GT1010
MIL-L-6081
GRADE 1010
NATO 0-133
UK.10
UK.60
NA.99
NA.214
AS.14
AS.15
AF.10
AUS.5
SA.2
UK.40
OMat
1069
Assembly fluid
Turbo 10
UK.10
NA.190
OMat
1070D
Compressor washing
fluid
Ardrox 6345
UK.2 NA. 127, 179
Eu.28 As1, 9
SA.10 Af.11 Aus.1
OMat
1071
Assembly oil
Aeroshell 750
DERD.2487
NATO 0-149
UK.10, 13
NA.10, 44
SA.7
Af.8
Aus.6
OMat
1071A
Assembly oil
Castrol 98
DERD.2487
UK.10, 60
NA.99, 214
Af.10
As.14, 15
Aus.5
AS.2
OMat
1071B
Assembly oil
Exxon ET0274
DERD.2487
UK.3, 10
NA.33
SA.6
Eu.36
EFF :
ALL
70-30-00
AFL
Page 30
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------Af.9
As.12
Aus.3
OMat
1076
MonoPropylene
Glycol
UK.71
(9) Section 12 - Packing
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------OMat
1208
Desiccant and
Humidity Indicator
Silica Gel BS.3523
Cobalt Chloride
type
UK.10,40,156,350
OMat
1221
Printed, waxed,
VCI coated kraft
paper
CARRS No.03181
Anti-corrosion
paper (CSS117)
MIL-P-3420
Class 1 Style A
Form B
UK.10, 279, 350
OMat
1222
PVC Sheeting
Grade 5S H200
embossed
Green 317
B.S.1763
Type 1A
UK.10,197, 350
OMat
1226
Grease resistant
paper
DEF STAN 81-93
UK.10, 350
OMat
1226A
Deleted
Replaced by Item
1222
OMat
1228
PVC self
adhesive tape
2in. wide black
Adhesive tape
UK.10
EFF :
ALL
70-30-00
AFL
Page 31
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------MANUFACTURERS
REFERENCE
ITEM No.
AND/OR
SUPPLIER
OMat
MATERIAL
SPECIFICATION
CODE
------------------------------------------------------------------------------(Sellotape)
OMat
1249
Polythene sheet
DEF.93-116/1
L-P-512TY1CLGD1
UK.40, 350, 10
D. Suppliers Names and Addresses
(1) United kingdom suppliers (UK.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------OMat
K6858
OMat
K3237
UK.2
Brent Europe Ltd,
Aerospace Systems Group,
Ridgeway,
Iver,
Buckinghamshire,
SLO 9JJ
Phone: 01753 630200
Telex: 847693
Fax: 01753 652460
UK.3
Esso Petroleum Co. Ltd,
Ermyn Way,
Leatherhead,
Surrey, KT22 8UX
Phone: 01372 222000
Telex:
Fax: 01372 223588
UK.7
Marston Bentley Ltd,
Hylo House,
Cale Lane,
New Springs,
Wigan WN2 1JR
Phone: 01942 824242
Telex: 67230
Fax: 01942 826653
EFF :
ALL
70-30-00
AFL
Page 32
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------OMat
UK.10
Med-Lab Limited,
K6835
Copeland Street,
Derby.
Phone: 01332 349094
Telex:
Fax: 01332 371237
e-mail: sales med-lab.co.uk
URL: www.med-lab.co.uk
UK.13
Shell Oils,
Rowlasndsway House,
on Rowlasndsway,
Wythenshawe,
Manchester, M225 5SB
Phone: 0161 499 4000
Telex:
Fax:
UK.16
D.A Stuart Oil Co. Ltd.,
Lincoln Street,
Wolverhampton,
WV10 ODZ
Phone: 01902 456111
Telex: 338228
Fax: 01902 453764
UK.22
Scapa Tapes,
The Woodside Est.,
Dunstable,
Bedfordshire.
LU5 4TP
Phone: 01582 478 111
Telex:
Fax: 01582 471 085
UK.27
Washington Mills Electro Minerals LTD,
Mosley Road,
Trafford Park,
Manchester.
M17 1NR
Phone: 0161 848 0276
Telex:
Fax: 0161 872 2974
EFF :
ALL
70-30-00
AFL
Page 33
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------OMat
UK.29
Saint-Gobain,
K3895
English Abrasives & Chemicals Ltd,
Doxey Road,
Stafford.
ST16 1EA
Phone: 01785 251288
Telex:
Fax: 01785 259428
e-mail:
URL: www.saint-gobain.com
UK.31
Multisol Ltd,
Welsh House,
83 Welsh Road,
Nantwich,
Cheshire,
CW5 5ET
Phone: 01270 610444
Telex:
Fax: 01270 610555
UK.32
Arrow Chemicals,
Anteco Ltd,
Stanhope Road,
Swadlincote,
Derbyshire,
DE11 9BE
Phone: 01283 221044
Telex:
Fax: 01283 225731
UK.38
Vantico,
Duxford,
Cambridge.
CB2 4QA
Phone: 01223 832121
Telex: 81101
Fax: 01223 838556
UK.40
Sourcerer LTD,
Rolls-Royce,
Site Building 26,
Ansty,
EFF :
ALL
70-30-00
AFL
Page 34
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Coventry.
CV7 9SR
Phone: 44 24 76625023
Telex:
Fax: 44 24 766 25061
UK.45
K & K Horgen Ltd,
Neilson Road,
Gateshead,
Tyne-and-Wear
NE10 0EW
Phone: 0191 478 7878
Telex: 537918
Fax: 0191 490 0261
UK.47
ICI Chemicals and Polymers Ltd,
P.O. Box 14,
The Heath,
Runcorn,
Cheshire WA7 4QG
Phone: 01928 511706
Telex:
Fax: 01928 581072
OMat
10675
UK.51
IMI Marston Ltd,
Wobaston Road,
Fordhouses,
Wolverhampton,
WV10 6QJ
Phone: 01902 397777
Telex:
Fax: 01902 397792
OMat
K0567
UK.52
Rocol Ltd,
Wakefield Road,
Swillington,
Leeds
LS26 8BS
Phone: 0113 286 6511
Telex: 55249
Fax: 0113 287 2159
EFF :
ALL
70-30-00
AFL
Page 35
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------OMat
UK.53
Dow Corning Ltd,
K7750
Cardiff Road,
Barry,
South Glamorgan
CF6 7YL
Phone: 01446 732350
Telex:
Fax:
UK.56
Owens Corning,
Prescot Road,
St Helens,
Merseyside,
WA10 3TR
Phone: 01744 24022
Telex:
Fax: 01744 612007
OMat
K0132
UK.60
Castrol (UK) Ltd,
Burmah House,
Pipers Way,
Swindon,
Wiltshire,
SN3 1RE
Phone: 01793 512712
Telex: 449221
Fax: 01793 513506
OMat
K1793
UK.61
Hellerman Electric Ltd,
Pennycross Close,
Plymouth,
Devon,
PL2 3NX
Phone: 01752 701261
Telex: 45244 HELLEC
Fax: 01752 790058
UK.71
Ely Chemical Co. Ltd,
Lisle Lane,
Ely
Cambs,
CB7 4AS
Phone: 01353 665881
EFF :
ALL
70-30-00
AFL
Page 36
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Fax: 01353 664623
OMat
U2215
OMat
K5549
UK.74
Miles Roystone,
Priory Works,
Mansfield Woodhouse,
Mansfield,
Notts.
NG19 9LJ
Phone: 01623 27157
Telex:
Fax: 01623 658618
UK.83
Bostik Limited,
Ulverscroft Road,
Leicester,
LE4 6BW
Phone: 0116 510015
Telex:
Fax: 0116 253 1943
UK.85
Avio-Diepen BV,
2 Kennet house,
19 High Street,
Hungerford,
Berkshire
RE17 ONL,
Phone: 01488 684625
Telex:
Fax: 01488 683184
UK.87
Magnaflux Ltd,
Faraday Road,
South Dorcan Industrial
Estate,
Swindon,
Wiltshire,
SN3 5HE
Phone: 01793 524566
Telex: 449068
Fax: 01793 619498
UK.89
McGean-Rohco (UK) Ltd.,
Cee-Bee Division,
EFF :
ALL
70-30-00
AFL
Page 37
Oct 01/08
TRENT 700
SERIES ENGINES
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Qualcast Road,
Lower Horseley fields,
Wolverhampton,
West Midlands,
WV1 2QP
Phone: 01902 451312
Telex: 339188 CBMRE G
Fax: 01902 457443
UK.101
Swan Stabilo Ltd,
74 Buckingham Avenue,
Slough,
Berkshire SL1 4PA
Phone: 01753 821941
Telex: 847829
Fax: 01753 691317
OMat
K0993
UK.108
3M UK Plc,
3M House,
28 Great Jackson Street,
Manchester,
M15 4PA
Phone: 0161 236 8500
Telex: 667510 MMMMAN G
Fax: 0161 237 6136
e-mail:
URL: www.mmm.com
OMat
U0406
UK.124
Loctite UK Limited,
Watchmead,
Welwyn Garden City,
Hertfordshire.
AL7 1JB
Phone: 01707 358800
Telex:
Fax: 01707 358900
OMat
K4958
UK.126
Turco Products Ltd,
Brunel road,
Earlstrees Industrial Estate,
Corby,
Northants,
NN17 2JW
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CODE
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------------------------------------------------------------------------------Phone: 4401536 263536
Telex: 342524
Fax: 4401536 263890
OMat
K2769
OMat
K5991
UK.128
USF Surface Preparation,
Craven Road,
Broadheath,
Altringham,
Cheshire.
WA14 5EP
Phone: 0161 928 6388
Telex:
Fax: 0161 929 0381
UK.134
Crosfield Chemicals Ltd,
4 Liverpool Road,
P.O. Box 26,
Warrington,
Cheshire, WA5 1AB
Phone: 01925 416100
Telex: 627067
Fax: 01925 659828
UK.142
Applied Chemicals Ltd.,
Applied House,
Wilsons Lane,
Coventry,
CV6 6JA
Phone: 01203 368800
Telex: 31693
Fax: 01203 366639
UK.153
General Engineering Supplies
Co. Ltd,
554, High Road,
Leytonstone, E11
Phone: 0181 5560201
Telex:
Fax: 0181 5589305
UK.161
Norton Abrasive,
Bridge Road East,
Hertfordshire,
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CODE
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------------------------------------------------------------------------------AL7 1HZ
Phone: 01707 323484
Telex: 267291
Fax: 01707 325231
OMat
K5635
OMat
K5720
UK.163
PRC Desoto International,
Darlington Road,
Shildon,
Co Durham.
DL4 2QP
Phone: 01388 772541
Telex:
Fax: 01388 774373
e-mail:
URL: www.prc-desoto.com
UK.171
Steadtler (U.K.) Ltd,
Cowbridge Road,
Talbot Green,
Pontyclum,
Glamorgan, CF72 8YJ
Phone: 01433 237421
Telex:
Fax: 01443 237440
UK.172
Berol Ltd,
Oldmedow Road,
Kings Lynn,
Norfolk PE30 4JR
Phone: 01553 761221
Telex: 817409
Fax: 01553 766534
UK.173
Pentel Stationery Ltd,
Hunts Rise,
South Marston Park,
Swindon,
Wilts, SN3 4TW
Phone: 01793 823333
Telex: 449750 (PEN UK)
Fax: 01793 823366
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------------------------------------------------------------------------------OMat
UK.175
Ambersil Ltd,
K7652
Wylds Road,
Castlefield Industrial Estate,
Bridgewater,
Somerset,
TA6 4DD
Phone: 01278 424200
Telex: 46796
Fax: 01278 425644
OMat
K1905
OMat
U1185
UK.190
G.E. Silicones,
(Division of GE Plastics Ltd,
Old Hall Road,
Sale,
Cheshire,
M33 2HG
Phone: 0161 905 5027
Telex: 635253
Fax: 0161 905 5022
UK.196
Carborundum Abrasives (GB) Ltd,
P.O. Box 55,
Trafford Park Road,
Manchester, M17 1HP
Phone: 0161 872 2381
Telex: 667344 CARBOM G
Fax: 0161 953 2982
UK.197
Weston Hyde Products Ltd.,
Industrial Division,
Vallis Road,
Frome,
Somerset,
BA11 3EQ
Phone: 01373 463271
Telex: 449571
Fax: 01373 473624
UK.209
Merck Ltd,
Hunter Boulevard,
Magna Park,
Lutterworth,
Leics.
EFF :
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------------------------------------------------------------------------------LE17 4XN
Phone: 0800 223344
Telex:
Fax: 01455 558586
e-mail: uk.sales merck-ltd.co.uk
URL: www.merck-ltd.co.uk
OMat
K3814
UK.236
Novamax Technologies Ltd,
Broad March,
Daventry,
Northants,
NN11 4HE
Phone: 01327 310230
Telex:
Fax: 01327 310232
OMat
K4182
UK.240
Kimberly Clark Ltd,
Larkfield,
Maidstone,
Kent ME20 7PS
Phone: 01622 782421
Telex: 94018168
Fax: 01622 782090
UK.242
Allchem (Midlands) Company,
Wingate Close,
Glaisdale Drive East,
Nottingham,
NG8 4LP
Phone: 0115 929 5258
Telex:
Fax: 0115 929 2379
UK.243
Silkolene Lubricants Plc.
Silkolene Oil Refinery,
Belper
Derbyshire, DE5 1WF
Phone: 01773 824151
Telex: 37219
Fax: 01773 823659
UK.245
Knight Precision Wire Ltd,
Hadley Works,
OMat
K0007
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------------------------------------------------------------------------------Cranborne Road,
Potters Bar,
Hertfordshire,
EN6 3JL
Phone: 01707 645261
Telex:
Fax: 01707 649225
OMat
K3504
UK.261
Indestructible Paint Co Ltd,
25 Pentos Drive,
Birmingham,
B11 3TA
Phone: 0121 702 2485
Telex:
Fax: 0121 778 4338
e-mail: sales indestructible.co.uk
URL: www.indestructible.co.uk
OMat
K0519
UK.272
Henkel Chemicals Ltd,
Henkel House,
292-308 Southbury Road,
Enfield,
Middlesex,
EN1 1TS
Phone: 0181 804 3343
Telex: 922708
Fax: 0181 443 2777
UK.273
B and K Resins Ltd,
Unit 2,
Ashgrove Road,
Ashgrove Estate,
Bromley,
Kent,
BR1 4TH
Phone: 0181 315 1200
Telex: 918593
Fax: 0181 313 0280
UK.277
Permabond,
Woodside Road,
Eastleigh,
Hampshire.
OMat
U1087
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CODE
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------------------------------------------------------------------------------S050 4EX
Phone: 0800 698 6000
Telex:
Fax: 0238 0619284
OMat
K6402
UK.279
Carrs Paper Ltd.,
Cranmore Boulevard Estate,
Shirley,
Solihull,
West Midlands,
B90 4LJ
Phone: 0121 733 3030
Telex: 337836
Fax: 0121 733 3811
UK.280
Elf Atochem (UK) Ltd,
Colthrop Lane,
Thatcham,
Newbury,
Berkshire,
RG13 4LW
Phone: 01635 870000
Telex: 847689
Fax: 01635 861212
UK.285
Barton Abrasives Ltd.,
George Henry Road,
Great Bridge
Tipton,
West Midlands
DY4 7BS
Phone: 0121 522 2777
Telex: 337719
Fax: 0121 522 2927
UK.323
Astor. Stag Ltd,
Tavistock Road,
West Drayton,
Middlesex,
UB7 7RA
Phone: 01895 445511
Telex: 28559
Fax: 01895 449199
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------------------------------------------------------------------------------OMat
UK.328
Cray Valley Ltd,
K3713
Machen,
Newport,
Gwent,
NP1 8YN
Phone: 01633 440356
Telex:
Fax: 01633 440006
OMat
K3167
UK.332
Aero Consultants (UK Ltd.),
13-14 Clifton Road,
Huntingdon,
Cambs.
PE29 7EJ
Phone: 01480 432111
Telex:
Fax: 01480 412910
e-mail: info aero-consultants.ch
URL: www.aero-consultants.ch
UK.350
Sawley Packaging Company Ltd.,
Nottingham Road,
Derby,
DE2 6AS
Phone: 01332 243006
Telex: 37494
Fax: 01332 290297
UK.356
Faber Castell A.W. (UK) Ltd.,
Crompton Road,
Stevenage,
Herts,
SG1 2EF
Phone: 01438 316511
Telex: 825049 FABER G
Fax: 01438 358022
UK.363
Trimite Ltd,
Arundel Road,
Uxbridge,
Middlesex UB8 2SD
Phone: 0189 525 1234
Telex: 934444
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------------------------------------------------------------------------------Fax: 0189 525 6789
(2) North american suppliers (NA.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------NA.2
Indestructible Paint Inc.,
66 Erna Avenue,
Milford,
CT 06460
U.S.A.
Phone: 1 203 877 9243
Telex:
Fax: 1 203 876 7680
e-mail:
URL: www.indestructiblepaint.com
NA.10
Royal Lubricants Co. Inc.,
72 Eagle Rock Avenue
East Hanover
New Jersey 07936
U.S.A.
Phone: 1800 242 7394
Telex: 710 986 8260
Fax: 201 887 1457
NA.12
Dow Chemical Co.,
2040 Willard H Dow Centre,
Midland,
MI 48674,
U.S.A.
Phone: 517 832 1000
Telex:
Fax: 517 810 2666
NA.16
Parker & Amchem,
32100 Stephenson Highway,
Madison Heights,
MI 48071,
U.S.A.
EFF :
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CODE
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------------------------------------------------------------------------------Phone: 313 583 9300
Telex:
Fax: 313 583 2976
OMat
37676
OMat
71984
NA.17
Pentel of America Limited,
Corporate Headquarters,
2805 Columbia Street,
Torrance,
Cal 90503
U.S.A.
Phone: 310 320 3831
Telex: 230674006
Fax: 310 533 0691
NA.19
Bostic Industrial Division,
Boston Street,
Middleton,
Massachusets 01949,
U.S.A.
Phone: 508 771 0100
Telex: 508 774 7376
Fax:
NA.20
Magnaflux Corporation,
7300 West Lawrence Ave.,
Chicago,
Illinois 60656,
U.S.A.
Phone: 708 867 3363
Telex:
Fax: 708 867 6833
NA.22
VT Plastics Inc.,
1055 Stevenson Court,
Suite 102W,
Roselle,
ILL 60172,
U.S.A.
Phone: 708 894 0940
NA.27
Dow Corning Corporation,
Midland,
MI 48686-09954
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------------------------------------------------------------------------------U.S.A.
Phone: 517 496 4000
Telex: 189806000
Fax: 517 496 6486
OMat
29700
NA.28
Boulevard,
Produits de bureau,
1616 Rue Eiffel,
Boucherville,
Quebec,
Canada,
J4B 7W1
Phone: 514 449 4449
Telex:
Fax: 514 449 2068
NA.30
Inco Alloys International Inc.,
P.O. Box 1958,
Huntington,
WV 25720,
U.S.A.
Phone: 304 526 5100
Telex: 886413
Fax: 304 526 5441
NA.33
Henri A Patoir,
Exxon Company International,
222 Park Avenue,
Florham Park
N.J. 07932-1002
U.S.A.
Phone: 201 765 5509
Telex: 132092
Fax: 201 765 4303
NA.36
I.C.I. Americas Inc.,
Wilmington,
Delaware,
DE 19879
U.S.A.
NA.37
Allied Resin Corp.,
Weymouth Industrial Park,
EFF :
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CODE
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------------------------------------------------------------------------------East Weymouth,
MA 02189,
U.S.A.
Phone: 617 337 6070
Telex:
Fax: 617 340 1431
NA.40
Vulcan Chemicals,
P.O. Box 530390,
1 Metroplex Drive,
Birmingham,
Alabama 35253-0390,
Phone: 1-(800) 633-8280
Telex:
Fax: 205/877-3448
OMat
36131
NA.44
Shell Canada Ltd,
520 Commissioners Street,
Toronto,
Ontario,
Canada, M4M 1A7
Phone: 416 469 7544
Telex:
Fax: 416 469 7534
OMat
71361
NA.52
McGean-Rohco Inc.,
Cee-Bee Division,
9520 E. Cee Bee Drive,
Downey,
CA 90241-0016
U.S.A.
Phone: 310 803 4311
Telex: 3735455
Fax: 310 803 6701
OMat
89204
NA.61
Washington Mills Electro Minerals Corp,
1801 Buffale Avenue,
PO Box 423,
Niagara Falls,
NY 1432,
U.S.A.
Phone: 1 716 278 6600
Telex:
EFF :
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CODE
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------------------------------------------------------------------------------Fax: 1 716 278 6650
OMat
98733
NA.63
Met-L-Chek Co.,
1639 Euclid Street,
Santa Monica,
CA 90404,
U.S.A.
Phone: 310 450 1111
Telex:
Fax: 310 452 4046
OMat
382743557
NA.65
Novamax Technologies (U.S.)
Inc.,
1615 Johnson Road N.W.,
Atlanta Georgia,
30318,
U.S.A.
Phone: 404 799 1292
Telex:
Fax: 404 799 1873
OMat
94960
NA.70
3M Company,
3M Centre,
St Paul,
MN 55144-1000,
U.S.A.
Phone: 1 651 733 1110
Telex:
Fax: 1 651 733 9973
e-mail:
URL: www.mmm.com
NA.72
Modern Chemical Inc.,
P.O. Box 368,
Jacksonville,
Arkansas 72076,
U.S.A.
Phone: 501 988 1311
Telex:
Fax: 501 988 2229
NA.73
Sundstrand Aviation
Corporation,
OMat
99167
EFF :
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------------------------------------------------------------------------------4747 Harrison Avenue,
P.O. Box 7002,
Rockford,
Illinois 61125,
U.S.A.
Phone: 815 874 4777
Telex: 257496
Fax: 815 874 3624
OMat
73165
NA.80
Loctite Corporation,
45 Bradrock Drive,
Des Plaines,
Illinois 60018,
U.S.A.
Phone: 1 847 824 0137
Telex:
Fax:
OMat
58401
NA.85
United States Welding Corp.,
3579 Highway 50 East,
104 Carson City,
NV 89701
U.S.A.
Phone: 702 883 7878
Telex:
Fax: 702 883 7776
OMat
83574
NA.87
PRC Desosto International Inc,
5454 San Fernando Road,
P.O. Box 1800,
Glendale.
California 91209,
U.S.A.
Phone: 818 242 6815
Telex:
Fax:
OMat
05972
NA.88
Loctite USA,
Loctite North America,
1001 Trout Brook Crossing,
Rocky Hill,
Connecticut 06067,
U.S.A.
EFF :
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CODE
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------------------------------------------------------------------------------Phone: 1 860 571 5100
Telex:
Fax: 1 860 571 5465
OMat
44197
NA.89
Vantico Inc.,
4917 Dawn Avenue,
East Lansing,
MI 48823-5691,
U.S.A.
Phone: 1 517 351 5900
Telex:
Fax: 1 517 351 9003
e-mail:
URL: www.adhesives.vantico.com
NA.95
Saint Gobain,
PO Box 15008,
Worcester,
MA 01615,
U.S.A.
Phone: 1 508 795 5000
Telex:
Fax: 1 508 795 5420
e-mail:
URL:
NA.96
P.Q. Corporation,
P.O. Box 840,
Valley Forge,
PA 19482
U.S.A.
Phone: 215 293 7200
Telex:
Fax: 215 688 3835
NA.99
Burmah Castrol Inc.,
16815 Von Carman Avenue,
STE 202,
Irvine,
CA 92714,
U.S.A.
Phone: 714 660 9414
Telex: 683386
EFF :
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CODE
CODE
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------------------------------------------------------------------------------Fax: 714 660 9374
OMat
9V632
NA.105
Berol Corp,
Berol USA Division,
105 West Park Drive,
Suite 300,
Brentwood,
TN 37027
U.S.A.
Phone: 615 371 1199
NA.107
Daniels Manufacturing Corporation,
526 Thorpe Road,
Orlando,
Florida 32824,
U.S.A
Phone: 407 855 6161
Telex:
Fax: 407 855 6884
NA.108
General Electric Canada Inc.,
Silicone Products Division,
2300 Meadowvale Blvd,
Mississauga,
Ontario,
Canada,
L5N 5P9
Phone: 416 858 5765
Telex:
Fax: 416 858 6687
NA.113
Bergen Cable Technologies,
Gregg Street,
P.O. Box 1300,
Lodi,
New Jersey
U.S.A.
Phone: 201 487 3521
Telex:
Fax: 201 368 0532
NA.116
Faber Castell Corp.,
4 Century Drive,
EFF :
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CODE
ADDRESS
------------------------------------------------------------------------------Parsippany,
NJ 07054,
U.S.A.
Phone: 201 539 4111
Telex: 6853078
Fax: 201 539 4537
OMat
OBYN5
NA.119
Turco Products Inc.,
Subsidiary of Elf Autochem
N.A. Inc.
2700 Temple Avenue,
Suite B,
Long Beach, 00
California 90806
U.S.A.
Phone: 310 981 8300
Fax: 310 981 8303
NA.124
Lalonde, Lalonde and Associates,
768 Westgate Drive,
Unit 2,
Oakville,
Ontario
L6L 5N2
Canada,
Phone: 905 847 8707
Telex:
Fax: 905 847 5584
OMat
01139
NA.125
General Electric Co.,
Silicone Sales Dept,
260 Hudson River Road,
Waterford,
NY 12188
U.S.A.
Phone: 518 237 3330
OMat
37127
NA.127
Ardrox Ltd,
PO Box 814,
17-19 Woodburns Ave,
St Catherines,
Ontario,
Canada,
EFF :
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CODE
CODE
ADDRESS
------------------------------------------------------------------------------L2R 6Y3
Phone: 416 688 1085
Telex:
Fax: 416 684 4214
NA.129
PRC Desoto International Inc,
11601 United States,
Mojave,
CA 93501,
U.S.A.
Phone: 1 661 824 4532
Telex:
Fax: 1 818 549 7999
e-mail:
URL: www.prc-desoto.com
NA.136
Sequoia Corporation,
4009 Renate Drive,
Las Vegas,
NV 89103,
U.S.A.
Phone: 1 702 253 1891
Telex:
Fax: 1 702 253 1891
e-mail:
URL:
NA.138
Rolls-Royce Inc.,
11911 Freedom Drive,
Reston,
VA 22090 5602
U.S.A.
Phone: 703 834 1700
Telex: 6438391
Fax: 703 709 6088
NA.140
Novamax Technologies (US) Inc.,
1615 Johnson Road,
NW Atlanta,
GA 30318,
U.S.A.
Phone: 404 799 1292
Telex:
EFF :
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SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Fax: 404 799 1873
OMat
33564
OMat
21405
NA.153
Miller-Stephenson Chemical Co. Inc.,
George Washington Hwy.,
PO Box 950,
Danbury,
CT 06810,
U.S.A.
Phone: 203 743 4447
Telex: 643711
Fax: 203 791 8702
NA.164
Dexter Adhesives & Structural Materials Div.,
2850 Willow Pass Road,
Bay Point,
CA 94565,
U.S.A.
Phone: 1 925 458 8000
Telex:
Fax: 1 925 458 8030
e-mail:
URL:
NA.168
National Starch And Chemical Corp.
Premabond International,
10 Finder Avenue,
Bridgeorder,
NJ 08807,
U.S.A.
Phone: 1 908 685 5001
Telex:
Fax: 1 908 685 5005
NA.171
Sherwin Incorporated,
5530 Borwick Avenue,
South Gate,
California 90280-7402,
U.S.A.
Phone: 310 861 6324
Telex:
Fax: 310 923 8370
EFF :
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CODE
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------------------------------------------------------------------------------OMat
NA.179
Ardrox - CWC,
23373
921 Sherwood Drive,
PO Box 215,
Lake Bluff,
Illinois 60044-0215,
U.S.A.
Phone: 708 2951660
Telex:
Fax: 708 2958748
NA.186
D.A. Stuart Ltd.,
43 Upton Raod,
Scarborough,
Ontario,
Canada,
M1L 2C1
Phone: 416 757 3226
Telex:
Fax: 416 757 3220
OMat
OAG11
NA.190
Aviation Fluids Service Inc.,
950 Kingsland,
St. Louis,
MO 63130
U.S.A.
Phone: 314 721 2910
Telex:
Fax: 314 721 4519
OMat
741667794
NA.199
Eldorado Chemical Company Inc.,
P.O. Box 34837,
San Antonio,
Texas 78265-4837,
U.S.A.
Phone: 210 653 2060
Telex:
Fax: 210 653 0825
NA.214
Castrol Industrial North America Inc.,
1001 West 31st Street,
Downers Grove,
IL 60515,
U.S.A.
EFF :
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CODE
CODE
ADDRESS
------------------------------------------------------------------------------H7S 1N7
Phone: 708 241 4000
Telex:
Fax: 708 241 4140
NA.216
Gallard Schlesinger Ind Inc,
777 Ceckendorf Boulevard,
Garden City,
NY 11530,
U.S.A.
Phone: 1 516 229 4000
Telex:
Fax: 1 516 229 4015
e-mail:
URL:
NA.218
Dow Corning Canada Ltd.,
6747 Campobella Road,
Mississauga,
Ontario,
Canada L5N 2MI
Phone: 416 826 9600
Telex:
Fax: 416 858 6005
NA.219
The Chatterson Company,
Div. of Chatterson Enterprises,
Weston Port,
Weston,
CT 06680,
U.S.A.
Phone: 1 203 256 7700
Telex:
Fax: 1 203 256 7703
EFF :
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(3) South american suppliers (SA.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------SA.5
Loctite Brasil LTDA,
Av Prof Vernon Krieble 91,
06690-111 Ilapevi,
Sao Paulo,
Brazil.
Phone: 55 114 264 011
Telex:
Fax:
SA.6
Esso Inter-America Inc.,
396, Alhambra Circle,
Coral Gables,
Florida 33134,
U.S.A.
SA.7
Shell Brazil S.A.,
Avenida Rio Branco 109,
Rio de Janeiro,
Brazil
SA.8
Dow Corning do Brazil Ltd,
Rua Francisco Tramontano,
100-80 Andar 05686
Sao Paulo,
Brazil
Phone: 011 531 5199
Telex: 11 57510
Fax: 011 531 5727
SA.10
Ardrox - Agena Quimica Ltda,
Rua Camboriu 112,
20.975-160,
Rio de Janeiro -RJ,
Brazil
Phone: 21 2018995
Telex: 2132495 AGNA BR
Fax: 21 2411045
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(4) Asian suppliers (As.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------As.1
Chemetall Asia PTE Ltd,
12 Loyang Crescent,
Singapore, 1750
Phone: 5430122/5430411
Telex: RS25259
Fax: 5421312/5421319
As.4
Pentel Co. Ltd,
7-2 Koami-Cho,
Kihonbashi,
Chuo-Ku
Tokyo
Japan
Phone: 03 667 3331
As.5
Shachihato,
1-5 Kodemma,
Nihonbashi,
Chuo-Ku,
Tokyo,
Japan
As.7
Sale Tilney (Japan) Ltd,
GPO Box No.578,
Tokyo,
Japan
As.9
Pyrene-Rai Metal Treatments Ltd,
Nirlon House,
254B, Dr. Annie Beasant Road,
Worli,
Bombay 400 025,
India
Phone: 22 4931878
Telex: 1171217
Fax:
As.10
Loctite (Japan) Corporation,
15 - 13 Fukuura 1-Chome,
Kanszawa - KU,
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Yokohama 236,
Japan.
Phone: 81 457 842151
Telex:
Fax:
As.11
Loctite (Asia) LTD,
Pacific Region Headquarters,
Room 2022-27,
Sun Hung Kai Centre,
30 Harbour Road
Wanchai,
Hong Kong.
Phone: 852 282 71223
Telex:
Fax:
As.12
Esso Eastern Inc.,
2401, South Gessner,
Houston, Texas 77063,
U.S.A.
As.14
Castrol Limited,
White House,
91, Walkeshwar Road,
Malabar Hill,
Bombay,
India
As.15
Castrol KK. Rseas Ltd,
Industrial,
7th Floor,
Toyo an Bldg,
3-23-22, Toyo, Koto-Ku,
Tokyo 135,
Japan
Phone: 03 5606 7140
Telex:
Fax: 03 5606 5565
As.16
Eishin Kagaku Company Ltd,
1-2-13 Higashi-shinbashi,
Minato-Ku,
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Tokyo 105,
Japan
Phone: 03 3573 4235
Telex:
Fax: 03 3573 4230
As.18
Dow Corning Asia Ltd,
Room 802-806, Glouster Tower,
The Landmark
11, Pedder Street,
Hong Kong
As.19
Dow Corning Kabushiki Kaisha,
Chemicals Product Group,
15-1, Nishishimbashi 1-chome,
Minato-Ku,
Tokyo 105
Phone: 03 503 6054
Fax: 03 503 3565
As.21
Safra Co. Ltd.,
Xenel Building,
P.O. Box 2824,
Jeddah 21461,
Saudi Arabia
Phone: 966 2 6444090
Telex:
Fax: 966 2 6431214
(5) African suppliers (Af.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Af.6
Henkel South Africa (Pty) LTD,
Business Unit Loctite,
PO Box 15068,
Private Bag X038,
Wadeville 1422,
Republic of South Africa.
Phone: 271 1 864 4950
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Telex:
Fax: 271 1 908 1214
F3082
Af.9
Esso Africa Inc.,
15-17, Suffold Street,
London, SW17 4HS,
U.K.
Af.10
Castrol (South Africa) Ltd,
Princess of Wales Terrace,
Parktown,
Johannesburg,
South Africa
Af.11
Chmserve Systems (PTY.) Ltd,
Po Box 12055,
Chloorkop 1624,
Transvaal,
South Africa
Phone: 11 9762162
Telex: 746124
Fax: 11 9761706
(6) European suppliers (Eu.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------OMat
F0883
Eu.4
International Celomer,
75 BD. Winston Churchill,
76052 Le Havre
France
Phone: 35 26 61 63
Eu.21
Met-L-Chek Europa N.V.,
Singel 386,
Amsterdam,
Holland
Eu.24
Schwan-Stabilo
Schwanhausser Gmbh 3 Co.,
EFF :
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Maxfeldstrasse 3,
P.O. Box 4554,
D-8500 Nurnberg,
Germany
Phone: 09 11 36090
Telex: 911851
Fax: 09 11 6309861
OMat
B1082
Eu.27
Avio-Diepen BV,
Ypenburg Airport,
P.O. Box 5952,
2280 HZ,
Rijswijk,
Netherlands
Phone: 31 70 3075 100
Telex: 32030
Fax: 31 70 3901 247
Eu.28
NV Brent SA,
Aerospace Systems Group,
Kaleweg 24-56,
B-9030 Mariakerke (Gent)
Belgium
Phone: 091 266386
Telex:
Fax: 091 266593
Eu.33
Turco-france S.A.,
3 - 5 Impasse du Quai de Lindustrie,
91200 Athis-Mons (Essonne)
France
Phone: 33 1 6048 1636
Telex: 601722
Fax: 33 1 6048 1220
Eu.34
Turco-Chemie Gmbh,
Postfach 32 33,
Wandsbeker Stieg 23,
22071 Hamburg 76,
Germany
Phone: 49 40 2516 080
Telex: 213820
Fax: 49 40 2516 0850
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Eu.35
Turco Italiana S.P.A.,
Via Artigianale 29,
25010 Montirone (Brescia),
Italy
Phone: 39 30 267 443
Telex: 305352 turco 1
Fax: 39 30 267 7137
Eu.36
Esso Europe Inc.,
50, Stratton Street,
London W1X 6AU,
U.K.
Eu.38
Aero Cnsultants Ltd AG,
P.O. Box 35,
CH-8606 Nanikon - Uster
Switzerland.
Phone: 41 1 905 2800
Telex:
Fax: 41 1 941 3117
e-mail: info aero-consultants.ch
URL: www.aero-consultants.ch
Eu.42
Dow Corning Europe,
154, Chausse de la Hulpe,
1170 Brussels,
Belgium
Eu.47
PT Technologies Europe,
Meenane,
Watergrasshill,
Co. Cork,
Ireland.
Phone: 353 21 488 9922
Telex:
Fax: 353 21 488 9923
e-mail: info pttecheurope.com
URL: www.pttecheurope.com
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(7) Australian suppliers (Aus.)
------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Aus.1
Surechem Industries Pty Ltd,
42, Forge Street,
Blacktown,
N.S.W. 2148,
Australia
Phone: 2 6215933
Telex:
Fax: 2 6217638
Aus.2
Loctite (Australia) Pty LTD,
3 Endeavor Road,
Caringbah,
N.S.W. 2229,
Australia.
Phone: 61 2 952 58366
Telex:
Fax: 61 2 952 55643
Aus.3
Esso Australia Ltd,
Esso House,
127, Kent Street
Sydney,
N.S.W.,
Australia
Aus.5
Castrol Australia Pty Ltd,
Mc Credie Road,
Guildford,
N.S.W.
Australia
Aus.7
Ajax Chemicals,
PO Box 239,
Factory Street,
Granville,
Australia
Phone: 02 682 1400
Telex:
Fax: 02 682 6771
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------------------------------------------------------------------------------FEDERAL
SUPPLIERS
SUPPLIERS
CODE
CODE
ADDRESS
------------------------------------------------------------------------------Aus.8
Dow Corning Australia Pty Ltd,
4, Ray Road,
Epping 2121
N.S.W.
Australia
Phone: 61 2 868 9111
Telex:
Fax: 61 2 868 1507
Aus.16
3M Industrial Markets
Speciality Tapes
2.74 Dunheved Circuit,
St Marys 2760
N.S.W
Australia
Phone 02 967 75649
Telex:
Fax: 02 967 75636
EFF :
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REPAIR SURFACES AFFECTED BY MINOR DAMAGE - MAINTENANCE PRACTICES
________________________________________________________________
TASK 70-42-11-300-801
Repair Surfaces Affected by Minor Damage - FRS3253
CAUTION : YOU MUST ONLY DO THIS REPAIR WHEN IT IS SPECIFIED IN THE RELATED
_______
INSPECTION/CHECK. THE PARTS MUST BE REPAIRED TO AS NEAR THEIR INITIAL
SHAPE AS POSSIBLE AND MUST BE IN THE PERMITTED ACCEPTANCE LIMITS
GIVEN IN THE RELATED INSPECTION/CHECK. IF YOU DO THIS REPAIR WHEN IT
IS NOT SPECIFIED YOU CAN CAUSE FAILURE OF THE PART.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
circuit breaker(s) safety clip(s)
access platform 2.5 m (8 ft. 2 in.)
B. Referenced Information
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-02-230-804
Energize the Ground Service Network
De-energize the Ground Service Network
3. __________
Job Set-up
Subtask 70-42-11-861-050
A. Energize the ground service network
(Ref. TASK 24-42-00-861-801).
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Subtask 70-42-11-941-050
B. Safety Precautions
(1) Make sure that the engine 1, (2) shutdown occurred not less than 5
minutes before you do this procedure.
Subtask 70-42-11-010-050
C. Get Access to the Avionics Compartment
(1) Put the access platform in position at the access door 811.
(2) Open the access door 811.
(3) Open the protective door of the AC/DC emergency power-center 740VU.
Subtask 70-42-11-865-050
D. Open, safety and tag this(these) circuit breaker(s):
------------------------------------------------------------------------------PANEL DESIGNATION
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-11-010-051
E. Do the applicable procedures to get access to the related work area.
4. Procedure
_________
CAUTION : YOU MUST ONLY USE SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE
_______
PAPERS TO REPAIR TITANIUM PARTS. ALUMINUM OXIDE TYPES WILL CAUSE
TOO MUCH HEAT AND CAUSE DAMAGE TO THE PART.
CAUTION : YOU MUST USE WHEELS, STONES OR ABRASIVE PAPERS LIGHTLY OR THE
_______
MATERIAL WILL OXIDIZE AND CRACK. THE MATERIAL HAS OXIDIZED IF THE
COLOR CHANGES TO BETWEEN DARK STRAW AND BLUE. YOU MUST REJECT THE
PART IF THIS COLOR CHANGE OCCURS.
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Subtask 70-42-11-350-050
A. Repair the minor damage.
(1) Repair where the material is scored, galled, fretted or has burrs or
pick-up.
(a) Remove high spots, burrs and pick-up (which includes pick-up on
threads): Use a stone and then lightly hand polish.
(2) Repair where the material is pitted or has stripping or rubbing
marks.
(a) Remove the pitting: Blend, use a stone and then lightly hand
polish.
(3) Repair where the material is distorted or dented.
(a) Remove the distortion and dents: Planish the area, blend and then
hand polish.
(b) Remove distortion: Planish the area.
(4) Repair where the material is nicked.
(a) Blend, scallop and hand polish to get a smooth shape.
(5) Repair where the material is burned.
(a) Remove material, blend and polish to the standards given in the
related Inspection/Check.
(6) Repair where the material is cracked.
(a) Blend the area with a rotary file and hand polish.
(b) Blend, scallop and hand polish to the standards given in the
related Inspection/Check.
(7) Repair where the material is battered.
(a) Blend edges of battering marks to the general surface profile and
hand polish.
(b) Scallop battering on the leading and trailing edges to 5: 1
length/depth minimum ratio and hand polish.
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(c) Examine the repair and make sure it agrees with the standards
given in the related Inspection/Check.
Subtask 70-42-11-370-050
B. Apply the applicable surface protection.
(1) Apply surface protection to the repaired areas.
Subtask 70-42-11-220-050
C. Inspect the repaired areas.
(1) Examine the repair, then do a fluorescent penetrant inspection for
cracks (Ref. TASK 70-20-02-230-804). Refer to the related
Inspection/Check procedure for the part.
5. Close-up
________
Subtask 70-42-11-410-051
A. Do the applicable procedures to close access to the work area.
Subtask 70-42-11-865-051
B. Remove the safety clip(s) and the tag(s) and close this(these) circuit
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-11-410-050
C. Close Access
(1) Make sure that the work area is clean and clear of tools and other
items.
(2) Close the protective door of the AC/DC emergency power center 740VU.
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(3) Close the access door 811.
(4) Remove the access platform(s).
Subtask 70-42-11-862-050
D. De-energize the ground service network
(Ref. TASK 24-42-00-862-801)
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PROTECT LOCALLY DAMAGED ENAMELLED SURFACE - MAINTENANCE PRACTICES
_________________________________________________________________
TASK 70-42-12-300-801
Protect Locally Damaged Surfaces of Aluminium Cases
1. __________________
Reason for the Job
Local surface protection must be applied to aluminium cases which have
damage to prevent deterioration of the parts. Touch-up enamel paint may be
applied to previously enamelled surfaces.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
clean plastic container
clean polythene container
clean stainless steel container
small clean brush
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 117
Material No.
OMat 175D
Material No.
OMat 2-7
Material No.
OMat 5-33
Material No.
OMat 5-35
Material No.
OMat 7-35
*
PHOSPHORIC ACID (Ref. 70-30-00)
*
CHROMATE CONVERSION COATING (Ref. 70-30-00)
*
WETTING AGENT (Ref. 70-30-00)
*
WATERPROOF SILICON CARBIDE (Grit size 320)
(Ref. 70-30-00)
*
WATERPROOF SILICON CARBIDE (Grit size 240)
(Ref. 70-30-00)
*
TOUCH-UP ENAMEL (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-01-100-801
List of maintenance Processes - Stripping and
Cleaning
3. __________
Job Set-up
Subtask 70-42-12-861-050
(Ref. TASK 24-42-00-861-801).
Subtask 70-42-12-941-050
Subtask 70-42-12-010-050
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Subtask 70-42-12-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-12-010-051
4. Procedure
_________
Subtask 70-42-12-370-050
A. Repair the damaged enamelled surface.
WARNING : YOU MUST FIND AND OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA
_______
FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO
MAKE SURE THAT THE PROCEDURES ARE DONE SAFELY. IF YOU DO NOT DO
THIS, AN INJURY OR ENVIRONMENTAL DAMAGE CAN OCCUR.
(1) If you find corrosion on the damaged surface, remove it with the
non-metallic scraper.
(2) Make the damaged surface smooth with the adjacent surface: Use the
WATERPROOF SILICON CARBIDE (Grit size 320) (Material No. OMat 5-33)
and the WATERPROOF SILICON CARBIDE (Grit size 240) (Material No. OMat
5-35).
(3) Clean the repair surface area (Ref. TASK 70-20-01-100-801).
(4) If the surface damage is larger than a scratch, apply the chromate
conversion coating as follows:
(a) Add the WETTING AGENT (Material No. OMat 2-7) to water until you
get a solution which contains 1 percent by volume of the agent.
Make the solution in a clean stainless steel container and keep
it at a temperature of 15 deg.C (59.00 deg.F) to 25 deg.C (77.00
deg.F).
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(b) Clean the surface with a small clean brush which is soaked with
the WETTING AGENT (Material No. OMat 2-7) in solution with water.
(c) Flush the area with clean cold water.
WARNING : YOU MUST NOT GET THE PHOSPHORIC ACID SOLUTION ON YOUR
_______
SKIN OR IN YOUR EYES. THE SOLUTION IS CORROSIVE. USE AN
APRON, APPLICABLE GLOVES AND EYE PROTECTION. IF YOU GET
THE SOLUTION ON YOUR SKIN, REMOVE IT WITH SOAP AND
WATER. REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED.
IF YOU GET THE SOLUTION IN YOUR EYES, FLUSH THEM WITH
IMMEDIATELY GET MEDICAL AID. IF THE SOLUTION TOUCHES
YOU IT CAN CAUSE DAMAGE TO YOUR BODY TISSUES.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE PHOSPHORIC ACID
_______
SOLUTION OR GET IT IN YOUR MOUTH. THE SOLUTION IS
SOLUTION IN AN AREA THAT HAS A GOOD FLOW OF AIR. IF YOU
GET THE SOLUTION IN YOUR MOUTH, FLUSH WITH WATER.
IMMEDIATELY GET MEDICAL AID. IF THE SOLUTION IS
BREATHED IN OR DRUNK IT CAN CAUSE DAMAGE TO YOUR BODY
TISSUES.
(d) Add 0.33 l (0.0871 USgal) of the PHOSPHORIC ACID (Material No.
OMat 117) to 0.67 l (0.1769 USgal) of water. Make the solution in
a clean polythene container and keep it at a temperature of 15
(e) Chemically etch the surface with a small clean brush which is
soaked with the PHOSPHORIC ACID (Material No. OMat 117) in
solution with water.
(f) Flush the area with clean cold water.
WARNING : YOU MUST NOT GET THE CHROMATE CONVERSION COATING
_______
SOLUTION ON YOUR SKIN OR IN YOUR EYES. THE SOLUTION IS
CORROSIVE. USE AN APRON, APPLICABLE GLOVES AND EYE
PROTECTION. IF YOU GET THE SOLUTION ON YOUR SKIN,
REMOVE IT WITH SOAP AND WATER. REMOVE CLOTHING IF
CONTAMINATION HAS OCCURRED. IF YOU GET THE SOLUTION IN
YOUR EYES, FLUSH THEM WITH ISOTONIC SALINE OR WATER FOR
15 MINUTES MINIMUM. IMMEDIATELY GET MEDICAL AID. IF THE
SOLUTION TOUCHES YOU IT CAN CAUSE DAMAGE TO YOUR BODY
TISSUES.
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WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE CHROMATE
_______
CONVERSION COATING SOLUTION OR GET IT IN YOUR MOUTH.
THE SOLUTION IS CORROSIVE. USE THE APPROVED FACE MASK.
ALSO USE THE SOLUTION IN AN AREA THAT HAS A GOOD FLOW
OF AIR. IF YOU GET THE SOLUTION IN YOUR MOUTH, FLUSH
WITH WATER. IMMEDIATELY GET MEDICAL AID. IF THE
SOLUTION IS BREATHED IN OR DRUNK IT CAN CAUSE DAMAGE TO
YOUR BODY TISSUES.
(g) Mix equal volumes of CHROMATE CONVERSION COATING (Material No.
OMat 175D) Parts A and B. Make the solution in a clean plastic
container and use immediately.
WARNING : YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE
_______
SOAKED WITH THE CHROMATE CONVERSION COATING SOLUTION
BECOME DRY. THE SOLUTION IS OXIDISING. IF THEY BECOME
DRY THERE IS A RISK OF FIRE (WITHOUT AN EXTERNAL
CAUSE).
NOTE : Only prepare sufficient solution for the area to be
____
treated.
(h) Apply with a small clean brush the CHROMATE CONVERSION COATING
(Material No. OMat 175D) solution. Monitor the effect of the
solution on the surface: The surface is satisfactorily treated
when you see an irridescent gold to light golden-brown color.
NOTE : Usually the surface is satisfactorily treated in
____
approximately 2 to 7 minutes.
(i) Flush the area with clean cold water.
(j) Carefully dry the area with clean dry cloths or with a warm air
blast.
(k) Safely discard the cloths and materials used during the chromate
conversion coating procedure as follows:
1
_
Use cold water to flush the chromate solution from the used
cloths and materials to decrease the risk of fire: Collect the
used water in a container.
2
_
Put the used cloths and materials in sealed plastic bags:
Identify the bags with a label which shows TOXIC CHROME WASTE.
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3
_
Discard the water with chromate contamination, the bags of
toxic chrome waste and the unwanted chromate conversion
coating solution: Refer to local regulations to correctly
discard them.
WARNING : YOU MUST KEEP THE TOUCH-UP ENAMEL AWAY FROM SPARKS,
_______
FLAMES AND HEAT. THE ENAMEL IS FLAMMABLE AND CAN
CAUSE A FIRE.
WARNING : YOU MUST NOT GET THE TOUCH-UP ENAMEL ON YOUR SKIN OR
_______
IN YOUR EYES. THE ENAMEL IS HARMFUL. USE AN APRON,
ENAMEL ON YOUR SKIN, REMOVE IT WITH SOAP AND WATER.
REMOVE CLOTHING IF CONTAMINATION HAS OCCURRED. IF
YOU GET THE ENAMEL IN YOUR EYES, FLUSH THEM WITH
IMMEDIATELY GET MEDICAL AID. IF THE ENAMEL GOES
THROUGH YOUR SKIN THERE CAN BE A HEALTH RISK.
WARNING : YOU MUST NOT BREATHE THE FUMES FROM THE TOUCH-UP
_______
ENAMEL OR GET IT IN YOUR MOUTH. THE ENAMEL IS
HARMFUL. USE THE APPROVED FACE MASK. ALSO USE THE
ENAMEL IN AN AREA THAT HAS A GOOD FLOW OF AIR. IF
YOU GET THE ENAMEL IN YOUR MOUTH, FLUSH WITH WATER.
IMMEDIATELY GET MEDICAL AID. IF THE ENAMEL IS
BREATHED IN OR DRUNK THERE CAN BE A HEALTH RISK.
NOTE : Touch-up enamel is only required on previously
____
enamelled surfaces.
(5) Apply with a small clean brush a layer of the TOUCH-UP ENAMEL
(Material No. OMat 7-35) if necessary. Let the enamel air dry for a
minimum time of 30 minutes.
(6) Apply with a small clean brush a second layer of the TOUCH-UP ENAMEL
(Material No. OMat 7-35) if necessary. Let the enamel air dry for a
minimum time of 30 minutes.
5. Close-up
________
Subtask 70-42-12-410-050
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Subtask 70-42-12-865-051
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-12-410-051
C. Close Access
items.
Subtask 70-42-12-862-050
(Ref. TASK 24-42-00-862-801)
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REPAIR THREADED HOLES BY FITTING WIRE THREAD INSERTS - MAINTENANCE PRACTICES
____________________________________________________________________________
TASK 70-42-13-300-801
Repair Threaded Holes by the installation of the Wirethread Inserts (FRS3002)
WARNING : YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE
_______
ENGINE IS SHUTDOWN. THE ENGINE PARTS CAN STAY HOT FOR ALMOST 1 HOUR.
_______
CAUTION : UNLESS SPECIFIED BY A ROLLS-ROYCE REPAIR: YOU MUST NOT INSTALL
_______
WIRETHREAD INSERTS INTO MAJOR ROTATING PARTS OR HIGHLY STRESSED AREAS
(SUCH AS ENGINE MOUNTS), OR INTO AREAS WHICH ARE DIRECTLY EXPOSED TO
THE HIGH TEMPERATURE GAS STREAM. IF YOU INSTALL INSERTS INTO THESE
PARTS/AREAS WITHOUT APPROVAL, THE SAFE OPERATION OF THE ENGINE WILL
BE AT RISK.
1. __________________
Reason for the Job
This task gives the procedure to repair damaged threaded holes in components
by the installation of wirethread inserts:
- damaged threads and damaged inserts can be repaired by the installation of
new inserts: but not in light alloy material
- damaged threads in light alloy material can be repaired by the
installation of repair inserts, into which wirethread inserts are
installed
- if a wirethread insert is damaged during assembly, a new wirethread insert
can be installed without the need for disassembly.
Types of insert:
- screw lock insert - one coil has an irregular shape which gives a
self-lock function to the insert
- free running insert - this has no self-lock device
- repair insert - this is a solid insert into which a wirethread insert is
installed.
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2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
container
cotton swab
lint-free cloths
paper tissues
plastic container
sealed plastic bags
small clean brush
vibration peen equipment
adjustable access platform 1.22 m (4 ft.)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 175D
Material No.
OMat 4-46
*
chromate conversion coating (Ref. 70-30-00)
*
jointing compound (Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-02-230-803
70-20-02-230-804
71-13-00-010-805
71-13-00-410-805
78-30-00-010-803
Open the Fan Cowl Doors
Close the Fan Cowl Doors
Open the Thrust Reverser Cowl Doors
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------78-30-00-410-803
78-31-00-040-805
78-31-00-440-805
70-42-13-991-001
70-42-13-991-008
70-42-13-991-007
70-42-13-991-004
70-42-13-991-012
70-42-13-991-002
70-42-13-991-014
70-42-13-991-005
70-42-13-991-006
70-42-13-991-003
70-42-13-991-009
70-42-13-991-010
70-42-13-991-013
70-42-13-991-015
70-42-13-991-011
Close the Thrust Reverser Cowl Doors
Deactivation of the Thrust Reverser for Maintenance
Activation of the Thrust Reverser after Maintenance
Fig. 201
Fig. 202
Fig. 203
Fig. 204
Fig. 205
Fig. 206
Fig. 207
Fig. 208
Fig. 209
Fig. 210
Fig. 211
Fig. 212
Fig. 213
Fig. 214
Fig. 215
3. __________
Job Set-up
Subtask 70-42-13-861-050
(Ref. TASK 24-42-00-861-801).
Subtask 70-42-13-941-050
Subtask 70-42-13-010-050
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Subtask 70-42-13-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-13-010-051
E. Get Access
(1) If necessary, open the fan cowl doors: (Ref. TASK 71-13-00-010-805)
- FOR 4030EM1
415AL, 416AR
- FOR 4030EM2
425AL, 426AR
Subtask 70-42-13-040-050
F. If necessary, make the thrust reverser unserviceable (Ref. TASK 78-31-00040-805)
Subtask 70-42-13-010-052
G. Get Access
(1) If necessary, open the thrust reverser: (Ref. TASK 78-30-00-010-803)
- FOR 4030EM1
417AL, 418AR
- FOR 4030EM2
427AL, 428AR
(2) Put the adjustable access platform in position.
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4. Procedure
_________
Subtask 70-42-13-350-050
A. Repair damaged threads and damaged inserts by the installation of new
inserts: But not in light alloy material.
(Ref. Fig. 201/TASK 70-42-13-991-001, 202/TASK 70-42-13-991-008)
NOTE : A modification to the tools will permit this
____
(Ref. Fig. 203/TASK 70-42-13-991-007)
(1) Remove the damaged wirethread insert: use the applicable extraction
tool (Item No. 1).
(Ref. Fig. 204/TASK 70-42-13-991-004, 205/TASK 70-42-13-991-012)
(2) Drill and tap the hole to permit the installation of the wirethread
insert (if not installed before):
(Ref. Fig. 201/TASK 70-42-13-991-001, 206/TASK 70-42-13-991-002)
Use the applicable roughing tap, plug tap and bottoming tap (Item No.
4, 5 and 6).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(3) Clean the hole and make an inspection of the threads: use the
applicable special gauge (Item No. 7)
(Ref. Fig. 205/TASK 70-42-13-991-012)
(4) Apply protection to the threads of magnesium components as follows:
_______
_______
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Wirethread Insert Dimensions - Before and After Installation of Insert
Figure 201/TASK 70-42-13-991-001
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Tool Dimensions to Install Wirethread Insert into Assembled Parts
Figure 202/TASK 70-42-13-991-008
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Modification of Tools to Install Wirethread Insert in Assembled Parts
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Modification of Tools to Install Wirethread Insert in Assembled Parts
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Remove the Existing Insert
Figure 204/TASK 70-42-13-991-004
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INTENTIONALLY BLANK
70-42-13
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Tools for Wirethread Inserts
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INTENTIONALLY BLANK
70-42-13
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Page 215
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Thread Hole Dimensions for Wirethread Inserts
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Thread Hole Dimensions for Wirethread Inserts
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WARNING : YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE SOAKED
_______
WITH THE CHROMATE CONVERSION COATING SOLUTION BECOME DRY.
THE SOLUTION IS OXIDISING. IF THEY BECOME DRY THERE IS A
RISK OF FIRE (WITHOUT AN EXTERNAL CAUSE).
(a) Mix equal volumes of chromate conversion coating (Material No.
OMat 175D) Parts A and B. Make the solution in a plastic
____
treated.
(b) Apply with a small clean brush the chromate conversion coating
solution on the threads: the threads are satisfactorily treated
____
(c) Clean the threads with a cotton swab which has been soaked in
clean cold water.
(d) Clean the threads with a cotton swab which has been soaked in
clean hot water.
(e) Carefully dry the area with clean dry lint-free cloths or paper
tissues.
(f) Safely discard the cloths and materials used during the chromate
1
_
use cold water to flush the chromate solution from the used
cloths and materials to decrease the risk of fire: collect the
used water in a container .
2
_
put the used cloths and materials in sealed plastic bags:
Identify the bags with a label which shows TOXIC CHROME WASTE.
3
_
discard the water with chromate contamination, the bags of
coating solution: refer to local regulations to correctly
discard them.
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(5) Make the selection of the applicable wirethread insert for
installation:
(Ref. Fig. 207/TASK 70-42-13-991-014)
- screw lock inserts must only be installed when they are specified
in the Power plant Illustrated Parts Catalog (PIPC).
(6) Apply a thin layer of jointing compound (Material No. OMat 4-46) to
the internal threads of the component and to the external threads of
the wirethread insert.
NOTE : You must do this step immediately before you install the
____
wirethread insert to the component.
(7) Install the wirethread insert to the component:
(Ref. Fig. 201/TASK 70-42-13-991-001, 208/TASK 70-42-13-991-005)
applicable inserting tool (Item No. 2)
(Ref. Fig. 205/TASK 70-42-13-991-012)
(8) Remove the tang from the wirethread insert:
(Ref. Fig. 209/TASK 70-42-13-991-006)
- use the applicable tang removal tool (Item No. 3).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(9) Do a fluorescent penetrant inspection of the repair area for cracks
(Ref. TASK 70-20-02-230-803) and (Ref. TASK 70-20-02-230-804).
(10) Make sure the wirethread insert is correctly installed:
(Ref. Fig. 201/TASK 70-42-13-991-001, 210/TASK 70-42-13-991-003)
- use the applicable cross thread gauge (Item No. 8).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(11) Do a check of the in-built torque of screw lock inserts:
(Ref. Fig. 211/TASK 70-42-13-991-009)
- use the applicable torque check plug, torque adapter and
torquemaster (Item No. 9, 10 and 11).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(12) Use vibration peen equipment to write FRS3002 adjacent to the part
number.
NOTE : This step is only applicable to components which have had a
____
wirethread insert installed where an insert has not been
installed before.
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Parts (Wirethread Inserts)
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Parts (Wirethread Inserts)
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Installation Procedure
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Installation Procedure
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Remove the Wirethread Insert Tang
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Remove the Wirethread Insert Tang
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Dimensions of Assembled Inserts
Figure 210/TASK 70-42-13-991-003
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In-built Torque of Screw Lock Inserts
Figure 211/TASK 70-42-13-991-009
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Subtask 70-42-13-350-051
B. Repair damaged threads in light alloy material by the installation of
repair inserts and wirethread inserts
(1) Make a dimensional inspection of the part to make sure the boss size
is sufficient to be machined
(Ref. Fig. 212/TASK 70-42-13-991-010)
(2) If the boss size is satisfactory:
- drill the hole for the repair insert
(Ref. Fig. 212/TASK 70-42-13-991-010)
- use the applicable tools.
(Ref. Fig. 213/TASK 70-42-13-991-013)
(3) Tap the hole for the repair insert:
- use the applicable tap (Item No. 11).
(Ref. Fig. 213/TASK 70-42-13-991-013)
(4) Clean the hole and make an inspection of the threads
(Ref. Fig. 212/TASK 70-42-13-991-010)
(5) Apply protection to the threads as follows:
_______
_______
WARNING : YOU MUST NOT LET CLOTHS OR OTHER MATERIALS WHICH ARE SOAKED
_______
WITH THE CHROMATE CONVERSION COATING SOLUTION BECOME DRY.
THE SOLUTION IS OXIDISING. IF THEY BECOME DRY THERE IS A
RISK OF FIRE (WITHOUT AN EXTERNAL CAUSE).
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(a) Mix equal volumes of chromate conversion coating (Material No.
OMat 175D) Parts A and B. Make the solution in a plastic
____
treated.
(b) Apply with a small clean brush the chromate conversion coating
solution on the threads: the threads are satisfactorily treated
____
(c) Clean the threads with a cotton swab which has been soaked in
clean cold water.
(d) Clean the threads with a cotton swab which has been soaked in
clean hot water.
(e) Carefully dry the area with clean dry lint-free cloths or paper
tissues.
(f) Safely discard the cloths and materials used during the chromate
1
_
use cold water to flush the chromate solution from the used
cloths and materials to decrease the risk of fire: collect the
used water in a container.
2
_
put the used cloths and materials in sealed plastic bags:
identify the bags with a label which shows TOXIC CHROME WASTE.
3
_
Discard the water with chromate contamination, the bags of
coating solution: refer to local regulations to correctly
discard them.
(6) Make the selection of the applicable repair insert for installation
(Ref. Fig. 214/TASK 70-42-13-991-015)
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Dimension Standards for Repair Insert in Light Alloy Materials
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Tools for Repair Inserts
Figure 213/TASK 70-42-13-991-013
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Parts (Repair Inserts)
Figure 214/TASK 70-42-13-991-015
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the internal threads of the component and to the external threads of
the repair insert.
____
repair insert.
(8) Install the repair insert to the component:
(Ref. Fig. 215/TASK 70-42-13-991-011)
- use the insert driver (Item No. 12)
(Ref. Fig. 213/TASK 70-42-13-991-013)
(9) Do a visual inspection of the repair insert to make sure the insert
is correctly installed
(Ref. Fig. 215/TASK 70-42-13-991-011)
(10) Make the selection of the applicable wirethread insert for
installation:
(Ref. Fig. 207/TASK 70-42-13-991-014)
- screw lock inserts must only be installed when they are specified
in the Power plant Illustrated Parts Catalog (PIPC).
the internal threads of the repair insert and to the external threads
of the wirethread insert.
____
wirethread insert to the component.
(12) Install the wirethread insert to the repair insert:
(Ref. Fig. 201/TASK 70-42-13-991-001, 208/TASK 70-42-13-991-005)
- use the applicable inserting tool (Item No. 2).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(13) Remove the tang from the wirethread insert:
(Ref. Fig. 209/TASK 70-42-13-991-006)
- use the applicable tang removal tool (Item No. 3).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(14) Do a fluorescent penetrant inspection of the repair area for cracks
(Ref. TASK 70-20-02-230-803) or (Ref. TASK 70-20-02-230-804).
(15) Make sure the wirethread insert is correctly installed:
(Ref. Fig. 201/TASK 70-42-13-991-001, 210/TASK 70-42-13-991-003)
- use the applicable cross thread gauge (Item No. 8).
(Ref. Fig. 205/TASK 70-42-13-991-012)
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Repair Inserts - Before and After Repair
Figure 215/TASK 70-42-13-991-011
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(16) Do a check of the in-built torque of screw lock inserts:
(Ref. Fig. 211/TASK 70-42-13-991-009)
- use the applicable torque check plug, torque adapter and
torquemaster (Item No. 9, 10 and 11).
(Ref. Fig. 205/TASK 70-42-13-991-012)
(17) Use vibration peen equipment to write FRS3002 adjacent to the part
number.
5. Close-up
________
Subtask 70-42-13-410-050
A. Close Access
items.
(2) If necessary, close the thrust reverser cowl doors: (Ref. TASK 78-3000-410-803)
- FOR 4030EM1
417AL, 418AR
- FOR 4030EM2
427AL, 428AR
Subtask 70-42-13-440-050
B. If necessary, make the thrust reverser serviceable (Ref. TASK 78-31-00440-805).
Subtask 70-42-13-865-051
C. Remove the safety clip(s) and the tag(s) and close this(these) circuit
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
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Subtask 70-42-13-410-051
D. Close Access
(3) If necessary, close the fan cowl doors: (Ref. TASK 71-13-00-410-805)
- FOR 4030EM1
415AL, 416AR
- FOR 4030EM2
425AL, 426AR
Subtask 70-42-13-862-050
E. De-energize the ground service network
(Ref. TASK 24-42-00-862-801)
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ACCEPTABLE CRACKS - STOP DRILLING - MAINTENANCE PRACTICES
_________________________________________________________
TASK 70-42-16-300-801
Stop Drilling of Acceptable Cracks - FRS3255
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-02-230-803
70-20-02-230-804
3. __________
Job Set-up
Subtask 70-42-16-861-050
(Ref. TASK 24-42-00-861-801).
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Subtask 70-42-16-941-050
Subtask 70-42-16-010-050
Subtask 70-42-16-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-16-010-051
E. Do the applicable procedure to get access to the related work area.
4. Procedure
_________
Subtask 70-42-16-350-050
A. Stop drill the crack.
(1) Do a fluorescent penetrant inspection of the crack to find if the
crack is in permitted limits (Ref. TASK 70-20-02-230-803) and
(Ref. TASK 70-20-02-230-804).
(2) Drill a hole at the end of the crack to make sure the crack can not
become larger: Use a 0.062 in. (1.5747 mm) drill.
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(3) Remove the burrs.
(4) Do a fluorescent penetrant inspection of the crack to make sure it is
correctly stop drilled (Ref. TASK 70-20-02-230-803) and (Ref. TASK
70-20-02-230-804)
(5) Vibro-emgrave FRS3255 adjacent to the part number.
5. Close-up
________
Subtask 70-42-16-410-050
Subtask 70-42-16-865-051
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-16-410-051
C. Close Access
items.
Subtask 70-42-16-862-050
(Ref. TASK 24-42-00-862-801)
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REPLACE DAMAGE OR LOOSE CAPTIVE NUTS - MAINTENANCE PRACTICES
____________________________________________________________
TASK 70-42-19-300-801
Replace Damaged or Loose Captive Nuts - FRS3035
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
hand grinder
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-02-230-804
70-42-19-991-001
Fig. 201
3. __________
Job Set-up
Subtask 70-42-19-861-050
(Ref. TASK 24-42-00-861-801).
Subtask 70-42-19-941-050
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Subtask 70-42-19-010-050
Subtask 70-42-19-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-19-010-051
4. Procedure
_________
(Ref. Fig. 201/TASK 70-42-19-991-001)
Subtask 70-42-19-350-050
A. Replace the damaged or loose captive nut:
(1) Use a hand grinder to remove the rivets from the assembly: Do not
decrease the thickness of the component when you remove the rivets.
(2) Remove the nut and the retainer plate.
(3) Put a bolt through the component and attach a new nut in the correct
position.
(4) Put the retainer plate in position and hold it in position with a
clamp.
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Captive Nut and Retaining Plate
Figure 201/TASK 70-42-19-991-001
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(5) If necessary, drill the holes in the retainer plate to agree with the
hole positions in the component.
NOTE : Drill oversize holes for oversize rivets, if necessary.
____
(6) Install new rivets.
(7) Remove the clamp and the bolt, then examine the nut to make sure it
is correctly aligned.
(8) Do a fluorescent penetrant inspection of the repair for cracks
(Ref. TASK 70-20-02-230-804).
5. Close-up
________
Subtask 70-42-19-410-050
Subtask 70-42-19-865-051
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-19-410-051
C. Close Access
items.
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Subtask 70-42-19-862-050
(Ref. TASK 24-42-00-862-801)
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REPLACEMENT OF STUD FASTENERS - MAINTENANCE PRACTICES
_____________________________________________________
TASK 70-42-21-300-801
Replace Stud Fasteners (Camlocs) - FRS3210
1. __________________
Reason for the Job
This task installs and replaces the stud fasteners.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
HS-471 HOLE SAW
HS-500 HOLE SAW
HS-625 HOLE SAWS
HS-687 HOLE SAWS
HS-812 HOLE SAWS
T16 DRILL JIG
T22 DRILL JIG
T26 SNAP RING TOOL
T96-1 RETAINING RING TOOL
4-GC COUNTERSINK TOOL
4-GC-500 COUNTERSINK TOOL
4-GM & T92-1 FLARING TOOLS
4-GM & 4-GF CLOSING TOOLS
4-GM & 4PF FLARING TOOLS
4-G2C COUNTERBORE TOOL
4-G200 M & F DIMPLING TOOL
4P3 STUD INSTALLATION PLIERS
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-42-21-991-001
70-42-21-991-002
70-42-21-991-003
70-42-21-991-004
70-42-21-991-005
70-42-21-991-006
70-42-21-991-007
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
Fig.
201
202
203
204
205
206
207
3. __________
Job Set-up
Subtask 70-42-21-869-050
A. Not applicable.
4. Procedure
_________
70-42-21-991-003, 204/TASK 70-42-21-991-004, 205/TASK 70-42-21-991-005,
206/TASK 70-42-21-991-006, 207/TASK 70-42-21-991-007)
Subtask 70-42-21-220-050
A. Measure the skin thickness.
(1) Measure and record the thickness of the loose and main skins.
NOTE : If you increase the skin thickness (for example with a doubler
____
plate), you must refer to the Camloc catalogue for a new stud
selection.
Subtask 70-42-21-350-050
B. Install the stud fastener.
(1) Prepare the loose skin.
(a) Make a template or use the unserviceable skin to find the
position of the pilot holes.
(b) Drill the pilot holes in the loose skin.
For 4002 series Camloc fasteners only:
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5F Series Camloc Fastener Assembly
Figure 201/TASK 70-42-21-991-001
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12F Series Camloc Fastener Assembly
Figure 202/TASK 70-42-21-991-002
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4002 Series Camloc Fastener Assembly
Figure 203/TASK 70-42-21-991-003
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Loose Skin Preparation
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INTENTIONALLY BLANK
70-42-21
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Page 213
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Main Skin Preparation
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Main Skin Preparation
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Rivet Selection
Figure 206/TASK 70-42-21-991-006
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Stud Selection
Figure 207/TASK 70-42-21-991-007
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(c) Make the pilot holes larger with HS-471 HOLE SAW or HS-500 HOLE
SAW as applicable.
(d) For loose skins less than 0.064 in. (1.6255 mm) thickness, dimple
the skin with 4-G200 M & F DIMPLING TOOL. Back spotface if
necessary.
(e) For loose skins more than 0.064 in. (1.6255 mm) thickness (for
flush-fit grommets), coutersink the skin with 4-GC COUNTERSINK
TOOL. Then counterbore the other side with 4-G2C COUNTERBORE
TOOL.
(f) For loose skins of 0.040 in. (1.0159 mm) to 0.219 in. (5.5625 mm)
thickness (for flare-fit grommets), countersink the skin with 4GC-500 COUNTERSINK TOOL.
(g) For loose skins less than 0.094 in. (2.3875 mm) thickness (for
plus flush-fit grommets), counterbore the skin with 4-G2C
COUNTERBORE TOOL.
(2) Install the grommet.
For 4002 series Camloc fasteners only:
(a) For flush and plus flush-fit grommets, put the grommet through
the loose skin and safety with R4G snap rings. Use the T26 SNAP
RING TOOL.
(b) For dimpled skin installations, use 4-GM & 4-GF CLOSING TOOLS to
push back the dimple.
(c) For flared grommets, use 4-GM & 4PF FLARING TOOLS or 4-GM & T92-1
FLARING TOOLS as applicable.
(3) Prepare the main skin.
(a) Make a template or use the unserviceable skin to find the
position of the pilot holes and the rivet holes.
(b) Drill the pilot holes in the main skin.
(c) For 4002 series Camloc fasteners only, make the pilot holes
larger with HS-625 HOLE SAWS , HS-687 HOLE SAWS or HS-812 HOLE
SAWS as applicable.
(d) Drill the rivet holes in the main skin. Use the T16 DRILL JIG or
T22 DRILL JIG as applicable.
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(e) For 244-16SD or 244-22D receptacles, dimple the rivet holes in
the main skin.
(f) For 5F, 12F and 4002 series Camloc fasteners, countersink the
rivet holes in the main skin.
(4) Install the receptacle.
(a) Attach the receptacle to the main skin with blind or solid rivets
as applicable.
(5) Install the stud assembly.
(a) Install the stud assembly through the hole or the grommet in the
loose skin. For short, spring-loaded stud assemblies, the use of
4P3 STUD INSTALLATION PLIERS is recommended.
(b) Install the applicable retaining ring to safety the stud. Use the
T96-1 RETAINING RING TOOL.
Subtask 70-42-21-350-051
C. Replace the stud fasteners.
(1) Remove the stud assembly.
(a) Remove the retaining ring from the stud assembly. Use hand tools.
(b) Remove the stud assembly from the loose skin. For short, spring
loaded stud assemblies, the use of 4P3 STUD INSTALLATION PLIERS
is recommended.
(2) Remove the grommet.
For 4002 series Camloc fasteners only
(a) Remove the snap ring from the grommet, then remove the grommet
from the loose skin. Use hand tools.
(3) Remove the receptacle.
(a) Drill out the rivets and remove the receptacle from the main
skin.
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(4) Examine the skin.
(a) Examine the grommet holes in the loose skin and the rivet holes
in the main skin. Reject the part if the holes are too large,
elongated or cracked.
(5) Install the replacement stud fasteners.
(a) Install the replacement grommet, receptacle or stud assembly as
necessary. refer to para. 4.B.2, 4 or 5.
Subtask 70-42-21-210-050
D. Examine the stud fasteners.
(1) Make sure the component parts of the stud fastener are correctly
aligned when the skins are closed.
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SEAL EXPOSED FIBERS ON FIBER REINFORCED COMPOSITES - MAINTENANCE PRACTICES
__________________________________________________________________________
TASK 70-42-22-300-801
Seal the Exposed Fibers on Fiber Reinforced Composites - FRS3254
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 805
Material No.
OMat 806
*
RESIN (Ref. 70-30-00)
*
HARDENER (Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
70-20-01-100-801
List of maintenance Processes - Stripping and
Cleaning
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3. __________
Job Set-up
Subtask 70-42-22-861-050
(Ref. TASK 24-42-00-861-801).
Subtask 70-42-22-941-050
Subtask 70-42-22-010-050
Subtask 70-42-22-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-22-010-051
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4. Procedure
_________
Subtask 70-42-22-340-050
A. Seal the exposed fibers.
(1) Clean the repair area (Ref. TASK 70-20-01-100-801).
(2) Mix the RESIN (Material No. OMat 805) with the HARDENER (Material No.
OMat 806) in the proportion - 100 parts of RESIN to 43 parts of
HARDENER: Mix fully to make an equal paste.
(3) Apply a thin layer of the paste to the repair area.
(4) Let the paste cure for 24 hours at room temperature, 72 deg.F (22.22
deg.C).
(5) Apply the surface protection to the repaired area as specified in the
maintenance procedure.
5. Close-up
________
Subtask 70-42-22-410-050
A. Do the applicable procedures to close access to the related work area.
Subtask 70-42-22-865-051
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
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Subtask 70-42-22-410-051
C. Close Access
items.
Subtask 70-42-22-862-050
(Ref. TASK 24-42-00-862-801)
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RIVETS - MAINTENANCE PRACTICES
______________________________
TASK 70-42-28-910-801
Remove and Install the Cherrymax and Cherrylock Blind Rivets - FRS7058
1. __________________
Reason for the Job
A. This TASK gives the procedure to remove and install Cherrymax and
Cherrylock Blind Rivets.
B. Cherrymax rivets are supplied as one piece that consists of three parts:
(1) A tubular sleeve that has a head at one end. Three types of heads are
available; a 100-degree countersunk head, a universal head and a unisink
head.
(2) A stem that goes through the sleeve. The stem has a head opposite the
sleeve head. It also has a lock-groove, a break-off groove and pull grooves.
There is also a driving anvil on the stem. This makes sure that the lock
collar seats correctly and that the stem always breaks off at the break-off
groove.
(3) A lock-collar on the stem. When the blind rivet is installed, the collar
is swaged into the lock-groove on the stem and in the sleeve. This makes
sure that the stem is locked into the sleeve.
C. Cherrylock rivets (standard and bulbed types) are supplied as one piece
that consists of three parts:
(1) A tubular sleeve that has a head at one end. Four types of heads are
available; a 100-degree countersunk head, a universal head, a unisink head
and a 156-degree countersink.
(2) A stem that goes through the sleeve. The stem has a head opposite the
sleeve head. It also has a lock-groove, a break-off groove and pull grooves.
The stem of the bulbed type also has a shear ring.
(3) A lock-collar on the stem. When the blind rivet is installed, the collar
is swaged into the lock-groove on the stem and in the sleeve. This makes
sure that the stem is locked into the sleeve.
D. These blind rivets are supplied with a layer of lubricant on them. Do not
clean them, or touch them more than necessary, before they are installed.
E. Hand- or power-operated tools can be used to install these rivets. These
tools must have the correct heads attached to them.
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F. It is recommended that a test procedure be performed on some unwanted
materials before the blind rivets are installed. The test must be performed
on the same thickness and type of material as the repair materials. Use the
same blind rivets (head type, diameter and grip-length) as those for the
repair.
G. Source demonstration is not necessary for this repair, but the repair
vendors who have shown Rolls-Royce plc that they can do this repair
satisfactorily are given in TSD 7019 (Authorised Repair Vendor Directory).
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No
No
No
No
No
No
No
No
No
No
No
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
specific
centre punch
hammer
inspection mirror
installation tool supplied by the rivet manufacturer
pointed tool
probe-light
rivet grip length gauge
suitable sized parallel pin punch
suitable sized twist drill
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------24-42-00-861-801
24-42-00-862-801
71-13-00-010-805
71-13-00-410-805
78-30-00-010-803
78-30-00-410-803
78-31-00-040-805
78-31-00-440-805
70-42-28-991-001
70-42-28-991-002
Open the Fan Cowl Doors
Close the Fan Cowl Doors
Open the Thrust Reverser Cowl Doors
Close the Thrust Reverser Cowl Doors
Deactivation of the Thrust Reverser for Maintenance
Activation of the Thrust Reverser after Maintenance
Fig. 201
Fig. 202
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-42-28-991-003
70-42-28-991-004
Fig. 203
Fig. 204
3. __________
Job Set-up
Subtask 70-42-28-861-050
(Ref. TASK 24-42-00-861-801).
Subtask 70-42-28-941-050
Subtask 70-42-28-010-050
(1) Put an access platform in position at the access door 811.
(3) Open the protective door of the AC/DC emergency power center 740VU.
Subtask 70-42-28-865-050
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
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Subtask 70-42-28-010-051
E. Get Access
(1) Open the fan cowl doors (Ref. TASK 71-13-00-010-805):
- FOR 4030EM1
415AL, 416AR
- FOR 4030EM2
425AL, 426AR
Subtask 70-42-28-040-050
F. Thrust Reverser Deactivation
WARNING : YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON
_______
OR AROUND IT.
IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND
CAUSE INJURY AND/OR DAMAGE.
(1) Deactivate the thrust reverser (Ref. TASK 78-31-00-040-805).
Subtask 70-42-28-010-052
G. Get Access
(1) Open the thrust reverser cowl doors (Ref. TASK 78-30-00-010-803):
- FOR 4030EM1
417AL, 418AR
- FOR 4030EM2
427AL, 428AR
4. Procedure
_________
70-42-28-991-003, 204/TASK 70-42-28-991-004)
Subtask 70-42-28-930-050
A. Identify the Rivet
(1) Use a centre punch to make an accurate mark in the centre of the
stem.
CAUTION : DO NOT LET THE RIVET SLEEVE TURN WHEN YOU DRILL THE STEM.
_______
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Cherrymax Rivet - Removal Details
Figure 201/TASK 70-42-28-991-001
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Bulbed Cherrylock Rivet - Removal Details
Figure 202/TASK 70-42-28-991-002
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Cherrymax Blind Rivet - Protrusion Limits
Figure 203/TASK 70-42-28-991-003
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Cherrylock Blind Rivet - Protrusion Limits
Figure 204/TASK 70-42-28-991-004
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Subtask 70-42-28-350-050
B. Drill the Stem
(1) Use a suitable sized twist drill that has the same diameter as the
stem. Make sure you drill to the bottom of the locking collar.
Subtask 70-42-28-350-051
C. Remove the Locking Collar with a pointed tool.
Subtask 70-42-28-350-052
D. Remove the Stem
(1) Use a suitable sized parallel pin punch and a hammer.
Subtask 70-42-28-420-050
E. Install the Fastener
(1) Clamp the repair materials. Make sure all of the holes are aligned.
(2) Inspect the rivet hole.
(a) Check the hole diameter.
(b) Use a rivet grip length gauge to check the necessary rivet grip
length.
(3) Put the fastener into the hole.
(4) Put the installation tool onto the fastener and operate.
(a) Use an installation tool supplied by the rivet manufacturer.
(b) Make sure that the fastener is correctly seated onto the material
face.
NOTE : The broken part of the stem is automatically pushed out of
____
the tool when the installation operation is completed.
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(5) If necessary, mill the end of the stem.
(a) Mill until the stem is in line with the sleeve head.
(b) Do not mill the locking-collar.
NOTE : Special tools are available for this step. Refer to the
____
manufacturers instructions for special rivet installation
if aerodynamic flushness is necessary.
Subtask 70-42-28-210-050
F. Inspect the Installed Fasteners
(1) Visually inspect the head seating.
(a) Make sure that the head touches the material correctly.
(2) Inspect the lock-collar and the stem.
(a) Make sure they are correctly installed.
(3) Visually inspect the formed head if it can be seen.
(a) Use a probe-light and inspection mirror if necessary.
(b) Make sure that the head is formed correctly.
(4) Visually inspect the head of the countersunk rivets.
(a) Make sure that the top of the head is in line with, or only
slightly above the top of the repair area.
(5) Visually inspect the rivet for cracks.
(a) No cracks are permitted in any part of the blind rivet.
Subtask 70-42-28-210-051
G. Inspect the Adjacent Structure
(1) Visually inspect the structure adjacent to the repair area.
(a) Refer to the relevant manual section for the damage limits.
(b) No cracks are acceptable in the structure adjacent to the
repaired area.
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5. Close-up
________
Subtask 70-42-28-410-050
A. Close Access
items.
(2) Close the thrust reverser cowl doors (Ref. TASK 78-30-00-410-803):
- FOR 4030EM1
417AL, 418AR
- FOR 4030EM2
427AL, 428AR
Subtask 70-42-28-440-050
B. Make the thrust reverser serviceable after maintenance (Ref. TASK 78-3100-440-805).
Subtask 70-42-28-865-051
C. Remove the safety clip(s) and the tag(s) and close this(these) circuit
breaker(s):
FIN
LOCATION
------------------------------------------------------------------------------FOR 4030EM1
722VU FADEC B ENG 1
13KS1
D44
742VU FADEC A ENG 1
12KS1
Q73
FOR 4030EM2
722VU FADEC B ENG 2
13KS2
K49
742VU FADEC A ENG 2
12KS2
Q74
Subtask 70-42-28-410-051
D. Close Access
items.
(2) Remove the CNA rear cover.
(3) Put the access platform into a safe position at the CNA.
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(6) Close the fan cowl doors (Ref. TASK 71-13-00-410-805):
- FOR 4030EM1
415AL, 416AR
- FOR 4030EM2
425AL, 426AR
Subtask 70-42-28-862-050
E. De-energize the ground service network
(Ref. TASK 24-42-00-862-801).
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CONNECTION OF ELECTRICAL PLUGS - MAINTENANCE PRACTICES
______________________________________________________
TASK 70-50-02-910-801
Connection of Electrical Plugs (Types ESC10 and ESC11)
1. __________________
Reason for the Job
An incorrectly connected electrical plug (connector) can let moisture get
into the connector and the mating receptacle. This can subsequently cause
incorrect electrical signals and/or failure of the applicable electrical
circuits.
This task gives the procedure for the correct connection of an electrical
connector to its mating receptacle.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
No specific
lint-free cloth
small clean brush
spray gun
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1-119
Material No.
OMat 2-67
*
ISOPROPANOL (Ref. 70-30-00)
*
DISPOSABLE CLEANING TISSUES (Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------73-21-00-710-812
73-21-00-710-813
70-50-02-991-001
Test of the FADEC System
Test of the EEC Configuration
Fig. 201
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3. __________
Job Set-up
Subtask 70-50-02-869-050
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-50-02-991-001)
Subtask 70-50-02-420-050
A. Connect the electrical connector to its mating receptacle:
(1) Remove the protective caps from the connector and its mating
receptacle: Keep the caps in a clean dry bag.
(2) Do a visual check of the connector and the receptacle for:
WARNING : YOU MUST NOT GET THE CLEANING FLUID ON YOUR SKIN, IN YOUR
_______
MOUTH OR IN YOUR EYES. YOU MUST USE APPLICABLE GLOVES, EYE
PROTECTION AND A FACE MASK. USE THE FLUID IN AN AREA THAT
HAS A GOOD FLOW OF AIR. DO NOT BREATHE THE FUMES FROM THE
FLUID. IF YOU GET THE CLEANING FLUID ON YOUR SKIN, IN YOUR
MOUTH OR YOUR EYES, FLUSH IT AWAY WITH WATER. GET MEDICAL
AID IF YOU GET FLUID IN YOUR MOUTH OR EYES. KEEP CLEANING
FLUID AWAY FROM SPARKS, FLAME AND HEAT. CLEANING FLUID IS A
POISONOUS FLAMMABLE SOLVENT WHICH CAN CAUSE INJURY AND/OR
DAMAGE.
CAUTION : YOU MUST NOT USE A COMPRESSED AIR SUPPLY THAN 15 PSI (1,03
_______
BAR) PRESSURE IF YOU USE A SPRAY GUN: OR WHEN YOU USE
COMPRESSED AIR TO DRY THE CLEANED PARTS. A COMPRESSED AIR
SUPPLY OF MORE THAN 15 PSI (1,03 BAR) WILL CAUSE DAMAGE TO
THE PARTS.
- corrosion
- defective parts (which include swollen, oil soaked or damaged
inserts and/or damaged pins)
- liquid/solid contamination.
If you find corrosion or defective parts, repair or replace the
parts as necessary. If you find liquid/solid contamination, do the
steps that follow:
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Electrical Connector and Mating Receptacle (Types ESC10 and ESC11)
Figure 201/TASK 70-50-02-991-001
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(a) Remove all contamination from the surfaces of the connector
and/or the receptacle: This must be done with the ISOPROPANOL
(Material No. OMat 1-119) applied with a small clean brush or
with a spray gun.
(b) Use DISPOSABLE CLEANING TISSUES (Material No. OMat 2-67) or a
lint-free cloth to absorb the used fluid. Alternatively use
compressed air to remove the used fluid.
NOTE : This step is necessary when the connector and/or
____
receptacle is in such a position that the used fluid
cannot drain out of the parts.
(c) Dry the cleaned surfaces with clean dry compressed air.
(3) Align the master-key (largest key) on the connector with the
receptacle master key-way.
(4) Push the connector on to the receptacle: Use only light hand
pressure.
CAUTION : YOU MUST NOT STOP AT THE BLUE MARKER LINE ON THE RECEPTACLE
_______
WHEN YOU TIGHTEN THE CONNECTOR. IF YOU STOP AT THE BLUE
MARKER LINE THE CONNECTION WILL NOT BE TIGHT. THIS WILL
CAUSE ELECTRICAL CIRCUIT DEFECTS AND/OR ELECTRICAL
FAILURES.
(5) Turn the knurled nut of the connector (identified by the blue marker
line) in a clockwise direction to engage the connector with the
receptacle threads. With the threads correctly engaged continue to
turn the knurled nut clockwise with your hand until the connection is
tight: Make sure that the blue marker line on the receptacle cannot
be seen when the connection is tight.
5. Close-up
________
Subtask 70-50-02-710-050
A. Test
(1) If electrical plugs are disconnected then connected, do an
operational test of the EEC (Ref. TASK 73-21-00-710-813).
(2) Also do an operational test of the FADEC system (Ref. TASK 73-21-00710-812).
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TORQUE TIGHTENING TECHNIQUE - MAINTENANCE PRACTICES
___________________________________________________
TASK 70-51-00-910-802
CAUTION : YOU MUST NOT USE UNIVERSAL JOINTS WITH TORQUE WRENCHES. A UNIVERSAL
_______
JOINT WILL GIVE YOU AN INCORRECT TORQUE VALUE.
1. __________________
Reason for the Job
A given torque load is applied to nuts, bolts and setscrews to prevent
stressed items and to make sure of maximum security. These torque load
values are given at the point of application in the maintenance manual
procedure.
The assembly of curvic couplings is included in this Standard Practice.
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
Torque Wrench : range 36.00 to 220.00 lbf.in
(0.40 to 2.60 m.daN)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1-260
Material No.
OMat 101
Material No.
OMat 1011
Material No.
OMat 1011
Material No.
OMat 1011
Material No.
OMat 4-46
Material No.
OMat 4-62
*
odourless kerosine (Ref. 70-30-00)
*
*
*
ENGINE LUBRICATING OIL (Ref. 70-30-00)
*
*
jointing compound (Ref. 70-30-00)
*
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------anti-seize compound - high temperature
(Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
70-51-00-991-001
70-51-00-991-002
70-51-00-991-003
70-51-00-991-004
70-51-00-991-005
70-51-00-991-006
101
Fig. 201
Fig. 202
Fig. 203
Fig. 204
Fig. 205
Fig. 206
3. __________
Job Set-up
Subtask 70-51-00-869-056
A. Not applicable.
4. Procedure
_________
Subtask 70-51-00-910-050
A. Lubrication
(1) Lubrication is important to get the correct tension in a threaded
part.
This is because most of the applied torque is absorbed by friction at
the screw thread: And on the mating faces of the parts.
(2) The corrosion protection coating on threaded parts, if not removed,
can cause very high end loads. This coating if found must be
initially removed from the part: Use odourless kerosine (Material No.
OMat 1-260) or kerosine (Material No. OMat 101) at a temperature of
122 deg.F (49.99 deg.C) to 133 deg.F (56.11 deg.C).
NOTE : The above procedure will not cause damage to silver plating.
____
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(3) Before you apply the recommended lubricant to bolts, studs, nuts and
other threaded parts, they must be degreased (Ref. TASK 70-20-01-100802).
(4) The standard lubricant to be used is clean engine lubricating oil
(Material No. OMat 1011), one of the approved oils used (for the
engine lubrication system): Or anti-seize compound - high temperature
(Material No. OMat 4-62) which must be applied to the bolt threads
and to the nut abutment faces.
(5) anti-seize compound - high temperature (Material No. OMat 4-62) is
the only lubricant (as an alternative to engine oil) which is
approved for general use on threaded parts. Other lubricants (which
includes solid film lubricants or lubricants that contain molybdenum
disulphide) must not be used unless they are specified.
(6) When a special lubricant is necessary (such as for very high torque
loads or for use in high temperature zones of the engine) the correct
lubricant will be specified at the point of application in the
maintenance manual procedure.
(7) The mean tensile load caused by the same applied torque can be as
much as 80 percent larger where incorrect lubricant is used. And
bolts can be dangerously stressed to the point of constant torquing.
Subtask 70-51-00-910-051
B. Tighten the Nuts Again.
CAUTION : YOU MUST OBEY THE INSTRUCTIONS THAT FOLLOW. IF YOU DO NOT YOU
_______
CAN GET AN INCORRECT CLAMPING LOAD. IF THE CLAMPING LOAD IS
INCREASED WITH MORE THAN THE MAXIMUM TORQUE, DAMAGE TO THE
THREADS CAN OCCUR. THIS CAN CAUSE THE FAILURE OF THE JOINT
DURING THE OPERATION OF THE ENGINE.
(1) When it is necessary to tighten nuts again, do the steps that follow:
(a) Remove the nuts.
(b) Clean the threads and the abutment faces.
(c) Lubricate the threads and the abutment faces.
(d) Install the nuts.
(e) TORQUE the nuts to the specified torque load.
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Subtask 70-51-00-910-052
C. Initially Make the Threads and the Mating Faces Smooth
(1) Make the threads smooth:
NOTE : It is only necessary to make the threads smooth when you
____
tighten threaded parts to more than 250 lbf.ft (33.89 m.daN).
(a) Lubricate the threads and the mating faces of the nut and the
washer with clean ENGINE LUBRICATING OIL (Material No. OMat
1011), or anti-seize compound - high temperature (Material No.
OMat 4-62) unless a different lubricant is specified.
(b) Install the nut then tighten it to approximately 50 percent of
the full torque load value.
(c) Remove the nut then lubricate the threads and the mating faces
again.
(d) Install the nut and TORQUE it to the full specified torque load
value.
(2) Make the mating faces smooth:
(a) Shrouded keywashers are not always flat and do not always flatten
satisfactorily with one applied torque load: Thus where shrouded
keywashers are used, do the procedure to torque the nut again as
follows:
1
_
Lubricate the screw threads and the mating faces with clean
engine lubricating oil (Material No. OMat 1011) (or anti-seize
compound - high temperature (Material No. OMat 4-62)) unless a
different lubricant is specified.
2
_
Install the nut then TORQUE it to the full specified torque
load value.
3
_
Remove the nut then lubricate the threads and the mating faces
again.
4
_
Install the nut and TORQUE it to the full specified torque
load value.
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Subtask 70-51-00-910-053
D. Torque Tighten when a Locking Device is Used
(1) Where locking plates, single-lock keywashers, or split cotter pins
are used as locking devices obey the instructions that follow:
CAUTION : YOU MUST OBEY THE INSTRUCTIONS THAT FOLLOW. IF YOU DO NOT,
_______
FAILURE OF THE UNIT OR THE ENGINE CAN OCCUR.
CAUTION : YOU MUST NOT LOOSEN THE NUT TO LESS THAN THE SPECIFIED
_______
MINIMUM TORQUE LOAD VALUE TO GET THE LOCKING POSITION. IF
YOU LOOSEN THE NUT TO LESS THAN THE MINIMUM VALUE, FAILURE
OF THE UNIT OR THE ENGINE CAN OCCUR.
(a) When you align the parts for these locking devices, the torque
load must be applied as follows:
1
_
If the torque load is given as a range, the torque load
applied (to find the position for the locking device) must be
in the given range.
2
_
If the torque load is not as a range (and the locking device
cannot be installed after the load has been applied) the
torque can continue to be applied to find the subsequent
locking position.
(2) Where double-lock single-hole keywashers are used as locking devices,
the applied torque load must not be more than that specified. These
keywashers are made to be locked at the position set by the given
torque load.
Subtask 70-51-00-910-054
E. Sequence to Torque Close-Pitched Bolts
(Ref. Fig. 201/TASK 70-51-00-991-001)
(1) Where a close-pitched bolt installation is used (and where it is
necessary to make a seal) adjacent fasteners must not be tightened
one after the other. Tighten the fasteners in a symmetrical sequence.
This will make sure that the application of the torque does not cause
damage to the structure. Unless specified at the point of application
in the maintenance manual, do the recommended procedure as follows:
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Examples of Sequence to Torque Close-Pitched Bolts on Ring Flange and
Half-Casing Joints
Figure 201/TASK 70-51-00-991-001
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(a) Flanges
1
_
On flanges lightly tighten the fasteners in the symmetrical
number sequence until the joint faces are in contact (with all
the fasteners lightly tightened).
2
_
Apply the specified torque load to each of the fasteners in an
equivalent symmetrical sequence.
(b) Half-casing split line joints.
1
_
On half-casing split lines (such as compressor casings) use
the same procedure as for flanges: But tighten the mid-section
fasteners first, then work out from the center.
Subtask 70-51-00-910-055
F. Sequence to Torque Curvic Couplings.
(Ref. Fig. 202/TASK 70-51-00-991-002)
(1) General:
(a) All curvic couplings must be assembled to the procedure that
follows.
This is to make sure of the high level of balance that is given
with these couplings. The procedure is applicable for engine
assembly, module installation and balancing (with engine and
slave components).
(b) The torque load values to be applied when the joint is tightened
are applicable to self-locking fasteners: And those fasteners
which are not self-locking.
(2) Initial procedure:
(a) Immediately before the two parts of the curvic coupling are put
together do the steps that follow:
1
_
Clean the teeth to remove all unwanted particles, grease and
oil:
This is important as small particles can cause the teeth to
engage incorrectly.
2
_
Do a visual check of the two parts of the coupling to make
sure the teeth have no burrs.
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Example of Sequence to Torque Curvic Coupling Bolts
Figure 202/TASK 70-51-00-991-002
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(b) When the engine is assembled in the horizontal position, the two
parts must be put together carefully with precision. It is
important to prevent shear loads and to make sure of equal mating
of the coupling teeth.
(c) Lubricate the fastener threads and the abutment faces of the nut
or bolt with clean engine lubricating oil (Material No. OMat
1011) (or anti-seize compound - high temperature (Material No.
OMat 4-62)).
NOTE : Make sure that the lubricant does not go on to the
____
coupling teeth.
(d) Install the nut or the bolt, then do the sequence to tighten.
(3) Sequence to tighten:
(a) Each bolt hole is identified with a number which shows the
sequence to tighten the nut or bolt as applicable.
(b) If the joint is to be assembled with its axis horizontal: Align
the holes 1 and 2 with the horizontal axis. If the number of
holes are not equal, hole number 1 is to be on the horizontal
axis.
(c) Start with the nut and bolt in hole 1 (and continue in the shown
number sequence): Tighten the nut and bolt to the initial torque
load value specified in the applicable TASK.
(d) Continue with the same sequence: Tighten each nut and bolt to the
subsequent torque load value specified in the applicable TASK.
(e) Continue with the same sequence: Tighten each nut and bolt to the
last torque load value specified in the applicable TASK.
(f) Do a check that each nut and bolt is at the last torque load
value specified in the applicable TASK: Start with hole 1 and
continue in a clockwise direction.
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Subtask 70-51-00-910-056
G. Torque Tighten Fasteners when a Joint Contains a Gasket (Corrujoint Seal)
(1) When a joint contains a gasket (corrujoint seal) it is necessary to
torque fasteners continuously (in sequence) until all the fasteners
are fully tightened. This is because the last bolts tightened can
compress the gasket to a point where the initially tightened bolts
become loose.
Subtask 70-51-00-910-057
H. Hand Torque Wrenches
(Ref. Fig. 203/TASK 70-51-00-991-003, 204/TASK 70-51-00-991-004)
(1) Flexible beam type:
(a) To get the correct indication, hold the handle lightly with one
hand.
To apply the torque, pull at 90 deg (90.0000 deg) to the center
line (AXIS) of the wrench: This will apply the force or load at
the correct point.
Do not move the position of the hand. This will move the
pivot-point center to some other position on the handle: Thus the
force or load will be incorrectly applied.
(b) Do a test of all wrenches at regular times on the setting rig to
make sure their indications are accurate. Adapters, extension
bars and sockets (which can be changed) can be used with all
wrenches.
(c) To make sure of the largest precision possible: Use a torque
wrench which will show in the higher range of the scale. The
first quarter and the last quarter of the scale cannot be used
for mandatory loads.
This is because the precision of the beam type wrench is not
correct at these positions. Some flexible beam torque wrenches do
not have the first quarter and the last quarter of the scale
shown. Set the torque wrench to the correct zero load before it
is used.
(2) Screwdriver type:
(a) To get a correct indication the handle must be held as if it were
a screwdriver. To apply the torque it must be turned smoothly
until the necessary torque load value is shown.
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Correct Procedure to Hold a Flexible Beam Torque Wrench
Figure 203/TASK 70-51-00-991-003
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Correct Procedure to Hold a Screwdriver Torque Wrench
Figure 204/TASK 70-51-00-991-004
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(b) Do a test of all screwdriver type wrenches on the setting rig to
make sure their indications are accurate.
(c) Do a check that the torque indication pointer shows zero on the
scale when no load is applied: If necessary adjust the pointer as
given in the torque wrench manufacturers instruction book.
Subtask 70-51-00-910-058
J. Power Wrenches
(1) A power wrench must only be used to initially tighten nuts and bolts.
You must not apply more than 50 percent of the specified full torque
load value with a power wrench. Apply the full torque load value with
an approved hand torque wrench.
Subtask 70-51-00-910-059
K. Torque Multiplier
(1) The torque multiplier is a mechanical gearbox or hydraulic unit which
is used with the torque wrench. It is used to get higher torque load
values than those possible with the usual range of torque wrenches.
It is important that the torque wrench scale indication agrees with
the ratio of the unit which is used. The torque multiplier must be
calibrated at regular times and kept in a satisfactory condition
(Refer to the manufacturers instructions).
Subtask 70-51-00-910-060
L. Extension Spanners
(Ref. Fig. 205/TASK 70-51-00-991-005)
(1) The extension spanner must always be used in line with the torque
wrench (unless access prevents this): A corrected torque load value
must be applied when the spanner is in line.
(2) Where the extension spanner has to be attached at one of the
alternative positions (because of the limit of access) the shortest
possible extension must be used. The torque load must be applied
carefully at the wrench handle at 90 degrees to the length of the
wrench. This will prevent errors. A corrected torque load value is
not usually applicable if the extension spanner is of the correct
design.
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Torque Wrench and Extension
Figure 205/TASK 70-51-00-991-005
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(3) To find the torque load value which must be used with the extension
spanner, use the formulae that follows:
(a) When the torque wrench length is increased by the extension
spanner, use:
R = L x T
----L + E
R = Corrected torque load value
L = Length of torque wrench
T = Specified torque for the part
E = Length of the extension spanner
Example:
A nut is to be tightened to a specified torque of to 210 lbf.in
(2.37 m.daN) with a torque wrench 15 in. (0.3809 m) in length. An
extension of 3 in. (76.1998 mm) is attached in the recommended
position to give a total lever length of 18 in. (0.4571 m)
The corrected torque load value is:
15 x 210 = 175 lbf.in. (1,97 m.daN)
-------18
NOTE : All lengths are measured with the pivot in the handle as
____
the datum.
NOTE : Length L + E must be measured parallel to the torque
____
wrench lever as shown.
NOTE : The lengths L + E can be in Imperial or Metric units, but
____
must be the same units.
Subtask 70-51-00-910-061
M. In-Built (Locking) Torque for Self-Locking Fasteners
(Ref. Fig. 206/TASK 70-51-00-991-006)
(1) The in-built torque is the force which safeties the nut or the
setscrew when:
(a) The nut is engaged on the stud or bolt (or the setscrew is
engaged in the insert or captive nut). And the full chamfer of
the stud or bolt (or setscrew) has gone through the locking part
of the nut (or the insert or captive nut).
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Range of In-Built Torque Limits for Self-Locking Nuts, Wire-Thread Inserts and
Captive Nuts
Figure 206/TASK 70-51-00-991-006
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(b) There is no axial load on the nut or bolt.
(2) Do not change the in-built torque of a nut or insert by crimping the
lock device: Or by easing it with a thread tap.
(3) The range of in-built torque is given in this TASK.
(4) There are different procedures available to do a check of the locking
torque: But the important condition is that the locking torque is
sufficient when the bolt, nut or setscrew is installed.
(5) Use of Gauges
CAUTION : YOU MUST NOT DO A CHECK OF SILVER PLATED NUTS WITH GAUGES
_______
WHICH HAVE TOUCHED CADMIUM OR MOLYBDENUM DISULPHIDE.
CADMIUM OR MOLYBDENUM DISULPHIDE WILL CAUSE CONTAMINATION
OF THE NUTS AND SUBSEQUENTLY CAUSE THEIR FAILURE.
(a) Do a check of the fasteners before assembly: Use the gauges given
in Job Set-up Information. This will make sure of the correct
locking torque and will prevent replacement of the fasteners
during assembly.
Subtask 70-51-00-910-062
N. Installation of Nuts and Bolts which are not Self-Locking
(1) When you install nuts which are not self-locking to studs and bolts:
Or install bolts (used as setscrews) in threaded holes which are not
self-locking, apply the torque loads specified in the applicable
TASK.
Subtask 70-51-00-910-063
P. Installation of Self-Locking Nuts and Bolts
(Ref. Fig. 206/TASK 70-51-00-991-006)
(1) When you install self-locking nuts to studs and bolts: Or install
bolts (used as setscrews) to self-locking wire thread inserts: Or to
self-locking thread captive nuts, apply the torque loads specified in
the applicable TASK.
(2) The life of self-locking nuts and inserts is related to their
in-built locking torque: To find if the locking torque is
satisfactory.
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Subtask 70-51-00-910-064
Q. Tube Connections (Union Nuts, Tube and Hose Connections)
CAUTION : YOU MUST HOLD THE TUBE(S) WHEN YOU LOOSEN/TIGHTEN THE
_______
CONNECTIONS. MAKE SURE THAT THE TUBE(S) CANNOT TWIST. DAMAGE TO
THE TUBE(S) CAN OCCUR IF THEY DO TWIST.
(1) Bed-in the connections as follows:
(a) Use clean engine lubricating oil (Material No. OMat 1011) as a
lubricant on the threads and the abutment faces: Then assemble
the nut to the union and tighten it to the torque load value
specified in the applicable TASK.
(b) Loosen the connection: Release the nut half a turn.
(c) Tighten the nut to the torque load value specified in the
applicable TASK.
(d) Loosen the connection: Release the nut half a turn.
(e) Do steps (c) and (d) again.
(f) Tighten the nut to the torque load value specified in the
applicable TASK.
CAUTION : YOU MUST NOT APPLY MORE THAN THE SPECIFIED TORQUE LOAD
_______
VALUE TO TRY TO REPAIR A LEAK. THIS CAN SUBSEQUENTLY
CAUSE THE FAILURE OF THE PARTS.
(2) To repair a leak from a connection: Disconnect the connection and
examine the parts for the cause of the failure to seal. If necessary,
install new parts and connect the connection as specified in steps
O.(1). (a) thru (f).
Subtask 70-51-00-910-065
R. Screwed Unions and Hexagon-headed Blanking Plugs
(1) The torque load values for screwed unions and hexagon-headed blanking
plugs are the same for given thread diameters. The unions are usually
tightened to an approximately 20 percent higher torque load value
than that of the union nut: This helps to prevent movement of the
union when the tube nut is tightenend or loosened.
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(2) When unions or plugs are to be installed, use clean engine
lubricating oil (Material No. OMat 1011) to lubricate the threads:
But not when they are to be installed into magnesium alloys. If they
are to be installed into magnesium alloys: Apply a thin layer of
jointing compound (Material No. OMat 4-46) to the threads and the
abutment face of the union or plug. Let the compound air-dry for
approximately 10 minutes before assembly.
(3) Make sure all the items are clean and all the necessary joint washers
are installed: Then assemble and tighten to the torque load value
specified in the applicable TASK.
Subtask 70-51-00-910-066
S. Installation of Studs
(1) Studs are usually installed as replacements. When replacement studs
are to be installed, refer to the related repair.
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TASK 70-51-00-910-804
Torque Stripe Technique
WARNING : YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE
_______
ENGINE IS SHUTDOWN. THE ENGINE PARTS CAN STAY HOT FOR ALMOST 1 HOUR.
WARNING : YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN
_______
CAUSE AN INJURY. IF YOU GET AN INJURY PUT IT IN COLD WATER FOR 10
MINUTES AND GET MEDICAL AID.
WARNING : YOU MUST OBEY THE MANUFACTURERS HEALTH AND SAFETY DATA FOR THE
_______
MATERIALS. YOU MUST ALSO REFER TO LOCAL REGULATIONS TO MAKE SURE THAT
YOU DO THE PROCEDURES SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR
ENVIRONMENTAL DAMAGE CAN OCCUR.
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
1 SCRAPER - NON METALLIC
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat 1-257
Material No.
OMat 150
Material No.
OMat 2-101
Material No.
OMat 582
Material No.
OMat 7-229
*
Cleaning solvent (Ref. 70-30-00)
*
Acetone (CH3) 2CO (Ref. 70-30-00)
*
Absorbant cloth lint free (Ref. 70-30-00)
*
Scotch Brite (Ref. 70-30-00)
*
Inspection Marking Lacquer (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-51-00-991-014
Fig. 207
3. __________
Job Set-up
Subtask 70-51-00-869-058
A. No special job set-up is necessary for this task.
4. Procedure
_________
(Ref. Fig. 207/TASK 70-51-00-991-014)
Subtask 70-51-00-910-087
A. Removal of the Torque Stripe
(1) Removal of the paint type torque stripe.
(a) Lightly rub the surface to remove the paint torque stripe with
Scotch Brite (Material No. OMat 582).
(b) Make an Absorbant cloth lint free (Material No. OMat 2-101) moist
with Acetone (CH3) 2CO (Material No. OMat 150) or Cleaning
solvent (Material No. OMat 1-257) and clean the surface.
(2) Removal of the Inspection Marking Lacquer (Material No. OMat 7-229)
type.
(a) Remove the torque stripe with a SCRAPER - NON METALLIC.
(b) Make an Absorbant cloth lint free (Material No. OMat 2-101) moist
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Torque Stripe
Figure 207/TASK 70-51-00-991-014
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Subtask 70-51-00-910-088
B. Installation of the Torque Stripe
(1) Preparation of the surface for the application of the torque stripe.
(a) Make an Absorbant cloth lint free (Material No. OMat 2-101) moist
(b) Allow for the surface to dry.
(2) Application of the torque stripe.
(a) Apply Inspection Marking Lacquer (Material No. OMat 7-229) to
engage both sides of the items to be torque striped to a minimum
length of 20 mm (0.78 in.).
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GENERAL VISUAL INSPECTION OF ATTACHING PARTS - MAINTENANCE PRACTICES
____________________________________________________________________
TASK 70-51-02-200-801
General Visual Inspection of Attaching Parts
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
small clean brush
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-20-01-100-802
70-20-02-230-803
70-20-02-230-804
70-42-11-300-801
70-42-13-300-801
70-51-00-910-802
101
Repair Surfaces Affected by Minor Damage - FRS3253
Repair Threaded Holes by the installation of the
Wirethread Inserts (FRS3002)
3. __________
Job Set-up
Subtask 70-51-02-941-050
A. Not Applicable
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4. Procedure
_________
Subtask 70-51-02-210-050
A. General
(1) This procedure is for the inspection of attaching parts to make sure
they are in a serviceable condition for installation. The procedure
contains instructions to examine:
- Parts for crack indications
- Silver plated parts
- Bolts and screws
- Studs and inserts
- Ring nuts
- Barrel Nuts
- Nuts, self-lock nuts and clip nuts
- Cupwashers (Steel)
- Washers and spacers
- Tube clips.
NOTE : You must refer to 70-01-02 - Part Condition Terminology to
____
correctly identify the specified part condition and/ or types
of damage. This will prevent errors that can occur when a part
condition or type of damage is known incorrectly by two
different names.
(2) To identify if there are special inspection instructions for the
part, refer to the inspection Tasks in the related area of the
manual.
(3) To identify if there are special cleaning instructions for the part,
refer to the cleaning Tasks in the related area of the manual.
(4) All parts must be visually examined for damage and wear.
Subtask 70-51-02-110-050
B. Clean the parts:
(1) Clean the parts (Ref. TASK 70-20-01-100-802).
(2) If the parts are unusually dirty or greasy, use a small clean brush
soaked in the cleaning fluid (Ref. TASK 70-20-01-100-802).
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Subtask 70-51-02-210-051
C. Examine Parts for Crack Indications
(1) Examine all parts for cracks. If you think there is a crack, use the
magnifying glasses (7X and 30X magnification) to help you make the
decision. Where specified, use the applicable crack inspection
procedure (Ref. TASK 70-20-02-230-803) or (Ref. TASK 70-20-02-230804).
(2) If you find a crack in a part and there are no specified limits,
reject it.
(3) If you think the result of a crack inspection procedure is incorrect,
refer to Rolls-Royce plc for a decision.
(4) The liquid penetrants specified in the Aircraft Maintenance Manual
(AMM) and the Overhaul Materials Manual (OMat) are those approved by
Rolls-Royce plc.
Subtask 70-51-02-210-052
D. Silver Plated Parts
(1) Examine the threads and the mating surfaces of silver plated parts.
If the silver plating is blistered, flaked, or very black in color,
reject the part for repair. If the silver plating is cracked, reject
it.
Subtask 70-51-02-210-053
E. Bolts and Screws
(1) Examine the surfaces of the parts for signs of damage. If there are
scratches, marks and/ or other damage, reject it.
(2) Examine the parts for crossed or stripped threads and pickup. If
there are crossed or stripped threads, reject it. If there are
threads that show pick-up, repair to FRS3253 (Ref. TASK 70-42-11-300801).
(3) Examine the parts for wear on the threads. If the threads are worn,
make sure that the in-built (locking) torque is satisfactory during
subsequent installation of the mating nut (Ref. TASK 70-51-00-910802). But, if there is a running torque check for the bolt, in the
related procedure, use the values given in that procedure.
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NOTE : If a self-lock nut is installed on a bolt, the bolt threads
____
can become worn at the point of the threads. This is caused as
the lock device in the nut engages with each thread of the
bolt as it is tightened.
(4) Examine the screw slots for signs of damage. If you find signs of
damage, reject the part for repair.
(5) Examine the hole locations for split cotter pins or lockwire/safety
cable. If the holes are damaged or blocked, reject the part for
repair.
(6) Examine a bolt that is held in position with a retaining ring. If the
retaining ring is worn, broken or missing, reject the part for
repair.
Subtask 70-51-02-210-054
F. Studs and Inserts
(1) Examine the surfaces of all related studs for signs of damage. If
there are scratches, marks and/ or other damage, reject it.
(2) Examine all related inserts for crossed or stripped threads. If the
threads are crossed or stripped, replace the insert (Ref. TASK 70-4213-300-801).
(3) Examine all related studs to make sure that they are tight and fully
installed.
Subtask 70-51-02-210-055
G. Ring Nuts
(1) Examine the surface of the nut for signs of damage. This is very
important in the area of the spanner slots. If there is damage,
reject it.
(2) Examine the nut for crossed or stripped threads and/or pick-up. If
there are signs of crossed or stripped threads and/or pick-up, reject
it.
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Subtask 70-51-02-210-056
H. Barrel-Nuts
NOTE : Disassembly of a barrel-nut for inspection is NOT permitted.
____
(1) Examine the body of the barrel-nut for signs of damage. If the nut is
cracked or there are scratches, marks and/ or other damage, reject
it.
(2) Examine the barrel-nut for discoloration caused by corrosion. If
there is discoloration caused by corrosion, reject the part for
repair.
(3) Examine the barrel-nut for crossed or stripped threads and/or
pick-up. If there are crossed or stripped threads, reject it. If
there are threads that show pick-up, repair to FRS3253 (Ref. TASK 7042-11-300-801).
(4) Examine the barrel-nut cradle for scoring and/ or galling. If there
is scoring and/ or galling, reject it.
(5) Examine the pins in the barrel-nut cradle. If one pin is broken,
reject it.
Subtask 70-51-02-210-057
J. Nuts, Self-Lock Nuts and Clip Nuts
NOTE : Identification of self-lock nuts is given in 70-00-05, Description
____
and Operation.
(1) Examine the nuts, self-lock nuts and clip nuts for signs of damage.
If there are scratches, marks and/ or other damage, reject it.
(2) Examine the part for crossed or stripped threads and pickup. If there
are crossed or stripped threads, reject it. If there are threads that
show pick-up, repair to FRS3253 (Ref. TASK 70-42-11-300-801).
(3) Examine the castellations for signs of damage. If the castellations
show signs of damage, reject it.
(4) Examine the clip on the clip nuts. If the clip shows signs of damage,
or does not hold in position, reject it.
(5) Do a check of the in-built torque of a self-lock nut (Ref. TASK 7051-00-910-802).
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Subtask 70-51-02-210-058
K. Cupwashers (Steel)
(1) Examine the rim of the cupwasher to find the quantity of scallop
marks. If there are two 60-degree lengths of arc without scallop
marks, and they are opposite to each other, accept it.
NOTE : Only one scallop is permitted on a cupwasher that is installed
____
on the engine primary assembly that turns.
(2) Do a penetrant inspection of the cupwasher (Ref. TASK 70-20-02-230803) or (Ref. TASK 70-20-02-230-804).
(a) If there are cracks that are parallel to the axis of the washer,
reject it.
NOTE : This is because the hoop strength is not sufficient.
____
(b) For cupwashers that are installed on the compressor and turbine
shafts: If there are small circumferential cracks between the
washer skirt and the backplate, accept them if:
- They are not longer than 0.125 in. (3.1749 mm).
- There are not more than four cracks in the cupwasher.
Circumferential cracks are not permitted on cupwashers that are
installed in other areas.
(c) For cupwashers that are installed in areas other than on
compressor and turbine shafts: If there are small circumferential
cracks between the washer skirt and the backplate, reject it.
(3) Examine the condition of the mating face. Make sure that it is
smooth, flat and parallel to less than 0.001 in. (0.0253 mm).
Subtask 70-51-02-210-059
L. Washers and Spacers
(1) Examine the bolt holes and surfaces for distortion and wear. If you
find one of these conditions and it also stops the correct assembly
of the part, reject it.
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Subtask 70-51-02-210-060
M. Tube Clips
(1) Examine the bolt holes and surfaces for distortion and wear. If you
find one of these conditions and it also stops the correct assembly
of the part, reject it.
(2) Examine the rubber sleeve(s) for tears, missing pieces and/ or signs
that it has become soft. If you find one of these conditions, reject
it.
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STORAGE OF FLEXIBLE RINGS, HOSES AND RUBBER COMPONENTS
______________________________________________________
_________________________
1. _______
General
(Ref. Fig. 001)
A. Storage (Shelf) Life
(1) The shelf life of a rubber or synthetic rubber part is calculated
from its cure date. This date can be on the part and/or on its
container. Parts which have a cure date include bonded
rubber-to-metal parts, cables, harnesses, hoses and hose assemblies.
(2) The cure date identifies the quarter of the year in which the part
was made. These quarters are specified as:
- 1Q (First quarter) January, February, March
- 2Q (Second quarter) April, May, June
- 3Q (Third quarter) July, August, September
- 4Q (Fourth quarter) October, November, December.
Also identified in the cure date is the year in which the part was
made (written as two numbers).
For example: 2Q92.
On some parts, the month that the part was made is included after
the year.
For example: 2Q92 (May).
(3) The last day of the quarter is used as the start point for the shelf
life of all parts made in that quarter. Thus a part with the cure
date 2Q92 will have a shelf life of one year at the end of the second
quarter of 1993 (30th June 1993).
B. Cure Date Identification
(1) Parts which are too small to be given an identification mark are
identified with a label (for the part or batch) and are contained in
identified envelopes. Seal rings are also identified by the same
procedure.
(2) Parts which can be given an identification mark (such as diaphragms
and bulkhead seals) are identified with permanent marking fluid. The
fluid used is of a color which lets the cure date be easily seen.
(3) The cure date is shown on all containers (envelopes, bags or
packages) in which the items are kept. Also shown is the
manufacturers name or reference, the Rolls-Royce part number and the
batch number.
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Material Groups
Figure 001
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(4) Hoses are identified along their length with two groups of numbers
and letters. The first group is related to manufacturers data (such
as the chemical mixture of the material). The second group gives the
length or batch number and the cure date.
For example: 01013Q92
- the first four numbers are the length or batch number
- the last three numbers and the letter are the cure date.
In the above example, the identification mark shows that the hose
was the 101st length or batch made during the third quarter of
1992. Thus the hose has a cure date of 30th September 1992.
(5) Hose assemblies are also identified with three tabs. One tab shows a
copy of the hose identification. One tab shows the hose part number,
test date, inspectors stamp and manufacturers identification. The
other tab shows the cure date of the hose.
C. Storage of Parts
(1) The storage conditions for rubber and synthetic parts must be
satisfactory to make sure of maximum shelf life. The conditions must
give the maximum possible protection from the effects of:
- strain
- direct sunlight
- ozone
- moisture
- too much air flow
- very high or very low temperature
- damage
and from contamination by
- fuels
- oils
- greases
- solvents.
(2) If the parts are supplied in envelopes, plastic bags or cartons they
must be kept in this condition until used.
(3) Parts which have been in storage longest must always be used first
(as shown by the cure date).
(4) Parts must not be kept in tension or put in a position that changes
their usual shape. It is important not to put too many parts in a
vertical stack. This can cause permanent distortion of the parts at
the bottom. Hoses must not be wound into a coil (unless necessary) as
ozone cracks can occur in the stressed material.
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(5) The storage area must have sufficient air flow to prevent
condensation: But parts must be kept out of air flows. Parts must
also be kept away from sources of ozone such as mercury vapor lamps
and electrical machinery. One more source is outdoor air which is
temperate climates alway contains ozone.
(6) Lip type seals must be kept in a position which prevents damage and
distortion of the seal edge. Tie labels must not be attached directly
to the seals.
(7) Seal rings must not be installed to ferrules or bobbins until
immediately before installation to an engine or unit. This will
prevent deterioration of the seal rings which can occur while the
rings are open to the atmosphere.
(8) The storage area must not become colder than 5 deg.C (41 deg.F) or
hotter than 38 deg.C (100 deg.F). For the best storage conditions,
keep the temperature of the area between 15 and 21 deg.C (59 and 70
deg.F) with an air relative humidity of 65 percent.
(9) Parts must be kept away from direct sunlight.
(10) Parts must be kept away from all sources of heat. The minimum
distance from a source of heat must be 3 feet.
(11) Group A parts are satisfactory for storage if their calculated life
since manufacture (refer to the cure date) is 5 years or less. Their
subsequent shelf life with the customer has no limit if they are kept
in the recommended conditions and examined each 2 years: It is only
necessary to examine a sample of the parts which have the longest
shelf life unless they are found defective.
(12) Group B parts (but not those made of nitrile) are satisfactory for
storage if their calculated life since manufacture (refer to the cure
date) is 7 years or less. Their subsequent shelf life with the
customer has no limit if they are kept in the recommended conditions
and examined each 3 years: It is only necessary to examine a sample
of the parts which have the longest shelf life unless they are found
defective.
(13) Group B parts made of nitrile are satisfactory for storage if their
calculated life since manufacture (refer to the cure date) is 7 years
or less. These parts have a maximum life of 10 years.
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(14) Group X parts have no life limits after manufacture or limits for
their shelf life with the customer. Inspection of these parts during
storage is also not necessary. Cure dates are only shown on their
containers to help with stock control.
D. Inspection of Parts
(1) Examine the parts for damage caused by oxidation: This is shown by
surface cracks and deterioration.
NOTE : Do not reject parts because they have bloom on their surface
____
which is white or has a color. The bloom can help to keep the
part in good condition and is caused by the anti-oxidants used
in high grade rubber.
(a) Bend the part carefully and discard it if cracks occur before or
after the part is bent.
(2) Examine all parts as follows: Discard them if they are defective.
(a) Look for permanent distortion, flat areas and other visual
defects.
(b) Look for tacky, hard or soft surfaces.
(c) Extend or bend the rubber and look for blisters, cracks and
surface peel.
(d) Look for chafed areas on the outer layers of hose assemblies.
(e) Look for corrosion or damage to the hose assemblies connections.
(f) Look for corrosion of the metal parts in bonded rubber-to-metal
assemblies.
(g) Look for blockage of the internal diameter of flexible hoses.
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POWER PLANT WIRING STANDARD PRACTICES - ATA INDEX - DESCRIPTION AND OPERATION
_____________________________________________________________________________
1. General
_______
All the data in Chapter/Section 70-71 is related to the Trent 700 series
Power Plant only. The location of the data for the repair of all the harness
connectors and wires is shown below:
------------------------------------------------------------------------|
SUBJECT
|
CH-SE-SU
|
|------------------------------------------------|----------------------|
| POWER PLANT WIRING STANDARD PRACTICES - ATA
|
70-71-00
|
| INDEX
|
|
|------------------------------------------------|----------------------|
| POWER PLANT WIRING - GENERAL
|
70-71-01
|
|------------------------------------------------|----------------------|
| VENDOR CODES, NAMES AND ADDRESSES
|
70-71-02
|
|-----------------------------------------------------------------------|
| CONNECTOR/INSERT ARRANGEMENT
|
70-71-12
|
|-----------------------------------------------------------------------|
| WIRE HARNESS LACING PROCEDURE
|
70-71-14
|
|-----------------------------------------------------------------------|
| CONNECTOR AND BACKSHELL REPLACEMENT PROCEDURE |
70-71-20
|
|------------------------------------------------|----------------------|
| CONTACT REPLACEMENT PROCEDURE
|
70-71-21
|
|------------------------------------------------|----------------------|
| SHIELDED CABLE REPLACEMENT PROCEDURE
|
70-71-24
|
|-----------------------------------------------------------------------|
| TERMINAL TAG REPLACEMENT PROCEDURE
|
70-71-26
|
|------------------------------------------------|----------------------|
| DISCONNECT AND HARNESS IDENTIFICATION MARKER
|
|
| REPAIR
|
70-71-27
|
-------------------------------------------------|----------------------For further details, refer to CMM:
Electrical Harness and Cables: CMM-EHC-TRENT-1RR
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POWER PLANT WIRING - GENERAL - DESCRIPTION AND OPERATION
________________________________________________________
1. General
_______
A. Characteristics
All the power plant electrical wire harnesses, components and connectors
are identified by a Functional Item Number referred to as the FIN.
(1) The ESC10 and ESC11 series of connectors have their contacts removed
and installed from the rear of the connector. The contacts are
released with the contact insertion/extraction tool and removed from
the rear of the connector. The contacts are installed into the rear
of the connector with the contact insertion/extraction tool and
locked in position. This permits the replacement of crimp contacts
without damage to the connector.
(2) The connectors have EMI backshells attached to the connector rear
accessory threads. The backshell gives:
(a) Strain relief to prevent mechanical loads, which can be
transmitted from the wires and cables to the contacts.
(b) The attachment point for the cable shields (the braided metal
layer).
(c) The conductive path to ground for the cable shields.
(d) Protection for the EMI window caused by the removal of sufficient
cable shield, necessary for the use of the contact
insertion/extraction tool.
(e) Protection against EMI, HIRF and the secondary effects of
lightning.
B. Conditions
Examine each harness assembly for these conditions:
(1) Cable for chafed outer jacket.
(2) Broken thermocouple terminals or lugs.
(3) Connectors for bent, broken, or recessed (pushed back) contacts.
(4) Connectors for broken, worn or stripped threads.
(5) Backshells for broken, worn or stripped threads.
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C. Detail Parts
Replace all the detail parts that show too much damage. Refer to the
applicable repair procedure in 70-71-00.
(1) All the connectors are not the same. Carefully examine each connector
for the correct FIN, part number and connection location. This
prevents the possible installation of a connector that is not
correct.
(2) A sharp bend, twist, or pull can cause damage to the wires and wire
bundles. This type of force can cause damage to the conductor.
(3) Good standard shop practices and safety precautions should be
followed at all times. This prevents injury to persons and damage to
the equipment.
(4) You must replace a wire or cable with the same type of wire or cable
(Refer to 70-71-24). To get the correct part number for the wire
type, wire gage and wire length; Refer to the Aircraft Wire List
(AWL) 92-90 Master Wire List for the applicable wire identification
number.
(5) You must replace a connector, contact or backshell with the same type
of connector, contact or backshell (Refer to the applicable repair
procedure in 70-71-00).
(a) To get the correct connector and backshell part number, refer to
the Aircraft Wire List (AWL), 92-10 Equipment List. Refer to the
Power Plant Illustrated Parts Catalog for alternative part
numbers.
(b) To get the correct contact part number for the connector, refer
to the 92-20 Hook-Up List/Plug and Receptacles for the applicable
FIN number.
(6) Wire circuit identification.
(a) All the wires are identified with an identification sleeve on
each cable.
(Ref. Fig. 001)
(b) Wires and cables used in the harness have outer jackets color
coded as follows:
Grey - General purpose cable
White with red tracer - Fire resistant cable
Green with red tracer - Fire resistant thermocouple cable.
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Harness and Cable Identification
Figure 001
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(c) The wire gage numbers that follow are used on the power plant:
16 American Wire Gage
0 American Wire Gage (IDG neutral cable)
000 American Wire Gage (IDG power cables).
EFF :
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Page 4
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SERIES ENGINES
VENDOR CODES, NAMES AND ADRESSES - DESCRIPTION AND OPERATION
____________________________________________________________
1. _______
General
This chapter gives all the supplier code numbers, names and addresses that
are used in Chapters 70-71.
-------------------------------------------------------------------|
SUPPLIER
|
SUPPLIER CODE
|
|-------------------------------------|----------------------------|
| AMP Inc. of Great Britain Ltd.
|
K1636
|
| Terminal House, Merrion Ave
|
|
| Stanmore, (London)
|
|
| Middlesex HA7 4RS England
|
|
|
|
|
| Glenair International Ltd.
|
U0419
|
| Park Works, Park Road
|
|
| Mansfield, Notts NG19 8EF England
|
|
|
|
|
| Pyle-National Ltd.
|
U0425
|
| Sherbrook Road
|
|
| Daybrook
|
|
| Nottingham NG5 6AT England
|
|
|
|
|
| Minnesota Mining and Mfg. Co. (3M) |
04963
|
| Adhesive Coatings and Sealer
|
|
| Div. Mail Stop A143-3N-01
|
|
| 6801 River Place Blvd.
|
|
| Austin, TX 78726-9000
|
|
|
|
|
| Glenair Inc.
|
06324
|
| 1211 Air Way
|
|
| Glendale, CA 91201
|
|
|
|
|
| Daniels Manufacturing Corp.
|
11851
|
| 526 Thorpe Road
|
|
| Orlando, FL 32824-8133
|
|
|
|
|
| Gudebrog Inc.
|
82110
|
| 262 King St.
|
|
| P.O. Box 357
|
|
| Pottstown, PA 19464
|
|
|
|
|
| Kembrey Industries Ltd.
|
U2824
|
| Kembrey Park
|
|
| Swindon
|
|
| Wiltshire SN2 6BJ
|
|
|
|
|
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SERIES ENGINES
-------------------------------------------------------------------|
SUPPLIER
|
SUPPLIER CODE
|
|-------------------------------------|----------------------------|
| Rolls-Royce
|
K0680
|
|
|
|
|Polamco Ltd.
|
U5792
|
|103 Locksbrook Road
|
|
|Bath
|
|
|Avon BA1 3EN
|
|
--------------------------------------------------------------------
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SERIES ENGINES
CONNECTOR/INSERT ARRANGEMENT - DESCRIPTION AND OPERATION
________________________________________________________
1. General
_______
A. Series Connectors
This chapter gives the supplier part number, part number description,
alternative key-way positions and contact arrangements for the connectors
used on the power plant.
(1) ESC10 series connectors.
(2) ESC11 series connectors.
B. Specifications
ESC connectors
(Ref. Fig. 001, 002, 003, 004, 005, 006, 007, 008)
(1) The ESC10 range of connectors are almost the same as the MIL-C-83723
series III connectors. The ESC10 connectors have some modifications
so they can be used on powerplants. They are:
- Metal to metal bottoming
- Torque differential locking
- 260 deg C operation.
(2) The ESC11 range of connectors are almost the same as the ESC10 range.
The only difference is that the ESC11 connectors are scoop proof.
(3) The insert arrangement is given by the connector shell size and the
contact arrangement. If the front face of a pin insert is shown:
- The rear face of the pin insert is opposite hand
- The front face of the socket is opposite hand
- The rear face of the socket insert is the same.
C. Key-Ways
The key-ways on ESC10 and ESC11 connectors are baulked. This prevents the
accidental connection of one series of connector with another series of
connector.
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70-71-12
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Page 1
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SERIES ENGINES
ESC Connector Identification
Figure 001
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Page 2
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SERIES ENGINES
ESC10 and ESC11 Connector Contact Arrangements
Figure 002
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Page 3
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TRENT 700
SERIES ENGINES
Figure 003
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70-71-12
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Page 4
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TRENT 700
SERIES ENGINES
Figure 004
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70-71-12
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Page 5
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TRENT 700
SERIES ENGINES
Figure 005
EFF :
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70-71-12
AFL
Page 6
Oct 01/08
TRENT 700
SERIES ENGINES
Figure 006
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70-71-12
AFL
Page 7
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TRENT 700
SERIES ENGINES
Figure 007
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70-71-12
AFL
Page 8
Oct 01/08
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SERIES ENGINES
ECS Accessory Identification
Figure 008
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Page 9
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SERIES ENGINES
WIRE HARNESS LACING PROCEDURE - DESCRIPTION AND OPERATION
_________________________________________________________
1. General
_______
A. Harness Tie
(1) This chapter gives the procedure to tie the harness with lacing tape.
(2) These are the wire harness parts:
(a) Wire - A single electrical conductor with insulation around it.
(b) Cable - A group of wires in a metal shield and an insulated
jacket.
(c) Harness - One or more cables with connectors or terminal lugs
attached to the ends of cables.
(3) Make the cables in the wire bundle as straight as possible with a
minimum of twists.
(4) Before you repair a harness, make a note of the position(s) of the
lacing tape. The lacing tape must be installed in the same positions
after the repair.
(5) The distance between the individual laces on the wire bundle is a
maximum of 2.00 in. (50,8 mm).
(6) A bundle of two or more cables must be laced together.
(7) Consumable materials can be replaced with equivalent items.
2. Standard
___________________
equipement
None
3. ___________________
Consumable Material
-----------------------------------------------------------------------------|
Part No.
|
Supplier Code
|
Designation
|
-----------------------------------------------------------------------------|
ESW1900
|
U5792
| Tape, Lacing
|
|-----------------------------------------------------------------------------
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4. Procedure
_________
A. General Lacing Procedure
(1) Install the ESW1900 lacing tape on the harness.
(Ref. Fig. 001)
(a) Make the cables in the harness as straight as possible, with a
minimum of twists before the lacing is installed.
(b) Use the lacing tape to tie the harness at least every 2.00 in.
(50,8 mm) along its length.
(c) Do not tie the knot too tight. If you do, you could cut or go
through the conductor jacket or insulation of the cable.
(d) Cut the two ends of the lacing tape between 0.25 and 0.50 in.
(6,35 and 12,7 mm) from the knot.
B. Harness Break-Out Support Ties (Breakouts Other Than 90 Degrees)
(1) Install the harness break-out support ties.
(Ref. Fig. 002)
NOTE : The support ties must be installed on the harness before and
____
after each harness break-out. All wire harness break-outs must
be in the same plane as the harness center line and go along
the same direction as the break-out.
(a) Make the cables in the harness group as straight as possible,
with a minimum of twists before the lacing is installed.
(b) Use the ESW1900 lacing tape and tie a clove hitch around the
larger harness.
(c) Make six whips (make in the shape of a figure of eight) around
the two harnesses.
(d) Thread lacing tape between the two harnesses and make three
frapping lashings around the center of the whips. Pull tight
after each lashing.
(e) On completion of the lashing, use a reef knot to tie the lacing
tape.
(f) Do not tie the knot too tight. If you do, you could cut or go
through the conductor jacket or insulation of the cable.
EFF :
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70-71-14
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Page 2
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TRENT 700
SERIES ENGINES
Harness Lacing
Figure 001
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70-71-14
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Page 3
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TRENT 700
SERIES ENGINES
Harness Lacing
Figure 002
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Page 4
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SERIES ENGINES
(g) Cut the two ends of the lacing tape between 0.25 and 0.50 in.
(6,35 and 12,70 mm) from the knot.
C. Harness Break-Out Support Ties (90 Degree Break-Outs)
(1) Use the ESW1900 lacing tape to tie the harness.
(2) Install the ties as shown.
(Ref. Fig. 001, 002)
(3) Cut the two ends of the lacing tape between 0.25 and 0.50 in. (6,35
and 12,70 mm) from the knot.
EFF :
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70-71-14
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Page 5
Oct 01/08
TRENT 700
SERIES ENGINES
CONNECTOR AND BACKSHELL REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
_________________________________________________________________________
1. _____________________________________________
Connector and Backshell Replacement Procedure
WARNING : DO NOT USE HEAT GUNS, SOLDERING GUNS, OR SOLDERING IRONS FOR THE
ON-WING REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND CAN CAUSE
INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
A. General
(1) This chapter gives the procedure for the replacement of a connector
and backshell on an electrical wire harness or cable assembly.
(2) These are the wire harness parts:
jacket.
attached to the ends of the cables.
(d) Receptacle - The fixed half of a connector.
(e) Plug - The free half of a connector.
(3) Refer to the Aircraft Wiring List (RR Engine Trent 700 Equipement
List) to find the Functional Item Number (FIN) to get the correct
connector and backshell part numbers.
(4) To identify alternative part numbers refer to the Power Plant
Illustrated Parts Catalog (PPIPC).
(5) Refer to the Aircraft Wiring List, 92-90 Master Wire List for the pin
to pin and wire color data.
(6) The connector contact/insert arrangements are fully specified in
70-71-12.
(7) The wire harness lacing procedures are fully specified in 70-71-14.
(8) Standard equipment and consumable material can be replaced with
equivalent items.
EFF :
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SERIES ENGINES
2. __________________
Standard Equipment
------------------------------------------------------------------------------|
PART No | SUPPLIER |
NOMENCLATURE
|
APPLICATION
|
------------------------------------------------------------------------------| TG-69P
|
11815
| Pliers, Connector
| Removal and installation |
|
|
06324
| Soft Jaw
| of connectors and
|
|
|
|
| backshells
|
|-------------|-----------|------------------------|--------------------------|
| M83723/31-16|
11851
| Insertion/Extraction
|
|
| Tool 16 gage
| of 16 gage contacts
|
|
|
| (MIL-C-83723 and
|
|
|
|
| MIL-C-5015 Connectors) |
|
|-------------|-----------|------------------------|--------------------------|
| M83723/31-20|
11851
|
|
| Tool 20 gage
| of 20 gage contacts
|
|
|
| (MIL-C-83723 and
|
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| Model 177
|
80164
| Digital Multimeter
| Used to measure
|
| Model 260
|
16902
| Ohmmeter
| continuity
|
|-------------|-----------|------------------------|--------------------------|
| HT250-4
|
11851
| Retention Test Tool
| Use to test the 16 and
|
|
|
|
| 20 gage contact retention|
|-------------|-----------|------------------------|--------------------------|
| 67-016-01
|
11851
| Replacement Socket Tip | Replacement tips for
|
|
|
|
| testing 16 gage contacts |
|
|
|
| with retention test tool |
|-------------|-----------|------------------------|--------------------------|
| 68-016-01
|
11851
| Replacement Pin Tip
| Replacement tips for
|
|
|
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| 67-020-01
|
11851
| Replacement Socket Tip | Replacement tips for
|
|
|
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| 68-020-01
|
11851
| Replacement Pin Tip
| Replacement tips for
|
|
|
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| PSC-1204-3-R|
| Phillips ACR
| Used to loosen and
|
|
|
| Screwdriver Bit
| tighten the backshell
|
|
|
|
| strain relief screws
|
-------------------------------------------------------------------------------
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70-71-20
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Page 2
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TRENT 700
SERIES ENGINES
3. ___________________
Consumable Material
------------------------------------------------------------------------------|
PART No
| SUPPLIER |
DESIGNATION
|
|-----------------------------------------------------------------------------| ESW1900
|
U5792
| Tape, Lacing
|
| 100P323
|
U5792
| Tape, Electrical Insulation
|
| Scotchboy 69
|
O4963
| Tape, Fiberglass
|
------------------------------------------------------------------------------4. Procedure
_________
A. Backshell Removal
(Ref. Fig. 001)
NOTE : At this time do not disconnect the mated connector pair.
____
(1) Use the PSC-1204-3-R Phillips Anti Cam-out Rib (ACR) screwdriver to
loosen the backshell strain relief screws.
(2) Use the TG-69P pliers to loosen the back clamp.
(3) Use the TG-69P pliers to loosen the backshell coupling nut connecting
the backshell to the connector.
(4) Use the TG-69P pliers to loosen the plug coupling nut.
(5) Disconnect the plug from the receptacle.
(6) It the backshell to be removed is angular (ESC76 or ESC77), do this
step:
(a) Make a mark on the engine bracket to show the position of the
connector key-way.
(7) If the backshell to be removed is on a receptacle, do these steps:
(a) Make a mark on the engine bracket to show the position of the
connector key-way.
(b) Remove the nuts and the bolts that attach the receptacle and
remove the receptacle from the engine bracket.
(8) Loosen the strain-relief clamp screws sufficiently to permit the
support bush to be moved rearward.
(9) If necessary, remove and keep the strain-relief screws and clamps.
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70-71-20
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Page 3
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SERIES ENGINES
Backshell Removal
Figure 001
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TRENT 700
SERIES ENGINES
(10) Carefully move the back clamp to the rear of the harness. Do not cut,
nick or damage the cables, wires or braided shields. If necessary,
remove the lacing tape to permit the rearward movement.
(11) Carefully cut the cord which holds the braided shields. Do not cut,
nick or damage the cables, wires or braided shields.
(12) Move the grounding ring rearward.
(13) Fold the braided shields rearward along the cable bundle. Make the
braided shields lie flat.
(14) Disconnect the backshell body from the connector. Move the backshell
body rearward, away from the connector.
B. Contacts Removal
Remove all the contacts as follows:
(Ref. Fig. 002)
(1) The contacts are released and then removed from the rear of the
connector with the contact insertion/extraction tool.
(2) If you have a contact location that is not used (contacts that do not
have a wire attached to them), it will contain a contact and sealing
plug.
(3) You must remove the sealing plugs and contacts that are not used
(contacts that do not have a wire attached to them) for installation
into a new connector.
(4) Use the applicable insertion/extraction tool given in the standard
equipment for the correct size contact.
CAUTION : IF TOO MUCH PRESSURE IS USED WHEN YOU REMOVE THE CONTACTS FROM THE
CONNECTOR, DAMAGE TO THE COLLET, CONTACT AND GROMMET CAN OCCUR.
(5) Remove the contacts as follows:
(a) Place the insertion/extraction tool on the wire.
(b) Hold the wire tight and move the tool back on the wire.
NOTE : This will permit the wire to go into the slot of the tool.
____
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Page 5
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TRENT 700
SERIES ENGINES
Contact Removal and Installation
Figure 002
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Page 6
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TRENT 700
SERIES ENGINES
(c) Push the tool along the wire into the rear of the connector
grommet until it touches the shoulder of the contact.
NOTE : When the tool touches the shoulder of the contact in the
____
connector grommet the collet will become larger. This
releases the contact and permits the contact to be
removed.
(d) Hold the wire against the serrated shoulder of the tool with
light hand pressure and remove the wired contact and tool.
(e) Remove the tool from the wire.
(f) Put a label on the wire, to identify the contact number for the
subsequent installation.
(g) Do step (a) thru step (f) again for the other contacts to be
removed.
(h) If a contact is damaged, refer to the procedure given in chapter
70-71-21.
C. Replace the Connector or Backshell
(1) If the connector or backshell is replaced, examine the new part
number to make sure it is correct for that FIN location. Refer to the
Aircraft Wiring List, 92-10 equipment list for the correct part
numbers.
(2) If the new backshell is angular (ESC76 or ESC77) do this step:
(a) Make a mark on the backshell in the same position as the mark on
the unserviceable backshell.
(3) Install the support bush (if installed) on the harness. Make sure the
support bush is the correct size for the harness.
(4) If the connector is to be connected to an angular backshell (ESC76 or
ESC77), do this step:
(a) Make sure the key-way or the connector aligns with the mark you
made on the angular backshell.
(5) Move the backshell and the support bush (if installed) rearward over
the harness to permit the contacts to be installed in the connector.
(Ref. Fig. 002)
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Page 7
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SERIES ENGINES
D. Install the Contact
(Ref. Fig. 002)
NOTE : The backshell and support bush (if installed) must be installed on
____
the harness before the contacts are installed in the connector.
(1) Use the applicable insertion/extraction tool given in the standard
equipment for the correct contact size.
(2) Install the insertion/extraction tool on the contact.
NOTE : When you install the contacts you must
____
located in the center of the connector
you install the correct contact in the
contacts are installed and locked from
connector.
start with the wire
arrangement. Make sure
correct location. All
the rear of the
(a) Put the insertion/extraction tool on the wire. Hold the wire
tight and move the tool rearward on the wire.
NOTE : This will permit the wire to go into the slot of the tool.
____
(b) Push the tool along the wire until the tip of the tool touches
the shoulder of the contact.
(3) Install the contact in the connector.
NOTE : When the contacts are installed, the contact holes that are
____
not used must have contacts and sealing plugs installed.
(a) Hold the connector in your hand.
(b) Use the label on the wire to identify the correct contact
location.
NOTE : Refer to the Aircraft Wiring Manual, 92-20 Hook-up
____
List/Plugs and Receptacles for detailed wiring data.
CAUTION : IF TOO MUCH PRESSURE IS USED WHEN YOU INSTALL THE CONTACT INTO THE
(c) Install the insertion/extraction tool with the wired contact (or
the contacts that are not used) into the correct hole at the rear
of the connector. Use strong and equal pressure.
(d) Remove the tool.
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SERIES ENGINES
(e) Lightly pull back on the wire to feel if the contact is locked in
the collet.
(4) Do the procedures given in paras (2) and (3) again for the other
contacts.
(5) Install the larger end of the sealing plugs in the connector grommet
of the contacts that are not used.
E. Do a Contact Retention Check
(Ref. Fig. 003)
NOTE : All the contacts
____
all the not used
to make sure the
and 15 lbf (44.5
must be locked in the connector. This includes
contacts . The contact retention force necessary
contact is locked in the connector is between 10
to 66.7 N).
(1) Use the correct retention test tool, replacement pin and replacement
socket tools that are given in the standard equipment for the correct
contact size:
- Use the pin replacement tips when you do a test of the socket
contacts.
- Use the socket replacement tips when you do a test of the pin
contacts.
CAUTION : BE CAREFUL WHEN YOU DO A CHECK OF THE CONTACTS. INCORRECT USE OF THE
RETENTION TEST TOOL COULD RESULT IN DAMAGE TO THE CONNECTORS, CONTACT
, COLLET, GROMMET OR TEST TOOL.
(2) Put the 16 to 20 gage retention test tool and replacement pin or
replacement socket on the contact so they are in a straight line.
NOTE : Keep this position when you do a test on each contact to get
____
the most accurate results.
(3) Apply hand pressure to the tester until the indicator band located on
the replacement pin or socket is aligned with the body of the tester:
- At this point, there is 13 lbf (57.8 N) of pressure applied.
- If the contact is still in position, the contact retention is
satisfactory.
(4) Do the procedures given in paras (2) and (3) again for all the other
contacts in the connector.
EFF :
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70-71-20
AFL
Page 9
Oct 01/08
TRENT 700
SERIES ENGINES
Retention Test Tools
Figure 003
EFF :
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SERIES ENGINES
F. Attach the Backshell Body to the Connector
(Ref. Fig. 004, 005)
(1) If necessary, install only the lacing tape you removed before. Refer
to the procedure given in 70-71-14.
(2) Make the braided shield flat and equal.
(Ref. Fig. 001)
(3) Fold the braided shields rearward over the cable jacket. Keep the
braided shields flat and equal.
NOTE : You can temporarily hold the braided shields to the harness
____
with tape, this permits an easier backshell installation.
(4) Hold the connector in your hand and move the backshell body over the
harness and the braided shields.
(Ref. Fig. 004)
(5) Connect the backshell coupling nut to the connector as follows:
(a) Move the backshell forward over the harness to the connector.
(b) Align the mark you made on the backshell with the master key
located on the front face of the connector.
NOTE : The mark you made on the connector backshell will
____
correctly align the connector master key and the backshell
when you assemble the backshell to the connector.
CAUTION : DAMAGE TO THE CONNECTOR AND BACKSHELL ANTI-ROTATION TEETH WILL RESULT
IF THEY ARE NOT ENGAGED CORRECTLY.
(c) Tighten the backshell nut with your hand. Make sure you correctly
engage the anti-rotation teeth on the connector with the
anti-rotation teeth on the backshell.
(d) Continue to tighten the nut with your hand and turn the backshell
clockwise and counterclockwise to engage the anti-rotation teeth.
(e) Make sure the mark on the backshell is aligned with the master
key on the connector.
(f) Fully tighten the backshell nut to the connector with your hand.
EFF :
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70-71-20
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Page 11
Oct 01/08
TRENT 700
SERIES ENGINES
Backshell Installation
Figure 004
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70-71-20
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Page 12
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TRENT 700
SERIES ENGINES
Backshell Installation
Figure 005
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SERIES ENGINES
(g) Hold the connector tight and:
- Move the backshell from side to side.
- Turn the backshell in a clockwise and counterclockwise
direction.
NOTE : This procedure is to make sure the anti-rotation teeth in
____
the backshell and connector are engaged.
(6) Open the braided shields out into a cone.
(Ref. Fig. 004)
(7) Move the conical ground ring forward.
(8) Catch the braided shields between the ground ring and the backshell
body. The shields must be equally spaced around the ring.
(9) Attach the braided shield tails to the main bundle with the ESW1900
lacing tape. Make sure the cut ends of the braided shield are covered
as shown.
(Ref. Fig. 005)
(10) Move the back clamp forward and screw it on to the thread of the
backshell body. Fully tighten the back clamp to the backshell with
your hand.
(11) Slide the support bush (if installed) forward into position.
(12) If the strain relief screws and clamps have been removed previously,
loosely re-assemble them.
(13) If there is a receptacle, install it on the engine bracket as
follows:
(a) Align the master key-way on the connector with the mark you made
on the engine bracket.
(b) Install the receptacle in the engine bracket.
(c) Install the screws through the engine bracket and receptacle.
(d) Attach the nuts to the screws and torque the nuts as follows:
- Connector shell sizes 08 to 22, thread size 4-40, TORQUE to 5
lbf.in (0,565 Nm).
- Connector shell sizes 24 and 28, thread size 6-32, TORQUE to 10
lbf.in (1,130 Nm).
EFF :
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TRENT 700
SERIES ENGINES
(14) Connect the connector plugs to the mating receptacles as follows:
(a) Align the master key on the plug with the master key-way on the
receptacle.
(b) Use light hand pressure to engage the plug with the receptacle.
(c) With the threads and contacts correctly engaged, connect the plug
coupling nut.
NOTE : Make sure the threads and contacts are correctly engaged.
____
(d) Push the plug into the receptacle and tighten the coupling nut
with your hand.
NOTE : Move the backshell from side to side when you tighten the
____
coupling nut. This will aid you to correctly seat the plug
in the receptacle.
CAUTION : DO NOT USE A METAL JAWED TOOL TO TIGHTEN THE CONNECTOR. THIS WILL
CAUSE DAMAGE TO THE CONNECTOR.
(e) Tighten the plug coupling nut until the pliers or strap wrench
move on the nut surface. Use the TG-69P pliers or equivalent.
NOTE : The indicator band on the receptacle (the colored band
____
nearest to the receptacle threads) is not a stop line. If
you can see the indicator band, the connector is not
installed correctly.
(15) Use the TG-69P pliers to fully tighten the backshell coupling nut or
nuts. While you tighten the nuts move the backshell from side to side
to aid correct accessory teeth engagement.
(16) Use the TG-69P pliers to fully tighten the back clamp.
(17) Close the strain-relief clamp to hold the harness.
(a) Use the PSC-1204-3-R screwdriver bit to tighten the strain-relief
clamp screws.
(b) Continue to tighten the screws until the saddle bars touch the
ears of the strain-relief clamp. Make sure the harness does not
move in the clamp.
EFF :
ALL
70-71-20
AFL
Page 15
Oct 01/08
TRENT 700
SERIES ENGINES
(c) If there is no support bush installed, make sure the harness does
not move in the clamp.
- If the harness moves in the clamp, add 100P323 tape around the
harness.
NOTE : No tape is permitted between the strain-relief clamp ears
____
and the saddle bars.
- If the saddle bar surfaces do not touch the ears of the
backshell strain-relief clamp, remove some of the tape.
G. Do the Electrical Checks
(1) Disconnet the wire harness connectors which attach to the ends of the
circuits that you will do a test of . Use the TG-69P pliers.
CAUTION : DO NOT BEND OR PUT STRESS ON THE CONTACTS WHEN YOU DO THE TEST.
DAMAGE TO THE CONNECTOR OR CONTACT CAN OCCUR.
(2) Wire continuity check
(a) Do a wire continuity check on all the contacts from
point-to-point (from one end of the wire to the other end of the
wire). Use a Model 177 Digital Multimeter, 260 Ohmmeter or
equivalent.
(b) Measure the resistance on all circuits. Each circuit must have
continuity from one end of the wire to the other end of the wire.
NOTE : Refer to the Aircraft Wiring List, 92-20 Master Wire List
____
for detailed pin to pin and wire color data.
WARNING : DO NOT USE A MEGOHMETER FOR THE INSULATION RESISTANCE TEST OF THE
ON-WING WIRE REPAIR. THIS COULD RESULT IN INJURY TO PERSONS OR
DAMAGE TO THE AIRPLANE.
CAUTION : YOU MUST DISCONNECT ALL THE CONNECTORS ON THE CIRCUIT WHICH YOU WILL
DO A CHECK. IF YOU DO NOT DO THIS, IT CAN CAUSE UNSATISFACTORY
RESISTANCE INDICATIONS AND POSSIBLE DAMAGE TO THE CIRCUITS.
(3) Do the insulation resistance check as follows:
NOTE : You can use a Model 177 Digital Multimeter, 260 Ohmmeter or
____
equivalent.
(a) Set the ohmmeter to the 100 Megohm scale.
EFF :
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70-71-20
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Page 16
Oct 01/08
TRENT 700
SERIES ENGINES
CAUTION : DO NOT BEND OR PUT STRESS ON THE CONTACTS WHEN YOU DO THE TEST.
(b) Attach the ohmmeter test leads as follows:
- Attach one ohmmeter test lead to one contact and the other lead
to contacts (which do not connect to the same circuit) one at a
time and do the steps (c) through (e).
- Attach one ohmmeter test lead to the backshell and the other
lead to all contacts one at a time and do the steps (c) through
(e).
(c) Measure the insulation resistance
- The resistance must be a minimum of 100 Megohms.
(d) Do the procedure again for all the other wires you will do a test
of.
(e) Remove the ohmmeter leads.
H. Connect the Connectors
(1) If there is a receptacle, install it on the engine bracket as
follows:
(a) Align the master key-way on the receptacle with the mark you made
on the engine bracket.
(b) Install the receptacle in the engine bracket.
(c) Install the screws through the receptacle and engine bracket.
(d) Attach the nuts to the screws and tighten the nuts.
(e) Torque the nuts as follows:
- Torque the No.4-40 nuts to a maximum of 5 lbf.in (0,57 Nm).
- Torque the No.6-32 nuts to a maximum of 10 lbf.in (1,13 Nm).
(2) Connect the connector plugs to the mating receptacles as follows:
(a) Align the master key on the plug with the master key-way on the
receptacle.
(b) Use light hand pressure to engage the plug with the receptacle.
EFF :
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70-71-20
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Page 17
Oct 01/08
TRENT 700
SERIES ENGINES
(c) With the threads and contacts correctly engaged, connect the plug
coupling nut.
NOTE : Make sure the threads and contacts are correctly engaged.
____
(d) Push the plug into the receptacle and tighten the coupling nut
with your hand.
NOTE : Move the backshell from side to side when you tighten the
____
coupling nut. This will aid you to correctly seat the plug
in the receptacle.
CAUTION : DO NOT USE A METAL JAWED TOOL TO TIGHTEN THE CONNECTOR. THIS WILL
CAUSE DAMAGE TO THE CONNECTOR.
(e) Tighten the plug coupling nut until the pliers move on the nut
surface. Use the TG-69P pliers or equivalent.
____
nearest to the receptacle threads) in not a stop line. If
5. ____
Test
Test the engine (Refer to the test reference table in the Aircraft
Maintenance Manual, 71-00-00-710-801).
EFF :
ALL
70-71-20
AFL
Page 18
Oct 01/08
TRENT 700
SERIES ENGINES
CONTACT REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
_________________________________________________________
1. _____________________________
General Replacement Procedure
WARNING : DO NOT USE HEAT GUNS, SOLDERING GUNS OR SOLDERING IRONS FOR THE
ON-WING REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND CAN
CAUSE INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
A. General
(1) This chapter gives the procedure for the replacement of a connector
contact (pin or socket) on an electrical wire harness or cable
assembly.
(2) These are the wire harness parts :
jacket.
(3) You can replace each contact on the shielded cable until the wire is
too short to install another contact (usually after the contact has
been replaced three times).
(4) If the wire is too short to install another contact, replace the
shielded cable (Refer to 70-71-24).
(5) Refer to the Aircraft Wiring Manual, 92-20 Hook-Up List/Plugs and
Receptacles for the connector Functional Item Number (FIN) to get the
correct contact part number.
(7) Refer to the Aircraft Wiring List, 92-20 Master Wire List for the
connector contact to contact hook-up and wire color data.
70-71-12.
EFF :
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70-71-21
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Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
(9) The wire harness lacing procedures are fully specified in 70-71-14.
(10) Standard equipment and consumable materials can be replaced with
equivalent items.
2. __________________
Standard Equipment
------------------------------------------------------------------------------| PART No.
| SUPPLIER |
NOMENCLATURE
|
APPLICATION
|
------------------------------------------------------------------------------| TG-69P
|
11815
| Pliers, Connector
|
|
06324
| Soft Jaw
| of connectors and
|
|
|
|
| backshells
|
|-------------|-----------|------------------------|--------------------------|
| M83723/31-16|
11851
| Removal and Installation |
|
|
| Tool 16 gage
| of 16 gage and 20 gage
|
|
|
| (MIL-C-83723 and
| contacts
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| M83723/31-20|
11851
| Removal and Installation |
|
|
| Tool 20 gage
| of 16 gage and 20 gage
|
|
|
| (MIL-C-83723 and
| contacts
|
|
|
|
|-------------|-----------|------------------------|--------------------------|
| Strip Master|
30119
| Wire Stripper
| Strip the wire for
|
| 45092
|
|
| contact replacement
|
|-------------|-----------|------------------------|--------------------------|
| M22520/7-01 |
11851
| Crimp Tool Frame
| Crimp the contact on the |
|
|
|
| wire
|
|-------------|-----------|------------------------|--------------------------|
| M22520/7-03 |
11851
| Crimp Tool Positioner, | Used with the crimp tool |
|
|
| 16 gage
| frame to crimp the 16
|
|
|
|
| gage contacts on the wire|
|-------------|-----------|------------------------|--------------------------|
| M22520/7-02 |
11851
| Crimp Tool Positioner, | Used with the crimp tool |
|
|
| 20 gage
| frame to crimp all the 20|
|
|
|
| gage contacts on the wire|
|-------------|-----------|------------------------|--------------------------|
| PSC-1204-3-R|
| Phillips ACR
|
|
|
| Screwdriver Bit
|
|
|
|
|
-------------------------------------------------------------------------------
EFF :
ALL
70-71-21
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Page 2
Oct 01/08
TRENT 700
SERIES ENGINES
3. ____________________
------------------------------------------------------------------------------|
PART
| SUPPLIER |
DESIGNATION
|
|-----------------------------------------------------------------------------| 100P323
|
U5792
| Tape, Electrical Insulation,
|
|
|
| Self-adhesive
|
------------------------------------------------------------------------------4. Procedure
_________
A. Repair
(1) Remove the applicable backshells (Refer to 70-71-20).
(2) Remove the damaged contacts as follows:
(Ref. Fig. 001)
(a) The contacts are released and then removed from the rear of the
connector with the insertion/extraction tool. Refer to the
procedure given in step (d).
(b) If you have a contact location that is not used (not used for a
circuit), it will contain a contact and sealing plug.
(c) Use the applicable insertion/extraction tool given in the
standard equipment for the correct size contact.
CAUTION: IF TOO MUCH PRESSURE IS USED WHEN YOU REMOVE THE CONTACTS FROM THE
(d) Remove the damaged rear release contacts as follows:
1
_
Place the insertion/extraction tool on the wire.
2
_
Hold the wire tight and move the tool back on the wire.
NOTE : This will permit the wire to go into the slot of the
____
tool.
3
_
Push the tool along the wire into the rear of the connector
grommet until it touches the botton.
NOTE : When the tool touches the botton of the connector
____
grommet the collet will become larger. This releases
the contact and permits the contact to be removed from
the connector.
EFF :
ALL
70-71-21
AFL
Page 3
Oct 01/08
TRENT 700
SERIES ENGINES
Contact Removal and Installation
Figure 001
EFF :
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70-71-21
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Page 4
Oct 01/08
TRENT 700
SERIES ENGINES
4
_
Hold the wire against the serrated shoulder of the tool with
light hand pressure and remove the wired contact and the tool.
5
_
Remove the tool from the wire.
6
_
Put a label on the wire, to identify the contact number for
the installation.
7
_
Do steps 1_ thru 6_ for the other damaged contacts.
(3) Cut the damaged contact in the middle of the crimp on the contact
barrel as shown
(Ref. Fig. 001)
NOTE : The individual contacts on a cable can be replaced up to a
____
maximum of three times . There is a minimum of 0.375 in. (9,6
mm) spare wire in the backshell . If the contact is replaced
more than three times, you must replace the complete cable
(Refer to 70-71-24).
(a) Carefully remove the remaining part of the contact from the
conductor.
NOTE : This procedure will decrease the length of the wire
____
insulation you have to remove to get the necessary length
of conductor. If you do this procedure, each contact can
be replaced three times.
(4) Use the wire strippers to remove the wire insulation from the end of
the conductor. Make sure you remove sufficient insulation so that you
can see 0.25 in. (6,4 mm) of the conductor.
(Ref. Fig. 002)
(5) Get the correct replacement contact. Refer to the Aircraft Wiring
Manual, 92-20 Hook-Up List/Plugs and Receptacles for the connector
FIN to get the correct contact part number. To identify alternative
part numbers refer to the PPIPC.
(6) Crimp the contact
(Ref. Fig. 003)
(a) Use the crimp tool frame and the applicable crimp tool positioner
for the correct contact type and wire gage.
EFF :
ALL
70-71-21
AFL
Page 5
Oct 01/08
TRENT 700
SERIES ENGINES
Prepare the Contact
Figure 002
EFF :
ALL
70-71-21
AFL
Page 6
Oct 01/08
TRENT 700
SERIES ENGINES
Contact Crimp Tool
Figure 003
EFF :
ALL
70-71-21
AFL
Page 7
Oct 01/08
TRENT 700
SERIES ENGINES
CAUTION: DO NOT RELEASE THE LATCH FOR THE CRIMP POSITIONER IF THE CRIMP TOOL
FRAME HANDLE IS IN THE CLOSED POSITION. THE TOOL HANDLE MUST BE OPEN
WHEN THE POSITIONER IS INSTALLED, REMOVED OR RELEASED. INCORRECT USE
CAN CAUSE DAMAGE TO THE POSITIONER AND CRIMP TOOL FRAME.
(b) Install the crimp tool positioner in the crimp tool as follows:
1
_
Remove the lock clip from the lock ring on the positioner.
2
_
Use the correct positioner which agrees with the contact type.
3
_
Put the positioner in the tool frame lock plate and align the
positioner pins with the lock plate ring slots.
4
_
Push the positioner into the tool frame and turn the
positioner 90 degrees in a clockwise direction until it locks
in position.
5
_
Install the lock clip to the positioner lock ring.
(c) Crimp the replacement contact to the wire as follows:
1
_
Remove the lock clip from the lock ring hole on the selector
knob.
2
_
Lift and turn the tool frame selector knob until the number of
the knob agrees with the number on the positioner data plate.
3
_
Install the lock clip in the lock ring hole.
CAUTION: IF THE TOOL FRAME SELECTOR KNOB IS PUT IN THE WRONG POSITION, DAMAGE
TO THE CONTACT AND WIRE CAN OCCUR. ALSO, THE CONTACT CAN BE LOOSELY
CRIMPED ON THE WIRE.
4
_
Align the number on the knob to the index mark on the tool
frame and release the knob.
5
_
Examine the wire to make sure the wire strands of the
conductor are not separated.
6
_
Install the end of the conductor into the contact wire hole.
If necessary, carefully twist the wire strands of the
conductor in their normal direction of twist.
7
_
Push the conductor into the contact wire hole until you feel
it touch the bottom.
EFF :
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70-71-21
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Page 8
Oct 01/08
TRENT 700
SERIES ENGINES
NOTE : If the insulation on the conductor was not removed
____
correctly:
- The wire will not touch the bottom of the contact
crimp barrel, or
- There will be too much bare wire at the rear shoulder
of the contact crimp barrel.
8
_
Examine the contact to make sure you can see the conductor
through the sight hole in the contact.
9
_
Install the contact and conductor through the tool frame hole
and into the positioner hole until it touches the bottom.
10
__
Move the tool frame handles together until the ratchet
releases.
11
__
Remove the crimped contact from the tool.
12
__
Hold the wire tight and lightly pull on the contact to make
sure the contact is crimped to the conductor.
13
__
Do the steps 1_ through 12_ until you crimp all the contacts
on the conductors.
(7) Install the contacts.
(Ref. Fig. 001)
(a) Move the backshell and the support bush (if installed) rearward
over the harness to permit the contacts to be installed in the
connector.
(b) Use the applicable insertion/extraction tool given in the
standard equipment for the correct contact size.
(c) Install the insertion/extraction tool on the contact.
NOTE : Make sure you install the correct contact in the correct
____
location. All contacts are installed and locked from the
rear of the connector.
1
_
Put the insertion/extraction tool on the wire.
2
_
Hold the wire tight and move the tool rearward on the wire.
NOTE : This will permit the wire to go into the slot of the
____
tool.
EFF :
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70-71-21
AFL
Page 9
Oct 01/08
TRENT 700
SERIES ENGINES
3
_
Push the tool along the wire until the tip of the tool is on
the rear shoulder of the contact.
(d) Install the contact in the connector.
1
_
Hold the connector in your hand.
2
_
Use the label on the wire to identify the correct contact
location.
NOTE : Refer to the Aircraft Wiring Manual, 92-20 Hook-Up
____
List/Plugs and Receptacles for detailed wiring data.
CAUTION: IF TOO MUCH PRESSURE IS USED WHEN YOU INSTALL THE CONTACT INTO THE
3
_
Install the insertion/extraction tool with the wired contact
(or the contacts that are not used) into the correct hole at
the rear of the connector. Use strong and equal pressure.
4
_
Remove the tool.
5
_
Lightly pull back on the wire to feel if the contact is locked
in the collet.
(e) Do the procedures given in paragraphs (c) and (d) again for the
other contacts you will install.
(f) Install the larger end of the sealing plugs in the connector
grommet of the contacts that are not used.
(8) Do a contact retention check (Refer to 70-71-20).
(9) Install the backshells (Refer to 70-71-20).
(10) Do the electrical checks (Refer to 70-71-20).
(11) Connect the connectors (Refer to 70-71-20).
5. ____
Test
- Test the engine (Refer to the test reference table in the Aircraft
EFF :
ALL
70-71-21
AFL
Page 10
Oct 01/08
TRENT 700
SERIES ENGINES
SHIELDED WIRE REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
_______________________________________________________________
1. ____________________________________
Shielded Cable Replacement Procedure
WARNING : DO NOT USE HEAT GUNS, SOLDERING GUNS, OR SOLDERING IRONS FOR THE
ON-WING REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND CAN CAUSE
INJURY TO PERSONS OR DAMAGE TO EQUIPMENT.
A. General
(1) The shielded cable must be replaced if:
- A cable gives an open circuit
- The jacket is damaged so that you can see the braided shield
- The wire is too short to install another contact (usually after the
contact has been replaced three times).
(2) This chapter gives the procedure to replace a shielded cable. The new
cable will be installed on the external side of the damaged wire
harness and in the harness clamps. For the replacement cable, use the
same type of cable as the damaged cable.
jacket.
(4) Refer to the Aircraft Wiring Manual, 92-20 Hook-Up List/Plugs and
Receptacles for the connector Functional item Number (FIN) to get the
correct contact part number.
(5) Refer to the Aircraft Wiring List for the correct wire type, gage,
length and connector contact to contact hook-ups.
70-71-12.
EFF :
ALL
70-71-24
AFL
Page 1
Oct 01/08
TRENT 700
SERIES ENGINES
(8) The harness lacing procedures are fully specified in 70-71-14.
(9) Standard equipment and consumable material can be replaced with
equivalent items.
2. __________________
Standard Equipment
-----------------------------------------------------------------------------|
PART No. |SUPPLIER |
NOMENCLATURE
|
APPLICATION
|
-----------------------------------------------------------------------------|
| TG-69P
| 11851 | Pliers, Connector
|Removal and installation of|
|
| 06324 | Soft Jaw
|connectors and backshells |
|----------------------------------------------------------------------------|
|Strip Master | 30119 | Wire Stripper
|
Strip the wire for
|
| 45092
|
|
|
contact replacement
|
|----------------------------------------------------------------------------|
| M22520/7-01 | 11851 | Crimp Tool Frame
|
Crimp the contact on
|
|
|
|
|
the wire
|
|----------------------------------------------------------------------------|
| M22520/7-03 | 11851 | Crimp Tool Positioner, |
Use with the crimp tool |
|
|
| 16 gage
|
frame to crimp the 16
|
|
|
|
|
gage contacts on the
|
|
|
|
|
wire
|
|----------------------------------------------------------------------------|
| M22520/7-02 | 11851 | Crimp Tool Positioner, |
Use with the crimp tool |
|
|
| 20 gage
|
frame to crimp the 20
|
|
|
|
|
gage contacts on the
|
|
|
|
|
wire
|
|----------------------------------------------------------------------------|
| PSC-1204-3-R|
| Phillips ACR
|
|
|
| Screwdriver Bit
|
|
|
|
|
|----------------------------------------------------------------------------|
3. ___________________
Consumable Material
-----------------------------------------------------------------------------|
PART No.
| SUPPLIER |
DESIGNATION
|
-----------------------------------------------------------------------------| OMat 2/134
|
| Pen, Ball-point (Black)
|
|----------------------------------------------------------------------------|
| 100P323
|
U5792
| Electrical Insulating Tape, Self-adhesive|
|----------------------------------------------------------------------------|
| ESW1900
|
U5792
| Tape, Lacing
|
|----------------------------------------------------------------------------|
| Scotchboy
|
04963
| Tape, Fiberglass
|
------------------------------------------------------------------------------
EFF :
ALL
70-71-24
AFL
Page 2
Oct 01/08
TRENT 700
SERIES ENGINES
4. Procedure
_________
A. Replace the Cable
(1) Get the replacement cable and contacts (Refer to the PowerPlant
Wiring Diagram, Aircraft Wiring List or 92-90 Master Wire List for
the correct replacement cable).
(2) Identify the damaged cable and find the connector at one end of the
cable.
(3) Cut, remove and keep the black FIN identification sleeve from around
the harness adjacent to the connector.
(4) Remove the applicable backshell (Refer to 70-71-20).
(5) Disconnect the applicable electrical connector. Use the TG-69P
pliers.
(a) If necessary, remove the receptacle from the engine bracket as
follows:
- Remove the nuts and screws that attach the receptacle to the
engine bracket.
(6) Remove the contacts from the connectors that are necessary to replace
the damaged cable(s) (Refer to 70-71-20).
(7) Pull the damaged cable(s) from the backshell and bush assemblies.
Prepare one end of the new cable.
(Ref. Fig. 001)
(a) Cut and remove the insulation jacket of the new cable at the same
location as the insulation jacket of the damaged cable.
(b) Push the braided shield down the insulated wires to make the
braid larger.
(c) Bend the braided shield ends in a U shape as shown in view A.
(Ref. Fig. 001)
CAUTION: DO NOT CUT, NICK OR DAMAGE THE CONDUCTORS OR BRAIDED SHIELDS. THIS
TYPE OF DAMAGE COULD RESULT IN A SHORT CIRCUIT IN THE CONDUCTOR.
(d) Use a scribe to carefully make a hole in the braid as shown in
view B.
(Ref. Fig. 001)
EFF :
ALL
70-71-24
AFL
Page 3
Oct 01/08
TRENT 700
SERIES ENGINES
Prepare the Contact
Figure 001
EFF :
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70-71-24
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Page 4
Oct 01/08
TRENT 700
SERIES ENGINES
(e) Pull the wires, one at a time, through the hole in the braid as
shown in view C.
(Ref. Fig. 001)
(f) Pull the braid tight to make a flat and equal conductor.
(g) Cut the new insulated wires the same length as the wires of the
damaged cable.
(h) Use the 45092 Mechanical Wire Stripper to remove 0.250 in. (6,35
mm) of wire insulation from the end of the conductors.
(i) Put the contact number labels from the old insulated wires on the
new cable insulated wires. Make sure the insulated wire color is
correct.
(j) Get the correct replacement contacts. Refer to the Aircraft
Wiring Manual, 92-20 Hook-Up List/Plugs and Receptacles for the
connector FIN to get the correct contact part number.
(k) Crimp the contacts on the new cable conductors.
(Ref. Fig. 002)
1
_
Use the crimp tool frame and the applicable crimp tool
positioner given in the standard equipment for the correct
contact type and wire gage.
2
_
Install the crimp tool positioner in the crimp tool frame as
follows :
- Remove the lock clip from the lock ring on the positioner.
- Use the correct positioner which agrees with the contact
type.
- Put the positioner in the tool frame lock plate and align
the positioner pins with the lock plate ring slots.
- Push the positioner into the tool frame and turn the
positioner 90 degrees in a clockwise direction until it
locks in position.
- Install the lock clip to the positioner lock ring.
3
_
Crimp the contact to the wire
CAUTION : IF THE TOOL FRAME SELECTOR KNOB IS PUT IN THE WRONG POSITION,
DAMAGE TO THE CONTACT AND WIRE CAN OCCUR. ALSO, THE CONTACT
CAN BE LOOSELY CRIMPED ON THE WIRE.
EFF :
ALL
70-71-24
AFL
Page 5
Oct 01/08
TRENT 700
SERIES ENGINES
Contact Crimp Tool
Figure 002
EFF :
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70-71-24
AFL
Page 6
Oct 01/08
TRENT 700
SERIES ENGINES
a
_
Set the correct number on the crimp tool as follows:
- Remove the lock clip from the lock ring hole on the
selector knob
- Lift and turn the tool frame selector knob until you get
the necessary number
NOTE : The number is found on the positioner data plate for
____
the correct wire gage.
- Install the lock clip in the lock ring hole
- Align the number on the knob to the index mark on the
tool frame and release the knob.
b
_
Install the wire in the contact as follows:
- Examine the wire to make sure that the wire stands of the
conductor are not separated.
- Install the end of the conductor into the contact wire
hole.
NOTE : if necessary, carefully twist the wire strands in
____
their normal direction of twist until you can
install the conductor.
- Push the conductor into the contact wire hole until you
feel it touch the bottom.
NOTE : If the insulation on the conductor was not removed
____
correctly, the wire will not touch the bottom of the
contact crimp barrel.
- Examine the contact to make sure you can see the
conductor strands through the sight hole in the contact.
Make sure you cannot see any bare wire at the rear
shoulder of the contact crimp barrel.
CAUTION : DO NOT RELEASE THE LATCH OF THE CRIMP TOOL POSITIONER IF THE CRIMP
TOOL FRAME HANDLE IS IN THE CLOSED POSITION. THE TOOL HANDLE MUST BE
OPEN WHEN THE POSITIONER IS INSTALLED, REMOVE, OR RELEASED.
INCORRECT USE CAN CAUSE DAMAGE TO THE POSITIONER AND CRIMP TOOL
FRAME.
c
_
Crimp the contact as follows:
- Install the contact and conductor through the tool frame
hole and into the positioner hole until it touches the
bottom.
- Move the tool frame handles together until the ratchet
releases.
EFF :
ALL
70-71-24
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Page 7
Oct 01/08
TRENT 700
SERIES ENGINES
- Remove the crimped contact from the tool frame hole.
(l) Hold the wire tight and lightly pull on the contact to make sure
the contact is crimped to the conductor.
(m) Do steps (g) through (l) until you crimp all the contacts on the
conductors.
(8) Put the prepared cable ends through the backshell and bush
assemblies.
(9) Install the contacts to the applicable connector (Refer to chapter
70-71-20).
(10) Do a contact retention check (Refer to chapter 70-71-20).
(11) Install the applicable backshell (Refer to chapter 70-71-20).
(12) Replace the damaged cable with the new cable as follows:
(a) Loosen the first harness cable clamp that the damaged cable
passees through adjacent to the connector.
(b) Cut all of the harness lacing ties between the connector and the
second clamp.
(c) Pull the damaged cable free from the harness as far as the next
clamp.
(d) Put the replacement cable in position through the first clamp.
(e) Tighten the first clamp.
(f) Use ESW1900 tape to replace any ties removed between the
connector and the first harness clamp.
(g) Loosen the second harness clamp that the damaged cable passees
through.
(h) Cut all of the harness ties between the second and third clamps.
(i) Pull the damaged cable free from the harness as far as the next
clamp.
(j) Put the replacement cable in position through the second clamp.
(k) Tighten the second clamp.
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(l) Use EWS1900 tape to replace the ties removed between the first
and second clamps.
(m) Do steps (g) thru (l) at each clamp location until the connector
at the other end of the damaged cable is reached.
(n) Do para (3) thru para (11) for the other connector.
(o) Discard the damaged cable complete with contacts.
(p) Use ESW1900 tape to replace any ties removed between this second
connector and the last harness clamp.
(13) Identify the new harness.
(a) Wind two layers of Scotchboy 69 fiberglass tape around the
harness at the two positions that the identification sleeves were
cut from.
(b) Use the OMat 2/134 ball-point pen to write the FIN, of the
harness, on the fiberglass tape.
NOTE : The FIN is found on the identification sleeves you cut off
____
the harness during the removal of the cable.
(14) Do the electrical checks.
(a) Use the TG-69P pliers to disconnect the harness connectors of the
circuits that you will do a test of.
CAUTION : DO NOT BEND OR PUT STRESS ON THE CONTACTS WHEN YOU DO THE CHECK.
(b) Wire continuity check
- Do a wire continuity check on all the contacts from
point-to-point (from one end of the wire to the other end of
the wire). Use a Model 177 Digital Multimeter, 260 Ohmmeter or
equivalent.
- Measure the resistance on all circuits. Each circuit must have
continuity from one end of the wire to the other end of the
wire.
NOTE : Refer to the Aircraft Wiring List, 92-90 Master Wire List
____
for detailed pin to pin and wire color data.
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WARNING : DO NOT USE A MEGOHMMETER FOR THE INSULATION RESISTANCE TEST
OF THE ON-WING WIRE REPAIR. THIS COULD RESULT IN INJURY TO
PERSONS OR DAMAGE TO THE AIRPLANE.
CAUTION : YOU MUST DISCONNECT ALL THE CONNECTORS ON THE CIRCUIT WHICH
YOU WILL DO A CHECK. IF YOU DO NOT DO THIS, IT CAN CAUSE
UNSATISFACTORY RESISTANCE INDICATIONS AND POSSIBLE DAMAGE TO
THE CIRCUITS.
(c) Do the insulation resistance check as follows:
NOTE : You can use a Model 177 Digital Multimeter, 260 Ohmmeter
____
or equivalent.
1
_
Set the ohmmeter to the 100 Megohm scale.
CAUTION : DO NOT BEND OR PUT STRESS ON THE CONTACTS WHEN YOU DO THE
CHECK. DAMAGE TO THE CONNECTOR OR CONTACT CAN OCCUR.
2
_
Attach the ohmmeter test leads as follows :
- Attach one ohmmeter test lead to one contact and the other
lead to contacts (which do not connect to the same circuit)
one at a time and do the steps (3_) through (5_).
- Attach one ohmmeter test lead to the backshell and the other
lead to all contacts, one at a time and do the steps (3_)
through (5_).
3
_
Measure the insulation resistance.
- The resistance must be a minimum of 100 Megohm.
4
_
Do the procedure again for all the other wires you will do a
test of.
5
_
Remove the ohmmeter leads.
(15) Connect the connectors.
(a) If necessary, install the receptacle on the engine bracket as
follows:
1
_
Align the master key-way on the receptacle with the mark you
made on the engine bracket.
2
_
Install the receptacle in the engine bracket.
3
_
Install the screws through the receptacle and the engine
bracket.
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4
_
Attach the nuts to the screws and tighten the nuts.
5
_
Torque the nuts as follows :
- Torque the No. 4-40 nuts to a maximum of 5 lbf.in (0.57m.N).
- Torque the No. 6-32 nuts to a maximum of 10 lbf.in
(1.13m.N).
(b) Connect the connector plugs to the their receptacles as follows :
1
_
Align the master key on the plug with the master key-way on
the receptacle.
2
_
Use light hand pressure to engage the plug with the
receptacle.
NOTE : Make sure the threads and contacts are correctly
____
engaged.
3
_
With the threads and contacts correctly engaged, connect the
plug coupling nut.
4
_
Push the plug into the receptacle and tighten the coupling nut
with your hand.
NOTE : Move the backshell from side to side when you tighten
____
the coupling nut. This will aid you to correctly seat
the plug in the receptacle.
CAUTION : DO NOT USE A METAL JAWED TOOL TO TIGHTEN THE CONNECTOR. THIS
WILL CAUSE DAMAGE TO THE CONNECTOR.
(c) Use the TG6-69P pliers to tighten the connector coupling nut
until the pliers move on the nut surface.
____
nearest to the receptacle threads) is not a stop line. If
5. ____
Test
Test the engine. (Refer to the test reference table in the Aircraft
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TERMINAL TAG REPLACEMENT PROCEDURE - DESCRIPTION AND OPERATION
______________________________________________________________
1. __________________________________
Terminal Tag Replacement Procedure
ON-WING REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND CAN
A. General
(1) This chapter gives the procedure to replace a damaged terminal tag.
jacket.
(3) Standard equipment and consumable material can be replaced with an
equivalent item.
2. __________________
Standard Equipment
------------------------------------------------------------------------------| PART No.
| SUPPLIER |
NOMENCLATURE
|
APPLICATION
|
------------------------------------------------------------------------------| Strip Master|
30119
| Wire Stripper
| Strip the insulation from|
| 45092
|
|
| the wire
|
|-------------|-----------|------------------------|--------------------------|
| 49935
|
00779
| Crimp Tool, Wire splice| Crimp the crimp terminal |
|
|
|
| on the ground wire
|
|
|
|
| conductor
|
|-------------|-----------|------------------------|--------------------------|
| Model 177
|
80164
| Digital Multimeter
|Used to measure continuity|
|-------------|-----------|------------------------|--------------------------|
| Model 260
|
16902
| Ohmmeter
|Used to measure continuity|
|-------------|-----------|------------------------|--------------------------|
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3. ____________________
------------------------------------------------------------------------------|
PART No
| SUPPLIER |
DESIGNATION
|
|-----------------------------------------------------------------------------| 100P323
|
U5792
| Tape, Electrical Insulation,
|
------------------------------------------------------------------------------4. Procedure
_________
A. Removal
(1) Remove the damaged terminal tag.
(a) Remove the bolt or nut that attaches the terminal tag.
(b) Cut, remove and discard the heat shrink sleeve from the terminal
tag.
(c) Cut the damaged terminal tag in the middle of the crimp.
NOTE : You can replace each terminal tag on the cable until the
____
wire is too short to install another terminal tag (usually
after the terminal tag has been replaced three times). If
the wire is too short to install another terminal tag,
replace the cable (Refer to 70-71-24).
(d) Carefully remove the remaining part of the terminal tag from the
conductor.
NOTE : This procedure will decrease the length of the wire
____
insulation you have to remove to get the necessary length
of conductor. If you do this procedure, each terminal tag
can be replaced at least three times.
B. Installation
(1) Install the terminal tag on the thermocouple ground wire as follows:
(Ref. Fig. 001)
(a) Get the replacement terminal tag. Refer to the Aircraft Wiring
List, 92-90 Master Wire List for the correct replacement part.
(b) Use the 45092 wire strippers to remove the wire insulation from
the end of the ground wire conductor. Make sure you remove
sufficient insulation so that you can see 0.25 in. (6,4 mm) of
the conductor.
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Terminal Tag Replacement
Figure 001
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(c) Put the conductor into the barrel of the terminal tag. Make sure
you can see the end of the conductor at the other end of the
barrel.
(d) Crimp the terminal tag as follows:
1
_
Use the 49935 wire-splice crimp tool. Align the number marked
on the terminal tag with the number marked on the jaws of the
crimp tool.
2
_
Put the terminal tag in the center of the jaws of the crimp
tool.
3
_
Move the crimp tool handles together until the ratchet
releases.
4
_
Pull on the wire to make sure it will not come out of the
terminal.
C. Check
(1) Do a continuity check as follows:
(a) Set the ohmmeter to the 100 ohm scale. Use a Model 177 Digital
Multimeter, 260 Ohmmeter or equivalent.
(b) Attach one ohmmeter test lead to a backshell in the harness and
the other lead to the crimp terminal.
(c) Measure the resistance. The resistance must be less than 1 ohm.
(d) Remove the ohmmeter leads.
D. Ground Wire Installation.
(1) Install the ground wire after the repair
(a) Wrap two turns of 100P323 tape over the terminal tag crimp-bucket
and attached wire to replace the discarded heat shrink sleeve.
(b) If the ground wire is installed on a stud, do this:
1
_
Put the terminal tag in position on the terminal stud.
2
_
Install a new nut and washer (if installed).
3
_
Torque the nut to the torque given in the arrangement book.
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(c) If the ground wire is installed with a nut and bolt,do these
steps :
1
_
Put the terminal tag in position on the engine bracket.
2
_
Install the bolt,the washer (if installed) and the nut.
3
_
Torque the nut to the torque given in the arrangement book.
5. ____
Test
Do a test of the engine (Refer to the test reference table in the Aircraft
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DISCONNECT AND HARNESS IDENTIFICATION MARKER REPAIR PROCEDURE
_____________________________________________________________
_________________________
1. _____________________________________________________________
Disconnect and Harness Identification Marker Repair Procedure
WARNING : DO NOT USE HEAT GUNS, SOLDERING GUNS AND SOLDERING IRONS FOR THE
ON-WINGS REPAIRS. THEY ARE NOT RESISTANT TO EXPLOSION AND CAN
A. General
(1) This chapter gives the procedure to repair or put a new
identification on a disconnect marker or harness marker.
(2) The disconnect identification marker is located on the harnesses near
each connector and backshell assembly.
(3) The harness identification marker is located at one location on the
harness.
jacket.
(c) Harness - One or mpre cables with connectors or terminal lugs
(5) Consumable materials can be replaced with equivalent items.
2. Standard
___________________
Equipement
None
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3. ___________________
Consumable Material
-----------------------------------------------------| PART No. | SUPPLIER CODE |
DESIGNATION
|
|----------------------------------------------------|
| OMat 2/134|
| Pen, Ball-point(Black) |
|----------------------------------------------------|
| Scotch 69 |
04963
| Tape, Fiberglass
|
-----------------------------------------------------4. _________
Procedure
- Cut and remove the black identification sleeve.
- Wind two layers of Scotch 69 fiberglass tape around the harness at the
position the sleeve was removed from.
- Use the OMat 2/134 ball-point pen to write the new identification number
on the tape.
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CABLE OUTER JACKET REPAIR - MAINTENANCE PRACTICES
_________________________________________________
TASK 70-71-28-300-802
Cable Outer Jaket Repair
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
A. Consumable Materials
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat1-40
Material No.
OMat2-134
Material No.
OMat2-140
Material No.
OMat2-147
Material No.
OMat2-147
Material No.
OMat2-30A
Material No.
OMat2-67
Material No.
OMat296
*
Isopropyl alcohol (Ref. 70-30-00)
*
black ball-point pen (Ref. 70-30-00)
*
Tying Cord (Ref. 70-30-00)
*
Tape Polyimide Film (Ref. 70-30-00)
*
tape Polyimide Film (Ref. 70-30-00)
*
Adhesive PTFE (Ref. 70-30-00)
*
Disposable Cleaning Tissues (Ref. 70-30-00)
*
Adhesive Tape (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------71-50-00-200-802
71-50-00-200-803
Wire Continuity Check on the Power Plant Electrical
Wire Harnesses and Cables
Insulation Resistance Checks on the Power Plant
Electrical Wire Harnesses and Cables
AMM 70-71-14 P.Block 001
AMM 70-71-24 P.Block 001
70-71-28-991-002
Fig. 201
3. __________
Job Set-up
Subtask 70-71-28-912-050
A. General
(1) Service experience has shown that damage can be caused to the
electrical harness cables by chafing. This repair is only applicable
if the cable outer jacket is damaged, but the metal braided shield
below the jacket shows no signs of damage.
(2) This procedure gives the instructions to do a temporary tape repair
of the cable outer jacket. You are only permitted to do this repair
if:
- There is no damage to the bare metal braided shield below the cable
jacket.
- The bare metal braided shield is not more than 50 percent of the
circumference of the cable.
- The bare metal braided shield is not more than 2.00 in. (50.7999
mm) long.
(a) If the damage is more than the limits given above, you must
replace the damaged cable (Ref. AMM 70-71-24 P.Block 001).
(3) This repair is applicable to all electrical harness cables that are
included in Chapters 71-51-00 and 71-52-00 of the Trent 700
Illustrated Parts Catalog (IPC).
(4) A temporarily repaired cable must be replaced at the subsequent shop
visit (Ref. AMM 70-71-24 P.Block 001).
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Subtask 70-71-28-010-050
B. Get access to the repair area
Subtask 70-71-28-862-050
C. Remove electrical power from the electrical harness cable(s) to be
repaired.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-71-28-991-002)
Subtask 70-71-28-350-054
A. General data
(1) An electrical wire harness and its related parts are as follows:
(a) A wire is one electrical conductor with insulation around it.
(b) A cable is a group of wires in a metal braided shield with an
insulated outer jacket.
(c) A harness is one or more cables with connectors or terminal lugs
(2) The consumable materials can be replaced with equivalent items.
Subtask 70-71-28-350-055
B. Temporary tape repair of the cable outer jacket
(Ref. Fig. 201/TASK 70-71-28-991-002)
(1) Inspect the damaged cable and make sure that the damage is in the
permitted limits for this repair (Ref. Job Set-up - General data).
(2) Remove the clips at the adjacent clip positions, as necessary, to get
access to the damaged cable. Record their position and how they are
assembled to make sure of correct assembly at the end of this
procedure.
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Temporary Tape Repair of the Cable Outer Jacket
Figure 201/TASK 70-71-28-991-002
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(3) Cut, remove and discard the lacing tape, as necessary, to get access
to the damaged cable.
NOTE : Before you remove the lacing tape you must record the
____
locations where it is installed. The lacing tape must be
installed in the same locations at the end of the repair.
(4) Clean the cable
WARNING : YOU MUST FIND AND OBEY THE MANUFACTURERS HEALTH AND SAFETY
_______
DATA FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL
REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE
SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL
DAMAGE CAN OCCUR.
(a) Clean the cable 3.0 in. (76.1998 mm) each side of the damage. Use
the Disposable Cleaning Tissues (Material No. OMat2-67) made
moist with the Isopropyl alcohol (Material No. OMat1-40).
(5) Wind one layer of the Tape Polyimide Film (Material No. OMat2-147)
around the cable with a 20 percent overlap on each turn of the tape
(step 1).
(Ref. Fig. 201/TASK 70-71-28-991-002)
Apply the tape so that it extends 1.00 in. (25.3999 mm) each side of
the damaged area of the cable outer jacket. Make sure that the tape
wrap is sufficiently tight to make a moisture-resistant seal.
(6) Wind one layer of the tape adhesive PTFE release film Adhesive PTFE
(Material No. OMat2-30A) around the cable, in the opposite direction
to the layer of tape Polyimide Film (Material No. OMat2-147) (step
2).
(Ref. Fig. 201/TASK 70-71-28-991-002)
the tape polyimide film, with a 20 percent overlap on that layer.
Make sure that the tape wrap is sufficiently tight to make a
moisture-resistant seal.
(7) Tie the tape wrap at each end with Tying Cord (Material No. OMat2140), (Ref. AMM 70-71-14 P.Block 001).
NOTE : Use the part of the procedure that installs the lacing tape on
____
the harness.
(8) Install the lacing tape at the locations where it was removed for
access to the damaged cable (Ref. AMM 70-71-14 P.Block 001).
NOTE : Use the notes that you made during the removal procedure.
____
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(9) Install the clips at the positions where they were removed for access
to the damaged cable. Make sure that they are correctly assembled.
____
Subtask 70-71-28-350-056
C. Test
(1) Do a wire continuity check and an insulation resistance check of the
cable (Ref. TASK 71-50-00-200-802) and (Ref. TASK 71-50-00-200-803).
Subtask 70-71-28-350-057
D. Identify the cable with the temporary repair number
(1) Wind two layers of the tape adhesive glass cloth insulating Adhesive
Tape (Material No. OMat296) around the cable adjacent to the repair.
(2) Use the black ball-point pen (Material No. OMat2-134) to write the
temporary repair number FRSJ179 on the tape.
Subtask 70-71-28-350-058
E. Record the temporary repair FRSJ179 in the engine log book.
(1) Write the temporary repair number and harness details in the engine
log book.
(2) Record that it is necessary to do the permanent repair (Ref. AMM 7071-24 P.Block 001) at the subsequent shop visit.
EFF :
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CABLE BRAIDED SCHIELD REPAIR - MAINTENANCE PRACTICES
____________________________________________________
TASK 70-71-29-300-801
Temporary Tape Repair of the Cable Braided Schield
1. __________________
Reason for the Job
This procedure permits the operator
braided shield if the damage occurs
protection- box. The repair is only
mm) of the cable after it comes out
to temporarily repair a damaged cable
adjacent to the electronic-unit
permitted along the first 3.0 in. (76,2
of the box through the fire/ fume seal.
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat1-40
Material No.
OMat2-134
Material No.
OMat2-140
Material No.
OMat2-147
Material No.
OMat2-153
Material No.
OMat2-153
Material No.
OMat2-30
Material No.
OMat2-67
Material No.
OMat296
*
isopropyl alcohol (Ref. 70-30-00)
*
black ball-point pen (Ref. 70-30-00)
*
tying cord (Ref. 70-30-00)
*
polyimide film (Ref. 70-30-00)
*
tape adhesive EMI (Ref. 70-30-00)
*
adhesive EMI (Ref. 70-30-00)
*
adhesive PTFE (Ref. 70-30-00)
*
cleaning tissue (Ref. 70-30-00)
*
Adhesive Tape (Ref. 70-30-00)
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------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------71-50-00-200-802
71-50-00-200-803
AMM 70-71-14 P.Block 001
AMM 70-71-24 P.Block 001
AMM 70-71-24 P.Block 001
70-71-29-991-001
Fig. 201
3. __________
Job Set-up
Subtask 70-71-29-912-050
A. General
(1) Service experience has shown that damage can be caused to the
electrical harness cables by chafing. This can go through the outer
protective jacket with subsequent damage to the cable-braided shield.
(2) This procedure gives the instructions to do a temporary repair of the
cable braided shield. You are only permitted to do this repair if:
- The chafed hole is in the first 3.0 in. (76.1998 mm) of the cable
after it comes out of the electronic-unit protection-box through
the fire/fume seal
- The chafed hole on the outer protective jacket is not more than
50-percent of the circumference of the cable
- The chafed hole in the braided metal shield is not more than 0.39
in. (9.9059 mm) along the length of the cable
- The chafed hole in the braided metal shield is not more than 0.157
in. (3.9877 mm) around the circumference of the cable
- The chafed hole in the braided metal shield does not remove more
than 20-percent of the metal strands in one location
- The insulation jackets of the conductors below the shield show no
signs of damage. If the damage is more than the limits given above,
you must replace the damaged cable (Ref. AMM 70-71-24 P.Block 001).
(3) This repair must NOT be done on the cables that follow:
- A generator feeder cable
- A temperature control cable (green cable)
- A low noise cable
- An N1 or N2 compressor speed probe cable
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- The pilot HPSOV cable (master lever)
- A cable that connects the EEC to the HPSOV
- Cables that connect to the OPU
- The thrust reverser cables
- The cable that connects to the hydraulic pump depressurisation
solenoid valve
- The cable that connects to the pressure-regulating valve
- The throttle resolver cables
- The cables that connect the dedicated alternator to the PCU
- The cables that connect the dedicated alternator to the OPU
- The FMV torque motor drive cables
- The FMV position feedback cables
- The cable that connects to the anti-ice valve.
(4) This repair is applicable to all other electrical harness cables that
are included in Chapters 71-51-00 and 71-52-00 of the Trent 700
Illustrated Parts Catalog (IPC).
(5) A temporarily repaired cable must be replaced at the subsequent shop
visit (Ref. AMM 70-71-24 P.Block 001).
Subtask 70-71-29-010-050
B. Get access to the repair area
Subtask 70-71-29-862-050
C. Remove electrical power from the electrical harness cable(s) to be
repaired.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-71-29-991-001)
Subtask 70-71-29-350-050
A. General data
(1) An electrical wire harness and its related parts are as follows:
(a) A wire is one electrical conductor with insulation around it.
(b) A cable is a group of wires in a metal braided shield with an
insulated outer jacket.
(c) A harness is one or more cables with connectors or terminal lugs
EFF :
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Temporary Tape Repair of the Cable Braided Shield
Figure 201/TASK 70-71-29-991-001
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(2) The consumable materials can be replaced with equivalent items.
Subtask 70-71-29-350-051
B. Temporary tape repair of the cable braided shield
(Ref. Fig. 201/TASK 70-71-29-991-001)
(1) Inspect the damaged cable and make sure that the damage is in the
permitted limits for this repair (Ref. Job Set-up - General data).
(2) Remove the clips at the adjacent clip positions, as necessary, to get
access to the damaged cable. Record their position and how they are
assembled to make sure of correct assembly at the end of this
procedure.
(3) Cut, remove and discard the lacing tape, as necessary, to get access
to the damaged cable.
NOTE : Before you remove the lacing tape you must record the
____
locations where it is installed. The lacing tape must be
installed in the same locations at the end of the repair.
(4) Release and move the applicable fire/fume seal to get access to the
damaged cable.
WARNING : YOU MUST FIND AND OBEY THE MANUFACTURERS HEALTH AND SAFETY
_______
DATA FOR THE MATERIALS. YOU MUST ALSO REFER TO LOCAL
REGULATIONS TO MAKE SURE THAT THE PROCEDURES ARE DONE
SAFELY. IF YOU DO NOT DO THIS, AN INJURY OR ENVIRONMENTAL
DAMAGE CAN OCCUR.
(5) Clean the cable 4.0 in. (101.5998 mm) each side of the damage. Use
the disposable cleaning tissue (Material No. OMat2-67) made moist
with the isopropyl alcohol (Material No. OMat1-40).
(6) Wind one continuous layer of the tape adhesive EMI shielding tape
adhesive EMI (Material No. OMat2-153) around the cable with a 0.5 in.
(12.6999 mm) overlap on each turn of the tape (Step 1) .
(Ref. Fig. 201/TASK 70-71-29-991-001)
the damaged area.
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(7) Wind one layer of the tape polyimide film (Material No. OMat2-147)
around the cable with a 20 percent overlap on each turn of the tape.
Apply the tape (Step 2)
(Ref. Fig. 201/TASK 70-71-29-991-001)
so that it extends 1.00 in. (25.3999 mm) each side of the layer of
tape adhesive EMI shielding adhesive EMI (Material No. OMat2-153).
Make sure that the tape wrap is sufficiently tight to make a
(8) Wind one layer of the tape adhesive PTFE release film adhesive PTFE
(Material No. OMat2-30) around the cable, in the opposite direction
to the layer of tape polyimide film (Material No. OMat2-147). (Step
3).
(Ref. Fig. 201/TASK 70-71-29-991-001)
the tape polyimide film, with a 20 percent overlap on that layer.
Make sure that the tapewrap is sufficiently tight to make a
(9) Tie the tape wrap at each end with tying cord (Material No. OMat2140), (Ref. AMM 70-71-14 P.Block 001).
NOTE : Use the part of the procedure that installs the lacing tape on
____
the harness.
(10) Move the fire/fume seal back into position and attach it correctly.
Make sure that you do not cause damage to the repaired area when you
move the fire/fume seal.
(11) Install the lacing tape at the locations where it was removed for
access to the damaged cable (Ref. AMM 70-71-14 P.Block 001).
____
(12) Install the clips at the positions where they were removed for access
to the damaged cable. Make sure that they are correctly assembled.
____
Subtask 70-71-29-350-052
C. Test
(1) Do a wire continuity check and an insulation resistance check of the
cable (Ref. TASK 71-50-00-200-802), (Ref. TASK 71-50-00-200-803).
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Subtask 70-71-29-350-053
D. Identify the cable with the temporary repair number
(1) Wind two layers of the Adhesive Tape (Material No. OMat296) glass
cloth insulating around the cable adjacent to the repair.
(2) Use the black ball-point pen (Material No. OMat2-134) to write the
temporary repair number FRSJ178 on the tape.
Subtask 70-71-29-350-054
E. Record the temporary repair FRSJ178 in the engine log book
(1) Write the temporary repair number and harness details in the engine
log book.
(2) Record that it is necessary to do an inspection of the repair area
regularly, each A check, for signs of deterioration.
(3) Record that it is necessary to do the permanent repair (Ref. AMM 7071-24 P.Block 001) at the subsequent shop visit.
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HARNESS TEMPORARY REPAIR (OVERTIE A NEW CABLE) - MAINTENANCE PRACTICES
______________________________________________________________________
TASK 70-71-40-300-801
Harness Temporary Repair (Overtie a New Cable)
1. __________________
Reason for the Job
This standard practice gives the procedure to do a temporary repair of a
damaged cable (overtie a new cable technique). The new cable will go along
the length of the harness, outside the clips or clamps. The temporary cable
must be of the same type as the damaged cable. Also you must replace the
damaged cable at the next shop visit.
Identification of the wire harness parts:
Wire - A singe electrical conductor with insulation around it.
Cable - A group of wires in a metal braided shield and an insulated jacket.
Harness - One or more cables with connectors or terminal lugs attached to
the ends of the cables.
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------Material No.
OMat256
Material No.
OMat256
Material No.
OMat274
*
adhesive tap (P.T.F.E.) (Ref. 70-30-00)
*
adhesive tape (P.T.F.E.) (Ref. 70-30-00)
*
lacing tape (Ref. 70-30-00)
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-50-02-910-801
70-71-40-991-001
Connection of Electrical Plugs (Types ESC10 and
ESC11)
Fig. 201
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3. __________
Job Set-up
Subtask 70-71-40-869-050
A. Not applicable.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-71-40-991-001)
Subtask 70-71-40-350-050
A. Do the applicable procedures to get access to the damaged cables on the
engine and disconnect the applicable electrical connectors.
(1) Repair the damaged cables.
(a) Cut the two ends of the damaged cable.
(b) At each end of the damaged cable, do the steps that follow:
1
_
Cut all the harness ties between the end of the cable and the
first clip or clamp.
2
_
Cut the damaged cable between the first and second clips or
clamps, 2.00 in. (50.7999 mm) from the first clip or clamp.
3
_
Remove and discard the shorter piece of cable.
4
_
Wind two turns of the adhesive tap (P.T.F.E.) (Material No.
OMat256) around the end of the damaged cable.
5
_
Tie back the damaged cables to the harness.
(c) Put the new cable through a fire seal.
1
_
If you are sure of the cable identification through (in and
out of) the fire seal:
- Cut all the harness ties on each side of the fire seal back
to the first clip or clamp.
- Cut the damaged cable 2.00 in. (50.7999 mm) each side of the
fire seal.
- Remove and discard the short piece of cable from the fire
seal.
- Wind two turns of the adhesive tape (P.T.F.E.) (Material No.
OMat256) around the ends of the damaged cable.
- Tie back the damaged cable to the harness.
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Overtie a New Cable
Figure 201/TASK 70-71-40-991-001
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- Put the new cable through the hole in the fire seal from
which you removed the damaged cable.
2
_
If you are not sure of the cable identification through (in
and out of) the fire seal:
- Disassemble the fire seal which the damaged cable goes
through.
- Remove the ceramic sealing plug from the fire seal.
- Assemble the fire seal.
- Put the new cable through the hole in the fire seal.
3
_
Do the steps (1_) or (2_) for each fire seal that the damaged
cable goes through.
4
_
Attach the new cable to the harness.
- Put the new cable along the length of the harness, not
through the clips or clamps.
Make sure the cable is clear of the adjacent components and
cannot rub against them.
- Put each end of the new cable through the first clip or
clamp.
- Tie the new cable to the harness with the lacing tape
(Material No. OMat274).
NOTE : It is not necessary to tie the harness where the new
____
cable goes over a clip or clamp.
(2) Connect the applicable electrical connectors (Ref. TASK 70-50-02-910801).
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HARNESS TYING - MAINTENANCE PRACTICES
_____________________________________
TASK 70-71-41-910-801
Harness Tying
1. __________________
Reason for the Job
This standard practice gives the procedure to tie a harness at a junction.
Identification of the wire harness parts:
Wire - A single electrical conductor with insulation around it.
Cable - A group of wires in a metal braided shield and an insulated jacket.
Harness - One or more cables with connectors or terminal lugs attached to
the ends of the cables.
2. ______________________
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-71-41-991-001
Fig. 201
3. __________
Job Set-up
Subtask 70-71-41-869-050
A. Not applicable.
4. Procedure
_________
Subtask 70-71-41-350-050
A. Install Harness Ties
(1) Install harness ties at two bunch junctions
(a) Make a selection of the largest bunch of cables and put the
harness tie through the middle.
(b) Make a clove hitch and then a half hitch.
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(c) Pull the harness tie
CAUTION : MAKE SURE THE HARNESS TIE IS NOT TOO TIGHT.
_______
DAMAGE TO THE CONDUCTOR JACKET CAN OCCUR.
1
_
Pull the harness tie tight and safety with a reef knot.
(d) At two bunch junctions or where harnesses cross, put end B of the
tie between the largest and smallest bunches of cables.
(e) Put end B one turn around the smallest bunch and then put it
again between the largest and smallest bunches.
(f) Put the end B one turn around the largest bunch and return the
tie to the initial position. This makes a figure of eight whip.
(Ref. Fig. 201/TASK 70-71-41-991-001)
(g) Pull the tie tight.
(h) Do steps (d) thru (g) six times.
(i) Put the end B of the tie between the bunches, then across the
waist of the completed figure of eight whips. Then put it back
through between the two adjacent bunches.
(j) Put end B across the backside of the figure of eight whips.
Then put it between the two adjacent bunches to make a frapping
lash.
(Ref. Fig. 201/TASK 70-71-41-991-001)
(k) Pull the tie tight.
(l) Do steps (i) thru (k) three times.
(m) Put end B of the tie to the initial position and make a reef
knot.
(n) Cut the ends of the tie to keep 0.31 in. (7.8739 mm) of tie at
the knot.
(2) Install harness ties at three bunch junctions
(a) Make a selection of the largest bunch of cables and put the
harness tie through the middle.
(b) Make a clove hitch and then a half hitch.
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Harness Tying
Figure 201/TASK 70-71-41-991-001
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(c) Pull the harness tie
CAUTION : MAKE SURE THE HARNESS TIE IS NOT TOO TIGHT.
_______
DAMAGE TO THE CONDUCTOR JACKET CAN OCCUR.
1
_
Pull the harness tie tight and safety with a reef knot.
(d) At three bunch junctions or where harnesses cross, put end B of
the tie between the largest and the adjacent bunch, then around
and between the next adjacent bunch.
(e) Put the end B one turn around the adjacent bunch and then put it
again between and around the other adjacent bunch.
(f) Put end B one turn around the largest bunch and return the tie to
the initial position. This makes a figure of eight whip.
(Ref. Fig. 201/TASK 70-71-41-991-001)
(g) Pull the tie tight.
(h) Do steps (d) thru (g) six times.
(i) Put end B of the tie between the largest bunch and the adjacent
bunch, then across the waist of the completed figure of eight
whips. Then put it back through between the largest bunch and the
adjacent bunch.
(j) Put end B across the backside of the figure of eight whips.
lash.
(Ref. Fig. 201/TASK 70-71-41-991-001)
(k) Pull the tie tight.
(l) Do steps (i) thru (k) three times.
(m) Put end B of tie between the other adjacent bunches, then across
the waist of the completed figure of eight whips. Then put it
back through between the two adjacent bunches.
(n) Put end B across the backside of the figure of eight whips.
lash.
(Ref. Fig. 201/TASK 70-71-41-991-001)
(o) Pull the tie tight.
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(p) Do steps (m) thru (o) three times.
(q) Put end B of the tie to the initial position and make a reef
knot.
(r) Cut the ends of the tie to keep 0.31 in. (7.8739 mm) of tie at
the knot.
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HARNESS TEMPORARY REPAIR (CABLE SPLICE) - MAINTENANCE PRACTICES
_______________________________________________________________
TASK 70-71-42-300-801
Harness Temporary Repair (Cable Splice), FRS J180
1. __________________
Reason for the Job
Self Explanatory
2. ______________________
------------------------------------------------------------------------------REFERENCE
QTY DESIGNATION
------------------------------------------------------------------------------No specific
No specific
copper brush
pin
------------------------------------------------------------------------------REFERENCE
DESIGNATION
------------------------------------------------------------------------------70-71-40-300-801
71-50-00-200-802
71-50-00-200-803
70-71-42-991-001
Harness Temporary Repair (Overtie a New Cable)
Fig. 201
3. __________
Job Set-up
Subtask 70-71-42-869-050
A. General
(1) In-service experience has shown that the electrical harness cables
can be damaged by chafing. This can go through the outer protective
jacket, braided metal shield and insulating jacket, with subsequent
damage to the conducting core.
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(2) This subject gives the procedure to do a temporary splice repair of a
cable until the cable can be replaced. The repair tells you how to
cut out the damaged area and splice a replacement section of cable
into position.
(3) After a satisfactory repair, the harness can be returned to service.
But the splice must be visually examined at every A Check for signs
of degradation, pending full substantiation of the repair by
Rolls-Royce plc.
(4) A new cable must be overtied at the next C check (Ref. TASK 70-7140-300-801).
(5) Effectivity
(a) The effectivity of this repair scheme includes all those cables
found in Chapters 71-51-00 and 71-52-00 of the Trent 700 IPC.
(b) You can do this temporary repair only if the limits given in
Table 201 apply:
TABLE 201
-----------------------------------------------------------------------------|1. | Do not put a splice in a cable or a wire at a distance of less than 6 |
|
| inches (150 mm) from the connector boot or backshell.
|
|---|------------------------------------------------------------------------|
|2. | A splice is not permitted on a generator feeder cable.
|
|---|------------------------------------------------------------------------|
|3. | A splice is not permitted on any temperature control cable
|
|
| (green cables).
|
|---|------------------------------------------------------------------------|
|4. | A splice is not permitted on a low noise cable.
|
|---|------------------------------------------------------------------------|
|5. | A splice is not permitted on the N1 and N2 compressor speed probe
|
|
| cables.
|
|---|------------------------------------------------------------------------|
|6. | A splice is not permitted on the Pilot HPSOV cable (master lever).
|
|---|------------------------------------------------------------------------|
|7. | A splice is not permitted on any cable linking the EEC and the HPSOV. |
|---|------------------------------------------------------------------------|
|8. | A splice is not permitted on any cables linking to the OPU.
|
|---|------------------------------------------------------------------------|
|9. | A splice is not permitted on any TRU cables.
|
|---|------------------------------------------------------------------------|
|10.| A splice is not permitted on any fire detector loops.
|
|---|------------------------------------------------------------------------|
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TABLE 201
-----------------------------------------------------------------------------|11.| A splice is not permitted on the cable connecting to the hydraulic
|
|
| pump depressurization solenoid valve.
|
|---|------------------------------------------------------------------------|
|12.| A splice is not permitted on the cable connecting to the Pressure
|
|
| Regulating Valve (PRV).
|
|---|------------------------------------------------------------------------|
|13.| A splice is not permitted on the throttle resolver cables.
|
|---|------------------------------------------------------------------------|
|14.| A splice is not permitted on the cable connecting the Dedicated
|
|
| Alternator to the PCU.
|
|---|------------------------------------------------------------------------|
|15.| A splice is not permitted on the cable connecting the Dedicated
|
|
| Alternator to the OPU.
|
|---|------------------------------------------------------------------------|
|16.| A splice is not permitted on the FMV torque motor drive cables.
|
|---|------------------------------------------------------------------------|
|17.| A splice is not permitted on the FMV position feedback cables.
|
|---|------------------------------------------------------------------------|
|18.| A splice is not permitted on the cable controlling the anti-ice valve. |
|---|------------------------------------------------------------------------|
|19.| Only one splice repair is permitted between adjacent cable clamps.
|
|---|------------------------------------------------------------------------|
|20.| Do not put a splice below a clamp or drip loop.
|
|---|------------------------------------------------------------------------|
|21.| A new cable must be overtied to replace the spliced cable at the next |
|
| C check.
|
|---|------------------------------------------------------------------------|
|22.| A record of accomplishment and of inspections specified in para A.(3) |
|
| must be kept.
|
-----------------------------------------------------------------------------(c) If the limits in Table 201 do not apply, you must replace the
damaged cable immediately (Refer to 70-71-24 Pb001).
(d) Identification of the wire harness parts:
1
_
Wire - A single electrical conductor with insulation around
it.
2
_
Cable - A group of wires in a metal braided shield and an
insulated jacket.
3
_
Harness - One or more cables with connectors or terminal lugs
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Subtask 70-71-42-869-051
B. Tools
-----------------------------------------------------------------------------| PART NUMBER | SUPPLIER | NOMENCLATURE
|
APPLICATION
|
|
|
CODE
|
|
|
|---------------|----------|-----------------|-------------------------------|
| Stripmaster |
30119 | Wire
| Strip the wire
|
| 45092
|
| Stripper
|
|
|---------------|----------|-----------------|-------------------------------|
| AMP46447
|
K1636 | Wire Splice
| To crimp the splice to the
|
|
|
| Crimp Tool
| wires
|
|-------------- |----------|-----------------|-------------------------------|
| MS22520/5-01 |
11851 | Crimp Tool
| Used to crimp the ferrules to |
|
|
|
| the wires
|
|---------------|----------|-----------------|-------------------------------|
| MS22520/5-39 |
11851 | Cable
| Used with the crimp tool to
|
|
|
| Ferrule
| crimp the BACS13S205BNP and
|
|
|
| Crimp Die
| BACS13S312CNP ferrules to the |
|
|
|
| wires
|
|---------------|----------|-----------------|-------------------------------|
| MS22520/5-41 |
11851 | Cable
|
|
|
| Ferrule
|
|
|
| Crimp Die
|
|
|
| wires
|
|---------------|----------|-----------------|-------------------------------|
| MS22520/5-43 |
11851 | Cable
|
|
|
| Ferrule
|
|
|
| Crimp Die
|
|
|
| wires
|
------------------------------------------------------------------------------
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Subtask 70-71-42-869-052
C. Consumable Materials
-----------------------------------------------------------------------------|
PART NUMBER
| SUPPLIER |
DESIGNATION
|
|
|
CODE
|
|
|---------------------|----------|-------------------------------------------|
| OMat 2/153, 1 inch |
K8767 | Tape, copper foil, conductive adhesive - |
|
|
| 3M Scotch 1181.
|
|---------------------|----------|-------------------------------------------|
| OMat 2-162
|
K1010 | Braid, fire resistant, Rayfast TSX-4MM
|
|
|
| -White
|
|---------------------|----------|-------------------------------------------|
| OMat 2-161
|
K1010 | Braid, fire resistant, Rayfast TSX-6MM
|
|
|
| -White
|
|---------------------|----------|-------------------------------------------|
| ESW1900
|
U5792 | Tape, lacing and tying
|
|---------------------|----------|-------------------------------------------|
| OMat 2/30A, 1 inch |
K8767 | Electrical tape, 3M Scotch 62.
|
|---------------------|----------|-------------------------------------------|
| OMat 2/174, 1 inch |
K8767 | Electrical tape, 3M Scotch 92.
|
|---------------------|----------|-------------------------------------------|
| 322326
|
K1636 | Splice, AMP322326
|
|---------------------|----------|-------------------------------------------|
| OMat 1/40
|
Local | Isopropyl Alcohol
|
|---------------------|----------|-------------------------------------------|
| OMat 2/67
|
Local | Kimwipes
|
|---------------------|----------|-------------------------------------------|
| BACS13S124BNP
|
K8516 | Inner ferrule for use with
|
|
|
| ESW1202-012-006 cable.
|
|---------------------|----------|-------------------------------------------|
| BACS13S187BNP
|
|
|
|
| ESW1202-022-006 cable.
|
|---------------------|----------|-------------------------------------------|
| BACS13S205BNP
|
|
|
|
| ESW1202-032-006 cable.
|
|---------------------|----------|-------------------------------------------|
| BACS13S187CNP
|
K8516 | Outer ferrule for use with
|
|
|
| ESW1202-012-006 cable.
|
|---------------------|----------|-------------------------------------------|
| BACS13S281CNP
|
|
|
|
| ESW1202-022-006 cable.
|
|---------------------|----------|-------------------------------------------|
| BACS13S312CNP
|
|
|
|
| ESW1202-032-006 cable.
|
------------------------------------------------------------------------------
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NOTE : Refer to Aircraft Wiring List, 92-90 Master Wire List to find the
____
wire number to get the correct cable part number.
NOTE : Use the same type of cable as the damaged cable. Make sure you
____
keep the same wire colours.
NOTE : To identify alternative part numbers, refer to the Power Plant
____
Subtask 70-71-42-860-050
D. Aircraft Maintenance Configuration
(1) Remove the power to the cables to be repaired. De-energize the
applicable circuits.
(2) Visually and dimensionally inspect the damaged cable. Make sure that
a satisfactory repair can be performed. The limits given in Table 201
must be applied.
(3) Get access to the repair area. Remove the harness lacing tape and
clamps in the area to be repaired.
4. Procedure
_________
(Ref. Fig. 201/TASK 70-71-42-991-001)
Subtask 70-71-42-350-050
A. Repair Procedure
_______
ON-WING REPAIRS. THEY ARE NOT RESISTANT OT EXPLOSION AND CAN
NOTE : This repair procedure is for a 2-wire cable. If you put a splice
____
in a 3-wire cable, make sure the insulation edges of all three
splices are at least 33.0 mm (1.2992 in.) apart from each other.
For a splice in a 1-wire cable, use this procedure but ignore the
instructions for the second wire.
(1) Identify the damaged area of the cable.
(a) Release clips (clamps) as necessary to get access to the damaged
cable.
(2) Remove lacing tape if necessary.
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(3) Cut and discard the damaged portion of the cable.
(a) Measure and record the length of removed cable.
(b) Verify and record the type of cable removed.
(c) Use hand tools.
NOTE : Repair one cable at a time.
____
(4) Prepare the ends of the remaining cable.
WARNING : ISOPROPYL ALCOHOL IS FLAMMABLE AND DANGEROUS TO THE SKIN,
_______
EYES AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS
NECESSARY. DO NOT HANDLE FOR LONG PERIODS. USE IN AN AREA
WITH GOOD VENTILATION.
(a) Use Isopropyl Alcohol to clean the cable 305 mm (12.0078 in.)
from the two ends.
(b) Cut and discard the insulating jacket 76 mm (2.9921 in.) from the
ends of the cable to show the braided metal shield. Use hand
tools.
(c) Cut and discard the braided metal shield 19 mm (0.7480 in.) from
the insulating jacket. Use hand tools.
(5) Prepare a replacement section of cable.
(a) Cut a piece of replacement cable that is 305 mm (12.0078 in.)
longer than the distance between the two ends of the remaining
cable. Use hand tools.
(b) Make sure that the splice ends of the replacement cable will be
clear of the clamps (clips).
(c) Prepare the two ends of the replacement cable.
1
_
Use Isopropyl Alcohol to clean the cable 305 mm (12.0078 in.)
from the two ends.
2
_
Cut and discard insulating jacket 76 mm (2.9921 in.) from the
ends of the cable to show the braided metal shield. Use hand
tools.
3
_
Cut and discard the braided metal shield 19 mm (0.7480 in.)
from the insulating jacket. Use hand tools.
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Harness Splice Repair
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4
_
Cut one wire 25 mm (0.9842 in.) from the insulating jacket.
Use hand tools.
(6) Install the replacement cable.
(a) Align the insulating colours of the replacement cable wires with
those of the engine cable wires.
(b) Cut the wires so that the long engine wire aligns with the
shorter replacement wire.
(c) Make sure you get the correct size of inner and outer ferrules.
(d) Put the outer ferrules on each of the two ends of the remaining
engine cable.
1
_
Move the ferrules away from the splice area.
(e) Put one inner ferrule on each of the two ends of the remaining
engine cable.
1
_
(f) Put two outer ferrules and two inner ferrules on the replacement
cable.
1
_
(g) Make sure that the metal strands of the braided shield are
straight at each of the four cables ends.
1
_
Brush the braided shield with a copper brush to remove any
corrosions or contamination spots.
2
_
Use a pin to unweave the metal strands of the braided shield
at each end of the two cables.
(h) Move the inner ferrule to the end of the insulating jacket.
1
_
Crimp the inner ferrule in position with a crimp tool and the
applicable die.
(i) Fold back the metal braided shield.
1
_
Smoothly fold the metal braided shield back over the inner
ferrules.
EFF :
ALL
70-71-42
AFL
Page 212
Oct 01/08
TRENT 700
SERIES ENGINES
2
_
Make sure the metal strands are evenly distributed around the
ferrule.
(j) Cut and install four lengths of fire resistant braid.
1
_
Cut two lengths of fire resistant braid of sufficient length
to cover the splices. Use Rayfast TSX4.
2
_
Put one length, with the braid expanded, on each of the two
longer wires.
3
_
Cut two more lengths of the fire resistant braid of sufficient
length to cover the splices. Use Rayfast TSX6.
4
_
Put one length, with the braid expanded, on each of the two
fire resistant braids previously installed.
CAUTION : DO NOT CAUSE DAMAGE TO THE WIRE STRANDS.
_______
(k) Use the approved wire stripper to remove between 6.35 mm (0.2500
in.) and 7.14 mm (0.2811 in.) of insulation from each of the four
wires.
(l) Connect the wires together.
1
_
Put a wire into each end of the applicable splice so that the
wires lie parallel beside each other.
2
_
Use crimp tool P/N AMP322326 to attach the splices.
3
_
Pull the wires to make sure the splices are correctly
installed.
4
_
Make sure that no loose strands are protruding from the
splice.
(m) Put the second fire resistant braids over the splices.
1
_
Use ESW1900 lacing tape to hold the braids in position.
(n) Wrap the repair area with copper tape.
1
_
Helically wrap with one continuous layer of 25 mm (0.9842 in.)
wide OMat 2/153 copper adhesive tape, with a 12.7 mm (0.5000
in.) overlap.
EFF :
ALL
70-71-42
AFL
Page 213
Oct 01/08
TRENT 700
SERIES ENGINES
2
_
Extend the wrapping for 12.7 mm (0.5000 in.) beyond the ends
of the ferrules.
(o) Put the outer ferrules over the inner ferrules.
1
_
Use the crimp tool and applicable die to install the outer
ferrules.
(p) Cut and discard the unwanted copper tape that protrudes beyond
the ferrules.
(q) Wrap the repair with the first layer of electrical tape.
1
_
Helically wrap one continuous layer of Scotch 92 electrical
tape around the repaired cable with a 50 percent overlap on
each turn of the tape.
2
_
Extend the wrapping for 25 mm (0.9842 in.) beyond each of the
ferrules.
NOTE : The tape wrap must be sufficiently tight to make a
____
(r) Wrap the repair with the second layer of electrical tape.
1
_
Helically wrap one continuous layer of Scotch 62 electrical
tape around the repaired cable with a 50 percent overlap on
each turn of the tape.
2
_
The tape must be wound in the opposite direction to the first
layer. Extend the wrapping for 12.7 mm (0.5000 in.) beyond
each end of the previously applied layer.
NOTE : The tape wrap must be sufficiently tight to make a
____
(s) Attach the ESW1900 lacing tape.
1
_
Make a clove hitch and a square knot at each end of the tape
wrap.
2
_
Cut the ends of the lacing tape between 6 mm (0.2362 in.) and
13 mm (0.5118 in.) from the knot.
EFF :
ALL
70-71-42
AFL
Page 214
Oct 01/08
TRENT 700
SERIES ENGINES
Subtask 70-71-42-220-050
B. Inspection
(1) Do a continuity and insulation resistance check.
(a) Do a continuity check (Ref. TASK 71-50-00-200-802).
(b) Do an insulation resistance check (Ref. TASK 71-50-00-200-803).
(2) Examine the repair.
(a) Make sure that the repair has been carried out in accordance with
the instructions in this repair scheme.
(3) Secure the harness.
(a) Put back the lacing tape and cable clamps where necessary.
EFF :
ALL
70-71-42
AFL
Page 215
Oct 01/08

REVISION NO. 02 Apr 01/09 Pages which have been revised are

Transcription

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