STANDARD PRACTICES MANUAL

DOCUMENT NUMBER HSPS 490001

AUXILIARY POWER UNITS

©2002, 2005, 2009, 2013-2015 Hamilton Sundstrand Corporation

NOTICE

THIS DOCUMENT IS THE PROPERTY OF HAMILTON SUNDSTRAND CORPORATION AND PRATT & WHITNEY AEROPOWER. YOU MAY NOT
POSSESS, USE, COPY OR DISCLOSE THIS DOCUMENT OR ANY INFORMATION IN IT, FOR ANY PURPOSE, INCLUDING WITHOUT LIMITATION, TO
DESIGN, MANUFACTURE OR REPAIR PARTS, OR OBTAIN ANY GOVERNMENT APPROVAL TO DO SO, WITHOUT EXPRESS WRITTEN PERMISSION.
NEITHER RECEIPT NOR POSSESSION OF THIS DOCUMENT ALONE, FROM ANY SOURCE, CONSTITUTES SUCH PERMISSION. POSSESSION, USE,
COPYING OR DISCLOSURE BY ANYONE WITHOUT EXPRESS WRITTEN PERMISSION IS NOT AUTHORIZED AND MAY RESULT IN CRIMINAL AND
OR CIVIL LIABILITY.

INFORMATION SUBJECT TO EXPORT CONTROL LAWS

SUBJECT TO THE EAR, ECCN 9E991

THIS INFORMATION IS SUBJECT TO THE EXPORT CONTROL LAWS OF THE UNITED STATES, SPECIFICALLY INCLUDING THE EXPORT
ADMINISTRATION REGULATIONS (EAR), 15 C.F.R. PART 730 ET. SEQ. TRANSFER, RE-TRANSFER, OR DISCLOSURE OF THIS DATA BY ANY MEANS
TO A NON-U.S. PERSON (INDIVIDUAL OR COMPANY), WHETHER IN THE UNITED STATES OR ABROAD, WITHOUT ANY REQUIRED EXPORT LICENSE
OR OTHER APPROVAL FROM THE U.S. GOVERNMENT IS PROHIBITED, INCLUDING WITHOUT LIMITATION ANY DIVERSION TO A MILITARY END
USER OR USE IN A MILITARY END USE APPLICATION.

NOTICE

THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON
SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER SYSTEMS AND/OR PARTS,
REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR
APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT
SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND
WITHOUT EVIDENCE THAT THE FEDERAL AVIATION ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN
THIS DOCUMENT IS VALID FOR SUCH USE.

TITLE PAGE, 1
ORIGINAL ISSUE DEC 01/02
REVISION 5 AUG 25/15
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Revision 5, Dated August 25, 2015

HIGHLIGHTS

TO: Holders of Standard Practices Manual, Document HSPS 490001, for Auxiliary Power Units, used
on all models.

Shown below are the highlights of the significant changes and the affected pages contained in this
revision. We recommend that you put this revision into your manual without delay. Mark the Record
of Revisions sheet with the new revision number and date, and write your initials on the Record of
Revisions sheet in the appropriate spaces after you have put the revised pages in your manual.

This manual is available in either electronic format (SGML, ATA Specification 2200) or on the Hamilton
Sundstrand Power Systems website, http://www.hs-powersystems.com (password required).

If you have any questions about this document, please contact Technical Publications by telephone
(858) 627-6000, fax: (858) 627-6601, or write to Hamilton Sundstrand, Technical Publications
Department 374-P1, P.O. Box 85757, San Diego, California 92186-5757.

The following Action Items are incorporated into this revision:

Action Items Location

RDE14061 CLEANING 38
RDE14096 CLEANING 15
RDE14121 CLEANING 45
RDE14140 ASSEMBLY
RDE14154, RDE14154R1, RDE14154R2 REPAIR 10
RDE14189 INSPECTION/CHECK 07
RDE15039 PRESERVATION

Page Number Description of Change

TITLE PAGE
Page 1 Revised to reflect revision 5.

LIST OF EFFECTIVE
PAGES
Page 1 Revised to reflect revision 5 changes.

INTRODUCTION
Page 1 Revised introduction section to update ordering of parts section.

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Page Number Description of Change

49-00-01 CLEANING 15
Page 601 Revised paragraph 1.D.(2) to add Ardrox 3705 to consumable list.
(RDE14096)
Added paragraphs 1.E.(6), 1.F.(6) and 1.G.(5) to add an optional procedure
to apply corrosion inhibitor to the part to prevent from rusting. (RDE14096)
49-00-01 CLEANING 38
Page 601 Revised Table 603 to correct the solution #1 material from "Ardrox 14358"
to "1435B". (RDE14061)
Revised paragraph 1.E.(11) to correct wrong solution temperature.
(RDE14061)
49-00-01 CLEANING 45
Page 601 Revised paragraph 1.D.(2) to add Plastic Media Blast Type II- Fisher JET
plastic to the consumable list. (RDE14121)
49-00-01 INSPECTION/CHECK 07
Page 801 Revised paragraph 1.D.(2) to update the consumablel list. (RDE14189)
Revised paragraph 1.E.(6) to revise the drying time of the part. (RDE14189)
Revised paragraph 1.E.(9) to add note. (RDE14189)
49-00-01 REPAIR 10
Page 901 Revised paragraph 1.D.(2) to add METCO 443 and METCO 450NS to
consumable list. (RDE14154) (RDE14154R1) (RDE14154R2)
Revised paragraph 1.D.(2) to add METCO 45VF-NS and METCO 45C-NS
to consumable list. (RDE14154R1)
Revised paragraph 1.E.(5).(e) to correct the metric value for Blasting
pressure. (PAR2015-SPM-1)
Revised Table 901 to revise the Hardness requirements for Mecto 450NS/
Metco 480NS. (RDE14154R2)
Deleted Table 902 "Mecto 320NS coating requirements". (RDE14154)
(RDE14154R1) (RDE14154R2)
Revised paragraph 1.H.(3).(b) to add acceptance specifications.
(RDE14154) (RDE14154R1) (RDE14154R2)
Revised paragraph 1.H.(5). (b) to add Table 902 for Mecto 320NS coating
requirements. (RDE14154R2)
Added new paragraph 1.H.(7) for powder plasma spray. (RDE14154R1)
Added paragraph 1.L for Required tests. (RDE14154R1)
Added Figure 908 for Acceptable cobalt coating. (RDE14154)
(RDE14154R1) (RDE14154R2)
Added Figure 909 for Acceptance cobalt coating. (RDE14154)
(RDE14154R1) (RDE14154R2)

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Page Number Description of Change

Added Figure 910 for Unacceptable cobalt coating: Excessive porosity and
Unmelted Globules. (RDE14154) (RDE14154R1) (RDE14154R2)
49-00-01 ASSEMBLY
Page 1001 Added assembly material “Self-bonding silicone tape” to Table 1002.
(RDE14140)
Added new task procedure for Installation of Harness on Engine - Wrapping
Harness Connectors with Self-bonding silicone tape. (RDE14140)
49-00-01 PRESERVATION
Page 1401 Revised paragraph 1.B.(2) to remove the specification "L-P-378" from
consumable list. (RDE15039)
Revised paragraph 2.C.(2) to revise the specifications of few consumables
in the consumable list. (RDE15039)

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SAFETY ADVISORY

1. SCOPE
This publication describes processes that may require the use of chemicals, solvents, paints,
or other materials that can affect a person's health or safety. It may also cover high energy
procedures that can affect a person's health or safety. Warnings are placed just ahead of these
procedures to bring attention to the existence of a procedure or material that can be dangerous.
2. SIGNIFICANCE OF MATERIAL SAFETY DATA SHEETS (MSDS) AND HOW TO OBTAIN
MSDS
Refer to the materials list at the beginning of each section of this manual for materials used to
repair and maintain the covered equipment.
If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials
list, contact the manufacturer and request that a MSDS be supplied before you use the
material.
3. PURPOSE
The warnings bring your attention to the existence of a procedure that can affect a person’s
health or safety.
WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN
HAMILTON SUNDSTRAND MAINTENANCE PUBLICATIONS, BE
AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL
PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR
SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER'S OR
SUPPLIER'S RECOMMENDATIONS MAY RESULT IN PERSONAL
INJURY OR DISEASE.
THE USER OF THIS PUBLICATION SHOULD OBTAIN THE
MATERIAL SAFETY DATA SHEETS [OCCUPATIONAL SAFETY
AND HEALTH ACT (OSHA) FORM 20 OR EQUIVALENT] FROM THE
MANUFACTURERS OR SUPPLIERS OF MATERIALS TO BE USED.
THE USER MUST BECOME COMPLETELY FAMILIAR WITH THE
MANUFACTURER OR SUPPLIER INFORMATION AND ADHERE TO
THE PROCEDURES, RECOMMENDATIONS, WARNINGS, AND
CAUTIONS OF THE MANUFACTURER OR SUPPLIER FOR THE
SAFE USE, HANDLING, STORAGE, AND DISPOSAL OF THESE
MATERIALS.

SAFETY ADVISORY
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Short warnings are supplied in this maintenance publication to alert operating and
maintenance personnel of potential hazards that could result in personal injury or health
hazards. The warnings do not replace the manufacturer’s recommendations. When there is a
reference to the Warnings Registry 341-006, that publication will provide more information
about the dangers of the material. The information contained in the Warnings Registry is a
summary of the manufacturer’s MSDS. The full length warnings provide three principle parts
of safety: (1) a listing of the known dangers, (2) what is needed to protect you from the dangers,
and (3) what to do if the dangers occur.
The detailed warnings in Warning Registry 341-006 are a summary of the manufacturer’s
MSDS and are not intended to replace the material on the sheet, but are intended to
supplement them.
Cautions are supplied in the maintenance publication or service bulletin to alert operating and
maintenance personnel to conditions that could result in equipment damage.
4 DEFINITIONS APPLYING TO WARNINGS
Flammable: A material that can catch fire easily and can be explosive. These
materials are labeled according to the flash point of the material.
Flash Point: The lowest temperature at which a flammable liquid gives off fumes that
can burn.
Ignition Source: Includes flames, sparks, or heat.
Flames: Materials that are burning such as lit matches, propane torches, or pilot
lights.
Sparks: Materials such as lighted cigarettes, electrical motors, or static
electricity.
Heat: Any source of energy that will raise the temperature of a flammable
material to its flash point and could include hot parts, heated tools, or
direct sunlight.
Corrosive: Acidic or alkaline material that will remove human tissue or create
chemical reactions with other materials.
Toxic: Material that is poisonous.
Reactive: Materials that will make fumes, burn, or can be explosive when mixed
with certain other materials.
Shock (Electrical): The result of any source of electricity more than 50 volts that causes
current to flow through a person and can result in dangerous burns to
human tissues or death.
Exposure: Contact with the material or physical process without protection.
Contact may be by the eyes, breathing, touch, skin absorption, or
swallowing.

SAFETY ADVISORY
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Irritation: Any sense of pain, soreness, rash, or general discomfort.

5 REPORTING MATERIALS OR PROCESSES NOT COVERED IN THIS MANUAL
Please call (815) 226-6000, FAX (815) 966-8525, or write to Hamilton Sundstrand, Technical
Publications, Department 768, 4747 Harrison Avenue, P.O. Box 7002, Rockford, IL
61125-7002, if you find a material in a Hamilton Sundstrand maintenance document that is
known to be covered by a material safety data sheet (MSDS) but is not covered by a warning
in the procedure.
6. List of Warnings Covered in this Publication
The following are list of all warnings used in this document.
WARNING: BEFORE USING ANY OF THE MATERIALS SPECIFIED IN
HAMILTON SUNDSTRAND MAINTENANCE PUBLICATIONS, BE
AWARE OF ALL HANDLING, STORAGE, AND DISPOSAL
PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR
SUPPLIER. FAILURE TO COMPLY WITH MANUFACTURER'S OR
SUPPLIER'S RECOMMENDATIONS MAY RESULT IN PERSONAL
INJURY OR DISEASE.
WARNING: THE USER OF THIS PUBLICATION SHOULD OBTAIN THE
MATERIAL SAFETY DATA SHEETS (OCCUPATIONAL SAFETY
AND HEALTH ACT (OSHA) FORM 20 OR EQUIVALENT) FROM THE
MANUFACTURERS OR SUPPLIERS OF MATERIALS TO BE USED.
THE USER MUST BECOME COMPLETELY FAMILIAR WITH THE
MANUFACTURER OR SUPPLIER INFORMATION AND ADHERE TO
THE PROCEDURES, RECOMMENDATIONS, WARNINGS, AND
CAUTIONS OF THE MANUFACTURER OR SUPPLIER FOR THE
SAFE USE, HANDLING, STORAGE, AND DISPOSAL OF THESE
MATERIALS.
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER
SUITABLE PROTECTION TO PREVENT BURNS WHEN LOADING
PARTS INTO A PREHEATED OVEN OR HANDLING HEATED OR
CHILLED PARTS. WARNING: DO NOT BREATHE THE OIL VAPORS.
USE THE OIL ONLY IN WELL-VENTILATED AREAS. USE THE EYE
PROTECTION AND USE RUBBER GLOVES. THE LUBRICATION
OIL CAN CAUSE DAMAGE TO YOUR SKIN.

SAFETY ADVISORY
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WARNING: DO NOT BREATHE THE DEGREASER SOLUTION VAPORS. USE

THE DEGREASER SOLUTION ONLY IN A WELL-VENTILATED
AREA WHERE THERE ARE NO SPARKS, NO FLAMES AND NO HOT
SURFACES. USE THE EYE PROTECTION AND USE SOLVENT-
RESISTANT GLOVES. IF THE DEGREASER SOLUTION TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A
DOCTOR. IF THE DEGREASER SOLUTION TOUCHES YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE DEGREASER
SOLUTION IS POISONOUS AND FLAMMABLE.
WARNING: DO NOT TOUCH THE IGNITION COMPONENTS UNTIL ALL THE
STEPS ARE DONE. THESE STEPS WILL RELEASE THE HIGH
VOLTAGE FROM THE IGNITION EXCITER. IF YOU DO NOT OBEY
THIS PROCEDURE, INJURY TO PERSONS CAN OCCUR. MAKE
SURE 5 MINUTES HAVE GONE BY SINCE THE LAST APU START.
DISCONNECT THE IGNITER CABLES FROM THE IGNITOR PLUGS.
GROUND THE IGNITOR CABLES TO THE APU.
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS,
MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30
POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT
DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS.
PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES.
THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR
DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY,
GET MEDICAL ATTENTION.
WARNING: THE FORCE MADE WHEN LOCKWIRE (ALSO KNOWN AS SAFETY
WIRE) IS TWISTED OR CUT CAN CAUSE THE LOCKWIRE TO
BECOME A PROJECTILE. THE FORCE CAN CAUSE THE
LOCKWIRE TO DAMAGE OR GO THROUGH THE SURFACE OF
YOUR EYES. THIS DAMAGE COULD CAUSE PERMANENT
BLINDNESS IN THE AFFECTED EYE. BEFORE YOU REMOVE OR
INSTALL THE LOCKWIRE, PUT ON SAFETY GLASSES WITH SIDE
SHIELDS OR SAFETY GOGGLES. IF THE LOCKWIRE GETS INTO
YOUR EYE, GET IMMEDIATE MEDICAL AID. IF THE LOCKWIRE
HAS GONE THROUGH THE SURFACE OF THE EYE, DO NOT TRY
TO REMOVE THE LOCKWIRE. MAKE SURE THAT A TRAINED
MEDICAL PERSON REMOVES THE LOCKWIRE.

SAFETY ADVISORY
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WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS

VERY FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE ACETONE, GET THE
MATERIAL SAFETY DATA SHEET FROM THE MANUFACTURER
OR SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY.
READ THE DETAILED WARNING, W0001SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE ACETONE, PUT ON
CHEMICAL-SPLASH GOGGLES, AND ACETONE-RESISTANT
GLOVES (BUTYL RUBBER), APRON, AND SHOES. MAKE SURE
THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ACETONE
FUMES BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.
ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR
SUPPLIER OF THE MATERIAL AND READ IT CAREFULLY. READ
THE DETAILED WARNING, W0046SE, IN THE WARNING
REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT ON
CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: USE SILICONE SEALANT, SILASTIC RTV732, CORRECTLY. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE SEALANT, GET THE MATERIAL SAFETY DATA
SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0206SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SEALANT, PUT ON SAFETY GLASSES.
MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE SEALANT FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.

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WARNING: USE HYDROCHLORIC ACID (ALSO KNOWN AS, HCL, MURIATIC

ACID, AND CHLOROHYDRIC ACID, AQUEOUS HYDROGEN
CHLORORIDE) CORRECTLY. THE ACID AND ITS FUMES ARE
REACTIVE, CORROSIVE, AND POISONOUS. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
ACID, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0005SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ACID, PUT
ON NEOPRENE GLOVES, CHEMICAL APRON, CHEMICAL-
SPLASH GOGGLES AND A FACE SHIELD. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE ACID FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT. DO NOT ADD WATER
TO ACID. VERY SLOWLY ADD ACID TO WARM WATER. KEEP THE
ACID-CONTAINER TIGHTLY SEALED EXCEPT WHEN POURING
THE ACID. AVOID SPILLS.
WARNING: USE THE CLEANER TURCO HTC CORRECTLY. THE CLEANER IS
CORROSIVE AND REACTIVE. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE CLEANER,
GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0196SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE CLEANER,
PUT ON CHEMICAL SAFETY GOGGLES AND CHEMICAL-
RESISTANT GLOVES, APRON, AND SHOES (NEO-PRENE). MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. ADD THE
CLEANER VERY SLOWLY TO MODERATELY WARM WATER. DO
NOT ADD LARGE AMOUNTS OF THE CLEANER TO WATER
QUICKLY AS THIS WILL CAUSE A DANGEROUS REACTION.
WARNING: USE CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING
SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS, NAPHTHA,
PETROLEUM SPIRITS, MILPRF- 680 TYPE II, ASTM D235 TYPE II,
OR AMS3160) CORRECTLY. THE SOLVENT IS FLAMMABLE. IT
CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0158SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SOLVENT, PUT ON CHEMICAL SPLASH
GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE SOLVENT FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

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WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS

MILC- 5541, MILC- 81706, AMS2473, ALODINE OR CHEMICAL-FILM
COATING) LIQUID OR POWDER FORM CORRECTLY. COATING IS
FLAMMABLE, POISONOUS, CORROSIVE, AND REACTIVE. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE
YOU USE THE COATING, GET THE MATERIAL SAFETY DATA
SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0059SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE COATING, PUT ON A CHEMICAL FACE
SHIELD, SOLVENT-RESISTANT GLOVES (BUTYL, NEOPRENE,
NITRILE, OR PVC), APRON, AND SHOES. MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING POWDER
OR FUMES BELOW THE MSDS LIMIT.
WARNING: SOLVENT, TRICHLORO-ETHYLENE, IS TOXIC AND FLAMMABLE.
DO NOT BREATHE VAPORS. USE IN WELL-VENTILATED AREA
FREE FROM SPARKS, FLAME, OR HOT SURFACES. PUT ON
SPLASH GOGGLES, SOLVENT-RESISTANT GLOVES, AND OTHER
PROTECTIVE GEAR. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.
WARNING: USE METHYL ETHYL KETONE (MEK) SOLVENT
CORRECTLY. THE SOLVENT IS FLAMMABLE AND REACTIVE. IT
CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE YOU USE THE SOLVENT, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0159SE, IN THE WARNING REGISTRY 341-006.
BEFORE YOU USE THE SOLVENT, PUT ON CHEMICAL SPLASH
GOGGLES, AND SOLVENT-RESISTANT GLOVES (BUTYL
RUBBER), RUBBER APRON, AND CHEMICAL SAFETY SHOES.
MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE SOLVENT FUMES BELOW THE MATERIAL SAFETY DATA
SHEET LIMIT.
WARNING: USE REFRIGERATED LIQUID NITROGEN (ALSO KNOWN AS
LIQUID NITROGEN) CORRECTLY. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE LIQUID
NITROGEN, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0125SE,
IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
LIQUID NITROGEN PUT ON A FULL FACE-SHIELD, APRON, AND
INSULATED GLOVES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE LIQUID NITROGEN FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

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WARNING: LUBRICATING OILS MIL-L-7808 AND MIL-L-23699 CONTAIN

MATERIALS HAZARDOUS TO HEALTH. THEY CAN CAUSE
PARALYSIS IF SWALLOWED. PROLONGED CONTACT WITH SKIN
CAN CAUSE IRRITATION. FIRE CAN RESULT IF EXPOSED TO
HEAT OR FLAMES. USE ONLY IN AREAS WITH ADEQUATE
VENTILATION. WASH HANDS THOROUGHLY AFTER HANDLING.
WARNING: ENGINE OIL IS HAZARDOUS AND MAY CAUSE INJURY TO SKIN
AND EYES. PUT ON RUBBER GLOVES AND SAFETY GOGGLES.
WARNING: TO PREVENT POSSIBLE INJURY TO EYES, WEAR
GOGGLES OR FACE SHIELD WHEN PERFORMING SAND
BLASTING.
WARNING: THE INCORRECT INSTALLATION OF THE TB3012 TOOL PULLING
SCREW CAN CAUSE INJURY TO THE PERSONNEL OR DAMAGE
TO THE EQUIPMENT. WARNING: THE PULLING SCREW OF TOOL
TB3017 MUST BE CORRECTLY FITTED TO THE SHAFT
THREADED END. THIS WILL PREVENT INJURY TO PERSONAL
AND DAMAGE TO EQUIPMENT.
WARNING: DO NOT STAND DIRECTLY IN FRONT OF THE BALANCE MACHINE
WHEN THE MACHINE IS IN OPERATION OR INJURY TO
PERSONNEL CAN OCCUR.
WARNING: CAREFULLY USE THE VAPOR BLASTING TO PREVENT DAMAGE
OF THE PARENT METAL. USE THE VAPOR BLASTING ONLY IN A
CORRECT AREA WHERE THERE ARE PROTECTIVE DOORS AND
SHIELDS. USE THE EYE PROTECTION AND THE PROTECTIVE
CLOTHES. IF THE VAPOR BLASTING TOUCHES YOUR SKIN, THIS
CAN CAUSE A DANGEROUS INJURY.
WARNING: THE DIELECTRIC STRENGTH TEST REQUIRES UTILIZATION OF
HIGH VOLTAGE SOURCES. TO MINIMIZE THE HAZARD OF
ELECTRIC SHOCK, AND TO PREVENT DAMAGE TO THE
DIFFERENTIAL PRESSURE INDICATOR SWITCH, MAKE SURE
THAT THE TEST EQUIPMENT INCORPORATES A CURRENT
LIMITING DEVICE THAT IS SET TO LIMIT CURRENT SURGES TO
4 mA, MAXIMUM. DO NOT TOUCH CONDUCTIVE METAL PARTS
DURING TEST AT ANY TIME, AND DO NOT ALLOW OTHER
CONDUCTIVE ITEMS TO COME IN CONTACT WITH THE
DIFFERENTIAL PRESSURE INDICATOR SWITCH OR THE TEST
SETUP.

SAFETY ADVISORY
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WARNING: THE INSULATION RESISTANCE TEST REQUIRES UTILIZATION OF

HIGH VOLTAGE SOURCES. TO MINIMIZE THE HAZARD OF
ELECTRIC SHOCK, AND TO PREVENT DAMAGE TO THE
DIFFERENTIAL PRESSURE INDICATOR SWITCH, MAKE SURE
THAT THE TEST EQUIPMENT INCORPORATES A CURRENT
LIMITING DEVICE THAT IS SET TO LIMIT CURRENT SURGES TO
4 mA. DO NOT TOUCH CONDUCTIVE METAL PARTS DURING
TEST AT ANY TIME, AND DO NOT ALLOW OTHER CONDUCTIVE
ITEMS TO COME IN CONTACT WITH THE DIFFERENTIAL
PRESSURE INDICATOR SWITCH OR THE TEST SETUP.
WARNING: USE THE 2087X PARCO CLEANER CORRECTLY. THE CLEANER
IS CORROSIVE AND REACTIVE. IT CAN HAVE A BAD EFFECT ON
YOUR HEALTH OR SAFETY. BEFORE YOU USE THE CLEANER,
GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0196SE, IN THE
WARNING REGISTRY 341- 006. BEFORE YOU USE THE CLEANER,
PUT ON CHEMICAL SAFETY GOGGLES AND CHEMICAL-
RESISTANT GLOVES, APRON, AND SHOES (NEO-PRENE). MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT. ADD THE
CLEANER VERY SLOWLY TO MODERATELY WARM WATER. DO
NOT ADD LARGE AMOUNTS OF THE CLEANER TO WATER
QUICKLY AS THIS WILL CAUSE A DANGEROUS REACTION.
WARNING: FLAME SPRAY MATERIAL PRODUCES TOXIC FUMES AND GASES
WHEN APPLIED. DO NOT BREATHE METALLIC VAPORS. USE IN
WELL-VENTILATED AREA. PUT ON HEARING PROTECTION AND
DARK GOGGLES.
WARNING: PRESERVATIVE OIL CAN HAVE AN ADDITIVE CALLED
TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN
ASPHYXIANT. IT IS POISONOUS AND CAN BE ABSORBED
THROUGH THE SKIN. USE PROPER PERSONAL PROTECTION.
WARNING: USE CALIBRATION FLUID, CORRECTLY. THE CALIBRATION
FLUID LIQUID AND FUMES ARE FLAMMABLE. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
CALIBRATION FLUID, GET THE MATERIAL SAFETY DATA SHEET
FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL
AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0107SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU
USE THE FLUID, PUT ON CHEMICAL-SPLASH GOGGLES,
SOLVENT-RESISTANT GLOVES, APRON, AND SHOES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE
CALIBRATION FLUID FUMES BELOW THE MATERIAL SAFETY
DATA SHEET LIMIT.

SAFETY ADVISORY
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WARNING: USE LOCQUIC PRIMER GRADE N OR T, CORRECTLY. THE

PRIMER IS FLAMMABLE AND A MILD POISON. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
PRIMER, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0135SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE PRIMER,
PUT ON CHEMICAL-SPLASH GOGGLES AND SOLVENT-
RESISTANT GLOVES (BUTYL RUBBER). MAKE SURE THAT YOU
HAVE SUFFICIENT AIRFLOW TO KEEP THE PRIMER FUMES
BELOW THE MATERIAL SAFETY DATA SHEET LIMIT.
WARNING: ACIDS ARE CORROSIVE TO HUMAN TISSUE. DO NOT BREATHE
VAPORS. USE IN A WELL-VENTILATED AREA. WEAR CHEMICAL
RESISTANT CLOTHING, GLOVES, SPLASH GOGGLES, AND FACE
SHIELD. IN CASE OF EYE OR SKIN CONTACT, FLUSH WITH
WATER AND SEEK MEDICAL ATTENTION.
WARNING: USE ANAEROBIC THREAD LOCKING COMPOUND CORRECTLY.
THE COMPOUND IS COMBUSTIBLE. IT CAN HAVE A BAD EFFECT
ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
COMPOUND, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING, W0069SE,
IN THE WARNING REGISTRY 341-006. BEFORE YOU USE THE
COMPOUND, PUT ON SAFETY GLASSES OR GOGGLES AND
NEOPRENE, RUBBER, OR BUTYL RUBBER GLOVES.

SAFETY ADVISORY
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RECORD OF REVISIONS

REV ISSUE DATE REV ISSUE DATE

NO. DATE INSERTED BY NO. DATE INSERTED BY
1 Apr 1/05 Apr 1/05 HS
2 Dec 15/09 Dec 15/09 HS
3 Dec 2/13 Dec 2/13 HS
4 Aug 25/14 Aug 25/14 HS
5 Aug 25/15 Aug 25/15 HS

RECORD OF REVISIONS
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THIS PAGE INTENTIONALLY LEFT BLANK

RECORD OF REVISIONS
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RECORD OF TEMPORARY REVISIONS

TEMPORARY PAGE ISSUE ISSUED DATE REMOVED

REV. NO. NUMBER DATE BY REMOVED BY
49-1 Cleaning-05, Page 603 I/ Sep 30/03 HS
C-03, Page 805 Apr 1/05 HS
49-2 Introduction, Page 1 Oct 15/07 HS
Dec 15/09 HS
49-3 Cleaning, Pages 602 Jun 15/12 HS
through 604 Cleaning-01, Dec 2/13 HS
Pages 601 through 605
Cleaning-05, Pages 601
through 608 Cleaning-06,
Pages 601 through 603
Cleaning-15, Pages 601
through 606 Cleaning-17,
Page 602 Cleaning-21,
Page 602 Cleaning-23,
Page 602 Cleaning-27,
Page 602 Cleaning-30,
Page 602 Cleaning-36,
Pages 601 through 604
Cleaning-37, Pages 601
through 604 Cleaning-38,
Pages 601 through 608
Cleaning-39, Pages 601
through 608 Cleaning-40,
Pages 601 through 604
Cleaning-41, Pages 601
through 604 Cleaning-42,
Pages 601 through 604
Cleaning-43, Pages 601
through 604 Cleaning-44,
Pages 601 through 604
Cleaning-45, Pages 601
through 604 Cleaning-46,
Pages 601 through 604
49-4 I/C, Page 804 I/C 21, Dec 15/13 HS
Page 801 Preservation, Aug 25/14 HS
Page 601
49-5 Repair 10: Pages 902, Jun 11/14 HS
908, 909, 913, 914, 918 Aug 25/14 HS
through 924.

RECORD OF TEMPORARY REVISIONS

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Subject Page Date Subject Page Date

TITLE PAGE 1 Aug 25/15 8 BLANK

2 BLANK
INTRODUCTION 1 Aug 25/15
HIGHLIGHTS 1 Aug 25/15 2 Aug 25/15
2 Aug 25/15 3 Aug 25/15
3 Aug 25/15 4 Aug 25/15
4 BLANK
AIRWORTHINESS 1 Aug 25/14
SAFETY ADVISORY 1 Aug 25/14 LIMITATIONS 2 BLANK
2 Aug 25/14
3 Aug 25/14 HOW TO USE 1 Aug 25/14
4 Aug 25/14 2 BLANK
5 Aug 25/14
6 Aug 25/14 49-00-01 101 Aug 25/14
7 Aug 25/14 DISASSEMBLY 102 Aug 25/14
8 Aug 25/14 103 Aug 25/14
9 Aug 25/14 104 Aug 25/14
10 Aug 25/14 105 Aug 25/14
106 Aug 25/14
RECORD OF 1 Aug 25/15
REVISIONS 2 BLANK 49-00-01 601 Aug 25/14
CLEANING 602 Aug 25/14
RECORD OF 1 Aug 25/14 603 Aug 25/14
TEMPORARY 2 BLANK 604 Aug 25/14
REVISIONS 605 Aug 25/14
606 BLANK
LIST OF EFFECTIVE 1 Aug 25/15
PAGES 2 Aug 25/15 49-00-01 601 Aug 25/14
3 Aug 25/15 CLEANING 01 602 Aug 25/14
4 Aug 25/15 603 Aug 25/14
5 Aug 25/15 604 Aug 25/14
6 Aug 25/15 605 Aug 25/14
7 Aug 25/15 606 BLANK
8 Aug 25/15
9 Aug 25/15 49-00-01 601 Aug 25/14
10 BLANK CLEANING 02 602 Aug 25/14
603 Aug 25/14
TABLE OF CONTENTS 1 Aug 25/15 604 Aug 25/14
2 Aug 25/15 605 Aug 25/14
3 Aug 25/15 606 BLANK
4 Aug 25/15
5 Aug 25/15 49-00-01 601 Aug 25/14
6 Aug 25/15 CLEANING 03 602 Aug 25/14
7 Aug 25/15 603 Aug 25/14

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Subject Page Date Subject Page Date

604 Aug 25/14 49-00-01 601 Aug 25/14

CLEANING 11 602 Aug 25/14
49-00-01 601 Aug 25/14
CLEANING 04 602 Aug 25/14 49-00-01 601 Aug 25/14
603 Aug 25/14 CLEANING 12 602 Aug 25/14
604 BLANK
49-00-01 601 Aug 25/14
49-00-01 601 Aug 25/14 CLEANING 13 602 Aug 25/14
CLEANING 05 602 Aug 25/14 603 Aug 25/14
603 Aug 25/14 604 BLANK
604 Aug 25/14
605 Aug 25/14 49-00-01 601 Aug 25/14
606 Aug 25/14 CLEANING 14 602 Aug 25/14
607 Aug 25/14 603 Aug 25/14
608 Aug 25/14 604 BLANK
609 Aug 25/14
610 Aug 25/14 49-00-01 601 Aug 25/15
611 Aug 25/14 CLEANING 15 602 Aug 25/15
612 Aug 25/14 603 Aug 25/15
604 Aug 25/15
49-00-01 601 Aug 25/14 605 Aug 25/15
CLEANING 06 602 Aug 25/14 606 Aug 25/15
603 Aug 25/14 607 Aug 25/15
604 Aug 25/14 608 Aug 25/15
609 Aug 25/15
49-00-01 601 Aug 25/14 610 Aug 25/15
CLEANING 07 602 Aug 25/14
603 Aug 25/14 49-00-01 601 Aug 25/14
604 BLANK CLEANING 16 602 Aug 25/14

49-00-01 601 Aug 25/14 49-00-01 601 Aug 25/14

CLEANING 08 602 Aug 25/14 CLEANING 17 602 Aug 25/14
603 Aug 25/14
604 BLANK 49-00-01 601 Aug 25/14
CLEANING 18 602 Aug 25/14
49-00-01 601 Aug 25/14
CLEANING 09 602 Aug 25/14 49-00-01 601 Aug 25/14
603 Aug 25/14 CLEANING 19 602 Aug 25/14
604 Aug 25/14
49-00-01 601 Aug 25/14
49-00-01 601 Aug 25/14 CLEANING 20 602 Aug 25/14
CLEANING 10 602 Aug 25/14
49-00-01 601 Aug 25/14
CLEANING 21

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Subject Page Date Subject Page Date

602 Aug 25/14 49-00-01 601 Aug 25/14

CLEANING 34 602 Aug 25/14
49-00-01 601 Aug 25/14 603 Aug 25/14
CLEANING 22 602 Aug 25/14 604 Aug 25/14
605 Aug 25/14
49-00-01 601 Aug 25/14 606 BLANK
CLEANING 23 602 Aug 25/14
49-00-01 601 Aug 25/14
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CLEANING 24 602 Aug 25/14 603 Aug 25/14
603 Aug 25/14 604 BLANK
604 BLANK
49-00-01 601 Aug 25/14
49-00-01 601 Aug 25/14 CLEANING 36 602 Aug 25/14
CLEANING 25 602 Aug 25/14 603 Aug 25/14
604 Aug 25/14
49-00-01 601 Aug 25/14 605 Aug 25/14
CLEANING 26 602 Aug 25/14 606 BLANK

49-00-01 601 Aug 25/14 49-00-01 601 Aug 25/14

CLEANING 27 602 Aug 25/14 CLEANING 37 602 Aug 25/14
603 Aug 25/14
49-00-01 601 Aug 25/14 604 Aug 25/14
CLEANING 28 602 Aug 25/14
49-00-01 601 Aug 25/15
49-00-01 601 Aug 25/14 CLEANING 38 602 Aug 25/15
CLEANING 29 602 Aug 25/14 603 Aug 25/15
604 Aug 25/15
49-00-01 601 Aug 25/14 605 Aug 25/15
CLEANING 30 602 Aug 25/14 606 Aug 25/15
607 Aug 25/15
608 Aug 25/15
49-00-01 601 Aug 25/14
609 Aug 25/15
CLEANING 31 602 Aug 25/14
610 BLANK
603 Aug 25/14
604 BLANK
49-00-01 601 Aug 25/14
CLEANING 39 602 Aug 25/14
49-00-01 601 Aug 25/14
603 Aug 25/14
CLEANING 32 602 Aug 25/14
604 Aug 25/14
605 Aug 25/14
49-00-01 601 Aug 25/14
606 Aug 25/14
CLEANING 33 602 Aug 25/14
607 Aug 25/14
603 Aug 25/14
608 Aug 25/14
604 BLANK
609 Aug 25/14

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Subject Page Date Subject Page Date

610 BLANK 49-00-01 701 Aug 25/14

ADDITIONAL 702 Aug 25/14
49-00-01 601 Aug 25/14 STANDARD PRACTICES 703 Aug 25/14
CLEANING 40 602 Aug 25/14 704 Aug 25/14
603 Aug 25/14 705 Aug 25/14
604 Aug 25/14 706 BLANK

49-00-01 601 Aug 25/14 49-00-01 801 Aug 25/14

CLEANING 41 602 Aug 25/14 INSPECTION/CHECK 802 Aug 25/14
603 Aug 25/14 803 Aug 25/14
604 BLANK 804 Aug 25/14
805 Aug 25/14
49-00-01 601 Aug 25/14 806 Aug 25/14
CLEANING 42 602 Aug 25/14 807 Aug 25/14
603 Aug 25/14 808 Aug 25/14
604 BLANK
49-00-01 801 Aug 25/14
49-00-01 601 Aug 25/14 INSPECTION/CHECK 01 802 Aug 25/14
CLEANING 43 602 Aug 25/14
603 Aug 25/14 49-00-01 801 Aug 25/14
604 BLANK INSPECTION/CHECK 02 802 Aug 25/14
803 Aug 25/14
49-00-01 601 Aug 25/14 804 Aug 25/14
CLEANING 44 602 Aug 25/14 805 Aug 25/14
603 Aug 25/14 806 Aug 25/14
604 Aug 25/14 807 Aug 25/14
808 Aug 25/14
49-00-01 601 Aug 25/15 809 Aug 25/14
CLEANING 45 602 Aug 25/15 810 Aug 25/14
603 Aug 25/15 811 Aug 25/14
604 BLANK 812 Aug 25/14

49-00-01 601 Aug 25/14 49-00-01 801 Aug 25/14

CLEANING 46 602 Aug 25/14 INSPECTION/CHECK 03 802 Aug 25/14
603 Aug 25/14 803 Aug 25/14
604 Aug 25/14 804 Aug 25/14
805 Aug 25/14
49-00-01 601 Aug 25/14 806 BLANK
CLEANING 47 602 Aug 25/14
603 Aug 25/14 49-00-01 801 Aug 25/14
604 Aug 25/14 INSPECTION/CHECK 04 802 Aug 25/14
803 Aug 25/14
804 Aug 25/14
805 Aug 25/14
806 Aug 25/14

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Subject Page Date Subject Page Date

807 Aug 25/14 806 BLANK

808 Aug 25/14
809 Aug 25/14 49-00-01 801 Aug 25/14
810 Aug 25/14 INSPECTION/CHECK 12 802 Aug 25/14
811 Aug 25/14 803 Aug 25/14
812 Aug 25/14 804 Aug 25/14
813 Aug 25/14 805 Aug 25/14
814 Aug 25/14 806 Aug 25/14
815 Aug 25/14 807 Aug 25/14
816 Aug 25/14 808 Aug 25/14
809 Aug 25/14
49-00-01 801 Aug 25/14 810 BLANK
INSPECTION/CHECK 05 802 Aug 25/14
49-00-01 801 Aug 25/14
49-00-01 801 Aug 25/14 INSPECTION/CHECK 13 802 Aug 25/14
INSPECTION/CHECK 06 802 Aug 25/14
803 Aug 25/14 49-00-01 801 Aug 25/14
804 Aug 25/14 INSPECTION/CHECK 14 802 Aug 25/14

49-00-01 801 Aug 25/15 49-00-01 801 Aug 25/14

INSPECTION/CHECK 07 802 Aug 25/15 INSPECTION/CHECK 15 802 Aug 25/14
803 Aug 25/15
804 BLANK 49-00-01 801 Aug 25/14
INSPECTION/CHECK 16 802 Aug 25/14
49-00-01 801 Aug 25/14
INSPECTION/CHECK 08 802 Aug 25/14 49-00-01 801 Aug 25/14
803 Aug 25/14 INSPECTION/CHECK 17 802 Aug 25/14
804 BLANK
49-00-01 801 Aug 25/14
49-00-01 801 Aug 25/14 INSPECTION/CHECK 18 802 Aug 25/14
INSPECTION/CHECK 09 802 Aug 25/14 803 Aug 25/14
803 Aug 25/14 804 Aug 25/14
804 Aug 25/14
805 Aug 25/14 49-00-01 801 Aug 25/14
806 BLANK INSPECTION/CHECK 19 802 Aug 25/14
803 Aug 25/14
49-00-01 801 Aug 25/14 804 BLANK
INSPECTION/CHECK 10 802 BLANK
49-00-01 801 Aug 25/14
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INSPECTION/CHECK 11 802 Aug 25/14 803 Aug 25/14
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Subject Page Date Subject Page Date

49-00-01 801 Aug 25/14 903 Aug 25/14

INSPECTION/CHECK 21 802 Aug 25/14 904 BLANK
803 Aug 25/14
804 Aug 25/14 49-00-01 901 Aug 25/14
805 Aug 25/14 REPAIR 06 902 Aug 25/14
806 Aug 25/14 903 Aug 25/14
807 Aug 25/14 904 BLANK
808 Aug 25/14
809 Aug 25/14 49-00-01 901 Aug 25/14
810 Aug 25/14 REPAIR 07 902 Aug 25/14

49-00-01 801 Aug 25/14 49-00-01 901 Aug 25/14

INSPECTION/CHECK 22 802 BLANK REPAIR 08 902 Aug 25/14
903 Aug 25/14
49-00-01 801 Aug 25/14 904 BLANK
INSPECTION/CHECK 23 802 Aug 25/14
49-00-01 901 Aug 25/14
49-00-01 901 Aug 25/14 REPAIR 09 902 Aug 25/14
REPAIR 902 Aug 25/14 903 Aug 25/14
903 Aug 25/14 904 Aug 25/14
904 Aug 25/14
905 Aug 25/14 49-00-01 901 Aug 25/15
906 Aug 25/14 REPAIR 10 902 Aug 25/15
907 Aug 25/14 903 Aug 25/15
908 BLANK 904 Aug 25/15
905 Aug 25/15
49-00-01 901 Aug 25/14 906 Aug 25/15
REPAIR 01 902 Aug 25/14 907 Aug 25/15
903 Aug 25/14 908 Aug 25/15
904 Aug 25/14 909 Aug 25/15
910 Aug 25/15
49-00-01 901 Aug 25/14 911 Aug 25/15
REPAIR 02 902 Aug 25/14 912 Aug 25/15
903 Aug 25/14 913 Aug 25/15
904 BLANK 914 Aug 25/15
915 Aug 25/15
49-00-01 901 Aug 25/14 916 Aug 25/15
REPAIR 03 902 Aug 25/14 917 Aug 25/15
918 Aug 25/15
49-00-01 901 Aug 25/14 919 Aug 25/15
REPAIR 04 902 Aug 25/14 920 Aug 25/15
921 Aug 25/15
49-00-01 901 Aug 25/14 922 Aug 25/15
REPAIR 05 902 Aug 25/14 923 Aug 25/15
924 Aug 25/15

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Subject Page Date Subject Page Date

925 Aug 25/15 49-00-01 901 Aug 25/14

926 Aug 25/15 REPAIR 17 902 Aug 25/14
927 Aug 25/15
928 Aug 25/15 49-00-01 901 Aug 25/14
929 Aug 25/15 REPAIR 18 902 Aug 25/14
930 BLANK 903 Aug 25/14
904 Aug 25/14
49-00-01 901 Aug 25/14 905 Aug 25/14
REPAIR 11 902 Aug 25/14 906 Aug 25/14
903 Aug 25/14 907 Aug 25/14
904 Aug 25/14 908 Aug 25/14
905 Aug 25/14 909 Aug 25/14
906 BLANK 910 BLANK

49-00-01 901 Aug 25/14 49-00-01 901 Aug 25/14

REPAIR 12 902 Aug 25/14 REPAIR 19 902 Aug 25/14
903 Aug 25/14 903 Aug 25/14
904 Aug 25/14 904 Aug 25/14
905 Aug 25/14 905 Aug 25/14
906 Aug 25/14 906 BLANK

49-00-01 901 Aug 25/14 49-00-01 901 Aug 25/14

REPAIR 13 902 Aug 25/14 REPAIR 20 902 Aug 25/14
903 Aug 25/14 903 Aug 25/14
904 BLANK 904 BLANK

49-00-01 901 Aug 25/14 49-00-01 901 Aug 25/14

REPAIR 14 902 Aug 25/14 REPAIR 21 902 Aug 25/14
903 Aug 25/14 903 Aug 25/14
904 BLANK 904 Aug 25/14
905 Aug 25/14
49-00-01 901 Aug 25/14 906 Aug 25/14
REPAIR 15 902 Aug 25/14
903 Aug 25/14 49-00-01 901 Aug 25/14
904 Aug 25/14 REPAIR 22 902 Aug 25/14
905 Aug 25/14 903 Aug 25/14
906 Aug 25/14 904 Aug 25/14
905 Aug 25/14
49-00-01 901 Aug 25/14 906 Aug 25/14
REPAIR 16 902 Aug 25/14 907 Aug 25/14
903 Aug 25/14 908 Aug 25/14
904 Aug 25/14 909 Aug 25/14
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Subject Page Date Subject Page Date

49-00-01 901 Aug 25/14 49-00-01 901 Aug 25/14

REPAIR 24 902 Aug 25/14 REPAIR 32 902 Aug 25/14
903 Aug 25/14 903 Aug 25/14
904 BLANK 904 Aug 25/14

49-00-01 901 Aug 25/14 49-00-01 901 Aug 25/14

REPAIR 25 902 BLANK REPAIR 33 902 Aug 25/14
903 Aug 25/14
49-00-01 901 Aug 25/14 904 Aug 25/14
REPAIR 26 902 BLANK
49-00-01 901 Aug 25/14
49-00-01 901 Aug 25/14 REPAIR 34 902 Aug 25/14
REPAIR 27 902 BLANK 903 Aug 25/14
904 Aug 25/14
49-00-01 901 Aug 25/14 905 Aug 25/14
REPAIR 29 902 Aug 25/14 906 Aug 25/14
903 Aug 25/14
904 Aug 25/14 49-00-01 901 Aug 25/14
905 Aug 25/14 REPAIR 35 902 Aug 25/14
906 Aug 25/14 903 Aug 25/14
907 Aug 25/14 904 BLANK
908 Aug 25/14
909 Aug 25/14 49-00-01 901 Aug 25/14
910 BLANK REPAIR 36 902 Aug 25/14
903 Aug 25/14
49-00-01 901 Aug 25/14 904 Aug 25/14
REPAIR 30 902 Aug 25/14 905 Aug 25/14
903 Aug 25/14 906 Aug 25/14
904 Aug 25/14 907 Aug 25/14
905 Aug 25/14 908 BLANK
906 Aug 25/14
907 Aug 25/14 49-00-01 1001 Aug 25/15
908 BLANK ASSEMBLY 1002 Aug 25/15
1003 Aug 25/15
49-00-01 901 Aug 25/14 1004 Aug 25/15
REPAIR 31 902 Aug 25/14 1005 Aug 25/15
903 Aug 25/14 1006 Aug 25/15
904 Aug 25/14 1007 Aug 25/15
905 Aug 25/14 1008 Aug 25/15
906 Aug 25/14 1009 Aug 25/15
907 Aug 25/14 1010 Aug 25/15
908 BLANK 1011 Aug 25/15
1012 Aug 25/15
1013 Aug 25/15
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Subject Page Date

1015 Aug 25/15

1016 Aug 25/15
1017 Aug 25/15
1018 BLANK

49-00-01 1101 Aug 25/14

SERVICING 1102 Aug 25/14

49-00-01 1401 Aug 25/15

PRESERVATION 1402 Aug 25/15
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1404 Aug 25/15
1405 Aug 25/15
1406 Aug 25/15
1407 Aug 25/15
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1409 Aug 25/15
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TABLE OF CONTENTS

Chapter
Section
Subject Subject Task Page Effectivity
INTRODUCTION 1

AIRWORTHINESS LIMITATIONS 1

HOW TO USE 1

49-00-01- GENERAL 49-00 101

General 49-00-01 101
DISASSEMBLY 49-00-01 101
DISASSEMBLY -040-801 101
CLEANING 49-00-01 601
General -100-801 601
CLEANING 01 49-00-01 601
Degrease and Desmut for Assemblies That
Cannot Be Submerged -110-831 601
CLEANING 02 49-00-01 601
Cleaning and Treatment of the Nickel or the
Cobalt Base Heat-Resistant Alloys, and
Cleaning and Treatment of the Heat-Resistant
Austenic Steels with High Nickel Content
(Z12CND, KW20, Z3NCT25) -110-802 601
CLEANING 03 49-00-01 601
Cleaning and Treatment of the Martinized
Stainless Steels (Z12CN13, Z5CNU17-04,
Z8CND17-04, C12CNDV12, Z15CN17-03,
Z30C13 and the Austenitic Steels
(ZIOCNT18-11) -110-803 601
CLEANING 04 49-00-01 601
Cleaning and Treatment of the Low Alloy Steels
and the Carbon Steels, Cleaning and
Treatment of the Parts before the Metal Felt
Parts are Brazed, and Cleaning and Treatment
of the Stainless or the Heat-Resistant Steels
and the Alloys with a Coating -110-804 601
CLEANING 05 49-00-01 601
Cleaning of the Ball and Roller Bearing -110-805 601
CLEANING 06 49-00-01 601
Cleaning of the Carbon Seals -110-806 601
CLEANING 07 49-00-01 601
Cleaning of the Titanium Parts (Usual Method)
-110-807 601

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Chapter
Section
Subject Subject Task Page Effectivity
CLEANING 08 49-00-01 601
Cleaning of the Titanium Parts (Full Method)
-110-808 601
CLEANING 09 49-00-01 601
Cleaning of the Titanium Impellers -110-809 601
CLEANING 10 49-00-01 601
Flushing -110-810 601
CLEANING 11 49-00-01 601
Cleaning of the Metallic Parts - General -110-811 601
CLEANING 12 49-00-01 601
Degrease and Desmut -110-812 601
CLEANING 13 49-00-01 601
Removal of the Carbon and the Oxidation -110-813 601
CLEANING 14 49-00-01 601
Degrease and Desmut -110-814 601
CLEANING 15 49-00-01 601
Degrease -110-815 601
CLEANING 16 49-00-01 601
Degrease -110-816 601
CLEANING 17 49-00-01 601
Degrease the Parts Which Show FPI Fluid -110-817 601
CLEANING 18 49-00-01 601
Removal of the Stop-off (Green or White) -110-818 601
CLEANING 19 49-00-01 601
Deglass -110-819 601
CLEANING 20 49-00-01 601
Degrease and Desmut -110-820 601
CLEANING 21 49-00-01 601
Degrease and Desmut -110-821 601
CLEANING 22 49-00-01 601
Desmut -110-822 601
CLEANING 23 49-00-01 601
Degrease -110-823 601
CLEANING 24 49-00-01 601
FPI Preparation of the Rotor Assembly Parts
-110-824 601
CLEANING 25 49-00-01 601
Desmut the Rotor Assembly -110-825 601
CLEANING 26 49-00-01 601
FPI Preparation of the Rotor Assembly -110-826 601
CLEANING 27 49-00-01 601
Degrease and Desmut -110-827 601
CLEANING 28 49-00-01 601
Passivate -110-828 601

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Chapter
Section
Subject Subject Task Page Effectivity
CLEANING 29 49-00-01 601
Degrease the Parts Which Show FPI Fluid -110-829 601
CLEANING 30 49-00-01 601
Degrease -110-830 601
CLEANING 31 49-00-01 601
Cleaning of the Titanium Parts (Alternate
Method) -110-832 601
CLEANING 32 49-00-01 601
Cleaning of the Aluminum Parts -110-833 601
CLEANING 33 49-00-01 601
Stripping Coatings with High-pressure Water
Blasting -110-834 601
CLEANING 34 49-00-01 601
Cleaning of the Titanium Parts (Alternate
Method) -110-835 601
CLEANING 35 49-00-01 601
Cleaning of Internal Cores, Ports, Lubricating
Passages, and/or Orifices of the Gearbox
Housing Assemblies and Oil Cooler by Flushing
-110-836 601
CLEANING 36 49-00-01 601
One-Step Alkaline Rust Remover for Cleaning
Titanium Parts Only -110-837 601
CLEANING 37 49-00-01 601
One-Step Alkaline Rust Remover Long Soak
-110-838 601
CLEANING 38 49-00-01 601
Four Step Alkaline Rust Remover and Acidic
De-scaler with Inhibited Phosphoric Acid -110-839 601
CLEANING 39 49-00-01 601
Four Step Alkaline Rust Remover and Acidic
Descaler Without Inhibited Phosphoric Acid. -110-840 601
CLEANING 40 49-00-01 601
De-greasing by Solvent wipe -110-841 601
CLEANING 41 49-00-01 601
Degreasing With Alkaline Bath -110-842 601
CLEANING 42 49-00-01 601
De-greasing With Alkaline Bath and Rust
Remover -110-843 601
CLEANING 43 49-00-01 601
De-greasing With Alkaline Bath -110-844 601
CLEANING 44 49-00-01 601
De-greasing With Alkaline Permanganate Bath
-110-845 601

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Chapter
Section
Subject Subject Task Page Effectivity
CLEANING 45 49-00-01 601
Dry Plastic Blast -110-846 601
CLEANING 46 49-00-01 601
Dry Abrasive Grit Blast -110-847 601
CLEANING 47 49-00-01 601
Dry Abrasive Shell Blast -110-848 601
ADDITIONAL STANDARD PRACTICES 49-00-01 701
Fits and Clearances -870-801 701
Standard Tools, Fixtures, and Equipment -940-801 701
Illustrated Parts List (or Illustrated Parts
Catalog) - General -99F-801 704
INSPECTION/CHECK 49-00-01 801
INSPECTION/CHECK -200-801 801
INSPECTION/CHECK 01 49-00-01 801
Inspection of the Superficial Defects by
Binocular Glasses -220-801 801
INSPECTION/CHECK 02 49-00-01 801
Inspection of the Bearings -220-802 801
INSPECTION/CHECK 03 49-00-01 801
Magnetic Particle Inspection -240-801 801
INSPECTION/CHECK 04 49-00-01 801
Inspection of the Gears -220-808 801
INSPECTION/CHECK 05 49-00-01 801
Demagnetize and Measure the Remaining
Magnetic Field -280-801 801
INSPECTION/CHECK 06 49-00-01 801
Inspection of the Self-Locking Helical Coil
Inserts and the Self-Locking Nuts -220-804 801
INSPECTION/CHECK 07 49-00-01 801
Penetrant Inspection -230-801 801
INSPECTION/CHECK 08 49-00-01 801
Inspection of the Flatness by the Optical Flat
Method -220-805 801
INSPECTION/CHECK 09 49-00-01 801
Inspection of the Surface Temper -280-802 801
INSPECTION/CHECK 10 49-00-01 801
Inspection of the V-band Clamps -220-806 801
INSPECTION/CHECK 11 49-00-01 801
Inspection of the Coupling Ring -220-807 801
INSPECTION/CHECK 12 49-00-01 801
Eddy Current Inspection -250-801 801
INSPECTION/CHECK 13 49-00-01 801
Inspection of the Ignition Exciter -210-801 801

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Chapter
Section
Subject Subject Task Page Effectivity
INSPECTION/CHECK 14 49-00-01 801
Inspection of the Igniter Plugs -210-802 801
INSPECTION/CHECK 15 49-00-01 801
Inspection of the Thermocouples -210-803 801
INSPECTION/CHECK 16 49-00-01 801
Inspection of the Tube Assemblies -210-804 801
INSPECTION/CHECK 17 49-00-01 801
Reusable Low Strength Mechanical Fasteners
-210-805 801
INSPECTION/CHECK 18 49-00-01 801
Inspection of the Thrust Ball Bearings -210-806 801
INSPECTION/CHECK 19 49-00-01 801
Inspection of the Roller Bearings -210-807 801
INSPECTION/CHECK 20 49-00-01 801
Inspection of the Silicone Fire Sleeved Hose
Assembly -210-808 801
INSPECTION/CHECK 21 49-00-01 801
Curvic Inspection Procedure -210-811 801
INSPECTION/CHECK 22 49-00-01 801
Inspection of the Electrical Connector and
Contact Pins -210-809 801
INSPECTION/CHECK 23 49-00-01 801
Inspection of the Tube Assemblies -210-810 801
REPAIR 49-00-01 901
General -300-801 901
REPAIR 01 49-00-01 901
Replacement of the Threaded Inserts -350-801 901
REPAIR 02 49-00-01 901
Cleaning and Treatment of Magnesium
Corrosion -380-801 901
REPAIR 03 49-00-01 901
Cleaning and Treatment of Aluminum
Corrosion -380-802 901
REPAIR 04 49-00-01 901
Repair of the Protective Finish -380-803 901
REPAIR 05 49-00-01 901
Surface Polishing -320-801 901
REPAIR 06 49-00-01 901
Chromating of the Aluminum Alloys -380-804 901
REPAIR 07 49-00-01 901
Removal of the Nicks, the Scratches and the
Burrs -350-802 901
REPAIR 08 49-00-01 901
Replacement of the Pins/Studs -350-803 901

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Chapter
Section
Subject Subject Task Page Effectivity
REPAIR 09 49-00-01 901
Replacement of the Components with a Layer
of Loctite -360-801 901
REPAIR 10 49-00-01 901
Application of Plasma and Flame Spraying -340-801 901
REPAIR 11 49-00-01 901
Bonding of the Abradable Felts -360-802 901
REPAIR 12 49-00-01 901
Instructions to Apply the Chromium Plating -330-801 901
REPAIR 13 49-00-01 901
Bonding with Araldite Compound -360-803 901
REPAIR 14 49-00-01 901
Weld Repair -310-801 901
REPAIR 15 49-00-01 901
Runout and Balance of the Engine Rotor -350-804 901
REPAIR 16 49-00-01 901
Shank Nut Repair -350-805 901
REPAIR 17 49-00-01 901
Anchor Nut Repair -350-806 901
REPAIR 18 49-00-01 901
Installation of the Oversized Threaded Inserts
in the Reduction Drive Assemblies -350-807 901
REPAIR 19 49-00-01 901
Installation of the Oversized Threaded Inserts
-350-808 901
REPAIR 20 49-00-01 901
Replacement of the Oil (Lee™) Jets and Oil
(Lee™) Plugs -350-809 901
REPAIR 21 49-00-01 901
Repair of the Silicone Fire Sleeved Hose
Assemblies -360-804 901
REPAIR 22 49-00-01 901
Removal and Installation of the Cherrylock
Rivets -350-814 901
REPAIR 24 49-00-01 901
Standard Fiberglass Composite Repair -360-805 901
REPAIR 25 49-00-01 901
Fiberglass Composite Repair -360-806 901
REPAIR 26 49-00-01 901
Fiberglass Composite Repair -360-807 901
REPAIR 27 49-00-01 901
Fiberglass Composite Repair -360-808 901

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Chapter
Section
Subject Subject Task Page Effectivity
REPAIR 29 49-00-01 901
Replacement of the Damaged Connector Pins
-350-810 901
REPAIR 30 49-00-01 901
Repair of Wire by Splicing -350-811 901
REPAIR 31 49-00-01 901
Repair of the Aluminum or Magnesium Gearbox
Housing Threaded Port(s) -320-802 901
REPAIR 32 49-00-01 901
Replacement of the Nut Plates on Oil Cooler
-320-803 901
REPAIR 33 49-00-01 901
Replacement of the Nut Plates on Attenuator
-310-802 901
REPAIR 34 49-00-01 901
Repair of the Wire Terminal Ends by
Replacement -350-812 901
REPAIR 35 49-00-01 901
Bonding Repair with Hysol Epoxy EA 9394
Adhesive -360-809 901
REPAIR 36 49-00-01 901
Replacement of the Damaged Rosan™ Inserts
and Lockrings -350-813 901
ASSEMBLY 49-00-01 1001
ASSEMBLY -400-801 1001
Installation of Harness on Engine. Wrapping
Harness Connectors with Self-Bonding Silicone
Tape -400-802 1016
SERVICING 49-00-01 1101
SERVICING -610-801 1101
PRESERVATION 49-00-01 1401
On-Wing Preservation of the Auxiliary Power
Unit -620-801 1401
Off-Wing Preservation of the Auxiliary Power
Unit -620-802 1404
De-preservation of the Auxiliary Power Unit -620-803 1408

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INTRODUCTION

1. General

A. The Standard Practices Manual for Auxiliary Power Units (49-00-01) issued by Auxiliary
Power International Corporation (APIC) and the Standard Practices Manual for Common
Standard Practices for Auxiliary Power Units (49-00-01) issued by Hamilton Sundstrand
Power Systems, have been combined to form this Standard Practices Manual, Document
Number HSPS 490001 for both APIC and Hamilton Sundstrand. Refer to Cleaning,
Inspection/Check, and Repair sections of this manual to locate and cross reference the
procedures from these two former manuals.

B. This manual provides standard practices and procedures used during repair or
maintenance of all Auxiliary Power Units (APUs). Specific instructions for each APU are
provided in the applicable engine manual.

C. This manual is intended to be used in conjunction with the engine manual for the APU being
maintained or repaired. The manual is applicable to all APUs manufactured by Hamilton
Sundstrand Power Systems.

D. The APU is supplied by Hamilton Sundstrand Power Systems, a United Technologies

Company, located at 4400 Ruffin Rd., P.O. Box 85757, San Diego, CA, 92186-5757, USA.

E. Action Item System

(1) Hamilton Sundstrand Corporation (HSC) used a controlled Action Item (AI) document
system to make changes to HSC Component Maintenance Manuals (CMMs). The AI
System is documented and controlled through HSC’s manufacturing FAA Part 21-
approved Quality Management System, and therefore, qualifies as approved
manufacturer’s data for continued airworthiness. HSC authorized the use of HSC-
issued Action Items as supplements to HSC CMMs. Certain AI's may subsequently
be incorporated into the CMM through the regular manual revision process. HSC also
uses the AI system to provide CMM clarifications without incorporating its contents
into the CMM.

(2) HSC also uses the AI System to document “No Technical Objections” for specific
deviations from the CMM. A “No Technical Objection” AI is not “approved
manufacturer’s data,” but may be used to obtain approval of the data from the local
airworthiness authority.

(3) Contact your Hamilton Sundstrand Field Service Representative for further
information regarding AIs.

2. Ordering of Parts

A. Direct all orders for spare parts to the address below:

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Hamilton Sundstrand
4747 Harrison Avenue, P.O. Box 7002
Rockford, IL 61125-7002 USA
Attention: Customer Service Spares and Administration

3. Ordering Copies of Publications

A. Requests for copies of publications should be directed to the address shown above.

4. Reference Publications

A. The standard practices and commercial standards given below provide shop practices that
may be used to maintain components of the APU.

Manual Number Nomenclature Type

24-10-00 Standard Practices Manual for Generator Drives and SPM
Related Equipment
Bulletin 985 Common Standard Practices for Fluid Systems SPM
Equipment
IPC-7711 Rework of Electronic Assemblies, dated February, IPC
1998
IPC-7721 Repair and Modification of Printed Boards and IPC
Electronic Assemblies, dated March, 2000

5. Support Equipment, Consumables, and Expendable Parts

A. Required support equipment, consumables, and expendable parts are listed in each of the
cleaning, inspection/check, and repair sections of this publication.

6. List of Abbreviations

A. The following abbreviations and a list of repair symbols (refer to REPAIR) are used in this
publication.

Abbreviation Definition
A/m amperes per meter
APU auxiliary power unit
AR as required (IPL)
ASSY assembly
ATA Air Transport Association
C Celsius
EFF effectivity

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Abbreviation Definition
F Fahrenheit
FIG. Figure
FPI Fluorescent Penetrant Inspection
gal gallon
g/l grams per liter
in. inch
IPL Illustrated Parts List
kPa kilopascal
KSI kinetic strength index
l liter
ml milliliter
mm millimeters
N•m newton meters
No. number
OD outside diameter
oz ounce
P/N Part number
RF reference
Vdc volts direct current
% percent
+ plus
± plus or minus
° degree
# number
Ω Ohm
m Meter
Ω/m ohm-metre
µS micro-Siemens

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Abbreviation Definition
cm centimeter
pH power of hydrogen

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AIRWORTHINESS LIMITATIONS

1. Not applicable. Please see the engine manual for your specific model APU for the airworthiness
limitations.

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HOW TO USE

1. Not Applicable.

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DISASSEMBLY

TASK 49-00-01-040-801
1. DISASSEMBLY

A. General

(1) This section gives the general procedures necessary to do the disassembly common
to all the Auxiliary Power Units (APUs). The disassembly of the APU must be kept to
the level necessary to correct the faults. Use the engine manual for full instructions
for the specified disassembly. Read all of the notes, cautions and warnings carefully
to prevent equipment damage and personal injury.

B. Disassembly Index

(1) The index, gives the standard disassembly procedures of this manual. (Refer to Table
101).

Table 101
Disassembly Index

Description Page Number

General Procedures 102
General Disassembly Practices 102
Work Area 102
Marking of Parts 103
Lockwire 104
Heat 104
Standard Tools 104
Magnetic Drain Plug 105
Removal of Dowel Pins, Studs or Roll Pins 105
Removal of Helical Inserts 105
Removal of Bearing Liners 105
Removal of Orifice Plugs 105
Removal of Loctited Parts 105
Identification Plates 106
Cleaning 106
Lubrication after Disassembly 106

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C. General Procedures

(1) Put each disassembled part on a clean workbench in the order of the disassembly in
preparation for the cleaning and the inspection. Keep the hardware and the small parts
together in the trays.

(2) Put the correct coverings on the supports to protect the shafts, the gears, the studs
and the protecting parts from damage.

(3) Do not use steel or lead hammers directly on the assemblies or their parts. Use the
cellulose-tipped hammers and the fiber or rawhide mallets as specified. Do not clamp
the parts directly in the steel jaws of a bench vice. Use a vice which has micarta jaws
(or equivalent).

(4) After the disassembly, spray the steel parts with lubricating oil, VV-L-800. Cover all
the parts with clean paper or correct coverings unless the cleaning or the inspection
is to be done immediately.

(5) Do not disassemble the tube assemblies, the hose assemblies, the wiring harness
assemblies, the riveted assemblies, the staked parts or the press-fit parts (this does
not include the seals and the bearings).

(6) Do not remove the nameplates, the modification plates, the lubrication plates, the
decals, the studs, the stud lockrings or the thread inserts, unless written in the text or
necessary for the replacement of a part.

(7) Always keep the ports, the bores and the passages of the assemblies or the
components sealed with the applicable closures between the repair procedures. Put
a cover on the large openings which must be safe tied.

NOTE: Do not use tape to seal the openings or the connections on the fuel or
lubrication system components.

(8) During the different stages of the disassembly, examine all the parts and assemblies
for signs of scoring, burning, or other defects.

(9) Tag the parts before they are cleaned and laid out for the detail inspection. Do a check
for evidence of damage caused by incorrect repair procedures. Write such damage
in accordance with the current practice.

(10) All the seals, gaskets, preformed packings, tabwashers, lockpins and lockwire are to
be discarded when removed and replaced with new items.

D. General Disassembly Practices

(1) Work Area

(a) The APU must be repaired in a workshop that is well-lighted and has no dust.
During the repair, a drip pan must be put under the APU to prevent oil drippings
in the work area.

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(b) If the repair is to be stopped for an extended period of time, apply a light layer
of lubricating oil, VV-L-800 or equivalent to all the parts to prevent corrosion.
Then, seal the assembly.
(c) The bench used for the disassembly of the APU must be installed at least 25
feet from all the grit-and-chip-producing operations (lapping and fine stoning are
permitted). If the disassembly is stopped for any cause, the APU must be sealed
with an applicable cover. All the ports and tubes must be sealed or have a cap
(as applicable).

(2) Marking of parts

(a) General

1 The marking of the parts is a procedure used to identify the parts by

marking directly on the part, by tagging or by marking a container.

2 The letters must be Gothic capitals and numerals. The letters must be of
a correct dimension to be read easily.

3 The parts for which it is not possible to do the marking must be tagged or
have a marked container.

(b) Procedure

1 The impression marking must only be used on the name plates and on the
non-stressed, and the non-critical sheet metal parts.

2 The rubber stamp marking must be applied to clean, dry surfaces, with a
contrasting, non-conducting ink (with no oil).

a Waterproof inks must not be applied to the painted surfaces or the

surface finish.

b Inks must be removed from the parts before the heat treatment.

3 The stencil marking must be used for the containers but it can be used on
the large external parts with a sufficient surface.

4 The electro-chemical marking must be done with a stencil or by an

electrolytic marking pen. The electro-chemical markings must not be done
after the surface treatment of a part.

5 The acid etch marking must be used carefully to prevent personnel injury
and damage to the part. When the marking can be read, clean the area
with an acid which has a neutral agent and fully flush and dry. Apply
preservative oil to prevent corrosion.

6 The decalcomania marking of the parts must be done only after the
procedures are completed. Use a clear overspray, such as Scotchlite No.
700 clear spray, to give a protective film.

DISASSEMBLY
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7 The tagging of the parts must be done with paper, cloth or metal tags, safe
tied to the part with a non-corroding wire.
8 The electric arc pencil marking has an effect only on iron and steel alloy
parts. The marking must be applied before you apply the protective
finishes.

9 The machine marking of the electric wire must be, at a minimum, on each
end of the wires with a length greater than 2 inches.

10 The high or the low temperature of the marker system (Raychem Thermofit)
is a different procedure for the wire identification.

11 The vibro-etching marking with a hand-held vibration-pencil can be used

on most of the materials. This marking must be used only in the areas of
low stress.

12 The laser etching marking is done by moving material with a laser beam.
The depth is controlled by a change in the pulse rate of the beam, the speed
of advance, the focus and the power. This procedure must be used only in
the areas of low stress.

(c) Lockwire

1 Wear eye protection and put your hand on the wire when the lockwire is
cut. The wire cuttings must not go into the assemblies or the parts. Discard
all lockwire.

(d) Heat

WARNING: USE GLOVES WITH HEAT-RESISTANT INSULATION AND

PROTECTION CLOTHES TO PREVENT BURNS FROM VERY
HOT PARTS.

1 Unless the instructions tell you to do differently, use a heat gun for local
heating. You can get a constant heat pattern if you keep the heat source
moving equally.

2 The instructions for an oven heat are given in the engine manual.

(e) Standard Tools

1 Always use the correct tool. If the correct tool is not used, the parts can be
damaged.

2 Make sure the wrenches are put correctly on the nuts or the bolt heads.

3 Use the screwdriver with the correct dimension on the screws.

4 Do not use a pair of pliers to remove the nuts, the screws or the bolts.

DISASSEMBLY
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5 Do not use the screwdrivers or other hard faced tools to divide the mating
housings or for prying. A soft-faced rod or mallet can be used for tapping
around a binding area.
6 Do not use the brass or the copper drift rods for tapping. The flakes from
these rods can cause an internal damage during the APU operation. If a
job requires the use of a drift rod, use a rod made of mild steel. Mild steel
rods will not chip or flake.

7 If you use a pair of pliers or a vice to hold small, round, slippery objects,
do a protection of the parts to prevent damage. Seal with soft materials
such as cloth or use the brass or the copper jaws.

(f) Magnetic Drain Plug

1 Before you remove the plugs to drain the APU, examine the magnetic drain
plug. Refer to the CHECK section of the engine manual.

(g) Removal of the Dowel Pins, the Studs or the Roll Pins

1 Do not remove the dowel pins, the studs or the roll pins unless they are
damaged (or if it is necessary to remove them for the repair). If the pins,
the studs or the roll pins are damaged and have to be replaced, refer to the
REPAIR section of the engine manual.

(h) Removal of the Helical Inserts

1 Do not remove the helical inserts unless they are damaged. If removal is
necessary, refer to the REPAIR section of this manual.

(i) Removal of the Bearing Liners

1 The bearing liners can be repaired. Refer to the REPAIR section of the
engine manual and/or the component maintenance manual.

(j) Removal of the Orifice Plugs

1 Do not remove the orifice plugs unless they are damaged (or if it is
necessary to clean the internal bores located under the plugs). If
necessary, refer to the REPAIR section of the engine manual for the
removal.

(k) Removal of the Loctited Parts

1 The parts that are safe tied by loctite retaining compound can be removed,
refer to the REPAIR section of the engine manual and/or the component
maintenance manual.

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(l) Identification Plates

1 Do not remove the identification plates unless they are damaged or unless
information is to be shown on them. If the marking of the information is
done with a vibro-etch or an air pencil, it is not necessary to remove these
plates. If the information is to be steel-stamped, remove the plate(s) before
the stamping to prevent damage to the housing.

(m) Cleaning

1 After the disassembly, all of the APU parts must be cleaned. Refer to the
CLEANING section of the engine manual and/or the component
maintenance manual.

2 Checks of cleaning solutions for proper titration should be done on a

scheduled recurring basis. Each facility should conduct these checks
based on the manufacturer’s recommendation.

3 Checks of cleaning equipment for proper operation and condition should

be done on a scheduled recurring basis. Each facility should conduct these
checks based on the manufacturer’s recommendation.

(n) Lubrication after Disassembly

1 If you do not examine the parts immediately after the disassembly, make
sure each part is lubricated with oil, VV-L-800 or equivalent (when
necessary), and has a protection to prevent corrosion.

DISASSEMBLY
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CLEANING

TASK 49-00-01-100-801
1. General

A. General

(1) This section gives the general procedures and safety solutions for the cleaning.

(2) Use the engine manual and/or the component maintenance manual for the full
explanations of the cleaning procedures.

(3) (Refer to Table 601), to locate and cross reference the cleaning procedures from
Standard Practices Manual for Auxiliary Power Units (49-00-01) issued by Auxiliary
Power International Corporation (APIC) and Standard Practices Manual for Common
Standard Practices for Auxiliary Power Units (49-00-01) issued by Hamilton
Sundstrand.

Table 601
Cross Reference of Cleaning Procedures

APS2000 /APS2100 /APS3200 APS500/APS1000 HSPS 490001

CLEANING CLEANING
CLEANING-01 CLEANING-07 AND -11
CLEANING-SP-223 CLEANING-01
CLEANING-02 CLEANING-02
CLEANING-03 CLEANING-03
CLEANING-04 CLEANING-04
CLEANING-05 CLEANING-SP-224 CLEANING-05
CLEANING-06 CLEANING-06
CLEANING-07 CLEANING-SP-202 CLEANING-07
CLEANING-08 CLEANING-SP-202 CLEANING-08
CLEANING-09 CLEANING-09
CLEANING-10 CLEANING-SP-203 CLEANING-10
CLEANING-SP-201 CLEANING-11
CLEANING-SP-204 CLEANING-12
CLEANING-SP-205 CLEANING-13
CLEANING-SP-206 CLEANING-14

CLEANING
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APS2000 /APS2100 /APS3200 APS500/APS1000 HSPS 490001

CLEANING-SP-207 CLEANING-15
CLEANING-SP-208 CLEANING-16
CLEANING-SP-209 CLEANING-17
CLEANING-SP-210 CLEANING-18
CLEANING-SP-211 CLEANING-19
CLEANING-SP-212 CLEANING-20
CLEANING-SP-213 CLEANING-21
CLEANING-SP-214 CLEANING-22
CLEANING-SP-215 CLEANING-23
CLEANING-SP-216 CLEANING-24
CLEANING-SP-217 CLEANING-25
CLEANING-SP-218 CLEANING-26
CLEANING-SP-219 CLEANING-27
CLEANING-SP-220 CLEANING-28
CLEANING-SP-221 CLEANING-29
CLEANING-SP-222 CLEANING-30

B. Standard Cleaning Procedures

(1) For a list of the standard cleaning procedures specified in this manual, (Refer to Table
602).

Table 602
List of Standard Cleaning Procedures

Cleaning Task Number

CLEANING 01 (Refer to TASK 49-00-01-110-831, Degrease and Desmut for
Assemblies That Cannot Be Submerged)
CLEANING 02 (Refer to TASK 49-00-01-110-802, Cleaning and Treatment of the Nickel
or the Cobalt Base Heat-Resistant Alloys, and Cleaning and Treatment
of the Heat-Resistant Austenic Steels with High Nickel Content
(Z12CND, KW20, Z3NCT25))

CLEANING
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Cleaning Task Number

CLEANING 03 (Refer to TASK 49-00-01-110-803, Cleaning and Treatment of the
Martinized Stainless Steels (Z12CN13, Z5CNU17-04, Z8CND17-04,
C12CNDV12, Z15CN17-03, Z30C13 and the Austenitic Steels
(ZIOCNT18-11))
CLEANING 04 (Refer to TASK 49-00-01-110-804, Cleaning and Treatment of the Low
Alloy Steels and the Carbon Steels, Cleaning and Treatment of the Parts
before the Metal Felt Parts are Brazed, and Cleaning and Treatment of
the Stainless or the Heat-Resistant Steels and the Alloys with a Coating)
CLEANING 05 (Refer to TASK 49-00-01-110-805, Cleaning of the Ball and Roller
Bearing)
CLEANING 06 (Refer to TASK 49-00-01-110-806, Cleaning of the Carbon Seals)
CLEANING 07 (Refer to TASK 49-00-01-110-807, Cleaning of the Titanium Parts (Usual
Method))
CLEANING 08 (Refer to TASK 49-00-01-110-808, Cleaning of the Titanium Parts (Full
Method))
CLEANING 09 (Refer to TASK 49-00-01-110-809, Cleaning of the Titanium Impellers)
CLEANING 10 (Refer to TASK 49-00-01-110-810, Flushing)
CLEANING 11 (Refer to TASK 49-00-01-110-811, Cleaning of the Metallic Parts -
General)
CLEANING 12 (Refer to TASK 49-00-01-110-812, Degrease and Desmut)
CLEANING 13 (Refer to TASK 49-00-01-110-813, Removal of the Carbon and the
Oxidation)
CLEANING 14 (Refer to TASK 49-00-01-110-814, Degrease and Desmut)
CLEANING 15 (Refer to TASK 49-00-01-110-815, Degrease)
CLEANING 16 (Refer to TASK 49-00-01-110-816, Degrease)
CLEANING 17 (Refer to TASK 49-00-01-110-817, Degrease the Parts Which Show FPI
Fluid)
CLEANING 18 (Refer to TASK 49-00-01-110-818, Removal of the Stop-off (Green or
White))
CLEANING 19 (Refer to TASK 49-00-01-110-819, Deglass)
CLEANING 20 (Refer to TASK 49-00-01-110-820, Degrease and Desmut)
CLEANING 21 (Refer to TASK 49-00-01-110-821, Degrease and Desmut)

CLEANING
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Cleaning Task Number

CLEANING 22 (Refer to TASK 49-00-01-110-822, Desmut)
CLEANING 23 (Refer to TASK 49-00-01-110-823, Degrease)
CLEANING 24 (Refer to TASK 49-00-01-110-824, FPI Preparation of the Rotor
Assembly Parts)
CLEANING 25 (Refer to TASK 49-00-01-110-825, Desmut the Rotor Assembly)
CLEANING 26 (Refer to TASK 49-00-01-110-826, FPI Preparation of the Rotor
Assembly)
CLEANING 27 (Refer to TASK 49-00-01-110-827, Degrease and Desmut)
CLEANING 28 (Refer to TASK 49-00-01-110-828, Passivate)
CLEANING 29 (Refer to TASK 49-00-01-110-829, Degrease the Parts Which Show FPI
Fluid)
CLEANING 30 (Refer to TASK 49-00-01-110-830, Degrease)
CLEANING 31 (Refer to TASK 49-00-01-110-832, Cleaning of the Titanium Parts
(Alternate Method))
CLEANING 32 (Refer to TASK 49-00-01-110-833, Cleaning of the Aluminum Parts)
CLEANING 33 (Refer to TASK 49-00-01-110-834, Stripping Coatings with High-
pressure Water Blasting)
CLEANING 34 (Refer to TASK 49-00-01-110-835, Cleaning of the Titanium Parts
(Alternate Method))
CLEANING 35 (Refer to TASK 49-00-01-110-836, Cleaning of Internal Cores, Ports,
Lubricating Passages, and/or Orifices of the Gearbox Housing
Assemblies and Oil Cooler by Flushing)
CLEANING 36 (Refer to TASK 49-00-01-110-837, One-Step Alkaline Rust Remover for
Cleaning Titanium Parts Only)
CLEANING 37 (Refer to TASK 49-00-01-110-838, One-Step Alkaline Rust Remover
Long Soak)
CLEANING 38 (Refer to TASK 49-00-01-110-839, Four Step Alkaline Rust Remover
and Acidic De-scaler with Inhibited Phosphoric Acid)
CLEANING 39 (Refer to TASK 49-00-01-110-840, Four Step Alkaline Rust Remover
and Acidic Descaler Without Inhibited Phosphoric Acid.)
CLEANING 40 (Refer to TASK 49-00-01-110-841, De-greasing by Solvent wipe)
CLEANING 41 (Refer to TASK 49-00-01-110-842, Degreasing With Alkaline Bath)

CLEANING
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Cleaning Task Number

CLEANING 42 (Refer to TASK 49-00-01-110-843, De-greasing With Alkaline Bath and
Rust Remover)
CLEANING 43 (Refer to TASK 49-00-01-110-844, De-greasing With Alkaline Bath )
CLEANING 44 (Refer to TASK 49-00-01-110-845, De-greasing With Alkaline
Permanganate Bath)
CLEANING 45 (Refer to TASK 49-00-01-110-846, Dry Plastic Blast)
CLEANING 46 (Refer to TASK 49-00-01-110-847, Dry Abrasive Grit Blast)
CLEANING 47 (Refer to TASK 49-00-01-110-848, Dry Abrasive Shell Blast)

CLEANING
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CLEANING
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CLEANING 01

TASK 49-00-01-110-831
1. Degrease and Desmut for Assemblies That Cannot Be Submerged

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Hand Gun, Pressure Rinse Commercially Available
Circulating Air Dryer Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Simple Green All-Purpose Cleaner Sunshine Makers, Inc.
(1Z575)
Extreme Simple Green Aircraft & Sunshine Makers, Inc.
Precision Cleaner (1Z575)
Ardrox 6077 Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)

CLEANING 01
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Part No./Spec. No. Source (CAGE Code)

Ardrox 6333A Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemethall PLC
(K6858)
Chemetall Chemical Products Inc
(02CA7)
Ardrox 6333 Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
Blue Gold Industrial Cleaner Modern Chemical Inc.
(0GA37)
Blue Gold Spray Wash (low foam) Modern Chemical Inc.
(0GA37)
Cee-Bee A-7X7 MC Gean-Rohco Incdiv Cee-Bee
Aviation Division DBA Cee-Bee Aviation
(71361)
Cee-Bee 300LF MC Gean-Rohco Incdiv Cee-Bee
Aviation Division DBA Cee-Bee Aviation
(71361)
Cee-Bee 300LFG MC Gean-Rohco Incdiv Cee-Bee
Aviation Division DBA Cee-Bee Aviation
(71361)
ED-306LF L Dorado Chemical Company Inc
(0HM34)
Mag-Chem DG Kleen Magnus Chemicals Ltd
(35502)
Mag-Chem Evasol Magnus Chemicals Ltd
(35502)
Mirachem 500 Mirachem, LLCDBA
(63247)

CLEANING 01
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Part No./Spec. No. Source (CAGE Code)

Mirachem 750 Mirachem, LLCDBA
(63247)
MC Spray & Wipe Modern Chemical Inc.
(0GA37)
Nuvite NuGear SC Nuvite Chemical Compounds Corporation
(1EYE7)
Turco 5948 DPM Henkel Corp
(71410)
Turco 6780 Henkel Corp
(71410)
Turco Liquid Sprayeze HP LT Henkel Corp
(71410)
Scotch Brite (3M - #96) Very Fine Commercially Available
or
Nylon Brush

(3) Expandable Parts

None

SUBTASK 49-00-01-110-001
E. Cleaning

NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

(1) Aqueous Spray or Wipe (with rising).

CAUTION: DO NOT USE NUVITE NU-GEAR CLEANING SOLUTION ON

MAGNESIUM PARTS THAT DO NOT HAVE CHROMATE
CONVERSION COATING. THIS SOLUTION WILL CAUSE A SMUT TO
FORM ON THE SURFACE OF THE MAGNESIUM PART.

(a) Install the protective plates on the assembly.

(b) Use one of the aqueous cleaner solutions shown, (Refer to Table 601).

CLEANING 01
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Table 601

Temperature
Make-up by Operating limit’s by
Material Volume Volume °F °C
Blue Gold Industrial 25% 20-30% Room Room
Cleaner
Blue Gold Spray 4% 2.5-5.5% Room Room
Wash (low foam)
Ardrox 6333 20% 10-20% Room Room
Ardrox 6333A 10% 5-20% Room Room
ED-306LF 25% 10-25% Room Room
Cee-Bee A-7X7 25% 15-25% Room Room
Cee-Bee 300LF 10% 5-10% Room Room
Cee-Bee 300LFG 10% 5-10% Room Room
Mag-Chem DG Kleen 20% 15-20% Room Room
Mirachem 500 50% 25-50% Room Room
Mirachem 750 33% 25-33% Room Room
Nuvite Nu-Gear SC 25% 20-25% Room Room
Turco 5948 DPM 25% 15-25% Room Room
Turco Liquid 25% 15-25% Room Room
Sprayeze NP-LTA

(c) Shake cleaner solution before use.

(d) Spray part and wipe or scrub with clean cloth, nylon brush or scotch brite (3M -
#96 very fine) wet with solution.

NOTE: Prevent getting the cleaning solution inside the gear boxes.

WARNING: PUT ON THERMALLY-INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

(e) Flush the part with 150 to 200°F (66 to 93°C) hot water until the temperature of
the part is at the temperature of the water to flash dry.

(f) Pressure rinse the part with the hand gun for 3 to 5 minutes.

CLEANING 01
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WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS,

MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30
POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT
DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS.
PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES.
THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR
DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET
MEDICAL ATTENTION.

(g) Air dry the part with the circulating dryer at 100 to 150°F (38 to 66°C) for 5 to 15
minutes.

(2) Aqueous Spray or Wipe (without rinsing).

(a) Spray or wipe part using a clean cloth, wet with cleaning solution, (Refer to Table
602). Solution concentration is “as-received”. If necessary scrub with nylon
brush or scotch brite pad.

(b) Wipe dry using a clean cloth.

Table 602
Cleaning Solutions

Material
Simple Green
Ardrox 6077
Mag-Chem Evasol
MC Spray & Wipe
Turco 6780

CLEANING 01
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CLEANING 01
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CLEANING 02

TASK 49-00-01-110-802
1. Cleaning and Treatment of the Nickel or the Cobalt Base Heat-Resistant Alloys, and Cleaning
and Treatment of the Heat-Resistant Austenic Steels with High Nickel Content (Z12CND, KW20,
Z3NCT25)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts
HSPS 490001 Task 49-00-01-110-804 Cleaning and Treatment of
the Low Alloy Steels and the
Carbon Steels, Cleaning and
Treatment of the Parts before
the Metal Felt Parts are
Brazed, and Cleaning and
Treatment of the Stainless or
the Heat-Resistant Steels
and the Alloys with a Coating

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Spray-Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

CLEANING 02
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Part No./Spec. No. Source (CAGE Code)

Nylon Brush Commercially Available
Ardrox 185/4 Brent SA
Concentration: 40% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Ardrox 1871 Brent SA
Concentration: 20% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Ardrox 1873 Brent SA
Concentration: 20% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Ardrox 188 Brent SA
Concentration: 160 g/l 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Turco 4181 Turco France SA
Concentration: 50% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4181L Turco France SA
Concentration: 50% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4931 Turco France SA
Concentration: 100 g/ 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4338/C Turco France SA
Concentration: 300 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4409 Turco France SA
Concentration: 50% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France

(3) Expandable Parts

None

SUBTASK 49-00-01-110-002
E. Procedure with an Ardrox bath (first method)

CLEANING 02
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WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CAUTION: DO NOT USE THIS PROCEDURE TO CLEAN THE PARTS WHICH HAVE
ONE OF THESE COATINGS: NICKEL-TUNGSTEN APPLIED WITH SWAB
(SELECTION), CHEMICAL NICKEL, CHROMIUM PLATING
METALLISATION OF TUNGSTEN/COBALT CARIBE. TO CLEAN THESE
PARTS, REFER TO REFERENCE INFORMATION FOR CLEANING AND
TREATMENT OF THE LOW ALLOY STEELS AND THE CARBON STEELS,
CLEANING AND TREATMENT OF THE PARTS BEFORE THE METAL
FELT PARTS ARE BRAZED, AND CLEANING AND TREATMENT OF THE
STAINLESS OR THE HEAT-RESISTANT STEELS AND THE ALLOYS WITH
A COATING.

(1) If necessary, remove the grease with a chlorinated solvent or an alkaline solvent
(Refer to Reference Information for the cleaning of the metallic parts).

(2) Flush the parts with clean water.

(3) Put the parts fully into a bath of Ardrox 185/4 at a temperature of 185 ±9°F (85 ±5°C)
for 15 minutes.

NOTE: If the parts have no organic deposits, do not do step (3).

(4) Pre-flush the parts with cold clean water above the bath.

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.

(5) Flush the parts with cold clean water and a nylon brush (do not use a metal brush) or
use a water spray-gun.

(6) Put the parts fully into a bath of Ardrox 1871 (or Ardrox 1873) at a temperature of 176°
F to 185°F (80°C to 85°C) for 15 minutes.

(7) Pre-flush with cold clean water (make sure you are above the bath to get back the
ARDROX).

CLEANING 02
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WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.
(8) Flush the parts with cold clean water and a nylon brush (do not use a metal brush) or
use a water spray-gun.

(9) Put the parts fully into a bath of Ardrox 188 at a temperature of 194°F ± 9°F (90°C ±
5°C) for 15 minutes.

(10) Pre-flush the parts with cold clean water (make sure your are above the bath to get
back the Ardrox).

(11) Flush the parts with demineralized water and a nylon brush (do not use a metal brush).

NOTE: If the oxidation is important, do the steps (9), (10), (11) again: one time for
the steels and as many times as necessary for the alloys with a nickel or
cobalt basis (in particular turbine wheels).

NOTE: If, after this procedure, the parts have a bronze color, do the steps (6), (7),
(8) again.

(12) Flush the parts with hot water.

(13) Dry the parts with hot air.

SUBTASK 49-00-01-110-003
F. Procedure with a Turco bath (second method)

WARNING: DO NOT BREATHE THE GASES OF THE TURCO PRODUCTS. USE THE
TURCO PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE TURCO
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE TURCO PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE TURCO PRODUCTS
ARE POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CLEANING 02
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CAUTION: DO NOT USE THIS PROCEDURE TO CLEAN THE PARTS WHICH HAVE
ONE OF THESE COATINGS: NICKEL-TUNGSTEN APPLIED WITH SWAB
(SELECTION), CHEMICAL NICKEL, CHROMIUM PLATING
METALLISATION OF TUNGSTEN/COBALT CARIBE. TO CLEAN THESE
PARTS, REFER TO REFERENCE INFORMATION FOR CLEANING AND
TREATMENT OF THE LOW ALLOY STEELS AND THE CARBON STEELS,
CLEANING AND TREATMENT OF THE PARTS BEFORE THE METAL
FELT PARTS ARE BRAZED, AND CLEANING AND TREATMENT OF THE
STAINLESS OR THE HEAT-RESISTANT STEELS AND THE ALLOYS WITH
A COATING.

(1) If necessary, remove the grease with a chlorinated solvent or an alkaline solvent
(Refer to Reference Information for the cleaning of the metal parts).

(2) Flush the parts in clean water.

(3) Put the parts fully into a bath of Turco 4181 (or Turco 4181L) at a temperature of 194°
F ±9°F (90 ±5°C) for 15 minutes.

NOTE: If the parts have no organic particles, do not do the step (3).

(4) Pre-flush the parts with cold clean water (make sure you are above the bath to get
back the ARDROX).

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.

(5) Flush the parts with cold clean water and a nylon brush (do not use a metal brush) or
use a water spray-gun.

(6) Put the parts fully into a bath of Turco 4931 at a temperature of 122°F to 131°F (50°
C to 55°C) for 15 minutes.

(7) Flush the parts with clean water.

(8) Put the parts fully into a bath of Turco 4338/C at a temperature of 194°F ±9°F (90°C
± 5°C) for 15 minutes.

(9) Flush the parts with clean water.

(10) Put the parts fully into a bath of Turco 4409 at a temperature of 64° F to 77° F (18° C
to 25°C) for 15 minutes.

(11) Flush the parts with clean water.

NOTE: If the oxidation is important, do the steps (8), (9), (10), (11) again: one time
for steels and as many times as necessary for the alloys with a nickel or cobalt
base.

(12) Flush with hot water.

(13) Dry with hot air.

CLEANING 02
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CLEANING 02
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CLEANING 03

TASK 49-00-01-110-803
1. Cleaning and Treatment of the Martinized Stainless Steels (Z12CN13, Z5CNU17-04,
Z8CND17-04, C12CNDV12, Z15CN17-03, Z30C13 and the Austenitic Steels (ZIOCNT18-11)

CAUTION: DO NOT USE THIS PROCEDURE TO CLEAN AND PREPARE THESE TYPES
OF STEELS WHICH HAVE CHROMALLOYA12 OR A TEFLON COATING.
REFER TO REFERENCE INFORMATION FOR THE CLEANING OF THE METAL
PARTS.

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Spray-Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Nylon Brush Commercially Available
Ardrox 185/4 Brent SA
Concentration: 40% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France

CLEANING 03
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Part No./Spec. No. Source (CAGE Code)

Ardrox 188 Brent SA
Concentration: 160 g/l 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Ardrox 1873 Brent SA
Concentration: 20% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Ardrox 1871 Brent SA
Concentration: 20% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Turco 4181 Turco France SA
Concentration: 250 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4181L Turco France SA
Concentration: 56% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4338/C Turco France SA
Concentration: 300 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4409 Turco France SA
Concentration: 50% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France

(3) Expendable Parts

None

SUBTASK 49-00-01-110-004
E. Procedure with an Ardrox bath (first method)

WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

CLEANING 03
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WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.
(1) If necessary, remove the grease from the parts with a chlorinated solvent or an alkaline
cleaner (Refer to Reference Information for the cleaning of the metallic parts).

(2) Put the parts fully into a bath of Ardrox 185/4 at a temperature of 185 ± 9°F (85 ± 5°
C) for 15 minutes.

(3) Pre-flush the parts (make sure you are above the bath to get back the Ardrox).

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.

(4) Flush the parts with cold running water and a nylon brush (do not use a metal brush)
or use a water spray-gun.

NOTE: Some steels are clean after the steps (2) to (4). If they are clean, it is not
necessary to do the steps (5) to (9).

(5) Put the parts fully into a bath of Ardrox 188 at a temperature of 194 ± 9°F (90 ± 5°C).

(6) Pre-flush the parts (make sure you are above the bath to get back the ARDROX).

(7) Flush the parts in a bath of cold running water.

(8) Put the parts fully into a bath of Ardrox 1873 (or Ardrox 1871) at a temperature of 176°
F to 185° F (80° C to 85° C) for 5 minutes to clean them.

NOTE: If you use Ardrox 1871, put the parts fully into the bath for 2 minutes.

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.

(9) Flush the parts with cold running water and a nylon brush or use a water spray-gun.

NOTE: If it is necessary, do the steps (5) to (9) again.

(10) Flush the parts with hot water.

(11) Dry the parts in an oven at 212° F (100° C).

(12) Remove the parts from the oven.

SUBTASK 49-00-01-110-005
F. Procedure with a Turco bath (second method)

CLEANING 03
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WARNING: DO NOT BREATHE THE GASES OF THE TURCO PRODUCTS. USE THE
TURCO PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE TURCO
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE TURCO PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE TURCO PRODUCTS
ARE POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTION

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

(1) If necessary, remove the grease from the parts with a chlorinated solvent or an alkaline
cleaner (Refer to Reference Information for the cleaning of the metal parts).

(2) Put the parts fully into a bath of Turco 4181 (or Turco 4181L) at a temperature of 194°
F ± 9° F (90° C ± 5° C) for 15 minutes.

(3) Pre-flush the parts (make sure you are above the bath to get back the Turco).

NOTE: Some steels are clean after the steps (2) to (3). If they are clean, it is not
necessary to do the steps (4) to (8).

(4) Flush the parts with cold running water and a nylon brush (do not use a metal brush).

(5) Put the parts fully into a bath of Turco 4338/C at a temperature of 194° F ± 9° F (90°
C ± 5° C) for 15 minutes.

(6) Flush in a bath of cold running water.

(7) Put the parts fully into a bath of Turco 4409 at a temperature of 64° F to 77° F (18° C
to 25° C).

(8) Flush the parts in a bath of cold running water.

(9) Flush the parts with hot water.

(10) Dry the parts in an oven at 212° F (100° C).

NOTE: If necessary, do the steps (7) to (10) one time again.

CLEANING 03
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CLEANING 04

TASK 49-00-01-110-804
1. Cleaning and Treatment of the Low Alloy Steels and the Carbon Steels, Cleaning and Treatment
of the Parts before the Metal Felt Parts are Brazed, and Cleaning and Treatment of the Stainless
or the Heat-Resistant Steels and the Alloys with a Coating

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Spray-Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Ardrox 185/4 Brent SA
Concentration: 40% in volume 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Turco 4181 Turco France SA
Concentration: 250 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco 4181L Turco France SA
Concentration: 56% in volume 3-5, impasse du quai de l’industrie
91200 Athis-Mons France

CLEANING 04
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Part No./Spec. No. Source (CAGE Code)

Ardrox 188 Brent SA
Concentration: 160 g/l 280, Rue J.B. Godin
02200 Villeneuve
St Germain France
Turco 4338 Turco France SA
Concentration: 300 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
Turco RINS Turco France SA
Concentration: 5 g/l 3-5, impasse du quai de l’industrie
91200 Athis-Mons France
VV-L-800 Oil Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-006
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

WARNING: DO NOT BREATHE THE GASES OF THE TURCO PRODUCTS. USE THE
TURCO PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE TURCO
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE TURCO PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER, THE TURCO PRODUCTS
ARE POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CLEANING 04
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CAUTION: AFTER THIS PROCEDURE, THE STEEL PARTS WITH A STRENGTH >
1450 MPA MUST HAVE A HEAT TREATMENT AT 392°F (200°C) FOR 2
HOURS.
(1) Remove the grease with a halogenous solvent or an alkaline solvent (Refer to
Reference Information for the cleaning of the metallic parts).

CAUTION: THE PARTS WITH A LAYER OF PHOSPHATE MUST BE PHOSPHATED

AGAIN AFTER A TREATMENT IN ARDROX 185/4 (OR TURCO 4181).

(2) Put the parts fully into a bath of Ardrox 185/4 at a temperature of 185°F ±90°F (85°C
±5°C) or a bath of Turco 4181 (or 4181L) at a temperature of 194°F ±9°F (90°C ±5°
C).

NOTE: On the parts painted in category P or S, the paint usually becomes soft with
Ardrox 185/4 (or Turco 4181). If necessary, remove the paint by sand-
blasting.

(3) Pre-flush the parts (make sure you are above the bath to get back the Ardrox).

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU USE A
SPRAY-GUN.

(4) Flush the parts in cold clean water and rub them with a nylon brush or use a water
spray-gun.

(5) If de-oxidation is not sufficient after the step (2) do the steps that follow:

(a) Put the parts fully into a bath of Ardrox 188 (or Turco 4338) at a temperature of
194° F ± 9° F (90° C ± 5° C) for 15 minutes.

WARNING: USE THE EYE PROTECTION AND RUBBER GLOVES WHEN YOU
USE A SPRAY-GUN.

(b) Flush the parts in cold clean water, and rub them with a nylon brush or use a
water spray-gun.

(c) Do the steps (2), (3) and (4) again.

(6) Flush the parts in a bath of hot water with Turco RINS.

(7) Dry the parts in an oven at 212° F (100° C).

(8) Let the parts become cold.

(9) Only for low alloy steels and carbon steels, apply a temporary protection product.

CLEANING 04
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CLEANING 04
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CLEANING 05

TASK 49-00-01-110-805
1. Cleaning of the Ball and Roller Bearing

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-210-806 Inspection of the Thrust Ball
Bearings
HSPS 490001 Task 49-00-01-210-807 Inspection of the Roller
Bearings

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Cart Commercially Available
Graymills Liftkleen Agitation Cleaner Commercially Available
Model
TH5362665LB-B Cleaning Tank,
Alkaline, Heated
System One Series 500, Re-cycling Parts Commercially Available
Washer
(with Solvent Spray Gun with Hose)
Magnaflux, Model SB2824 Demagnetizer Commercially Available
Solvent Gun Commercially Available
Tank, Water Remover Commercially Available
Tank, Fingerprint Remover Commercially Available
Tank, Stoddard Solvent Commercially Available
Glasses, Safety Commercially Available

CLEANING 05
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Part No./Name Source (CAGE Code)

Magnaflux #105645 Field Strength Commercially Available
Indicator
Tank for Alkaline Cleaner Commercially Available
Tank for Cold Water Rinse Commercially Available
Ultrasonic Tank (optional) Commercially Available
Mechanical Agitator for Chemical Tanks Commercially Available
Demagnetizer Commercially Available
Non-metallic or Coated Basket Commercially Available
Heaters (and chillers) for Tank Commercially Available
Temperature Control
Tampico Brush, Soft Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

MIL-PRF-6081 Commercially Available
Grade 1010 Preservation Oil
Braycote 120 Commercially Available
Fingerprint Remover
ZEP PLS 1043 Commercially Available
Water Remover
MIL-PRF-680 Commercially Available
Type II Stoddard Solvent
Chemical-Resistant Rubber Gloves Commercially Available
Chemical-Resistant Apron Commercially Available
MIL-PRF-6085 Commercially Available
Preservation Oil
Turco 4181 Henkel Corp
(26-29 oz wt./gal) (71410)
Turco 4181L Henkel Corp
(40-45% by volume) (71410)
Aero-Dip (1.0 - 1.5 lb/gal) Commercially Available

CLEANING 05
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Part No./Spec. No. Source (CAGE Code)

Ardrox 185 Technische Verfahren MBH
(1.8-2.1 lb/gal) (D1940)
Ardrox 185L Technische Verfahren MBH
(30-35% by volume) (D1940)
Cee-Bee J-84AL Mc Gean-Rohco Incdiv Cee-Bee Aviaiton
(40 - 48 fl oz./gal) Divisiondba Cee-Bee Aviation
(71361)
HDL-202 Magnus Chemicals Ltd
Mag-Chem (30-35% by volume) (35502)
Ardrox 185 Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical
Products Inc
(02CA7)
Chemethall PLC
(K6858)
Ardrox 185L Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical
Products Inc
(02CA7)
Chemethall PLC
(K6858)
Ardrox 3962 Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical
Products Inc
(02CA7)
Chemethall PLC
(K6858)

CLEANING 05
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Part No./Spec. No. Source (CAGE Code)

Ardrox 3968 Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical
Products Inc
(02CA7)
Chemethall PLC
(K6858)
Cee-Bee J-84AL Cee-Bee Aviation Products
(71361)
Cee-Bee J-84A Cee-Bee Aviation Products
(71361)
Cee-Bee WDO Cee-Bee Aviation Products
(71361)
HDL-202 MagChem
Mag-Chem (35502)
Mag-Chem Protectol ID MagChem
(35502)
Turco Aquasorb Henkel
(71410)
Turco 4181 Henkel
(71410)
Turco 4181L Henkel
(71410)
Brayco 885 Castrol Industries
(2R128)
Windsor L245C Fuchs Lubricants Co.
(0FB35)
Nycolube 11B Societe Nyco
(F4101)
Royco 885 Anderol Inc.
(07950)
Aeroshell Fluid 12 Shell Aviation Ltd
(KA832)

CLEANING 05
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(3) Expendable Parts

None
SUBTASK 49-00-01-110-007
E. Cleaning (OPTION 1)

(1) Alkaline cleaning of the bearings to be done on as-received, fielded bearings.

NOTE: This procedure is a general cleaning procedure for all types of ball and roller
bearings. This procedure may not be appropriate in all geographic areas due
to environmental regulations covering the cleaning materials specified.

NOTE: If the bearing has an outer race, which is not part of the bearing, remove the
outer race prior to cleaning.

NOTE: Refer to the applicable repair or component maintenance manual for the item
being cleaned for the specific cleaning procedures.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER
PROTECTIVE GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK
MEDICAL ATTENTION.

WARNING: PUT ON THERMALLY-INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

CAUTION: DO NOT USE THIS CLEANING OPTION FOR CLEANING BALANCE

BEARINGS. THIS CLEANING OPTION WILL DISSOLVE THE
ALUMINUM RIVETS THAT ARE USED IN BALANCE BEARINGS.
CLEAN BALANCE BEARINGS BY FLUSHING WITH STODDARD
PETROLEUM SOLVENT BEFORE INSPECTION.

(a) Turn on the alkaline cleaning tank for approximately 15 to 20 minutes to achieve
a cleaning solution temperature of 120 to 150°F (49 to 66°C).

NOTE: Do not stop between the individual steps of the cleaning process.

1 For water-based cleaners proceed as follows:

a Fill the tank with cold water to 50% of operating volume.

b Slowly and carefully add necessary amount of alkaline cleaner.

c Fill the tank to 100% of operating volume.

(b) Put the bearings in the basket/screen.

NOTE: Do not allow the bearings to touch the metallic surfaces.

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(c) Put the basket/screen with the bearings in the alkaline cleaning solution for 10
to 20 minutes depending on the amount of buildup; a calibrated timer should be
used to monitor this cleaning time. Agitate solution for duration of cleaning time.
(d) Remove the basket/screen that has the bearings from the cleaning solution. Let
the cleaning solution drain from the bearing surfaces.

(e) Put the bearings on a plastic carrier.

(2) Cold water rinse using water remover

(a) Rinse the bearings under cold running water in a sink for no more than 2 minutes
to remove the remaining alkaline cleaning solution.

(b) Immediately submerge the bearings in the water remover and hand agitate.
Leave the bearings in the water remover for 5 minutes.

(c) Remove the bearings from the water remover. Drain for 5 to 10 minutes until
dripping of fluid from the bearing stops.

(3) Demagnetize the bearings to make sure that small, unwanted metal particles are not
captured within the bearing during the final solvent cleaning operation. Make sure that
the magnetic field is less than or equal to 0.5 kA/m (3 Oesteds) using the field strength
indicator. If measured magnetic field strength is greater than or equal to 0.5 kA/m (3
Oesteds), do the Demagnetize process again.

WARNING: STODDARD SOLVENT IS TOXIC AND FLAMMABLE. DO NOT BREATHE

VAPORS. USE IN WELL VENTILATED AREA FREE FROM SPARKS,
FLAME OR HOT SURFACES. USE SPLASH GOGGLES, SOLVENT-
RESISTANT GLOVES AND OTHER PROTECTIVE GEAR. IN CASE OF
EYE CONTACT, FLUSH WITH WATER AND SEEK MEDICAL ATTENTION.
IN CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

(4) Dip the bearing in the fingerprint remover tank. Drain the fingerprint remover. Dip the
bearing in the stoddard solvent tank, then drain the Stoddard solvent.

(5) Move bearing to System One parts washer

NOTE: Make sure that the exhaust fan is on at all times. Keep the tank/washer
covers/lids closed at all times when not in use.

CAUTION: AVOID SPINNING BEARINGS AT HIGH SPEED WITH SOLVENT

GUN.

(a) Spray the solvent into each bearing raceway, on balls, rollers, OD, ID, and
separators using the solvent gun.

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WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS,

MAKE SURE THAT THE PRESSURE IS NOT MORE THAN 30
POUNDS PER SQUARE INCH (207 KILOPASCALS). DO NOT
DIRECT THE AIRSTREAM AT PERSONNEL OR LIGHT OBJECTS.
PUT ON GOGGLES OR A FACE SHIELD TO PROTECT YOUR EYES.
THIS WILL HELP TO PREVENT INJURIES TO PERSONNEL OR
DAMAGE TO THE EQUIPMENT. IF YOU HAVE AN EYE INJURY, GET
MEDICAL ATTENTION.

CAUTION: AVOID SPINNING BEARINGS WITH FORCED AIR GUN.

(b) Spray each bearing with forced air gun to remove the solvent from raceways,
rollers, balls, OD, ID, and retainers.

CAUTION: DO NOT USE BARE HANDS TO HANDLE THE BEARINGS. CLEAN

BEARINGS MUST ONLY BE HANDLED USING GLOVES. DO NOT
LET THE BEARINGS BE WITHOUT LUBRICATION FOR MORE THAN
60 MINUTES.

(c) Prepare a cart to place clean bearing on, wipe the surface of the cart to remove
any oil solvent, then cover cart with clean paper. Place each bearing onto the
paper-covered, cart surface.

CAUTION: ALL VISUAL INSPECTIONS MUST BE DONE ON FRESH SOLVENT

CLEANED, OIL FREE BEARINGS. INTERNAL RADIAL CLEARANCE
INSPECTIONS MUST BE DONE ON CLEAN, LIGHTLY OILED
(PRESERVATION OIL) BEARINGS.

(6) Do an inspection of the bearings (refer to Reference Information for inspection of the
thrust ball bearing and roller bearings).

(7) Do a dynamic analysis of bearing, if equipment is available, to aid visual inspection.

(8) Repeat cleaning of bearings if necessary.

(9) Preserve bearings in preservation oil.

(10) Package preserved bearings in vacuum-sealed material.

SUBTASK 49-00-01-110-008
F. Cleaning (OPTION 2)

CAUTION: DO NOT USE THIS CLEANING OPTION FOR CLEANING BALANCE

BEARINGS. THIS CLEANING OPTION WILL DISSOLVE THE ALUMINUM
RIVETS THAT ARE USED IN BALANCE BEARINGS. CLEAN BALANCE
BEARING BY FLUSHING WITH STODDARD PETROLEUM SOLVENT
BEFORE INSPECTION.

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CAUTION: THE ALKALINE RUST REMOVER, WATER RINSE, DE-WATERING OIL,

AND THE PRESERVATION OIL TANKS MUST BE USED ONLY FOR
BEARINGS.
NOTE: Components of disassembled bearings must be kept together.

(1) Check bearing for magnetism. Make sure that bearing magnetism is within ± 3 Gauss.
If magnetism is greater than ± 3 Gauss, demagnetize the bearing as follows:

(a) Demagnetize non-separable bearing as assemblies. Slowly turn the inner and
outer races in opposite directions when the bearing goes through the
demagnetizer.

(b) Demagnetize, one at a time, components of separable bearings.

(c) Remove bearing from the demagnetizer.

(d) Check bearing for magnetism. Remaining magnetism must be within ± 3 Gauss.

CAUTION: THE REMAINING STEPS IN THUS CLEANING PROCEDURE MUST BE

PERFORMED WITHOUT ANY INTERRUPTIONS TO AVOID ANY
CORROSION THAT COULD FORM ON THE SURFACES OF THE
BEARING.

CAUTION: DEMOUNTABLE BEARINGS SHALL BE CLEANED IN DETAIL. DO NOT

REMOVE ROLLING ELEMENTS FROM THE CAGE.

CAUTION: THE DETAIL RING FROM SEMI-DEMOUNTABLE BEARINGS MUST BE

CLEANED SEPARATELY. (A SEMI-DEMOUNTABLE BEARING HAS ONLY
ONE RING THAT CAN BE REMOVED FROM THE BEARING ASSEMBLY)

CAUTION: DO NOT PLACE THE BASKET ON THE BOTTOM OF THE TANK.

CAUTION: DO NOT STACK BEARINGS ON TOP OF ONE ANOTHER.

CAUTION: DO NOT USE AIR AGITATION.

(2) Alkaline Clean.

NOTE: If ultrasonic agitation is used, do not exceed 170° F (77° C) because the
higher temperature reduces the effects of the ultrasonic agitation.

(a) Put bearing in a coated or non-metallic basket and soak for five minutes with
agitation, in one of the alkaline rust remove solutions, (Refer to Table 601).

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Table 601

Make-up by Operating Limits

Material Volume by Volume Temperature
Cee-Bee J-84AL 48 fl.oz/gal 369.6 40-48 oz/gal 180-195°F
ml/l (37% by (308.0-369.6 ml/l) (82-91°C)
Volume) (30-37)
Ardrox 185L 35% by Volume 30-35 180-195°F
(82-91°C)
Ardrox 185 2.1 lbs/gal (252 g/ 1.8-2.1 lbs/gal 180-195°F
l) (216-252 g/l) (82-91°C)
Turco 4181L 45% by Volume 40-45 165-175°F
(74-79°C)
Turco 4181 29 oz. wt/gal 26-29 oz. wt/gal 165-175°F
(217.5 g/l) (240-360 g/l) (74-79°C)
Mag-Chem 35% by Volume 30-35 165-180°C
HDL-202 (liquid) (74-82°C)

1 Mechanical Agitation Method (Preferred):

a Use up and down motion of the basket, or

b Circulation solution pump, or

c Use a mixer.

CAUTION: IF ULTRASONIC AGITATION IS USED AS AN OPTION, THE

MAXIMUM ULTRASONIC TIME MUST NOT BE MORE THAN
FIVE (5) MINUTES. DAMAGE WILL RESULT TO THE ROLLING
ELEMENTS OF THE BEARING IF THE TOTAL TIME IS
EXCEEDED. THIS WILL RESULT IN A FAILURE OF THE
BEARING.

CAUTION: POWER MUST BE OFF DURING IMMERSION AND

WITHDRAWAL OF THE BEARING.

2 Ultrasonic Agitation Method (Optional):

a The following types of equipment can be used, (Refer to Table 602):

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Table 602

High Intensity ultrasonic system Power rating to be 6 to 11 watts/

with 20 to 40 kHz frequency. square inch (0.9 to 1.7 watts/
square centimeter) of tank cross-
section
or
For systems with
magnetostrictive transducers,
power rating in watts/volume to
be 79 to 80 watts/gallon (20.9 to
21.4 watts/liter). Do not exceed
81 watts/gallon (21.4 watts/liter).
or
For systems with piezoelectric
transducers, power rating in
watts/volume to be 55 to 56
watts/gallon (14.5 to 14.8 watts/
liter). Do not exceed 56 watts/
gallon (14.8 watts/liter).
Multiple frequency ultrasonic Power rating to be 34 watts/
system with random sweep rates gallon (9 watts/liter) in a 113
and random amplitude gallon (427.8 liter) tank. Other
modulation frequencies, and power ratings and tank sizes
operating at frequencies may be qualified by local
between a minimum of 35 kHz engineering and quality
and a maximum of 108 kHz. authority.

b Must be equipped with a timer that automatically shuts off ultrasonic

generator.

c Must have a solution level marker and a low solution automatic shut-
off.

d Processing tank must be equipped with heating and/or cooling

elements capable of controlling temperature of process solution
within the specified operating range. Ultrasonic energy will increase
temperature of cleaning solution, so cooling capability may be
needed, in addition to heating capability.

e Parts must be submerged under surface of cleaning solution by 1 in.

(25.4 mm) minimum.

f All parts must be separated from sides and bottom of tank by 2 in.
(50.8 mm) minimum. Basket cannot rest on bottom of tank or against
sides of tank.

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g Inspect all functional surfaces of semi demountable assessory

bearings for ultrasonic damage (such as scratches and scuffing) after
cleaning.
(3) Cold Water Spray Rinse.

(a) Flush the bearings in the basket over the alkaline solution tank with cold water.
Do not use air for pressuring water spray.

1 If the bearing is not clean, it is permitted to soak, the bearing in the alkaline
solution by only the Mechanical Agitation Method, one more time.

2 It is not permitted to repeat the ultrasonic cleaning method.

3 Make up a new alkaline solution when it is not possible to do the cleaning

within the parameters of the solution cleaning step and when a recycle step
is routinely necessary.

4 It is permissible to use a soft tampico brush to remove any soil that remains.
It is not necessary to remove stains.

(4) Cold Water Rinse Tank

CAUTION: FAILURE TO PERFORM IMMERSION/RINSE STEPS IMMEDIATELY

AFTER SPRAY RINSING CAN CAUSE DRYING AND FLASH
RUSTING OF BEARING AND RESULT IN BEARING DAMAGE.

(a) Immediately put bearing fully into cold water tank for a maximum of one minute.
Counter-rotate non-demountable and semi-demountable bearings to be sure
that they are fully flushed.

(5) De-watering Oil

CAUTION: PLACING PARTS OTHER THAN BEARINGS IN DE-WATERING OIL

TANK MAY CONTAMINATE DE-WATERING OIL AND CAUSE
DAMAGE TO BEARINGS.

(a) Remove the bearings from the water and immediately put the bearing in one of
the following de-watering oils at room temperatures for 5 minutes.

Water Dispacing Oil

Ardorx 3962
Ardorx 3968
Turco Aquasorb
Cee-Bee WDO
Mag Chem Protectol ID

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(b) Lightly agitate to make sure that remaining water is removed. Counter-rotate
nondemountable and semi-demountable bearings to make sure that they are
fully flushed.
(c) Remove bearing from dewatering oil and allow to drain.

(6) Preservation Oil

NOTE: The following long term preservations oils are compatible with synthetic
engine oil, so it does not have to be removed before the installation of
bearings into the engine.

(a) Submerse the bearing fully into one of the following lubricating and preservation
oils:

Preservation Oil
Brayco 885
Windsor L245X
Nycolube 11B
Royoco 885
Aeroshell Fluid 12

(b) Remove and allow to drain.

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CLEANING 06

TASK 49-00-01-110-806
1. Cleaning of the Carbon Seals

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Ultrasonic generator Commercially Available
Spray-Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Fluorocarbon Solvent Promosol
(F5927)
TMC FREON Promosol
(F5927)
HYSO 97/1 Socomor
Kerosene Commercially Available
Box Commercially Available

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Part No./Spec. No. Source (CAGE Code)

ASTM D235 Commercially Available
Stoddard Solvent
Engine Lubricating Oil Andersol Inc.
(07950)
AVI-Oil India Private Unlimited
(SFV07)
BP Corp North America
(1UGB2, 4XLA9)
Castrol lnd.North America, Inc
(2H517)
Chemical Spec and Dev, Inc.
(4N760)
Chemtura Corp
(5XXK3)
Cognls Corp
(0JS01)
Cononophillips
(3DFL8)
Chevron Corp
(4RKV9)
Exxon Mobil Oil Corp
(77988, 53C29)
Sentinel Lubricants Corp
(3AD00)
Shell Aviation Ltd.
(KA832)
Shell U.K. Oil Products
(KD4F0)
Societe Toumaisienne de Produits
(B6561)
Total Lubricants
(F2622)

(3) Expendable Parts

None

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SUBTASK 49-00-01-110-009
E. Procedure for Carbon Seal Cleaning
WARNING: REFER TO THE MANUFACTURER'S MATERIAL SAFETY DATA SHEETS
FOR CONSUMABLE MATERIAL'S INFORMATION SUCH AS:
HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL
CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD
DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL
MEASURES.

CAUTION: NEVER WIPE DIRTY SEALS WITH A CLOTH. DO NOT WASH SEALS
WITH ANY TYPE OF CARBON SOLVENT OTHER THAN ASTM D235
SOLVENT. CARBON SOLVENTS CAN REMOVE THE CARBON SEAL
IMPREGNANT. THE RESULT IS AN INCREASED SURFACE POROSITY
AND HIGHER WEAR RATES.

(1) Clean carbon seals by one of the methods that follow:

(a) Soak seals in clean engine lubricating oil at 120° to 140°F (49° to 60°C) for a
minimum of 30 minutes. Use one of the oils in the following table. Refer to
QPL-23699-QPD and QPL-7808-QPD Grade3.

Table 601

Aeroshell Turbine
Oil 308 CastroL 5000 Mobil Jet Oil 291 Sensyn 23699 A
Aeroshell Turbine Castrol 5050 Mobil Jet Oil 387 Sensyn 23699 B
Oil 500
Aeroshell Turbine Castrol Aero J5 Mobil Jet Oil II Sensyn 23699 C
Oil 529
Aeroshell Turbine Chevron Regal SGT 22 Sensyn 23699 C/l
Oil 531 Synthetic Turbine
Oil SGT
Aeroshell Turbine Emgard 2867 RM-249A Sent-7808
Oil 560 Synthetic Turbine
Lubricant
Arpolair 23699 Emgard 2949 RM-269A Sent-7808A1
Synthetic Turbine
Lubricant
Arpolav 699 Emgard 2952 RM-270A Syndustrial
Synthetic Turbine Turbine Oil
Lubricant
Arpolav 808 Enersysn Mgt RM-288A Total Aeroturbine
535

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Aeroshell Turbine
Oil 308 CastroL 5000 Mobil Jet Oil 291 Sensyn 23699 A
Arcolube 23699 Enersysn Mgt RM-305A Total Aeroturbine
540
Arpolube 3699C/I Hatcol 1278 RM-308A Total Preslia SE
Jet
Arpolube 7808 Hatcol 1280 Royco 808 Turbonycoil 160
Avrex S Turbo Hatcol 1625 Royco 808 HC Turbonycoil 600
256
BP Turbo Oil Hatcol 3211 Royco 899 Turbonycoil 601
2197
BP Turbo Oil Hatcol 3212 Royco 899HC Turbonycoil 602
2380
BP Turbo Oil Hatcol 3213 Royco Turbine Oil Turbonycoil 610
2389 500
BP Turbo Oil Hatcol 3214 Royco Turbine Oil
Aero-D 560
Castrol 399 Mobil Jet Oil 254 Senlube 7808

(b) Soak seals in ASTM D235 cleaning solvent for up to four (4) hours.

(2) If necessary, remove coke deposits by one of the two following methods:

(a) Use a dull-edged tool to remove coke deposits.

WARNING: CLEANING SOLVENT (ALSO KNOWN AS DRY CLEANING

SOLVENT, STODDARD SOLVENT, MINERAL SPIRITS,
PETROLEUM SPIRITS, MILPRF- 680 - TYPE II, ASTM D235 - TYPE
II, OR AMS3160) AND ITS FUMES ARE FLAMMABLE AND
EXPLOSIVE AT TEMPERATURES MORE THAN 142 DEGREES
FAHRENHEIT (61 DEGREES CELSIUS). THE CLEANING SOLVENT
FUMES ARE HEAVIER THAN THE AIR AND CAN MOVE ALONG THE
GROUND WITH THE AIRFLOW. THESE FUMES CAN CAUSE AN
EXPLOSION OR FIRE IF THEY TOUCH HOT SURFACES, FLAMES,
OR SPARKS. THE FIRE CAN MOVE IMMEDIATELY BACK TO THE
SOURCE OF THE FUMES.

(b) Spray with ASTM D235 cleaning solvent.

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CLEANING 07

TASK 49-00-01-110-807
1. Cleaning of the Titanium Parts (Usual Method)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-808 Cleaning of the Titanium
Parts (Full Method)

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

TT-I-735 Commercially Available
Isopropyl Alcohol
O-A-51 Commercially Available
Acetone
Alkaline Solvent Commercially Available
Demineralized Water (see Note) Commercially Available
Plastic Bag Commercially Available
Alkaline Cleaner Commercially Available
NOTE: The demineralized water used to flush the parts must have a resistivity more
than 50 000 Ω/m (conductivity less than 20 μS/cm).

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(3) Expendable Parts

None
SUBTASK 49-00-01-110-010
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE ALKALINE SOLVENT USE THE
ALKALINE SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ALKALINE
SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ALKALINE SOLVENT TOUCHES YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ALKALINE
SOLVENT IS POISONOUS AND FLAMMABLE.

WARNING: DO NOT BREATHE THE GASES OF THE ACETONE OR ISOPROPYL

ALCOHOL. USE THE ACETONE OR ISOPROPYL ALCOHOL ONLY IN THE
AREAS WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE SURE
THERE ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES IN
THESE AREAS. IF THE ACETONE OR ISOPROPYL ALCOHOL TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR.
IF THE ACETONE OR ISOPROPYL ALCOHOL TOUCHES YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE ACETONE OR
ISOPROPYL ALCOHOL IS POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CAUTION: DO NOT CLEAN TITANIUM PARTS WITH CHLORINATED, FLUORINATED

OR FLUOROCHLORINATED SOLVENTS.

CAUTION: DO NOT TOUCH CLEANED PARTS WITH BARE HANDS. IF YOU DO NOT
USE CLEAN RUBBER GLOVES, THE PART CAN BREAK AT HIGH
TEMPERATURES.

CAUTION: CLEAN THE PARTS IMMEDIATELY BEFORE ASSEMBLY OR NO MORE

THAN EIGHT HOURS BEFORE ASSEMBLY.

NOTE: This procedure is used to clean the titanium parts which are not very dirty. If it is
necessary to do a more important cleaning [Refer to Reference Information for the
cleaning of the titanium parts (full method)].

(1) Remove the oils or the greases with acetone or isopropyl alcohol.

(2) Put the parts in an alkaline cleaner at a temperature of 140 ±9° F (60 ± 5° C) for 5 to
30 minutes.

NOTE: Make sure there are not bubbles in the cleaner. Do not put too many parts in
the cleaner.

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(3) Flush the parts with a flow of cold demineralized water.

(4) Make sure all the parts are clean.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN YOU
USE COMPRESSED AIR TO CLEAN OR DRY. USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(5) Dry the parts with compressed air or in an oven at a temperature of 160° F to 275° F
(71° C to 135° C).

NOTE: Use filtered air without water, oil, and dirt.

(6) Put the parts in a plastic bag if they are not used immediately.

(7) Put on the plastic bag a tag which has the indication “CLEANED TITANIUM PARTS.
DO NOT TOUCH WITH BARE HANDS.”

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CLEANING 08

TASK 49-00-01-110-808
1. Cleaning of the Titanium Parts (Full Method)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Diversey 909 Turco France SA
Concentration: 50 g/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco Aviation Turco France SA
Concentration: 40 to 50 g/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco 4316L Turco France SA
Concentration: 816 cm³/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco 4104 Turco France SA
3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Nitric Acid Commercially Available

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Part No./Spec. No. Source (CAGE Code)

Demineralized Water (see Note) Commercially Available
NOTE: The demineralized water used to flush the parts must have a resistivity more
than 50 000 Ω/m (conductivity less than 20 μS/cm).

(3) Expendable Parts

None

SUBTASK 49-00-01-110-011
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE TURCO PRODUCTS. USE THE
TURCO PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE TURCO
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE TURCO PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE TURCO PRODUCTS
ARE POISONOUS AND FLAMMABLE.

WARNING: DO NOT BREATHE THE GASES OF THE NITRIC ACID. USE THE NITRIC
ACID ONLY IN THE AREAS WHERE THE AIR IS CONTINUOUSLY
CHANGED. MAKE SURE THERE ARE NO SPARKS, NO FLAMES AND NO
HOT SURFACES IN THESE AREAS. IF THE NITRIC ACID TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR.
IF THE NITRIC ACID TOUCHES YOUR SKIN, WASH YOUR SKIN WITH
SOAP AND WATER. THE NITRIC ACID IS POISONOUS AND
FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CAUTION: DO NOT CLEAN TITANIUM PARTS WITH CHLORINATED, FLUORINATED

OR FLUOROCHLORINATED SOLVENTS.

CAUTION: DO NOT TOUCH CLEANED PARTS WITH BARE HANDS. IF YOU DO NOT
USE CLEAN RUBBER GLOVES, THE PART CAN BREAK AT HIGH
TEMPERATURES.

CAUTION: CLEAN THE PARTS IMMEDIATELY BEFORE ASSEMBLY OR NO

LONGER THAN EIGHT HOURS BEFORE ASSEMBLY.

(1) Remove the oils or the greases with acetone.

(2) Put the part in a bath of Diversey 909 or Turco Aviation at a temperature of 140 ± 9°
F (60 ± 5° C) for 10 to 30 minutes.

(3) Flush the part in a bath of cold demineralized water.

CLEANING 08
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(4) Put the part fully in a bath of TURCO 4316L at a temperature of 240 ± 9° F (115 ± 5°
F) for 60 minutes.
(5) Flush the part with cold demineralized water for 30 minutes.

(6) Drain the part fully, use a vegetal sponge to remove the remaining products in the
holes or the grooves.

(7) Prepare a solution of nitric-acid/Turco 4104 with :

(a) Nitric acid (64 % in volume if its density = 1.33, or 47 % in volume if its density
= 1.47).

(b) Turco 4104 (4.5 % in volume).

(c) Demineralized water (31.5 % in volume).

(8) Put the part fully in the solution of nitric-acid/Turco 4104 at a temperature of 40° F to
77° F (15° C to 25° C) for 10 minutes. Do not shake.

(9) Drain the part fully, use a vegetal sponge to remove the remaining products in the
holes or the grooves.

(10) Dry the part in an oven at a temperature of 212° F (100° C) for 30 to 50 minutes.

(11) Put the part in a plastic bag if it is not used immediately.

(12) Put on the plastic bag a tag which has the indication "CLEANED TITANIUM PARTS.
DO NOT TOUCH WITH BARE HANDS."

CLEANING 08
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CLEANING 08
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SPM

CLEANING 09

TASK 49-00-01-110-809
1. Cleaning of the Titanium Impellers

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Diversey 909 Turco France SA
Concentration: 50 g/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco Aviation Turco France SA
Concentration: 40 to 50 g/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco 4316L Turco France SA
Concentration: 816 cm3/l 3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco 4104 Turco France SA
3-5, impasse du quai de l'industrie
91200 Athis-Mons France
Turco Mask 522 (TFM522) Turco France SA
3-5, impasse du quai de l'industrie
91200 Athis-Mons France

CLEANING 09
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Part No./Spec. No. Source (CAGE Code)

Nitric Acid Commercially Available
O-A-51 Commercially Available
Acetone
Demineralized Water (see Note) Commercially Available
NOTE: The demineralized water used to flush the parts must have a resistivity more
than 50 000 Ω/m (conductivity less than 20 μS/cm).

(3) Expendable Parts

None

SUBTASK 49-00-01-110-012
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE TURCO PRODUCTS. USE THE
TURCO PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE TURCO
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE TURCO PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THE TURCO PRODUCTS
ARE POISONOUS AND FLAMMABLE.

WARNING: DO NOT BREATHE THE GASES OF THE NITRIC ACID. USE THE NITRIC
ACID ONLY IN THE AREAS WHERE THE AIR IS CONTINUOUSLY
CHANGED. MAKE SURE THERE ARE NO SPARKS, NO FLAMES AND NO
HOT SURFACES IN THESE AREAS. IF THE NITRIC ACID TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR.
IF THE NITRIC ACID TOUCHES YOUR SKIN, WASH YOUR SKIN WITH
SOAP AND WATER. THE NITRIC ACID IS POISONOUS AND
FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CAUTION: DO NOT CLEAN TITANIUM PARTS WITH CHLORINATED, FLUORINATED

OR FLUOROCHLORINATED SOLVENTS.

CAUTION: DO NOT TOUCH CLEANED PARTS WITH BARE HANDS. IF YOU DO NOT
USE CLEAN RUBBER GLOVES, THE PART CAN BREAK AT HIGH
TEMPERATURES.

CLEANING 09
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CAUTION: CLEAN THE PARTS IMMEDIATELY BEFORE ASSEMBLY OR NO

LONGER THAN EIGHT HOURS BEFORE ASSEMBLY.
(1) Prepare the part.

(a) Put the part fully in a bath of Diversey 909 (or Turco Aviation) at a temperature
of 140 ± 9 °F (60 ± 5° C) for 10 to 30 minutes.

(b) Flush the part in a bath of cold demineralized water.

(c) Dry the part with hot air.

(d) Apply two layers of Turco Mask 522 (TFM522) varnish on the curvic-coupling
with a brush :

1 Apply one layer.

2 Stop for 2 to 5 minutes.

3 Apply a second layer.

4 Dry at the ambient air for 12 hours or in an oven at 212° F (100° C) during
60 minutes.

(e) Put a plastic (or teflon) cap on each locating holes or centering holes.

(2) Clean the part.

(a) Put the part fully in a bath of Turco 4316L at a temperature of 240 ± 9° F (115 ±
5° C) for 60 minutes.

(b) Flush the part with cold demineralized water for 30 minutes.

(c) Drain the part fully. Use a vegetal sponge to remove the remaining products in
the holes or the grooves.

(d) Prepare a solution of nitric-acid/Turco 4104 with:

1 Nitric acid (64 % in volume if its density = 1.33 or 47 % in volume if its

density = 1.47)

2 Turco 4104 (4.5 % in volume)

3 Demineralized water (31.5 % in volume)

(e) Put the part fully in the solution of nitric acid/Turco 4104 at a temperature of 40°
F to 77° F (15° C to 25° C) for 10 minutes. Do not shake.

(f) Flush the part with cold demineralized water.

(g) Drain the part fully, use a vegetal sponge to remove the remaining products in
the holes or the grooves.

(h) If necessary, do the steps C.(2).(a) to C.(2.).(g) again.

CLEANING 09
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(i) Dry the part in an oven at a temperature of 212° F (100° C) for 30 to 50 minutes.

(3) Remove the varnish from the curvic-couplings with acetone.

(4) Remove all the caps from the locating holes (or the centering holes).

(5) Dry the part with hot air for 60 minutes.

CLEANING 09
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CLEANING 10

TASK 49-00-01-110-810
1. Flushing

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

P-D-680 Commercially Available
Type II Dry-Cleaning Solvent
VV-L-800 Commercially Available
Oil

(3) Expendable Parts

None

SUBTASK 49-00-01-110-013
E. Cleaning

(1) If the gearbox has an internal contamination caused by a hardware failure, a wear or
damage, flush the housings.

Do the subsequent procedure.

(2) If the housings are machined or contaminated, flush the internal core, the drilled oil
passages, and the blind holes with a solvent.

Do the subsequent procedure.

CLEANING 10
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WARNING: DO NOT BREATHE THE GASES OF DRY CLEANING SOLVENT USE THE
DRY CLEANING SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE DRY
CLEANING SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES WITH
WATER AND CALL A DOCTOR. IF THE DRY CLEANING SOLVENT
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DRY CLEANING SOLVENT IS POISONOUS AND FLAMMABLE.

(3) Flush the housing internal core, the drilled oil passages and the blind holes with a dry
cleaning solvent. Flush from the inside to the outside when it is possible.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN YOU
USE COMPRESSED AIR TO CLEAN OR DRY. USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(4) Drain the housing of as much of the solvent as possible.

(5) Remove the solvent with compressed air.

(6) Let the housing dry at the ambient temperature.

(7) After you dried the housings, apply oil to the steel parts to prevent corrosion.

CLEANING 10
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CLEANING 11

TASK 49-00-01-110-811
1. Cleaning of the Metallic Parts - General

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Vapor De-greaser Commercially Available
Non-Metallic Brush Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

P-D-680 Commercially Available
Type II Dry-Cleaning Solvent
VV-L-800 Commercially Available
Oil

(3) Expendable Parts

None

CLEANING 11
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SUBTASK 49-00-01-110-014
E. Cleaning
NOTE: This procedure is a general cleaning procedure for all types of metal parts, except
titanium parts. This procedure may not be appropriate in all geographic areas due
to environmental regulations covering the cleaning materials specified.

NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

WARNING: KEEP PRESSURE AT 29 POUNDS PER SQUARE INCH (200 KPA) OR

LESS WHEN YOU USE COMPRESSED AIR. PUT ON GOGGLES OR FACE
SHIELD TO PROTECT EYES.

WARNING: DO NOT BREATHE THE GASES OF DRY CLEANING SOLVENT. USE THE
DRY CLEANING SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE DRY
CLEANING SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES WITH
WATER AND CALL A DOCTOR. IF THE DRY CLEANING SOLVENT
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DRY CLEANING SOLVENT IS POISONOUS AND FLAMMABLE.

(1) Clean the metal parts with a non-metallic brush and dry-cleaning solvent to remove
oil, grease, and contamination. Dry with compressed air.

(2) To clean new parts, remove most of the preservative grease with an non-metallic
brush and dry cleaning solvent, then clean in a vapor de-greaser. Remove from the
vapor de-greaser and check as required.

WARNING: KEEP PRESSURE AT 29 POUNDS PER SQUARE INCH (200 KPA) OR

LESS WHEN YOU USE COMPRESSED AIR. PUT ON GOGGLES OR FACE
SHIELD TO PROTECT EYES.

(3) Drain the housings of as much of the solvent as possible. Use the compressed air to
remove the solvent from the pockets, the cores, and the drilled passages. Let the
housing air dry.

NOTE: The air must be filtered to remove water, oil, and dirt.

(4) Spray all the parts with lubricating oil if they will not be used immediately.

CLEANING 11
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CLEANING 12

TASK 49-00-01-110-812
1. Degrease and Desmut

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Nylon Brush Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-015
E. Cleaning

(1) This procedure is applicable to the following alloys

CLEANING 12
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15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless Steel
(Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A) Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel-713(LC) WI-52

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, CALL A DOCTOR.

(2) Mix the alkaline cleaner with water to a concentration of 6 to 12 oz/gal (40 to 80 g/l)
in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 45 to 60 minutes.

(4) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(5) Pressure rinse the part with the hand gun for 3 to 5 minutes.

(6) Rinse the part in the hot rinse tank for 3 to 5 minutes.

(7) Brush any areas that have oxidation with the nylon brush and hot water.

CLEANING 12
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SPM

CLEANING 13

TASK 49-00-01-110-813
1. Removal of the Carbon and the Oxidation

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Alkaline Cleaner (4008) Commercially Available
Alkaline Cleaner (4181) Commercially Available
Alkaline Cleaner (4338) Commercially Available
Stainless Steel Wire Brush Commercially Available
or
Scotch Brite

(3) Expendable Parts

None

CLEANING 13
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SUBTASK 49-00-01-110-016
E. Cleaning
(1) This procedure is applicable to the following alloys:

15-5 PH 915 Alloy Haynes-230 MAR-M-421

17-4 PH A-286 Haynes-6 N-155
17-7 PH CA-15 IN-738 Nitronic-33
300 Series Custom-455 IN-792(5A) Nitronic-40
Stainless Steel
(Except 303)
410 Hast-S Inco-718 WI-52
430 Hast-X Inconel-713(LC)
440-C Haynes-12 L-605
4777 Alloy Haynes-188 MAR-M-247

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
specific cleaning procedures.

(2) Put the part to be cleaned in the cold rinse tank for 3 to 5 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(3) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(4) Put the part to be cleaned in the cleaning tank for 5 to 10 minutes.

(5) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(6) Mix the alkaline cleaner (4181) with water to a concentration of 2.5 to 3 lb/gal (300 to
350 g/l) in the cleaning tank and heat the solution to 170 to 190ºF (77 to 88ºC).

(7) Put the part to be cleaned in the cleaning tank for 10 to 15 minutes.

(8) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

CLEANING 13
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WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(9) Put the alkaline cleaner (4008) as received in the cleaning tank and heat the solution
to 225 to 245º F (107 to 118º C).

(10) Put the part to be cleaned in the cleaning tank for 60 to 75 minutes.

(11) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(12) Mix the alkaline cleaner (4338) with water to a concentration of 2.0 to 2.5 lb/gal (240
to 300 g/l) in the cleaning tank and heat the solution to 180 to 200º F (82 to 93º C).

(13) Put the part to be cleaned in the cleaning tank for 45 to 60 minutes.

(14) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(15) Mix the alkaline cleaner (4181) with water to a concentration of 2.5 to 3 lb/gal (300 to
350 g/l) in the cleaning tank and heat the solution to 170 to 190º F (77 to 88º C).

(16) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(17) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(18) Pressure rinse the part with the hand gun for 2 to 4 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(19) Rinse the part in the hot rinse tank for 3 to 4 minutes.

(20) Using the stainless steel wire brush or Scotch Brite and hot water, brush any areas
that show oxidation.

CLEANING 13
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CLEANING 13
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SPM

CLEANING 14

TASK 49-00-01-110-814
1. Degrease and Desmut

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Alkaline Cleaner (4181) Commercially Available
Nylon Brush Commercially Available
or
Scotch Brite

(3) Expendable Parts

None

CLEANING 14
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SPM

SUBTASK 49-00-01-110-017
E. Cleaning
(1) This procedure is applicable to the following alloys:

15-5 PH 915 Alloy Haynes-230 MAR-M-421

17-4 PH A-286 Haynes-6 Nitronic-33
17-7 PH CA-15 IN-738 Nitronic-40
300 Series Custom-455 IN-792(5A) WI-52
Stainless Steel
(Except 303)
410 Hast-S Inco-718
430 Hast-X Inconel-713(LC)
440-C Haynes-12 L-605
4777 Alloy Haynes-188 MAR-M-247

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(4) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Mix the alkaline cleaner (4181) with water to a concentration of 2.5 to 3 lb/gal (300 to
350 g/l) in the cleaning tank and heat the solution to 170 to 190ºF (77 to 88ºC).

(6) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(7) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(8) Pressure rinse the part with the hand gun for 1 to 2 minutes.

CLEANING 14
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WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(9) Rinse the part in the hot rinse tank for 3 to 4 minutes.

(10) Using the nylon brush and hot water, brush any areas that show traces of grease or
oil.

CLEANING 14
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THIS PAGE INTENTIONALLY LEFT BLANK

CLEANING 14
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CLEANING 15

TASK 49-00-01-110-815
1. Degrease

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Ultrasonic Commercially Available
Cleaning Tank, Hot Commercially Available
Spray Wash Machine Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Simple Green All-purpose Cleaner Sunshine Makers, Inc.
(1Z575)
Extreme Simple Green Aircraft & Sunshine Makers, Inc.
Precision Cleaner (1Z575)
Applied 4204 Applied Chemicals Pty Ltd
(Z0142)

CLEANING 15
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Part No./Spec. No. Source (CAGE Code)

Ardrox 6333 Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
Ardrox 6333A Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
Ardrox 6376 Chemetall GMBH Chemisch-
Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
Blue Gold Industrial Cleaner Modern Chemical Inc.
(0GA37)
Blue Gold Spray Wash Modern Chemical Inc.
(0GA37)
Brulin 815 GD Brulin & Company, Inc.
(94058)
Cee-Bee 300LF Mc Gean-Rohco Incdiv Cee-
Bee Aviaiton Division DBA
Cee-Bee Aviation
(71361)

CLEANING 15
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Part No./Spec. No. Source (CAGE Code)

Cee-Bee 300LFG Mc Gean-Rohco Incdiv Cee-
Bee Aviaiton Division DBA
Cee-Bee Aviation
(71361)
Cee-Bee A-7X7 Mc Gean-Rohco Incdiv Cee-
Bee Aviaiton Division DBA
Cee-Bee Aviation
(71361)
CleanSafe 787C 0WUAB
CRP-240 Ondeo Nalco Co
(89524)
ED-306LF El Dorado Chemical Company Inc
(0HM34)
Mag-Chem DG Kleen Magnus Chemicals Ltd
(35502)
Mag-Chem Soluwax Magnus Chemicals Ltd
(35502)
Mirachem 500 Mirachem, LLCDBA
(63247)
Mirachem 750 Mirachem, LLCDBA
(63247)
Nuvite Nu-Gear SC Nuvite Chemical Compounds Corporation
(1EYE7)
Turco 5948 DPM Henkel Corp
(71410)
Turco Liquid Sprayee NP LT Henkel Corp
(71410)

CLEANING 15
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Part No./Spec. No. Source (CAGE Code)

Nylon Brush Commercially Available
or
Scotch Brite (3M, # 96 very fine)
Ardrox 3705 Chemetall GMBH Chemisch-Technische
Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemetall PLC
(K6858)

(3) Expendable Parts

None

SUBTASK 49-00-01-110-018
E. CLEANING - IMMERSION IN TANK

NOTE: Refer to the applicable maintenance manual for the item being cleaned to the
specification cleaning procedures.

NOTE: It is necessary to control the temperature of the cleaning solution. If the solution
temperature increases to more than the specified maximum temperature, the
chemistry of the solution will change and subsequently make the solution
ineffective.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN.WEAR

SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

CAUTION: DO NOT USE NUVITE NU-GEAR CLEANING SOLUTION ON MAGNESIUM

PARTS THAT DO NOT HAVE A CHROMATE CONVERSION COATING.
THIS SOLUTION WILL CAUSE A SMUT TO FORM ON THE SURFACE OF
THE MAGNESIUM PART.

(1) Put part fully into the tank of one of the aqueous cleaner solutions, (Refer to Table
601). Agitate solution using mechanical agitation (for example, mixer, circulating
pump, or up-down agitator). Air agitation is not recommended. Use of antifoam
additives is not allowed.

CLEANING 15
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Table 601

Operating Temperature
Make-up by limits by
Material Volume Volume °F °C
Applied 4204 30% 20-30% 122-158 50-70
Ardrox 6333 20% 10-20% 130-160 54-71
Ardrox 6376 30% 20-30% 140-180 60-82
Blue Gold 25% 20-25% 130-140 54-60
Industrial
cleaner
Blue Gold 30% 20-30% 130-140 54-60
Spray Wash
(low Foam)
Brulin 815 20% 10-20% 140-180 60-82
Cee-Bee 15% 15-25% 140-160 60-71
300LF
Cee-Bee 25% 15-25% 140-160 60-71
300LFG
Cee-Bee 25% 15-25% 120-160 49-71
A-7X7
CleanSafe 15% 10-15% 140-150 60-66
787C
ED-306LF 25% 10-25% 120-160 49-71
Mag-Chem DG 20% 15-20% 155-165 68-74
kleen
Mag-Chem 10% 5-10% 140-170 60-77
Soluwax
Mirachem 500 50% 25-50% 110-120 43-49
Nuvite Nu- 25% 20-25% 140-170 60-77
Gear-SC
Simple Green 100% 45-100% 105-140 41-60

CLEANING 15
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Operating Temperature
Make-up by limits by
Material Volume Volume °F °C
Turco 5948 25% 15--25% 140-180 60-82
DPM
Turco Liquid 25% 15-25% 90-190 32-88
Sprayeze NP
LT

(2) Soak part for 5 to 30 minutes. For Mag-Chem Soluwax, soak time is 10 to 15 minutes
with a 30 minute maximum. The maximum soak time for Applied 4204 is 40 minutes.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse the part with a hand gun for 3 to 5 minutes or put the part fully into the
cold or hot water to rinse. If necessary, scrub part with nylon brush or scotch-brite pad
to remove loosened soil or surface film remaining on part.

(4) If necessary, pressure rinse the part or immerse in cold or hot water to rinse.

NOTE: It is optional to put the part in hot water at 150 to 200° F (66 to 93° C) until
temperature of the part is at temperature of water to flash dry.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(5) Air dry the part using the circulating dryer at 125 to 250° F (50 to 121º C) for 5 to 15
minutes.

(6) Apply corrosion inhibitor on the part, if necessary.

SUBTASK 49-00-01-110-019
F. Ultrasonic Cleaning

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) Put the part fully into the tank of one of the aqueous cleaner solutions, (Refer to Table
602). Use of anti-foam additives is not allowed.

CLEANING 15
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Table 602

Operating Temperature
Make-up by limits by
Material Volume Volume °F °C
Applied 4204 30% 20-30% 122-158 50-70
Ardrox 6333 20% 10-20% 130-160 54-71
Ardrox 6376 30% 20-30% 140-180 60-82
Blue Gold 25% 20-25% 130-140 54-60
Industrial
cleaner
Blue Gold 30% 20-30% 130-140 54-60
Spray Wash
(low Foam)
Brulin 815 20% 10-20% 140-180 60-82
Cee-Bee 15% 15-25% 140-160 60-71
300LF
Cee-Bee 25% 15-25% 140-160 60-71
300LFG
Cee-Bee 25% 15-25% 120-160 49-71
A-7X7
CleanSafe 15% 10-15% 140-150 60-66
787C
ED-306LF 25% 10-25% 120-160 49-71
Mag-Chem DG 20% 15-20% 155-165 68-74
kleen
Mag-Chem 10% 5-10% 140-170 60-77
Soluwax
Mirachem 500 50% 25-50% 110-120 43-49
Nuvite Nu- 25% 20-25% 140-170 60-77
Gear-SC
Simple Green 100% 45-100% 105-140 41-60

CLEANING 15
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Operating Temperature
Make-up by limits by
Material Volume Volume °F °C
Turco 5948 25% 15-25% 140-180 60-82
DPM
Turco Liquid 25% 15-25% 90-190 32-88
Sprayeze NP
LT

(2) Soak part in ultrasonic cleaning tank for 5 to 10 minutes.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Flush the part with a hand gun for 3 to 5 minutes or keep the part fully in cold or hot
water to rinse. If necessary, scrub part with nylon brush or scotch-brite pad to remove
loosened soil or surface film remaining on part.

NOTE: It is optional to put the part in hot water at 150 to 200º F (66 to 93º C) until
temperature of the part is at temperature of water to flash dry.

(4) If necessary, pressure flush the part or put in cold or hot water to rinse.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Air dry the part using the circulating dryer at 125 to 250º F (52 to 121º C) for 5 to 15
minutes.

(6) Apply corrosion inhibitor on the part, if necessary.

SUBTASK 49-00-01-110-020
G. Spray Wash Machine

(1) Place parts into spray wash machine so direct spray touches most areas of each part.

CLEANING 15
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CAUTION: DO NOT USE ARDROX 6333 OR ED-306LF ON MAGNESIUM PARTS

WITHOUT A CHROMATE CONVERSION COATING BECAUSE THESE
SOLUTIONS WILL CAUSE A SMUT TO FORM ON THE SURFACE OF
UNCOATED MAGNESIUM PARTS.

(2) Spray wash parts in a 5 to 30 minute wash cycle with one of the solutions, (Refer to
Table 603).

NOTE: It is optional to immerse part in hot water at 150 to 200ºF (66 to 93ºC) until
temperature of the part is at temperature of water to flash dry.

Table 603

Operating Temperature
Make-up by limits by
Material Volume Volume ºF ºC
Blue Gold 5% 5-10% 130-140 54-60
Spray Wash
(low Foam)
Ardrox 6333 10% 2-10% 140-160 60-71
Mag-Chem DG 10% 5-10% 155-165 68-74
kleen
ED-306LF 10% 8-10% 120-160 49-71
Ardrox 6333A 10% 5-10% 150-160 66-71
Turco Liquid 10% 5-10% 90-190 32-88
Sprayeze NP
LT
Cee-Bee 10% 5-10% 140-160 60-71
300LFG
Cee-Bee 25% 15-25% 140-160 60-71
300LF
Mirachem 750 33% 25-33% 145-165 63-74
CRP-240 10% 5-10% 140-150 60-66

(3) Pressure-flush the part with a hand gun for 3 to 5 minutes or immerse part in hot water
to rinse.

CLEANING 15
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(4) Air dry the part using the circulating dryer at 125 to 250º F (52 to 121º C) for 5 to 15
minutes.

(5) Apply corrosion inhibitor on the part, if necessary.

CLEANING 15
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CLEANING 16

TASK 49-00-01-110-816
1. Degrease

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Nylon Brush Commercially Available
or
Scotch Brite

(3) Expendable Parts

None

CLEANING 16
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SUBTASK 49-00-01-110-021
E. Cleaning
(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A) Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel-713(LC) WI-52

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(4) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(5) Pressure rinse the part with the hand gun for 1 to 2 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(6) Rinse the part in the hot rinse tank for 3 to 4 minutes.

(7) Using the nylon brush or Scotch Brite and hot water, brush any areas that show grease
or oil.

CLEANING 16
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CLEANING 17

TASK 49-00-01-110-817
1. Degrease the Parts Which Show FPI Fluid

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Ultrasonic Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)

(3) Expendable Parts

None

SUBTASK 49-00-01-110-022
E. Cleaning

NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

(1) Pressure rinse the part with the hand gun for 3 to 5 minutes.

CLEANING 17
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WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Put the alkaline cleaner (Simple Green or equivalent) in the cleaning tank to 40 to
50% of tank capacity and heat the solution to 120 to 140ºF (49 to 60ºC).

(3) Put the part to be cleaned in the cleaning tank for 10 to 15 minutes.

(4) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(5) Pressure rinse the part with the hand gun for 1 to 2 minutes.

(6) Rinse the part in the hot rinse tank for 3 to 5 minutes.

CLEANING 17
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CLEANING 18

TASK 49-00-01-110-818
1. Removal of the Stop-off (Green or White)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Nylon Brush Commercially Available
or
Scotch Brite

(3) Expendable Parts

None

SUBTASK 49-00-01-110-023
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 18
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15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A) Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel-713(LC) WI-52

(2) Pressure rinse the part with the hand gun for 3 to 5 minutes.

(3) Using the nylon brush or Scotch Brite and hot water, brush any areas that show loose
stopoff powder. An unremovable stain is acceptable.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(4) Rinse the part in the hot rinse tank for 3 to 5 minutes.

CLEANING 18
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CLEANING 19

TASK 49-00-01-110-819
1. Deglass

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Alkaline Cleaner (4181) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-024
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 19
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15-5 PH 440-C Haynes-12 MAR-M-247

17-4 PH 4777 Alloy Haynes-188 MAR-M-421
17-7 PH 915 Alloy Haynes-230 N-155
300 Series A-286 Haynes-6 N-792(5A)
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 Inco-718 Nitronic-40
430 Hast-S Inconel-713(LC) Titanium 6AL4V
4340 Hast-X L-605 WI-52

(2) Pressure rinse the part with the hand gun for 3 to 5 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(3) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(4) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(5) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(6) Mix the alkaline cleaner (4181) with water to a concentration of 2.5 to 3 lb/gal (300 to
350 g/l) in the cleaning tank and heat the solution to 170 to 190ºF (77 to 88ºC).

(7) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(8) Pressure rinse the part with the hand gun for 1 to 2 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(9) Rinse the part in the hot rinse tank for 3 to 4 minutes.

CLEANING 19
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SPM

CLEANING 20

TASK 49-00-01-110-820
1. Degrease and Desmut

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Nylon Brush Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-025
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 20
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SPM

15-5 PH 440-C Haynes-12 MAR-M-247

17-4 PH 4777 Alloy Haynes-188 MAR-M-421
17-7 PH 915 Alloy Haynes-230 N-155
300 Series A-286 Haynes-6 N-792(5A)
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 Inco-718 Nitronic-40
430 Hast-S Inconel-713(LC) Titanium 6AL4V
4340 Hast-X L-605 WI-52

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210º F (71 to 99º C).

(3) Put the part to be cleaned in the cleaning tank for 20 to 30 minutes.

(4) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(5) Pressure rinse the part with the hand gun for 3 to 5 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(6) Rinse the part in the hot rinse tank for 3 to 5 minutes.

(7) Using the nylon brush and hot water, brush any areas that show oxidation.

CLEANING 20
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SPM

CLEANING 21

TASK 49-00-01-110-821
1. Degrease and Desmut

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)
Nylon Brush Commercially Available
or
Scotch Brite

(3) Expendable Parts

None

CLEANING 21
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SPM

SUBTASK 49-00-01-110-026
E. Cleaning
NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

(1) Put the part to be cleaned in a 1 to 1 solution of alkaline cleaner (Simple Green or
equivalent) and water at ambient temperature for 90 to 120 minutes.

(2) Pressure rinse the part with the hand gun and scrub using a nylon brush or Scotch
Brite to remove the surface contaminants.

(3) Pressure rinse the part with the hand gun for 2 to 4 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(4) Rinse the part in the hot rinse tank for 2 to 4 minutes.

CLEANING 21
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SPM

CLEANING 22

TASK 49-00-01-110-822
1. Desmut

A. Prerequisites

(1) None

B. Reference Information

(1) None

C. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-027
D. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421

CLEANING 22
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SPM

300 Series A-286 Haynes-6 N-155

Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel- 713(LC) WI-52

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 50 to 65 minutes.

(4) Pressure rinse the part with the hand gun for 5 to 7 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Rinse the part in the hot rinse tank for 3 to 5 minutes.

CLEANING 22
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SPM

CLEANING 23

TASK 49-00-01-110-823
1. Degrease

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)

(3) Expendable Parts

None

SUBTASK 49-00-01-110-028
E. Cleaning

NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

(1) Put the part to be cleaned in a 1 to 1 solution of alkaline cleaner (Simple Green or
equivalent) and water at ambient temperature for 15 to 25 minutes.

CLEANING 23
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SPM

(2) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(3) Pressure rinse the part with the hand gun for 2 to 4 minutes.
WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(4) Rinse the part in the hot rinse tank for 3 to 4 minutes.

CLEANING 23
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SPM

CLEANING 24

TASK 49-00-01-110-824
1. FPI Preparation of the Rotor Assembly Parts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Ultrasonic Commercially Available
Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Dryer, Forced Air Commercially Available
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)
Alkaline Cleaner (HTC) Commercially Available
White Gloves Commercially Available

(3) Expendable Parts

None

CLEANING 24
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SPM

SUBTASK 49-00-01-110-029
E. Cleaning
(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel- 713(LC) WI-52

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Put the alkaline cleaner (Simple Green or equivalent) in the ultrasonic cleaning tank
to 40 to 50% of the tank capacity and heat the solution to 120 to 140ºF (49 to 60ºC).

(3) Put the parts to be cleaned in the ultrasonic cleaning tank for 20 to 40 minutes.

(4) Rinse the parts in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the air-agitated cleaning tank and heat the solution to 160 to 210ºF (71 to
99ºC).

(6) Put the parts to be cleaned in the air-agitated cleaning tank for 20 to 30 minutes. Parts
should not touch while being agitated.

(7) Pressure rinse the parts with the hand gun.

CLEANING 24
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SPM

(8) Use the forced air dryer to dry the parts.

(9) Using the clean white gloves, inspect the parts under ultraviolet light. If parts show
background, repeat steps A through G.

CLEANING 24
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THIS PAGE INTENTIONALLY LEFT BLANK

CLEANING 24
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SPM

CLEANING 25

TASK 49-00-01-110-825
1. Desmut the Rotor Assembly

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Dryer, Forced Air Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-030
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 25
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SPM

15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel- 713(LC) WI-52

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 50 to 65 minutes. Parts must not
touch while being agitated.

(4) Pressure rinse the part with the hand gun for 5 to 7 minutes.

(5) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(6) Using the forced air dryer, dry the part.

CLEANING 25
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SPM

CLEANING 26

TASK 49-00-01-110-826
1. FPI Preparation of the Rotor Assembly

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
White Gloves Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-031
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 26
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SPM

15-5 PH 440-C Haynes-12 L-605

17-4 PH 4777 Alloy Haynes-188 MAR-M-247
17-7 PH 915 Alloy Haynes-230 MAR-M-421
300 Series A-286 Haynes-6 N-155
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-33
4130 Custom-455 IN-792(5A) Nitronic-40
430 Hast-S Inco-718 Titanium 6AL4V
4340 Hast-X Inconel- 713(LC) WI-52

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(2) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(3) Put the part to be cleaned in the cleaning tank for 20 to 30 minutes. Parts must not
touch while being agitated.

(4) Pressure rinse the part with the hand gun for 5 to 7 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Rinse the part in the hot rinse tank for 3 to 4 minutes.

(6) Using the clean white gloves, inspect the part under ultraviolet light. If part shows
background, repeat steps A through D.

CLEANING 26
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SPM

CLEANING 27

TASK 49-00-01-110-827
1. Degrease and Desmut

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Dryer, Forced Air Commercially Available
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)
Nylon Brush Commercially Available
or
Scotch Brite
White Gloves Commercially Available

(3) Expendable Parts

CLEANING 27
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SPM

None

SUBTASK 49-00-01-110-032
E. Cleaning

NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) Put the alkaline cleaner (Simple Green or equivalent) in the cleaning tank to 40 to
50% of tank capacity and heat the solution to 120 to 140ºF (49 to 60ºC).

(2) Put the parts to be cleaned in the cleaning tank for 20 to 60 minutes. Parts must not
touch while being agitated.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse the parts with the hand gun.

(4) Using the nylon brush or scotch brite and water, brush areas which might show traces
of oil or grease.

(5) Pressure rinse the parts with the hand gun for 3 to 5 minutes.

(6) Rinse the parts in the cold rinse tank for 3 to 5 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(7) Rinse the parts in the hot rinse tank for 1½ to 3 minutes.

(8) Use the forced air dryer to dry the parts.

(9) Using the clean white gloves, inspect the parts under ultraviolet light. If parts show
background, repeat steps (1) through (8).

CLEANING 27
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SPM

CLEANING 28

TASK 49-00-01-110-828
1. Passivate

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Acid, Nitric 42% Baume, 25% by Volume Commercially Available
Scotch Brite Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-033
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 28
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SPM

Nitronic-33 Stainless Steel 321

Nitronic-304 Stainless Steel 347

WARNING: DO NOT BREATHE THE GASES OF THE NITRIC ACID. USE THE NITRIC
ACID ONLY IN THE AREAS WHERE THE AIR IS CONTINUOUSLY
CHANGED. MAKE SURE THERE ARE NO SPARKS, NO FLAMES AND NO
HOT SURFACES IN THESE AREAS. IF THE NITRIC ACID TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR.
IF THE NITRIC ACID TOUCHES YOUR SKIN, WASH YOUR SKIN WITH
SOAP AND WATER. THE NITRIC ACID IS POISONOUS AND
FLAMMABLE.

(2) Put the nitric acid in the cleaning tank at ambient temperature.

(3) Put the parts to be cleaned in the cleaning tank for 30 to 45 minutes.

(4) Rinse the parts in the cold rinse tank and scrub using the Scotch Brite for 5 to 10
minutes.

(5) Pressure rinse the parts with the hand gun to thoroughly flush all of the cavities.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(6) Rinse the parts in the hot rinse tank for 5 to 10 minutes.

CLEANING 28
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SPM

CLEANING 29

TASK 49-00-01-110-829
1. Degrease the Parts Which Show FPI Fluid

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Cold Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (HTC) Commercially Available
Alkaline Cleaner (4181) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-034
E. Cleaning

(1) This procedure is applicable to the following alloys:

NOTE: Refer to the applicable maintenance manual for the item being cleaned for
the specific cleaning procedures.

CLEANING 29
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15-5 PH 440-C Haynes-12 MAR-M-247

17-4 PH 4777 Alloy Haynes-188 MAR-M-421
17-7 PH 915 Alloy Haynes-230 N-155
300 Series A-286 Haynes-6 Nitronic-33
Stainless
Steel (Except 303)
410 CA-15 IN-738 Nitronic-40
430 Custom-455 IN-792(5A)
Hast-S Inco-718 WI-52
Hast-X Inconel- 713(LC) L-605

(2) Pressure rinse the part with the hand gun for 3 to 5 minutes.

(3) Rinse the part in the cold rinse tank for 1 to 2 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(4) Mix the alkaline cleaner (HTC) with water to a concentration of 6 to 12 oz/gal (40 to
80 g/l) in the cleaning tank and heat the solution to 160 to 210ºF (71 to 99ºC).

(5) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes. Parts must not
touch while being agitated.

(6) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(7) Mix the alkaline cleaner (4181) with water to a concentration of 2.5 to 3 lb/gal (300 to
350 g/l) in the cleaning tank and heat the solution to 170 to 190ºF (77 to 88ºC).

(8) Put the part to be cleaned in the cleaning tank for 15 to 30 minutes.

(9) Rinse the part in the cold rinse tank for 1½ to 3 minutes.

(10) Pressure rinse the part with the hand gun for 1 to 2 minutes.

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CLEANING 30

TASK 49-00-01-110-830
1. Degrease

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Cleaning Tank, Air-Agitated Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Alkaline Cleaner (Simple Green or Commercially Available
equivalent)

(3) Expendable Parts

None

CLEANING 30
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SUBTASK 49-00-01-110-035
E. Cleaning
NOTE: Refer to the applicable maintenance manual for the item being cleaned for the
specific cleaning procedures.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) Put the alkaline cleaner (Simple Green or equivalent) in the cleaning tank to 40 to
50% of tank capacity and heat the solution to 120 to 140ºF (49 to 60ºC).

(2) Put the parts to be cleaned in the cleaning tank for 5 to 10 minutes. Parts must not
touch while being agitated.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse the weld joints of the parts with the hand gun for 3 to 5 minutes.

(4) Pressure rinse the parts with the hand gun for 3 to 5 minutes.

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES, AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Rinse the parts in the hot rinse tank for 3 to 4 minutes.

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CLEANING 31

TASK 49-00-01-110-832
1. Cleaning of the Titanium Parts (Alternate Method)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Hot WaterTank Commercially Available
Alkaline Tank Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Ardrox 185L Brent SA
Concentration: 175 ±25 ml/l at 60°C (±6° 280, Rue J.B. Godin
C) to 85°C (±5°C) 02200 Villeneuve St.
Germain France
MIL-C-6529 Type II Commercially Available
Castrol Brayco 482, Engine Preservation
Oil
Plastic Bag Commercially Available
White Spirit Commercially Available
Tag Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-110-036
E. Cleaning
WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

WARNING: LUBRICATING OIL MAY CAUSE SKIN RASH. DO NOT BREATHE

VAPORS. USE IN A WELL-VENTILATED AREA. WEAR EYE PROTECTION
AND RUBBER GLOVES.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

CAUTION: DO NOT CLEAN TITANIUM PARTS WITH CHLORINATED, FLUORINATED

OR FLUOROCHLORINATED SOLVENTS.

CAUTION: DO NOT TOUCH CLEANED PARTS WITH BARE HANDS. IF YOU DO NOT
USE CLEAN RUBBER GLOVES, THE PART CAN BREAK AT HIGH
TEMPERATURES.

(1) If required, white spirit wash the part to remove oil and grease.

(2) Dry the part with compressed air.

(3) Put the part in alkaline de-rust solution (Ardrox 185L) for 15 to 30 minutes.

(4) Pressure spray rinse the part.

(5) Put the part in hot water rinse.

(6) Dry the part with a clean, dry, and oil-free air blast.

(7) Put the parts in a plastic bag if the part will not be used immediately.

(8) If the part is to be stored, re-protect with preservation oil (Brayco 482).

CLEANING 31
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(9) Put a tag on the plastic bag which has the indication “CLEANED TITANIUM PARTS.
DO NOT TOUCH WITH BARE HANDS.”

CLEANING 31
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CLEANING 32

TASK 49-00-01-110-833
1. Cleaning of the Aluminum Parts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Ultrasonic Tank Commercially Available
Tanks (with heater) Commercially Available
Spray Washing Machine Commercially Available
Spray Gun Commercially Available
Oven Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Ardrox 295 GD Commercially Available
Commercially Available(Concentration:
20% by volume)
Ardrox 6333 Commercially Available
Turco 3878 Commercially Available

(3) Expendable Parts

None

CLEANING 32
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SUBTASK 49-00-01-110-037
E. Cleaning
WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(1) Remove surface dirt by immersing the part(s) fully into a bath of Ardrox 6333 at 68°F
(20°C) for 30 minutes.

NOTE: As an alternate, Ardrox 6333 may be used in a spray washing machine at

122 to 176°F (50 to 80°C) for 30 minutes.

(2) Pre-flush with clean water.

(3) Remove any oil deposits or grease by immersing the part(s) fully into a bath of Turco
3878 at 68°F (20°C) for 45 minutes.

NOTE: The part(s) may be immersed up to 60 minutes, as required, to remove oil/

grease residuals.

NOTE: As an alternate, Ardrox 6333 may be used in a spray washing machine at

122 to 176°F (50 to 80°C), or immerse in an ultrasonic tank at 140 to 167°F
(60 to 75°C) for 30 minutes.

(4) Flush the part(s) in clean water, or use a water spray gun.

(5) Remove surface oxidation by immersing the part(s) fully into a bath of Ardrox 295 at
68°F (20°C) for 15 minutes.

(6) Flush the part(s) in clean water, or use a water spray gun.

(7) Dry the part(s) with filtered air.

NOTE: As an alternate, the part(s) may be dried in an oven at 212°F (100°C) to

remove moisture.

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CLEANING 33

TASK 49-00-01-110-834
1. Stripping Coatings with High-pressure Water Blasting

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

High-powered Waterjet Commercially Available
Stripping System
Magnification (50X or better) Commercially Available

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-110-038
E. Cleaning

(1) This procedure is applicable to the following alloys:

15-5 PH 440-C Custom-455 L-605

17-4 PH 4777 Alloy Hast-S MAR-M-247
17-7 PH 6061 Hast-X MAR-M-421
2024 915 Alloy Haynes-12 N-155
300 Series A-286 Haynes-188 Nitronic-33
Stainless

CLEANING 33
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Steel (Except 303) A-356 Haynes-230 Nitronic-40

410 A-357 Haynes-6 QQ-A-591
4130 A-380 IN-625 Titanium 6A14V
430 Aluminum Alloy IN-738 WI-52
4340 C355 IN-792(5A) Inconel- 713(LC)
CA-15 Inco-718 Magnesium Alloy

NOTE: Equipment must be automated to ensure continuous relative motion between

the water jet nozzle and the work piece. Automation should control the nozzle
position and movement, part movement, and water pressure.

NOTE: Equipment must include correct fail-safe devices to prevent part damage
caused by excessive dwell time due to mechanical failures.

NOTE: Typical stripping pressures are between 20,000 and 55,000 psi (137,895 and
379,211 kPa) with water flow from 0.05 to 6 gpm (0.19 to 22.71 lpm).

NOTE: Typical nozzle jet size is from 0.003 to 0.018 inch (0.08 to 0.46 mm) with the
number of jets/nozzle depending on application and flow capability.

WARNING: REFER TO THE MANUFACTURER’S MATERIAL SAFETY DATA SHEETS

FOR CONSUMABLE MATERIALS INFORMATION SUCH AS HAZARDOUS
MATERIALS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE,
EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS
FOR SAFE HANDLING, USES, AND CONTROL MEASURES.

(2) Fixture the part to prevent movement during blasting.

(3) Water blast the part to remove coating(s). Use the previously qualified parameters.

NOTE: The maximum set point water pressure is 55,000 psi (379,211 kPa).

(4) Remove the part from the fixture.

(5) Do a visual inspection for total coating removal. If there is any remaining coating,
proceed as follows:

(a) Make additional passes, if allowed, by the process authorization, or

CLEANING 33
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(b) Strip the part by the usual process (such as chemical, grit-blasting or machining
techniques) if all dimensional and minimum wall thickness requirements are met.
NOTE: To obtain a Hamilton Sundstrand authorization, an equipment
manufacturer or repair source seeking Special Application
Authorization must complete a program that will:

1 Metallographically evaluate test coupons at various operating parameters

for excessive stock loss by examination at 50X magnification or greater,
with no violation of material thickness tolerance as the acceptable level of
stock loss, and

2 Include a satisfactory review of equipment and process operation sheets

by Hamilton Sundstrand Engineering, and

3 Can include an on-site process demonstration.

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CLEANING 34

TASK 49-00-01-110-835
1. Cleaning of the Titanium Parts (Alternate Method)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks (with heater) Commercially Available
Ultrasonic Cleaning Commercially Available
Equipment (optional)
Beaker Commercially Available
Pipette Commercially Available
Graduated Pipette Commercially Available
Oven Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Ardrox 6376 Commercially Available
Demineralized Water Commercially Available
0.1N Hydrochloric Acid Commercially Available
ASTM D770 Commercially Available
Isopropyl Alcohol

CLEANING 34
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Part No./Spec. No. Source (CAGE Code)

ASTM D329 Commercially Available
Acetone
Plastic Bag Commercially Available
Bromophenol Blue Indicator Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-039
E. Titration Procedure for the Ardrox 6376 Solution

WARNING: USE HYDROCHLORIC ACID (ALSO KNOWN AS HCL, MURIATIC ACID,

CHLOROHYDRIC ACID, AQUEOUS HYDROGEN CHLORORIDE)
CORRECTLY. THE ACID AND ITS FUMES ARE REACTIVE, CORROSIVE,
AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACID, GET THE MATERIAL SAFETY
DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0005SE, IN THE WARNING REGISTRY 341-006. BEFORE YOU USE
THE ACID, PUT ON NEOPRENE GLOVES, CHEMICAL APRON,
CHEMICAL-SPLASH GOGGLES AND A FACE SHIELD. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ACID FUMES BELOW
THE MATERIAL SAFETY DATA SHEET. DO NOT ADD WATER TO ACID.
VERY SLOWLY ADD ACID TO WARM WATER. KEEP THE ACID-
CONTAINER TIGHTLY SEALED EXCEPT WHEN POURING THE ACID.
AVOID SPILLS.

(1) Make sure that the tank is clean and free of debris.

WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(2) Fill the tank 3/4 full with room-temperature water. Do not heat above 90° F (32° C).
Slowly pour in the required amount of Ardrox 6376. Add more water to fill the holding
tank to operating capacity. Heat the solution to the operating temperature.

NOTE: The concentration (and occasionally the pH) of Ardrox 6376 solution must be
monitored to achieve best results. Use the following titration procedure to
determine the concentration and replenish, as indicated. Perform this at the
start of every shift or more frequently if production is heavy.

(3) Take a 5 ml sample of the Ardrox 6376 solution from the tank with a pipette and place
it in a beaker.

(4) Add three drops of bromophenol blue indicator to the sample.

(5) Fill a graduated pipette to the 5 ml mark with 0.1 N hydrochloric acid.

(6) Drop by drop, add it to the beaker, gently swirling until the solution changes from blue
to yellow. Note the amount (number of ml used). These are called points of titration.

(7) Compare these points to the initial points, (Refer to Table 601).

Table 601
Point of Titration

Initial Concentration
Initial Points (gal/100 gal)
5.5 20
6.0 22
6.6 24
7.1 26
7.6 28
8.2 30

(8) Add 2.5 gallons of Ardrox 6376 for each 100 gallons to bring the solution strength up
1 titration point. The concentration should be 20 to 30%.

NOTE: Normally, the pH will remain stable. If problems occur and the concentration
and temperature are within range, check the pH to verify that it is correct.

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SUBTASK 49-00-01-110-040
F. Cleaning
WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY
FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

CAUTION: CLEAN THE PARTS IMMEDIATELY BEFORE ASSEMBLY OR NO MORE

THAN EIGHT HOURS BEFORE ASSEMBLY.CLEAN THE PARTS
IMMEDIATELY BEFORE ASSEMBLY OR NO MORE THAN EIGHT HOURS
BEFORE ASSEMBLY.

(1) Remove oils or grease with acetone or isopropyl alcohol.

WARNING: DO NOT BREATHE THE GASES OF THE ARDROX PRODUCTS. USE THE
ARDROX PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE ARDROX
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THE ARDROX PRODUCTS TOUCH YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE ARDROX
PRODUCTS ARE POISONOUS AND FLAMMABLE.

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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(2) Put the parts in the Ardrox 6376 solution for 15 to 30 minutes. Maintain the solution
at 140 to 180°F (60 to 82°C).

NOTE: As an alternate, ultrasonic cleaning equipment may be used in the tank.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Flush the parts with a flow of cold demineralized water, or immerse in a tank of cold
demineralized cold water. Then flash dry the part by immersing in demineralized hot
water at 160°F (71°C) minimum.

(4) Make sure that all the parts are clean.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Dry the parts with compressed air or in an oven at 160 to 275°F (71 to 135°C).

NOTE: Use filtered air without water, oil, and dirt.

(6) Do not touch the parts with bare hands after cleaning. Put the parts in a plastic bag if
they are not used immediately.

(7) Put a tag on the plastic bag which says “CLEANED TITANIUM PARTS. DO NOT
TOUCH WITH BARE HANDS.”

CLEANING 34
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CLEANING 35

TASK 49-00-01-110-836
1. Cleaning of Internal Cores, Ports, Lubricating Passages, and/or Orifices of the Gearbox Housing
Assemblies and Oil Cooler by Flushing

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Flushing and Filtering Equipment with Commercially Available
Fixtures (10-micron filter canister on
system)
Mechanical Shaker Commercially Available
Inspection Filter (100 mesh) Commercially Available
Air Furnace (or equivalent) Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Preservation Oil Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-041
E. Cleaning of the Oil Cooler

(1) Clean the part, as required, according to an appropriate cleaning procedure(s) in the
Standard Practices Manual, HSPS 490001.

CLEANING 35
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(2) Install the part in a flushing and filtering station capable of delivering a flow of 25 gpm
(94.6 lpm) of solvent or preservation oil.
(3) Flush the part with a flow of solvent or preservation oil at 30 psi (207 kPa) while
shaking the oil cooler with a mechanical shaker.

(4) Maintain the flow for 15 to 20 minutes, then reverse the flow for another 15 to 20
minutes, while continuing the mechanical shaking.

(5) Install an inspection filter (100 mesh) on the outlet side, and flush the oil cooler for 5
minutes in each direction.

NOTE: When reversing the flow, do not backflush the filter.

(6) Do a visual inspection of the inspection filter for particles.

NOTE: No particles are allowed.

(7) If particles are still present, repeat steps (1) through (6), as required, until the particles
are removed.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(8) Drain and flush the solvent from the oil cooler using hot water at 160 to 180° F (71 to
82° C).

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(9) Dry the oil cooler with filtered air (or in an oven) at 300° F (149° C) to remove moisture.

NOTE: Use filtered air without water, oil and dirt.

SUBTASK 49-00-01-110-042
F. Cleaning of the Gearbox Housing Assemblies

(1) Clean the part, as required, according to an appropriate cleaning procedure(s) in the
Standard Practices Manual, HSPS 490001.

(2) Install the part in a flushing and filtering station capable of delivering a flow of 25 gpm
(94.6 lpm) of solvent or preservative oil.

(3) Flush the part with a flow of solvent or preservation oil at 30 psi (207 kPa) while
shaking the gearbox housing with a mechanical shaker.

(4) Maintain the flow for 15 to 20 minutes, then reverse the flow for another 15 to 20
minutes, while continuing the mechanical shaking.

CLEANING 35
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(5) Drain and flush the solvent from the gearbox housing using hot water at 160 to 180°
F (71 to 82° C).

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(6) Dry the gearbox housing with filtered air (or in an oven) at 300° F (149° C) to remove
moisture.

NOTE: Use filtered air without water, oil and dirt.

(7) Do a boroscope inspection to check all cores and passages for debris. If any debris
is found, repeat the flush procedure until the gearbox housing is clean.

CLEANING 35
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CLEANING 36

TASK 49-00-01-110-837
1. One-Step Alkaline Rust Remover for Cleaning Titanium Parts Only

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Hand Spray-Gun, Pressure Rinse Commercially Available
Dryer, Air Circulating (Forced Air) Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

5-840 Applied Chemicals PTY Ltd
Applied (Z0142)
185 & 185L Chemetall GMBH Chemisch-
Ardrox Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)

CLEANING 36
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Part No./Spec. No. Source (CAGE Code)

J-84A Mc Gean-Rohco Inc
Cee-Bee (71361)
J-84AL Mc Gean-Rohco Inc
Cee-Bee (71361)
HDL-202 Magnus Chemicals Ltd
MagChem (liquid) (35502)
4181 Henkel Corp
Turco (71410)
4181L Henkel Corp
Turco (71410)
Nylon Brush Commercially Available
Acid resistant gloves Commercially Available
Deionized or Demineralized Water Commercially Available
Lint-free Cloth Commercially Available
White cotton gloves Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-043
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE CHEMICAL PRODUCTS. USE

ONLY IN AREAS WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE
SURE THERE ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES
IN THESE AREAS. IF THE SOLUTIONS TOUCHES EYES, FLUSH EYES
WITH WATER AND CALL A DOCTOR. IF THE SOLUTION TOUCHES
YOUR SKIN, WASH WITH SOAP AND WATER. THE SOLUTIONS ARE
POISONOUS AND FALMMABLE.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

CAUTION: THIS CLEANING PROCEDURE MUST ONLY BE USED WHEN SPECIFIED

BY AN ENGINE MANUAL. TITANIUM PARTS MAY CONTAIN NON-
TITANIUM DETAILS THAT CAN BE DAMAGED BY THIS SOLUTION.

CAUTION: THE SOLUTION TANK MUST HAVE A TIMER TO PREVENT EXCESSIVE

STOCK LOSS DUE TO UNCONTROLLED IMMERSION TIMES.

CLEANING 36
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CAUTION: THE ALKALINE RUST REMOVER CLEANING SOLUTION TANK USED

FOR TITANIUM MUST BE RESTRICTED TO TITANIUM PARTS ONLY.
NOTE: This cleaning process must only be used when specified in the appropriate engine
manual. Titanium parts may contain non-titanium details and coatings that can be
damaged by this procedure.

(1) If necessary, remove any grease or oils with an alkaline cleaner. (Refer to Reference
Information for the cleaning of the metallic parts).

CAUTION: EXCEEDING SPECIFIED IMMERSION TIME MAY RESULT IN EXCESSIVE

STOCK LOSS THAT CAN ERODE PART SURFACES BEYOND
DIMENSIONAL LIMITS.

(2) Soak the part in one of the alkaline rust remover solutions, (Refer to Table 601) or
(Refer to Table 602), for the specified time and temperature.

Table 601
Short Soak

Operating Time
Material Make-up Limits (minutes) Temperature
Ardrox 185 3.0 lbs/gal (360 2.5-3.0 lbs/gal 1 to 4 180 -200°F (82-
g/l) (200-360 g/l) 93°C)
Ardrox 185L 50% by volume 34-50 by 1 to 4 180 -200°F (82-
volume 93°C)
Cee-Bee 3.0 lbs/gal (360 2.0-3.0 lbs/gal 1 to 4 180 -200°F (82-
J-84A g/l) (240-360 g/l) 93°C)
Cee-Bee 48 fl.oz/gal 40-48.oz/gal 1 to 4 180 -200°F (82-
J-84AL (369.6 ml/l) (308.0-369.6 93°C)
(37% by ml/l) (30-37 by
volume) volume)
MagChem 35% by volume 30-40 by 1 to 4 180 -200°F (82-
HDL-202 volume 93°C)
(liquid)
Turco 4181 3.0 lbs/gal (360 2.0-3.0 lbs/gal 1 to 4 180 -200°F (82-
g/l) (240-360 g/l) 93°C)
Turco 75% by volume 50-75 by 1 to 4 180 -200°F (82-
4181L volume 93°C)

CLEANING 36
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Table 602
Long Soak

Operating
Material Make-up Limits Time (minutes) Temperature
Ardrox 185 19.3 oz wt/gal 14.5-19.3 wt/ 15 to 30 160-170°F (71
(144 g/l) gal (108-144 g/ -77°C)
l)
Ardrox 185L 20% by volume 15-20% by 15 to 30 160-170°F (71
volume -77°C)
Cee-Bee 16 oz wt/gal 12-16 oz wt/gal 15 to 30 160-170°F (71
J-84A (120 g/l) (90-120 g/l) -77°C)
Cee-Bee 13% by volume 9-13% by 15 to 30 160-170°F (71
J-84AL volume -77°C)
MagChem 18% by volume 12-18% by 15 to 30 160-170°F (71
HDL-202 volume -77°C)
(liquid)
Turco 4181 12.1 oz. wt/gal 8.0-12.1 oz. wt/ 15 to 30 160-170°F (71
(90 g/l) gal (60-90 g/l) -77°C)
Turco 20% by volume 12-20% by 15 to 30 160-170°F (71
4181L volume -77°C)
Applied 6.7 oz.wt/gal 5.4-6.7 oz.wt/ 15 to 30 160-170°F (71
5-840 (50 g/l) gal (40-50 g/l) -77°C)

(3) Pre-rinse the parts above the Alkaline Rust Remover bath using a minimum amount
of cold water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(4) Immerse the part in cold clean demineralized water, then pressure rinse.

NOTE: Handle parts with clean white cotton gloves.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(5) Air dry or flash dry by putting the part fully into hot water at 150 to 200°F (66 to 93°C)
until temperature of part is at water temperature.

CLEANING 36
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WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(6) As necessary, use clean, dry shop air that contains no oil vapors, to blow the water
from the part.

(7) Visually inspect part to make sure that the part surfaces and cavities are clean.

(8) If necessary, place part in plastic bag if it is not to be used immediately.

CLEANING 36
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CLEANING 37

TASK 49-00-01-110-838
1. One-Step Alkaline Rust Remover Long Soak

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Hand Spray-Gun, Pressure Rinse Commercially Available
Dryer, Air Circulating (Forced Air) Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

CLEANING 37
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Part No./Spec. No. Source (CAGE Code)

5-840 Applied Chemicals PTY Ltd
Applied (Z0142)
185 & 185L Chemetall GMBH Chemisch-
Ardrox Technische Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
J-84A Mc Gean-Rohco Inc
Cee-Bee (71361)
J-84AL Mc Gean-Rohco Inc
Cee-Bee (71361)
HDL-202 Magnus Chemicals Ltd
MagChem (liquid) (35502)
4181 Henkel Corp
Turco (71410)
4181L Henkel Corp
Turco (71410)
Nylon Brush Commercially Available
Acid resistant gloves Commercially Available
Deionized or Demineralized Water Commercially Available
Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-044
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE CHEMICAL PRODUCTS. USE

ONLY IN AREAS WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE
SURE THERE ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES
IN THESE AREAS. IF THE SOLUTIONS TOUCHES EYES, FLUSH EYES
WITH WATER AND CALL A DOCTOR. IF THE SOLUTION TOUCHES
YOUR SKIN, WASH WITH SOAP AND WATER. THE SOLUTIONS ARE
POISONOUS AND FALMMABLE.

CLEANING 37
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
CAUTION: DO NOT USE THIS PROCEDURE TO CLEAN ALUMINIUM OR
MAGNESIUM PARTS OR PACK WITH ALUMINUM COATINGS BECAUSE
DAMAGE CAN OCCUR.

NOTE: Do not use this cleaning procedure on titanium parts.

(1) If necessary, remove any grease or oils with an alkaline cleaner. (Refer to Reference
Information for the cleaning of the metallic parts).

(2) Put the parts fully into a bath of alkaline rust remover solution, at a temperature of 180
to 200°F (82 to 93°C) for 30 to 90 minutes.

NOTE: If a part is heavily scaled, remove the part from the solution, (Refer to Table
601) up to two times, during the cleaning cycle and pressure spray rinse the
degraded scale. Make sure that the total time in the solution is not more than
the maximum time specified.

Table 601

Material Make-up Operating Limits

Applied 5-840 33.5 oz.wt/gal (250 g/l) 26.8-33.5 oz.wt/gal
(200-250 g/l)
Ardrox 185 3.0 lbs/gal (360 g/l) 2.5-3.0 lbs/gal (200-360 g/
l)
Ardrox 185L 50% by volume 34-50% by volume
Cee-Bee J-84A 3.0 lbs/gal (360 g/l) 2.0-3.0 lbs/gal (240-360 g/
l)
Cee-Bee J-84AL 48 fl.oz/gal (369.6 ml/l) 40-48 fl.oz/gal
(37% by volume) (308.0-369.6 ml/l)
(30-37% by volume)
MagChem HDL-202 35% by volume 30-40% by volume
(liquid)
Turco 4181 3.0 lbs/gal (360 g/l) 2.0-3.0 lbs/gal (240-360 g/
l)
Turco 4181L 75% by volume 50-75% by volume

(3) Pre-rinse the parts above the Alkaline Rust Remover bath using a minimum of cold
clean water.

CLEANING 37
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WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.
(4) Put the parts in cold clean water and remove any loose surface debris with a nylon
brush (do not use a metal brush) or use a water spray-gun.

NOTE: If the part is not clean, it is acceptable to repeat this procedure, one time only.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(5) Air dry the part or dry in a re-circulating oven at 100 to 250° F (38° to 121° C) for 5 to
20 minutes or flash dry by immersing the part in hot water at 150° to 200° F (66 to 93°
C) until temperature of part is at water temperature.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(6) As necessary, use clean, dry shop air that contains no oil vapors, to blow the water
from the part.

(7) Visually inspect part to make sure that the part surfaces and cavities are clean.

(8) If necessary, apply corrosion inhibitor on part.

CLEANING 37
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CLEANING 38

TASK 49-00-01-110-839
1. Four Step Alkaline Rust Remover and Acidic De-scaler with Inhibited Phosphoric Acid

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Hand Spray-Gun, Pressure Rinse Commercially Available
Dryer, Air Circulating (Forced Air) Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

5770 Applied Chemicals PTY Ltd
Applied (Z0142)
2-690 Applied Chemicals PTY Ltd
Applied (Z0142)

CLEANING 38
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Part No./Spec. No. Source (CAGE Code)

185 Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
185L Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
188 Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
188 RFU Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)

CLEANING 38
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Part No./Spec. No. Source (CAGE Code)

1218 Chemetall GMBH Chemisch-Technische
Ardorx Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
1435 (A) Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
1435 (B) Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
1873 A Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
C-623 Mcgean-Rohco Inc
Cee-Bee (71361)
J-3 Mcgean-Rohco Inc
Cee-Bee (71361)

CLEANING 38
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Part No./Spec. No. Source (CAGE Code)

J-84A Mcgean-Rohco Inc
Cee-Bee (71361)
J-84AL Mcgean-Rohco Inc
Cee-Bee (71361)
J-88 Mcgean-Rohco Inc
Cee-Bee (71361)
J-88L Mcgean-Rohco Inc
Cee-Bee (71361)
AP-954 Magnus Chemicals ltd
MagChem (35502)
AP-988 Magnus Chemicals ltd
MagChem (35502)
HDL-202 Magnus Chemicals ltd
MagChem (Liquid) (35502)
HDL-2524 Magnus Chemicals ltd
MagChem (35502)
HDL-2524C Magnus Chemicals ltd
MagChem (35502)
HDL-2524P Magnus Chemicals ltd
MagChem (35502)
4181 Henkel Corp
Turco (71410)
4181L Henkel Corp
Turco (71410)
4338 Henkel Corp
Turco (71410)
4338L Henkel Corp
Turco (71410)
4409 Henkel Corp
Turco (71410)
Nylon Brush Commercially Available
Acid resistant gloves Commercially Available
Deionized or Demineralized Water Commercially Available
Lint-free Cloth Commercially Available

CLEANING 38
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(3) Expendable Parts

None
SUBTASK 49-00-01-110-045
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE CHEMICAL PRODUCTS. USE

ONLY IN AREAS WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE
SURE THERE ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES
IN THESE AREAS. IF THE SOLUTIONS TOUCHES EYES, FLUSH EYES
WITH WATER AND CALL A DOCTOR. IF THE SOLUTION TOUCHES
YOUR SKIN, WASH WITH SOAP AND WATER. THE SOLUTIONS ARE
POISONOUS AND FLAMMABLE.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

NOTE: Aluminized, thermally sprayed coatings and plated parts are subject to corrosion
of varying intensity when cleaned using this process. Part must be inspected for
the presence of coatings/plating and handled accordingly.

NOTE: It is acceptable to use a four-step alkaline rust remover and acidic descaler (without
inhibited phosphoric acid) as an alternate to this cleaning procedure.

(1) If necessary, remove any grease or oils with an alkaline cleaner. (Refer to Reference
Information for the cleaning of the metallic parts).

(2) Put the parts fully into a bath of Alkaline Rust Remover solution, (Refer to Table
601) at a temperature of 180 to 200°F (82 to 93°C) for 15 to 30 minutes.

Table 601

Material Make-up Operating Limits

Applied 5-840 33.5 oz.wt/gal (250 g/l) 26.8-33.5 oz.wt/gal
(200-250 g/l)
Ardrox 185 3.0 lbs/gal (360 g/l) 2.5-3.0 lbs/gal (200-360 g/
l)
Ardrox 185L 50% by volume 34-50% by volume
Cee-Bee J-84A 3.0 lbs/gal (360 g/l) 2.0-3.0 lbs/gal (240-360 g/
l)
Cee-Bee J-84AL 48 fl.oz/gal (369.6 ml/l) 40-48 fl.oz/gal
(37% by volume) (308.0-369.6 ml/l)
(30-37% by volume)

CLEANING 38
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Material Make-up Operating Limits

MagChem HDL-202 35% by volume 30-40% by volume
(liquid)
Turco 4181 3.0 lbs/gal (360 g/l) 2.0-3.0 lbs/gal (240-360 g/
l)
Turco 4181L 75% by volume 50-75% by volume

(3) Pre-rinse the parts above the Alkaline Rust Remover bath using a minimum amount
of cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(4) Put the parts fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray-gun.

(5) Put the part fully into a bath of acidic scale conditioner solution, (Refer to Table
602) at the temperature specified for 15 to 30 minutes.

Table 602

Material Make-up Operating Limits Temperature

Ardrox 1873A 25% by volume 20-25% by 175-185ºF
volume (79-85ºC)
Cee-Bee J-3 20% by volume 15-20% by 175-185ºF
volume (79-85ºC)
MagChem 20% by volume 15-20% by 175-185ºF
AP-988 volume (79-85ºC)
Turco Scale Gon 300 ml/I (30% by 200-300 ml/I 175-195ºF
#5 volume) (20-30% by (79-90ºC)
volume)

(6) Pre-rinse the parts above the acidic scale conditioner solution bath using a minimum
amount of cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(7) Put the part fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray gun.

(8) Put part fully into a bath of alkaline permanganate solution, (Refer to Table 603) at a
temperature of 180 to 200°F (82 to 93°C) for 15 to 30 minutes.

CLEANING 38
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Table 603

Solution Material Make-up Operating Limits

#1 Ardrox 1435A 25% by volume 15-25% by volume
Ardrox 1435B 25% by volume 15-25% by volume
#2 Ardrox 188 RFU 100% by volume Additives
#3 Cee-Bee J-88L 100% by volume 65-100% by volume
#4 Turco 4338L, Part 1 25% by volume 15-25% by volume
Turco 4338L, Part 2 25% by volume 15-25% by volume
#5 Ardrox 188 (powder) 1.35 lbs/gal Sodium Hydroxide=
(160 g/l) 80-120 g/l
Potassium
Permanganate=30-
90 g/l
#6 Cee-Bee J-88 2.0 lbs/gal 1.3-2.0 lbs/gal
(powder) (240 g/l) (156-240 g/l)
#7 MagChem 2.0 lbs/gal 1.3-2.0 lbs/gal
HDP-2524 (powder) (240 g/l) (156-240 g/l)
#8 Turco 4338 2.5 lbs/gal 2.0-2.5 lbs/gal
(powder) (300 g/l) (240-300 g/l)
#9 MagChem 50% by volume 30-50% by volume
HDL-2524C
MagChem 25% by volume 15-25% by volume
HDL-2524P
#10 Sodium Hydroxide 25 oz/gal 2.0-3.0 oz/gal
Caustic soda) (187 g/l) (150-225 g/l)
Potassium 10 oz/gal 6-12 oz/gal
Permanganate (75 g/l) (45-90 g/l)
– commercial grade
A-A-59787
#11 Alkaline 30% to 50% by 100-250 g/l
Permanganate volume

(9) Pre rinse the parts above the alkaline permanganate solution bath using a minimum
amount of cold clean water.

CLEANING 38
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WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.
(10) Put the parts fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray-gun.

WARNING: USE PHOSPHORIC ACID (ALSO KNOWN AS H3PO4, OR

ORTHOPHOSPHORIC ACID) CORRECTLY. THE ACID IS REACTIVE,
CORROSIVE, AND POISONOUS. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE ACID, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0008SE, IN THE WARNING REGISTRY 341- 006. BEFORE
YOU USE THE ACID, PUT ON RUBBER GLOVES, CHEMICAL APRON,
CHEMICAL SPLASH GOGGLES AND A FACE SHIELD. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ACID FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT. DO NOT ADD WATER TO
ACID. VERY SLOWLY ADD ACID TO WARM WATER. KEEP THE ACID-
CONTAINER TIGHTLY SEALED EXCEPT WHEN POURING THE ACID.
AVOID SPILLS.

(11) Put part fully into a bath of inhibited phosphoric acid solution at room temperature
for 15 to 30 minutes.

Table 604

Material Make-up Operating Limits

Ardrox 1218 50% by volume 45-50% by volume
Mag-Chem AP 954 50% by volume 45-50% by volume
Cee-Bee C-623 50% by volume 45-50% by volume
Turco 4409 50% by volume 45-50% by volume
Applied 2-690 50% by volume 45-50% by volume

(12) Pre-rinse the parts above the inhibited phosphoric acid solution bath using a minimum
amount of cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(13) Put the parts into the cold clean water and remove any loose scale with a nylon brush
(do not use a metal brush) or use a water spray-gun.

(14) Visually inspect part to make sure part surface and cavities are clean. If the part is not
clean, then it is permitted to clean the part per this procedure again, one time only.

CLEANING 38
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(15) Air dry or dry in a re-circulating oven at 100 to 250° F (38 to 121° C) for 5 to 20 minutes
or flash dry by immersing part in hot water 150 to 200° F (66 to 93° C) until temperature
of part is at water temperature.

(16) If necessary, apply corrosion inhibitor on part.

(17) One additional cleaning option to remove stubborn soil is permitted. Complete all rinse
and preservation steps after cleaning.

CLEANING 38
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CLEANING 39

TASK 49-00-01-110-840
1. Four Step Alkaline Rust Remover and Acidic Descaler Without Inhibited Phosphoric Acid.

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic Parts
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tanks with heater Commercially Available
Hand Spray-Gun, Pressure Rinse Commercially Available
Dryer, Air Circulating (Forced Air) Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

5770 Applied Chemicals PTY Ltd
Applied (Z0142)
5-840 Applied Chemicals PTY Ltd
Applied (Z0142)

CLEANING 39
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Part No./Spec. No. Source (CAGE Code)

185 Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
185L Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
188 Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
188 RFU Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)

CLEANING 39
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Part No./Spec. No. Source (CAGE Code)

1435 (A) Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
1435 (B) Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
1873 A Chemetall GMBH Chemisch-Technische
Ardrox Verfahren MBH
(D1940)
Brent America Inc
(23373)
Chemetall Chemical Products Inc
(02CA7)
Chemethall PLC
(K6858)
J-3 Mcgean-Rohco Inc
Cee-Bee (71361)
J-84A Mcgean-Rohco Inc
Cee-Bee (71361)
J-84AL Mcgean-Rohco Inc
Cee-Bee (71361)
J-88 Mcgean-Rohco Inc
Cee-Bee (71361)
J-88L Mcgean-Rohco Inc
Cee-Bee (71361)
AP-988 Magnus Chemicals ltd
MagChem (35502)

CLEANING 39
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Part No./Spec. No. Source (CAGE Code)

HDL-202 Magnus Chemicals ltd
MagChem (Liquid) (35502)
HDL-2524 Magnus Chemicals ltd
MagChem (35502)
HDL-2524C Magnus Chemicals ltd
MagChem (35502)
HDL-2524P Magnus Chemicals ltd
MagChem (35502)
4181 Henkel Corp
Turco (71410)
4181L Henkel Corp
Turco (71410)
4338 Henkel Corp
Turco (71410)
4338L Henkel Corp
Turco (71410)
Turco Scale Gon #5 Henkel Corp
(71410)
Nylon Brush Commercially Available
Acid resistant gloves Commercially Available
Deionized or Demineralized Water Commercially Available
Lint-free Cloth Commercially Available
White cotton gloves Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-110-046
E. Cleaning

WARNING: DO NOT BREATHE THE GASES OF THE CHEMICAL PRODUCTS. USE

ONLY IN AREAS WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE
SURE THERE ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES
IN THESE AREAS. IF THE SOLUTIONS TOUCH EYES, FLUSH EYES WITH
WATER AND CALL A DOCTOR. IF THE SOLUTION TOUCHES SKIN,
WASH WITH SOAP AND WATER. THE SOLUTIONS ARE POISONOUS
AND FLAMMABLE.

CLEANING 39
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
NOTE: Aluminized, thermally sprayed coatings and plated parts are subject to degrading
and/or corrosion of varying intensity when cleaned using this process. Part must
be inspected for the presence of degraded coatings/plating and handled
accordingly.

NOTE: It is acceptable to use a four-step alkaline rust remover and acidic descaler (with
inhibited phosphoric acid as an alternate to this cleaning procedures).

NOTE: It is acceptable to interchange the position of the acidic scale conditioner and
alkaline permanganate steps in the specified sequence of steps in this procedure.
The chemical from some supplier gives more satisfactory results when the acidic
scale conditioner and alkaline permanganate steps are in the opposite sequence.

NOTE: This cleaning process shall only be used when specified in the appropriate engine
manual.

NOTE: If a part is heavily scaled, remove the part from the solution, two times maximum
during one or more of the chemical solution steps in the cleaning cycle and
pressure spray rinse the part to remove degraded scale before it is returned to the
solution.

(1) If necessary, remove any grease or oils with an alkaline cleaner. (Refer to Reference
Information for the cleaning of the metallic parts).

(2) Put the parts fully into a bath of alkaline rust remover solution, (Refer to Table 601)
at a temperature of 180 to 200º F (82 to 93º C) for 15 to 30 minutes.

Table 601

Material Make-up Operating Limits

Applied 5-840 33.5 oz.wt/gal 26.8-33.5 oz.wt/gal
(250 g/l) (200-250 g/l)
Ardrox 185 3.0 lbs/gal 2.5-3.0 lbs/gal
(360 g/l) (200-360 g/l)
Ardrox 185L 50% by volume 34-50% by volume
Cee-Bee J-84A 3.0 lbs/gal 2.0-3.0 lbs/gal
(360 g/l) (240-360 g/l)
Cee-Bee J-84AL 48 fl.oz/gal 40-48 fl.oz/gal
(369.6 ml/l) (308.0-369.6 ml/l)
(37% by volume) (30-37% by volume)

CLEANING 39
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Material Make-up Operating Limits

MagChem HDL-202 35% by volume 30-40% by volume
(liquid)
Turco 4181 3.0 lbs/gal 2.0-3.0 lbs/gal
(360 g/l) (240-360 g/l)
Turco 4181L 75% by volume 50-75% by volume

(3) Pre-rinse the parts above the alkaline rust remover bath using a minimum amount of
cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPARY
GUN.

(4) Put the parts fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray-gun.

(5) Put the part fully into a bath of acidic scale conditioner solution, (Refer to Table
602) at the temperature specified for 15 to 30 minutes.

Table 602

Material Make-up Operating Limits Temperature

Ardrox 1873A 25% by volume 20-25% by volume 175-185ºF
(75-85ºC)
Cee-Bee J-3 20% by volume 15-20% by volume 175-185ºF
(79-85ºC)
MagChem AP-988 20% by volume 15-20% by volume 175-185ºF
(79-85ºC)
Turco Scale Gon 300 ml/I 200-300 ml/I 175-195ºF
#5 (30% by volume) (20-30% by (79-90ºC)
volume)

(6) Pre-rinse the parts above the acidic scale conditioner solution bath using a minimum
amount of cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(7) Put the parts fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray-gun.

(8) Put part fully into a bath of alkaline permanganate solution, (Refer to Table 603) at a
temperature of 180 to 200°F (82 to 93°C) for 15 to 30 minutes.

CLEANING 39
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Table 603

Solution Material Make-up Operating Limits

#1 Ardrox 1435A 25% by volume 15-25% by volume
Ardrox 1435B 25% by volume 15-25% by volume
#2 Ardrox 188 RFU 100% by Additives
volume
#3 Cee-Bee J-88L 100% by 65-100% by volume
volume
#4 Turco 4338L, Part 25% by volume 15-25% by volume
1
Turco 4338L, Part 25% by volume 15-25% by volume
2
#5 Ardrox 188 1.35 lbs/gal Sodium Hydroxide =
(powder) (160 g/l) 80-120 g/l
Potassium Permanganate
=30-90 g/l
#6 Cee-Bee J-88 2.0 lbs/gal 1.3-2.0 lbs/gal
(powder) (240 g/l) (156-240 g/l)
#7 MagChem 2.0 lbs/gal 1.3-2.0 lbs/gal
HDP-2524 (240 g/l) (156-240 g/l)
(powder)
#8 Turco 4338 2.5 lbs/gal 2.0-3.0
(powder) (300 g/l) (240-300 g/l)
#9 MagChem 50% by volume 30-50% by volume
HDL-2524C
MagChem 25% by volume 15-25% by volume
HDL-2524P
#10 Sodium Hydroxide 25 oz/gal 2.0-3.0 oz/gal
Caustic soda) (187 g/l) (150-225 g/l)
Potassium 10 oz/gal 6-12 oz/gal
Permanganate (75 g/l) (45-90 g/l)
– commercial
grade
A-A-59787
#11 Alkaline 30% to 50% by 100-250 g/l
Permanganate volume

CLEANING 39
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(9) Pre-rinse the parts above the Alkaline Permanganate solution bath using a minimum
amount of cold clean water.
WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(10) Put part full into a cold clean water and remove any loose scale with a nylon brush
(do not use a metal brush) or use a water spray-gun.

(11) Put part full into a bath of alkaline rust remover solution, (Refer to Table 604), 190º -
200º F (88º- 93º C) for 15 to 30 minutes.

Table 604

Material Make-up Operating Limits

Applied 5-840 33.5 oz.wt/gal 26.8-33.5
(250 g/l) (200-250 g/l)
Ardrox 185 3.0 lbs/gal 2.5-3.0 lbs/gal
(360 g/l) (200-360 g/l)
Ardrox 185L 50% by volume 34-50% by volume
Cee-Bee J-84A 3.0 lbs/gal 2.0-3.0 lbs/gal
(360 g/l) (240-360 g/l)
Cee-Bee J-84AL 48 fl.oz/gal 40-48 fl.oz/gal
(369.6 m/l) (308.0-369-6 m/l)
(37% by volume) (30-37% by volume)
MagChem HDL-202 35% by volume 30-40% by volume
(liquid)
Turco 4181 3.0 lbs/gal 2.0-3.0 lbs/gal
(360 g/l) (240-360 g/l)
Turco 4181L 75% by volume 50-75% by volume

(12) Pre-rinse the parts above the alkaline rust remover bath using a minimum amount of
cold clean water.

WARNING: USE EYE PROTECTION AND RUBBER GLOVES WHEN USING SPRAY
GUN.

(13) Put the party fully into the cold clean water and remove any loose scale with a nylon
brush (do not use a metal brush) or use a water spray-gun.

(14) Visually inspect part to make sure that the part surfaces and cavities are clean. If the
part is not clean, then it is permitted to clean the part per this procedure again, one
time only.

CLEANING 39
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WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.
(15) Air dry or dry in a re-circulating oven at 100 to 250ºF (52 to 127ºC) for 5 to 20 minutes
or flash dry by immersing part in hot water 150 to 200ºF (66 to 93ºC) until temperature
of part is at water temperature.

(16) If necessary, apply corrosion inhibitor on part.

CLEANING 39
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CLEANING 39
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CLEANING 40

TASK 49-00-01-110-841
1. De-greasing by Solvent wipe

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Acetone-resistant gloves Commercially available
ASTM D329 Commercially available
Acetone (Regent Grade)
Acetone (Technical Grade) Commercially available
105 Vantage Specialties, Inc.
Bioact (0WUA8)
C.I.C. Remover CRC Industries Inc
(023V4)
Cynergy (L-SX-94) Selig Chemical Industries Inc
(86938)
DeSoClean45 Prc-Desoto Intl Inc DBA ASC-
Philadelphia
(23354)
Diestone M-SK Magnus Chemicals Ltd
(35502)
Socomore
(F6892)

CLEANING 40
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Part No./Spec. No. Source (CAGE Code)

Diestone M-TK Magnus Chemicals Ltd
(35502)
Socomore
(F6892)
655 Fine Organics Corporation
Envirosolv (Aerosol or Liquid) (05867)
EZE 662 Ondeo Nalco Co
(89524)
GB-SX-94 Selig Chemical Industries Inc
Isoblast (86938)
ASTM D770 Commercially available
Isopropyl Alcohol (Regent Grade)
Isopropyl Alcohol (Technical Grade) Commercially available
Lotoxane Fast & Fastwipes Reabrook Ltd T/A Arrow Chemicals
(U3115)
Magnaflux SKC-S Illinois Tool Works Inc Magnaflux Div
(37676)
ASTM D740 Commercially available
Methyl Ethyl Ketone (MEK) (Regent
Grade)
Methyl Ethyl Ketone (Technical Grade) Commercially available
Positron Ecolink, Inc.
(0WU71)
2000 Selig Chemical Industries Inc
Quantum (CE-SX-94 AERO) (86938)
1000 Solutia Inc
SkyKleen (1CHP6)
Socomore
(F6892)
Skysol Mag-Chem Inc.
(02ER0)
Deionized or Demineralized Water Commercially Available
Lint-free Cloth Commercially Available
White cotton gloves Commercially Available

CLEANING 40
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(3) Expendable Parts

None
SUBTASK 49-00-01-110-047
E. Cleaning

WARNING: THE SOLVENTS IN THIS PROCEDURE ARE FLAMMABLE.

CAUTION: USING CLOTH THAT CONTAINS SIZING OR OTHER CHEMICALS MAY

CAUSE CONTAMINATION OF THE SURFACE BEING CLEANED.

CAUTION: IMMERSING PART ASSEMBLIES CONTAINING NONMETALLIC

MATERIAL IN SOLVENT MAY DAMAGE NONMETALLIC MATERIALS.

(1) Use one of the solvents approved for metallic or composite parts, (Refer to Figure
601).

NOTE: Cloth used for cleaning must be clean, lint-free, plastic-free, resin and
chemical free.Cloth used for cleaning must be clean, lint-free, plastic-free,
resin and chemical free.

NOTE: Dipping cloth into solvent container may contaminate solvent. Use dispenser
that squirt or pour solvent onto the cloth to prevent dipping and contamination
by work cloth.

(2) Wipe part with solvent wetted cloth.

(3) Air dry the cleaned part.

NOTE: Do not use compressed air to dry parts. Shop air contains water, oil and dirt
particles that will contaminate the cleaned surface.

(4) Wear clean cotton gloves to handle parts that are to be bonded or painted.

(5) If necessary, seal clean part in protective container.

CLEANING 40
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Figure 601

CLEANING 40
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CLEANING 41

TASK 49-00-01-110-842
1. Degreasing With Alkaline Bath

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Cleaning Tank Commercially Available
Cleaning Tank, Ultrasonic Commercially Available
Cleaning Tank, Hot Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Shop compressed air Commercially Available
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

CLEANING 41
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SPM

Part No./Spec. No. Source (CAGE Code)

Simple Green All-Purpose Cleaner Sunshine Makers, Inc.
(1Z575)
Extreme Simple Green Aircraft & Sunshine Makers, Inc.
Precision Cleaner (1Z575)
2087X Henkel Corp
Parco Cleaner (71410)

(3) Expendable Parts

None

SUBTASK 49-00-01-110-048
E. Cleaning

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOOGLES, INSULATED BLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) If necessary, pressure rinse the part to remove any loose debris or other contaminates
from part surfaces and interior cavities prior to immersing into cleaning solution.

NOTE: Air agitation is not recommended because it constantly decreased the

solution temperature and can drive off active cleaning ingredients.

NOTE: Time in cleaning solution will depend on the number, size and mass of parts
and if tank solution agitation is used.

(2) Soak part in cleaning solution, (Refer to Table 601).

Table 601

Cleaning Temperature
Solution Operating
Cleaning Makeup by % Limits by % Soak Time
Solution Volume Volume °F °C (Minutes)
Simple 50 40 to 50 105 to 41 to 52 2 to 60
Green 125
Simple 60 40 to 50 105 to 41 to 52 3 to 10
Green 125
Simple 20 10 to 20 Ambient Ambient 10 to 60
Green

CLEANING 41
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Cleaning Temperature
Solution Operating
Cleaning Makeup by % Limits by % Soak Time
Solution Volume Volume °F °C (Minutes)
Simple 50 40 to 50 Ambient Ambient 5 to 120
Green
Parco 13 8.8 to 13 150 to 66 to 77 20 to 65
Cleaner 170
2087X

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse or put the part fully in cold or hot water to rinse. If necessary, scrub
part with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

NOTE: Unless otherwise specified, cleaning procedures may be repeated once, if

necessary.

(4) If necessary, put part in cleaning solution a second time and re-rinse.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Optional step: Use clean, dry shop air that contains no oil vapors, to blow the water
from the part.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(6) Air dry the part or dry in an air re-circulating oven at 100° to 250° F (38° to 121° C)
for 5 to 20 minutes.

(7) Visually inspect part to make sure that the part surfaces and cavities are clean. If
necessary, use an ultraviolet light to make sure that the part has been cleaned of any
fluorescent penetrant inspection chemicals.

CLEANING 41
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CLEANING 42

TASK 49-00-01-110-843
1. De-greasing With Alkaline Bath and Rust Remover

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Cleaning Tank, Hot Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Shop compressed air Commercially Available
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

2087X Henkel Corp
Parco Cleaner (71410)
4181-L Henkel Corp
Turco (71410)
SPS-158 -
Nylon Brush Commercially Available
or
Scotch-Brite Pad

CLEANING 42
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(3) Expendable Parts

None
SUBTASK 49-00-01-110-049
E. Cleaning

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) If necessary, pressure rinse the part to remove any loose debris or other contaminates
from part surfaces and interior cavities prior to immersing into cleaning solution.

(2) Soak part in cleaning solution, (Refer to Table 601).

NOTE: Air agitation is not recommended because it constantly decreased the

solution temperature and can drive off active cleaning ingredients.

NOTE: Time in cleaning solution will depend on the number, size and mass of parts
and if tank solution agitation is used.

Table 601

Cleaning Temperature
Solution Make- Operating
Cleaning up by % Limits by % Soak Time
Solution Volume Volume °F °C (Minutes)
Parco 13 8.8 to 13 150 to 170 66 to 77 15 to 30
Cleaner
2087X

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse or put part fully in cold or hot water to rinse. If necessary, scrub part
with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

(4) Soak part in cleaning solution, (Refer to Table 602).

CLEANING 42
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Table 602

Cleaning Cleaning Operating Limits Temperature Soak Time

Solution Solution Make- by % Volume (Minutes)
up by % °F °C
Volume
Turco 75 50 to 75 150 to 66 to 77 15 to 30
4181L 170

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(5) Pressure rinse or put part fully in cold or hot water to rinse. If necessary, scrub part
with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

NOTE: Unless otherwise specified, cleaning procedures may be repeated once, if

necessary.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(6) Optional step: use clean, dry shop air that contains no oil vapors, to blow the water
from the part.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(7) Air dry the part or dry in an air re-circulating oven at 100 to 250° F (38 to 121° C) for
5 to 20 minutes.

(8) Visually inspect the part to make sure that the part surfaces and cavities are clean.

CLEANING 42
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CLEANING 43

TASK 49-00-01-110-844
1. De-greasing With Alkaline Bath

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Cleaning Tank, Hot Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Shop compressed air (clean, dry and oil Commercially Available
free)
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Simple Green All-Purpose Cleaner Sunshine Makers, Inc.
Extreme Simple Green Aircraft & (1Z575)
Precision
Cleaner Sunshine Makers, Inc.
(1Z575)

CLEANING 43
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Part No./Spec. No. Source (CAGE Code)

2087X Henkel Corp
Parco Cleaner (71410)
Nylon Brush Commercially Available
or
Scotch-Brite Pad

(3) Expendable Parts

None

SUBTASK 49-00-01-110-050
E. Cleaning

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) If necessary, pressure rinse the part to remove any loose debris or other contaminates
from part surfaces and interior cavities prior to immersing into cleaning solution.

NOTE: Air agitation is not recommended because it constantly decreased the

solution temperature and can drive off active cleaning ingredients.

NOTE: Time in cleaning solution will depend on the number, size and mass of parts
and if tank solution agitation is used.

(2) Soak part in cleaning solution, (Refer to Table 601).

Table 601

Cleaning Cleaning Operating Temperature Soak Time

Solution Solution Make- Limits by % (Minutes)
up by % Volume Volume °F °C

Simple 50 40 to 50 105 to 41 to 52 20 to 40
Green 125

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Pressure rinse or put part fully in cold or hot water to rinse. If necessary, scrub part
with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

(4) Soak part in cleaning solution, (Refer to Table 602).

CLEANING 43
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SPM

Table 602

Cleaning Operating Temperature

Cleaning Solution Make- Limits by % Soak Time
Solution up by % Volume Volume °F °C (Minutes)
Parco 13 8.8 to 13 150 to 66 to 77 15 to 30
Cleaner 170
2087X

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(5) Pressure rinse or put part fully in cold or hot water to rinse. If necessary, scrub part
with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(6) Optional Step: Use clean, dry shop air that contains no oil vapors, to blow the water
from the part.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(7) Air dry the part or dry in an air re-circulating oven at 100° to 250° F (38° to 121° C)
for 5 to 20 minutes.

(8) Visually inspect part to make sure that the part surfaces and cavities are clean. If
necessary, use an ultraviolet light to make sure that the part has been cleaned of any
fluorescent penetrant inspection chemicals.

CLEANING 43
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CLEANING 43
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SPM

CLEANING 44

TASK 49-00-01-110-845
1. De-greasing With Alkaline Permanganate Bath

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Cleaning Tank, Hot Commercially Available
Rinse Tank, Cold Commercially Available
Rinse Tank, Hot Commercially Available
Hand Gun, Pressure Rinse Commercially Available
Shop compressed air Commercially Available
(clean, dry and oil free)
Ultraviolet Light Source Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

4338 Henkel Corp
Turco (71410)
4181-L Henkel Corp
Turco (71410)

CLEANING 44
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SPM

Part No./Spec. No. Source (CAGE Code)

Scale Gon #5 Henkel Corp
(71410)
Nylon Brush Commercially Available
or
Scotch-Brite Pad

(3) Expendable Parts

None

SUBTASK 49-00-01-110-051
E. Cleaning

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(1) If necessary, pressure rinse the part to remove any loose debris or other contaminates
from part surfaces and interior cavities before immersing into the cleaning solution.

(2) Soak part in cleaning solution, (Refer to Table 601).

NOTE: Air agitation is not recommended because it constantly decreased the

solution temperature and can drive off active cleaning ingredients.

NOTE: Time in cleaning solution will depend on the number, size and mass of parts
and if tank solution agitation is used.

NOTE: Put the parts in cold rinse, immediately following Step (2).

Table 601

Cleaning Temperature
Solution Operating
Cleaning Make- up by Limits by % Soak Time
Solution % Volume Volume °F °C (Minutes)
Turco 75 50 to 75 150 to 170 66 to 77 30 to 35
4181L

(3) Immediately put the part fully in cold water to rinse.

(4) Soak part in cleaning solution, (Refer to Table 602).

CLEANING 44
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SPM

Table 602

Cleaning Temperature
Solution Operating
Cleaning Make- up by Limits by % Soak Time
Solution % Volume Volume °F °C (Minutes)
Turco 4338 33 30 to 33 170 to 180 77 to 83 3 to 5

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOOGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(5) Pressure rinse or put the part fully in cold or hot water to rinse.

(6) Soak part in cleaning solution, (Refer to Table 603).

Table 603

Cleaning Temperature
Solution Operating
Cleaning Make- up by Limits by % Soak Time
Solution % Volume Volume °F °C (Minutes)
Scale Gon 30 20 to 30 150 to 170 66 to 77 50 to 70
#5

(7) Pressure rinse or put part fully in cold or hot water to rinse. If necessary, scrub part
with a nylon brush or scotch-brite pad to remove loosened soil or surface film
remaining on part.

(8) Soak part in cleaning solution, (Refer to Table 604).

Table 604

Cleaning Temperature
Solution Operating
Cleaning Make- up by Limits by % Soak Time
Solution % Volume Volume °F °C (Minutes)
Turco 75 50 to 75 150 to 170 66 to 77 30 to 35
4181L

WARNING: HOT SOLUTION MAY CAUSE BURNS TO EYES AND SKIN. WEAR
SPLASH GOGGLES, INSULATED GLOVES AND OTHER PROTECTIVE
GEAR. IN CASE OF EYE OR SKIN CONTACT, SEEK MEDICAL
ATTENTION.

(9) Pressure rinse or put the part fully in cold or hot water to rinse.

CLEANING 44
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SPM

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(10) Optional step: Use clean, dry shop air that contains no oil vapors to blow the water
from the part.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(11) Air dry the part or dry in an air re-circulating oven at 100 to 250° F (38 to 121° C) for
5 to 20 minutes.

(12) Visually inspect part to make sure that the part surfaces and cavities are clean.

CLEANING 44
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SPM

CLEANING 45

TASK 49-00-01-110-846
1. Dry Plastic Blast

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-831 Degrease and Desmut for
Assemblies That Cannot Be
Submerged
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Blasting Cabinet (configured for Plastic Commercially Available
Media) Pressure Type
Shop compressed air (clean, dry and oil Commercially Available
free)
ISO 8573.1, Quality 2, 3, 2 or better.

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Polyplus Prime US Tech Corp
Plastic Blast Media -Industrial Grade (1AM56)
Perstrip Type II Composite Materials Co.
PLASTI-GRIT Type II (98231)
Plastic Blast Media -Industrial Grade

CLEANING 45
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SPM

Part No./Spec. No. Source (CAGE Code)

SFC-1734, Type II MPC Industries (27438)
Plastic Blast Media -3.5 Moh Hardness or
Screen Size 12-20 & 20-30 Patent Plastics Inc
(1GM63)
Ammo 301 Select- Tech Inc.
Plastic Blast Media – 3.5 Moh Hardness (0M5H8)
Screen Size 12-16
Cystrip U, Type 2 AC Molding Compounds
Plastic Blast Media (0NAK0)
Sieve Size -16+20, -20+30, -30+40
Type II Fischer JETplast
Media, Plastic Blast - 3.5 Moh Hardness (DM077)
ASTM D770 Commercially Available
Isopropyl Alcohol
ASTM D329 Commercially Available
Acetone

(3) Expendable Parts

None

SUBTASK 49-00-01-110-052
E. Procedure

NOTE: This procedure is for removal of paint, Room Temperature Vulcanization (RTV)
rubber, graphite varnish, and anti-galling compound. Aluminum enamel and
sealant from compressor blades, disks, impellers and hubs.

NOTE: Exceeding specified air pressure may cause premature breakdown of plastic
media and generate excessive dust, resulting in decreased process efficiency. A
very long hose may cause a pressure drop at nozzle and a worn nozzle reduces
effectiveness of process.

NOTE: Use only equipment that is dedicated to plastic media blasting.

(1) Clean the part to remove oils and dirt to prevent the contamination of the plastic media.
Refer to reference information for the cleaning tasks.

(2) Mask, as necessary, to prevent plastic media from becoming entrapped inside of the
part. Mask all surface that have coating (for example: thermal spray coatings) or
features that need to be protected (for example: tightly tolerance features).

(3) Set plastic media blasting pressure at 30 to 40 psig (206.8 to 275.8 kPa).

NOTE: Use only pressure-type blasting machine.

CLEANING 45
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STANDARD PRACTICES MANUAL
SPM

(4) Blast with dry plastic media with a nozzle-to-part distance of 3.0 to 4.0 in. (76 to 102
mm) and at an angle of 45 to 60 degrees to the work surface.
WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Blow clean with clean (filtered), oil free and dry compressed air or argon at 30 psig
(206.8 kPa) maximum to remove all remaining media from part.

(6) Remove masking, if present.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL SPLASH GOGGLES, AND
ACETONE- RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(7) If present, remove masking residue with isopropyl alcohol or acetone.

(8) Visually inspect to make sure that the part has been cleaned and there is no remaining
or residual blasting media or masking. Make sure that there is no caught media.

(9) Apply corrosion inhibitor, as specified, in the appropriate engine manual.

CLEANING 45
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CLEANING 45
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CLEANING 46

TASK 49-00-01-110-847
1. Dry Abrasive Grit Blast

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-831 Degrease and Desmut for
Assemblies That Cannot Be
Submerged
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Blasting Cabinet Pressure Commercially Available
or
Suction Type
Shop compressed air (clean, dry and oil Commercially Available
free)
ISO 8573.1, Quality 2, 3, 2 or better.

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

No. 240 grit Commercially Available
Aluminum Oxide ANSI B74.12, Table 3
No. 320 grit Commercially Available
Aluminum Oxide ANSI B74.12, Table 3

CLEANING 46
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Part No./Spec. No. Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol
ASTM D329 Commercially Available
Acetone

(3) Expendable Parts

None

SUBTASK 49-00-01-110-053
E. Procedure

CAUTION: ABRASIVE BLASTING, IF NOT DONE CORRECTLY, CAN CAUSE A

SMEARED SURFACE. THIS MAKES SURFACE DEFECTS NOT EASY TO
FIND DURING NON-DESTRUCTION INSPECTION. DIFFERENT
MATERIALS AND PROCESSES WILL SHOW DIFFERENT EFFECTS.

CAUTION: THE USE OF ALTERNATE SIZE MEDIA OR MATERIAL TO THOSE

SPECIFIED IN THIS CLEANING PROCEDURE IS NOT PERMITTED
UNLESS SPECIFIED DIFFERENTLY BY AN ENGINE MANUAL,
CLEANING, INSPECTION, OR REPAIR MANUAL.

CAUTION: THE SPECIFIED ALUMINUM OXIDE IS FOR NEW MATERIAL ONLY. DO

NOT ORDER RECYCLED OR RECOVERED ABRASIVE MATERIAL.

CAUTION: DO NOT USE THIS PROCEDURE FOR CLEANING OR STRIPPING

TITANIUM PARTS BEFORE FLUORESCENT PENETRANT INSPECTION
(FPI).

CAUTION: WHEN GRIT BLAST CLEAN IS SPECIFIED FOR CLEANING BEFORE FPI
OR FMPI, THE PART MUST FIRST BE CHEMICALLY CLEANED AS
SPECIFIED IN THE ENGINE MANUAL, CLEANING, INSPECTION, OR
REPAIR MANUAL.

CAUTION: EQUIPMENT USED TO CLEAN PARTS PER THIS PROCEDURE CANNOT

BE USED TO CLEAN OR STRIP CADMIUM COATED PARTS.

CAUTION: EXCEEDING SPECIFIED DWELL TIME MAY CAUSE EROSION OR

THINNING OF PART SURFACES BEYOND DIMENSIONAL LIMITS.

NOTE: It is not permissible to mix various blasting media.

(1) Clean the part to remove oils and dirt to prevent the contamination of the abrasive
blasting media. Refer to reference information for the cleaning tasks.

(2) Mask, as necessary, to prevent blasting media from becoming entrapped inside of the
part. As necessary, mask all surfaces that have coatings (for example: thermal spray
coating) of features that need to be protected (for example: tightly tolerance features).

CLEANING 46
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(3) Set blasting pressure at 25 to 30 psig (171 to 207 kPa) for pressure-type machine or
50 to 60 psig (345 to 414 kPa) for suction-type machines.
CAUTION: EXCEEDING SPECIFIED DWELL TIME MAY CAUSE EROSION OR
THINNING OF PART SURFACES BEYOND DIMENSIONAL LIMITS.

(4) Blast with aluminum oxide media of 240 or 320 grit with a nozzle-to-part distance of
3.0 to 4.0 in. (76 to 102 mm) and at an angle of 45 to 60 degrees to the work surfaces.
Do not dwell in one area for more than two seconds. Use continuous motion

(a) Make sure that critical dimensions and snap diameters are not altered by
blasting.

(b) Do not blast coated surfaces unless specified by engine manual instructions.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Blow clean with clean (filtered), oil free and dry compressed air or argon at 30 psig
(207 kPa) maximum to remove all remaining media from part.

(6) Remove masking.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

CLEANING 46
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WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL SPLASH GOGGLES, AND
ACETONE- RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(7) If present, remove masking residue with isopropyl alcohol or acetone.

(8) Visually inspect to make sure that the part has been cleaned and there is no remaining
or residual blasting media or masking. Make sure that there is no caught media.

(9) Apply corrosion inhibitor, as specified, in the appropriate engine manual.

CLEANING 46
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CLEANING 47

TASK 49-00-01-110-848
1. Dry Abrasive Shell Blast

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-831 Degrease and Desmut for
Assemblies That Cannot Be
Submerged
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No. /Name. Source (CAGE Code)

Blasting Cabinet Pressure Commercially Available
or
Suction Type
Shop compressed air (clean, dry and oil Commercially Available
free)
ISO 8573.1, Quality 2, 3, 2 or better.

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

CLEANING 47
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Part No./Spec. No. Source (CAGE Code)

Ground Shell South Eastern Reduction Company ,Inc
12/20 (5E40B)
Pecan Shell
Ground Shell Louis O. Beede & Sons,Inc Nielsen Div.
12/20
Black Walnut Shell
20/30
Black Walnut Shell
35/60
Black Walnut Shell
Ground Shell Composition Materials & Inc
12/20 (98231)
Black Walnut Shell
35/60
Black Walnut Shell
1368 Kleen Blast
Black Walnut Shell #20/40
ASTM D770 Commercially Available
Isopropyl Alcohol
ASTM D329 Commercially Available
Acetone

(3) Expendable Parts

None

SUBTASK 49-00-01-110-054
E. Procedure

CAUTION: THE USE OF ALTERNATE SIZE MEDIA OR MATERIAL TO THOSE

SPECIFIED IN THIS CLEANING PROCEDURE IS NOT PERMITTED
UNLESS SPECIFIED DIFFERENTLY BY AN ENGINE MANUAL,
CLEANING, INSPECTION, OR REPAIR MANUAL

CAUTION: DO NOT USE THIS PROCEDURE FOR CLEANING OR STRIPPING

TITANIUM PARTS BEFORE FLUORESCENT PENETRANT INSPECTION
(FPI).

CAUTION: WHEN GRIT BLAST CLEAN IS SPECIFIED FOR CLEANING BEFORE FPI
OR FMPI, THE PART MUST FIRST BE CHEMICALLY CLEANED AS
SPECIFIED IN THE ENGINE MANUAL, CLEANING, INSPECTION OR
REPAIR MANUAL.

CLEANING 47
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CAUTION: EQUIPMENT USED TO CLEAN PARTS PER THIS PROCEDURE CANNOT

BE USED TO CLEAN OR STRIP CADMIUM COATED PARTS.
CAUTION: EXCEEDING SPECIFIED DWELL TIME MAY CAUSE EROSION OR
THINNING OF PART SURFACES BEYOND DIMENSIONAL LIMITS.

NOTE: It is not permitted to mix various blasting media.

(1) Clean the part to remove oils and dirt to prevent the contamination of the abrasive
blasting media. Refer to reference information for cleaning tasks.

(2) Mask, as necessary, to prevent blasting media from becoming entrapped inside of the
part. As necessary, mask all surfaces that have coatings (for example: thermal spray
coatings) or features that need to be protected (for example: tightly tolerance
features).

(3) Set blasting pressure at 25 to 30 psig (171 to 207 kPa) for pressure- type machines
or 50 to 60 psig (345 to 414 kPa) for suction-type machines.

CAUTION: EXCEEDING SPECIFIED DWELL TIME MAY CAUSE EROSION OR

THINNING OF PART SURFACES BEYOND DIMENSIONAL LIMITS.

(4) Blast with Ground shell, with a nozzle-to-part distance of 3.0 to 4.0 in. (76 to 102 mm)
and at an angle of 45 to 60 degrees to the work surface. Do not dwell in one area for
more than two (2) seconds. Use continuous motion.

(a) Make sure that the critical dimensions and snap diameters are not altered by
blasting.

(b) Do not blast coated surfaces unless specified by engine manual instructions.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(5) Blow clean with clean (filtered), oil and dry compressed air or argon at 30 psig (207
kPa) maximum to remove all remaining media from part.

(6) Remove masking.

CLEANING 47
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SPM

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE- RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(7) If present, remove masking residue with isopropyl alcohol and acetone.

(8) Visually inspect to make sure that the part has been cleaned and there is no remaining
or residual blasting media or masking. Make sure that there is no caught media.

(9) Apply corrosion inhibitor, as specified, in the appropriate engine manual.

CLEANING 47
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ADDITIONAL STANDARD PRACTICES

TASK 49-00-01-870-801
1. Fits and Clearances

A. Prerequisites

(1) None

B. Reference Information

(1) None

C. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

D. Procedure

(1) This section contains a general discussion of fits and clearances procedures found in
the engine manuals and/or the component maintenance manuals.

E. Spring Specifications

(1) The spring specification figures can be used to help identify the correct spring during
assembly and determine usability. The information includes the spring dimensions
and the load/height requirements.

F. Fits and Clearances Illustrations

(1) The fits and clearances illustrations give the fits and clearances data and the wear
tolerances for the check and assembly procedures.

G. Torque Tables

(1) The torque values are given in the applicable engine manual and/or component
maintenance manual. If a torque is not specified, refer to the figures in the CHECK or
ASSEMBLY section of this manual.

TASK 49-00-01-940-801
2. Standard Tools, Fixtures, and Equipment

ADDITIONAL STANDARD PRACTICES

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A. Prerequisites

(1) None
B. Reference Information

(1) None

C. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-940-001
D. General

(1) This section lists the standard tools and machines required for repairing the Auxiliary
Power Unit (APU) and its components. It only provides guidelines for the equipment
selection. Equivalent tools and machines can be used.

SUBTASK 49-00-01-940-002
E. Machine List

(1) Crane Lapmaster

(a) This is a precision flat-surface lapping machine with a 24-inch diameter lapping
plate. The machine has three conditioning rings and one ring positioner.

(b) This machine is used to lap seal faces and housings.

(c) The Crane Lapmaster is manufactured by Crane Packing Company, 6427

Oakton Street, Morton Grove, IL.

SUBTASK 49-00-01-940-003
F. Number 2 Brown and Sharpe Universal Grinder

(1) This grinding machine has a 14- inch swing with a 30- inch, center-to-center capacity.
It has a special face plate, automatic cycle and spark-timing arrangement, left and
right hand wheel mounting equipment, and slot grinding switches. It is fitted with a
special plain bearing headstock.

(2) This machine is used to grind the bearing races.

ADDITIONAL STANDARD PRACTICES

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(3) The Number 2 Brown and the Sharpe Universal Grinder are manufactured by Brown
and Sharpe Manufacturing Company, Machine Tool Division, Precision Park, North
Kingstown, RI.
SUBTASK 49-00-01-940-004
G. Standard Equipment

(1) A list of standard equipment referred to in this manual for overhaul or repair of the
APU is given below, (Refer to Table 701).

Table 701
Standard Equipment

Description Use
Bench lapping stone (Norton Company Code Used to touch lap the seals or any
LAH7-B, surface having a flatness
(12 inches in diameter, 1 1/2 inch thickness, requirement.
center hole 1-1/2 inches)
Type 1) (See Note)
Vapor Degreaser Used to clean and remove the oil
and grease from parts.
NOTE: Manufactured by Norton Company, 25 Bond Street, Worchester, MA.

SUBTASK 49-00-01-940-005
H. Standard Gauges and Inspection Equipment

(1) A list of inspection equipment referred to in this manual for overhaul or repair of the
APU is given below, (Refer to Table 702).

Table 702
Inspection Equipment

Description Use
Magnetic Particle Inspection Equipment Used to check the damaged or reworked
steel parts for cracks.
Penetrant Inspection Equipment Used to check the damaged or reworked
magnesium or aluminum parts for
cracks.

SUBTASK 49-00-01-940-006
I. Special Tools

(1) The special tools required for repairing the APU are listed in the SPECIAL TOOLS,
FIXTURES, AND EQUIPMENT section of the applicable engine manual and/or the
component maintenance manual.

ADDITIONAL STANDARD PRACTICES

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(2) The Illustrated Tools and Equipment Manual lists all the ground support equipment
and the special tools required to support the APU and its electronic components.
SUBTASK 49-00-01-940-007
J. Test Equipment

(1) The test equipment requirements for testing the APU are listed in the TESTING AND
FAULT ISOLATION section of the engine manual and/or the component maintenance
manual.

TASK 49-00-01-99F-801
3. Illustrated Parts List (or Illustrated Parts Catalog) - General

A. Prerequisites

(1) None

B. Reference Information

(1) None

C. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-99F-001
D. General

(1) This section provides general information about the Illustrated Parts Lists of the
component maintenance manuals and/or the engine Illustrated Parts Catalog (IPC).
The index, Figure 703, lists the IPC information in this manual.

SUBTASK 49-00-01-99F-002
E. Purpose of the Illustrated Parts List (or Illustrated Parts Catalog)

(1) The purpose of the Illustrated Parts List/Catalog is to list all of the parts of a
component. The figures are used to illustrate each part and show its location. The
Illustrated Parts List/Catalog provides usage and interchangeability information. It
also defines parts that can be procured from other suppliers.

ADDITIONAL STANDARD PRACTICES

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SUBTASK 49-00-01-99F-003
F. Part Numbering System
(1) The part numbering system used in the engine IPC and/or the component
maintenance manual IPL include three basic part number series; the Hamilton
Sundstrand part number series, the Federal Standard part number series, and the
Vendor supplied part numbers.

(a) Part Number Series

1 This series applies to Hamilton Sundstrand detailed parts and can contain
four to ten digits. For example: 5380, 57435, 692902, 02-12345, 27061094,
26000070-1, OR 26316002-39.

(b) Federal Standard Part Numbers

1 These part numbers apply to various parts such as screws, washers, nuts,
retaining rings, and pins. These parts are prefixed by the letters M, AN,
MS, or NAS making them easy to identify as federal standard parts.

(c) Vendor Supplied Part Numbers

1 These part numbers apply to the vendor supplied parts listed in the detailed
parts listing that use varying part numbering systems. Because these
numbers are different from those described in the paragraphs above, their
identity as vendor supplied parts is apparent. A vendor code number in the
NOMENCLATURE column is a further identification.

SUBTASK 49-00-01-99F-004
G. Illustrated Parts List (or Illustrated Parts Catalog)

(1) The IPL or IPC is prepared in disassembly sequence. It breaks the equipment down
into major assemblies, then subassemblies, and attaching parts. The detail parts are
indented to show their relationship to the next higher assembly of which they are a
part.

ADDITIONAL STANDARD PRACTICES

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INSPECTION/CHECK

TASK 49-00-01-200-801
1. INSPECTION/CHECK

A. General

(1) This section contains the instructions for the standard check procedure. These
instructions give the general precautions, the safety solutions, the specialized
techniques and the standard procedures for the check.

(2) Use the engine manual and/or the component maintenance manual for the full
explanations of the check procedures.

(3) Read all the notes, warnings and cautions to prevent damage to the equipment and
personal injury.

(4) To locate and cross reference the inspection/check procedures from Standard
Practices Manual for Auxiliary Power Units (49-00-01) issued by Auxiliary Power
International Corporation (APIC) and Standard Practices Manual for Common
Standard Practices for Auxiliary Power Units (49-00-01) issued by Hamilton
Sundstrand, (Refer to Table 801).

Table 801
Cross Reference of Inspection/Check Procedures

APS2000/APS2100/
APS3200 APS500/APS1000 HSPS 490001
INSPECTION/CHECK INSPECTION/CHECK- INSPECTION/CHECK
SP-301
INSPECTION/CHECK-01 INSPECTION/CHECK- INSPECTION/CHECK-01
SP-314
INSPECTION/CHECK-02 INSPECTION/CHECK-02
INSPECTION/CHECK-03 INSPECTION/CHECK- INSPECTION/CHECK-03
SP-308
INSPECTION/CHECK-04 INSPECTION/CHECK- INSPECTION/CHECK-04
SP-307
INSPECTION/CHECK-05 INSPECTION/CHECK-05
INSPECTION/CHECK-06 INSPECTION/CHECK- INSPECTION/CHECK-06
SP-310
INSPECTION/CHECK-07 INSPECTION/CHECK- INSPECTION/CHECK-07
SP-313

INSPECTION/CHECK
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APS2000/APS2100/
APS3200 APS500/APS1000 HSPS 490001
INSPECTION/CHECK-08 INSPECTION/CHECK- INSPECTION/CHECK-08
SP-311
INSPECTION/CHECK-09 INSPECTION/CHECK- INSPECTION/CHECK-09
SP-309
INSPECTION/CHECK-10 INSPECTION/CHECK- INSPECTION/CHECK-10
SP-303
INSPECTION/CHECK-11 INSPECTION/CHECK-11
INSPECTION/CHECK-12 INSPECTION/CHECK- INSPECTION/CHECK-12
SP-312
INSPECTION/CHECK- INSPECTION/CHECK-13
SP-302
INSPECTION/CHECK- INSPECTION/CHECK-14
SP-304
INSPECTION/CHECK- INSPECTION/CHECK-15
SP-305
INSPECTION/CHECK- INSPECTION/CHECK-16
SP-306
INSPECTION/CHECK- INSPECTION/CHECK-17
SP-315

(5) For a list of the standard inspection/check procedures specified in this manual, (Refer
to Table 802).

Table 802
List of Standard Inspection/Check Procedures

Inspection/Check Task Number

INSPECTION/CHECK 01 (Refer to TASK 49-00-01-220-801, Inspection of
the Superficial Defects by Binocular Glasses)
INSPECTION/CHECK 02 (Refer to TASK 49-00-01-220-802, Inspection of
the Bearings)
INSPECTION/CHECK 03 (Refer to TASK 49-00-01-240-801, Magnetic
Particle Inspection)
INSPECTION/CHECK 04 (Refer to TASK 49-00-01-220-808, Inspection of
the Gears)

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Inspection/Check Task Number

INSPECTION/CHECK 05 (Refer to TASK 49-00-01-280-801, Demagnetize
and Measure the Remaining Magnetic Field)
INSPECTION/CHECK 06 (Refer to TASK 49-00-01-220-804, Inspection of
the Self-Locking Helical Coil Inserts and the Self-
Locking Nuts)
INSPECTION/CHECK 07 (Refer to TASK 49-00-01-230-801, Penetrant
Inspection)
INSPECTION/CHECK 08 (Refer to TASK 49-00-01-220-805, Inspection of
the Flatness by the Optical Flat Method)
INSPECTION/CHECK 09 (Refer to TASK 49-00-01-280-802, Inspection of
the Surface Temper)
INSPECTION/CHECK 10 (Refer to TASK 49-00-01-220-806, Inspection of
the V-band Clamps)
INSPECTION/CHECK 11 (Refer to TASK 49-00-01-220-807, Inspection of
the Coupling Ring)
INSPECTION/CHECK 12 (Refer to TASK 49-00-01-250-801, Eddy Current
Inspection)
INSPECTION/CHECK 13 (Refer to TASK 49-00-01-210-801, Inspection of
the Ignition Exciter)
INSPECTION/CHECK 14 (Refer to TASK 49-00-01-210-802, Inspection of
the Igniter Plugs)
INSPECTION/CHECK 15 (Refer to TASK 49-00-01-210-803, Inspection of
the Thermocouples)
INSPECTION/CHECK 16 (Refer to TASK 49-00-01-210-804, Inspection of
the Tube Assemblies)
INSPECTION/CHECK 17 (Refer to TASK 49-00-01-210-805, Reusable Low
Strength Mechanical Fasteners)
INSPECTION/CHECK 18 (Refer to TASK 49-00-01-210-806, Inspection of
the Thrust Ball Bearings)
INSPECTION/CHECK 19 (Refer to TASK 49-00-01-210-807, Inspection of
the Roller Bearings)
INSPECTION/CHECK 20 (Refer to TASK 49-00-01-210-808, Inspection of
the Silicone Fire Sleeved Hose Assembly)

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Inspection/Check Task Number

INSPECTION/CHECK 21 (Refer to TASK 49-00-01-210-811, Curvic
Inspection Procedure)
INSPECTION/CHECK 22 (Refer to TASK 49-00-01-210-809, Inspection of
the Electrical Connector and Contact Pins)
INSPECTION/CHECK 23 (Refer to TASK 49-00-01-210-810, Inspection of
the Tube Assemblies)

B. General Check Procedures

(1) Magnetic drain plug

(a) This plug keeps the magnetic material in the oil system. Make sure this plug
gives the operational condition of the gearbox. The magnetic chips or the
quantity of the steel particles can show the gearbox is correct or a possible
bearing failure. A few fine particles are correct. This procedure helps to find the
defective parts before the check.

(2) Visual check for condition

(a) A part with a mechanical or physical damage must be repaired or replaced.

Check the dimensions of the parts which show too much wear after a visual
check. Examine all the mating parts carefully for constant wear patterns.

(3) Visual thread check

(a) Examine visually the general condition of all the threads. Reject the threads
which are extended or have no cover. Make an inspection of the threads you are
not sure about with the applicable thread gauges.

(4) Springs

(a) If you use the springs again, it is necessary to do a load test and a visual check.
Replace the springs if they have nicks, abrasions or other distortions that can
cause the spring to operate incorrectly.

(5) Tubes

(a) Examine the tubes for dents, kinks, bends and nicks that have bent the tube wall.
Reject the tube with a distortion.

(b) Examine visually the general condition of all the threads. Reject the threads
which are extended or have no cover. Make an inspection of all the threads you
are not sure about with the applicable thread gauges. The thread of some cases
can be repaired and an applicable insert can be installed.

(6) Electrical connectors

(a) Examine the connector for bent pins, contamination or damage.

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(b) Examine the connector for thread damage.

(7) Dimensional inspection

(a) Do a dimensional inspection to find if the parts have a correct condition, can be
used or must be repaired. The engine manual and/or the component
maintenance manual give the instructions for the dimensional inspection.

(8) Rivet check

(a) General

1 Do a visual inspection of all the rivets for damage, (Refer to Figure 801). If
a rivet is damaged more than 50 percent over the tolerances, remove and
replace the rivet.

2 Unless the contrary is written in the engine manual and/or the component
maintenance manual, the rivets must be assembled with their heads on the
external surface of the part.

3 Remove and replace the rivet if the rivet heads do not make a continuous
surface with the surface of the part, or if the rivet is loose, (Refer to Figure
802).

4 If a 0.004 inch (0.102 mm) shim can be put between the head and the
surface, reject the rivet.

5 If a 0.004 inch (0. 102 mm) shim can be put between the head of the rivet
and the countersink (for more than 20 percent of the countersunk rivets
which attach a part or a surface), reject the part, (Refer to Figure 802).

6 If the rivet has circumferential cracks, reject the rivet, (Refer to Figure
802).

7 If the rivet has more than one crack across the head, reject the rivet.

8 If the rivet has gouges on the head, reject the rivet, (Refer to Figure
802)).

(b) Shop heads

1 Use a rivet head with a diameter between 1-1/3 and 1-2/3 of the shank
diameter. The height of the head must be more than 1/3 of the shank
diameter, (Refer to Figure 802).

(c) Surface around the rivets

1 The maximum clearance where the parts must make a line, at the rivets or
between the rivets is 0.006 inch (0. 152 mm), (Refer to Figure 802).

2 The contours of the sheets must be adapted to the mating parts in less than
1/32 in 1 inch (0.794 mm in 25.4 mm). The metal must not be damaged.

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(d) Countersunk rivet (100°)

1 The heads shall not project above or below the immediate adjacent surface
more than indicated, (Refer to Table 803).

Table 803
100° Countersunk Head Rivets

Maximum Size of Rivet Maximum Above Below

1/16 0.005 0.005
3/32 0.010 0.005
1/8 0.010 0.005
3/16 0.015 0.005
1/4 0.020 0.007

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Types of Rivet Heads

Figure 801

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Unacceptable Rivets
Figure 802

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INSPECTION/CHECK 01

TASK 49-00-01-220-801
1. Inspection of the Superficial Defects by Binocular Glasses

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Binocular (40X) Commercially Available

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-220-001
E. Inspection

NOTE: This inspection is used to find cracks, surface defects or corrosion when it is not
possible to find them with the dye penetrant inspection, the ziglo or the
magnetoscopy.

(1) Set the switch to on.

(2) Set the magnifying power to a minimum.

(3) Adjust the two oculars to your view.

(4) Do not lock the binocular before you do the focusing.

(5) Do a near focusing. Point the aiming assembly near the middle of the focusing range.
Use the mobile arms and the extension bars to light fully the area of the part which
must be examined.

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(6) Do a correct focusing with a 40x magnifying power.

NOTE: After this adjustment, it is not necessary to change the focusing when the
magnifying power is changed.

(7) Lock the binocular in position.

(8) Examine the part, refer to the engine manual for the values of the defects.

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INSPECTION/CHECK 02

TASK 49-00-01-220-802
1. Inspection of the Bearings

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-805 Cleaning of the Ball and
Roller Bearings

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Inspection, Type 1 - Stylus Commercially Available
Inspection, Type 2 - Stylus Commercially Available
Inspection, Type 3 - Stylus Commercially Available
or
Local Manufacturer
NOTE: (Refer to Figure 801)

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

97/1 Socomor
Hyso ZI du prat - Ave P. Dupleix -
RP3707
56037 Vannes Cedex
France
MIL-PRF-6085 Commercially Available
Preservation Oil

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Part No./Spec. No. Source (CAGE Code)

Cloth, Lint-free Commercially Available
Alcohol Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-220-002
E. General

(1) The bearings are precision parts, they turn at high speeds and are highly loaded. The
bearings must be examined with special precautions and in the applicable work
rooms.

(2) The work rooms must :

(a) be isolated from the other workshops

(b) have a ventilation by filtered air

(c) keep a slight pressure (more than the environment pressure)

(d) have a layer of shock-proof material applied to the work surfaces and the ground.

(3) The personnel must always use a clean, lint-free cloth.

SUBTASK 49-00-01-220-003
F. Terms used

(1) Functional or non-functional surfaces

(a) The functional surfaces are:

1 the balls

2 the rollers

3 the surfaces in contact with the balls or the rollers (the bearing races, the
ring shoulders of the roller bearing)

4 the cages

(b) The non-functional surfaces

1 the other surfaces

(2) Types of bearings

(a) Type-A bearing: The type-A bearings are the bearings which have a ball or roller
diameter less than 0.48 inch (12 mm).

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(b) Type-B bearing: The type-B bearings are the bearings which have a ball or roller
diameter between 0.48 in (12 mm) and 0.98 inch (25 mm).
(c) Type-C bearing: The type-C bearings are the bearings which have an internal
diameter less than 1.97 inch (50 mm).

(d) Type-D bearing: The type-D bearings are the bearings which have an internal
diameter more than 1.97 inch (50 mm).

SUBTASK 49-00-01-220-004
G. Types and limits of the defects

(1) Burnishing-glazing

(a) Appearance

1 The result of burnishing is a mechanically polished surface, without

displacement or removal of matter.

2 It is possible that the periphery of the burnished areas has a different color.

3 The glazing is the last step of burnishing. The result of glazing is a surface
discoloration from brown to black.

(b) Limits of the defect

1 The burnishing/glazing is permitted if there are no metal transfer or

adhesion.

2 The glazing can be removed with a cloth soaked with alcohol.

(2) Coloration by the heat

(a) Appearance

1 The color of the surfaces is from straw yellow (low temperatures) to violet
(high temperatures).

NOTE: See also "glazing."

(b) Limits of the defect

1 A light coloration is permitted.

2 Discard the bearing if the color is violet or blue or if you are not sure that
the color is correct.

(3) Corrosion

(a) Appearance

1 The surface is damaged, pitted or with no color, with an orange-peel

appearance.

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2 The corrosion areas make large groups of small and superficial pits.

(b) Limits of the defect on the functional surfaces

1 Type-A bearings

a The bearing is serviceable if the defect is not felt with a type-1 stylus.

2 Type-B bearings

a The bearing is serviceable if the defect is not felt with a type-2 stylus.

3 All types of bearings

a Remove corrosion. Use a fine abrasive cloth (micrographic polishing

type) and rub lightly the damaged areas.

(c) Limits of the defects on the non-functional surfaces

1 All types of bearings.

a Corrosion is permitted.

b Remove corrosion with a fine abrasive cloth.

(4) Fretting corrosion

(a) Appearance

1 The fretting corrosion is found most frequently between the inner ring and
the shaft, between the outer ring and its housing. It is also found frequently
on the lateral faces of the rings and on the parts which keep the
components.

2 The result of fretting corrosion is a rusted surface, with a black and shiny
color.

(b) Limits of defects on outer or inner diameters

1 Fretting corrosion is permitted if :

a The depth is less than 0.0006 in (15 μ).

b The damaged surfaces are less than 40 % of the total surface.

c The diameters are in the geometrical check limits.

(c) Limits of defects on the contact faces between the inner half-cages

1 The fretting corrosion is not permitted.

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(d) Limits of defects on the other faces

1 The fretting corrosion is permitted if:

a The depth is less than 0.0006 in (15 μ).

b The damaged surface is less than 10 % of the total surface.

(5) Cracks

(a) Appearance

1 The cracks are narrow slits.

(b) Limits of the defects

1 The cracks are not permitted in the functional or non-functional surfaces.

2 Discard the bearing if there are cracks.

(6) Flaking

(a) Appearance

1 The holes with some irregular shapes, they have some sharp angles and
a small depth.

(b) Limits of defects

1 Flaking is not permitted.

2 Discard the bearing if there are signs of flaking.

(7) Brinell effect (correct or incorrect)

(a) Appearance

1 The correct Brinell effect shows, on the bearing races, some smooth marks
made by balls or rollers. The balls or rollers frequently show a small flat
area (which can be on two opposite positions on the diameter).

2 The incorrect Brinell effect shows, on the bearing race surfaces, some
superficial marks. The marks usually have a glossy or polished
appearance. There are marks on the roller bearing races. These marks are
lines perpendicular to the direction of the turn.

(b) Limits of the defects

1 Type-A bearings

a The bearing is serviceable if the defect is not felt with a type-1 stylus.

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b The bearing is unserviceable if the defect is felt with a type-1 stylus

and its length is more than 0.0078 inch (0.20 mm) or its depth is more
than 0.0024 inch (0.06 mm).
2 Type-B bearings

a The bearing is serviceable if the defect is not felt with a type-2 stylus.

b The bearing is unserviceable if the defect is felt with a type-2 stylus

and its length is more than 0.0118 inch (0.30 mm) or its depth is more
than 0.0024 inch (0.06 mm).

(8) Marks with rounded or sharp bottoms.

(a) Appearance

1 The shallow holes with rounded or angular bottoms.

2 On the functional surfaces, each mark with a rounded bottom has a

polished appearance around its periphery. This appearance is caused by
the flattening of the metal pile-up.

3 On the non-functional surfaces, the pile-up is around the periphery of the

marks.

(b) Limits of the defects on the functional surfaces.

1 Type-A bearings

a The bearing is serviceable it the defect is not felt with a type-1 stylus.

b The bearing is unserviceable if the defect is felt with a type-1 stylus

and its length is more than 0.0078 inch (0.20 mm) or its depth is more
than 0.0024 inch (0.06 mm).

2 Type-B bearings

a The bearing is serviceable if the defect is not felt with a type-2 stylus.

b The bearing is unserviceable if the defect is felt with a type-2 stylus

and its length is more than 0.0118 inch (0.30 mm) or its depth is more
than 0.0024 inch (0.06 mm).

(c) Limits of the defects on the non-functional surfaces.

1 Type-C bearings

a The bearing is serviceable if the marks with a rounded or sharp

bottom have their largest dimension less than 0.0315 inch (0.8 mm)
(when the peripheral pile-up is removed).

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2 Type-D bearings
a The bearing is serviceable if the marks with a rounded or sharp
bottom have their largest dimension less than 0.06 inch (1.5 mm)
(when the peripheral pile-up is removed).

(9) Nicks

(a) Appearance

1 The multiple scores with a large depth which can be seen on all surfaces
of the bearings.

(b) Limits of the defects on the functional surfaces

1 Type-A bearings

a The bearing is unserviceable if the defect is felt with a type-1 stylus.

2 Type-B bearings

a The bearing is unserviceable if the defect is felt with a type-2 stylus.

(c) Limits of the defects on the non-functional surfaces

1 All types of bearings

a The bearing is serviceable if the depth of the defect is less than 0.0079
in (0.2 mm).

(10) Scores - Scratches

(a) Appearance

1 The scores are narrow, shallow, linear grooves on the surface of the
bearing components. The scores move the material but they do not remove
it.

2 The scratches are small tangled scores, they are usually seen on the rolling
parts and races.

(b) Limits of the defects

1 Balls of the type-A bearings

a The bearing is unserviceable if the defects are felt with a type-1 stylus.

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2 Races of the type-A bearings

a The bearing is unserviceable if the defects are felt with a type-1 stylus.

NOTE: The circumferential defects which have a length less than

0.24 inch (6 mm) are permitted. The axial defects with a
length less than 1/4 of the width of the bearing race are
permitted.

3 Rollers of the type-A bearing

a The bearing is unserviceable if the axial defects are felt with a type-1
stylus.

b The bearing is unserviceable if the circumferential defects are felt with

a type-2 stylus.

4 Balls of the type-B bearings

a The bearing is unserviceable if the defects are felt with a type-2 stylus.

5 Races of the type-B bearings

a The bearing is unserviceable if the defects are felt with a type-2 stylus.

NOTE: The circumferential defects with a length less than 0.24 in (6

mm) are permitted. The axial defects with a length less than
1/4 of the width of the bearing race are permitted.

6 Rollers of the type-B bearing

a The bearing is unserviceable if the axial defects are felt with a type-2
stylus.

b The bearing is unserviceable if the circumferential defects are felt with

a type-3 stylus.

(11) Seizing

(a) Appearance

1 The seizing has the same appearance as the fretting corrosion, but is more
important.

2 The seizing is a movement of the metal. The movement of the metal is

made by friction and subsequently, by pick-up of the metal particles.

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(b) Limits of the defects

1 The bearing is unserviceable if it has signs of seizing on the functional
surfaces.

NOTE: On the non-functional surfaces, light signs of seizing are permitted

after you make the defect smooth.

(12) Skidding

(a) Appearance

1 The skidding occurs when the internal or the external race turns but the
balls (or rollers) do not.

2 On the roller bearings, skidding is shown by gray areas (which are not
bright) on the bearing races and rollers. These areas are pointed in the
direction of the displacement.

3 On the ball bearings, skidding is shown by not bright annular areas on the
balls and by not bright irregular areas on the bearing races.

4 An important wear of the cage recesses is usually an indication of skidding.

(b) Limits of the defects.

1 The bearing is unserviceable if it has signs of skidding.

(13) Pitting

(a) Appearance

1 The result of pitting is some small holes with irregular shapes. There is a
loss of metal and shiny metal.

(b) Limits of the defects on functional.

1 Type-A bearings.

a The bearing is serviceable if, on functional surfaces:

- the defects are not felt with a type-1 stylus

- an isolated defect is felt with a type-1 stylus and its dimension is less
than 0.006 inch (0.15 mm)

- a group of defects is felt with a type-1 stylus and the dimension of

the defects is less than 0.0024 inch (0.06 mm)

NOTE: A group of defects is a minimum of 3 pits in a 0.118 inch (3 mm)

diameter circle.

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2 Type-B bearings.
a The bearing is serviceable if, on functional surfaces.

- the defects are not felt with a type-2 stylus

- an isolated defect is felt with a type-2 stylus and its dimension is less
than 0.0098 inch (0.25 mm)

- a group of defects is felt with a type-2 stylus and the dimension of

the defects is less than 0.0024 inch (0.06 mm)

NOTE: A group of defects is a minimum of 3 pits in a 0.236 inch (6 mm)

diameter circle.

(c) Limits of the defects on non-functional surfaces

1 Type-C bearings

a The bearing is serviceable if:

- an isolated defect has a dimension less than 0.0275 inch (0.7 mm)

- in a group of defects, the dimension of each defect is less than 0.012

inch (0.3 mm)

NOTE: A group of defects is a minimum of 3 pits in a 0.118 in (3 mm)

diameter circle.

2 Type-D bearings

a The bearing is serviceable if:

- an isolated defect has a dimension less than 0.059 inch (1.5 mm)

- in a group of defects, each defect has a dimensionless than 0.0236

inch (0.6 mm)

NOTE: A group of defects is a minimum of 3 pits in a 0.236 inch (6 mm)

diameter circle.

(14) Wear at the ends of the rollers.

(a) Appearance

1 The ends of the rollers have circular scores. The circular scores are in or
out of the center position.

(b) Limits of the defects.

1 The wear at the ends of the rollers is permitted if:

a there is not a lifted surface of more than 0.0006 inch (0. 015 mm)

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b the surfaces are not rough

c there are no sharp angles

d there is no burnishing near the periphery of the rollers

(15) Exfoliation, peeling, blistering on the cages.

(a) Appearance

1 The silver layer is no longer bonded to the base metal (exfoliation, peeling).

2 The silver layer has blisters (blistering).

(b) Limits of the defects.

1 All types of bearings

a The bearing is unserviceable, if there is exfoliation, peeling or

blistering on the cage.

(16) Wear of the cages

(a) Limits of the defects

1 The bearing is unserviceable if:

a The silver layer has burrs caused by creeping.

b The base metal can be seen.

c The balls or the rollers fall out of the housings because of their weight.

SUBTASK 49-00-01-220-005
H. Inspection

CAUTION: PUT SYNTHETIC RUBBER GLOVES, NYLON GLOVES WITH

POLYETHELENE PALMS AND FINGERTIPS, OR CLEAN COTTON
GLOVES, BECAUSE THE PERSPIRATION CAN CAUSE AN OXIDATION.

(1) Clean the bearing. Refer to Reference Information for the cleaning of the ball and
roller bearings.

(2) Examine all the parts of the bearing.

(3) Make sure there are no defects.

NOTE: The types of the defects are identified in paragraph 1.

(4) Discard the bearing if one or more defects are not permitted.

NOTE: The values of the permitted defects are given in paragraph 1.

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(5) When the check is correct, and before you install the bearing on the engine:

(a) Put the bearing in an oven at a temperature of 176°F (80°C) during 30 minutes.
(b) Remove the bearing from the oven.

(c) Put the bearing fully into the bath of preservation oil, MIL-PRF-6085.

(d) Drain the bearing fully.

CAUTION: PUT SYNTHETIC-RUBBER GLOVES, NYLON GLOVES WITH

POLYETHELENE PALMS AND FINGERTIPS, OR CLEAN COTTON
GLOVES, BECAUSE THE PERSPIRATION CAN CAUSE AN OXIDATION.

(6) Put the bearing in an applicable box when you do not use it immediately.

Inspection - Stylus type

Figure 801

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INSPECTION/CHECK 03

TASK 49-00-01-240-801
1. Magnetic Particle Inspection

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Cleaning 11 Cleaning of the Metallic
Task 49-00-01-110-811 Parts-General
HSPS 490001 Inspection/Check 05 Demagnetize and Measure
Task 49-00-01-280-801 the Remaining Magnetic
Field

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Magnetic Particle Inspection Equipment Commercially Available
Demagnetizer Commercially Available
Magnetic Field Controller Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Fluorescent Developer Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-240-001
E. Inspection
(1) Refer to ASTM-E-1444 for the quality of the persons, installations and procedures.

(2) The magnetic particle inspection can only be used on ferromagnetic materials (μR >
300).

(3) The approved procedures used to magnetize the parts are:

(a) Circular magnetization (or transversal magnetization)

1 By current through the part.

2 By current through an auxiliary conductor.

3 By induced current.

(b) Longitudinal magnetization

1 By direct magnetization.

2 By solenoid.

3 By flat spiral coil.

(4) The value of the intensity of the magnetic field is the important parameter for the quality
of the magnetic particle inspection. The minimum value of the magnetic field must be
6.4 kA/m (80.4 Oersteds) at the inspection point.

(5) Approved fluorescent developers

(a) Only fluorescent developers used in the wet procedure (mixed in kerosene or
aliphatic compounds) are approved for the inspection of the APIC parts.

(b) The use of all the other developers, specially the fluorescent developers in a
water base, must be approved by a written approval from the APIC supervisors.

(c) The list of the developers for the magnetic particle inspection which are approved
by APIC, (Refer to Table 801).

Table 801
Fluorescent magnetic developers approved by APIC

Nominal Related
concentratio value of
n sedimentatio
Manufactur g/l) in n in
Name of Product er Supplier Kerosene % (1)
FLUXO 6C SREM SREM
FLUXO 6 D1 SREM SREM 0.80 0.25

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Nominal Related
concentratio value of
n sedimentatio
Manufactur g/l) in n in
Name of Product er Supplier Kerosene % (1)
FLUXO 6 D2 SREM SREM 0.80 0.25
MAGNAGLO MAGNAFL ESCOFFIER 1.25 0.22
14A UX
SY8000 A/1 ARDROX BRENT SA 1 ±0.50 0.20
TIEDE E TIEDE KRAUT- 0.80 0.10
KRAMER
8530 ARDROX BRENT SA 1 0.22
MAGNAGLO MAGNAFL ESCOFFIER 1 0.10
410 UX
LUMOR 3X CASTROL IPSI 1.20 0.30
LUMOR X CASTROL IPSI 1.20 0.10
FLUOFLUX TIEDE ARIEL 1.20 0.20
61210 (2)
MAGNAGLO 14 MAGNAFL ESCOFFIER 1.25 (3) 0.22
H-F UX

NOTE: Permitted tolerance on the new or used products - ±0.05%.

NOTE: Ready to use the product only or paste.

NOTE: Ready to use with aliphatic support (odorless - EXXSOL D 100

recommended).

(6) How to apply the developers

(a) Let the developers flow for 15 minutes before the developer is applied to the
parts.

(b) The developer flow must be small. If the flow is high, it can change the
indications.

(c) The flow of the developers must be stopped before the magnetism stops.

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(7) Ultraviolet radiation sources

(a) The ultraviolet lighting device must give a minimum energy lighting level at 15
W/m² on the surface of the parts (with a peak at 365 nm ±15 nm). The distance
between the lamps and the surface of the part must permit correct inspection
conditions.

(8) Demagnetization

(a) After each magnetic particle inspection, the parts must be demagnetized.

(b) The value of the remaining magnetism field must be equal to or less than 0.250
kA/m (3.1 Oesteds).

SUBTASK 49-00-01-240-002
F. Magnetic Inspection

WARNING: DO NOT BREATHE THE GASES OF THE FLUORESCENT SOLUTION.

USE THE FLUORESCENT SOLUTION ONLY IN THE AREAS WHERE THE
AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS. IF
THE FLUORESCENT SOLUTION TOUCHES YOUR EYES, FLUSH YOUR
EYES WITH WATER AND CALL A DOCTOR. IF THE FLUORESCENT
SOLUTION TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND
WATER. THE FLUORESCENT SOLUTION IS POISONOUS AND
FLAMMABLE.

(1) Carefully clean the part to remove the grease oxidation dirt and other materials. Use
halogenous solvents in vapor phase or alkaline solvents (Refer to Reference
Information for the cleaning of the metal parts) or a different chemical procedure.

NOTE: Every time you can clean the part with a chemical procedure, do not use a
mechanical procedure (sand blasting, polishing, etc.). The mechanical
procedure can clog the smaller defects, or cause some small plastic
distortions of the surfaces. It can crimp the lips of the defects and thus make
a modification of the magnetic field leaks.

(2) Make sure the part has no remaining magnetic field. If the remaining magnetic field
is more than 0.5 kA/m (6.3 Oersteds), demagnetize.

(3) Magnetize the part with the transversal procedure.

(a) Keep a magnetic field at a minimum of 6.4 kA/m (80.4 Oersteds) during 2
seconds or more.

(b) Apply the developer, do not use a high flow.

(c) Stop the developer flow immediately before the magnetic field stops.

(4) Examine the part with an ultraviolet lamp.

(5) Refer to the Engine Manual for the values of the defects.

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(6) Demagnetize the part until you get a remaining magnetic field less than 0.5 kA/m (6.3
Oersteds) (Refer to Reference Information for demagnetizing and measuring the
remaining magnetic field).
(7) If necessary, do the steps (3) to (5) again to examine the part fully.

(8) Magnetize the part with the longitudinal procedure.

(a) Keep a magnetic field at a minimum of 6.4 kA/m (80.4 Oersteds) for 2 seconds
or more.

(b) Apply the developer, do not use a high flow.

(c) Stop the developer flow immediately before the magnetic field stops.

(9) Examine the part with an ultraviolet lamp.

(10) Refer to the Engine Manual for the values of the defects.

(11) Demagnetize the part until you get a remaining magnetic field less than 0.5 kA/m (6.3
Oersteds) (Refer to Reference Information for demagnetizing and measuring the
remaining magnetic field).

(12) If necessary, do the steps (7) to (9) again to examine the part fully.

(13) Demagnetize the part until you get a remaining magnetic field less than 0.25 kA/m
(3.1 Oersteds) (Refer to Reference Information for demagnetizing and measuring the
remaining magnetic field).

(14) Clean the part with an halogenous solvent or an alkaline solvent (Refer to Reference
Information for the cleaning of the metal parts).

(15) If necessary, apply a protection to prevent corrosion.

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INSPECTION/CHECK 04

TASK 49-00-01-220-808
1. Inspection of the Gears

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Dazor M-270 Magnifier (or equivalent) Commercially Available
Tampico Brush (12 to 14 inches) Commercially Available
Inspection Stylus Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Jewelers Rouge Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-220-006
E. Inspection

(1) Polish the gear teeth using a 12 to 14 inch natural fiber Tampico brush in a high speed
chuck. Apply jewelers rouge moderately to the brush while polishing.

NOTE: Polishing will remove stains and darkened areas and highlight any abnormal
wear areas.

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(2) Visually check the gear teeth for cracking, pitting, and obvious wear using a 3 to 5
power illuminated magnifier (Dazor M-270 or equivalent). Destructive pitting (surface
fatigue) at or above the pitch line is cause for rejection.
(3) Remove sharp edges, nicks, and burrs by stoning. Edge and corner nicking is
acceptable if the tooth face width loss does not exceed 10 percent of the tooth face.

(4) Perform the following checks to determine serviceability of gears:

NOTE: The gear tooth wear surfaces will be inspected for roughness using a 0.02
inch spherical radius stylus hand held in comfortable position. Apply the
stylus to the gear tooth with moderate pressure and stroke as near to
perpendicular to the tooth face as possible. Stroke in direction required to
determine wear, (Refer to Figure 801).

(a) Visually check the gears for corner nicks, (Refer to Figure 802).

(b) Check the surface wear accordingly, (Refer to Figure 803) and (Refer to Figure
804).

(c) Visually check the gears for tooth breakage, (Refer to Figure 805).

(d) Check the gear surface appearance accordingly, (Refer to Figure 806), (Refer
to Figure 807), (Refer to Figure 808), (Refer to Figure 809), (Refer to Figure
810), (Refer to Figure 811), (Refer to Figure 812), (Refer to Figure 813) and
(Refer to Figure 814).

(e) OPTIONAL: Magnetic particle inspection may be used as necessary by the

repair engineer to collect data on a sampling basis for a new style part having
limited or no previous operating experience, or to supplement an existing
inspection whose results are questionable or non-conclusive. Any indication of
cracking is cause for rejection.

(5) Parts that have been subjected to overheating (indicated by definite light to dark blue
discoloration) should be inspected as follows:

(a) Clean the parts according to the acid cleaning procedure in CLEANING. If
discoloration is removed by the acid cleaning procedure, the parts do not require
a hardness check.

(b) Parts that do not come clean by the above method should be checked with a
Rockwell hardness tester. Hardness below manufactured tolerance of more than
two points Rockwell C scale or one point Rockwell A scale is cause for rejection.
(Specific limits are given in the engine manual or reduction drive component
maintenance manual).

NOTE: Due to the manufacturing changes, many gears are no longer hardened
on the sides of the gear teeth. Therefore, the hardness checks must be
taken on the gear tooth face with a non-destructive type instrument such
as the Branson Sonodur hardness tester or equivalent.

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Stroking Directions
Figure 801

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Corner Nicking
Figure 802

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Surface Wear
Figure 803

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Surface Wear
Figure 804

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Tooth Breakage
Figure 805

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Light Frosting
Figure 806

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Scoring
Figure 807

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Frosting and Some Polishing

Figure 808

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Frosting
Figure 809

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Scoring
Figure 810

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Abrasive Wear and Scoring

Figure 811

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Pitting and Frosting

Figure 812

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Pitting
Figure 813

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Destructive Pitting
Figure 814

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INSPECTION/CHECK 05

TASK 49-00-01-280-801
1. Demagnetize and Measure the Remaining Magnetic Field

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Magnetic Field Controller Commercially Available
De-magnetizer Commercially Available

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-240-003
E. Procedure with a de-magnetizer (first method).

(1) Put the part in the de-magnetizer, then move the part slowly out. Move the part along
the solenoid axis.

NOTE: The magnetic field at the center of the coil must not be less than 6.4 kA/m
(80 Oersteds).

(2) Measure the value of the remaining magnetic field. Refer to paragraph F.

(3) Do the steps (1) to (2) until you get a correct value of the residual magnetism.

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SUBTASK 49-00-01-240-004
F. Procedure with a demagnetizer (second method).
(1) Adjust the intensity of the magnetic field.

NOTE: The magnetic field at the center of the coil must not be less than 6.4 kA/m
(80 Oersteds).

(2) Put the part in the demagnetizer, then decrease the intensity manually (or
automatically if the installation permits it).

(3) Measure the value of the remaining magnetic field.

(4) Do the steps (1) to (3) until you get a correct value of the remaining magnetic field.

SUBTASK 49-00-01-240-005
G. Procedure with the installation for the magnetic particle inspection.

(1) Put the part between the coils of the installation.

CAUTION: USE ONLY ALTERNATING CURRENT OR A MAGNETIC FIELD.

(2) Send the alternating current or the magnetic field through the part.

(3) Decrease the intensity slowly and continuously until you have the minimum intensity.

(4) Measure the remaining magnetic field (refer to paragraph F).

(5) Do the steps (2) to (4) until you get a correct value of the remaining magnetic field.

SUBTASK 49-00-01-240-006
H. Procedure to measure the remaining magnetic field.

(1) Use a magnetic field controller to measure the remaining magnetic field.

NOTE: Obey the instructions given by the manufacturer to use or calibrate the
magnetic field controller.

(2) If there are no other values indicated, the remaining magnetic field must be less than
0.25 kA/m.

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INSPECTION/CHECK 06

TASK 49-00-01-220-804
1. Inspection of the Self-Locking Helical Coil Inserts and the Self-Locking Nuts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-801 Replacement of the
Threaded Inserts
HSPS 490001 Task 49-00-01-350-808 Installation of the Oversized
Threaded Inserts

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-220-007
E. Definitions

(1) Maximum locking torque: The maximum torque for any installation or removal of a
screw or bolt into a self-locking helical coil insert or nut.

(2) Minimum breakaway torque: The minimum torque necessary to overcome the static
friction of the locking coil in a self-locking helical coil insert or nut.

(3) Fully installed bolt or screw: For the purpose of this inspection, a bolt or screw is
considered fully installed when three threads extend past the end of the locking coil
of a self-locking helical coil insert or nut.

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SUBTASK 49-00-01-220-008
F. Inspection and Assembly Requirements
NOTE: Self-locking helical coil inserts or nuts are designed for a limited number of reuses.
To provide the new part torque values for the self-locking helical coil inserts and
nuts, (Refer to Table 801) and (Refer to Table 802).

(1) Inspection

(a) Before reuse, test each self-locking helical coil insert or nut to determine if the
locking function meets the minimum breakaway torque and maximum locking
torque, (Refer to Table 801) and (Refer to Table 802).

Table 801
Reuse Torque for Lubricated Fasteners (English Units)

TORQUE (LB.-IN.) TORQUE (LB.-IN.)

MIN. MIN.
THREAD BREAKA MAX. THREAD BREAKAW MAX.
SIZE WAY LOCKING SIZE AY LOCKING
0.112 - 40 0.5 3 0.500 - 14 24.0 150
0.112 - 48 0.5 3 0.500 - 20 18.0 150
0.138 - 32 1.0 6 0.5625 - 12 30.0 200
0.138 - 40 1.0 6 0.5625 - 18 24.0 200
0.164 - 32 1.5 9 0.625 - 11 40.0 300
0.164 - 36 1.5 9 0.625 - 18 32.0 300
0.190 - 24 2.0 13 0.750 - 10 60.0 400
0.190 - 32 2.0 13 0.750 - 16 50.0 400
0.250 - 20 4.5 30 0.875 - 9 82.0 600
0.250 - 28 3.5 30 0.875 - 14 70.0 600
0.3125 - 7.5 60 1.000 - 8 110.0 800
18
0.3125 - 6.5 60 1.000 - 14 92.0 800
24
0.375 - 16 12.0 80
0.375 - 24 9.5 80

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TORQUE (LB.-IN.) TORQUE (LB.-IN.)

MIN. MIN.
THREAD BREAKA MAX. THREAD BREAKAW MAX.
SIZE WAY LOCKING SIZE AY LOCKING
0.4375 - 16.5 100
14
0.4375 - 14.0 100
20

Table 802
Reuse Torque for Lubricated Fasteners (Metric Units)

TORQUE (LB.-IN.) TORQUE (LB.-IN.)

MIN. MIN.
THREAD BREAKA MAX. THREAD BREAKAW MAX.
SIZE WAY LOCKING SIZE AY LOCKING
0.112 - 40 0.056 0.339 0.500 - 14 2.712 16.948
0.112 - 48 0.056 0.338 0.500 - 20 2.034 16.948
0.138 - 32 0.113 0.678 0.5625 - 3.390 22.567
12
0.138 - 40 0.113 0.675 0.5625 - 2.712 22.567
18
0.164 - 32 0.169 1.017 0.625 - 11 4.519 33.895
0.164 - 36 0.169 1.017 0.625 - 18 3.616 33.895
0.190 - 24 0.226 1.469 0.750 - 10 6.779 45.194
0.190 - 32 0.226 1.469 0.750 - 16 5.649 45.194
0.250 - 20 0.508 3.390 0.875 - 9 9.265 67.791
0.250 - 28 0.395 3.390 0.875 - 14 7.909 67.791
0.3125 - 0.847 6.779 1.000 - 8 12.428 90.388
18
0.3125 - 0.734 6.779 1.000 - 14 10.395 90.388
24
0.375 - 16 1.356 9.039
0.375 - 24 1.073 9.039

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TORQUE (LB.-IN.) TORQUE (LB.-IN.)

MIN. MIN.
THREAD BREAKA MAX. THREAD BREAKAW MAX.
SIZE WAY LOCKING SIZE AY LOCKING
0.4375 - 1.864 11.298
14
0.4375 - 1.582 11.298
20

(b) With the fingers, assemble a new bolt or screw into the self-locking helical coil
insert or nut until it touches the locking-coil.

NOTE: The bolt or screw used for this inspection must be of sufficient length to
ensure that it can be fully installed without the head engaging the self-
locking helical coil insert or nut.

NOTE: The bolt or screw must assemble freely until it contacts the locking coil.

(c) Fully install the bolt or screw into the self-locking helical coil insert or nut.

NOTE: Install at a rate slow enough to avoid heating the bolt or screw.

(d) Measure the maximum locking-torque and minimum breakaway torque

accordingly, (Refer to Table 801) and (Refer to Table 802).

NOTE: The measurement must be run at a rate slow enough to give a

dependable measure of torque and avoid heating the bolt or screw.

(e) Discard or replace self-locking helical coil insert or nut that failed in step (d)
above.

(2) Statistical Sampling

(a) A statistically valid sampling inspection plan may be used instead of a 100%-
inspection.

(3) Assembly

(a) When necessary, check the maximum locking-torque and minimum breakaway
torque at reassembly accordingly, (Refer to Table 801) and (Refer to Table
802).

(b) Replace any defective self-locking helical coil insert or nut with a new part. Do
not attempt to repair a defective self-locking helical coil insert or nut.

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INSPECTION/CHECK 07

TASK 49-00-01-230-801
1. Penetrant Inspection

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic
Parts-General
HSPS 490001 Task 49-00-01-110-815 Degrease

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Penetrant Inspection Equipment Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec No. Source (CAGE Code)

AMS 2644, Type I, Method A, B, or D, Commercially Available
Sensitivity Level 3
Penetrant - for rotating parts
AMS 2644, Type I, Method A, B, or D, Commercially Available
Sensitivity Level 2
Penetrant - for static parts
Magnaflux Carrier II Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-230-001
E. Inspection- Perform Fluorescent Penetrant Inspection according to ASTM E1417 and the
following:
(1) Clean the parts in vapor phase. Refer to Reference Information for the cleaning of the
metal parts.

The parts must be cleaned fully before the inspection.

NOTE: If the cleaning in vapor phase is not sufficient, do a chemical cleaning.

NOTE: If necessary, Skysol Wipe Solvent may be used to clean the part(s) just
before the penetrant inspection.

(2) If necessary, decrease the temperature of the parts to 104°F (40°C).

(3) Apply the penetrant at the ambient temperature. (See section 1.D.2 for required
sensitivity level).

The minimum dwell time must be 10 minutes for static parts and 20 minutes for rotating
parts.

(4) If you use the post-emulsifiable penetrants (symbol P), clean the parts with water at
a maximum temperature of 95°F (35°C).

(5) Remove the penetrant with a manual or an automated water spray or a manual wipe.

The maximum temperature of the water must be 95°F (35°C). Use an ultra-violet light
source to check the washing.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(6) Dry the parts in an oven or with compressed air at a maximum pressure of 29 psi (200
kPa).

The maximum temperature of the oven must be 160°F (71°C). Drying time must be
necessary to sufficiently dry the part.

(7) Apply the developer to the parts. The minimum dwell time must be 10 minutes.

(8) Examine the parts.

(9) Clean the parts in vapor phase. Refer to Reference Information for the cleaning of the
metal parts.

NOTE: If the cleaning in vapor phase is not sufficient, do a chemical cleaning.

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(10) Apply a light layer of lubrication oil to the parts to prevent corrosion.

(11) Put the parts in clean plastic bags to prevent contamination.

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INSPECTION/CHECK 08

TASK 49-00-01-220-805
1. Inspection of the Flatness by the Optical Flat Method

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Optical Flat and Monochromatic Light Acme Scientific
200 N. Lapin
Chicago, IL 60647

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec No. Source (CAGE Code)

Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-220-011
E. Inspection

NOTE: The coverage gives the general information on how to use an optical flat and a
monochromatic light. The manufacturer can give more instructions.

(1) If it is necessary to examine the flatness of a part to 0.000050 inch (0.00127 mm) or
less, a Lapmaster Monochromatic Light is recommended. It has a helium light source
with a strong 40-foot candle power. It is in the recess of the cover. It has a diffusing
glass, which transmits one wave length light of 23.2 millionths of an inch (0.000589
mm) to the work surface. This gives checking precisions within one light band or 11.6
microinches (0.295 micrometers).

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(2) The optical flats used are made of a highly transparent quartz : this quartz is distortion
resistant, abrasive resistant, and has a protection against the thermal shocks.
(3) The surface examined must be clean, shiny and smooth so that the light will be
reflected back through the optical flat.

(4) On very hard materials, such as hardened alloy steel and other high quality metals,
the lapped finish will cause the reflection of sufficient light to give the accurate
readings. On softer materials, it is necessary to polish the surface by rubbing the part
on a polishing medium (such as 4/0 paper), with a figure eight motion similar to that
used in hand lapping. The operator must hold the part in such a way as no distortion
occurs from the manual pressure applied. It is important to clean the part before, since
it is not possible to polish correctly if there is liquid or foreign matter.

(5) When the part is polished to the correct reflectivity, it is put on the stage under the
Monochromatic Light source and the optical flat is installed on the surface to be
examined. Both the flat and the part must be fully clean and dry (clean with a lint-free
material such as facial tissue). The optical flat must be put directly on, and removed
directly from the examined part. Do not move the optical flat across the surface of a
part because this will cause a scratch to the flat and also to the surface of the part.

(6) The width of the light bands is related to the thickness of the air wedge which you
always find between two parts. Minute particles of dust, or projection from either
surface, will hold the flat sufficiently far away from the part so that very narrow light
bands will be seen. The thickness of the air wedge can be decreased by greater
cleanliness or, in many cases, by lightly pushing on the optical flat to push out some
of the air. As the air wedge thickness is decreased, the light bands become
increasingly large.

(7) The width of bands or number of bands does not change the surface measurement.
It only changes the precision of the reading. It is not necessary to have them any wider
than needed for definite interpretation of their curvature.

(8) Do a check of the light wave bands for straightness. If the bands are straight, parallel
and equally spaced, the surface is flat.

(9) If the bands are curved or are not equally spaced, the surface is not flat.

(10) When you look at the bands, try to keep the eyes approximately 18 to 24 inches above
the optical flat.

(11) If you can not see the bands, the cause can be:

(a) Dust or foreign particles hold the flat away from the surface. Do not move the
flat around on the surface as this causes a scratch to the flat.

(b) Moisture or oil can bond the flat to the part.

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(12) The work is an indication of the condition of the lapping plate. The condition of the
piece or work is the opposite of the condition of the lap plate. If the lapping plate is
convex, the work will be concave. If the lapping plate is concave, the work will be
convex.

(13) To find whether the part is convex or concave, move the eyes slowly and continuously
away from the optical flat, along the line of vision. The light bands will flow either toward
or away from the center of the circle. Visualize the light bands as a piece of a large
circle, the center of which is off in the distance. As the eyes are moved away from the
optical flat along the line of vision and if the bands apparently go in toward the center,
the part is low toward the center and the lapping plate is high. If the bands apparently
go away from the center, the part is high toward the center and the lapping plate is
low.

(14) Even though each light band is actually 0.0000116 inch (0.000294 mm) for practical
purposes each band can be considered as being 0.000010 inch (0.000254 mm).
Therefore, if the repair figure requires a 0.000030 inch (0.000762 mm) flatness, 3 light
bands are permitted.

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INSPECTION/CHECK 09

TASK 49-00-01-280-802
1. Inspection of the Surface Temper

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Vapor Degreaser Installation Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec No. Source (CAGE Code)

VV-L-800 Commercially Available
Oil
4/0 Commercially Available
Polishing Paper
Hydrochloric Acid (HC1) Commercially Available
Denatured Alcohol Commercially Available
Nitric Acid (HNO3) Commercially Available
Sodium Pyrophosphate Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-280-001
E. Inspection
NOTE: This check is used to find the incorrect tempering, re-hardening or hardness
changes on the hardened surfaces after the repair.

The check of the surface temper is used for the bearing races or the other areas
which have a load applied.

The check of the surface temper must be done before the last dimensioning.

This procedure is non-destructive but can remove approximately 0.0001 inch

(0.0025 mm) of the stock (material hardness or immersion time).

WARNING: DO NOT BREATHE THE GASES OF THE DE-GREASING SOLVENT. USE

THE DE-GREASING SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE DE-
GREASING SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE DE-GREASING SOLVENT
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DE-GREASING SOLVENT IS POISONOUS AND FLAMMABLE.

(1) Clean the parts in a vapor de-greaser.

WARNING: DO NOT BREATHE THE GASES OF THE HYDROCHLORIC ACID. USE

THE HYDROCHLORIC ACID ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE
HYDROCHLORIC ACID TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE HYDROCHLORIC ACID
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE HYDROCHLORIC ACID IS POISONOUS AND FLAMMABLE.

(2) Put fully into a solution of hydrochloric acid (2 %) and denatured alcohol.

NOTE: The immersion is the recommended method for the inspection of the surface
temper. But, for the inspections with the localized machining or without an
acid bath, the method by hand swabbing of the acid can be used.

WARNING: DO NOT BREATHE THE GASES OF THE DENATURED ALCOHOL. USE

THE DENATURED ALCOHOL ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE
DENATURED ALCOHOL TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE DENATURED ALCOHOL
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DENATURED ALCOHOL IS POISONOUS AND FLAMMABLE.

(3) Flush the part in clean and denatured alcohol to make the cleaning easier.

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(4) Flush the part in water to decrease the temperature.

WARNING: DO NOT BREATHE THE GASES OF THE NITRIC ACID. USE THE NITRIC
ACID ONLY IN THE AREAS WHERE THE AIR IS CONTINUOUSLY
CHANGED. MAKE SURE THERE ARE NO SPARKS, NO FLAMES AND NO
HOT SURFACES IN THESE AREAS. IF THE NITRIC ACID TOUCHES
YOUR EYES, FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR.

CAUTION: IF THE NITRIC ACID TOUCHES YOUR SKIN, WASH YOUR SKIN WITH
SOAP AND WATER. THE NITRIC ACID IS POISONOUS AND
FLAMMABLE. THE TYPE OF THE MATERIAL HARDNESS AND THE
IMMERSION TIME GIVE THE QUANTITY OF STOCK TO BE REMOVED.

THE IMMERSION TIME MUST BE NO LONGER THAN NECESSARY TO

GIVE SATISFACTORY RESULTS AND TO MAKE SURE A MINIMUM OF
THE STOCK IS REMOVED. IF THE STOCK REMOVAL IS VERY
IMPORTANT, THE IMMERSION TIME MUST BE KEPT TO THE MINIMUM
NECESSARY.

(5) Put fully the part into a solution of nitric acid (3 to 5 %) and water at room temperature
for 7 to 15 seconds.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN YOU
USE COMPRESSED AIR TO CLEAN OR DRY. USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(6) Flush the parts fully in clear cold water to remove the nitric acid solution. Then put
momentarily in alcohol and dry with the compressed air to prevent a possible spotting
by water.

WARNING: DO NOT BREATHE THE GASES OF THE DE-GREASING SOLVENT USE

THE DE-GREASING SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE DE-
GREASING SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE DE-GREASING SOLVENT
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DE-GREASING SOLVENT IS POISONOUS AND FLAMMABLE.

(7) Increase the temperature of the part in a vapor de-greaser for 3 to 5 minutes.

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WARNING: DO NOT BREATHE THE GASES OF THE HYDROCHLORIC ACID. USE

THE HYDROCHLORIC ACID ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE
HYDROCHLORIC ACID TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE HYDROCHLORIC ACID
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE HYDROCHLORIC ACID IS POISONOUS AND FLAMMABLE.

(8) Put fully the part in a solution of hydrochloric acid (2 to 3 %) and denatured alcohol at
room temperature for 10 to 15 seconds.

(9) Flush the part fully in clean cold water to remove the solution of hydrochloric acid.

(10) Put momentarily in a solution of saturated alkaline, such as a sodium pyrophosphate

to make the acid neutral on the damaged surfaces.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN YOU
USE COMPRESSED AIR TO CLEAN OR DRY. USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(11) Flush the part fully in clear cold water. Then, put momentarily the part in alcohol and
dry with compressed air.

(12) Put momentarily the part in a lubricating oil or an oil which prevents the corrosion.

(13) Do a check of the surface temper on the part as follows :

(a) The areas which are darker than the surrounding of the treated surface show
the lower hardness of the surface caused by an incorrect tempering as a result
of the local overheating.

If there is no sign of tempering, the part must be rejected. Refer to steps (c) and
(d).

(b) The areas which are of a lighter color than the surrounding of the treated surface
show the higher hardness of the surface caused by rehardening as a result of
the local heating which is more than the transformation temperature of the steel.

The re-hardened areas can be surrounded by a border to tempered metal.

If there is no sign of re-hardening, the part must be rejected. Refer to the steps
(c) and (d).

(c) The incorrect indication caused by smears, stains, wheel patterns, smutty finish,
finger marks and difference in the surface condition is not the true indication of
the temper.

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(d) When a part shows any sign of the extreme surface tempering or the re-
hardening has more grinding stock on the damaged surface, machine again to
remove the damaged area and send the part to the inspection of the surface
temper to accept or to reject the part.

(e) If the degree of the burning shows more damage as given in step (a), the part
must be inspected by the magnetic particle for cracks before the machining.

(f) The bearing surfaces must be polished after the inspection of the surface
temper.

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INSPECTION/CHECK 10

TASK 49-00-01-220-806
1. Inspection of the V-band Clamps

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-220-009
E. Inspection

(1) Do a check of the V-band clamps for:

(a) Corrosion: Remove the corrosion.

(b) Cracks, weld separations, thread damage: Replace the V-band coupling.

(c) Missing parts: Install the missing parts.

(d) Twisted or distorted coupling: Replace the V-band coupling.

(e) Distortion of flange face: Replace the V-band coupling.

(f) Twisted or stretched T-bolt: Replace the T-bolt.

(g) T-bolt thread damage: Replace the T-bolt.

(h) Worn or damaged nut: Replace the nut.

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INSPECTION/CHECK 11

TASK 49-00-01-220-807
1. Inspection of the Coupling Ring

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Marking Compound Commercially Available
Mallet, Soft Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-220-010
E. Inspection

(1) The tooth bearing surface and the spacing, (Refer to Figure 801) and (Refer to Figure
802).

(a) Apply a thin coat of the marking compound to the teeth of the coupling ring.

NOTE: A thin coating is the one which will be visually different from the adjacent
area with a minimum of 0.003 mm (0.0008 inch).

(b) Apply a thin coat of the marking compound of a different color to the mating teeth
of the control coupling.

(c) Lock the checking-machine spindle in the lifted position and attach the control
coupling to the spindle.

(d) Engage the teeth of the control coupling and the coupling ring together.

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(e) Tap with a soft mallet on the back face of the coupling ring to get a color transfer.
Tap in a uniform surface opposite the curvic teeth.
(f) Examine the bearing surface and make sure that:

1 the contact area is rectangular and centrally engaged.

2 the minimum contact length is equal to 75 percent of the tooth width.

3 the minimum surface depth is equal to 90 percent of the tooth contact.

(g) If the defect is out of the tolerances, replace the coupling ring or the compressor
impeller.

(2) The minimum surface acceptance limits

(a) A minimum of 90 percent of the total number of the teeth must engage the
necessary contact surface, (Refer to Figure 801).

(b) The remaining 10 percent of the total number of the teeth show a small contact
surface or no contact surface at all, (Refer to Figure 802).

If the defect is out of the tolerances, replace the coupling ring or the compressor
impeller.

(3) Tooth spacing

(a) Look at the bearing surface markings for incorrect surfaces on all the teeth.

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Correct Bearing Surface

Figure 801

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Incorrect Bearing Surfaces

Figure 802 (Sheet 1 of 2)

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Incorrect Bearing Surfaces

Figure 802 (Sheet 2 of 2)

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INSPECTION/CHECK 12

TASK 49-00-01-250-801
1. Eddy Current Inspection

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

ATA 105 - Guidelines for Training/
qualificating Personnel in Non-
Destructive Inspection
NAS 410 - NAS Certification &
Qualification of Non-Destructive
Test Personnel
SNT-TC-1A - Recommended Practice No.
SNT-TC-1A (Latest Edition)
ISO 10012 - Quality Assurance
Requirements for Measuring
Equipment
ASM Handbook - Non-Destructive Evaluation and
Quality Control (Volume 17)
ASQR-02 - UTC Supplier Quality System
Requirements
AS9110 - Quality Management System -
Aerospace requirements for
Maintenance and Overhaul
services

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

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Part No./Name Source (CAGE Code)

Eddy Current Inspection Equipment:
MIZ27SI Zetec, Inc.
Eddy-Current Test Instrument 1370 NW Mall Street
P.O. Box 140
Issaquah, WA 98027, USA
Zetec Z0001663-1 Multi-Axis Turbine Disk Zetec, Inc.
Eddy (special order) 1370 NW Mall Street
P.O. Box 140
Issaquah, WA 98027, USA
Alternate Eddy-Current equipment and Commercially Available
multi-axis capable equipment with
equivalent accuracy
Probe:
Zetec D#5011-1-1A (special order) Zetec, Inc.
1370 NW Mall Street
P.O. Box 140
Issaquah, WA 98027, USA
Alternate articulated dual-coil, spring- Commercially Available
loaded probes of equivalent accuracy
(capable of following the contours of the
bore and back face)
Eddy-Current Masters:
AGE70046 Hamilton Sundstrand
Load Compressor Master (55820)
AGE70047 Hamilton Sundstrand
Generator Compressor Master (55820)
AGE70048 Hamilton Sundstrand
1st Stage Turbine Disk Master (55820)
AGE70049 Hamilton Sundstrand
2nd Stage Turbine Disk Master (55820)
AGE70057 Hamilton Sundstrand
Compressor Master (APS500R) (55820)
AGE70058 Hamilton Sundstrand
Compressor Master (APS500) (55820)
AGE70059 Hamilton Sundstrand
Compressor Master (APS1000) (55820)

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Part No./Name Source (CAGE Code)

AGE70559 Hamilton Sundstrand
Compressor Master (APS2000/2100) (55820)
AGE70201 Hamilton Sundstrand
2nd-Stage Turbine Disk Eddy Current (55820)
Master (2nd-Stage Turbine Wheel, P/N
4506285)
AGE70202 Hamilton Sundstrand
1st-Stage Turbine Disk Eddy Current (55820)
Master (1st-Stage Turbine Wheel, P/N
4506284)
AGE70203 Hamilton Sundstrand
Eddy Current Master (P/N 4506255) (55820)
AGE70586 Hamilton Sundstrand
Eddy Current Master-Impeller (APS500- (55820)
Heritage)
AGE70658 Hamilton Sundstrand
Eddy Current Master (Compressor (55820)
Impeller)
NOTE: Masters require periodic calibration to make sure that EDM slots are within
their requirements specified by the drawings.

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Adhesive-Backed Teflon Tape, 0.003 to Commercially Available
0.006 inch (0.076 to 0.152 mm) thick (for
protection of probe contact surface)
7447, Type A 3M Company
Scotch-Brite, Very fine (maroon) Abrasive (27293)
pad or equivalent
7448, Type S 3M Company
Scotch-Brite, Ultra fine (grey) Abrasive (27293)
pad or equivalent
Cotton Swabs Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-250-001
E. Inspection
CAUTION: DO NOT USE A BLASTING PROCESS TO CLEAN PART BEFORE EDDY
CURRENT INSPECTION. BLASTING PROCESS MAY CAUSE SMEARING
OF THE PART MATERIAL AND RESULT IN THE MASKING OF CRACKS.

NOTE: The Eddy-Current inspection is used for the detection of surface or subsurface
cracks of the part.

NOTE: All inspection/check procedures for Eddy-Current Inspection and the personnel
doing the work must be certified under one of the following: ATA 105 or NAS 410
or SNT-TC-1A.

(a) Other certifications may apply on individual basis, but must be approved by the
certifying authorities.

(b) Only qualified operators in accordance with the above and certified by a Level
III or European equivalent may do this Eddy-Current inspection.

(c) The equipment must be calibrated at intervals to establish basic system

performances as to sensitivity stability (drift), frequency, and noise level
production.

(d) The equipment must be calibrated for each setup according to the equipment
manufacturer’s instructions. The equipment must find all EDM’ed slots in the
Masters.

(e) Masters require periodic calibration to make sure that EDM slots are within their
requirements specified by the drawings.

NOTE: The procedure below may vary depending on the inspection equipment used. It
may be automated.

(1) Use the appropriate part-specific master to calibrate the system.

(a) Eddy-Current System:

1 The Eddy-current system must have a 3:1 noise level to signal ratio or
better when performing the original calibration using the applicable Master.

2 Set the alarm level to the signal created by the slot in the Master.

(b) The probe must cover the entire surface during the inspection cycle. Speeds
may be adjusted to accomplish this.

(c) The probe speed and movement sequence for the inspection must be the same
as used for the equipment calibration and actual inspection.

(d) The equipment must be re-calibrated if equipment has been shutdown for any
reason. Refer to the manufacturer’s recommendations for any required warmup
times.

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(2) Do a check of the part. It must be clean and free of oil, chips, other buildup or foreign
objects.
(3) Place the part on the holding fixture of the multi-axis machine.

(4) Mark a starting point for reference on the bore and/or back face whichever is
applicable.

(5) For checking the bore: Make sure that the probe is in contact with the bore and
correctly aligned (refer to the probe manufacturer’s data for proper alignment). Use
the reference mark for a starting position.

(6) Inspect the surface of the bore for the length required by the component inspection
criteria. If the bore is the only part to be inspected, go to step 9.

(7) For checking the back face: Make sure that the probe is in contact with the back face
and correctly aligned on impellers (refer to the probe manufacturer’s data for proper
alignment). Use the reference mark for a starting position.

(8) Inspect the surfaces as required by the component inspection criteria.

(9) Retract/remove the probe and the part.

(10) Remove the part from the holding fixture.

(11) Review the results to make sure that there are no indications in the part. Any indication
exceeding the background level will be rejected. Validation can be performed by
polishing per Section F (one time only) and then re-inspecting part.

NOTE: For a correctly calibrated system, the typical indication of a crack is a signal-
to-noise ratio of 3:1 or higher.

SUBTASK 49-00-01-250-002
F. General part polishing of ECI area using abrasive impregnated nylon pad

CAUTION: DO NOT USE THIS POLISHING PROCEDURE ON ECI MASTER OR

WORKING STANDARDS.

CAUTION: ABRASIVE CLOTH OR PAPER BACKED ABRASIVES ARE NOT

PREMITTED AND CAN CAUSE DAMAGE TO THE PART.

NOTE: Removal of parent material greater than 0.0005 in. (0.013 mm) is not permitted.

(1) If eddy current indication exceeds signal reject limit, polish affected area as follows:

(a) Cut abrasive-impregnated nylon pad to fit comfortably in hand or to fit locally
manufactured tool holding fixture. Cut pad large enough to cover the area being
polished.

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WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0001SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ACETONE, PUT ON CHEMICAL-
SPLASH GOGGLES, AND ACETONE RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ACETONE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

(b) Wipe area to be polished with isopropyl alcohol or acetone.

(c) Polish affected area initially with maroon abrasive pad using hand pressure only.
Maintain polishing direction with same direction as eddy current probe.

(d) Polish affected area finally with gray abrasive pad using hand pressure only.
Maintain polishing direction with same direction as eddy current probe.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

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WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0001SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ACETONE, PUT ON CHEMICAL-
SPLASH GOGGLES, AND ACETONE RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ACETONE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

(e) After last polish step is completed, wipe polished area and part with isopropyl
alcohol or acetone to clean.

(2) Return to respective part eddy current inspection procedure to determine if indication
is still present and rejectable. If indication is repeated, part must be rejected.

SUBTASK 49-00-01-250-003
G. Calibration

(1) A calibration system for the control of measuring and test equipment must be
established per AS9110: “Control of Monitoring and Measuring Devices.”

(2) Test Equipment (Eddy-Current Signal Instrument and Probe)

(a) In general, the manufacturer’s recommendation should be followed for

calibration, maintenance and/or standardization of the test equipment.

(b) If no such recommendations are provided, a routine check of the equipment

should be made on periodic basis and after each problem and repair.

(c) The methods used to determine calibration, maintenance and/or standardization

of the test equipment must be described in a documented procedure.

(d) The interval must be reviewed and adjusted as necessary to make sure
compliance with the specified calibration requirements. Refer to AS9110.

(3) Eddy-Current Inspection Master

(a) There is no standard time interval for re-calibration interval can be established
based on experience and work environment.

(b) A three year calibration interval is a typical frequency suggested.

(c) If three year schedule is not used, the methods used to determine or change the
interval must be described in a documented procedure.

(d) The interval must be reviewed and adjusted as necessary to make sure
continuous compliance with the specified calibration requirements.

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(4) Storage of Eddy Current Masters

(a) Eddy Current Masters should be stored when not in use. Storage method used
must prevent physical damage, corrosion and contamination.

(5) Before performing Inspection

(a) Visually inspect the ECI master to make sure that the master is not damaged
during previous use or storage.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0001SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ACETONE, PUT ON CHEMICAL-
SPLASH GOGGLES, AND ACETONE RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ACETONE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

(b) If necessary, clean the surfaces using isopropyl alcohol or acetone and cotton
swabs.

NOTE: Do not polish or blend the ECI surfaces on the master.

(6) Make sure that the instrument performance using the appropriate ECI master. This
test must produce a useable response from all of the test notches and must be
discernable from any material surface noise signal.

(7) This verification must be accomplished at the following times:

(a) Immediately before to starting an inspection.

(b) Whenever an inspection is been interrupted by the equipment being turned off
or left unattended by the inspector.

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(c) Whenever the inspector has reason to suspect that conditions affecting the
calibration have changed.
(d) When in use, not less than every four hours.

SUBTASK 49-00-01-250-004
H. Records

(1) The data that must be used on any written report on eddy-current test results:

(a) The inspection date.

(b) A complete part identification, which includes:

1 Part Number

2 Serial Number

3 Total Hours

4 Total Cycles

5 Specific Part Inspection Area

(c) A complete identification of the probe and the associated instrument(s) and
setting(s) used during test application.

(d) Acceptance Criteria.

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INSPECTION/CHECK 13

TASK 49-00-01-210-801
1. Inspection of the Ignition Exciter

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-802 Cleaning and Treatment of
Aluminum Corrosion
HSPS 490001 Task 49-00-01-350-802 Removal of the Nicks, the
Scratches, and the Burrs

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-001
E. Inspection

(1) Check the ignition exciter for the defects and accomplish the corrective actions
shown, (Refer to Table 801).

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Table 801
Ignition Exciter Inspection/Check

Defect Corrective Action

Nicks, burrs, or scratches on exciter Blend/polish out the nicks, the burrs, or the
housing and mounting bracket scratches (Refer to Reference Information
for the removal of the nicks, the scratches,
and the burrs).
Dents, distortion, or cracks in exciter Replace the ignition exciter.
housing
Cracks in mounting bracket Replace the ignition exciter.
Distortion in mounting bracket Straighten mounting bracket and restore to
the original contour.
Corrosion on connectors Remove the corrosion (Refer to Reference
Information for the cleaning and treatment
of aluminum corrosion).
Broken connector pins Replace the ignition exciter.
Bent connector pins Straighten bent pins with a mating
individual socket. Bent pins should not be
straightened with pliers.
Damaged threads If three or less of the threads are damaged,
chase the threads. If more than three
threads are damaged, replace the ignition
exciter.
Possible electrical failure Perform a functional test of the exciter. The
exciter should produce at least four sparks
per second with a 12 Vdc input. If it is less,
replace the exciter.

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INSPECTION/CHECK 14

TASK 49-00-01-210-802
1. Inspection of the Igniter Plugs

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-802 Cleaning and Treatment of
Aluminum Corrosion

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-002
E. Inspection

(1) Check the igniter plugs for the defects and accomplish the corrective actions
shown, (Refer to Table 801).

Table 801
Igniter Plugs Inspection/Check

Defect Corrective Action

Damaged threads Check if three or less of the threads are
damaged, then chase the threads. If more
than three of the threads are damaged,
replace the ignitior plug.
Cracked ceramic, eroded electrode Replace the igniter plug.

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Defect Corrective Action

Corrosion Remove the corrosion (Refer to
Reference Information for the cleaning
and treatment of aluminum corrosion).
Igniter plug electrically shorted Replace the igniter plug.

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INSPECTION/CHECK 15

TASK 49-00-01-210-803
1. Inspection of the Thermocouples

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-003
E. Inspection

(1) Check the thermocouples for the defects and accomplish the corrective actions
shown, (Refer to Table 801).

Table 801
Thermocouples Inspection/Check

Defect Corrective Action

Damaged threads Check if three or less of the threads are
damaged, chase the threads. If more than
three of the threads are damaged, replace
the thermocouple.
Cracked insulator Replace the thermocouple.
Thermocouple electrically shorted or Replace the thermocouple.
open
Damaged thermocouple probe Replace the thermocouple.

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Defect Corrective Action

Frayed cable shield Replace the thermocouple.
Damaged wiring Replace the thermocouple.

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INSPECTION/CHECK 16

TASK 49-00-01-210-804
1. Inspection of the Tube Assemblies

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-802 Cleaning and Treatment of
Aluminum Corrosion
HSPS 490001 Task 49-00-01-350-802 Removal of the Nicks, the
Scratches, and the Burrs

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-004
E. Inspection

(1) Check the tubing assemblies for the defects listed and accomplish the corrective
actions shown, (Refer to Table 801).

Table 801
Tube Assemblies Inspection/Check

Defect Corrective Action

Cracks or leakage Replace the tube assembly
Cracked B-nuts or damaged threads Replace the tube assembly

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Defect Corrective Action

Corrosion Remove the corrosion (Refer to Reference
Information for the cleaning and treatment of
aluminum corrosion).
Nicks or scratches in tube flares Replace the tube assembly.
Nicks or scratches on tube OD Check for scratches or nicks on the tube OD
no deeper than 10% or the wall thickness, that
are not in the heel of a bend, may be repaired
by burnishing with the hand tools (Refer to
Reference Information for the removal of the
nicks, the scratches, and the burrs).
Otherwise, replace the tube assembly.
Dents Check for dents or deformation up to 0.050 in
(1.3 mm) are acceptable. If the dents or
deformation are beyond the limit, replace the
tube assembly.
Bent or misaligned tube assembly The tubes bent less than 20° may be cold
straightened. Otherwise, replace the tube
assembly.

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INSPECTION/CHECK 17

TASK 49-00-01-210-805
1. Reusable Low Strength Mechanical Fasteners

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-005
E. Inspection

(1) Check that the fasteners meet the following criteria:

(a) The fasteners must be identified as low strength (160KSI or less), (Refer to Table
801).

(b) The fastener must not have a non-metalic integral locking feature included in the
design.

(c) The threaded portion must be free of visual damage, i.e. stretched threads, galls,
tears, burrs, cracks and other visual damage.

(d) The non threaded portions must be free of cracks, burrs, and other visual
damage.

(e) The fastener must be clean.

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Table 801
Reusable Fasteners

Fastener Number Fastener Number

AN3 (Series) MS2142-4
AN5 (Series) MS35206-215
AN6 (Series) MS35265-27
AN6289J4 MS35265-27
AN924 (Series) MS35649-242
MS1351-3-12 MS9210 (Series)
MS16996 (Series) MS9915 (Series)
MS16997 (Series) NAS1351 (Series)
MS16998 (Series) 160652-1
MS21045 (Series) 162418-1
MS21046 (Series) 167847-1
MS21094-4008 169430-1
MS21279 (Series) 4500138
MS21280 (Series) 49689-1
MS21288 (Series)

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INSPECTION/CHECK 18

TASK 49-00-01-210-806
1. Inspection of the Thrust Ball Bearings

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-006
E. Inspection

CAUTION: DO NOT USE BARE HANDS TO HANDLE BEARINGS. CLEAN BEARINGS

SHALL ONLY BE HANDLED USING GLOVES.

(1) In the following inspection procedures, the continuity of the surface inspection may
be open to interpretation. The order for inspection of the bearing active surfaces shall
be as follows:

NOTE: Bearings must not be separated to perform this inspection.

(a) Visually check for surface defects with the unaided eye (20/20 close vision
required). If no defects are seen, go to step (b).

(b) Evaluate bearing with a radius scribe of the same approximate diameter (scribe
held vertical with light finger pressure). If no defects are felt, the bearing is
acceptable. Defects felt with the scribe should be evaluated according to step
(c).

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(c) Measure the defect size to determine whether the defect is within the allowable
criteria (a calibrated reticule is often used for this inspection). Accept or reject
bearings based on this evaluation.
(2) Inspect the bearings for wear.

(a) Diameter of outer race must be within the dimensional limits, (Refer to Table
801).

(b) Diameter of inner race must be within the dimensional limits, (Refer to Table
801).

(c) Internal radial clearance must be within the dimensional limits, (Refer to Table
801).

(d) Functional surface must not have any raised material on the surrounding
surface, (Refer to Figure 801).

(e) Replace the bearings if it is not within the limits specified above.

(3) Inspect the bearing surfaces.

(a) Examine the bearings for corrosion.

(b) Stains are acceptable in any amount. Examine for deposits that cannot be
removed by light polishing.

(c) Examine for any material raised above the surrounding surface.

(d) Examine for small, irregular cavities (pits) in the surface, usually dark at the
bottom, and can be felt with a 0.020 inch (0.50 mm) radius scriber point.

(e) Examine for slight depressions or hollows (indentations) made by mechanical

injury to the surface, usually by a blow or pressure.

(f) Examine for linear abrasions (scratches) on the surface that can be felt with a
0.020 inch (0.50 mm) radius scriber point.

(g) Replace the bearings when the defective conditions listed above are found.

(4) Inspect the bearings for irregularities.

(a) Examine for pits more than 0.004 inch (0.10 mm) in length.

(b) Examine for clusters of pits (three or more) within an area of 0.250 inch (6.35
mm) in diameter and having one pit more than 0.006 inch (0.15 mm) in length.

(c) Examine for indentations more than 0.015 inch (0.38 mm) in length.

(d) Examine for scratches that extend more than halfway around the periphery of
the ball, or multiple scratches that extend more than 0.250 inch (6.35 mm)
around the periphery of the ball.

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(e) Replace the bearings when the defective conditions listed above are found.

(5) Inspect the bearing raceways for irregularities.

(a) Examine for pits more than 0.006 inch (0.15 mm) in length.

(b) Examine for clusters of pits (three or more) within an area of 0.250 inch (6.35
mm) in diameter and having one pit more than 0.006 inch (0.15 mm) in length.

(c) Examine for indentations more than 0.006 inch (0.15 mm) in length.

(d) Examine for scratches that extend more than halfway across raceway, or
scratches more than 0.500 inch (12.7 mm) in length.

(e) Replace the bearings when the defective conditions listed above are found.

Table 801
Thrust Bearing Dimensional Criteria

BEARIN
G PART OUTER RACE
NUMBE DIAMETRAL INNER RACE INTERNAL RADIAL
R LIMITS DIAMETRAL LIMITS CLEARANCE
INCH MM INCH MM INCH MM
4502042 2.0472 (51.9989) 0.7874 (20.0000) 0.0025 (0.0635)
2.0469 (51.9913) 0.7872 (19.9949) 0.0017 (0.0432)

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Thrust Ball Bearing Inspection

Figure 801

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INSPECTION/CHECK 19

TASK 49-00-01-210-807
1. Inspection of the Roller Bearings

A. Prerequisites

(1) None

B. Reference Information

(1) None

C. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-007
D. Inspection

CAUTION: DO NOT USE BARE HANDS TO HANDLE BEARINGS. CLEAN BEARINGS

SHALL ONLY BE HANDLED USING GLOVES.

(1) In the following inspection procedures, the continuity of the surface inspection may
be open to interpretation. The order for inspection of the bearing active surfaces shall
be as follows:

(a) Visually check for surface defects with the unaided eye (20/20 close vision
required). If no defects are seen, go to step (b).

(b) Evaluate bearing with a radius scribe of the same approximate diameter (scribe
held vertical with light finger pressure). If no defects are felt, the bearing is
acceptable. Defects felt with the scribe should be evaluated according to step
(c).

(c) Measure the defect size to determine whether the defect is within the allowable
criteria (a calibrated reticule is often used for this inspection). Accept or reject
bearings based on this evaluation.

(2) Inspect the bearings for wear.

(a) Diameter of outer race must be within the dimensional limits, (Refer to Table
801).

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(b) Diameter of inner race must be within the dimensional limits, (Refer to Table
801).
(c) Internal diametral clearance must be within the dimensional limits, (Refer to
Table 801).

(d) Replace the bearings if it is not within the limits specified above.

(3) Inspect the bearing surfaces.

(a) Examine the bearings for corrosion.

(b) Stains are acceptable in any amount. Examine for deposits that cannot be
removed by light polishing.

(c) Examine for any material raised above the surrounding surface.

(d) Examine for small, irregular cavities (pits) in the surface, usually dark at the
bottom, and can be felt with a 0.020 inch (0.50 mm) radius scriber point.

(e) Examine for slight depressions or hollows (indentations) made by mechanical

injury to the surface, usually by a blow or pressure.

(f) Examine for linear abrasions (scratches) on the surface that can be felt with a
0.020 inch (0.50 mm) radius scriber point.

(g) Replace the bearings when the defective conditions listed above are found.

(4) Inspect the bearings for irregularities.

(a) Examine for pits more than 0.004 inch (0.10 mm) in length.

(b) Examine for clusters of pits (three or more) within an area of 0.250 inch (6.35
mm) in diameter and having one pit more than 0.006 inch (0.15 mm) in length.

(c) Examine for indentations more than 0.015 inch (0.38 mm) in length.

(d) Examine for scratches that extend more than halfway around the periphery of
the ball, or multiple scratches that extend more than 0.250 inch (6.35 mm)
around the periphery of the ball.

(e) Replace the bearings when the defective conditions listed above are found.

(5) Inspect the bearing raceways for irregularities.

(a) Examine for pits more than 0.006 inch (0.15 mm) in length.

(b) Examine for clusters of pits (three or more) within an area of 0.250 inch (6.35
mm) in diameter and having one pit more than 0.006 inch (0.15 mm) in length.

(c) Examine for indentations more than 0.006 inch (0.15 mm) in length.

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(d) Examine for scratches that extend more than halfway across raceway, or
scratches more than 0.500 inch (12.7 mm) in length.
(e) Replace the bearings when the defective conditions listed above are found.

Table 801
Roller Bearing Dimensional Criteria

BEARIN
G PART INTERNAL
NUMBE OUTER RACE INNER RACE DIAMETRAL
R DIAMETRAL LIMITS DIAMETRAL LIMITS CLEARANCE
INCH MM INCH MM INCH MM
4502040 1.8473 (46.9214) 0.9754 (24.7752) 0.0012 (0.0305)
1.8471 (46.9163) 0.9752 (24.7701) 0.0008 (0.0203)
4951506 1.7848 (45.3339) 0.9754 (24.7752) 0.0012 (0.0305)
1.7846 (45.3288) 0.9752 (24.7701) 0.0008 (0.0203)

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INSPECTION/CHECK 20

TASK 49-00-01-210-808
1. Inspection of the Silicone Fire Sleeved Hose Assembly

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 TASK 49-00-01-360-804 Repair of the Silicone Fire Sleeved
Hose Assemblies

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec No. Source (CAGE Code)

ASTM D329 Commercially Available
Acetone
ASTM D770 Commercially Available
Isopropyl Alcohol

(3) Expendable Parts

None

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SUBTASK 49-00-01-210-008
E. Inspection
NOTE: This inspection/check is used to determine the repairability of the silicone fire
sleeved hoses used to carry flammable fluids.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(1) Clean the exterior area of the silicone fire sleeved hose with acetone or isopropyl
alcohol to remove all traces of dirt, oil, and foreign matter.

(2) Inspect the insulation for cuts, tears or gouges.

(3) Inspect for damage to the wire braid reinforcement located under the silicone cover.

(4) If the wire braid is damaged, the assembly is not repairable and must be replaced.

(5) If there are small cuts in the silicon cover of less than 0.50 inch (12.7 mm) in length,
repair accordingly, (Refer to TASK 49-00-01-360-804, Repair of the Silicone Fire
Sleeved Hose Assemblies).

(6) If there are tears or cuts in the silicon cover of less than 1.00 inch (25.4 mm) in length
laterally, repair accordingly, (Refer to TASK 49-00-01-360-804, Repair of the Silicone
Fire Sleeved Hose Assemblies).

(7) If there are tears, cuts or gouges of material missing from the silicon cover and they
do not exceed 4 inches (102 mm) in length laterally and 0.50 inch (12.7 mm)
circumferentially, repair accordingly, (Refer to TASK 49-00-01-360-804, Repair of the
Silicone Fire Sleeved Hose Assemblies).

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(8) Damage to the silicon insulation greater than those in step E.(7) above are not field
repairable and must be returned to Hamilton Sundstrand for repair.

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INSPECTION/CHECK 21

TASK 49-00-01-210-811
1. Curvic Inspection Procedure

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Pneumatic Press Commercially Available
Plastic Mallet Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec No. Source (CAGE Code)

Mallet, Soft Commercially Available
Gear Marking Compound Commercially Available
Prussian Blue (Marking Compound) Commercially Available
True Hard Arkansas (extra fine) stone Commercially Available
Cratex Rubberized Abrasive (fine and Commercially Available
extra fine)
ASTM D770 Commercially Available
Isopropyl Alcohol
631 ITW
Rustlick™ (Preservation Oil) (30323)
Devcon
(16059)

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(3) Expendable Parts

None
SUBTASK 49-00-01-210-009
E. Pattern Check utilizing a curvic master

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. IT IS A

DANGEROUS MATERIAL - FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY.
BEFORE USING THE ALCOHOL, GET THE MATERIAL SAFETY DATA
SHEET (MSDS) FROM THE MANUFACTURER OR SUPPLIER OF THE
MATERIAL AND READ IT CAREFULLY. READ THE DETAILED WARNING,
W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE USING THE
ALCOHOL, PUT ON CHEMICAL SPLASH GOGGLES. MAKE SURE THAT
YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES
BELOW THE MSDS LIMIT.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(1) Clean the correct master (convex master for concave part) using isopropyl alcohol (or
other non-filming solvent) and soft brush to remove dirt or oil from the master. Blow
dry with clean dry shop air. Cover the curvic with a clean cover.

(2) Clean the part with isopropyl alcohol (or other non-filming solvent) and soft brush to
remove dirt or oil from the part. Blow dry with clean dry shop air. Cover the curvic with
a clean cover.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(3) Remove the cover from the master and apply marking compound or equivalent to the
master. Apply only enough to break the shine on the part. Applying too much will give
false readings on the gearing contact area. Use a two-brush method. One to apply
the color, and other to smooth out the color and remove any excess color. Blow off
with clean, dry shop air and set in a clean area while step (4) is completed.

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WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(4) Remove the cover from the part and apply Prussian Blue dye or equivalent to the part.
Apply only enough to break the shine on the part. Applying too much will give false
readings on the bearing contact area. Use a two-brush method. One to apply color
and one to smooth out the color and remove any excess color. Blow off with clean dry
shop air and set in a clean area while doing step (5) is completed.

(5) Mate the master and part to create a bearing pattern using one of the two methods
below.

(a) Pneumatic Press Method:

1 The part and master need to be bolted to the pneumatic press in a manner
that pulls straight through the center line of the part and master, and does
not cause a tilt of the part and master while applying pressure.

2 Adjust actuation pressure to 50 psi (345 kPa) ± 5 psi (35 kPa) of air
pressure.

3 Trip the air cylinder 4-6 times, then unbolt and reposition the part and
master 90 degrees to 120 degrees from the first position and re-bolt the
part to the pneumatic press and trip the cylinder 4-6 times.

(b) Hammer Tap Method:

1 Engage the master carefully on the part that is securely supported in such
a way as to not damage the part when the master is struck with a plastic
mallet.

2 Lightly tap the master face opposite the teeth with a plastic mallet in a
uniform pattern to get a color transfer pattern.

3 Disengage the master from the part and reposition the part and master 90
degrees to 120 degrees from the first position and re-tap.

(c) Examine the bearing surface as follows:

1 The pattern is acceptable only if,

a 90% of the total number of teeth must have 75% of the tooth width in
contact and no two teeth in a row have little or no contact, (Refer to
Figure 801).

b The minimum surface depth is equal to 90% of the tooth contact.

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c The remaining 10% of the total number of teeth may show some
pattern contact, or no contact pattern.
d The contact area is rectangular and centrally located, (Refer to Figure
801).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. IT IS

A DANGEROUS MATERIAL - FLAMMABLE, EXPLOSIVE, AND
A MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE USING THE ALCOHOL, GET
THE MATERIAL SAFETY DATA SHEET (MSDS) FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING,
W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE
USING THE ALCOHOL, PUT ON CHEMICAL SPLASH
GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MSDS LIMIT.

2 Clean the part with isopropyl alcohol or other non-filming solvent and soft
brush to remove all the color and blow dry with clean, dry shop air. Cover
with a clean cover and place in a clean box.

3 Clean the master with isopropyl alcohol or other non-filming solvent and
soft brush to remove all the color and blow dry with clean, dry shop air. If
no other checks are going to be made with this master, spray with non
drying oil and cover with a clean cover and replace it in its storage box. If
additional checks are to be done, do not oil the part, just place a clean cover
on the master after blowing off with clean, dry shop air.

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SUBTASK 49-00-01-210-010
F. Radial Runout Check of the repaired Curvic verses the Curvic Master and Stacking Height
Check of the repaired part:
NOTE: Stacking height is the axial distance from the forward shaft datum to the curvic
datum.

NOTE: Make sure that the curvic faces are inspected for damage (dings, marks etc.),
before performing radial runout. These imperfections may affect the radial runout
and stacking height measurement. If necessary, do pattern check and carefully
rework imperfections in the finish or variations in the bearing faces by using a True
Hard Arkansas (extra line) stone, Cratex (fine or extra fine grit) rubberize abrasive
or by polishing. Do not use a buffing wheel or other types of power tools on any of
the curvic features. Re-inspect curvic pattern and surface finish after any rework
to the curvic.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(1) Clean the correct master for the part (convex master for a concave part) with isopropyl
alcohol or other non-filming solvent and a soft brush to remove any dirt and blow dry
with clean dry shop air.

(2) Setup the master on a Gleason Curvic Coupling Checking Machine, rotating table or
concentricity plate. Adjust the plate using the locating diameter with a 0.0001 in. (0.002
mm) accuracy gauge. Make sure the plate locating face is within 0.0001 in. (0.002
mm) total runout.

(3) If using a Gleason Curvic Coupling Checking Machine or rotating table, make sure
the master is bolted to the table and that it will not shift when the bolts are tightened.
If using a concentricity plate, make sure the master turns with slight drag.

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(4) Determine the stacking height of the part using the repair instructions, (Refer to Table
801).
(5) Determine the stacking height of the curvic master.

(6) Using the repair instructions, table and the stacking height of the curvic master,
determine the gage block height that is required to make sure the parts stacking height
on the checking equipment.

(7) Build a gage block stack that is nominal for the stacking height that is being inspected.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(8) Clean the part and curvic master with isopropyl alcohol or other non-filming solvent
and soft brush to remove any oil or dirt. Blow off with clean dry shop air.

(9) Mate the curvic master and part together on the checking equipment.

(10) Make sure the stacking height and axial face runout against the gage block stack that
is determined in step (7).

(11) Make sure the radial bearing run-out with an indicator.

(12) Remove the part from the curvic master and blow off the curvic master and clean the
part with dry shop air. Rotate the part and curvic master 90 degrees to 120 degrees
and recheck per steps (10) and (11). Repeat this step three times.

INSPECTION/CHECK 21
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SUBTASK 49-00-01-210-011
G. Preserving curvic master:
WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL
ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(1) Clean the master with isopropyl alcohol or other non-filming solvent and a soft brush
to remove any dirt and blow dry with clean dry shop air.

(2) Visually inspect to make sure that there is no damage.

(3) Coat the master with Rustlick 631 or equivalent, moisture-displacing corrosion
preventative oil.

(4) Store curvic master in container to perfect from damage.

Table 801
Stacking Height

Part Number(s) Stacking Height in. (mm)

4503345/4503351 5.568-5.578
(141.427-141.681)
4505380/4505405/4505446 5.568-5.578
(141.427-141.681)
4504253 5.527-5.533
(140.385-140.538)
4503310 5.563-5.573
(141.300-141.544)
168049-101/4504260 3.6655-3.671
(93.103-93.243)

INSPECTION/CHECK 21
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Part Number(s) Stacking Height in. (mm)

4506255 7.232-7.238
(183.692-183.45)
4504836/4504835 4.740-4.748
(120.396-120.599)
0332207090 4.740-4.748
(120.396-120.599)
4504434/4504321 4.740-4.748
(120.396-120.599)
0332207100/0332207060 4.740-4.748
(120.396-120.599)
4504834/4504320 4.484-4.490
(113.893-114.046)
0332250210/0332250190 4.484-4.490
(113.893-114.046)
0332250150/0332250120 4.484-4.490
(113.893-114.046)

Correct Bearing Surface

Figure 801 (Sheet 1 of 3)

INSPECTION/CHECK 21
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Incorrect Bearing Surface

Figure 801 (Sheet 2 of 3)

INSPECTION/CHECK 21
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Incorrect Bearing Surface

Figure 801 (Sheet 3 of 3)

INSPECTION/CHECK 21
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INSPECTION/CHECK 22

TASK 49-00-01-210-809
1. Inspection of the Electrical Connector and Contact Pins

A. Prerequisites

(1) None

B. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-810 Replacement of the
Damaged Connector Pins

C. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-210-012
D. Inspection

NOTE: This inspection is used to find the damaged APU engine wiring harness connectors
and contact pins.

(1) Gain access to the connector(s).

(2) Check the connector(s) for corrosion, dents, and cracks.

(3) No corrosion, dents, or cracks are allowed (refer to the applicable CMM, REPAIR).

(4) Check the contact pins for signs of corrosion, cracked, or bent pins.

(5) No corrosion, cracks, or bent pins are allowed ((Refer to TASK 49-00-01-350-810,
Replacement of the Damaged Connector Pins) or the applicable CMM, REPAIR).

INSPECTION/CHECK 22
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INSPECTION/CHECK 22
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INSPECTION/CHECK 23

TASK 49-00-01-210-810
1. Inspection of the Tube Assemblies

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

MIL-STD-1247D Commercially Available
Identification Tape

(3) Expendable Parts

None

SUBTASK 49-00-01-210-013
E. Do an Inspection of the Tube Assemblies

(1) Visually inspect the tube assembly for cracks or leakage - Replace the tube assembly,
if cracks or leakage are found.

(2) Visually inspect the B-nuts for cracks and damaged threads - Replace the tube
assembly if cracks or leakage are found.

(3) Visually inspect the tube assembly for corrosion - Remove the corrosion from the tube
assembly.

(4) Visually inspect the tube assembly for nicks or scratches in the tube flares - Replace
the tube assembly, if nicks or scratches are found.

INSPECTION/CHECK 23
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(5) Nicks or scratches on the outer diameter of the tube - Scratches or nicks on the outer
diameter of the tube must not be above 10 percent of the wall thickness. Those are
not in the heel of a bend, must be repaired by burnishing with the hand tools. Replace
the tube assembly, if nicks or scratches are above 10 percent of the wall thickness.

(6) Visually inspect the tube assembly for Dents - Dents or deformation as much as 0.050
in. (1.27 mm) is permitted. Replace the tube, if dents or deformation are more than
0.050 in. (1.27 mm).

(7) Dent or tubes not aligned - Tubes which are bent less than 20 degrees can be made
straight by a cold procedure. If the tube is bent more than 20 degrees, replace the
tubes.

(8) Visually inspect the tube assembly for tube blockage- Clean the tube for any
obstruction.

(9) If threaded fittings are worn or damaged, chase threads to restore the fitting. If the
threads are not restored after it has been chased, replace the fitting.

(10) Check for missing or damaged line Identification Tape. Replace the Identification Tape
(MIL-STD-1247D).

INSPECTION/CHECK 23
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REPAIR

TASK 49-00-01-300-801
1. General

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-300-001
E. General

(1) This section contains the instructions which are standard repair procedures. These
instructions give the general precautions and safety precautions, the specialized
procedures, and the standard procedures for the repair.

(2) To locate and cross reference the repair procedures from Standard Practices Manual
for Auxiliary Power Units (49-00-01) issued by Auxiliary Power International
Corporation (APIC) and Standard Practices Manual for Common Standard Practices
for Auxiliary Power Units (49-00-01) issued by Hamilton Sundstrand, (Refer to Table
901).

Table 901
Cross Reference of Repair Procedures

APS2000/APS2100/
APS3200 APS500/APS1000 HSPS 490001
REPAIR REPAIR
REPAIR-01 REPAIR-SP-408 REPAIR-01

REPAIR
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APS2000/APS2100/
APS3200 APS500/APS1000 HSPS 490001
REPAIR-02 REPAIR-SP-402 REPAIR-02
REPAIR-03 REPAIR-SP-401 REPAIR-03
REPAIR-04 REPAIR-SP-411 REPAIR-04
REPAIR-05 REPAIR-SP-404 REPAIR-05
REPAIR-06 REPAIR-06
REPAIR-07 REPAIR-SP-403 REPAIR-07
REPAIR-08 REPAIR-SP-407 REPAIR-08
REPAIR-09 REPAIR-SP-410 REPAIR-09
REPAIR-10 REPAIR-10
REPAIR-11 REPAIR-11
REPAIR-12 REPAIR-SP-405 REPAIR-12
REPAIR-13 REPAIR-13
REPAIR-14 REPAIR-SP-406 REPAIR-14
REPAIR-15 REPAIR-15
REPAIR-16 REPAIR-16
REPAIR-17 REPAIR-17
REPAIR-SP-409 REPAIR-18
REPAIR-SP-412 REPAIR-19

(3) For a list of the standard repair procedures specified in this manual, (Refer to Table
902).

Table 902
List of the Standard Repair Procedures

Repair Task Number

REPAIR 01 (Refer to TASK 49-00-01-350-801, Replacement of the
Threaded Inserts)
REPAIR 02 (Refer to TASK 49-00-01-380-801, Cleaning and
Treatment of Magnesium Corrosion)

REPAIR
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Repair Task Number

REPAIR 03 (Refer to TASK 49-00-01-380-802, Cleaning and
Treatment of Aluminum Corrosion)
REPAIR 04 (Refer to TASK 49-00-01-380-803, Repair of the
Protective Finish)
REPAIR 05 (Refer to TASK 49-00-01-320-801, Surface Polishing)
REPAIR 06 (Refer to TASK 49-00-01-380-804, Chromating of the
Aluminum Alloys)
REPAIR 07 (Refer to TASK 49-00-01-350-802, Removal of the
Nicks, the Scratches and the Burrs)
REPAIR 08 (Refer to TASK 49-00-01-350-803, Replacement of the
Pins/Studs)
REPAIR 09 (Refer to TASK 49-00-01-360-801, Replacement of the
Components with a Layer of Loctite)
REPAIR 10 (Refer to TASK 49-00-01-340-801, Application of
Plasma and Flame Spraying)
REPAIR 11 (Refer to TASK 49-00-01-360-802, Bonding of the
Abradable Felts)
REPAIR 12 (Refer to TASK 49-00-01-330-801, Instructions to
Apply the Chromium Plating)
REPAIR 13 (Refer to TASK 49-00-01-360-803, Bonding with
Araldite Compound)
REPAIR 14 (Refer to TASK 49-00-01-310-801, Weld Repair)
REPAIR 15 (Refer to TASK 49-00-01-350-804, Runout and
Balance of the Engine Rotor)
REPAIR 16 (Refer to TASK 49-00-01-350-805, Shank Nut Repair)
REPAIR 17 (Refer to TASK 49-00-01-350-806, Anchor Nut Repair)
REPAIR 18 (Refer to TASK 49-00-01-350-807, Installation of the
Oversized Threaded Inserts in the Reduction Drive
Assemblies)
REPAIR 19 (Refer to TASK 49-00-01-350-808, Installation of the
Oversized Threaded Inserts)
REPAIR 20 (Refer to TASK 49-00-01-350-809, Replacement of the
Oil (Lee™) Jets and Oil (Lee™) Plugs)

REPAIR
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Repair Task Number

REPAIR 21 (Refer to TASK 49-00-01-360-804, Repair of the
Silicone Fire Sleeved Hose Assemblies)
REPAIR 22 (Refer to TASK 49-00-01-350-814, Removal and
Installation of the Cherrylock Rivets)
REPAIR 23 Not Used
REPAIR 24 (Refer to TASK 49-00-01-360-805, Standard
Fiberglass Composite Repair)
REPAIR 25 (Refer to TASK 49-00-01-360-806, Fiberglass
Composite Repair)
REPAIR 26 (Refer to TASK 49-00-01-360-807, Fiberglass
Composite Repair)
REPAIR 27 (Refer to TASK 49-00-01-360-808, Fiberglass
Composite Repair)
REPAIR 28 Not Used
REPAIR 29 (Refer to TASK 49-00-01-350-810, Replacement of the
Damaged Connector Pins)
REPAIR 30 (Refer to TASK 49-00-01-350-811, Repair of Wire by
Splicing)
REPAIR 31 (Refer to TASK 49-00-01-320-802, Repair of the
Aluminum or Magnesium Gearbox Housing Threaded
Port(s))
REPAIR 32 (Refer to TASK 49-00-01-320-803, Replacement of the
Nut Plates on Oil Cooler)
REPAIR 33 (Refer to TASK 49-00-01-310-802, Replacement of the
Nut Plates on Attenuator)
REPAIR 34 (Refer to TASK 49-00-01-350-812, Repair of the Wire
Terminal Ends by Replacement)
REPAIR 35 (Refer to TASK 49-00-01-360-809, Bonding Repair with
Hysol Epoxy EA 9394 Adhesive)
REPAIR 36 (Refer to TASK 49-00-01-350-813, Replacement of the
Damaged Rosan™ Inserts and Lockrings)

REPAIR
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SUBTASK 49-00-01-300-002
F. General Information
(1) The procedures specified for the repair of the APU components are given in the
REPAIR section of the engine manual (and/or in the component maintenance
manual). The text contains the illustrations, the full instructions, the dimensions, and
the tools and the equipment necessary to do the repair.

NOTE: It is possible to replace the tools and the equipment for the repair with
equivalent tools and equipment. The equivalent tools and equipment must
give the same repair precision.

(2) The overhaul workshop makes the decision to repair the part. The overhaul workshop
makes sure it has the applicable equipment and the tools to repair each part. The
procedures contained in this manual are and are not mandatory, because all the repair
procedures are not possible or money saving for all the operators. But the parts must
be replaced if they are not correct and if they are not repaired.

SUBTASK 49-00-01-300-003
G. Standard Manual Tolerances

NOTE: If the contrary is not recommended during the repair, the standard tolerances given
below are applicable during the repair of a special part.

(1) The re-machined surfaces must have a maximum surface finish of 125 micro-inches
(3.175 micrometers).

(2) The external corners must be broken at a minimum of 0.001 inch (0.0254 mm) and a
maximum of 0.025 inch (0.635 mm), The internal corners must have a minimum radius
of 0.005 inch (0.127 mm) and a maximum of 0.025 inch (0.635 mm).

(3) The tolerances are the total values given by the indicator.

(4) The straight screw threads must be made in relation with the information given in MIL-
S-8879. The external threads must be examined with the Method A and the internal
threads must be examined with the Method B.

SUBTASK 49-00-01-300-004
H. Adhesive Materials

(1) A list of the approved adhesives is given in the engine manual and/or the component
maintenance manual.

(2) When you apply the adhesive, refer to the engine manual, the component
maintenance manual or the instructions given with the adhesive. This information
gives the procedure to mix the adhesive, and the correct time and/or temperature to
cure it.

REPAIR
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SUBTASK 49-00-01-300-005
I. Geometric Tolerances
(1) The geometric symbols used to give the repair quality are given in the REPAIR section
of the engine manual and/or the component maintenance manual. The symbols used
obey the ANSI specification Y14.5, (Refer to Figure 901).

(2) The symbols are used by the person who repairs the component to know the repair
tolerances of some components.

SUBTASK 49-00-01-300-006
J. Lubrication of the Repaired Parts

(1) If the repaired parts are not assembled immediately, they must be correctly lubricated
with the oil to prevent corrosion.

(2) If the parts are not used for a long time, refer to the storage procedures in the engine
manual and/or the component maintenance manual.

The symbols below obey the ANSI specification Y14.5M, dated 1982. Refer to ANSI
Y14.5M.

REPAIR
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Geometric Symbols REPAIR

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REPAIR
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REPAIR 01

TASK 49-00-01-350-801
1. Replacement of the Threaded Inserts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-801 Cleaning and Treatment of
Magnesium Corrosion
HSPS 490001 Task 49-00-01-380-802 Cleaning and Treatment of
Aluminum Corrosion
HSPS 490001 Task 49-00-01-220-804 Check of the Self-Locking
Helical Inserts and the Self-
Locking Nuts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Threaded Insert Removal/Installation Emhart Technologies
(3LKZ8)
Tap Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

REPAIR 01
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Part No./Spec. No. Source (CAGE Code)

MASTINOX 6856K PPG Coatings SA
Sealant (corrosion prevention) (F1419)
MIL-A-907 Loctite
Conductive Vaseline (Turbomeca (1UW17)
8677840081) Jet-Lube.INC
or (07431)
Silver filled grease (aluminum alloys)
AMS 2518 Commercially Available
Graphite Petroleum Grease (nickel based
alloys or corrosion resistant steels)
Chlorinated Solvent Commercially Available
Acetone Commercially Available
Isopropyl Alcohol Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-350-001
E. Remove the damaged threaded insert.
(Refer to Figure 901)
(1) Use a removal tool of the applicable dimension.

(2) Insert the blade of the tool in the helical coil insert.

NOTE: One side of the blade must be at a quarter of a turn from the insert coil end.

(3) Hit the head of the tool lightly with a hammer.

(4) Maintaining a steady pressure on the handle of the tool, and turn it slowly
counterclockwise.

NOTE: Keep the pressure until the insert coil is removed. Discard the removed insert.

(5) Remove all the burrs from the hole.

(6) Remove all the dirt, chips or unwanted material from the hole.

(7) Examine the condition of the threads in the hole. If necessary, clean the thread with
a tap of the applicable dimension.

REPAIR 01
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SUBTASK 49-00-01-350-002
F. Install the threaded insert
(1) Apply a protection coating to the threaded hole of the part:

(a) For the magnesium alloy (Refer to Reference Information for the cleaning and
treatment of magnesium corrosion).

(b) For the aluminum alloy (Refer to Reference Information for the cleaning and
treatment of aluminum corrosion).

(2) If the threaded insert is installed in a magnesium-alloy part, apply a small quantity of
MASTINOX 6856K to the threaded hole.

(3) If an electrical conductivity is necessary:

WARNING: DO NOT BREATHE THE GASES OF THE CHLORINATED OR

FLUOROCHLORINATED SOLVENT. USE THE CHLORINATED OR
FLUOROCHLORINATED SOLVENT ONLY IN THE AREAS WHERE
THE AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE ARE
NO SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE
AREAS. IF THE CHLORINATED OR FLUOROCHLORINATED
SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES WITH
WATER AND CALL A DOCTOR. IF THE CHLORINATED OR
FLUOROCHLORINATED SOLVENT TOUCHES YOUR SKIN, WASH
YOUR SKIN WITH SOAP AND WATER. THE CHLORINATED OR
FLUOROCHLORINATED SOLVENT IS POISONOUS AND
FLAMMABLE.

(a) Remove the varnish from the threaded insert, use a chlorinated solvent.

(b) Apply a small quantity of conductive vaseline immediately before you install the
threaded insert.

(4) Make sure the new threaded insert has a correct dimension.

(5) Obey the procedure given by the manufacturer of the threaded-insert installation kit.

(6) Make sure that the end of the insert coil is 0.5 to 1 pitch below the surface of the tapped
hole.

(7) Break with the special tool and discard the driver tag.

NOTE: If the helical coil insert has a self locking feature, visually inspect the threads.
Do not use a threaded plug gauge to inspect.

(8) Examine the threaded insert with the plug gauge.

(9) Inspect the threaded insert(s) according to INSPECTION/CHECK 06. (Refer to TASK
49-00-01-220-804, Inspection of the Self-Locking Helical Coil Inserts and the Self-
Locking Nuts).

REPAIR 01
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Removal of a Threaded Insert

Figure 901

REPAIR 01
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REPAIR 02

TASK 49-00-01-380-801
1. Cleaning and Treatment of Magnesium Corrosion

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-803 Repair of the Protective
Finish

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Sodium Hydroxide Commercially Available
Sodium Phosphate Commercially Available
Soluble Soap Commercially Available
Chromic Acid Commercially Available
Calcium Sulfate Commercially Available
Distilled Water Commercially Available
Nylon Brush Commercially Available
AMS-M-3171, Type VI or VII Commercially Available
Cleaning Solution (Alkaline)

(3) Expendable Parts

None

REPAIR 02
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SUBTASK 49-00-01-380-001
E. Repair
WARNING: DO NOT BREATHE THE GASES OF THE SODIUM HYDROXIDE OR THE
SODIUM PHOSPHATE, OR THE CHROMIC-ACID CALCIUM SULFATE.
USE THESE PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THESE
PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES WITH WATER
AND CALL A DOCTOR. IF THESE PRODUCTS TOUCH YOUR SKIN,
WASH YOUR SKIN WITH SOAP AND WATER. THESE PRODUCTS ARE
POISONOUS AND FLAMMABLE.

CAUTION: DO NOT TOUCH THE CLEANED SURFACES WITH BARE HANDS TO

PREVENT A NEW CONTAMINATION.

(1) Prepare an alkaline solution:

NOTE: Alkaline cleaning solution, AMS-M-3171, Type VI or VII may be used as an

alternate.

(a) Measure 2 to 3 ounces (59 to 89 ml) of sodium hydroxide.

(b) Measure 1.3 ounce (38 ml) of sodium phosphate.

(c) Measure 0.1 ounce (3 ml) of soluble soap.

(d) Measure 1 gallon (3.8 l) of distilled water.

(e) Mix the solution.

(2) Clean the damaged areas with the alkaline solution and a nylon brush.

(3) Flush the damaged areas with cold clean water.

(4) Prepare a pickling solution.

(a) Measure 1.3 ounce (38 ml) of chromic acid.

(b) Measure 1 ounce (29 ml) of calcium sulfate.

(c) Measure 1 gallon (3.8 l) of distilled water.

(d) Mix the pickling solution with force for a minimum of 15 minutes (use a
mechanical mixer or mix the solution with air).

(5) Apply the pickling solution to the damaged areas.

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CAUTION: APPLY THE PICKLING SOLUTION ONLY TO THE DAMAGED AREAS. PUT
ON THE NECESSARY PROTECTIONS BECAUSE THE PICKLING
SOLUTION MUST NOT GO TO THE NOT DAMAGED AREAS.
(6) Keep the damaged areas wet with the pickling solution for 1 to 3 minutes, until the
damaged areas become brown.

CAUTION: DO NOT USE HOT WATER.

(7) Flush the brown areas with cold clean water.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN YOU
USE COMPRESSED AIR TO CLEAN OR DRY. USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(8) Let the component dry in the ambient air or use dry compressed air [the pressure must
be less than 30 psi (207 kPa)].

NOTE: Do not rub the component to dry it because the brown layer can be removed.

(9) Do the protective finish. Refer to Reference Information for the repair of the protective
finish.

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REPAIR 03

TASK 49-00-01-380-802
1. Cleaning and Treatment of Aluminum Corrosion

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-803 Repair of the Protective
Finish

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Nylon Wheel Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Aluminum Oxide Abrasive Cloth (320-grit) Commercially Available
MIL-A-9962, Type I, Grade B Commercially Available
Aluminum Oxide Abrasive Mat
MIL-C-5541, Type 1A Commercially Available
Anodic Coating, Alodine 1200
Cleaning Compound (Water Emulsion) Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-380-002
E. Repair
(1) Remove the surface corrosion with an aluminum oxide abrasive cloth (or a nylon
wheel) with aluminum-oxide abrasive bonded on it.

NOTE: Do not remove more than 4 % of the material thickness when you remove
the corrosion.

(2) Clean the repaired surface with an aluminum-oxide abrasive cloth (or aluminum oxide
abrasive mat) and a water emulsion cleaning compound.

(3) Apply the anodic coating to the repaired surfaces.

(4) Flush the prepared surfaces carefully, with cold water.

(5) Let the surfaces dry in the ambient air.

(6) Do a protective finish. Refer to Reference Information for the repair of the protective
finish.

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REPAIR 04

TASK 49-00-01-380-803
1. Repair of the Protective Finish

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-801 Cleaning and Treatment of
Magnesium Corrosion

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

AMS-M-3171 Type I (Dow #1) Commercially Available
for heavy corrosion
or
AMS-M-3171 Type VI (Dow #19)
for normal corrosion
(320-grit) Commercially Available
Aluminum Oxide Abrasive Cloth
TT-P-1757 Commercially Available
Zinc Chromate Primer
Wax Commercially Available
or
Varnish

(3) Expendable Parts

None

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SUBTASK 49-00-01-380-003
E. Repair
WARNING: OBEY ALL WARNINGS AND CAUTIONS GIVEN ON THE CONTAINERS
OF THE CONSUMABLES. DO NOT BREATHE THE GASES OF THE
CONSUMABLES. USE THE CONSUMABLES ONLY IN THE AREAS
WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE
ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE
AREAS.

(1) Apply a layer of wax or varnish to the holes, the worked surfaces and the identification
plates.

(2) Remove all the loose or the flaking paint.

(3) Rub the damaged surfaces (or the surfaces where the paint is removed) with the
aluminum-oxide abrasive cloth (320-grit).

(4) Apply pickling solution to the rubbed magnesium surfaces.

NOTE: Refer to Reference Information for the cleaning and treatment of magnesium
corrosion to mix the pickling solution.

(5) Flush the surfaces fully with cold clean water.

(6) Let the surfaces dry in the ambient air.

(7) Apply one layer of the zinc-chromate primer to the prepared surfaces.

(8) Let the zinc-chromate primer dry for one hour.

CAUTION: DO NOT PAINT THE HOLES, THE INTERNAL SURFACES OR THE

WORKED SURFACES.

(9) Apply two layers of the paint to the prepared surfaces.

NOTE: Let the first layer of the paint dry for 4 hours before the second layer of the
paint is applied.

(10) Let the layers of the paint cure for 24 hours after the second layer is applied.

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REPAIR 05

TASK 49-00-01-320-801
1. Surface Polishing

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Grinding Machine Commercially Available
Air Grinder Commercially Available
Electric Drill Commercially Available
Speed Chuck Commercially Available
Lathe Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

W-L-800 Commercially Available
Oil
AA600-V7-WS Carborundum Company
Carborunclum (Aluminum oxide) P.O. Box 337
Niagara Falls, NY 14302
J.R. No. 1 Devine Brothers Co.
Jewelers Rouge Utica, NY 13503

REPAIR 05
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Part No./Spec. No. Source (CAGE Code)

Exel No. 304 Bacon Felt Company
Felt Pad and Medium-Hard Felt 11 fifth street
Taunton, MA 02780
MIL-PRF-680, Type II Commercially Available
Dry Cleaning Solvent

(3) Expendable Parts

None

SUBTASK 49-00-01-320-001
E. Repair

NOTE: If necessary, polish the rough surface and grind the crests of the repaired surface.
It is not necessary to make a better microinch finish in this operation. Two types
of procedures are used to polish. Use the general procedure to grind the bearing
races and the thrust surfaces. The felt bob procedure is necessary for the internal
bores with the movable preformed packings.

(1) General procedure to polish

(a) After you grind, remove all the unwanted particles from the surface to be
polished. Be careful you do not damage or cause scratches on the surface.
When the procedure is completed, the races are put in lubricating oil or rust
preventive oil.

(b) Grind again the surfaces with a compound of carborundum (white fused
aluminum oxide, water-soluble, grit-size 600 and viscosity of V7) (carborundum
number AA600-V7-WS). Make it thin with water in a small quantity. Mix correctly
the compound with a clean paddle to get a thick paste.

WARNING: CONTROL THE PRESSURE AT 30 PSI (207 KPA) OR LESS WHEN

YOU USE COMPRESSED AIR TO CLEAN OR DRY USE THE EYE
PROTECTION AND USE RUBBER GLOVES.

(c) Hold and turn the part in a speed chuck, a lathe or a grinding machine. Put the
polishing compound on the part by hand, air grinder or electric drill, with an Excel
No. 304 felt pad, or equivalent. Polish parallel to the grinding ridges. After you
polished the part, clean with a dry-cleaning solvent. Let the part dry in the open
air or use a clean, filtered, compressed air.

(2) Finish procedure with a felt bob

(a) Install the part in a speed chuck or a lathe. Turn at 500 to 2500 revolutions per
minute. Make sure that the procedure to attach or hold the part in a speed chuck
or a lathe does not damage, spring, or twist the part. Use the arbors or the clamps
to hold the part correctly.

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(b) Use a medium-hard, mandrel-mounted felt bob. Put the jewelers rouge on the
pad. Turn the felt bob against the surface to be finished at a minimum speed of
8000 revolutions per minute. Turn in an opposite direction.
(c) Move on the surface continuously for two minutes with sufficient pressure to
keep a light drag on the felt bob. Replace the felt bob when you cannot see the
drag.

WARNING: DO NOT BREATHE THE GASES OF DRY CLEANING SOLVENT. USE

THE DRY CLEANING SOLVENT ONLY IN THE AREAS WHERE THE
AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS.
IF THE DRY CLEANING SOLVENT TOUCHES YOUR EYES, FLUSH
YOUR EYES WITH WATER AND CALL A DOCTOR, IF THE DRY
CLEANING SOLVENT TOUCHES YOUR SKIN, WASH YOUR SKIN
WITH SOAP AND WATER. THE DRY CLEANING SOLVENT IS
POISONOUS AND FLAMMABLE.

(d) Clean fully in a dry cleaning solvent to remove all the compound used for the
finish.

(e) Let the item dry in the air. Do not use compressed air.

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REPAIR 06

TASK 49-00-01-380-804
1. Chromating of the Aluminum Alloys

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic
Parts-General

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Turco Smut Go Turco France
Concentration: 120 g/l 3-5 impasse du quai de
l’industrie
91200 Athis-Mons
France
Diversey 514 Commercially Available
Concentration: 125 g/l
CFPI Deoxidine D Commercially Available
Turco Alumigold 4178 Turco France
Concentration: 10 g/l 3-5 impasse du quai de
l’industrie
91200 Athis-Mons
France
MIL-C-5541, Type 1A Commercially Available
Alodine 1200, Concentration: 22 g/lt

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Part No./Spec. No. Source (CAGE Code)

Alodine 1200 S Commercially Available
Concentration: 7.5 g/l
Wax Commercially Available
or
Varnish

(3) Expendable Parts

None

SUBTASK 49-00-01-380-004
E. Repair

WARNING: OBEY ALL WARNINGS AND CAUTIONS GIVEN ON THE CONTAINERS

OF THE CONSUMABLES. DO NOT BREATHE THE GASES OF THE
CONSUMABLES. USE THE CONSUMABLES ONLY IN THE AREAS
WHERE THE AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE
ARE NO SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE
AREAS.

(1) Apply a layer of wax or varnish to the holes, the repaired surfaces and the identification
plates.

CAUTION: DO NOT USE CHLORINATED SOLVENTS TO REMOVE OIL OR GREASE

FROM THE ASSEMBLIES WHICH HAVE TITANIUM ALLOY PARTS. IF IT
IS NOT POSSIBLE TO REMOVE THE TITANIUM PARTS, USE ALKALINE
SOLVENT TO REMOVE OIL OR GREASE.

(2) Remove the oil or grease. Use a chlorinated solvent in liquid or vapor phase (Refer
to Reference Information for the cleaning of the metal parts).

(3) Put the part fully in a bath of one of these solutions:

(a) Turco Smut Go at a temperature of 104°F (40°C) or

(b) Diversey 514 at the ambient temperature or

(c) CFPI Deoxidine "D" at the ambient temperature.

(4) Put the part in the bath for 5 to 10 minutes.

(5) Flush the part carefully with clean water.

(6) Make sure that the solution is fully removed from all the holes.

(7) Put the parts in a bath of one of these solutions at a temperature between 77° to 95°
(25° to 35°C):

(a) Turco Alumigold 4178 or

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(b) Alodine 1200 or Alodine 1200 S.

(8) Make sure to drain the solution in the open air for 30 to 60 seconds.
(9) Flush the part with cold clean water.

(10) Dry with hot air at a maximum temperature of 140°F (60°C).

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REPAIR 07

TASK 49-00-01-350-802
1. Removal of the Nicks, the Scratches and the Burrs

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-803 Repair of the Protective
Finish

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Abrasive Stone Commercially Available
Fine-Tooth File Commercially Available
Thread Tape Set Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

320-grit Commercially Available
Aluminum Oxide Abrasive Cloth
MIL-A-9962, Type 1, Grade B Commercially Available
Aluminum Oxide Abrasive Mat
MIL-C-5541, Type 1A Commercially Available
Anodic Coating, Alodine 1200

(3) Expendable Parts

None

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SUBTASK 49-00-01-350-003
E. Repair
(1) Polish the small nicks or scratches with an aluminum oxide abrasive cloth (or
aluminum oxide abrasive mat). Apply a layer of anodic coating on the polished
aluminum surfaces.

(2) Flush carefully the worked surfaces with cold clean water. Let the surfaces dry in the
open air.

(3) Repair the small thread damage. Chase the threads with a correct diametral-pitch
thread tap. Apply a layer of anodic coating on the chased threads.

(4) Remove the burrs with a fine-tooth file. Apply a layer of anodic coating on the polished
aluminum surface.

(5) Flush carefully the worked surfaces with cold clean water. Let the surfaces dry in the
open air.

(6) Polish the small nicks or scratches on the flanges and mating face with a fine abrasive
stone.

(7) Repair the protective finish (Refer to Reference Information for the repair of the
protective finish).

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REPAIR 08

TASK 49-00-01-350-803
1. Replacement of the Pins/Studs

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Locking Pliers Commercially Available
Drill Set Commercially Available
Pipe Wrench Commercially Available
Electrical Discharge Machine Commercially Available
Stud Removal Tool Commercially Available
Electrode Commercially Available
Standard Stud Driver Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Grade 40 Loctite Corporation
Loctite 4450 Cranwood Ct.
Cleveland, OH 44128-4004

(3) Expendable Parts

None

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SUBTASK 49-00-01-350-004
E. Repair
WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE
CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

CAUTION: INSTALL A PROTECTION PLATE WITH A SUFFICIENT CLEARANCE

HOLE ABOVE THE STUDS TO BE REPLACED. THE PLATE IS THICKER
THAN THE ADJACENT INPUT FLANGE PILOT.

(1) Remove the dowel pins, the roll pins and the studs if they are damaged or if the repair
is not possible when they are installed.

(a) If the end of the dowel pin, the roll pin or the stud is sufficient to grip, apply a
local heat of 200°F to 250° F (93°C to 121°C).

(b) Remove the dowel pins with the locking pliers.

(c) For the roll pins, put a maximum dimension drill into the pin, to prevent damage
before you hold it with pliers.

(d) Remove the studs with a pipe wrench or a stud removal tool.

(e) Drill the dowel pins, the roll pins, or the studs if they are sufficiently hard. Use a
drill with a smaller diameter than that of the defective part.

(f) If the dowel pins, the roll pins or the studs cannot be pulled or drilled because
of their dimension, hardness or position, you can burn them with an electrical
discharge machine (EDM). Use an electrode with a smaller diameter than that
of the defective part.

(g) Remove the thin shell and/or the pieces from the hole or the threads.

(h) Examine the condition of the hole.

(2) Install the dowel pins, the roll pins and the studs.

(a) Refer to the engine manual and/or the component maintenance manual for the
installation of the dowel pins, the roll pins and the studs.

CAUTION: INSTALL A PROTECTION PLATE WITH A SUFFICIENT CLEARANCE

HOLE ABOVE THE STUDS TO BE REPLACED. THE PLATE IS
THICKER THAN THE ADJACENT INPUT FLANGE PILOT.

(b) Use a standard stud driver or two jam nuts.

(c) Install the stud of the dimension given in the engine manual and/or the
component maintenance manual.

(d) If you cannot get the indicated torque value, remove and replace with an
oversized stud.

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(e) If you cannot get again the indicated torque value, apply a layer of Loctite (grade
40) (refer to the procedure), Apply a check torque as indicated in the engine
manual and/or the component maintenance manual.
(f) If the check torque is not correct, do the Loctite procedure again.

(g) If the check torque is not correct after this second Loctite procedure, repair the
tapped hole by welding.

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REPAIR 09

TASK 49-00-01-360-801
1. Replacement of the Components with a Layer of Loctite

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Electric Heat Gun Commercially Available
Oven, 0 to 500°F (18 to 260°C) Commercially Available
Vapor Degreaser Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Grade N or T Loctite Corporation
Loctite, Newington, CT 06111
Grade 40, 2422, 271 or 271 Loctite Corporation
Primer and Loctite Newington, CT 06111
Retaining Compound Commercially Available
O-A-51 Commercially Available
Acetone
Decaploc 98 Framet
10, Avenue Eugene Cazaux
60304 Senlis cedex
Hydrochloric Acid Commercially Available

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(3) Expendable Parts

None
SUBTASK 49-00-01-360-001
E. Repair

(1) These compounds are used to seal and lock the threaded fasteners, the plugs and
the other threaded fittings and also to bond the loose bushings, the sleeves and the
inserts.

(2) Remove the parts installed with Loctite as follows : (method 1)

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND

PROTECTIVE CLOTHES TO PREVENT BURNS FROM VERY HOT
PARTS.

(a) Heat lightly the housing for 15 minutes at 400°C ±25°F (204° ±13°C) for the
Loctite 40. Use an oven or an electric heat gun.

(b) Heat lightly the housing for 15 minutes from 325° to 350°F (163° to 177°C) for
all the other Loctites. Use an oven or an electric heat gun.

(c) Remove the part with the applicable tool.

(d) Clean the loose Loctite and the remaining Loctite on the housing.

(3) Remove the parts installed with Loctite as follows : (method 2)

WARNING: DO NOT BREATHE THE GASES OF THE DECAPLOC 98 MATERIAL.

USE THE DECAPLOC 98 MATERIAL ONLY IN THE AREAS WHERE
THE AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE ARE
NO SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE
AREAS. IF THE DECAPLOC 98 MATERIAL TOUCHES YOUR EYES,
FLUSH YOUR EYES WITH WATER AND CALL A DOCTOR. IF THE
DECAPLOC 98 MATERIAL TOUCHES YOUR SKIN, WASH YOUR
SKIN WITH SOAP AND WATER. THE DECAPLOC 98 MATERIAL IS
POISONOUS AND FLAMMABLE.

CAUTION: DO NOT USE THE DECAPLOC 98 MATERIAL TO REMOVE THE

LOCTITE ON THE "TITANIUM, ALUMINIUM AND MAGNESIUM"
PARTS. USE ONLY THE DECAPLOC 98 MATERIAL ON THE STEEL
PARTS.

(a) Put the parts fully in a bath of Decaploc 98 at the ambient temperature for 15 to
20 hours.

(b) Remove the parts with the applicable tool.

(c) Clean the loose Loctite and the remaining Loctite on the parts.

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(4) Apply and cure the Loctite as follows:

NOTE: Do not use the Loctite products which are kept during more than one year.
Do not use the Loctite products which are removed and put again in the initial
container.

WARNING: DO NOT BREATHE THE GASES OF THE HYDROCHLORIC ACID.

USE THE HYDROCHLORIC ACID ONLY IN THE AREAS WHERE THE
AIR IS CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS.
IF THE HYDROCHLORIC ACID TOUCHES YOUR EYES, FLUSH
YOUR EYES WITH WATER AND CALL A DOCTOR. IF THE
HYDROCHLORIC ACID TOUCHES YOUR SKIN, WASH YOUR SKIN
WITH SOAP AND WATER. THE HYDROCHLORIC ACID IS
POISONOUS AND FLAMMABLE.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND

PROTECTIVE CLOTHES TO PREVENT BURNS FROM VERY HOT
PARTS.

(a) Remove chemically the black oxide treatment on the surfaces before you do the
Loctite cleaning procedure. The solution for the chemical removal is 50 percent
of hydrochloric acid and 50 percent of water. If the part has a 40 Rockwell
harness or more, heat at 300°F to 325°F (163°C to 177°C) in an oven during
one hour to remove the possible embrittlement.

WARNING: DO NOT BREATHE THE GASES OF THE ACETONE. USE THE

ACETONE ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS.
IF THE ACETONE TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE ACETONE TOUCHES
YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE
ACETONE IS POISONOUS AND FLAMMABLE.

(b) Clean the part carefully in a vapor degreaser, or in acetone.

NOTE: If the surface is less than 20 micro finish:

Put a protection on the easily damaged surface.

Grit blast the bonding surface with a 80-grit steel shot.

Clean the part carefully before you bond.

NOTE: The Loctite bonding is not the applicable procedure on the cadmium
plating and the passivated stainless steel. Use primer T to prepare the
surface of these materials.

NOTE: For a full locking and the strength, the bond line clearance between the
parts is 0.003 inch (0.076 mm) as a maximum.

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WARNING: DO NOT BREATHE THE GASES OF THE LOCTITE. USE THE

LOCTITE ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS.
IF THE LOCTITE TOUCHES YOUR EYES, FLUSH YOUR EYES WITH
WATER AND CALL A DOCTOR. IF THE LOCTITE TOUCHES YOUR
SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THE LOCTITE
IS POISONOUS AND FLAMMABLE.

(c) Apply the Locquic type N or T primer to the cleaned parts in less than one hour
after cleaning.

(d) Let the primer dry for five minutes at the ambient temperature.

NOTE: If you use type N primer, dry the type N primer from ten to fifteen minutes
at the ambient temperature.

CAUTION: DO NOT APPLY A LAYER OF LUBRICANT OR ANY SOLVENT TO

THE PARTS BEFORE COMPLETE CURING OF THE LOCTITE
COMPOUND. DO NOT TOUCH THE PREPARED SURFACES
BEFORE ASSEMBLY.

(e) Apply the Loctite retaining compound to the mating parts. Apply a smooth, thin
layer.

(f) Assemble the parts immediately and apply the necessary torque.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND

PROTECTIVE CLOTHES TO PREVENT BURNS FROM VERY HOT
PARTS.

(g) Cure the Loctite in an oven at 210°F to 250°F (99°C to 121°C) for thirty minutes.

(h) Keep the parts at the ambient temperature.

(i) Apply a check torque to the pipe plugs and the threaded inserts. Refer to the
engine manuals and/or the component maintenance manuals.

If the inserts loosen below the indicated torque, they must be removed, cleaned
and installed again.

(j) If a check torque is not indicated for the threaded inserts or the screws, use up
to 130 percent of the maximum installation torque.

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REPAIR 10

TASK 49-00-01-340-801
1. Application of Plasma and Flame Spraying

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic
Parts-General
HSPS 490001 Task 49-00-01-110-807 Cleaning of the Titanium
Parts (Usual Method)
HSPS 490001 Task 49-00-01-380-804 Chromating of the Aluminum
Alloys
AMS 2437 - Coating, Plasma Spray
Deposition
ASTM C633 - Standard Test method for
Adhesion or Cohesion
Strength of Thermal Spray
Coatings
ASTM E384 - Standard Test method for
Knoop and Vickers Hardness
or Materials
ISO 8573.1 - Compressed air-
Contaminants and Purity
Classes

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

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Part No./Name Source (CAGE Code)

Plasma Spraying Equipment Commercially Available
Combustion Wire (Flame) Spray Commercially Available
Equipment
Combustion Power (Flame) Spray Commercially Available
Equipment
Electric Arc Wire Spray Equipment Commercially Available
Sand-Blasting Equipment Commercially Available
Pressure-type machine
or
Suction-type machine
Sand-Blast Nozzle size Commercially Available
0.125 IN to 0.500 IN Diameter
Grind Machine Commercially Available
Lathe Commercially Available
Oven Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Description Source (CAGE Code)

METCO 320NS Powder, Plasma Spray Sulzer Metco
AL-8Si-20BN (01FK3)
METCO 404-NS Powder, Plasma Spray, Sulzer Metco
Nickel- Aluminum 80Ni-20Al (01FK3)
METCO 405-NS Wire - Flame Spray, Nickel- Sulzer Metco
Aluminum 80Ni-20Al (01FK3)
METCO 443 Powder, Plasma Spray, Sulzer Metco
Nickel Chromium-Aluminum (01FK3)
METCO 8400 Wire - Electric Arc Spray, Sulzer Metco
Nickel-Aluminum 95Ni-5Al (01FK3)
METCO 480NS Powder, Plasma Spray, Sulzer Metco
Nickel-Aluminum 95Ni-5Al (01FK3)
METCO 450 NS Powder, Plasma Spray, Sulzer Metco
or Nickel- Aluminum 95Ni-5Al (01FK3)
AMDRY 956

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Part No./Spec. No. Description Source (CAGE Code)

METCO 45VF-NS Powder, Plasma Spray Sulzer Metco
or Very Fine Cobalt Co 25.5, Cr (01FK3)
METCO 45C-NS 10.5 Ni 7.5 W 0.5 C
Al-1037 Powder, Plasma Spray, Praxair
or Nickel- Aluminum 95Ni-5Al (33870)
NI-109
or
NI-970
METCO 106NS Powder, Plasma Spray, Sulzer Metco
Chromium OxideCr2O3 (01FK3)
AMPERT 413.284 Powder, Plasma Spray Stark
Ni-22Cr-10Al-1.0Y (DK026, 4D776)
AMDRY 962 Powder, Plasma Spray Sulzer Metco
Ni-22Cr-10Al-1.0Y (01FK3)
NI-164 Powder, Plasma Spray Praxair
or Ni-22Cr-10Al-1.0Y (33870)
NI-211
METCO 301NS Powder, Plasma Spray, Sulzer Metco
Composite, (01FK3)
Ni-14Cr-8Fe-5.5BN-3.5Al
(NOTE 1)
METCO 601NS Powder, Flame Spray, Sulzer Metco
or Polyester-Aluminum 60 (01FK3)
AMDRY 2010 (88Al-12Si) + 40 Polyester
(NOTE 1)
AL-288 Powder, Flame Spray, Praxair
Polyester-Aluminum 60 (33870)
(88Al-12Si) + 40 Polyester
(NOTE 1)
METCO SF ALUMINUM Wire - Flame Spray, Sulzer Metco
Aluminum- Silicon 94Al-6Si (01FK3)
(NOTE 2)
METCO 312NS Powder, Flame Spray, Sulzer Metco
Composite (01FK3)
Ni-4Cr-4Al-21Bentonite
(NOTE 1)

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Part No./Spec. No. Description Source (CAGE Code)

NI-769 Powder, Flame Spray, Praxair
Composite (33870)
Ni-4Cr-4Al-21Bentonite
(NOTE 1)
21213BLACK Spray shield Varnish (for the Metallisation LTD
Plasma Spraying) (U1525)
1000238 Metco Antibond Lacquer Sulzer Metco
(01FK3)
1000021 Metco Masking Compound Sulzer Metco
(01FK3)
1000598 Metco Super Spray Mask Sulzer Metco
(01FK3)
1000427/1000428/ 29871 Flame Spray Masking Tape Sulzer Metco
(01FK3)
No. 361, 363 Tape, High Temperature Glass 3M
Cloth (52152)
23816 Tape, Heat Resistant Fluoglas
(07512)
469 Tape, High Temperature, Dewal Industries
Glass Cloth (60890)
Fluorolin 409 Tape, Heat-Reflective Dewal Industries
(60890)
D/W 498 Tape, Double Layer (Al/Si/ Dewal Industries
Glass) (60890)
26020 Tape, Aluminum Foil, Heavy Saint-Gobain
Duty (18632)
CHR 2905-7R Tape, Glass Cloth Saint-Gobain
(18632)
ASTM D329 Acetone Commercially Available
ASTM D770 Isopropyl Alcohol Commercially Available
- Aluminum Oxide (60 grit or Commercially Available
finer)

NOTE: Recommend Nickel/Aluminum (5%) bond coat.

NOTE: Recommend Nickel/Aluminum (20%) bond coat.

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(3) Expendable Parts

None
SUBTASK 49-00-01-340-001
E. Preparation of the surfaces (See AMS 2437)

(1) Completely remove all of the previous surface coating by employing one or all of the
following materials:

(a) With a grind machine or a lathe for the mechanical parts with a simple geometry.

(b) By dry sand-blasting (seal the areas for which sand-blasting is not used) for the
sheet metal parts or the parts with a complex geometry.

(c) By electrolytic or chemical procedure (APIC Engineering must give its

agreement for this procedure) for the sheet metal parts or the parts with a
complex geometry.

(d) By water jet stripping (APIC Engineering must give it agreement for this
procedure for all parts). Refer to Cleaning-33.

(2) Clean the parts as follows:

(a) Clean the part (other than titanium parts) with chlorinated solvent in vapor phase.
Refer to Reference Information for the cleaning of the metal parts.

(b) Clean the titanium part with an alkaline cleaner. Refer to Reference Information
for the cleaning of the titanium parts (usual method).

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Dry the part with dry, filtered and oil free compressed air or in an oven.

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(4) Seal the areas where the plasma spraying must not be applied and all internal cavities.
Use the applicable protection (scotch tape or varnish or lacquer). A tolerance of -0.0
in. (-0.0 mm) and +0.125 in. (3.2 mm) is allowed on boundaries of areas to be coated.
NOTE: It is recommended to seal the part before the sand-blasting procedure. After
the sand-blasting procedure, make sure that the seal is in the correct
condition.

Use the correct protection for the seal.

Mechanized equipment shall be used for grit blast preparation and coating
of disks, hubs, shafts, seals, spacers and bearing seal faces in such a
manner that gun-to-work distance and spray angle remain fixed. Mechanized
or manual equipment may be used to prepare all other parts.

(5) Perform a dry sand-blasting as follows:

(a) Use aluminum oxide (60 grit or finer).

(b) Angle of blast is to be 45 to 90 degrees.

(c) Nozzle to part distance shall be 4 to 6 in. (101.6 to 152.4 mm).

(d) Nozzle size must be 0.125 in. (3.175 mm) thru 0.5 in. (12.7 mm) in diameter.

(e) Blasting pressure must be 40 to 70 psi (275 to 482 kPa) for suction-type
equipment and 20 to 35 psi (138 to 241 kPa) for direct pressure-type equipment.

NOTE: To prevent contamination, do not touch areas where coating is to be

applied. Use clean white gloves when handling parts.

Make frequent checks of amount of grit deterioration. Grit must be kept

free of dirt, oil, excessively worn grit and other foreign contaminates.

(6) Check grit blasted area and if necessary repeat the blasting procedure until the area
to be sprayed has a uniform matte surface with no shiny areas.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

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WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE- RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(7) Clean grit blasted area using a brush and Isopropyl alcohol or acetone. Blow off all
loose grit using argon or dry, filtered, oil-free air.

(8) As necessary, touch-up masking or replace masking tape.

NOTE: The coating must be applied within 30 minutes after sand-blasting for parts
made of aluminum, magnesium and titanium alloys to prevent the effects of
oxidation.

The coating must be applied within 2 hours for all other materials. Parts
required to be heat treated shall be heat treated prior to coating application
unless otherwise provided in the Engine Manual or authorized by HSPS
Engineering.

(9) Coating must be deposited onto the designated surfaces to the thickness specified,
or to a sufficient thickness to permit finishing by grinding to the dimensions specified.
Surface temperature of surfaces to be coated must not exceed 500°F (260°C) for
titanium, steel, nickel alloy parts. Surface temperature must not exceed 400°F (204°
C) for aluminum alloy parts.

(10) Remove masking. Remove any remaining tape or tape adhesive using isopropyl
alcohol or acetone. If necessary, smooth rough edges with a stone.

NOTE: Make sure that internal cavities have been cleaned of any grit.

SUBTASK 49-00-01-340-002
F. Application parameters for the bond coatings

(1) Nickel/Aluminum (20 %) powder or wire (80Ni-20Al) Air Plasma/Combustion (Flame)

Wire (bond).

(a) Characteristics

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Max.
Under-layer Operational
Composition Thickness in (mm) Temperature Diameter of Wire Used
Nickel: 80% 0.002 to 0.006 1594°F 1/8 in. (3.175 mm)
Al:20% (0.05 to 0.15) 850°C

(b) Acceptance specification

Min. Hardness Min Tensile Bond Unbonded

HV 0,3 Strength RSC (MPa) Porosities Particles
140 5.1 (35) 8% max. 15% max. on a
diameter <2362
μin (60 μm)

(c) Application parameters: Apply per compound and/or equipment manufactures

recommendations.

(2) Nickel/Aluminum (5 %) powder or wire (95Ni-5Al) - Air Plasma or Combustion (Flame)

or Arc Wire.

(a) Characteristics

Max.
Under-layer Operational
Composition Thickness in (mm) Temperature Diameter of Wire Used
Nickel: 95.5% 0.002 to 0.008 1594°F 1773 to 3536
Al: 4.5% (0.05 to 0.20) 850°C (45 to 90)

(b) Acceptance specifications. Coatings must meet the requirements as listed,

(Refer to Table 901).

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Table 901
Mecto 450NS/Metco 480NS coating requirements

Powder
Design
ation or
Specific Nomin
ation Bond al
Numbe Cup Bend Stre Hardn Compo
r Test Test ngth ess Micro-examination sition
Metco® Accept Applica 3000 65-80 At 200X magnification 4.5% –
450NS able ble psi HRB Porosity: ≤ 8%,(Refer 5.5%
Metco® alternati AMS24 mini per to Figure 904) and Alumin
480NS ve to 37 mum ASTM (Refer to Figure 905), um
Bend Coatin E18 Cracking: None Balanc
test g or Bondline separation: e:
Coating Thickn 140H None Nickel
Thickne ess V 0.3 Bondline oxides or
ss 0.008-0 minim embedded particles: ≤
0.008-0 .010 in. um per 25%
.010 in. (0.20-0 ASTM Unmelted Globules: ≤
(0.20-0. .25 E384 15%
25 mm) mm) Unles Acceptable
s Microstructure
specifi (Refer to Figure 904)
ed and (Refer to Figure
otherw 905).
ise on Unacceptable
drawin Microstructure
g (Refer to Figure 906)
and (Refer to Figure
907).

(c) Application parameters: Per compound and/or equipment manufactures

recommendations.

(3) NiCrAIY (Ni-22Cr-10Al-1.0Y) powder - Air Plasma (bond).

(a) Characteristics

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Under-layer Max. Granular Structure

Compositio Thickness in Operational micro-inch (micrometer)
n (mm) Temperature
Nickel: base 0.002 to 0.008 2108°F 1773 to 4137
(0.05 to .020) 1153°C (45 to 105)
Chromium:
22%
Aluminum:
10%
Yitrium: 1%

(b) Acceptance specifications

Min Tensile
Min. Bond
Hardnes Strength Rough Ra after machining Unbond
s HV 0,3 Ksi (MPa) micro-inch (micrometer) Porosity Particles
200 5.1 (35) 63 - 591 8% max. 15% max.
(1.6 - 15) on a
diameter <
2362 μin.
(60 μm)

(c) Application parameters: Per compound and/or equipment manufacturers

recommendations.

(d) Machining parameters: Per compound and/or equipment manufacturers

recommendations.

SUBTASK 49-00-01-340-003
G. Do a heat treatment as follows (optional)

(1) DELETED

SUBTASK 49-00-01-340-004
H. Application parameters for the finish (top coat) layers

(1) Nickel/Chromium/Boron nitride (Ni-14Cr-8Fe-5.5BN-3.5Al) - Combustion (Flame)

powder spray (abradable).

(a) Characteristics

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Under-layer Max.
Thickness in Operational Granular Structure
Composition (mm) Temperature micro-inch (micrometer)
Nickel: base
Chromium: 0.020 to 0.120 1531°F 1973 to 4921
14% (0.5 to 3) 815°C (45 to 125)
Iron: 8%
Boric Nitride:
5.5%
Al: 3.5%

(b) Acceptance specifications

Rough Ra after machining micro-

HardnessR15Y Density (g/cc) inch (micrometer)
50 - 60 4.4 - 4.5 236 - 787
(average of 5 (6 - 20)
readings)

1 Free of cracks and excessive oxides.

2 Free of contamination at the coating - base metal interface. A maximum of

25 percent interface contamination and intermittent area of straight line
interface are acceptable.

3 Adhesion - Coating, after exposure to 1000°F ±25 °F (538°C ± 13°C) for

5-10 minutes and water quenched, shall be free of craking, flaking or
spalling.

(c) Application parameters

1 Per Compound and/or equipment manufacturers recommendations.

Nickel-Aluminum bond coating (metco 450NS or equivalent) 0.002 to 0.008
in. (0.05 to 0.20 mm) thick is recommended prior to coating application.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

(2) Aluminum/Silicone/ Polyester resin (60(88Al-12Si) +40 Polyester) - Air Plasma

(abradable).

(a) Characteristics

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Thickness
After Max.
Machining in Operational Granular Structure
Composition (mm) Temperature micro-inch (micrometer)
Aluminum
Alloys: 88%
Silicone: 12% 0.020 to 653°F 196 to 4134
0.120 345°C (5 to 150)
(0.5 to 3)
Polyester:
40%

NOTE: Do a chromating protection after the machining. Refer to Reference

Information for the chromating of the aluminum alloys.

(b) Acceptance specifications

Rough Ra after
Min Tensile Bond machining micro-inch
HardnessR15Y Strength RSC (MPA) (micrometer)
50 -70 0.9 (6.205) 32 - 276
(average of 5 readings) (0.8 - 7.0)

1 Free of cracks and excessive oxides.

2 Free of contamination at the coating - base metal interface. A maximum of

25 percent interface contamination and intermittent area of straight line
interface are acceptable.

3 Adhesion - Coating, after exposure to 1000°F ±25 °F (538°C ± 13°C ) for

5- 10 minutes and water quenched, shall be free of craking, flaking or
spalling.

(c) Application parameters

1 Per compound and/or equipment manufacturers recommendations Nickel-

Aluminum bond coating (Metco 450NS or equivalent) 0.002 to 0.006 in.
(0.05 to 0.15 mm) thick is recommended prior to coating application.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

(3) Aluminum/Silicone 6% - Combustion (Flame) or Arc Wire Spray (Abradable)

(a) Characteristics

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Thickness After Max. Operational Diameter of Wire

Composition Machining in. (mm) Temperature Used
Aluminum: 94% 0.016 - 0.040 842°F 1/8 in.
(0.4 - 1) (450°C) (3.175 mm)
Silicone: 6%

(b) Acceptance specifications.

Roughness Ra
Minimum Minimum Tensile after machining
Hardness Bond Strength micro inch Porosite Not Melted
15 Y RSC (Mpa) (micrometer) s Particles
50 - 70 3.6 (25) 16 - 47 8% max 15% max. on
(0.4 - 1.2) diameter ≤ 60 µm

(c) Application parameters

1 Per compound and/or equipment manufacturers recommendations.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

NOTE: Do a chromating protection after the machining. Refer to

Reference Information for the chromating of the aluminum alloys.

(4) NICRAL-BENTONITE – Combustion (Flame) powder (Abradable)

(a) Characteristics

Thickness After Max. Operational Granular Structure

Composition Machining in (mm) Temperature (micrometer)
Nickel: base 0.012 to 0.079 2108°F 2955 - 5911
(0.3 to 2.0) 1153°C (75 - 150)
Bentonite: 21
Chromium: 4%
Aluminum: 4%

(b) Acceptance specifications

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Min Tensile Rough Ra after

Bond machining
R
Hardness 15 Strength micro-inch Not Melted
Y RSC (MPA) (micrometer) Porosities Particles
40 -60 0.4 63 - 591 8% 15% max. on
(average of 5 (0.0275) (1.6 - 15) a diameter ≤
readings) 60 μm

1 Hardness measurement require the use of a standard superficial hardness

tester, utilizing a 1/2 in. (12.7 mm) ball and a 15 kilogram load (R15Y).

(c) Application parameters

1 Per compound and/or equipment manufacturers recommendations.

2 Apply Nickel-Aluminum (95 Ni-5Al) or Nickel-Chromium-Aluminum-Yttra

bond coating, as specified by the component engine manual, 0.002 - 0.008
in. (0.05 - 0.2 mm) thick before to coating application.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

(5) Aluminum/Silicone/Boron Nitride (AI-8Si-20BN) – Air Plasma (abradable).

(a) Characteristics

Thickness After Max. Operational Granular Structure

Composition Machining in (mm) Temperature (micrometer)
Aluminum: 72% 0.020 - 0.120 900°F 1773 - 4137
(0.8 - 3) (480°C) (45 - 105)
Silicon: 8%
Boron Nitride:
20%

NOTE: Do a chromating protection after machining. Refer to Reference

Information for the “Chromating of the Aluminum Alloys”.

(b) Acceptance Specifications: Coatings must meet the requirements as listed,

(Refer to Table 902)

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Table 902
Metco 320NS Coating Requirements

Powder
Designat
ion or
Specifica Bond Nominal
tion Bend Streng Hardn Microexamin Compositi
Number Cup Test Test th ess ation on
Metco® Acceptable Applica Not 55-70 At 200X 8%
320NS alternative ble Applic HR15 magnificatio Silicon
to Bend test AMS able Y Per n 20%
Acceptanc 2437 ASTM Porosity: Boron
e Standard: Coating E18 (Refer to Nitride
No Thickn Figure 901), 8%
separation ess: (Refer to Organic
of bond 0.004-0 Figure 902) Solids
coat from .006 in. and (Refer to Balance:
substrate (0.10-0. Figure 903) Aluminum
or top coat 15 mm) Cracking:
from bond None
coat. Bondline
Coating Separation:
Thickness: None
0.004-0.00 Bondline
6 in. oxides or
(0.10-0.15 embedded
mm) particles: ≤
20%
Unmelted
Globules: ≤
15%
Acceptable
Microstructur
e:
(Refer to
Figure 901),
(Refer to
Figure 902)
Unacceptabl
e
Microstructur
e:
(Refer to
Figure 903)

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(c) Application Parameters

1 Per compound and/or equipment manufacturers recommendations.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

(6) Chromium oxide (CR2O2) - Air plasma (Wear Resistant Coating)

(a) (a) Characteristics

Thickness After Max. Operational Granular Structure

Composition Machining in (mm) Temperature (micrometer)
Chromium oxide: 0.002 - 0.015 1000°F 196 - 2165
98% (0.05 - 0.38) 540°C (5 - 55)

(b) Acceptance Specifications

Min Min Tensile

Hardness Bond Strength Roughness Ra after Machining
HV 0.3 Ksi (MPa) Porosities micro inch (micrometer)
1000 6.5 (45) 3% max 3 - 35
(0.076 - 0.9)

(c) Application parameters

1 Per compound and/or equipment manufacturers recommendations.

(d) Machining parameters

1 Per compound and/or equipment manufacturers recommendations.

(7) Very fine/coarse cobalt (Co 25.5, Cr 10.5 Ni 7.5 W 0.5 C) - powder plasma spray (hard
coating).

(a) Characteristics

Under-Layer
Thickness
Machining in Max. Operational Granular Structure
Composition (mm) Temperature Micro inch (micrometer)
Balance: NA 1000 - 1550°F -1773+197 - Metco 45VF-
Cobalt 540 - 840°C NS
(-45+5 µm)
-2952+1773 - Metco 45C-
NS
(-75+45 µm)

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(b) Acceptance Specifications: Coatings must meet the requirements as listed,

(Refer to Table 903)
Table 903
Metco 45VF-NS/Metco 45C-NS Coating Requirements

Powder
Designat
ion or
Specifica Nominal
tion Bend Bond Hardne Microexamin Compos
Number Cup Test Test Strength ss ation ition
Metco® Applicabl Accepta 4700 psi For At 200X 25.5%
45VF- e AMS ble (32405. 45VF- magnification Chromiu
NS 2437 alternati 36 kPa) NS: 78 Porosity: ≤ m
Metco® Coating ve to minimu HR15N 3% (Refer to 10.5%
45C-NS Thicknes Cup m. min, for Figure 908) Nickel
s: Test 45C- and (Refer to 7.5%
0.002-0.0 Coating NS: Figure 909) Tungste
04 in. Thickne 59HRA Cracking: n
(0.05-0.1 ss: min. None 0.5%
0 mm) 0.005-0. Bondline Carbon
008 in. Separation: Balance
(0.13-0. None : Cobalt
20 mm) Bondline
0.002-0. oxides or
004 in. embedded
(0.05-0. particles: ≤
10 mm) 25%
Unmelted
Globules: ≤
10%
Acceptable
Microstructur
e:
(Refer to
Figure 908)
and (Refer to
Figure 909)
Unacceptable
Microstructur
e:
(Refer to
Figure 910)

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(c) Application parameters

1 Apply per compound and/or equipment manufacturers recommendations.

(d) Machining parameters

1 Apply per compound and/or equipment manufacturers recommendations.

SUBTASK 49-00-01-260-005
I. Do a treatment and a protection of the aluminum as follows:

(1) DELETED

SUBTASK 49-00-01-260-006
J. Machine the parts as follows:

(1) DELETED

SUBTASK 49-00-01-260-007
K. Inspection of the parts as follows:

(1) Do a micro-graphy check and a Rockwell HR15Y hardness check on the test
specimen in accordance with ASTM E18.

(2) Do a visual inspection and a dimensional inspection after the machining. Examine the
parts for:

(a) Cracks (not permitted).

(b) Incorrect seal (not permitted).

(c) Flakes (not permitted).

(d) Separation of the layers (not permitted).

(3) Coating shall be uniform in quality and condition, it shall be adherent to the base metal
and free of spalling, chipping, flaking, cracking or other objectionable imperfection,
unless otherwise specified in the component repair manual.

SUBTASK 49-00-01-260-008
L. Required Tests

(1) Acceptance Tests must be performed to represent per every part/spray lot:

(a) Coating thickness.

(b) Cup test or bend test on the test specimens per AMS 2437.

NOTE: Bend test/cup test is optional if microexamination test, bond strength

test is performed for every part or spray lot.

(c) Microexamination on the test specimens per AMS 2437.

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Check for:
1 Porosity: Estimate visually, quantify by image analysis, quantify by grid
count or compare to appropriate photo standards, (Refer to Figure 901),
(Refer to Figure 902), (Refer to Figure 903), (Refer to Figure 904), (Refer
to Figure 905), (Refer to Figure 906) and (Refer to Figure 907). Porosity
must be uniformly distributed.

2 Bondline separation: A defect that follows, or is associated with, the contour

of the interface. It must be longer than 0.005 in. (127 µm) to be ratable.

3 Bondline oxides or embedded particles: Coating must be free of oxide

clusters. Oxides must be uniformly distributed.

4 Unmelted Globules: Unreacted powder particles are contained within the

coating matrix. These particles have round or globular appearance (3:2
ratio), and are not adhered to the surrounding coating matrix not more than
25% and are greater than 0.002 in. (51 µm) in any direction.

5 Quality per AMS 2437.

6 Tolerances per AMS 2437.

(2) Periodic Tests are frequently specified by HSPS.

(a) Bond strength test on the test specimens per ASTM C633.

(b) Hardness of coated parts per AMS 2437.

SUBTASK 49-00-01-260-009
M. Inspection of the parts

(1) DELETED

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Acceptable Aluminum Alloy-Boron Nitride Abradable Powder Plasma-Sprayed Coating

Figure 901

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Acceptable Aluminum Alloy-Boron Nitride Abradable Powder Plasma-Sprayed Coating

Figure 902

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Unacceptable Type A Coating: Excessive Porosity Aluminum Alloy-

Boron Nitride Abradable Powder Plasma-Sprayed Coating: Excessive Porosity
Figure 903

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Acceptable Nickel Aluminum Composite Powder Plasma-Sprayed Coating

Figure 904

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Acceptable Nickel Aluminum Composite Powder Plasma

-Sprayed Coating: Low Amounts of Bondline Particles (arrows)
Figure 905

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Unacceptable Nickel Aluminum Composite Powder Plasma

-Sprayed Coating: Non-Uniform Bondline Thickness
Figure 906

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Unacceptable Nickel Aluminum Composite Powder Plasma

-Sprayed Coating: Excessive Porosity (arrows)
Figure 907

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Acceptable Cobalt Coating

Figure 908

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Acceptable Cobalt Coating

Figure 909

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Unacceptable Cobalt Coating: Excessive Porosity and Unmelted Globules

Figure 910

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REPAIR 11

TASK 49-00-01-360-802
1. Bonding of the Abradable Felts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic
Parts-General

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Rubber Press Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Hysol EA 9394/C-2 Epoxy Commercially Available
Sermabond 481 Compound Commercially Available
OHC 732 Compound Commercially Available
Abradable Felt, Type OHP Onera-Heur Chrome
Chlorinated Solvent Commercially Available
Ardrox 185/4 Brent SA
Concentration: 40% in volume 280, Rue J.B. Godin
02200 Villeneuve St
Germain France

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Part No./Spec. No. Source (CAGE Code)

Turco 4181 Turco France SA
Concentration: 250 g/l 3-5, impasse du quai de
l'industrie
91200 Athis-Mons France
Turco 4316L Turco France SA
Concentration: 816 cm3/1 3-5, impasse du quai de
l'industrie
91200 Athis-Mons France
Caustic Soda Commercially Available
Aluminum Oxide (80 to 140, or 60 or 180) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-360-002
E. Preparation of the surfaces

NOTE: This procedure gives the acceptance conditions for the bonding of the abradable
felts, type OHP 820C1 5 (Nickel/Chromium 20 %).

(1) Do a lathe procedure as follows:

(a) Pitch: 0.50 mm (0.0196 inch)

(b) Depth: 0.10 mm (0.0039 inch)

(c) Total radius : 0.20 mm (0.0078 inch)

(d) If the parts are made of aluminum alloys, do the lathe procedure before the
anodisation.

(2) Clean the parts with the chlorinated solvent. Refer to Reference Information for the
cleaning of the metal parts.

(3) If there are remaining compounds, remove them in a bath of the Ardrox 185/4 (40 %
volume) at 176 to 194°F (80 to 90°C) or in a bath of the Turco 4181 (250 g/l) at 185
to 203°F (85 to 95°C). The immersion time is approximately 5 minutes.

(4) Flush the parts with clean cold water.

(5) Dry the parts with dry compressed air.

(6) Glass bead blast using the aluminum oxide (80 - 140, or 60 or 180 mesh size) on the
bore of the parts.

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SUBTASK 49-00-01-360-003
F. Bonding of the abradable felt
(1) OPTION 1: Prepare the compound, Hysol EA 9394/C-2 according to the
manufacturer’s instructions by mixing two parts of the compound, 100:20. Keep the
epoxy at 77°F (25°C) or cooler. The compound can be used for 480 minutes (8 hours)
after the preparation.

(2) OPTION 2: Prepare the compound (Sermabond 481) at least 12 hours before and
keep the cement in a closed container between 39.2 to 50°F (+ 4 and + 10°C).

NOTE: The part n°2 of the compound in powder must be put in an oven at 80 to 100°
C (176 to 212°F) during one hour. Then, use a screen (50- micron mesh) to
remove the larger grain.

(a) Mix the two parts of the compound as follows:

1 Part n°1: 98 to 102 g

2 Part n°2:2.30 to 2.40 g

3 The compound can be used for 24 to 36 hours after the preparation.

4 The compound must be kept in a closed container between 39.2 to 50°F

(+ 4 and + 10°C).

(b) The OHC 732 compound can be used as an alternative. The preparation is the
same as for the Sermabond 481 compound.

(3) Prepare the abradable felt as follows :

(a) Cut the abradable felt with a ribbon or a circular saw.

1 The cut width must be approximately 2 mm oversize.

2 The cut length must have a light oversize, you will get the correct length
during the bonding.

3 The installation of the abradable felt in a bore must be done with a complete
ring. The complete ring must have a bevel at 45°.

(4) Make in the shape of the abradable felt as follows:

(a) Do a compacting in many times and a bending of the abradable felt with the
applicable tools.

NOTE: One of the rollers must have a knurl to get a better adherence of the
compound on the abradable felt.

(b) Make in the last shape in one or two times without a reduction of the thickness.

(5) Apply the compound on the parts.

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(6) Blow with dry compressed air the abradable felt, then quickly install the abradable felt.

(7) Keep the abradable felt in position on the parts with a rubber press or other applicable
fixtures to the shape of the parts.

(8) Bond as follows:

(a) If Hysol EA 9394/C-2 epoxy was used for bonding, leave the tool in the assembly
with the felt metal for the entire time. Keep the part/abradable felt assembly at
room temperature for 24 hours, or place this assembly in an oven to cure at 200°
F (93°C) for 1 hour. Proceed to step (11).

(b) If Hysol EA 9394/C-2 epoxy was not used, proceed to step (8).

(9) Keep the part/abradable felt assembly at room temperature for approximately one
hour, then put this assembly in an oven at 167 to 185°F (75 to 85°C) for 4 hours.

(10) Remove the part from the oven, then remove the rubber press or other applicable
fixtures.

(11) Put the part in an oven at 626 to 662°F (330 to 350°C) for 30 minutes or at 293 to
311°F (145 to 155°C) for 6 hours if the base metal is aluminum or magnesium alloy
or a cadmium steel.

(12) Cut the width of the abradable felt.

SUBTASK 49-00-01-280-002
G. Do a binocular inspection (16 X) or use a magnifying glass (6 X).

(1) Make sure that the parts have:

(a) no tool marks

(b) are not locally crushed

(c) are not undulated

(d) no separation at the join.

(2) If there is a border of the compound around the periphery of the abradable felt, the
adherence is correct.

(a) If there is a border of the compound around the periphery of the abradable felt,
the adherence is correct.

(b) If there is no border of compound :

1 over 20 mm (0.787 inch) in one length

2 over 10 % of the total length

3 over a depth of more than 2 mm (0.0787 inch) from the surface.

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(c) Remove the abradable felt again.

(3) The joins of the abradable felt must have a bevel with a maximum clearance of 0.5
mm (0.019 inch).

NOTE: For the diameters of less than 40 mm (1.574 inches), the join can be 2 mm
(0.0787 inch). The join must be filled with the compound.

(4) Make sure that the adherence is correct during the machining.

SUBTASK 49-00-01-360-004
H. Bonding of the defects is as follows:

(1) If the border of the compound around the periphery of the abradable felt is not
continuous, prepare the compound, refer to paragraph F.

(a) Lift lightly at the location of the defect, then put a compound under the abradable
felt.

(2) Keep the abradable felt on the part with the applicable fixture, then put the part in an
oven. Refer to the paragraph F.

(3) Removal of the defective abradable felt

(a) Remove the abradable felt by machining.

WARNING: DO NOT BREATHE THE GASES OF THESE PRODUCTS. USE

THESE PRODUCTS ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO
SPARKS, NO FLAMES AND NO HOT SURFACES IN THESE AREAS.
IF THESE PRODUCTS TOUCH YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THESE PRODUCTS TOUCH
YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER. THESE
PRODUCTS ARE POISONOUS AND FLAMMABLE.

CAUTION: DO NOT USE THESE BATHS FOR THE ALUMINIUM ALLOYS.

(b) Remove the remaining compound with one of these baths:

1 Bath of Ardrox 185/4 (40%) at 185°F (85°C).

2 Bath of Turco 4181 (250 g/l) at 194°F (90°C).

3 Bath of Turco 4316L (816 cm3/l) at 239°F (115°C).

4 Bath of caustic soda (20 to 30%) at 194°F (90°C).

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REPAIR 12

TASK 49-00-01-330-801
1. Instructions to Apply the Chromium Plating

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-811 Cleaning of the Metallic
Parts-General

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Chromium Plating Equipment Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Varnish Commercially Available
or
Lead Adhesive Tapes
or
Wax Bath
Chromic Acid Anhydrid Commercially Available
Sulfuric Acid Commercially Available
Heet 25 Liquid Commercially Available
Alkaline Solvent Commercially Available
Hydrochloric Acid Commercially Available
Concentration: 50%

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Part No./Spec. No. Source (CAGE Code)

Caustic Soda Commercially Available
Concentration: 100 to 150 g/l
Sodium Bisulphite Commercially Available
Concentration: 2 g/l

(3) Expendable Parts

None

SUBTASK 49-00-01-330-001
E. Preparation of the surfaces

(1) Machine the area of the parts to be chromium plated with a grind machine (procedure
recommended) or a lathe.

(2) Clean the parts with chlorinated solvent in vapor phase. Refer to Reference
Information for the cleaning of the metal parts.

(3) Do a stress relief treatment as follows:

Steels Non Case-Hardened Parts Case-Hardened Parts

R < 1300 mPa None None
1300 ≤ R < 1450 1 h at 365 to 383°C 2 h at 275 to 293°F
mPa (185 to 195°C) (135 to 145°C)
R ≥ 1450 mPa 2 h at 275 to 293°F
(135 to 145°C)
NOTE: R = Breaking load of base steel

(a) If you have nitrided parts, do a stress relief treatment at 374°F (190°C) for one
hour.

(b) If you have parts with nickel base or cobalt base alloys, do a stress relief
treatment at 374°F (190°C) for 3 hours.

(4) If you have parts under fatigue, do a pre-stressing shot-peening. Do a sand-blasting

with corundum or glass micro-balls on the shot-peened areas. The pressure of the
sand-blasting must be low and adjusted with the type of the sand-blast machine used.

(5) Seal the areas where the chromium plating must not be applied with the applicable
protection.

(6) Clean the parts with an alkaline solvent. Refer to Reference Information for the
cleaning of the metal parts.

(7) Flush the parts with cold water.

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SUBTASK 49-00-01-330-002
F. Do a chromium plating as follows:
(1) The minimum thickness of the chromium plating must not be lower than 5 microns
after the grinding.

(a) The maximum thickness of the chromium plating is 0.3 mm on the repaired parts.

(b) This thickness can be 0.5 mm for a special condition, this procedure will be
written in the engine manual.

(2) Put the parts in a bath of hydrochloric acid at 65% volume.

(a) Concentration of hydrochloric acid during the procedure: 650 ml/l.

(b) Concentration of free hydrochloric acid during the procedure: 600 to 700 ml/l.

(c) Density at 68°F (20°C) during the installation: 1.11.

(d) Density at 68°F (20°C) during the operation: 1. 10 to 1. 12.

(e) Temperature of the bath: room temperature.

(f) Anodes: graphite plates.

(g) Lightly alloyed steel: do an etching for one minute.

(h) Stainless steel: Do a cathode etching for 40 sec under 5 to 10 A/dm2.

(i) Nickel or cobalt base alloy: Do an anode pickling under 22A/dm2 for 40 to 50
sec, then do a cathode etching under 5 to 10 A/dm2 for 15 to 20 sec.

(3) For the parts with lightly alloyed steel, the bath of hydrochloric acid at 65 % volume
can be replaced by a bath of chromic acid.

(a) The concentration of the bath is the same as for the standard chroming.

(b) The temperature of the bath is 122 to 140°F (50 to 60°C) under 10 to 30 A/dm2.

(c) The immersion time is between 30 seconds and 3 minutes.

(d) For the shot-peened parts, the immersion time is 30 seconds to one minute.

(4) Flush the parts with cold water.

(5) Put the parts into one of the chroming baths as follows:

(a) Bath of standard chroming

1 Chromic acid anhydrid: 250 g/l

2 Sulfuric acid: 2.5 g/I

3 Bath temperature: 122 to 140°F (50 to 60°C)

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4 Current intensity: 20 to 40 A/dm2

(b) Bath of high-efficiency chroming (bath HEEF25)

1 Heet 25 liquid: 500 ml/l

2 Sulfuric acid: 3.5 g/l

3 Bath temperature: 131 to 140°F (55 to 60°C)

4 Current intensity: 20 to 40 A/dm2

(6) Flush the parts with cold water.

(7) Remove the applicable protection.

(8) Apply a thin layer of protection oil or grease on the chromium plated areas.

(9) Do a degassing treatment of the parts for 4 hours after the chromium plating as
follows :

(a) Parts which are not under fatigue.

STEELS R < 1450 mPa Case-Hardened Parts

Non-Case Hardened Parts
Degassing 3 hours at 365 to 374°F 5 hours at 275 to 293°F
(185 to 195°C) (135 to 145°C)
STEELS R ≥ 1450 mPa
Degassing 8 h at 365 to 374°F
(185 to 195°C) or
15 h at 275 to 293°F
(135 to 145°C)
if the hardness is damaged at
374°F (190°C)
NOTE: R = Breaking load of the base steel

Other Cast Iron Nickel Base and Copper Base and

Alloys Cobalt Base Aluminum Base
Degassing 3 h at 365 to 374°F 3 h at 365 to 374° 3 h at 293 to 311°F
(185 to 195°C) (185 to 195°C) (145 to 155°C)

(b) Parts that are under fatigue :

1 Parts which have had a shot-peening before the chromium plating: do a

degassing at 185 to 195°C (365 to 374°F) during 3 hours.

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2 Parts that can not be shot-peened: do a degassing at 824 to 860°F (440

to 460°C) during one hour.
3 If the part is not made in stainless steel: this treatment must be done in a
heat treatment furnace.

4 Grind the chromium plating to the necessary dimension.

5 Too much heating can cause a decrease in hardness or cracks.

(10) Do a visual inspection of the chromium plating.

(a) The chromium plating must have a smooth and bright surface with fine grain.

(b) The blisters, the holes, the burns or other defects are not permitted.

(c) A fine array of micro-cracks without cracking is correct.

(d) If necessary, remove the chromium plating from the defective parts.

(11) Measure the thickness of the chromium plating with:

(a) a magnetic measurement, if the base-metal is magnetic,

(b) an electrical measurement that uses the Eddy currents, if the base-metal is not
magnetic,

(c) an instrument that can give a micron.

(12) Do an adherence check as follows:

(a) An incorrect adherence gives a separation of the layer or a flaking during the
grind procedure.

(13) Do a hardness check:

(a) The Vickers hardness must be : HV ≥ 750 if the surface and the adherence are
correct.

SUBTASK 49-00-01-330-003
G. Instructions to remove the chromium plating

(1) Removal of the chromium plating by electrolytical procedure.

(a) The parts must have a seal protection before the removal of the chromium
plating.

(b) Removal of the chromium plating on the steels and on the cast iron.

1 Put the parts in the bath :

a Caustic soda: 100 to 150 g/l

b Sodium bisulphite: 2 g/l

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c Room temperature
d Current intensity 1.5 to 3 A/dm2 under 6 V

(c) Removal of the chromium plating on the stainless steels and the nickel or the
cobalt-based alloys.

1 Put the parts into the bath:

a Hydrochloric acid: 50 % volume

b Room temperature

(d) Removal of the chromium plating on aluminum and copper base alloys. APIC
Engineering must give its agreement for this procedure.

(e) Do a stress relief treatment before the subsequent chromium plating.

(f) Refer to paragraph E.

(2) The chromium plating can also be removed with a lathe or a grind machine.

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REPAIR 13

TASK 49-00-01-360-803
1. Bonding with Araldite Compound

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

AV138M In Europe
Araldite Comet
or 60304 Senlis Cedex
HV998 In North America
Compound Ciba-Geigy Corporation
7 Skyline Drive
N.Y. Hawthorne
Chlorinated Solvent Commercially Available
Isopropyl Alcohol Commercially Available
or
Acetone

(3) Expendable Parts

None

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SUBTASK 49-00-01-360-005
E. Repair
(1) Use the Araldite compound as follows:

(a) Clean the areas of the parts where the Araldite compound must be applied with
chlorinated solvent.

1 For the titanium parts, clean the areas of the parts where the Araldite
compound must be applied with isopropyl alcohol or acetone.

(b) Carefully mix the resin AV138M with the hardener HV998 in the quantities as
follows:

1 Resin AV138M: 100 parts

2 Hardener HV998: 40 parts

NOTE: This mixture can be used for 30 to 40 minutes at a temperature of

68°F (20°C).

(c) Apply this mixture in the thin layers on the two surfaces to be assembled.

(d) Put the two surfaces in contact and hold with a weight or a press.

(e) Remove the unwanted compound with a clean cloth soaked with solvent. Do this
operation while the compound is still soft.

(f) Characteristics

Hardening 8 h at 68°F (20°C)

(Duration/temperature) or
(Minimum durations) 6 h at 140°F (60°C)
or
15 min. at 176°F (80°C)
or
10 min. at 212°F (100°C)
Resistance to shearing 15 to 25 mPa
when stretched
(on steel at room temperature)
Limit temperature for use:
long period (see note) 248°F (120°C)
short period 302°F (150°C)
Rigidity of joint Semi-rigid
Electrical characteristic Insulator
Resistance to chemicals Excellent

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Recommended roughness Ra : 1.6 to 6.3 microns on the surfaces

to be assembled
Recommended radial clearance 0.03 to 0.1 mm
(0.0011 to 0.0039 inch)
Permitted radial clearances Approximately 0.2 mm (0.0078 inch)

NOTE: At this temperature, the mechanical resistance is approximately 50% of

its value at room temperature. Where there are no mechanical strains,
this Araldite compound can be used at the lightly higher temperatures.

(g) Cure date :

1 Araldite compound can be used for at least one year.

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REPAIR 14

TASK 49-00-01-310-801
1. Weld Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-230-801 Penetrant Inspection

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Tungsten-Inert Gas (TIG) Commercially Available
Consumable Metal-Inert-Gas (MIG) Commercially Available
Copper Heat Sinks Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Electrode Commercially Available

(3) Expendable Parts

None

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SUBTASK 49-00-01-310-001
E. Repair
NOTE: Do the weld repair on an individual basis.

NOTE: Welding is permitted in all the areas of the casting if:

(a) the area is visible,

(b) the area can be inspected and cleaned easily,

(c) there is no distortion,

(d) the dimensions stay in the specified limits,

(e) the dimensions can be re-machined to the specified limits.

(1) Remove the paint from the area to be repaired.

WARNING: DO NOT BREATHE THE GASES OF THE DE-GREASING SOLVENT. USE

THE DE-GREASING SOLVENT ONLY IN THE AREAS WHERE THE AIR IS
CONTINUOUSLY CHANGED. MAKE SURE THERE ARE NO SPARKS, NO
FLAMES AND NO HOT SURFACES IN THESE AREAS. IF THE DE-
GREASING SOLVENT TOUCHES YOUR EYES, FLUSH YOUR EYES
WITH WATER AND CALL A DOCTOR. IF THE DE-GREASING SOLVENT
TOUCHES YOUR SKIN, WASH YOUR SKIN WITH SOAP AND WATER.
THE DE-GREASING SOLVENT IS POISONOUS AND FLAMMABLE.

(2) Degrease the housing.

CAUTION: USE A CARBIDE CUTTER. REMOVE BASE METAL. STEEL OR ABRASIVE

CUTTERS WILL LEAVE RESIDUES IN THE WELD AND CAUSE WELD
INCLUSION.

(3) Machine the base metal from the cracked area and remove all the damaged metal.

NOTE: Remove the material in a form of a 90-degree included angle (V-groove).

(4) Do a penetrant inspection (Refer to Reference Information for the penetrant

inspection).

(5) Clean the housing.

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

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CAUTION: DO NOT USE TOO HIGH A TEMPERATURE WHEN YOU WELD. TOO
HIGH A TEMPERATURE CAN CAUSE DAMAGE TO THE HOUSING.
(6) Weld the part with the MIG or the TIG method:

(a) Use an electrode of two percent thoriated tungsten and filler rod material of the
same material as the base metal.

NOTE: The base material specification is cast on all the housings.

(b) Attach the copper heat sinks to the housing in the weld area or preheat the
housing between 350°F and 400°F (176.6°C and 204.4°C).

(c) Use the multiple pass method (10 seconds per pass recommended).

(d) Cool the housing and clean it with a stainless steel brush after each pass.

(7) Machine the weld area to agree with the original housing contour. Use a new housing
as a guide to repair the contour lines of the housing. Use a view template to help the
repair of the contour.

(8) Do a penetrant inspection (Refer to Reference Information for the penetrant

inspection).

(9) Radiographic inspection must be in accordance with the applicable standards. No

defects are permitted.

NOTE: If the weld is not correct, machine the weld material and do again the weld
procedure.

(10) Examine the bearing bores for size, roundness and location (see the housing repair
figures in the engine manual) if you weld at or near the bearing bores.

(11) Examine the mounting flange, the pilot diameter, the split line diameter or the adjacent
surface if you weld.

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REPAIR 15

TASK 49-00-01-350-804
1. Runout and Balance of the Engine Rotor

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Balance Machine Commercially Available
(SHENCK H20 or equivalent)
Balance Tool Commercially Available
Pencil Dye Grinder Commercially Available
Inine Extended Grinder Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

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Part No./Spec. No. Source (CAGE Code)

Aluminum Oxide (orange, white, pink, Modern Abrasive Corporation
grayish white), Spring Grove, IL 60081
Hard Fiber 80, B52 or W185 or W163 (815) 672-2352
(shape),
1/8 x 1-1/2 inch (shank diameter and length)
or equivalent
Carbide Cutter (rotary file) P/N H72.11060 Brasseler USA Dental
H251.11.070, H72G.11.070, H251GE. Instrumentation One Brasseler
11.060, H71.11.050, or equivalent Boulevard Savannah,
GA 31419
(800) 841-4522
Mx Laminated Abrasives Cratex Manufacturing Company
80-grit (A, B and W shapes) in soft bonds 328 Encinitas Blvd., Suite 200
(CXG), Encinitas, CA 92024-3723
regular cone, wide cone, or round cone, or (800) 800-4077 and (760) 942-2877
equivalent

(3) Expendable Parts

None

SUBTASK 49-00-01-350-005
E. Repair

(1) Assemble the engine rotor and install the balance tool on the engine rotor.

(2) Do a check of the runout on the engine rotor.

(3) Install the engine rotor on the balance machine.

(4) Set the balance machine.

The parameters are for this example:

(a) A = 20 mm (0.7874 inch)

(b) B = 5200 mm (204.7243 inch)

(c) C = 20 mm (0.7874 inch)

(d) Rotating speed : 1100 tr/min. (11100 rpm)

NOTE: Read the values on the planes A (or P1) and B (or P2).

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(5) Measure the unbalance value of the engine rotor on the two planes P1 and P2. Write
these values on the card below and call them P1-1 and P2-1.
(a) Do a check of the static unbalance at this stage (0° angular position), showed
by the resultant vector OM. (Refer to Figure 901). Write this value on the card
below.

Value P1-1 measured Value P2-1 measured Resultant vector OM

(6) Remove the rotor engine from the balance tool.

(7) Install the balance tool on the rotor engine at 180° of its last position.

(8) Measure the unbalance value of the engine rotor on the two planes P1 and P2. Write
these values and call them P1-2 and P2-2.

(a) Do a check of the static unbalance at this stage (180° angular position), showed
by the resultant vector ON. (Refer to Figure 901). Write this value on the card
below.

Value P1-2 measured Value P2-2 measured Resultant vector ON

(9) Calculate the balance of the engine rotor. (Refer to Figure 902).

(a) Calculate the value A. Write this value on the card below.

1 P1 : (P1 -1) / (P1 -2 / 2) A

2 The result (correct balance) is showed by the vector AC. Write this value
on the card below.

(b) Calculate the value B. Write this value on the card below.

1 P2 : (P1 -2) / (P2-2 / 2) B

2 The result (correct balance) is showed by the vector BD. Write this value
on the card below.

Value A Value B Vector AC Vector BD

(10) Compare the values of the unbalance calculated and measured. Make sure that:

(a) the unbalance is less than 2 cm.g (0.02777 oz. inch),

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(b) the static unbalance (vector 01) is less than 2.5 cm.g (0.0347 oz. inch).

(c) If the unbalance (vectors AC or BD) is more than 8 cm.g (0.1111 oz.in):
1 Disassemble the engine rotor

2 Examine each part

3 Balance each part

4 Do again the runout and the balance of the engine rotor.

(d) If the unbalance (vectors AC or BD) is between 2 cm.g (0.02777 oz. inch) and
8 cm.g (0.1111 oz. inch):

1 Turn each part of the engine rotor by an angle offset.

2 Do again the runout and the balance of the engine rotor.

(11) Do a "0" mark by electro-chemical etch on the aligned components near the reference
marks on the engine rotor. (Refer to Figure 903).

Static Unbalance of the Rotating Assembly

Figure 901

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Balance of the Rotating Assembly

Figure 902

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Unbalance of the Rotating Assembly

Figure 903

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REPAIR 16

TASK 49-00-01-350-805
1. Shank Nut Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-220-804 Check of the Self-Locking
Helical Inserts and the Self-
Locking Nuts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Arbor Press Commercially Available
Drill Press Commercially Available
Drill Bit, Commercially Available
0.235 to 0.239 inch
(5.97 to 6.07 mm)

(2) Consumable Materials

None

(3) Expendable Parts

Description Quantity
Nut shank As needed

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SUBTASK 49-00-01-350-006
E. Remove the damaged shank nuts as follows:
NOTE: As necessary, mask surrounding areas to prevent debris from falling into internal
cavities.

(1) Set up the item on drill press. Fixture the item such that no force from the drill will be
imparted locally to the item flange.

(2) Turn the part to provide access to the shank nut from the side of the nut that is flared.

(3) Drill out the flared portion of the nut shank with an appropriate size drill bit. The drill
bit should be large enough to thin the wall of the nut shank but do not touch the
diameter of the item hole. Use adequate backing to support the nut and item while
drilling.

(4) Close or break away any remaining nut shank material to remove nut. Discard the
nut.

(5) Visually inspect item hole to make sure no damage is present and hole is not
elongated. If necessary, remove any burrs or raised edges. If cracks are still visible
then discard the part from service.

SUBTASK 49-00-01-350-007
F. Install the shank nuts as follows:

CAUTION: FOR SELF-LOCKING SHANK NUTS, DO NOT THREAD SHANK FLARING

TOOL INTO THE SELF-LOCKING FEATURE OF THE NUT.

(1) Install shank nut into item assembly using the appropriate flaring tool, make sure that
the nut anti-rotation feature (if present) is properly seated against the item. (Refer to
Figure 901).

(2) Use tool and fixture (in accordance with the requirements), (Refer to Figure 902), and
a press, progressively apply loading a punch to 1,900 ±200 lb (861.8 ±90.7 kg). (Refer
to Figure 901).

SUBTASK 49-00-01-350-008
G. Inspect

(1) Shank should be flushed with or below the surface of the item.

NOTE: No cracks are allowed in the nut shank and shank shall be free of pit marks.

(2) If the shank nut has a self locking feature, visually inspect the threads for damage.
Do not use a threaded plug gauge to inspect the threads.

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Swaged Nut
Figure 901

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Tool Dimensions
Figure 902

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REPAIR 17

TASK 49-00-01-350-806
1. Anchor Nut Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Grinder Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

MIL-W-6858 Commercially Available
Class C Resistance Weld

(3) Expendable Parts

Description Quantity
Nut Anchor 1

SUBTASK 49-00-01-350-009
E. Remove the damaged anchor nuts as follows:

CAUTION: DO NOT OVERHEAT (AS OBSERVED BY METAL DISCOLORATION)

BASE FLANGE MATERIAL.

(1) Remove the captured nut by grinding through the resistance weld.

(2) Hand finish to remove any of the remaining weld.

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SUBTASK 49-00-01-350-010
F. Install the anchor nuts as follows:
(1) Install the anchor nuts by resistance weld. Pull test specimens must exceed 500 lb
(227 kg).

NOTE: The nut retaining plate must not interfere with fillet radius. The nut retaining
plate may be repositioned within the free play limits.

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REPAIR 18

TASK 49-00-01-350-807
1. Installation of the Oversized Threaded Inserts in the Reduction Drive Assemblies

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-801 Replacement of the
Threaded Inserts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Threaded Insert Removal/Installation Helicoil Products
Tools Div. of Mite Corp.
Shelter Rock Lane
Danbury, CT 06810
Twinsert Tap 3893-3 Helicoil Products
Div. of Mite Corp.
Shelter Rock Lane
Danbury, CT 06810
Pliers Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

MIL-C-5541 Anchem Products, Inc.
Grade 1A Anodic Coating, Alodine 1200 Ambler, PA 19002
MIL-M-3171 Commercially Available
Type VI Chromic Acid Brush on Solution

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Part No./Spec. No. Source (CAGE Code)

MIL-P-23377 Commercially Available
Class 1 or 2 Primer, Insert
Loctite 620 Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-350-011
E. Remove the damaged threaded insert(s) (Refer to Reference Information for the
replacement of the threaded inserts).

NOTE: These procedures are applicable to Sundstrand products with damaged screw
thread insert holes.

NOTE: Each pack contains the quantity of Twinserts indicated, an oversize bottoming tap,
an outer insert installation tool, and a tang break-off tool for the larger outer
insert, (Refer to Figure 901) and (Refer to Figure 902). Packs are available for 1
1/2 diameter or 2 diameter lengths of inserts. For individual parts, (Refer to Figure
903).

(1) If holes are severely damaged and the threads cannot be re-tapped, re-drill the holes
to a minor diameter dimension given to the original depth, (Refer to Figure 904) and
(Refer to Figure 905).

(2) Tap the hole, using the bottoming tap furnished in the pack, to the original depth.

(3) Remove any burrs from the bore.

WARNING: KEEP PRESSURE AT 29 POUNDS PER SQUARE INCH (200 KPA) OR

LESS WHEN YOU USE COMPRESSED AIR. PUT ON GOGGLES OR FACE
SHIELD TO PROTECT YOUR EYES.

(4) Use compressed air to remove any foreign material from the bore.

(5) Touch up the repaired holes with Alodine 1200 anodic coating.

(6) Install the outer insert 1/4 to 1/2 turn below top surface with the installation tool
furnished in the pack.

(7) Break off the driving tang with the tang break-off tool furnished in the pack.

(8) Install the inner insert to the position where its end is flush with the outer insert.

(9) Remove the tang with pliers. The assembled inner insert will provide a Class 2B fit.

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SUBTASK 49-00-01-350-012
F. Installation of Oversized Inserts in Magnesium Housings
(1) Remove the damaged threaded insert(s) (Refer to Reference Information for the
replacement of the threaded inserts).

NOTE: Each pack contains the quantity of twinserts indicated, an oversized bottom
tap, an outer insert installation tool, and a tang break-off tool for the larger
outer insert, (Refer to Figure 901) and (Refer to Figure 902). Packs are
available for 1 ½ diameter or 2 diameter lengths of inserts. For individual
parts, (Refer to Figure 903)

(2) If the holes are severely damaged and the threads cannot be re-tapped, re-drill the
holes to a minor diameter given to the original depth, (Refer to Figure 904) and (Refer
to Figure 905).

(3) Tap the hole, using the bottoming tap furnished in the pack, to the original depth.

(4) Clean the drilled/tapped area to remove the oil and all of the contamination.

(5) Wipe the drilled/tapped, and any of the exposed area with the chromic acid brush on
solution, for one to three minutes.

CAUTION: DO NOT FLOOD THE AREA. SOLUTION SHOULD NOT TOUCH STEEL
PARTS.

(6) Wipe the area with a damp cloth to remove all of the residual chromic acid brush on
solution.

NOTE: Key locked inserts per MS51830-202 (I.D. thread = 0.250-28 and O.D. thread
= 0.375-16 UNC-2A) may be used to restore damaged gearbox mounting
boss threads, instead of oversize helicoils. Install with Loctite 620 (and Primer
T or N) after drilling out previously installed inserts, and tapping to 3/8-16
threads. Remove unwanted Loctite 620 with cotton swab.

NOTE: Key locked inserts per MS51830-203 (I.D. thread = 0.3125-24 and O.D.
thread = 0.4375-14 UNC-2A) may be used to restore damaged lifting eye
hold threads. Install with Loctite 620 (and Primer T or N) after drilling out
damaged hole (and/or previously installed insert), and tapping to 0.4375-14
threads. Remove unwanted Loctite 620 with cotton swab.

(7) Oven or hot air dry.

(a) Install the outer insert ¼ to ½ turn below the top surface with the installation tool
furnished in the pack.

(b) Break off the driving tang with the tang break-off tool furnished in the pack.

(c) Install the inner insert to the position where its end is flush with the outer
insert, (Refer to Figure 906).

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(d) Remove the tang with pliers. The assembled inner insert will provide a Class 2B
fit.

1 1/2 Diameter Twinsert Packs

Figure 901

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2 Diameter Twinsert Packs

Figure 902

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Available Sizes and Part Numbers for Twinserts and Tools That May Be Purchased Separately
Figure 903

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Twinsert Coarse Series Tapped Hole Dimensions (Class 2B)

Figure 904

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Twinsert Fine Series Tapped Hole Dimensions (Class 2B)

Figure 905

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Installation of Inner Insert

Figure 906

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REPAIR 19

TASK 49-00-01-350-808
1. Installation of the Oversized Threaded Inserts

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-801 Replacement of the
Threaded Inserts
HSPS 490001 Task 49-00-01-350-807 Installation of the Oversized
Threaded Inserts in the
Reduction Drive Assemblies

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Threaded Insert Removal/Installation Helicoil Products
Tools Div. of Mite Corp.
Shelter Rock Lane
Danbury, CT 06810
Oversize Bottoming Tap Helicoil Products
Div. of Mite Corp.
Shelter Rock Lane
Danbury, CT 06810
Pliers Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

REPAIR 19
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Part No./Spec. No. Source (CAGE Code)

MIL-C-5541 Anchem Products, Inc.
Type 1A Anodic Coating, Alodine 1200 Ambler, PA 19002
Loctite 620, Loctite Corporation
Grade N or T Newington, CT 06111
Cotton Swab Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-350-013
E. Repair

NOTE: These procedures are applicable to Sundstrand products with damaged screw
thread insert holes.

(1) Remove the damaged threaded insert(s) (Refer to Reference Information for the
replacement of the threaded inserts).

NOTE: Each pack contains the quantity of inserts indicated in the Figure 901 and a
special oversize bottoming tap. The inserts, whether standard or screw lock
are 1 1/2 diameters long. For identification, the oversize inserts are color-
coded: The tang and bottom coil are dyed yellow.

(2) Retap the damaged hole using the special oversize bottoming tap furnished in the
pack. (Refer to Table 901) and (Refer to Table 902).

(3) Remove any burrs from the bore.

WARNING: KEEP PRESSURE AT 29 POUNDS PER SQUARE INCH (200 KPA) OR

LESS WHEN YOU USE COMPRESSED AIR. PUT ON GOGGLES OR FACE
SHIELD TO PROTECT YOUR EYES.

(4) Use the compressed air to remove any foreign material from the bore.

(5) Touch up the repaired holes with the Alodine 1200 anodic coating.

(6) Install the insert to the proper depth (3/4 to 1 1/2 turns below top surface).

(7) Check the class of fit of the assembled insert.

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(8) If the assembly is still oversize, use a Twinsert (Refer to Reference Information for
the installation of the oversized threaded inserts in the reduction drive assemblies).
NOTE: Key locked inserts per MS51830-202 (I.D. thread = 0.250-28 and O.D. thread
= 0.375-16 UNC-2A) may be used to restore damaged gearbox mounting
boss threads, instead of oversize helicoils. Install with Loctite 620 (and Primer
T or N) after drilling out previously installed inserts, and tapping to 3/8-16
threads. Remove excess Loctite 620 with cotton swab.

NOTE: Key locked inserts per MS51830-203 (I.D. thread = 0.3125-24 and O.D.
thread = 0.4375-14 UNC-2A) may be used to restore damaged lifting eye
hold threads. Install with Loctite 620 (and Primer T or N) after drilling out
damaged hole (and/or previously installed insert), and tapping to 0.4375-14
threads. Remove excess Loctite 620 with cotton swab.

(9) When the assembly is satisfactory, remove the tang with the pliers.

(10) Inspect the threaded insert(s) according to INSPECTION/CHECK 06, (Refer to TASK
49-00-01-220-804, Inspection of the Self-Locking Helical Coil Inserts and the Self-
Locking Nuts).

Table 901
Available Sizes and Part Numbers for Oversize Threaded Insert Packs

PACK PART NUMBER

Effective
With Screw- Correctio
Lock Quantity n
NOMINAL With Standard Inserts Nominal of to
THREAD Inserts (Internal- Length * Inserts Oversize
SIZE (Free-running) lock) (1 1/2 dia.) per pack Hole
UNIFIED COARSE
2-56 3167-02 3171-02 .129 25 .0028
4-40 3167-04 3171-04 .168 25 .0034
5-40 3167-05 3171-05 .188 25 .0034
6-32 3167-06 3171-06 .207 25 .0040
8-32 3167-2 3171-2 .246 25 .0040
10-24 3167-3 3171-3 .285 25 .0050
12-24 3167-1 3171-1 .324 25 .0050
1/4-20 3167-4 3171-4 .375 25 .0060
5/16-18 3167-5 3171-5 .469 20 .0060
3/8-16 3167-6 3171-6 .562 15 .0066

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SPM

PACK PART NUMBER

Effective
With Screw- Correctio
Lock Quantity n
NOMINAL With Standard Inserts Nominal of to
THREAD Inserts (Internal- Length * Inserts Oversize
SIZE (Free-running) lock) (1 1/2 dia.) per pack Hole
7/16-14 3167-7 3171-7 .656 10 .0074
1/2-13 3167-8 3171-8 .750 10 .0056
UNIFIED FINE
6-40 3169-06 3173-06 .207 25 .0034
10-32 3169-3 3173-3 .285 25 .0040
1/4-28 3169-4 3173-4 .375 25 .0042
5/16-24 3169-5 3173-5 .469 20 .0050
3/8-24 3169-6 3173-6 .562 15 .0050
7/16 3169-7 3173-7 .656 10 .0060
1/2-20 3169-8 3173-8 .750 10 .0060
* 2 diameter length inserts are available. Refer to Figure 902.

Table 902
Available Sizes and Part Numbers for Inserts and Tools That May Be Purchased
Separately

INSERT PART
NUMBER Nominal Length **
Screw- Effective
Standard Lock Oversize Correction
NOMINAL Insert Insert Bottoming to
THREAD (Free- (Internal- 1 1/2 Tap Oversize
SIZE + running) lock) dia. 2 dia. Part No. Hole
UNIFIED COARSE
2-56 8185-02CN 3885-02C .129 .172 56187-02- .0028
N 2
4-40 8185-04CN 3885-04C .168 .224 56187-04- .0034
N 2

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INSERT PART
NUMBER Nominal Length **
Screw- Effective
Standard Lock Oversize Correction
NOMINAL Insert Insert Bottoming to
THREAD (Free- (Internal- 1 1/2 Tap Oversize
SIZE + running) lock) dia. 2 dia. Part No. Hole
5-40 8185-05CN 3885-05C .188 .250 56187-05- .0034
N 2
6-32 8185-06CN 3885-06C .207 .276 56187-06- .0040
N 2
8-32 8185-2CN 3885-2CN .246 .328 56187-2-2 .0040
10-24 8185-3CN 3885-3CN .285 .380 56187-3-2 .0050
12-24 8185-1CN 3885-1CN .324 .432 56187-1-2 .0050
1/4-20 8185-4CN 3885-4CN .375 .500 56187-4-2 .0060
5/16-18 8185-5CN 3885-5CN .469 .625 56187-5-2 .0060
3/8-16 8185-6CN 3885-6CN .562 .750 56187-6-2 .0066
7/16-14 8185-7CN 3885-7CN .656 .875 56187-7-2 .0074
1/2-13 8185-8CN 3885-8CN .750 1.000 56187-8-2 .0056
UNIFIED FINE
6-40 8191-06CN 3891-06C .207 .276 56193-06- .0034
N 2
10-32 8191-3CN 3891-3CN .285 .380 56193-3-2 .0040
1/4-28 8191-4CN 3891-4CN .375 .500 56193-4-2 .0042
5/16-24 8191-5CN 3891-5CN .469 .625 56193-5-2 .0050
3/8-24 8191-6CN 3891-6CN .562 .750 56193-6-2 .0050
7/16-20 8191-7CN 3891-7CN .656 .875 56193-7-2 .0060
1/2-20 8191-8CN 3891-8CN .750 1.000 56193-8-2 .0060
**When ordering, include the length of the Insert as a suffix to the part number.
Example: 8185- 4CN 0375.
+ Other sizes and lengths are available on special order.

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REPAIR 20

TASK 49-00-01-350-809
1. Replacement of the Oil (Lee™) Jets and Oil (Lee™) Plugs

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

A00921 Hamilton Sundstrand
(for APS2000/2100 APU only) 4400 Ruffin Road
P.O. Box 85757
San Diego, CA 92186-5757
(55820)
A00931 Hamilton Sundstrand
(for APS3200 APU only) 4400 Ruffin Road
P.O. Box 85757
San Diego, CA 92186-5757
(55820)
Slide Hammer Commercially Available
MS9556-28, Commercially Available
Bolt
Arbor Press Commercially Available
Heat Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

REPAIR 20
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Part No./Spec. No. Source (CAGE Code)

ASTM D329, Commercially Available
Acetone
ASTM D770, Commercially Available
Isopropyl Alcohol

(3) Expendable Parts

Nomenclature Quantity
Oil (Lee™) Plug As needed
Oil (Lee™) Jet As needed

SUBTASK 49-00-01-350-014
E. Remove oil (Lee™) jets and (Lee™) plugs as follows:

(1) If required, drill and tap both the cap and cone for corresponding thread size of
appropriate removal tool.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(2) Using heat gun, heat the material around the cone and cap as required to facilitate
removal.

(3) Thread the appropriate tool or bolt into the cone only.

(4) Using appropriate tool or slide hammer, remove the cone.

(5) Repeat steps (3) and (4) above to remove the cap.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

REPAIR 20
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WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(6) If repaired part is a gearbox assembly, clean the gearbox assembly by power flushing,
as required. Do a boroscope inspection to make sure that all cores and passages are
clear. Otherwise, flush with acetone or isopropyl alcohol until no debris or sediment
remains.

SUBTASK 49-00-01-350-015
F. Install new oil (Lee™) jets and (Lee™) plugs as follows:

(1) Install the cap to full depth.

(2) Using arbor press, install the cone into the cap to within ± 0.005 inch (± 0.127 mm) of
flush with the rim of the cap.

(3) Inspect the cone and cap for appropriate installation depths.

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REPAIR 21

TASK 49-00-01-360-804
1. Repair of the Silicone Fire Sleeved Hose Assemblies

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Electrical Heat Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

ASTM D329, Commercially Available
Acetone
ASTM D770, Commercially Available
Isopropyl Alcohol
RTV 116 Commercially Available
Silicone Sealant
EP4227 Hamilton Sundstrand
Uncured Silicone Strip 4400 Ruffin Road
P.O. Box 85757
San Diego, CA 92186-5757
(55820)
Lint-Free Cloth Commercially Available
Rubber Gloves Commercially Available

(3) Expendable Parts

REPAIR 21
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None
NOTE: These repairs are intended as temporary, in-service repairs to allow
continued APU operation for as long as possible without sacrificing regulatory
requirements. It is recommended that damaged or repaired fire sleeving be
replaced whenever practical.

NOTE: If there is any damage to the wire reinforcement located under the silicone
cover, the assembly is not repairable and must be replaced.

SUBTASK 49-00-01-360-006
E. Repair small cut [less than 0.5 inch (12.7 mm) in length] in the silicon cover as follows:

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(1) Clean the area of the cut with acetone or isopropyl alcohol to remove all traces of dirt,
oil, and foreign matter.

(2) Fill the cut as follows:

(a) Fill cuts with RTV 116 silicone sealant until the sealant is flush with the outside
diameter of the silicone hose.

(3) Allow the RTV 116 silicone sealant to cure for 24 hours minimum.

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CAUTION: THE HOSE ASSEMBLY OR FUEL MANIFOLD ASSEMBLY MUST BE

INSTALLED SO THAT THE RTV 116 PATCH IS LOCATED ON A STRAIGHT
PART OF THE ASSEMBLY OR LOCATED ON THE INSIDE DIAMETER OF
A BEND. ADJUST THE HOSE OR FUEL MANIFOLD ASSEMBLIES SO
THAT THE PATCH IS LOCATED ON THE INSIDE RADIUS OF THE BEND.
DO NOT INSTALL THE FUEL MANIFOLD OR HOSE ASSEMBLIES WITH
THE RTV 116 PATCH ON THE OUTSIDE RADIUS OF A BEND. IF THE
PATCH HAS TO BE ON THE OUTSIDE OF A BEND, REPAIR IN
ACCORDANCE WITH STEP F.

(4) Inspect the repair for a good bond by bending the hose or fuel manifold assembly at
the repair. The RTV 116 must not separate from the silicone cover. If the RTV 116
separates from the cover, the repair procedure must be repeated or repaired in
accordance with step F. Discard the hose or fuel manifold assembly if proper bonding
cannot be obtained.

SUBTASK 49-00-01-360-007
F. Repair of cut or torn covers [less than 0.75 inch (19.5 mm)] as follows:

NOTE: EP4227 uncured silicone strip will not bond if surface is contaminated.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(1) Clean the damaged area of the hose with acetone or isopropyl alcohol. Apply acetone
or isopropyl alcohol to a clean, lint-free cloth and wipe the surrounding area of the
hose thoroughly. Remove all traces of any type of dirt, oil, or foreign matter. Clean
both the inside and outside areas of the hose.

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(2) Fill the cut or tear as follows:

(a) Full cuts or tears with RTV 116 silicone sealant until the sealant is flush with the
outside diameter of the silicone hose.

(b) Make sure that all areas of the cut or tear are completely filled and there are no
air pockets present in the fill.

(3) Allow the RTV 116 silicone sealant to cure for 24 hours minimum.

(4) Once the RTV 116 silicone sealant is fully cured, cover the repair area with an EP4227
uncured silicone strip as follows:

(a) Measure the distance of the damaged section and cut a strip of the EP4227
uncured silicone strip to length.

(b) Remove the protective sleeve from the EP4227 uncured silicone strip and make
sure that clean, uncontaminated rubber gloves are worn.

(c) Wrap the EP4227 uncured silicone strip around the damaged area once over.
Leave a smooth finish by sliding your thumb over the area with some force.

(5) Smooth the surface of the hose over to leave a tidy finish.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(6) Cure the repaired area with the electrical heat gun at a temperature of 392 ± 41° F
(200 ± 5° C) for a period of 10 minutes.

(7) After 10 minutes, let the repaired area to cool for about 45 minutes.

(8) Inspect the repair for a good bond by bending the hose or fuel manifold assembly at
the repair. The EP4227 uncured silicone strip must not separate from the silicone
cover. If the strip separates from the cover, repeat the repair. Discard the hose or fuel
manifold assembly if proper bonding cannot be achieved.

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SUBTASK 49-00-01-360-008
G. Repair of cut, torn, or gouged covers [greater than 0.75 inch (19.5 mm)] as follows:
NOTE: EP4227 uncured silicone strip will not bond if surface is contaminated.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(1) Clean the damaged area of the hose with acetone or isopropyl alcohol. Apply acetone
or isopropyl alcohol to a clean, lint-free cloth and wipe the surrounding area of the
hose thoroughly. Remove all traces of any type of dirt, oil, or foreign matter. Clean
both the inside and outside areas of the hose.

(2) Measure the distance of the damaged section and cut a strip of the EP4227 uncured
silicone strip to length.

(3) Remove the protective sleeve from the EP4227 uncured silicone strip and make sure
that clean, uncontaminated rubber gloves are worn.

(4) Place the EP4227 uncured silicone strip over the damaged area and pack into the
section. Push the EP4227 uncured silicone strip into the split and make sure that all
areas of the braid are covered.

(5) Make sure that no air gaps are present once whole area is filled. Squeeze the hose
around the damaged area and check for air gaps. If the area feels “spongy” then apply
more EP4227 uncured silicone strip to the split.

(6) Make sure the whole area is filled and the surrounding area of the damaged section
is tightly packed. Leave a smooth finish by sliding your thumb over the area with some
force.

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(7) Smooth the surface of the hose over to leave a tidy finish.
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(8) Cure the repaired area with the electrical heat gun at a temperature of 392 ±41°F (200
±5°C) for a period of 10 minutes.

(9) After 10 minutes, let the repaired area to cool for about 45 minutes.

(10) Inspect the repair for a good bond by bending the hose or fuel manifold assembly at
the repair. The EP4227 uncured silicone strip must not separate from the silicone
cover. If the strip separates from the cover, repeat the repair.

(11) Make sure that no air gaps are present once the repair is cured. Squeeze the hose
around the damaged area and check for air gaps. If the area feels “spongy” then air
has expanded during the curing process and has formed an air gap. If an air gap has
been formed, repeat the repair.

(12) Discard the hose or fuel manifold assembly if proper bonding cannot be achieved.

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REPAIR 22

TASK 49-00-01-350-814
1. Removal and Installation of the Cherrylock Rivets

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Drilling Equipment Commercially Available
Riveting Equipment Commercially Available
Tooling Equipment (NOTE) Commercially Available
Tapered Steel Drift Commercially Available
Drift Pin Commercially Available
NOTE: Tooling equipment for pulling head necessary to install rivet diameter: A
quick reference to select the correct pulling head for a specific rivet size for
the cherry hydro-shaft riveter. (Refer to Table 901).

Table 901
Selecting Pulling Head

Rivet Diameter Pulling Head Number

1/8 inch (3.175 mm) H681-4U Universal Head
H681-4C Countersunk Head
H681-B166-4 Uni-Sink Head
5/32 inch (3.969 mm) H681-5U Universal Head
H681-5C Countersunk Head
H681-B166-5 Uni-Sink Head

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Rivet Diameter Pulling Head Number

3/16 inch (4.762 mm) H681-6U Universal Head
H681-6C Countersunk Head
H681-B166-6 Uni-Sink Head
1/4 inch (6.35 mm) H681-8U Universal Head
H681-8C Countersunk Head

(2) Consumable Materials

None

(3) Spare Parts

Cherrylock Rivets that conform to:

NAS 1398 Blind Rivet
(Protruding Head Locked Spindle)
NAS 1399 Blind Rivet
(Flush Head Locked Spindle)

SUBTASK 49-00-01-350-016
E. Remove the rivets as follows:

NOTE: The rivets described and/or used in this repair are primarily used in structural
applications where blind riveting must be employed.

(1) To drill out rivet stem, use a tapered steel drift in thick materials. For thin materials,
use a small center drill to provide a guide hole for larger drill to remove stem.

(2) Pry the locking collar out of the rivet head with drift pin.

(3) Drill nearly through the head of the rivet using a drill recommended for drilling
installation hole. (Refer to Table 902).

Table 902
Drilling Installation Hole (NOTE)

Rivet Diameter Recommended Hole Size

Nominal, in (mm) Drill Size
Minimum, in (mm) Maximum, in (mm)
3/32 (2.381 mm) #40 0.098 (2.49) 0.101 (2.56)
1/8 (3.175 mm) #30 0.129 (3.28) 0.132 (3.35)
5/32 (3.969 mm) #20 0.160 (4.06) 0.164 (4.16)

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3/16 (4.762 mm) #10 0.192 (4.88) 0.196 (4.98)

1/4 (6.32 mm) F 0.256 (6.50) 0.261 (6.63)

NOTE: The hole sizes must be used to receive these rivets. Hole sizes listed are
used to ensure proper rivet performance and reliability.

(4) Break off the rivet head using drift pin as a pry.

(5) Drive out the remainder of the rivet with a pin having the same diameter as the rivet
shank.

SUBTASK 49-00-01-350-017
F. Install the rivets as follows:

NOTE: The rivets described and/or used in this repair are primarily used in structural
applications where blind riveting must be employed.

(1) Check the total thickness of the part to be riveted. Make sure that the cherrylock rivets
have their grip length (maximum grip) marked on the rivet head. For grip range that
corresponds to the grip number on the head. (Refer to Table 903). Make sure that the
rivet selected has the proper grip length for the material thickness being riveted.

(2) Check to hole sizes (refer to step E.(3)). (Refer to Table 902).

(3) Check the countersink diameter. The countersink diameter must be as specified. The
countersink pilot should be no more that 0.001 inch (0.03 mm) smaller than the hole
diameter to produce the desired concentricity between the countersink and hole.

(4) Place the rivet into the hole. (Refer to Figure 901). Do not force the rivet into the hole.
If forcing is necessary, the hole size or hole alignment is incorrect and should be
corrected before continuing. This pertains to both flush and universal head rivets.

Table 903
Grip Range

Material Thickness Range Rivet Grip No.

Minimum Maximum
- 1/16 inch (1.587 mm) 1
- 1/8 inch (3.175 mm) 2
1/8 inch (3.175 mm) 3/16 inch (4.762 mm) 3
3/16 inch (4.762 mm) 1/4 inch (6.35 mm) 4
1/4 inch (6.35 mm) 5/16 inch (7.938 mm) 5
5/16 inch (7.938 mm) 3/8 inch (9.525 mm) 6

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3/8 inch (9.525 mm) 7/16 inch (11.112 mm) 7

7/16 inch (11.112 mm) 1/2 inch (12.7 mm) 8
1/2 inch (12.7 mm) 9/16 inch (14.287 mm) 9
9/16 inch (14.287 mm) 5/8 inch (15.875 mm) 10
5/8 inch (15.875 mm) 11/16 inch (17.462 mm) 11
11/16 inch (17.462 mm) 3/4 inch (19.05 mm) 12
3/4 inch (19.05 mm) 13/16 inch (20.637 mm) 13
13/16 inch (20.637 mm) 7/8 inch (22.225 mm) 14
7/8 inch (22.225 mm) 15/16 inch (23.812 mm) 15
15/16 inch (23.812 mm) 1 inch (25.4 mm) 16

(5) Check the universal head seating. When riveting the flat surfaces together, a 0.002
inch (0.05 mm) shim must be used to check if visible head has seated properly.
Position the shim as shown in the figure and, if it can be slid freely under the head far
enough to contact the shank of the rivet, the rivet must be considered improperly
installed and be replaced.(Refer to Figure 902). When the riveting tubular parts
together, the above inspection must be made along the axis of the tube, and not at
right angles to the tube axis.

(6) Inspect the tube axis at right angles. Make sure that the difference between the gaps
on opposite sides of the rivet head must not exceed 0.010 inch (0.25 mm).

(7) Check the flush head seating. When the riveting is either flat or tubular parts are
together, the rivet head must be flush or below the surface. The amount of recess into
the surface must be as shown on the engineering drawing.

(8) When the riveting is either flat or tubular parts, gap or head cocking is allowed. (Refer
to Figure 903).

(9) Check the stem and collar protrusion. The rivet stem and collar must be flush within
the limits. (Refer to Figure 904). This pertains to both flush and universal head rivets.
All dimensions involving the rivet stem should be referenced from the edge of the
break notch groove, at stem O.D. regardless of fracture surface indentation or
protrusion at stem center. (Refer to Figure 905).

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Placing Rivet into Hole

Figure 901

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Positioning Shim
Figure 902

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Gap or Head Cocking

Figure 903

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Rivet Stem and Collar Protrusion Limits

Figure 904

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Installation
Figure 905

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REPAIR 24

TASK 49-00-01-360-805
1. Standard Fiberglass Composite Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Autoclave/Curing Oven Commercially Available
Composite Fabrication Tools Commercially Available
Vacuum Bag Forming Tools Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol
Lint-Free Cloth Commercially Available
Abrasive Cloth, 180 and 320 Grit Commercially Available
MIL-C-9084, Class 4, Type VII VIIA, or Commercially Available
VIIIB
Fiberglass Cloth
EA 956 (MIL-R-9299) Commercially Available
Phenolic Resin,
Parting Film (porous and non-porous) Commercially Available
Bleeder Cloth and Breather Cloth Commercially Available

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Part No./Spec. No. Source (CAGE Code)

Abrasive Disc Commercially Available
EA9394 - MS34.50-01-02 Commercially Available
Hysol
EA956 Commercially Available
Hysol

(3) Expendable Parts

None

SUBTASK 49-00-01-360-009
E. Repair

(1) Sand the damaged area and 2.5 to 3.0 inches (63.5 to 76.2 mm) of the adjacent
surface with abrasive cloth (180 grit), followed with abrasive cloth (320 grit).

WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN EYE INJURY, GET MEDICAL ATTENTION.

(2) Use compressed air to blow off dust.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(3) Clean the sanded surface with isopropyl alcohol and dry with lint-free cloth. Clean the
area again with isopropyl alcohol and a lint-free cloth.

(4) Cut two plies of fiberglass cloth to the same size as the sanded area. Make sure the
orientation of the lay is +/-90 degrees.

(5) Impregnate the fiberglass with phenolic resin EA 956.

(6) Lay the plies of impregnated material over the sanded area.

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(7) Cover the area with porous parting film, bleeder cloth, a non-porous parting film
(release cloth), and a breather cloth. Place the part in a vacuum bag, insert vacuum
port, and seal with tacky tape.
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(8) Draw vacuum from the bag to a minimum of 22 in. (558.8 mm) of mercury, and place
the part into an oven or autoclave as per manufacturer instructions.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(9) Remove the part from the oven (or autoclave), and remove the bag and the bleeder
cloth.

(10) Optional step coat the dust using Hysol EA956.

(11) Do a visual inspection of the repaired area.

SUBTASK 49-00-01-360-010
F. Localized Damage

(1) Repair the localized damage not penetrating through the part and less than 0.05 inch
(1.27 mm) in diameter, as follows:

WARNING: ADHESIVE, DEXTER HYSOL EA 9394, IS TOXIC. USE IN WELL

VENTILATED AREA. PREVENT EYE AND SKIN CONTACT AND DO
NOT BREATHE VAPORS. IN CASE OF EYE CONTACT, FLUSH WITH
WATER FOR 15 MINUTES AND SEEK MEDICAL ATTENTION. IN
CASE OF SKIN CONTACT, WASH WITH SOAP AND WATER.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

(a) Apply Dexter Hysol EA 9394 adhesive locally over the damaged area and allow
to dry as per manufacturer instructions.

(b) Do a visual inspection of the repaired area.

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REPAIR 25

TASK 49-00-01-360-806
1. Fiberglass Composite Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-360-011
E. Repair

(1) (Refer to TASK 49-00-01-360-805, Standard Fiberglass Composite Repair).

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REPAIR 26

TASK 49-00-01-360-807
1. Fiberglass Composite Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-360-012
E. Repair

(1) (Refer to TASK 49-00-01-360-805, Standard Fiberglass Composite Repair).

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REPAIR 27

TASK 49-00-01-360-808
1. Fiberglass Composite Repair

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

None

(3) Expendable Parts

None

SUBTASK 49-00-01-360-013
E. Repair

(1) (Refer to TASK 49-00-01-360-805, Standard Fiberglass Composite Repair).

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REPAIR 29

TASK 49-00-01-350-810
1. Replacement of the Damaged Connector Pins

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

M81969/14-02 Commercially Available
Insertion/Removal Tool (20 AWG)
M81969/14-03 Commercially Available
Insertion/Removal Tool (16 AWG)
M22520/1-01 Commercially Available
Crimper (12 to 20 AWG)
M22520/2-01 Commercially Available
Crimper (20 to 28 AWG)
M22520/1-02 Commercially Available
Standard Positioner (12 to 20 AWG)
M22520/2-02 Commercially Available
Standard Positioner (20 to 28 AWG)
Thermal Stripper Commercially Available
or
Precision-Type (Calibrated) Cutting
Stripper

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Part No./Spec. No. Source (CAGE Code)

BT-ST-751 Daniels Manufacturing
Torque Wrench Corporation
(11851)
BT-BS-609 Daniels Manufacturing
Strap Wrench Corporation
(11851)

NOTE: Some pins and sockets require special positioners that may not be tabulated.
Refer to applicable documentation for part numbers.

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

M22759/8-XX-9 Commercially Available
Electrical Wire (XX=Wire size in AWG)
MIL-I-23594 Commercially Available
Type I, CL 1, 1 inch
or
MIL-I-23594
Type II, CL 2, 1 inch, Insulation Tape
M39029 Commercially Available
Pins and Sockets (Refer to CMM for part
number)
MS20995C20 Commercially Available
Lockwire
MS51496P68 Commercially Available
Washer

(3) Expendable Parts

None

SUBTASK 49-00-01-350-018
E. Replace the harness assembly pins as follows:

(1) Gain access to the pins by removing the connector plug strain relief (refer to the
applicable CMM, DISASSEMBLY).

(a) Remove the lockwire from the strain relief screws, if present.

(b) Loosen the harness connector plug strain relief screws and disengage the strain
relief clamp. (Refer to Figure 901).

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(c) Loosen the harness connector plug strain relief coupling nut and move it to a
position away from the connector plug.
(d) Remove any insulation tape, if present.

(2) Remove the damaged pin with an insertion/removal tool. (Refer to Figure 902).

(3) Cut the pin from the wire at the base of the pin so that no bare wire protrudes past the
insulation.

(4) Remove a 0.25 inch (6.35 mm) of insulation from the wire.

NOTE: If the wire is too short to reach the connector, replace the entire length of
wire.

(5) Insert the wire in the replacement pin and crimp using a crimper and positioner.

(6) Install the replacement pin using an insertion/removal tool. (Refer to Figure 903).

(7) Reinstall the strain relief (refer to the applicable CMM, ASSEMBLY).

(a) Verify the correct clocking of the connector and assemble the strain relief onto
the connector plug.

(b) Torque the strain relief coupling nut onto the back of the connector.

NOTE: Use torque wrench and strap wrench to torque the plug and strain relief
nuts. Torque the strain relief accordingly, (Refer to Table 901).

NOTE: Do not allow the insulation tape length to exceed 1.0 inch (25.4 mm)
past the strain relief clamp.

(c) If necessary, use insulation tape to increase the wire bundle diameter at the
strain relief for a snug fit of the clamp.

(d) Install the washers on the strain relief screws between the backshell and clamp,
as required, to adjust the clamping force for a snug fit.

(e) Torque the strain relief screws to 5 to 7 pound-inches (0.56 to 0.79 N•m).

(f) Lockwire the strain relief screws, if applicable. (Refer to Figure 904) and (Refer
to Figure 905).

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Table 901
Strain Relief Torque Values

SHELL SIZE TORQUE LB-IN (N•M)

8/9 50 - 60 (5.6 - 6.8)
10/11 70 - 80 (7.9 - 9.5)
12 90 - 100 (10.2 - 11.3)
16 110 - 120 (12.4 - 13.6)
21 130 - 140 (14.7 - 15.8)
22/23 130 - 140 (14.7 - 15.8)

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Typical Connectors
Figure 901

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Pin Removal
Figure 902

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Pin Installation
Figure 903

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Lockwire Installation on Straight Strain Reliefs

Figure 904

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Lockwire Installation on 90-Degree Strain Reliefs

Figure 905

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REPAIR 30

TASK 49-00-01-350-811
1. Repair of Wire by Splicing

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

(1) None

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Terminal Commercially Available
M22520/10-1 Commercially Available
Crimping Tool
M22520/10-XXX Commercially Available
Crimping Tool, Terminal Dye (XXX=104
for 26-16 AWG wire, 103 for 16-12 AWG
wire)
Thermal Stripper Commercially Available
or
Precision-Type (Calibrated) Cutting
Stripper
Heat Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol

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Wire (AS 22759/XX-YY-Z) (XX = Commercially Available

Insulation and conductor specifications
(Refer to CMM or applicable document)
YY = Wire size Z = o for Black, 1 for
Brown, 2 for Red, 3 for Orange, 4 for
Yellow, 5 for Green, 6 for Blue, 7 for Violet,
8 for Grey, 9 for White)
M81824/1-X Commercially Available
Insulated Butt Crimp Splice (X=1 for 26,
24, 22, 20 AWG wire X=2 for 20, 18, 16
AWG wire X=3 for 16, 14, 12 AWG wire)
MIL-T-43435 Commercially Available
Type 1B, Size 3, Nylon Harness Lacing
Tape
Cotton Swabs Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-350-019
E. Repair the wires by splicing using butt crimp as follows:

NOTE: Wiring splices may be used to repair the existing wiring or incorporate product
improvement changes to the equipment. Wiring splices are acceptable with the
following restrictions:

(a) Only one splice is allowed in any one wire between any two connectors or
disconnect points. Splices installed by the manufacture are not included.

(b) Splices in wire bundles must be staggered. The splices must not increase the
size of a wire bundle in a way that causes maintenance problems, prevents its
installation in a cable clamp, or exceeds its assigned space.

(c) Splices must not be used to salvage scrap lengths of the wire.

(1) Splice the wires as follows:

NOTE: A precision type (calibrated) stripper or thermal stripper are the preferred
tools for removing insulation from leads and wires. Knives, scissors, plier type
strippers, or similar tools must not be used.

NOTE: A precision type (calibrated) stripper or thermal stripper are the preferred
tools for removing insulation from leads and wires. Knives, scissors, plier type
strippers, or similar tools must not be used.

(a) Remove insulation from the wire to the extent necessary to facilitate the repair.

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WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

(b) After stripping, avoid touching the stripped ends with bare hands except to
restore disturbed lay of the stranded wire. If the stripped ends are touched with
bare hands, clean using isopropyl alcohol and cotton swabs to remove skin oils.

(c) Prior to crimping, install the insulating sleeve on to one of the wires and slide it
past the stripped region.

(d) Insert the wires to be spliced into either end of butt crimp, (Refer to Figure
901). Make sure that both wires are against the wire stop and can be seen in
the inspection window, (Refer to Figure 902). Crimp using an approved crimping
tool, (Refer to Figure 903) and (Refer to Figure 904).

(e) Examine the crimped terminal and make sure of the following conditions:

1 The wire is in the conductor crimp area.

2 The insulation is not caught in the crimped terminal.

3 The wire can be seen through the inspection hole.

4 The wire is tightly attached, and the parts in the crimped connection do not
move.

(f) Slide the sleeve over the crimped region and make sure that it covers all non-
insulated wire.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

(g) Heat the sleeve with heat gun until it tightly covers the crimped region.

NOTE: The heat shrink sleeve contains adhesive to seal the ends and will melt
when heated.

(h) Do a final inspection to the splice, and make sure that no bare wire is exposed
and that no damage to the splice or surrounding wire exists.

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Installation Procedure
Figure 901

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Wiring Splice
Figure 902

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Crimping Tool
Figure 903

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Crimping Method
Figure 904

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REPAIR 31

TASK 49-00-01-320-802
1. Repair of the Aluminum or Magnesium Gearbox Housing Threaded Port(s)

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-380-801 Cleaning

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

Machining Equipment Commercially Available
De-burring Equipment Commercially Available
Air Furnace Commercially Available
NDT Equipment Commercially Available
(fluorescent penetrant inspection)

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

ASTM D329 Commercially Available
Acetone
ASTM D770 Commercially Available
Isopropyl Alcohol
AMS 4082 or AMS 4117 Commercially Available
6061-T6 Aluminum
AZ31B-T6, AZ63A-T6, or AZ91C-T6 Commercially Available
Magnesium Alloy

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AMS-C-5541 or Alodyne 1204 Commercially Available

Chemical Conversion Coating
Plugs (for protection of bores, ports, Commercially Available
lubricating passages)
Masking Tape Commercially Available
Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-320-002
E. Repair the aluminum or magnesium gearbox housing threaded port(s) as follows:

(1) Clean the gearbox housing according to CLEANING-11, (Refer to TASK

49-00-01-110-811, Cleaning of the Metallic Parts - General).

(2) Mask or plug all undamaged ports, cores, and lubricating passages prior to machining.

(3) Machine the gearbox housing to enlarge the damaged threaded port(s) accordingly,
(Refer to Figure 901 (Sheet 1 of 3)). Make sure that a minimum wall thickness of 0.050
in. (1.27 mm) is maintained in gearbox housing adjacent to the port.

(4) De-burr and hand polish, as required.

(5) Do a fluorescent penetrant inspection according to ASTM E1417, Type I, Method A,

B, or D, minimum Sensitivity Level 2.

NOTE: No cracks or linear indications are allowed.

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

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WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(6) Clean the gearbox housing with acetone or isopropyl alcohol, and lint-free cloth.

WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MILC-

5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING)
LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE,
POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT
ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES
(BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING
POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(7) Apply chemical conversion coating according to AMS-C-5541, Class 1A to exposed

aluminum housing. Treat exposed magnesium housing according to REPAIR-02,
(Refer to TASK 49-00-01-380-801, Cleaning and Treatment of Magnesium
Corrosion).

(8) Fabricate the threaded repair plug(s) accordingly, as required, (Refer to Figure
901). Adjust the plug length, as required. Use aluminum alloy plug on aluminum
housing and a magnesium alloy plug on a magnesium housing.

(9) Install the new threaded plug(s) using Epoxylite 6203.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(10) Cure the epoxy at 350 ±10°F (177 ±5°C) for one hour.

(11) Finish machine the gearbox housing assembly accordingly, (Refer to Figure 901
(Sheet 3 of 3)).

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WARNING: WHEN YOU USE COMPRESSED AIR TO CLEAN OR DRY PARTS, MAKE
SURE THAT THE PRESSURE IS NOT MORE THAN 30 POUNDS PER
SQUARE INCH (207 KILOPASCALS). DO NOT DIRECT THE AIRSTREAM
AT PERSONNEL OR LIGHT OBJECTS. PUT ON GOGGLES OR A FACE
SHIELD TO PROTECT YOUR EYES. THIS WILL HELP TO PREVENT
INJURIES TO PERSONNEL OR DAMAGE TO THE EQUIPMENT. IF YOU
HAVE AN INJURY, GET MEDICAL ATTENTION.

(12) Remove the tape and/or plugs and use compressed air to clean any contamination
from the cores and passages.

(13) Clean the gearbox housing by power-flushing. Do a boroscope inspection to make

sure that all cores and passages are clear.

WARNING: USE THE CHEMICAL CONVERSION COATING (ALSO KNOWN AS MILC-

5541, MIL-C-81706, AMS2473, ALODINE OR CHEMICAL-FILM COATING)
LIQUID OR POWDER FORM CORRECTLY. COATING IS FLAMMABLE,
POISONOUS, CORROSIVE, AND REACTIVE. IT CAN HAVE A BAD
EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU USE THE
COATING, GET THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0059SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE COATING, PUT
ON A CHEMICAL FACE SHIELD, SOLVENT-RESISTANT GLOVES
(BUTYL, NEOPRENE, NITRILE, OR PVC), APRON, AND SHOES. MAKE
SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP THE COATING
POWDER OR FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(14) Hot water wash and apply chemical conversion coating according to AMS-C-5541,
Class 1A to exposed aluminum housing. Treat exposed magnesium housing
according to REPAIR-02, (Refer to TASK 49-00-01-380-801, Cleaning and Treatment
of Magnesium Corrosion).

(15) Do a visual and dimensional inspection to make sure that no defects exist and the
dimensions are correct, (Refer to Figure 901).

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Hole Preparation for Threaded Plug

Figure 901 (Sheet 1 of 3)

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Plug Fabrication for Port

Figure 901 (Sheet 2 of 3)

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Final Dimensions
Figure 901 (Sheet 3 of 3)

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REPAIR 32

TASK 49-00-01-320-803
1. Replacement of the Nut Plates on Oil Cooler

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-814 Removal and Installation of
Cherrylock Rivets

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Drilling Equipment Commercially Available
Riveting Equipment Commercially Available
Machining and Grinding Equipment Commercially Available
Resistance Spot Welding Equipment Commercially Available
GTA or TIG Welding Equipment Commercially Available
Copper Heat Sinks Commercially Available
Magnifying Glass (10X) Commercially Available
FPI Equipment Commercially Available
Wire Brush Commercially Available
Stainless Steel Brush Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

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Part No./Spec. No. Source (CAGE Code)

ASTM D329 Commercially Available
Acetone
ASTM D770 Commercially Available
Isopropyl Alcohol
Filler Rod or Wire (same as base metal) Commercially Available
Electrode (tungsten) Commercially Available
Solid Rivets Commercially Available
Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-320-003
E. Rivet Repair

(1) Do this procedure to replace the riveted nut plate(s), or to repair the elongated or
oversized nut holes.

(a) Remove the nut plate(s) from the oil cooler flange. To remove the rivets, (Refer
to TASK 49-00-01-350-814, Removal and Installation of the Cherrylock
Rivets).

(b) Machine the rivet holes oversize, only if necessary.

(c) Install the new nut plate(s) and new rivets. To install the rivets, (Refer to TASK
49-00-01-350-814, Removal and Installation of the Cherrylock Rivets).

(d) Do a visual inspection for proper fastening.

SUBTASK 49-00-01-320-004
F. Resistance Spot Weld Repair of the Nut Plates

(1) Grind or blend existing welds to remove the damaged nut plate(s).

NOTE: Blended areas should have a smooth, flat surface. Any evidence of old nut
plate(s) or weld nuggets must be removed.

(2) Wire brush the blended areas to prepare for welding.

REPAIR 32
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WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(3) Wipe blended area clean with acetone or isopropyl alcohol and lint-free cloth until no
residue shows on cloth.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(4) Position the replacement nut plate(s) onto the oil cooler flange. Resistance spot weld
in place according to AMS-W-6858, Class C.

(5) Do a visual inspection to make sure that there are no defects after welding using a
magnifying glass (10X).

(6) Do an inspection for proper dimensions.

SUBTASK 49-00-01-320-012
G. GTA (or TIG) Weld Repair of the Nut Plates

(1) Grind or blend existing welds to remove the damaged nut plate(s).

NOTE: Blended areas should have a smooth, flat surface. Any evidence of old nut
plate(s) or weld nuggets must be removed.

REPAIR 32
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SPM

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL-SPLASH GOGGLES, AND
ACETONE-RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(2) Clean the repaired area with a stainless steel brush. Wipe clean with acetone or
isopropyl alcohol and a clean cloth until no residue shows on the cloth.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) Manually tack weld the nut plate(s) onto the oil cooler flange with the Gas Tungsten
Arc (GTA or TIG) welding process according to AMS-STD-2219, Class C, using DCEN
(or DCSP) polarity. Use tapered and pointed electrode tip for DCEN welding, and pure
argon for shielding (including the backside of the weld repair). Place a minimum of
two tack welds per nut plate using filler rod material of the same material as the base
material. If several nut plates are being welded, alternate the weld passes among
them. Avoid overheating the metal.

(4) Do a visual inspection of the repaired areas using a magnifying glass (10X).

(5) Do a fluorescent penetrant inspection on the repaired areas according to ASTM

E1417, Type I, Method A, B, or D, minimum Sensitivity Level 2.

NOTE: No cracks or linear indications are allowed.

(6) Do an inspection for proper dimensions.

REPAIR 32
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REPAIR 33

TASK 49-00-01-310-802
1. Replacement of the Nut Plates on Attenuator

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-814 Removal and Installation of
Cherrylock Rivets

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Drilling Equipment Commercially Available
Riveting Equipment Commercially Available
Machining and Grinding Equipment Commercially Available
Resistance Spot Welding Equipment Commercially Available
GTA or TIG Welding Equipment Commercially Available
Copper Heat Sinks Commercially Available
Magnifying Glass (10X) Commercially Available
FPI Equipment Commercially Available
Blending Equipment Commercially Available
Wire Brush Commercially Available
Stainless Steel Brush Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

REPAIR 33
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Part No./Spec. No. Source (CAGE Code)

ASTM D329 Commercially Available
Acetone
ASTM D770 Commercially Available
Isopropyl Alcohol
Filler Rod Commercially Available
or
Wire (same as base metal)
Tungsten Electrode Commercially Available
Solid Rivets Commercially Available
Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-310-002
E. Repair the rivets as follows:

(1) Replace the riveted nut plate(s), or to repair the elongated or oversized nut holes as
follows:

(a) Remove the nut plate(s) from the attenuator. To remove the rivets, (Refer to
TASK 49-00-01-350-814, Removal and Installation of the Cherrylock Rivets).

(b) Machine the rivet holes oversize, only if necessary.

(c) Install the new nut plate(s) and new rivets. To install the rivets, (Refer to TASK
49-00-01-350-814, Removal and Installation of the Cherrylock Rivets).

(d) Do a visual inspection for proper fastening.

(2) Resistance spot weld repair the nut plates as follows:

(a) Grind or blend existing welds to remove the damaged nut plate(s).

NOTE: Blended areas should have a smooth, flat surface. Any evidence of old
nut plates or weld nuggets must be removed.

(b) Wire brush the blended areas to prepare for welding.

REPAIR 33
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SPM

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0001SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ACETONE, PUT ON CHEMICAL-
SPLASH GOGGLES, AND ACETONE RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ACETONE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

(c) Wipe the blended area clean with acetone or isopropyl alcohol and lint-free cloth
until no residue shows on the cloth.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

(d) Position the replacement nut plate(s) onto the attenuator. Resistance spot weld
in place according to AMS-W-6858, Class C.

(e) Do a visual inspection to make sure that there are no defects after welding using
a magnifying glass (10X).

(f) Do an inspection for proper dimensions.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(3) GTA (or TIG) weld repair the nut plates as follows:

(a) Grind or blend the existing welds to remove the damaged nut plate(s).

NOTE: Blended areas should have a smooth, flat surface. Any evidence of old
nut plates or weld nuggets must be removed.

REPAIR 33
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SPM

WARNING: USE ACETONE, ASTM D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0001SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ACETONE, PUT ON CHEMICAL-
SPLASH GOGGLES, AND ACETONE RESISTANT GLOVES (BUTYL
RUBBER), APRON, AND SHOES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ACETONE FUMES BELOW
THE MATERIAL SAFETY DATA SHEET LIMIT.

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD
POISON. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ALCOHOL, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER
OF THE MATERIAL AND READ IT CAREFULLY. READ THE
DETAILED WARNING, W0046SE, IN THE WARNING REGISTRY
341-006. BEFORE YOU USE THE ALCOHOL, PUT ON CHEMICAL-
SPLASH GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE MATERIAL
SAFETY DATA SHEET LIMIT.

(b) Clean the repaired area with a stainless steel brush. Wipe clean with acetone or
isopropyl alcohol and a lint-free clean cloth until no residue shows on the cloth.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO
A PREHEATED OVEN OR HANDLING HEATED OR CHILLED
PARTS.

(c) Manually tack weld the nut plate(s) onto the attenuator with the Gas Tungsten
Arc (GTA or TIG) welding process according to AWS-D17.1, Class C using
DCEN (or DCSP) polarity. Use tapered and pointed electrode tip for DCEN
welding, and pure argon for shielding (including the backside of the weld repair).
Place a minimum of two tack welds per nut plate using filler rod material of the
same material as the base material. If several nut plates are being welded,
alternate the weld passes. Avoid overheating the metal.

(d) Do a visual inspection of the repaired areas using a magnifying glass (10X).

(e) Do a fluorescent penetrant inspection on the repaired areas according to ASTM

E1417, Type I, Method A, B, or D, minimum Sensitivity Level 2.

NOTE: No cracks or linear indications are allowed.

(f) Do an inspection for proper dimensions.

REPAIR 33
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SPM

REPAIR 34

TASK 49-00-01-350-812
1. Repair of the Wire Terminal Ends by Replacement

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-811 Repair of Wire by Splicing

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Terminal Crimping Tool (M22520/5-01 Commercially Available
for use with MIL-C-22520/5-100 Dies
or
M22520/10-01 for use with MIL-
C-22520/10-101 Dies)
M22520/X-XXX, Terminal Crimping Tool Commercially Available
Die (X-XXX=5-100 for 26-10 AWG wire,
X-XXX=10- 101 for 26-14 AWG wire)
Thermal Stripper Commercially Available
or
Precision Type (Calibrated)
Cutting Stripper Commercially Available
Heat Gun Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

REPAIR 34
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Part No./Spec. No. Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol
AS 22759/XX-YY-Z, Commercially Available
Copper (XX = insulation and conductor
specifications) (Refer to CMM or
applicable document) YY = Wire size Z =
0 for Black, 1 for Brown, 2 for Red, 3 for
Orange, 4 for Yellow, 5 for Green, 6 for
Blue, 7 for Violet, 8 for Grey, 9 for White)
MS25036-XXX, Terminal Lug Commercially Available
Refer to Table 901 for Terminal Lug
diameters
MIL-T-43435 Commercially Available
Type 1B, Size 3, Nylon Harness Lacing
Tape
Cotton Swabs Commercially Available
Table 901
Terminal Lug Diameters

Wire Size Dash No. Screw Size Terminal Diameter

22 - 18 102 6/32 0.142 - 0.152
149 8/32 0.168 - 0.178
103 10/32 0.193 - 0.203
150 1/4 0.260 - 0.275
16 - 14 107 6/32 0.142 - 0.152
153 8/32 0.168 - 0.178
108 10/32 0.193 - 0.203
154 1/4 0.260 - 0.275

(3) Expendable Parts

None

SUBTASK 49-00-01-350-020
E. Do a check as follows:

(1) Check the lugs for security, corrosion, bends, and cracks. No looseness, corrosion,
bends, or cracks are allowed.

(2) Remove the terminal lug and check the length. If necessary, extend the length of the
wire by splicing a new section accordingly, (Refer to TASK 49-00-01-350-811, Repair
of Wire by Splicing).

REPAIR 34
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SPM

SUBTASK 49-00-01-350-021
F. Repair the terminal lug as follows:
WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE
PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

NOTE: A precision type (calibrated) stripper or thermal stripper are the preferred tools for
removing insulation from leads and wires. Knives, scissors, pliers type strippers,
or similar tools must not be used.

NOTE: Be careful not to nick the wire when removing insulation. If wires are nicks, that
segment must be replaced or repaired.

(1) Remove insulation from the wire 0.250 ±0.050 inch (6.35 ±1.27 mm) to facilitate the
repair, (Refer to Figure 901).

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY. ISOPROPYL

ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A MILD POISON. IT CAN
HAVE A BAD EFFECT ON YOUR HEALTH OR SAFETY. BEFORE YOU
USE THE ALCOHOL, GET THE MATERIAL SAFETY DATA SHEET FROM
THE MANUFACTURER OR SUPPLIER OF THE MATERIAL AND READ IT
CAREFULLY. READ THE DETAILED WARNING, W0046SE, IN THE
WARNING REGISTRY 341-006. BEFORE YOU USE THE ALCOHOL, PUT
ON CHEMICAL-SPLASH GOGGLES. MAKE SURE THAT YOU HAVE
SUFFICIENT AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

(2) After stripping, avoid touching the stripped ends with bare hands except to restore the
disturbed lay of the stranded wire. If the stripped ends are touched with bare hands,
clean using isopropyl alcohol and cotton swabs to remove skin oils.

(3) Insert the wires to be repaired into the end of the terminal lug, and make sure that the
wire can be seen protruding past the end of the inspection hole no more than 0.031
inch (0.787 mm) maximum, (Refer to Figure 901). Crimp using an approved crimping
tool and a method, (Refer to Figure 902) and (Refer to Figure 903).

(4) Examine the crimped terminal and make sure of the following conditions:

(a) The wire is in the conductor crimp area.

(b) The insulation is not caught in the crimped terminal.

(c) The wire can be seen through the inspection hole.

(d) The wire is tightly attached and the parts in the crimped connection do not move.

(5) Do a final inspection of the splice and make sure that no bare wire is exposed, and
that no damage to the splice or surrounding wire exists.

REPAIR 34
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Installation Procedure
Figure 901

REPAIR 34
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Crimping Tool
Figure 902

REPAIR 34
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SPM

Crimping Method
Figure 903

REPAIR 34
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SPM

REPAIR 35

TASK 49-00-01-360-809
1. Bonding Repair with Hysol Epoxy EA 9394 Adhesive

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-110-807 Cleaning of the Titanium
Parts (Usual Method)
HSPS 490001 Task 49-00-01-110-808 Cleaning of the Titanium
Parts (Full Method)
HSPS 490001 Task 49-00-01-380-801 Cleaning and Treatment of
Magnesium Corrosion
HSPS 490001 Task 49-00-01-380-802 Cleaning and Treatment of
Aluminum Corrosion
HSPS 490001 Task 49-00-01-380-803 Repair of the Protective
Finish

D. Equipment and Materials

(1) Special Tools

None

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol
Lint-Free Cloth, Commercially Available
Abrasive Cloth (100 - 180 grit) Commercially Available
Hysol Epoxy EA 9394 Commercially Available

REPAIR 35
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Part No./Spec. No. Source (CAGE Code)

Cotton Swabs Commercially Available
Cloth (or tissue) Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-360-014
E. Preparation of Surface

NOTE: Once an adhesive component is removed from the container, do not put back.

(1) Surface must be free of burrs or surface imperfections. Make sure that 100% of the
entire mating surface is in contact.

(2) Clean the surfaces as follows:

(a) Aluminum surfaces: anodize the surface accordingly, (Refer to TASK

49-00-01-380-802, Cleaning and Treatment of Aluminum Corrosion) or (Refer
to TASK 49-00-01-380-803, Repair of the Protective Finish).

(b) Magnesium surfaces: Prepare the surface accordingly, (Refer to TASK

49-00-01-380-801, Cleaning and Treatment of Magnesium Corrosion)

(c) Titanium surfaces: Clean the surface accordingly, (Refer to TASK

49-00-01-110-807, Cleaning of the Titanium Parts (Usual Method)) or (Refer to
TASK 49-00-01-110-808, Cleaning of the Titanium Parts (Full Method)).

(d) Non-metallic surfaces: Clean the surface as follows:

WARNING: USE ISOPROPYL ALCOHOL, ASTM D770, CORRECTLY.

ISOPROPYL ALCOHOL IS FLAMMABLE, EXPLOSIVE, AND A
MILD POISON. IT CAN HAVE A BAD EFFECT ON YOUR
HEALTH OR SAFETY. BEFORE YOU USE THE ALCOHOL, GET
THE MATERIAL SAFETY DATA SHEET FROM THE
MANUFACTURER OR SUPPLIER OF THE MATERIAL AND
READ IT CAREFULLY. READ THE DETAILED WARNING,
W0046SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ALCOHOL, PUT ON CHEMICAL-SPLASH
GOGGLES. MAKE SURE THAT YOU HAVE SUFFICIENT
AIRFLOW TO KEEP THE ALCOHOL FUMES BELOW THE
MATERIAL SAFETY DATA SHEET LIMIT.

1 Wipe the surface with a clean cloth (or tissue) soaked with isopropyl alcohol
to remove contamination and mold release.

2 Abrade the surface with 100 - 180 grit abrasive cloth or equivalent.

REPAIR 35
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3 Wipe the abraded surface with a clean cloth (or cotton swab) soaked in the
isopropyl alcohol.
4 Flush the surface with isopropyl alcohol to remove abrasive residue.

SUBTASK 49-00-01-360-015
F. Preparation of Adhesive

(1) Prepare the Hysol epoxy EA 9394 adhesive by mixing 100 parts, by weight, of Part A
(resin) to 17 parts, by weight, of Part B (hardener). Stir the mixture until a smooth,
even paste is obtained.

NOTE: The pot/shelf life of 100 grams of mixed adhesive is 90 minutes at 77° F (25°
C). Prepare only the amount of adhesive that can be used in that time.

SUBTASK 49-00-01-360-016
G. Application of Adhesive and Curing

(1) Apply a thin layer of the Hysol epoxy EA 9394 adhesive to one of the surfaces, as
required.

(2) Align and join the surfaces.

NOTE: Fixtures may be used, as required, to maintain alignment and provide firm
contact between the surfaces.

(3) Remove any excess Hysol epoxy EA 9394 adhesive by wiping with cotton swabs,
cloth or tissue, dampened with a compatible solvent.

WARNING: PUT ON THERMALLY INSULATED GLOVES AND OTHER SUITABLE

PROTECTION TO PREVENT BURNS WHEN LOADING PARTS INTO A
PREHEATED OVEN OR HANDLING HEATED OR CHILLED PARTS.

(4) Cure the Hysol epoxy EA 9394 adhesive for 5 days at 77°F (25°C).

NOTE: As an alternate, Hysol epoxy EA 9394 adhesive may be cured at 150 to 200°
F (66 to 93°C) for one hour, minimum.

REPAIR 35
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THIS PAGE INTENTIONALLY LEFT BLANK

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SPM

REPAIR 36

TASK 49-00-01-350-813
1. Replacement of the Damaged Rosan™ Inserts and Lockrings

A. Effectivity

(1) None

B. Prerequisites

(1) None

C. Reference Information

Document Reference Designation

HSPS 490001 Task 49-00-01-350-801 Replacement of the
Threaded Inserts

D. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

NDT Equipment (fluorescent penetrant Commercially Available
inspection)
Drilling and Tapping Equipment Commercially Available
Air Furnace Commercially Available
Machining Equipment Commercially Available
Deburring Equipment Commercially Available
Punch Commercially Available

(2) Consumable Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Spec. No. Source (CAGE Code)

ASTM D770 Commercially Available
Isopropyl Alcohol
ASTM D329 Commercially Available
Acetone

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Part No./Spec. No. Source (CAGE Code)

Epoxyamine 30 Primer Commercially Available
Loctite 272 Epoxy Loctite Corp.
(05972)
Lint-free Cloth Commercially Available

(3) Expendable Parts

None

SUBTASK 49-00-01-350-022
E. Replace the damaged Rosan™ inserts and lock rings as follows:

(1) If inserts and/or lock rings are loose, apply epoxy (Loctite 272), re-install, and allow
to cure. If damaged, go to step (2).

(2) Remove the damaged Rosan™ inserts and lock rings, if necessary, as follows:

NOTE: For the required step drill, basic tap size, wrench, and lockring drive tool,
(Refer to Figure 901).

(a) Securely clamp the part from which the insert is to be removed. Align the drill
spindle with the hole in the insert.

(b) Secure the removal drill and set the spindle speed at 300 to 700 rpm.

(c) Drill through the lock ring into the neck of the insert to destroy serration interlock.
Do not drill beyond the depth of the counter bore in the parent material.

(d) Drive the square screw extractor into the insert and apply removal torque.
Continued removal torque will cause the lock ring to be jacked out. Insert removal
may thus be completed. If the lock ring has been drilled completely through and
fails to lift out with the insert, the remaining portion may be collapsed with a punch
and removed.

(3) Prepare for suitable Rosan™ inserts and lock rings to meet the resultant thread and
wall thickness requirements.

NOTE: For standard dimension for lockring hole preparation, (Refer to Figure 902)
and (Refer to Figure 903).

(a) Machining surface(s) must be 125 microinches (3.175 microns) according to

ANSI/ASME 846.1.

(b) Axis of the hole must be normal to the entry surface or provide spot face, as
required, for proper lockring entry. Diameter “B” and minor diameter of thread
must be concentric within 0.003 FIM in the figures accordingly, (Refer to Figure
902) and (Refer to Figure 903).

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(c) Thread, as shown in the tabulation of the figure according to MIL-S-8879, is

preferred, (Refer to Figure 903). Alternate thread according to MIL-S-7742,
Class 3B or National Class 3 is applicable, as specified.
(d) Remove all burrs and sharp edges, as required.

(4) Do a fluorescent penetrant inspection of the machined areas according to ASTM

E1417, Type I, Method A, B, or D, minimum Sensitivity Level 2.

NOTE: No cracks or linear indications are allowed.

(5) Touch up the repair areas of the air inlet housing (disregard for steels) according to
AMS-M-3171, Type III or Type VI (DOW) for magnesium, and according to AMS-C-
5541, Class 1A, less salt spray testing for aluminum.

(6) Inspect the hole dimensions prior to installation of Rosan™ inserts and lockrings.

WARNING: PRIMER IS TOXIC AND FLAMMABLE. DO NOT BREATHE VAPORS. USE

IN WELL-VENTILATED AREA FREE FROM SPARKS, FLAME, OR HOT
SURFACES. PUT ON SPLASH GOGGLES, SOLVENT-RESISTANT
GLOVES, AND OTHER PROTECTIVE GEAR. IN CASE OF EYE CONTACT,
FLUSH WITH WATER FOR 15 MINUTES AND SEEK MEDICAL
ATTENTION. IN CASE OF SKIN CONTACT, WASH WITH SOAP AND
WATER.

(7) Install the applicable Rosan™ inserts and lockrings as follows:

(a) The inserts and lockrings must be installed using wet Epoxyamine 30 primer
unless otherwise specified. (Refer to TASK 49-00-01-350-801, Replacement of
the Threaded Inserts).

(b) Using the applicable wrench, install the insert to the depth shown, (Refer to
Figure 904).

(c) Using an applicable lockring drive tool, drive the lockring into the parent material
until drive tool bottoms against the top of the parent material surface. This will
set the lockring to the proper depth as shown, (Refer to Figure 904).

NOTE: Rotate the new lockring, if necessary, before driving, to a position in

which the external serrations are aligned with those in the parent
material.

(d) Inserts and lockrings must be flush or slightly below the surface, as required,
(Refer to Figure 904).

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Removal Tools
Figure 901

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Fine Internal and Coarse External Threads

Figure 902

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Hole Preparation
Figure 903

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Installation
Figure 904

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THIS PAGE INTENTIONALLY LEFT BLANK

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ASSEMBLY

TASK 49-00-01-400-801
1. ASSEMBLY

A. General

(1) This section provides the general procedures necessary to perform the assembly
common to all the auxiliary power units (APUs). Use the engine manual and/or
component maintenance manual for detailed explanations of the specific assembly
instructions.

(2) Read all the notes, the cautions, and the warnings to prevent equipment damage and
personal injury. The equipment and materials required for assembly are listed
respectively, (Refer to Table 1001) and (Refer to Table 1002). The index lists the
standard assembly procedures in this manual, (Refer to Table 1003).

(3) Apply a light coating of assembly fluid No. 1 to the preformed packings before
installing.

(4) Apply a light coating of assembly fluid No. 1 to the lips of seals and the gaskets before
installing.

Table 1001
Assembly Equipment

Part No./Name Source (CAGE Code)

M203-020 Crimping Tool (for Ferrules Bergen Cable Technologies, Inc.
F20-B) Gregg Street
P.O. Box 1300
Lodi, NJ 07644
M303-030 Crimping Tool (for Ferrules Bergen Cable Technologies, Inc.
F30-B)

Table 1002
Assembly Materials

Part No./Spec No. Source (CAGE Code)

Assembly Fluid No. 1 Ultrachem Incorporated
1400 North Walnut Street
Wilmington, DE 19899
P-D-680 Commercially Available
Type II Dry-Cleaning Solvent
F20-B Bergen Cable Technologies, Inc.
Ferrule

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Part No./Spec No. Source (CAGE Code)

F30-B Bergen Cable Technologies, Inc.
Ferrule
Lacquer Stick Number 51123 LA-CO Industries, Inc.
250 N. Washtenaw Avenue
Chicago, IL 60612-2014
MS20995C20 Commercially Available
Lockwire, Corrosion Resistant 0.020 in. or
0.6mm
MS20995C32 Commercially Available
Lockwire, Corrosion Resistant 0.032 in. or
0.8 mm
Lubrication Oil Commercially Available
(Aircraft Turbine Engine, Synthetic Base)
(Refer to specific engine manual for
approved oils)
C20-B18 Bergen Cable Technologies, Inc.
Safety Cable
C30-B18 Bergen Cable Technologies, Inc.
Safety Cable
Soft-Bristled Brush Commercially Available
MIL-I-46852C, Type 1 Commercially Available
Self-Bonding Silicone Tape

Table 1003
Assembly Index

Description Page Number

General 1001
Approved Oils 1003
General Assembly Instructions 1003
Thread Protrusion 1003
Torque Values 1003
Torque Sequence 1006
Lockwire 1007
Safety Cable 1007

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Description Page Number

Self-Locking Screws and Nuts 1008
Heat 1008
Specific Assembly Instructions 1009
Retaining Rings 1009
Pins and Studs 1009
Threaded Inserts 1009
Sealing and Retaining Compounds 1009
Modification and Identification Plates 1009
Storage Instructions 1010
General 1010
Packing Materials and Shipping Parts 1010

B. Approved Oils

(1) Approved oils for use in the Auxiliary Power Units must conform to MIL-L-7808 or MIL-
L-23699.

(2) Refer to the specific engine manual for the approved commercial lubricating oils.

C. General Assembly Instructions

(1) Thread Protrusion

(a) Normally, at least two threads of all bolts or screws should protrude through the
accompanying nut. However, if the strength requirements are met, some
acceptable reasons for flush threads are:

1 The protruding threads would interfere with the placement of another part.

2 A possibility of arcing or corona discharge from the screw point.

3 The tapped part engages the screw by at least 1.25 times the screw
diameter.

4 A self-locking nut is used.

(2) Torque Values

(a) When tightening the bolts, the screws, and the nuts, refer to the torque values
in the engine manual and/or component maintenance manual.

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(b) If a torque value is not given, (Refer to Table 1004). These values have been
established for the dry threads unless otherwise specified in the engine manual
and/or the component maintenance manual.
Table 1004
Torque Values for Steel Bolts, Nuts, and Self-Locking Nuts

Fine Thread Series Coarse Thread Series

Minimum Minimum Maximum
Pound Maximum Nut or Pound Pound
Nut or Bolt Inches Pound Bolt Inches Inches
Size (N•m) Inches (N•m) Size (N•m) (N•m)
2-56 2 (0.2) 3 (0.3) 8-32 13 (1.4) 18 (2.0)
10-32 24 (2.7) 27 (3.0) 8-36 16 (1.8) 19 (2.1)
1/4-28 55 (6.2) 70 (7.9) 10-24 20 (2.2) 23 (2.6)
5/16-24 100 (11.3) 130 (14.7) 1/4-20 40 (4.5) 60 (6.7)
3/8-24 190 (21.4) 230 (25.9) 5/16-18 70 (7.9) 110 (12.4)
7/16-20 300 (33.9) 360 (40.6) 3/8-16 160 (18.0) 210 (23.7)
1/2-20 480 (54.2) 570 (64.4) 7/16-14 250 (28.2) 320 (36.1)
4-40 5 (0.5) 7 (0.7) 1/2-13 450 (50.8) 510 (57.6)
6-32 11 (1.2) 13 (1.4)

NOTE: Use half of the above values for the thin steel nuts. The thin steel nuts
are those having a height of less than 60% of the inside diameter and
less than 80% of the inside diameter for the self-locking nuts.

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Table 1005
Torque Values for Plugs and Unions

Minimum Torque Maximum Torque

Tube OD Foot Pound Foot
Inches Fitting Pound Pounds Inches Pounds
(mm) Dash No. Inches (N•m) (N•m) (N•m) (N•m)
1/8 (3.1) -2 40 (4.5) --- 50 (5.6) ---
3/16 (4.7) -3 90 (10.1) --- 100 (11.3) ---
1/4 (6.3) -4 135 (15.2) --- 150 (16.9) ---
5/16 (7.9) -5 155 (17.5) --- 175 (19.7) ---
3/8 (9.5) -6 180 (20.3) --- 200 (22.6) ---
1/2 (12.7) -8 270 (30.5) --- 300 (33.9) ---
5/8 (15.8) -10 360 (40.6) --- 400 (45.1) ---
3/4 (19.0) -12 --- 45 (61.0) --- 50 (67.7)
1 (25.4) -16 --- 58 (78.6) --- 70 (94.9)
1-1/4 -20 --- 75 (101.7) --- 87 (117.9)
(31.7) -24 --- 83 (112.5) --- 100
1-1/2 (135.5)
(38.1)

Table 1006
Torque Values for Tubing Nuts and Hose Fittings (Flared Tubing)

Minimum Torque Maximum Torque

Tube OD Foot Pound Foot
Inches Fitting Pound Pounds Inches Pounds
(mm) Dash No. Inches (N•m) (N•m) (N•m) (N•m)
1/8 (3.1) -2 75 (8.4) --- 85 (9.6) ---
3/16 (4.7) -3 95 (10.7) --- 105 (11.8) ---
1/4 (6.3) -4 135 (15.2) --- 150 (16.9) ---
5/16 (7.9) -5 170 (19.2) --- 200 (22.6) ---
3/8 (9.5) -6 270 (30.5) --- 300 (33.9) ---
1/2 (12.7) -8 450 (50.8) --- 500 (56.4) ---
5/8 (15.8) -10 650 (73.4) --- 700 (79.0) ---
3/4 (19.0) -12 --- 75 (101.7) --- 83 (112.5)

NOTE: The above values apply only if the female sealing surface is steel. The
male sealing surface can be aluminum or steel.

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Table 1007
Torque Values for Plugs and Unions Used in Bosses and for Universal Bulkhead
Fitting Locknuts (Aluminum and Steel)

Minimum Torque Maximum Torque

Das Foot Foot
Thread h Pound Pounds Pound Pounds
Size No. Inches (N•m) (N•m) Inches (N•m) (N•m)
0.3125-2 -2 40 (4.5) --- 50 (5.6) ---
4 -3 90 (10.1) --- 100 (11.3) ---
0.375-24 -4 135 (15.2) --- 150 (16.9) ---
0.4375-2 -5 155 (17.5) --- 175 (19.7) ---
0 -6 180 (20.3) --- 200 (22.6) ---
0.500-20 -8 270 (30.5) --- 300 (33.9) ---
0.525-18 -10 360 (40.6) --- 400 (45.1) ---
0.750-16 -12 540 (61.0) 45 (61.0) 600 (67.7) 50 (67.7)
0.875-14 -16 700 (79.0) 58 (78.6) 850 (96.0) 70 (94.9)
1.0625-1 -20 900 (101.7) 75 (101.7) 1050 (118.6) 87 (117.9)
2 -24 1000 (112.9) 83 (112.5) 1200 (135.5) 100 (135.6)
1.3125-1
2
1.625-12
1.875-12

Table 1008
Torque Values for Tubing Nuts and Hose Fittings (Flareless - Steel) Tube

Minimum Maximum
Torque Torque
Tube OD Hose or Minimum Wall
Inches Tube Thickness In. Pound Pound
(mm) Dash No. (mm) Inches (N•m) Inches (N•m)
1/8 (3.1) -2 0.012 (0.30) 50 (5.6) 60 (6.7)
1/4 (6.3) -4 0.016 (0.40) 95 (10.7) 105 (11.8)
5/16 (7.9) -5 0.020 (0.50) 135 (15.2) 145 (16.3)

D. Torque Sequence

(1) Torque the fasteners in the sequence as shown, (Refer to Figure 1001).

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E. Lockwire
NOTE: Do not use lockwire to secure the fasteners or the fittings that are more than 6
inches (152 mm) apart, unless points are provided which shorten the span of the
lockwire to less than 6 inches (152 mm).

(1) If required, lockwire the small screws (with holes less than 0.045 inch (1.1 mm)
diameter) with 0.020 inch (0.6 mm) diameter wire. Wire all the others with 0.032 inch
(0.8 mm) diameter wire. Refer to the following paragraphs and (Refer to Figure
1002).

(a) Lockwire the fasteners so wire is put in tension when the part loosens. Insert
and twist the wire to tighten the loop around the head of the fastener or the fitting.
Make sure the wire will stay down and not slip off. Make sure the wire is tight,
but not overstressed.

(b) For closely-spaced, closed geometric patterns (triangles, squares, rectangles,

and circles), the single-wire method can be used. This method can also be used
when the double-twist method is not practical. When using the single wire
method, use the largest nominal size wire than will fit in the wire hole.

(c) When wiring widely-spaced groups by the double-twist method, three units shall
be the maximum in any series. When wiring closely-spaced groups, the
maximum shall be the number that can be wired by a 24 inch (610 mm) strand.

(d) After wiring, make a pigtail at the wire end. Bend the pigtail back or under so it
will not snag.

F. Safety Cable

NOTE: Safety cable may be used in place of the lockwire at all locations, except where
the lockwire is specified in the applicable component maintenance manual. Use
the 0.020 inch (0.6 mm) diameter safety cable C20-B18 and the ferrules F20-B to
secure the parts with holes less than 0.045 inch (1.1 mm). Use the 0.032 inch ( 0.8
mm) diameter safety cable C30-B18 and the ferrules F30-B to secure the fasteners
with holes of 0.045 inch (1.1 mm) or greater.

(1) Select the correct size safety cable, ferrules, and crimping tool.

(2) Route the safety cable through the parts so that the safety cable exerts a neutral or
positive pull on each of the part, (Refer to Figure 1003). Pull the safety cable through
the parts until the cable end fitting is flush against the first part, (Refer to Figure
1004). Do not exceed a safety cable length of 6 inches (152 mm) between tensioning
points.

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(3) Use the ferrule magazine to install a ferrule on the safety cable, (Refer to Figure
1004). Pull the magazine in a direction perpendicular to the cable to release the ferrule
from the magazine and move the ferrule along the safety cable until it contacts the
part.

NOTE: Do not hold the crimping tool by both handles during the steps (4) and (5).
Otherwise, you may partially close the tip of the tool and prevent insertion of
the safety cable and ferrule.

(4) Hold the crimping tool by one handle and put the end of the safety cable through the
tip of the crimping tool (flat side of the tip toward the ferrule). Then, move the crimping
tool along the safety cable until the tip of the crimping tool is flush against the part.
Make sure the ferrule is inside the tip of the crimping tool, (Refer to Figure 1004). If
the ferrule does not go into the tip of the crimping tool, remove the crimping tool from
the safety cable, push the handles all the way together, release the handles, and
repeat this step until the ferrule goes into the tip.

(5) Hold the tip of the crimping tool firmly against the part and put the cable in the slotted
wheel, (Refer to Figure 1004).

(6) Turn the large tensioning wheel counterclockwise until you hear or feel two clicks.
Stop turning the wheel after the two clicks. If you lose tension on the cable, repeat
this step.

NOTE: The tensioning wheel moves outward (away from the body of the tool) as you
turn it. If you turn the tensioning wheel too far, the safety cable will lose
tension and the wheel will move inward (toward the body of the tool).

(7) Push the handles of the crimping tool all the way together, release the handles to
release the tool, and remove the crimping tool with the excess safety cable from the
ferrule, (Refer to Figure 1004). Do not let the excess cable become trapped between
the pin guide/stop blocks when you push the handles together. This will cause the tool
to lock up.

G. Self-Locking Screws and Nuts

(1) The self-locking screws and the nuts removed at disassembly can be used again if
the self-locking composition is not damaged. The torque values for used self-locking
screws or nuts is about 10 percent lower than the values for new items.

H. Heat

WARNING: USE GLOVES WITH HEAT RESISTANT INSULATION AND PROTECTIVE

CLOTHES TO PREVENT BURNS FROM VERY HOT PARTS.

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CAUTION: TO AVOID DISTORTION AND HEAT-TREATMENT EFFECTS, DO NOT

OVERHEAT PARTS. DO HOT HEAT PARTS TOO LONG IN ANY ONE
SPOT. KEEP THE HEAT SOURCE MOVING EVENLY TO OBTAIN
UNIFORM HEAT PATTERNS.

(1) Unless otherwise stated, use the electric heat gun for localized heating. Depending
on the material and type of the fit involved, some of the parts will require more heat
than others. You can get uniform heat patterns if you keep the heat source moving
evenly.

(2) The requirement for the oven heat is given in the engine manual and/or the component
maintenance manual.

I. Specific Assembly Instructions

(1) Retaining Rings

(a) When installing the retaining rings, make sure the round side of each ring
contacts the part to be retained. The flat side, with the sharp corner, will fit in the
ring groove and ensure a good, secure assembly.

(2) Pins and Studs

(a) Refer to Reference Information for the replacement of the pins/studs.

(3) Threaded Inserts

(a) Refer to Reference Information for the replacement of the threaded inserts.

(4) Sealing and Retaining Compounds

(a) These compounds are used to seal and lock the threaded fasteners, the plugs,
and the other threaded fittings against the loosening effects of vibration,
pressure, and shock.

(b) The compounds may also be used to bond loose bushings, sleeves, and inserts.
Refer to Reference Information for replacement of the components with a layer
of loctite.

(5) Modification and Identification Plates

(a) The APU has an identification plate which provides information on the unit's
ratings as well as the part number and, in some instances, the aircraft
manufacturer's part number.

(b) In addition to the identification plate, on most APU’s a modification plate is used
to record the incorporation of modifications.

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(c) On completion of assembly, mark the identification plate and (if installed) the
modification plate as follows:
CAUTION: IF INFORMATION IS TO BE STEEL-STAMPED INSTEAD OF
VIBRO ETCHED ON THE IDENTIFICATION PLATE, REMOVE
THE PLATE FROM THE APU BEFORE MARKING TO PREVENT
DAMAGE TO THE HOUSING.

1 For an overhaul, mark the date, initials of facility performing the overhaul.

2 For an overhaul and a modification, mark the date, initials of facility

performing the overhaul, and the modification symbol.

3 For a modification, mark the modification symbol as directed by the

modification or service bulletin.

4 When all the spaces on the modification plate have been filled, it is
necessary to replace the plate and summarize all the modifications on the
new plate. If all modifications were performed, start the new plate with the
last modifications symbol. If any modifications were not performed, then it
is necessary to show all completed modifications on the new plate.

(d) If a modification advances the part number of the APU, mark the identification
plate with the new part number.

(e) The APU parts that have been reworked as the result of a modification, should
be numbered to reflect the new part number or should otherwise be marked as
indicated in the modification or service bulletin. The old part number should be
removed and the new part number added using the method called in the
modification instructions. If a symbol other than a part number is used, do not
remove the existing part number, add the symbol next to the part number.

J. Storage Instructions

(1) General

(a) Instructions for the packing, the shipping, and the storage of the APU are given
in the engine manual and/or the component maintenance manual. For a list of
shipping covers required for the specific APUs, (Refer to Figure 1005).

(2) Packing Materials and Shipping Parts

(a) The packing materials and the shipping parts removed from an APU should be
retained for future use.

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Torque Sequence
Figure 1001

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Lockwire Methods
Figure 1002

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Safety Cable Routing Patterns

Figure 1003

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Safety Cable Installation Details

Figure 1004

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Shipping and Storage Covers

Figure 1005

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TASK 49-00-01-400-802
2. Installation of Harness on Engine. Wrapping Harness Connectors with Self-Bonding Silicone
Tape

A. Wrapping Harness Connectors with Self-Bonding Silicone Tape

(1) Apply tape, MIL-1-46852C, onto the harness assembly connectors/connector

backshells by wrapping the tape (with the 'blue string' on the outside) in a clockwise
rotation starting in front of the strain relief screws as shown in Figure 1006, ZONE
A, (Refer to Figure 1006). Initially, start with two layers of 100 percent coverage for a
tight seal. Stretch the tape as it is being applied. The tape must be stretched so that
the width of the tape decreases by about 25 percent. Continue wrapping the tape by
a 50 percent overlap through ZONE A, Figure 1006 and onto ZONE B, (Refer to Figure
1006). Finish the wrapping in ZONE B with two layers of 100 percent coverage. Allow
the tape to cure according to the manufacturer's instructions.

(2) The tape cures to an airworthy condition in approximately one hour and fully cures in
48 hours at an ambient temperature of 70° to 80°F (21º to 27°C). The tape chemically
bonds with itself and not with the surface of the connectors/connector backshells.
Therefore, the tape can be easily removed by cutting with scissors or a knife and will
not leave a surface residue that requires cleaning, once removed.

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Wrapping Harness Assembly Connectors/Connector Backshells with Tape

Figure 1006

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SERVICING

TASK 49-00-01-610-801
1. SERVICING

A. General

(1) This section gives servicing information for all auxiliary power units (APUs)
manufactured by Hamilton Sundstrand Power Systems (HSPS).

(2) Use the engine manual and/or component maintenance manual for a description of
servicing procedures.

(3) A list of lubricating oils for all HSPS APUs are given, (Refer to Table 1101).

Table 1101
APU Lubricating Oils

MIL- MIL- Approve Restrictions/

Brand Name PRF-7808 PRF-23699 d Limitations
Aeroshell Turbine Oil 390 X Approve
d
Castrol 325 X Approve
d
BPTO or Esso Turbo Oil X Approve
2389 d
Mobil Avrex S Turbo 256 X X Approve
d
Castrol 5000 X Approve
d
BPTO or Esso Turbo Oil X Approve
2380 d
BPTO or Esso Turbo Oil X Approve
2197 d
Hatcol 3211 X Approve
d
Mobil Jet Oil II X Approve
d
Mobil Jet Oil 254 X Approve
d
Royco or Aeroshell Turbine X Approve
Oil 500 d

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MIL- MIL- Approve Restrictions/

Brand Name PRF-7808 PRF-23699 d Limitations
Royco or Aeroshell Turbine X Approve
Oil 560 d
Turbonycoil 525-2A X Approve
d
Castrol 5050 X Approve
d
Calstex Sato 5S X Approve
d
Total Aero Turbine Oil 535 X Approve
d
Turbonycoil TN 600 X Approve
d
Mobil 291 X

B. Restrictions/Limitations

(1) The Mobil 291 oil, used on APU models T-40C11 and T-40C14, may cause
deterioration when used on the fluoro-silicone o-rings located on the fuel pump input
shaft.

(2) Check the fuel control drain for oil leakage within 15 minutes of the APU shutdown. If
the oil leakage is more than one drop, replace the fuel control assembly (P/N 4504616
or 4504616A) during the first shop visit.

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PRESERVATION

TASK 49-00-01-620-801
1. On-Wing Preservation of the Auxiliary Power Unit

NOTE: Refer to Aircraft Maintenance Manual for specific applications for on-wing preservation.

NOTE: The preservation procedure is suggested as a guideline for each operator to use as a
baseline. This procedure can be used to know necessary precautions to be exercised
to give sufficient protection to the APU based on operator's experience with local
environmental influences and preservation practices used before. The APU
preservation policy of operator must be a flexible program, implemented to give a
maximum of protection to critical APU components ( such as gears, bearings and
accessory components) and which takes into consideration seasonal changes in local
conditions (such as temperature and humidity). Make sure special care must be taken
in locations where exposure to high temperature changes, high humidity or salt water
over extended periods of time could cause a higher risk of damage to APU parts.

NOTE: Ultimately, it is the responsibility of the operator to give sufficient protection for APU's
out of service for extended periods of time. It is also important that APU's must not be
preserved and put into storage and forgotten. Regular checks are necessary to be sure
the preservation material and the internal environment is satisfactory. APU preservation
guidelines are for the use of operators to help start and implement a viable preservation
plan.

NOTE: For those APU's with an expired tag, send the APU to a test cell or to an aircraft for a
test run. Send the APU by an approved procedure only to prevent damage to the APU.
De-preservation of the APU must agree with the requirements specified in this manual.

A. This section provides procedures necessary for long-term, on-wing preservation of the
auxiliary power units (APUs).

B. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

APU Air Inlet Cover Refer to applicable Engine Manual (EM)
for the APU
APU Exhaust Cover Refer to applicable Engine Manual (EM)
for the APU
Oil Cooler Inlet Cover Refer to applicable Engine Manual (EM)
for the APU
Oil Cooler Exhaust Cover Refer to applicable Engine Manual (EM)
for the APU

PRESERVATION
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Part No./Name Source (CAGE Code)

Gearbox Vent Cover Refer to applicable Engine Manual (EM)
for the APU
Plugs Refer to applicable Engine Manual (EM)
for the APU
Container Commercially Available

(2) Consumables Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Oil Filter Element(s) Refer to applicable Engine Manual (EM)
for the APU
Kraft Paper Commercially Available
Desiccants (24 units) Commercially Available
Humidity Indicator Commercially Available
Tag(s) “WARNING - NO OIL IN THE Commercially Available
GEARBOX”
Engine Oil Commercially Available
Permeable Polyethylene Bags Commercially Available
(8 in each bag)
Preservation Labels Commercially Available

C. On-Wing Preservation

(1) Inoperable APUs

(a) Inoperable APUs should be removed before aircraft storage. Inoperable APUs
not intended for immediate repair (more than 45 days) should be packaged and
preserved.

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(2) Operable APUs

(a) Operable APUs stored in conditions where a scheduled operation check is

permitted:

1 APU should be operated for a minimum of 10 minutes one time in a 45 day

interval.

a Install the APU air inlet, APU exhaust, oil cooler inlet, and exhaust
covers, or plugs (as applicable). This procedure applies if the relative
humidity is 40% or less. If the relative humidity is 40% or greater, then
place humidity indicator and desiccant bags in the inlet and exhaust
duct, tag, and record the number of desiccant bags in the aircraft
records. Examine the desiccant indicator during the regular
scheduled checks. If the desiccant indicator is blue, they are
permitted for continued use. If the desiccant indicator is pink, then
replace the bags. Remove the desiccant bags before APU operation.

NOTE: APU operation interval must not be more than 45-day. APUs
stored under these conditions are not subjected to a
maximum storage period.

b Attach a label to the APU indicating: “THIS PRESERVATION IS

VALID UNTIL MM/DD/YY.”

NOTE: The date should be 45 days from the beginning of the

preservation of the APU.

(b) Operable APUs stored in conditions where a scheduled operation check is not
permitted:

1 Up to 180 days

NOTE: This procedure will allow the APU to be stored for 180 days. The
APU may not be stored for one more 180 days term without
inspection and operational test, (Refer to TASK 49-00-01-620-
803, De-preservation of the Auxiliary Power Unit).

a Install the APU air inlet, APU exhaust, oil cooler inlet and exhaust
covers or plugs (as applicable).

b Install the gearbox vent line plug as applicable.

c Drain the oil tank or gearbox and attach tag “NO OIL IN GEARBOX”.

d Drain the fuel from the fuel filter bowl.

e Install APU desiccant with humidity indicator [refer to step 3 below for
Desiccant installation].

f Perform a 45-day inspection of the moisture indicator.

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g Replace desiccant if indicator is above 40% [refer to step 3 below for

Desiccant installation]
NOTE: It is recommended that all openings to the APU compartment
in the aircraft be sealed as part of this process.

h Attach a label to the APU indicating: “THIS PRESERVATION IS

VALID UNTIL MM/DD/YY.”

NOTE: The date should be 180 days from the beginning of the
preservation of the APU

2 Greater than 180 days

a Remove the APU from airframe and return to an authorized repair

center for inspection, testing, and barrier bag preservation.

3 Desiccant installation

a Put 8 units into one permeable polyethylene bag, 16 units into a

second permeable polyethylene bag, and leave the end of each bag
open.

b Put one humidity indicator card into each desiccant filled bag.

c Put the desiccant filled bag with 8 units on kraft paper and put it into
the APU exhaust duct with the humidity indicator visible.

d Tape the desiccant filled bag with 16 units to the inside of the air inlet
protective cover with the humidity indicator visible.

e Install the APU air inlet, APU exhaust, oil cooler inlet and exhaust,
gearbox vent covers and/or plugs (as applicable).

NOTE: The humidity indicator’s color will be blue at safe levels (up
to 40% humidity). The color will change to pink as the
humidity level increases. Partially or completely pink
indicators require replacement of the desiccant.

TASK 49-00-01-620-802
2. Off-Wing Preservation of the Auxiliary Power Unit

A. Effectivity

(1) Refer to applicable Engine Manual (EM) for the APU.

B. Prerequisites

(1) Within 30 days of Test or APU operation.

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C. Equipment and Materials

(1) Special Tools

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Container, 1 gal. (3.8 lts) Commercially Available
Goggles or Face Mask Commercially Available
Protective Caps and Plugs Commercially Available
Solvent Resistant Gloves Commercially Available
Gearbox Vent Line Plug Commercially Available
Backing Wrench Commercially Available

(2) Consumables Materials

NOTE: Equivalent items can be used for those listed below.

Part No./Name Source (CAGE Code)

Humidity Indicator Cards Refer to applicable Engine Manual (EM)
for the APU
Lint-free Cloth Commercially Available
Tag(s) “WARNING - NO OIL IN THE Commercially Available
GEARBOX”
L-P-378 Commercially Available
Polyethylene Bags, Permeable
MIL-B-131 Commercially Available
Water-Vapor-Proof Barrier Material
MIL-D-3464 Commercially Available
Desiccant (24 units i.e. 16 inlet and 8
outlet)
PPP-T-60 Commercially Available
Adhesive Tape, Waterproof
Alkaline Cleaner (with a pH of 8-9) Commercially Available
MIL-PRF-22019D Type 1 or MIL- Commercially Available
B-22020D Class 1
Blue VCI Poly Bag
Kraft Paper Commercially Available

PRESERVATION
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Part No./Name Source (CAGE Code)

Shipping Container Refer to Engine manual
Preservation Labels Commercially Available

(3) Expendable Parts

None

D. APU Preservation (1 to 45 days)

(1) Drain the fuel from the fuel filter bowl.

(2) Drain the oil from the APU.

(3) Attach a tag to the oil filler caps indicating: “WARNING- NO OIL IN THE GEARBOX.”

(4) Install the APU air inlet, APU exhaust, oil cooler inlet, and exhaust covers, or plugs
(as applicable). This procedure applies if the relative humidity is 40% or less. If the
relative humidity is 40% or greater, then place humidity indicator and desiccant bags
in the inlet and exhaust duct, tag, and record the number of desiccant bags in the
aircraft records. Check the desiccant indicator as part of the regular scheduled
checks. If the desiccant indicator is blue, they are acceptable for continued use. If the
desiccant indicator is pink, then replace the bags. Remove the desiccant bags before
APU operation.

(5) Install a gearbox vent line plug as applicable.

(6) Cover all the open connections, ports, and openings with caps or barrier material and
masking tape.

(7) Attach a label to the APU indicating: “THIS PRESERVATION IS VALID UNTIL MM/
DD/YY.”

NOTE: The date should be 45 days from the beginning of the preservation of the
APU.

NOTE: Store APU indoors, out of the natural elements (i.e. rain).

E. APU Preservation (Up to 18 months)

NOTE: This procedure will allow the APU to be stored for 18 months. The APU may not
be stored for another 18 month term without inspection and operational test, (Refer
to TASK 49-00-01-620-803, De-preservation of the Auxiliary Power Unit).

(1) Drain the fuel from the fuel filter bowl.

(2) Drain the oil from the APU.

(3) Attach a tag to the oil filler cap indicating: “WARNING - NO OIL IN THE GEARBOX.”

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(4) Install the desiccant and moisture indicators as follows:

(a) Put 8 units into one permeable polyethylene bag, 16 units into a second
permeable polyethylene bag, and leave the end of each bag open.

(b) Put one humidity indicator card into each desiccant filled bag.

(c) Put the desiccant filled bag with 8 units on kraft paper and put it into the APU
exhaust duct with the humidity indicator visible.

(d) Tape the desiccant filled bag with 16 units to the inside of the air inlet protective
cover with the humidity indicator visible.

(5) Clean the external surfaces of the APU with a lint-free cloth dampened with alkaline
cleaner.

(6) Wipe off any residual alkaline cleaner with a dry, lint-free cloth.

(7) Install protective covers on all the openings of engine.

(8) Install a gearbox vent line plug as applicable.

(9) Cover all the open connections, ports, and openings with caps or barrier material and
masking tape.

(10) Attach a label to the APU indicating: “THIS PRESERVATION IS VALID UNTIL MM/
DD/YY”.

NOTE: The date should be 18 months from the beginning of the preservation of the
APU.

F. Packing and Long Term Storage of the Auxiliary Power Unit

(1) Prepare the APU for storage as follows:

(a) Make sure that protective covers are installed on all openings to engine.

(b) Make sure that all open connections, ports, and openings are covered with caps
or barrier material and waterproof tape.

(c) Wrap all protruding corners and sharp edges with cushioning material and tape
to prevent cutting the blue VCI poly bag.

(d) Wrap the APU with the blue VCI poly bag, if possible place the opening at the
top.

(e) Install APU into shipping container.

(f) Close the blue VCI poly bag and secure with tape or staple to bottom of shipping
container. Place a third humidity indicator in the bag in line with the shipping
container window.

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(g) Attach labels to the blue VCI poly bag and the outside of the shipping container
lid indicating: “THIS PRESERVATION IS VALID UNTIL MM/DD/YY”.
NOTE: The date should be 18 months from the beginning of the preservation
of the APU.

(h) Install lid onto shipping container.

(i) Examine the humidity indicator interval every two weeks for engines stored in
non-controlled or high humidity locations or every month for engines stored in
controlled or low humidity locations.

NOTE: The interval may be adjusted as necessary, depending on

environmental conditions and operator’s experience. Intervals are not
to exceed 90 days.

(j) If the humidity indicator’s color is blue, the humidity level is less than 40% and
the desiccant is acceptable for continued use.

(k) If the humidity indicator’s color is pink or partially pink, the desiccant must be
replaced and the humidity indicator rechecked monthly.

(l) If the humidity indicator’s color is pink or partially pink a second consecutive
month then the APU must be re-tested and re-preserved.

(m) A log recording the results of the inspections should be attached to the engine.

TASK 49-00-01-620-803
3. De-preservation of the Auxiliary Power Unit

A. De-preserve the APU as follows:

(1) Remove all caps, barrier material and waterproof tape from the connections, ports,
and openings.

(2) Remove the protective covers from all openings of engine.

(3) Remove the plug from the gearbox vent line as applicable.

(4) Remove the eight unit desiccant filled bag from the APU exhaust duct and the sixteen
unit desiccant filled bag from the air inlet protective cover.

(5) Inspect the APU exhaust duct, and the air inlet for any foreign debris.

(6) Remove the tag from the oil filler cap indicating the oil system is empty.

(7) Service the APU with oil.

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WARNING: USE ACETONE, ASMT D329, CORRECTLY. THE ACETONE IS VERY

FLAMMABLE. IT CAN HAVE A BAD EFFECT ON YOUR HEALTH OR
SAFETY. BEFORE YOU USE THE ACETONE, GET THE MATERIAL
SAFETY DATA SHEET FROM THE MANUFACTURER OR SUPPLIER OF
THE MATERIAL AND READ IT CAREFULLY. READ THE DETAILED
WARNING, W0001SE, IN THE WARNING REGISTRY 341-006. BEFORE
YOU USE THE ACETONE, PUT ON CHEMICAL SPLASH GOGGLES, AND
ACETONE RESISTANT GLOVES (BUTYL RUBBER), APRON, AND
SHOES. MAKE SURE THAT YOU HAVE SUFFICIENT AIRFLOW TO KEEP
THE ACETONE FUMES BELOW THE MATERIAL SAFETY DATA SHEET
LIMIT.

(8) Clean the external surfaces of the APU with a lint-free cloth dampened with alkaline
cleaner.

(9) Wipe off any residual alkaline cleaner with a dry, lint-free cloth.

(10) Visually inspect harness for any disconnected connectors or missing hardware.

(11) Perform start procedure as follows:

(a) Disconnect connector to exciter and connector to fuel solenoid valve(s) as

appropriate.

(b) Perform one cold crank.

(c) Reconnect connector to exciter and connector to fuel solenoid valve(s).

(d) Start and operate the APU unloaded for a minimum of five minutes.

(e) Shut down the APU.

(f) Visually inspect the APU for fuel or oil leaks.

(g) Start and operate the APU unloaded for a minimum of ten minutes.

(h) APU is available for normal operation.

PRESERVATION
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