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INDEX COPYRIGHT 2003
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ATP Grid Index to Manufacturer’s Publications:
General Electric Co.
CJ610-1, -4, -5, -6, -8, -8A, -9 (Turbojet Engine)
Maintenance Manual
Section Topic
General Information
Title Page
Manufacturer’s Introduction
Temporary Revision Introduction 001
Record of Revisions
Record of Temporary Revisions
Letter of Transmittal (Highlights of Changes)
List of Effective Pages
Aircraft General
05.00.00 Time Limits/Maintenance Checks
05.00.00 Letter of Transmittals (Highlights of Changes)
05.00.00 List of Effective Pages
05.10.00 Time Limits
05.11.00 Life Limits of Engine Rotating Parts
05.11.02 Compressor Rotor
05.11.02 Temporary Revision No. 5-002
05.11.02 Temporary Revision No. 5-004
05.11.03 Turbine Rotor
05.11.04 Bearing
05.11.04 Temporary Revision No. 5-005
05.20.00 Scheduled Maintenance Checks
05.21.00 Maintenance Practices Inspection/Checks
Power Plant
72.00.00 Engine
72.00.00 Letter of Transmittals (Highlights of Changes)
02/11/2003 Copyright Aircraft Technical Publishers Page 1 of 5
GE 0201 MM)
Section Topic
72.00.00 List of Effective Pages
72.00.00 Complete Engine
72.00.00 Description and Operation
72.00.00 Temporary Revision No. 72-475
72.00.00 Troubleshooting
72.00.00 Starting Problems
72.00.00 Stall Problems
72.00.0´•0 Acceleration Problems
72.00.00 Low Engine Speed
72.00.00 Performance Problems
72.00.00 Abnormal Engine Noise
72.00.00 Lube System
72.00.00 Troubleshooting Flow Chart
72.00.00 Altitude Stall/Flameout Troubleshooting Guide
72.00.00 Maximum Engine Speed-Alt Stall Troubleshooting Guide
72.00.00 Performance Troubleshooting Guide
72.00.00 Maintenance Practices
72.00.00 Servicing
72.00.00 Removal and Installation
72.00.00 Adjustment/Test
72.00.00 General
72.00.00 Safety Precautions
72.00.00 Temporary Revision No. 72-474
72.00.00 Functional Test Run
72.00.00 AbnormalOperations
72.00.00 Engine Adjustment
72.00.00 Operating Limits
72.00.00 Inspection/Checks (Deleted Section)
72.00.00 Cleaning and Preservation
72.00.00 Special Tools
72.00.00 Temporary Revision No. 72-476
72.01.00 General Assembly Information
72.01.01 Lubricants, Preservatives and Anti-Seize Compounds
72.01.02 Locking Procedure
72.01.03 Torque Valves Tightening Practices
72.01.04 Procedure for Inst of Position-Type Universal Fitting
72.01.05 Conversion Tables
72.02.00 General Inspection/Repair Information
72.02.00 Marking of Engine Parts
72.02.01 Hose, Tube and Clamp-Inspection and Repair
72.02.02 Carbon Seal and Runner-Inspection and Repair
02/11/2003 Copyright Aircraft Technical Publishers Page 2 of 5
GE 0201 MM)
Section Topic
72.02.03 Anti-Friction Bearing Method of Inspection
72.02.04 Welding Procedures
72.02.05 Touchup, Protective coating (Sermetel and Solaramic)
72.02.06 Touchup, A12/H151 Intermetallic Diffusion Coating
72.02.07 Touchup, TSM-3 Intermetallic Diffusion Coating
72.02.08 Touchup, Sermetel 725 Protective Coating
72.02.09 Blending Procedures
72.03.00 General Inspection Techniques
72.03.01 Spot Method of Post Emulsion-Penetrant Inspection
72.30.00 Compressor Section
72.30.00 Temporary Revision No. 72-477
72.30.00 Temporary Revision No. 72-478
72.30.00 Temporary Revision No. 72-479
72.31.00 Front Frame Assembly
72.32.00 Compressor Stater Casing Assembly
72.33.00 Compressor Rotor Assembly
72.34.00 Mainframe Assembly
72.40.00 Combusion Section
72.41.00 Outer Combustion Casing
72.42.00 Combustion Liner
72.43.00 Inner Combustion Casing
72.45.00 Turbine Stationary Outer Seal
72.46.00 No. 3 Bearing Sump Components
72.46.01 No. 3 Carbon Seal Support
72.46.02 Insulation Blanket (No. 3 Bearing Area)
72.46.03 Carbon Seal (No. 3 Bearing)
72.46.04 No. 3 Bearing Support
72.46.05 No. 3 Bearing
72.47.00 Heat Shield
72.50.00 Turbine Section
72.51.00 First-Stage Turbine Nozzle Assembly
72.52.00 Turbi ne Casing Assembly
72.53.00 Turbine Rotor Assembly
72.60.00 Accessory Drives
72.62.00 Transfer Gearbox
72.63.00 Horizontal Drive Shaft and Covers
72.64.00 Accessory Drive Gearbox
73.00.00 Engine Fuel and Control
73.00.00 List of Effective Pages
73.00.00 General
02/11/2003 Copyright Aircraft Technical Publishers Page 3 of 5
GE 0201 MM)
Section Topic
73.00.00 Description and Operation
73.00.00 Troubleshooting
73.00.00 Maintenance Practices
73.10.00 Distribution
73.12.00 Fuel Flowmeter (Airframe Furnished)
73.13.00 Fuel Pump
73.14.00 Fuel Filter-O.S.G. Servo
73.15.00 Fuel Pressurizing Valve (CJ610-1,-5, and -9 Engines)
73.16.00 Fuel Drain Valve (CJ610-1,-5 and -9 Engines)
73.17.00 Fuel Pressurizing Drain Vlv (CJ610-4.-6,-8 -8A ENG)
73.18.00 Fuel Nozzles
73.19.00 Fuel Manifolds
73.20.00 Fuel Controlling
73.21.00 Fuel Control
73.22.00 Overspeed Governor
73.23.00 CDP Line to Fuel Control
73.24.00 CDP Line to Aspirator
73.25.00 Variable Geometry Actuator Lines
75.00.00 Air
75.00.00 List of Effective Pages
75.00.00 Air System
75.00.00 Description and Operation
75.00.00 Troubleshooting
75.00.00 Maintenance Practices
75.10.00 Engine Anti-Icing
75.11.00 Anti-Icing Valve
75.12.00 Anti-Icing Tube
75.20.00 Cooling
75.21.00 Eigth-Stage Leakage Air Tubes
75.30.00 Compressor Control
75.31.00 Variable Geometry Actuators
75.32.00 Air Bleed Valve
75.33.00 Feedback Cable
77.00.00 Engine Indicating
77.00.00 Letter of Transmittal (Highlights of Changes)
77.00.00 List of Effective Pages
77.00.00 General
77.10.00 Power
77.11.00 Pressure Ratio Probes Manifold
02/11/2003 Copyright Aircraft Technical Publishers Page 4 of 5
GE 0201 MM)
Section Topic
77.20.00 Temperature
77.21.00 Thermocouple Harness and Engine Temperature Protector
78.00.00 Exhaust
78.00.00 List of Effective Pages
78.00.00 General
78.10.00 Collector System
78.11.00 Exhaust Cone Assembly
79.00.00 Oil
79.00.00 List of Effective Pages
79.00.00 Lubrication System
79.00.00 Description and Operation
79.00.00 Troubleshooting
79.00.00 Maintenance Practices
79.10.00 Storage
79.11.00 Oil Tank
79.12.00 Oil Tank Relief Valve
79.20.00 Distribution
79.21.00 Lube and Scavenge Pump
79.22.00 Oil Filter
79.23.00 Oil Cooler
79.40.00 Sump Pressurizing and Vent System
79.41.00 Eighth-Stage Air Leakage Valve
79.42.00 Oil Tank Check Valves
79.43.00 Oil Manifold Check Valve
80.00.00 Starting
80.00.00 List of Effective Pages
80.00.00 General
80.10.00 Cranking
80.11.00 Starter
80.20.00 Ignition
80.21.00 Ignition Exciter
80.22.00 Igniter Leads
80.23.00 Igniter Plugs
End of Index
02/11/2003 Copyright Aircraft Technical Publishers Page 5 of 5
GE 0201 MM)
nn FG
INTRO
SE1~186
Q GEAirc~ft Engines
CJ610
TURBOJET ENGINE
CJ 6 1 011
CJ61014
CJ61015
CJGIOIG
CJ61018
CJ61018A
CJ61019
MA1NTENANCE MANUAL
NOTICE TO AIRCRAFI OWNER
If you sell your aircraft, the new owner will require the material in this manual to maintain
and service the engines. Please forward this manual to the new owner as soon as
possible after the sale is completed.
MARCH 30, 1967
REVISION 21 JULY 15, 1999
RECORD OF REVISIONS
MFG REV
NO DESCRIPTION ISSUEDATE ATPREVDA INSERTED BY
20 See Highlights 5/31/98 6/25/98 ATP/GM
21 See Highlights 7/15/99 10/28/99 ATP/ZS
CJ610 TURBOJET ENGINES
C;EAircraftEnsines MAINTENANCE MANUAL
RECORD OF REVISIONS
Rev. Revision Date of Insertion
No. Date Approval Date By
Basic Mar 30/67 Mar 14/67
1 Nov 15/67 Dec 11/67
2 Apr 15/68 Mar 1/68
3 Jan 15/69 Jan 7/69
4 Sep 15/69 Sep 12/69
5 May 15/70 Apr 27/70
6 Oct 15/70 Oct 16/70
7 Jun 1/71 May 10/71
8 Nov 15/72 Oct 10/72
9 Nov 15/73 Oct 5/73
10 Sep 1/75 Jul 15/75
11 Sep 1/76 Jul 8/76
12 Feb 23/77 Feb 17/77
13 Dec 1/77 Sep 29/77
14 Dec 30/78 Nov 14/78
15 Dec 1/79 Sep 24/79
16 Nov 1/80 Oct 14/80
17 Mar 30/84 May 31/84
18 Dec 31/91 Mar 10/92
19 Dec 31/95 Nov 15/96
Retain this record in the front of the manual. On receipt of revisions, insert revised
pages in the manual, enter revision number, date inserted, and name.
Page 1
CJ610 TURBOJET ENGINES
GE Aircraft En~sines MAINTENANCE MANUAL
RECORD OF REVISIONS
Rev. Revision Date of Insertion
No. Date Approval Date By
20 May 31/98 Apr 15/98
21 Jul 15/99 Jun 8/99
10/28/99 ATP/ZS
Retain this record in the front of the manual. On receipt of revisions, insert revised
pages in the manual, enter revision number, date inserted, and name.
Page 2
RECORD OF TEMPORARY REVISIONS
P~
TEMP ATP REV INSERT DATE REV REMOVE
REV NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY
72-433 72-32-00:204 2/1 4/86 11/21/02 ATPNP
72-474 72-00-00:504 5/23/00 9/28/00 ATP/JRS
72-475 72-00-00:1 10/1 0/00 4/1 2/01 ATP/VDR
72-476 72-00-00:1003
72-477 72-00-00:3
72-478 72-00-00:4
72-479 72-00-00:208
5-002 5-11-02:1
5-004 5-11-02 11/30/00
Intro 001 Introduction:e 12/3/01 2/14/02 ATP/VP
5-005 5-11-4:1 1/9/03 2/27/03 ATP/MG
GENERAL ELECTRIC--------
SEI-186 RECORD OF TEMPORARY REVISIONS
Temporary Inserted Date
Section No. Page No. Issue Date By
Rev. No. By Removed
72-433 72-32-0 204 2-14-8 1/21/02 /VP
73 72-00 504 10-28-97 ATF/II~ ~/25/981-sTP
II II
4 2 504 23-00
-475 72-00 1 1
72-476 72-00 rr rr
r21477 72-00 n II n
’i
-478 72-00 It n n
72’00 1&2 i, i, ~1
5-1 1 1/9/03 ATP G
Retain this record in the front of the manual. On receipt of Temporary Revisions, insert
revisions into the manual and enter appropriate informa~ion in this record.
Page 1
GENERAL ELECTRIC------
CJ61 OTURSOJET
SEI-186
RECORD OF TEMPORARY REVISIONS
Temporary Inserted Date
Section No. Page No. Issue Date
Removed
BY
Rev. No. By
Retain this record in the front of the manual. On receipt of Temporary Revisions. insert
revisions into the manual and enter appropriate information in this record.
Page 2
GE Aircraft Engines
General Electric Company
1000 Western Ave., Lynn, MA 01910
June 8, 1999
SUBJECT: Revision 21, dated July 15,1999, to the CJ610 Maintenance Manual SEI-186
Highlights of this revision are included in the front of every Chapter that is affected by this Revision.
Insert Revision 21 pages and remove the deleted pages in accordance with the List of Effective Pages included
with Revision 21. Make sure that all the previous revisions have been inserted. After you insert the pages of
Revision 21, note the necessary information on the Record of Revisions page, which contains the FAA approval
date.
To help improve our manuals, please report any deficiencies or submit any suggestions to the undersigned.
Please direct any questions concerning distribution (changes in address, incorrect quantities,
addressee changes, etc.) to:
Technical Services
10525 Chester Road
Cincinnati, Ohio 45215
USA
ATTENTION: Diane Pienjng
Telephone: (513) 672-8400, Ext. 130
Fax: (513) 672-8422
THE INFORMATION (INCLUDING TECHNICAL DATA) CONTAINED IN THIS DOCUMENT IS THE
PROPERTY OF GE. IT IS DISCLOSED IN CONFIDENCE AND THE TECHNICAL DATA THEREIN rS
EXPORTED UNDER U.S. GOVERNMENT LICENSE. THEREFORE, NONE OF THE INFORMATION MAY BE
DISCLOSED TO ANYONE OTHER THAN THE RECIPIENT, OR USED FOR PURPOSES OTHER THAN TO
RENDER SERVICES TO GE, WITHOUT THE EXPRESS PRIOR WRITTEN AUTHORIZATION OF GE. IN
ADDITION,THE TECHNICAL DATA THEREIN, AND THE DIRECT PRODUCT OF THE DATA, MAY NOT BE
DIVERTED, TRANSFERRED, RE-EXPORTED OR DISCLOSED IN ANY MANNER NOT PROVIDED FOR BY
THE LICENSE WITHOUT THE PRIOR WRITTEN APPROVAL OF THE UNITED STATES GOVERNMENT.
L.C. Swart
Technical Information Operation
Telephone: (781) 594-2994
Fax: (781) 594-0600
CJ610 TURBOJET ENGINES
GEAircraftEnaines MAINTENANCE FIANUAL
REVISION NO. 21, DATED JUL 15/99
CHAPTER/SECTION DESCRIPTION OF CHANGE PAGE (S)
INTRODUCTION Added step D(precautions to prevent 2
unwanted objects or materials from
going into the engine, controls, or
accessories)
HIGHLIGHTS
Jul 15/99 INTRODUCTION
Page 1 of 1
CJ610 TURBOJET ENGINES
GEAirCTalfEnaines MAINTENANCE MANUAL
INTRODUCTION
LIST OF EFFECTIVE PAGES
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
List of
Effective
Pages *I Jul 15/99
INTRO 1 Dec 31/95
"2 Jul 15/99
*2A thru 2B Jul 15/99
3 Feb 23/77
4 Dec 31/95
5 Feb 23/77
6 Dec 31/95
7 Feb 23/77
Asterisk denotes pages added, changed, or deleted by this revision.
INTRODUCTION
Jul 15/99 I
CJ610 TURBOJET ENGINES
GEAircraftEn~ines MAINTENANCE MANUAL
INTRODUCTION
i. General.
A. This maintenance manual is written to cover the varying degrees of
maintenance that may be performed on the CJ610-1, -4, -5, -8, -8A,
and -9 engines as used in business aircraft listed below. To overcome
the variances that are involved
dealing with an installed engine,
in
this manual is written on the premise that all areas of the engine are
accessible as when the engine is removed from the aircraft. The format
of the manual is based on the Air Transport Association Specification
100. Because of this format, the continuity of the chapter numbers is
broken down.
ENGINE MODEL AIRCRAFT APPLICATION
CJ610-1 LearJet 23, Hansa Jet, Jet Commander 1121/1121A
CJ610-4 LearJet 23 and 24
CJ610-5 Jet Commander 1121B, Hansa Jet
CJ610-6 LearJet 24B and 25
CJ610-8A LearJet 25, 28, 29
CJ610-9 Commodore Jet, Hansa Jet
NOTE: GE Engines will not assume responsibility for engines
Aircraft
maintained, inspected, and repaired per the instructions of the
this manual which have been installed and operated in aircraft
other than those listed above.
NOTE: Unless otherwise specified, all instructions in this manual
identified as pertaining engines also pertain
to the CJ610-8
to the CJ610-8A engines. Existing references to the -8 engine
throughout the manual also apply to -8A engines. The manual
will be revised on an attrition basis to include the reference
to -8A engine.
B. Standard safety procedures, and precautionary measures
shop practices,
should be observed at all
times to avoid damage or injury to equipment
and persons. Warnings for hazardous substances have been developed from
dated Material Safety Data Sheets IMSDS), when available. Each warning
is valid as of its specific preparation date. To ensure compliance with
current precautionary information:
(1) Read and follow specific instructions in MSDS for types of
personal protective equipment (safety glasses, gloves, apron,
etc.), for use of ventilators or respirators, for types of fire
extinguishers, and for treating medical emergencies.
INTRODUCTION
Dec 31/95 Pagel
CJS10 TURBOJET ENGINES
GE A~Pcraft En~qines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION INTRO 001
Filing
Instructions: Put this Temporary Revision (TR) in the C3610
TURBOJET ENGINES Maintenance Manual SEI-186,
adjacent to
page 2, dated Jul 15/99, in Chapter
INTRODUCTION.
Record this TR number in the Record of Temporary
Revisions.
Subject: Replacement Parts and Life-Limited Low Cycle
Fatigue (LCF) Parts
Reason: Revised the CAUTION stating to use only genuine
GEAE parts for the maintenance of GEAE engines.
Ghange: Revised the CAUTION before step C.
GE PROPRIETARY INFORMATION
The information contained in this document is CE proprietary
information and is disclosed in confidence. It is the property of GE
and shall not be used, disclosed to others or reproduced without the
express written consent of GE, including, but without limitation, it
is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, designs, or
configuration changes or to obtain FAA or any other government or
regulatory approval to do so. If consent is given for reproduction
in whole or in part, this notice and the notice set forth on each
page of this document shall appear in any such reproduction in whole
or in part. The information contained in this document may also be
controlled by U.S. export control laws. Unauthorited export or re-
export is prohibited.
Copyright (1967) General Electric Company, U.S.A.
FAA APPROVED DECEMBER 3, 2001
INTRODUCTION
Page I of 2
Dec 3/01
CJ610 TURBOJET ENGINES
GEAircraft Ensines MAINTENANCE MANUAL
SEI´•1 86
TEMPORARYREVISION INTRO 001 icor.tinue~)
CAUTION: GEAE RECOMMENDS THAT GENUINE GEAE PARTS BE USED IN
MAINTAINING YOUR GEAE ENGINES. GEAE’S MANUALS, SERVICE
BULLETINS AND OTHER MAINTENANCE DOCUMENTS RELATING TO
INSPECTION LIMITS, REPAIR METHODS, OPERATIONAL LIMITS, LIFE
LIMITS, AND THE LIKE ARE DEVELOPED AND APPROVED FOR USE
WITH GENUINE GEAE PARTS. GEAE DOES NOT TEST, CERTIFY FOR
ASSEMBLY OR USE, NOR ADDRESS IN ITS TECHNICAL DOCUMENTS
NON-GEAE PARTS.
e GEAE CUSTOMER CONTRACTS CONTAIN IMPORTANT WARRANTY AND
GUARANTEE BENEFITS, WHICH, UNDER CERTAIN CIRCUMSTANCES,
MAY BE IMPACTED BY THE USE OF NON-GEAE PARTS OR NON-GEAE-
SUBSTANTIATED REPAIRS. FOR EXAMPLE, NON-GEAE PARTS OR
REPAIRS NOT PERFORMED BY GE GENERALLY ARE NOT COVERED BY
THE GEAE WARRANTY. FURTHERMORE, ANY ENGINE DAMAGE CAUSED
IN WHOLE OR IN PART BY THE FAILURE OR MALFUNCTION OF A
NON-GEAE PART OR A REPAIR PROVIDED BY OTHE.RS MAY NOT BE
COVERED UNDER WARRANTY. THE SPECIFIC CONDITIONS AND
QUALIFICATIONS FOR WARRANTY/GUARANTEE COVERAGE ARE
DELINEATED IN THE PRODUCT SUPPORT PLAN PROVISIONS OF
THE APPLICABLE CUSTOMER CONTRACT.
IF ANY DOUBT EXISTS ON THE FLIGHTWORTHINESS OF A PART,
GE AIRCRAFT ENGINES MUST BE CONTACTED FOR A RECOMMENDED
COURSEOF ACTION.
INTRODUCTION
Page 2 of 2
Dec 3/01
CJ610 TURBOJET ENGINES
RAINTENANCE ~ANUAL
(2) Read and follow the hazardous materials label posted on the
container for the specific substance and the MSDS supplied by
the manufacturer.
(3) Follow established shop practices and procedures when you use,
handle, and store hazardous materials.
(4) Dispose of hazardous materials by complying with existing
federal, state, and local regulations.
CAUTION: ONLY REPLACEMENT PARTS CERTIFIED AIRWORTHY BY GE AIRCRAFT
ENGINES, AN FAA-APPROVED CS610 REPAIR FACILITY, OR A REPAIR
FACILITY OUTSIDE THE U.S. AUTHORIZED BY GE AIRCRAFT ENGINES
AND APPROVED BY THE LOCAL CIVIL AVIATION AUTHORITY SHOULD BE
USED IN THE MAINTENANCE, REPAIR, AND OVERHAUL OF CJ610 ENGINES.
GE AIRCRAFT ENGINES SHALL ASSUME NO LIABILITY OR RESPONSIBILITY
FOR DAMAGES CAUSED BY THE USE OF PARTS WHICH ARE NOT CERTIFIED
AIRWORTHY PER THE ABOVE. FURTHER, ANY USED, NON-CERTIFIED GE
AIRCRAFT ENGINES PARTS SHOULD NOT BZ USED AS REPLACEMENT PARTS.
THESE PARTS MAY HAVE BEEN EXPOSED TO CONDITIONS WHICH COULD
RESULT IN UNANTICIPATED FAILURE IF USED AS REPLACEMENT PARTS.
GE AIRCRAFT ENGINES SHALL ASSUME NO LIABILITY OR RESPONSIBILITY
FOR DAMAGES CAUSED BY THE USE OF USED, NON-CERTIFIED REPLACEMENTS
PARTS; IF ANY DOUBT EXISTS ON THE AIRWORTHINESS OF A PART, GE
AIRCRAFT ENGINES SHOULD BE CONTACTED FOR A RECOMMENDED COURSE
OF ACTION.
C. These instructions do not purport co cover all details or variations
in eguipment nor to possible con=ingency to be me~
provide for every
in connections with installation, operation, or maintenance. Should
further information be desired, or particular problems arise which are
not covered sufficiently for the purchaser’s purpose, the matter should
be referred to:
Manager, CJ610/CF700 Programs
GE Aircraft Engines
1000 Western Avenue
Lynn, MA 01910
USA
D. Precautions must taken to prevent all unwanted objects or materials
be
from going engine or controls and accessories. If at any time,
into the
you think unwanted objects or materials have gone into the engine or
controls anb accessories, the maintenance procedure must stop until
the unwanted objects or materials are located and removed. Before you
assemble or install engine parts, make sure that the part is fully
cleaned to prevent unwanted objects or materials from going into the
engine or controls and accessories. Suitable plugs, caps, and other
coverings must be used to protect all openings from unwanted objects or
materials.
NOTE: Please see the
TEMPORARY
REVISION
INTRODUCTION that revises this page.
Page 2 Jul 15/99
CJ610 TURBOJET ENGINES
GEAireraffEnaines MAINTENANCE MANUAL
2. Organization of Manual.
A. Numbering System.
The Maintenance Manual employs a 3-element numbering system. The first
element denotes the Chapter, the second element denotes the Section,
and the third element denotes the Subject or item. Example: 72-42-0.
(1) The chapters used in this manual are denoted as follows:
Chapter Chapter
Number Designation
5 Life Limits
72 Engine
73 Engine Fuel and Control
75 Air
Indicating
78 Exhaust
79 Lubrication
80 Starting
INTRODUCTION
Ju115/99 Page 2A
CJGiO TURBOJET ENGINES
GEAircraftEn~aines MAINTENANCE MANUAL
(2) The sections used within the above chapter designation are
identified as follows:
Chapter Section Number Section Designation
5 -11 Life Limits
-21 Maintenance Practices Inspection/Check
72 -00 Engine General
-01 General Assembly Information
-02 General Inspection/Repair
-03 General Inspection Techniques
-30 Compressor Section
-31 through 39 Major Components of the Compressor Section
-40 Combustion Section
-41 through 49 Major Components of the Combustion Section
-50 Turbine Section
-51 through 59 Major Components of the Turbine Section
-60 Accessory Drives
-61 through 69 Major Components of the Accessory Drive
Section
73 -00 General
-10 Distribution
-11 through 19 Components of Distribution Section
-20 Controlling
-21 through 29 Components of Controlling Section
75 -00 General
-10 Power Plant Anti-Icing
-11 through 19 Components of Anti-Icing System
-30 Compressor Control
-31 through 39 Components of Compressor Control System
-00 General
-10 Power
-11 through 19 Components of Power Indicating System
-20 Temperature
-21 through 29 Components of Temperature Indicating System
78 -00 General
-10 Collector
-11 through 19 Major Components of Collector System
INTRODUCTION
Page 2B Jul 15/99
SEIEIALB~ OLECIII~
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
79 -00 General
-10 Storage
-11 through 19 Major Components of Storage System
-20 Distribution
-21 through 29 Major Components of Distribution System
-40 Sump Pressurizing and Vent Systems
-41 through 49 Major Components of Sump Pressurizing and
Vent Systems
80 -00 General
-10 Cranking
-11 through 19 Components of Cranking System
-20 Ignition
-21 through 29 Components of Ignition System
(3) Separate subjects or units are covered within the respective section
of each chapter. These subjects are denoted by the third element
digits. 1 and up indicates a part of the major component.
NOTE: The use of a zero (O) in the third element indicates coverage
of the entire assembly or major component as defined by the
second number.
B. Page Numbers.
Page number blocks are assigned to separate the subjects into topics.
The following blocks have been assigned for the respective topic uses:
Description and Operation pages 1 through 100
Troubleshooting pages 101 through 200
Maintenance Practices pages 201 through 300
NOTE: When individual sub-topics are too lengthy to include under the
above heading, they are treated as individual topics and are
found within the following blocks of page numbers.
Servicing pages 301 through 400
Removal/Installation pages 401 through 500
Adjustment/Test pages 501 through 600
Inspection/Check pages 601 through 700
Cleaning/Preservation pages 701 through 800
Repairs pages 801 through 900
A complete breakdown of pages, as shown above, is not used when the part
is small and extremely simple and can be covered in from 1 to 5 pages.
These subject parts are page-numbered 201 through 205.
INTRODUCTZON
Feb 23/77 Page 3
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
C. Figure Numbers.
Illustrations are numbered consecutively within each topic. The figure
numbers within a topic use the same block of numbers as the page numbers.
Figures in Description and Operation 1 through 100
Figures in Maintenance Practices 201 through 300
D. Chapter Coverage.
(1) Complete coverage for the maintenance of a particular part is included
under each subject head or is referenced in all chapters except sec-
tions 72-01. 72-02. and 72-03 general procedures.
on These sections do
not cover any parts, only processes and procedures.
(2) When a process is used many times and it is a standard General Electric
process or procedure, it is included in either 72-01, 72-02, or 72-03
and are referenced in the other chapters.
(3) All special and standard torques for this engine are listed in 72-01-3.
When a special torque is required for a particular application it will
be given in the text as well as on the torque chart in this section.
Use standard torque value when a special torque value is not specified.
E. Organization of Inspection Data.
(1) The inspection of data for individual parts in most cases is arranged
in tables, which may or may not include an illustration of the part.
(2) To use the tables, first inspect the part to determine what deviation
is present. When the deviation is located in the "Inspect" column.
then check the corresponding columns for "Maximum Serviceable Limit" to
ascertain whether the defect is serviceable. If the defect exceeds the
Maximum Serviceable Limits the part must be rejected from further ser-
vice until the defect in the part or section of the part is corrected.
INTRODUCTION
Page 4 Dec 31/95
GENERAL ELECTRIC-------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
3. Supplementary Publication. The following is a list of C3610 publications, which
directly support this maintenance publication:
A. Operating Instructions (SEI-188)
The operating instructions give operating limits and special operating proce
dures useful for pilots and maintenance personnel who will operate the engine
while installed in the aircraft. These instructions are not to be used for
testing the engines after maintenance or overhaul. Operations Engineering
Bulletins are also filed with this publication and offer pertinent informa-
tion.
B. Illustrated parts Catalog (SEI-137)
(1) The Illustrated Parts Catalog lists, describes, and illustrates asse~-
blies, subassemblies, parts and detailed
engine. of the It is intended
only for requisitioning, issuing, and identifying parts and for iil~s-
trating relationships for disassembly, where applicable. It is not to
be used as the authority for procedures of assembly or disassembly.
(2) The catalog is also a historical record of parts used, superseded, andl
or discontinued.
4. Other SuDDlementarv Publications. The following list includes additional ?ujli-
cations that support the engine but do not directly relate to the maintenan~e
phase of this engine.
A. Overhaul Manual (SEI-136)
(1) The Overhaul Manual defines the work that can be done at an overhaul
facility. Overhaul is defined as the work necessary to restore the
engine to its optimum level of performance.
(2) The manual procedures outlining the methods of disassembly.
consists of
inspection, repair, assembly of individual engine components.
and En-
gine test procedures are presented to enable the user to evaluate the
success of the overhaul.
B. Accessories Overhaul Manual and Illustrated Parts Catalog (SEI-154)
(1) The Accessories Overhaul Manual and Illustrated Parts Catalog contains
detailed overhaul instructions for the accessories furnished on the
engine.
(2) The manual covers disassembly. cleaning, inspection, repairs, assembly
and testing of the accessories as listed in the Illustrated Parts Cata-
log (SEI-137). The manual also includes an illustrated p~rts catal3g
for each of these accessories.
INTROD~CTION
Feb 23/77 Page 5
GENERAL ELECTRl(i------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
5. Definitions. The following terms are used in the overhaul manual and are de-
fined as follows:
NOTE: Notes call attention to methods which make the job easier.
CAUTION: CAUTIONS CALL ATTENTION TO METHODS AND PROCEDURES WHICH, IF NOT
PRECISELY FOLLOWED, POSE A PARTICULAR RISK OF EQUIPMENT DAMAGE.
WARNING: WARNINGS CALL ATTENTION TO METHODS, PROCEDURES OR LIMITS WHICH, IF NOT
PRECISELY FOLLOWED, POSE A PARTICULAR RISK OF INJURY OR DEATH
TO PERSONS.
6. En~ine Directional References. (See figure i.) "Clockwise" and "counter-clock-
wise", "clock position" and other directional references apply to the engine in
a horizontal position, viewed from the rear, and with the accessories section at
the bottom. When components or struts are numbered in a circumferential direc-
tion the No. 1 position is at 12 o’clock, or immediately clockwise from 12
o’clock. The remaining positions increase arithmetically in a clockwise posi-
tion.
7. Special Tools. The tools listed in this publication are identified by part
numbers of General Electric Company. These tools, or their equivalent, may be
used but are not required. Copies of the tool prints are available, or if de-
sirable, the tools may be purchased from General Electric.
Asbestos. The following warning is for asbestos parts, and must be strictly
complied with.
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORKING WITH
THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIGIDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE ILLUS-
TRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE HARDWARE TO
BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING, GRINDING,
BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL BUILD-UP ON PARTS
THAT CONTAIN ASBESTOS IS NECESSARY, APPROPRIATE PERSONAL PROTECTIVE
EQUIPMENT MUST BE WORN, AND NATIONAL ENVIRONMENTAL CONTROLS REQUIRED
FOR THE HANDLING OF ASBESTOS-CONTAINING MATERIAL MUST BH COMPLIED
WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAINING HARD-
WARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND NATIONAL ENVIRON-
MENTAL CONTROLS MUST BE STRICTLY ADHERED TO FOR HANDLING ASBESTOS-
CONTAINING HARD~ARE.
INTRODUCTION
Page 6 Dec 31/95
GPWEIAL 4~ BLECTIIC
CJ616 TURBOJET
SET-186 MAINTENANCE MANUAL
TOP
(12 O’CLOCK)
RIGHT ’,4
(3 O’CLOCK) AFT
4’
=c’ Ltl) r(´•Q
.´•C’
DIRECTION
´•Q’ i OF
I/ ROTATION
3
´•´•i~
i r:
I
FORWARD r
!´•3
TI
i~wE
i:xi´•
I LEFT
(P O’CLOCK)
BOTTOM
(6 O’CLOCK)
C)6 10´•6 IO)´•0-DI
Engine Directional Reference
Figure 1
INTRODUCTION
I Feb 23/77
Page 7
CHAPTER
TIME LIMITS/
MAINTENANCE
CH EC KS
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
CHAPTER_5 LIFE LIMITS
TABLE OF CONTENTS
5-11 LIFE LIMITS OF ENGINE ROTAING PARTS
General 1
Definitions 1
Examples
Affected Components 3
Recording Cycles 3
5-11-2 COMPRESSOR ROTOR LIFE LIMITS
General 1
Life Limits of Components of the Compressor Rotor 1
5-11-3 TURBINE ROTOR LIFE LIMITS 1
General
Life Limits of Components of the Turbine Rotor 1
5-11-4 BEARING LIFE LIMITS
General 1
Bearings 1
5-21 MAINTENANCE PRACTICES INSPECTION/CHECKS 1
General 1
Five-Year Corrosion Inspection Requirement 1
Ten-Year Corrosion Inspection Requirement 2
Non-Scheduled (Over-Limits) Inspection/Checks 2
Inspection of
Engines Subjected to Excessive
In-Flight G-Loading 2
Inspection of Engines Subjected to Overtemperature Operation... 3
Inspection of Engines Which Show Evidence of Hot-Streaking
(Burnouts) 3
Inspection Engines Subjected
of to Overspeed 3
Inspection Installed Engines Following Bleed Valve
of
Malfunction of Compressor Deceleration Stall 4
Accident and Incident Damage Special Inspection Workscope.... 6
Inspection of Engines After the Aircraft Has Been
Hit by Lightning.............................................. 7
Scheduled Inspection/Checks 8
General 8
Daily Checks Preflight/Postflight 8
Periodic Inspection 5
Hot Section Inpsection 6
Inspection Guide !1
TABLE OF CONTENTS
Dec 31/95 Page 1
CJ610 TURBOJET ENGINES
GEAircraftEnpines MAINTENANCE MANUAL
REVISION NO. 20, DATED MAY 31/98
CHAPTER/SECTION DESCRIPTION OF CHANGE PAGE IS)
5-11, Deleted step B.(5), in paragraph 2 2
LIFE LIMITS (incorporation of TR 5-001)
5-11-4, Revised paragraph 1.B. (the life 1
LIFE LIMITS limits of bearings is measured in
hours TSN), and added the reference
to 72-02-3 for the inspection
requirements
HIGHLIGHTS
May 31/98 5
Page 1 of 1
CJ610 TURBOJET ENGINES
GEAircraftEn~aines MAINTENANCE MANUAL
CHAPTER 5 LIFE LIMITS
LIST OF EFFECTIVE PAGES
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
List of
Effective
Pages *I May 31/98
Table of
Contents 1 Dec 31/95
5-11 1 Dec 31/95
*2 May 31/98
3 Dec 31/95
5-11-2 1 thru 3 Dec 31/95
5-11-3 1 thru 2 Dec 31/95
5-11-4 *1 May 31/98
5-21 1 thru 21 Dec 31/95
Asterisk indicates pages added, changed, or deleted by this revision.
May 31/98 I
CJ610 TURBOJET ENGINES
GEAircraftEnaines MAINTENANCE MANUAL
LIFE LIMITS OF ENGINE ROTATING PARTS
General.
A. The FAA has approved service life limit cycles for rotating parts
installed in the GE Aircraft Engines CJ610-1, -4, -5, -6, -8, -8A, and
-9 model turbojet engines.
B. Rotating parts of all turbine engines have some type of service limits.
Critical rotating parts are those parts whose sudden failure could
threaten the structural integrity of the engine. These parts, when
subjected to large, repeated, and/or alternating stresses, can fail
through fatigue. The material properties of a part are depleted by
fatigue as a function of the number of stress cycles the part
experiences. Stress cycles of turbine engine rotating parts result from
the transients of engine speed and temperatures occurring during normal
engine operation. Therefore, the life limit cycles provide the operator
with a means of tracking the useful service life of a part so that the
part can be removed from service before possible fatigue failure. These
life limits are usually expressed in terms of cycles, and can be
related almost directly to the number of stress cycles that occur
during engine operation. It is for this reason that the limits are in
terms of cycles.
C. Life limits of the critical rotating parts are established through
analysis and testing. Accumulated cycles are compared to the life
to determine if the affected hardware is still serviceable. No
limits
component must be permitted to remain in service beyond its life limit
cycles. Refer to paragraph 2 for the definitions of a cycle.
2. Definitions.
A. A cycle is defined as a flight consisting of a start, takeoff, landing,
and shutdown.
NOTE: Use of thrust reverser is not included in this cycle count.
B. Operational procedures affecting the cycle life limits of rotating
parts are counted as follows:
NOTE: Engine starts and shutdowns for operational checks, ground
maintenance, and taxiing do not count against cycle limits.
(1) An air start is considered one cycle on rotating parts.
(2) Partial cycles such as the following must be counted if such
operations either occur on more than 10 percent of total flights
or subject the engine to conditions which accelerate low cycle
fatigue.
5-11
Dec 31/95 Page 1
CJB10 TURBOJET ENGINES
MAINTENANCE MANUAL
GEAircraftEnaines
(a) Landing without engine shutdown followed by another flight
counts 1/6 cycle for each rotating part.
(b) A touch-and-go landing or go-around counts 1/6 cycle for
each rotating part.
(3) An air start performed for pilot training counts as one cycle for
each rotating part.
(4) Each flight (takeoff and landing) counts as one cycle regardless
of whether or not the engines are shut down prior to the next
takeoff.
1 (5) Deleted.
(6) When the thrust reverser is used and the throttle is advanced
beyond 65
percent Ng, 1/6 cycle is added to the cycle count of
each rotating part.
(7) When the thrust reverser is used but the throttle is not advanced
beyond 65 percent Ng, no additional cycles are added.
(8) Every APR takeoff event counts as three additional cycles for
each life limited part and five additional hours for engine
operating hours.
3. Examples.
A. During a flight, operator makes an air start on the right-hand engine,
lands using the thrust reverser, and shuts down engines. During thrust
reverser operation, the throttle is advanced to 70 percent Ng.
Cycle count, right-hand engine: 1 normal mission
1 air start
1/6 thrust reverser
2-1/6 total
Cycle count, left-hand engine: 1 normal mission
1/6 thrust reverser
1-1/6 total
5-11
Page 2 May 31/98
GENERAL 4~ ELECTRIC-------
CJ610 TURSOJ ET
SEI-186
MAIEP~ENANCE MANUAL
B. More than 10 are used for pilot training (10 percent rule
percent of missions
applies). flight consists of a takeoff, landing with thrust reverser,
Normal
and shutdown. During thrust reverser operation, the throttle is not advanced
beyond 65 percent Ng. The flight includes three touch-and-go landings.
Cycle count, left- and right-hand engines:
1 normal flight
1/2 touch-and-go (1/6 cycle each)
1-1/2 total
NOTE: Thrust reverser operation did not add to cycle count because throttle
was not advanced beyond 65 percent Ng.
C. Landing without engine shutdown occurs on more than 10 percent of missions.
An operator starts the engines, takes off, and lands using thrust reverser.
Engines are not shut down. Operator makes second takeoff and landing using
thrust reverser, and does not shut down engines. Operator then makes a third
takeoff and landing, without
using thrust reverser. The throttle was ad-
vanced beyond 65 percent Ng during thrust reverser operation.
Cycle count, left- and
right-hand engines:
1 normal takeoff and landing
2/6 thrust reverser (1/6 for each)
2/6 landing without shutdown (1/6 for each)
1-2/3 total for all rotating parts
CAUTION: LIFE LIMITED PARTS DEFINED HEREIN MUST NOT BE OPERATED BEYOND THE ESTAB-
LISHED LIMITS.
4. Affected Components. Engine parts that are life limited by this section are as
follows:
A. Compressor Rotor Components (See figure 1 and table 1 in Section 5-11-2)
B. Turbine Rotor Components (See figure 1 and table 1 in Section 5-11-3)
5. RecordinP Cycles.
A. The operator responsible for maintaining an accurate record of the cycles
is
experienced during engine operation. The operator must also monitor the
status of the parts to ensure that none of the parts listed in paragraph 4
exceed the established life limit cycles.
B. The Engine Service Record book provides forms for recording the engine cycle
history.
C. The operator and/or the Service or Overhaul Facility is responsible for mak-
ing appropriate engine logbook entries to reflect the changes in components.
5-11
Dec 31/95 Page 3
CJG1OTURBOJET
GE Aircraft En_s~nes MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 5-002
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610
MAINTENANCE MANUAL SEI-186, adjacent to page i, dated
Dec 31/95 in Chapter 5-11-2.
Record this TR number in the Record of Temporary
Revisions.
Subject: Compressor Rotor Life Limits
Reason: This TR changes paragraph 2 to add steps A and B
referencing the location of the figures 1 and 1A.
Change: Revise paragraph 2.
2. Life Limits of Components of the Compressor Rotor.
I
A. See figure 1 and table 1 for all non-spool rotors.
B. See figure 1A and table 1A for CJ610-6
engines
modified to the spool rotor configuration (SB CJ72-
148)
FAA APPROVED OCTOBER 10, 2000
5-~1-2
Page 1 of 1
Oct. 10/2000
GENERAL ELECTRIC-------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAI.
COMPRESSOR ROTOR LIFE LIMITS
General
A. This section contains the FAA-approved life limits for the compressor rotor
components.
B. The life limit is determined by the total number of flight cycles. Refer to
5-11. paragraph 2, for the requirements. (The operator is
responsible to
make sure that the cycle limited parts are not used beyond their cycle limi~.
Life Limits of Components of the Compressor Rotor. (Refer to figure 1)
2A 3A 4A 5A 6A 7A
8A
88
a Y Y\7 58 68 78
1A
28---~1 38--1 ~c48
000CF7-894800
Figure 1
Compressor Rotor Components
NOTE: Please see the
L
TEMPORARY
REVISION
that revises this page.
5-1!-2
Dec 31/95 "age i
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
TABLE 1
Compressor Rotor Comoonents Life Limits
Location Life Limits
(Ref. Fie. 1) Component Nomenclature Part Number Cycles Since New
1B Stage 1 Diskshaft 37E501428P102* 7.000
37E501428P106* 7,000
5001T26P04* 7,000
2B Stage 2 Disk 37D401312P101 7,000
5045T88P01 7,000
1A Stage 1 Seal 646C638P2 7,000
2A Stage 2 Spacer 37D401302P101 5,000
37D401302P103 6,600
3B Stage 3 Disk 37D401313P101 7,000
5045T89P01 7.000
3A Stage 3 Spacer 37D401303P101 5,000
37D401303P102 5,000
37D401303P104 6,600
4B Stage 4 Disk 37D401314P101 5,000
37D401314P102 5,000
5018T16P01 6,600
4A Stage 4 Spacer 37D401304P103 4,400
37D401304P104 4,400
3920T04P02 4,400
5013T88P01 6,600
5B Stage 5 Disk 37D401315P101 3,900
4920T32P01 3.900
5013T79P01 6.600
5A Stage 5 Spacer 37D401305P103 4,000
37D401305P104 4,000
3920T05P02 4.000
5013T89P01 6,600
6B Stage 6 Disk 37D401316P101 4.600
4920T33P01 4,600
5013T80P01 6,600
6A Stage 6 Spacer 37D401306P103 5,000
37D401306P105 6,600
*Incorporated in assembly P/N 37C311035
5-11-2
Page 2 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-~86
MAINTENANCE MANUAL
TABLE 1
Compressor Rotor ComDonenlcs Life Limits (Cont)
Location Life Limi~s
(Ref. Fig. 1) Component Nomenclature Part Number Cv~les New
7B Stage 7 Disk 37D40!317P101 4.503
4920T34P01 4.500
5013T82P01 6.600
7A Stage 7 Spacer 37D401307P103 5,000
5013T90P01 6.600
8B Stage 8 Disk 37D401709P101 5.000
4920T35P01 5.005
5013T83P01 6.60
8A Stage 8 Seal (Double Step) 37D401510P102 6.500
8A Stage 8 Seal (Single Step) 4010T01P01 6.600
9 Rear Driveshaft 37E501234P101 :3.200
5004T73P01 13.200
5004T73P02’ 13.200
(’Incorporated in assembly P/N 3007T98G01.
i-11-2
Dec 31/95 Page 3
CJG1OTURBOJET
GE Aircraft Ensines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 5-004
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610
MAINTENANCE MANUAL SEI-186, after page 3, dated Dec 31/95 in
Chapter 5-11-2.
Record this TR number in the Record of Temporary Revisions.
Subject: Compressor Rotor Life Limits
Reason: This provides life limits for the spool
TR rotor
configuration (CJ610-6 engines modified to SE CJ72-148)
Change: Add a new figure 1A and table 1A as shown on page 2.
FAA APPROVED NOVEMBER 30, 2000
5-11-2
Page 1 of 2
Nov. 30/00
CJG1OTURBOJET
GEAircraftEn~gines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 5-004(con~nued)
´•L~
Figure 1A
Compressor Rotor Components For CJ610-6
Engines Modified to Spool Rotor
Configuration SE CJ72-148
TABLE 1A
Compressor Rotor Components Life Limits
(For CJ610-6 Engines Modified to Spool Rotor Configuration SE CJ72-148)
Location Life Limits
Ref. Fio. 1A Component Nomenclature Part Number Cycles Since New
1 Spool, Forward 5126T30P02 10,000
2 Disk, Stage 3 5126T33P02 10,000
3 Shaft, Drive 5126T36P01 20,000
4 Spool, Rear 5126T37P03 10,000
5-11-2
Page 2 of 2
Nov. 30/00
GENERAL ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
~AINTENANCE MANUAL
TURBINE ROTOR LIFE LIMITS
Gene ral
A. This section contains the FAA-approved life limits for the components of the
turbine rotor.
B. The life limit determined by the total number of flight cy~les.
is
Refer to
5-11, paragraph 2 for the requirements. (The operator is responsible to make
sure that the cycle limited parts are not used beyond their
~ycie limi~.)
Life Limi_ts of Components of the Turbi~e Rotor. (Refer to fig~re 1.:
\B
1D
1A
1C
ZA
000CF7´•894900
Figure 1
Turbine Rotor Components
5-11-3
Dec 31/95
Page I
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
TABLE 1
TURBINE ROTORCOMPONENTS LIFE LIMITS
Location Life Limits
(Ref. Fie._l) Component Nomenclature Part Number Cycles Since New
1A Stage 1 Wheel 634E583P4 3,100
634E583P4Y 3,100
634E583P5 5,000
5011T75P01 10.000
5011T75P03 10.000
4920T29P01 Retire per note 1
6028T44P01 7,000
1C Stage 1 Inner Seal 646C501P1 7,000
3002T74P01 10.000
1B Stage 1 Outer Seal 646C590P2 10,000
1D Torque Ring 37D401014P101 5,000
37D401014P102 5,000
5011T74G01 10.000
5011T74G02 10.000
2A Stage 2 Wheel 646C596P1 3,300
646C596P1Y 3,300
6466596P2 5.000
4036T24P01 5.500
5011T76P01 10.000
5011T76P03 10,000
4920T27P01 Retire per note 2
NOTE: i. Refer to ALERT Service Bulletin (CJ610) A72-106.
2. Refer to ALERT Service Bulletin (CJ610) A72-107.
5-11-3
Page 2 Dec 31/95
CJG1OTURBOJET ENGINES
GE Aircraft En~qines MAINTENANCE MANUAL
SEI-186
TEMPORARY REVISION 5-005
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610
Turbojet MAINTENANCE MANUAL SEI-186, adjacent
to page 1, dated May 31/98, in Chapter 5-11-4.
Record this TR number in the Record of Temporary
Revisions.
Subject: Life Limit of Bearings
Reason: Bearing life analysis substantiated a bearing life
higher than 20,000 hours of operation. Bearing
failures are near random events and not a wear-out
condition and, as such, negate the application of
a life limit.
Change: Removed the Life Limits for the bearings of the
power takeoff, transfer gearbox, and accessory
gearbox in paragraph 2.
GE PROPRIETARY INFORMATION
The information contained in this document is GE proprietary
information and isdisclosed in confidence. It is the property of GE
and shalt not be used, disclosed to others or reproduced without the
express written consent of GE, including, but without limitation, it
is not to be used in the creation, manufacture, development, or
derivation of any repairs, modifications, spare parts, designs, or
configuration changes or obtain FAA or any other government or
to
regulatory approval to do so. If consent is given for reproduction
in whole or in part, this notice and the notice set forth on each
page of this document shall appear in any such reproduction in whole
or in part. The information contained in this document may also be
controlled by U.S. export control laws. Unauthorized export or re-
export is prohibited.
Copyright (1967) General Electric Company, U.S.A.
FAA APPROVED JANUARY 9, 2003
5-11-4
Page 1 of 2
Jan 9/03
CJ610 TURBOJET ENGINES
GEAircraftEn~ines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 5005 cc,i~d,
BEARING LIFE LIMITS
1. General.
A. This section contains the FAA-approved life limits for the engine
bearings.
B. The life limit of bearings is measured in hours time-since-new
(TSN). Refer to Section 72-02-3 for inspection information.
2. Bearings.
Cumulative Life Limits on serviceable bearings are as follows:
Life Limit Life Limit
Bearing Part No. (+30 Hours) (+30 Hours)
CJ610-1, -5, -9 CJ610-4, -6, -8A
Power Takeoff Refer to
SEI-137
Transfer Gearbox Refer to
SEI-137
Accessory Gearbox Refer to
SEI-137
No. 1 Refer to 2,100 21100
SEI-137
(Excluding
5020TZ0P01)
5020T20P01 SAME AS ENGINE TBO SAME AS ENGINE TBO
No. 2 Refer to SAME AS ENGINE TBO SAME AS ENGINE TBO
SEI-137
No. 3 Refer to SAME AS ENGINE TBO SAME AS ENGINE TBO
SEI-137
Refer to CJ610 Service Bulletin 72-43
5-11-4
Page 2 of 2
Jan 9/03
CJ610 TURBOJET ENGlNES
GEAircraftEnoines MAINTENANtE MANUAL
BEARING LIFE LIMITS
i. General.
A. This section contains the FAA-approved life limits for the engine
bearings.
B. The life limit of bearings is measured in hours TSN. Refer to
Section 72-02-3 for inspection information.
2. Bearings.
Cumulative life limits on serviceable bearings are:
*Life Limit *Life Limit
(+30 Hours) (+30 Hours)
Bearing Part No. CJ610-1, -5, -9 CJ610-4, -6, -8A
Power Takeoff Ref. SEI-137 4,800 5,000
Transfer Gearbox Ref. SEI-137 4,800 5,000
Accessory Gearbox Ref. SEI-137 4,800 5,000
No. 1 Ref. SEI-137 2,100 2,100
(Excluding
5020T20P01)
5020T20P01 SAME AS ENGINE TBO SAME AS ENGINE TBO
No. 2 Ref. SEI-137 SAME AS ENGINE TBO SAME AS ENGINE TBO
No. 3 Ref. SEI-137 SAME AS ENGINE TBO SAME AS ENGINE TBO
*Reference CJ610 Service Bulletin 72-43.
NOTE: Please see the
TEMPORARY
REVISION
that revises this page.
5-11-4
May 31/98 Page 1
GENERAL ELECTRIC--~--
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
MAINTENANCE PRACTICES INSPECTION/CHECKS
General. The maintenance of the engine requires that inspection/checks be made
on a periodic, scheduled basis to make certain the engine will function at its
most efficient point. In addition to the inspection/checks, there
scheduled are
certain inspection/checks that are required whenever the engine is subjected to
an over-limit operation, such overspeed or overtemperature,
as etc. This sec-
tion will describe the requirements for both the scheduled and non-scheduled
inspection/checks.
A. Five-Year Corrosion Inspection Requirement.
CAUTION: ENGINES NOT IN COMPLIANCE WITH THE EXTENDED LIFE COMPRESSOR AS
DEFINED IN SERVICE BULLETIN (CJ610) 72-129, WHICH DO NOT REACB
OVERHAUL WITHIN A 5-YEAR PERIOD FROM DATE OF INSTALLATION
IN AIRCRAFT, MUST BE SCHEDULED FOR A COMPRESSOR CORROSION
INSPECTION.
(1) Inspect the engine as follows:
(a) Both compressor casing halves should be removed from the engine.
If all the vane segments in
stages through 3 7 can be removed with
the lower compressor casing half installed, do not remove the lower
compressor casing half for inspection of vane segments. Install
the vanes in the same positions as they were when they were re-
moved.
(b) Inspect all compressor blade and vane airfoils for corrosion.
(c) Inspect stage 1 and stage 2 vane segments for corrosion. Removal
of vane segments for inspection is not required.
WARNING: HANDLING BLADED COMPONENTS
WEAR LEATHER PALM GLOVES (WELDER’S TYPE WITH GAUNTLET) WHEN
HANDLING COMPONENTS WITH ASSEMBLED BLADES AND VANES. BLADES
AND VANES ARE SHARP AND CAN CAUSE SERIOUS INJURY.
(d) Remove all stainless steel vane segments in stages 3 through 7.
Inspect vane segment platforms for corrosion. Install the vane
segments in the same positions as they were when they were removed.
(e) If both compressor casing halves have been removed from the engine
and the vane segments in stages 3 through 7 are made fron INCO
material, it is not necessary to remove vane segments from co~pres-
sor casing halves to inspect the vane platforms for corrosion.
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(2) Corrosion inspection limits are defined in the Overhaul Manual as
follows:
O/H Manual SEI-136
Compressor Casing Section 72-32-1
Blades Section 72-33-2
Vane Segments Section 72-32-2
B. Ten-Year Corrosion Inspection Requirement.
.CAUTION: ENGINES IN COMPLIANCE WITH SERVICE BULLETIN (CJ610) 72-129 (EX-
TENDED LIFE COMPRESSOR) MUST BE SCHEDULED FOR A COMPRESSOR CORRO-
SION INSPECTION EVERY 10-YEARS. ALSO, ONLY ENGINES THAT CONTAIN
VANE SEGMENTS MADE FROM INCO MATERIAL QUALIFY FOR A 10-YEAR CORRO-
SION INSPECTION. THIS INSPECTION CAN BE ACCOMPLISHED DURING RE-
PLACEMENT OF CYCLE LIMITED PARTS, DURING ENGINE OVERHAUL, OR
10-YEAR CALENDAR.
(1) Inspection requirements of engines in compliance with Service Bulletin
(CJ610) 72-129 are as follows:
WARNING: HANDLING BLADED COMPONENTS
WEAR LEATHER PALM GLOVES (WELDER’S TYPE WITH GAUNTLET) WHEN
HANDLING COMPONENTS WITH ASSEMBLED BLADES AND VANES. BLADES
AND VANES ARE SHARP AND CAN CAUSE SERIOUS INJURY.
(a) Both compressor casing halves should be removed from the engines.
If all the vane segments in
stages through 3 7 can be removed with
the lower compressor casing half installed, do not remove the lower
compressor casing half for inspection of vane segments.
(b) On either of the compressor casing halves that have been removed
from the engine, removal of stages 3 through 7 vane segments is not
required for this inspection.
(2) Corrosion Inspection Limits are defined in the Overhaul Manual as fol-
lows:
O/H Manual SEI-136
Compressor Casing Section 72-32-1
Blades Section 72-33-2
Vane Segments Section 72-32-2
Non-Scheduled (Over-Limits) Inspection/Checks.
A. Inspection of Engines Subjected to Excessive In-Flight G-Loading.
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(1) Inspect the entire engine for evidence of engine contact with the air-
craft structure.
(2) Inspect the exterior of the engine for buckling and "oil-canning." loose
bolts and clamps, bent brackets and tubes, and evidence of damage to
externally mounted equipment.
(3) Inspect the accessory mounting studs and fasteners for looseness or
bending.
(4) Inspect the accessory mounting flanges for damage or distortion.
(5) Inspect the gearbox mounting studs, brackets, and bolts for looseness,
distortion, and cracks.
(6) Inspect the engine mounts, attaching bolts, and flange areas for bolt
damage, hole elongation, and flange distortion.
(7) Perform a functional test on the engine per AdjustmentjTest 72-00.
(8) Record the results of the above inspection/checks. If any of the above
conditions exist, or if the functional test shows discrepancies, the
engine should be replaced.
B. Inspection of Engines Subjected to Overtemperature Operation. If the engine
exceeds the maximum temperature of the operating limits, a Hot Section In-
spection, paragraph 3.D., must be performed and turbine rotor given the fol-
lowing additional inspections:
(1) All turbine blades must be removed and inspected per the Overhaul
Manual, SEI-136.
(2) A hardness check must be made on the turbine wheels in three equally
spaced locations adjacent to the dovetail slots on the forward and aft
faces of the wheels. A minimum hardness of 29 R, must be obtained.
NOTE: The turbine rotor must be balanced when reassembled.
C. Inspection of Engines Which Show Evidence Hot-Streaking (Burnouts)
of
Engines which show evidence hot-streaking, denoted by severe damage
of to
turbine nozzles, turbine blades, etc., should be inspected as follows:
(1) Perform hot section distress inspection (refer to figure 1)
(2) Replace all fuel nozzles so they may be bench checked.
D. Inspection of Engines Subjected to Overspeed. If an engine exceeds the maxi-
mum speed operating limits for the time specified, return the engine to Over-
haul for dimensional inspection of the rotors.
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LEADING EDGE TIPRUB UP TO 3/4" IS
NORMAL. LITE RUB WILL NOT CAUSE
BURR ON EDGES. HEAVY RUB (AP-
PROACHING 3/4" LENGTH) CAN
RESULT IN BURR ON EDGE. LEADING
EDGE TIP RUB IS A~CEPfABLE.
CRACK IN AFT TANG
INSPECT FOR
LEADING EDGE CRACKS IN
THIS AREA
CRACK AND/OR DEFORMATION IN THIS PIN HOLE AREA IN
BLADE OR DISCSHAFT WILL ALLOW BLADE TO TIP FURTHER
FORWARD AND CAUSE TRAILING EDGE TIP RUB UP TO 1/2"
LONG. ASSOCIATED WITH THIS TIP RUB WILL BE BURRS ON
EDGES AND PAINT DISCOLORATION. TRAILING EDGE TIP
RUB IS UNACCEPTABLE. VIEW A
C16 IBb I Il-C E)
Compressor First Stage Blade-Decel Stall Inspection Criteria
Figure 1
E. Inspection of Installed Engines Following Bleed Valve Malfunction of Compres-
sor Deceleration Stall.
(1) Use the following procedural steps to inspect for compressor damage if
the following operating conditions are observed:
(a) Compressor air bleed valves jam or hangup between the one-half
closed to the fully closed position.
(b) Compressor stalls during deceleration for any cause.
NOTE: A compressor stall is normally associated with a rapid
rise in EGT and higher than normal vibration or audible
sound such as a rumble, woosh. boom, or bang.
(2) Visually inspect, using a strong light, the trailing edges (figure 1) of
the first stage blade tips for rubbing (burrs on tip edges near trailing
edge). Rubbing indicates that the retaining pin holes in either the
blades or the diskshaft have cracked or deformed. If
rubbing is ob-
served, remove the engine from the aircraft and proceed to perform more
complete inspection per step (4). Leading edge tip rub is acceptable.
(3) Visually inspect both concave and convex surfaces, using a dental mirror
and a strong light, for cracking of the first stage blade airfoil trail-
ing edges between the root and the midsection of the blade. If a crack
is found, remove the engine from the aircraft and proceed to step (4).
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ABNORMAL DISTRESS
INSPECT STAGE 2 TURBINE NOULE BLUISH-WHITE DISCOLORATION OF
FOR HEAT DISTRESS CAUSED BY RANDOM PARTITIONS WITH WRINK-
CONTAMINATED FUEL SYSTEM. LED COATING AND/OR BURNOUT,
DARK BLUE DISCOLORATION WITH
SPOTS OF SEVERE DAMAGE.
FOR EACH DISTRESSED AREA REMOVE
THREE FUEL NOZZLES, ONE DIRECTLY
NORMAL DISTRESS
UPSTREAM AND ONE FROM EACH SIDE
BLUISH-WHITE DISCOLORATION OF OF THE DISTRESSED AREA. (FUEL
PARTITIONS AT ABOUT 3 AND 7 NOULES SHOULD BE PROCESSED AT
O’CLOCK POSITIONS (AFT LOOKING AN OVERHAUL SHOP.)
FORWARD) WITH MINOR WRINKLING
OF COATING AND/OR PARTITION
BURNOUT.
MINOR CONTAMINATION DISASSEMBLE FUEL NOULES AND
INSPECT INLET SCREENS FOR CON-
SMALL AMOUNTS OF LINT, PAINT, TAMINATION PER SEI-154, SECTION
FUZZY PARTICLES. 73-16-1.
MAIOR CONTAMINATION
LARGE AMOUNTS OF LINT, PAINT,
FUZZY PARTICLES, AND METALLIC
CHIPS.
CLEAN AND TEST FUEL NOZZLES PER REMOVE REMAINING
SECTION 73-18-0, PARAGRAPH 4, NOZZLES
RETURN TO SERVICE. FOR PROCESSING.
REMOVE MFC AND INSPECT COVER.
NOT CONTAMINATED SLEEVE. SPEED SENSOR, AND FILTER.
CONTAMINATED
ASSEMBLE AND TEST PER SEI-154, INSPECT MFC FOR CAUSE OF CON-
CAUSE
SECTION 73-20-1, AND RETURN TAMINATION AND CLEAN PER
IDENTIFIED
MFC TO SERVICE. SEI-154, SECTION 73-20-1.
CAUSE NOT
IDENTIFIED
INSPECT ALL REMAINING FUEL
,TEST, AND RETURN TOI_ i CAUSE
SECTION PARTS FOR CAUSE
OR REPLACE PART. rl IDENTIFIED
CONTAMINATION PER SEI-154.
CAUSE NOT
IDENTIFIED
REPAIR HOT SECTION PER INSPEC-
TION PARAGRAPH FOR APPLICABLEI_ I INSPECT AIRFRAME FUEL SYSTEM
PART(S) AND RETURN ENGINE TO I- IFOR CAUSE OF CONTAMINATION.
SERVICE.
00DBC-0291-01
Fuel System Induced Hot Section Distress Inspection Guide
Figure 2
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(4) Use the following procedure if blade tip rubbing is observed or if a
cracked blade is found:
(a) Remove all stage 1 compressor blades per Section 72-30.
(b) Thoroughly inspect all blade trailing edges, blade retaining pin
holes (see figure 1), and diskshaft retaining pin holes for cracks
using either of the following two methods.
L Visually inspect using a strong light.
2 Spot method of post emulsification penetrant inspection, per
72-03-1.
(c) Replace all stage 1 compressor blades if a cracked blade is found.
Scrap removed blades.
(d) Return the engine to overhaul for diskshaft and stage 1 blade re-
placement if a cracked diskshaft retaining pin hole is found.
(5) Return the engine to service if visual inspection does not show blade
tip rub or trailing edge cracks.
(6) Refer to Troubleshooting Section for correction of cause for compressor
stall or bleed valve hangup.
F. Accident and Incident Damage Special Inspection Workscope.
CAUTION: ANY ENGINE EXPOSED TO THE ABNORMAL CONDITIONS OF AN ACCIDENT OR
INCIDENT REQUIRES SPECIAL INSPECTIONS AND DISPOSITION STANDARDS
THAT ARE MORE STRICT THAN THE MANUAL INSPECTION REQUIREMENTS.
(1) Some of the abnormal conditions of operation which the engine may become
exposed to during an accident or incident may include one or more of the
following:
(a) Shock loading, collision impact, crash damage, or separation from
the aircraft.
(b) Structural overstress; engine structure supporting weight of air-
craft, such as failure or separation of landing gear.
(c) Sudden seize or stoppage.
(d) G-loading during operations, in excess of airframe manual limits.
(e) Extreme ingestion events.
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(f) Fire exposure:
Aircraft totally or partially consumed by fire.
Post-crash engine exterior fire, engine only.
Engine undercowl fire.
(g) Thermal quench; submersion or partial submersion into water, severe
quench during fire extinguishing.
(h) Severe exposure to corrosives, chemicals, fire extinguisher fluids.
or dry powder.
(i) Immersion in brackish water, salt water, or sewage.
(j) Post-crash damage during rescue/recovery actions.
(k) Other extreme environments such as hostile action.
(2) When accident or incident damage
engines which have been in-
occurs,
volved must subjected to a special workscope.
be Each event and each
engine must have the special workscope completed before return of the
engine to service. The owner/operator has the responsibility for con
tinued airworthiness of the engine, which includes replacement of parts.
Special workscopes are available through the Lynn Product Support De-
partment. Please direct your request to:
ATTN: Manager, CJ610/CF700 Programs
GE Aircraft Engines
1000 Western Avenue
Lynn, MA 01910
G. Inspection of Engines After the Aircraft Has Been Hit by Lightning.
NOTE: If defects or out-of-limits parameters are found while doing steps (1)
(2). or (3), get more instructions from your GE Aircraft Engines Repre-
sentative.
(1) Examine both engines installed in the aircraft, including components,
for damage caused by arcing (noticeable black discoloration, pitting,
burn holes, or heat discoloration). If no defects are found, go to step
(2).
(2) Examine engine and aircraft related wiring, including connectors. Look
for burn marks, pitting, or broken wires. If no defects are found. go
to step (3).
(3) Do an installed engine run to be sure all parameters are within limits.
(4) If no defects are found and engine parameters are within limits, con-
tinue to operate.
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Scheduled Inspection/Checks.
A. General.
(1) The inspection categories of table 1 are broken down into four inspec-
tion intervals: Daily inspections, periodic 300-hour and 60D-hour in-
spections, and Hot Section Inspection (HSI). The checks outlined in
these intervals indicate minimum inspection requirements for satisfac-
tory inspection compliance.
(2) Visually inspect the items listed in table 1 under the appropriate In-
spection Time Categories.
(3) When the condition of a part is questionable, refer to the maintenance
limits and procedures which apply to the individual part.
(4) The following lube system maintenance must be performed on new engines
or whenever the engine has undergone overhaul, Hot Section Inspection,
or repair.
(5) The lube filter must be inspected for metallic particles per Inspection/
Checks, Section 79-00, at 5-10 hours and 50-60 hours,
B. Daily Checks PreflightlPostflight.
(1) Visually check the engine inlet and exhaust areas. Remove the duct
covers and use a flashlight to check the items listed in table 1 under
the column for daily checks.
(2) Check the ground surface area and any aircraft surfaces in the immediate
vicinity of the engine inlets for foreign debris.
C. Periodic Inspections.
(1) A thorough visual inspection of the engine is required at regular inter-
vals of approximately 300-310 operating hours and 600-610 operating
hours.
(2) Clean the compressor section at Inspection Time Categories 3 and 4 of
table 1 by using procedures in Maintenance Practices Cleaning, Section
72-00. Use either paragraph 2 or 3, depending upon the nature of the
contaminant and the calendar time.
(3) Visually inspect the items listed in table 1 under the appropriate In-
spection Time Categories.
D. Hot Section Inspection. (See Service Bulletin (CJ610) 72-43 for time inter-
vals and limiting items.)
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(1) Inspect items listed in table i, category 4. Disassemble the basic
engine to the point where the combustion liner can be removed. Remove
only the parts necessary to provide access to the liner. After removing
necessary airframe QEC parts, disassemble the engine in the following
sequence:
Removal/Installation Inspection/Check
Section Section
(a) Exhaust Cone Assembly 78-11-0 78-11-0
(b) Combustion Casing Upper 72-40 72-47-0
and Lower Shaft Shield
Insulation Blankets (Heat
Shields, if installed)
(c) Igniter Plugs Alternate replacement of top and bottom
igniter is recommended. See table i,
Item 5.(2), NOTE.
(d) Turbine Stater Assembly 72-50 72-52-0
(Casing and Stage 2 Nozzle)
CAUTION: DO NOT MIX HORIZONTAL AND VERTICAL FLANGE BOLTS OF DIFFERENT
PART NUMBERS. PART CODE IS NOTED ON TOP SURFACE OF ALL BOLT
HEADS.
NOTES: 1. The lower half of the stage 2 nozzle receives more deterio-
ration than the upper half. To increase nozzle life, record
the position of nozzle halves at disassembly (upper or lower)
and reverse their positions at assembly. Halves are identi-
fied by the letters "A" or "B" marked after the serial number
on the inner band. If no letter is present, mark one half "A"
and the other half "B". Mark with a vibropeen pencil or
equivalent.
2. Because the stage 2 is more susceptible to
turbine nozzle
hot section distress engine parts, it is used as an
than other
indicator of abnormal distress. Therefore, during Hot Section
Inspection (HSI), if the nozzle is abnormally distressed,
inspect the engine fuel system as described in figure 2.
(e) Turbine Rotor Assembly 72-50 72-53-0
(f) First-stage Turbine Nozzle 72-40 72-51-0
(g) Combustion Liner 72-40 72-42-0
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Removal/Installation Inspection/Check
Section Section
(h) No. 3 Bearing 72-40 72-02-3
(i) Compressor Interstage 75-32-0 75-32-0
Bleed Valves
(j) Any Exposed Carbon Seals 72-30/72-40 72-02-2
and Seal Runners
(k) Fuel Nozzle 73-18-0 73-18-0
(2) Inspect the removed parts per the requirements of the sections refer-
enced under Inspection/Check.
NOTE: It is not necessary to disassemble the subassemblies, such as
turbine rotor, turbine casing, and No. 3 bearing and seal, un-
less condition indicates.
(3) Inspect all other items listed in table 1 and the exposed internal parts
(visible areas) per the requirements of individual sections.
(4) Clean and repair or replace defective part (if condition indicates).
(5) Reassemble the engine according to the instructions in the Sections
referenced under Removal/Installation.
(6) Functionally check engine operation per Section 72-00, Adjustment/Test.
figure 503. After acceleration check, perform the following seal run-in
procedure.
(a) With engine at idle, throttle burst to limiting EGT or RPM (see 72-
00, figure 504, 505, 505A, or 510 for limits), stabilize for 1
minute, then chop throttle to idle and stabilize for 1 minute.
Repeat five times.
(b) After last chop, stabilize for 2 minutes and shut down engine.
(c) Three minutes after rotation stops, start engine and operate at
idle for 2 minutes and shut down.
WARNING: HANDLING BLADED COMPONENTS
WEAR LEATHER PALM GLOVES (WELDER’S TYPE WITH GAUNTLET) WHEN
HANDLING COMPONENTS WITH ASSEMBLED BLADES AND VANES. BLADES
AND VANES ARE SHARP AND CAN CAUSE SERIOUS INJURY.
(d) For next 30 minutes, periodically check rotor for seizure by turn-
ing rotor by hand. If none occurs, repeat take-off power check.
(e) If seizure occurs, repeat steps (a) through (d). If this does not
clear seizure, investigate to determine cause of seizure.
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TABLE 1
INSPECTION GUIDE
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 1 3 4
A. Check the engine inlet duct for:
(1) Deterioration, damage, and x I x I x I x
loose rivets.
(2) Integrity of anti-icing boot x I x I x I x
(if installed).
(3) Presence of foreign objects, x I x I x I x
B. Check theoverspeed governor-to-
flowmeter line, engine
fuel
external lines, ports, flanges,
clamps, and brackets for the
following:
(1)Check the overspeed governor- x I x x
to-flowmeter fuel line for
chafing. Replace line if
evidence of chafing exists
(73-00)
(2)Check engine external lines,
ports, flanges, clamps, and
brackets for:
(a) Security. x I x I x I x
(b) Damage. x I x I x I x
(c) Evidence of Leakage. x I x I x I x
(d) Chafing. x I x I x I x
C. Evidence of leakage (fuel,
(1)Surface beneath the engine. x
(2) Engine surface and accessories. x I x x
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TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
CAUTION: REPLACE O-RINGS WHENEVER THEY ARE EXPOSED DURING WORK ON~THE
LUBE SYSTEM.
D. Check the lube system for
contamination as follows:
NOTE: A leak check must be performed after any part of the lube system
is disrupted/disconnected and reassembled as referenced in Section
72-00, figure 503.
(1) Remove and inspect the lube x I x I x
filter for metallic particles
per Inspection/Checks, Section
79-00. Clean and reinstall
filter.
NOTES: 1. At 300 disposable Type "D" filter is to be
hours, the
replaced may inspected and rinsed in clean engine oil
or be
or rinsed in Stoddard Solvent. Federal Specification
P-D-680 (Shell Chemical Co.. Petro Chemical Division, 750
Union Commerce Bldg.. Cleveland. OH 44115) and dried.
Replace filter at 600 hours.
2. Inspect accessory and transfer gearbox magnetic drain plugs
whenever lube and filter exhibits metal.
(2) Remove the magnetic drain X I X I X
plugs from the accessory and
transfer gearboxes. Inspect
the plugs for metallic
particles per Inspectionj
Checks. Section 79-00. Clean
and reinstall plugs.
(3) Check oil level. Maintain x I x I x I x
oil level at or slightly
below the FULL mark on the
oil tank dipstick.
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TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
NOTE: Oil will seep from the oil tank to the gearbox when the engine
is inactive and will give a false indication of a low oil
level. Check oil level immediately after engine shutdown.
(4) Change oil. Refer to x I x
Servicing Section 79-00.
Inspect drained oil for
presence of particles per
Inspection/Checks. Section
79-00.
CAUTION: REPLACE O-RINGS WHENEVER THEY ARE EXPOSED DURING WORK ON THE
FUEL SYSTEM.
E. Check the fuel system for
contamination: (Refer to
Section 73-00.)
NOTE: A leak check must be performed after any part of the fuel system
is disrupted/disconnected and reassembled as referenced in Section
72-00, figure 503.
(1) Remove the filters from the x I x I x
fuel (Section 73-13) and
pump
fuel control (Section 73-21);
check contamination, clean
and reinstall filters.
(2) Clean the overspeed governor I I I I
servo filter per
Section 73-14-0.
NOTE: Always check overspeed governor servo filter whenever other
fuel filters are found to be contaminated. Source of
contamination should be determined.
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TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 1 3 1 4
F. Check the engine inlet and front
frame areas for: (Refer to
Section 72-31-0 for serviceable
limits.)
NOTE: A leak check must be performed after any part of the air
system is disrupted/disconnected and reassembled as referenced in
Section 72-00, figure 503, step 12,
(1) Security and cracks at the x x I x
forward engine mount.
(2) Front frame casing cracks. X I X
(3) Dome assembly (Bullet nose) for:
(a) Dents. X I X I X I X
(b) Looseness. X I X I X
(c) Cracks. x I x I x
(4) Front frame struts for:
(a) Nicks and dents. x I x I x I x
(b) Cracks. x 1 x
(5) Variable vanes for:
(a) Nicks and dents. x I x I x 1 x
(b) Cracks. x I x
(6) Missing pin and clips from x I x I x
visible variable vane levers.
(7) Missing cotter pins from visiblel I X I X
variable vane outer shanks.
(8) Rubs between variable vanes and x I x
shrouds.
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MAINTENANCE MANUAL
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Pera.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 i;
(9) Distorted variable vane r.
actuator ring.
(10) Security of anti-icing valve, x I x
line, and clamps.
(11)Evidence of leaking gaskets at x I x
anti-icing valve.
(12) Variable geometry system I I I I
looseness. (Check per
Section 75-00.)
G. Check the compressor stater and
rotor assemblies for: (Refer to
Sections 72-32-0 and 72-33-0.)
WARNING: HANDLING BLADED COMPONENTS
WEAR LEATHER PALM GLOVES (WELDER’S TYPE WITH GAUNTLET) WHEN HA~-
DLING COMPONENTS WITH ASSEMBLED BLADES AND VANES. BLADES AND VANES
ARE SHARP AND CAN CAUSE SERIOUS INJURY.
(1) Free rotation of the compressor x I x I x I x
rotor.
NOTE: Check by spinning rotor by hand or watching rotor during
coastdown.
(2) Broken rotor studs Rotate x I x I x I x
rotor slowly (by hand) and
listen for rattling noise, or
listen as rotor coasts down
during shutdown.
(3) Visible compressor rotor blades x I x I x I x
for nicks, dents, and tip curl.
(4) Cracked rotor blades. x I
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TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
11213 4
(5) Compressor casings for dents I I I I x
and cracks.
(6) Bleed valve for:
(a) Security. x I x
(b) Lubricate. (Refer to I I I I x
Section 75-32-0.)
(c) Inspect rollers. (Refer to I I I I x
to Section 75-32-0.)
WARNING: PENETRANT METHOD OF INSPECTION
PROLONGED OR REPEATED INHALATION OF POWDERS AND VAPORS OF
CLEANING SOLVENTS, DEVELOPERS, AND EMULSIFIERS USED IN FLUO-
RESCENT PENETRANT INSPECTION CAN IRRITATE MUCOUS MEMBRANE AR-
EAS OF THE BODY.
CONTINUAL EXPOSURE TO PENETRANT INSPECTION MATERIALS CAN IRRI-
TATE THE SKIN. DIRECT EXPOSURE OF EYES TO BLACK LIGHT AND
PROLONGED EXPOSURE OF SKIN TO BLACK LIGHT CAN INFLAME AND DAM-
AGE EYES AND SKIN.
WEAR NEOPRENE GLOVES WHEN HANDLING PENETRANT INSPECTION MATE-
RIALS. KEEP INSIDES OF GLOVES CLEAN.
STORE ALL PRESSURIZED SPRAY CANS CONTAINING PENETRANTS, DEVXL-
OPERS, AND EMULSIFIERS IN A COOL, DRY AREA PROTECTED FROM DT-
RECT SUNLIGHT, HEAT, AND OPEN FLAMES. TEMPERATURES HIGHER
THAN 1200F (490C) MAY CAUSE PRESSURIZED CAN TO BURST AND CAUSE
INJURY.
IF DIRECT EYE CONTACT WITH BLACK LIGHT CAUSES EYE PROBLEMS,
IMMEDIATELY GET MEDICAL HELP.
WHEN USING BLACK LIGHT FOR FLUORESCENT INSPECTIONS, WEAR
SAFETY GLASSES.
(d) Fluorescent-penetrant I I I I
inspect pushrod assembly.
5-21
Page 16 Dec 31/95
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
(7) Igniter leads for security I I I I x
and damage.
(8) Ignition exciter for security x I x
and damage.
(9) Eighth-stage and exit guide I I I x
vanes.
H. Check the mainframe assembly for:
(Refer to Section 72-34-0.)
(1) Fuel manifold for security x I x I x
and chafing.
(2) Mainframe casing and struts I I I I x
for cracks.
(3) Mainframe internal flowpath I I I I x
for corrosion.
(4) Fuel nozzles for condition and I I I I x
operation per Section 73-18-0,
paragraph 3.A.(2), 3.1.(2) and
3.0. Flow check per Section
73-18-0, paragraph 4.
I. Check the accessory drive section
for: (Refer to Sections 72-62-0,
72-63-0, and 72-64-0.)
(1) Security of transfer gearbox on x I x I x
brackets and brackets on
mainframe.
(2) Security of accessory gearbox on x I x I x
brackets and brackets on front
frame and/or mainframe.
5-21
Dec 31/95 Page 17
GENERAL ELECTRIC--------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAT,
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
(3) Security of components mounted x x x
on gearboxes.
(4) Spline wear:
(a) Axis spline(s) driving
C X* I X* X*
generator(s).
(b) All splines:
accessory fuell I I I x´•
pump, overspeed governor,
hydraulic pump, and A-C
generator (if installed).
J. Check the combustion section for:
(Refer to Section 72-40.)
(1) Hot spots, bulges, and cracks x I x I x I x
on the outer casing per
Section 72-41-0.
WARNING: IGNITER PLUGS
BEFORE ENERGIZING THE IGNITION CIRCUIT, BE
CERTAIN THAT NO FUEL OR OIL IS PRESENT. HAVE FIRE
EXTINGUISHING EQUIPMENT PRESENT.
HIGH VOLTAGE IS PRESENT. BE CERTAIN THE IGNITION UNIT AND
PLUGS ARE GROUNDED BEFORE ENERGIZING THE CIRCUIT.
NEVER TOUCH OR MAKE CONTACT WITH THE ELECTRICAL OUTPUT
CONNECTOR WHEN OPERATING ANY IGNITION COMPONENT.
NEVER HOLD OR MAKE CONTACT WITH THE IGNITER PLUG WHEN
ENERGIZING THE IGNITION COMPONENT
(2) Replace igniter plugs per See X I X
Section 80-23-0. Note
Clean and lubricate mating splines.
5-21
Page 18 Dec 31/95
GENERAL ELECTRIC--~--
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 L,
(3) The´•combustion liner shells I I I I x´•
must be removed permanently
and replaced with new shells.
The cowl and dome assembly,
including the fuel nozzle
ferrules and igniter washer,
are not to be disassembled
or replaced unless there is
an obvious defect. Refer to
SEI-136, Section 72-42-0 for
limits.
NOTE: Igniter plug life is a function of engine time, proper
immersion depth, ignition cycles, and period of ignition use.
The most reliable operation can be obtained by alternatively
replacing the top and bottom units at intervals of 100-150
hours, or at intervals consistent with the operator’s
experience and use of ignition in flight.
(4) Combustion inner casing for I I I x
hot spots, bulges, and cracks.
(5, Inspect outer combustion I I I I x
casing per Section 72-41-0.
K. Check the turbine section for:
(Refer to Sections 72-51-0, 72-52-0,
and 72-53-0 for serviceable limits.)
(1) Turbine casing cracks. I I I I x
(2) Turbine nozzles for operation I I I I x
defects.
(3) Turbine rotor assembly. I I I I x
On CJ610-9 engines, the inner and outer shells are life limited to 1.200
hours and must be replaced at every other 600-hour hot section inspection.
This applies to Part No. 6008T94 liners only.
5-21
Dec 31/95 Page 19
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
HSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
L. Check the exhaust cone for:
(1) Casing cracks, distortion, and x I x I x I x
hot spots (Refer to Section
78-11-0.)
(2) Security of exhaust pressure x I x I x I x
probes (Refer to Section
77-11-0.)
(3) Inspect and clean exhaust I I I I x
pressure probes (Refer to
Section 77-11-0.)
(4) The exhaust gas thermocouple
harness for:
(a) Breaks or missing loops. x I x I x I x
(Refer to Section 77-21-0.)
(b) Insulation resistance. I I I I x
(Refer to Section 77-21-0.)
(c) Indication when local heat I I I I x
is (Refer
applied. to
Section 77-21-0.)
M. Functionally check engine operation See See x
per Adjustment/Test. Section 72-00. Note 1 Note 1
figure 503.
N. Motoring check. See See x
Note 2 Note 2
O. Clean compressor per Section 72-00. See See See
Note 3 Note 3 Note 3
5-21
Page 20 Dec 31/95
GENERAL ELECTRIC--~--
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 1
INSPECTION GUIDE (Cont)
INSPECTION TIME CATEGORIES
iiSI
Periodic (Ref.
Every Every Para.
ENGINE COMPONENT AND INSPECTION Daily 300 HRS 600 HRS 3.D.)
1 2 3 4
NOTES: i. Functional Checks indicated at 300 or 600 hour intervals are
recommended if engines have been idle for more than 1 month
prior to the check. This check is also recommended if pilot’s
post flight report indicates there may be an engine
operational problem.
2. This check can be accomplished as part of cleaning or igniter
plug change. Pilot’s normal starting procedure can be used to
monitor starter torque capability of 12% Ng RPM in 12
seconds or better.
3. A high rate of landings, especially in areas where there is
airborne soot or dirt, may require additional cleaning
intervals to maintain efficient compressor operation.
5-21
Dec 31/95 Page 2:
CHAPTER
ENGINES
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MAN~AL
CHAPTER 72 ENGINE
TABLE OF CONTENTS
a?
,czr
72-00 COMPLETE ENGINE
Description and Operation 1
Troubleshooting 101
Maintenance Practices
Servicing 3C1
Removal and Installation 401
Adjustment/Test 501
Inspection/Checks (see 5-21) Deleted
Cleaning and Preservation 7Ci
Special Tools 13C1
72-01 GENERAL ASSEMBLY INFORMATION
72-01-1 Lubricants, Preservatives, and Anti-Seize Compounds
72-01-2 Locking Procedures 1
72-01-3 Torque Values Tightening Practices 1
72-01-4 Procedure for the Installation of the Positioning-Type
Universal Fitting 1
72-01-5 Conversion Tables
72-02 GENERAL INSPECTION/REPAIR INFORMATION
72-02-0 Marking of Engine Parts 1
72-02-1 Hose, Tube and Clamp Inspection
Repair and 1
72-02-2 Carbon Seal and Runner Inspection and Repair 1
72-02-3 Anti-Friction Bearing Method of Inspection 1
72-02-4 Welding Procedures General
72-02-5 Touchup, Protective Coating (SermeTel and Solaramic) 1
72-02-6 Touchup, A12/HI51 Intermetallic Diffusion Coating 1
72-02-7 Touchup, TSM-3 Intermetallic Diffusion Coating 1
72-02-8 Touchup, SermeTel 725 Protective Coating 1
72-02-9 Blending Procedures 1
72-03 GENERAL INSPECTION TECHNIQUES
72-03-1 Spot Method of Post Emulsified Liquid Penetrant Inspection
72-30 COMPRESSOR SECTION
Description and Operation
Maintenance Practices Removal/installation
Front Frame 20!
No. Bearing
1 204
No. 1 Bearing Carbon Seal 205
Compressor Upper Casing 205
First-Stage Compressor Rotor Blades 239
Accessory Gearbox Bracket (CJ610-1, -5 and -9 205A
Accessory Gearbox Bracket (CJ610-4, -6, -8 and -8A) 2ic
Scavenge Tubes 2124
TABLE OF CONTENTS
72
Dec 31/95 Page 1
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
CHAPTER 72 -_E_NGINE
TABLE OF CONTENTS (Cont)
Page
72-30 COMPRESSOR SECTION (Cont)
Air Pad Covers or Airframer Fittings 213
Stater Sector 213
72-31-0 Front Frame Assembly
Maintenance Practices...................~......´•´•´•´•´•´•´•´•´•-´• 201
72-32-0 Compressor Stater Casing Assembly
Maintenance Practices..................´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•-´•´•´• 201
72-33-0 Compressor Rotor Assembly
Maintenance Practices...................´•´•´•.´•´•´•´•´•´•´•´•´•´•´•´•´•´• 201
72-34-0 Mainframe Assembly
Maintenance Practices.........................~.´•´•.´•´•´•´•´•´•´• 201
72-40 COMBUSTION SECTION
Description and Operation..............................-´•...´•´•´• 1
Maintenance Practices Removal/Installation 201
Heat Shield 201
Combustion Liner 202
Outer Combustion Casing..................................... 205
208
I Inner Combustion Casing´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•-´•-´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•
No. 3 BearFng...........................´•´•´•´•--.´•´•´•´•´•´•´•´•´•´•-´•´• 208
72-41-0 Outer Combustion Casing
Maintenance Practices 201
72-42-0 Combustion Liner
Maintenance Prac t ices 201
72-43-0 Inner Combustion Casing
Maintenance Practices..................~..........´•´•.´•´•´•´•´• 201
72-45-0 Turbine Stationary Outer Seal
Maintenance Practices 201
72-46-0 No. 3 Bearing Sump Components
72-46-1 No. 3 Carbon Seal Support
Maintenance Practices..............................´•´•´•´•´•´•´• 201
72-46-2 Insulation Blanket (No. 3 Bearing Area)
Maintenance Practices.~ 201
72-46-3 Carbon Seal (No. 3 Bearing)
Maintenance Practices......................~.......´•´•´•´•´•.´• 201
72-46-4 No. 3 Bearing Support
Maintenance Practices..............................´•´•´•´•´•´•´• 201
72-46-5 No. 3 Bearing
Maintenance Practices~..............................´•-´•´•´•´• 201
72-47-0 Heat Shield
Maintenance Practices 201
TABLE OF CONTENTS
72 Dec 31/91
Page 2
GEWERAL~b ELOCIRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
CHAPTER 72 ENGINE
TABLE OF CONTENTS (Cont)
Page
72-50 TURBINE SECTION
Description and Operation...................................... 1
Maintenance Practices Removal/Installation
Removal of Turbine Stator................................... 201
Removal of Turbine Rotor....................~.......-....... 202
Installation of Turbine Rotor........................,...... 204A
Determination of Axial Clearances between Turbine Rotor
and Combustion Section Parts 207
Installation of Turbine Stater 210
Clearance Checks Between Turbine Rotor and Stater 213
72-51-0 First-Stage Turbine Nozzle Assembly
Maintenance Practices 201
72-52-0 Turbine Casing Assembly
Maintenance Practices 201
72-53-0 Turbine Rotor Assembly
Maintenance Practices..................................... 201
72-60 ACCESSORY DRIVE SECTION
Description and Operation...................................... 1
72-62-0 Transfer Gearbox
Maintenance Practices..................................... 201
72-63-0 Horizontal Drive Shaft and Covers
Maintenance Practices..................................... 201
72-64-0 Accessory Drive Gearbox
Maintenance Practices 201
TABLE OF CONTENTS
31/91 72
I Dec
Page 3
CJ610 TURBOJET ENGINES
GEAircraftEnsines MAINTENANtE MANUAL
REVISION NO. 21, DATED JUL 15/99
CHAPTER/SECTION DESCRIPTION OF CHANGE PAGE (S)
72-00, 5 i 8A
Added NOTE 3 before step I1(1)
ADJUSTMENT/TEST
72-02-3, Revised para 1, step A. (deleted the 1
INSPECTION requirement to re-install the bearings
that have remaining residual life in
the same engine)
HIGHLIGHTS
Jul 15/99 72
Page 1 of 1
C3610 TURBOJET ENGINES
GEAircraftEn~ines MAINTFNANCE MANUAL
CHAPTE~ 72 ENGINE
LIST OF EFFECTIVE PAGES
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
72 *I thru IV Jul 15/99 72-00 132A/132B Mar 30/84
(Cont) 133 Mar 30/84
Contents 1 Dec 31/95 134 Nov 15/72
2 thru 3 Dec 31/91 135 thru 137 Mar 30/84
138 thru 139 Nov 15/72
72-00 1 Dec 31/95 140 Dec 30/78
2 May 15/70 140A/140B Dec 31/91
141 Dec 31/91
101 Mar 30/84 142 thru 143 Sep 1/75
102 May 15/70
102A/102B May 15/70 301 Sep 1/75
103 Sep 15/69 302 Dec 31i9i
104 Oct 15/70 303 thru 304 Jan 15!69
104A/104B Dec 31/95 304A thru 304B Jun 1/7i
105 Dec 31/95 305 thru 306 Sep 15/69
106 Sep 15/69 307 Sep 1/75
107 thru 109 Nov 15/72 308 Jun i
110 Mar 30/84 309 Jan 15/69
11OA/11OB Nov 15/73 310 Sep 15/69
Iii Mar 30/84 311 Jan 15/69
112 Nov 15/73 312 Apr :5/68
113 Dec 30/78 313 Dec 30/78
114 Nov 15/73 314 thru 315 Jan ?5/69
114A thru 114B Mar 30/84 316 Apr 15:68
114C/114D Mar 30/84 317 Sep 15/69
115 thru 116 Mar 30/84 318 Jan 15/69
116A Dec 31/95 319 Apr 15/68
116B Mar 30/84
116C/116D Mar 30/84 401 Sep 1/75
117 Sep 1/75
118 Nov 1/80 501 Dec 1/77
118A/118B Sep 1/75 502 thru 503 Mar 30/67
119 Sep 1/75 504 May 31/98
120 Nov 1/80 504A/504B Dec 30/78
121 thru 122 Sep 1/75 505 Dec 31/91
122A thru 122B Sep 1/75 506 Mar 30/67
123 Nov 1/80 507 Oct 15/70
124 Sep 15/69 508 Feb 23/77
125 Nov 15/73 509 Dec 30/78
126 Jun 1/71 510 Dec 30/78
126A/126B Jun 1/71 510A thru 510B Dec 30/78
127 Dec 31/91 510C/510D Dec 31/91
128 Jun 1/71 511 thru 512 Sep 1/75
128A/128B Mar 30/84 512A/512B Sep 1/75
129 Mar 30/84 513 Dec 31/91
130 Dec 31/95 514 Dec 1/79
131 thru 132 Sep 15/69 514A May 15!70
Asterisk indicates pages added, changed, or deleted by this revision.
72
Jul 15/99 I
CJ610 TURBOJET ENGINES
GEAircraftEnsines MAINTENANCE MANUAL
CHAPTER 72 ENGINE (Cont)
LIST OF EFFECTIVE PAGES (Cont)
CHAPTERI CHAPTERI
SECTION PAGE DATE SECTION PAGE DATE
72-00 514B Sep 1/75 72-01-1 1 Dec 31/91
(Cont) 514C May 15/70 2 thru 3 Dec 31/95
514D Dec 31/95
514E/514F Dec 31/95 72-01-2 1 Dec 31/95
515 Dec 31/91 2 thru 4 Mar 30/67
516 Dec 31/95
516A thru 516B Mar 30/84 72-01-3 1 thru 3 Mar 30/67
517 Mar 30/84 4 Jan 15/69
518 Jan 15/69 5 thru 6 Mar 30/67
k518A Jul 15/99 7 May 15/70
518B Mar 30/84 8 thru 9 Dec 31/95
518C thru 518F Sep 1/75
518G Mar 30/84 72-01-4 1 Mar 30/67
518H thru 518J Sep 1/75
518K thru 518M Mar 30/84 72-01-5 1 thru 2 May 15/70
519 Mar 30/67
520 Dec 31/91 72-02-0 1 Oct 15/70
521 Feb 23/77
522 Apr 15/68 72-02-1 1 thru 2 Dec 31/95
522A/522B Dec 1/77 2A/2B Dec 31/95
523 thru 524 Dec 31/91 3 thru 4 Mar 30/67
524A/524B Dec 31/91 5 Dec 31/95
525 Dec 1/77 6 thru 7 Mar 30/67
526 Dec 31/95 8 Dec 31/95
527 Dec 1/77 8A/8B Dec 31/95
528 Dec 31/91 9 thru 10 Mar 30/67
528A/528B Dec 31/91 11 Dec 31/95
529 thru 530 Dec 1/77 12 thru 13 Mar 30/67
14 May 15/70
601 Dec 31/95 15 Dec 1/79
16 thru 18 Dec 31/95
701 thru 702 Mar 30/84
702A Mar 30/84 72-02-2 1 thru 3 Mar 30/67
702B Dec 31/91 4 Sep 15/69
703 Nov 1/80
704 Mar 30/84 72-02-3 X1 Jul 15/99
705 Sep 1175 2 thru 18 Dec 31/91
706 Nov 1/80
706A Mar 30/84 72-02-4 1 Dec 31/91
706B Sep 1/75 2 thru 3 Sep 1/75
707 thru 709 Jan 15/69 4 Dec 31/91
1001 Dec 30/78 72-02-5 1 Dec 1/77
1002 thru 1003 Dec 31/95
72-02-6 1 thru 2 Dec 30/78
Asterisk indicates pages added, changed, or deleted by this revision.
72
II Jul 15/99
CJ610 TURBOJET ENGINES
GEAjrCraffEnQjneS MA~NTENANtE ~ANUAL
CHAPTER 72 ENGINE (Cont)
LIST OF EFFECTIVE PAGES (Cont)
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
72-02-7 1 Dec 30/78 72-32-0 210A/210B Dec 31/95
2 Sep 1/75 (Cont) 211 thru 213 Sep 1/75
72-02-8 1 thru 2 Dec 30/78 72-33-0 201 thru 202 Mar 30/84
203 Sep 1/75
72-02-9 1 thru 2 Dec 31/91 204 thru 205 Dec 31/91
206 thru 207 Sep 1/75
72-03-1 1 thru 2 Dec 31/95
72-34-0 201 Dec 31/95
72-30 1 Mar 30/67 202 thru 203 Dec 31/91
2 Dec 31/91
3 Dec 31/95 72-40 1 thru 3 Mar 30/67
4 thru 6 Mar 30/67 201 thru 202 Dec 30/78
7 Dec 31/95 203 May 15/70
201 thru 202 Dec 31/95 204 Dec 31/91
202A thru 202B Dec 31/95 205 Dec 30/78
202C/202D Dec 31/95 206 thru 207 Nov 15/73
203 thru 204 Dec 31/95 208 thru 209 Dec 31/91
204A Mar 30/84 210 Dec 1/77
204B Sep 1/76 211 Dec 30/78
205 Dec 31/95 212 Nov 15/73
206 Dec 31/91 213 thru 218 May 31/98
206A/206B Dec 31/95
207 Dec 1/77 72-41-0 201 JLin 1/71
208 Dec 30/78 202 thru 203 Dec 1/77
208A/208B Dec 30/78 204 Jun 1/77
209 May 15/70
210 Dec 30/78 72-42-0 201 thru 207 Dec 1/:7
211 Mar 30/67 208 Dec 31/95
212 Dec 31/95 209 thru 215 Dec 1/77
212A/212B Dec 31/95
213 Dec 31/95 72-43-0 201 Dec 31/91
214 Nov 15/72 202 Dec 1/77
72-31-0 201 Dec 31/91 72-45-0 201 Dec 1/77
202 Sep 15/69
203 thru 204 Dec 1/77 72-46-1 201 thru 202 Mar 30/67
205 Dec 31/95
206 Nov 15/73 72-46-2 201 Mar 30/67
207 thru 208 Dec 1/77
72-46-3 201 Mar 30/67
72-32-0 201 thru 202 Mar 30/84
203 Sep 1/75 72-46-4 201 thru 202 Jun 1/71
204 Dec 31/91
205 thru 207 Sep 1/75 72-46-5 201 Oct 15/70
208 Nov 1/80
209 thru 210 Dec 31/95 72-47-0 201 thru 202 Mar 30/67
Asterisk indicates pages added, changed, or deleted by this revision.
72
Jul 15/99 III
C~61o TURBOJET ENGINES
GEAircraftEnqines MAINTENANCE MANUAL
CHAPTER 72 ENGINE (Cont)
LIST OF EFFECTIVE PAGES (Cont)
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
72-50 1 Mar 30/84 72-53-0 201 Dec 31/95
2 Jan 15/69 202 Mar 30/84
3 Mar 30/84 202A thru 202B Dec 31/95
4 Nov 15/73 202B.1 thru
201 thru 202 Mar 30/84 202B.2 Dec 31/95
203 thru 204 Sep 1/76 202C thru 202D Dec 31/91
204A thru 204B Sep 1/76 203 thru 205 Dec 31/91
205 Mar 30/67 206 Dec 1/77
206 Apr 15/68 206A/206B Dec 31/91
207 Mar 30/84 207 Dec 31/91
208 Dec 31/95 208 Dec 1/77
209 Mar 30/84 208A Dec 31/91
210 Dec 1/79 208B Dec 30/78
210A/210B Dec 1/79 208C/208D Dec 30/78
211 thru 212 Dec 31/95 209 Sep 1/76
212A/212B Dec 31/95 210 thru 211 Apr 15/68
213 Sep 1/75 212 thru 215 Sep 15/69
72-51-0 201 Dec 31/95 72-60 1 Sep 1/75
202 Sep 1/75 2 Sep 1/76
202A/202B Dec 31/95 3 Sep 1/75
203 Dec 30/78
204 Mar 30/84 72-62-0 201 Sep 1/75
204A/204B Mar 30/84 202 Dec 31/95
205 thru 206 Dec 31/91 203 thru 204 Sep 1/75
206A/206B Dec 31/91
207 Jan 15/69 72-63-0 201 thru 202 Sep 1/75
208 Mar 30/84 203 thru 204 Sep 1/76
209 Nov 15/73
210 thru 211 Mar 30/84 72-64-0 201 Sep 1/76
212 thru 218 Dec 31/91 202 thru 206 Sep 1/75
206A Sep 1/75
72-52-0 201 Jan 15/69 206B Dec 1/77
202 Dec 30/78 206C/206D Sep 1/75
202A Dec 31/91 207 thru 209 Sep 1/75
202B Dec 1/77 210 Dec 31/95
203 Sep 1/76 211 thru 214 Sep 1/75
204 thru 205 Mar 30/84
206 Sep 1/76
206A Mar 30/84
206B Dec 31/91
207 thru 210 Mar 30/84
210A thru 210B Sep 1/76
210C/210D Nov 15/72
211 thru 212 Sep 1/76
Asterisk indicates pages added, changed, or deleted by this revision.
72
IV Jul 15/99
CJGIOTURBOJET
GEAircraftEn~9ines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVBION 72-475
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610
MAINTENANCE MANUALSEI-186, adjacent to page i, dated Dec
31/95 in Chapter 72-00.
Record this TR number in the Record of Temporary Revisions.
Subject: Engine Description and Operation
Reason: This TR revises paragraph 2 to reflect the weight of CJ610-6
engines modified to the spool rotor configuration (SB CJ72-
148)
Change: Revise paragraph 2, Engine Weight (Dry)
Engine Weight (Dry)
Engines Without Compressor Spool Rotor Configuration 400 (Ibs) Approx.
CJ610-6 Engines Modified to Compressor Spool Rotor
Configuration (SB C572-148) 418 ~lbs)
FAA APPROVED OCTOBER 10, 2000
72-00
Page 1 of 1
Oct. 10/00
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
CHAPTER 72 ENGINE
DESCRIPTION AND OPERATION
1. General. The General Electric C3610-1, -4, -5, -6, -8 and -9 engines are axial
flow, turbojet engines. They are compact, high thrust, lightweight engines with
three main bearings supporting an eight stage axial flow compressor and a ~wo
stage turbine coupled to the compressor rotor. The engine is controlled by a
hydro-mechanical fuel system and a combination variable geometry-air bleed con-
trol on the compressor.
2. Eneine Data.
Engine Length Front Flange to Rear Flange 40.5 inches (approx.)
Extremes 51.1 inches (ao~rox.)
Engine Diameter Maximum 17.56 in~hes (approx.:
Engine Weight (Dry) 4CO (Ijs) :a?pros.
Direction of Rotation (Rear Locking Forward) Clockwise
3. Sections of Eneine. (See figure i.)
Basically, the engine consists of the following major sections: the compressor
section, the combustion section, turbine section, accessory drive section and
exhaust section. The description of each of these is given in the corresponding
sections of this chapter.
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORKING WITH
THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIGIDLY ADE3RED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THX ILLUS
TRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE HARDWARE TO
BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING. GRINDING,
BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL BUILD-UP ON PARTS
THAT CONTAIN ASBESTOS IS NECESSARY, APPROPRIATE PERSONAL PROTECTIVE
EQUIPMENT MUST BE WORN, AND NATIONAL ENVIRONMENTAL CONTROLS REQUIRED
FOR THE HANDLING OF ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED
WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAINING HARD-
WARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND NATIONAI ENVIRON
MENTAL CONTROLS MUST BE STRICTLY ADHERED TO FOR HANDLING ASBESTOS-
CONTAINING HARDWARE.
RIOTE: Please see the
TEMPORARY
~I REVISION
that revises this page.
Dec 31/95 ~age
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANL~AL
QCT\O’~
~\o"
Co~"B\´•’S
hO
ACCESSORY DRIVE SECTION
(tJ610-4,-6, AND-8)
L;11T ou~
tie
DRIVE SECTION
(CJ610-1,-5 AND-9)
01104010.1-)2
CJ610 Basic Engine Cutaway
Figure 1
72-00
Page 2
May 15/70
GEWLRAL E LE CTR it
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TROUBLESHOOTING
1. General. Troubleshooting is a systematic analysis of the symptoms which indi-
cate engine malfunction; these are usually a deviation from normal operating
parameters. Since the operating limits section of this manual describes nor-
mal engine indications, troubleshooting is closely related to this informa-
tion. Since it would be impractical to list all the possible malfunctions
which could occur in a modern jet engine, this section will cover only the
most common malfunctions. A thorough knowledge of the engine systems,
ap~lied with logical reasoning, will solve any remaining problems which may
occur.
As a guide to troubleshooting, the most probable troubles have been listed and
analyzed. (See Table 101.) Possible solutions have been listed, in most
cases, in the order of their probability. The only deviation from the proba-
bility sequence occurs when checking the least probable is much easier than
checking the more probable. For instance, changing the fuel control is an
extensive operation, hence the fuel control is not removed and replaced until
all other areas of malfunction are eliminated.
As a further guide to troubleshooting, the most probable troubles have also
been listed in flow chart form (see figure 101).
the fuel control is adjusted lower density setting, maximum
I
2. Whenever to a a
(See MAINTE-
edutitla2I ac omplished.or
acceleration check of the engine must be
NANCE PRACTICES ADJUSTMENT/TEST, paragraph 3. 3.
I3´•)
Mar 30/84 72-00
Page 101
CrlLIIL~ LL[CIRIO
CJ610 TURBOJET
MAINTENANCE MANUAL
SEI-186
TABLE 101
TROUBLE SHOOTING GUIDE
Problem Probable Cause Inuestigation/Corrective Action
STARTING PROBLEMS
i. Engine Fails to Rotate W_hen Starteris-Ene~Lzed.
WARNING: WHEN ROTATING COMPRESSOR ROTOR BY HAND, TAIG PRECAUTIONS TO PREVENT
HAND FROM BEING CAUGHT BETWEEN ROTATING AND STATIONARY PARTS.
A. Starter (1) Rotate compressor Ca) Check for simultaneous ro-
Inoperative rotor by hand tation of the starter arma-
ture. If the armature
rotates, refer to the air-
draft electrical system
manual for troubleshooting
of a possible electrical
system malfunction.
Cb) If armature does not rotate,
remove starter and check
starter shaft shear section
for failure.
Cc) Check for rotation of drive
spline at accessory gearbox
pad. If drive spline does
not rotate, investigation
into the accessory drive
section will be necessary.
This work should only be
performed by a proper mainte-
nance agency.
B. Compressor (1) Attempt hand Ca) If the engine rotor will not
or Turbine rotation of com- rotate and visual inspection
Rotor Seized presser rotor of the compressor and tur-
bine reveals no damage, al-
low engine to cool at least
one hour. During cool down,
attempt hand rotation of
rotor.
72-00 May 15/70
Page 102
CJB10 TURBOJET
MAINTENANCE MANUAL
SEI-L86
TABLE: 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
1. After cool period four
hours if necessary if
rotor is still frozen,
pull forward on compres-
sor rotor in an attempt
to shift rotor forward.
72-00
May 15/70
Page 102A/102B
6LY ERIL IIICTRIC
CJ610 TURBOJET
SEI-186 MCIINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
If rotor frees, turn by
hand and listen for un-
usual noises. If none
are heard, motor engine
with starter and listen
for unusual noises. If
none are heard, continue
normal operation of en-
gine. If unusual noises
are noted, determine and
correct cause before
proceeding.
2. If engine rotor does not
become free after cool
period, remove lube fil-
ter and magnetic drain
plug and check for metal
contamination per section
79-00, Maintenance Prac-
tices, before proceeding.
If metallic contamination
is found, the source must
be determined and correc-
tive action taken by a
qualified maintenance
agency. If no metal con-
tamination is found,
loosen all bolts in for-
ward flange of turbine
casing and attempt to
rotate rotor. If rotor
is retighten bolts
free,
per section 72-01-3,
figures 2 and 3. If
rotor will rock but tur-
bine casing is frozen to
the rotor, the turbine
stater casing must be
removed and inspected.
If rotor is still frozen
in position, the turbine
rotor must be removed and
the turbine laby-
outer
rinth and inter-stage
72-00
Page 103
Sept. 15/69
GEW ERAL O~
cJsio ’iU’IRSOJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
seals inspected for in-
terference. Maintenance
facility should have Hot
Section capability if
they are to proceed.
NOTE: Engine will have to be removed from aircraft if all turbine casing flange
bolts cannot be loosened in order to complete this check.
C. Accessory Drive (1) Attempt hand ro- (a) If the rotor will roch, the
Section Seized tation of compres- seizure is probably in the
sor rotor accessories or accessory
drive section and will re-
quire individual removal
and inspection of each ac-
cessory beginning with the
starter.
2. Motoring Speed on Starter is Low.
NOTE: The most common cause for low motoring speed is low battery voltage.
Check this by using a ground power unit with capability of 27.5-28.5
volts de, 1000 amps to motor engine. A good system either battery or
ground power unit, should have capability of motoring engine to, at
least 12 percent engine speed (Ng) in 12 seconds for ambient tempera-
ture conditions of OOF (-180C) or higher.
A.Compressor Rotor (1) Turn rotor by hand (a) When excessive drag is noted,
Dragging and check for ex- remove the aircraft hydraulic
cessive drag pump and the starter-genera-
tor and again check for ex-
cessive drag. If excessive
drag is still noted, trouble-
shoot the
engine per preced-
ing paragraph i.
WARNING: WHEN ROTATING COMPRESSOR ROTOR BY HAND, TAKE PRECAUTIONS TO
PREVENT HAND FROM BEING CAUGHT BETWEEN ROTATING AND STATIONARY
PARTS
B. Electrical Input (1) Check motoring (a) If neither engine will
to Starter speed of opposite motor to proper speed, re-
engine, noting fer to aircraft electrical
max attainable system manual for trouble-
rpm, then recheck shooting of a possible elec-
engine in question trical system malfunction.
72-00 Oct. 15/70
Page 104
GENERAL ELECTRIC------
CJ61 6 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
(b) If there is a substantial
difference in indicated
RPM’s, switch RPM indica-
tors to check for indica-
tor malfunction.
(c) If indication remains the
same. switch starter from
good side to bad side or re-
place starter with known
good unit and recheck motor-
ing speed. If this corrects
problem reject faulty start-
er.
(d) If, after installation of
known good starter, the
RPM remains low, consult
applicable aircraft elec-
trical manual.
72-00
31/95 104Ai104B
I Dec Page
GENERAL ELECTRI~----
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
Problem Probable Cause Investigation/Corrective Action
3. Failure of Eneine to Light-Off Durine Attempted Start.
WARNING: IGNITER PLUGS
BEFORE ENERGIZING THE IGNITION CIRCUIT, BE CERTAIN THAT N3 ~UE3 OR
OIL IS PRESENT. HAVE FIRE EXTINGUISHING EQUIPMENT PRESENT.
HIGH VOLTAGE IS PRESENT. BE CERTAIN THE IGNITION UNIT AND PLUGS
ARE GROUNDED BEFORE ENERGIZING THE CIRCUIT.
NEVER TOUCH OR MAKE CONTACT WITHT THE ELECTRICAL OUTPUT CONNECTOR
WHEN OPERATING ANY IGNITION COMPONENT.
NEVER HOLD OR MAKE CONTACT WITH THE IGNITER PLUG WHEN ENERGIZI~S
THE IGNITION COMPONENT.
NOTE: If motoring speed of 12 percent in 12 seconds for ambient temperature
conditions of OOF (-180C) or higher can be achieved, and fuel mist is
tailpipe
from with throttle in idle detent and no continuous
coming
fuel drainage from engine drains, proceed on the assumption that the
problem is in the ignition system.
A. No audible spark (1) Motor engine and (a) If check is insufficien~
from either check for proper voltage, check input to
input voltage to exciter using air-start
igniter.
igniter box (min- ignition system.
imum 19 volts).
(b) If proper voltage can only
be attained using airstart
system or if proper voltage
cannot be attained using
either system, refer to air-
craft electrical system
manual for troubleshooting
of possible aircraft system
malfunction.
(c) If proper voltage is present,
shut off power supply to the
ignition, remove both igniter
plugs from engine per
80-23-0 and position
them where spark.
72-00
31/95 Page 105
Dec
GEILIAL ~D ELeCfllC
CJ6~0 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
gap is visible. Energize
ignition exciter and check
both igniters for strong,
blue colored, rapid firing
arcs. If either or both
igniters exhibit weak arcs,
replace the weak igniters
per section 80-23-0 and
check again.
(d) If strong arcs are observed,
check for proper immersion
of the igniters and assemble
per section 80-23-0.
(e) If neither igniter fires
properly, replace the igni-
tion exciter per 80-21-0
and recheck igniter plugs
again.
(f) If only one igniter produces
a strong are, switch the
high tension leads at the
exciter box to check the
plugs for breakdown. When
weak are is consistent with
switch, replace the bad plug.
Should the same igniter con-
tinue to exhibit a weak are,
replace the ignition exciter
per 80-21-0.
B. Faulty Fuel Nozzle
NOTE: Before with fuel system investigation, ensure there is
proceeding
no severe hot section distress in the form of burned metal on the
second-stage turbine nozzle and deposits on the second-stage turbine
blades.
(1) Motor engine with (a) If a heavy mist is observed
throttle in idle and it has been previously
established that ignition is
detent; a heavy
mist should be satisfactory, it is recom-
from mended that the two fuel
seen coming
72-00
Sept. 15/69
Page 106
G E W E RAL E LL CT R lC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Invest~gation/Corrective Action
tailpipe. See nozzles, those immediately
following step upstream of the two igniter
(2) if no or plugs which might interfere
slight mist is with the spray pattern, be
observed. removed and checked for
cracks or carbon build-up
per section 73-18-0. De-
termine if there was an in-
crease during
in EGT the
previous flight.
NOTE: A rough approximation for amount of mist is that the output of all fuel
nozzles together is about one quart every 30 seconds at starter motor-
ing speed.
(2) If tailpipe is (a) If boost pressure indication
not wet after is not observed, consult ap-
motoring engine plicable aircraft electrical
with throttle in and fuel system manuals for
idle detent, the troubleshooting of possible
fuel system should aircraft system malfunction.
be investigated
starting with the (b) If proper boost pressure
aircraft system, indication is observed, and
then proceeding to continuous drainage noted
the engine. Check from engine gang drains,
aircraft fuel sys- during motoring with throt-
tem by observing tie in idle detent or at
the aircraft in- anytime boost pumps are oper-
struments for ating, replace the manifold
positive indica- drain valve per 73-16-0 on
tion of boost CJ610-1, -5 and -9 engines
while or P and D valve per 73-17-0
pressure
attempting a nor-
on CJ610-4, -6 and -8 en-
mal start per the gines.
aircraft flight i. Replace the fuel pump,
manuals.
73-13-0, if fuel drains
from the fuel pump shaft
NOTE: Check the
seal drain. It is impor-
aircraft fuel
tant to check the fuel
shut-off valve
pump and control filters
for proper for contamination. Should
operation. the control filter show
signs of having bypassed
(heavily contaminated)
the fuel control must be
replaced per 73-21-0. In
72-00
Nov. 15/72 Page 107
ELICTIIIC
CJ610’ TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
addition, the filter in
the servo fuel supply
line to the overspeed
governor must be cleaned.
2. Replace the manifold
drain valve per 73-16-0
on CJ610-1, -5 and -9
engines; P and D valve
per 73-17-0 on CJ610-4,
-6 and -8 engines, if
fuel drains from the
valve at a steady flow
rate while engine is
being motored with throt-
tle in idle detent.
(c) Carry out start attempt-
advance throttle to higher
setting. If engine starts,
check the following:
i. Correct throttle rigging
if shaft fails to reach
idle detent or fuel con-
trol lever is not at
ground idle mark on the
control when throttle
shaft is in the idle de-
tent.
2. Deleted.
72-00
Page 108 Nov. 15/72
OEWERAL ~B E LE CTA It
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
3. Deleted.
(d) If engine does not start
when throttle is pushed
forward. Carry out the
following:
1. If proper boost pressure
indication is observed
and the control throttle
shaft is positioned
properly, check for air
locked pump by first
disconnecting reference
pressure line to pres-
surization valve. Turn
on aircraft electrical
boost pumps until at
least one quart of fuel
drains from line then
reconnect line. If air
was present in the sys-
tem, perform a "Motoring
Check", 72-00, Adjust-
ment/Check Section, to
prime system then attempt
a start.
72-00
Nov. 15/72
Page 109
OL!nEIAL ~Ob ELECTIIC
CJB10 TUCPBOJET
MAINTENANCE MANUAL SEL-186
TABLE 101
TROUBZESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
2. If air was not present,
and engine will not
start, check fuel pump
and fuel control filters
for contamination. If
either filter contains
sufficient contamination
to have bypassed, that
component must be re-
placed.
3. Excessive internal leak
age in the overspeed
governor, check by dis-
connecting The line from
the overspeed governor
"bypass" port. Cap the
line but leave the over-
speed governor port un-
plugged. Disarm ignition
and motor engine. Place
throttle in idle position.
I Leakage
be less
from port shall
than 80 pph. If
over 80 pph, the over-
speed governor must be
replaced per section
73-22-0.
Mar 30/84
72-00
Page 110
6EW ERALO ELECTIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAI,
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
4. High Exhaust Gas Temperature (EGT) During Starts.
NOTE: Be sure engine achieves 12 percent speed in 12 seconds for ambient tem-
perature conditions of OOF (-180C) or higher. A slow acceleration to a
speed below 12 percent may result in a hot start. Hot starts represent
over-temperature conditions within the engine; therefore, troubleshoot-
ing should be approached with caution. Any overtemperature of the en-
gine requires inspection checks per 72-00, Inspection/Checks. Prior to
troubleshooting the engine, position aircraft facing into the wind.
A. Turbine Tempera- (1) Improper EGT (a) Ensure EGT indicating system
ture (T5)
EGT indication. is functioning correctly by
Rises Abnormally checking aircraft/engine
Requiring Start system with a Jetcal Ana-
To Be Aborted. lyzer, or equivalent, which
actually applies heat to
the thermocouple harness
probes. If the aircraft/
engine EGT indicating sys-
tem does not check out
satisfactory, check each
component (thermocouple
harness, engine temperature
protector, aircraft wiring,
aircraft indicator) for re-
sistance and determine the
malfunctioning component.
NOTE: If an engine tempera-
ture protector (ETP)
is installed on the
engine, the aircraft
indicating system
should read 130C
lower than the Jetcal
Analyzer for
every one
ohm of resistance in
the ETP above 1.5
and 130C higher than
the Jetcal Analyzer
for every one ohm of
resistance in the ETP
below 1.5 ohms.
Nov. 15/73 72-00
Page 11OA/11OB
CEWERAL ~g ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
P:oblem Probable Cause InvestigationjCorrec t ive Action
(2) Improper fuel Check fuel density setting for
density setting. proper combination of fuel and
position. If setting is incor-
rect, reset to proper detent
(73-21-0).
Whenever the fuel control is lower
I
NOTE: adjusted to a
density setting, a maximum altitude acceleration
check of the engine must be accomplished. (See
MAINTENANCE PRACTICES ADJUSTMENT/TEST, para-
graph 3. 12 or 3.
I3´•)
(3) Foreign object Inspect compressor and turbine
damage (FOD). for signs of FOD. If damage is
evident, repair as necessary
(72-32-0 and 72-33-0 or 72-52-0
and 72-53-0).
(4) Improper starting Ensure throttle is not advanced
procedure, to idle until at least 10 per-
cent (Ng) is reached. (12 per-
cent or higher is preferable if
obtainable.)
(5) Air in fuel This is likely to occur if any
control, portion ofsystem has
the fuel
been opened upstream of the fuel
control. If this has occurred,
make a normal (wet) start at-
tempt without ignition for 20
seconds. Allow engine to drain,
then make a normal start. Do
not open stopcock until 15 sec-
onds after initiation of start.
This will blow residual fuel
from the engine.
Mar 30/84 72-00
Page 111
OEW EIAL ~Bb ELEETRIC
CJ610 7URBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
(6) Delayed ignition. (a) Check that engine lights
off within 5 seconds of
throttle advance to ground
idle detent. If not, check
ignition system. If this
proves satisfactory, sus-
pect fuel nozzles.
(7) Improper over- (a) Motor engine with throttlg
board drainage. in ground idle detent and
ignition off. When motor-
ing speed has stabilized,
stopcock the throttle and
allow engine to shut down.
A minimum of 100 cc of fuel
should flow from the over-
board drain. If there is
no or little overboard
drainage replace the drain
valve per 73-16-0 on
C5610-1, -5 and -9 engines;
P and D valve per 73-17-0
on CJd10-4, -6 and -8
engines.
(8) Ice in fuel con- (a) Apply heat to fuel control
trol Pg sensing sensing bellows before at-
bellows. tempting next start.
(b) Remove the water from the
sensing bellows and fill the
bellows with diethylene
glycol monobutyl ether,
antifreeze fluid (Butyl
CarbitoL, manufactured by
Union Carbide Corp., Box
8361, 437 MacCorkle Ave.,
South Charleston, West
Virginia, 25303, or MCB Manu-
facturing Chemists, 2909 High-
land Ave., Norwood, Ohio
45212, or equivalent) as
follows:
Disconnect the P3 line
1~. from the fuel control.
72-00 Nov. 15/73
Page 112
GEIEIALQ ELECnlG
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Action
2. Deleted.
3. Heat (evenly distributed)
the control, if necessary,
to 75"-1350F and stabi-
lize the temperature.
4. Close antifreeze valve
(No. 2) and open vacuum
pump valve (No. i).
Maintain a constant tem-
perature and the correct
pressure/vacuum for at
least 1 hour.
5. After the bellows has
been evacuated for 1 hour
at the proper temperature
and pressure/vacuum,
close the vacuum pump
valve (No. 1) and open
the antifreeze valve
(No. 2) to allow complete
filling of the bellows
with antifreeze.
6. Close antifreeze valve
(No. 2). Reconnect the
P3 line to the fuel
control.
(c) The following procedure may
be used to remove the water
from the sensing bellows and
to fill the bellows with
antifreeze fluid.
72-00
Dec. 30/78
Page 113
GEW ERAL ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAI; SEL-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
NOTE: This procedure is to
be used only as an
interim procedure
and must be followed
by the procedure des-
cribed in paragraph
(b) at the first
possible opportunity.
1. Disconnect the P, line
from the fuel control.
2. Allow moisture or water
to drain out of P3 fit-
ting on fuel control.
Using a syringe inserted
suck
out
theellows.fitting,
3. Pour squirt a small
or
amount diethylene
of
glycol monobutyl ether
into the P3 fitting to
fill the bellows (approx.
5 cc).
4. Reconnect the P3 line to
the fuel control.
NOTE: If the foregoing does not correct problem, make more rigorous FOD
inspection. If no damage, change fuel control per 73-21-0.
5. Engine Will Nor Accelerate to Idle Speed in 40 Seconds
NOTE: Deleted.
A. Hang-Up Occurs (1) Starting system (a) Trouble shoot start system
Below 20 ~ercent will not acceler- per paragraph 2. of this
Engine Speed. ate engine to 12 troubleshooting guide.
percent speed in
less than 12
seconds.
72-00 Nov. 15/73
Page 114
eEWERAL~B ILECTRIC
CJGIO TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
B. Hang-Up Occurs (1) Engine accelerates Correct throttle rigging if
Above 20 Percent out of hang-up throttle shaft fails to reach
Engine Speed. when throttle is idle detent or fuel control lever
advanced. is not at idle mark when throttle
shaft is in idle detent.
(2) Engine does not (a) Inspect P3-to-fuel control
accelerate out of tube for tightness and
hang-up when cracks. Repair as necessary.
throttle is ad- (72-02-1).
vanced.
(b) Check overboard drain line
for fuel flow, replace drain
valve if any fuel flows from
drain at hang-up condition.
(c) Inspect for FOD in compres-
sor and turbine sections.
Repair necessary (73-32-0
as
and 72-33-0 or 72-52-0 and
72-53-0).
(d) Measure overspeed governor
internal leakage by discon-
necting the return line from
the overspeed governor by-
pass port. Cap the line but
leave the overspeed governor
port unplugged. Disarm igni-
tion and motor engine. Place
throttle in idle position.
Leakage from port should be
less than 80 pph. If great-
er, the overspeed governor
must be replaced (73-22-0).
(e) Adjust fuel control density
setting one click to a lower
density setting and try
another start.
NOTE: Whenever the fuel control is adjusted density setting, a maximum
to a lower
altitude acceleration check of the engine accomplished.
must (See
be
MAINTENANCE PRACTICES ADJUSTMENT/TEST, Paragraph 3. 12 or 3. 13.)
Mar 30/84 72-00
Page 114A
GEWERAL ~gB E Lf eTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
(f) Check for leakage of fuel
pressurizing valve by open-
ing valve reference pressure
line, capping off line from
main fuel pump, cranking and
engine with stopcock open.
If leakage occurs, change
fuel pressurizing valve
(73-15-0 on CJ610-1, -5 and
-9 engines; 73-17-0 on
CJ610-4, -6 and -8A engines).
(g) Replace fuel control if con-
trol checks do not correct
problem (73-21-0).
C. Air Start (1) Improper air- Make sure the start was attempted
Hang-up. start envelope. within the air-start envelope
of the Aircraft Flight Manual.
(2) Improper fuel Check fuel density setting for
type setting, proper combination of fuel and
position. If setting is incor-
rect, reset to proper detent
(73-21-0).
NOTE: If a lower density setting is made, a maximum
altitude acceleration check of the engine must be
accomplished. (See MAINTENANCE PRACTICES
ADJUSTMENT/TEST, paragraph 3.
12 or 3.
Ij´•)
(3) Faulty ignition Check ignition system (paragraph
system. 3.A.).
5A. En_gine Undergoes RPM Roll-back or RPM Roll-back and Flameout After Engine
Reaches Idle Speed. (CJ610-4, 6, and -8A engines.)
A. Engine RPM (1) Air leaking into Change overspeed governor
rall-back or overspeed governor (73-22-0).
RPM roll-back through carbon
and flameout seal, allowing fuel
after engine to drain back to
reaches idle tank when engine is
speed. shut down.
72-00 Mar 30/84
Page 114B
GLNERAL~sb ELECTllt
CJGIO TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause InvestigationlCorrective Action
(2) Air leaking Remove fuel pump and replace
through fuel pump a-ring beneath fuel pump high-
high-pressure pressure relief valve cover
relief valve (73-13-0).
cover when engine
is shut down,
allowing fuel to
drain back to
tank. Evidenced
by small external
fuel leak at high
pressure relief
valve cover when
engine is running.
STALL PROBLEMS
6. Compressor Stalls.
NOTE: Stalls may be divided into two types; steady state and those occurring
during acceleration or deceleration. Steady state stalls are those
that occur each time an engine reaches a certain speed regardless of
how slowly it is accelerated. Acceleration/deceleration stalls depend
on the rate of acceleration or deceleration. Stalls occur when the
air flow through the compressor is disrupted.
Mar 30/84 72-00
Page 114C/114D
e E n E a ~i L ~s E LE CT R lC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
A. All Types of (1) Loss of compres- (a) Check compressor and turbine
Stalls (Steady- sor stall margin sections for FOD (72-32-0 and
State, Accel- and turbine 72-33-0 or 72-52-0 and
eration and efficiency. 72-53-0).
Deceleration).
(b) Check compressor (through in-
let and bleed valves) for
cleanliness or corrosion. A
contaminated compressor will
result in loss of stall mar-
gin. Clean as necessary
(Cleaning and Preservation,
paragraph 4).
(2) Variable geometry Check variable geometry system
system not working (75-00) by operating system
properly. by hand for:
i. Excessive wear.
2. Binding linkages.
3. Actuator jamming.
4. Broken/kinked feedback cable.
NOTE: The actuators should move smoothly but have firm resistance.
(3) Variable geometry Check variable geometry system.
system out-of-
limits.
NOTE: If bleed valves have closed during shutdown, turn on boost pumps
and motor the engine with ignition OFF. This will open the bleed
valves.
(4) Improper fuel type Check fuel density setting for
setting. proper combination of fuel and
position. If setting is incor-
I rect, reset
(73-21-0).
to proper detent
72-00
Mar 30/84
Page 115
GEILIALQ ELEeTIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SF~I-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
I
NOTE: If a lower density setting is made, a maximum
altitude acceleration check of the engine must be
accomplished. (See MAINTENANCE PRACTICES
ADJUSTMENT/TEST, Paragraph 3.
I2 or 3.
Ig´•)
(5) Faulty compressor Check CIT sensing air hoses from
inlet temperature inlet to aspirator for signs of
sensing systems. chafing, collapse or blockage.
(6) Incorrect stater Check alignment of stater seg-
alignment. ment bleed holes with holes in
compressor casing (view through
customer bleed ducts).
NOTE: The above checks should eliminate steady-state stall problems.
Further checks for acceleration or deceleration stalls should be
carried out with the engine running. Ensure aircraft is facing
into the wind when performing these checks.
B. Engine stalls (1) Bleed valve sched- (a) Performs variable geometry
during accel- ule out-of-limits. check (Adjustment/Test).
eration or If adjust-
schedule cannot be
deceleration. ed within limits, replace
fuel control (73-21-0).
(b) Perform fast acceleration
followed by fast decelera-
tion. If engine does not
stall, return engine to ser-
vice.
(2) Stall occurs in Check fuel density setting on
50-to-70-percent fuel control for correct setting.
speed range. If setting is incorrect, reset to
proper detent (73-21-0).
NOTE: If a lower density setting is made, a maximum
altitude acceleration check of the engine must be
accomplished. (See MAINTENANCE PRACTICES
ADJUSZ~’MENT/TEST,´•Paragraph 3.
12 or 3.
I3´•)
(3) Stall occurs (a) Either FOD or basic engine
above 70-percent problem. If stall occurs
speed range, above 90 percent, remove
compressor top half and In-
spect for FOD or stater vane
sector reversal (72-32-0).
72-00 Mar 30/84
Page 116
GENERAL ELECTRIC------´•
CJ61 6 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probab~e Cause Investigation/Corrective Action
(b) If fuel density setting is
at recommended
setting.
set it one click to a jlgjs
specific gravity setting ar.d
perform Acceleration
(Adjustment/Test). If this
corrects problem, perform
Maximum Speed Setting proce-
dure (Adjustment/Test). If
problem still exists, replace
fuel control (73-21-0)
C. Engine stalls during
altitude acceleration
or steady state condi-
tions.
NOTES: l.liecord inlet temperature (T2) and speed (Ng) at which stall
occurred.
2. See figure 103 for troubleshooting guide and for references to
overhaul inspection and repair procedures.
3.’10 make sure that the stall problem has been corrected, perform
an altitude acceleration check after all repairs and
have been accomplished.
(1) Compressor or (a) Inspect and repair per
turbine FOD. overhaul manual.
(2) VG system worn, (a) Check VG system by operating
binding or broken by hand. The actuators
and feedback cable should move smoothly and
broken or kinked. have firm resistance.
(b) Inspect and repair per
overhaul manual.
(3) P3 line to MFC (a) Inspect for damage or
damaged. blockage.
(4) Contaminated (a) Inspect aircraft and engine
fuel filters. filters for blockage per
SEI-154, Sections 73-20-1
73-13-0. 73-14-0, and 7?-21-0.
C3
Dec 31/95 Page IlbA
StrEIAt ~ED ELfCTIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
ProblemI Probable Cause Invest igat ion lCo rrec t ive Ac t ion
(5) Top speed in ex- (a) Bench test fuel control and
cess of 108% gas recalibrate topping schedule
generator. downwards per SEI-154,
Section 73-20-1.
(6) Shift in fuel (a) Check fuel control for
control accel- proper specific gravity
eration schedule.´• setting per SEI-154,
Section 73-20-1.
NOTE: If a lower density setting is made, a maximum
altitude acceleration check of the engine must be
accomplished. (See MAINTENANCE PRACTICES
ADJUSTMENT/TEST, Paragraph 3. 12 or 3.
13)
(b) Bench test fuel control and
recalibrate acceleration
schedule per SEI-154,
Section 73-20-1.
(7) Engine/aircraft (a) Check inlet duct for damage
system problem. or misalignment.
(b) Check nacelle area for air
leakage or exhaust recircu-
lation.
(c) Check aircraft for engine
throttle rigging fault.
(d) Inspect T2 sensor hose for
damage or cracking.
(e) Check sample of fuel for
contamination (debris or
water)
(f) Check aircraft for boost
pumps failure.
(g) Check bleed duct for mis-
alignment.
(h) Check tail pipe area. Use
average of 12 U) measure-
ments.
72-00 Mar 30/84
Page 116B
O E W E RI I E LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
(8) High-compressor (a) Inspect turbine for FOD,
operating line. tip rubs, and blade damage
repair per overhaul manual.
(b) Inspect turbine shroud for
excessive clearance and re-
pair per overhaul manual.
(c) Inspect for undersize tur-
bine nozzle flow areas and
repair per overhaul manual.
(d) Inspect compressor for ex-
cessive corrosion and for
tip rubs per overhaul manual.
(e) Inspect compressor for ex-
cessive FOD rework per over-
haul manual.
(f) Inspect compressor for
excessive blade and vane tip
clearance and repair per
overhaul manual.
(g) Inspect for clogged fuel
passages and/or clogged
cooler repair per overhaul
manual.
(h) Inspect for compressor blade
leading edge quality (fac-
tory check) and replace if
necessary.
(i) Inspect for compressor vane
orientation angle (factory
check) and replace if neces-
sary.
Mar 30/84 72-00
Page 116C/116D
OCWERAL B%D ELEeTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
ACCELERATION PROBLEMS
7. Slow Engine Acceleration From Idle to Takeoff Power.
A. Acceleration (1) Compressor and/or (a) Inspect the compressor
Time f’rom Idle turbine area blades for non-serviceable
rpm to Stabil- damage. damage through the engine
ized Takeoff inlet and bleed valve ports.
EPR is Greater Check for non-serviceable
than 15 Seconds damage to the turbine sec-
tor what was tion by looking up the
previously tailpipe.
"Normalll for
the particular (2) Low idle RPM. (a) Check idle rpm and correct,
engine), since the slowest accelera-
tion is in the range below
65 percent rpm a low idle
rpm will extend the accel-
eration time.
(3) Aircraft bleed (a) Check the bleed air system
air system, for leakage by making ac-
celerations with customer
bleed air on and off. Check
for large increase in ac-
celeration time with cus-
tomer bleed air on. If this
occurs, consult applicable
aircraft manual for trouble-
shooting of bleed air system.
Check engine anti-ice system
for proper operation. If
valve has failed, replace
the valve, 75-11-0, and re-
check acceleration time.
(4) Compressor dis- (a) Check compressor discharge
charge pressure pressure sensing line to the
(P3) sensing line, fuel control for leaks,
especially at the gasket on
the engine mainframe. Re-
move and replace the gasket
if a leak is found and re-
peat the acceleration test.
72-00
Page 117
SeF1/75
GEIERAL ~b E LE CIR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont.)
Problem Probable Cause Investigation/Corrective Action
(5) Low fuel flow Check fuel control fuel density
from fuel If setting is for
I
con- setting. a
trol. higher specific gravity fuel than
that being used, reset it for
type of fuel being used and check
acceleration. If this does not
correct problem, reset density
setting one click to a lower
specific gravity setting. Ac-
celerate from idle to takeoff.
If this corrects the problem,
perform Acceleration Check and
Maximum Speed Setting procedure
(Adjustment/Test). If problem
still exists, replace fuel
control (73-21-0).
LOW ENGINE SPEED
8. Low RPM Engine Unable to Reach Selected Speed.
NOTE: Deleted.
A. Engine fails to (1) Turbine section Visually inspect turbine section
attain selected damage. for nonservlceable damage.
engine speed.
(2) Fuel control Check fuel control shaft travel
shaft position, by positioning aircraft throttle
against takeoff stop and then
checking control shaft for proper
position. Rig aircraft throttle
system according to aircraft
manual if required.
(3) Compressor dis- Check for ruptured gasket at
charge pressure mainframe end of compressor dis-
(Pg) sensing line. charge pressure sensing line.
Check for loose fitting at fuel
control.
(4))Aircraft bleed Inspect aircraft bleed air sys-
air system. tem for evidence of leaks.
Correct according to aircraft
manual if required.
72-00 Nov 1/80
Page 118
sElf~AL8 tLLGtllC
CJ6(0 TURIBJEV
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
(5) Perform engine (a) Check the indicating system
run. by replacing the low read-
ing indicator with a known
good item or by switching
indicator from opposite
engine.
(b) Check Maximum Speed Setting
per 72-00 Adjustment/Test.
Adjust maximum speed setting
higher; if necessary.
(c) Check for
overspeed gover-
nor making
malfunction by
an overspeed governor check.
If test speed on overspeed
governor is not within
limits, replace the gover-
nor, 73-22-0.
(d) Check for defective fuel
pump by inspecting the fuel
pump and fuel control fil-
ters. Check boost element
by removing inlet line to
pump and attempt rotation
of boost element through
the inlet.
(e) Check for defective fuel
control by making bleed
valve schedule check per
72-00, Adjustment/Test. If
there is a large shift in
the downward direction
(bleed valves close much
sooner than they are sup-
posed to, i.e. 1 2 per-
cent or more under schedule)
replace the fuel control per
73-21-0.
72-00
Sep 1/75
Page 118A/118B
GEN ERAL 4~8 E~Eetlle
CJ610. TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
B. Engine speed (1) Failed engine (a) Disconnect fuel pump inlet
decreases fuel pump hose. Carefully rotate en-
approx. 2% Ng. impeller shaft, gine while attempting to
Speed regained hold impeller with a nylon
by turning on rod. If impeller does not
A/C boost rotate replace fuel pump.
pump.
WARNING: WHEN ROTATING COMPRESSOR ROTOR BY HAND, TAKE PRECAUTIONS TO PREVENT
HAND FROM BEING CAUGHT BETWEEN ROTATING AND STATIONARY PARTS.
PERFORMANCE PROBLEMS
NOTE: Before Troubleshooting any performance problem, calibrate instrumenta-
tion for the following parameters:
Gas generator speed (Ng)
EGT (T5). See paragraph 4.A.(l)(a).
Fuel Flow (Wf)
Engine Pressure Ratio (EPR) (aircraft instrumentation)
9. Insufficient performance margin. (See figure 104.)
A. Aircraft engine (1) Aircraft instru- (a) Recalibrate aircraft
instrument(s) ment(s) out of instruments as noted.
over limits, calibration.
(b) Using Engine Analyzer Model
NOTE: Aircraft problem possibilities should
1300, R-L Instruments, Co-
be eliminated before rejecting newly
installed engines. Refer to figure lumbia Station, Ohio 44028
104 for troubleshooting guide. (or equivalent), check each
parameter through the entire
engine operating range.
Advise operator to replace
or repair defective instru-
ments.
(2) Bleed air loss. (a) Test engine with the main-
frame customer bleed ports
blanked off; if engine per-
formance margin is suffi-
cient, troubleshoot aircraft
for losses.
72-00
Sep 1/75
Page 119
eEwEaAL ~g E LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont.)
Problem Probable Cause Investigatian/Corrective Action
B. EGT limited at (1) EPR error. (a) Check probes for cracks and
takeoff (or carbon buildup covering
maximum cruise) sensing holes. Remove carbon
EPR conditiori. or replace probe (77-11-0).
(b) Check lines for cracks and
leaks. Replace defective
parts.
(c) Check variable geometry
system for integrity, free-
dom of movement, and proper
rigging (75-00).
(2) CIT sensing Check CIT inlet aspirator hoses
error. for signs of collapse, damage
or blockage.
(3) Compressor FOD, (a) Check compressor blades and
erosion or ex- vanes, and check bleed valves
cessively dirty. for FOD, cleanliness, and
corrosion (72-32-0 and
72-33-0).
(b) Check 8th-stage seal clear-
ances according to Overhaul
Manual (SEI-136).
(4) Faulty air bleed Turn off bleed air system, and
system or IGV’s check for increase in EPR. If
incorrectly EPR, fuel flow, and EGT return
rigged, to normal, inspect bleed air
system. Check engine variable
geometry schedule (75-00), and
check IGV static rigging. With
IGV’s in fully-open position, the
scribe mark on actuating ring
must line up with zero mark
(longest line of the five lines
on front frame). Adjust IGV
rigging (75-00).
72-00 Nov 1/80
Page 120
tlteTllt
CJ610 TURIOJLT
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
(5) Faulty fuel (a) With engine running, station
nozzles, in- an observer in a safe posi-
dicated by tion where he can see into
torching. the engine tailpipe. In-
struct the observer to look
for a continuous visible
flame and to note its posi-
tion. Proceed as follows:
CAUTION: DURING A NORMAL START THERE CAN BE NO
VISIBLE FLAME OR TORCHING FROM THE TAIL-
PIPE WHILE THE ENGINE ACCELERATES TO
IDLE. THE ENGINE START SYSTEM SHOULD BE
CAPABLE OF MOTORING THE ENGINE TO AT
LEAST 12 PERCENT ENGINE SPEED (Ng) IN
12 SECONDS. THE THROTTLE SHOULD BE AD-
VANCED TO IDLE AT 10 PERCENT, MINIML~M,
ENGINE SPEED (Ng). IF THESE REQUIREMENTS
ARE NOT MET CONSISTENTLY, THE TORCHING
MAY RESULT IN DAMAGE TO THE HOT SECTION
PARTS.
1 If a continuous flame is
observed at idle, termi-
nate engine run immediate-
ly and remove three fuel
nozzles; the one clockwise
of the flame and the next
two in the counterclock-
wise direction (aft look-
ing forward). Inspect
these nozzles, in the noz-
xle annulus and on front
face, for carbon deposits
and/or cracks which might
alter the nozzle spray
pattern. Replace fuel noz-
zles per 73-18-0.
CAUTION: DO NOT EXCEED
RPM OR EGT
LIMITS.
2 If no torching is observed
at idle, advance power
slowly until either
72-00
Sep 1/75
Page 121
OflLOAL fLfCIIIO
CJ610 TURIOJaT
MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
torching is observed or
EGT RPM limits power
or
increases.
3 If torching is observed at
any speed between idle and
max power, terminate run
and remove fuel nozzles
and inspect per step 1
above.
(6) Engine temper- (a) Perform cell test to check
ature protector engine temperature pro-
set incorrectly., tector per overhaul manual.
(7) Turbine damage, (a) Carefully inspect for any
erosion or rubs. evidence of abnormal metal
erosion, FOD or other forms
of damage such as missing
and/or damaged nozzle par-
titions or rotor blades, or
damage to the tailpipe exit
area. Inspect and repair
damaged parts per 72-50.
(b) Inspect turbine shroud for
excessive clearances or
rubs. Replace as necessary
per 72-50.
(c) Inspect turbine nozzles for
cracks and missing metal.
Repair and resize per
overhaul manual.
(d) Inspect first-stage turbine
blades for bow and warp per
72-53-0.
(8) Combustor dam- (a) Inspect for abnormal metal
age. burnout, erosion or miss-
ing rivets. Repair as nec-
essary per 72-42-0.
72-00 Sep 1/75
Page 122
)tlLlAL´•IIICIIIC
CJ610 TURIOJLT
MANUAL
SEI-186 MAINTENANCE
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
C. High gas gen- (1) Undersize tur- (a) Inspect and repair flow
erator speed at bine nozzle area per overhaul manual.
takeoff EPR. flow area.
(2) Leaking inter- (a) Inspect for proper rigging
stage bleed and operation of valves
valve. per 75-00.
(3) Leaking anti- (a) Inspect for operation of
icing valve. valve per 72-00 or replace
per 75-11-0.
(4) Excessive com- (a) Inspect clearance and re-
pressor 8th- place parts as necessary
stage seal per overhaul manual.
clearance.
(5) Excessive tur- (a) Inspect per 72-50. Repair
bine shroud or replace parts if nec-
clearance. essary.
(6) Misrigged IGV (a) Inspect and rig per 75-00.
and variable
geometry.
D. High or low (1) Excessive un- (a) Inspect first-stage turbine
thrust at EPR. twist of tur- blades for bow and warp per
bine blades. 72-53-0.
(2) Cracked or (a) Inspect and repair per
plugged EPR 77-11-0.
probe.
72-00
Sep 1/75
Page 122A
t~tC1IIE
CJ6I0 TURIOJaT
MAINTENANCE MANUAL SEI-186
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
E. High specific (1) Leaking anti- (a) Inspect and repair per
fuel consump- icing or bleed 75-00.
tion (SFC). valves.
(2) Excessive tur- (a) Inspect per 72-50. Repair
bine blade tip or replace parts if nec-
clearance. essary.
(3) Excessive tur- (a) Inspect first-stage turbine
bine blade un- blades for bow and warp
twist. per 72-53-0.
(4) Compressor FOD. (a) Inspect and repair per
72-31-0, 72-32-0 and
72-33-0.
(5) Excessive CDP (a) Inspect and replace if nec-
seal leakage, essary per overhaul manual.
(6) Turbine FOD. (a) Inspect and repair per
72-53-0.
(7) Oversize tur- (a) Inspect and repair per
bine nozzle overhaul manual.
areas.
10. Apparent Excessive T2 Cutback (Speed and EPR Low at Altitude).
NOTE: These checks must be made with throttle at Max. position.
(See figures 507 and 508.)
A. Speed and EPR (1) Speed can be (a) Check aircraft and engine
are low at al- increased by throttle system and rigging.
titude when advancing
compared to throttle. (b) Check P3 to fuel control
figure 507 or line for tightness, cracks
508, 72-00, or bad gasket at mainframe.
Adjustment/ Test.
72-00 Sep 1/75
Page 1228
CLWERAL ~g E LE eTR It
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont.)
Problem Probable Cause Investigation/Corrective Action
(c) Check fuel control top speed
setting during ground runup
(Adjustment/Test).
(2) Slow start as Reset fuel control density ad-
well T2 cut- justment to a lower specific
I as
back is experi- gravity setting. Adjust idle and
enced. top speed, then perform fast
idle-to-maximum acceleration.
If engine stalls, replace fuel
control (73-21-0). If engine
operation is satisfactory, make
flight test to determine if ex-
cessive speed cutback has been
eliminated.
NOTEI Engine-to-control system tolerance stackup may create a throttle
mismatch situation which should not be interpreted as excessive T2
cutback.
(3) Speed cannot be (a) Check for correct function-
increased by ad- ing of aircraft boost pump.
vancing throttle. If low pressure, trouble-
shoot aircraft fuel system.
(b) Inspect CIT sensing system
damage, collapsed
rof.sesoh
blocked orZnspect as-
pirator housing for cracks
or other damage.
(c) During throttle retard-to-
idle, engine stalled or
flamed-out between 80-90
percent speed (indicates
T2 bellows failure or IGV
feedback cable problem).
Inspect compressor and tur-
bine for FOD and other dam-
age (i.e. thermal distress)
(72-32-0 and 72-33-0 or
72-52-0 and 72-53-0). If
satisfactory, start engine
and check bleed valve
schedule while accelerating.
If bleed valves start to
close early (approx. 70
Nov 1/80 72-00
Page 123
OEWERAL aD ELE:C~IIC
CS610 TURB03ET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
percent speed) do not con-
tinue to accel engine as
speed hang-up may occur in
70-75 percent (Ng) range.
Replace fuel control (’12
bellows failure) per 73-21-0.
(d) If engine does not stall or
flame out on decel, turn on
anti-icing air and observe
engine speed. This should
be done at the flight con-
dition at which problem oc-
curs. If speed does not
change, replace fuel control
per 73-21-0.
(4) Excessive metered (a) Check overspeed governor
flow leakage for internal
leakage per
3,B.(2)(d)3.
(b) Check drain valve on CJ610-
i, -5 and -9
engines for
overboard leakage with en-
gine running. If leakage,
’replace valve per 73-16-0.
(c) Check pressurizing valve
for leakage through refer-
ence port by disconnecting
hose at fuel
pump. Cap off
fuel pump connection and
start engine. Fuel should
not leak from the open
pressurizing valve port. If
it does, replace valve per
73-15-0 on CJ610-1, -5 and
-9 engines; P and D valve
per 73-17-0 on CJ610-4, -6
and -8 engines.
72-00
Page 124 Sept. 15/69
GE#ERAL ECECTIIC
CJ610 TURBOJ6T
SEI-186 MAINTENANCE MANUAL
TABLE 101(Cont)
Problem Probable Cause Investigation/Corrective Action
11. High or Erratic EGT (T5) Readings in Flight Envelope.
A. High EGT in (1) EPR is low ~a) Check the EGT indicating
Flight compared to EGT. system per paragraph
Envelope.
(b) Check physical security of
the EGT wiring harness and
any other wires in its
vicinity. Incorrect read-
ings can result due to
bunches of other wires com-
ing close to the EGT wiring
harness, setting up an in-
duced current.
(2) Anti-icing (a) Check functioning and re-
air is on, lated wiring of anti-ice
valve. This is a fail-safe
system, and so if any part
of electrical system in
the
the anti-ice circuit fails,
then the valve opens.
ABNORMAL ENGINE NOISE
12. Excessive Engine Noise.
NOTE: There are certain normal noises associated with engine starts and
shutdowns, such as "ticking", "scraping" and "rubbing" because of
basic design features such as pinned No. 1 stage compressor rotor
blades, backlash in the accessory gear train and variable clearances.
Departures from normal noises are to be investigated. A normal engine
coastdown time is usually greater than 30 seconds and a slight "kick-
back"at the moment the rotor stops turning usually indicates that the
rotor is free.
A. Noise During Gearbox, Compress- (a) Turn rotor by hand to deter-
Start and or, Turbine. mine the amount of drag asso-
Shutdown. ciated with the noise, if
NOTE: Scraping noises are possible determine the
sometimes associated approximate location of the
with newly overhauled noise, i.e., gearbox, com-
or repaired engines presser, turbine.
and usually associ-
ated with "wearing in"
Nov. 15/73 72-00
Page 125
GEWIIALQILECtllC
cJeio TURei~OJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
NOTE: (Cont)
of new or re-
located seals.
This may becon-
sidered normal.
(b) If coastdown time is less
than 20 seconds, remove the
.hydraulic pump from its pad,
then start engine. After
engine has stabilized at
idle, shutdown engine and
note coastdown time.
(c) If time is less than 25
seconds and can be deter-
mined that the noise comes
from the turbine, perform
engine run as follows.
Start engine and advance
power until max is obtained.
Hold max power approxi-for
mately four minutes then
reduce RPM in increments of
5 percent holding each speed
for two minutes until idle
or 50 percent speed is
reached. Shutdown engine
and listen for noise and
check coastdown time.
i. If either or both improve,
observe proper shutdown
procedure after subsequent
flights and monitor shut-
down noise.
2. If engine run has not cor-
rected turbine noise,
teardown of the engine
hot section by a facility
having this capability
should be made to deter-
mine the source and cor-
rect the problem.
B. Noises such as Generally associated Using some sound amplification
"Bumps","Thumps" with bearings. probe method check the starter,
and "Squeaks~ gearbox, and external engine
72-00 June 1/71
Page 126
GEWLIIAL ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
adjacent to main engine bearings
at starter motoring speeds and
during coastdown from either
start or idle RPM. If it is
believed that the noise is a
bearing, the engine or acces-
sory component should be re-
moved and replaced at a facility
having proper capability.
June 1/71 72-00
Page 126A/126B
666 ERAL ~B ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
C. Operational Noises
NOTE: Abnormal engine operation can result from fuel or combustion
system instability, vibration of the engine structures or
piping, and noise internal to the engine or accessories due to
interference.
(1) Fuel or com- (a) instability within either
bustion system. system is heard as a
"rumble." The condition
canbe corrected by
orderly removal and
replacement of components
within either system.
However, prior to
replacing components it is
GE
I recommended
AircraftEngines
that a
representative be
consulted.
(2) Vibrating engine (a) This condition usually re-
structures and suits from an unbalance
piping. condition of an engine ro-
tating component. Correc-
tion be performed only
can
at engine overhaul level
an
facility.
(3) Interference (a) The offending accessory can
noise. be detected by removal and
replacement.
(b) Rubbing within the engine
usually occurs in the tur-
bine section (seals and
blade rubs) and can be de-
tected by using a sound
amplification probe method.
Rubbing noises within the
compressor section require
detailed inspection and
correction at an engine
overhaul facility.
72-00
Dec 31/91 Page 127
GLWERAL ELPCTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
12A. Engine "Rumbler’ in Speed Ral2ge 48-650Jo NI~
A. Fuel System (1) Air in pressuriz- (a) Turn on boost pump, open
Malfunction. ing valve reference stop cock and loosen refer-
line. ence pressure line at pres-
suring valve. Allow flow to
continue until fuel is free
of air bubbles. Tighten
fuel line, close stop cock
and switch off boost pump.
(2) Pressurizing (a) Change pressurizing valve.
valve instability.
(3) Overspeed gover- (a) Change overspeed governor.
nor servo valve
instability.
(4) Fuel nozzle flow (a) Change all fuel nozzles.
divider insta-
bility.
B. improper (1) Combustor incom- (a) Change combustor.
Combustion. patability with
other engine
components.
NOTE: Aircraft fuel system boost pressure level can cause "rumble". Con-
sideration should be given to changing the aircraft boost pump if
difficulty is found in eliminating rumble.
LUBE SYSTEM
I NOTE: Before Trouble
pressure,
Shooting Lube System problems of
check the instrumentation calibration of these parameters.
temperature or
13. Lube System Troubleshooting,
NOTE: Theengine lube supply system basically consists of a supply tank, a
positive displacement pump, a cooler, a filter and the jets. Oil
pressure is sensed before it enters the filter. If the filter becomes
dirty or the flow through the jets is restricted the indicated pressure
will increase. At the present time there are two basic lube systems.
The center vent (CV) and non-center vent (non-CV) systems, In trouble-
shooting the CV vs. the non-CV system, the most significant difference
is that the internal sump and gearbox pressures in the CV engine run
considerably higher than those of the non-CV engine.
72-00 June 1/71
Page 128
GEWERAL E LE CTR It
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
CAUTION: IF THE ENGINE HAS OPERATED WITH NO OIL PRESSURE, A COMPLETE LUBE
SYSTEM INSPECTION MUST BE MADE BY AN OVERHAUL FACILITY. A SUDDEN
INCREASE OR DECREASE IN OIL PRESSURE OF 10 PSI FROM THAT OIL PRES-
SURE CONSIDERED TO BE NORMAL FOR THE ENGINE IS CAUSE FOR INVESTIGA-
TION.
A. High Oil (1) Contaminated (a) Remove filter and check for
Pressure. lube pump filter. contaminatFon as stated in
section 79-00, Servicing.
NOTE: Check lube (2) Defective oil (a) Replace defective transmit-
filter and pressure trans- ter or gage.
perform gear- mitter or gage.
box pressure Install a direct NOTE: During engine opera-
check if en- reading gage tion the direct read-
gine has non- (0-200 psi scale) ing gage on CV engines
CV system. If in the line to the will indicate higher
filter is clean aircraft transmit- pressure than non-CV
and gearbox ter. If engine is engine at same RPM.
pressure is CV type install a Reference (main sump)
less than 5 second (0-30 psi) pressure must be sub-
Ibs., engine gage in parallel tracted from supply
should be re- with the lube pressure when checking
moved for com- pressure reference lube pressures of CV
plete lube sys- line. engines.
tem inspection
by an overhaul (3) Defective oil (a) Thermostat or relief valve
facility. cooler. failure/ruptured oil cooler
(internal). Replace oil
cooler per 79-23-0.
(4) Damaged/defective (a) Remove supply line. Inspect
oil supply line. for blockage or damage.
Repair or replace supply
line.
NOTE: Do not change lube pump because it cannot cause
high oil pressure.
B. Low or No Oil (1) Low oil in oil (a) Service lubrication system
Pressure. tank, per 79-00.
Mar 30/84 72-00
Page 128A/128B
SEILlaL ~B ELE~CTIIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investfgation/Corrective Action
(2) Defective lubri- (a) Retorque or replace defec-
cation lines tive line and fittings.
and/or fittings.
(3) Defective pres- (a) Replace defective pressure
sure transmitter transmitter or gage. Check
or gage. using direct reading page.
(4) Defective or ob-´• (a)´• Cleanjreplace relief valve.
structed relief
valve.
(5) Defective oil (a) Faulty thermostat valve.
cooler. Comply with engine service
bulletin (ESB) No. 72-45 or
replace cooler per 79-00.
(6) Defective lube (a) Disconnect No. 1 bearing
pump. lube inlet line at 10
o’clock (aft looking for-
ward) front frame connec-
tion. Motor engine. If oil
does not discharge, remove
lube pump. Check lube pump
inlet for clogged condition.
Clean as required or replace
lube pump per section
79-21-0.
NOTE: If pressure remains low after lube pump replacement, reject engine to
overhaul facility for inspection of internal lube system components.
C. No oil pressure (1) Defective lube (a) Determine cause df pump
and loss of Ng failure. Check lube supply
pump,
indication. filter per 79-22-0.
1. If clean, remove pump and
check for failed gear
and/or No. 1 element
bearing seizure. Remove
primp and send to engine
overhaul facility. Flush
engine lube system and
service with new oil.
2. If contaminated, remove
engine and sendover- to
haul facility for inspec-
tion and repair.
Mar 30/84 72-00
Page 129
GENERAL ELECTRIC--------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
D. Fluctuating oil (1) Low oil in tank. (a) Check and service lubrica-
tion system per section 79-00.
pressure.
NOTE: A fluctuation of +5 PSI is cause for investigation.
(2) Defective pres- (a) Replace defective pressure
sure transmitter transmitter or gage. Check
or gage. using direct reading gage as
stated in preceeding para-
graph A. (2)
(3) Contaminated or (a) Remove filter and check for
weak check valve contamination as stated in
spring in lube section 79-00.
pump filter.
(4) Defective lube (a) Check pump operation as
pump, stated in preceding para-
graph B. (5)
(5) Defective swivel (a) Remove pump from tank per
pendulum pickup. section 79-21-0 and check
pickup for proper movement.
(1) Oil tank filler (a) Replace O-ring, install and
E. Hig~ oil
consumption. cap loose. lock cap.
(2) Defective lube (a) Replace seal per Section
pump tachometer 79-21-0.
generator drive
shaft seal.
(3) External lube (a) Retorque or replace defective
lines and fit- lube lines or fittings.
tings for leakage.
(4) Defective oil tank (a) Replace valve per Section
relief valve. 72-12-0.
(5) Oil on compressor (a) If oil is present, operate
blades pooling
and the engine at IDLE speed
of oil droplets at after running for at least
6 o’clock position three minutes at approxi-
inside compressor mately 100 percent and with
casing, stabilized oil temperature,
check for oil mist blowing
from the compressor bleed
72-00
130 Dec 31/95
Page
GENERAL P LE CIR I C
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101 (Cont)
Problem Probable Cause Investigation/Corrective Action
valves. Oil will be appar-
ent inside the cowling or
at the bleed valve duct
exits. (Do not misconstrue
compressor rotor preserva-
tion oil which blows out
during start,) Replace the
No. 1 carbon seal, if oil
mist is noted, by a quali-
fied maintenance facility,
per Section 72-30.
(6) Faulty carbon (a) Check No. 2 and 3 sumps as
seals, O-rings, follows:
etc.
i. Disconnect No. 1 sump
vent line. Cap off end
of vent line or fitting
to prevent oil loss dur-
ing engine operation.
2. Connect a vacuum-pressure
gage (30 in. Hg vacuum to
30 psig) to the mainframe
vent fitting for center
vent (CV) or axis IIBlt aft
fitting for non-center
vent (non-CV).
3. Operate engine at take-
off for 5 minutes stabi-
lization period and then
record sump pressure.
Operate engine at idle
for 3 minutes stabiliza-
tion period and then re-
cord sump pressure.
4. Nos. 2 and 3 sump read-
ing must be within the
following limits. Read-
ing lower than these in-
dicate an internal leak.
72-00
Sept. 15/69 Page 131
Gf WERAL ELECTIIC
CJ610 TUCPBOJ~T
MAINTENANCE MANUAL SEI-186
TABLE 101 (Cont)
Problem Probable Cause In_vest igat ion/Corrective pction
CV Non-CV
Idle 0 psig -1.0 in Hg.
Take-off 10 psig 0 psig
5. If leakage is determined
to be
internal, remove
the engine and return to
overhaul for investiga-
tion (per Overhaul Manual)
of No. 2 and No. 3 sump
areas. This will require
engine disassembly to
areas required for leak-
age isolation. If No. 2
and sumps are within
3
limits, continue trouble-
shooting as follows:
(b) The engine should be removed
from the aircraft for ease
of troubleshooting.
(c) Remove external hoses and
lines and inspect for bloch-
age or breaks. Clear or
replace as necessary.
(d) Check No. 1 sump area as
follows:
i. Remove bullet nose.
2. Remove line from oil
supply, scavenge and
vent fittings on front
frame.
3. Cap the oil supply and
scavenge line. Supply
5-10 psig of clean air
to No. 1 sump through
the vent line.
72-00
Page 132 Sept. 15/69
OEW ERAL ~BB E LECfRle
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
4. Soap check all brazed
joints outside of No. 1
sump. No leaks allowed.
Leakage from the carbon
seal is normal.
5. If leakage occurs, return
the engine to overhaul.
(7) Oil foaming in (a) Small amounts of silicone oil
oil tank, or grease in the lube system
will cause oil foaming which
may result in engine oil
being forced out of the
overboard vent. If silicone
contamination is suspected,
replace the engine oil per
Section 79-00, Paragraph 2.E.
F. Fuel Mixed (1) Ruptured oil (a) Watch oil tank overboard
with Lube Oil. cooler, air relief valve for over-
flow of lube oil and/or
fuel. Replace oil cooler
per 79-23-0. Drain, flush,
and fill lube system.
(b) Drain oil tank; check drain-
ings for fuel contamination
by smell or by feel. Replace
oil cooler per 79-23-0. Drain,
flush, and fill lube system.
(2) Fuel plunp shaft (a) Check fuel pump overboard
seal failure, drain for excessive fuel
drainage. Replace defective
fuel pump per 73-13-0. Drain,
flush, and fill lube system.
(3) Accessory gearbox (a) Check for defective seal.
fuel pump drive Replace defective seal per
gear seal failure. 72-64-0. Drain, flush, and
fill lube system.
Mar 30/84 72-00
Page 132A/132B
CLW ERAL ~B ELECTRIC
CJB10 TURBOJeT
SEI-186 MAINTENANCE MANUAL
TABLE 101
TROUBLESHOOTING GUIDE (Cont)
Problem Probable Cause Investigation/Corrective Action
G. Oil Tank (1) Oil tank relief (a) Check valve for proper
Ballooned. valve. operation and replace the
valve if required per 79-12-0.
(2) Fuel contamination. (a) Refer to preceding paragraph
F for procedure.
W. Lube System (1) Contaminated lube (a) If filter’has less than 10%
Contamination. pump filter, element coverage, flush
system, change filter, and
monitor. Refer to 79-00.
(b) If filter has more than 10%
element coverage, lube system
investigation is required.
Bypass of filter is possibly
allowing contaminates to pass
into lube jets, sumps, lube
pump, oil tank, and oil
cooler.
(2) System contamina- (a) Define by examination of the
tion. extent of contamination.
(b) If system is contaminated
beyond filter, remove engine
for examination by overhaul
shop. (For example, examina-
tion is required if metal
particles are detected on
magnetic plug of accessory
gearbox.)
Mar 30/84 72-00
Page 133
OEIIRALQ6LLC7lle
CJB10 TUFPBOJET
MAINTENANCE MANUAL SEI-186
NO START
NO EGT RISE
STARTING SYSTEM
MUST ACHIEVE
O
LEAST 12% IN
12 SEC. O
MOTOR ENGINE I ICHECK BATTERY PER
WITH THROTTLE IN PARAGRAPH 2 AND
FUEL SYSTEM
IDLE DETENT. IGNITION SYSTEM PER
IGNITION OFF PARAGRAPH 3.A. OF
TABLE 1O1.
IS
A HEAVY MIST IS I (TAILPIPE IS IIOT WET ~:SR:
SEEN COMING FROM
TAILPIPE ADVANCE THROTTLE
CHECK FOR CHECK ALL OVER-
TO HIGHERPOWER O
POSITIVE AIRCRAFT I SETTING
BOARD DRAINS
BOOST PRESSURE DURING THE
IF IGNITION SYSTEM
AND MAKE SURE MOTORING CHECK.
IS OPERATING AIRCRAFT SHUT-OFF
SATISFACTORILY, VALVE IS OPEN
REPLACE THE TWO FUEL
EXCESSIVE OYER-
NOZZLES UPSTREAM OF
BOARD DRAINAGE O
THE TWO IGNITERS
II IISOLATE AND
REPLACE DEFECTIVE
FUEL SYSTEM COMPONENT
(MANIFOLD DRAIN VALVE,
OR P AND D VALVE)
ENGINE STARTS
IF ENGINE STARTS,
REPLACE SOLENOID
ON LEAR A/C
CHECK THROTTLE EQUIPPED WITH JET
RIGGING TO
FUEL CONTROL
O NO CHANGE IN
OBSERVED
REPLACE OSG PUMP tAP OFF LINE
FROM ENGINE FUEL
SYMPTOMS PUMP
EXCESSIVE
LEAKAGE
LEAKAGE WITHIN
OK I I I(OVER 100 PPH)
LIMITS
PERFORM PRESSURE
CHECK AT FUEL
PUMP DR AT PRES-
FUEL
O SURIZING YALYE PERFOI(H OYER-
SPEED GOYERNOR
INTERNAL LEAKAGE O
TEST
REPLACE PUFIP OR
PRESSURIZING I I PRESSURE LEVELS
VALVE AS RE- NORMAL
QUIRED
NOTE:
ANY OF THE ITEMS LISTED MAY CAUSE THE PROBLEM, THEREFORE ME ENTIRE CHART SHOULD BE READ
AND UNDERSTOOD BY THE USER. HOWEVER, FIELD EXPERIENCE HAS INDICATED THAT THE MOST
PROBABLE CAUSES (IN DESCENDING ORDER) ARE THOSE INDICATED BY THE NUMBERED CIRCLES. IT J
IS SUGGESTED THAT THEY BE FOLLOWED IN SEQUENCE. BC-O120
Trouble-Shooting Flow Chart (Sheet 1 of 6)
Figure 101
72-00 Nov. 15/72
Page 134
OEUIII~LO ~LICTIIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
SLOW START
(EXCEEDS 40 SEC)
DOES STARTING SYSTEM ACHIEVE
12% SPEED IN LESS THAN 12 SEC O
CHECK BATTERY PER PARAGRAPH 2
YES, 1
NO tc~ AND IGNITION SYSTEM PER
PARAGRAPH 3.A. OF TABLE 101
00E5 ADVANCING THROTTLE SLOW START L~REPLACE L~ILITTLE OR NO L~CHECK FOR METERED
TO A HIGHER POWER SETTING STILL OCCURSI IFUEL CONTROLI IIMPROVEMENT I IFLOW LEAKAGE
IMPROVE START TIME I r I IIN START TIME
IDECREASE FUEL
ICONTROL DENSITY
NO I SETTING SNE
ICLICK
L- I
CHECK THRO~ILE DEFINE WHICH PORTION OF r
O RIGGING START CYCLE IS SLOW -I---~
I
r----C-----~
ISTART
TIMEI ISLOW START
~MPROVES i :_SITL_L__D_C_C_U_RS_~
ENGINE LIGHT-OFF ---c--
CK IDLE SPEED r
TIME AFTER THROTTLE
RE-ADJUST IF IPERFORM FAST1
ADVANCE IS EXCESSIVE IDLE-MAX
ow CHECK FOR EXCESSIVE
(2-B 5EC AVG) CHECK OVERSPEED
ACCELS LEAKAGE FROM PRES-
GOVERNOR INTERNAL
SURIZING VALVE REF
LEAKAGE (100 PPH
t LINE WHILE AT IDLE
MAX)
ENGINE STILL SUSPECT IGNITION SPEED
r----C------’-´•
STARTS SLOW SYSTEM ILOWER I I I I
IGNITER 5 1
NO OPERATING
PROBLEMS OK
O
j READJUST IDLE
i AND MAX SPEED
REPLACE FUEL I I SUSPECT FUEL IF
i RE4UIRED
CONTROL NOZZLES
ON LEAR A/C EqUIPPEO
(7 O’CLOCK) I t I"---~-
ITH JET PUMP, CAP OFF
I WHENEVER DENSITY i IENGINE FUEL PUMPLINE
I IS ADJUSTED TO A
LIGHT-OFF, ENGINE I LOWER SETTING, A
CEL TIME TO IDLE I MAX ALTITUDE ACCEL IF START TIME
IS EXCESSIYE
(15-20 5EC AYG)
I CHECK MUST BE MROE
(SEE MAINTENANCE
i IMPROYES, REPLACE
SOLENOID
i PRACTICES- ADJUST-i
MENT/TEST, ~’ARA
SUSPECT LOW FUEL SUSPECT FUEL
3,I2 OR 3.13)
SCHEDULING TO ENGINE I----,--,-,--------’ NOZZLES
INSPECT ENGINE
FOR FOD OR
CHECK FOR EXCESSIVE I_IDURING COLD WEATHER I I OTHER DPI~MAGE
OVERBOARD LEAKAGE I ICHECK FOR ICE OR WATER
IN P3 TO FUEL CONTROL
LINE IWCHECK P3 TO FUEL CONTROL
SOLATE AND REPLACE I 1 IIINE FOR TIGHTNESS,
CTIVE COMPONENT CRACKS ANO BAD GASKET O
APPLY HEAT TO AT MAINFRAME
(MANIFOLD DRAIN VAL
P AND D VALVE) FUEL CONTROL
NOTE: ANY OF THE ITEMS LISTED MAY CAUSE THE PROBLEM, THEREFORE THE ENTIRE CHART SHOULD
BE READ AND UNDERSTOOD BY THE USER. HOWEVER, FIELD EXPERIENCE, HAS INDICATED
THAT THE MOST PROBABLE CAUSES (IN DESCENDING ORDER) ARE THOSE INDICATED BY THE 00-0121-1
NUMBERED CIRCLES. IT IS SUGGESTED THAT THEY BE FOLLOWED IN SE9UENCE.
Troubleshooting Flow Chart (Sheet 2 of 6)
Figure 101
Mar 30/84 72-00
Page 135
cJsto TURBOJET
MAINTENANCE MANUAL SEI-186
HUNG START
ENGINE LIGHTS, BUT DOES NOT
ACCELERATE TO IDLE SPEED
CHECK BATTERY PER PARAGRAPH 2
AND IGNITION SYSTEM PER
DOES STARTING PARAGRAPH 3.A. OF TABLE 101
RESET FUEL CONTROL
THAN 12 SEC.
DENSITY ADJUSTMENT
TD R LOWER SPEtlFI~
YES no
O GRAVITY 9ETTING
O.
DURING COLD WHENEVER DENSITY
WEATHER SUSPECT APPLY HEAT TO ENGINE ACCELS IS ADJUSTED TO A
OUT OF HANG-UP
P3 TO FUEL CONTROL LINE AND FUEL LOWER SETTING, A
LINE HAS WATER OR ICE CONTROL I I I I MAX ALTITUDE ACCEL
IN IT I I CHECK MUST BE MADE
CHECK THROTTLE SEE MAINTENANCE
RIGGING TO PRACTICES-ADJUST-
CHECK FOR EXCESSIVE O iUEi CON~RDL MENT/TEST, PRRA
HANG-UP OCCURS OVERBOARD LEAKAGE 3.12 or 3.I3)
BELOW 20% SPEED (MANIFOLD DRAIN VALVE
OR P AND D VALVE) I I IIF
~IREPLACE FUEL CONTROL
HANG-UP OCCURS ADVANCE
ABOVE 20% SPEED THROTTLE TO HIGH-
IF BLEED VALVES
ER POWER SETTING NO CHANGE IN ENGINE
SPEED RE CLOSED, CHECK
VARIABLE GEOMETRY
LINKAGE SYSTEM FOR
CHECK FOR OPEN BINDING OR JAMMING
BLEED VALVES AND
CUSTOMER BLEED
DUCT ALIGNMENT
O IF NOTHING WRONG
WITH VARIABLE
INSPECT Pj TO FUEL GEOMETRY SYSTEM,
REPAIR AS NO VISIBLE
OK CONTROL LINE FOR REPLACE FUEL CONT
RE9UIRED FOD
TIGHTNESS AND CRACKS
ON A/C EqUIPPED
REPLACE FUEL CONTROL INSPECT ENGINE
WITH LEARJET PUMP,
FOR FOD
CAP OFF EtNGINE
FUEL PUMP LINE
ENGINE STILL I t (FOD EXCEEDS
HANGS-UP LIMITS
IF ENGINE ACCELS
TO IDLE, REPLACE REPLACE OSG IF
SOLENOID LEAKAGE EXCEEDS REPLACE
LIMITS (100 PPH) ENGINE
PERFORM OVERSPEED PRESSURE CHECK
REPLACE NOZZLES
GOVERNOR INTERNAL~-r IFUEL NOZZLES IF
IF PRESSURE CHECK
LEAKAGE CHECK OSG LEAKAGE FLOW
EXCEEDS LIMITS
IS WITHIN LIMITS
NOTE:
ANY OF THE ITEMS LISTED MAY CAUSE THE PROBLEM, THEREFORE THE ENTIRE CHART SHOULD BE READ
AND UNDERSTOOD BY THE USER. HOWEVER, FIELD EXPERIENCE HAS INDICATED THAT THE MOST
PROBABLE CAUSES (IN DESCENDING ORDER) ARE THOSE INDICATED BY THE NUMBERED CIRCLES. fT
8(3-0122-2
IS SUGGESTED THAT THEY BE FOLLOWED IN SEOUENCE.
Troubleshooting Flow Chart (Sheet 3 of 6)
Figure 101
72-00 Mar 30/84
Page 136
OtIIIIAL~DtllCTRIC--
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
HOT START
DOES STARTING CHECK BATTERY PER PARAGRAPH 2
SYSTEM ACHIEVE O AND IGNITION SYSTEM PER
PARAGRAPH 3.A. OF TABLE 1O1.
12% SPEED IN LESS
THAN 12 SECONDS
WHENEVER DENSITY
YES I I’~V I I IS ADJUSTED TO A
2) 1 LOWER SETTING, A
DOES FUEL CONTROL MAX ALTITUDE ACCEL
CHECK MUST BE MADE
HAVE CORRECT DEN-
SEE MAINTENANCE
SITY ADJUSTMENT
RESET PRACTICES-AOJUST-
HOT STARTS CAN
AS MENT/TEST, PARA.
88 CAUSED BY /-----I YES I 1 NO
REPUIREO 312 OR
13)
O i
ENGINE STILL tcl INSPECT COMBUS-
DEFECTIVE EGT I IF ENGINE STILL
STARTS HOT TION LINER AND
INDICATING SYSTEM~ STARTS HOT AFTER PERFORM MORE
ALL POSSIBLE
RIGOROUS FOO
CAUSES HAVE BEEN
INSPECTION
INVESTIGATED,
IMPROPER START REPLACE FUEL
TECHNIQUE CONTROL.
DO NOT ADVANCE
THROTTLE UNTIL ~t-’ INO
SPEED OF 10% SUSPECTFuEL
NOZZLES
MAKE A STOPCOCK
DELAYED IGNITION I IlyES START. I.E. MANU-
ALLY METER FUEL
CHECK IGNITION TO THE ENGINE BY
DOES ENGINE LIGHT-OFF
SYSTEM PER MEANS THROTTLE
IME EXCEED 5-SEC
PARAGRAPH 3.A. MOVEMENT TO
AFTER
PREVENT OVERTEMP.
THROTTLE ADVANCE
RUN ENGINE AT IDLE
MOTOR ENGINE SPEED FOR 3 MIN.
IR IN FUEL CONTROL. SHUTDOWN AND MAKE
WITH THROTTLE IN
I)ITHIS IS LIKELY TO A NORMAL START
IDLE DETENT AND
IF ANY PORTION
IGNITION OFF STOP-
F THE FUEL SYSTEM
COCK THROTTLE
HAS BEEN OPENED UP-
AND ALLOW ENGINE I nDRAINAGE MEETS
STREAM OF THE CONTROL
TO SHUTDOWN. A I I ILIMITS
MINIMUM OF 100 CC
5 IMPROPER OYER-
OF FUEL SHOULD
BOARD DRAINAGE
COME FROM DRAIN
LITTLE OR NO WREPLACE MANIFOL
VALVE OVERBOARD
OVERBOARD DRAIN VALVE OR
ICE IN FUEL CONTROL IPORT
DRAINAGE P AND O VALVE
Pg SENSING SYSTEM
IN COLD WEATHER
SUSPECT ICE IN
FUEL CONTROL
BELLOWS. APPLY
HEAT TO FUEL (7
CONTROL BEFORE
ATTEMPTING
ANOTHER START
INSPECT TURBINE
FOD
AND COMPRESSOR
FOR FOD
NOTE:ANY OF THE ITEMS LISTED MAY CAUSE´• THE PROBLEM, THEREFORE THE ENTIRE CHART SHOULD BE READ
AND UNDERSTOOD BY THE USER. HOWEVER, FIELD EXPERIENCE HAS INDICATED THAT THE m)ST
PROBABLE CAUSES (IN DESCENDING ORDER) ARE THOSE INDICATED BY THE NUMBERED CIRCLES. IT BC-0123-1
IS SUGGESTED THAT THEY BE FOLLOWED IN SEQUENCE.
Troubleshooting Flow Chart (Sheet 4 of 6)
Figure 101
Mar 30/84 72-00
Page 137
61W TR11 ~D IL~CTR(C
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
STALL
PERFORM VISUAL I I HOT GAS
INSPECTION I I INGESTION
CHECK VARIABLE GEOMETRY I I CHECK CIT
EXAMINE ENGINE
SYSTEM FOR: SENSING SYSTEM
FOR FOD IN NO VISIBLE FOD
COMPRESSOR AND
1) EXCESSIVE WEAR
TURB~NE
2) BINDING LINKAGES
3) ACTUATOR JAMMING REPLACE OR
4) BROKEN/KINKED REPAIR AS
FEEDBACK CABLE REQUIRED
FOD EXCEEDS
ALLOWABLE LIMITS
REPLACE AND REPAIR I ICHECK ALIGNMENT
AS REQIIIRED I IOF CUSTOMER BLEED
ENGINE I I IDUCT
CHECK VARIABLE
GEOMETRY SYSTEM REPAIR AS
RIGGING REQUIRED
ADJUST VARIABLE
GEOMETRY SYSTEM
PER 75-00
ALL VISUAL INSPECTIONS
OK TO
COMPLETED WITH NO
START ENGINE
DISCREPANCIES
PERFORM SLOW
ACCEL AND CHECK
BLEED ADJUSTMENT
PER 75-00
REPLACE ENGINE
FLY
BLEED VALVE BLEED VALVE
ADJUSTMENT I I ADJUSTMENT ENGINE STALLS NO STALL
IN LIMITS OUT OF LIMITS
PERFORM FAST ADJUST BLEED I I UNABLE TO ADJUST REPLACE FUEL PERFORM FAST
IDLE-MAX ACCELS VALVE BLEED VALVE IN rC1 CONTROL IDLE-MAX ACCELS
LIMITS
ENGINE STALLS
CHECK FUEL INCREASE FUEL PERFORM FAST
STALL OCCURS
DENSITY SETTING DENSITY SET- IDLE-MAX ACCELS
IN 50-70%
FOR RIGHT TING.
SPEED RANGE
POSITION
NO STALL
STALL OCCURS ENGINE MEETS
REPLACE ENGINE ACCEL TIME
ABOVE 70I N
NO STALL
FLY
FLY
BC-0124
Trouble-Shooting Flow Chart (Sheet 5 of 6)
Figure 101
72-00 Nov. 15/72
Page 138
LLlelllC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAt
FLAMEOUT
DIO A/C LOW PRESSURE CHECK FUEL SYSTEM CHECK FUEL PUMP
WARNING LIGHT FOR CONTAMINATION ROOST ELEMENT
COME ON OR WATER
NO tc-( FOD
YESI I I I IF FUEL SYSTEM ND CONTAMINATION
CONTAMINATED
REPLACE FUEL
CHECK FUEL SUPPLY
AND/OR AIRCRAFT
BOOST PUMP BOOST ELEMENT
REPLACE FUEL PUMP
IF BOOST ELEMENT OK
IS DEFECTIVE
INSPECT COMPRESSOR
AND TURBINE FOR
FLY
DAMAGE
ACCEL
INSPECT FUEL
CONTROL TO
IF DAMAGE EXCEEDSI I ND DETECTABLE DEFINE TYPE Pj LINE
ALLOWABLE LIMITS FOD 3F FLAMEOUT
REPAIR DAMAGE OR
REPLACE ENGINE REPAIR AS OK
RE9UIRED
STEADY STATE I I DECEL I _
ICHECK FOR RUPTURED I I CHECK THROTTLE
Tp BELLOWS RIGGING TO FUEL
CONTROL
INSPECT P3 TO WAS THROTTLE RETARDED
FUEL CONTROL BELOW THAT RECOMMENDED
REPAIR AS OK
LINE FOR MIN IDLE SPEED OK
RE-RIG
REQUIREO
UNDETECTED
YES FLY STALL
REPAIR AS I OK
FLY
REQUIPED NO STALL L~ FOLLOW TROUBLE-SHOOTING
OCCURS I- I FLOW CHART FOR STALL I UNDETECTED
STALL
FLY
RUN ENGINE AND FOLL(r~ TROUBLE-SHOOTING
PERFORM FUEL MANI- FLOW CIIART FOR STALL
FOLD PRESSURE CHECK
NO STALL
OCCURS
NO FLAMEOUTS FLY
FLIGHT IS REOUIRED
OUT OF LIMITS IN LIMITS TO DETERMINE IF
FLAMEOUT IS REPEATABLE FLAMEOUT OCCURS
REPLACE FUEL
FLY IOBTAIN FLIGHT
NOZZLES
TEST DATA ON
FLAME OUT
;iC-0125
Trouble-Shooting Flow Chart (Sheet 6 of 6)
Figure 101
Nov. 15/72 72-00
Page 139
GElfRAL a,,,,,,,,,
CJ610 TURBOJET
MAINTENANCE MAM~AL SEI-186
Figure 102 Deleted.
TABLE 102 Deleted,
72-00
Dec. 30/78
Page 140
GEWERAL~PLECIRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Nacelle Area 21~2IE: All references apply to SEI-l86, unless
In-Service
Leakage or othenise noted.
Stall/Flameout
Recirculation
Check Engine Do an Engine Performance Test and Compressor
for Each.of the A/C Engine Operating Line Check (561-136, 72-00, TESTING)
Follovlng: Throttle
Rigging Fault
and Turbi
sor ~ILLE: Perform all of the steps In sheet 2
T2 Sensor Hose
ons for FOD unless an obvious reason for stall is
-32-0 and 72-33-0, Damaged or
Cracked (Rwove
found, such as physically damaged com-
-52-0 and 72-53-0) pressor blades or vanes.
and Inspect)
VG System (75-00) for
Hear, Binding Link-
Fuel System
Contamination Doan Engine Performance Test and CoPlpressor
,,Actuator Janming Operating Line Check (561-136. 72-00,TESTING
nked F
(Debris or Water)
le
Aircraft Boost
Pump Failed
to-Fuel icontrol
ube for Tightness and
Tighten or Passes
Aircraft Bleed
Ir (72-621) Test
Duct Misaligned
AIC and Engi Incorrect Tai!lPipe Remove Engine
uel Miters iiir Area (Weasured at 12 1 From A/C
(73-13-0, f I ILocations ior Average
14-0, 73-21-0) IReading) Do a Hax
Altitude
Acceleration
Fuel Control
Check_(72-00,
Unit for Proper Fuel Do VG Check (72-00,
a ADJUSTIENT
ity Setting ADJUSTMENTITEST). I No
73-21-0, or 561-154,
Necessary, Adjust VG Probable
73-20-1 TESTING). System (75-00) Cause
Check Aircraft
Ho
for Each of the
5tall
Following: 1 I I Stall
Correct Tailpipe
Do a Nar
RETURN
Found Altitude No
TO
Inlet Duct Damaged Probable Acceleration Stall
SERVICE
or Misaligned Cause I ICheck (72-00,
ADJUSTWENT
000CJF-8841OA
Altitude Stall/Flameout Troubleshooting Guide
Figure 103 (Sheet 1 of 2)
Dec 31/91 72-00
Page 140A/140B
tEYERIL~ELICTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANLIAL
~E: All references apply to SU-136, For extended-life compressor, the
unless otherwise noted, aluminum-base intermetallic
diffusion coating oust be removed,
Record the following data upon engine or stages 5 thru 8 co~ressor blades
’as received’ condition and inspect as must be replaced per Service
instructed in manual. Bulletin tCJ61O) 72-129, Revision i.
If one or more stages of blades
i. Combtessor requires replacement, use the
W610-8A clearance limits tables I
Measure compressor rotor blade tips thru IV t72-33-0, ASSEMBLY).
(shadowgtaph) and concentricity
of compressor rotor spacers 2. Turbine Nonl~es
t72-33-0, ASSEMBLY). Do a dimensional
check (EROH) of compressor casing Stage 1 Nonle
lands t72-32-1, INSPECTION). Neasute area of nonle ’as re-
Calculate the average blade-tip ceived´•.
clearances t72-33-0, ASSMBLY). For W610-BA engines, nonle
Be sure all blades and vanes are clean. area Is not adjustable; therefore
Replace all FOD blended blades and replace noale if required.
vanes. For all other engines, adjust
Replace all blades exceeding nonle area t72-51-0, FITS AND
runouts of 0.008 inch nR, CLEARANCES) to max area.
Inspect compressor casing t72-32-1, Check partitions; no reverse
INSPECTION), stater sectors t72-32-2, bends are allowed.
INSPECTION), and compressor blades Stage 2 noale to be within manual
t72-32-2, INSPECTION) for FOD tdents), area limits; nofurthet adjustment
corrosion tpIts), and tip rubs. is allowed.
Repair t72-32-1, REPAIR) compressor
casings that exceed 0.007 Inch land 3. Turbine
runout.
Reject all airfoils which do not neasure and record ’as received´•
meet the requirements of surface clearances.
finish (32 Iptcroinches max for Inspect for FOO t72-53-0,
stages 1 thru 4, and 20 mictolnches INSPECTION), Replace blades or
for stages 5 thru 8) and do not shrouds as necessary to obtain
meet the leading edge radius tip clearance limits (72-534.
requirements (72-32-1, REPAIR). ASSEWBLY). No oversize turbine
Replace vanes as necessary to shrouds are permitted on W61~UU\
obtain the following: engines.
Maximum vane runout not to Measure and record RID and AFT seal
exceed 0.007 Inch nR. clearances ~or’dnf-turbine’ as-
Maximum average step between semblies. Oisassemble standard
adjacent vane sectors: 01003 inch. turbine wheel assemblies and Ilea-
Maximum scallop for each indl- sure/calculate ~nterstage-to-torque
vidual vane sector: 0.006 inch. ring clearances.
Machine vanes to obtain the fol-
lowing end-gap on each half of 4. Fuel Control Unit tFCU)
compressor casing:
Stage End-Gap Pet Case Half Test and recalibrate tSEI-154,
3, 4, 5 0.030 to 0.055 inch 73-2~1, TESTING).
6, 7 O.WO to 0.100 inch
If more than 0.005 inch of metal 5. Fuel System
removal is required, laackine vanes
uniformly on each sector. Adjust Flow-check fuel nonles tSEI-154,
end-gap to maximum side of tolerance, t73-16-1).
Record clearance data. tTo obtain
the average value, all calculations 6. Encrine Rfa~ina
must be based on 1001 of the blades
and vanes.) Adjust variable vanes trigging) to
´•tero degree’ position tfully open)
(72-00, ASSEMBLY).
0OOCjF-890000
Altitude Stall/Flameout Troubleshooting Guide
Figure 103 (Sheet 2 of 2)
Dec 31/91 72-00
Page 141
99
(DO
O
~L ENGINE INLET RAM AIR TEMPERATURE OF
c-
h, _60 -40 -20 0 20 40 60 80 100 120 140
102 16830
101
16665
Illnl, I Illln Hm~n II 1 11111 1111 I 11 111111 1 I I I
16500
m I II IIIIII 16335
n, 16170
E
t
´•d~ ~TmmmT1 B 9)
Z
w
ap p. r
a
16005 O
E: Y
z
y
r´• n
~t
09~ m
r
ss
15840 cl
rt´• w
(D r´•
rt w
~zC
r u
o& O
i
a 15675 B
~Wm c
vl m
8
rtr
c-3
1111.1~111111111031 1111111111711111111 Ilrr~n
93´•1lllrlll1´•111111 1111111111111111 Ilrllllllll-nllllll Inrlllllllllllllr´•l
111
1
a’
92
5 15180
91
15015
09
90
14850
cn 1 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60
Q EIIGIIE INLET RAM AIR TEMPERATURE OC H
r I 80-0214
r
a,
cn a
cn vr
(p M
H
r
PERFOR\UNCE
Oo
u IN AIRCRAPI
QI
1´• TEST YIPI EPIGINE ~YIDEL 1300
Cn KOtc:
BT R-L COPP., 23610
pmblen E. RIVER ROAD, eOLlMEIA, STATION, OflIO, 44028.
VISUALLY CHECP idenfified
probla cIr spaSme aOsESr apd 1 2. MLPSE OTBEPIISE INDICATED, IIISPBC-
rot -L-----~ corrected I TIOI1 P~L TBg SECTION OP THE BRGINB
identified I ownaaa MILLmhL.
TEST wrral I~ ~so colpon
CHgCL 13P) COPBBCT
ENGINE I passes
CIRCUIT RESISTANCE
test
fails
test
Prm arts 1IlID CORRECT ~BBCI CBBBECT
passes
BLBI:OIF LOSSES BLEED AIR, ~I-ICIlIG VALVE
test
Cd BLEED ALR HEaTEB hIB LEaPS, ETC 75-1~0 (SgI-154)
(0
~1
Itl ew PROBE U)CIPPESSOR 1?JEL MZZLBS problen
Epa LIRE
fails for each OR POD OR DIRTP F~UTLTP identified passes
C)=
test of the PLA;GED 77- Rrccme 72-32-2, (STREM) and test
WILYZEB C 3L
folloving 11-1 (591-154) ~LILDP 72-00 72-33-2 73-16~1 (SEI-154 corrected
01
C) proble~ f´•ils
TEST CELL
(D rl
t
72-00
L~--J
smprons
""I
identifiedQ
not
~4C(
09O
II=
EXCESSIVE
r= C arcH 15 URONC EXCESSIVE 5TI TURBINE NOZZLE LW(INCA?IT1-
c
(0 r
n,
AT
TAKEOFF
EPR
I cheer
o,
of
each
the
IENGINE
TEWERAT~JI1E
pROTECTOR
I I TURBIIPe
~LaDg
IMMST
I IFOD
72-32-2.
72-33-2.
I(DkU~GE
72-42-0
I ICDP SE~L ARUS
72-51-0.
OYERSIZE
72-52-3
TURBINE
SHROL~
~2-00
I IICE
VALVES
OR
75-~D-O(SEI-
BLEED
72-00
g OC,
folloving SETTING 72-53-1 72-53-1. 72-00 15()
0 ~f
f-o
72-00 "O
o t
r+
E n
UNDERSIZE LW(ING uFrI- EXCESSIVE EICESSIVE IG9~ AaD
RICE Ng checl
m~sr2uE ICE OR BLEED CDP SEAL I TURBINE I
AT Lforeach TES? CELL
O AREAS VALVES 72-00. LEAKAGE/ SRROUD GEOIIETPY
e TAI(EOFF of the RUS 12-00
72-51-0. 75-10-0(SEI- CLEARANCE CLEARMICE IIISPIGCB)
C1´• EPR fol~oving 72-00
72-52-3 151) 72-00 72-00
P.
(9
chect
RICE EXCESSIVE I IEPR PROBE
for each
LOV TURBINE BLUDEI ICRACKU) OR
of the
TNRUST UIITJIST PZUGCED 77-
fo~loving 72-53-1
AT EPR
LWKINC ANTI-I IU(CESSIVEI 1EC(ISSI7ml I CQIP1RSSORI IEIC~SSmEJ IELCESSNEI
chect
HIGB for each
ICE OR BLEED I ITURBINE I rCB I ICDP SEAL I ITIIII~IHE I ITURBINE
SFC ~ofthe
VALVES 72-00. nBLADE TrpnarapE n72-32-2, nLEAUGElnPOD n 11OZW ARBIS
75-10-O(SEI- CLEIRANCEI IUNIVIST 72-33-2 1 172-53-1 1 172-51-0.
follovinl
154) 1 172-00 72-53-111 1 172-00 i 1 1172-52-3 rRm´•Ru
pr I I
09 SEfi~ICT
I)C-0197
(ou
h)
E-O
wO
GEWERAL~ LLPCTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
ENGINE MAINTENANCE PRACTICES SERVICING
i. General.
The items that
require servicing are listed in this section along with the
service performed. It also contains instructions fro activating the
to be
engine after storage, preserving and storing the engine for specific time
periods either in the airframe or the shipping container.
I NOTE: Engines
installed in
removed from aircraft for
a horizontal stand,
servicing
such as
or
205349.
maintenance should be
2. Lubrication System.
A. Check lube level in lube tank. (Refer to 79-00.)
B. Clean and check lube filter. (Refer to 79-22-0.)
C. Check for metallic particles. (Refer to 79-00.)
D. Procedure for changing lube oil. (Refer to 79-00.)
E. Prime the lube and scavenge prrmp as instructed in paragraph, this Section,
titled Activating Engine After Storage Procedures if any of the following
conditions exist.
(1) Engine has not been operated within the last 14 days.
(2) The engine is being tested for the first time since installation into
an aircraft.
(3) The engine is being tested for the first time after having been pre-
served.
(4) The engine is being testedfor the first time after replacement of the
lube and scavenge pump.
3. Fuel System.
A. Clean and check fuel filter. (Refer to 73-13-0.)
B. Clean and check fuel control filter. (Refer to 73-21-0.)
C. Clean and check high-pressure fuel filter. (Refer to 73-14-0.)
4. Activating Engine After Storage Procedures.
NOTE: Preserved engines must be depreserved before operation.
A. Remove all protective covers from the engine.
Sep 1/75 72-00
Page 301
tlWERII~IILGIIIIC---
CJ610 TURSOJET
MAINTENANCE MANLTAL SEI-186
B. TJisually inspect the engine for damage. Insure that no foreign material
is lodged in any of the engine ports such as the bleed valves, fuel in-
let, etc.
C. Depreserve the lubrication system as follows:
(1) Drain any residue oil from the accessory gearbox and the transfer
gearbox by removing the drain plugs.
(2) Reinstall drain plugs and torque to 60-80 Ib-in.
(3) Remove the oil filter cap from the lube tank and fill the tank with
oil that has been filtered through a lO-micron metallic filter (tank
capacity is 4 quarts). Refer to Chapter 79-00, Lubrication System
Maintenance Practices for the list of approved oils.
(4) Prime the number 1 scavenge element of the lube and scavenge pump
with engine oil by using any of the following methods:
(a) For CJ610-1, -5, and -9 engines:
1 Disconnect the No. 1 sump oil supply line from the elbow (fig-
ure 301) at the top left side of the accessory gearbox (aft look-
ing forward), Add one pint of engine oil toil must be clean and
filtered through a lO-micron filter) into the hose so it will
enter the No. 1 sump and drain through the No, 1 scavenge
element of the pump.
2 Remove the dome assembly (bullet nose) and the front frame
sump cover from the forward side of the front frame hub. Add
one pint engine oil toil must
of be clean and filtered through
a l0-micron filter) to enter the No. 1 sump scavenge tube to
the inlet port of the No. 1 scavenge element of the pump.
NOTE: Remove and replace the bullet nose and the sump cover
asoutlined in Section 72-30, Front Frame
Removal/Installation.
1 2 os use any other method approved by GE Aircraft Engines.
I (b) For CJ610-4, -6, -8, and -8A engines:
1 Remove plug (figure 301) at the top left side of the
the
accessory gearbox (aft looking figure). Add one pint of
engine oil toil must be clean and filtered through a l0-micron
filter) into the gearbox so it will enter the inlet port of
the No. 1 scavenge element of the pump.
I 1 Or, use any othe method approved by GE Aircraft Engines.
72-00 Dec 31/91
Page 302
GPI~RIL ~D fLICTRIC
eJsio TURBOJET
SEI-186 MAINTENANCE MANUAL
(5) Allow the added oil to settle in the lube and scavenge pump parts for
at l~ast 10 minutes to assure the No. 1 scavenge element is primed.
CAUTION: BEFORE THE ENGINE IS STARTED A PINT OF OIL MUST BE DRAINED
FROM THE OIL TANK TO MAKE CERTAIN THE LUDE SYSTEM HAS NOT
BEEN OVER-SERVICED.
(6) Replace the oil tank cap and lock it. Connect lines.
D. Depreservation of the compressor and exhaustsections of the engine is
not required. Make sure the engine inlet and exhaust areas are free of
foreign material that could damage the engine.
E. Depreservation of the variable geometry actuators is not necessary. The
preservative oil and any entrapped air will mix with fuel before it is
discharged through the fuel nozzles,
F. Depreserve the fuel system as follows:
(1) Connect a fuel supply to the fuel pump inlet adapter. The fuel
should be supplied to the engine through a l0-micron filter at a
pressure between 7.5 psi (above true vapor pressure) and 50 psig.
Refer to Chapter 73-00, Maintenance Practices.
re
o o
0,
ELBOW
ACCESSORY
PLUG ACCESSORY
GEARBOX
GEARBOX
LEFT-HAND SIDE LEFT-HAND SIDE
CJ610-1, -5, AND -9 CJ610-4, d, AND -8 CJ610-611)-QL2
Lube and Scavenge Pump Priming
Figure 301
Jan, 15/69 72-00
Page 303
GEaERAL E LE CTR IC __-
cJsio TUReJET
MAINTENAJCE MANUAL SEI-186
(2) Motor the engine, with the throttle set at 15 degrees, for 2 minutes
as follows:
CAUTION: MAKE SURE THE IGNITION IS TURNED OFF. DO NOT EXCEED THE
DUTY CYCLE PERIOD FOR THE STARTER. THE 8-MINUTE MOTORING
PERIOD MAY BE ACCOMPLISHED IN INCREMENTS OF THE STARTER
DUTY CYCLE. RETURN THE THROTTLE TO 0 DEGREES AT THE END
OF EACH DUTY CYCLE.
(a) Check the tailpipe. A fine mist should be seen coming from the
tailpipe during motoring.
(b) Check the engine piping for Leaks. No leaks allowed.
(c) Check the combustion section drain. Fuel should drain out of
the combustion drain line during motoring.
(d) Check the fuel manifold drain valve for proper operation. Fuel
should drain from the valve during motoring.
(3) At the completion of the motoring period,‘allow the engine to drain
for 3 minutes.
(4) With the throttle closed, motor the engine for 1 minute.
G. Start the engine and perform the following check per Adjustment/Test,
72-00. Adjustments should be made as required, per Adjustment/Test,
72-00.
(1) Start engine.
(2) Check engine idle. Allow the engine to remain at idle RPM for a
minimum of 5 minutes operating time before advancing the throttle to
higher power or speed settings.
(3) Check the variable geometry system.
(4) Perform the takeoff check.
(5) Check the overspeed governor.
(6) Check engine acceleration.
(7) Shut down engine.
5. Preservation Procedure 1 to 30 Days,
NOTE: A preservation run is not required for oil system preservation.
1 72-00 Jan. 15/69
Page 304
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
A. After the last engine run, drain fuel from the bottom of the fuel tanks
and check the fuel for water. If there is none, the engine has been shut
down with water-free fuel in the main fuel control and there is no need
to preserve the fuel system or VG actuator system.
B. If the engine is to remain inactive for more than 15 days, spray the
compressor section per paragraph 6, step D. Also preserve the fuel
system per step C, using fuel (filtered through a 25-micron filter)
instead of MIL-L-6081, grade 1010 oil.
C. Install the closures per paragraph 6, step "E".
D. Engine preservation does not require additional work to maintain engine
preservation for the 1 to 30-day period. However if for any reason the
fuel system is drained or partially drained, the fuel system should be
refilled with a fresh supply of fuel to prevent internal corrosion and
drying out of rubber packing rings, etc.
E. Engine preservation for the 1 to 30 day period may be renewed once.
I Renew engine preservation by motoring the engine for 2 minutes
:swollofsa
(L) Make sure the ignition is OFF.
(2) Make sure there is oil in the oil tank.
(3) Motor the engine for 2 minutes. While motoring the engine, provide
fuel filtered through a 25-micron filter to the fuel pump inlet
adapter at a pressure between 0 and 50 psig.
CAUTION: DO NOT EXCEED THE STARTER DUTY CYCLE. IF THE ENGINE IS
MOTORED WITH STARTER, THE THROTTLE SHOULD BE ADVANCED TO
15 DEGREES, HELD FOR 15 SECONDS, TO 0 DEGREES RETARDED AND
HELD FOR 15 SECONDS. CONTINUE WITH THIS CYCLE FOR THE
DURATION OF THE MOTORING PERIOD (SEE ADJUSTMENT/TEST,
72-00).
6. Preservation Procedure 30 to 120 Days.
NOTE: This procedure may be used for preservation of engines regardless of
whether a shipping container is or is not used. If the engine will be
installed in shipping container, steps "F" and
a G of this procedure
do not apply (refer to the instructions in paragraph 8).
I A. Delgted.
June 1/71 72-00
Page 304A
O EW EIIAL CLECTR LB
i
i
SEI-1BB
NOTE: Deleted.
B. Preserve the variable @eeoeety (VG) actuators asfollows:
(1) Preservation of CJ610-1, -5 and -9 VG actuator.
72-00 June 1/71
Page 304B
GENERAL ELE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
NOTE: For preservation of CJ610-4, -6 and -8 VG actuators see
step (2).
(a) Disconnect the 2 VG actuator lines at the fuel control. Cap the
fuel control fittings.
(b) Manually operate the VG actuators several times to remove all
the fuel from the lines. Position the actuators in the fully
extended position (bleed valves closed).
NOTE: Two men, one at each bell crank, are required for manual
operation of the VG actuators.
(c) Remove the 2 plugs from the underside of the left-hand actuator.
Allow the fuel to drain.
(d) Supply oil (Specification MIL-L-6081, grade 1010) through a 25-
micron filter, to each of the actuator lines. Flow the oil
through each of the actuator lines until fuel-free oil is seen
coming from the open ports on the underside of the left-hand
actuator.
(e) Reinstall the plugs in the open ports of the left-hand actuator
and lockwire. Install plugs in the open ends of the VG actuator
lines.
(f) Wipe a light film of oil (Specification MLL-L-6081, grade 1010)
on the extended VG actuator piston rods.
(2) Preservation of CJ610-4, -6 and -8 VG actuator.
NOTE: For preservation of CJ610-1, -5 and -9 VG actuators see
step (1).
(a) Disconnect the 2 VG actuator lines at the fuel control. Cap the
fuel control fittings.
(b) Manually operate the VG actuators several times to remove all the
fuel from the lines. Position the actuators in the fully extend-
ed position (bleed valves closed).
NOTE: Two men, one at each bell crank, are required for manual
operation of the VG actuators.
(c) Remove the 2 plugs from the top side of the left-hand actuator.
(d) Supply oil (Specification MI~-L-6081, grade 1010) through a 25-
micron filter, to each of the actuator lines. Flow the oil
through each of the actuator lines until fuel-free oil is seen
coming from the open ports on the actuator.
Sept. 15/69 72-00
Page 305
O LW ERAL ELLCTRIC
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
(e) Reinstall the plugs in the open ports of the left-hand actuator
and lockwire.
(f) Remove the 2 plugs from the top side of the right-hand actuator
and repeat step (d).
(g) Reinstall the plugs in the open ports of the right-hand actuator
and lockwire.
(h) Install plugs in the open ends of the VG actuator lines.
(i) Wipe a light film of oil on the exte~ded VG actuator piston rods.
I C. Preserve the fuel system by introducing oil, MIL-L-6081, grade 1010, into
the fuel system as follows:
(1) Make sure the caps and plugs installed in fuel control fittings, VG
actuator and VG actuator lines are tight. Make sure all other plugs
in the fuel system are installed and tight.
(2) Remove the cover from the fuel pump inlet adapter.
(3) Supply oil through a 25-micron filter to the engine fuel pump inlet
adapter at pressure between O and 50 psig.
a (The oil supply system
must be capable of supplying oil at the rate of at least 1 gpm.)
(4);Motor the engine (see Adjustment/Test, 72-00) with the starter (with-
in the limits of the starter duty cycle) to raise engine speed to
starting RPM. Advance the throttle to 15 degrees and allow 2 gal-
lons of oil to pass through the fuel pump.
CAUTION: MAKE SURE THE IGNITION IS OFF. BEFORE MOTORING THE EN-
GINE, MAKE SURE THERE IS OIL IN THE OIL TANK. IF THERE
IS NO OIL ON THE OIL TANK DIPSTICK, ADD ENGINE OIL UNTIL
IT CAN BE SEEN ON THE DIPSTICK.
IF THE LIMITS OF THE STARTER DUTY CYCLE WILL NOT ALLOW
(IN A SINGLE PERIOD) ENOUGH TIME TO PUMP 2 GALLONS OF OIL
THROUGH THE ENGINE, USE AS MANY STARTER DUTY CYCLE PERIODS
AS REQUIRED, PROVIDING THE THROTTLE IS RETURNED TO O DE-
GREES AT THE END OF EACH DUTY CYCLE.
(5) Retard the throttle to O degrees and allow the engine to coast to a
complete stop.
(6) Reconnect the VG actuator lines to the fuel control.
(7) Reinstall the cover to the fuel pump inlet adapter.
72-00 Sept. 15/69
Page 306
GEnE L E Lr cr re
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
D. Preserve the compressor section as follows:
CAUTION i: BEFORE MOTORING THE ENGINE, MAKE SURE THERE IS OIZ, IN THE OIL
TANK.
CAUTION 2: IF THE LIMITS OF THE STARTER DUTY CYCLE WILL NOT ALLOW, IN A
SINGLE PERIOD, ENOUGH TIME TO SPRAY THE ENTIRE 1/2 PINT, USE AS
MANY DUTY CYCLE PERIODS AS REQUIRED TO USE UP THE ENTIRE
AMOUNT
(1) While the engine is being motored, spray 1/2 pint of oil (MIL-C-6529)
Type II) into the compressor inlet. Adjust the spray gun to spray a
fine mist or Spray the
fog. oil
compressor into the section by hold-
ing the gun about 18 inches from the engine inlet and moving
spray
the gun radially and circumferentially to cover the entire inlet area.
NOTE: To effectively spray the compressor section, the engine motoring
speed should be close to starting RPM, but not less than 10% RPII.
(2) Allow the engine to coast down and the excess preservation oil to
drain off.
E. Install closuresall engine openings, namely the bleed valves, eighth-
to
stage bleed ports, engine inlet, engine exhaust, instrumentation bosses
or connectors, and accessory drive pads. The openings are sealed to pre-
vent water and foreign material from entering the engine. If pre-~abricatcd
type closures are not available, any waterproof type material can be used
and fixed in place with a suitable pressure sensitive tape. Only manu-
facturer approved plastic caps are recommended for protection of electric31
connectors.
F. If the engine is not installed into a shipping container after the engine
is preserved per steps B through E, engine preservation is maintained
during the 30 to 120 day inactive period as follows:
NOTE: The fuel, anti-icing and VG actuator systems do not require any
additional work to maintain their preservation.
(1) At least once every 30 days, motor the engine for 2 minutes using the
installed starter.
CAUTION: BEFORE MOTORING THE ENGINE, MAKE SURE THERE IS OIL IN THE OT~.
TANK.
DO NOT EXCEED THE DUTY CYCLE PERIOD OF THE STARTER.
WHILE MOTORING THE ENGINE, SUPPLY OIL (SPECIFICATION
MIL-L-6081, GRADE 1010) FILTERED THROUGH A 25-MICRON
FILTER TO THE FUEL PUMP INLET AT A PRESSURE BETWEEN
O AND 50 PSIG.
72-00
Sep 1/75
Pagcl 307
GlltlAl ELEn~lC
CJ610 TURIOJIT
hlAINTENANCE MANUAL SEI-186
(2) See if there is an oil film on the engine inlet. If it has deteri-
orated, respray per step "D".
G. If the engine is not installed in a shipping container, engine preserva-
tion must be renewed at the end of 120-day period.
each There is no
limit to the number of times that engine preservation may be renewed.
Renew engine preservation as Follows:
(1) Depreserve the engine per paragraph 4.
1 (2) Represerve engine per steps B through E of this paragraph.
7. Installation of Engine Into Shipping Containers.
NOTE: After engine is preserved per paragraph 6,
the install the engine into
the shipping container.
A. Vapor-barrier bag. (See figure 302.)
(1) Remove the cover and stored hardware from the engine shipping con-
tainer. Unfold vapor-barrier bag so
the that the engine may be
placed in the shipping container inner frame.
(2) Wi~h the engine held in a horizontal position with a sling, 2C5327
(1, figure 302) and hoist, lower it into the shipping container so
that the trunnion mount monoball adapters rest on the container
inner frame.
CAUTION: BE CAREFUL NOT TO TEAR THE VAPOR-BARRIER BAG.
(3) Secure the 2 adapters to the container inner frame with 4 nuts and
bolts. (Do not tighten the nuts.)
(4) Install support yoke over the engine forward support
the forward
ring. yoke to the container inner frame with 4 bolts and
Secure the
nuts. Secure the engine forward support ring to the yoke with the
shoulder bolt and nut. Torque the nut to 160-190 Ib-in.
(5) Align the engine with the monoball adapters and torque the 4 nuts
that secure the adapters to the inner frame to 160-190 Ib-in.
(6) Remove the sling from the engine.
(7) Fasten 15, 8-unit bags (or equivalent) of dehydrating agent, Specifi-
caeion NIIL-D-3464, to the containerinner frame around the engine,
(8) Pad the sharp corners of the engine and inner frame to protect the
vapor-barrier bag when it is folded around the engine.
72-00 June 1/71
Page 308
GEW ERAL LLECtlllC
CJ610. TURBOJET
SEI-186 MAINTENANCE MANUAL
r-
REMOVE CONTAINER TOP
CUT SEAM
2----cl) 3
I 2
/i-
3
3~ r---- 2
r,
i´•~
I
rb.
Ir
IS
REMOVE ENGINE FROM CONTAINER
C REMOVE YOKE d RETURN IT TO
CONTAINER
ilk~
I. ENGINESLING
2. LIFTING CABLES
3. PIPPINS
4. YOKE
UNFOLD WRAPPING
ATTACH SLING L REMOVE
NUTS L BOLTS (4 ON EACH
SIDE)
CJb1040)00~1*
Removal of Engine from the Shipping Container
Figure 302
Jan. 15/69 72-00
Page 309
cEn EIAL O LLECTRIC
CJB1C) TURBOJET
MAINTENANCE MANUAL SEI-186
(9) Fold the vapor-barrier bag around the engine and heat-seal a seam
approximatelyl-inch wide. Leave approximately a 2-inch opening at
one end of the seam so that a nozzle may be inserted to evacuate the
excess air from the bag.
(10) Insert the nozzle in the seam opening and evacuate the excess air
from inside the vapor-barrier bag.
NOTE: The bag will collapse and hug the engine and container inner
frame.
(11) Remove the nozzle, and heat-seal the nozzle opening. (The engine is
now sealed inside the vapor-barrier bag.)
(12) Fold the loose vapor-barrier material (that did not collapse against
the engine when the air was evacuated) close to the engine and secure
it with cloth tape.
(13) Secure the engine records (enclosed in a plastic bag) inside the
container. Place the cover on the container and secure it with the
bolts. Band the cover with 3/4-inch bands in 3 locations.
B. Metal Shipping Container. (See figure 303.)
(1) Remove lid of shipping container. Place to the side.
CAUTION: USE WOOD SLATS UNDER CORNERS OF LID.
(2) Check container, including the horizontal flange gasket recess, for
rust and
loose paint. Remove rust, and repaint any place which needs
touching up. Wipe and/or vacuum-clean the inside of the container
and the gasket recess to ensure cleanliness.
(3) Remove two container brackets (1), shipping support ring (2) and con-
tainer yoke (3) from the container,
(4) Install the two container brackets (1) on the engine trunnion mount
pads located at the 3 and 9 o’clock positions. Secure with eight
1/4-28 x 1 inch long hex head bolts (4). Tighten bolts do not
torque or lockwire at this time.
(5) Install the shipping support ring on the flange of the front frame.
The 7/16 inch diameter hole in the shipping support ring must be in
the 12 o’clock position. Secure with fourteen 10-32 x 1/2 inch long
bolts (5) locknuts and lockwire as required.
(6) Secure compressor inlet plastic cover (6) in place by criss-crossing
lockwire (7) in front of cover, running wire through 1/8 inch diame-
ter holes located on outer edge of shipping support ring (2).
72-00 Sept. 15/69
Page 310
eEnrulOO E~rstnic
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
i. CONTAINER BRACKET
2. SHIPPING SUPPORT RING
3. CONTAINER YOKE
4. BOLT
5. BOLT 8 LOCKNUT
6. COMPRESSORINLET PLASTIC COVER
7. LOCKWIRE
8. ENGINE SLING
9. INNERFRAME
a rl i lo. BOLT, WASHER& LOCKNUT
11. PIN, 8WASHER 8 COTTER PIN
12. BOLT, WASHER 8 LOCKNUT
´•2i~i,
a,
CJ610´•)168´•0-*2*
Metal Shipping Container
Figure 303
Jan. 15/69 72-00
Page 311
cEn FRAL
dJ8-10 ;:TURB:OJET
MAINTENANCE MANUAL SEI-186
(7) Using sling (8) 2C5327 and hoist, position engine over the lower
half of the container.
(8) Lower engine into the container until the container brackets (1) rest
on the inner frame (9). Align the holes of the brackets with the
holes of theinner frame.
(9) Secure the two´•brackets to the inner frame with 7/16-20 hex head
bolts (10) washers and locknuts. Thread nuts to a snug fit. Do not
torque at this time. Threaded section of bolts must be in up posi-
tion.
(10) Place the container yoke (3) over shippingsupport ring (2).
the
Insertthe 7/16 inch diameter pin (11) through the yoke and shipping
support ring link. Install washer and 1/8 inch diameter cotter pin.
Spread cotter pin.
(11) Align holes of container yoke and inner frame. Insert 7/16-20 hex
head bolts (12) threaded section of bolts must be in up position.
Turn on locknuts until finger tight.
(12) Remove engine sling (8) from the engine.
(13) Tighten bolts (4) that secure container bracket to"engine mount pad
and lockwire.
(14) Tighten bolts (10) that secure container bracket tolriner’frame and
bolts (12) that secure aontainer:yoke to Inner frame Ib-ft
of torque.
(15) When engine is ready to be enclosed with container lid, fill,.wire
basket located in lower half of container with eight (83 unit bags
of desiccant.
NOTE: If dehydrated air is not used to:pressQrize the cont’stiner, an
additional eight’(8) unit bags of desiccant $hould be taped
to container inner frame around engine.
(16) Hoist cover over engine container and 1ower.intoposition on lower
half immediately;
CAUTION: LID MUST BE IN PLACE AND BOLTS TORQUED AS QUICKLY AS POS-
SIBLE AFTER PLACING DESICCANT IN CONTAINER TO AVOID CON-
TAMINATLON OF THE DESICCANT.
(17) Install with threaded ends up, eighteen 1/2-13 bolts and nuts in
closure flanges.
(18) Tighten bolts i, 4, 6, 9, 11, 13, 15, 17 in that order to pull cover
down evenly on gasket.
72-00 April 15/(68
Page 312
G EW ORAL O ELICTRIe
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(19) Starting with bolt No. 1 tighten each successive bolt to 70-75 Ib-ft.
NOTE: If shipping container contains an air relief valve omit
steps (20) through (25).
(20) Remove outer cover of the desiccant port, valve cap and valve insert.
I (21) Install
5
psig. o an air-filler valve
connection,and pressurize container
t
CAUTION: USE DEHYDRATED AIR ONLY UNLESS EXTRA DESICCANT WAS PLACED
INSIDE CONTAINER.
(22) Recheck with an air gage for proper pressure; then remove the filler
valve connection and install the valve cap.
(23) Brush the air-filler valve and all joints, seams andflanges with a
liquid soap solution. Correct the leaks that any resulting air
bubbles indicate.
(24) At the end of a 60-minute period, recheck for proper pressure.
(25) Bolt the outer cover of the desiccant port in place.
(26) Coat exposed surfaces of flange-bolts and nuts with a
the corrosion
preventative compound conforming to MIL-C-16173, Grade I.
(27) Place engine records shipping papers in plastic bag
and or envelope.
Place in record receptacle. Tighten bolts securely.
8. Storage of Engines Installed in Shipping Containers.
A. Vapor-barrier bag.
(1) Engines may be stored in their shipping containers for the period
specified on the outside of the shipping container.
(2) The humidity indicators should be checked every 90 days to make sure
the moisture content within the plastic bag has not exceeded the
maximum acceptable limit.
(3) The engine must be represerved if any of the humidity indicators have
changed to a pink color.
B. Metal shipping containers lair relief-valve type).
(1) Engines may be stored in their shipping containers indefinitely pro-
vided periodic inspection indicates that humidity condition in the
container is satisfactory.
72-00
Dec. 30/78
Page 313
GENERAL E Lf CTI IC
CJ61O TURBOJEV
MAINTENANCE MANUAL SEI-186
(2) The humidity indicators should be checked every 30 days to make sure
the moisture content within the container has not exceeded the maxi-
mum acceptable limit.
(3) The engine must be represerved if any of the humidity indicators
have changed to a pink color.
C. Metal shipping containers (pressurized type).
NOTE: When an engine has been preserved and packed according to the
preceding instructions, it is considered to be preserved indefi-
nitely provided periodic inspection indicates that pressure and
humidity conditions in the container are satisfactory. The fol-
lowing Periodic Inspection must be made at least once every 180
days.
(1) Observe and record pressure and humidity in the shipping container
within 7 days and at least once every 180 days thereafter.
(2) If inspection reveals that internal pressure is more than 1 psig and
humidity indicator is blue, no action is required.
(3) If inspection reveals that internal pressure is less than 1 psig and
that in an initial inspection, the humidity indicator is blue, re-
pressurize the container to 5 (f 1) psig with clean, dry air. Check
the pressure again after 7 days. If pressure has not been maintained,
remove the engine and represerve it in another container.
(4) If inspection reveals that humidity indicator is pink (a corrosive
condition) remove the engine from the container and inspect it for
indication of rust or corrosion.
(a) If ~the engine is serviceable, represerve it in another container.
(b) If inspection shows evidence of rust or corrosion, reinstall the
shipping cover, replace the desiccant, repressurize the contain-
er to 5 1) psig and return the engine to overhaul for inspec-
tion and repair.
9. Removal of Engine from the Sliipping Container.
I A. Vapor-barrier bag. (See fi~ure 302.)
(1) Place the shipping container under a hoist.
(2) Cut and remove the wire bands (if installed) that secure the cover
to the container.
(3) nemove the bolts that attach the cover to the container. Remove the
cover.
72-00 Jan. 15/69
Page 314
OIWERAL ELECTIIS
GJBiO TURBOJET
SEI-186 NIAINTENANCEMANUAL
(4) Remove and check the
engine historical records. (Note any deficien-
cies.) Record anydamage to the shipping container; record damage
of any consequence to the engine.
(5) Carefully remove the cloth tape that is used to hold the corners of
the moisture-barrier bag close to the engine. Cut off the sealed
seam on the top of the bag.
CAUTION: DO NOT TEAR THE MOISTURE-BARRIER BAG. CUT THE BAG CARE-
FULLY SO THAT IT CAN BE REUSED.
(6) Unfold the bag carefully so as to expose the engine for removal.
(7) Attach the engine sling (1), tool No. 205327, to the engine as
follows:
(a) Place the sling on the hoist.
(b) Adjust lifting eye to proper center of gravity on bar.
(c) Adjust the lifting cables (2) to proper location on bar.
(d) Install the locking pip pins (3) to engine installation lug.
(e) Raise the hoist to take up the slack in the lifting cables of
the sling.
(8) Remove the nuts and bolts that attach the trunnion mount adapters and
the forward support yoke to the inner frame of the shipping container.
(9) Carefully raise the engine and the yoke free of the container.
CAUTION: BE CAREFUL SO AS NOT TO DAMAGE THE ENGINE OR TEAR THE
VAPOR-BARRIER BAG.
(lO) Remove the nut and bolt that attaches the yoke to the forward sup-
port ring.
(11) Score the yoke and hardware in the shipping container for reuse.
NOTE: If the engine requires maintenance and if it will not be
operated before being torn down, no depreservation is
required.
B. Ugtal shipping container. (See figure 303.)
(1) Release air shipping container by removing the
pressure from the
desiccant port unscrewing the core of the air filler valve.
cover and
The container is pressurized to approximately 5 psig. After pressure
has been released, reinstall core.
Jan. 15/69 72-00
Page 315
G EIORAL
GJ610’ TUR´•B6UI~T
MAINTENANCE MANUAL SEI-186
NOTE: Step ´•(1) is not necessary for shipping containers that contain
airrelief valve as they are notpre8surbzed.
(2) Remove the bolts which fasten the top half of the container to the
bottom half.
(3) Attach a sling to the cover. Lift the cover carefully.
CAUTION: BE CAREFUL NOT TO STRIKE TIIE.ENGINE WHEN LIFTING THE COVER.
(4) Attach the engine sling (8) tool No. 2C5327 to the engine as follows:
(a) Place the sling on the hoist.
(b) Adjust lifting eye to proper center of gravity onbar.
(c) Adjust the lifting cables to properlocation on bar.
(d) Install the locking pip pins to engine installation lug.
(e) Raisethe hoist to take up the slack in the lifting cables of
the sling.
(5) Remove the nuts and bolts (10), (12) that attach the container
bracket (1) and container yoke (3) to the inner-frame (9) of the
shipping container.
(6) Remove pin, washer and cotter pin(ll) fromcontaineryoke and remove
the yoke.
(7) Carefully raise the engine free of the container.
CAUTION: BE CAREFUL NOT TO STRIKE THE ENGINE AGAINST THE CONTAINER.
(8) Remove bolts (4) that attach the container brackets (1) to the engine
trunnion mount pads. Return brackets and yoke to the .shipping con-
tainer for reuse.
NOTE: If engine requires maintenance and if it will, not
the be
operated before being torn down, no depreservation is
required
10. Preservation of Accessories.
NOTE: If an accessory is removed from the engine´•andplaced in spare parts
stock, it properly prepared for storage.
must be By observing normal
practices of proper packaging and performing the following preserva-
tion procedures, all engine accessories can be stored.without detri-
mental effects.
72-00 Apjt’il 15~68
Page 316
GEIIERAL PLECTRIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
A. Fuel System Components.
(1) If component has been subjected to commercial kerosene, as in engine
operation, it can be stored for periods up to 30 days by draining
excess fluid, installing protective covers over drive shafts and
control shafts, and capping all openings.
(2) To store components for periods in excess of 30 days, the component
should be flushed with MIL-L-6081, grade 1010 oil. Drain excess
fluid, install protective covers over drive shafts and control shafts,
and cap all openings.
B. Lubrication System Components.
(1) Pour a sufficient amount of engine oil, listed in approved oils,
Chapter 79, into the component to coat the internal parts. Rotate
the drive shaft of engine driven components to assure a thorough
coating of oil.
(2) Drain excess fluid.
(3) Cap all openings.
(4) Install protective covers over drive shafts.
C. Electrical Components. To store electrical components, install protec-
tive covers on amphenol connectors and drives.
D. Air System Components. To store air system components, install caps on
all openings.
11. Installation of Engine into Maintenance Stand.
A. Place engine in a horizontal position with a lift sling, 2C5327 (1, fig-
ure302) and hoist.
B. Position maintenance stand, 2C5349 under engine, with the rear support
swing positioned to one side.
NOTE: Remove transportation brackets from engine trunnion mount pads
and the yoke.
C. Lower engine until engine trunnion mount pads are at same level and in
alignment with the maintenance stand pivots. Center engine between the
maintenance stand side supports and attach pivots to engine trunnion
mount pads with 4 bolts on each side and snug the bolts for holding stand
pivots to side supports.
Sept. 15/69 72-00
Page 317
GIWERAL qb ELLCTRIC
CJBIO TURBOJET
MAINTENANCE MANUAL SEI-186
"r
i ~E
CJ610´•6111-0´•82
Engine Installation into Maintenance Stand
Figure 304
72-00 Jan. 15/69
Page 318
GelERAL Q ELICTIIC
C3610 TURBOJET
SEI-186 MAINTENANCE MANUAL
D. Release the rear cable of the lift sling, 205327, from engine and connect
the maintenance stand rear support.
NOTE: The engine may have a tendency to tilt when rear support to en-
gine is removed.
E. Release the Front cable of lift sling from machine.
April 15/68 72-00
Page 319
Ctlfll;AL8 ELECIIIIG
CJBlO TURIOJ~T
SEI-186 MAINTENANCE MANUAL
ENGINE MAINTENANCE PRACTICES REMOVAL AND INSTALLATION
i. General.
A. The detailed removal and installation information is covered in the Air-
frame Maintenance Manual.
B. Whenever the engine is removed from the aircraft, it should be preserved in
accordance with Engine Maintenance Practices Servicing, 72-00.
C. Install engine in maintenance stand, 2C5349, when engine is removed from
aircraft for maintenance.
72-00
Sep 1/75
Page 401
GLIEIAL~ ELICIIIC
CJES1Q TURBOJET
SEI-186 MAINTENANCE MANUAL
MAINTENANCE PRACTICES ADJUSTMENT/TEST
i. General.
To operate properly, engine must be correctly adjusted. The checks for
an
proper.adjustment, and the adjustments themselves, can best be made during
operation of the engine; therefore, a functional run-up procedure is out-
lined In this section. This is followed by adjustment procedures and oper-
ating limits. The pre-start check is to ensure that the engine inlet and
area around the engine area are clean, no fuel or oil leaks are evident, fuel
and oil supply is adequate and the gas generator rotor turns freely. The
functional test run takes the engine through a full running cycle. This pro-
cedure should be followed for a newly installed engine, and for troubleshoot-
ing an engine with a malfunction. The functional run has been divided into a
number of different categories called checks. Each check has been selected
to evaluate one engine operation. Generally, only one
particular phase of or
two of these checks need to be made on an engine, depending on the extent of
the maintenance the engine has undergone. A record of engine instrument
readings at T.O. and cruise including air speed, RAT, and altitude every
10-15 hours is very useful for troubleshooting.
2. Safety Precautions.
A. Observe routine safety precautions while operating the engine.
(1) Be sure that personnel are standing clear of the exhaust area.
(Refer to figures 501 and 502.)
standing clear of the engine inlet and
(2) Be sure that personnel are
compressor bleed valves.
(3) Be sure that fuel drainage does not present a fire hazard.
ground beneath the engine is clean and free of loose
(4) Be sure the
debris which might possibly be picked up and ingested by the engine.
B. Do not exceed the exhaust gas temperature or engine speed limits during
starting or subsequent engine operation.
72-00
Dec 1/77
Page 501
6iW ERAL ELECTRII:
CJGIO TURBOJET
MAINTENANCE MANUAL SEI-186
IDLE
I
42
o
INDICATED VELOCITY FT´•:SEC
/i
350 250 200 1150 1 100 70
i
J
it
Q
INDICATED TEMPERATURE OF
6000F 5000F 4000F 3000F 200"F 1500F
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38
DISTANCE FROM JET NOZZLE- FT.
ciaio-ioo3-o-c?
Jet Wake Temperature and Velocity Profile at Idle
Figure 501
72-00 Mar. 30/67
Page 502
CJ610 TURBOJET ENGINES
GEAircraftEn~rines MAINTENANCE MANUAL
TAKE Off
INDICATED VELCITY
ZI I i\ I 1
FI/SEC.
S 1709---t- 1200 800--$-600 400--C XK)~-- 100-
Y 4
INDICATED TEMCERATUI(E -´•F
1100´•F 7DO´•F 500´•F 400´•F 300´•F 200´•F IXTF
8 Z 4 6 8 10 It 14 16 18 20 22 24 26 28 30 32 34 16 38
DISTANCE FROM IET NOfZLE -FT.
cute.
lool4El
Jet Wake Temperature and Velocity Profile at Takeoff
Figure 502
72-00
Mar 30/67 Page 503
CJG1OTURBOJET
GE Aircraft Ensines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-474
Filing
mstructions: Put this Temporary Revision (TR) in the CJ~10
Turbojet MAINTENANCE MANUAL SEI-186, adjacent to
page 504, dated May 31/98, in Chapter 72-00.
Record this TR number in the Record of Temporary
Revisions.
Subject: Function Check Guide
Reason: To add the requirement to do a function check
after overhaul and major repairs in figure 503,
item 1.
Change: Change figure 503, item i.
~z:
Zj
Zj r x
r x ui ~o
c~
p~Y Z
I io U
o X
2; "8oU 9
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1. INITIAL ENGINE
INSTALLATION, OVERHAUL,
OR MAJOR REPAIR X IX X X X X X X X X X X X
FILA APPROVED MAY 23, 2000
72-00
Page 1 of 1
May 23/00
CJ610 TURBOJET ENGINES
nAINSENANCE MANUAL
GEAircraftEn~ines
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1. INITIAL ENGINE
XIX X X X X X X X X X X
INSTALLATION
(REFER TO SECTION 5-21, TABLE i, ITEM M)
2. PERIODIC
XXXXXXXXXX X
INSPECTION
3. HOT SECTION
XIX X X X X X X X X X I:
INSPECTION
4. FUEL CONTROL
XIX X X X X X XIX X
CHANGED
5. VARUBBLE GEOMETRY
X’ X X X X X
SYSTEM ADJUSTED
IGhTTER PLUG
X XI 1 I I I I I I I IX
CHANGED
7. LWE PUc~
X X X X XI I I I I fX
CHANGED
8. LUBE TANK
X X X X XI I I I I IX
CHANGED
9. OVERSPEED
XIX X1 IXIXI IX I I I 1X
GOVERNOR CHANGED
10. ANY LUEE SYSTEM
CONNECTION X X
DISRUPTION
11. ANY ma SYSTEM
CONNECTION X X
DISRUPTTON
12. ANY AIR SYSTEM
CONNECTION X Z
DISRUPTION
Function Check Guide
Figure 503
NOTE: Please see the
72-00
~ae: 1
TEMPORARY
REVISION
that revises this page.
~age 504
May 31/98
GEn EIIAL ~B ELECtRIC
C31g;~0 TURBOJET
SEI-186 MAINTENANCE MANC~AL
3. Punc~ional Test Run.
NOTE: Refer to 72-00, SERVICING, Lubrication System to determine if the lube
and scavenge pump requires priming before starting the engine.
The functional test run is intended to give an engine a thorough test for
mechanical soundness and for correct indications of engine operation parame-
72-00
Dec 30/78
Page 504A1504B
GEntRAL~ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
ters. The functional test has been divided into categories called "checks";
these are defined in Figure 503. types of maintenance, it will
After some
be ´•necessary to perform all of the checks listed. Figure 503 can be used as
a guide to decide what checks are necessary after certain types of
maintenance. The checks may be performed with the engine installed in a
test cell, test stand, or in the aircraft. If the engine is in a test
I facility, a bellmouth and tailpipe which conforms to GE Aircraft Engines
specifications must be used. If the engine is installed in an aircraft, the
inlet portion of the nacelle and the tailpipe must be attached. Face engine
into the wind, if possible, so that the exhaust gases are not ingested by
the engine.
A. Preset Check.
(1) Check the oil level indicated on the oil tank dipstick. If the
dipstick indicates that additional oil is required, use the following
steps to prevent overservicing the oil tank.
NOTE: When the engine is shut down, oil seeps from the oil tank to
the accessory and transfer gearboxes.
(a) Motor the engine with the starter for a period not to exceed
the starter duty cycle. (Motoring scavenges the oil back to the
oil tank.)
(b) Drain the accessory and transfer gearbox s~rmps. Replace the plugs.
(c) If the dipstick still indicates that oil is required, add oil that
has been filtered through a l0-micron metallic filter to bring the
oil level up to the FULL mark on the oil tank dipstick.
(d) Replace the oil tank filler cap. Turn the locking tab clockwise to
seat the cap.
(2) Check the power lever actuator rigging at the IDLE position. If adjust-
ment is necessary, do the following:
(a); Set the fuel control input shaft at the IDLE position. Insert the
rigging pin, 2C5320, through the input shaft rigging hole and
into the slot in the fuel control casing.
(b) Connect the power lever clamp and linkage to the fuel control
input shaft.
Dec 31/91 72-00
Page 505
´•G F W ER A L ELIE CtR TC
C3610 TURBOJET
MAINTENANCE MANUAL SEI-186
NOTE: The input shaft has a missing serration which can be used
for alignment purposes.
(c) Exert slight pressure on the input shaft toward the OFF direc-
a
tion, and adjust the linkage so that the power lever is set at
the IDLE position.
(d) Remove the rigging pin and check the input shaft travel. The
travel should be 93-94 degrees.
(3) Inspect the engine and engine installation.
(a) Check the engine mounts, and the fuel and electrical connections.
(b) Check all engine fuel, air, and lube lines. Check the engine
accessories for proper installation and security of mounting.
(c) Check the compressor rotor for free rotation.
(d) Check to determine that the density knob on the ~uel control is
set at the correct location for the particular type fuel being
used.
B. Motoring Check.
(1) The motoring check is after inspection or maintenance
required only
and it ensures engine rotates freely, that the instrumen-
that the
tation functions properly, that the fuel and lube systems are leak-
free, and that starter operation meets the speed requirements for
successful starts. Motoring primes the fuel and lube systems when
maintenance has required replacement of fuel or lube system com-
ponents.
(2) Position the engine controls as follows:
(a) Fuel Boost ON
(b) Anti-Icing OFF
(c) Power Lever OFF
(d) Ignition OFF
(e) Starter OFF
(f) Customer Air Bleed System OFF
CAUTION: THE FUEL PUMP AND FUEL CONTROL ARE FUEL-LUBRICATED.
DO NOT MOTOR, START, OR OPERATE THE ENGINE UNLESS A
POSITIVE F~EL INLET PRESSURE IS INDICATED.
72-00 Mar. 30/67
Page 506
BEUEIAL ~D ELICTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(3) Turn the starter ON. Advance the power lever to IDLE and hold only
aslong as
necessary (20 seconds max.) to check the instruments for
positive indications of engine speed, oil pressure, and fuel flow.
(a) The starter must be capable of turning the engine rotor to at
least 12 percent within 12 seconds for ambient temperature con-
ditions of OOF (-18"C) or higher to achieve normal starts. If
these conditions cannot be met, refer to Troubleshooting Guide.
(b) Normal oil pressure indication is 1 to 10 psig. However, ini-
tially there may be no indication if any of the lube system
components have been replaced, or if the oil has been changed
during maintenance.
(4) Retard the power lever to OFF and continue motoring (20 seconds
min.) for the time remaining within the starter-usage limit to purge
the combustion and exhaust sections of fuels and vapors.
NOTE: If the fuel flow does not drop to zero when the power lever
is returned to OFF, check the rigging of the power lever.
(5) De-energize the starter. During engine coastdown, make the follow-
ing checks:
(a) Listen for unusual noise from the rotating components. Check
the engine front frame, mainframe, and turbine areas for unusual
roughness.
NOTE: Normal rotational noise consists of clicking compressor
and turbine blades, gear noise, and rubs at the second-
stage turbine shroud and turbine torque ring.
(b) Inspect the fuel and lube system lines and their fittings for
leakage.
(c) Check the combustor and fuel manifold drain valve for proper
drainage operation.
(6) After rotation ceases, turn the fuel boost OFF. Shut off the power
and supply systems to the engine.
(7) Refer to Troubleshooting, 72-00, for the correction of any discrep-
ancies found during the motoring check.
(8) Retorque or replace fittings as necessary, to correct fuel or lube
leaks.
(9) Check the oil tank oil level. If necessary, add oil per procedure
specified in Prestart Check.
j (10) Allow a 2 minute (min.) period for fuel to drain from the engine be-
fore attempting to start the engine after the motoring check.
Oct. 15/70 72-00
Page 507
GEIYCRAL ELECt~lC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
C. Engine Start.
(1) Position the engine controls and switches as follows:
(a) Fuel Boost ON
(b) Anti-Icing OFF
(c) Power Lever OFF
(d) Ignition OFF
(e) Starter OFF
(f) Customer Air Bleed System OFF
CAUTION: THE FUEL PUMP AND FUEL CONTROL ARE FUEL-LUBRICATED.
DO NOT MOTOR, START, OR OPERATE THE ENGINE UNLESS A
POSITIVE FUEL INLET PRESSURE IS INDICATED.
(2) Turn the starter and ignition ON, and advance the power lever to
IDLE at 10 percent rpm.
(a) Be prepared to retard the power lever slightly, or if necessary,
to chop completely OFF should the starting fuel flow exceed 350
pounds per hour. Chop power lever to OFF if EGT indication does
not occur within 10 seconds.
CAUTION: FUEL FLOW IN EXCESS OF 350 POUNDS PER HOUR WILL CAUSE
H(YT STARTS. DO NOT ALLOW THE STARTING FUEL FLOW TO
EXCEED 350 POUNDS PER HOUR BEFORE COMBUSTION OCCURS.
(3) Ohserve the exhaust gas temperature (EGT), fuel flow, and oil pres-
sure instrument readings.
If EGT reaches 9000C (16500F) and is rising rapidly during an
attempted start, chop the power lever to OFF, and continue oper-
ating the starter to maintain EGT within the starting tenipera-
ture limits.
I CAUTION: DO NOT ALLOW EGT
TEMPERATURE LIMITS
TO EXCEED
IN FTGURES
THE TEMPERATURE,
504, 505, 505A,
OR TIME-AT-
OR 5058.
(4) Turn the starter and ignition OFF when the engine speed exceeds 37~
(6105) rpm.
(5) Allow the engine to stabilize at IDLE. Check the engine instrumen-
tation readings for values within the operating limits.
72-00 Feb 23/77
Page 508
(O V1
D M
U
O
1000 03
ex,
I:: I: t;:;-:i::-:IINVESTI GATE" MAXIMUM
1800~ LIMIT- "C
800 0-2 SECONDS 910
it:1 800 5 SECONDS 854
782 10 SECONDS 782
;1 704 5 MINUTES (TAKEOFF) 704
17 ~T: i 677 MAX. CONT. 677
i i.
i
LL 10 ;if-
900
t
-i•´i -;t-’ i-i
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OPERATION ABOVE I.
:iii:111~1
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t~´• i
ENGINE OPERATION FOR A TIME-AT-TEMPERATURE
4’ BELOW THE CURVE IS WITHIN ALLOWABLE LIMITS
QI -1=
CT:
a 750 B
CD"
o Iv O
a a CONTINUED STARTS IN THIS AREA t
z r 704"0
1300 ARE CAUSE FOR CORRECTIVE ACTION m
700 11
i
i 6770C
--II´• ´•´•´•--´•´•´•´•*´•--------r -7-_--:t´•´•´•´•´•I´•-:´•"r- j
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,,.,,,,,,-~C:TIME-MINUTES1
5
"START TEMPERATURES SHOULD NEVER EXCEED THE SOLID LINE TIME.TEMPERATURE CURVE. AT AMBIENT TEMPERATURES
~d OOF APPROXIMATELY 300C (860F) ANO ABOVE, NORMAL START TEMPERATURES MAY EXCEED 8000C (14720F) BUT SHOULD J
do" BE LESS THAN 8200C (15080F). BC-0085-1
ul
oo
\oo Exhaust Gas Temperature Starting and Transient Limits (CJ610-1 and -4 Engines)
Figure 504
"8
Ln 1
r
C´• INVESTIGATE" MAXIMUM
o 1 :Ij::.::::::: i::..: ABOVE "C LIMIT "C
i: i
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800
a-n sEcoaos
5 SECONDS
910
854
1000 782 1O SECONDS 782
1
:r: i
_I_-i:--;: i
it 716 5 MINUTES (TAKEOFF) 716
ii
702 MAX. CONT,
IU i
::--:!::::t 702
’´•´•I
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900 OPERATION ABOVE
w w
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THIS CURVE NOT
I j
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w
PERMITTED j
1 tl
i
Y Q,
850
Fb
ENGINE OPERATION FOR A TIME-AT-TEMPERATURE
I" BELOW THE CURVE IS WITHIN ALLOWABLE LIMITS
2:
800
t E ;D
01"
5 u m"g
C
1400-1 n
750~-´•--i- 111
CONTINUED STARTS IN THIS AREA
ARE CAUSE FOR CORRECTIVE ACTION
1 702"Ci~
700t--::--´•i-- i
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1200’ 650
5
.I’TIME-MINUTES-I
O 2 10
t~ ’START TEMPERATURES SHOULD NEVER EXCEED THE SOLID LINE TIMELTEMPERATURE CURVE. AT AMBIENT TEMPERATURES
n,
o OF APPROXIMATELY300C (860F) AND ABOVE, NORMAL START TEMPERATURES MAY EXCEED 8000C (14720F) BUT SHOULD J
w BE LESS THAN 8200C (15080F), 80-0084-1
o
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u
03
o~
Exhaust Gas Temperature Starting and Transient Limits (CJ610-5 and -6 Engines) o\
Figure 505
cn
r; w
L,
O
1050 r
i INVESTIGATE MAXIMUM Oo
1 ’1 LIMIT OCI I
u ABOVE OC
800 0-2 SECONDS 910
bOO 5 SECONDS 854
1000 782 10 SECONDS 782
i
:-i 1 746 5 MINUTES (TAKEOFF) 746
1800
729 MAX. CONT. 729
r ::i: iI i I~
950 ----~´•--´•-´•-´•-t´•----´•´•$´•-- ’´•´•F--
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THIS CURVE NOT
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w ....1.~_._:
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i´•-´•´•--S-.´•-: -´•5´•---;1---1..,_- -5
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CONTINUED STARTS IN THIS AREA
ARE CAUSE FOR CORRECTI\IE AC~TON
1300
---I--:------
1 650 03
20
/-ITIME-5
O 2 10
*START TEMPERATURES SHOULD NEVER EXCEED THE SOLID LINE TIME-TEMPERATURE CURVE. AT AF?L3IENT TEMPERATURES
rd OF APPROXIMATELY 300C (860F) AND ABOVE, NORMAL START TEMPERATURES MAY EXCEED e000C (14720F) BUT SHOULD J
BE LESS THAN 8200C (15080F). 85-0006-1
~nN
r
oo Exhaust Gas Temperature Starting and Transient Limits (CJ610-8 and -9 Engines)
Figure 505A
rdy
09
mo
o 1050 i--
cn i i
1900 1´•
i
O INYEST1GP.TE f
MAXIMUM
I I i.-i i~-l ABOVE OC LIMIT oC
I !:1 800 0-2 SECONDS 910
1000
800 5 SECONDS 854
782 10 SECONDS 782
735 5 MINUTES (:AKEOFF; 735
18(10 724 MAX. CONT. 724
i I
950
:i :-i i
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1700
ou
rr
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OPERATION ABOVE
c
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i/ THIS CURVE NOT
PERMITTED I 61=
c
t z
r 14
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m
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C
C~
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i "t-l t t-i---i´•´•´• -f
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CONTINUED STARTS IN THIS AREA i;
ARE CAUSE fOR CORRECTIVE ACTION
1300 +:.L
700
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i’----- TIElil~CONOS -----tl-TIIII?’INUTEI-I
*START TEMPERATURES SHOULD NEVER EXCEED THE SOLID LINE TIME-TEMPERATURE CURVE. AT AMBIENT TEMPERATURES
~S
1~ I OF APPROXIMATELY 300C AND ABOVE,,NORMAL START TEMPERATURES MAY EXCEED 8000t BUT SHOULD BE LESS THAN J
m 82000. BC-0384
n m
m
u H
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Exhaust Gas Temperature Starting and Transient Limits (CJ610-8A Engines) r
~x,
co
Figure 505B En
GLIERAL~ BLEErRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
D. Idle Check.
(1) The idle check consists of checking for proper engine operation as
evidenced by leak-free connections, normal operating noise, and
proper indications of all engine-related instruments, controls, and
switches. While the engine is running, a malfunction is indicated by
abnormal readings of the instruments.
(2) After the engine has stabilized at IDLE, check the following
instruments:
(a) Engine Speed:
1 Applies to all 48 1)% (7755-8085 rpm)
engines except
CJ610-9 with
Service
Bulletin 73-47.
2 Applies to 53 1)X (8580-8910 rpm)
CJ610-9 engines
after compliance
with Service
Bulletin 73-47.
(b) Oil Pressure:
1 Applies to all 5,0-25,0 psig (with oil tank
engines except temperature stabilized above 1760F
CJ610-9 with (800C)). Operate engine at maximum
Service continuous for 5 minutes to warm up
Bulletin 73-47. oil just prior to taking reading.
2 Applies to 6-30 psig (with ail tank
CJ610-9 engines temperature stabilized above 1760F
after compliance (800C)). Operate engine at maximum
with Service continuous for 5 minutes to warm up
Bulletin 73-47. oil just prior to taking reading.
(c) Exhaust´•Gas Temperature,.,.,,, See figures 504, 505, 505A, or
505B.
(d) Fuel Inlet Pressure,..,,,...,.,, 50 psig (max.)
Dec 31/91 72-00
Page 510C/510D
~I
GLWEIAL~b ELfCt~lC
CJ610 TURIOJLT
SEI-186 MAINTENANCE MANUAL
NOTE: Do not adjust the IDLE speed adjustment until after the
MAXIMUM speed adjustment has been made.
(3) Inspect the engine and accessories as follows:
(a) Check for leakage at the horizontal (split-line) and vertical
flanges of the compressor and turbine casings.
(b) Check all engine accessories, lines, and fittings for fuel, air,
or oil leakage.
NOTE: Little or no fuel drainage from the combustion casing or
fuel manifold drain valve should be evident after several
minutes of operation.
(c) Check each gearbox-mounted accessory at the mounting pads for oil
leakage. Disregard normal oil leakage from the provided drains.
(See TABLE 504 for limits.)
(4) Before proceeding with the operational check, retorque any leaking
fittings lines, and replace defective instruments. If necessary,
or
shut the engine down to make repairs. All instrument indications
should be within limits and the fuel or oil leaks corrected before
running the engine at TAKEOFF power.
E. Variable Geometry Check.
(1) The variable geometry operating schedule, which is a function of
compressor inlet temperature (CIT) and engine speed (RPM), is regu-
lated by the main fuel control. The fuel control closes the inlet
guide vanes and opens the compressor bleed valves at lower engine
speeds. At higher engine speeds the inlet guide vanes are fully
opened, and the compressor bleed valves are closed to allow maximum
air flow through the engine.
(2) Check the variable geometry operating schedule as follows:
NOTE: A calibrated tachometer accurate within +0.25 percent, or
equivalent Jetcal
analyzer, is recommended when checking engine
speed. However, aircraft instrumentation may be used for a rough
check. Use observed ambient temperature in the engine inlet for
CIT. To determine compressor bleed valve position, use tool
2C5425.
(a) While observing the compressor bleed valves, slowly advance the
power lever until the valves begin to close. Record the CIT and
RPM at this point.
1 Plot the observed point on figure 506.
72-00
Sep 1/75
Page 511
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-55-50 -95 -40 -35 -30 -25 -20 -15 -10 -5 D 5 10 15 20 25 30 35 40
CO)PRESSOR INLET TMPEI~TURE-OC
m
I 1 I r I 1 1 1 7 1 I f I -I I 1 1 1
CA
-70 -60 -50 -40 -30 -20 -10 O 10 20 30 40 50 60 70 80 g0 100
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COn3kESU)R INLET TEMPERA~TURE-OF w-olt) r
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OEIEIAL´• tLICtllC
CJ~10 TURIIOJLT
SEI-186 MAINTENANCEMANUAL
2 If the point falls within the maximum-minimum limits at the
initial closing band, this portion at the variable geometry
check is complete and no adjustment is necessary.
3 If the point falls outside the limit, adjust the variable
geometry system per Maintenance Practices, 75-00.
(b) Increase engine speed until the bleed valves are fully closed.
Slowly engine speed until bleed valves just begin to
decrease
open. Record this speed (RPM) and the compressor inlet temperature
(CIT). Tool 265425 reads 0.5% high due to pressure and mechanical
lag. Correct for lag by subtracting 0.5% from RPM (observed) prior
to plotting the point.
1Plot the observed point on figure 506.
2 If the point falls within the maximum-minimum limits of the full
closed band, the variable geometry check is complete and no
adjustments are necessary.
3 If the point falls outside the limit, adjust the variable
geometry system per Maintenance Practices, 75-00.
(c) Deleted.
I Sep 1/75 72-00
Page 512A/512B
6EWERAL~ ~LPCtRIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
F. Takeoff Power Check.
NOTE: Takeoff power is attained when the required engine pressure ratio
(EPR) for the existing compressor inlet temperature is attained
without exceeding engine speed or exhaust gas temperature limits.
(1) The takeoff power check determines the capability of the engine to
meet the minimum power requirements for optimum takeoff performance
using the engine pressure ratio (EPR) system. However, the data is
applicable only if the following conditions exist:
(a) Inlet duct recovery equal to 100%. Compressor total inlet
pressure equal to barometric pressure.
(b) An engine tailpipe which conforms to GE Aircraft Engines
specifications.
(c) No anti-icing airflow.
(d) No customer bleed or power extraction.
(e) Instrumentation is as follows:
Parameter Gage Range
RPM 0-110%
Exhaust Gas Temperature 0-10000C
Exhaust Gas Pressure 0-50 in Hg.
NOTE: If the takeoff check is conducted with the engine in the
aircraft with the aircraft inlet ducting and tailpipe
attached, the operator must use the AIRCRAFT EPR takeoff power
curve.
(2) Conduct the takeoff power check with the engine facing into the wind
so that the exhaust gases are not ingested by the engine.
(3) If exhaust gas pressure (EGP) is to be read directly instead of
engine pressure ratio (EPR), convert EPR to EGP before operating the
engine by using the following formula:
EGP (gage) (EPR x barometric pressure) barometric pressure
(4) Accurately determine and record compressor inlet temperature
(ambient) and barometric pressure.
Dec 31/91 72-00
Page 513
GEWERAL~ ELECfRle
CJ610 7URBOJET
MAINTENANCE MANUAL SEI-186
(5) Determine the following for the particular compressor inlet tempera-
ture that was recorded:
(a) Engine speed limit. (See Figure 507for all engine models
except CJ610-8A. See Figure 507A for CJ610-8A engines.)
NOTE: The curve Figure 507 (Figure 507A for C3610-8A engines
in
only) represents the engine speed cutback limits only
when the throttle is at maximum setting. The cutback will
be zero at IDLE and will increase, roughly proportional
with engine speed, to maximum limits in Figure 507
(qigure 507A for CJ610-8A engines only).
(b) Exhaust gas temperature limit (figures 504, 505 or 505A).
(c) Engine pressure ratio (EPR) required at takeoff power (refer to
the Aircraft Operating Manual).
(6) Perform maximum speed adjustment check per paragraph Fl. If EPR de-
termined in step (5)(c) is achieved with RPM and EGT within limits,
the engine has demonstrated satisfactory takeoff performance. If EPR
requirement is not met due to:
(a) Maximum speed adjustment:being too low, the maximum speed will have
to be raised per paragraph Fl. and another EPR check made.
(b) Speed limit or EGT limit, other maintenance action is required.
Refer to Troubleshooting.
Fl. Maximum Speed Setting. This procedure is used for ambient temperatures
above OOF for G10 and lower controls and minus 100F for G11 and above
controls.
(1) Perform a speed check (MSC) by slowly advancing the power
maximum
lever to maximum unless
an engine operational limit is exceeded
(refer to Table 504). If the engine is speed or temperature
limited, stabilize the engine at the highest limiting factor and
record engine speed, EGT and EPR. Retard power lever to idle
position.
72-00 Dec 1/79
Page 514
e E n t aA L E LE eT I IC
CJ610 TURBOPIET
SEr-186 IdAINTENANCE MANUAL
TABLE 501. DELETED
(2) Compare the readings to Table 502 to determine which of the two
procedures (direct or indirect) is to be used to make the maximum
speed adjustment (MSA).
TABLE 502
Maximum Speed Setting Procedures
Operating
Case Parameter Result Procedure
i. Power lever Maximum (920 or more) None required.
Engine speed (Ng) Equal to 100.7 to 101.2 percent Adjustment is
EGT (Tg) Equal to or less than limiting correct.
Power lever Less than maximum Direct. See step
Engine speed Equal to 101.2 percent (3) for procedure.
EGT Equal to or less than limiting (MSA is too high)
3. Power lever Equal to or less than maximum Indirect. See
Engine speed Less than 100.7 percent step (4) for pro-
EGT Equal to limiting cedure. (MSA not
directly deter-
minable.)
4. Power lever Equal to maximum As the MSA is too
Engine speed Less than 100.7 percent low, an estimate
EGT Less than limiting should be made to
determine the re-
sult on Tg when
increasing the
MSA. This esti-
mate will deter-
72-00
Page 514A
May 15/70
eEIEIAL~ILLCTIIC
63610 TURIOJBT
MAINTENANCE MANUAL SEI-186
TABLE 502 (Cont)
Operating
Case Parameter Result Procedure
mine which pro-
cedure is to be
used so an addi-
tional cycle will
not be required.
See step (5) for
procedure.
N(TrE: In theregion of 97 percent corrected engine speed, EGT increases at the
rate ofapproximately 200C per By multiplying this rate times
the difference between 100.7 percent percentand
observed speed, an approxi-
mation of the increase in this parameter can be determined. Adding this
approximation to the observed speed and comparing the sum to limits in
Table 504 will determine if the engine will be limited when engine speed
is increased to 100.7 percent. If the estimate is not limiting, use the
direct method; if the estimate is limiting, use the indirect method.
(3) Direct procedure. (Power lever less than maximum, engine speed of
101.2 percent is obtainable and EGT is within limits of Table 504.)
(a) Set maximum speed in accordance with Maintenance Practices,
73-21-0.
(b) Slowly advance the power lever to maximum and observe that speed
is within limits of figure 307.
(c) Return power lever to idle. Adjust idle speed per Maintenance
Practices, 73-21-0, if required.
(4) Indirect procedure. (Power lever equal to or less than maximum,
engine speed less than 100.7 percent and EGT is equal to limiting.)
(a) Determine the number of clicks required to set maximum speed to
desired limit by the following:
1 Subtract recorded engine speed from 101.2 percent.
2 Divide result of step 1 by 0.2 percent per click. Round off
any fraction to next highest number. 1
counterclockwise (CCW) clicks required to set maximum speed
approximately 1 to 1-1/2 percent below EGT limiting speed.
72-00 Sep.1/75
Page 514B
GEWEIAL ~B ELE~tllC
CJ610 TURSOJET
SE1-186 MAIKTENANCE MANUAL
3 Add 5 clicks to results of step 2 to ensure that MSA is lowered
sufficiently.
(b) Adjust the MSA with the number of CCW clicks determined in step
3 per Maintenance Practices, 73-21-0. Adjust at idle or with
engine shutdown.
(c) Repeat maximum speed check. Conditions of case (4) Table 502
must be met. If not, repeat steps (a) and (b) until these con-
ditions are met. Record engine speed. Retard power lever to
idle. Label this, "speed reading number one."
(d) Adjust maximum speed 10 clicks CCW per Maintenance Practices,
73-21-0 and run another check. R~cord engine speed. Retard
power lever to idle. Label this ’(speed reading number two."
(e) Determine the gain of this adjustment by the following:
1 Subtract "speed reading number two(’ from ()speed reading number
one
2 Divide by
result of step 1 ten (the number of CCW clicks
I p
(d), e tsni
(f)’Determine number of clicks required for adjustment by the follow-
ing:
1 Subtract "speed reading number twol’, step (d) from 101.2 per-
cent.
2 Divide the result of step 1 by the gain (found in step (e) 2).
Round off to the next lowest whole number.
(g) Change the maximum speed adjustment by the number of clicks de-
termined in step (f) 2 and adjust per Maintenance Practices,
73-21-0.
(h) Check idle speed and adjust per Maintenance Practices, 73-21-0,
if required.
(5) Estimating procedure. (Power lever at maximum, engine speed less
than 100.7 percent, and EGT is less than limiting.)
(a) Determine if EGT is limiting by the following:
1 Subtract the recorded engine speed from 100.7 percent.
2 Multiply result of step 1 by 200C. (Change per percent Ng´•)
72-00
May 15/70 Page 514C
GENERAL ELECTRIC-------
CJ610 TURBOJET
SEI-186
MGINTENANCE MANUAL
3 Add result of step 2 to recorded EGT. Compare sum with limits
in Table 504.
4 If the sum of step a is equal to or less than maximum operat-
ing limit, engine will not be temperature limited and the
direct procedure is used to adjust maximum speed.
5 If the sum of step 3 is more than maximum operating limit,
engine will be temperature limited. Determine the amount the
temperature exceeds limit by subtracting the maximum operating
limit from this.
6 Divide the result of step 5 by 200C (change per percent Ng)-
NOTE: The estimated engine speed (Ngo) will be used in place of the
recorded engine speed tin theindirect procedure).
7 Subtract the result of step 4 from 100.7 percent. Label this
estimated engine speed "N With this estimated N use
go go´•
the indirect procedure for adjusting the maximum speed.
CAUTION: DO NOT ADJUST THE IGV’S IN THE OPEN DIRECTION MORE THAN
THE ZERO DEGREE POSITION.
DO NOT ADJUST THE IGV’S IN THE CLOSED DIRECTION MORE
THAN THREE DEGREES.
NOTE: 1. Do step (6) only if you can not bring the engine speed
up to limits by making the adjustments described in
steps (1) through (5).
2. If you lengthen the adjustable link to close the IGV’s,
you will increase engine speed. (One turn of the
adjustable link is approximately 1.7 degrees; 1-1/2
turns 2.5 degrees: and 2 turns 3 degrees.)
(6) Loosen the variable vane actuator ring adjustable link (turnbuckle) jam-
nut. Turn the link to increase the length as necessary, but no more
than 2 turns. Torque the jamnut to 6-8 Ib-in.
(7) If necessary, do the maximum speed check/set procedure again to get the
correct limits (see figure 507 or 507A).
72-00
Page 514D Dec 31/95
GENERAL ELECTRIC-------
CJ61 OTURBOJET
SEI-186
MAINTENANCE MANUAL
G. Anti-Icing Check.
(1) Set the engine to operate at approximately 95% speed (15.675 rpm)
(2) Turn the anti-icing system ON. (When the anti-icing system is turned
ON, the exhaust gas temperature increases.) Check for an increase in
exhaust gas temperature. (When a gage is installed, check the anti-
icing gage for pressure indication.) Turn the anti-icing system OFF.
(3) Retard the power lever to IDLE.
72-00
I Dec 31/95 Page 514E/514F
GEIIER*L~ ELISTRIC
BOJET
SEI-186 MAINTENANCE MANLTAL
too
102
CIAX WOUABLE RmIU\L
98
i. RPH SHDULO BE TRDWED TO U)I1T OF IUX. KUYABLE PMSIUL SPm)
OW TLIE 6RWDD HITH THE aRQTTLE AT fItE IUXPIN POSITIOII.
t. WAU. PMSIW SP;EQ) UI1~D )IDT BE‘ PfIlllTmE) TO U(EED
3. 00 Hlf AT~BB5T Tn moc eaac -1~´• c ur.
4. THE I(IIIIM RPII QTIBAOI UIIE IS TIIE MX. RPW PERIITTTOD UIOER T2
OOTHAo; ODHDITIWLF,
S. THE)UX. RPW QrmAO: LIIE fS THE nrr. Rpn 060(17160 upwl r~
92 MBAO; a#Prnoffs. HOBVEP, AT LQIER RPn YALUES-IS
AteEPIIStE PROVUIED THE EPR Af THIIT RPI( IS AT´• Q1 ABWEI T1~
VAUIE REQUIRED RR THE n16HT auonrac sr nn AUZQWT NBIT
-60 -9D -30 -20 -10 O r0 20 JD 60 so
ENGINE INLETfOTALTEMPERANRE Y
-80 -8) -60 -M -60 -30 -20 d0 O 10 20 30 60 SD 66 70 80 90 100 110 120
ENGINE INLET K3TAL TEMPERAIRE ´•F
Q#WF921601
Engine Speed at Maximum Throttle
Figure 507
a. Overspeed Governor (OSG) Check. Check the operation of the OSG using one
of the two following procedures.
(1) If the overspeed governor has a knurled-knob on the control arm, and
with the engine shutdown or at IDLE proceed as follows:
(a) Grasp the knurled knob on the governor control arm and push up
approldmately 1/8 inch to free it from its locked position.
(b) Rotate the knob clockwise 1/8 turn.
(c) Pull the knob´• downward so that the square part of the arm is below
the bracket.
Dec 31/91 72-00
Page ~15
GENERAL ELECTRIC-------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
102
MAX ALLOWABLE PHYSICAL SPEED 101.2Xi
100.61
100
´•i´•~; 30,000 ft.
n
gs ~Sj´•´•
Typical CJ610-8A
9-~CI 45,000 ft. Max Continuous
Engine Speeds
w
C +2%
96
;c~t‘
FL 51,000 ft.
94~ NOTES:
1. RPM SHOULD BE TRIMMED TO LIMIT OF MAX; ALLOWABLE PHYSICAL SPEED
ON THE GROUND WITH THE THROTTLE AT THE MAXIMW POSITION.
2, MAX. PHYSICAL SPEED SHOULD NOT BE PERMITTED TO EXCEED 101,2X.
92
3. DO NOT ATTEMPT TO TRIM BELOW -140 C CIT.
4. THE HINIMLM RPM CUTBACK LINE IS THE MAX. RPM PERHI~ED UNDER T2
CUTBACK CONDITIONS.
5, THE MAX. RPM CUTBACK LINE IS THE MIN. RPM PERMITTED UNDER
90 CUTBACK CDNDITIONS. HOWEVER, OPERATION AT LOWER RPn VALUES T2IS
ACCEPTABLE PROVIDED THE EPR AT THAT RPM IS AT, OR ABOVE, THE
VALUE REPUIRED FOR THE FLIGHT CONDITION BY THE AIRCRAFT FLIGHT
MANUAL.
88
-60 -50 -4~0 -30
ENGINE INLET TOTAL TEMPERATURE OC
I I I I I I I I I I I I I I I I i I I I
-80 -70 -60 -50 -40 -30 -20 -10 O 10 20 30 40 50 60 70 80 90 100 110 120
ENGINE INLET TOTAL TEMPERATURE OF
000CJF-OqO7O2
Engine Speed at Maximum Throttle (CJ610-8A Engines)
Figure 507A
72-00
Page 516
Dec 31/95
OEIERAL ~B fLECtMC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Figure 508 Deleted
(d) Rotate the knob 1/8 turn counterclockwise so that the square part
of the arm snaps into the locked position.
(e) With the engine operating at IDLE, advance the power lever to the
Engine speed should be limited to 90.5 (+1.5)X
I
TAKEOFF position.
(14,708-15,156 rpm) for satisfactory governor operation. If not,
replace the overspeed governor per 73-22-0.
(f) Retard the power lever to IDLE land shut-down the engine if
desired).
(g) Return the governor control arm to the normal (up) position as
follows:
1. Grasp the knurled knob on the governor control arm and pull
down approximately 1/8 inch to free it from its locked posi-
tion.
2. Rotate the knob clockwise 1/8 turn.
3. Push the knob upward so that the square part of the arm is
above the bracket.
Mar 30/84 72-00
Page 516A
OIW EUI O IIICTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
FLIGHT CHECK AT 41K.
SEE Ij(2j(a)
OK NOT OK
FLIGHT CHECK AT 45K. RESTRICT ALT BELOW 41K
SEE 13(2)(b) OR CONTACT AUTHORIZED
OVERHAUL OR REPAIR FACILITY
FOR CORRECTIVE ACTION.
OK NOT OK
FLIGHT CHECK AT 45K.
COMPLY WITH I I RESTRICT ALT
SEE I3(2)(c) I3(2j(b)’ I TO 41K
NOT OK
I OK I NOT OK
OK
TEST COMPLETED I COMPLY WITH
13(2)(b)
OK 1 I FLIGHT CHECK AT 45K.
SEE I3(2)(c)
INSTALL -8A TAILPIPE,
LEARJET KIT NO.
I NOT OK SSK959, AND EPR PROBE
OK
PN 3704017392110,
FLIGHT CHECK AT 45K.
SEE I3(2)(c).
TEST COMPLETED
NOT OK
OK
NOT OK
TEST COMPLETED
INSTALL -8A TAILPIPE,
LEARJET KIT NO.
OK SSK959, AND EPR PROBE
PN 370401739P11O.
FLIGHT CHECK AT 45K.
SEE STEP I3(2)(c).
NOT OK
RESTRICT OPERATION ABOVE
41K TO NACELLE HEAT ON OR
CONTACY AUTHORIZED OVERHAUL
OR REPAIR FACILITY FOR
CORRECTIVE ACTION.
80-0427
Flight Checks
Figure 509
72-00 Mar 30/84
Page 51611
GEWERAL ~B ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
k´• Rotate the knob 1/8 turn counterclockwise so that the square
part of the arm snaps into the locked position.
(2) If the overspeed governor has a lever-type control arm and with the
engine shutdown or at IDLE proceed as follows:
(a) Push the control arm aft until the rocker arm firmly seats
against the stop.
(b) With engine operating at IDLE, advance the aircraft power lever
to the TAKEOFF position. Engine should be limited to 90.5 (~1)%
RPM for satisfactory governor operation. If not, replace the
overspeed governor per 73-22-0.
(c) Retard the power lever to IDLE land shutdown the engine if
desired).
(d) Complete the overspeed governor check by returning the control arm
to the forward position.
I. Acceleration Check.
Make throttle in smooth and normal Quick
I
NOTE: movements a manner.
throttle retard followed by immediate advance (Bodie burst) will
make the check invalid.
(1) The acceleration check determines engine capability for reaching
TAKEOFF power output in a specified time and indirectly checks com-
pressor performance, fuel scheduling, variable geometry operation,
and governor speed control.
Mar 30/84 72-00
Page 517
GEWEIIAL ~i E1~CTRIC
CJ610 TURBOJET
IMAINTENANCF, MANUAL SEI-180,
(2) Advance the power lever from IDLE to TAKEOFF setting in 1 second or
less. The engine should attain takeoff power stabilization within
6-8 seconds.
NOTI~: During power-burst; accelerationsc, EGT and RPM may overshoot
the steady-state operating limits momentarily. See figures
504, 505, 505A and 510 for the allowable transient overeem-
perature and overspeed limits.
(3) Retard the power lever to fDLE.
los
;:;:.: :,r:.:.:.: : : :.: :~;:.:;: : :;:;: : :I:;: : :;: : : : : I:
106
i i i i j i jijpiji ijiji i ijiji i:a:::;i:ir::r:i:a:::i:#:i:::i:i:l~iiiii ENGINE SPEED IN THIS AREA
REQUIRES INSPECTION OF THE
a
104
,5 :::1
102
t: 01.2~
)00
1 2 345
TIME- MINUTES
cJslo.loa7-o.c2
Engine Transient Overspeed Limits
Figure 510
72-00 Jan. 15/69
Page 518
CJ610 TURBOJET ENGINES
GEAircraftEn~sines MAINTENANCE MANUAL
Il. Exhaust Gas Temperature (EGT) Check.
NOTES: i. The objective of this check is to assure that takeoff EPR
is available within the certified EGT limit at all values
of CIT. It should be done after specific maintenance work
(see figure 503) and can be used as a general engine
performance health check at any time.
2. Because altitude affects engine performance, do not do this
check at altitudes above 2000 feet.
3. If specific maintenance work figure 503) is done at
(see
altitudes above 2000 feet, engine should be operated
the
in accordance with the applicable Aircraft Flight Manual.
(1) Set the Engine Pressure Ratio (EPR) for the model engine
installed per the applicable figure 510A through figure 5101.
(2) Read the indicated EGT.
(3) If the EGT is at or below the temperature line shown on the
applicable figure 510A through 5101, takeoff EPR is available
within the certified EGT limit at all values of CIT.
(4) If the EGT is above the temperature line by 200C (680F) or more,
troubleshooting and corrective action per Section 72-00, Table
101, paragraphs 4, 9, and 11 is recommended before you operate
the aircraft. If EGT is above the value determined in step (2)
by less than 200C (680F), troubleshooting and corrective action
should be taken at practical time. Operation of the
the earliest
aircraft prior to corrective action is acceptable only for CIT
values that produce EGT within the certified limit.
Iz~ Max Altitude Acceleration Check for All Aircraft Except Learjet.
(See paragraph 13 for Learjet aircraft.)
NOTES: 1. This check is required on newly installed engines and on
engines that have been subjected to maintenance procedures
which can affect engine performance (see figure 503). This
check must be done in flight tone engine at a time) at
maximum altitude certified for the particular aircraft
involved.
2. Refer to FAA approved Aircraft Flight Manual for maximum
certified altitude for the specific aircraft involved.
(1) Prepare for acceleration check as follows:
ta) Establish stabilized flight parameters within the aircraft
flight envelope. Any aircraft flight problem encountered
must be corrected before you continue the check.
(b) Turn off the anti-icing system.
72-00
Jul 15/99 Page 518A
CJ610 TURBOJET ENGINES
GEAircraftEnaines MAINTENANCE MANUAL
(C) Establish airspeed at 190 200 KIAS (Knots Indicated Air
Speed). Stabilize engine power and ram air temperature
(RAT)
(d) Record engine parameters: RPM, EGT, RAT, fuel flow,
airspeed (Mach No.), and EPR.
(2) Acceleration Check.
NOTE: Make throttle movements in a smooth, and normal manner.
Quick throttle retard followed by immediate advance (Bodie
burst) will make the check invalid.
(a) Retard throttle to 85% gas generator speed (Ng) while
maintaining aircraft altitude and airspeed.
(b) Stabilize Ng at 858 for 25 35 seconds.
NOTE: While performing this check, it is permissible to
exceed max continuous Tg UP to the levels and times
specified in EGT curves, figures 504, 505, 505A and
505B. Reset throttle at or below max continuous
power as soon as practical.
(c) Advance the throttle tin a smooth and normal manner) in one
second or less to the maximum throttle stop on the
quadrant. Record max RPM obtainable and RAT.
(3) If engine fails altitude acceleration test at maximum
certificated altitude, troubleshoot per Section 72-00, Table 101,
Item 6.C.
I,. Max Altitude Acceleration Check for Learjet Aircraft. iSee paragraph 12
for all other model aircraft.)
NOTES: i. This check is
required on newly installed engines and on
engines having been subjected to maintenance procedures
which can affect engine performance. (See figure 503.) This
check shall be made in flight tone engine at a time) at
maximum altitude certified for the particular aircraft
involved.
2. Refer to FAA aircraft approved flight manual for maximum
certified altitude for the specific aircraft involved.
(1) Prepare for acceleration check.
(a) Establish stabilized flight parameters within the aircraft
flight envelope. Any aircraft flight problem encountered
shall be corrected before continuing the check.
(b) Turn off anti-icing system.
(c) Establish airspeed at 0.68-0.72 Mach nurriber. Stabilize
engine power and ram air temperature (RAT)
72-00
Page 518B Mar 30/84
C3~10 TURI031T
SEI-186 MAINTENANCE MANUAL
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20 30 40 50
-30 -20 -10 O 10
COMPRESSOR INLET TEMPERATURE OC
BC-0164
Power Assurance Check for CJ610-5 Engines
Installed in Hansa 320 Aircraft
Figure 510G
I Sep 1/75
Page
518I72-00
Srw rl~L IIICIIIC
CJ610 TUR´•OJLT
MAINTENANCE PeJAUAL SEI-186
"QO
oU
700
C
600
500
PRESSURIZATION
AND
ANTI-ICING OFF
2.5
2.4
62.3
~2.2
2.1
2.0
-30 -20 -10 O 10 20 30 40 50
COMPRESSOR INLET TEMPERATURE OC J
BC-O215
Power Assurance Check for CJ610-9 Engines
Installed in Hansa 320 Aircraft
Figure 510H
72-00 Sep 1/75
Page 5185
0ENERAL E LE Crft IC
CJ610 VURBOJET
SEI-186 MAINTENANCE MANUAL
800
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8C-0343-2
Power Assurance Check for CJ610-8A Engines
Installed in Gates-Learjet Models 24, 25, 28, and 29 Aircraft
Figure 5101
Mar 30/84 72-00
Page 518K
GEWERAL ~g ELtCTRIC
CJ610 TURBOJET
SEI-186
(d) Record engine parameters: RPM, EGT, RAT, fuel flow, airspeed
(Mach No.), and EPR.
(e) Keep gas generator speed (Ng) of non-test engine 2% below the Ng
of the test engine.
(2) Acceleration Check.
WARNING: THE MAXIMUM ALTITUDE CHECK DESCRIBED IN THESE INSTRUCTIONS
MAY CAUSE LOSS OF ENGINE POWER. BE PREPARED FOR SINGLE
ENGINE OPERATION AND AIRSTART.
NOTE: Prior to making this check, the aircraft/engine dual ignition
system must be checked for satisfactory operation in accordance
with instructions in Section 72-00, Table 101, item 3.
NOTE: Make throttle movements in a smooth, and normal manner. Quick
throttle retard followed by immediate advance (Bodie burst)
will make the check invalid.
NOTE: While performing this check, it is permissible to exceed max
continuous T Up to the levels and times specified in EGT
5
curves, figures 504, 505, 5058 and 505B. Reset throttle at or
below max continuous power as soon as practical.
In fair weather conditions, p.roceed to FL 410 with engine anti-icing
heat turned off and perform the following checks:
NOTE: See figure 509 for recommended procedures and options.
(a) Stabilize air speed at 0.68
Set engines 2% below
to 0.72 mach.
max RPM and increase by rapid throttle movement on
to maximum RPM
test engine. Repeat on opposite engine if required. Record max
RPM and RAT. If step I3(2)(a) is OK, proceed to step I3(2)(b). If
step I3(2)(a) is not satisfactory, restrict altitude below FL 410
or contact authorized overhaul or repair facility for corrective
action.
NOTE: While checking one engine, other engine should be 2% below max
RPM.
CAUTION: OPERATION WITH ENGINE ANTI-ICING HEAT ON CAN ADVERSELY
EFFECT SPECIFIC FUEL CONSUMPTION.
72-09 Mar 30/84
Page 518L
G E W IE R A L (S~g E LE CT R IC
CJ610 TURSOJET
MAINTENANCE MANUAL
SEI-186
(b) Turn engine anti-icing switch and climb to FL 450 at 98% Ng or
on
max lever angle (PLA) at 0.68 to 0.72 mach.
power Stabilize at
FL 450. Set engine 2% below max RPM and increase to max RPM by
rapid throttle movement on test engine. Repeat on opposite engine
if required. Record max RPM, RAT, air speed, EGT, EPR, and fuel
flow.
NOTE: While checking one engine, other engine should be 2% below
max RPM.
i. If step I3(2)(b) is OK (engine meets requirements of this
step), proceed to step I3(2)(c).
2 If step I3(2)(b) is not satisfactory (engine fails to meet
requirements of this step), return to base and set engine speed
down to 99.5% Ng or the speed required for takeoff power whFch-
ever is higher and repeat step
13(2).
3 If compliance with I3(2)(b)2 is not effective in clearing the
problem, refer to figure 509.
(c) Turn off engine anti-icing switch on test engine and repeat accel-
eration checks described in paragraph
I3(2)(b) at mach 0.68 0.72.
1 If OK (engine passes altitude acceleration test), no further
action is required.
2 If step I,(2)(c) is not satisfactory (engine fails to meet
requireme~ts of this step), refer to figure 509 for corrective
action.
(d) Corrective action options available, If required, to continue
flight operations include:
1 Turn on engine anti-icing switch.
2 Reduce engine speed.
3 Larger tailpipe.
4 Restrict max altitude.
NOTE: See figure 509 logic chart.
(3) If engine stalls (fails altitude acceleration test at maximum
certificated altitude), troubleshoot according to TROUBLESHOOTING,
Section 72-00, figure 103.
72-00
Mar 30/84
Page 518M
G EW e aAL ~B t LE C’IR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE ~IANUAL
J. Shutdown Procedure.
(1) Prior to a normal shutdown, operate the engine at IDLE for 2 minutes
to dissipate heat and stabilizeoperating temperatures. In an emer-
gency, such as-an ´•overtemperature, flameout, or loss of oil pressure,
shut the engine down immediately.
(2) Normal Shutdown.
(a) Set the power lever at IDLE for 2 minutes to stabilize operating
temperatures.
(b) While observing EGT and fuel flow, retard the power lever to
OFF (00). EGT and RPM should decrease, and fuel flow should
immediately drop to zero.
CAUTION: IF EGT REMAINS ABNORMALLY HIGH, MOTOR THE ENGINE WITH
THE STARTER TO ELIMINATE ANY mTEL IN THE HOT SECTION
OF THE ENGINE.
(c) During coastdown, listen for any unusual rotational noises.
Check for an abrupt or binding stop.
(d) Inspect the engine and repair any fuel or lube oil leaks. Ob-
serve the amount of fuel drainage from the engine drain lines.
(3) Abnormal Shutdown.
(a) Chop the power lever to OFF (00). Shut off the engine fuel
supply. If a post-shutdown fire occurs, motor the engine to
the limits of the starter.
NOTE: A post-shutdown fire is evidenced by black smoke from the
engine inlet or exhaust sections.
(b) If a post-shutdown fire is still evident, motor the engine with
the starter and apply a CO2 fire extinguisher to the engine in-
let section.
NOTE: Exercise judgment in the use of the starter when applying
a extinguisher to control a post-shutdown fire.
fire
Motor the engine only if the coastdown is reasonably
smooth; otherwise additional damage to the engine may
occur.
(c) During coastdown, listen for any unusual rotational noises.
Mar. 30/67 72-00
Page 519
GLIIIRAL ELECtRIC
CJ610 TURBOJ6T
I\6AINTENANCE I\6ANU~LTAL SEf-186
(d) Inspect the compressor through the inlet section and through the
bleed valve ports for rubs or damage. Inspect the turbine through
the exhaust section for burned or damaged parts. If damage is
evident, visually inspect all compressor rotor blades and stater
vanes and perform a Hot Section Inspection (HSI).
4. Abnormal O~eration.
A. Emergency Procedures. The following paragraphs describe abnormal condi-
tions which may be encountered during engine operation and the emergency
action to be taken to correct the condition.
B. No Start. If the engine does not light off within the prescribed
I time/temperature (see figures 504 through 505B), the cause is usually a
malfunctioning fuel or ignition system. If the engine fails to start,
refer to Troubleshooting, 72-00.
C. Hot Start. During a hot start, the exhaust gas temperature increases very
rapidly and will exceed the limits if the start is not discontinued in
time. This is usually caused by an excessively rich mixture in the com-
bustion section or by low motoring speed. By keeping a close check of
starting speed and exhaust gas temperature, the operator should be able
to anticipate a hot start and discontinue it before the temperature
limits are exceeded. If temperature limits are exceeded, refer to In-
spection, 72-00, for engine disposition. If EGT reaches 9000C (16500F)
and is rising rapidly, chop power lever to OFF.
D. False Start. The engine lights off normally during a false start; but
the engine, instead of increasing to idle speed (47 to 49~, 7755 to 8055
rpm), remains at some lower value. The start should be discontinued as
soon as this condition is recognized by chopping the power lever to OFF.
If a second attempt produces the same results, refer to Troubleshooting,
72-00.
E. Compressor Stall.
(1) Compressor stall is recognized by overtemperature, speed "hang-up,"
and a rapid audible change in the characteristic sound of normal
engine operation. The stall usually occurs during throttle-burst
accelerations and may result from improper adjustment or from
malfunctioning components in the variable geometry system.
NOTE: The objective of the technique for handling the power lever
during a stall condition is to recover from the stall and to
return the engine to IDLE speed for a cooling stabilization
period before shutting the engine down.
72-00 Dec 31/91
Page 520
CINERAL Ld~b E LE CT R IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
C
(2) As soon as a stall is recognized, or the stall occurs, immediately
retard the power lever toward IDLE. Use care to ensure that the
engine does not flameout because of too rapid or great movement of
the power lever (below the IDLE position); however, the movement
must be rapid and great enough to prevent overtemperature and sub-
sequent damage to the engine.
CAUTION: IF EGT INCREASES TOO RAPIDLY TO ATTEMPT RECOVERY AFTER A
STALL HAS OCCURRED, CHOP THE POWER LEVER TO OFF.
NOTE: Successful recovery from a stall depends on how far the con-
dition has
progressed. Early recognition will increase the
possibility of a quick recovery and lessen the chance of
damage from overtemperature,
(3) If the stall condition is corrected after the initial movement of
the power lever toward IDLE, advance the power lever slightly to
prevent flameout; but not so far as to cause re-entry into stall.
(4) After regaining control of the engine, retard the power lever to
IDLE. Allow the engine to stabilize for 2 minutes, then shut it
down.
(II (5) During coastdown, listen for any unusual rubbing, clicking or
the
grinding noises. Inspect the engine for any damaged, loose or miss-
ing Darts. Give special attention to the variable geometry system
linkage. Inspect the compressor rotor interior for damaged blading
or dirty condition by looking through tile ports of both bleed valves
and through the compressor inlet section. Take all possible measures
to eliminate the cause of stall before restarting the engine.
(6) Refer to Inspection/Checks for deceleration stalls.
F. Overtempcrature.
(1) Whenever the exhaust gas temperature (EGT) esceeds the established
limits, first retard the power lever to bring EGT within operating
limits. If it still appears that EGT will exceed limits, chop the
I,ower lever to OFF. Do not allow EGT to exceed the limits bePore
taking corrective action.
(2) nccoi´•cl the magnitude (degrce F or C) (seconds) of the
and durntion
ovcrtcmpcrature, then determine engine serviccal,ility per figure
504, 505, 505A or 505B. Refer to InspecTion, 72-00, for engine
disposition if the limits have been exceeded.
G. Overspeed.
(1) If the engine speed stabilizes at 103.5 (e0.5)C (16996-17160
rpm), and cannot be by retarding the power lever to IDLE,
reduced
engine speed is being controlled by the overspeed governor. Retard
C_ the power lever to OFF (O-degrees).
72-00
Feb 23/77 Page 521
GENfAAL~ ELECIRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
CAUTION: DO NOT ATTEMPT TO RESTART UNTIL CAUSE OF OVERSPEED IS
DETERMINED AND CORRECTED.
(2) Remove the fuel pump, fuel control and fuel filters and check for
contamination.
NOTE: If the fuel control fails, the overspeed governor limits
engine speed to 103.5qb RPM (NOMINALLY).
(a) Replace fuel control.
(b) Inspect~the high pressure fuel filter, OSG servo filter and the
fuel control filters. If metal contamination is found, replace
fuel pump.
(c) If other contamination observed, which is abnormal for oper-
is
ating period and conditions, determine the source and correct
the situation.
(d) Clean and examine the pump fuel filter, OSG servo filter and fuel
control filter in accordance with the applicable sections of this
manual. Especially determine that the screening elements are
physically intact (not ruptured or torn).
(e) Install serviceable units, replace others.
C
(3) If the engine exceeds a sustained speed of (16,700 rpm) or a tran-
sient speed of 108% (17820 rpm), determine engine serviceability
per figure 510.
NOTE: Engine operation above 17,820 rpm requires an engine inspec-
tion as defined in Inspection, 72-00.
(4) Shut the engine down. Refer to the Troubleshooting, 72-00, and
correct the cause of the overspeed.
H. F1 ameou t A flameout is usually caused by an imbalance in the fuel-air
ratio in the engine combustion section. The Elameout is accompaiiied by
a decreasing EGT, RPM and EPR along with a change in the pitch of a
normal engine sound. If an engine flameout occurs, do the Following:
j
(1) Chop the throttle to OFF and motor the engine with the starter to
purge the engine of residue fuel.
(2) Check for any unusual noise from the rotating components during
engine coastdown.
7’-00 AI,i‘il 15/6(3
Pajic 522
6EIIIAL ELLCnlG
CJ610 TURBOJET
SEI-186 NALNTENANCE ~NUAT,
I. Oil Leakage Due Engine Windmill Operation.
to Oil leakage may occur, due
to inefficient sumpscavenging, when the engine is allowed to windmill at
low speeds. Windmilling of the engine during’ flight may cause some in-
crease in oil consumption above the engine normal usage rate depending on
time, conditions and engine speeds. Regardless of oil loss during wind-
milling operation, it is not cause for rejecting the engine. After a
windmilling condition, oil consumption should be confirmed during normal
engine ope~ation. Oil level must be checked before engine operation.
TnaLB 5~3
Deleted
5. Engine Adjustments.
A. The following adjustments are allowable on the fuel system components.
Refer to Maintenance Practices, 73-21-0.
(1) Idle speed adjustment.
(2) Maximum speed adjustment.
C: (3) Fuel density adjustment.
B. Adjustment of the variable geometry system. Refer to Maintenance
Practices, 75-00.
6. Operating Limits. (See Table 504.)
TABLE 504
OPERATING LIMITS
Item Requirements Remarks
C A. Exhaust gas temperature.
(1) Starting. Refer to figure 504, 505,
505A, or 505B for allowed
starting temperatures.
(2) Idle. EGT indication should Refer to figure 504, 505,
occur within 10 seconds 505A, or 505B for allowed
after throttle movement starting and transient
to idle position. overtemperature limits.
C
1 Dec 1/77 72-00
Page 522A/5223
6fW ERAL~B ELEE~RIC
CJGld TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 504 (Cont)
Item Requirements Remarks
(3) Take-off. 7040C (13000F) maximum Refer to figure 504, 505,
CJ610-1/-4. 505A, or 505B for allowed
temperature limits.
716"0 (13210F) maximum
CJ610-5/-6.
7460C (13750F) maximum
CJ610-8/-9.
7350C (13550F) maximum
CJ610-8A.
(4) Oscillation at 100C (180F) not exceed- Provided steady state
take-off. ing maximum. limits are not exceeded.
B. Speed RPM.
(1) Starting. See paragraph 3.C. Starting system must be
for starting instruc- capable of turning the
tions. engine rotor to at least
12 percent speed in 12
seconds at ambient tem-
perature conditions to OOF
(-180C) or higher to
achieve normal start.
(2) Idle. 47-49 percent (7755- When adjusting IDLE
8085 rpm). speed on all engines
except CJ610-9 with
Service Bulletin 73-47.
52-54 percent (8580- When adjusting IDLE
8910 rpm). speed on CJ610-9 engines
after compliance with
Service Bulletin 73-47.
(3) Takeoff (5 101.2 percent (16,700 Refer to Figure 510 for
minute rating). rpm) maximum. transient overspeed
limits. See Figure 507
for cold day limits.
(4) Time to reach Approximately 40 Measured from starter
idle. seconds. energizing to stabilizing
IDLE speed.
Dec 31/91 72-00
Page 523
CJ610 TURBOJET
MAINTENANCE MAMTAL SEI-186
TABLE 504 (Cont)
Item Reauirements Remarks
(5) Repeatability 46.5-49.5 percent Applies to all engines
at idle. (7670-8170 rpm), except CJ610-9 with
Service Bulletin 73-47.
51.5-54.5 percent Applies to CJ610-9 engines
(8485-8995 rpm). after compliance with
Service Bulletin 73-47.
(6) Oscillation.
(a) Idle. 3 percent (495 rpm). Within range of 46.5-49.5
percent (7670-8170 rpm)
for all other engines
except CJ610-9 with
Service Bulletin 73-47.
3 percent (557 rpm). Within range of 51.5-54.5
percent (8495-8995 rpm)
for CJ610-9 engines after
compliance with Service
Bulletin 73-47.
~b) Takeoff. 2 percent not exceeding
101.2 percent.
C. Oil System. Stabilized oil pressure will vary between engines from 20
psig to 60 psig in the cruise-to-take-off power range. Determine what
the engine’s normal operating oil pressure should be by referring to the
engine test and operation records. Investigate any deviation of more
than +10 psig from the normal under the same operating conditions. See
Figures 511 and 511.1 for operating range. It is possible for an
engine’s normal operating limits to shift after lube system parts have
been replaced or after a changeover to Type 2 oil. There may be a slight
delay in oil pressure indication after changing or servicing oil.
Extremely low ambient temperatures during the first few seconds of start
may cause abnormally high oil pressure. Wait until oil pressure
stabilizes below 70 psig before operating the engine above IDLE (with oil
tank temperature below 1760F (806C)). Operate engine at maximum
continuous for 5 minutes to stabilize oil temperature just prior to
reading idle oil pressure.
(1) Engine Oil Pressure.
I (a) Starting Positive indication. May peak to 175 psig
under extremely cold
conditions.
72-00 Dec 31/91
Page 524
C3610 TURBOJET
SEI-186 MAINTENANCE MANLTAL
TABLE 504 (Cont)
Item Reauirements Remarks
(b) Idle.
i For all 5-25 psig (with oil Lube oil pressure on
engines tank temperature center vent engines is
except above 1760F (800C)). measured as differential
CJ610-9 Operate engines at between filter inlet and
with maximum continuous main sump vent.
Service for 5 minutes to
Bulletin stabilize oil temp-
73-47. erature just prior
to reading idle oil
pressure.
2 For 6-30 psig (with Lube oil pressure on
CJ610-9 oil tank temperature center vent engines is
engines above 1760F (800C)). measured as differential
after Operate engines at between filter inlet and
compli- maximum continuous main sump vent.
lance for 5 minutes to
with stabilize oil temp-
Service erature just prior to
Bulletin reading idle oil
73-47, pressure.
*(c) All other Refer to figures 511 and
I conditions. 511.1.
~(d) Drop across 10 psig max.
engine.
(2) Oil pressure +2 psig.
fluctuations.
(3) Oil consumption. 0.40 pints per hour
(max.).
Trend conditions are best observed and recorded in flight
under steady-state conditions (such as 15 to 30 minutes of
cruise operation) by the pilot.
Dec 31/91 72-00
Page 5248/524B
C LI f I1,L 4~ L LE CTIII~
CJglO TURS03ET
SEI-186 MAINTENANCE MANUAL
TABLE 504
OPERATING LIMITS (Cont)
Item Requirements Remarks
(4) Oil temperature.
(a) Oil in tank. 3650F (1850C). Max. steady-state.
3800F (1930C). Max. transient (3 minutes).
See figure 511A.
(b) No. 2 bearing 3800F (1930C). Max. steady-state.
scavenge.
(c) No. 3 bearing 3800F (1930C). Max. steady-state.
scavenge.
(5) Oil leakage.
(a) Oil tank vent 10 cc per hour.
relief valve.
NOTE: Approximately 18 drops of oil equal I cc.
(b) Accessory drive 3 drips in 5 minutes During engine operation.
gearbox seals. at each mounting pad.
(c) Oil blaring None allared. Check at idle.
from bleed
valves
(d) Front frame oil None allowed up to 10
accumulation minutes after normal
(after shut- shutdown.
down).
(e) Front frame No. 10 cc per hour. Check at Bot Section In-
I bearing seal spection and whenever there
drain line. are indications of ex-
cessive leakage,
D, Fuel System.
(1) Fuel pump inlet Positive indication
pressure. (min) to 50 psig (max.).
(2) Starting fuel flow. 200-350 pounds per hour.
I Dec 1/77 72-00
Page 525
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE 504 (Cont)
Item Requirements Remarks
(3) Fuel pump inlet
temperature
(a) JP-5. -200F (min) estimated to
1100F (max).
(b) JB-4. -650E (min) to 1100F
(max)
(c) Jet A, Jet Al, -450F (min) estimated
jp-g. to 1100F (max).
(d) Av-gas. -650F (min) to 1100E Emergency use only. 25
(max). hours within any one over-
haul period when mixture
contains more than 50 per-
cent Av-gas by volume.
(4) Fuel drainage.
(a) Fuel pump. 30 cc per hour.
(b) Fuel control. 3 cc per hour.
(c) Drain valve. 5 cc per hour. Other than starting or
shutdown.
(d) Overspeed 6 cc per hour.
governor.
(e) IGV actuator. 90 cc per hour. Drain port leakage static
or dynamic.
NOTE: Approximately 21 drops of fuel equal 1 cc.
E. Starting and Ignition
System.
(1) Starting duty Refer to starter manual.
cycle.
(2) Ignition exciter. (a) 2 minutes ON, (a) First start.
3 minutes OFF.
72-00
Page 526 Dec 31/95
GEWERAL~ ELICtRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 504 (Cont)
Item Requirements Remarks
(b) 2 minutes ON. (b) Second start.
23 minutes OFF,
(c) Alternate: 5 minutes
ON, 25 minutes OFF.
(d) Extended duty-during
landings and take-
offs, adverse
weather and possible
bird strikes; use as
required.
F, Vibrations.
Vibration standards are established for test cell operation and these
standards acceptable for all CJ610 engine/aircraft installations.
are Pilot
reports of change of or excessive vibration attributed to the engine can be
confirmed by running the engine in the test cell and performing a vibration
check in accordance with overhaul manual test requirements.
When observing engine operation in the aircraft, evidence of "blurry"
the
fuel, oil hard lines, cracked standoff brackets, cracked air tubing, foreign
object damage or a rattling noise in the compressor during coast down are
usually signs of excessive engine vibration.
If these symptoms evident, careful checks of engine mounts for tight-
are not
ness, aircraft doors, nacelle cowling, flat fit, or antennae fit in accord-
ance with the airframe maintenance instructions should be undertaken prior to
removing engine for vibration testing.
Dec 1/77 72-00
Page 527
OEYER*L~IIIGIIIIC----
CJ6~0 TURSOJET
MAINTENANCE MANUAL SEI-186
So
RANGE III
OIL PRESSURE AT OIL
BnOW 800C FOR
~W(IMIM OF 12 NINUTE LIMIT
70
OPERATING RANGE I
MAXIMUM OIL PRESSURE
60 AT OIL TEMPERANRES
BELOW 800C.
OPERATING RANGE II
40 EW(IMUKOLL PRESSURE
AT OIL TEMPERATURES
ABOVE 8DOC.
30
NORMAL OPERATlNG RANGE
20
10
101.2X
40 50 60 70 80 90 100
ENGINE RPM 7;
000CJF-88080O
Oil Pressure Limits For All CJ610 Engines, Except CJ610-9 Engines Installed
On Kansa Jets With Fuel Control PN 5002T94646
Figure 511
72-00 Dec 31/91
Page 528
GILIIRIL~IIIETRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
so
OPERARNC RANGE 111
tlbXIHUI OZt PRESSURE A’P OIL
sEurw soOc FOR
MAXIMUM OF 12 MNVIE tI~Ifr.
70
OPERATING RANGE I
MAXfMUM O1L
60 AT OIL TEMPERATURES
BELOW 800C.
so
B OPERATING RANGE II
40 MAXIMUM OIL PRESSURE
o AT OIL TEMPERATURES
ABOVE 800C.
i-i -´•r;.
I I L( II I I I I I L I !1L i I I I I II.ILI I II L
30
NORMAL OPERATING RANGE
20 iSI~I-11?
ii i ii
.I~i
H i-L-L;
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i tt
40 50 60 70 so 90 100
ENGINE RPM 9b
000CJF-ssO7OO
Oil Pressure Limits For CJ610-9 Engines Installed
On Hansa Jets With Fuel Control PN 50021‘94646
Figure 511.1
Dec 31/91 72-00
Page 528A/528B
66 WE IAL O fLf CtllC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
~i4"
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(-40) (-17.8) (4.4) (26.7) (49.0) (oC)
COMPRESSOR INLET TEMP (T2) OF OC)
NOTES:
i. TEMPERATURE RANGE BASED ON STEADY-STATE RPM OF 95 to 102%.
2. MAX STABILIZED LIMIT MAY BE EXCEEDED UP TO THE TRANSIENT
LIMIT OF 380UF (1930C) FOR 3 MINUTES PROVIDED TEMPERATURE
RETURNS TO BELOW THE MAX LIMIT CURVE WITHIN 6 MINUTES.
3. ON COLD DAYS OR INITIAL RUNUPS, TEMPERATURES MAY BE BELOW
MIN STABILIZED LIMITS PROVIDED THEY STABILIZE ABOVE THE MIN
LIMIT CURVE WITHIN 5 MINUTES AT TAKEOFF POWER AND 7 MINUTES
IN MAX CLIMB OR BELOW.
60-0149
Oil Tank Temperature~Limits in Aircraft
Figure 511A
Dec 1/77 72-00
Page 529
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GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINT%N~NCE MANUAL
Deleted Section
Maintenance Practices Inspection/Checks
(See Sections 5-11 and 5-21)
72-OC
Dec 31/95 Page 601
GENERAL ~s ELE.CTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
MAINTENANCE PRACTICES CLEANING AND PRESERVATION
1. General, The following procedures are practices applicable to the basic
engine. The cleaning procedures applicable to a system component are fully
covered within its respective chapter. Refer to table 701 for cleaning or
presenration of compressors.
NOTE i: A coated compressor is one that meets the following conditions:
All stages 1 through 8 rotor blades and all stages 1 and 2 vane sectors
must be coated.with aluminum-base intermetallic diffusion coating A-12
or HI51.
All stages 3 through 8 vane sectors must be made of Inconel 718
material.
The compressor casing must be coated with magnesium-base intermetallic
diffusion coating TSM-3 or SermeTel 725.
NOTE 2: An uncoated compressor is any compressor not completely conform-
ing to the coated configuration (see note i). That is, if one
blade, one stater segment,
vane the compressor stater does
or
not conform to the coated configuration, the compressor is
considered uncoated.
I Ld~r 30/8472-00
GEN ERAL ~b ELECTRIC
CJ610 +URBOJET
MAINTENANCE MANUAL SEI-186
TABLE 701
MAINTENANCE PROCEDURES FOR
COATED AND UNCOATED COMPRESSORS
The following definitions are associated with coated and uncoated compressors:
Water-Wash Use to remove salt and other Light deposits from compressor
airfoils.
Cleaning Use to remove heavy industrial grime and smog deposits,
using an approved solvent and water.
Preservation Use to inhibit corrosion on uncoated compressor parts,
using a corrosion preventive fluid.
CAUTION: IF USED EXCESSIVELY, OILS LN PRESERVATION SOLUTIONS WILL CAUSE INTER-
METALLIC DIFFUSION COATINGS TO DETERIORATE.
Configuration Water-Wash Cleaning Preservation
Coated Compressor Not required. When compressor is Not required.
Stater Cases, visibly dirty, when
Coated Blades (Stg engine performance
1-8), or Coated has deteriorated,
Blades (Stg 1-4). or when loss of
(Refer to Service stall margin is
Bulletin (CJ610) noted.
72-129 and 72-129,
Revision 1.)
Uncoated Every 60 days or When compressor is Every 60 days or
Compressor Rotor/ 100 hours, which- visibly dirty, when 100 hours, which-
Stater Cases. ever occurs first, engine performance ever occurs first.
Every 30 days or has deteriorated, Every 30 days or
50 hours, which- orwhen loss of 50 hours, which-
ever occurs first, stall margin is ever occurs first,
when operated in noted. when operated in
or near salt-laden salt-laden air
air or high-humidity (see Note).
conditions (see
Note).
NOTE i: Salt-laden air can be expected as far as 100-150 miles inland.
NOTE 2: The above recommendations are for normal aircraft operation; aircraft
operating under extreme conditions should be water-washed/cleaned as
required to maintain engine integrity.
72-00 Mar 30/84
Page 702
GEN ERAL E LE CTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
2. Removal of Compressor Contaminants. This procedure is recommended for clean-
ing the compressor of an engine subjected to the deteriorating effects of
industrial grime or smog and the exposure to salt-laden or warm humid atmos-
pheres. Industrial grime or smog may be detected by a dark film on compressor
airfoil surfaces. The film will be much more noticeable on the rear or high
pressure side of the compressor blades. Salt deposits are evidenced by white
deposits- on vanes and blades. All compressor contaminants must be promptly
removed if corrosion is to be controlled.
NOTE: Engine compressors not protected by diffusion coatings should always
be water-washed with a cleaner prior to instituting a preservation
program. Do not apply preservative in a dirty compressor.
A. Equipment and Material Required.
(1) Engine Inlet Cover, 2C5505, used to block the airflow through the engine
inlet.
(2) Power Spray, "Dobbins" Power Sprayer Cart, No. 14125-0, or equivalent.
Used to supply water for washing. This pump type sprayer is a 30
gallon tank unit on wheels with a 3 HP gasoline engine. The adjustable
pressure regulator set at 300-400 psi will deliver the required 5.5-
6.0 GPM through the number 9 disc (orifice). The 25 foot hose and the
4 footwand allow insertion of the spray nozzle into the engine inlet.
(Fimco, Inc. Ist and Court Streets, Sioux City, Iowa, 51101.)
(3) Corrosive Preventative and Cleaning Compound Applicator, 2C5503.
An ordinary lawn and garden pump type sprayer modified with a 4 foot
wand to allow insertion of the spray nozzle into the engine inlet.
Mar 30/84 72-00
I Page 702A
6EN ERA L ~B ELECTRIC
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
(4) Mixer. Used to externally mix cleaner and water at the desired
proportion so that only water need be put into the power sprayer
cart:. Mixer may be obtained from B B Chemical Co., Miami,
Florida.
(5) All engines can be cleaned using plain water; however, the following
cleaning solutions, or other solutions approved by GE Aircraft
I Engines, can be used to clean compressors:
NOTE:: The water used for this process will be more effective if
it is hot (1400-1600F; 60"-710C) and demineralized
(softened) to prevent mineral deposits on the blades and
vanes. fiowever, ordinary tap water may be used for water-
washing
Name Manufacturer Solution
B B 3100 B B Chemical Co. 4 parts water to
Gas Path Cleaner General Offices and 1 part B B 3100
Main Plant Gas Path Cleaner
Miami, Florida 33166
Harco 141 Harley Chemical Co. Mix per manufacturer’s
17th and Federal Streets reconrmendat ion.
Camden, New Jersey
08105
Rust-Lick No. 606 Rust-Lick, Inc. Use full strength;
92 Taylor Street allows to soak for 6-8
Danbury, Conn. 06810 hour period and then
wat er-wash
Androx 9PR4L Ardrox Limited Mix according to
Commerce Road manufacturer’s in-
Brentfard, England structions.
1 (6) The following preservative, or any other GE Aircraft Engines approved
preservative, can be used to preserve compressor parts:
N~ime Manufacturer
WD-40 WD-40 Co.
5390 Napa Street
San Diego, Calif. 92110
Diversey MP71 Diversey Chemical Co.
212 West Monroe Street
Chicago, Illinois 60606
72-00
Dec 31/91
Page 702B
CE N E RAL E LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Name Manufacturer
Rust-Lick No. 606 Rust-Lick, Inc.
92 Taylor Street
Danburn, Conn. 06810
B. Preparation of Aircraft for Cleaning:
WARNING: DO NOT USE TRICHLOROETHANE (FED SPEC 0-T-620) NEAR OPEN
FLAMES OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURCE OF CONCENTRATED
ULTRAVIOLET RAYS. INTENSE ULTRAVIOLET RAYS CAN CAUSE THE
FORMATION OF PHOSGENE GAS WHICH IS INJURIOUS TO THE LUNGS.
VAPORS ARE HARMFUL. USE ONLY WITH ADEQUATE VENTILATION.
AVOID PROLONGED OR REPEATED BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. WEAR
APPROVED GLOVES AND GOGGLES (OR FACE SHIELD) WHEN HANDLING
AND WASH HANDS THOROUGHLY AFTER HANDLING.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
IN APPROVED METAL SAFETY CONTAINER AND KEEP
TIGHTLYSTORE .DEREVOCTI
(1) Wipe all dirt deposits from engine inlet, IGV’s, front frame
and both sides of stage 1 compressor blades using a suitable
solvent, such as trichloroethane.
(2) Check to be sure the cabin air conditioning and anti-icing air
valves are in the OFF position.
(3) Face the aircraft into the wind to carry the exhaust discharge
away from the aircraft.
(4) Allow the engine to cool until EGT is less than 1000C (2120F) before
applying the cleaning agent.
NOTE: High "soak back" temperatures after shutdown’will cause
cleaners and contaminants bake onto the blades,
to re-
sulting in a loss of performance and stall margin.
Nov 1/80 72-00
Page 703
C EN ERAI t LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(5) Install the engine inlet cover 205505 wedged into the engine inlet
against the front frame struts with the application hole located
between struts near 12 o’clock. Install cover with the attached
red flag left dangling outside the aircraft inlet duct.
(6) If engine has not complied with Service Bulletin (CJ610) 73-38 or
73-41,disconnect the P3 (CDP) line at the fuel control and plug the
line.
C. Cleaning and water-washing shall be accomplished follows:
I
as
Every 60 days or 100 hours, whichever occurs first.
Every 30 days or 50 hours, whichever occurs first, when operated
in or near salt-laden air or high-humidity conditions.
CAUTION: DO NOT TURN IGNITION ON DURING THIS PROCEDURE.
(1) Mix the approved cleaners per the manufacturer’s recommendations
and put in power sprayer cart 14125-G, or equivalent.
NOTE: If a mixer is used, only water need be put into the
power sprayer cart.
(2) Assemble equipment and adjust nozzle of power sprayer cart 14125-G,
or equivalent, to provide a delivery of 2.5 gallons of solution at
the rate of 5.5-6.0 GPM. Determine proper flow by first spraying
into a container for 30 seconds.
NOTE: i. Use of a ground power unit (GPU) during motoring cycles
will eliminate discharge of aircraft battery. Ensure
that GPU voltage is set 0.5 to 1.0 volt below aircraft
system voltage.
2. Refer to aircraft manuals for starter duty limitations
for water washing.
(3) Motor the engine to maximum starter speed (about 10 to 13 percent gas
generator speed).
CAUTION: i. BEFORE STARTING TO SPRAY WATER, ALLOW ENGINE TO REACH
MAXIMUM MOTORING SPEED, THIS WILL BUILD UP PRESSURE IN
THE COMPRESSOR DISCHARGE AIR BLEED TUBES TO PREVENT
SPRAY FROM ENTERING THE TUBES.
2. A SOLID STREAM OF WATER WILL DAMAGE THE ROTATING
COMPRESSOR BLADES. A FINE SPRAY MUST BE USED.
72-00 Mar 30/84
Page 704
EflflAL81LtCIIIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(4) With the engine rotating, spray approximately 2.5 gallons of the
mixed solution, at the rate of 5.5-6.0 GPM, or 4 ounces´•of Rust-
Lick No. 606, at full strength, through the opening of inlet cover
205505. On completion of spraying, discontinue motoring and allow
to coast down to static conditions.
(5) Maintain the engine in a static condition for a period of 10 to 15
minutes for the mixed solution or several hours (overnight) for
Rust-Lick 606 to permit the cleaner to soften contamination de-
posits. Install aircraft exhaust cover during period of inactivity.
NOTE: Do not start engine(s) until after washing compressor with
fresh water. If this is not done, the deposits are likely
to be baked onto the blade airfoils, and result in loss of
stall margin or performance.
(6) Remove exhaust cover.
(7) Motor the engine to maximum starter speed (about 10 to 13 percent
gas generator speed).
(8) With the engine rotating, spray approximately 2.5 gallons of water,
at the rate of 5.5-6.0 GPM through the opening of inlet cover
i 205505. On completion of spraying, discontinue motoring and allow
engine to coast down to static conditions.
D. Dry-out Cycle Procedure. Immediately after water washing, dry out engine
as follows:
(1) If used, remove plug from P3 (CDP) line at fuel control. Blow
through P3 line to force trapped fluids back into engine. Connect
and tighten P3 line onto fuel control.
(2) Remove inlet cover 205505.
CAUTION: ENGINE WILL BE DAMAGED IF THE INLET COVER IS NOT REMOVED.
(3) Start engine and stabilize at idle speed.
(4) Turn ON aircraft anti-icing and cabin air conditioning valves to
purge these lines of fluids that may have collected.
NOTE: Refer to aircraft manuals for anti-icing and cabin air con-
ditioning ground operation limitations.
I
(5) Operate for 5 minutes, then turn OFF aircraft anti-icing and cabin
airconditioning valves and shut-down engine.
72-00
Sep 1/75
Page 705
Q F.I I I A L Q t IE CTlle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
I E. Preserve engines having compressors that are uncoated as follows:
(1) Allow engine to cool so that EGT is below 1000C (2120F).
NOTE: Engine cooling period is required to permit the liquid pre-
servative to deposit on the compressor rear stages. These
stages are hot enough at engine shutdown to vaporize the
liquid preservative compound, which will bake onto the
blades, resulting in a loss of performance and stall margin.
(2) Install engine inlet cover 2C5505 wedged into the engine inlet
against the front frame struts with the application hole between
struts near 12 o’clock. Install the cover with the attached red
flag left dangling outside the aircraft inlet duct.
CAUTION: DO NOT TURN IGNITION ON DURING THIS PROCESS.
(3) Use applicator 2C5503 to spray approximately 4 ounces of the pre-
servative into the inlet cover application hole during coastdown
from maximum motoring speed. Refer to paragraph 2.A.(6).
(4) Remove inlet cover 2C5505.
(5) Install aircraft inlet and exhaust covers during periods of in-
activity.
F. Inspection of the cloth filters (coalescer bags) in the cabin air condi-
tioning system may be required with repeated application of the preserva-
tive compound. Although liquid preoervative compounds are non-toxic, the
accumulation of preservative in the filters may cause a disagreeable odor
in the cockpit until the excess material is dissipated.
3. Removal of Salt Deposits Washing and Preserving. Engines operated over or
near (within 150 miles from sea coast) large bodies of salt water, or in
warm humid climates are particularly susceptible to corrosive attack. This
procedure is recommended for those aircraft encountering the above types of
atmosphere either in operation or storage. The following procedure is re-
commended every 30 days or 50 flying hours, with applications of the preser-
vative compound once a week.
and Material Required.
(1) Same as paragraph 2.A. except the mixer will not be required since
only water is used for this wash procedure.
B. Preparation of Aircraft for Cleaning.
(1) Prepare aircraft and engine according to instructions in paragraph
2.B.
72-00
ORIGINAL AS RECEIVED BY ATP
Nov 1/80
Page 706
CIW ERAL ~B ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
C. Cleaning and water-washing shall be accomplished as follows:
Every 60 days or 100 hours, whichever occurs first.
Every 30 days 50 hours, whichever occurs first, when operated
or in
or near salt-laden air or high-humidity conditions.
(1) Assemble equipment and adjust nozzle of power sprayer cart 14125 -G, or
equivalent, to provide a delivery of 2.5 gallons of water at the rate
of 5.5-6.0 GPM.
CAUTION: DO NOT ENERGIZE IGNITION DURING THIS PROCEDURE.
NOTE: 1. Use of a ground power unit (GPU) during motoring cycles
will eliminate discharge of aircraft battery. Ensure that
GPU voltage is set 0.5 to 1.0 volt below aircraft system
voltage.
2. Refer to aircraft manuals for starter duty limitations for
water washing.
(2) Motor the engine to maximum starter speed (about 10 to 13 percent gas
generator speed).
CAUTION: 1. BEFORE STARTING TO SPRAY WATER, ALLOW ENGINE TO REACH
MAXIMUM MOTORING SPEED. THIS WILL BUILD UP PRESSURE IN
THE COMPRESSOR DISCHARGE AIR BLEED TUBES TO PREVENT
SPRAY FROM ENTERING THE TUBES.
2. A SOLID STREAM OF WATER WILL DAMAGE THE ROTATING COM-
PRESSOR BLADES. A FINE SPRAY MUST BE USED.
(3) With the engine rotating, approximately 2.5 gallons of water, at
spray
the rate of 5.5-6.0 GPM the opening of inlet cover 205505.
through On
completion of spraying, discontinue motoring and allow engine to coast
down to static conditions.
D. Dry-out Cycle Procedure.
(1) Immediately after water washing, dry out engine according to instruc-
tions in paragraph 2.D.
E. Apply Preservative (weekly) to applicable engines according to instructions
in paragraph 2.E.
F. Inspection of the cloth filters (coalescer bags) in the cabin air condi-
tioning system may be required with repeated applications of the preser-
vative compound. Although liquid preservative compounds are non-toxic,
the accumulation of preservative in the filters may cause a disagreeable
odor in the cockpit until the excess material is dissipated.
Mar 30/84 72-00
Page 706A
G EN tRAL t LE CT R IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
4. Abrasive Cleaning-Compressor Section (Shellblast). This procedure is
recommended in instances where a considerable loss of stall margin or engine
performance is experienced and the condition is suspected to be the result
of compressor contamination or corrosion. This procedure is most useful in
removing hard or baked-on deposits from compressor airfoils which cannot be
removed by the recommended liquid cleaning compounds. Such deposits may
result from washing the compressor with cold hard water or from repeated
compressor preservation without the benefit of the compressor water washing
cycle, or preservation of a hot engine. This type of compressor contamination
generally occurs in the latter stages of the compressor where higher operating
temperatures promote rapid evaporation of preservative and baking of con-
taminant residues. Compressor internal inspection through the stage 5 bleed
valve ports, is helpful in detecting hard, baked-on airfoil deposits.
CAUTION: DO NOT SHELLBLAST ENGINES HAVING COMPRESSOR PARTS THAT ARE INTER-
METALLIC DIFFUSION COATED. ABRASIVE CLEANING (SHELLBLAST) WILL
DAMAGE THE COATING.
A. Equipment and Material Required.
(1) Shop air supply (50-120 psig with a 8 CFM continuous duty).
(2) Air pressure regulator capable of 25 psig setting at outlet when
connected to shop air supply.
(3) Walnut shell shellblast, size AD-9B, mesh 40/100, (Manufactured by
Agra Shell Inc., 4500 East 26th Street, Los Angeles, California) or
equivalent.
I 72-00
Page 706B
Sep 1/75
c IE I L R A L
d~ E LE CTC IC
CJ610 TURBOJET
SE1-186 MAINTENANCE MANUAL
NOTE: Do not use mesh size other than that recommended.
(4) Kit-Shellblast-Engine Compressor Cleaning, 20537302 (Lear Jet) or
26537303 (Jet Commander).
NOTE: A cleaning kit and procedure for the Hansa Jet 320 will be
supplied at a later date.
B. Preparation for Cleaning.
(1) Orient the aircraft into the wind to carry away shellblast material
from the aircraft.
(2) Protect or remove the EPR probes (located in the exhaust cone) to
prevent the probe holes from becoming plugged by shellblast material.
(3) Disconnect sensing line at fuel control (1,
the P3 figure 701). In-
stall plug assembly 2C5373P6, in the sensing line.
(4) Disconnect P3 line at aspirator (2, figure 701). Connect aspirator
P3 line (2, figure 701) to filter inlet, 2C5373P5. Connect filter
discharge hose to P3 fitting on fuel control (1, figure 701). In-
stall cap assembly, 2C5373P7, on fitting (3, figure 701).
(5) Loosen securing flexible hose (not shown,
clamp but located above 4,
figure 701) aspirator tube (5, figure 701).
to Cap off tube using
the 2C5373P8, rubber cap assembly.
L------t#- ~U i. Pg SENSING LINE AT FUEL CONTROL
2. Pg SENSING LINE CONNECTION AT ASPIRATOR
3. ASPIRATOR CONNECTOR FOR Pj SENSING LINE
4. CLAMP FOR ASPIRATOR TUBE
5. ASPIRATOR TUBE CONNECTION FDR FLEXIBLE HOSE
6. FUEL CONTROL AIR MANIFOLD CONNECTION
o
C o
2 VIEW IN DIRECTION OF ARROW
Dynamic Compressor Cleaning Cap Off Points Fuel Control
Figure 701
Jan. 15/69 72-00
Page 707
CLIEIAL %B E1E C1111C
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
(6) I~oosen (not shown) securing flexible hose to fuel control air
clamp
manifold (6, figure 701). Cap off inlet to manifold using a second
rubber cap assembly, 265373P8.
(7) Remove the anti-ice tube; disconnect at tee on mainframe and the
anti-ice valve on the front frame. Slip on and clamp a suitable
length of rubber hose (1-1/8 inch ID) or equivalent to the tee on
the mainframe, to discharge blast material overboard. Install blank-
off plate, 2C5373P9, on the anti-ice valve.
(8) Perform the following steps on Lear aircraft.
(a) Disconnect the cabin air supply at the top of the engine by re-
moving the Merman clamp on the air tube in the area of the com-
bustion casing. Refer to airframe manual for location of con-
nection.
(b) Slip on and clamp a suitable length of hose 1-3/4 or 1-1/2 inch
ID (dependent on size of Merman joint flange) or equivalent to
engine end of air tube to discharge blast material overboard.
NOTE: Some -23 model aircraft take the cabin air from the 5 or
7 o’clock pad on the mainframe. On these installations
disconnect the flange at the mainframe and install blank-
off plate assembly, 2C5373P10.
(9) Perform the following steps on Jet Commander aircraft.
(a) Disconnect the joint between the air manifold (from
elbow at the
the engine) and the
supply. Rotate the elbow so the
cabin air
blast material will be discharged below the engine, then reclamp
elbow in position. Refer to airframe manual for location of con-
nection.
(b) Disconnect the fuel
air supply at the front of engine, aft
heater
of bulkhead. duct, 2C5373P15, on the engine end of air
Install
tube and clamp in position, using 1-1/2 inch hose clamp 2C5373P23,
so the blast material will be discharged away from fuel heater
inlet.
(10) Connect the hose assembly, 2C5373P12 (less blow gun 2C5373P12-1), to
air source and the other end to quick-disconnect on blast gun,
2C5373P11.
(11) Remove the blast gun cannister and fill with 8 pounds of shellblast
(AD-SB). Reassemble cannister to blast gun.
NOTE: Make sure cannister is clean prior to filling.
72-00 Jan. 15/69
Page 708
CENER L E LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
C. Cleaning Procedure.
(1) Adjust the air pressure to give a flow rate of shellblast of approxi-
mately 1/2 pound per minute. (Approximately 25-30 psig to blast
gun.)
(2) Install the six foot tube extension (2 pieces), 2C5373P18 and P26,
on the blast gun and clamp in place using clamps, 2C5373P19 and P20,
for Lear aircraft. On Jet Commander aircraft install the 90 degree
extension, 2C5373P21, on blast gull and clamp in place using clamp,
2C5373P20.
(3) Start engine and set engine speed at IDLE.
(4) Direct shellblast into engine inlet, with engine running at IDLE
speed, at a flow rate of 1/2 pound per minute. Direct discharge
around entire engine inlet to obtain complete coverage until 8 pounds
of blast material is discharged into engine.
(5) Purge air lines after blasting by advancing engine to 60 percent en-
gine speed for five minutes and shut do~iil engine.
(6) Clean the accessible areas in the compressor inlet by hand using a
clean cloth and suitable solvent, such as trichloroethylene or
equivalent. (Areas to be cleaned are the inlet duct, bulletnosc,
front frame struts and ID, IGV’s and both sides of the first stage
blades.)
D. Restore engine to operating condition.
(1) Remove cleaning hardware with exception of aspirator caps, 2C5373P8.
(2) Remove blast gun from air supply and install blow gun, 2C5373P12-1,
and use Blow Gun to reverse purge the P3 lines (1 and 2, figure 701)
to the fuel control and aspirator and reconnect. Blow off aspirator
adapter to front frame and any area where shells may have accumulated.
(3) Remove aspirator caps, 2C5373P8, and restore engine to normal operat-
ing configuration,
Jan. 15/69 72-00
Page 709
a all ~ie
CJ610 TURBOJET
SEI-18~ MAINTENANCE MANUAL
MAINTENANCE PRACTICES SPECIAL TOOLS
i. General. The special tools numerically listed below are the recommended
tools for engine maintenance. The ReconrmMded Tool No. column lists the
I or preferred tool part number;
dednemmocereb the Alt Tool No. column lists,
but ncit in numerical order, an alternate tool part number which may
substituted, if necessary, for the recommended tool; the Nomenclature
cohn~n lists the identifying name of the tool; and the Topic/Sect./Para. No.
column lists the area of the text where the tool is referenced.
A. Tool List.
I iReconnnendedl Alt 1 Text Ref.
Tool No. Tool No. Nomenclature I Topic/Sect./Para. No
205300 210506 Pusher, Hydraulic Turbine Removal-Znstall.j
Rotor Assembly 72/50/2
205301601 None Tab Beader Stage 2, Turbine Repair/72-53-0/4
Rotor (C5610-1,-4,-5 6 -6)
2C5301602 None Tab Bender Stage 2, Turbine Repair/72-53-0/4
Rotor (CJ610-8 6 -9)
205302001 None Tab Bender Stage i, Turbine Repair/72-53-0/4
Rotor (C5610-1,-4,-5 6 -6)
2C5302G02 None Tab Bender Stage i, Turbine Repair/72-53-0/4
Rotor (CJ610-8 6 -9)
2C5303 210518 Stand Turbine Rotor Assembly Renoval-Install./
72-50/2
Repair/72-53-0/4
205304 21C531 Wrench, Spanner No. 3 Repair/72-53-0/4
Bearing Locknut
2C5305 210532 Puller, Hydraulic Turbine
Rotor Assembly 72-50/2
2C5306 210533 Puller, No. 3 Bearing Inner Repair/72-53-0/4
Race 6 Seal Runner
2C5308 210565 Gage, Runout No.3 Bearing Renoval-Install./
Area 72-40/5
2C5309 210641 Pusher No. 3 Bearing Removal-Install./
Outer Race 72-40/5
2C5310 21C665 Pusher No. 1 Bearing Inner Removal-Install.l
Race 6 Seal Runner 72-30/3
205311 210666 Puller No. 1 Bearing Inner Removal-Install.j
Race 6 Seal Runner 7.2-30/3
265312 21C669 Pusher No. 1 Bearing Removal-Install./
Outer Race i 72-30/3
2C5313 2102663 Puller No. 1 Bearing Removal-Install./
Outer Race 72-30/3
72-00
Dec 30/78
Page 1001
GENERAL ELECTRIC-------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Recommended Alt Text Ref.
Tool No. Tool No. Nomenclature Topic/Sect./Para.No.
2C5315 21C822 Wrench, Combustion Special, Removal-Install,/
Accessory Gearbox 72-64-0/2 6 3
2C5316 21C823 Wrench, Half-Moon Special, Remvoal-Install./
Accessory Gearbox 72-64-0/2 3
2C5317 21C862 1 Wrench, Spanner Sr Torque Removal-Install,l
Turbine Rotor Locknut 72-30/2 6r 3
Removal-Install.l
72-50/2
2C5318 21C863 Gage, Depth Igniter Plug Removal-Install.l
80-23-0/1
2C5319 1 21C866 Pliers. Seating Pin Retainer, Removal-Install./
Ist Stage Compressor Rotor 72-30/6
2C5320 21C868 Pin, Rigging Fuel Control Adj.-Test/72-00/3
2C5321 1 21C2615 Wrench, Spanner, Runup Removal-Install.l
Turbine Rotor Locknut 72-50/2
2C5322 1 21C2640 Wrench, Socket. Extension Anti- Removal-Install./
Icing Valve, Air Leakage Duct 73-18-0/2
6 Fuel Nozzle Removal-Install.l
75-11-0/2
2C5323 21C2900 Fixture, Alignment Gearbox Removal-Install,/
Brackets (CJ610-1,-5,-9) 72-30/7
265324 None Gage, Alignment Accessory Install.l
Transfer Gearbox Splined Shafts 72-64-0/2
2C5325 None Pliers, Special Gearbox Snap Removal-Install,l
Ring 72-63-0/2
2C5326 1 None Guide, Pilot Front Frame Removal-Install.l
72-30/2 3
2C5327 21C2997 Sling. Universal Aircraft Servicing/72-00/7,
9 &11
2C5331 21C3029 1 Tool Kit Replacement, Lube Pump Repair/79-21-0/5
Shaft Seal
2C5333 21C2901 Kit. Puller Accessory 6r Transfer Repair/72-62-0/4
Gearbox Seal
Housing Repair/72-64-0/5
2C5334 21C2619 Kit, Replacement Carbon Seal, Repair/72-62-0/4
Accessory 6( Transfer Gearbox Repair/72-64-0/5
2C5335 21C2636 Inserter Mating Ring Packing, Repair/72-62-0/4
Accessory Transfer Gearbox Repair/72-64-0/5
2C5336 21C631 1 Kit, Guide Mating Ring Sr Repair/72-62-0/4
Packing Installation, Repair/72-64-0/5
Accessory Transfer Gearbox
2C5337 None I Kit Hydraulic Actuating Removal-Install./
72-50/2
2C5349 None Stand, CJ610 Maintenance I Servicing/72-00/1
Horizontal 1 72-00/11
Removal -Install,l
72-00/1
2C5353 21C940 Fixture. Alignment Gearbox Removal-Install,/
Brackets (C5610-4,-6,-8) 72-30/8
2C5356 21C630 Gage. Alignement IGV Actuator Adj.-Test/75-00-2
Ring
72-00
Page 1002 Dec 31/95
GENERAL ELECTRIC-------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE KANUAL
Recommended Alt Text Ref.
Tool No. Tool No. Nomenclature Topic/Sect./Para.No.
2C5359 1 None Wrench, Spanner No. 1 Removal-Install./
Bearing Locknut 72-30/2 3
2C5360 None Adapter, Locking Gearbox Removal-Instail/
Axis "B* Aft 72-30/2 6 3
2C5371 21C661 6r Tool Set Removal Install- Removal-Instail./
21C2664 ation of Stater
Segments 72-30/11
2C5373G2 21C3041 Kit, Shellblast Engine Clean.-Fres.lT2-S0/4
Compressor Cleaning (Learjet)
2C5373G3 21C3041 IKit, Shellblast Engine Clean -Pres.!i2-03i4
Compressor Cleaning
(Jet Commander)
2C5374 21C3097 Clamp, Alignment Inlet Guide Adj.-Test/75-00/2
Vane
2C5377 1 None Holding Fixture, Tip Grinding Repair/72-53-3/4
Turbine Blades (CJ610-8,-9)
2C5388 21C863 Gage, Immersion Depth Removal-Insrail,l
Ignitor Plug 83-i3-0/!
2C5425 None Indicator Position Actuator, Adj.-Tes~/7i-00"3
Bleed Valve
2C5436 None Kit, Installation Removal I Repair/79-21-3/5
Aft Seal, Lube Scavenge Pump
2C5424 None Applicator, Grease Stater Removal-~nstall,/
Case Tracks 72-30/11
2C5450 21C3067 Spreader Louvers, Swirl Cup, Repair/72-42-0/4
Combustion Liner
2C5451 21C3077 Closing Tool Louvers, Swirl Repair/72-42-0/4
Cup, Combustion Liner
2C5452 1 21C3068 Gage, Go-No-Go Louvers, Swirl ReDair/72-42-0/4
Cup, Combustion Liner
2C5453 21C2681 Kit, Maintenance Louvers, Repair/72-42-0/4
Combustion Liners
2C5482 1 21C3065 Spreader Louvers, Dome, Repair/72-42-0/4
Combustion Liner
2C5483 1 21C3066 Gage, Go-No-Go Louvers, Repair/72-42-0/4
Dome, Combustion Liner
2C5484 1 None Puller Mating Ring, Repair/79-21-0/5
Main Lube Pump
2C5501 21C2639 Gage, Plug, Alignment Bleed Removal-Install.l
or I Air Ports 72-30/5
equivalent
2C5503 1 None Applicator, Preservative I Clean.-Pres./72-001
Engine 2 3
2C5505 None Plug, Engine Inlet Duct Clean.-Pres./72-001
2&3
21C6198P01 None Gage, Thickness Stage 2 Nozzle Repair/72-52-0/3A
21C6277 None Set, Cutter and Bushing Repair/72-02-1/9
72-03
Dec 31/95 Page 1003
CJ610TORBOJET
GEAircraftEn~aines MAINTENAN~E MANUAL
SEI-1 86
TEMPORARY REVISION 72´•476
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610
MAINTENANCE MANUAL SEI-186, adjacent to page 1003, dated Dec
31/95 in Chapter 72-00.
Record this TR number in the Record of Temporary Revisions.
Subject: Tools List
Reason: This TR revises paragraph 1.A. tool list table to add tools
needed to remove and install the stage 1 blade retaining
rings, for the compressor spool rotor configuration.
Change: Revise paragraph 1.A. "tool list" table to add the following
new tools at the end of the table
Recommended Alt Text Ref.
Tool No. Tool Nomenclature Topic/Sect./Para. No.
No.
21C6302G01 None Installation tool, Stage 1 Remova 1- Ins tall
Blade Retainer
72-30, 6.A B.
21C6302P07 None Installation tool, Stage 1 Removal Ins tall
Blade Retainer Pin Set
72-30, 6.A.
21C6309G01 None Gage, No-Go ,Retaining Ring, Remova 1- Ins tall
Stage 1 Blade
72-30, 6.B.
FAA APPROVED OCTOBER 10, 2000
72-00
Page 1 of 1
Oct. 10/00
CEWERIL~ELECTRIC.---
CJ610 TURBOJET
SEI-186 MAINTENP.~rCE MAM3AL
LUBRICANTS. PRESERVATIVES. ANT) ANTI-SEIZE CQMPOUNI)S
i. General.
The following table contains the lubricants, preservatives, and anti-seize
compounds used on various parts of the engine.
Specification Number Name Typical Uses
A. W-P-236 Petzolatum Kold and lubricate
O-rings.
B. GE Aircraft Engines
Specificaton A50TF92 Mobil RT403C Bold and lubricate
O-rings.
C, GE Aircraft Engines Engine oil (See 79-00, ~a) Threads of all
Specification D50TF1 Servicing, for list fittings
(See applicable of approved oils) (except fuel).
Operations Engineering (b) All gears and
Bulletin) splines in
lubrication
system.
(c) Preservation of
engine
bearings.
D. MIL-L-6081, 1005 or 1010 Lubricating oil (a) Threads of fuel
fittings.
(b) Preservation of
VG actuator,
fuel system,
and compressor
1-30 days.
E. MIL-L-6529, Type III Corrosion Preventive, Preservation of
Aircraft Engine compressor 30-120
days.
F. Deleted.
Dec 31/91 72-01-1
Page 1
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Specification NLlmber Name Typical Uses
G. GE Aircraft Engines Plastilube Moly Na. 3 (a) Fuel pump shaft
Specification A50TF18. (Thiem Automotive Div., spline.
Subsidiary of (b) O/S governor
Koppers Co., Inc., shaft spline.
5151 Denison Ave., (c) Starter pad
Cleveland, OH 44101) spline.
or Moly Lube 503 Grease (d) Hydraulic pump
(Bel-Ray Co., Inc., pad spline.
P.O. Box 526, (e) Tachometer pad
Farmingdale. NJ 07727) spline.
or approved equivalent. (f) Customer PTO
pad spline.
MIL-G-81322 Mobil Grease 28
(alternate). (Mobil Oil Corp.) or
Royco 228
(Royal Lubricants) or
Aeroshell 22
(Shell Oil Co.)
MIL-L-3545 Aeroshell 5 Accessory pa~ splines.
(alternate). (Shell Oil Co.)
H. MIL-L-23398. Solid film, air Bleed valves.
drying lubricant.
Molybdenum Disulfide Fan liner segments.
Electrofilm Lubribond A.
I. MIL-A-907. knti-seize compound or Turbine rotor
Molykote M-77 locknut threads.
(Dow Coming Corp.
3901 S. Saginaw Rd.,
Midland, MI 48602).
J. No known Milk of magnesia (a) Thermocouple
specification. (unflavored). bosses.
(b) Igniter plugs.
(c) Pressure probe
threads.
K. No known Ease Off 990, Bolt threads.
specification, (Texacone Co.,
4111 Forney Rd.,
Mesquite, TX 75149)
72-01-1
Page 2 Dec 31/95
GENERAL ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
Specification Number Name Typical Uses
L. No known MPL662 (Kidde Inc., Compressor rotor
specification. Wake Forest, NC 27587). drive shaft and
turbine rotor shaft.
M. MIL-A-46106. RVT-106 (GE Silicon (a) Front frame
Products Division, bulletnose.
260 Hudson River Road, (b) Fan front frame
Waterford, NY liner panels.
12188-1910). (c) Pan rear frame
exit guide vanes.
N. MIL-T-5544. Braycote 665 Turbine rotor
petrolatum graphite locknut threads.
(Bray Oil Co.
801 Wharf St.
Richmond. CA 94804).
72-01-1
Dec 31/95 Page 3
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
LOCKING PROCEDURES
i. General. This section covers lockwiring practices and cotterpin practices which
are used many times on many different parts of the engine.
2. Lockwiring Practices. Lockwiring is the securing together of two or more parts
with a wire which shall be installed in such a manner that any tendency for a
part to loosen will be counteracted by an additional tightening of the wire, It
is NOT a means of obtaining or maintaining torque, but rather a safety device
used to prevent the disengagement of the lockwired parts. (See figure 1.:
A. Observe the following general rules for lockwiring unless specific instruc-
tions to the contrary are given in the text.
(1) The installing lockwire shall consist of two strands of wire
method of
twisted together (so called double-twist method), where one twist is
defined as being produced by twisting the wires through an are of 180
degrees and is equivalent to half a complete turn. Use the single
strand method (3) only when specified. Single strand lockwire met’nod
may be used in the following applications.
(a) Mainframe customer bleed ports.
(b) Anti-ice valve forward and aft end.
(c) Stage 8 leakage valve and elbow duct.
(d) Outer combustion case viewport covers.
(e) Aft fan assembly, forward and aft shield P/N 3003T22/3005T19.
(2) Lockwire shall not be installed in such a manner as to cause the wire to
be subjected to chafing, fatigue through vibration, or additional ten
sion other than the tension imposed on the wire to prevent ioosening.
(3) In all cases wiring must be done through the holes provided. In r~e
event that no wire hole is provided, wiring shall be to a n~igjboring
part (6, 7) in a manner so as not to interfere with the function of the
parts, and in accordance with the basic principles described herein.
(4) The maximum span of lockwire between tension points shall be six inches
unless otherwise specified. Where multiple groups are lockwired by
either the double-twist single strand method, the maximum number
or the
in a series shall be determined
by the number of units that can be
lockwiredby a twenty-four inch length of wire. When lockwiring widely
spaced multiple groups using the double-twist method, three units s~all
be the maximum number in a series (8, 9)
(5) Both 0.020 inch and 0.032 inch lockwire are used throughout the engine.
The application is determined by the size hole in the unit to be
lockwired. Generally, whenever possible, use the 0.032 inch size
lockwire.
NOTE: Only new lockwire shall be used upon each application.
72-01-2
Dec 31/95 Page 1
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
RH TWIST
LH TWIST
PIGTAII
‘UY Ld
8 1 9 1 10 1 11
12
Zockwiring Practices
72-01-2 Figure 1
Page 2 Mar 30/67
r
RAi 9~ eT R le
cJsio TURB~OJET
SEI-186
(6) The lockwire shall be pulled taut while being twisted, and shall
have approximately 9-12 twists per inch for 0.020 inch wire and 7-10
twists per inch for 0.032 inch wire.
(7) Hose and electrical coupling nuts shall be lockwired in the same
manner as the tube coupling nuts (6, 7, 10, 11, 12, 13).
(8) Caution must be exercised during the twisting operation to keep the
wire tight without overstressing, or allowing it to become nicked,
kinked or otherwise mutilated,
B. The following lockwiring procedures are to be used throughout the engine
during assembly.
(1) Check the lockwire holes of the parts to be lockwired for proper
alignment. If a part has properly torqued
been but is improperly
aligned, replace it with another part.
NOTE: Proper alignment means that the lockwire holes are aligned in
such a way that the installed lockwire will prevent loosening
of the lockwired part.
Do NOT attempt to either over-torque or under-torque a part
to align the lockwire hole.
(2) Insert the lockwire through the first part and bend the ;Ipper end
either over the head of the part or around it. If bent ~round it,
the direction of wrap and twist of the strands shall be ~:uch that
the loop around the part under the strand protruding from the
comes
hole. Done this way, loop will stay down and will not tend to
the
slip up and leavea slack loop (8, 9).
(3) Twist the strands while taut until the twisted part is just short of
a hole in the next part. The twisted portion should be within one-
eighth inch of the hole in either part.
(4) If the free strand is to be bent around the headof the second part,
Insert the uppermost strand through the hole in this part, then re-
peat step "B, (2)". If the free strand is to be bent over the unit,
the direction of twist is unimportant. If there are more than two
units in the series, repeat the preceding steps.
(5) After wiring the last part, continue twisting the wires to form a
pigtail of 3 to 6 twists tone quarter to one-half inch long) and cut
off the excess wire. Bend the pigtail in toward the part in such a
manner as to prevent it from becoming a snag.
Mar. 30/67 72-01-2
Page 3
OEWERAL ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
NOTE: Although possible combination of lockwiring is not
every
shown in illustration, all lockwiring must generally
the
correspond to the examples shown.
C. If, after lockwiring per the preceding instructions, the lockwire is not
taut, use the following limits to determine its acceptability.
NOTE: Use light finger pressure,, applied at the mid point of the lock-
wire span, and flex in both directions.
Length of lockwire Total flexing
between parts at center
(inches) (inches)
1/2 1/8
1 1/4
2 3/8
3 1/2
4 3/4
5 3/4
6 3/4
3. Cotterpin Practices. (Refer to figure 2 for installation of cotterpins.)
NOTE: Cotterpins are not to be bent into position more than once.
cJsio-eo69-o-Fz
Cotterpin Practices
Figure 2
72-01-2 Mar. 30/67
Page 4
GENEAAL ~B ~LECTRIC
F S CJ610 TURBOJET
SEI-L86 MAINTENANCE MANUAL
TORQUE VALUES TIGHTENING PRACTICES
i. Torque Tightening Practices.
A. General. Torque is expressed as Ib-in. (pound-inches) or Ib-ft. (pound-
feet). pound-inch (or one pound-foot) is the twisting stress of one
One
pound applied to a twist-type fastener (such as a bolt or nut) with one
inch (or one foot) of leverage. This twisting stress is applied to the
fastener to secure the components. Unless otherwise specified, all
torque values prescribed within this manual shall be obtained with lu-
bricated threads.
B. Torque Tightening Procedures.
(1) Tighten uniformly increasing rate until the desired tor´•que is
at a
obtained. In
some cases, where gaskets or other parts cause a slow
permanent set, be sure to hold the torque at the desired value until
the material is seated.
(2) Apply a uniform, average torque to a series of bolts of varying
cross-sectional area on one flange or in one area. This prevents
the tighter bolts from shearing or snapping loose because of force
concentrations.
(3) It is not desirable to tighten to the final torque value during the
first drawdown; uneven tension can cause distortion or overstressing
of parts. Seat and torque mating parts by drawing do\m the bolts or
nuts gradually until the parts are firmly seated, then loosen each
one separately and apply final tightening. Tightening in a diam-
etrically opposite (staggered) sequence is desirable in most cases.
Do not exceed listed maximum torque values.
CAUTION: WHEN CHILLING OR HEATING ENGINE PARTS DURING ASSEMBLY, DO
N(n‘ TORQUE LOCKNUTS OR RETAINING BOLTS UNTIL THE PART RE-
TURNS TO ROOM TEMPERATURE. IF THE PART HAS BEEN HEATED,
THE FASTENER MAY LOOSEN AS THE PART COOLS. IF THE PART
HAS BEEN CHILLED, THE FASTENER MAY BE OVERSTRESSED AS THE
PART EXPANDS.
C. Suggested Torque Wrench Sizes. The torque wrenches listed below are
recommended for use within the indicated ranges. Larger wrenches have
too great a tolerance, and use of these wrenches can result in inaccu-
racies.
Mar. 30/67 72-01-3
Page 1
GE# ORAL ~B ELECTRIC
CJGIO TURBOJET Q-- 3
MAINTENANCE MANUAL SEI-186
Torque Torque
Between Wrench Tolerance
0-25 Ib-in. 30 Ib-in. +1 Ib-in.
25-140 Ib-in. 150 Ib-in. f5 Ib-in.
140-550 Ib-in. 600 Ib-in. t20 Ib-in.
30-140 Ib-ft. 150 Ib-ft. ’5 Ib-ft.
140-240 Ib-ft. 250 Ib-ft. f10 Zb-ft.
240-1000 Ib-ft. 1000 Ib-ft. +20 Ib-ft.
D. Use of Offset Extension Wrench (Crowfoot). When a crowfoot extension
wrench is used with a torque wrench, the effective length of the torque
wrench is changed. The torque wrench is so calibrated that when an´•ex-
tension used, the indicated torque (torque which appears on a
wrench is
dial or gage torque wrench) may be different from the actual
on the
torque that is applied to the nut or bolt. Therefore, when a crowfoot
extension is used, the torque wrench shall be preset to compensate for
the increase or decrease in actual torque as compared to indicated
torque. Refer to paragraphs E. and i". for the proper method of comput-
ing the adjustment.
E. Measuring Effective Length of Offset Extension Wrench (Crowfoot). (See
figure i.) The addition or subtraction of the effective length of the
crowfoot extension wrench (E) is determined by the position of the ex-
tension wrench on torque wrench.
the When the extension wrench is
pointed in the same direction as the torque wrench add the effective
length of the extension wrench to the effective length of the torque
wrench (L E). When the extension wrench is pointed back toward the
handle of the torque wrench, subtract the effective length of the ex-
tension wrench from the effective
torque E).
length of the wrench (L
When the pointed
extension is the torque wrench, the
at right angles to
actual value does not change. The effective length of the torque wrench
is a variable and a different figure will be used for each type of
torque wrench. The effective length of the crowfoot extension wrench is
determined by measuring from the center of the drive opening to the
center of the extension wrench opening (E).
F. Determination of Gage Reading When Using Offset Extension Wrench (Crow-
foot). (See figure i.)
(1) The object is to find the gage reading which indicates the required
torque.
72-01-3 Mar. 30/67
Page 2
GtllERIL~$DILECTRle----
CJ610 TURBOJET
t
SEI-186 MAINTENANCE MANUAL
NOTE --------7 1--------- LEGEND
WHEN USING A TORQUE WRENCH ADAPTER WHICH Lo-:i: I T ACTUAL (DESIRED) TORQUE
CHANGES THE DISTANCE FROM THE TORQUE WRENCH v -APPARENT (INDICATED) TORQUE
DRIVE TO THE ADAPTER DRIVE, APPLY THE L EFFECTIVE LENGTH LEVER
FOLLOWING FORMULAS TO OBTAIN THE CORRECTED Briii-si: I E: EFFECTIVE LENGTH OF EXTENSION
TORQUE READING:
A
TORQUE TORQUE WRENCH
ADAPTER
WRENCHWRENCHI ’(PREDETERMINED)~
DRIVE HANDGRIP WRENCH HANDGRIP
CENTERLINE CENTERLINE DRIVE CENTERLINE
I CENTERLINE, ADAPTER (PREDETERMINED)
DRIVE DRIVE
CENTERLINE CENTERLINE
E
L-----------ci
Txl Txl
FORMULA Y FORMULA Y
L+E L E
EXAMPLE: (WITH "E" AS PLUS DIMENSION) EXAMPLE: (WITH "E~’ AS MINUS DIMENSION)
10 1350 135 x 10 1350
135 x
)58.82
T 135 LB. IN. Y 117.39 T 135 LB. IN. Y
10 1.5 8.5
1011.5 )1.5
Y VNI(NOWN I Y-UNKNOWN
L-IO.OIN. L’IO.OIN.
E -1.5 IN. Y -117 LB. IN. E=1.51N. Y 159 LB. IN.
NOTE
I
CORRECTED TORPUE READING IS HOT REPUIRED
WHEN IN ADAPTER IS USED WHICH DOES NOT CHINGE
DIMENSIOH’L’. DO NOT USE I HANDLE EXTENSION
TORQUE WRENCH ON AEIY TOROUE WRENCH.
ADAPTER
t1610-6060-0-87
Computing Effective Length of Extension Wrench (Crowfoot)
Figure 1
Mar. 30/67 72-01-3
Page 3
GfIERAL ~B LE CfA I C
CJ6tO TURBOJET
MAINTENANCE MANUAL SEI-186
(2) Determine the effective length of the torque wrench (which is des-
ignated as I1L" in the following example) and the effective length
of the crowfoot wrench (E).
(3) Multiply the required torque by the effective length of the torque
wrench (L).
(4) Divide this result by (L E), or (L E), as determined from figure
i. This answer is the gage reading which indicates the required
torque.
For example: Required torque 265 Ib-in. Effective length of
torque wrench 8.4 in. Effective length of crowfoot 1.5 in.
Therefore, (L E) 9.9 in.
265 x 8.4 2226.0
2226.0 i 9.9 224.8 Ib-in.
reading of 225 Ib-in. indicates required torque of
Thus, a gage a
265 Ib-in.
2. Standard Torque Values for Steel Nuts and Bolts.
I.
A. General. The torque values for standard steel nuts (including self-
locking) and bolts are shown in the following table.
UNC and 8 Series UNF and 12 Series
Threads Threads
Size Per Inch Torque Per Inch Torque
0.112 40 3-5 Ib-in.
0.138 32 6-8 Ib-in.
0.164 32 13-16 Ib-in. 36 16-19 Ib-in.
0.190 24 20-23 Ib-in. 32 24-27 Ib-in.
0.250 20 40-60 Ib-in. 28 55-70 Ib-in.
0.3125 18 70-110 Ib-in. 24 100-130 Ib-in.
0.375 16 160-210 Ib-in. 24 190-230 Ib-in.
0.4375 14 250-320 Ib-in. 20 300-360 Ib-ln.
0.500 13 420-510 Ib-in. 20 480-570 Ib-in.
Jan. 15/69
72-01-3Page 4
GEWERAL ELICTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
B. Exceptions. Use one-half of the values given in the above table for
following applications.
(1) Thin steel hex nuts, these nuts having a height of less than 0.6
pitch diameter for plain nuts and less than 0.8 pitch diameter for
self-locking nuts.
(2) Nuts and bolts of non-ferrous alloys.
(3) All bolts threaded directly into aluminum, magnesium or non-ferrous
alloys.
3. Standard Torque Values for Stud Bolts and Stepped Studs in Aluminum or
Magnesium.
A. General. The following torque values are for stud bolts and stepped
studs, installed in aluminum or magnesium, that are held in position by
only the locking action of the interference fit between mating parts.
NOTE: These torque values are not applicable to "Lok-Threadlt studs.
Bolt Size Torque (Pound Inches)
.190 -24 35-40
.250 -20 75-80
.3125 -18 135-145
.375 -16 240-250
.4375 -14 370-380
.500 -13 580-600
B. Exceptions. Studs which have different thread sizes on opposite ends
shall be torqued to the smaller size regardless of which end is fitted
into the installation.
4. Standard Torque Values for Flared Tubing and Hose Fittings. The following
table contains the dimensions of flared tubing and hose fittings and their
standard torque values:
Mar. 30/67 72-01-3
Page 5
CJ610 TURBOJET t
MAINTENANCE MANUAL SEI-186
All Steel Tube-
Tube Thread Aluminum Aluminum or Torque
OD Size Parts Steel Nuts Units
.125 .3125 -24 35-40 Ib-in.
.1875 .375 -24 30-50 90-100 Ib-in.
.250 .4375 -20 40-65 135-150 Ib-in.
.3125 .500 -20 60-80 180-200 Ib-in.
.375 .5625 -18 75-125 270-300 Ib-in.
.500 .750 -16 150-250 450-550 Ib-in.
.625 .875 -14 200-350 650-770 Ib-in.
.750 1.0625 -12 35-41 75-91 Ib-ft.
1.000 1.3125 -12 41-58 100-128 Ib-ft.
1.250 1.625 -12 50-75 125-150 Ib-ft.
1.500 1.875 -12 50-75 158-183 Ib-ft.
5. Standard Torque Values for Fittings with Gaskets. The following table con-
tains the dimensions of the fittings with gaskets and their standard torque
values:
Tube Thread Nut (AN924) Plug Nut Torque
OD Size Union (ANS15) (AN814) (AN6289) Units
.125 .3125 -24 25-35 10-16 25-35 Ib-in.
.1875 .375 -24 50-75 30-40 50-75 Ib-in.
.250 .4375 -20 55-80 40-65 75-100 Ib-in.
.3125 .500 -20 75-100 60-80 90-120 Ib-in.
.375 .5625 -18 100-150 80-120 150-200 Ib-in.
.500 .750 -16 180-230 150-200 200-250 Ib-in.
.625 .875 -14 250-350 200-350 275-400 Ib-in.
.750 1.0625 -12 420-600 300-500 450-650 Ib-in.
1.000 1.3125 -12 50-70 38-50 55-75 Ib-ft.
1.250 1.625 -12 60-80 50-60 65-85 Ib-ft.
1.500 1.875 -12 70-90 50-70 75-90 Ib-ft.
72-01-3 Mar. 30/67
Page 6
GLILIAL ELEtrRle
CJ610 tURSOJET
SEI-186 IbAINTENANCE MANUAL
6. Standard Torque Values for JamNuts of Fitting Without Gaskets. The follow-
ing tablkcontains the dimensions of fittings and their standard torque
values:
Tube Thread To rque
OD Size Aluminum Steel Units
.125 .3125 -24 35-50 Ib-in.
.1875 .375 -24 65-80 70-90 Ib-in.
.250 .4375 -20 90-105 110-130 Ib-in.
.3125 .500 -20 105-125 140-160 Ib-in.
.375 .5625 -18 125-145 225-275 Ib-in.
.500 .750 -16 240-280 400-450 Ib-in.
.625 .875 -14 330-370 550-650 Ib-in.
.750 1.0625 -12 45-55 70-80 Ib-ft.
1.000 1,3125 -12 70-80 85-100 Ib-ft.
1.250 1.625 -12 80-100 l&ft.
1.500 1.875 -12 100-120 Ib-ft.
7. Special Torque Values. (See figures 2 and 3.)
72-01-3
May 15/70
Page 7
GENERAL ~j ELECTR~D------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
NO. 3 BEARING OIL
AIR BAFFLE (2 BOLTS)~ NOZZLE; (SCREW 6-8)
35-40
NO. 2 BEARING 011
20-40 PLUS RUN ON
COMPRESSOR ´•ROTOR STAGE NOZZLE; (3 SCREWS) 14-23
THRU 8 60-65
2w
vl
h)
O
rn
O
Odo
o
u
O
o P
,VI
‘O
r
o
p
P
i
m
IGNITOR PLUG
’225-275
O
cr
i
o vl
i
p
P Llnl~ w
Ln
h,
P
O
o c: O‘
rL J J
Co do 031 10 ~O \o
ANTI-ICE VALVE
TO FRONT 5-so
20-25 11 II~ I I\B\I /r28-32
18-2
LP *40-50
6-10 15-25
NO. 1 BEARING OIL
NOZZLE (1 SC
225-230 LB. FT.
8-10 2 85-3 00
~-ld’- ’275-10 ~ FT. 28-32 11(2C50-5
HOLES 22 AND NI u w 16-1 150-170
o ~n
28 TORQUE TQ JJ 1111 24-27
24-27 h, o a
25-30 140-160
35-40-call 1 ´•7T;tLllll_illl 5F~ilL _~
OSG
25-35 711n 11~60-9
60-90
MFC PUMP \II mi Is I I~I I Il NOTES:
60-90 1. LUBRICATE THREADS OF ALL
BLEED VALVE: I 1 TI I t I I I BOLTS, NUTS AND STUDS
~3
(1) FEED BACK ’O cr N ~3 h3
TACH. GEN.
WITH ENGINE O1L UNLESS
CABLE AND o o ui o o OTHERWISE SPECIFIED
do G 28-35
ADJUSTABLE ul 2. *LUBRICATE WITH UNFLAVORED
LINK JAM-NUTS O o or
~o MILK OF MAGNESIA
6-8 LUBE PUMP
TO OIL TANK
(MAGNESIUM OXIDE, MGO)
(2) ROD END 3. ’*TORQUE, LOOSEN; RETORQUE
JAM-NUT, 24-27
25-30 4. TORQUE ALL DRAIN PLUGS
KLINCHER OIL COOLER TO OIL TO 60-80
TYPE NUT TANK (2 BOLTS) 5. TORQUE VALUES ARE GIVEN
95-125 14-18 1N LB.-IN.
CJ610-6061-03
Engine Torque Chart C3610-1. CJ610-5. and CJ610-9
72-01-3 Figure 2
Page 8 Dec 31/95
GENERAL O~ ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
NO. 3 BEARING OIL 20-40 PLUS RUN ON
NO. 2 BEARING OIL NO
NOZZLE; (SCREW 6-8)
(3 SCREWS) 14-23
35-40 AIR BAFFLE o~ a
a u
do I-IGNITERPLUG
COMPRESSOR ROTOR i
m o ´•o ’225-275 ow
STAGE 2 THRU 8 0
O
a a
w
0 cr
~3
ul
m a a
60-65 a
~>o V1
i i C$ i L i ´•o
h3 0~
O q, O 03 O
mo VI
45-50
28-32
ANTI-ICE 18-22
20-25 ’4
VALVE TO 11 15-25
FRONT FRAME
20-25
6-10---7 c~Ff 225-230 LB. FT.
"75-100
6-10 I fU4t~a LB. FT, ,LB. FT. 28-32
50-55
NO. 1 BEARING OIL 16-19 150-170
NOZZLE (1 SCREW) 8-1
25-30 1 I1II Iii"
220-325
OSG 25-35
*40-50
V
MFC PUMP -1Jb IACH. GEN.
BLEED’VALVE: 60-90 28-35
(1) FEEDBACK [220-2351 LUBE PUMP TO OIL
CABLE AND TANK, 24-27
25-35
ADJUSTABLE OIL COOLER TO OIL TANK
LINK JAM-NUTS 25-35 120-150
(2 BOLTS) 14-18
6-8
NOTES:
(2j ROD END
JAM-NUT, 1. LUBRICATE THREADS OF ALL 3. "TORQUE, LOOSEN; RETORQUE
25-30
BOLTS, NUTS AND STUDS
KLINCHER WITH ENGINE OIL UNLESS 4. TORQUE ALL DRAIN PLUGS
TYPE NUT OTHERWISE SPECIFIED TO 60-80
95-125
2.’LUBRICATE WITH UNFLAVORED 5. TORQUE VALUES ARE GIVEN
MILK OF MAGNESIA (MAGNESIUM IN LB.-IN.
OXIDE, MGO)
CJS10-6062-02
Engine Torque Chart CJ610-4, CJ610-6, and CJ610-8A
Figure 3
72-01-3
Dec 31/95 Page 9
eelIlLL tltC1IIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
PROCEDURE FOR THE INSTALLATION OF THE POSITIONING-TYPE UNIVERSAL FITTING
i. General. These instructions apply to the positioning-type universal fit-
tinge. See figure i.
PIPE FITTING
I. INSPECT YISUALLY.
2. CLEAN if NECESSARY
3. LUBRICATE FITTINGS.
4. ASSEMBLE FITTING, SCREWING DOWN TO WITHIN ONE´•HALF TURN OF
FINAL POSITION.
5. REMOVE. CLEAN. ANO INSPECT MALE THREAD.
6. RELUBRICATE.
7. REASSEMBLE AND SCREW DOWN TO FINAL POSITION.
O-RINC
UNION
i. LUBRICATE THE O´•RING AND ASSEMBLE THE O-RING TO THE GROOVE
ON THE UNION.
2. SCREW THE UNION INTO THE BOSS UNTIL CONTACT 15 MADE WITH THE
SURFACE OF THE BOSS.
3. TIGHTEN THE UNION TO THE PROPER TORPUE VALUE. ~IB
r-
BULKHEAD FITTINt
i. LUBRICATE THE FITTING END. ASSEMBLE THE NUT TO THE FITTING
UNTIL THE WASHER FACE OF THE NUT LINES UP WITH THE UPPER
CORNER OF THE SEAL GROOVE.
2. LUBRICATE THE O-RING AND ASSEMBLE THE O-RING TO THE GROOVE
ON THE FITTING 50 THAT IT CONTACTS THE NUT.
3. SCREW THE FITTING AND NVT SIMULTANEOUSLY INTO THE BOSS UNTIL
THE SEAL CONTACTS THE CHAMFER AT THE FACE OF THE BOSS AND
UNTIL THE NUT CONTACTS THE BOX
4 POSITION THE FITTING BY EITHER TURNING ]N AS MUCH AS 3 4 TURN
270 DEGREES’I OR TURNING OUT AS MUCH AS 1 4 TURN (-90 DEGREES).
ASSEMBLE THE LINE TO THE FITTING TO CHECK THE ALIGNMENT OF NUT O-RING
THE FITTING. TIGHTEN THE NUT TO THE PROPER TOROUE.
FI’TTINGS WITH BACKUP RINGS
i. LUBRICATE MALE THREADS DF FITTI*IG. BACKUP RING AND O´•RINC.
2. ASSEMBLE THE NUT TO THE FITTING WITH THE COUNTERBORE SIDE
BACKUP
FACING THE FITTING END.
3. ASSEMBLE THE BACKUP RING TO THE FITTING AND SEAT IT IN THE
RING
COUNTERBORE OF THE NUT WITH ITS CONVEX SIDE FACING THE NUT
FITTING END.
4. ASSEMBLE THE O´•RING TO THE GROOVE ON THE FITTING.
5. ADJUST THE NVT 50 THAT THE BACKUP RING FORCES THE O-RINC
FIRMLY AGAINST THE LOWER THREADED PORTION OF THE FITTING.
6. SCREW THE FITTING AND NUT SIMULTANEOUSLY INTO THE BOSS UNTIL
8
THE O-RING CONTACTS TME CHAMFER AT THE FACE OF THE 80SS.
7. HOLD THE NUT AND TURN THE FITTING INTO THE BOSS 1-1 2 TURNS.
I O-RING
THE FITTING MAY BE POSITIONED FURTHER BY ONE ADDITIONAL TURN. NUT
BOSS
B. ASSEMBLE THE LINE ’10 THE FITTING TO CHECK THE A~IGNMENT OF
THE FITTING.
9. HOLD THE FITTING AND TIGHTEN THE NUT 70 THE PROPER TORQUE.
cr,sii~io´•si
Assembly Procedures Hose and Tube Fittings
Figure 1
Mar. 30/67 72-01-4
Page 1
CIYERIL a~ ,I,,,R,, --_
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
CONVERSION TABLES
i. General. The limits (dimensional) or values (torque) etc. are expressed in
the English system of measurement. A table for converting English to Metric
is added in this section for customers using the Metric system.
TABLE I
CONVERSION OF ENGLISH TO METRIC SYSTEM
METRIC AND DECIMAL EQUIVALENTS FOR FRACTIONS OF AN INCH AND FOOT
IN. 25.4 MM MM 0.03937 IN.
FRACTIONS OF AN INCH FRACTIONS OF AN INCH FRACTIONS OF AN INCH FRACTIONS OF A FOOT
IN. DECIMALS MM IN. DECIMALS MM IN. DECIMALS MM IN.DECIMALS MM
1/64=0.016 0.4 11/32 =0.344 8.7 43/64:0.672 17.1( 1´•0.0833 j 2S.a
1/32 =0.031 0.8 23/64=0.359 9.1 11/16 =0.688 17.5
3/64=0.047 1.2 3/8 =0.375 9.5 45/64-0.703 17.9 2:0.1667 50.8
~1/16 =0.063 1.6 25/64 =0.391 9.9 23/32 ~0.719 18.3
5/64=0.078 2.0 13/32 =0.406 10.3( 47/64=0.734
18.7 3 =0.2500 76.2
3/32 =0.094 2.4 27/64=0.422 10.7 3/4 =0.750 19.1
7/61=0.109 2.8 7/16 =0.438 11.1 49/64=0.766 19.4 4 10.3333 101.6
1/8 =0.125 3.2 29/64=0.453 11.5 25/32 =0.781 19.8
9/64=0. 141 3.6 15/32 =0.469 11.9 51/64=0.797 20.2 5 ;(j.4~67 127.0
5/32 =0.156 4.0 31/64=0.484 12.3 13/16 =0.813 20.6
11/64=0.172 4.4 1/2 =0.500 12.7 53/64-0.828 21.0 6 -0.5000 152.4
3/16 =0.188 4.8 33/64=0.516 13.1 27/32 =0.844 21.4
13/64=0.203 5.2 17/32 =0.531 13.5 55/64-0.859 21.8 7 -0.5833 177.a
7/32 =0.219 5.6 35/64=0.547 13.9 7/8 =0.875 22.2
15/64=0.234 6.0 9/)6 =0.563 14.3 57/64=0.891 22.6 8 ´•:G.1667 203.2
1/4 =0.250 6.4 37/64=0.578 14.7 29/32 -0.906 23.0
17/64=0.266 6.7 19/32 =0.594 15.1 59/64=0.922 23.4 9 =0. 7500 225.~
9/32 =0.281 7.1 39/64=0.609 15.5 15/16 =0.938 23.8
19/64=0.297 7.5 5/8 =0.625 15.9 61/64=0.953 24.2 10 =0.8333 254.0
5/16 =0.313 7.9 41/64=0.641 16.3 31/32 -0.969 24.6
21/64=0.328 8.3) 21/32 =0.656 i 16.7 63/64=0.984 25.0 11 -0.9167 279.4
C758-3591(1)-0-D2
May 15/70 72-01-5
Page 1
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TABLE I(Cont.)
CONVERSION OF ENGLISH TO METRIC SYSTEM
INCHES TO MILLIMETERS
IN, MM IN, MM IN, MM IN, MM IN, MM
0.001 0.0254 0.01 0.254 0.1 2.54 1 1 1 25.4 10 254
0.002 0.0508 0.02 0.508 0.2 5.08 2 50.8 20 1 5C8
0, 003 0.0762 0.03 0.762 0.3 7. 62 3 76.2 30 762
O, 004 0.1016 0.04 1.016 0.4 10, 16 4 101.6 40 1016
0.005 0.1270 0.05 1.270 0,5 12.70 5 127.0 50 1270
0.006 0.1524 0.06 1.524 0,6 15.24 6 152.4 60 1524
0.007 0.1778 0.07 1.778 0.7 17.78 7 177. 8 70 1778
0.008 0,2032 0.08 2.032 0.8 20.32 8 203.2 80 2032
0.009 0.2286 0.09 2.296 0.9 22.86 9 228.6 90 2286
100 2540
FEET EQUIVALENTS OF METERS
(1 METER=3,2808 FEET)
METERS: O 2 3 4 5 6 7 8 9
M FEET
O 3.28 6, 56 9.84 13, 12 16.40 19.69 22.97 26.25 29.53
10 32.81 36.09 39.37 42.65 45.93 49.21 52.49 55.77 59.06 62.34
20 65.62 68.90 72. 18 75.46 78.74 82.02 85.30 88.58 91.86 95.14
30 98.43 101.71 104.99 108.27 111.55 114.83 118.11 121.39 124.67 127.95
40 131.23 134.51 137.80 141.08 144.36 147.64 150.92 154.20 157.48 160.76
50 164.04 167.32 170.60 173.88 177.17 180.45 183.73 187.01 190.29 193.57
60 196.85 200.13 203.41 206,69 209.97 213.26 216.54 219.82 223.10 226.38
70 229.66 232.94 236.22 239.50 242.78 246.06 249.34 252.63 255.91 259.19
80 262.47 265.75 269.03 272.31 275.59 278.87 282.15 285.43 288.71 291.99
90 295.27 298.56 301.84 305.12 308.40 311.68 314.96 318.24 321.52 324.80
WEIGHT: 1 LB 0.454 KG
SQUARE INCHES AND SQUARE CENTIMETERS EQUIVALENTS
(1 SQ IN, 6.452 SQ CM 1 SQ CM 0.155 SQ, IN.)
KG 2.205 LBS.
SQ SQ SQ SQ SQ SQ SQ SQ SQ SQ SQ SQ
IN, CM IN, CM IN, CM IN, CM IN CM IN, CM
PRESSURE: 1 PSI 0.0703 KG PER CM2
1 6.45 18 116.13 35 225.81 52 335.48 69 445.16 86 554.84
2 12.90 19 122.58 36 232.26 53 341.93 70 451.61 87 561.29
1 PSF =4.88 KG PER M2
3 19.36 20 129.03 37 238.71 54 348.39 71 458.06 88 567.74
4 25.81 21 135.49 38 245.16 55 354.84 72 464.51 89 574.19
VOLUME: 1 CU FT 0.02832 CU M
5 32.26 22 141.93 39 251.61 56 361.29 73 470.97 90 580.64
6 38.71 23 148.39 40 258.06 57 367.74 74 477.42 91 587.10
CU M= 35.31 CU FT.
7 45.16 24 154.84 41 264.52 58 374.19 75 483.87 92 593.55
8 51.61 25 161.29 42 270.97 59 380.64 76 490.32 93 600.00
9 58.06 26 167.74 43 277.42 60 387.09 77 496.77 94 606.45
64.52 27 174.19 44 283.87 612.90 TORQUE: LB-IN,X1.15=KG-CM.
10 61 393.55 78 503.22 95
11 70.97 28 180.64 45 290.32 62 400.00 79 509.68 96 619.35 ~B-FT. X 13.84=KG-CM.
12 77.42 29 187.10 46 296.77 63 406.45 80 516.13 97 625.80
83.87 30 193.55 47 303.22 64 412.90 81 522.58 98 632.26 LENGTH: 1 INCH 25.4 MM.
13
14 90.32 31 200.00 48 309.68 65 419.35 82 529.03 99 638.711 1 MM=0,03937 INCH
15 96.77 32 206.45 49 316.13 66 425.81 83 535.48 1001645.161 1 FT 30.48 CM
16 103.23 33 212.90 SO 322.581 67 432.26 84 541.93)--1 I 1 M 3.2808 FT
17 109.68 34 219.35’ 51~329.03 68 438.71 85 548.391--
CTSB-3591´•(1)´•0´•*ZA
72-01-5 May 15/70
Page 2
CJ610 TURBOJET
MAINTENANCE MANUAL
SEI-186
MARKING OF ENGINE PARTS
i. General. When it is necessary to mark an engine part only approved marking
method shall be used.
2. Temporary Marking of Engine Parts. In general, lead and sulphur containing
materials are unacceptable for marking. All marking materials listed are
equally recommended for all parts.
CAUTION: GREASE PENCILS MUST NOT BE USED TO MARK ENGINE PARTS.
Chalk
Dykem red, yellow, black.
Ink Justrite Slink, black; Marco 5-1141, black; Marsh Stencil Ink.
Soapstone
Oct. 15/70 72-02-0
Page 1
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
HOSE, TUBE AND CLAMP INSPECTION AND REPAIR
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. The following are general limits and repair and will apply unless
specific part information is given.
2. Fire Sleeve Inspection and Re~air.
A. Inspection of Fire Sleeve.
(1) Tears, scratches and cuts may be treated as chafing (below) provided
none of them are completely through the sleeve; if through sleeve, the
sleeve must be replaced per paragraph B.(1).
(2) Chafing and wear is serviceable in any amount provided it is not deeper
than 0.06 inch; if deeper repair per paragraph B.(2).
(3) Broken clamps must be replaced.
B. Repair of Fire Sleeve.
72-02-1
Dec 31/95 Page 1
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANLJAL
B. Repair of Fire Sleeve.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
(1) Replacement of fire sleeve.
NOTE: Lines requiring only replacement of fire sleeve may be repaired
without teardown by replacing with an oversized fire sleeve, per
paragraph (b) below or by installing a split fire sleeve and sta-
pling it in place, per paragraph (c) below.
(a) Remove old fire sleeve by removing the wire clamps, then cutting
the sleeve material from the line with a sharp knife or razor
blade.
(b) If replaceing old fire sleeve with an oversize fire sleeve, (which
applies only to straight and standard elbow hose line), select a
fire sleeve from Table I below. Cut the sleeve to proper length by
using the measurement taken between nipple heres on the end fit.ting
of the hose. Install fire sleeve and secure with several turns of
safety wire (MS9226 or equivalent) over the socket or select wire
clamps to fit from Table II.
NOTE: These fire sleeve sizes are optional with the operator and
may be used if a bulkier fire sleeve installation is not
objectionable.
72-02-1
Page 2 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE I
AEROQUIP 624 FIRE SLEEVE SIZES RE4UIRED TO SLIP OVER SWIVEL
NUT STYLE HOSE FITTINGS
Hose Dash No. Fire Sleeve P/N
-3 624-11
-4 -11
-5 -14
-6 -14
-8 -18
-10 -20
-12 -24
-16 -28
-20 -42
NOTE: Fire sleeve installation will be easier if the
sleeve is bunched and pushed on so as to in-
crease sleeve diameter.
TABLE II
FIRE SLEEVE CLAMP SIZES
OD Range (In.)
From To Aeroquip Part No.
1/2 9/16 900976-8
19/32 11/16 -10
3/4 7/8 -14
15/16 1-1/8 -18
1-3/16 1-3/8 -22
1-7/16 1-5/8 -26
1-11/16 1-7/8 -30
1-15/16 2-1/8 -34
2-3/16 2-3/8 -38
2-7/16 2-5/8 -42
2-11/16 3 -48
72-02-1
IDec 31/95 Page 2Ai2B
GEWIRAL ELICTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(c) If replacing old fire sleeve with a split fire sleeve (624A),
proceed with the following instructions:
1 Select proper sleeve width from Table III and cut to proper
length as measured between nipple heres. Add "Y" dimen-
sions to length per Table IV, before cutting.
2 Open crease and fold fire sleeve to a double thickness
(width-wise).
3 Trim ends on a 4 degree angle, cutting from the center fold
to the sleeve edges to form a trapezoid. Refer to figure i.
4 Coat each end of fire sleeve by dipping into synthetic
sealer, Table V, a minimum of 1/2 inch, and allow to dry.
The sleeve can be assembled with ends "tackyll if these ends
are powdered with talc or powdered soap stone.
5 Adjust Stapling Fixture Stop to 1IX" dimensions as referenced
in figure 2 and Table III. (Use Aeroquip Corp. Stapling
Fixture No. 51067, or equivalent.) Dimension t~XII can vary
according to desired tightness of sleeve application; how-
ever, dimension "X" must be considered a minimum for rec-
ommended practice.
:11-140 FOLDED OPEN
CJ(IO~)695-0-F2
Fire Sleeve Trim Cut
Figure 1
72-02-1
Mar. 30/67
Page 3
ciN iRA L i LE CT R IC
CJB10 TURBOJET
IdAINTENANCE MANUAL SEI-186
1/4" t 1/16"
"X" DIM.
CJB05~96PCO´•F?
Fire Sleeve Staple Spacing
Figure 2
6 Wrap fire sleeve around hose, aligning cut end edges, and
clinch first staple approximately 8 inches from one end or,
in the case of a short hose assembly, at the mid-point of
the assembly. (Use Aeroquip staples, part number 900122-1
or equivalent.)
7 Complete the stapling of the first section (working from
the center to the end), placing staples approximately 1/4
inch apart per figure 2 until the sleeve is closed to with-
In 2 inches of the socket.
8 Complete the stapling on opposite end in a like manner.
9 Flip the stop downStapling Fixture and continue
on the
stapling each end
as as close
possible to the socket. As
this is being done, there will be a gradual opening of the
flap. Continue to staple as far as possible by stapling
through the flap as close as possible to the socket.
10 Select proper wire clamp for the assembly from Table III
and assemble onto the hose. The two wire strands should
straddle the hex on the hex socket and In the relatively
same position on the round and two (2) flat socket designs.
11 Place wires in snubber (Aeroquip No. 81072, or equivalent),
and turn clamp to hold wires.
72-02-1 Mar. 30/67
Page 4
GENERAL ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
TABLE III
Hose Dash No. 624A-No. Wire Clamp "X" Dimension
-4 -1 900591A-14C 5/32
-5 -2 -14C 5/32
-6 -3 -16C 5/32
-8 -4 -18C 3/16
-10 -5 -22C 7/32
-12 -6 -24C 7/32
-16 -7 -32C 1/4
-20 -8 -36C 9/32
-24 -9 -42C 9/32
12 Turn crank. This will tighten the wires around the sleeve.
Roll the hose assembly in a direction that will start a bend in
the wire strands in a direction over the loop. This is a
slight bend and is intended to be enough of a bend to hold the
tightness when the wire’s ends are cut off. (See figure 3.)
13 Lift the wire cut-off handle. This will part the hose assem-
bly-sleeve-wire clamp assembly from the snubber.
14 Fold the cut wire ends back against the sleeve tightly and the
assembly is complete.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ
GENERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE
SAFETY AND ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE,
PERSONAL INJURY MAY RESULT.
(2) Repairing fire sleeve.
(a) Abrasions and scuffs. Cover with application
brush of synthetic
sealer, Table V, if minor. If damaged beyond minor abrasions and
scuffs, wrap with fireproof tape for three thicknesses then coat
with fireproof sleeve sealer, Table V.
(b) Frayed ends. Trim loose frayed ends and
or brush or dip ends at
least 1/2 inch into synthetic sealer, Table V.
72-02-1
Dec 31/95 Page 5
CEIEIAL ELEEIIIE
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
CUT TO LENGTH
.30 REF
IPLACES
i
-m- 1
~----10- I
"’i~´•i
I 1~1 1111
L--_----’
Clamping of Fire Sleeve
Figure 3
TABLE IV
624A No. 1 2 3 4 5 6 7 8 9
"y" .158 .115 .193 .231 ,263 ,291 .385 .463 .532
TABLE V
FIRE SLEEVE SEALER
Trade Name Manufacturer
Pliobond Goodyear Rubber Company
3. Metal Braid.
A. Inspect metal braid for frayed or broken strands. Hose is serviceable
if no more than 9 strands1/2 inch square is damaged.
in any 1/2 x If
more than 9 but less than 15 strands are damaged in any 1/2 x 1/2 inch
square the hose must be repaired in accordance with paragraph B.
72-02-1 Mar. 30/67
Page 6
GEIERIL ELEEtRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
B. Repair frayed or broken strands as follows:
(1) Carefully bend back each broken strand so it does not stick into the
teflon.
(22~ Cut and fold a piece of 100 mesh, 0.004 inch diameter, stainless
steel cloth (Buffalo Wire Works, Buffalo, N.Y. or equivalent) in ac-
cordance with figure 4.
(3) Wrap the patch around the damaged section of the hose with the folds
against the hose and the smooth side facing out.
(4) Secure the patch in place with 0.032 inch stainless steel lockwire
formed into a knot as shown in
figure 5. Knots should be placed
along the length of the patch so they are no more than one hose
diameter apart. The knot is formed as follows:
(a) Make a loop of the lockwire and wrap around the hose.
(b) Feed the ends of the wire through the loop, around the house and
back through the loop.
(c) Use needle nose pliers on the free ends to tighten the knot.
When tight, bend the ends back and cut off.
(LENtTH OF BROKEN BRAID
PLUS 2.5 HOSE DIA.)
WRAF PATCH
AROUND HOSE
(2-1/3 TURNS AROUND HOSE)
b (s EM;S)1/2 HOSE DIA.
FOLD ON
DOTTED LINES
CTY´•3131´•D´•E)
Metal Braid Repair Wire Cloth Patch
Figure 4
Mar. 30/67 72-02-1
Page 7
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAT,
WIRE
CUT OFF
EXCESS WIRE
O Q
FINISHED REPAIR CT~B-12)3´•0´•FI
Metal Braid Repair Knot Construction
Figure 5
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS
ASBESTOS. WHICH IS HIGHLY TOXIC TO SKIN. EYES, AND RESPIRA-
TORY TRACT. READ GENERAL INFORMATION BEFORE PROCEEDING, AND
ADHERE TO ALL SITE SAFETY AND ENVIRONMENTAL CONTROLS CONCERN-
ING ASBESTOS. OTHERWISE, PERSONAL INJURY MAY RESULT.
4. Hose Clam~s.
Visually inspect clamps and cushion material for serviceability if damage is
suspected. Repalce clamps with notches formed in the tangs by bolt heads, nuts
or brackets, or those that have suffered other mechanical damage. Replace
clamps whose cushion material is torn (damaged), have swollen due to the effects
of fuel and oil or have been compressed so that the clamp will not securely hold
a tube or hose.
5. Chafinn Shield.
A. Inspect hose and tubing shafting shield for chafing and wear. Any amount of
chafing or wear is serviceable provided shield is not cut through.
72-02-1
Page 8 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
B. Replacement of Chafing Shield.
(1) Measure length of damaged chafing shield; note location on hose or tub-
ing and remove.
(2) Cut Teflon spiral wrap to length, choosing SWT 3/8 or 1/2 as the hose or
tubing diameter requires. (Manfuactured ty Illumintronic Engineering
Corporation, 680 East Taylor Avenue, Sunnyvale, Calif.)
(3) Clean hose and wire braid with tichloroethane.
72-02-1
I Dec 31/95 Page 8AlsB
O[WLI~L ´•IlleTIIC
CJ610 TUePe)OJCT
SEI-186 MAINTENANCE MANUAL
(4) Assemble spiral wrap to hose or tube. Wrap tightly, keeping space
between each successive spiral to a minimum.
NOTE: Hold hose straight while wrapping.
(5) Tape one end of spiral wrap to hose or tube starting approximately
1/2 inch from end of wrap. (Use 1/2 inch Mystic Tape #7010, or as
an alternate, use Minnesota Minning and Mfg. Co., St. Paul 6, Minn.)
Use approximately 3 to 4 wraps of tape to secure this end and pull
tape tight during wrapping.
(6) Re-adjust and tighten spiral wrap each 5 to 6 inch interval using 3
to 4 turns of electrical tape pulled tightly each time to secure the
spiral wrap. Continue this procedure, finishing off with a tape
wrap approximately 1/2 inch from the end.
6. Tubing and Fittings Inspection. When serviceable limits are exceeded the
parts may be repaired in accordance with the Overhaul Manual.
InsDect Maximum Serviceable Limits Remarks
A. Tubing for:
(1) Splits or cracks None allowed.
(2) Nicks, scratches, Not serviceable if of meas-
gouges, wear or urable depth.
chafing except
chafing due to
tubing clamps
(3) Chafing caused 0.003 inch below adjacent
by tubing clamps non-defective surface with
no high metal.
(4) Dents Depth of defect no more
than 1’/5 of the tube OD if
there are no sharp corners
and the defect is not on
the heel of a sharp bend
(radius of bend is less
than twice the tube OD).
(5) Flattened cross- Tube Is acceptable if the
section OD is not reduced more
than 25"/o.
Mar. 30/67 72-02-1
Page 9
OEWEAAF~ ELterRIC
CJ610 TORB03ET
MAINTENANCE MANUAL SEI-186
Inspect Maximum Serviceable Limits Remarks
B. The bolt flanges on tubes for:
(1) Flatness of the Flat within 0.005 inch.
mating surface
(2) Cracks None allowed.
C. Teflon lined flex hoses for:
(1) Kinks None allowed.
(2) Frayed or broken Nine strands in any 1/2
wire braid inch x 1/2 inch square.
D. Combination flex those) and rigid (tube) assemblies for:
(1) Tubing defects Refer to step A.
(2) Frayed or broken Refer to step C.
braid in the flex
section
E. Hex coupling nuts for:
(1) Damaged corners Any amount with no high
on wrenching metal if at least 2 oppo-
flats site corners are not
rounded making it impos-
sible to use a wrench.
(2) Cracks None allowed.
(3) Nicks and burrs Any amount with no high
metal.
(4) Distortion None allowed.
(5) Stripped threads 1/2 of the entrance thread
missing with no high metal
if nut can be used without
cross threading, and the
rest of the threads are not
damaged.
7~-02-1 Mar. 30/67
Page 10
G EW ERAL BE LLEC~RIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspect Maximum Serviceable Limits Remarks
(c) Nicks and gouges Any number, 1/32 inch deep
on the end of with no high metal if the
flares fitting passes the pressure
check per paragraph 8.
(d) Dirt on OD of None allowed. Remove with tri-
flare chloroethylene or
an equivalent sol-
vent and a clean
shop rag.
(3) Hose sockets for:
(a) Cracks and None allowed.
distortion
(b) Nicks and Any amount with no high
scratches metal.
(4) Tube flare sleeves for:
(a) Cracks None allowed.
(b) Shiny, burnished Any amount.
surfaces due to
normal assembly
(c) Adhesion to flare Any amount if nut and sleeve
nuts are free to slide on tube.
7. Torn Lockwire Hole Repair. (See figure 6.)
A. Choose same drill siae for new lockwire holes.
B. Blind hole fittings (caps, plugs, etc.) shall be redrllled for lockwire
not closer than 1/2 the drill diameter and parallel to the wrenching
flat. Locate hole midway along flat.
C. Through-hole fittings (unions, connectors, etc.) shall be redrilled for
lockwire across the hexagon corners. Locate hole to provide at least
one drill diameter wall thickness to corner and position midway along
flat.
Mar. 30/67 72-02-1
Page 13
OEN LRAL ELECTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
j CONNECTORS
c~MNtoala (TUBULAR)
nuw~ns I I un PLUGS
AND hWS
CAPS IliD (HOLLOW)
(nOUOli I
~´•´•´•o*,1 LOtKWIRE HOLES TORN OUT
LOCKWIRE HOLES
DRILLED HOLE NOT CLOSER
TO INNER CAVITY THAN
DRILL DIAMETER.
,A
IIC~ION *´•A II IICIION
r DRILL ACROSS CORNERS II DRILL PARALLEL TO FLATS
CJ610´•6063´•O.EZ
Torn Lockwire Hole Repair
Figure 6
D. Deburr holes to remove sharp edges.
CAUTION: REDRILLED LOCKWIRE HOLES MUST NOT PASS ANY CLOSER TO AN INNER
CAVITY THAN 1/2 OF THE DRILL DIAMETER.
8. Pressure Checking Hose and Tube Assemblies.
Pressure checking hose and tube assemblies requires two separate tests.
They are a high pressure hydraulic test in which a fluid under high pressure
is introduced into the assembly and a low pressure test in which air under
low pressure is introduced into the assembly and the
entire assembly sub-
merged in tap water or a transparent liquid. The high pressure test is used
to determine the mechanical integrity of the assembly and the low pressure
test is used to determine minute leaks. In both tests cap off all openings
of the assembly except the one through which the pressure will be introduced.
Use suitable MS or AN caps which are known to be serviceable. On openings
which require gaskets, be sure the proper gasket is used under the cap.
Perform the pressure tests in the sequence shown as follows:
A. Low Pressure Check.
(1) Connect the assembly to a 90 to 110 psi source of clean dry air.
72-02-1 May 15/70
Page 14
GENERAL ELECTRIC------
CJ610 TL´•IRBOJ ET
SEI-186
PIAINTE~ANCK MIINUAI,
Inspect Maximum Serviceable Limits Remarks
(6) Damaged threads Cumulative length of defects
(nicks, burrs, no more than 1/2 of one
high metal). thread length with no high
metal.
(7) Torn lockwire At least one hole not torn Drill a lockwire
holes (applicable out, hole in a corner
only if nut is not already drilled,
no rmally ’lock per paragraph 7.
wired).
E. Tube fittings.
(1) The male fittings for:
(a) Nicks, scratches, Any number of circumfer- Reface the sealing
ridges, dents, and ential defects no rougher surface per para-
pits on sealing than a 63 microinch finish graph 9, if the
surfaces. if fitting passes the pres- cutting edge of
sure check per paragraph the refacing tool
8. Any number of super- does not touch the
ficial axial defects, with fitting’s threads.
no high metal, on aft half
(nearest the fitting threads)
of the sealing surface if the
fitting passes th~ check per
paragraph 8. 4 superficial
nicks, dents or pits with no
high metal on the aft half
of the sealing surface if
the fitting passes the pres-
sure check per paragraph 8.
(b) Shiny, burnished Any amount if the fitting
surfaces on seal- passes the pressure check
ing surfaces due per paragraph 8.
to normal assem-
bly.
(c) Nicks, scratches, Cumulative length of defects
dents, gouges, not more than 1/2 of one
and burrs on thread length, with no high
threads. metal.
72-02-1
Dec 31/95 Page 11
6LI ERAL LLEtTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspect Maximum Serviceable Limits Remarks
(d) Nicks, scratches, Any number, 0.005 inch deep
dents, and gouges with no high metal.
on remaining sur-
faces of fitting
(e) Stripped threads 1/2 of entrance thread mis-
sing with no high metal if
fitting can be used without
cross threading.
(f) Cracks None allowed.
(g) Torn lockwire At least one hole not torn Drill a lockwlre
holes (appli- out, hole in a corner
cable only if not already drilled,
fitting is nor- per paragraph 7.
mally lockwired)
(2) The female fittings (includes tubing flares) for:
(a) Nicks, scratches, Any number of circumfer-
ridges, dents and ential defects no rougher
pits on sealing than a 32 microinch finish
surfaces if the fitting passes the
pressure check per para-
graph 8. Any number of
superficial axial defects
with no high metal, on the
leading half (nearest as-
sembly extremity) of the
sealing surface if the
fitting passes the pres-
sure check per paragraph
8. 4 superficial nicks,
dents or pits with no
high metal on the leading
half of the sealing sur-
face if the fitting passes
the pressure check per
paragraph 8.
(b) Shiny, burnished Any amount if the fitting
surfaces on seal- passes the pressure check
ing surfaces due per paragraph 8.
to normal assembly
72-02-1 Mar. 30/67
Page 12
GEI6RAL ~OB ELECTRIE
CJ610 ’TURB03ET
SEI-L86 MAINTENANCE MANUAL
(2) Check all caps and fittings to be sure all are secure.
(3) Immerse the manifold in a tank of clean tap water or some available
transparent liquid.
(4~ Pressurize the assembly to 90-110 psi.
(5) After the assembly has been pressurized for approximately 3 minutes,
check all sections of the assembly for escaping air bubbles. Leaks
anywhere on the assembly are cause for rejection unless otherwise
stated.
(6) After completing the check, dry off the-assembly and subject it to
the high pressure check.
B. High Pressure Check.
(1) If checking metal bellows (pneumatic) hoses, connect the
hose to475-525 psi soursl? of dry air or
a
nitrogen, then
check for leaks using the
pl:ocedure for the low pressure
check. Connect other hoses or tube assemblies
to a 2500
psi sourse of oil or water.
(2) Check all capsand fittings to be sure all are secure.
(3) Pressurize the assembly to %450 to 2550 psi.
(4) After the assembly has been pressurized for 30 seconds, check all
sections for weepage, leaks or ruptures. All are cause for rejec-
tion.
WARNING: TRICKLOROETHANE V~SORS ARE HARMFUL DO NOT
’JSE NEAR OPEN FLIL~IES, OR ON VERY HOT SURFACES.
DO NOT USE NEAR WI:LDING AREAS, A SOURCE OF
CONCENTRATED ULTRP,VZOLET RAYS. INTENSE
ULTRAVIOLET RAYS C:AN CAUSE THE FORMATION OF
PHOSGENE GAS, !JHIC:H IS INJURIOUS TO TEE LUNGS.
USE ONLY tJITR ADEOUATE VENTILATION, AVOID
PROLONGED OR REPEP~SED BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED CONTACT WITH SKIN.
WCf~AR APPROVED GLOF’ES AND GOGGLES (OR FACE
SHIELD) WHEN HANDF,ING AND WASH HANDS THOROUG~Y
AFTER HANDLING. DO NOT TAKE INTERNALLY. DO
NOT SMOKE WHEN USI:h7G IT. STORE IN APPROVED
METAL SAFETY CONTAINERS.
(5) After completing the test, I?ressure flush the assembly with
trichloroethane solvent (Fed Spec 0-T-620) in both directions.
Cap all inlets and outlets with plastic caps after flushing.
72-02-1
Dec 1/79 Page 15
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
Procedure to Reface Sealine Surfaces of Male Fitting Flare Connector Ends.
A. Use this procedure to reface the sealing surfaces of standard tube end con-
nectors (MS33656 and R494 series). The sets of cutters and bushings found
with tool set, 21C6277, cover most of the fitting sizes found in the engine.
(1) Determine the style and size of the fitting being refaced. Refer to
Table VI of this instruction to see if the fitting is listed there. If
it is, obtain cutter and bushing set, 21C6277. Table VI indicates the
group number to be used for the various sizes.
(2) Select the desired group number cutter/bushing from the set.
(3) Note that there is a shoulder in the bushing bore. Screw the bushing
down onto the threads of the defective fitting until it bottoms against
the fitting hex or shoulder. If neither a hex nor a shoulder exists,
screw the bushing in until the lead thread is just above the bushing
shoulder.
(4) A drill press or equivalent can be used provided the spindle can be hand
fed. Install the cutter in the machine’s chuck.
(5) Set up the part with the defective fitting in a suitable clamping ar-
rangement secured to the machine table so the fitting is in line with
the machine spindle. Position the part so the cutter in the machine
spindle will slide freely in and out of the bushing on the defective
fitting. Secure the part in this position.
(6) Move the cutter into the bushing, with the machine off. until it con-
tacts the fitting. Set the machine stop so the cutter will move no
further than 0.005 inch beyond the point of contact.
NOTE: The cutter may have a tendency to chatter: therefore, a slow
spindle speed (200-500 RPM) and the use of cutting oil is recom-
mended when refacing a fitting.
(7) Slowly and carefully run the cutter onto the fitting just enough to
remove the defects. Do not remove any more material from the fitting
than is necessary to clean it up. Most defects will clean up with 0.002
inch spindle movement. Total cumulative metal removal is limited up to
the point where the cutter runs into the lead thread of the fittings.
Do not run the cutter into the bushing shoulder.
(8) Remove the part and the cutter from the machine and the bushing from the
fitting. Return the cutter and bushing set to its storage case.
72-02-1
Page 16 Dec 31/95
GENERAL ELIETRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTE~[ANCE MANUAL
WARNING: DRY CLEANING SOLVENT (STODDARI~ SOLVENT) P-D-680
COMBUSTIBLE DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR
ON HOT SURFACES.
PROLONGED CONTACT OF SKIN WITB LI4UID CAN CAUSE DERMATITIS. RE-
PEATED INHALATION OF VAPOR CAI~ IRRITATE NOSE AND THROAT AND CAN
CAUSE DIZZINESS.
IF ANY LIQUID CONTACTS SKIN 01~ EYES, IMMEDIATELY FLUSH AFFECTED
AREA THOROUGHLY WITH WATER. RI~MOVE SOLVENT-SATURATED CLOTHING. IF
VAPORS CAUSE DIZZINESS, GO TO FRESH AIR.
WHEN HANDLING LIQUID OR WHEN APPLYING IT IN AN AIR-EXHAUSTED, PAR-
TIALLY COVERED TANK, WEAR APPI~OVED GLOVES AND GOGGLES.
WHEN HANDLING LIQUID OR WHEN APPLYING IT AT UNEXHAUSTED, UNCOVERED
TANK OR WORKBENCH, WEAR APPROVED RESPIRATOR, GLOVES, AND GOGGLES.
NOTE: Protective caps are to be installtad onto all fitting ends once they
have been cleaned.
(9) Wash all chips and oil from the repair areapaying particular attention
to ensure that the internal passagc´• is freeof all foreign material.
Use dry cleaning solvent, P-D-680, or anequivalent solvent.
(10) Inspect the repaired fitting end to its serviceable limits and check it
for leaks per the pressure check sl,ecified for the component on which
the fitting is used. No leaks allowed.
72-02-1
Dec 31/95 Page 17
GENERAL ELECTRIC~----
CJ610 TURBOJET
SEI-186
MAINTENANCE: MANUAZ,
TABLE VI 2106277 CUTTER/BUSHING SETS FOR
REFACING STANDARD TUBE CONNECTION ENDS
R494 SDherical Style
21C6277 Tube Size R494
Grou No. Inch Part No.
G05 0.500 1/2 P08
MS33656 Conical 370 Style
21C6277 Tube Size MS33656
Gr No. Inch D ah No.
G13 0.750 3 4 -12
72-02-1
Page 18 Dec 31/95
orlrn~il8 r~rcrnlc------
CJB10 TURBOJET
SEI-186 MAINTENANC~ MANUAL
CARBON SEAL AND RUNNER I:NSPECTION AND REPAIR
N03
N02
N01
C16104W~4´•F2
Carbon Rubbing Seal Runners
Figure 1
i. General. The following instructions apply to the inspection of carbon seals
and runners.
2. Carbon Rubbing Seal Runner Inspection. (See figure i.) When serviceable
limits are exceeded the parts may be repaired in accordance with the Over-
haul Nlanual.
Inspect Maximum Serviceable Limits Remarks
A. Seal runners for:
(1) Cracks None allowed.
(2) Dents, nicks, None allowed.
scratches on
sealing surfaces
NOTE: Sealing surface is the area which contacts the carbon seal, plus a
1/16 inch beyond on each side. On No. 1 seal runner, the sealing
surface is the area between the end of the axial slots and the front
edge of the pulling slots.
Mar. 30/67 72-02-2
Page 1
GEWLIAL
e~ ELEICTRIC
CJB10 TURBO´•JET
MAINTENANCE MANUAL SEI-186
Inspect Maximum Serviceable Limits Remarks
(3) Dents, nicks and Any amount, 0.015 inch deep
scratches on sur- with no high metal.
faces other than
sealing surfaces
(4) Chipping of chrome None allowed.
plating
(5) Circumferential Any amount that cannot be
grooves felt with a pointed scribe.
(6) Chatter marks Chatter marks allowed.
(7) Heat discolor- Discoloration of blueing
ation with no apparent change in
surface finish is allowed.
Obvious burns are not
allowed.
(8) Foreign material Any amount no higher than Clean with solvent.
deposits base surface. Carbon A600 grit polishing
crazing and fine pits paper or crocus
normal. cloth may be used
on non-sealing sur-
faces.
NOTE: Carbon deposits that remain after cleaning may be removed bybuffing
the lathe-spun carbon seal runner with a soft, cotton buffing wheel.
(9) Crazing of chrome Any amount that cannot be
plate (superficial felt with a pointed scribe.
honeycomb cracks)
CAUTION: USE EXTREME CARE DURING BUFFING PROCESS TO ASSURE REQUIRED FINISH
ON MATING SURFACE IS MAINTAINED.
72-02-2 Mar. 30/67
Page 2
orw ERIL ILEC~RIC
CJ610 TURBOJET
SEI-186 MAINTENANCE: MANUAL
SURFACE X ii
12 15
AREA"X.. Ijlil
9
j
SURFACE Y
4
II
II
1~21
10 1 3 Z
7
S n
1
NO. 1 CARBON SEAL ASSEMBLY
1. SEALING DAM 13. LOCKING KEY
2. ROUNDED CORNERS 14. LI~IEUP PINS
3. GROOVES ADJACENT TO GAPS 15. SNAP RING
4. AXIAL SPRINGS 16. CARBON SEGMENT
5. SEAL HOUSING 17. KE’I SLOT
6. GARTER SPRINGS 18. GARTER SPRING
7. AXIAL GROOVES 19. SE/~L HOUSING
8. AXIAL GAPS 20, LOCATING PINS
9. BACK RING SEGMENT 21. LIP WASHER
10. CARBON SEGMENT 22. PlhlPLE SPRING-BACKPLATE ASSEMBLY
11. COVER RING 23. SNAPRING
12. COVER PLATE
clslo4a65a.o?
Carbon Seal Assembly
Figure
3. Carbon Seal Assembly Inspection. (See ligure 2.) Inspect the No. 1 and No.
3 carbon seals in thl? assembled conditic,n. If a seal does not meet inspec-
tion limits, or the carbon segments appc~ar sticky when actuated gently with
the fingers, replace the seal.
Inspect Maximum Serviceable Limits Remarks
CAUTION: THE RUNNING SURFACES OF THE CAIEBON OIL SEALS ARE EXTREMELY BRITTLE:
AND EASILY DAMAGED. BE CAREFUI; WHEN HANDLING THEM. DO NOT ATTEMPT
TO REPAIR THE CARBON SURFACES c~F THE SEAL. REWORK SURFACE DEFECTS
ON THE SEAL HOUSING ´•AND RETAIN:[NG PLATE. REPLACE THE OIL-SEAL AS-
SEMBLY IF THERE ARE CRACKS IN ’PHE HOUSING OR PLATE.
A. Assembled carbon seals for:
(1) Chipped sealing None allowed.
dam (1)
Mar. 30/67 72-02-2
Page 3
G E N E RAL B~B E LE CTR IC
CJ610 TURBQJET
MAINTENANCE MANUAL SEI-186
Inspect Maximum Serviceable Limits Remarks
(2) Cracks in carbon None allowed.
segments
(3) Foreign material None allowed.
imbedded in ca’r-
bon segments
(4) Any chips (other Chips not exceeding 0.020
than in sealing inch.
dams or at axial
gaps)
(5) Excessive wear of Surface wear allowed up to
carbon segments a 50~ depth of
maximum of
grooves adjacent to gaps
(3). (Measure by comparing
to a new seal.)
(6) Coked axial springs None allowed.
(4). (Carbon seal
segments sticky and
binding when checked
by depressing gently
with the fingers)
(7) Buildup of coked Coked oil or hard material
oil or hard mate- buildup allowed to maximum
rial in axial of 25~ of the original depth
grooves (7) of the grooves.
(8) Buildup of coked None allowed.
oil or hard mate-
rial in axial
gaps (8)
B. Assembled carbon seal housings, cover plate and snap ring for:
(1) Nicks, dents; Any number, 0.005 inch Remove high metal
burrs, carbon with no high metal, using a fine file
and varnish or stone, wash part
deposits in trichloroethyl-
ene.
72-02-2 Sept. 15/69
Page 4
CJ610 TURBOJET ENGINES
MAINTENANCE MANUAL
ANTI-FRICTION BEARING METHOD OF INSPECTION
i. General.
A. If any of the mainshaft
bearings require replacement during hot section
inspection repair, the bearing must be replaced with a new or
or
serviceable bearing with enough residual life to reach the next
scheduled engine overhaul or bearing exposure. In any event, all
mainshaft bearings must be replaced with new bearings at engine
overhaul. Cumulative life limits on serviceable bearings are given in
Chapter 5-ii.
CAUTION i: BEARING COMPONENTS ARE MATCHED ASSEMBLIES. IF ANY PART OF A
BEARING DOES NOT MEET THE INSPECTION REQUIREMENTS SPECIFIED
AND IS REJECTED, THE ENTIRE BEARING MUST BE REJECTED.
CAUTION 2: MATCHED DUPLEX BEARINGS MUST HAVE THE SAME SERIAL NUMBER AND
THE SAME PART NUMBER.
B. Any of these bearings that have residual
remaining must meet life
serviceability limits of this
reassembly to the engine.
section before
To control bearing reuse, the "~’IME SINCE NEW" must be vibropeened on
all serviceable bearings. Location of time marking on all bearings
(except mainshaft bearings) must be on the outer race, on the side
opposite the part identification number. See figure 1 for location
of the time marking on the mainshaft bearings.
2. Bearing Cleaning Procedure.
k. Bearings may become magnetized eind attract small foreign particles to
the balls, rollers, or races. The attraction can be so strong that the
particles will not durj.ng the soaking and washing operations.
come off
Therefore, completely demagnetize each bearing before cleaning.
B. Demagnetize non-separable bearirigs as assembly, but demagnetize the
an
component parts of separable individually; be extremely
careful not to mix the parts of one bearing with those of another.
CAUTION: HOLD TIGHTLY TOGETHER THE ~NNER AND OUTER RACES OF NON-SEPARABLE
BEARINGS TO PREVENT THE BAI,LS OR ROLLERS FROM VIBRATING.
C. Turn the bearing races slowly as you pass them through the
demagnetizer; turn the inner anc~ outer races of non-separable bearings
in opposite directions. Pass the! bearings or bearing components through
the demagnetizer at a rate not to exceed 12 feet per minute. Remove the
bearings from the demagnetizing field before you de-energize the
magnet.
D. After the demagnetization, use it Gaussmeter (RFL Model 1890 or
equivalent) to test the bearings or bearing components for residual
magnetism. If the reading exceet~s 5 Gauss at any point, the
demagnetization is incomplete.
72-02-3
Jul 15/99 Page 1
CJ610 TURBOJET ENGINES
GEAircraftEnsines MAINTENANCE MANUAL
TIME MARKING
(SEE NqTE)
RACE
GAGE OR
RETAINER
RACE
TIME MP~RKING
(SEE NOTE)
NO. 1 ROLLER BEARTNG
s
i25~
TIME MARKING
(SEE NOTE)
NO. 3 ROLLER BEARING
NOTE: VIBRO-PEEN ME "TIFE SINCE HEW’ ON
SIDE OPPOSITE ANTI-ROTATION SLOT. NO- 2 BALL BEARING J
HAND POLISH TO REMOYE HIGH METAL. 8C-Dlll
Time-Marking of Engine Bearings
Figure 1
E. Separable bearings should be assembled before cleaning. All components
of one bearing should be kept together during the cleaning process.
CAUTION: DO NOT INTERMIX COMPONENTS OF ONE BEARING WITH ANOTHER. DO
NOT ALLOW THE COMPONENTS OR BEARINGS TO BUMP AGAINST EACH
OTHER DURING THE CLEANING PROCESS. NEVER SPIN OR ROTATE
BEARINGS PRIOR TO CLEANING.
F. Allow the bearings to reach the temperature of the cleaning solvent
before cleaning in order to prevent corrosion due to condensation.
WARNING i: COMPRESSED AIR WHEN USING COMPRESSED AIR FOR ANY COOLING,
CLEANING, OR DRYING OPERATION, DO NOT EXCEED 30 PSIG AT THE
NOZZLE.
EYES CAN BE PERMANENTLY DAMAGED BY CONTACT WITH LIQUID OR
LARGE PARTICLES PROPELLED BY COMPRESSED AIR. INHALATION OF
AIR-BLOWN PARTICLES OR SOLVENT VAPOR CAN DAMAGE LUNGS.
WHEN USING AIR FOR CLEANING AT AN AIR-EXHAUSTED WORKBENCH,
WEAR APPROVED GOGGLES OR FACE SHIELD.
WHEN USING AIR FOR CLEANING AT AN UNEXHAUSTED WORKBENCH,
WEAR APPROVED RESPIRATOR AND GOGGLES.
72-02-3
Page 2 Dec 31/91
OEWIIII~ILIE1110
CJ61’0 TURBOJET
SEI-186 MAINTENAr~CE MANUAL
WARNING 2: DRY CLEANING SOLVENT P-D-680 COMBUSTIBLE DO NOT USE NEAR
OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT SURFACES.
PROLONGED CONTACT OF SKIN WITH LIQUID CAN CAUSE DERMATITIS.
REPEATED INHALATION OF VAPOR CAN IRRITATE NOSE AND THROAT AND
CAN CAUSE DIZZINESS.
IF AM LIQUID CONTACTS SK:[N OR EYES, IMMEDIATELY FLUSH
AFFECTED AREA THOROUGHLY WITH WATER. REMOVE SOLVENT-SATURATED
CLOTHING. IF VAPORS CAUSE DIZZINESS, GO TO FRESH AIR.
WHEN HANDLING LIQUID OR FI~IEN APPLYING IT IN AN AIR-EXHAUSTED,
PARTIALLY COVERED TANK, WISAR APPROVED GLOVES AND GOGGLES.
WHEN HANDLING LIQUID OR W~IEN APPLYING IT AT UNEXHAUSTED,
UNCOVERED TANK OR WORKBENCH, WEAR APPROVED RESPIRATOR, GLOVES,
AND GOGGLES.
G. Pressure flush each bearing component with a clean solvent-air spray. Do
not allow
bearing to spin during flushing. Dry cleaning
(Stoddard) solvent,
Fed Spec P-D-68O (Van Waters and Rogers, Colonial Rd., Salem, MA., 01970) is
recommended. Solution should be 1300F. Use cleaning tank equipped with
pump, %0-micron filtration and stand pipes. Immerse bearings for 5 to 10
minutes and dip several times to give a thorough rinsing action before
removal.
WARNING: CARBON REMOVAL COMPOUND MIL-I:-25107 COMBUSTIBLE DO NOT USE
NEAR OPEN FLAMES, NEAR WE~LDIIIJG AREAS, OR ON NOT SURFACES.
CONTACT WITH DRY MATERIAL OR LIQUID WILL CAUSE SEVERE EYE AND
SKIN IRRITATION, AND BURNS. INHALATION OF VAPOR CAN CAUSE
DROWSINESS AND PERMANENT LIVER, LUNG, AND KIDNEY DAMAGE.
IF ANY SOLUTION OR POWDER CO:NTACTS SKIN OR EYES, FLUSH AFFECTED
AREA THOROUGHLY WITH WATER. IMMEDIATELY GET MEDICAL HELP.
IMMEDIATELY REMOVE SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE
DROWSINESS, GO TO FRESH AIR.
WHEN MIXING OR HANDLING SOLUTION AT AIR-EXHAUSTED, PARTIALLY
COVERED TANK OR WORKBENCH, WEAR APPROVED GLOVES AND APRON, AND
WEAR FACE SHIELD OR GOGGLES.
WHEN MIXING OR HANDLING SOLUTION AT UNEXHP.USTED, UNCOVERED TANK
OR WORKBENCH, WEAR APPROVED RESPIRATOR, GLOVES AND APRON, AND
WEAR FACE SHIELD OR GOGGLES.
CAUTION: FILTER AND SOLUTION MUST BE CHANGED REGULARLY TO MINIMIZE
CONTAMINATION.
Dec 31/91 72-02-3
Page 3
BIYII*1~ILleTIIE
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
H. If carbon deposits, varnish, or other foreign material remains on the
bearing surfaces, soak the part for five minutes in an ultrasonic
cleaning tank using a carbon remover. Turco2538 (MIL-C-25107) may be
used (Turco Products, Inc., P.O. Box 195, Marion, Ohio, 43302, U.S.A.).
Reflush per paragraph G. Do not allow the carbon’ rem~over to contaminate
the Stoddard Solvent Tank.
WARNING: DRY CLEANING SOLVENT P-D-68O OBSERVE WARNING IN STEP G.
I. Rinse bearings in a solution of P-D-680 at room temperature in a tank
equipped with a pump and l0-micron filtration. Dip -bearings (handle with
tongs, gloves or a metal rack) in the solution at least 5 times and drain
for 1 minute. Filter and solution must be changed regularly
WARNING: ENGINE OIL IF OIL IS DECOMPOSED BY HEAT, TOXIC GASES ARE
RELEASED.
PROLONGED CONTACT WITH LIQUID OR MIST MAY CAUSE DERMATITIS AND
IRRITATION.
IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AREA WITH
SOAP AND WATER. IF SOLUTION CONTACTS EYES, FLUSH EYES WITH
WATER IMMEDIATELY. REMOVE SATURATED CLOTHING.
IF OIL IS SWALLOWED, DO NOT TRY TO VOMIT. GET IMMEDIATE
MEDICAL ATTENTION.
WHEN HANDLING LIQUID, WEAR RUBBER GLOVES. IF PROLONGED
CONTACT WITH MIST IS LIKELY, WEAR APPROVED RESPIRATOR.
J. After rinsing, dip the bearing in an engine oil conforming to GE Aircraft
Engines Specification D50TF1 (see 79-00, Servicing, for listing of
approved oils) and rotate one race slowly relative to the other to ensure
that all surfaces are covered with oil,
(1) Bearings to be used for immediate requirements are to be wrapped and
placed in their individual containers.
(2) Bearings to be stored for an unknown time duration are to be wrapped
in grease-proof wraphing paper and placed in covered containers.
3. Handling of Bearings.
A. Keep handling of bearings to a minimum. When inspecting, wear clean
synthetic rubber gloves so that bare hands do not contact the bearing
balls, rollers or´•race active surfaces at any time. See figure 2 for
identification of bearing components.
B. Do not allow components of one~bearing to mix with those of another.
72-02-3 Dec 31/91
Page 4
BIWllllt~ll[tTIIC----
CJ610 TUFIBOJET
SEI-186 MAINTENAFJCE MANUAL
TYPICAL TYPICAL
ROLLER BEARING BALL BEARING
RACEWAY
1 RACEWAY
CAGE
INNER RACES
~eJ
ROLLER
INNER RACE
OUTER RACE
OUTER RACE
i BALL
CAGE 000585-718600
Engine Bearings Typical
Figure 2
C. If, for any reason, one unit of a bearing is rejected, always reject the
complete bearing.
D. Do not (or components) by the magnetic-particle
inspect bearings
inspection (This precaution is taken to prevent burning of the
method.
parts during magnetization.) If a bearing component is assembled to a
part which is to be magnetic-particle inspected, the bearing component
must be removed from the part.
4. List of Terms.
A. Nicks. Sharp indentation.
B. Scratch. Long narrow impression.
C. Dents. Smooth surface cavity.
D. Pitting.~ A shallow, irregular sharp-edged hole with a rough bottom and
no material displacement. Fitting is caused by corrosion or spalling on
the’bearing active surfaces.
E. Skidding. Skid marks appear as a frosted film on the otherwise highly
polished surface. Microscopic examination will show that the film is a
transfer of metal.
F. Groove. Continuous channel having no sharp edges.
G. Scoring. Circumferential polished groove on either the race or rollers.
Scoring is caused by foreign material trapped in the bearing and being
pushed by the rollers.
Dec 31/91 72-02-3
Page 5
Brllll*L~rUe’lRIC
CJ610 TORBOJET
MAINTENANCE MANUAL SEI-lR6
H. Active Surface. Surface which comes in contact with roller or ball
during engine opration.
I. Inactive Surface. Surface which is not active.
J. Wear. Removal of parent material.
K. Discoloration. Bearing in service usually has a brownish color, caused
by varnish deposits left by oil. Bluing or black carbon buildup on
bearing is a sign of overheating and is cause for rejecting bearing.
L. Spalling. A sharply roughened area caused by cracking off, or flaking
off of small particles of metal.
M. Fretting. Loss of metal caused by rubbing against another metal.
N. Distortion. Twisting or bending out of a normal, natural or original
shape.
5. Preliminary Instructions. (See figure 2.)
Inspect ball and roller bearings as instructed in paragraph 6. The
inspection limits engine bearings in paragraph 6 take precedence
for main
over all other technical references for bearing inspection.
A. Bearings shall be inspected when:
(1) Bearings are removed from the engine during engine disassembly.
(2) Bearing housings containing assembled bearings are removed from the
engine (remove bearings from housing and inspect).
(3) Chip detector inspection indicates contaminants in the lube system.
(4) Turbine or compressor rotor are removed because vibration limits have
been exceeded.
B. Bearing surface defects shall be located and identified using a scriber
with a 0.030 inch radius tip.
C. Visually inspect all bearing surfaces for heat discoloration as
instructed in paragraph 6. Bearing steels that have been subjected to
high temperatures will vary in color from light straw, to brown, to
purple, to blue, to black.
D. Visually inspect bearings for surface defects (pits, grooves, scratches,
dents, fretting, etc.) as instructed in paragraph 6.
E. Using a scriber having a 0.030inch radius tip, inspect any defects that
are found during visual inspection as follows:
(1) Position scriber at right angles to surface having defects.
72-02-3 Dec 31/91
Page 6
CJ610 TUC;IBOJET
SEI-186 MAINTENAI~CE MANLIAL
(2) Apply light pressure to scriber and move tip transversely across
defect.
NOTE: Defects shall be disregartled if they can be seen but not felt
when using a 0.030 inch radius tip scriber;
(3) Disregard defect if it cannot be felt when scriber tip is moved
across it.
6. Roller Bearin4 Inspection. (See figure 2.)
This inspection is limited to those surfaces exposed during normal engine
maintenance or repair. Do not remove r3llers from their retainers to
inspect the inner or outer race.
Inspection/Check Maximum Serviceable Limits Remarks
A. Engine Main a~d Accessory Bearings.
CAUTION i: BEARING COMPONENTS ARE MATCHED ASSEMBLIES. IF ANY PART OF A
BEARING DOES NOT MEET INSPECTION REQUIREMENTS AND IS
REJECTED, THE ENTIRE BEARING MUST BE REJECTED.
C~ON 2: BE SURE THAT ANTI-ROTATION PIN OF NO. 1 BEARING IS FLUSH TO
0.005 INCH BELOW SURFACE AT OD.
NOTE: Inspection of bearings for h.eat discoloration is done only after
cleaning opration has remove:d all oil stains and deposits.
(1) All bearings for:
(a) Heat dis- Straw or light Replace bearing.
coloration and brown color is
stains on balls, acceptable.
rollers, and Purple, blue
raceways, or black color
is not acceptable,
(b) Correct Attracted to a Replace bearing.
material. magnet.
(2) Cage for:
(a) Scratches, Any number Not applicable.
pits, and nicks allowed.
on inactive
surfaces.
(b) Dents. Visible dents Replace bearing.
are not allowed.
Dec 31/91 72-02-3
Page 7
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(c) Distortion. Visible distor- Replace bearing.
tion is not
allowed.
CAUTION: IF WEAR IS FOUND ON SILVER PLATE, A HIGH VIBRATION
CONDITION MAY EXIST. REFER TO OPERATING LIMITS.
(d) Worn silver
plate (determined
visually):
1 Polished Any amount Not applicable.
appearance. allowed.
2 Feath- Not allowed. Replace bearing.
ering (over-
lap) of
silver plate
into roller
or ball
socket.
3 Wear thru Base material exposure Replace bearing.
silver plate limited to 100 to
on ID or on a radial plane passing
No. 2 ball circumferentially thru the
socket. ball socket.
4 Wear thru Base material exposure Replace bearing.
silver plate in a line of width that
on No. 1 and does not exceed 0.060
3 roller inch is acceptable.
pocket.
(e) Dents, nicks, Not allowed. Replace bearing.
and scratches
on active
and/or inactive
surfaces.
(f) Cracks. None allowed. Replace bearing.
CAUTION: BE SURE THAT ANTI-ROTATION PIN OF NO. 1 BEARING IS FLUSH TO
0.005 INCH BELOW SURFACE AT OD.
NOTE: Roller bearing visual inspection is limited to those surfaces
visible after removal from engine.
72-02-3 Dec 31/91
Page 8
CJ610 TUIRBOJE7
SEI-186 MAI~TENANCE MIIMTIIL
Inst~ection/Check Maximum Servic;eable Limits Remarks
(3) Roller bearings
for:
(a) Circumfer- Three per roller Replace bearing.
ential grooves on 50% of ro3.-
or scores on lers, with ntme
rollers. wider than
0.010 inch, or
that cannot
definitely be
felt with a
0.030 inch
radius scriber.
(b) Scratches (1) Scratches Replace bearing.
on rollers. that exceed
0,010 inch
width are not
allowed.
(2) Crossed Replace bearing.
scratches are
not allowed.
(3) One scratch Replace ´•bearing.
per roller
allowed up tc,
half the circ-um-
ference, pro´•-
vided width is
within limit:s.
(4) Three Replace bearing
scratches per
roller allowed
up to 25’6 of
the circum-
ference pro-
vided width is
within limits.
(5) Any number Replace bearing.
less´•than 0.1
inch in length,
provided width
is within
limits.
Dec 31/91 72-02-3
page 9
fPYIR114~ILISrlllE
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Ins´•pection/l=heck Maximum Serviceable Limits Remarks
(c) Pits on None allowed. Replace bearing.
rollers.
id) Concentric Any roller Replace bearing.
wear on roller having end
ends. (See wear with a
figure 3.) detectable
step is not
usable.
(e) Eccentric Not allowed. Replace bearing.
wear. (See
figure 3.)
(f) Cracks on None allowed. Replace bearing.
rollers.
(g) Nicks and (1) Nicks or Replace bearing.
smooth dents dents that
on rollers. exceed 0.015
inch in
greatest
dimension are
not allowed.
(2) Three nicks Replace bearing.
or dents
per
roller within a
0.25 inch diam-
eter circle if
greatest dirnen-
sion of defect
is within limits.
(h) Flat spots Not allowed. Replace bearing.
on rollers.
(4) Roller bearing
raceway active
surfaces for:
(a) Scratches on (1) Scratches Replace bearing.
roller path. that exceed
0.010 inch in
width are not
allowed.
72-02-3 De~ 31/91
Page 10
03610 TURBOJET
SEI-186 MAINTENA~NCE MANUAL
ECCENTRIC CONCENTRIC
ROLLER END WEAR ROLLER END WEAR
NOT ALLOWED NOi ALLOWED
ROLLER
PATH
DISCOLORED AND OF NO
APPARENT DEPTH, DR
FROSTED BAND (DIRT
TRACKING) OF NO I SCORE OR GROOVE
APPARENT DEPTH,
(2 BANDS) IS
AC CE PTAB LE
BURNISHED (BRIGHT)
CIRCULAR EIAND (2 BANDS)
WITH NO APPARENT DEPTH
ROLLER IS ACCEPT~IBLE.
PATH
AXIAL OR TRANSVERSE SCORING FLAT SPOT OR AXIAL SCORE ON ROLLER
CAUSED BY DAMAGED ROLLERS SURFACE, (SINGLE OR MULTIPLE), NOT
NOT ALLOWED. THOROUGHLY ALLOWED.
EXAMINE ALL ROLLERS.
000CJ~-882500
Race Way and Roller Imperfections
Figure! 3
Dec 31/91 72-02-3
Page 11
GIWIR*L~,lltCIRIC----
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
I~Insoection/Check Maximum Serviceable Limits Remarks
(2) No crossed Replace bearing.
scratches
allowed.
(3) One circum- Replace bearing.
ferential scratch
allowed per
raceway up to
0.50 inch in
length, pro-
vided width is
within limits.
(4) Three Replace bearing.
scratches
allowed per
raceway up to
50% across
raceway, pro-
vided width
is within
limits,
(5) Any number Replace bearing.
less than 0.1
inch in length,
provided width
is within
limits.
(b) Pits on None allowed. Replace bearing.
roller path.
(c) Scoring. Any amount Replace bearing.
that cannot
be felt with a
0.030 inch
radius scriber.
(d) Cracks. None allowed. Replace bearing.
(e) Skidding Not allowed. Replace bearing.
(dull areas in
an otherwise
shiny roller
path) on roller
path.
72-02-3 Dec 31/91
Page 12
CJ610 TUFIBOJET
SEI-186 MAINTENANCE MANITAL
Inspection/Check Maximum Serviceable Limits Remarks
(5) Roller bearing
raceway inactive
surfaces for:
(a) Axial (1) Axial Replace bearing.
scratches on OD scratches are
of outer race acceptable, pro-
and ID of inner vided defect
race, dimensions are
within limits
and scratch does
not extend acjcoss
corner radii or
chamfers onto
the bore or
outer diamete:e
surface. No
hish metal
allowed.
(2) Scratches Replace bearing.
that exceed
0.015 inch in
width are not
allowed.
(3) Ten Replace bearing.
scratches per
race greater
than 0.1 inch
long with no
high metal,
provided width
is within
limits.
(4) Any number Replace bearing.
of scratches
per race less
than 0.1 inch
long with no
high metal,
provided width
is within
limits.
Dec 31/91 72-02-3
Page 13
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(b) Corrosion 25% of width, Replace bearing.
stains on thickness or
surfaces circumference
other than with no
roller measurable
track, depth.
(c) Fretting Max fretted Replace bearing.
on ID, OD and area 0.5 square
side surfaees inch; max depth
of roller in fretted area
bearing. 0.001 inch,
with no high
metal.
(d) Pits. None allowed. Replace bearing.
(e) Nicks and (1) Nicks and Replace bearing.
smooth dents. dents that do
not exceed 0.015
inch in greatest
dimension are
within limits.
(2) Up to three Replace ~bearing.
nicks or dents
per raceway
allowed within
0,25 inch dia.
circle, provided
defect dimensions
are within limits.
NOTE: The only ball bearing that can be easily inspected is the
No. bearing.
2 Accessory gearbox, transfer gearbox and
PTO ball bearings can be 100% inspected only after
disassembly by a qualified bearing inspection vendor.
(6) Ball bearings
for:
(a) Scratches (1) Scratches that Replace bearing.
on balls, exceed 0.010 inch
in width are not
allowed.
(2) No crossed Replace bearing.
scratches allowed.
72-02-3 Dec 31/91
Page 14
CJ610 TURIBOJET
SEI-186 MAINTEN~ICE MIINUAL
Inspection/Check Maximum Servicc!able Limits Remarks
(3) One scratch per Replace bearing.
ball allowed up to
half the circlunference,
provided width is within
limits.
(4) Any numbe;e less Replace bearing.
than 0.1 inch in
length, provitied
width is within
limits.
(b) Pits on None allowed. Replace bearing.
balls.
tc) Nicks and (1) Nicks or dents Replace bearing,
smooth dents that exceed 0.025
on balls. inch in greatest
dimension are not
allowed.
(2) Three nicks Replace bearing.
or dents per ball
allowed in 0.25
inch dia. circle,
provided defect
dimensions are
within limits.
(d)~ Skidding None allowed. Replace bearing,
(dull areas in
an otherwise
shiny path) on
balls.
(e) Scoring on None allowed. Replace bearing.
balls.
(f) Cracks on None allowed. Replace bearing.
balls.
(7) Ball bearing
raceway tactive
surfaces) for:
(a) Scratches. (1) Scratchez; that Replace beating.
exceed 0.010 inch
width are not
allowed.
Dec 31/91 72-02-3
Page 15
OIWfRIL~[LIETRIC----
CJ6~0 TURBOJE7
MAINTENANCE MAIWAL SEI-186
Ins~ection/Check M_aximum ServiceableLimits Remarks
(2) No crossed Replace bearing.
scratches allowed.
(3) One circum- Replace bearing.
ferential scratch
allowed per raceway
up to 0.50 inch in
length, provided
width is within
limits.
(4) Three scratches Replace bearing.
allowed per raceway,
no more than 50%
across raceway, pro-
vided width is within
limits.
(5) Any number less Replace bearing.
than 0.1 inch in
length, provided
width is within
limits.
(b) Pits. None allowed. Repla~e´•bearing,
(c) Nicks and (1) Nicks or dents Replace bearing.
smooth dents. that exceed 0.010
inch in greatest
dimension are not
allowed.
(2) Three nicks or Replace bearing.
dents per raceway
allowed in 0.25
inch diameter circle,
provided defect dim-
ensions are within
limits.
72-02-3 Dec 31/91
Page 16
EEl(tllL~ILEETFIIE
CJ610 TUFIBOJET
SEI-186 MAINTENAIICE MANIIAL
Insvection/Check Maximum Serviceable Limits Remarks
(8) Ball bearing
raceway inactive
surfaces for:
(a) Axial (1) Axial scratches Replace bearing.
scratches on are acceptable pro-
the OD of outer vided defect dim-
race and ID of ensions are within
inner race. limits and sc:ratches
do not extend across
corner radii or cham-
fers or to th~e bore
or outer diameter
surface. No :high
metal allowed.
(2) Scratches that Replace bearing.
exceed 0.015 inch
in width are ´•not
allowed.
(3) Any number of Replace bearing.
scratches per race
less than 0.10 inch
long, with no high
metal, provided
width is within
limits.
(4) Up to ten. Replace bearing.
scratches longer
than 0.10 inch,
with no high metal,
provided width is
within limits.
(b)’Fretting on Max fretted area Replace bearing.
OD of bearing 1.0 so. inch in a
outer race. 6-inch circun~-
ference; max depth
in fretted ar´•ea
0.001 inch wi.th no
high metal.
(c) Corrosion Twenty percent of Replace bearing.
stains on sur- width,
faces other or circumference
than raceway with no measurable
path. depth.
Dec 31/91 72-02-3
Page 17
OEYIR*L~blLEC7RIC---
CJGIO TURBOJET
MAINTENANCE MANUAL SEI-186
Ins~ection/Check Maximum Serviceable Limits Remarks
(d) Pits. Any number that Replace bearing.
cannot be detected
using 0.030 inch
radius scriber not
exceeding 20X of
contact area of the
inner race bore,
outer race outside
diameter and surfaces
affecting face
squareness or
assembly.
(e) Cracks. None allowed. Replace bearing.
72-02-3 nec 31/91
Page 18
CJ610 TUFZBOJET
SEI-186 MAINTENAIICE MANUAL
WELDING PROCEDURISS GENERAL
i. General.
All welding should be qualified welding operator.
done by a No repair welds
other repair procedures
than those authorized in the should be attempted
I without approval of a GE Aircraft Enginos Representative. Any procedure
involving the melting of a filler or of the parent metal will be performed
in accordance with this section. This includes welding, brazing, or
soldering.
2. General Welding Procedures.
NOTE: Weld repairs may be difficult in some areas due to space
restrictions. In these cases it may be helpful to consider the use
of torches having flexible-type necks.
A. Clean all oils and grease from surface to be welded. If any other
foreign material is present, remove it by wire brushing, vapor degreasing,
or vapor blasting the surface.
B. Remove any defect in the part before welding. Grind out the cracked area
and spot fluorescent-penetrant, per 72-03-1, to make sure entire cracked
area has been removed.
C. Weld the damaged area using the rod suited for the metal being repaired.
A suitable weld rod will be found in the repair procedure for any part
that has allowable weld repair.
D. After repair welding is completed, the weld should be cleaned and
inspected to make sure a good quality weld has been performed.
Dec 31/91 72-02-4
Page 1
OEWBRAL~ fLECTRIG
CJ610 TURBOJET
MAINTENANCE MANLTAL SEI-186
3. General Inert Are Procedure.
A. Preparation of Material. Prior to welding the area to be welded should be
cleaned, inspected, ground, etched and inspected.
WARNING: TRICHLOROETHANE VAPORS ARE HARMFUL DO.NOT USE NEAR OPEN FLAMES,
OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURCE OF CONCENTRATED ULTRA-
VIOLET RAYS. INTENSE ULTRAVIOLET RAYS CAN CAUSE THE FORMATION
OF PHOSGENE GAS, WHICH IS INJURIOUS TO THE LUNGS.
USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED
OF VAPORS.
BREATHING
AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. WEAR APPROVED
GLOVES AND GOGGLES (OR FACE SHIELD) WHEN HANDLING AND WASH
HANDS THOROUGHLY AFTER HANDLING.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
STORE IN APPROVED METAL SAFETY CONTAINERS.
(1) Clean the area of all dirt, paint, scale, rust and inorganic foreign
material. Remove all oil or grease by wiping area with a solvent
that does not leave a film upon drying. Trichloroethane, Fed. Spec.
0-T-620, is recommended.
(2) Inspect the area, using spot fluorescent penetrant, to determine
location and extent of crack. Where possible both sides of material
should be inspected.
(3) Cracks should be prepared for welding by grinding and/or benching.
72-02-4 Sep 1/75
Page 2
GE#ERAL ~B ELEetRle
CJGIO TURE~OJET
MAINTENAETCE MANIJAL SEI-186
(a) Cracks that do not extend to both surfaces shall be completely
removed. Length should extentl 0.125 inch beyond the end of the
crack and the width should be enough to completely remove the
crack.
(b) Through-cracks should be prepared as follows:
Stock Thickness Preparation
to 0.045 inch GriIld to 50 percent of parent metal
thickness
0.045 to 0.090 inch GriIld to 75 percent of parent metal
thickness
0.090 inch and larger GriIld to within 0.030 inch of opposite
surface.
(4)Etch all areas to be welded.
(5)Inspect the area using spot fluorescent penetrant method to make
certain all of the crack has been removed.
B. Weld the crack using the following:
(1)Filler Material See specific pa~et information.
(2)Shielding Gas Argon to 10 to 15 cubic feet per hour
(3)Amperage requirements:
Nominal Thickness Amp~´•rage (DC Straight Polarity)
to 0.045 30-40
0.045 to 0.065 50-60
0.065 to 0.090 60-80
over 0.090 60-80 (Multipass)
Castings 60-100
NOTE: A remote control, variable current device should be employed
to minimize heat input. A~rctrol (Mullenback Electrical Manu-
facturing Co., P.O. Box 15436, 2300 East 27th Street, Los
Angeles, Calif.) or equiva:lent is recommended.
(4jUse gas and/or copper backing dir~ectly behind repair weld areas.
Never allow the weld penetration to be directly exposed to air since
this causes the formation of oxid~es on the weld bead which reduces
the strength of the weld.
72-02-4
I Sep 1/75
Page 3
GE#ERAL~LLECTRIC
CJ610 TURBOJE7
MAINTENANCE MANLTAL SEI-186
NOTE: Gas backing provides the best protection against oxidation
while copper backing is used mainly to prevent distortion of
the part in the repair area. If both backing methods cannot
be used at the same time, gas’is the preferred backing. method.
.(5) Multipass weld if required. thoroughly cleaned
Each bead should be
by grinding rotary filing,
or wire-brushing.
followed by Wipe clean
with acetone prior to next pass. Where welding is performed on both
sides, the root shall be ground or rotary-filed to sound metal,
inspected, wire-brushed, and cleaned with acetone before resuming
welding.
C. Clean the welded area thoroughly with a wire brush to remove scale or
oxide.
D. Inspect weld area using spot fluorescent-penetrant method.
4. Weldinn Standards.
All welds should conform to standards contained in GE Aircraft Engines
Specification M50T1.
72-02-4 Dec 31/91
Page 4
OEILIAL~ILECtllC
CJ610 TURBC)SE.T
SEI-186 MAINTENANCE MANUAL
TOUCHUP PROTECTIVE COATING (SERMETEL AND SOLARAMIC)
1. General. Solaramic S5-8A (International IIarvester Co., Solar Division,
22~lb Pacific Highway, San Diego, Californ:ta 92101) is an oven fired ceramic
coating. -Solaramic coated parts having m:lnor damage may be touched-up in
place with SermeTel 413. The part must be removed and returned to an over-
haul facility to accomplish touch-up with Solaramic.
SermeTel 413 (Teleflex Inc., North Wales, Pennsylvania) is a room tempera-
ture curing chromium oxide coating compound. If unavailable, SermeTel 196
or 250 may be used.
WARNING: SERMETEL COMPOUNDS ARE HIGHLY COIYIBUSTIBLE. CARE SHALL BE TAKEN
TO MINIMIZE DANGER OF EXPLOSION liWD FIRE HAZARDS.
2. Procedure. SermeTel may be used to touch´•-up areas not exceeding 10 percent
of the total coated area.
A. Clean the area touched up, using only dry or wet blasting with
to be
220-500 mesh aluminum oxide or with ab:rasive cloth. If wet blasting is
used, part should be dried immediately after rinsing to prevent corrosion.
WARNING: TRICHLOROETHANE VAPORS ARE HARMF;L~L DO NOT USE NEAR OPEN FLAMES,
OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURCE OF CONCENTRATED ULTRAVIOLET
RAYS. INTENSE ULTRAVIOLET RAYS CAN CAUSE THE FORMATION OF PHOSGENE
GAS, WHICH IS INJURIOUS TO THE LUNGS.
USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED
BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED CONT,ACT WITH SKIN. WEAR APPROVED GLOVES
AND GOGGLES (OR FACE SHIELD) WHEN HANDLING AND WASH HANDS THO-
ROUGHLY AFTER HANDLING.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
STORE IN APPROVED METAL SAFETY C~DNTAINERS.
B. Clean the part by vapor degreasing or by wiping the area with a clean rag,
moistened in trichloroethane, Fed. Spec.´•0-T-620, or equivalent.
C. Apply SermeTel 413 by brushing (1 coat) or by spraying (3 coats). If
SermeTel 413 (green color) is not available, use SermeTel 196 or 250
(aluminum color).
D. Air dry for 24 hours (10 minutes between spray coats).
NOTE: Make sure that no water or foreign matter comes in contact with the
coated surface during this period.
72-02-5
Dec 1/77
Page 1
G E W E RAL ~D E1E CT R IC
CJ610 TORIBOJET
SEI-186 MAINTENAI~CE MANUAL
TOUCHUP A12/HI51 INTERMETAILLIC DIFFUSION COATING
i. General.
A. A12 Oianufactured by Chromalloy Amer:ican Corp., Turbine Support Division
(TSD), 4430 Director Drive, San Antolaio, Texas 78220). The touchup solu-
tion (TSD process No. SPM-1771) is available with touchup kit, P/N PM-11.
The kits have a shelf-life of 6 months (90 days maximum after container is
opened).
B. HI51 (Manufactured by Alloy Surfaces, 100 Justison Road, Wilmington,
Delaware 19849).
NOTE: HI51 and A12 material may be used interchangeably to touch
up surfaces.
C. These coatings arealuminum base, intermetallic diffusion types which give
ferrous alloys excellent corrosion rc~sistance.
WARNING: AVOID PROLONGED OR REPEATED CONTACT WITH SKIN WASH HANDS WITH
SOAP AND WATER AFTER USE.
2. Surface Preparation:
WARNING: TRICHLOROETHANE VAPORS ARE HAIIMFUL DO NOT USE NEAR OPEN FLAMES,
OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURCE OF CONCENTRATED ULTRA-
VIOLET RAYS. INTENSE ULTRAVIOLET RAYS CAEJ CAUSE THE FORMATION
OF PHASGENE GAS, WHICH IS INJ1JRIOUS TO THE LUNGS.
USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED
BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED C(INTACT WITH SKIN. WEAR APPROVED
GLOVES AND GOGGLES (OR FACE SI~IELD) WHEN HANDLING AND WASH
HANDS THOROUGHLY AFTER HANDLIIJG.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
STORE IN APPROVED METAL SAFET11 CONTAINERS.
A. Remove contaminants from the area to be repaired, using an abrasive pad
such as Scotchbrite (manufactured by 3M Co.) or equivalent.
Dec 30/78 72-02-6
Page 1
GE W ERAL tlf CTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
B. Degrease the surface area, using an abrasive pad moistened with trichlor-
oethane.
C. Remove loose particles in area to be touched up, using 600-grit silicon
carbide abrasive paper.
D. Remove abrasive dust, using oil-free and moisture-free compressed air or a
lint-free swab and trichloroethane.
3. Application.
A. Apply A12 or HI51 solution, using a brush or other suitable lint-free
applicator. Cover all exposed metal completely. Remove all excess
solution to produce a thin, continuous film before curing.
B. Air-cure for at least 10 minutes.
NOTE: For maximum protection, 2 touchup coats are recommended, Allow
the first coat to cure for at least 10 minutes before applying
the second coat.
72-02-6
Page 2 Dec 30/78
GEnfRAL~ ELECIIIC
CJB10 TURBOJET
SEI-186 MAINTEN.ANCE MANUAL
TOUCHUP, TSM-3 INTERMETALLIC DIFFUSION COATING
i. General. TSM-3 (Manufactured by Chromal:Loy American Corp., Turbine Support
Division (TSD), 4430 Director Dr., San 19ntonio, Texas, 78220) is a magnesium
base, Intermetallic diffusion coating that has a dark gray appearance which
gives low alloy steels excellent corrosion resistance. The touchup material
(TSD process No. SPM-1777) adheres to parent metal and to surfaces coated with
TSM-S when properly applied. The touchu´•p mixture, P/N PM-12, can be applied
with a brush or thinned with solvent, P/N PM-13, and applied with a spray gun.
The shelf-life of the touchup kit is limited to 90 days. Kits can be purchased
from Chromalloy American Corp.
WARNING: TSM-3 TOUCHUP COATING VAPORS I~RE HARMFUL USE ONLY IN WELL
VENTILATED AREAS.
FLAMMABLE DO NOT USE NEAR W]SLDING AREAS, OR NEAR OPEN FLAMES
OR SPARKS.
AVOID PROLONGED OR REPEATED CONTACT WITH SKIN WASH HANDS WITH
SOAP AND WATER AFTER USE.
STORE IN APPROVED METAL SAFET’II CONTAINERS.
DO NOT SMOKE IN VICINITY OF Af’PLICATION.
2. Surface Preparation.
WARNING: TRICHLOROETHANE VAPORS ARE HARMFUL DO NOT USE NEAR OPEN FLAMES,
OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURCE OF CONCENTRATED ULTRA-
VIOLET RAYS. INTENSE ULTRAVIOL,ET RAYS CAN CAUSE TH’E FORMATION
OF PHOSGENE GAS, WHICH IS INJC´•RIOUS TO THE LUNGS.
USE ONLY WITH ADEQUATE VENTILA.TION. AVOID PROLONGED OR REPEATED
BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED CCINTACT WITH SKIN. WEAR APPROVED
GLOVES AND GOGGLES (OR FACE SHIELD) WHEN HANDLING AND WASH
HANDS THOROUGHLY AFTER HANDLING.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
STORE IN APPROVED METAL SAFETY CONTAINERS.
Dec 30/78 72-02-7
Page 1
6EIERAL~ ELI’CIIIC ------e
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
A. Remove contaminants from the area to be repaired, using an abrasive pad
such as Scotchbrite (manufactured by 3M Co.) or equivalent.
B. Degrease the surface area, using an abrasive pad moistened with trich-
loroethane.
C. Remove loose particles in area to be touched up, using 600-grit silicon
carbide abrasive paper.
D. Remove abrasive dust, using oil-free and moisture-free compressed air or a
lint-free swab and trichloroethane.
3. Touchup Application.
A. Thoroughly mix contents in bottle of touchup coating material.
B. Apply mixture, while particles are in suspension, using a brush or other
suitable lint-free applicator. Cover all exposed metal completely.
NOTE: To keep particles in suspension while using the touchup mixture,
repeat step A. as required.
C. Heat the coated area to 500-5500F (260-2880C) for at least 10 minutes.
Curing can be done In an oven or with a heat gun providing the cure
cycle limits are adhered to.
D. Trial-fit mating parts and, if necessary, remove high spots, using
600-grit silicon carbide paper.
72-02-7
Sep 1/75
Page 2
GeWEAAL ~B ELECTRIC
CJB10 TURB6JET
SEI-186 MAINTENANCE MANUAL
TOUCHUP, SERMETEL 725 PR.OTECTI7E COATING
i. General. SermeTel. (725 Teleflex Inc., North Wales, PA) coating is applied
as aprotective coating to surfaces that are subject to corrosion. SermeTel
coating is light gray and has a dull finish similar to a vapor-blasted sur-
face. The procedure is of a general natu.re and should be used in conjunction
with details given for individual parts.
WARNING: SERMETEL 725 COATING CONTAINS A.LUMINUM PARTICLES OF A 5 TO ~O
MICRON SIZE. THESE PARTICLES, WHEN ACCUMULATED IN THE DRIED
STATE, REACT SIMILAR TO PURE ALUMINUM OF THE SAME PARTICLE SIZE
WHEN IGNITED. EXPLOSIVE PRESSU’RES ARE GENERATED WHEN IGNITION
OF AN AIR MIXTURE (DUST CLOUD) OCCURS.
SERMETEL 725 COATING ALSO REAC~’S WITH ALKALINE SOLUTIONS AND
MANY ACIDS TO LIBERATE HYDROGE~I GAS WHICH, WHEN IGNITED,
GENERATES EXPLOSIVE PRESSURE.
CARE SHALL THEREFORE BE TAKEN ?’O PREVENT ACCUMULATION OF SERMETEL
725 COATING OVERSPRAY RESIDUES. PARTICULAR ATTENTION SHALL BE
TAKEN TO ASSURE ACCUMULATIONS L~O NOT OCCUR WHERE THEY CAN BE
DISPERSED IN AIR (SHAKEDOWN OF A DUCT FOR EXAMPLE) OR WHERE THEY
MAY BECOME MIXED WITH ALKALINES; OR CERTAIN ACIDS.
2, Preparation for Coating.
A. Mask all areas not to be painted per dletailed part instructions.
B. Wipe clean with a lint-free cotton cloth.
NOTE: Following cleaning operations Clo not handle parts with bare
hands. Clean, white, cotton gl.oves should be worn to handle
parts after cleaning. If parts are not to be coated within
four hours after cleaning, they should be stored in clean,
sealed polyethylene bags.
3. application of Coating.
A. Coating shall be applied to the requir:ed thickness in separately cured
coats.
NOTE: Unless otherwise specified, coating shall be 0.0015-0.003 inch
thick.
B. Standard paint: spray equipment is prefierred for application. Use a
DeVilbiss Model PEGA-502-390F nozzle (DeVilbiss Corporation, Somerset,
Pennsylvania) or equivalent.
72-02-8
Dec 30/78
Page 1
GENERAL L LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
C. SermeTel 725 is used as received; no thinning is necessary.
NOTE: During use, the coating should be continuously agitated to
assure that solids do not settle out of suspension.
4. Procedure.
A. Apply touchup coat by either brush or spray as follows:
(1) Spray part until a uniform green coating is obtained. Spray with
nozzle held 8 inches from and parallel to the work piece.
(2) Brush coating material on the part.
(3) Air-dry part at room temperature for at least: 15 minutes.
CAUTION: CURING MUST BE ACCOMPLISHED AS SOON AS POSSIBLE A~TER
SPRAYING OR BRUSHING: IF NOT, THE COATING WILL ABSORB
MOISTURE AND WEAKEN THE EFFECTIVENESS OF THE PROTECTIVE
COATING.
B. Apply and cure second base coat same as the first coat if necessary.
C. Check the finish as follows:
(1) Coating should be free from cracks, foreign matter, bubbles, pin holes,
runs, sags, or other imperfections.
(2) When finish is rubbed with either cloth or cotton dampened with water,
the base metal will not be exposed; if it is, the coating must be
stripped and reapplied.
NOTE: A light uniform deposit of powdery material may be deposited
on the cotton swab and not require re-finishing.
72-02-8
Dec 30/78
Page 2
GEW ERAL~ ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
BLENDING PROCEDURES
i. General.
Blending is a repair procedure used to remove stress concentrationcaused by
nicks, scratches, etc. on critical parts. Removal of the material that
surrounds the stress concentration, in a smooth contour, relieves this
stress concentration and permits further use of the part by lessening the
danger of cracking.
2. Hand Blending.
A. Blending may be’ done with an Arkansas stone, a fine file, or a crocus
cloth. If a large or deep blend is to be made, a medium file or heavy
grade abrasive paper may be used to shorten the time required to remove
the metal, but a fine finish must then be applied.
B. When blending compressor rotor blades, stater vanes, turbine blades and
similar parts, the part will be blended in a radial direction in relation
to engine.
the To avoid reworking leading and trailing edges into sharp,
thin sections, initial benching should be directed in the chordial
direction with subsequent blending into the airfoil surface to maintain
the original contour. Refer to the inspection limits in the inspection
section of this manual for specific instructions on benching limits
applicable to each part of the engine.
C. When blending a cylindrically-shaped part, blend in a circumferential
direction, not along the axis of the part.
D. The finish onthe blended area must be as close as practical to the
original finish of the part.
E. When blending part involves a radius, maintain radius as specified
on a
in detailed parts section. If radius is not specified, maintain as near
as possible to original radius. (Refer to similar part, if necessary to
determine original radius.)
3. Power Blending.
A. Blending may be done by using power driven polishing wheel when
instructions on the individual part permit.
CAUTION: POWER BLENDING MOST ONLY BE USED WHEN SPECIFIED BY INDIVIDUAL
PART INSTRUCTIONS.
B. Rough out defects using a coarse grade of silicon carbide impregnated
rubber wheels and points. Use fine and extra-fine grade of rubberized
abrasive wheels and points to finish blend area. Abrasive wheels and
points to be Crater Tool and Die Maker’s Kit No. 777, Crater
Manufacturing Co. Inc., 1600 Rollins Road, Burlingame, California, or
equivalent.
I Dec 31/91
72-02-9Page 1
GEWERIL~ILEeTRle------
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
CAUTION: THE POWER BLENDING DEVICE MOST BE A TYPE THAT WILL NOT
GENERATE EXCESSIVE HEAT AND THERMAL STRESSES IN THE PART.
C. Thetechniques of paragraph 2, are to be followed when power blending.
Spot-fluorescent penetrant inspect after blending.
72-02-9 Dec 31/91
GENERAL ELECTRlC---
CJ61 O TU RBOJ ET
SEI-186
MAINTErJANCE MANUAL
I SPOT METHOD OF POST EMULSIFIED LIQUID PENETRANT INSPECTION
1. General. This method is not intended as a substitute for the standard method of
I post emulsified liquid penetrant inspection. However, it is considered an ac-
ceptable alternate process for the detection of surface defects after repair
operations to remove known defects, or for the inspection of isolated areas when
it is not considered practical to process the entire part.
2. Materials and EauiDment Reauired.
A. Post emulsifiable fluorescent liquid penetrant (Type I, Method C or D, or
equivalent). Sensitivity level 2, 3, or 4 approved for use and listed on
Qualified Products List (QPL) 25135-15.
B. Penetrant remover approved for use and listed on QPL 25135-15.
C. Dry powder developer or nonaqueous deve:toper approved for use and listed on
QPL 25135-15.
D. Black light that meets requirements of MIL-STD-6866 and/or GE Aircraft En-
gines Specification P3TF2.
E. A darkenedinspection area that meets requirements of MIL-STD-6866 and/or GE
Specification P3TF2. (May be a hood m;ide from canvas or similar opaque
material.)
3. Procedure.
A. Thoroughly clean parts by a process that will remove all traces of scale,
carbon, grease, and oils or other foreign matter that could mask or interfere
with detection of discontinuities.
72-03-1
Dec 31/95 Page 1
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
WARNING: PENETRANT METHOD OF INSPECTION
PROLONGED OR REPEATED INHALATION OF POWDERS AND VAPORS OF CLEANING
SOLVENTS, DEVELOPERS, AND EMULSIFIERS USED IN FLUORESCENT PENETRANT
INSPECTION CAN IRRITATE MUCOUS MEMBRANE AREAS OF THE BODY.
CONTINUAL EXPOSURE TO PENETRANT INSPECTION MATERIALS CAN IRRITATE THE
SKIN. DIRECT EXPOSURE OF EYES TO BLACK LIGHT AND PROLONGED EXPOSURE
OF SKIN TO BLACK LIGHT CAN INFLAME AND DAMAGE EYES AND SKIN.
WEAR NEOPRENE GLOVES WHEN HANDLING PENETRANT INSPECTION MATERIALS.
KEEP INSIDES OF GLOVES CLEAN.
STORE ALL PRESSURIZED SPRAY CANS CONTAINING PENETRANTS, DEVELOPERS,
AND EMULSIFIERS IN A COOL, DRY AREA PROTECTED FROM DIRECT SUNLIGHT,
HEAT, AND OPEN FLAMES. TEMPERATURES HGIHTER THAN 1200F (490C) MAY
CAUSE PRESSURIZED CAN TO BURST AND CAUSE INJURY.
IF DIRECT EYE CONTACT WITH BLACK LIGHT CAUSES EYE PROBLEMS, IMMEDI-
ATELY GET MEDICAL HELP.
WHEN USING BLACK LIGHT FOR FLUORESCENT INSPECTIONS, WEAR SAFETY
GLASSES.
B. Apply penetrant only to areas to be inspected. Penetrant oil may be applied
by either brushing, spraying, or dipping.
C. Allow penetrant oil to remain on parts for a minimum of 15 minutes,
D. Remove all excess penetrant oil from surface of part by first wiping with a
clean, dry lint-free cloth.
E. Complete penetrant removal by wiping with a lint-free cloth moistened with
approved remover.
NOTE: Do not spray. remover onto surface of inspection area as this may remove
penetrant from shallow or tight discontinuities.
F. Check inspection area with black light to ensure complete removal of excess
penetrant oil.
G. Apply developer uniformly and allow to remain on areas for a minimum of 10
minutes.
H. In darkened inspection area, inspect all treated parts and surfaces for de-
fects or discontinuities.
I. Use approved marking pen to identify discontinuities that warrant rejection.
J. Clean liquid penetrant and developer from all treated areas using approved
cleaning materials and procedure.
72-03-1
Page 2 Dec 31/95
GEIERAL ~B ELIGTRIC
CJ610 TURBOJET
SEI-186 E~INTENANCE MANUAL
COMPRESSOR SECTION DESCRIPTION AND OPERATION
i. Gene ral The Compressor Section of th.e CJ610 engine consists of the com-
pressor front frame, compressor stater casing, compressor rotor and main-
frame assemblies. A brief description of their construction and function
will be covered in the following paragraphs.
2. Description.
A. Compressor Front Frame. The compressor front frame (see figure 1) is a
stainless steel fabrication made up of an inner and outer casing joined
together by fifteen hollow struts. Three of the struts are larger and
house the No. 1 bearing service tu.bes. The No. 3 strut houses the No. 1
bearing sump vent tube; the No. 8 strut houses the scavenge oil tube and
the No. 13 strut houses the oil inlet tube. An over board drain tube is
located in th’e No. 9 strut to drain any oil that may leak past the No. 1
bearing carbon seal.
The No. 1 bearing housing, the No. 1 bearing outer race, is
which houses
brazed to the rear ca.sing and reinforced at the front by
of the inner
three stiffening ribs. The carbon seal, inlet guide vane shroud and
seal ring and collector assemblies are bolted to the No. 1 bearing hous-
ing. A sump cover is bolted to the front of the inner casing and pre-
vents oil leakage from the bearing area and also functions as a retainer
for the outer race of the No. 1 bearing.
The front frame also provides a mount for the fifteen variable inlet
guide vanes which directly behind each strut.
are located Around the
outer casing the inlet guide vane actuating ring is assembled and is
connected through linkage to the variable vane actuators. Movement of
the actuator piston is transmitted through the linkage to the actuating
ring, which positions the vanes.
B. Compre_ssor Stater Casing. The compressor stater casing assembly (see
figurel2) is a matched chromoloy steel unit, split and flanged along
the horizontal centerline. Mounted on the inner surface are seven
stages of fixed stater vanes. The vanes are held in segments, 12 per
stage, which are assembled circumferentially into tracks that are ma-
chined into the inner diameter of the casings. Locking keys are as-
sembled at the split line to prevent the vane segments from rotating.
The first and second-stage vanes ~lave shroud rings attached to the inner
bands. The shroud rings form the static halves of the interstage laby-
rinth seals. All parts are split at the horizontal split line to permit
assembly/disassembly of the casing halves.
Mar. 30/67 72-30
Page 1
CJ610 TURBOJET
MAINTENANCE MANLiAL SEI-186
15
~dB, ’1.
2.
FRONT FRAME CASING ASSEMBLY
INNER SHELL
3. OUTER SHELL
20 4. NO. 1 BEARING OUTER RACE AND ROLLERS
5. OIL INLET FITTING
21--7 19
6. OIL SUMP FITTING
14
7. OIL VENT FITTING
7 8. OIL NOZZLE
9. CARBON RUNNING RUBBING SEAL
a-~a 10.
o’. OIL COLLECTOR
11. OVERBOARD SEAL DRAIN FITTING
3 12. VARIABLE VANE
13. STRUT
12 14. ACTUATOR RING
15. MANIFOLD
16. FRONT FRAME DOME "BULLET NOSE"
17. SHROUD AND SEAL RING
18. SUMP COVER
19. ACTUATOR LEVER
13 17
20. LOCKING CLIP
10 21. PIVOT PIN
9 8
18
2f
,Ci
O
11
DOOWF-884600
Front Frame Assembly
Figure 1
72-30
Page 2 Dec 31/91
CJBIOTURBOJET
GE Aircraft En9ines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-477
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610 MAINTENANCE
MANUAL SEI-186, adjacent to page 3, dated Dec 31/95 in Chapter
72-30.
Record this TR number in the Record of Temporary Revisions.
Subject: New Compressor Rotor Description and Operation
Reason: This TR revises paragraph 2.C. to describe the compressor spool
rotor configuration for CJ610-6 engines modified to SE CJ72-148.
Change 1: Revise existing paragraph 2.C.to add an applicability statement
at the start.
C. Compressor Rotor
I
FOR ALL ENGINES INCLUDING CJ610-6 ENGINES NOT MODIFIED TO SPOOL
ROTOR CONFIGURATION, SE C572-148
Change l:Add the following description after the existing paragraph.
FOR CJ610-6 ENGINES MODIFIED TO SPOOL ROTOR CONFIGURATION
(SB C572-148)*
The compressor rotor assembly (see figure 2A) is an 8-stage axial rotor.
The rotor consists of a forward spool (DA 718) for stages 1 and 2, a stage
3 disk (DA 718), a rear spool (DA 718) for stages 4 through 8, and a drive
shaft.
FAA APPROVED OCTOBER 10, 2000
72-30
Page 1 of 2
Oct. 10/2000
CJGIOTURBOJET
GEAircraftEnaines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-477(continued)
The stage 1 blades are attached to the forward spool by pins and retaining
rings. Stage 2 and stage 3 blades are dovetailed into the forward spool
and stage 3 disk respectively, and are held in by retaining rings. The
remaining stages of the blades are dovetailed to the rear spool in
circumferential grooves, and are held by one retainer key on each stage.
Stages i, 3, and 4 blades are of AM 355 material and are coated with a
corrosion resistant coating. Stage 2 blades are titanium and uncoated.
Stages 5 through 8 blades are AM 355 material and uncoated.
The drive shaft is of INCO 718 material and is bolted between the stage 3
disk and the rear spool. Two external splines on the rear of the shaft
mate with the power take-off bevel gear and the turbine rotor front shaft.
Holes through the main drive shaft cone provide a path for the forward
seal pressurizing air.
The labyrinth air seal is integral with the forward spool and mates
front
with stationary seal on the front frame, providing seal pressurization.
a
The stage i labyrinth seal is integral with the forward spool, the stage 2
labyrinth seal is integral with the stage 3 disk, and these mate against
the first and second stage compressor shroud seals. The eighth stage air
seal is integral with the rear spool and mates with a stationary seal on
the rear frame, and controls compressor air leakage, which is then used
for sump pressurization.
FOR ALL
72-30
Page 2 of 2
Oct. 10/2000
GENERAL ELECTRIC--------
CJ61 O TU RBOJ ET
SEI-186
MALNTENANCE MANUAL
Holes drilled through the casings at stages 3, 4 and 5 allow compressor air
to enter manifolds around the compressor casings. The manifolds direct the
air to the four bleed port pads on the outside of the casings. Each pad has
three openings, one for each of the three stages, on each half of the cas-
ings.
Two variable vane actuators, one at 10 o’clock, one at 5 o’clock, are mounted
on the compressor casing. Two bleed va.lves, one at 3 o’clock, one at 9
o’clock are mounted on the compressor casing bleed port pads. The ignition
unit is mounted at the 12 o’clock position on brackets attached to the front
and rear compressor casing flanges.
C. Compressor Rotor. The compressor rotor assembly (see figure 2) is an 8 stage
axial rotor. The rotor consists of a front disc shaft and blade assembly.
seven stages of discs and blades, seven spacers, a main drive shaft, seals
and hardware. The front disc shaft (AM 355) is a one piece assembly made up
of a shaft, disc and spacer. The serrated rotating half of the compressor
front labyrinth air seal is attached to the front shaft.
The first-stage blades are attached to the first-stage dise shaft by pins and
snap rings. The remaining stages of blades are dovetailed to the disc and
held in by the spacers. The first and second-stage blades are of greek
ascoloy material and coated with a corrosion resistant coating. The remain-
ing blades, disc, and spacers are of AM: 355 material.
The main drive shaft is of A-286 material and is bolted to the rear of the
fourth-stage disc and 3rd stage spacer inner flange. Two external splines on
the rear of the shaft mate with the power take-off bevel gear and the turbine
rotor front shaft.
The rotor has an air duct of A-286 material assembled between the third and
fourth-stage discs. The duct provides positive pressurization of the No. 1
bearing seal.
The first and
second-stage spacers have serrated labyrinth type seals. The
seals against the first and second-stage compressor stater shroud seals.
mate
The eighth-stage air seal is mounted on the rear of the eighth-stage dise and
is a labyrinth-type seal. This seal mates with a stationary seal on the rear
frame and controls compressor air leakage, which is then used for sump pres-
surization.
D. Mainframe. The mainframe (see figure 3) is either an Inconel 718 casting
(figure 3A) or a chromoloy steel fabrication made up of an inner and outer
casing joined by six hollow struts welded in openings in the casings. Struts
No. 2 and 6 vent eighth-stage leakage air through poppet valves mounted on
the strut pads. The No. 3 strut houses the No. 3 bearing scavenge tube and
the sump vent tube.
NOTE: Please see the
Dec 31/95
4I e)- that revises
TEMPORARY
REVISION
this page.
72-30
Page 3
CJ610 TURSOJET
MAINTENANCE MANUAL SEI-186
134
p,
7
j i----9
i. CASING UPPERHALF
2. CASINGLOWER HALF
3. STA’TORVANE
4. MANIFOLDS
10------~-C; 5.
6. FRONT SHAFTASSEMBLY
7. DRIVESHAFT
8. SPACER
9. ROTORDISC
10. ROTORBLADE
U61D~QI(-OC1
Compressor Stater and Rotor Assemblies
Figure 2
The No. 4 strut provides a passage way for the radial drive shaft. The
No. 5 strut houses the No. 2 and 3 bearing lube supply tube and the No.
2 bearing scavenge tube. The No. 1 strut is not used during engine
operation and is blanked-off.
The No. bearing support is aligned and bolted to the front inner (main-
2
frame) flange and supports the front of the power take-off (PTO) housing
and the No. 2 bearing carbon seal support. The PTO drive assembly is
assembled in the PTO housing and transfers power from the main engine
drive shaft through the radial drive shaft to the accessory drive train.
72-30 Mar. 30/67
Page 4
CJB1DTURBOJET
GEAircraftEn~ines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-478
Filing
Instructions: Put this Temporary Revision (TR) in the CJ610 MAINTENANCE
MANUAL SEI-186, adjacent to page 4, dated Mar. 30/67 in Chapter
72-30.
Record this TR number in the Record of Temporary Revisions.
Subject: Compressor Stater and Rotor Assemblies
Reason: This TR adds a new figure 2A to show a section of the compressor
stater and rotor for CJ610-6 engines modified to the spool rotor
configuration.
Change i: Revise title for figure 2.
Compressor Stater and Rotor Assemblies
(For All Engines Including CJ610-6 Engines Not Modified to Spool
Rotor Configuration SB-CJ72-148)
Change 2:Add figure 2A as shown on page 2.
FAA APPROVED OCTOBER 10, 2000
72-30
Page 1 of 2
Oct. 10/00
CJG~OWRBOJFT
GE Aircraft Engines MAINTENANCE MANUAL
SEI-1 86
’IEMPORARY REVISION M-478 icontinued)
Compressor Stater and Rotor Assemblies
(For CJ610-6 Engines Modified to Spool Rotor Configuration, SE C572-148)
Figure 2A
72-30
Page 2 of 2
Oct.10/00
GEIIIAL LLICIIIE
CJ810 TURBOJET
SEI-186 MAINTENANCE MANUAL
C o~
1, 9
i. MAINFRAME
I
9 2. POWER TAKEOFF HOUSING
3. FUELNOZZLE
I 4.
5.
FUEL MANIFOLD
EIGHTH-STAGE STATOR-EXIT
GUIDE VANE SECTOR
#YIIIII I 1 6. NO. 2 (MID) SEAL SUPPORT
7. DRIVER SHAFTGEAR
B. NO. 1(MID) BEARING
9. DRIVERSHAFTGEAR BEARING
1D. INSULATION BLANKET
Il. NO. 2 (MID) BEARING SUPPORT
tl61PdOl~-O-C?
Mainframe Assembly
Figure 3
The outer casing hasequally spaced pads for mounting the fuel
twelve
nozzles. Four compressor bleed port pads for customer connection are
located at the i, 5, 7 and 11 o’clock positions. Additional compressor
discharge air pads are provided to supply compressor discharge air (CDP)
as aspirator air for the T2 sensing bellows and P3 bellows of the fuel
control.
exit mounted in 12 segments and
The eight-stage stater and vanes are
assembled in the machined track on the ID of the outer casing.
72-30
Mar. 30/67
Page 5
orlrnu´• rucrnle
CJB10 TURBOJEt
MAINTENANCE MANUAL SEI-186
3. Operation.
A. The compressor front frame provides the support for the front engine
mount, the No. 1 bearing, and on some model engines the accessory gear-
box.
The front frame forms the inlet for air into the compressor and directs
the air into the compressor. The inlet guide vanes (IGV) which are
mounted behind the front frame struts and are movable through linkage
from the variable vane actuators and can change the angle and meters the
air that enters thecompressor.
Anti-icing air is necessary to prevent the formation of ice in the air
inlet. A anti-icing valve is mounted on the front frame and allows
anti-icing air to enter a manifold around the outer casing of the frame.
The air can then enter each strut of the frame and the IGV’s. The frame
also has passages to allow anti-icing air to the bulletnose and the
shroud and seal assembly.
B. The compressor stater casing is bolted to the rear flange of the front
frame and provides the support for the stater vanes. The vanes direct
the air flow through the compressor. The manifold around stage 3, 4
and 5 allows for bleeding-off compressor air when necessary for proper
compressor operation.
C. The compressor rotor is a axial compressor and compresses the air in the
compressor section by means of rotation. The rotor is coupled to and
driven by the turbine
through the compressor rotor
rotor drive shaft.
The compressorrotor is supported at the front by the No. 1 bearing and
at the rear by the No. 2 bearing.
D. The mainframe provides the support for the
engine mounts. The rear
mainframe also
provides mounting the
2 bearing and the for
power the No.
take-off drive assembly. The compressor stater casing rear flange is
bolted to the mainframe front flange and the combustion casing is bolted
to the rear flange. The mainframe struts and the eighth-stage stater
and exit guide vanes direct the air flow from the compressor into the
combustion section. The mainframe provides for the collection of com-
pressor air for air frame and engine use.
72-30 Mar. 30/67
Page 6
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
10
SEE DETAIL B O
15.535 12
\\\~9
15.495
DIA L 8
~----11
4
1:3
16 15
SECTION A-A
i. Fuel Noule Pad (12 Pads)
2. Leakoge-Air Duct Pod
(2 Pods)
3. Bleed Pod (4 Pods)
DFTAIL B 4. Scavenge Pod (2 Pods)
5. P3 Pad (2 Pods)
0.035 6. Forward Outer Flonge
CHAM 7. Forward Inner Flonge
0.015
8. Aft Outer Flonge
9. Aft Inner Flonge
10. ID of Forward Outer Flonge
11. Outer Band
12. Inner Bond
13. Strut
16.000
14. Gang Channel Nuts
15. Bracket
15.996
16. Stage 8 Seal Mounting Holes
DIA H
I ALL DIMENSIONS I
IAREININCHES 000CPI-89910O
MAINFRAME Cast (Inco 718) Configuration (6051T95)
All 8 Stage Models
Figure 3A
72-30
Dec 31/95 Page 7
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
COMPRESSOR SECTION MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUTPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE E4UIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General.
The following paragraphs describe the removal, installation, disassembly, and
assembly procedures that are approved for the compressor section.
2. Front Frame Removal/Installation.
NOTE 1: Whenever the front frame is removed, a complete gearbox bracket align-
ment per paragraph 7 and a complete accessory drive gearbox alignment
per 72-64-0 is required.
NOTE 2: Whenever the shroud and seal (6, figure 201) is exposed, check that
each bolt (9) is a 12-point head with letter A marked on head. Replace
only those bolts that are not 12-point head with latest part number.
A. Removal. It is recommended that the front frame be removed with the engine
in the position, front end up, suitably supported on the
vertical rear tur-
bine casing flange. However, the front frame can be removed with the engine
in a horizontal position in which case the removal of the exhaust cone per
step (1) is not required.
(1) Remove the exhaust cone as instructed in 78-11-0.
(2) Remove the accessory drive gearbox as instructed in 72-64-0.
NOTE: This step is to be omitted on the CJ610-4, -6, -8, and -8A engines
as the gearbox is not mounted on the front frame.
72-30
Dec 31/95 Page 201
GENERAL ELECTRIC--------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
9
4
3 b8
o
b6
3. OUTERRACEANDROUERS-
NO. 1 BEARING
4. OIL COLLECTOR
5. GASKET
6. SHROUDAND SEAL
7. CARBON RUBBING SEAL
8. O-RING
9. BOLT
10. SCREW
1~. FRONTFRAME
clsla4olt-o-DI
Front Frame
Figure 201
(3) Remove the anti-icing valve as instructetd in 75-11-0.
(4) Disconnect the turnbuckle (bellcrank to actuating ring) as instructed in
75-31-0.
(5) Remove the gearbox mounting bracket as instruccted in paragraph 7.
NOTE: This step is to be omitted on the CJ610-4. -6 and -8 engines.
(6) Remove the bulletnose as follows:
(a) Using a screwdriver or other suitable tool, depress, toward the
engine centerline, the plunger that locks the dome to the forward
hub of the front frame.
(b) Turn the dome approximately 1/6 of a turn clockwise (facing the
front frame). Remove the dome.
(c) If bulletnose cannot apply several turns of cloth tape
be turned,
to circumferential that is adjacent to front frame.
surface of dome
(See figure 201A.) Place a flat band those type) clamp over the
taped area of the dome. (2 clamps may be jointed together to fit
the diameter.) Tighten clamp so that it does not slip.
(d) Depress the plunger that locks the dome to the forward hub of the
front frame. Tap the clamp, with a mallet, in a clockwise direc-
tion to loosen dome. Remove the dome. (After removal of
bulletnose, remove clamp and tape.)
72-30
1 Page 202 Dec 31/95
GENERAL ELECTRIC-------
CJ610 TLJR BOJ ET
SEI-186
MAINTENANCE MANUAL
PLUN~EP I C~ ji’
\i
c´•´•
Bulletnose Removal
Figure 201A
(7) Remove the sump cover as follows:
(a) Remove the 3 bolts that secure the sump cover (1. figure 201) to
the forward face of the front frame inner hub.
(b) Remove the sump cover. Remove the O-ring from the coverand dis-
card the 0-ring.
(c) Remove No. 1 bearing locknut retaining ring and remove the
the
locknut using spanner wrench 2C5359. Prevent the engine rotor from
turning by locking the gearbox with the gearbox locking adapter,
205360, as follows:
1 Remove the four locknuts, four washers and cover frtom the
axis gearbox aft pad.
"1" (Accessory drive gearbox for CJ610-
4, -6 and -8 engines; transfer gearbox for CJ610-1, -5 and -9
engines.
2 Install the gearbox locking adapter, 2C5360, onto the axis "B"
aft gearbox pad by engaging the axis "B" gearshaft female
spline with the tool male spline. Assemble the flat plate of
the tool against the gearbox pad face, with the four gearbox
pad studs protruding through the four holes in the tool.
72-30
IDec 31/95 Page 202A
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
NOTE: Alignment in the tool with the gearbox pad
of the holes
studs accomplished by positively engaging the
can be
spline teeth and slowly rotating the tool by hand until
alighnment is accomplished.
3 Press the tool firmly in place against the gearbox pad face,
install two washers and two nuts on two studs (diagonally
opposite). Use the fingers to run-on and tighten the nuts.
Do not torque; the nuts are used only to position the tool in
place to assure rotor locking.
NOTE: The use of plain nuts rather than locknuts is recom-
mended. Be certain that the nuts used have the same NF
threads as the studs to assure that thread damage does
not occur.
4 Check the compressor rotor for locking by carefully inserting
the hand past the front frame struts and attempting to rotate
the compressor. With the locking tool in place, rotor "play"
may be as much as one stage 1 blade platform width.
(d) Remove the bearing spacer.
(8) Remove the engine support ring as instructed in the Aircraft Maintenance
Manual, if necessary.
CAUTION: BOTH CASING HALVES MUST BE INSTALLED.
(9) If the front frame is being removed with the engine in a horizontal
position, support the forward end of the compressor rotor by inserting
shims between the first-stage blade tips and the compressor casing ID.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS AS-
BESTOS, WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY
TRACT. READ GENERAL INFORMATION BEFORE PROCEEDING, AND ADHERE
TO ALL SITE SAFETY AND ENVIRONMENTAL CONTROLS CONCERNING AS-
BESTOS. OTHERWISE, PERSONAL INJURY MAY RESULT.
(10) Screw the pilot guide 2C5326G1 and G2 (depending on type of No. 1 bear-
ing) into the compressor rotor forward shaft.
72-30
Page 202B Dec 31/95
GENERAL ELECTRIC-------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
(11) Disconnect the oil scavenge, vent, and supply lines at the 6, 2 and 10
o’clock positions on the front frame.
CAUTION: TO PREVENT DAMAGE TO THE NO. 1 CARBON SEAL, DO NOT ALLOW THE
FRONT FRAME TO BECOME "COCKED" DURING REMOVAL.
(12) Remove the bolts and nuts that secure the front frame to the compressor
casing. Carefully move the front frame forward, away from the compres-
sor casing, until it is free of the compressor rotor front shaft.
72-30
I Dec 31/95 Page 202C/202D
GENERAL ELECTRIC~----
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
B. Installation.
CAUTION: TO PREVENT DAMAGE TO THE NO. I CARBON SEAL, DO NOT ALLOW THE FRONT
FRAME TO BECOME "COCKED DURING INSTALLATION.
(1) Carefully install the front frame over the Pilot assembly 2C5326G1 or G2
(depending on type of No. 1 bearing) and the compressor rotor front
shaft until the frame seats on the compressor casing flange. Be sure
the No. 1 bearing outer race does not move axially forward off its seat.
(2) Rotate the frame into position so that the oil scavenge port is at the 6
o’clock position.
(3) Install the accessory gearbox mounting bracket as instructed in para-
graph 7.
NOTE: This step is to be omitted on theCJ610-4. -6 and -8 engines.
(4) Install the accessory gearbox as instructed in 72-64-0.
NOTE: This step is to be omitted on the CJ610-4, -6 and -8 engines.
(5) Connect the turnbuckle (bellcrank to actuating ring) as instructed in
75-31-0.
(6) Install the anti-icing valve as instructed in 75-11-0.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ
GENERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE
SAFETY AND ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE,
PERSONAL INJURY MAY RESULT.
(7) Connect the oil scavenge, vent, and oil supply lines at the 6, 2 and 10
o’clock positions on the front frame.
(8) Replace the remaining bolts and nuts at the front frame-compressor cas-
ing flange. Torque the nuts to 35-40 Ib-in.
(9) Remove the pilot guide from the compressor rotor forward shaft. Install
the spacer and No. 1 bearing Locknut per paragraph 3.G.
(10) Install the sump cover as follows:
(a) Lubricate the O-ring with a light coat of petrolatum, Specification
VV-P-236, or engine oil, and install it in the groove of the front
frame sump cover.
72-30
Dec 31/95 Page 203
GENERAL ELECTRIC-------
CJ610 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
(b) Install the sump cover (1, figure 201) into the bore of the front
frame. Secure the cover with 3 bolts. Torque the bolts to 6-10
Ib-in. and lockwire them.
NOTE: Insure that the sump cover is seated against the front frame
flange before securing with the 3 bolts. The sump cover is
seated if a 0.001 inch shim will not slip between the two
mating flanges. When installed properly, the sump cover
prevents the No. 1 bearing outer race from moving axially
forward.
(11) Install the bulletnose as follows:
(a) Clean frame and bulletnose contact areas with trichloroethylene.
(b) Apply sealant RTV 106 (G.E. Silicone Products Dept., Waterford,
N.Y.), equivalent,
or on the outer circumference of shoulder in 3
places 1/2-inch long, opposite the three flange lugs.
(c) Depress the locking plunger inward and insert the dome into the
front frame hub. Turn the dome counterclockwise until the plunger
engages the slot in the front frame.
(12) Install the engine support ring as instructed in the Aircraft Mainte-
nance Manual, if it was removed.
3. No. 1 Bearinn Removal/Installation.
A. Remove the front frame per paragraph 2.
B. Place front frame on bench, rear side down. Insert hand into frame bore and
check bearing outer race (3,
figure 201) for looseness. If bearing is loose,
use puller, 2C5313, to remove bearing from bore. If bearing is tight in
bore, turn frame over so that front side is down. Remove oil collector (4,
figure 201), shroud and seal (6) and carbon seal (7) by removing the bolts
that secure them to frame. Turn frame over so that rear side is down and
proceed to remove bearing outer race, using puller, 2C5313, as follows:
(1) Adjust the puller legs to obtain the maximum grip on the bearing outer
race and pull bearing approximately 0.250 inch forward.
(2) Reposition puller legs on tool to grip the outer aligning ring and re-
movebearing.
C. Remove the No. 1 bearing locknut retaining ring, bearing locknut, and bearing
spacer per paragraph 2. A. (7) steps (c) and (d).
72-30
I Page 204 Dec 31/95
GEIJERAL ~g
CJ610 TUReaJET
SEI-186 MAINTENANCE MANI~AL
D. Use puller, 2C5311, and remove the No. 1 bearing inner race and seal runner
from the compressor rotor front shaft.
NOTE: The seal runner must be removed as it has the puller grooves.
I CAUTION: BEFORE INSTALLATION,
BEARING IS FLUSH TO
BE
0.005
SURE TI~AT ANTIROTATION PIN OF NO.
INCH BELOW SURFACE AT OD.
1
E. Place the front frame on the bench, front side up. Lubricate the bore
lightly with engine oil. Using pusher, %C5312, if necessary, to seat the
No. 1 bearing outer race and rollers in the bore. Be sure the pin in the
bore nests in the groove of the bearing outer race.
NOTE: Be sure the No. 1 bearing oil slinger is in place on the compressor
rotor front shaft before doing the next step.
F. Heat both the No. 1 bearing inner race and the seal runner in an oven at
121"C (2500F) for 20 minutes; then seat them on the compressor rotor front
shaft (after lubricating lightly with engine oil) with pusher, 2C5310.
Check to be sure they are seated after the parts return to normal tempera-
ture.
G. Screw the pilot guide 2C5326G1 or G2 (deFending on type of No. 1 bearing)
into the compressor rotor forward shaft and install the front frame per
paragraph 2.B.
(1) Install No. 1 bearing locknut. Prevent the engine rotor from turning
by locking the gearbox using gearbox locking adapter, 2C5360, per
paragraph 2.A. (7) (c) steps 1 thru 6.
(2) Observe the clock positions of the two notches in the forward edge of
the compressor rotor shaft. Using a colored marking pencil (grease
or felt tip), mark the corresponding notch locations on the sump cover
mounting flange of the front frame. These marks will facilitate loca-
tion of the shaft notches during assembly of the locking nut and
installation of the retaining ring. (Notches are not visible after
installation of the locking nut.)
(3) Assemble the spacer onto the exposed end of the compressor rotor shaft.
Seat the spacer firmly against the No. 1 bearing inner race.
NOTE: The spacer must extend beyond end of compressor rotor shaft
when seated against the No. 1 bearing inner race.
Mar 30/84 72-30
Page 204A
E~rctlle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(4) Using engine oil, lubricate the threads and the surface of the nut that
contacts the compressor rotor shaft threads and the spacer, respective-
ly. Assemble the nut into the exposed end of the compressor rotor shaft.
(5) Insert the
spanner wrench, 2C5359, lugs into the holes on the forward
side of the nut. Using a standard torque wrench, torque the nut to
450 Ib-in. to seat the parts on the compressor rotor shaft.
(6) Back-off the nut to free running torque. Torque the nut to 150 Ib-in.
and remove the torque wrench and spanner wrench.
(7) Using the marks on the sump cover mounting flange (see step (2)) as
references, locate a radial hole on the ID of the nut that aligns with
either of the notches in the compressor rotor shaft.
NOTE: A short piece of drill rod, or equivalent, that has been flat-
tened on the end to be similar to the tang on the retaining ring,
will facilitate determining an aligned radial/hole shaft notch
condition.
(8) Observe the following conditions:
(a) If alignment has occurred, proceed to the following step (9).
(b) If alignment has not occurred, advance the nut in the tightening
direction by torquing until alignment is accomplished, then pro-
ceed to step (9). DO NOT exceed 450 Ib-in. of torque.
(c) If alignment DOES NOT occur at 450 Ib-in. of torque, remove the
nut. Using a new nut, perform steps (4) through (7).
9) After establishing radial hole/shaft notch alignment, assemble the
retaining ring.
CAUTION: ASSURE THAT THE RETAINING RING IS PROPERLY SEATED INTO THE
NUT AND WILL NOT "POP OUT"
(10) Remove marks made on the sump cover mounting flange in step (2). Do not
use abrasive material or action that will damage or otherwise remove
material from the mounting flange.
I (11) Remove
"B" pad
the
cover
gearbox locking adapter and reinstall the gearbox axis
using a new gasket. Torque the nuts to 120-150 Ib-in.
72-30 sept 1/76
Page 204B
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
4. No. 1 Bearine Carbon Seal Removal/Installation.
A. Removal.
(1) Remove the front frame as instructed in paragraph 2.
(2) Place the frame on a bench, front side down.
(3) Remove the oil collector (4, figure 201), shroud and seal (6, figure
203) and carbon seal (7, figure 201) by removing the bolts that secure
them to the frame. Discard the oil collector, gasket, andcarbon seal
preformed packing (O-ring).
B. Installation.
NOTE: Whenever the shroud and seal (6, figure 201) is exposed, check that
each bolt (9) is a 12-point head with letter A marked on head. Replace
only those bolts that are not 12-point head with latest part number.
(1) Install a new carbon seal and preformed packing (O-ring) on frame inner
hub.
(2) Install the shroud and seal to the frame.
(3) Install a new gasket and the oil collector to rear of shroud and seal
and install on the frame.
(4) Secure the oil collector, shroud and seal, and carbon seal with bolts.
Torque the bolts to 20-24 Ib in. and lock-wire.
(5) Install the front frame as instructed in paragraph 2.
5. Compressor UDDer Casing Removal/Installation
A. Removal. (May be done with engine in vertical or horizontal position.)
(1) Remove the ignition exciter as instructed in 80-21-0.
(2) Remove the right-hand variable geometry actuator as instructed in
75-31-0.
(3) Remove both bleed valves as instructed in 75-32-0.
(4) Remove the anti-icing valve as instructed in 75-11-0 and anti-icing air
tube as instructed in 75-12-0.
(5) Disconnect the upper half of the synchronizing cable at the left-hand
variable geometry actuator by removing the cotter pin, washer, and
clevis pin. The cable was disconnected on the right-hand side when the
right-hand actuator was removed.
72-30
Dec 31/95 Page 205
GINERAL~ELL CfRIC
CJ610 TURBOJET
MAINTENANCE ~IANLTAL SEI-186
(6) Remove the upper half of the compressor casing (upper casing) as
follows:
CAUTION: DO HOT REMOVE THE COMPRESSOR CASING UPPER HALF IF THE FRONT
FRAME HAS BEEN REMOVED AND THE ENGINE IS IN A HORIZONTAL
POSITION.
(a) Holding the boltheads, remove the locknuts and washers from the
body-bound bolts (first, fifth, and eleventh bolts from the front
flange) in both horizontal flanges. Remove the body-bound bolts,
using a platic or brass pin to drive the bol.ts out of the holes.
CAUTION: DO NOT ALLOW BODY-BOUND BOLTS TO TURN WHEN REMOVING THE
NUTTS. ALSO, DO NOT TURN THE BOLTS TO AID BOLT
REMOVAL. TURNING OF THE BODY-BOUND BOLTS WILL ENLARGE
THE HOLES, AND TfFE OF THE COMPRESSOR CASING
WITH THE COMPRESSOR ROTOR WILL BE AFFECTED.
(b) Remove the remaining bolts and locknuts from the horizontal
flanges.
(c) Remove the bolts from the front and rear flanges of the
compressor upper casing. Note the location of all brackets and
supports that are attached to the flanges.
(d) Remove the compressor upper casing upper-half (3, figure 202) by
pulling it radially away from the engine. Remove 2 locking vane
keys (1, figure 202).
B. Installation.
NOTE: Whenever stater have been
removed, be sure that holes in
I
sectors
stages 3, 4, and 5 sectors aligned with the bleed holes in
are
the bleed manifold. Sectors are aligned krhen gage 205501 fits
into both holes with sectors positioned against retainer key at
the splitline flange. properly assembled, at least one hole
in each bleed port must be aligned.
(1) Place the vane locking keys (1, figure 202) in the slots of the
compressor casing horizontal flanges. The keys must seat on the
slots so that they are either flush or below the mating surfaces of
the horizontal flanges. The endsof the stater sectors (stages 1 and
2) and vane segments (stages 3 through 7) must be either flush or
below the flange faces.
(2) Install the compressor casing upper half (upper casing) (3, figure
202). Be careful not to damage the blades or vanes.
72-30 Dec 31/91
Page 206
GENERAL ELECTRIC-------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
CAVTT_ON: THE HORIZONTAL FLANGE BOLT TORQUING SEQUENCE HAS A DEFINITE EFFECT
ON COMPRESSOR CASING RUNOUTS. TIGHTEN OR TORQUE THESE BOLTS AND
NUTS ONLY IN THE SPECIFIED ORDER.
(3) Bolt casing halves together tighten nuts in the sequence of 5.
and i,
11, 6, 4, 7, 3, 8, 2, 10, and 9.Torque nuts 1-7 to 44-48 Ib in, and
nuts 8-11 to 70-80 Ib in. Inspect the following:
Maximum Maximum
Inspect Serviceable Limits Repairable Limits Corrective Action
(a) The rear Reference No. 3. 16.972 maximum Repair per para-
rabbet ID diameter. graph 7.
diameter X
(average
measurement of
eight loca-
tions).
(b) Local With flanges Any amount. Cold-work flanges
distortion. bolted together, within maximum
a 0.001 inch wide serviceable lim-
shim cannot be its. Fluorescent-
inserted anywhere penetrant inspect
along the outside area for cracks.
or inside of the None allowed.
flange.
(4) Install the body-bound bolts, nuts, and washers in both horizontal
flanges in the first, fifth, and eleventh holes from the front flange.
CAUTION: DRIVE THE BODY-BOUND BOLTS STRAIGHT THROUGH AT INSTALLATION. DO
NOT TURN THEM. TURNING THE BOLTS MAY ENLARGE THE BOLTHOLES AND
ADVERSELY AFFECT ALIGNMENT OF THE CASING.
(5) Install the synchronizing cable supports and the remaining bolts, nuts,
and washers in the horizontal flanges. Torque the first seven nuts to
44-48 Ib in. Torque the last four nuts to 70-80 Ib in.
72-30
Dec 31/95 Page 206A/206B
GEIERAL~ tLteTIIC
CJ610 TORBOJET
SEI-186 MAINTENANCE MANUAL
C
i. VANE KEYS
2. STATOR LOWER HALF
3. STATOR UPPER HALF
4. VERTICALSUPPORT
1
CJ610-6013DCf
Compressor Stater Upper Half Removal
Figure 202
Dec 1/77 72-30
Page 207
CJBIOTURBOJET
GEAircr;7ftEn~aines MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-479
Filing
Instr~-uctions: Put this Temporary Revision (TR) in the CJ610
MAINTENANCE MANUAL SEI-186, adjacent to page 208, dated Dec
30/78 in Chapter 72-30.
Record this TR number in the Record of Temporary Revisions.
Subject: Removal and Installation of Stage 1 Blades.
Reason: This provides instructions for removing and installing
TR
stage 1 blade retaining rings, for CJ610-6 engines modified
to the spool rotor configuration, SE C572-148.
Change i: Revise paragraph 6.A. (3) (a).
FOR ALL ENGINES INCLUDING CJ610-6 NOT MODIFIED TO SPOOL
I ROTOR CONFIGURATION SE C572-148.
(a) Remove the pin retaining ring, using a sharpened
screwdriver. Use care so as not to damage air seal
serrations. Remove the pin that secures the blade to the
disc.
FOR CJ610-6 ENGINES MODIFIED TO SPOOL ROTOR CONFIGURATION,
SE CJ72-148
(a) Remove the pin retaining ring using tool 21C6302P07.
Discard the retaining ring. Remove the pin.
FOR ALL
FAA APPROVED OCTOBER 10, 2000
72-30
Page 1 of 2
Oct. 10/2000
CJG1OTURBOJET
MAINTENANCE MANUAL
SEI-1 86
TEMPORARY REVISION 72-479(contjnued)
Change 2: Revise paragraph 6.A. (3)(b).
(b) Mark the blade for location on the disc (or forward
spool if modified C572-148); then
to SE remove the blade
land balancing washer if installed).
Change 3: Revise paragraph 6.B. (1) and (2)
(1) the blade (or its moment-weighted equivalent)
Assemble
to the (or forward spool if modified by SE C572-148,
disc
with the balancing washer, if applicable) in the location
for which the blade was marked at removal. Secure the blade
to the disc (or spool) With the pin. (The head of the pin
is on the forward side of the disc or flange of spool.)
I FOR ALL ENGINES
ROTOR CONFIGURATION
INCLUDING CJ610-6 NOT MODIFIED
SE C572-148.
TO SPOOL
(2) Assemble the retaining ring to the pin using tool
21C5319. -Be sure the retaining ring is seated properly in
the pin groove.
FOR CJ610-6 ENGINES MODIFIED TO SPOOL ROTOR CONFIGURATION
SE C572-148 A
(2) Using new retaining ring, assemble it to the pin using
tool 21C6302G01. Be sure theretaining ring is seated
properly in the pin groove by using the retaining ring
gage 21C6309G01.
FOR ALL
72-30
Page 2 of 2
Oct. 10/2000
GtlERAL~ ELECIRIC
CJ810 TURBBJET
MAINTENANCE MANUAL SEI-186
(5) Install the vertical flange bolt and any brackets or supports. Torque
the front flange bolts to 35-40 Ib-in. and the rear flange bolts to
44-48 Ib-in. Use a 0.001 inch thick by 0.200 inch wide piece of shim
stock to check the gap between the mating surfaces of the horizontal
flanges, The shim shall not enter more than 0.100 inch anywhere
along the inside or the outside of the flange,
(6) Install the anti-icing valve and tube as instructed in 75-11-0 and
75-12-0,
(7) Install both bleed valve as instructed in 75-32-0.
(8) Install the right hand actuator as instructed in 75-31-0,
(9) Install the ignition exciter as instructed in 80-21-0,
(10) Connect the synchronizing cadre to the left-hand actuator using the
pin, washer and cotterpin.
(11) Adjust the variable geometry system as instructed in 75-00, Maintenance
Practices.
6. First-Stage Rotor Blade Removal/Installation.
A, Removal.
(1) Remove the front frame as instructed in paragraph 2.
(2) Remove the compressor casing upper-half as instructed in paragraph 5.
(3) Remove any number of first-stage compressor rotor blades tall of them
if required) as follows:
CAUTION: THE COMPRESSOR ROTOR IS DYNAMICALLY-BALANCED TO A CLOSE TOLER-
ANCE WHICH MUST BE MAINTAINED. TO PREVENT DISTURBANCE OF THIS
BALANCE CONDITION, ALWAYS IDENTIFY EACH BLADE (WHEN IT IS RE-
MOVED) AND PIN HOLE WITH THE CORRECT MOMENT WEIGHT OF THE BLADE
TO ENSURE THAT A REPLACEMENT BLADE OF EQUAL MOPIENT WEIGHT IS
USED. ALSO IF BALANCING WASHERS ARE USED, BE SURE THE WASHER
IS IDENTIFIED WITH ITS PIN HO;LE.
(a) Remove the pin retainer, using a sharpened screwdriver. Use care so
as not to damage air seal serrations. Remove the pin that secures
the blade to the disc.
NOTE: Please see the i i_
TEMPORARY
REVISION
7 2- 30 that revises this page.
1
Page 208
Dec 30/78
GDNERAL ~g f LT CIR It
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(b) Mark the blade for location on the disc; then remove the blade land
balancing washer if installed).
B. Installation.
NOTE: The preferred method of blade replacement is with equal moment
weight blades. However, replacement by pan weight in grams is
acceptable provided the replacement blade is within t0.1 gram
of the removed blade. The removed blade must have all of the
original material remaining for an accurate pan weight. Blend-
ing of the blade being installed to provide equal pan weight is
j not permitted.
(1) Assemble the blade (or its moment-weighted equivalent) to the dise
(with the balancing washer, if applicable) in the location for which
the blade was marked at removal. Secure the blade to the dise with the
pin. (The head of the pin is on the forward side of the disc.)
(2) Assemble the retaining ring to the pin using tool. 21C5319. Be sure
the retaining ring is seated properly in the pin groove.
(3) Install the compressor casing upper-half as instructed in paragraph 5.
(4) Install the front frame as instructed in paragraph 2.
s 7. Accessory Gearbox Bracket Removal/Installation (CJ610-1, -5 and -9 engines.)
A. Removal.
(1) Remove the accessory gearbox as instructed in 72-64-0.
(2) Remove the bolts and nuts that secure the accessory gearbox mounting
bracket to the front frame and compressor casing flanges.
(3) Remove the bracket and shims.
t
Dec 30/78 72-30
Page 208A/208B
BEWERAL ELECTRIC
CJ810 TURBOJET
881-186 MAINTENANCE MANUAL
B. Instalo~ation.
(1) Position the gearbox bracket onto the rear side of the front flange
of the front frame at the 6 o’clock position.
(2) Secure with 2 bolts at holes 22 and 28 of the front flange of the
front frame.
NOTE: Bolt holes are numbered in a clockwise direction, starting at
12 o’clock; aft looking forward.
(3) Install alignment fixture, 2C5323, onto the engine at the trans-
the
fer gearbox adapter, with the large locating plug inserted into the
bore of the transfer gearbox adapter.
CAUTION: THE DOWEL PIN ON THE ADAPTER WILL FIT INTO THE BUSHING OF
THE FIXTURE. USE EXTREME CARE WHEN INSERTING THE LOCATING
PLUG TO PREVENT FORCING OR BENDING THE DOWEL PIN.
(4) Loosen the handknob on the fixture and locate the 2 pin locators of
the cross into the gearbox bracket; install 2 shoulder bolts with
the heads of the bolts on the side of the fixture.
(5) Install the 4 bolts (1/4-28) into the transfer gearbox adapter and
torque to 60-90 Ib-in.; tighten the bolts on the cross pad.
(6) Tighten bolts securing bracket front flange and tighten handknob.
Loosen the bolts and tighten again.
(7) Check the gap between the bracket and the rear side of the compres-
sor casing front flange; add shims at each set of 2 holes to main-
tain a gap of 0.000-0.004 inch.
(8) Removethe alignment fixture to provide access for installing shims.
(9) Install shims and all bolts and nuts in bracket rear flange. Do not
tighten.
(10) Reinstall alignment fixture per steps (3) through (6).
(11) Torque the bolts in the bracket rear flange to 35-40 Ib-in; in
bracket front flange to 24-27 Ib-in.
(12) Remove alignment fixture.
(13) Install the accessory gearbox as instructed in 72-64-0 and’the
transfer gearbox as instructed in 72-62-0.
May 15/70 72-:
Page 2C
gAeE to 9
OtWIAAL LLECIIIC
CJB10 TUF1BOJeT
MAINTENANCE MANUAL SEI-186
8. Accessory Gearbox Rracket Removal/Installation. (CJ610-4, -6 and -8 engines.)
A. Removal. (See figure203.)
VERTICAL CENTERLINE
I
P
1 I i
0.166-0.170
P:~J je 2
-i
Io
II
0.166-0.170 IN. I ~c---- 15
i. MAINFRAME 9. AXIS "A" COUNTERBbRE
2. GEARBOX BRACKET 10. CLAMPING DOG
3. FORWARD FLANGE Il. SMALL HANDKNOB
4. AFT FLANGE 12. CENTER PLUG
5. SHIM 13. CLAMPING SCREW
6. BOLT 14. BACKUP WEDGE
7. BOLT 15. LARGE HANDKNOB
8. GEARBOX MOUNT 16. SHIM C16 1040114´• 41
Gearbox Bracket Assembly (CJ610-4, -6 and -8)
Figure 203
72-30
Dec 30/78
Page 210
ELltllAL~ ELf
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(1) Remove the accessory gearbox as instructed In 72-64-0.
(2) Remove the bolts (6, 7) that secure the accessory gearbox mounting
bracket (2) to the mainframe flanges (3, 4).
(3’3 Remove the bracket and shims (5).
NOTE: The shims are an "as required" item and may not have been
used.
B. Installation. (See figure 203.)
(1) Install the accessory gearbox brackets (2) to the mainframe flanges
(3, 4).
(2) Position the left-hand and right-hand gearbox brackets ~2) between
the flanges (3, 4) of the mainframe
forward and aft so that the
gearbox mounting surface, formed by the two gearbox brackets is per-
pendicular to the engine vertical centerline.
(3) Hold the forward flange of the gearbox brackets firmly against the
forward flange (3) of the mainframe. Use a feeler gage to check the
gaps between the gearbox brackets and the aft flange (4) of the
mainframe. If the gap is greater than 0.004 inch, install a shim
(5) of the required thickness to reduce the gap to 0.000 to 0.004
inch.
(4) Secure each gearbox bracket to the mainframe with 4 bolts (6) in the
forward flange (3) and 3 bolts (7) in the aft flange (4).
NOTE: Only partially tighten bolts (6, 7) so that the gearbox
brackets (2) are free to move for final alingment.
(5) Use fixture 2C5353 and proceed as follows, if original brackets are
being assembled.
(a) Back off the small handknobs (11) and turn the 2 clamping dogs
(10) in towards each other to permit the center plug (12) to
enter the axis A bore.
(b) Carefully insert the center plug (12) into the axis A bore and
the two diamond-shaped pin locators and the two clamping screws
(13) into the four gearbox mounting holes in the gearbox
brackets.
NOTE: Be sure the shoulder plug (12), the axis A
on the center
counterbore (9) and the gearbox bracket mating surfaces
are clean and free burrs and high metal.
72-30
Mar. 30/67
Page 211
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
(c) Install backup wedges (14) on the two clamping screws (13) to se-
cure the fixture to the gearbox brackets (2). Do not tighten the
large handknobs (15) at this time. Leave about 0.060 inch end play
in the clamping screws.
(d) Turn the feet of the two clamping dogs (10) away from each other
until they enter the slots in the center plug (12).
(e) Tighten the two small handknobs (11) until the shoulder on the
center plug seats against the axis A counterbore (9).
(f) Tighten the two large handknobs (15) to pull the gearbox brackets
(2) snugly against the mating surface on the fixture. The 0.166-
0.170 inch dimension is now established.
(g) Torque bolts (6. 7) to 44-48 Ib-in. and remove fixture.
(6) Use fixture, 205353 and proceed as follows if other than original brack-
ets are being assembled.
(a) Perform steps (5) (a). (b). (d) and (e). If the fixture bottoms on
the gearbox brackets before the cetner plug (12) bottoms on the
counterbore (9) the brackets are too long and must be replaced or
machined in accordance with Overhaul Manual instruction. If a gap
exists between fixture and brackets aftercetner plug bottoms pro-
ceed with the next steps.
(b) Do not tighten the large handknobs (15). but move the brackets out
as far as they will go.
(c) Measure the gap between the fixture and gearbox brackets to deter-
mine amount of shims (16) that are required.
(d) Remove fixture and assemble shims (16). Repeat all steps of (5)
Keep shim with gearbox bracket and use when gearbox is assembled to
engine.
72-30
I Page 212 Dec 31/95
GENERAL g~ ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
9. Scavenge Tubes Removal/Installation.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Remove bolts that secure scavenge tubes to the mainframe.
(2) Remove scavenge tubes by pulling radially from the mainframe.
(3) Discard O-rings, backup rings and gaskets.
B. Installation.
(1) Lubricate O-rings and backup rings with engine oil. Install the backup
rings on the tubes first, then install the O-rings. Install gasket on
the scavenge tubes with raised side toward mainframe pad.
(2) Assemble the scavenge lube tube to the mainframeat the 8 o’clock posi-
tion and the scavenge air tube at the 4 o’clock position. Push in
firmly to seat.
(3) Secure the tubes with bolts lubricated with EaseOff 990 (Texacone Co.,
Box 4236. Dallas, Texas) or G-392 Versilube (G.E. Products Co.,
Waterford, N.Y.). Torque bolts to 10-12 Ib-in. and lockwire in 2 groups
of 2.
72-30
Dec 31/95 Page 212A/212B
GENERAL ELECTRIC--´•----
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
10. Installation of Air Pad Covers or Airframer Fittinas.
A. Air pad covers or airframer fittings should be secured to mainframe with
bolts lubricated with EaseOff 990 Texacone Co., Box 4236, Dallas, Texas) or
G-392 Versilube (G.E. Products Co., Waterofrd, N.Y.).
Il. Stater Sector Removal/Replacement
A. Removal. (Compressor casing upper half must be removed from engine per para-
graph 5.)
NOTE: Stater sectors are normally identified as to their position in the
stage in the numerical order at the time of original installation.
This order is 1 through 12 inclusive, in the clockwise direction start-
ing at the right horizontal (split-line) flange, aft looking forward.
During removal of sectors, check the outer support of each sector as it
is removed verify the numerical order.
to If the sector is not marked,
or the marking is illegible, identify and mark the sector by vibro-peen
or electro-chemical etch 0.003 inches deep on the sector outer support
being careful not to touch the brazed joints in any of the sectors and
the bleed holes in the third, fourth and fifth stage sectors.
(1) Position the upper casing half in support 2C5371.
NOTE: Removal of sectors from lower casing half may be accomplished with
casing in place on engine, and upper casing half removed.
(2) Remove stage 1 and stage 2 sector assemblies using pusher 2C5371. If
sector assemblies are difficult to remove, penetrating oil may be used
along hte lands and grooves of the casing.
(3) Remove stages 3 through 7 sector stops and sectors using pusher 2C5371.
Use penetrating oil on vane sector grooves, if necessary, to facilitate
removal of sectors.
72-30
IDeF 31/95 Page 213
CflEIAL ~DB rrocriis
CJ610 TURB03ET
MAINTENANCE MANUAL 681-186
NOTE: The sector stop is the vane sector that is located at the
9 o’clock position on each stage of the lowerhalf compressor
casing and the 3 o’clock position on each stage of the upper
half.
B. Replacement. (On CJ610-1 and -4 engines, any number of sectors per
stage may be replaced with preground sectors. On 0J610-5, -6, -8 and -9
engines, replacement of stater sectors, with preground sectors, is
limited to 50 percent per stage.)
(1) Using applicator tool 205442, lubricate the stater sector grooves
with General Electric Grease, 0-392, or equivalent.
(2) Assemble the stage 1 and stage 2 sector assemblies into the casing.
(3) Assemble the sector stops and sectors, stages 3 through 7, into the
casing, using pusher, 205371.
CA~ION: ll4EE CERTAIN THE VANE SECTORS IN EACH STAGE, 3 THROUGH 7,
ARE PROPERLY POSITIONED. IT IS POSSIBLE TO ASSEMBLIS~ THESE
SECTORS IN REVERSE ORDER SINCE THE SECTOR SUPPORTS ARE
SYMMETRICAL.
(4) Assemble the key st the horizontal flange.
1 72-30 Nov. 15/72
Page 214
GEWERAL~B ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
FRONT FRAME ASSEMBLY MAINTENANCE PRACTICES
th.ose items
i. General, Maintenance of the front frame assembly is limited~to
that are accessible. Refer to 72-30 for part identification/location.
I
2. Inspection/Check. Where serviceable limits are exceeded, parts may be re-
paired in accordance with Overhaul Manual instructions.
Maximum Serviceable Limits Remarks
Inspection/Check
A. Visually inspect the front frame (with the frame assembled to engine) as
follows:
(1) Cracks (see figure
201).
(a) In "U" section One crack per strut, 1-1/2
at rear of inches long, provided adja-
strut. cent struts are not cracked.
(b) All other areas. Not serviceable.
(2) Nicks and scratches
(see figure 201).
(a) Struts. One per strut, 0.010 inch
deep, 2 inches long; or
any n~rmber up to 2 inches
cumulative length, 1/2
inch from doublers.
(b) All other. Any n~nnber 0.010 inch deep.
areas.
(3) Dents (see figure
201),
(a) Inner and Any number 1/8 inch deep.
outer casings.
(b) Struts. Any number 1/16 inch deep.
(c) Anti-icing Any number, provided cross
manifold. section area is not re-
duced more than 25 percent
and no sharp edges or bends
are present.
(4) Missing paint. Any amount.
Dec 31/91 72-31-0
Page 201
GERERIL O ELEGTRIE
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
3 a MAXIMUM ENGAGEMENT
MINIMUM ENGAGEMENT
I
4
1
0.065 MINIMUM
BULLETNOSE PLUNGER ENGAGEMENT
0.050 MAXIMUM
13 FITT1NGS
2. DRAIN
3. ANTI-ICING MANIFOLD
:s 7
4.
5.
6.
AFTFLANGE
FORWARD FLANGE
OUTER CASING
BOSSES
11 s. DOUBLER
10
9. STRUT
10. INNER CASING
3 11. STIFFENER
12. BEARING HOUSING
13. BULLETNOSE RING
V)EW 1N DIRECTION OF ARROWA C)610d017-)-EZ
Front Frame Inspection Limits
Figure 201
NO NUBELON F1NISH
ON THESE SURFACES.
SECTION a-A
0.08150.07350.075 0.060
1. BULLETNOSE (PARABOLIC DOME)
-r
DIA.
4. SPRING
8 5. S~EEVE
6. NUT
0.025
CHAM.
0.015
4.025
mnm 0.015 4.015
DIA.
R
0.005 clslo~ole-,-el
Bulletnose Inspection Limits
Figure 202
72-31-0 Sept. 1S/69
Page 202
Olrfl~C´• tLIC’IIIC
CJ610 TU~LIOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(5) Fittings for thread One full thread, continuous
damage (see figure or cumulative may be mis-
201). sing after chasing.
(6) Bulletnose Plunger Not to exceed 0.050 inch install new plunger in
height above frame above inner casing; mini- bulletnose. It must not
inner casing (see mum plunger engagement exceed more than 0.040
figure 201). be 0.065 inch. inch above inner casing.
(7) Missing Any
.gnitaoc21A amount.
B. Visually inspect the front frame as follows: (Frame removed from engine.)
(1) Rear flange ID for Up to 0.003 inch deep;
rotor blade rub. 15 inches in length;
from 0.003 inch to 0.007
inch deep; 6 inches in
length; from 0.007 to
0.010 inch deep; 4
inches in length, after
removal of all high
metal.
(2) Bearing housing Not serviceable.
stiffness for
cracks or dents.
(3) Bearing housing
for:
(a) Cracks. Not serviceable.
(b) Damaged threads. 25 percent of threads
may be missing after
chasing.
Dec 1/77 72-31-0
Page 203
CJ610 TURBOJeV
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
C, Visually inspect the bulletnose for: (See figure 202.)
NOTE: Bulletnose should be removed from engipe for inspection. Bulletnose
to be removed for inspection only wnen~ it is excessively loose,
(1) Cracks in:
(a) Outer shell. 3 cracks, 1/2 inch long, Stop-drill both ends of
cracks.
(b) Inner shell. Not serviceable.
(c) Ring. Not serviceable.
(d) Retainer sup- Not serviceable.
port.
(2) Braze defects. Cumulative length not to
exceed 20 percent of
braze area.
(3) Dents.
(a) Nose area One dent, 1/8 inch deep,
(first 1/2 5/8 inch in diameter.
inch).
(b) All other Four dents, 1/8 inch
areas. deep, 5/8 inch in
diameter.
(4) Retaining ring wear
on:
(a) OD (Dia. F, 4.272 inches minimum.
figure 202), (Average of 6 equally
spaced readings.)
(b) Front face 0.236 inch maximum.
(Dim, A, figure
202.) (If
noted visually).
(5) Missing paint. Any amount.
I (6) Missing
.gnitaoc21A Any amount.
72-31-0 Dec 1/77
Page 204
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
D. Visually inspect the variable vanes for:
(1) Cracks. Not serviceable.
(2) Bends. 1/32 inch from original
contour.
(3) Nicks, scratches Any number, 0.010 inch deep.
and pit.S.
(4) Dents. Any number, 0.020 inch
deep; 5 per vane 0.060
inch deep.
(5) Missing paint. Any amount.
(6) Missing A12 coat- Any amount.
ing.
(7) Radial Inlet guide vane (IGV) Replace IGV. Send vane to
movement. shall not move more than an approved GE Aircraft
0.020 inch maximum. Engines overhaul facility
for repair.
E. The actuator ring for:
(1) Cracks. Not serviceable.
(2) Scratches nicks
or chafing.
(a) Rear band of Any number, 0.020 inch
ring (with 1/4 deep up to 1 inch long
inch x 1/2 after removal of all high
inch through metal.
slots)
(b) Remainder of Any number, 0.010 inch
ring, deep after removal of
all high metal.
(3) Ring pivot pin 0.099 inch maximum
holes for wear, if diameter.
noted visually.
(4) Lug pinholes. 0.130 inch maximum
diameter.
(5) Braze joint defect. Any number up to 0.030
inch long and not
closer together than
0.120 inch.
72-31-0
Dec 31/95 ?age 205
6 E I E I ~L E LE CTI IC
CJ610 TURSOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
F. The actuator levers for:
(1) Cracks, dents,
Or bends, Not serviceable. Replace lever.
(2) Ball for:
(a) Movement. Ball shall move freely with Replace lever.
not more than 0.002 inch
radial movement. Bearing
assembly must be tight in
lever but the torque to move
ball not to exceed 4 inch-
ounces.
(b) Wear in I.D. 0,097 inch maximum diameter. Replace lever.
(3) Wear in square hole. No looseness allowed between Replace lever.
lever and variable vane.
(4) Nicks and scratches. Any number after removal of
all high metal.
G. The locking clips for:
(1) Cracks or distortion. Not serviceable. Replace clip.
(2) Spring characteristic. Clip surfaces must meet when Replace clip.
removed from actuator ring.
(3) Nicks and scratches. Any number after removal of
all high metal.
72-31-0 Nov. 15/73
Page 206
GEIEIAL~ ELICIIIC
CJ610 TURBOJtT
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
H. The pivot pins for:
(1) Cracks, bends or Not serviceable. Replace pin.
distortion.
(2) Wear if noted 0.0922 inch minimum. Replace pin.
visually.
(3) Nicks and Any number after removal
scratches. of all high metal.
I. Gearbox mounting bracket for:
(1) Cracks. Not serviceable.
(2) Cracked or missing Not serviceable. Touch-up per 72-02-5.
Solaramic coating.
(3) All areas for Not serviceable if base Any amount up to 1 square
missing A12 metal is exposed. inch may be touched-up
coating. per 72-02-6. Return
bracket to Overhaul
Facility for stripping
and recoating if any
amount exceeds 1 square
inch.
J. No. 1 bearing for:
NOTE: Remove the bulletnose and sump cover as instructed in 72-30,
Maintenance Practices, paragraph 2.
(1) Missing rollers or Not serviceable. Replace bearing.
tangs.
(2) Discoloration Not serviceable. Replace bearing.
(evidence of over
heating).
K. Sump cover for:
(1) Cracks. Not serviceable.
(2) Nicks and dents. Any number after removal
of high metal.
Dec 1/77 72-31-0
Page 207
eEnEIAl~ ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
L. Shroiid and senl for:
(I) Cracks. Not serviceable. Replace shroud and seal.
(2) Nicks and dents. Any number up to 1/16 Replace shroud and seal
inch deep after removal if depth exceeds 1/16
of high metal. inch.
(3) Missing paint. Any amount.
(4) Missing A12 Any amount.
coating.
72-31-0 Dec 1/77
Page 208
G f R E:R 14 L ~B E LE CI R IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
COMPRESSOR STATOR CASING ASSEMBLY MAINTENANCE PRACTICES
i. General. Maintenance of the compressor stater assembly is limited to those
items that are accessible.
1A. Preparation for Inspection. Prior to inspection, it is acceptable to prepare
the stater sector vane leading and trailing edges by hand using a fine stone
or 600-grit wet or dry abrasive paper or equivalent. Time used to prepare
each leading or trailing edge shall not exceed 2 minutes. No localized pre-
paration is allowed.
2. Inspection/Check. Where serviceable limits are exceeded, parts may be repaired
in accordance with Overhaul Manual Instructions.
Inspection/Check Maximum Serviceable Limits Remarks
A. Visually inspect the compressor casings as follows: (See figure 201.)
(1) Cracks.
(a) In welds be- 2 per Ilange, 1/8 inch
tween casing long spaced 2 inches
and flanges. apart.
(b) All other Not serviceable.
areas.
(2) Nicks and scratches.
(a) Casing body and An~ nu~ber 0.015 inch deep.
air manifold.
(b) Casing flanges. Any number 0.020 inch deep.
(3) Dents.
(a) Casing. Any number 0.020 inch deep.
(b) Air manifold. Any number 0.040 inch deep.
(4) Cracked missing
or Not serviceable. Touch-up per
Solaramic coating. 72-02-5.
(5) Casings coated with
TSM-3 for missing
coating on:
Mar 30/84 72-32-0
Page 201
GEWtRAL 6 LC CIR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
I. FORWARD FLANGE
i. C*SINO
3. BLEED VALVE MOUNTING FLANGE
4. HORIZONTAL FLANGE
5. AIR MANIFOLD
6. REAR FLANGE
2 5 CJ(IWO)I´•O-D1
Compressor Casing Inspection
Figure 201
Inspection/Check Maximum Serviceable Limits R~marks
(a) External Not serviceable. Cumulative area
surfaces. not to exceed 2
square inches.
Touch-up per
72-02-7.
(b) Blade path Any amount.
lands.
(6) Flanges (1,4,6) With flanges bolted together, Cold-work flanges
for local a 0.001 inch thick by 0.200 within max. service-
distortion, inch wide shim shall not be able~ limits. Fluo-
able to be inserted more rescent penetrant-
than 0.100 inch anywhere inspect area for
along the outside or cracks. None
inside of the flange. allowed.
72-32-0 Mar 30/84
Page 202
CEIEIAL~ tLECTlle
CJ610 TURIOJET
SEI-186 MAINTENANCE MANUAL
3. Inspection of Stater Sector Vanes for Pits (Corrosion). (See figure 202.)
NOTE: The eighth-stage and exit guide vane are included in this inspection.
A. Vanes with the following defects in the airfoil are to be scrapped:
(1) Corrosion pits leading or trailing edge which can be felt with
on the
a wire. (Refer to inspection paragraph 4 for applicable wire sizes).
Slide the wire up and down the edge at different angles to pick up
defects on all portions of the edge.
(2) Corrosion of the leading or trailing edge which may appear as a stain,
darker than the balance of the vane surface, and containing occasional
pits.
(3) Rough appearance of the surface including eroded areas which are
depressed from the surrounding surface and appear as black or dark
patches on the surface (random visible pits are acceptable).
NOTE: If a single vane is found to contain any of the above conditions
the entire vane sector/segment shall be scrapped.
B. Intermetallic diffusion coated vanes with more than 10% of the coating
missing after all other defects have been repaired shall be touched up
per 72-02-6.
NOTE: Disregard missing coating within 0.100 inch of the vane tip.
C. Vanes with defects, other than those described in steps A. and B., in
the vane airfoil shall be inspected per paragraph 4.
72-32-0
Sep 1/75
Page 203
CJG1C~ fURBOJET
MANUAL SEf-186
STAGES 1 AND e I 514665 i THRDUO1 I STAGE B Awn 669
(~PIUILJ (7PI1IIL)
tONCIIVE CQ1IBX
SIL i
1 1
I Ho.Lotl x
3 SfAtES 3 ARD 4---2 i
LIZ
574655 5, 6 IIl~D 7--X V3
S CURLE~ nP tORHERS
4 /IIIP1 Lu I 0.100 IrAX.
F~ ER~TICU UW
I I Nac-carI~L ~REa
101E: CRITICAL AREA DD~ Igt INttME
BRAZE FIL~F, 601 UWSEO VANE 1. Outcrsupport
~YLTERIAL UNOER frllFT SHnu SE 2. InnerSupport
CQI~IPERED AS CRITIW AREA. j. InncrBand
a. RSvet
5. Shroud
6. Shroud Ring
7. Airf0l~
8. Eighth-Stage and ECY Inner Rand
9. Shroud Clip
1II. Side of Inner Suppore (TypScal)
11. Top of Ledge (fypical)
12. Botlan of Ledge (Typicll)
SC-gZI 0-2
Stater Sectors Inspectior~
Figure 202
72-32-0 I)ec 31/91
Pase 204
GEIPRAL~ ELLC~IIC --L-.´•
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
4. Inspect the Vane Sectors/Segments as follows: (See figure 202.)
Inspection/Check Maximum Serviceable Limits Remarks
A. First- and second-stage
sector halves for:
(1) Loose or missing Not serviceable. Replace rivets.
rivets (4).
B. First- and second-stage inner band (3) for:
(1) Cracks. Not serviceable.
(2) Nicks and scratches. Any number 0.015 inch
deep after removal of
all high metal.
(3) Dents. Any number 0.015 Cold-work to original
inch deep. contour. Fluorescent-
penetrant inspect
no cracks allowed.
(4) Pits. Any number 0.010 inch
deep.
(5) Elongated None allowed.
rivet holes.
Sep 1/75 72-32-0
Page 205
ELLCt~lr
CJS10 TUiF1BOJeT
MAINTENANCE MANUAL SEI-186
InspectionlCheck
ns t on ec Maximum Serviceable
TV cea e Limits
s Remarks
C. First- and second-stage shroud (5) for:
(1) Cracks. Not serviceable.
(2) Nicks and scratches. Any number 0.015 inch
deep after removal of
all high metal.
(3) Dents. Any number 0.015 inch Cold-work to original
deep. contour. Fluorescent-
penetrant inspect
no cracks allowed.
(4) Broken spot welds Not serviceable.
on clips (9).
(5) Pits. Any number 0.010 inch
deep.
(6) Rubs, Not more than 0.005 inch
deep after removal of
high metal.
D. First- and second-stage shroud ring (6) for:
(1) Cracks. Not serviceable.
(2) Nicks, dents, Any amount 0.030 inch
pits, and deep after removal
scratches. of all high metal.
(3) Wear grooves. Any number not over
0.020 inch deep.
Sep 1/75
72-32-0
Page 206
OIWCI~L´• tLIC1IIC
C38t0 TURIOJLT
SEI-186 MAINTENANCE MANUAL
Inspection/Chec_k Maximum Serviceable Limits Remarks
E. Inner support (2) all stages) for:
(1) Cracks. None allowed.
(2) Nicks, Any number 0.015 inch
scratches, deep after removal of all
and dents. high metal.
(3) Rubs. Any amount 0.005 inch
deep after removal of
all high metal.
(4) Pits. Any number 0.010 inch
deep.
(5) Wear. Any amount provided:
(a) 0.005 inch minimum
stock thickness.
remaining on radial
side of support (10)
at end showing most
sever wear.
(b) Top (11) or bottom (12)
layer of ledge material
is not reduced more
than 25% of stock
thickness.
F. Outer support (1) tall stages) for:
(1) Cracks. Not serviceable.
(2) Nicks and Any number 0.015 inch
scratches. deep after removal of all
high metal.
~3) Dents. 0.060 inch deep with
no torn metal.
(4) Pits. Any number 0.010 inch
deep.
Sep 1/75 72-32-0
Page 207
OLWIRAL~ ELEetllC
CJ610 TURBOJBT
MAINTENANCE MANUAL SEI-186
STATOR SECTORS/SEGMENTS INSPECTION
inspection/Check Maximum Serviceable Limits Remarks
G. Airfoils (7) in all stages for:
(1) Cracks. Not eerviceable.
(2) Edge wavines~ Any number 0.050 inch Cold-work to original
and bends. from original contour. shape. Fluorescent
penetrant-lnspect; no
cracks allowed.
(3) Trailing edge Any amount if edges
erosion (air- are not curled or
foil thinning), rolled.
(4) Missing coating
on A12 coated
vanes in:
(a) Area within Any amount.
0.100 inch
of blade tip.
10% of coating missing, Refer to paragraph 3.B.
(b) Other areas.
2 airfoils Any number which cannot Blend within limits
H. Stages 1 and
for nicks, dents, pits, be felt. (refer to paragraph 5).
and scratches on
0.030 inch area along
entire leading and
trailing edges.
(Using light finger
pressure, slide a
0.070-0.075 inch
diameter wire along
edge at various
angles.
NOTE: For CJ610-8A engines, all blade and vane tip clearances shall be
measured (for all stages) if compressor rater has been disassembled
and disks and spacers have been separated. Blade and vane tip
clearances shall be measured using procedures in, SEI-136, 72-00,
FITS and CLEARANCES.
72-32-0 Nov 1/80
Page 208
GENERAL ELECTRIC-------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
STATOR SECTORS INSPECTION
Inspection/Check Maximum Serviceable Limits Remarks
I. Stages 3 thru 7 airfoils for:
(1)Nricks. dents
pits, and
scratches on:
(a) Critical areas. i. On assembled vanes, If the defect cannot
(Using light any number that can- be felt using a
finger pressure, not be f~lt, 0.120-0.125 inch
slide a 0,070- diameter wire or if
0.075 inch dia- they are clearly the
meter wire along direct result of FOD,
the edge at blend within limits
various angles). (refer to paragraph 5).
2. On unassembled vanes, If the defect can be
any number that can- felt with a 0.120-
not be felt. 0.125 inch diameter
wire and is not clearly
the result of FOD, the
sector is not repair-
able and shall be re-
placed.
(b) Non-critical Any number which cannot Blend within limits
areas of lead- be felt. (refer to paragraph 5).
ing and trail-
ing edges.
(Using light
finger pres-
sure, slide a
0.120-0.125
inch diameter
wire along
edge at various
angles)
(2) Corrosion (except Any amount which cannot (a) Stages 3 and 4:
leading and trail- be felt. use a 0.070-0.075
ing edges). (Using inch diameter
light finger wire.
pressure, slide
a wire across the (b) Stages 5, 6, and
corroded area). 7, use a 0.120-
0.125 inch diam-
eter wire.
72-32-0
Dec 31/95 Page 209
GENERAL ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
NOTE 1: After inspection, mark the first vane (counting clockwise, aft
looking forward) of each serviceable stater sector. This will
ensure proper installation of the stage 6 and 7 stater sectors
at assembly. Make the mark on the aft (concave) side of vane
in the form of a 1/2-inch dot, using yellow dykem or equiva-
lent. (See figure 203.)
NOTE 2: For CJ610-8A engines, all blade and
tip clearances shall vane
be measured for stages (using procedures in SEI-136, 72-00,
all
FITS and CLEARANCES) under any of the following conditions:
When compressor rotor has been disassembled and disks and spac-
ers have been separated.
When vane segment(s) have been replaced.
Inspection/Check Maximum Serviceable Limits Remarks
J. Stage 8 and EGV airfoils for:
(1)Nicks, dents, Any amount which cannot Blend within limits
pits, and be felt. per paragraph 5.
scratches on a
0.030 inch area
along leading and
trailing edges.
(Using light finger
pressure, slide a
0.070-0.075 inch
diameter wire along the
edge at various angles.)
(2) Corrosion (except Any amount which cannot
leading and be felt.
trailing edges)
(Using light finger
pressure, slide a
0.070-0.075 inch
diameter wire across
the corroded area.)
K. Cracks, gaps, and
porosity in all
brazed joints:
(1)Stage 1 and 2 Any number 1/4 inch long,
vane sector cumulative length not to
inner band (3). exceed 50 percent of joint
length.
72-32-0
I Page 210 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(2) Stage 1 and 2 Any number up to 1/8 inch
outer support long, cumulative length
(1) and inner not to exceed 50 percent
support (2). of joint length.
(3) Stages 3 through Any number up to 1/8 inch
8. long, cumulative length
not to exceed 50 percent
of joint length.
72-32-0
Dec 31/95 Page 210A/210B
GEIEIALQ
CJ610 TURIOJET
SEI-186 MAINTENANCE MANUAL
5. Airfoil Blending Procedure. (See figure 204.)
A. Blending is done to remove the stress concentration of nicks, pits,and
scratches to prevent vane failure. The removal of high metal is done to
restore the airfoil to nearly its original aerodynamic shape.
NOTE: Blending is restricted to leading and trailing edges and tip
corners.
B. Hand blending should be finished with a fine stone or 600 grit wet or
dry abrasive paper. Finish blending must be done in a direction along
the length of the vane and must remove all evidence of crosswise marks
that may have been made during initial blending.
C. All FOD defects than 1/4-inch apart should be blended separately;
more
those less 1/4-inch apart should be blended together. All blends
than
must have a minimum radius of 1/4-inch. The total reduction in chord
width may be taken on either side or split between the sides. Amount
of rework is controlled by the minimum chord width limit. Minimum
allowable chord is given for root and tip of airfoil, minimum chord at
other points is proportional. (See figure 204.)
D. If FOD minor repair limits are not exceeded in a stage, any number of
vanes in that stage may be repaired. If both major and minor FOD repair
is required in a stage, major repair is limited to 10 percent of the
vanes, and minor repair is allowed on the remaining vanes of that stage.
Tip rubs may be repaired on any number of vanes.
CAUTION:~ EXCESSIVE BLENDING OF CORROSION PITS MAY HIDE DEFECTS THAT
COULD LEAD TO VANE FAILURE. THE CHORD LIMITS SPECIFIED IN
FIGURE 204 APPLY TOFOD ONLY.
E. Corrosion pits shall be hand blended parallel to the leading and trailing
edges using a fine Arkansas stone. If blending for several minutes does
not reduce corrosion pits to within serviceable limits the vane sector
shall be scrapped.
F. The shape of the vane leading edge is very important to engine performance.
Leading edges are to be smoothly radiused as shown in figure 2-5.
G. Repair and touchup of A12 coated vanes shall not exceed limits specified
in paragraph 3.B.
Sep 1/75 72-32-0
Page 211
rlrsnle
C4si8 TURIBJET
MkINTENANCE %IANUAL SEI-186
APPROX. 1/2 INCH DISK
MARKED ON AFT (CONCAVE)
SIDE OF VANE
CF70030990-F?
Marking of Stage 6 and 7 Stater Sectors (Typical)
Figure 203
T\P CORNER REPAIR MAY BE PERFORMED ON VANESWHICH HAVE BEEN
REWORKED TO MAXIMUM MINOR OR MAJOR LIMITS
DEFECTS MORE THAN 1´•4 INCH APART
(BLEND SEPARATELY)
STAGE 2 3 4 5 b 7 8 EG
MINOR REPAIR
DEFECTS LESS THAN
A-MIN. CHORD ROOT .900 1.7001.5801.4901. 4301.4001. .4001.
1;’4 INCH APART (BLEND
TOGETHER) 8-MIN. CHORD TIP .8301. b601.5601.4801. .4001. .4001.
MAJOR REPAIR
A-MIN. CHORD ROOT .8301.6501.5801. 4901.4301.4001. .3601.
B-MIN. CHORD TIP .7701.61 .j201.4401.3901 .360(. .3601.
*I TIP RADIUS Y MAX. .1251.1 .1001.1001.1
NOTE
MINIMUM CHORD IS MEASURED FROM THE
BASE OF ANY REWORKED AREA ACROSS
RADIUS Y THE AIRFOIL TO THE OPPOSITE EDGE
CONCAVE SIDE
OR TO THE BASE OF ANY OPPOSITE
REWORKED AREA CJ610-3068´•~´•E?
Stater Vane FOn Repair
Figure 204
72-32-0 Sep 1/75
Page 212
OTIEIAL~ CltCt~lC
CJ610 TURBOJeT
SEI-186 MAINTENANCE MANUAL
I
RAD. I
I
I
CORRECT INCORRECT
8(3-0224
Typical Leading Edge After Blending
Figure 205
Sep 1/75 72-32-0
Page 213
Gf BIRIL IILCTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
COMPRESSOR ROTOR ASSEMBLY MAINTENANCE PRACTICES
i. General. Maintenance of the compressor rotor assemby is limited to those
items that are accessible.
1A. Preparation for Inspection. Prior to inspection, it is acceptable to prepare
the compressor rotor blade leading and trailing edges by hand using a fine
stone or 600-grit, wet or dry abrasive paper or equivalent. Time used
TRAILING
EDGE
CONCAVE DISTANCE
SIDE ~L CUT
CURLED
COSNER
DAMAGE
-I
DENT
DEPTH
DEPTH
0.040 L 0.040
-e
I-
I SIDE
Z 0.030
w/2
STCGE I
0.030
W
w/2
CONVEX CONCAVE
SIDE S1DE
CRITICAL AREA I I MINC2 AREA
STAGE
DIMENSION I 1 1 2 3 4 5 6 7 8
AIRFOIL CRITICAL AREAS
Z 1/3 L 2/3L 1/2L 1/2L 2/3L 2/3L 2/3L 2/3L
EXTEID DOWN TO AtID
FILLET
F;-CCi_-I
Compressor Rotor Blades Inspection
Figure 201
Mar 30/84 72-33-0
Page 201
G ~)I P R A L 1~B E:Lf CT R IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
I to prepare each leading
localized preparation is allowed.
or trailing edge shall not exceed 2 minutes. No
2. Inspection of Compressor Rotor Blades for Pits (Corrosion)
A. Blades with the following defects in the airfoil critical areas (see figure
201) are to be scrapped:
(1) Corrosion pits on the leading or trailing edge which can be felt with a
wire (refer to paragraph 3 for applicable wire sizes), or pits which
appear to be sharp notches in the leading or trailing edge. Slide the
wire at different angles to pick up defects on all portions of the edge.
(2) Rough appearance of the surface including eroded areas which are
depressed from the surrounding surface and appear as black or dark
patches on the surface (random visible pits are acceptable).
B. Intermetallic diffusion coated blades with more than 10% of the coating
missing after all other defects have been repaired shall be touched up
(72-02-6).
NOTE: Disregard missing coating within 0.100 inch of the blade tip.
C. Inspect blades with defects, other than those described in step A, in
the leading or trailing edge of the airfoil (refer to paragraph 3).
3. Inspection/Check. Where serviceable limits are exceeded, parts may be re-
paired in accordance with instructions in Overhaul Manual (SEI-136).
COMPRESSOR ROTOR BLADES INSPECTION
Inspection/Check Maximum Serviceable limits Remarks
A. Entire blade for:
(1) Fatigue crack Not serviceable. If crack is within 3/16
indications. inch of corner of
trailing edge tip,
blend out crack but do
not exceed limits in
paragraph 4.
(2) Manufacutring Not serviceable.
process defect
indications,
NOTE: For CJ610-8A engines, all blade and vane tip clearances shall
be measured (for all
stages) compressor rotor has been
if
disassembled and if disks and spacers have been separated.
Blade and vane tip clearances shall be measured using pro-
cedures in SEI-136, 72-00, FITS and CLEARANCES.
72-33-0 Mar 30/84
Page 202
CLNERAL~ fLECrRIC
CJGIO TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
B. Airfoils all stages for:
(1) Bends, distortion, Leading and trailing
or edge waviness. edges´•must be straight
within 0.015 inch per
inch of height; provided
such defects form long,
smooth curves.
(2) Nicks, dents, pits,
and scratches on:
(a) Critical areas. Any amount which Blend within limits
(Using light cannot be felt, per paragraph 4 if
finger pressure the defect cannot
slide a 0.070- be felt with a 0.120-
0.075 inch dia- 0.125 inch diameter
meter wire along wire.
the edge at var-
ious angles).
(b) Non-critical Any amount which Blend within limits
areas, cannot be felt. per paragraph 4.
(Using light
finger pressure,
slide a 0.120-
0.125 inch dia-
meter wire along
the edge at var-
ious angles).
(3) Visible corrosion in
critical areas:
(a) Stage i, 2, 5, Any amount if the
6, 7,and 8. area does not appear
rough or eroded.
(b) Stage 3 and 4. Not serviceable.
C. Blade tips for:
(1) Curled corners. Not over 0.010 inch. Repair per paragraph
(2) Burrs due to rubs. Not serviceable. Remove burrs.
Sep 1/75 72-33-0
Page 203
GEIIERIL~ELICTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
D. Pin holes (first stage) for:
(1) Wear. Not over 0.255 inch ID.
(2) Burrs on edge. Not serviceable. Remove burr. Edges
of holes must have
a 0.005 inch
minimum radius.
E. Critical areas of Any number 0.005 inch
blade shanks (Ist deep after removal of all
stage) for nicks, high metal.
dents, scratches,
and pits.
F. Minor area of plat- Any number 0.020 deep
form and blade after removal of all
shanks (Ist stage) high metal.
for nicks, dents,
scratches, and pits.
G. Missing coating
on A12 coated
blades in:
(1) Area within Any amount.
0.100 inch of
blade tip.
(2) Other areas. 10 percent of coating Refer to paragraph
missing. 2.3.
I H. Spacer path
vane Any amount not exceeding Blend per 72-02-9.
for nicks, dents, 0.005 inch deep, with no
Pits, scratches, high metal.
and rubs.
72-33-0 Dec 31/91
Page 204
GLNERAL~ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Checks Maximum Serviceable Limits Remarks
I. Stage 1 blade retaining pin:
(1) All areas for Not serviceable. Replace pin.
cracks.
(2) Pin shank for:
(a) Nicks, dents, Any number less Blend per
II and scratches. than 0.005 inch 72-02-9.
deep,´• with no high
metal
(b) Wear. 0.2490 inch min OD. Replace pin.
(3) Pin head for Any number less Blend per
I nicks, dents, than~0. 010 inch 72-02-9.
and scratches, deep, with no high
metal
(4) All areas for Not serviceable. Replace pin.
pits due to
corrosion or
fretting.
4. Airfoil Blending Procedure. (See figure 202.)
A. Blending_is done to remove the stress concentration of nicks, pits, and
scratches to prevent blade failure. The removal of high metal is done to
restore the airfoil to nearly its original aerodynamic shape.
CAUTION: BLENDING OF CONCAVE AND CONVEX AIRFOIL SURFACES WHICH WOULD
REDUCE THICKNESS IS PROHIBITED. OM;Y REMOVAL OF HIGH METAL
IS PERMITTED ON THESE SURFACES.
B. Hand blending should be finished with a fine stone or 600 grit wet or
dry abrasive paper. Finish blending must be done in a direction along
the length of the vane and must remove all evidence of crosswise marks
that may have been made during initial blending.
C. All FOD defects more than 1/4-inch apart should be blended separately;
those less 1/4-inch apart should be blended together. All blends must
than
have a minimum radius of 1/4-inch. The total reduction in chord width may
be taken on either side or split between the sides. Amount of rework is
controlled by the minimum chord width limit. Minimum allowable chord is
given for root and tip of airfoil: minimum chord at other points is pro-
portional. (See figure 202.)
Dec 31/91 72-33-0
Page 205
6 EW E I~L ~b tlE tf)lC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
r01
11R~olus yj/ I
STAGE 1 1 2 1 3 1 4 1 5 1 617 8
NOR REPAIR
A-MIN.CHORD ROOT11.2401. 7801.6101.5401.4601.4201.4001 .495
B- MIN. CHORD TIP 1.530(.7901.61 01.5401.4601.4401.4201 .445
DEFECTS LESS THAN 1/4 INCH
OR REPAIR
APART (BLEND TOGETHER)
A-MIN. CHORD ROOTll
B- MIN. CHORD TIP 1.4201. 7301.5701.5001. 4301.4001.3901.415
RADIUS Y MAX. .250 l.i501.1501.1001. 100).1001.1001.100
TIP CORNER REPAIR MAY BE PERFORMED ON BLADES WHICH
HAVE BEEN REWORKED TO MAXIMUM MINOR OR MAJOR LIMITS.
NOTE
MINIMUM CnORD IS MEASURED FROM THE BASE OF
ANY REWORKED AREA ACROSS THE AIRFOIL TO THE
OPPOSITE EDGE OR TO THE BASE OF ANY OPPOSITE
REWORKED AREA.
CONVEX SIDE
C~610´•3079´•102
Compressor Rotor Blade FOD Blending Limits
Figure 202
D. If FOD minor repair limits
are not exceeded in a stage, any number of
blades in that
stage may be repaired. If both major and minor repair
is required in a stage, major repair is limited to 10 percent of the
blades, and minor repair is allowed on the remaining blade of that
stage. Tip rubs may be repaired on any number of blades.
CAUTION: EXCESSIVE BLENDING OF CORROSION PITS MAY HIDE DEFECTS THAT
COULD LEAD TO BLADE FAILURE. THE CHORD LIMITS SPECIFIED
IN FIGURE 202 APPLY TO FOD ONLY.
E. Corrosion pits shall be hand blended parallel to the leading and trailing
edges using a fine Arkansas stone. If blending for several minutes
does not reduce corrosion pits to within serviceable limits the blade
shall be scrapped.
72-33-0
S~p 1/75
Page 206
GEICIALB~ ELfC~IIC
CJ610 TURBOJeT
MAINTENANCE MANUAL SEI-186
I
RAD.
I"r\ I
I I
I I
I I
CORRECT INCORRECT
BC-0224
Typical Leading Edge After Blending
Figure 203
F. The shape of the bladeleading edge is very important to engine perfor-
mance. Leading edges are to be smoothly radiused as shown in figure 203.
G. Repair and touchup of A12 coated blades shall not exceed limits specified
in paragraph 3.B.
Sep 1/75 72-33-0
Page 207
GENERAL ELECTRIC-------
CJ61 6 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
MAINFRAME MAINTENANCE PRACTICES
1. General. Maintenance of the mainframe assembly is limited to those items that
are accessible. Disregard this inspection when mainframe is Inconel 718 cast-
ing.
2. Inspection/Check. Where serviceable limits are exceeded, parts may be repaired
in accordance with Overhaul Manual instructions.
NOTE: Confirm suspected cracks per 72-03-1.
Inspection/Check Maximum Serviceable Limits Remarks
A. Visually inspect the external areas of the mainframe as follows:
(1)Mounting pads for:
(a) Damaged threads. Damage equivalent to one
full thread missing after
chasing.
(b) Cracks. One per pad, 3/4 inch
long.
(c) Nicks, dents, Any number, 0.020 inch deep.
scratches and
pits.
(d) Broken bolts. Not serviceable. Remove and replace
all broken bolts.
(2) Flanges for cracks. Not serviceable.
(3) Outer band for:
(a) Cracks. Not serviceable.
(b) Nicks and Any number, 0.020 inch deep.
scratches.
(c) Dents. Any number, 0.030 inch deep,
1 inch in diameter.
(4) All welds for No through cracks allowed.
cracks. Surface cracks 0.030 inch
long, with a cumulative
length of 0.090 inch in any
1.0 inch of weld. Cumula-
tive length not more than 8
percent of joint length.
72-34-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAZ.
Inspection/Check Maximum Serviceable Limits Remarks
(5) Gearbox bracket Not serviceable.
adapter for
cracks.
(6) Mainframe for Not serviceable. Touch-up per
cracked or 72-02-5.
missing Solaramic
coating.
(7) Mainframes coated Not serviceable. Cumulative area not
with TSM-3 for to exceed 2 square
missing coating, inches. Touch-up
per 72-02-7.
B. Visually inspect the internal areas of the mainframe as follows:
NOTE: Inspect these areas only when the combustion section has been removed,
(1) Struts and inner band for cracks.
(a) Outer band. Not serviceable.
(b) Strut. Not serviceable.
(c) Inner band. Not serviceable.
(2) Nicks, pits, and Any number, 0.020 inch
scratches. deep, with no high
metal.
(3) Dents. Any number, 0.030 inch deep,
1 inch diameter that does not
cause interference or improper
fit.
(4) Welds for cracks. No through cracks allowed.
Surface cracks 0.030 inch
long, with cumulative
length of 0.090 inch in
any 1.0 inch of weld.
Cumulative length not
more than 8% of joint
length.
(5) Eighth-stage See 72-32-0,
stater vanes, paragraph 3.
72-34-0
Page 202 Dec 31/91
GIWERIIL~tLfelRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANITAL
Inspection/Check Maximum Serviceable Limits Remarks
(6) Bearink~support Not serviceable. Touch-up per
for cracked or 72-02-5.
missing Solaramic
coating.
NOTE: Inspect this area only when the combustion section has been
removed.
C. Borescope-inspect No surface roughness Remove excess
internal flowpath due to corrosion corrosion with
area for corrosion. allowed. emery cloth or
equivalent.
oo
0 4
13 i. MOUNTING PADS
D 2. FRONT OUTER FLANGE
3 a
D a 5 3. FRONT INNER FLANGE
4. REAR OUTER FLANGE
5. REAR INNER FLANGE
12 6. OUTER BAND
2 7. STRUTS
14 8. INNER BAND
O 9. GUSSETS
10. SUPPORTS
11. STRUT SUPPORT
10 12. GANG CHANNEL
13. RIVETS
O 14. GANG CHANNEL NI)TS
s 15. EIGHTH-STAGE SEAL RABBET
6 16. REAR-FLANGE RABBET
OoO 1
ii
1
Poq
U610dM10C2
Mainframe
Figure 201
Dec 31/91 72-34-0
Page 203
OEIEIAL´• ELECtllE
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
COMBUSTION SECTION DESCRIPTION AND OPERATION
i. General.
The combustion section, figure i, consists basically of the outer combustion
casing, inner combustion casing, combustion liner, the number 3 bearing and
support, the number 3 carbon seal and support, the turbine stationary air
seal, the shaft shield and the combustion heat shield (optional equipment).
The first-stage turbine nozzle is shown because it attaches to the combus-
tion section rather than the turbine section. The description for the first-
stage turbine nozzle is covered in the turbine section.
2. Description.
A. Outer Combustion Casing. The outer combustion casing (13) is one piece,
and is made of chromoloy material. It is a major structural unit, bolt-
ing to the mainframe at~the front and to the turbine stater at the rear.
An igniter plug is seated at each of the two igniter bosses (1) and
extend through the casing into the combustion liner. An insulation
shield (optional) is secured around the outer surface of the casing to
shield airframe components from excessive heat.
B. Inner Combustion Casing. The annular inner combustion casing (11) is
made of chromoloy and is one-piece. At the front, it bolts to the inner
casing of the mainframe and at
rear and supports the No. 3 bearing sup-
port (5). Extra holes provided in the rear flange
are to form passages
so air´•can enter the balance piston chamber area.
C. Combustion Liner. The combustion liner (12) consists of a cowl section,
a dome section, an outer.shell, an inner shell, and the outer and inner
shell, and the outer and.inner flanges. All of these components are
welded and riveted to form a one-piece fabrication, made from Hastolloy
material. Air from the compressor section enters the liner through per-
forated areas designated as thimble ho~es and louvers. The thimble
holes direct air into the burning provide bound-
area while the louvers
ary layers of
along air the prevent for-
inner surfaces of the liner to
mation of hot spots. Free thermal expansion of the liner is allowed by
the following method of support. The twelve fuel nozzles protrude into
the liner at the swirl cups (2) and provide a steady support at the
front. At the rear, the outer flange is held in place by the common
joint ~of the turbine casing and the outer combustion casing.
The flange is held in place by the common joint of the inner com-
inner
bustion casing and the first-stage nozzle. Thus, the liner is supported
mainly by its inner and outer flanges at the aft end. Equally spaced
holes in the outer flanges direct the passage of the relatively cool air
from along the outer combustioncasing into the hollow partitions of the
first-stage turbine nozzle (4).
Mar. 30/67 72-40
Page 1
008 EIIAL ELEnllC
CJ610 TURBOJET
MAINTENANCE MANUAL 887-186
i I i. IGNITER BOSS
~83,
4. FIRST-STAGE TURBINE NOZZLE
5. NO. 3 (REAR) BEARING SUPPORT
;8
6. NO. 3 (REAR SEAL SUPPORT
7. NO. 3 (REAR) CARBON SEAL
/I
OI a.
9.
10.
NO. 3 (REAR) BEARING
INSULATION BLANKET
TURBINE STATIONARY SEAL
2 5 ii. INNER CASING
s 12. COMBUSTION LINER
13. OUTER CASING
’4´• DRA’N BOSS
7
j
s
------10
3
a
13 12 11
CI(IOJO?I´•O-C2
Combustion Section
Figure 1
D. No. .3 Rearing Support. The No. 3
bearing support is made from chromoloy
snrl retains the outer race and assembly of the No. 3 bearing (8);
cage
it I´•r´•tains the oil nozzle assembly’which lubricates the No. 3 bearing;
and it also retains the No. 3 seal support. The seal support retains
the ciil seal and the inner turbine air bearing support
seal. The No. 3
and the forward race of first-stage turbine wheel form the balance
the
piston air chamber. Boundary layerair from the inner combustion casing
enters this chamber and bears against the face of the turbine wheel to
counteract the rotor forward thrust.
E. Shaft Shield. The shaft shield (3) is made from 321 stainless steel.
The forward flange is bolted to the collar of the power take-off assem-
bly and the aft flange is bolted to the No. 3 bearing support (5). It
72-40 Mar. 30/67
Page 2
OEIEIAL´• ELECIIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
protects the oil lines and the engine shaft from excessive heat and con-
nects the No. 2 bearing area to the No. 3 bearing area to form a common
oil sump.
3. Operation.
Fuel enters the through the 12 fuel nozzles.
combustor Each fuel nozzle in-
corporates a divider, a primary
flow and secondary flow passages, ensuring
a proper fuel spray pattern and flow through the engine operating speed
range. The compressor discharge air enters the space between the outer com-
bustion casing and inner combustion casing, and passes through the louvers
and thimble holes into the liner where combustion takes place with the fuel.
A small amount of air enters the combustion dome through the swirl cups to
provide primary combustion, dome cooling and fuel no~zle carbon sweeping.
The resulting gases pass to the turbine through an annular opening at the
rear of the liner and the first-stage turbine nozzle.
Mar. 30/67 72-40
Page 3
6EW ORAL Q ELOCTRIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
COMBUSTION SECTION MAINTENANCE PRACTICES
i. General. following paragraphs describe removal, installation, disassem-
The
bly andassembly procedures that are approved for "hot section" inspection
and No. 3 bearing replacement.
2. Removal/Installation Procedures for Combustion Heat Shield. (Optional
Equipment)
A. Bernoval.
(1) Disconnect the two igniter leads. Remove the igniter plugs.
(2) Remove the 2 nuts from the igniter bosses.
(3) Remove the 2 bolts and washers from ignition lead supports.
(4) Remove the 2 nuts, bolts and gaskets from the 2 pairs of supports
located at the aft end of the horizontal split line. Note that the
nut, bolt and gasket on the left side of the engine also attaches a
bracket for the ignition lead clamp.
(5) Remove the union and packing from the combustion casing drain (lo-
cated at 6 o’clock position).
(6) Remove the 16 bolts and washers that attach the heat shield to the
heat shield brackets that are bolted to the forward side of the
outer combustion’casing rear flange.
(7) Remove the heat shield halves.
I B. Installation.
(1) Install the upper-half of the heat shield over the outer combustion
casing. Install the lower-half of heat shield so that the splitline
edge fits between the inner and outer spring clips of the upper half.
(2) Align and insert the 16 bolts and washers that attach the heat
shield to the heat shield brackets. Torque the bolts to 21-27 Ib-in.
Lockwire the bolt heads to the brackets if no firewall has to be in-
stalled later.
(3) Insert the 2 bolts (bolt head up) that are used to bolt the two
halves of the heat shield
together at the
sup- forward heat shield
ports. Insert the
gasket-type washers between the 2 pair of sup-
ports. Assemble the locknut and the clamp for the thermocouple
harness on the left-hand side of the engine. Assemble the locknut
72-40
Dec 30/78 Page 201
GLIEIAL ELECTRIG
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
to the bolt on the right-hand the engine.
side of Torque the lock-
nuts to 24-27 Ib-in. and lockwire the bolt head to the support.
(4) Using a new packing, assemble and torque the combustion casing drain
fitting to 40-60 Ib-in.
(5) Attach ignition lead brackets to the heat shield using 2
the 2 bolts
and 2 washers, Torque the bolts to 24-27 Ib-in. and lockwire.
(6) Assemble gasket and nut that
the secures the heat shield to the outer
combustion casing igniter boss.
(7) Igniter plug tips must have an immersion depth into the combustion
liner of 0.000-0.015 inch. The immersion depth is controlled by the
number of washers or shims used on the plug. Set the immersion depth
per section 80-23-0.
3. Removal/Ins tallat ion Procedures for Combus tion Section Inspec t ion. (See
figure 201.) Use this procedure for routine combustion section removal,
inspection and re-installation.
A. Removal.
(1) Remove the exhaust section and turbine sections as outlined in the
sections 87-11, and 72-50 respectively, the necessary external lines
and leads, and the igniter plugs per section 80-23-0.
(2) Remove the turbine stationary seal, the first-stage nozzle, and the
combustion liner as follows:
NOTE: First-stage turbine nozzles have 5 "T" positions (T1 through
T5) stamped circumferentially around the aft face of the outer
flange. Before removing the nozzle, record in the engine
records the "T" number located at the 12 o’clock position.
(a) Match-mark the turbine outer stati.onary seal with first-stage
nozzle. Match-mark the first-stage nozzle with the outer com-
bustion easing.
(b) Remove the bolts (5) that attach the turbine stationary seal (6).
Remove the seal, first-stage nozzle (7), and the combustion
liner (8).
B. Installation. Install the combustion liner (8), first-stage nozzle (7),
and the turbine stationary seal as follows:
NOTE: Use procedure outlined in paragraph 5 if the No. 3 bearing support:
has been removed from engine.
72-40 Dec 30/78
Page 202
GtllERAL~E LICTRIC
CJ610 TURBOJET
SEI-186´•: MAINTENANCE MANUAL
9~TP
2~ r-------’-"--~
3 r
I
I I
Id
<3-- 4 1’ 11
5--!1 11
I
i I
I I
I
I
X I
Il
i
7
1 1 13 ’1
II
I
I 14
I
II I 1--´•15
II _I
ii
/7
8
It
I I
II I
11 19--2 1 j~18
I I
II L-~ o
L-----,_---,,---,~
1. INSULATION BLANKET i 1! 20
2. BOLT, SEAL SUPPORT 22 21
3. REAR SEAL SUPPORT SUB-ASSEMBLY
4.
5.
O-RING
BOLT, TURBINE STATIONARY SEAL O
eB~y
6. TURBINE STATIONARY SEAL
7. FIRST-STAGE TURBINE NOZZLE Il/c~P- 23
8. COMBUSTION LINER
9. BOLT
10. VIEW-PORT COVER
11. GASKET
12. OUTERCOMBUSTION CASING
13. IGNITERBOSS
14. OILNOZZLE
15. BOLT, SHAFT SHIELD
16. NO. 3 BEARING SUPPORT SUB-ASSEMBLY
18.17. GNIR-OGNISAC
INNER COMBUSTION
19. BOLT
20. O-RING
21. NO. 3 BEARING LUBE TUBE
22. SHAFTSHIELD
23. MAINFRAME CJ610d028´•2-82
Combustion Section Installation
Figure 201
May 15/70 72-40
Page 203
6EW ERAL ~g ELPCTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(1) Install the combustion liner (8) over the inner combustion casing
(18) and line up the opening for the igniter with the igniter boss
(13) on the outer combustion casing (12).
(2) Visually check the rear flanges of the combustion liner (8) to be
sure they are seated on the rear flanges of the inner and outer
combustion casings (12, 18).
(2A) Check the fit between the first-stage nozzle and the combustion liner
before assembly to the liner.
See figure 201A, View A. The nozzle
outer band should fit snugly into the liner and should be capable of
rotating in it. If interference exists between these parts, proce~d
as follows:
Interference Corrective Action
(a) Nozzle fits into liner, but Bend tabs uniformly outward
interferes with outer tabs; around circumference of liner.
or nozzle fits into liner on Max allowable bend on any tab is
one side, but interferes 0.02 in. See figure 201A, View a
with rivets on the other.
(b) Nozzle fits into liner, but Bend rivets inward until nozzle
interferes with rivets. fits without interference. See
figure 201A, View C.
(c) Nozzle band has a wavy Remove waves from nozzle outer
pattern and interferes band, using rawhide mallet or
a
with outer tabs and plastic hammer. Nozzle outer
rivets. band must be 15.35-15,37 inch ID
on forward end.
(3) Install the first-stage turbine nozzle (7) by inserting the nozzle
outer band the flanges of the combustion liner (8).
over Check the
engine disassembly records for the designation of the "T" number that
is located at the 12 o’clock position. Before seating the nozzle,
align the belt circles at the inner and outer combustion casing
flanges with the designated "T" mark on the nozzle at the 12 o’clock
I position. (See NOTE, paragraph 3.A.) Secure the nozzle to the aft
flange of the combustion casing (12) with 4 bolts and locknuts
equally spaced. Install the bolts from the combustion casing side of
the flange.
(4) Lubricate the threads of bolts (5) with a light coat of engine oil.
72-40 Dec 31/91
Page 204
GEW~RAL ELECTRle
CJ610 TURBOJ~T
SEI-186 MAINTENANCE MANUAL
(5) Position the turbine stationary seal (6) so that the match-marks on
the seal and nozzle are aligned. first-stage Secure the nozzle (7)
and the stationary seal to the inner combustion casing (18) with 4
equally spaced bolts (5). Torque the bolts to 10-12 Ib-in. Check
each bolt to make certain that
snug against it is
stationary the
seal. any bolt is not snug remove the bolts; realign and reseat
If
the parts and reinstall the bolts. When each bolt is snug with a
10-12 Lb-in. torque, apply a final torque of 45-50 Ib-in.
NOTE: The bolts (5) are assembled into shank nuts in the inner com-
bustion casing aft flange. Turn the bolts into the shank nuts
by hand until the first few threads are engaged. Then torque
the bolts carefully to avoid unseating the shank nuts.
(6) Check the radial runout between the engine certerline and LD (bronze
sealing surface) of the No. 3 seal support and ID of stationary seal"
per paragraph 5.B.(4).
(7) Lubricate threads of remaining bolts (5) with a light coat of engine
oil and install. Torque the bolts to 10-12 Ib-in. Check each bolt
to make certain that it is snug against the stationary seal. If any
bolt is not snug remove the bolt, inspect threads for other condi-
tions causing bolt hang up. When each bolt is snug with a 10-12
Ib-in. torque, apply a final torque of 45-50 Ib-in.
(8) Lockwire the turbine stationary seal bolts being careful not to pass
the lockwire over the louveredges so as to block the louver openings.
(9) Prior to assembling the turbine casing, remove the bolts used to
attach nozzle to combustion outer casing.
D. Install the turbine and exhaust sections per 72-50 and 78-11 respective-
ly. Assemble all removed lines, leads, and accessories removed per
applicable sections of manual; such as ignitor plugs per 80-23-0.
4. Removal/Installation Procedures for the Outer Combustion Casing.
A. Removal.
(1) Remove the first-stage turbine nozzle and combustion liner as
outlined in paragraph 3, before removing casing as follows:
I (a) Remove casing by removing all bolts, locknuts, the installation
lug and brackets from the combustion casing mainframe flange.
NOTE: On CJ610-4/-6 engines the ascessory drive gearbox must be
removed per 72-46-0.
Dec 30/78 72-40
Page 205
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
OUTER TAB
COMBUSTION LINER
VIEW A
FIRST-STAGE
NOZZLE
RIVET
WOODEN BLOCK OR
EQUIVALENT
OUTER TAB MAY BE
DUCKBILL
BENT OUTWARD
PLIERS OR
0.020 INCH MAX
EQUIVALENT
VIEW B
MASK END OF
PLIERS TO PREVENT ~PLIERS MUST NOT TOUCH
NICKING OR GOUGING AFT FLANGE OF LINER
OF LINER
END MAY BE GROUND BACK
TO CLEAR OUTER TAB
RIVET MAY BE BENT INWARD
VIEW C 0.’020 INCH MAX
ROUND THE END OF PLIERS
AND MASK TO PREVENT
GOUGING OF LINER
DUCKBILL
PLIERS
DRILL 0.12-0.19 HOLE IN
PLIERS TO CLEAR RIVET HEAD
BC-O143
Fitting First-Stage Nozzle to Combustion Liner
Figure 201A
72-40 Nov. L5/73
Page 206
OENERALQELIETRIC-----
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAt
(2) Remove the casing from engine.
(3) Remove view port cover and discard gasket.
B. Install the outer combustion casing as follows: (See figure 202.)
(1) Position the outer combustion casing on the mainframe with the drain
boss at the 6 o’clock position and the flange bolt holes aligned.
(2) Secure the forward flange of the outer combustion casing to the
mainframe as follows:
NOTE: Be sure the flange bolt holes are aligned before
tightening
the flange bolts. If the bolt holes arealigned it may
not
notbe possible to install the gearbox brackets properly on
CJ610-4/-6 engines.
(a) Install the 2 bolts at holes 24 and 25. Torque the bolts and
lockwire them.
(b) Secure the trunnion mount adapters to the flange at bolt holes
10 through 15 and 35 through 39 with the bolts. Torque the
bolts.
(c) Secure the 4 offset brackets (4) to the aft side of flange, at
holes 2, 40, 43 and 46 with bolts and loclanuts. Torque the
bolts.
I
oo
O
O LOCmlRED BOLTS (TRUNNION MOUNT ADAPTI6)
I (6414~1 2 i
Q
Ct
4 4
5 O~
6
LOCKWIRED BOLTS
4
42
1~ /O
a
OIGNITION LEAD BRPCKET (Cj6l0d/d)
lo
ts
a Il
37 12
1 Il
11
15
4 a 16 ASSEMBLY NOTES
o
o 11
32
It-/ \o 31 .APPLY LIGHT COAT OF ENGINE OIL TO ALL BOLTS
o 30 19
zJ
a
22
21
m INSERT ALL BOLTS (U(CEPT ITEMSO, OAND O)
2731333413 WITH BOLT HEADS FORWARD
o o TORQUE ALL BOLTS TO 24-26 LB -IN. (CJ610-1/-5)
9 3
TORQUE ALL BOLTS 44-48 LB -IN. (CJ610-4/-6~
t
LOCYWIRE ITEMS O,OAND O. NO NLITS USED
AT THESE LOCATIONS
C1610~029-0-E2
Outer Combustion Casing Mainframe Flange Bolt Circle
Figure 202
72-40
Nov. 15/73 Page 207
GelERII~ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANITAL SEI-186
(d) Secure a bracket to flange at hole 34 with a bolt and torque it.
(e) The bolts and locknuts at holes 19, 20, 21, 28, 29 and 30 on
CJ61O-4/-6 installed later with the gearbox brackets per
are
72-30, Maintenance Practices. Install accessory drive gearbox
per 72-64-0.
(f) Assemble the remaining bolts and locknuts to the flange. Torque
all the bolts.
(3) Coat both sides of new gasket (11, figure 201) with a light coat of
sealing compound, Plastiseal F (Johns-Manville Co., 22 East 40th
Street, New York, N.Y. 10016) or equivalent. Coat mating surfaces
of viewport cover (10) with a light coat of Molykote Type 2 (I)ow
Coming Corp., Alph-Molykote Plant, 65 Harvard Ave., Stamford,
Conn., 06902) or equivalent. Secure the viewport cover and gasket
to the inspection port on the outer combustion casing with the 6
bolts. Tighten bolts and lockwire. Lubricate bolts with Ease-Off
990 (Texacone Co,, Box 4236, Dallas, Texas).
NOTE: Be sure to install viewport cover (10, figure 201) with
concave surface external.
4A. Removal/Installation Procedure for Inner Combustion Casing. (See figure
201.)
NOTE: Use this procedure whenever it is necessary to remove the inner
combustion casing.
A. Removal.
(1) Remove 16 bolts (19) that attach the inner combustion casing (18) to
the mainframe.
(2) Remove the inner combustion casing.
B. Installation,
(1) Install inner combustion casing (18) over shaft shield (22).
(2) Attach the forward flange to the mainframe with 16 bolts (19).
(3) Turn the bolts all the way in; then, back them off one-half of a
turn. This will allow the inner combustion casing to line up with
the outer bolt circle of No. 3 bearing support after it is installed.
5. Removal/Installation Procedure for No. 3 Bearing.
NOTE: This procedure is to be followed when removing the No. 3 bearing.
72-40 Dec 31/91
Page 208
eEwEaAL E Lr crR Ic
CJ610 TURBOJET
SEI-186 MAINTENANCE MAN[I~TAL
A. Removal. Remove the’first-stage nozzle as outlined in paragraph 3,
prior to the following procedure for removal of No. 3 bearing.
(1) Remove the lockwire from bolts (2, figure 201) and then remove the
seal support insulation blanket (1).
(2) Remove the bolts (2) that attach the seal support to the bearing
support. the seal support and the attached carbon seal
Remove
assembly. (The carbon seal assembly can be removed from the support
by removing screws. Discard 0-ring).
(3) Remove and discard the 0-ring (4).
(4) The No. 3 bearing support (16) is removed with the No. 3 bearing
locking key attached to the support and the outer race and cage of
the No. 3 bearing installed in the support. Remove the support and
oil nozzle (14) as follows:
(a) Remove the bolts (15) that attach the bearing support to the
shaft shield. Remove the No.3 bearing support with the oil
nozzle attached.
(b) Remove and discard the 0-rings (17 and 20) for the oil nozzle
supply tube and the No. 3 bearing support.
(c) Remove the Na. 3 bearing ring (4, figure 204).
outer race snap
Remove the 2 screws (1) and nuts (2) that
secure the locking key
(3) to the No. 3 bearing support; remove the key. Remove the 2
bolts or screws (9) that secure the oil nozzle (8). Use a pusher
(205309) and push the bearing outer race (5) out of the bearing
support by tapping the pusher with a soft faced mallet.
1Dec 31/91 72-40
Page 209
OEWER*L ELIETRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
5 8
No. 3 Bearing Support
Runout Check IIC 6
~4 -8~- 12--c~ I a 13
lo
12
;12
11
I
1 1
Turbine Stationary Seal
5 a
RUnoUt Check
ii 13
10
12
12 1
11
1. FIRST-STAGE TURBINE NOIZLE 8. NO. 3 BEARING OIL NOZZLE
2. INDICATOR 9. THUMBSCREW
3. INDICATOR ROD 1O. DRIVER
4. TURBINE STATIONARY SEAL Il. COMPRESSOR ROTOR DRIYE SHAFT
5. BOLT 12. COMBUSTION LINER
5. NO. 3 BEARING SUPPORT 13. INNER COMBUSTION CASING
JF
7. BOLT 14. OUTER COMBUSTION CASING
500044-1
15. SIMULATOR
No. 3 Bearing Support and Turbine Stationary Seal Runout Check
Figure 203
72-40 Dec 1[77
Page 210
G E )I ERAL ~s ELEC’IRIC
CJ610 TURBOJ~T
SEI-186 MAINTENANCE MANUAL
NOTE: The No. 3 bearing inner and outer races are matched
assemblies and must be replaced with a matched set.
Refer to section 72-50 for removal and installation
of the No. 3 bearing inner race with the turbine
rotor shaft.
B. Installation. Install the No. 3 bearing outer race, bearing support, seal
support and first-stage turbine nozzle in accordance with the following
procedure.
(1) Sub-assemble the No. 3 bearing support as follows: (See figure 204.)
(a) Lubricate the OD of the bearing outer race (5) with engine oil.
(b) Align the key slot in the outer race with the key slot in the
bearing support (1800 from the oil nozzle position).
(c) Assemble the outer race bearing support (6).
into the The bearing
support may require slight heating with a lamp in order to seat
the bearing.
.i
ilk, 2. LOCKNUT
3. KEY
4. SNAP RING
5. NO. 3 BEARING OUTER RACE
6. NO. 3 BEARING SUPPORT
O
7. KEY SLOT
4 8. OIL NOZZLE
9. SCREW
g 7 CJ610d03~4-F2
No. 3 Bearing Support Assembly
Figure 204
Dec 30/78 72-40
Page 211
e Ew ERAL B~ ELECfRIC
CJBIO TURBOJET
MAINTENANCE MANUAL SEI-186
~obB
_-
i. SCREW
2. NO. 3 CARBON RUBBING SEAL
3. O-RING
4. REAR SEAL SUPPORT
CJ610A031-0-rZ
Rear Carbon Seal Support Build-Up
Figure 205
(d) Assemble key (3) to the bearing support and secure with the
screws (1) and locknuts; torque the screws 8-10 Ib-in and lock-
wire.
(e) Install the snap ring (4) that ~etains the outer race in the
support.
(f) Assemble the No. 3 oil nozzle (8) to the bearing support.
Torque the screws (9) to 6-10 Ib-in. and lockwire.
(2) Assemble the carbon seal to rear seal support if removed as follows:
(See figure 205.)
(a) Install the O-ring (3) into the groove in the bore of the rear
seal support (2); assemble the rear carbon seal (2) into the
support.
CAUTION: DO NOT DAMAGE: THE O-RING.
(b) Assemble screws (1) to the carbon seal and seal support.
Torque the screws 6-10 Ib-in. and lockwire.
(3) Install the No. 3 bearing support to engine as follows: (See figure
201.)
(a) Install new O-ring (17) into the groove in the shaft shield aft
flange and new O-ring (20) on the No. 3 oil nozzle supply tube.
I 72-40Page 212
Nov~ 15/73
CJ61 O TURBOJET ENGINES
GEAircraffEnaines MAINTENANCE MANUAL
(b) With the No. 3 bearing lube tube adapter hole aligned
in the No.bearing support, install the No. 3 bearing
3
support (16). Use a straight downward motion, and seat
the bearing support, being careful not to damage or cut
the O-ring (17)
(c) Align the bolt and the air cooling holes tin the bearing
support) with the bolt and the air holes in the shaft
shield and the inner combustion casing.
(d) Attach the No. 3 bearing support to the shaft shield with
four bolts.
(e) Install the remaining bolts that attach the No. 3 bearing
support to the shaft shield. Torque all bolts to
28-32 Ib-in.
(f) Cross-torque the 16 bolts (19) that attach the inner
combustion casing to the mainframe (these bolts were
installed in paragraph 4.A.) to 45-50 Ib-in.
1 (4) Install the first-stage turbine nozzle (refer to figure 201) as
follows:
(a) Install the combustion liner (8) on the inner combustion
casing (18); then, align the opening for the igniter with
the igniter bosses (13) on the outer combustion casing.
(b) Inspect the aft inner flange of the combustion liner [8)
for burrs and sharp edges. Remove any burrs and blend the
sharp edges.
(C) Install the nozzle as follows:
1 Put the nozzle one or more "T" positions from where it
was when removed (the "T" position must be aligned to
obtain proper cooling of the nozzle). If the new "T"
position cannot be identified, the nozzle must be
marked again (refer to 75-51-0, paragraph 4.D.)
2 Put the nozzle on the engine. Connect the forward edge
of the turbine nozzle outer band with the aft flange of
the combustion liner.
(d) Install four bolts (5), equally-spaced, through the turbine
nozzle inner flange and the No. 3 bearing support outer
flange. Torque the bolts to 10-12 Ib-in. Check each bolt to
make sure that the bolt is snug against the turbine nozzle.
If any bolt is not snug remove the bolts, re-align and
reseat the parts, and install the bolts again.
(e) Use your handand install the bolts (5) in the shank nuts
on the aft flange of the inner combustion casing until the
first few threads are engaged. Then torque the bolts to
10-12 Ib in. carefully to avoid unseating the shank nuts.
72-40
May 31/98 Page 213
CJ610 TURBOJET ENGINES
GEAircraftEnnines MAINTENANCE MANUAL
(f) Remove the bolts that you installed in step (d). Be careful
not to unseat the turbine nozzle.
(g) Measure the axial runout on the aft face of the No. 3
bearing support, adjacent to the seal support rabbet.
The maximum TIR limit is 0.005 inch. If the maximum
TIR limit is exceeded, do as follows:
1 Remove the No. bearing support and check its mating
3
surfaces for burrs or foreign particles. Remove the
burrs or particles.
2 Install the No. 3 bearing support and measure the axial
runout again. If the maximum TIR limit is still out-of-
limits, remove the inner casing and check
combustion
the forward flange for burrs foreign particles.
or
Remove the burrs or foreign particles.
2 Re-install the inner combustion casing (refer to
paragraph 3)
(h) Use four bolts and locknuts, at approximately the 1:30,
4:30, 7:30, and 10:30 clock positions, and attach the
turbine nozzle to the outer combustion casing. Make sure
that the nozzle flange rabbet is seated
(i) For CJ610-1, -4, -5, -6 or -9 engines, check the radial
runout between the engine centerline and the rabbet, on
the No. 3 bearing support, that locates the No. 3 seal
support. Use tool 2C5308, as shown in figure 203, and do
as follows:
NOTE: i. If the No. 3 seal support has not been removed
to expose the rabbet on bearing
the No. 3
support, measure the runout check using the
non-grooved area of the bronze sealing surface,
on the ID of the No. 3 seal support.
NOTE: 2. For CJ610-1, -4, -5 and -6 engines, a
0.005-0.012 inch TIR runout is necessary
to preload the bearing.
1 Put the dial indicator (2, figure 203) at the 12
o’clock position. Set the dial indicator to read minus
0.014 inch if the engine is in the horizontal
position, or zero if the engine is in the vertical
position.
2 Put the dial indicator at the 6 o’clock position, and
record the indicator reading.
3 Put the dial indicator at 3 o’clock position, and set
the indicator to read zero.
72-40
1 Page 214 May 31/98
CJB10 TURBOJET ENGINES
GEAircraftEncrines MAINTENANtE MANUAL
4 Put the dial indicator at the 9 o’clock position, and
record the indicator reading.
5 The readings obtained in steps 2 and 4 must be within
these limits:
For CJ610-1, -4, -5, -6 0.005 to 0.012* inch
engines
For CJ610-9 engines 0.000 to 0.020* inch
*Readings can be plus or minus
6 If the TIR is not within these limits, remove bolts and
turn the nozzle to another "T" number position. Attach
the nozzle and check the rabbet runout again. Repeat
this procedure until the runout is within the limits.
(j) For CJ610-8A engines only, measure the radial runout
between the engine centerline and the rabbet OD as follows:
1 Install a nut and bolt in every third bolthole of the
stage 1 nozzle-to-outer combustion casing flange. Do
not tighten the nuts.
2 Make sure that the nozzle flange is seated.
3 Set the dial indicator to read the runout of the
No. 3 bearing support rabbet diameter, as shown in
figure 203.
4 Slide a 0.010 inch thick shim between the No. 3
bearing support and the dial indicator lever. Note
the direction of movement on the dial indicator.
This is the plus direction.
5 Put the dial indicator at the 6 o’clock position, and
set the dial indicator to zero.
6 Turn the dial indicator assembly 3600 around the No. 3
bearing support, and record this information:
Clock location of maximum runout.
Clock location of minimum runout.
If the runout is within the requirements of step 10,
go to step 11. If the runout is not within the limits
of step 10, do steps 1 through 13.
7 Put a small drift pin in the stage 1 nozzle inner bolt
circle, at the 3 and 9 o’clock positions.
8 Use drift pins and pull the stage 1 nozzle and the
the
No. bearing assembly toward the 12 o’clock position.
3
Deflect this assembly until the dial indicator reads
approximately these values for the rear bearing support
part number and the engine positions being assembled:
72-40
Page 215
May 31/98
CJ610 TURBOJET ENGINES
GEAircraftEnQineS MAINTENANCE IMANUAL
Engine Position
Rear Bearing
Support Part Number Vertical Horizontal
37D401649P107 -0.005 inch -0.013 inch
6041T49G01/G02 0.000 inch -0.009 inch
9 As you hold the stage 1 nozzle and the No. 3 bearing
assembly, hand-tighten half the bolts in the outer
flange of first-stage nozzle; then, torque the bolts
to 55-60 Ib in.
NOTE´• It may be necessary to turn the No. 1 nozzle to a
different "T" position to obtain the required
runout.
10 Check the No. 3 bearing offset, and determine the
runout and clock position of the maximum positive
reading (refer to figure 206). The runouts must be
as follows for the rear bearing support part number,
and the engine position being assembled:
Engine Position
RearBearing
Support Part Number Vertical Horizontal
37D401649P107 0.005/0.012 0.013/0.022
inch TIR inch TIR
between between
10 and 2 10 and 2
o’clock o’clock
6041T49G01/G02 0.003 inch 0.009/0.013
max TIR in inch TIR
any circum- between
ferential 10 and 2
position o’clock
11 Install the remaining bolts and nuts in the outer
flange. Torque the bolts to 55-60 Ib in., and repeat
step 10.
12 At the point opposite the maximum positive dial
indicator reading, try to insert a 0.001-inch shim
between the stage 1 nozzle and the No. 3 bearing
support circumferential flanges. The shim must not
enter. If the shim enters, repeat step 10.
13 Continue to assemble the engine and comply with these
instructions:
CAUTION: DO NOT REMOVE MORE THAN HALF THE BOLTS THAT
ATTACH THE STAGE 1 NOZZLE TO THE OUTER
COMBUSTION CASING AT ONE TIME. IF MORE THAN HALF
THE BOLTS ARE REMOVED, THE NO. 3 BEARING OFFSET
MUST BE RESET PER THIS PROCEDURE, AS DEFINED IN
STEPS 1 THROUGH 13.
72-40
I Page 216 May 31/98
CJ810 TURBOJET ENGINES
GEAircraftEnoines MAINTENANCE MANUAL
14 Final-torque the on bolts, on the forward flange of the
turbine casing, to 55-60 Ib in.
(5) Install the No. 3 seal support assembly and insulation blanket
(refer to figure 201) as follows:
(a) Install the O-ring (4) in the groove on the flange of the
rear seal support (3). Check the position of the O-ring,
and attach the seal support to the bearing support (16)
with bolts (2). Torque the bolts to 18-22 Ib in.
(b) Lockwire the bolts (2) with 0.032-inch diameter, single
strand, safetywire.
(c] Install the insulation blanket (1) on the rear seal
support. Work the tabs on the insulation blankets under
the back, around the lockwire for bolts (2), to retain the
insulation blanket in position.
(6) Install the turbine stationary air seal (refer to figure 201) as
follows:
(a) Put the turbine first-stage
stationary seal (6) on the
turbine nozzle. Install four bolts
equally spaced, (5),
through the seal flange, the inner flange of the turbine
nozzle, and the outer flange of the No. 3 bearing support.
Torque the bolts to 10-12 Ib-in.
(b) Check each bolt 15] to make sure that each bolt is snug
against stationary seal. If any bolt is not
the snug,
remove the bolts, re-align and reseat the parts, and
install the bolts again.
(C) Use your hand and install the ~bolts (5) in the shank nuts
on the aft flange of the inner combustion casing until the
first few threads are engaged. Then torque the bolts to
10-12 Ib in, carefully to avoid unseating the shank nuts.
(d) Install the simulator (15, figure 203), and check the
runout on the ID of the stationary seal (4). Remove the
bolts and turn the seal to obtain minimum runout.
(e) Remove the simulator (15)
WARNING: LUBRICATING OIL
DO NOT LET LUBRICATING OIL STAY ON YOUR SKIN. DO NOT
BREATHE THE FUMES RELEASED FROM LUBRICATING OIL FOR A
LONG TIME. LUBRICATING OIL IS DANGEROUS TO YOUR EYES,
NOSE, AND LUNGS.
(f) Use lubricating oil and lubricate the threads of the bolts
for the turbine stationary seal (6, figure 201)
72-40
May 31/98 Page 217
CJ610 TURBOJET ENGICI~ES
GEAircraftEngines MAINTENANCE MANUAL
(g) Install the bolts. Pre-tighten the bolts to 10-12 Ib-in.
Make sure that all the bolts are seated against the seal
(6). If the bolts are not seated, remove the bolt and
inspect the threads for damage. When each bolt is seated
and pre-tightened to 10-12 Ib-in., apply a final torque of
45-50 Ib-in.
(h) Lockwire the turbine stationary seal bolts, being careful
not to pass the lockwire over the louver edges so as to
block the louver openings.
(i) Before you assemble the turbine casing, remove the bolts
used to attach the nozzle to the combustion outer casing.
12 O’CLOCK
AGE I NO~Z;LE
NO. 3 BEARING SUPPORT
45" 450
MAXIMUM POSITIVE
SWPORT1
RUNOUT IN THIS AREA
PULL NOZZLE/BEARING
IN THIS DIRECI?ON
COMPRESSOR DRIVE SHAFT
BC-8085
No. 3 Bearing Offset CJ610-8A Only
Figure 206
72-40
Page 218 May 31/98
GEWERAL ELECTRIC
CJ610 TURBOJE7
SEI-186 MAINTENANCE MANUAL
OUTER COMBUSTION CASING MAINTENANCE PRACTICES
i. General. Maintenance of the outer combustion casing is limited to those items
which are accessible. (See figure 201.)
A. Visual inspection of the casing usually involves only the external area
of casing.
B. Visual inspection of the internal area is required when the combustion
liner is removed from engine.
C. Internal inspection per 72-03-1 of the welds around the drain, viewport
bosses, igniter bosses is required at hot section inspection (HSI)
and
when the combustion liner is removed from the engine.
2. Removal/Installation. Refer to section 72-40 for procedures.
3. Inspection/Check. When serviceable limits are exceeded, the casing may be
repaired in accordance with overhaul manual.
Inspection/Check Maximum Serviceable Limits Remarks
A. Combustion section assembled to engine:
(1) Cracks in shell Not serviceable.
or body.
(2) Dents in shell Any number, 1/4 inch deep Cold-work any
or body. with a minimum radius of number up to 3/8
8 times depth and not
the inch deep and
closer together than 3 not closer than
inches. 1 inch to flange.
No cracks are
serviceable.
(3) Igniter boss for:
(a) Cracks. Not serviceable.
(b) Igniter boss Not serviceable.
broken off.
(4) Drain boss for:
(a) Clogging.- Not serviceable. Pass a wire (No.
9 gage) through
the drain, in-
cluding the 2
holes in casing
skin.
(b) Cracks or boss Not serviceable.
broken off.
3une 1/71 72-41-0
Page 201
GEIIERAL ~B ELECTRle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(c) Excessive weld Weld repairs at edge of drain
repair, pad or across drain pad skin
are not allowed. (See figure
202.)
(5) All fusion welds Any number, cumulative
for cracks. length of cracks in any one
inch of weld not to exceed
0.100 inch.
(6) View port pads Not serliceable.
for cracks.
(7) View port pads for Not serviceable. Replace gasket.
gasket blowout.
(8) Casing for cracked Not serviceable. Tpughrup per
or missing 72-02-5.
Solaramic coating.
B. Combustion section removed from engine:
(1) Flanges for:
(a) Cracks. Mot serviceable.
(b) Dents. Any number of dents pro-
vided sealing capability
of the flange is main-
tained and the casing
can be assembled to
mating parts without
abnormal force.
I (c) Missing
.gnitaoc21A Any amount.
(2) Damaged threads in Cumulative length of Chase threads if
drain or igniter damage not to exceed damage does not
boss. 1-1/2 threads with no exceed 1-1/2
high metal, threads.
(3) Casing for:
(a) Cracked or miss- Not serviceable. Touch-up per
ing Solaramic 72-02-5.
coating.
(b) Corrosion pits. Any number 0.010 inch
deep if protective coat-
ing is intact in the
defect area.
72-41-0 Dec 1/77
Page 202
CEN ERALQ ELECTIIC
CJ600 TURBOJET
SEI-286 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(c) Areas of general None allowed that reduce
corrosion that wall thickness to less
reduce wall than 0.023 inch.
thickness.
(d) Missing A12 Any amount.
coating.
~St--´• 3
IGNITION BOSS
2. IGNITERPAD
3. AFTFLANGE
id
4. VIEW-PORT BOSS
5. VIEW-PORTPAD
6. CASINGSHELL
7. DRAIN
i4 8 DRAIN BOSS
i 9 FORWARD FLANGE
8--,3LJ ~7
CJ610d0)6-OF2
Outer Combustion Casing
Figure 201
72-41-0
Dec 1/77
Page 203
GENERAL E LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
COMBUSTOR DRAIN PAD
OUTER COMBUSTION CASING O DRAIN BOSS REPAIR WELDS
IN SWADED AREA-
REJECT CASING
s::::~
f-Ce cc
c,
cc_
~e c c ct
c~
REPAIR WELD
IN THIS AREA FILLET WELDING
ORIGINAL MANUFACTURE ALONG EDGE OF
(WITHIN 1/4 INCH
SPOT WELD ALLOWED DRAIN BOSS I DRAIN PAD REJECT
OF WASHER OR
CAST FITTING)- I CASING
ALLOWED
3
jlr 333
;i´•:´•:´•:´•:´•::
C
C C
CCC
JF
BC-0002
Outer Combustion Casing Drain Pad Weld-Inspection
Figure 202
72-41-0 June 1/71
Page 204
GEIERAL~ ELtCTRIC
CJ610 TORBOJET
SEI-186 MAINTENANCE MANUAL
COMBUSTION LINER MAINTENANCE PRACTICES
1. General. Visual inspection and maintenance of the combustion liner is usually
required only at time of "hot section" inspection.
NOTE 1: At "hot section" inspection the inner and outer shells
are to be replaced with new shells and the cowl and dome
assembly reconditioned in accordance with overhaul manual
or replace the combustion liner with a new or overhauled
liner with zero time.
NOTE 2: On CJ610-9 engines the inner and outer shells of com-
bustion liner Part No. 6008’194 are life-limited to 1200
hours and shall be replaced every other 600 hour hot
at
section inspection. The shells shall be inspected per
paragraph 3. at every 600 hours. Record the time on the
combustion liner in the engine log book.
2. Removal/Installation. Refer to section 72-40 for procedures.
9. Inspection/Checks. When the combustion liner is made accessible at other
than the specified inspection interval as stated in Service Bulletin
(CJ610) 72-43, the liner may be removed from the engine to perform the
inspection checks as listed in the following section of this maintenance
manual.
If only maximum serviceable crack limits of the inner and outer shells are
exceeded, repair weld them at an authorized CJ610/CF700 overhaul facility
in accordance with applicable sections of this manual. Inner and outer
shell replacement prior to the specified Hot Section inspection interval is
not required unless the maximum serviceable limits cannot be met by weld
repair. If replacement of the inner and/or outer shells is required, the
cowl-dome assembly must be reconditioned (along with the replacement of the
shells) at an authorized CJ610/CF700 overhaul facility in accordance with
the overhaul manual.
72-42-0
Dec 1/77
Page 201
GEIPIALQ ELECT8IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
20
~88a
SURFACE A
THIMBLE HOLE LIP BURNOUT
21
DIMENSION X
ORIGINAL CONTOUR
a\ 7’
1 2 314 r
´•r;
a
~ra b
a.
~a´• 9 LL
cC L
20 10 C~
I
19
"1
cfTI \i
~jD L L
L
Ir
II
I
I
11ro
,td !rfZ) i~-.
r
O
\\b, )!:r
I
ALTERNATE CONFIGURATION
Iti)! ~iI
I rI r 12
I
td7d,S,co, FORMATION
CRACK
LOUVER
o~
13
14
15
18 17 16
CONVERGING
LINER CRACK NOT
LOUVER DIE
ALLOWED
MARKS
GENERALLY
TYPICAL DIE MARK CRACKS
APPEAR HERE
SERVICEABLE LIMIT 0.062
1. Cowl 13. Thimble Hole
2. Fuel Nozzle Ferrule 14. Outer SheT1
3. Swirl Cup 15. Cowl O.D. Louvers
4. Dome 16. Shield
5. Igniter Washer 17. Fuel Nozzle Cutouts
6. Inner Shell 18. Cowl I.D. Louvers
7. Aft End of Inner Shell 19. Dome Louvers
8. Inner Flange Cooling Holes 20. Swirl Cup Louver
9. Inner Flange 21. Washer, Fuel Nozzle Ferrule
10. Cowl Tab
11. Louver
12. Outer Flange Cooling Holes
8C-O321-1
Combustion Liner
Figure 201
72-42-0 Dec 1/77
Page 202
6EW EIAL ELLCTIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
B. The inner and outer shells for:
(1) Burn holes. Not serviceable.
(2) Thimble holes for Any number of burned or
burned or eroded eroded lips, provided dimen-
lips. sion "X", figure 201 is no
less than 3/16 inch and two
thimble lips per alternate
axial row with dimension
"X" no less than 5/32 inch
and one lip no less than
1/8 inch.
(3) Burned metal.
(a) At outer shell aft None allowed unless cor- Blend burned
inner edge. rective action has been areas to unburned
taken. edge to max of
1/4 inch from
aft edge, 1 inch
long and 3 inches
apart.
(b) At the inner None allowed unless cor- One area can be
shell aft edge. rective action has been blended to un-
taken. burned edge, to
max cepth of 1/4
inch from aft
edge, not to ex-
ceed 1.50 inches
long. Blend tB
smooth contour.
(c) At all other areas. Not serviceable.
72-42-0
sept 1/76
Page 202A/202B
GEIPIALQ ELEC~IIC
cJs~o TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Checks Maximum Serviceable Limits Remarks
A. The liner for:
(1) Missing or Not serviceable. Replace liner.
broken rivets.
(2) Loose rivets. Not serviceable. Replace liner.
(3) Missing metal. Not serviceable. Replace liner.
(4) Louver openings Any amount. Reset louver per
(Inspect visually) paragraph 4.A.
(5) Rivet tack-weld Not serviceable. Retack-weld rivet
cracks. heads, 180 degree
from original tack
weld, per paragraph
4.C.
B. The inner and outer shells for:
(1) Burn holes. Not serviceable.
(2) Thimble holes for Any number of burned or
burned or eroded eroded lips, provided dimen-
lips. sion "X", figure 201 is no
less 3/16 inch and two
than
thimble lips per alternate
axial row with dimension
"X" no less than 5/32 inch
and one lip no less than
1/8 inch.
(3) Burned metal.
(a) At outer shell None allowed unless cor- Blend burned areas
aft inner edge. rective action has been to unburned
edge to
taken. max 1/4 inch from
of
aft edge, 1 inch long
and 3 inches apart.
(b) At the inner None allowed unless cor- One area can be
shell aft edge. rective action has been blended to unburned
taken, edge, to max depth
of 1/4 inch from aft
edge, not to exceed
1.50 inches long.
Blend to smooth con-
tour.
(c) At all other Not serviceable.
areas.
Dec 1/77 72-42-0
Page 203
IENERAL~ ELECIIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(4) Buckles, warps or Not serviceable. Cold-work any de-
dents. formation 3/8 inch
or less to original
contour.
(S) Cracks at rivet Not serviceable. Replace liner.
holes.
(6) Cracks at louver
and thimble holes:
NOTE i: The dies that are used in forming the louvers tin the
combustion liner) leave a mark on the surface being
formed and also cracks, approximately 0.030 inch long.
These marks and cracks do not represent any deterioration
of the liner and should not be identified as defects.
When viewed with a 10 power glass they can be distin-
guished from the thermal stress cracks by their even,
uniform pattern. The cracks that are to be inspected
around the louvers generally appear to be jagged and
the material is usually separated. When measuring the
length of the louver crack, begin where the louver
embossment radius blends with the surface of the dome
or shell. See figures 201 and 202.
NOTE 2: Previous weld repairs that are cracked, cannot be weld
repaired.
Any amount provided the Repair-weld per
sum of the uncracked paragraph 4.B., all
fractional portion of each cracks longer than
ligament in any crack loop 1/16 inch to meet
is more than 2. (See serviceable limits.
figure 202.)
1 72-42-0 Dec 1/77
Page 204
OEIEIAL ~D ELCC~IIC
cJeio TORBOJEt
SEI-186 MAINTENANCE MANUAL
DEFINITIONS
Liga´•nent tree v;ewB) shell material between any 2
NOTES:
should exis~ any
odjacent rtamped openings. If a crack
uncrocked portion of s)lell material between such openings Only the shell materiol between stamped openings is
~´•;ill be considered a fraction of the ligament. used to establish a crack-loop.
LIGAMENT STRENGTH VALUES
This method is to determine the strength of the remaining
(See view C) material to retain a shell section, not to measure clock
A Connecting crack :O
length
B No crack I
Crocks rhown in views A thru D are typical and do not
show all configurations of crack loops which could develop.
C 1/2 length uncracked 1/2
=3/4
Add only Jncrocked ligaments and/or uncracked fractions
D 3/4 length uncracked
,ofligaments to determine serviceable status of cracks in
Crock-Loops (see view D and E) Any number of any loop.
ligaments which, if completely cracked, would allow a
shell section to fall out. There must be at least 2 partially
cracked ligaments to establish a crock-loop.
INSPECTION PROCEDURE
a. Inspect the liner for thimble hole or louver cracks. d. Determine serviceability of cracks in a crock-loop os follows:
i. Add the uncracked ligaments or fractional parts in the
b. Using viewA, find the smallest crack-loop. crack-loop.
2. If the sum is more than 2, the cracks in the crack-loop
Expand crack-loop concept to determine
the the
c.
are rerviceoble.
serviceabi lity of larger areas or applicable, serviceable.
3. If the sum is2 or less, the crocks ore not
~t:
ri~.
c
VIEW A VIEW C
VIEW B VIEW D VIEW E
c~slo´•6004.l.n2n
Combustion Liner Crack Loop Analysis
Figure 202
I Dec 1/77 72-42-0
Page 205
CE1E RAL~ ELECTRIC
eJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
C. The ou~er flange for:
(1) Cracks at the for- Any number 1/16 inch long, Repair-weld per
ward and aft cool- not more than one per hole. paragraph 4.B. to
ing holes, meet serviceable
limits.
D. The inner flange for:
(1) Cracks at the Any number 1/16 inch long, Repair-weld per
holes. not more than one per hole. paragraph 4.B. to
meet serviceable
limits.
E. The same weld be-
tween the aft end of
the inner shell and
the inner flange for:
(1) Cracks. Not serviceable.
F. The dome for:
(1)Cracks. Any number, 1/16 inch long; Stop-drill cracks
1 per louver 1/8 inch long over service limit,
provided no piece is in but extending no
danger of falling out. closer to another
louver than 1/16
inch and no more
than 2 such cracks
at each fuel nozzle
louver pattern. Use
a 0.047 inch dia-
meter drill.
(2) Swirl cup for Any number, 1/16 inch
cracks, long.
1 72-42-0 Dec 1/77
Page 206
CflEIAL~ LLEETIIE
CJ610 tURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(3) Wear on swirl cup
end plate (cowl and
dome assembly).
(8) Plate wear. With fuel nozzle ferrule Remove fuel nozzle
and washer moved off center ferrule and washer
to extreme limit in four and measure thickness
directions (see figure 201), of end plate. If
there shall be no wear thickness is under
grooves in Surface A. Use 0.025 inch, replace
a 0.030 inch radius ball end plate at an ap-
scribe to measure wear. proved overhaul
facility.
(b) End plate With fuel nozzle ferrule Remove fuel nozzle
opening. and washer moved off center ferrule and washer and
to extreme limit in four measure inside dia-
directions (see figure 201), meter of end plate
the edge of the end plate opening. if the
opening shall not be opening exceeds 0.800
uncovered. inch, replace end
plate at an approved
overhaul facility.
G. The cowl for:
(1) Cracks. 6 cracks 1/8 inch long
per each band of rivets.
1 (2) Deleted.
72-42-0
Dec 1/77
Page 207
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
H. The fuel nozzle ferrules for:
(1)Burnt metal. Remaining material must ex-
tend 1/8 inch minimum beyond
ferrule ID for 270 degrees
of are and 5/32 inch minimum
for remaining 90 degrees of
are.
(2) Seizure. The ferrules shall slide Work ferrule free;
freely. application of lubri-
cating oil may help
to free seized parts.
I. The igniter washers for:
(1)Tightness. The washer shall slide Work washer free;
freely. application of lubri-
cating oil may help
to free seized parts.
(2) Burnt metal. Not serviceable.
(3) Looseness. Clearance between washer Re-swage or replace
and cowl not to exceed washer.
0.030 inch.
4. Repair.
A. Louver Inspection and Resetting Procedures.
CAUTION: DO NOT USE THE GOINO-GO GAGES FOR PRYING THE LOUVERS OPEN. DO
NOT BEND LINER INTO COMBUSTION AREA. SEE FIGURE 203.
(1) Inspect and reset the dome louvers as follows:
(a) Inspect the dome louver openings using gage, 205483.
72-42-0
Page 208 Dec 31/95
GE#ERAL~ ~LICTRIC
CJ610 TURBOJET
8111-186 MAINTENANCE MANUAL
LINER r- LOUVER I LINER LOUVER
I : : : : : : : : i: : : : : : : : : : : : : : :~j: : : : : : :
COMBUSTION
ciP~eWRONG
AREA
´•:2:is~
DO NOT BEND LINER
INTO COMBUSTION AREA.
CJ610-3264-0-F2
Resetting Louver Openings
Figure 203
1 If opening is too small, use tool, 205482, to open.
2 If opening is too big, use tool, 205482, to close by tapping
lightly with small brass hammer.
(2) Inspect and reset swirl cup louvers as follows:
(a) Inspect and reset swirl cup louver openings using gage, 205452.
1 If opening is too small, use spreader, 205450, to open.
2 If opening is too big, use tool, 205451, to close.
(3) Inspect and reset cowl louvers as follows:
(a) Inspect inner cowl louver openings using gage, 2C5453Pl1.
1 If opening is too small, use spreader, 2C5453P08, to open.
2 If opening is too big, use small brass hammer to close.
(b) Inspect outer cowl louver openings using gage, 2C5453P12.
1 If opening is too small, use spreader, 2C5453P07, to open.
2 If opening is too big, use small brass hammer to close.
Dec 1/77 72-42-0
Page 209
GEWERAL~ ELECTIIG
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-18S
(4) Inspect and reset inner and outer shell louvers as follows:
(a) Inspect inner shell louver openings to the dimensions shown in
figure 203A, using standard steel wire-type plug gages.
NOTE: The go-size of the gage shall be the minimum louver size
and the no-go size shall be the maximum louver size. The
wire-type plug gage shall be made of hardened tool steel
and be manufactured within +0.0001 inch of the go-no-go
size Wire-type plug gages in standard sizes are
required.
available from most precision measuring tool manufacturers.
One such source is the Van Keuren Company, Watertown,
Massachusetts.
1 If opening is too small, use spreader, 2C5453P05, to open.
2 If opening is too big, use small brass hammer to close.
(b) Inspect outer shell louver openings to the dimensions shown in figure
203B using standard steel wire-type plug gages.
NOTE: The go-size ofthe gage shall be the minimum louver size and
the no-go size shall be the maximum louver size. The wire-
type plug gage shall be made of hardened tool steel and be
manufactured within +0.0001 inch of the go-no-go size required.
Wire-type plug gages in standard sizes are available from most
precision measuring tool manufacturers. One such source is
the Van Keuren Company, Watertown, Massachusetts.
1 If opening is too small: use spreader, 2C5453P06, P07 or P08, as
applicable, to open.
2 If opening is too large: use small brass hammer to close.
B. Weld Repair of Combustion Liner.
CAUTION: THIS PROCEDURE MUST BE PERFORMED BY A CERTIFIED WELDER.
(1) Grind out through-cracks to a depth of approximately 0.020 inch, from
the outside, keeping width to an absolute minimum.
(2) Cracks that do not ground 1/16 inch beyond end
connect 2 openings are
of crack and checked with a 10 power glass. Keep grinding width to a
minimum. Grind to an approximate depth of 0.020 inch.
(3) Clean surface and back side of weld area within 1/4 to 1/2 inch of the
crack, using fine emery cloth or soft abrasive wheel. Do not reduce
material thickness.
72-42-0 Dec 1/77
Page 210
GEnllAL~b ELOCTIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
(4) Use aluminum foil to make a pocket for back-up gas on the back side of
the weld area. Permit gas to flow for 3-4 minutes to force out all air
before welding.
(5) Weld using data specified in Table 201.
(6) Blend out all repair welds that obstruct louver openings. Blend as
necessary all repair welds flush with parent material.
CAUTION: DO NOT UNDERCUT PARENT MATERIAL.
(7) Inspect welds with 10 power glass. No cracks permitted. If cracked,
repeat paragraph 4.B.
C. Tack-weld of Rivet Heads:
(1) Clean both manufactured and upset rivet heads, and liner metal, in
areas to be tack-welded, using 80-100 grit emery cloth.
(2) Vapor degrease or clean the area to be welded using trichloroethylene
or equivalent.
(3) Tack-weld both manufactured and upset rivet heads per figure 204 using
weld data in Table 201.
Dec 1/77 72-42-0
Page 211
orrru~g ruerlle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
5/0:
ABO :J
v
vD, x Ix"
FWD
LOUVERS HEIGHT GAGE GAGE
GD SIZE ND-GO SIZE
V 0.018
0.013 0.013 0.018
X 0.027 0.023 0.027
0.023
Z 0.042 0.038 0.042
0.038
AB 0.018 0.013 0.018
0.013
BC-0141
Inner Shell Louver Measurements
Figure 203A
72-42-0 Dec 1/77
Page 212
GTIEIAL~ ELltTRIG
CJ610 TUREI´•OJ~T
SEI-18~ MAINTENANCE MANUAL
;i
o ,I
oW T
o
B
T
T TT
AM
T
T o
o
O II
o
"O
I o
oII O
B AM
LOUVERS HEIGHT GO SIZE NO GO SIZE
0.025
T 0.025 0.030
0.030
NOTP:LOUYERS MARKED M L AT
0.017
EACH IGNITER CUT OUT. I AM 0.017 0.022
0.022
0.025
Z )ic 0.025 0.030
0.030
0.020
M ~C 0.020 0.024
0.024
0.017
B 0.017 0.022
0.022
0.020
C 0.020 0.024
0.024
BC-0351
Outer Shell Louver Inspection
Figure 203B
72-42-0
Dec 1/77
Page 213
OlntlALa~B ILletlllC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
TACK-WELD WIDTH NOT TO EXTEND
TACK-WELD OUTER SHELL
BEYOND DIAMETER OF RIVET H
(SEE NOTE)
WELD
RIVET
RIVET 0.10
AN123336
0.05
IVET AN123319
-T/0.20
0.04
MIN
I
0.20
0.10
DOME TACK-WELD TACK-WELD NOT TO
(SEE NOTE) EXTEND BEYOND
CENTER OF RIVET HEAD
g rRIVET
AN123319
L
INNE SHELL
RIVET TYPICAL TACK-WELD 0.07 0´•07
AN1 23336 ~9 1 0.04 0.04
TACK-WELD
(SEE NOTE)
NOTE: MANUFACTURED HEAD OF RIVETS SHALL BE
AGAINST THE COWL FOR COWL/DOME AND
OUTER SHELL RIVET BANDS, AND AGAINST
THE SHELL FOR THE INNER SHELL RIVET RIVET
BAND. ORIENTATION OF THE TACK-WELDS AN123319
MAY BE FORWARD OR AFT (OPTIONAL) OF OUTER IGNITER
THE RIVET HEADS. TACK-WELD BOTH HEADS TACK-WELD
WASHER
OF EACH RIVET. (SEE NOTE) OUTER SHELL
COWL
TACK-WELD
(SEE NOTE)
INNER IGNITER WASHER
JF
DC-8020
Tack-Welding Combustion Liner Rivet Heads
Figure 204
72-42-0 Dec 1/77
Page 214
C E W E RA L E LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TABLE 201
WELD DATA
NOTE:
Use 1/16 inch diameter, pointed, one percent thoriated tungsten electrode.
Keep the torch in a near vertical position to achieve good gas coverage over
and around the melt. Electrode extension 1/8 3/16 inch beyond ceramic cup.
Upon reaching end of weld, rotate the torch so that the are goes back into
the bead and, with the remote control, slowly decrease the current until the
are goes out. Hold torch over the bead with gas flowing until the red glow
disappears.
Use 1/32 1/16 inch diameter filler wire (1/32 inch preferred).
Keep filler rod in gas stream to keep hot end from oxidizing.
Filler
Current Torch Backup
Combustion
Component (Amps) Gas Gas Weld
Liner Wire
Material DC Straight Flow Flow Contour
Component Material
Polarity (CFH) (CFH)
(1) Inner and Hastelloy X Hastelloy X 15-35 Argon Argon Flush
outer shell (AMS5536) (AMS5798) 8-14 5-10
and outer
flange.
or
Alternate
Hastelloy W
(AMS5786)
(2) Inner flange. Incoloy T Hastelloy X 10-35 Argon Argon Flush
(AMS5552) (AMS5798) 8-14 5-10
or
Alternate
Hastelloy W
(AMS5786)
Rivet heads. Inconel 600 Hasteloy W Argon Tack-
(3)
(AMS5540) (AMS5786) 5-10 weld
3( Use a remote control variable current device to minimize heat input.
Actrol (Mullenback Electrical Manufacturing Co., 2300 East 27th St.,
Los Angeles, California) or equivalent, is recommended.
72-42-0
Dec 1/77 Page 215
6EIORAL~ LLfCfRIE
CJ610 TURBOJET
SEI-186 MAINTENANCE M~NUAL
INNER COMBUSTION CASING MAINTENANCE PRACTICES
1. General. Inspection of the inner combustion casing is usually required only
at time _of "hot section" inspection.
A. Visu~l inspection of the casing usually involves only the outer areas of
casing.
B. Visual inspection of the internal areas, which are accessible, is re-
quired when the No. 3 bearing support is removed from engine.
1 2. RemovallInstallation. Refer to section 72-40 for procedures.
3. Inspection/Check. When serviceable limts are exceeded, the casing may be
repaired in accordance with the Overhaul Manual.
Inspection/Check Maximum Serviceable Limits Remarks
A, Inner combustion casing with No. 3 bearing support installed on engine:
(1) Welds for cracks. Total length of cracks in
any joint shall not ex-
ceed 1/4 inch.
(2) Shell for dents. Any ntnnber of small dents
with smooth indention,
1/4 inch deep.
(3) Shell for nicks Any n~rmber 0.010 inch
and scratches. deep,
(4) Casing for Not serviceable. Touch-up per
cracked or missing 72-02-5.
Solaramic.
B. Inner combustion casing with No. 3 bearing support removed from engine:
(1) Flange 50r:
(a) Cracks. Not serviceable.
(b) Nicks and Any number 0.010 inch deep,
scratches. with no high metal.
Dec 31/91 72-43-0
Page 201
6EnE RAL ~B ELEOTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(c) Dents. Any number of small dents
with no high metal on the
flange faces or on mating ID.
(d) Missing A12 Any amount,
coating.
(2) Casing for:
(a) Cracked or Not serviceable. Touch-up per
missing 72-02-5.
Solaramic
coating.
(b) Missing A12 Any amount.
coating.
72-43-0 Dec 1/77
Page 202
GEWtRAL~ LLECTRIG
CJ610 TUWBOJET
SEI-186 MAINTENANCE MANUAL
TURBINE STATIONARY OUTER SEAL MAINTENANCE PRACTICES
i. General. inspection and maintenance of the turbine stationary
Visual seal
is usually required only at time of "hot section" inspection.
2. Removal/Installation. Refer to section 72-40 for procedures.
3. Inspection/Checks. When serviceable limits are exceeded, the seal may be
repaired in accordance with overhaul manual. (See figure 201.)
Inspection/Check Maximum Serviceable Limits Remarks
A. Seal support for:
(1) Cracks. Not serviceable.
(2) Nicks and scratches. Any number 0.015 inch deep
after removal of high metal.
(3) Dents. Any number 0.015 inch deep
after removal of high metal.
B. The silver brazed surface for:
(1) Grooves. Any depth, provided they do
not penetrate to the steel
ring and not wider than
0.090 inches.
i. SEAL SUPPORT
2. SILVER BRAZED SURFACE
CJb10-60)7-0-F2
Turbine Stationary Outer Seal
Figure 201
Dec 1/77 72-45-0
Page 201
cEWEIAL8E LPCT~IC:-------
cjeio Tulilio3eT
SEI-186 I~INTENANCE MANUAL
NO. 3 CARBON SEAL SUPPORT MAINTENANCE PRACTICES
i. General. Visual inspection and maintenance of the seal support is usually
required only at time of "hot section" inspection.
2. Removal/Installation. Refer to section 72-40, No. 3 Bearing Replacement,
for procedures.
3. Inspection/Checks. When serviceable limits are exceeded, the seal support
may be repaired in accordance withoverhaul manual. (See figure 201.)
Inspection/Check Maximum ServiceableLimits Remarks
A. Seal support for:
(1) Cracks Not serviceable.
(2) Nicksand scratches Any number 0.010 inch deep
after removal of high metal.
(3) Pits due to cor- Any number, 0.015 inch diam-
rosion eter, 0.010 inch deep.
B. Welds for cracks Any number, 0.030 inch long,
provided cumulative length
in any 1 inch does not ex-
ceed 0.090 inch or does not
exceed 1/4 inch in any
joint.
C. Silver bra2;e surface Any number 0.080 inch wide
for~ grooves and depth not into base
material.
D. Threaded holes for Cumulative length of damage
defects (with sup- not to exceed 1-1/2 threads
port removed from with no high metal.
engine)
Mar. 30/67 72-46-1
Page 201
OIYERII´•ILftllllC----
eJ810 TURBOJET
MAINTENANCE MANUAL SEI-186
i. REAR SEAL SUPPORT
2, SILVER BRAZE
3. WELD JOINT
CJ610d038´•0-r?
No. 3 Carbon Seal Support
Figure 201
72-46-1 Mar. 30/67
Page 202
BEIEIAL8 ELECTRIC
CJBIO TUCPBOJET
SEI-186 MAINTENANCE MANUAL
INSULATION BLANKET (NO. 3 BEARING AREA) MAINTENANCE PRACTICES
i. General. inspection and maintenance of
Visual the insulation blanket is
usually required only at time of No. 3 bearing carbon seal replacement.
2. Inspection/Checks, When serviceable limits are exceeded, the seal support
may be repaired in accordance with the overhaul manual (see figure 201).
Inspection/Check Maximum Serviceable Limits Remarks
A. Cracks in foil or Any amount, provided
separation at welds, Insulation is not missing
or oil soaked.
B. Missing tabs. 3 per blanket provided no
2 are adjacent.
i. FOIL
2. TAB
cJaio-sos7.o-Fz
No. 3 Bearing Insulation Blanket
Figure 201
Mar. 30/67 72-46-2
Page 201
GLWERAL [LCCTRIC
CJ810 TUR8OJET
SEI-186 MAINTENANCE MANUAL
CARBON SEAL (NO. 3 BEARING) MAINTENANCE PRACTICES
i. General, Visual inspection of the No. 3 bearing carbon seal is outlined in
section 72-02-2. Inspection is usually required only at time of "hot sec-
tion" inspection.
2. Removal/Installation. Refer to section 72-40, No. 3 Bearing Replacement,
for procedures.
Mar. 30/67 72-46-3
Page 201
GEIEIAL ELECTIIE
CJ610 TURIOJhT
SELc186 MAINTENANCE MANUAL
NO. 3 BEARlNG SUPPORT MAINTENANCE PRACTICES
i. General. Inspection of the No. 3 bearing support is usually required only
at time of "hot section" inspection.
A. Visual inspection of the No. 3 bearing support usually involves only the
aft surfaces of the support.
B. Visual inspection of the forward surfaces is required when the No. 3
bearing support is removed from engine.
2. Ieeovall/ Installation. Refer to section 72-40, No. 3 Bearing Replacement
procedure.
3. Inspection/Check. When serviceable limits are exceeded, the support may be
repaired in accordance with overhaul manual. (See figure 201.)
Inspection/Check Maximum Serviceable Limits Remarks
A. No. 3 bearing support installed on engine
(I) Cra~ks. Not serviceable.
(2) Nicks, scratches Any number 0.010 inch
anddents. deep after removal of
high metal from mating
surface6.
(3) Corrosion pits.
(a) Conical portion 0.030. inch of metal re-
of web, maining.
(b) All other areas. 0.050 inch of metal re-
maining.
(4) Support for cracked Not serviceable. Touch-up per
or missing Solaramic 72-02-5.
coating´•
B. No. 3 bearing support removed from engine.
(1) Gang channel nuts for:
(a) Cracks or broken Not serviceable.
nut retainers.
(b) Nuts for self- Serviceable provided a
locking capability. bolt can not be threaded
(using fingers only) all
the way through the nut.
June 1/71 72-46-4
Page 201
OIYERIL ILICTIIC
CJ810 TURBQJeT
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(2) Surfaces R and Y, Any number 0.010 inch deep
Diameter F for with not over 50 percent of
nicks, dents and surface damage in any one
local scoring. quadrant after removal of
high metal.
(3) Support for cracked Not serviceable. Touch-up per
or missing Solaramic 72-02-5.
coating.
AFT.
SURF Y
NOZZLE MOUNTING RABBET
I
DIA S
SEAL SUPPORT MOUNTING RABBET
SHAFT SHIELD
FWD.
MOUNTING RABBET
-f AFT.
DIA F
SECTION
C
A-A
SURF R
i. SUPPORT
2. BEARING BORE
3. GANG CHANNEL NUT~
J
CJ610403~´•0-F2
No. 3 Bearing Support
Figure 201
72-46-4 June 1/71
Page 202
D EW ERAL ELECTRIC
CJ610 TURIOJET
SEIr186 MAINTENANCE MANUAL
NO. 3 BEARING MAINTENANCE PRACTICES
i. General. Visual inspection of the No. 3 bearing is outlined in section
72-02-3. Inspection is usually required only at time of "hot section" in-
spection.
2. Removal/Inspection. Refer to section 72-40, No. 3 Bearing Replacement, for
procedure,
Oct. 15/70 72-46-5
Page 201
ELfClIIIC
’CJ 810 TLjRBOJET
SE1-186 MAINTENANCE MANUAL
HEAT SHIELD MAINTENANCE PRACTICES
i. General. Maintenance of the heat shield (optional equipment) is limited to
those items which are accessible. (See figure 201.)
A. Visual inspection of the heat shield usually involves only the external
area.
B. Visual inspection of the internal area is only required if the heat
shield is suspected to have damage.
2. Removal/Installation. Refer to 72-40 for procedures.
3. Inspection/Check. When serviceable limits are exceeded the heat shield may
be repaired in accordance with overhaul manual.
Inspection/Check Maximum Serviceable Limits Remarks
A. Cracks in shell 4 per half, 1/4 inch long.
(body) or welds
B. Cracks in gussets 1 per gusset or boss, 1/8
or bosses inch long.
C. Rivets
(1) Missing Not serviceable. Replace rivet.
(2) Loose Not serviceable. Re-strike rivet or
replace.
D. Dents in shell Any number, 1/4 inch deep
or body provided they do not in-
terfere with assembly and
are not cracked.
E. Anchor nuts for:
(1) Cracked or broken Not serviceable. Replace anchor nut.
nut retainer
(2) Damaged thread Not serviceable. Replace anchor nut.
(3) Self-locking Serviceable provided a
capability bolt cannot be threaded
(using fingers only) all
the way through the nut.
Mar. 30/67 72-47-0
Page 201
GEWERAL E LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
CJ610-60~0´•0´•F?
Heat Shield
Figure 201
72-47-0 Mar. 30/67
Page 202
G tN RA L f LE CT R IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TL?IBINE SECTION DESCRIPTION AND OPERATION
2 _t
f
i’
d i
I
r´•
r
1
,r,
b:
i; i
~’sJ
r(:
t´• r~
’i
7;
5
r!;
i j i:
ITiV
~O.
3 FIRST-STAGE TURSIHE NOZZ:E
i.
2. FIRST-STAGE TURBINE ~HROJD 72-ET-;
3. SECON3-S;AGE TURE;hE HC;:-I
i
I
4. TURB;~E CAS!NG i- f:-
j. SECOHD-STAGi
64 6. RAOi~:IOI SEAL 7:.5T
7. INTiRSTAGE SEAL :i’
~c-s TURGIHE ROTOR ASSE~6-’
SE~E 72-53-:
E.
2 Ir
i,i
SECTIONAL VIEV?
CJ~10-8 AND 9 AT ARROW A 8C-0459
Turbine Section
Figure 1
Ilar 30/84
ORIGINAL As
i2-50
RECEIVED BY ATP PaeE 1
tLECTRIC
CtNERAL~
CJ610 TURBOJET
blAI~iTENANCE MANUAL SEI-186
i, General. The turbine section consists of the turbine casing, shrouds, noz-
ties, and rotor. The primary function of the turbine is to extract energy
from the heated air to drive the compressor.
2. Description.
A. Turbine Casing. The turbine casing is an annular shaped steel case,
split and flanged along its horizontal centerline. Tracks inside the
mounts for the first- and second-stage turbine shrouds
casing serve as
and the second-stage turbine nozzles. Two external bosses admit the
anti-rotation bolts which lock the second-stage nozzle to the casing.
The CJ610-8 and -9 engines have cooling air passages to provide addition-
al cooling air to the second-stage nozzle area and also has dams adjacent
to the split-lines to decrease leakage.
B. Turbine Shrouds. On CJ610-1, -4, -5 and -6 engines, the first-stage
shroud is a solid, metal shroud; the second-stage shroud is a honeycomb
shroud. Each shr’oudinterlocking segments which slide
consists of four
into mounting tracks inside the turbine case. On CJ610-8 and -9 engines,
the first- and second-stage turbine shrouds are Bradelloy-filled honey-
comb shrouds. Each stage of shrouding consists of four interlocking seg-
ments which slide into mounting tracks inside the turbine case.
C, Turbine first-stage nozzle consists of an outeS:.band joined
Nozzles. The
to an by radially positioned, hollow partitions, welded in the
inner band
outer combustion casing, the first-stage nozzle and the turbine casing
together. An inner support flange, welded to the inner band, is bolted
to the number thr’ee bearing support and the inner combustion casing. The
second-stage nozzle consists of an outer band joined to an inner band bS
welded partitions and is split horizontally. The outer band mounts in
tracks inside the turbine casing. The inner band flange retains the
stationary position of the turbine interstage CJ610-1, -4,
seal on the
-5 and -6 engines. The CJ610-8 and -9 turbine
interstage seal consists
of 6 segments bolted to the inner flange of the second-stage nozzle.
Both engine models employ a honeycomb construction type seal.
D, Turbine Rotor. l‘he major components of
assembly are: the turbine rotor
two turbine wheel
assemblies, a interstage turbine
assembly, a seal
torque ring assembly, and standard hardware. The first-stage turbine
wheel is integral with an internally splined shaft which mounts the en-
tire assembly on the engine drive shaft. Turbine blades are inserted
into dovetails in the circumference of the wheel and are held in place
by locking strips. Baffles are inserted between turbine blade shanks
to prevent cross-flow of gases, and to dampen vibration. The inner air
seal labyrinth ring is riveted to the forward face of the first-stage
wheel
A locking nut and a washer retain the No. 3 rubbing seal runner and the
No. 3 roller bearing race. inner The torque ring assembly is mounted on
the rear of the first-stage wheel. The boltsthat secure this assembly
72-50 Jan. 15/69
Page 2
GtnERbl~tlECTRIC----
CJ610 TURBOJET
SEI-186 MAINTEPITANCE MANUAL
ITEM
NO. NOMENCLATURE
i. TURBINE ROTOR ASSEWBLY
2. FIRST-STAGE TURBINE WHEEL
5
3. FIRST-STAGE TURBINE BLADE
4. SECOND-STAGE TURBINE WHEEL
5. SECOND-STAGE TURBINE BLADE
6. TORpUE RING
3 7. BALANCE WASHER
8. BALANCE WASHER
9. OUTER LABRYRINTH SEAL
)O. INNER LABRYRINTH SEAL
11. NO. 3 BEARING CARBON SEAL
RUNNER
12. NO. J BEARING INNER RACE
0 13. NO. 3 BEARING LOtKWASHER
14. NO. 3 BEARING LOCKNUT
NOT SHOWN
FIRST-STAGE BLADE LOCKING STRIP
FIRST-STAGE TURBINE BLADE BAFFLE
a ------u~ :hJY SECOND-STAGE BLADE LOCKING STRIP
SECOND-STAGE TURBINE BLADE BAFFLE
14 13 12 11 10 I yi~ 7 INTERSTAGE SEAL
2 1 NOTE: FOR INSPECTION Of AL:
PARTS, SEE SEtT:ON 7P-53-L.
BC-045F
Turbine Rotor Assembly
Figure 2
Mar 30/84
72-50
Page 3
GLN ERAL ~B ELECTRIC
CJ610 TURBOJE~T
MAINTENANCE MANUAL SEI-186
also secure the outer air seal labyrinth ring on the forward face of the
first-stage wheel. The torque ring assembly couples the two turbine
wheels and has an integral baffle with holes that allow the passage of
cooling air. The turbine interstage seal on the CJ610-1, -4, -5 and -6
engines is supported by pins which rest on the slotted inner band of the
second-stage nozzle ton CJ610-8 and -9 engines the ineerstage seal bolts
to the second-stage nozzle). The honeycomb portion of this seal bears
against the torque ring for sealing. The labyrinth portion of the seal
is integral with the torque ring.
3. Operation.
The heated gases pass from the combustion chamber through the turbine noz-
ties, across both tu:rbine wheels and out the exhaust cone. The turbine
wheels extract energ:ir from the heated gases and transmit this energy for-
ward by means of the engine drive shaft to drive the compressor rotor and
accessories. Temperatures of the exhaust gases are so high that without
provisions for cooling air, the life of the turbine components would be very
short. A portion of the compressed air not used for combustion flows from
the combustion section outward through radial holes in the first-stage noz-
zle outer band and aft to cool the first-stage nozzle and the turbine casing
at which point it re-enters the main gas stream. The remainder of the air
flows inward through the hollow partitions of the first-stage nozzle into
the inner band of the nozzle, and is expelled aftward against thF! shanks of
the first-stage turbine buckets. Some of the air, as it passes through the
partitions is expelled through small slots drilled in the concave surface
and cools the trailing edges of the partitions. Another portion of air
flows aft from the combustion section through holes in the first-stage noz-
zle inner flange and pressurizes the balance piston chamber formed by the
inner and outer air seals on the forward face of the first-stage turbine
wheel. This pressure utilizes the wheel as a piston to offset the forward
thrust moment compressor rotor, reducing
of the loading the on the number
two bearing. Some o:E the balance piston air flows through the inner air
seal and pressurizes the number three carbon seal. The remainder of the air
flows aft through holes in the first-stage wheel and cools the remainder of
the turbine rotor before passing into the main exhaust stream.
1 72-50 Nov. 15/73
Page 4
GLN ERAL LE CTR IC
CJ610 TURBOJET
SEL-186 MAINTENANCE MANUAL
TURBINE SECTION MAINTENANCE PRACTICES
1. General. This section gives the procedures for the removal/installation of
the turbine section parts required for hot section inspection or component
replacement.
Preliminary Procedures. Prior to removal of turbine stater casing, check
eccentricity of second-stage turbine blades using a feeler gage as follows:
A. Place feeler gage between any second-stage blade tip and shroud at 5 o’clock
position. Rotate the turbine rotor and measure this clearance for each
blade. The difference from the minimum to maximum measurement will estab-
lish the turbine blade eccentricity. Record this measurement in the engine
records.
B. Review previous engine records. If eccentricity is the same or less than
that at the last eccentricity check,
determined if there has been no re-
ported noise or vibration, and if the first-stage nozzle is not cracked,
re-balance of the turbine rotor assembly is not required.
C. If no prior records are available and turbine blade eccentricity is 0.010
inch or greater, if there has been a report of noise or vibration, or if
there is a cracked first-stage nozzle inner band, re-balance the turbine
rotor assembly per SEI-136.
D. Matchmark the turbine rotor with compressor drive shaft at teardown for re-
assembly in the same location.
2. Removal/Installation.
NOTE: The exhaust cone (see Section 78-11) and the combustion heat shield
(see Section 72-40) must be removed prior to starting this procedure.
The required special tools are listed in Section 72-00.
A. Removal of Turbine Stater. Remove the turbine stater halves (with second-
stage nozzle and turbine shrouds installed) as follows:
CAUTION: ON CJ610-8A ENGINES, DO NOT UNBOLT OR LOOSEN MORE BOLTS THAN
NECESSARY TO DISASSEMBLE OR ASSEMBLE ONE TURBINE STATOR HALF AT A
TIME. CLAMPING FORCE OF THE FIRST-STAGE NOZZLE FLANGE TO THE
COMBUSTION CASING MUST BE MAINTAINED ON AT LEAST ONE HALF OF THE
FLANGE CIRCUMFERENCE AT ALL TIMES. A MINIMUM OF 8 EVENLY-SPACED
BOLTS ON A STATOR HALF IS REQUIRED WITHTORQUE AS SHOWN ON FIGURE
205.
NOTE: Antirotation bolts (used on CJ610-1, -4, -5, and -6 engines) with
rectangular heads marked "Y" on the shank are not reusable. Those
marked with "A" must pass inspection per 72-52-0, before reuse. Oval
head bolts (not marked) (used on C3610-8A, and -9 engines) must pas’s
inspection per 72-52-0, before reuse.
Mar 30/84 72-50
Page 201
CENIRA ~b E LE CT I IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(1) Remove the flange (see figure 205) nuts and bolts on each
9 horizontal
side of the engine. Do not let the body-bound bolts, which align the
stater halves, turn when removing the nuts. If the bolts are
allowed to turn, alignment of the halves may be affected. After the
I nuts are removed, tap the bolts out of the holes using a plastic drift.
(2) Remove the forward flange bolts from the upper turbine stater half.
Note the location of the heat shield brackets and matchmark the upper
stater half with the combustion casing. Remove the upper stater half
by carefully pulling it radially away from the engine.
(3) Matchmark the interstage seal with the second-stage nozzle.
(4) Remove the forward flange bolts from the lower turbine stater half.
Note the location of the heat shield brackets. Remove the lower
stater half by carefully pulling it radially away from the engine.
B. Removal of Turbine Rotor. (See figure 201.) Remove the turbine rotor
as follows:
(1) Remove the turbine rotor locknut by straightening the bent tab of lock-
washer, and then removing the locknut using the spanner and torque
wrench (2C5317). Be sure that the wrench properly engages with the
locknut and that the 12 bushings of the wrench are seated over the heads
of the 12 bolts of the turbine rotor. Hold one of the handles of the
wrench and back off the turbine rotor locknut using a wrench with a
standard 1/2 inch square drive. Remove the wrench, locknut and lock-
washer. Discard the lockwasher.
(2) pull the turbine rotor using the hydraulic puller (2C5305) as follows:
(a) Matchmark the turbine rotor and the compressor rotor by marking
the end of the compressor rotor shaft and the inside diameterof
the turbine rotor using paint, chalk, or other suitable marking
material,.
(b) Holding the puller arms close to the puller anchoring stem, screw
the hydraulic puller anchoring stem into the compressor rotor
driveshaft. Turn in the hydraulic puller until it is hand tight
and then back it off 1/2 turn.
Mar 30/84
72-50
Page 202
CTWLI~LQ IIPCTIIC
CJ610 TURBOJET
SEX-186 MAINTENANCE MANUAL
5----~ 1 It-i
USING TURBINE ROTOR
LOCKNUT SPANNER
AND TORPUE WRENCH
i. Turbine Rotor Locknut
2. Lockwasher
3. Turbine Rotor Assembly
a. Turbine Rotor Locknut Spanner
USING TURBINE ROTOR and Torque Wrench 2C5317
HYDRAULIC PULLER I I- 8 5. Spanner and Torque Wrench Bushing
6. Bolt
7. Spanner and Torque Wrench Shaft
8. Turbine Rotor Hydraulic Puller
2(35305
9. Puller Anchoring Stem
ID. Puller An
11. Compressor Rotor Drive Shaft
16
ii
BC-0286
Removal of Turbine Rotor
Figure 201
72-50
Sept 1/76 Page 203
GEWLRAL~ OLfETRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Figure
20DELTD
NOTE: A force of 5000 psig is usually required to free the rotor.
If this force does not free the rotor, check the puller for
proper insta.llation. If properly installed, continue to
apply pressure until the rotor becomes free.
CAUTION: REMOVAL 13F THE TURBINE ROTOR IS A TWO MAN OPERATION.
ONE MAN MUST SUPPORT THE ROTOR TO PREVENT DAMAGE IF
THE ROTOR SUDDENLY BREAKS FREE.
(c) Connect hydraulic actuator, 2C5337, or equivalent, to the puller
coupling. Apply pressure to the hydraulic puller to unseat the
turbine rotor. While pressure is being applied to the puller,
hold the turbine rotor by hand so that should it suddenly break
free, it will not drop down onto the engine and damage the No. 3
carbon seal or the No. 3 bearing. Continue to apply hydraulic
pressure until the turbine rotor is free of the end of the com-
pressor rotor shaft. (The turbine rotor is free when it can be
lifted by hand from the end of the compressor rotor shaft.) Dis-
engage the hydraulic puller from the turbine rotor by pushing the
3 puller arms in close to the anchoring stem and at the same time
carefully reseating the turbine rotor onto the end of the com-
pressor shaft. Disconnect the hydraulic line from the puller and
remove the puller.
(3) Remove the turbine rotor being careful not to damage the No. 3 car-
bon seal and the No. 3 bearing.
(4) Install the turbine rotor onto the turbine rotor stand (205303).
72-50 Sept 1/76
Page 204
OEltlALQ BLLCIIIC
CJ610 TURBOJeT
SEI-186 MAINTENANCE MANUAL
C. Determination of Turbine Rotor Rotating Seal Clearances. The turbine
rotor radial clearances must be determined before the rotor is assembled
to the engine.
NOTE: Turbine rotor radial clearances are not required unless affected
parts have been replaced.
(1) Measure the diameter of the seals in 3 places.
(2) Determine the minimum radial clearance by subtracting the largest OD
of the
rotating seal from the smallest diameter ID of the mating
stationary seal. The result is the minimum diametral clearance be-
tween the parts. Divide the result by 2 to obtain the minimum ra-
dial clearance.
(3) Determine the maximum radial clearance by subtracting the smallest
OD of rotating
the seal from the largest ID of the stationary seal
and dividing by 2.
(4) Determine the minimum and maximum radial clearances between:
(a) The turbine outer rotary seal and the outer stationary seal.
(See figure 204, ref. No. 8.)
(b) The turbine inner rotary seal and the inner stationary seal.
(See figure 204, ref. No. 9.)
(c) Turbine interstage seal and torque ring. This clearance applies
to CJ610-8 and -9 engines only. (See figure 204A, reference No.
13.)
(d) Torque ring seal and second-stage nozzle inner baffle. This
clearance applies to CJ610-8 and -9 engines only. (8ee figure
204A, reference No. 12.)
D. Installation of Turbine Rotor. Install the turbine rotor as follows:
CAUTION: THE NO. 3 BEARING INNER RACE, LOCATED ON THE TURBINE ROTOR
SHAFT, MUST BE REPLACED IF THE OUTER RACE WAS REPLACED. BEAR-
ING COMPONENTS ARE MATCHED ASSEMBLIES AND MUST NOT BE INTER-
MIXED.
(1) Check the mating surfaces of the turbine rotor shaft and the com-
pressor rotor shaft for burrs and pickup that could interfere with
assembly. Remove any burrs or pickup. Using a light coat of engine
Sept 1/76 72-50
Page 204A
GIWERILQ ~lleTRIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
oil lubricate the mating splines of the compr´•essor rotor shaft and
the turbine rotor shaft.
CAUTION: DO EIOT DAMAGE THE NO. 3 SEAL OR THE NO. 3 BEARING DURING
TUREIINE ROTOR ASSEMBLY. THE PUSHER TUBE AND ANCHORING
STE~I IS USED AS A GUIDE AND PROTECTOR.
NOTE: Axial clearances between turbine rotor and combustion section
parts must be determined per paragraph E.
(2) Assemble the turbine rotor pusher (2C5300) as follows: (See figure
203.)
72-50
Page 204B Sept 1176
o Elf RAL ELECTRIC
CJB10 TURBOJET
SEI-18B MAINTENANCE MANUAL
PUSHER PIN
ANCHORING STEM j PUSHER TUBE
TURBINE ROTOR
COMPRESSOR ROTOR DRIVE SHAFT
SHIM GAGE CHECK POINT
clsla4aslool
Turbine Rotor Hydraulic Pusher
Figure 203
(a) Remove the thread-protector cap from the anchoring stem. Screw
the anchoring stem out of the tool.
(b) Screw the anchoring stem into the end of the compressor rotor
shaft, until it seats and then back it off 1/2 turn.
CAUTION: THE POSITION OF THE ANCHORING STEM IS IMPORTANT. IF
THE STEM SEATS AGAINST THE END OF THE COMPRESSOR ROTOR
SHAFT, IT I$ DIFFICULT TO REMOVE. IF THE STEM IS N(YT
TURNED IN FAR ENOUGH THE TOOL WILL BOTTOM AGAINST THE
STEM AND WILL NOT SEAT THE ROTOR.
(c) Install the pusher tube inside the turbine rotor.
(d) Align the matchmarks for the turbine rotor and compressor rotor
shaft. Carefully assemble´•the turbine rotor onto the end of the
compressor rotor shaft.
Mar. 30/67 72-50
Page 205
G EW ERAL O~ e LE CiR IC
CJ810- TURBOJET
MAINTENANCE MANUAL SE1-186
(e) Screw the rest of the tool assembly onto the end of the anchor-
ing stem by aligning the 6 holes in the pusher housing with the
6 pins in the pusher tube. Turn in the tool assembly until it
seats against the turbine rotor.
CAUTION: MAKE SURE THE ANCHORING STEM DOES NOT TURN WHILE THE
TOOL ASSEMBLY IS BEING INSTALLED. IF THE ANCHORING
STEM BOTTOMS ON THE END OF THE COMPRESSOR ROTOR SHAFT
IT MAY BE VERY DIFFICULT TO REMOVE THE ANCHORING STEM
AFTER THE TURBINE ROTOR IS PUSHED INTO PLACE.
(f) Connect hydraulic actuator 2C5337, or equivalent, to the pusher
coupling. Apply up to 5000 psi to tool.
CAUTION: DO NOT EXCEED 5000 PSI.
(g) Remove the pusher assembly and replace the thread-protector cap
on the anchoring stem.
(h) Using a 0.001-inch thickness gage, check the seating. The 0.001-
inch feeler gage shall not fit between the end of the compressor
rotor shaft and the shoulder in the turbine rotor.
(i) If the turbine rotor is not seated, make sure the tool was not
seating ~on the anchoring stem. Next, pull the turbine rotor
again and remove any burrs or pickup that could Interfere with
assembly. Do not heat or cool parts to aid assembly.
(3) Lubricate a :new turbine rotor lockwasher (figure 201) with engine oil
and install it so that the 2 tabs mate with the key slots in the com-
pressor rotor shaft.
CAUTION: NE’VER REUSE A LOCKWASHER.
(4) Check the surfaces of the turbine rotor locknut for burrs. If nec-
essar;y, L´•emo´•ve burrs. Lubricate the locknut threads with Molykote
Type M77, anti-seizecompound per MIL-A-907 or equivalent. Lubri-
cate the lockwasher mating surface with engine oil. Assemble the
locknut handtight using the turbine rotor spanner wrench, 2C5321.
Remove the wrench and check the lockwasher for proper seating and
alignment wi´•th the key slot in the compressor rotor shaft. Match-
mark one loc:kwasher tab with-the inside of the turbine rotor shaft.
(5) :Torque the turbine rotor locknut’ using the spanner and torque wrench,
2C5317. Install the turbine rotor locknut spanner and torque wrench
on the turbine rotor. Be sure that the spanner wrench properly en-
gages the tu:rbine rotor locknut and that the 12 bushings of the
72-50 April 15/68
Page 206
c nE RAL E lE c!~ it
CJ610 TURBOJET
SEI-186 MATNTENANCE MANUAL
wrench are seated on the 12 bolt heads on the second-stage turbine
wheel. Install a standard 0-50 Ib ft torque wrench on the drive shaft
of the spanner and torque wrench. Hold the handles of the spanner and
torque wrench to prevent the turbine rotor from turning. Torque the
turbine rotor locknut to Ib ft by multiplying the torque indi-
225-250
cared on torque wrench indicator by the ratio on the name plate of the
spanner wrench.
NOTE: Due to the internal gearing in the turbine rotor locknut span-
ner and torque wrench, each Ib ft of torque applied through a
standard torque wrench is equal to the result of the ratio ton
the name plate of the spanner wrench) times the indicated torque
on torque wrench.
(6) Remove the torque wrench and check the lockwasher for alignment b~
noting the position of the matchmarks made in step (4).
CAUTION: BE SURE TKE: LOCKWASHER DOES NOT MOVE WHEN TORQUING THE LOCK-
NUT. IF THE LOC~WASHER MOVES, THE BENT TABS THAT FIT INTO
TKE COMPRESSOR ROTOR SHAFT KEY SLOTS MAY SMEAR OFF.
NEVER LOOSEN THE TURBINE ROTOR LOCKNUT TO LINE UP A LOCK-
WASHER TAB AND A LOCKNUT SLOT.
(7) Select a lockwasher tab that lines up with one of the slots in the
turbine rotor locknut and bend the tab into the slot. If none of the
lockwasher tabs line up with a slot, gradually tighten the nut until
one does.
E. Determination of Axial Clearance Between Turbine Rotor and Combustion
Section Parts. (See figure 204 or 204A.)
(I) Axial clearance between turbine outer stationary seal rear edge and
first-stage turbine wheel (reference No. 1) must be determined at as-
sembly.
(2) Axial clearance between turbine-inner stationary seal rear edge and
first-stage turbine wheel (reference No. 2) must be checked only when
the seal support has been replaced.
(3) Axial clearance between No. 3 seal support attaching screw heads and
first-stage turbine wheel (reference No. 3) must be checked only when
the carbon seal has been replaced.
(4) Clearances may be taken as follows:
Mar 30/84 72-50
Page 207
GENERAL ELECTRIC------
CJ61 OTU RBOJET
SEI-186
MAINTENANCE: MANUAL
10 11
O00
5
)-r
r
REF DIR.
MIN. MAX.
NO. MEAS.
1 A 0.154
2 A 0.154
3 A 0.130
4 A 0.110 1 II III t
THE AVERAGE CLEARANCES FOR ENGINES HAVING
5 A 0.165 1 II II I PERFORMANCE PROBLEMS SHALL BE MEASURED
6 A 0.110 1 II II I AND CORRECTED AS DESCRIBED IN THE OVER-
7 A 0.210 1 I HAUL MANUAL. THESE CORRECTIONS SHOULD
8 R 0.001 0.008 BE MADE IN CONIUNCTION WITH OTHER
9 R 0.001 0.006 ESTABLISHED MAINTENANCE PROCEDURES
10 R 0.050 0.058" 1 FOR TROUBLESHOOTING ENGINE PERFORMANCE
11 R 0.005
000BC-0179-01
Turbine Section Clearances CJ610-1. -4, -5 and -6
Figure 204
72-50
Page 208 Dec 31/95
GEWIIIU9 ELICIIIIC
CJ610 TURBOJeT
SEI-186 MAINTENANCE MANUAL
10
13
12
REF DIR.
NO. MEAS. MIN. FIAX.
1 A 0,170
A 0.170
A O
4 A 0.1
5 A 0.160
NOTE: THE AVERAGE CLEARANCES FOR ENGINES HAVING
6 1 .A 0.1
PERFORMANCE PROBLEMS SHALL BE I4EASURED
0.001 0.008 AND CORRECTED AS DESCRIBED IN THE OVER-
8 R
9 R
HAUL MANUAL. THESE CORRECTIONS SHOULD
BE MRDE IN CONJUNCTION WITH OTHER
10
1
R
R
0.045
O.Mi
~SI ESTABLISHED MAINTENANCE PROCEDURES
0.100 FOR TROUBLESHOOTING ENGINE PERFORMANCE.
12 R 0.070
13 R 0.010 0.035 nLL DIMENSIONS
AREININCHES
8C-0178-3
Turbine Section Clearances CJ610-8A and -9
Figure 204A
Mar 30/84 72-50
Page 209
GEWERAL~B ELECTRle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(a) Place sufficient thickness of wax at 6 equally spaced locations at
each required clearance check point.
(b) Install turbine rotor per paragraph 2.D. except do not install
locknut.
(c) Rotate rotor one complete revolution.
(d) Remove rotor per paragraph 2.B.
(e) Determine clearances by measuring minimum thickness of wax at
point of clearance.
F. Installation of Turbine Stater. After the turbine rotor is installed, in-
stall the turbine stater halves. Check the serial number to be sure that
the stater halves are matched halves. Install the stater halves as follows:
CAUTION: ON CJ610-8A ENGINES, DO NOT UNBOLT OR LOOSEN MORE BOLTS THAN
IS NECESSARY TO DISASSEMBLE OR ASSEMBLE ONE TURBINE STATOR
HALF AT A TIME. CLAMPING FORCE OF THE STAGE 1 NOZZLE FLANGE
TO THE COMBUSTION CASING MUST BE MAINTAINED ON AT LEAST ONE
HALF OF THE: FLANGE CIRCUMFERENCE AT ALL TIMES. A MINIMUM OF
8 EVENLY SPACED BOLTS ON A STATOR NALF IS REQUIRED WITH TORQUE
AS SHOWN ON FIGURE 205.
NOTE: If either the turbine casing, second-stage nozzle, interstage seals,
turbine rotor, turbine rotor torque ring and first- or second-stage
wheels replaced, it is necessary to assemble the lower half
have been
of thestater to the engine and then make the clearance checks
specified in paragraph G.
(1) Position the interstage seal in the same relationship to the second-
stage nozzle as previously installed.
(2) Align the stater half with casing using the match-
the outer combustion
marks made during disassembly. half to the engine.
Assemble the stater
On CJ610-1, -4, -5,and -6 engines make sure that the inner flange of
the second-stage nozzle is engaged with the interstage seal, and the
3 rivets of the interstage seal are in the 3 slots in the nozzle inner
flange.
(3) Install two bolts in the forward flange and snug but do not tighten.
(4) Assemble the other CJ610-1, -4, -5,and -6 engines,
stater half. On
make sure that second-stage the inner flange is properly fitted
nozzle
between the flanges of the seal support on the interstage seal as
follows:
72-50 Dec 1/79
Page 210
GEWERAL ~g E LE Cf R It
CJ610 TURBOJET
SET-186
(a) Guide the stater half place until the horizontal flanges
slowly into
on both sides of the staterapproximately one inch from
half are
mating with the horizontal flanges of stater half already installed.
With the aid of a bright light, visually assure that the second-
stage nozzle inner flange is properly engaged between the flanges of
the seal support on the interstage seal. Proper engagement must be
possible and visible; if not, the second-stage nozzle inner band
flange or interstage seal support flange must be inspected for dis-
tortion or warpage. If necessary, correct these faults before pro-
ceeding with further installation attempts.
Dec 1/79 72-50
Page 210A/B
GENERAL ELECTRIC-------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAZ,
COMBUSTION CASING-TURBINE CASING FLANGES TURBINE CASING-EXHAUST CONE FLANGES
ASSEMBLY NOTES I ASSEMBLY NOTES
APPLY LIGHT COAT OF ENGINE OIL TO ALL BOLTS APPLY LIGHT COAT OF ENGINE OIL TO ALL BOLTS
INSERT ALL BOLTS WITH HEADS FORWARD INSERT ALL BOLTS WITH HEADS AFT
10 USE A WASHER BETWEEN HEAT SHIELD BRACKET B AND FLANGE THE LIFTING LUG C AND BRACKETS D ARE LOCATED ON
ALL BRACKETS ARE LOCATED ON THE AFT SIDE OF FLANGES THE FORWARD SIDE OF FLANGES
TORQUE ALL NUTS TO 35-39 LB IN., EXCEPT ON CJ610-8A USE A WASHER BETWEEN THE BRACKETS O AND FLANGE
TORQUE ALL NUTS TO 55-60 LB IN. FOR CJ610-8A TORQUE ALL LOCKNUTS TO 28-32 LB IN.
AB
B B C; D
a O O O b d-o~ D
B O
a
a It 1 2 B
IS
46 (7 3
I
o
oO (D(I(( t 1 3
IS
6 D "41 s
/O qj o 13 6
42 7 O
I O~D
B
31O
(1 o 4(
9 a
(D ID 9
I,
lo
39 39 r9
It
´•j~ II
B 12 a 37
31 It o
AFT LOOKING FORWARD 13 AFT LOOKING FORWARD
a 36 o Jb 13 o
11 a
35 75 1( O
IS
34 o D a 3( IS
tb 33 16
B32 17
o
o
32
17
D
Is
a 31
19 o
B o 31 I(L O
30 o ~O 19
20
029 11 21 2J 20
B a 27 22 o Zd 21
26 25 2( 23 o 21 22
o
B a 26 25 24 23 a
O O0 0O O D
B B
B A. THERMOCOUPLE HARNESS BRACKET (0FFSET AFT)
B. HEAT SHIELD BRACKETS (OFFSET FORWARD) (CJd10-1)
C. LIFTING LUG
D. THERMOCOUPLE HARNESS BRACKETS (0FFSET FORWARD)
HORIZONTAL FLANGES
LEFT SIDE RIGHT SIDE
FORWARD
4 4
5 5
BODY-BOUND BOLTS
6 6
7 7
8 8
ASSEMBLY NOTES
APPLY LIGHT COAT OF ENGINE OIL TO ALL BOLTS
INSERT ALL BOLTS WITH HEADS UP
USE A WASHER UNDER LOCKNUTS OF BODY-BOUND BOLTS
TORPUE ALL LOCKNUTS TO 50-55 LB IN.
DO NOT ALLOW BODY-BOUND BOLTS TO TURN WHEN TORQUING LOCKNUTS C
TOROUE THE BOLTS IN THIS SEQUENCE ORDER: 1, 9, 5, 6, 4, 7, 3, 8, AND 2 000(336-608502
Bolting Diagrams for Turbine Stater
Figure 205
72-50
Dec 31/95 Page 211
GENERAL ELECTRIC~----
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
(b) After proper engagement of the second-stage nozzle inner flange and
interstage seal is visually made, seat and mate the stater horizon-
tal flanges.
(c) An alternate method of assuring proper engagement of the second-
stage nozzle inner flange and
interstage seal can be achieved by
tilting the stater half until the second-stage nozzle inner flange
at the 3 o’clock location is engaged between the flanges of the
seal support on the interstage seal. Before final seating of the
stater half, assure that proper engagement of second-stage nozzle
and interstage seal can be made as described in step (a). After
proper engagement is visually made, assure that the engagement
achieved at the 3 o’clock location is maintained; then seat and
mate the stater horizontal flanges.
(5) Bolt the turbine casing horizontal flanges together as follows:
NOTE: Refer to figure 205 for assembly notes.
(a) Using a soft-face mallet
and starting at the forward end of the
horizontal flange with bolthole No. 1, tap the four body-bound
bolts (figure 205) into boltholes No. 1 and No. 9 alternating from
left side to right side until all four body-bound bolts and their
locknuts have been installed. Then, alternating from side to side,
tighten each locknut fingertight.
(b) Install the remaining bolts and locknuts starting with bolthole No.
5 and
alternating from the left side to the right side following
torque sequence in figure 205. Tighten remaining bolts
fingertight.
CAUTION: DO NOT ALLOW THE BODY-BOUND BOLTS IN BOLTHOLES NO. 1 AND 9 TO
TURN WHILE TORQUING THE LOCKNUTS.
(c) Using the sequence in figure 205, torque all locknuts to 50-55 Ib
in., starting with the body-bound bolts, alternating from the left
side to right side for each locknut.
(d) Back off the locknuts and retorque each locknut in the same torque
sequence (figure 205) used in step (c).
(e) Using a piece of shim stock, 0.002 inch thick X 1/8 inch wide,
check the gap between the mating surfaces of the horizontal
flanges. Shim shall not slide into flange more than 3/8 inch.
(6) Install two bolts in the forward flange of the upper casing half and
snug but do not tighten.
72-50
Page 212 Dec 31/95
GENERAL ELECTRIC--------
CJ610 TUR BOJ ET
SEI-186
MAINTENANGE MANUAL
(7) Check turbine rotor for freedom of rotation.
(a) If rotor is binding determine point of rub.
(b) Thecasing can be repositioned by tapping firmly with a soft mallet
opposite the point of rub.
(c) When rotor turns free tighten the four bolts in the forward flange.
72-50
I Dec 31/95 Page 212A/212B
GEWEIAL~ ELECIIIC
CJ610 TUTPBOJeT
SEI-186 MAINTENANCE MANUAL
(8) Attach the forward flanges of the stater halves to the outercombustion
casing. See figure 205 for assembly notes and torques.
(a) Insert the bolts around the forward flange. The longer bolts are
used to attach the thermocouple harness and the heat shield brackets.
(b) Assemble the thermocouple harness support with the offset facing aft.
Assemble the heat shield supports with the offset facing forward.
(c) Assemble the locknuts to all the bolts.
(d) Starting with the bolts next to the horizontal flanges and working
towardsthe center of the flanges (top or bottom), torque all the
bolts except those for the heat shield brackets.
G. Clearance Checks Between Turbine Rotor and Stater. After the turbine stater
has been assembled engine,to the rotate the engine rotor clockwise and
listen for Rubbing is not allowed except a light drag or rub between
rubs.
the turbine rotary and stationary seals is permissible. Rubbing between the
turbine rotary seals and the stationary seals is normal and allows the seals
to wear or cut in, particularly if new seals have been installed. If the
rotor does not turn easily by hand it is advisable to remove the turbine
stater and rotor and reposition the turbine outer stationary seal and tur-
bine interstage seal. Re-assemble removed components per applicable para-
graphs.
(1) With the upper half of the turbine case removed, measure the following
clearances (see figure 204 or 204A) using a standard commercially
available feeler gage.
(a) Axial clearance between first-stage turbine blades and the
second-stage nozzle (ref. No. 4).
(b) Axial clearance between second-stage nozzle outer band and
second-stage turbine blades (ref. No. 5).
(c) Axial clearance between first-stage turbine blade platform and
second-stage nozz~le inner band (ref. No. 6).
(d) Axial clearance between second-stage nozzleinner band and
second-stage turbine blade platform (ref. No. 7).
(e) Radial clearance between first-stage turbine blade tips and
first-stage shroud (ref. No. 10).
(f) Radial clearance between second-stage turbine blade tips and
second-stage shroud (ref. No. 11).
(2) Install turbine stater upper half per paragraph F.
JSep 1/75 72-50
Page 213
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
FIRST-STAGE TURBINE NOZZLE ASSEMBLY MAINTENANCE PRACTICES
i. General. The first-stage nozzle can only be inspected when removed from the
engine.
2. Removal/Installation. Refer to Section 72-40.
3. Inspection/Check. Visually inspect the first-stage nozzle assembly as follows:
Any crack or cracks that may converge and permit metal breakout during further
service is not allowed. Where serviceable limits are exceeded, parts may be
repaired in accordance with the Overhaul Manual.
NOTE: Two nozzle configurations are used in the CJ610 engine. The "non-film-
cooled" nozzle is shown in Detail C (figure 201). The "film-cooled"
nozzle, which has
cooling air holes in the partition leading edges, is
shown in Detail D.Inspection limits apply to both types except where
otherwise specified.
A. Incoming Inspection.
If Diameter U, H, or V has evidence of previous weld repair, measure over
existing welds to determine serviceability. (Example: If there are eight
equally spaced welds, make four measurements). If no welds are present, make
six equally spaced measurements. (All other requirements apply.)
B. In Process Repair. Repair/Inspection of Diameter U, H, or V.
This may require repair of one, two, or three diameters. Repair only out-of-
limit diameters. On diameters requiring repair, process as directed per
applicable paragraphs. If weld repair is required, process as directed per
applicable paragraphs and T.R.’s. After weld and machine, measure across
welded areas (Example: Eight equally welded areas on a diameter requires
four measurements). All other requirements apply.
Inspection/Check Maximum Serviceable Limits Remarks
A. The partitions for:
(1) Axial cracks in the Any number, 1/8 inch long.
trailing edge (15,
figure 201). 5 per partition, 3/8 inch
long, max. 15 partitions.
2 partition, 5/8 inch
per
long, max. 5 partitions.
(2) Cracks in the leading edge.
(a) Non-film cooled Any number, 1/8 inch long.
nozzle. Four per partition, 1/4 inch
long, max. 15 partitions.
72-51-0
Dec 31/95 Page 201
GEIIEIIL~B tLEETIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
~FWD. 15
i
CFWD.$~,/5 ‘Z
14~1
16
i I
b ~v is
as 7 6
DETAIL A DETAIL B
I
C FWD.
11
a
CDaE s
6 ;~D´•
t a
i
CFWD.
j
2
DETAIL D
11 /-10 LL~
DETAIL C 12
i. OUTER FLANGE ii. INNER FLANGE
2. OUTER BAND 12. PARTITION SLOTS
3. PARTITION 13. COOLING AIR HOLES
COOLING AIR SLOTS
C FW\D. 4.
5. INNER BAND
14. PARTITION SLOT CRACKS
(CRACKS EXTENDING FROM END OF SLOT)
12 6. SEAL 15. PARTITION TRAILING EDGE AXIAL CRACKS
~1 7. SEAL HOLES 16. PARTITION RADIAL CRACK
8. EXPANSION SLOT 17. SEAL HOLE CRACK EXTENDING FWD.
9. LOUVER OPENINGS 18. SEAL HOLE CRACK EXTENDING AFT
DETAIL f
1D. SEAL SUPPORT
CJ610-8 AND -9 C1( IOd00P.~´•8)
First-Stage Turbine Nozzle
Figure 201
72-51-0 Sep 1/75
Page 202
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(b) film-cooled 10 cracks per partition with Any number. any
nozzle. max. of 10 cracked partitions. length may be
No triangular cracks which repaired per
might allow loss of parent paragraph 4.C.
metal. No cracks within 3/16 provided not
inch of outer band. more than 5 cool-
ing air holes are
plugged during
weld repair.
(3) Radial cracks (16, Any number, 1/16 inch long.
figure 201). One crack partition. 3/8
51-0
31/Y5 202Ai202B
I Dec Page
CEWBRAL O~ ELECTRIC
CJ610 TURBOJET
SEI-L86 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
inch trailing half
in of
partition. Max. of 15 par-
titions.
(4) Burns or erosion.
(a) Trailing edge. 1/8 inch in from trailing
edge axial. One inch long
radial. Max. of 20 partitions,
(b) Leading edge. 1/4 inch wide axial by one
inch radial. Max. of 20
partitions, provided erosion
does open into partition
not
cavity when inspected visu-
ally.
(5) Nicks, dents or Any number, 0.015 inch deep, Remove high
gouges along trailing with no high metal. metal.
edge (within 3/16
inch of edge).
(6) Nicks, dents or Any number, 0.040 inch deep, Remove high
gouges other than with no high metal, or punctures, metal.
on trailing edge.
(7) Cooling air holes in Not serviceable. Clean holes with
leading edge blocked fine wire.
by other than weld
repair (film-cooled
nozzle).
(8) Trailing edge cooling air slots (4, figure 201).
(a) Cracks extending Two per slot 3/32 inch long
into partition max.
(Not converging).
(b) Converging cracks. Not serviceable if crack Replace parti-
extension would allow loss tion.
of parent metal.
(c) Closed area (when 0.013 inch min. opening. Open to 0.013-
noted visually). 0.019 inch.
(d) Baffles for:
1 Cracks. Any number 1.0 inch long. Replace nozzle.
2 Missing pieces. One piece, 1.0 inch long. Replace nozzle.
72-51-0
Dec 30/78
Page 203
GENEIALQ ELECllle
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
InSpectidnlCheC1 Maximum Serviceable Limits Remarks
B. The weld area (parti- One crack, 5/8 inch long per
tion to inner and outer partition. Maximum of 15
band) for cracks. partitions per nozzle.
C. The seal and the inner or outer band for:
(1) Buckling and/or No distortion allowed which Cold-work and
distortion. causes interference at inspect for
assembly. cracks.
(2) Cracks.
(a) Cracks extending 12 cracks in each band (inner
from the end of the and outer).
partition slot to
the leading or
trailing edge of
the band (14,
figure 201).
(b) Cracks extending Any number.
from the partition
slot and terminating
in the band.
(3) Circumferential cracks:
(a) Inner band and Ten cracks,
support structure 1/2 inch long.
(6, figure 202).
(b) Outer band Not Serviceable. Repair-weld per
(2, figure 201). paragraph 4.C.
(c) Seal holes One crack per hole, 5/16 inch Repair as in-
(7, figure 201). long, if crack does not branch structed in para-
out, and if no material is in graph 4.E. pro-
danger of breaking loose. vided circumfer-
ential crack does
not produce a
step (at the ex-
pansion Joint on
the inner band)
exceeding 0.030
inch.
Mar 30/84
72-51-0
Page 204
GENERAL I LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
6 4
5
0
i. AXIAL CRACK LEADING EDGE
(TYPICAL FOR TRAILING EDGE)
2. RADIAL CRACK LEADING EDGE
3. AXIAL CRACK INNER AND
OUTER BAND
4. CIRCUMFERENTIAL CRACK (EXTENDED
1 INTO AREA BETWEEN PARTITIONS)
5. BUCKLING OR DISTORTION
6. CIRCUMFERENTIAL CRACK
CJ61060(L1)0~1
First-Stage Nozzle Defects
Figure 202
Inspection/Check Maximum Serviceable Limits Remarks
(4) Burnouts touter band). Not Serviceable.
(5) Burnouts (inner band). Not Serviceable.
D. The seals for cracks originating at the seal holes:
(1) Cracks extending aft (18, figure 201):
(a) In non-film-cooled Any number that have not Repair per para-
nozzles. branched provided there is graph 4.B.
no danger of any material
breaking off.
(b) In film-cooled One crack per hold, 5/16
nozzles. inch long, provided the
crack does not branch and
there is no danger of
parent metal loss.
72-51-0
I Mar 30/84
Page 204A/204B
GEWERAL~ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Ins~ection/Check Maximum Serviceable LimitS Remarks
(2) Cracks extending Any number, 5/16 inch long,
forward (17, provided the crack does not
figure 201). branch and there is no danger
of parent metal loss.
E. Outer flange (1) for:
(1) Radial cracks from Any amount, providing cracks
boltholes. do not connect and there is
no danger of any material
breaking off.
All "T" positions must Re-locate and
(2) "T" position
marking. be clearly marked. mark per para-
graph 4.D.
(3) Fretting and galling, Not closer than 0.060 inch Repair per
to edge of boltholes. Flange paragraph
thickness not less than 4.F.
0.050 inch.
(4) Visual damage (dents, Two circumferential lengths
distortion, etc.) to each 1-3/4 inch long, at
rabbet diameter least 90 degrees apart.
and/or boltholes.
(5) Elongated boltholes. Any number, 0.060 inch
oversize.
(6) Aft outer rabbet 15.984-15.992 inch diameter. 15.969 inch
OD (diameter V, fig- Free state average diameter diameter max.
ure 207). taken at six equally spaced rapairable.
locations must fall within Repair per
these limits. Individual paragraph 4.6.
readings may exceed limits.
NOTE: Concentricity of diameter V relative to diameter U is taken
with an axis established by diameter U and surface AP (see
figure 207).
(7) Diameter V (figure 0.010 inch TIR. Any amount can
207), concentricity be repaired per
with diameter U. paragraph 4.6.
Dec 31/91 72-51-0
Page 205
BEWERIL~ELECn)C
CJ610 TURBOJET
MAINTENANCE MANITAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
F. Inner flange (11,
figure ~01) for:
(1) Out-of-flatness. Not visually out-of-flat. Repair per
paragraph 4.A.
(2) Fretting and galling. Not closer than 0.060 inch to Repair per
end of boltholes. Flange paragraph 4.F.
thickness not less than 0.050
inch.
(3) Undersize (dia-
ID 7.296-7.306 inch diameter. 7.321 inch dia-
meter U, figure 207). Free state average and meter max. re-
individual minimum readings pairable per
taken at six equally spaced paragraph 4.6.
locations must fall within
these limits. Individual
maximum readings may exceed
limits.
(4) Undersize inner rabbet 8.271-8.275 inch diameter. 8,290 inch dia-
ID (diameter H, figure Free state average and indi- meter max. re-
207). vidual minimum readings taken pairable per
at six equally spaced loca- paragraph 4.6.
tions must fall within these
limits. Individual maximum
readings may exceed limits.
NOTE: Concentricity of diameter H relative to diameter U is taken
with an axis established by diameter U and surface AP (see
figure 207).
(5) Diameter H (figure 0.004 inch TIR. Any amount can
207) concentricity be repaired per
with diameter U. paragraph 4.6.
4. Repair.
A. Repair of Bent Inner Flange. (See figure 203.)
(1) Gradually and locally cold-work to matchorginal contour.
(2) Finish cold-work to the drop dimension from the forward face of the
inner flange to the forward face of the outer flange as shown in
figure 203.
(3) Control cold-working by using a parallel bar to obtain the final drop
dimensions.
72-51-0 Dec 31/91
Page 206
CJ610 TURBOJET
SEI-186 MIIINTENANCE MANUAL
8.275 DIA
8.271
0.062
0.052
I ALL DIMENSIONS j
WOWF-605501
I"E’N’NCHES I
Bent Inner Flange Repair
Figure 203
NOTE: A crescent wrench with smooth-face jaws may be used effectively
to cold-work the flange.
(4) Measure the aft rabbet diameter on the inner flange at 6 equally
spaced locations. The average diameter must be within the limits
shown in figure 203. If the average diameter is not within limits,
the nozzle is not usable.
(5) Spot fluorescent-penetrant inspect the reworked area per Section
72-03-1. No cracks allowed.
(6) When assembling the nozzle, check the bolt hole alignment using the
proper stationary air seal and bolts.
B. Repair of Seal. (Non film-cooled nozzle only)
(1) Cracks originating at the seal and extending aft to the trail-
holes
ing edge of the louver opening and/or spot weld joint may be re-
paired as follows:
(a) Starting at air seal hole, cut parent metal as required to re-
move all cracks. Parent metal cutouts should have generous radii
throughout. (See figure 204.)
(b) Blend all edges.
Dec 31/91 72-51-0
Page 206A/206B
GE ERAL ~B E LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
SPOT WELD JOINTS LOUVER OPENINGS
TYPICAL CR~CK
TYPICAL METAL TYPICAL CRACK
REMOVAL
SEAL HOLE IN LINE WITH SEAL HOLE IN LINE WITH
SPOT WELD JOINT LOUVER OPENING
CJ610´•60~1´•0-F2
Seal Hole Crack Repair
Figure 204
C. Partition Weld Repair. Weld per 72-02-4, using the following informa-
tion.
(1) Grind out cracks before welding.
(2) Inert are weld partitions using the filler specified in paragraph (7).
(3) Keep amperages at a minimum to reduce shrinkage.
(4) Purge interior of partition thoroughly with inert gas by feeding gas
through the open end, at the outer band.
(5) Do not weld in one area so as to overheat the nozzle. Cool with dry
ice or weld in opposite sections if required.
(6) Bench after welding to remove all excess material. Use small diam-
eter or pointed files to work into corners. Maintain smooth sur~-
faces. Restrictions in the nozzle area are undersirable. Repair
welding is to be kept to a minimum.
(7) The welding rod and part material are as follows:
(a) Partition Material AIMS 5537 (L-605)
(b) Welding Rod ARIIS 5796 (L-605)
Jan. 15/69 72-51-0
Page 207
GEWERALO ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
D. Locating and Marking "T" Number Positions.
(1) Place the nozzle on a table with the partition trailing edges up.
NOTE: The inner band is sectioned into 6 segments. One of the
segments has 8 partitions; all the other segments have 7
partitions.
(2) Locate the segment with the 8 partitions and place it in the position
shown in figure 205.
NOTE 1: The first partition in the 7-partition segment, clockwise
from the 8-partition segment, is the number 1 partition.
r The centerline of the number 1 partition corresponds to the
centerline of the nozzle.
NOTE 2: The number 1 bolthole is the first hole clockwise from the
nozzle centerline. Boltholes are numbered 1 through 48 in
a clockwise direction. "T" marks are located between the
following bolthole numbers:
"T" Mark Between Bolt Holes
T5 162
T1 11 6 12
T2 21 6 22
T3 30 6 31
T4 40 6 41
(3) Notch the nozzle flange OD at each "T" position using a small rat-
tail file. Notches to be 0.01-0.02 inch deep with no sharp edges
or burrs. Notch as follows:
"T" Position No. of Notches
T1 1
T2 2
T3 3
T4 4
T5 5
E. Repair of Circumferential Cracks Around Seal Holes.
seal holes at both forward
(1) Inspect and mark locations of all cracks at
and aft locations.
(2) Align surfaces at cracks to minimize offset.
(3) Assure all foreign material is removed from weld-repair area.
(4) Place backing-gas hose in one of the seal holes.
72-51-0 Mar 30/84
Page 208
CEWERAL ~gB LLECTRIC
CJ610 TURBOJeT
SEI-186 MAINTENANCE MANUAL
VERTICAL
OUTER BOLT
CENTERLINE
CIRCLE
7
8 PARTITION
SEGMENT
bO
O
0~
\I I \T d INNER BAND
SAW CUT
41 O
NO. 1 PARTITION
O
40 O
01 ‘a
0 12
AFT O
3 O’CLOCK
9 O’CLOCK LOOKING FORWARD
O
O
31~0
30\ O
00
22
6 O’CLOCK
88-1094´•1
Location of "T" Marks on First-Stage Turbine Nozzle
Figure 205
Nov. 15/73 72-51-0
Page 209
GEW ERAL ~g ELEeTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(5) Mask remaining seal holes and slots to provide backing-gas cavity.
(6) Punch a hole through the masking of one of the holes for purging.
(7) Purge for 3 to 5 minutes before welding.
(8) Extend electrode approximately 0.6 inch beyond gas lens on torch.
(9) Weld-repair cracks using welding rod AMS 5796 (L-605). Assure weld bead
at hole has a radius and is smooth. Hold torch with gas flowing over
weld-repair area while cooling takes place.
NOTE: Weld-repair bead to extend beyond end of crack at least 1/4 inch.
Current 15-35 amps. DCSP. Torch gas argon 15 CFH.
(10) Revise masking as required and weld-repair other crack locations.
Assure weld-repair area is clean prior to welding.
(11) Visually inspect, using a 5X glass minimum, to be sure that all cracks
have been repaired completely.
(12) Inspect as instructed in paragraph 4, step A.(4).
F. Repair of Inner Flange.
This repair should be done only after out-of-flatness of inner flange has been
restored to serviceable limits. See paragraph 3, item G.(1).
(1) Secure nozzle in a locally made turning fixture, functionally similar to
the one shown in figure 206.
(2) Diameter U shall be within 0.005 inch TIR when using the Lc-point check
method. Surfaces A and N shall be within 0.005 inch TIR.
(3) Mask outerpartition ports to avoid contaminating air-cooling passages
during repair. Masking should be made of heat-resistant material.
(4) Machine off all fretted and galled metal, removing a minimum amount of
material. Note the minimum thickness allowed for each flange.
(5) Remove nozzle from fixture.
(6) Prepare and plasma-spray machined surfaces with Metco 450 per STANDARD
PRACTICES, 70-49-1, paragraph 6, step D of Overhaul Manual (SEI-136).
(7) Remove all masking except at outer partition ports.
72-51-0 Mar 30/84
Page 210
GEN ERIL ~g EL~CTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
i. SECURE STAGE 1 TURBINE NOZZLE IW FIXTURE.
s EQUWY
8 EQUALLY INNER III lli N OUTER SPACED CLAMPS
_~
SPACED CLAMPS FLANGE PLANCZ
SURFACEA suaPi~calr
DIAMETER U
i~lTir II
if
81 Dme~sIoN B
8.25414 TI 1.00 0.01
8.240
i
ii
1.00
0.057 LESS THAN
DIMENSION B 0.01
16.055218 AA 1 18.50DIA
16.052 18.45
2. MACHINE TO REMOVE PRE~ITED END GALLED METAL.
0.060 EW
0.060 MIN
HOLE HOLE
0.090
EDGE HCIE
I
450
’45"
0.052 MIN
3. MACHINE PLASMA COAT.
0.002 STEP WOWED
0.060 MIN 0.060 MIN
HOLE HOLE
PLASMA COAT
EDGE EDGE
BREAK EDGE
45" 450
ALL DIIIENSIONS
ARE IN INCHES I \r- BC-0454
Repair of Flanges with Plasma Spray
Figure 206
Mar 30/84 72-51-0
Page 211
bEn ER*L IltCTllt
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(8) Secure nozz.le in turning fixture per steps (1) and (2).
(9) Machine plasma coat until it is flush with parent metal. A 0.002 inch
step is allowed as indicated in figure.
(10) -Remove nozzle from fixture. Remove all masking. Clean and
vapor-degrease nozzLe per STANDARD PRACTICES, 70-20-1 of Overhaul
Manual (SEI-136).
(11) Inspect flanges using a lO-power magnifying glass. Cracks, chips,
and loose plasma are not allowed. Plasma overspray is not allowed and
must be removed.
G. Repair of First-Stage Turbine Nozzle Flanges.
(1) Repair undersize diameters U and/or H (figure 207) as follows:
WARNING: TRICHLOROETHANE 0-T-620 DO NOT USE NEAR OPEN FLAMES,
WELDING AREAS, OR ON VERY HOT SURFACES. DO NOT SMOKE WHEN
USING IT. HEAT AND FLAMES CAN CAUSE THE FORMATION OF
PHOSGENE GAS WHICH IS INJURIOUS TO THE LUNGS.
REPEATED OR PROLONGED CONTACT WITH LIOUID OR INHALATION OF
VAPOR CAN CAUSE SKIN AND EYE IRRITATION, DERMATITIS,
NARCOTIC EFFECTS, AM) HEART DAMAGE.
AFTER PROLONGED SKIN CONTACT, WASH CONTACTED AREA WITH SOAP
AND WATER. REMOVE CONTAMINATED CLOTHING. IF VAPORS CAUSE
IRRITATON, GO TO FRESH AIR. GET MEDICAL ATTENTION FOR
OVEREXPOSURE OF SKIN AND EYES.
WHEN HANDLING LIQUID IN VAPOR-DEGREASING TANK WITH HINGED
COVER ANI) AIR EXHAUST, OR AT AIR-EXHAUSTED WORKBENCH, WEAR
APPROVED GLOVES AND GOGGLES.
WHEN HANDLING LIQUID AT OPEN, UNEXHAUSTED WORKBENCH, WEAR
APPROVED RESPIRATOR, GLOVES, AND GOGGLES.
DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(a) Clean nozzle with trichloroethane or equivalent.
(b) Setup and restrain nozzle on diameter P and surface N.
(c) Obtain best runout on diameter U.
(d) Machine diameters U and/or H to repairable limits. Limit
machining to minimum amount.
72-51-0 Dec 31/91
Page 212
GLYERIL~p ELEC~RIC
CJ610 7URBOJET
SEI-186 MAINTENANCE MANUAL
0.020
RAD
DIA P II o.oio
SURF N
DIA V
15.990
15.986
0.07
RAD
0.020 0.04
OIA H
O.O1ORAD
8.274
8.272
t C 0.064
DIA U 0.052
7.302 0.035
CHAMFER
7.300 0.020 ALL DIMENSIONS
ARE IN INCHES
000385-714500
First-Stage Nozzle Flange Repair
Figure 207
Dec 31/91 72-51-0
Page 213
CEWERIL~IIECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
NOTE: Flame spray is the preferred method,
(2) Repair oversize diarneters U and/or H using either the flame spray
ar the weld repair method.
(a) For flame spray method proceed as follows:
1 Set up and restrain nozzle on diameter P and surface N.
Obtain best runout on diameter U or diameter H.
2 Machine diameters U and H only enough to produce a finished
machine metal spray material thickness of 0.010 inch.
Machining cleanup dimensions prior to metal spray must not
exceed the
following:
Diameter U 7.310 inches
Diameter H 8,284 inches
3 Vapor-degrease nozzle.
WARNING: COMPRESSED AIR WHEN USING COMPRESSED AIR FOR ANP
COOLING, CLEANING, OR DRYING OPERATION, DO NOT
EXCEED 30 PSIG AT THE NOZZLE.
EYES CAN BE PERMANENTLY DAMAGED BY CONTACT WITH
LIQUID OR LARGE PARTICLES PROPELLED BY COMPRESSED
AIR. INHALATION OF AIR-BLOWN PARTICLES OR SOLVENT
VAPOR CAN DAMAGE LUNGS.
WHEN USING AIR FOR CLEANING AT AN AIR-EXHAUSTED
WORKBENCH, WEAR APPROVED GOGGLES OR FACE SHIELD.
WHEN USING AIR FOR CLEANING AT AN UNEXHAUSTED
WORKBENCH, WEAR APPROVED RESPIRATOR AND GOGGLES.
4 Vapor-blast surface to be metal sprayed to remove oxides and
other contaminants.
I Mask off all areas that are not to be sprayed.
72-51-0 Dec 31/91
Page 214
GEIIERIL~ILECTRIE
CJ610 T~RSOJET
SEI-186 MAINTENANCE MANLTAL
WARNING: NICKEL METCO POWDERS HIGHLY REACTIVE DO NOT MIX
WITH STRONG ACIDS AND COMBUSTIBL~E MATERIAL SUCH AS
WOOD, PAPER, AND SULFUR.
DO NOT HAVE ANY CONTACT WITH POWDER. CONTAINS
NICKEL. CONTACT WITH POWDER CAN CAUSE SKIN
SENSITIZATION AND EYE IRRITATION. REPEATED
INHALATION OF POWDER CAN CAUSE COUGHING AND
WHEEZING, AND CAN CAUSE PERMANENT DAMAGE TO LUNGS
AND NASAL PASSAGES.
IF ANY POWDER CONTACTS SKIN OR EYES, FLUSH AFFECTED
AREA THOROUGHLY WITH WATER. REMOVE CONTAMINATED
CLOTHING. IF COUGHING AND WHEEZING PERSIST, GET
MEDICAL ATTENTION.
CHARGING AND REMOVAL OF POWDER FROM SPRAY GUN AND
APPLICATION OF COATING MUST BE PERFORMED IN
AIR-EXHAUSTED, PARTIALLY ENCLOSED SPRAY BOOTH. WHEN
SPRAY GUN IS IN OPERATION, F~TEAR APPROVED GOGGLES AND
HEARING PROTECTION. IF ANY AIRBORNE POWDER IS
PRESENT, WEAR APPROVED RESPIRATOR.
DO NOT EAT, SMOKE, OR CARRY SMOKING MATERIALS IN
AREAS WHERE POWDER IS HANDLED.
NOTE: Metco 405 spray requires grinding. Metco 450 may be
machined by means other than grinding.
6 Metal spray diameters U and/or H using either Metco 405 or
Metco 450. Be sure spray is thick enough to produce a finished
spray thickness of 0.010 inch.
WARNING: POWER GRINDING AVOID PROLONGED OR REPEATED CONTACT
WITH DUST. INHALATION OF DUST MAY CAUSE TEMPORARY
COUGHING AND WHEEZING, RESPIRATORY TRACT IRRITATION,
AND PERMANENT LUNG PROBLEMS. IF COUGHING OR
WHEEZING PERSISTS, GET MEDICAL HELP.
IF DUST CONTACTS"EYES, FLUSH THEM THOROUGHI,Y WITH
WATER
WHEN USING AN AIR-EXHAUSTED GRINDING WHEEI,, hTEAR
APPROVED RESPIRATOR, GOGGLES, OR FACE SHI~LD.
IF GRINDER IS NOT EQUIPPED WITH LOCAL EXNAUST
VENTILATION, ~TEAR AN APPROPRIATE RESPIRATOR AND
GOGGLES OR FACE SHIELD.
Dec 31/91 72-51-0
Page 215
tEYLRIL~ELEerRIC
CJ610 TURBOJET
MAINTENANCE MAN~AL SEI-186
7 Grind or machine to dimensions shown in figure 207.
8 Dimensionally inspect nozzle.
(b) For weld repair method proceed as follows:
1 Install turbine nozzle into locally manufactured stage 1
turbine nozzle welding fixture (figure 208) to prevent
excessive distortion.
2 Restrain nozzle on diameter P and surface- N.
3 Restrain inner flange forward surface (surface AP, figure 207).
WARNING: GENERAL WELDING DO NOT LET FLAMMABLE SOLVENTS SUCH
AS ACETOmE AND METHYL ETHYL KETONE CONTACT HEATED
WELDED PARTS.
CONTACT WITH FUMES MAY CAUSE SKIN IRRITATION,
DERMclTITIS, AND EYE IRRITATION. REPEATED INHALATION
OF FUMES CAN CAUSE COUGHING, WHEEZING, AND PERMANENT
LUNG DAMAGE.
IF FUMES CAUSE IRRITATION, GO TO FRESH AIR. IF
COUGHING OR WHEEZING PERSISTS, GET MEDICAL ATTENTION.
WELDING SHOULD ONLY BE DONE IN AN AIR-EXHAUSTED
ENCLOSED OR SHIELDED WORK AREA.
CONTACT WITH ULTRAVIOLET RAYS MAY CAUSE FATIGUE,
NAUSEA, AND FEVER. REPEATED CONTACT MAY CAUSE
PERMANENT SKIN AND TISSUE DAMAGE.
COVER ALL EXPOSED SKIN TO AVOID REDDENING OF SKIN.
IF REDDENING OF SKIN OCCURS AFTER REPEATED USE OF
WELDING MACHINE, GET MEDICAL ATTENTION.
ONLY EXPERIENCED TRAINED PERSONNEL SHOULD USE
WELDING MACHINES. WHEN USING EQUIPMENT, FOLLOW
APPROVED SAFETY PROCEDURES FOR SHIELDING AND
PERSONAL PROTECTIVE EQUIPMENT.
4 Build up diameter U and/or H as required, using TIG weld
method and weld data table.
Fluorescent penetrant-inspect welds for cracks. No cracks are
allowed.
4 Machine diameter U and/or H to dimensions shown in figure 207.
72-51-0 Dec 31/91
Page 216
OIIEIIL~D ELPCTRlt
CJ610 TURBOJET
SEI-186 MAINTENANCE MAN~AL
0.020 CHAMFER X 450 DRILL AND TAP FOR ND.
0.030 (TYPICAL 4 PLACES) 10-32 NC 0.600 DEEP 16 HOLES
Eq. SPACED AND LOCATED
WITHIN 0.005 R OF TRUE
1’6.926 DIA. POSITION.
16.921
125
DRILL AND TAP FOR NO.
1~
1.500 8-36NF-3A 0.650 DEEP 16
16.54 DIA.
DIA. HOLES EQ. SPACED AND
BOLT CIRCLE
LOCATED WITHIN 0.005 R
OF TRUE POSITION.
0.062 R
(TYPICAL)
060
/eO O 054
125
MATERIAL: LOW
8.450 DIA. CARBON STEEL
MAX
7.650 DIA.
I ALL DIMENSIONS
BOLT CIRCLE
I"REINlncnEl I
3.00
7.450 DIA.
MIN
000585-716600
Stage 1 Turbine Nozzle Welding Fixture
Figure 208
WELD DATA TABLE
Filler Wire
Material Torch Backup
Material (1/32- Gas Gas
Being 1/16 inch Current Flow Flow Weld
Nomenclature Welded dia.) Amperes (CFH) (CFH) Contour
Outer Flange AMS 5759 AMS 5786 20-35 DC Argon, Argon, Buildup
(Hastelloy W) Straight 8-14 10-15
Polarity
Inner Flange AMS 5510 AMS 5786 20-35 DC Argon, Argon, Buildup
(Hastelloy W) Straight 8-14 10-15
Polarity
Dec 31/91 72-51-0
Page 217
GEWERAL ELECTRIC
CJ610 TURBOJET
MAINTENANCE MAN~AL SEI-186
Z Correct concentricity of diameter H or diameter V as follows:
1?; Restrain nozzle on diameter P and surface N and obtain best
runout on diameter U.
b Buildup diameters U, H or V with weld as required, using
eight equally spaced welds 3/8 to 1/2 inch long. Use weld
data from flange weld repair.
c Set up same as step a. If diameter U is being repaired, the
inner flange forward surface must also be restrained.
d Machine diameters U, H, and V as required to dimensions
shown in figure 207.
72-51-0 Dec 31/91
Page 218
G C N E R AL I LE C~R IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
TURBINE CASING ASSEMBLY MAINTENANCE PRACTICES
Q
RECTANGULAR HEAD
~J
OVAL HEAD
CJ610-8 AND 9
´•i
I
0~- g
5
CJ610 -1 -4-5 AND 6
1 5 O
~6
´•h--~
)I Is
12
P
p
BI
1
1-3
10
’1-
1’" 13
12
1
i. UPPER HALF TURBINE CASING
2. LOWER HALF TURBINE CASING
3. BODY-BOUND BOLT
4. NUT
7
5. SHROUD, SECOND-STAGE
6. SEALING SHROUD, SECOND-STAGE
7. NOZZLE, SECOND-STAGE
15 8. NUT
9. WASHER
1 10. BOLT, ANTI-ROTATION
11. SHROUD, FIRST-STAGE
12. SEALING SHROUD, FIRST-STAGE
13. NUT
1 14. BOLT
11 1 15. RADIATION SEAL
1 16. INTERSTAGE SEAL
12
I SECTIONAL VIEW
CJ610-8 AND9 AT ARROW A tJ610-6121´•0´•*2*
Turbine Stater Assembly
Figure 201
Jan. 15/69
72-52-0
Page 201
G EW EIAL LLLCTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
i. General, Only the external areas of the turbine casing are inspected unless
the casing is removed from the engine.
2. Removal/Installation. Refer to Section 72-50.
3. Inspection/Check. Visually inspect the turbine casing assembly as follows:
Where serviceable limits are exceeded, parts may be repaired in accordance
with the Overhaul Manual.
Inspection/Check Maximum Serviceable Limits Remarks
A. The turbine casing: (Figure 2012.)
(1) The forward (1), aft (2), and horizontal flanges for:
(a) Cracks. Not serviceable.
(b) High spots Not serviceable. Remove high spots.
(caused by
nicks), on the
mating surface.
(c) Loose bolts. Not serviceable. Re-torque flange
bolts.
(2) The casing for Not serviceable.
cracks.
(3) The horizontal 3 cracks, each 1/8 inch
flange (3) welds long and not closer
for cracks. together than 1/2 inch.
NOTE: Thefollowing items are to be inspected if the turbine casing as-
sembly is removed from the engine.
(4) The turbine Any amount which does
shroud tracks(6) not cause interference
for deformation. during assembly of the
shrouds.
(5) Dents. Any number .020 inch
deep, 3 per casing half
.060 inch deep providing
there is no interference
at casing.
(6) Cooling air tubes Not serviceable. Reset tab on forward
in first stage end of tube with
shroud tracks for brass drift.
looseness (CJ610-8
and -9 only),
72-52-0 Dec 30/78
Page 202
CEILRAL ~g ELECTRIC
CJ610 TURBOJ´•ET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
B. Anti-rotation bolt (rectangular head, marked "A" on shank and unmarked oval
head bolt for:
(1) Fluorescent Not serviceable. Replace bolt.
penetrant-inspect
for cracks.
(2) Thread damage. Cumulative length one full Replace bolt.
thread after chasing.
(3) Shank deformation. Not serviceable. Replace bolt.
C. First-stage shrouds (11 and 12, figure 201) for:
NOTE1: First-stage shrouds on engines are machined during
CJ610-5 and -6
engine assembly and cannot be replaced according to this manual. If
the shrouds are removed for inspection, be sure to identify them as to
location to facilitate re-installation,
Note 2: Inspect first- and second-stage filled honeycomb shrouds (CJ610-8, -8A,
and -9) according to paragraph 3.D. If the shrouds are removed for in-
spection, be sure to identify them as to location to facilitate re-in-
stallation. Remove and re-install according to the Overhaul Manual.
(1) Cracks. 1 crack3/8 inch long, 3 cracks Shrouds (CJ610-1
3/16 inch long per segment, pro- and -4) may be
vided no material is in danger replaced per
of falling out. No cracks al- paragraph 4.A.
lowed in rails.
(2) Burns. Not serviceable.
(3) Rubs. Any amount 0,025 inch deep,
with no high metal.
(4) Missing anti- Not serviceable.
rotation stops.
(5) Distortion Any amount 0.025 inch deep, with
(blisters). no high metal.
(6) Nicks and dents. Any amount 0.025 inch deep, with Remove high
no high metal. metal.
(7) Metal deposits. Any amount with no high metal.
Dec 31/91 72-52-0
Page 202A
EBIERILQ IIECtRIC
CJ610 TURBOJET
MAINTENANCE MANITAL SEI-186
HONEYCOMB CELLS ARE FILLED
WITH A SINTERED NICKEL-ALUMINUM
POWDER COMPOSITION.
FILLED HONEYCOMB SHROUD
SOLID METAL SHROUD
NON-FILLED HONEYCOMB SHROUD CF700´•6050´•kF2
Typical Turbine Shrouds
Figure 201A
i. Forward Flange
;sr 2. Aft Flange
3. Horizontal Flange
a 4. Anti-Rotation Bolt
5. Locating Hole
1 2 6. Turbine Shroud Tracks
7. Body Bound Bolt Holes
b
Qee
3
a os
8(30308
Turbine Casing
Figure 2012
72-52-0
I Page 202B Dec 1/77
GLn ERAL PLECIRIC
CJ610 TU BOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
D. Second-stage shrouds for: (Figure 201C.)
NOTE: First- and second-stage shrouds on the CJ610-8, and -9 engines are
filled honeycomb shrouds (see figure 201A). These shrouds are ma-
chined during engine assembly and cannot be replaced according to
this manual. If the shrouds are removed for inspection, be sure to
identify as to location to facilitate re-installation.
(1) Cracks Any number 1/4 inch long with Non filled shrouds
no danger of a piece breaking may be welded per
away, provided there are no paragraph 4.E. (pro-
cracks in the rails, vided honeycomb re-
moval does not ex-
ceed serviceable
limits) or may be
replaced per para-
graph 4.B.
(2) Rubs. Any amount not into the band.
(3$ Deleted.
(4) Nicks and dents. Any amount 0.025 inch deep Remove high metal.
with no high metal.
i. Honeycomb
2. Support Strip
3
2
C
2 3
SECTION A-A
CC- 004?
Second-Stage Shroud
Figure 2010
72-52-0
Sept 1/76 Page 203
e En ERAL ELleTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL
SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
(5) Missing or damaged Not to exceed 80 missing or
honeycomb. damaged cells per segment.
(6) Missing support strips. One per segment except end strips.
E. The second-stage nozzle for: (Figure 202.)
NOTE: Any crack or cracks that may converge and permit metal breakout during
further service, is not allowed. An unserviceable half of a stage 2
nozzle may be replaced with a serviceable half having a different serial
number. For replacement procedure see paragraph 4.0.
(1) The partitions for:
(a) Axial cracks in Any number, 1/8 inch long. Five
trailing edge (1l). per partition, 3/8 inch long,
max of 8 partitions per half.
Two per partition, 5/8 inch long,
max of 6 partitions per half.
(b) Axial cracks in the Any number, 1/8 inch long. Four
leading edge (10). per partition, 1/4 inch long,
provided crack does not open
into partition cavity, when in-
spected visually.
(c) Radial cracks (12). Any number, 1/16 inch long. One
crack per partition 3/8 inch
long in trailing half of par-
tition. Max of 15 partitions.
(d) Burns or erosion on:
1 Trailing edge. 1/8 inch in from trailing edge
axial. One inch long radial.
Max of 12 partitions per noz-
zle half.
2 Leading edge:
a PN 6028T79GO1 Thickness of leading edge shall
and 3902T49P01 be at least 0.024 inch at loca-
nozzles. tion 1.8
inches in from parti-
tion opening, and at least 0.029
inch at location 0.250 inch in
from partition opening. See
paragraph 3A.
72-52-0 Mar 30/84
Page 204
GEW ERAL ~B fLECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
b All other 1/4 inch wide axial by one inch
nozzles. long radial. Max of 12 parti-
tions per nozzle half, provided
erosion does not open into par-
tition cavity when inspected
visually.
(e) Nicks, dents
or Any number, 0.015 inch deep Remove high
gouges along trail- with ~no high metal. metal.
ing edge (within
3/16 inch of edge).
(f) Nicks, dents or Any number, 0.040 inch deep
gouges other than with smooth deformation.
trailing edge.
(g) Type IA and Type Any amount providing there
II nozzles for are no cracks, burns or
missing coating erosion beyond serviceable
in gas passage. limits.
(2) The partition brazed Not over 25% of any joint
joint for cracks (14). affected.
(3) The inner band flange and the inner or outer band for:
(a) Distortion. No distortion which would pre- Cold work to
vent assembly of nozzle in original shape
casing or affect engagement and inspect for
of interstage seal. cracks.
(b) Axial cracks ex- 15 cracks in each band (inner
tending from the and outer) per nozzle half.
end of the parti- Axial cracks connecting to
tion slot to the circumferential cracks are
leading or trail- not serviceable.
ing edge of the
band (13).
(c) Axial cracks ex- Any number.
tending from the
partition slot and
terminating in the
band.
(d) Circumferential 10 cracks, 1/2 inch long, in
cracks (15). each band and the support
structure.
(e) Burnouts. Not serviceable.
Mar 30/84 72-52-0
Page 205
CtYERIL8 ILECTIIIE
CJ610 TURBOJET
MAINTENANCE MAMJAL SEI-186
VIEW A I VIEW A SHOWING NOZZLE
DEFECTS
13
4 ,TRAILING EDGE I rY~Y/h( 11
16
VIEW A I ~-LEADING EDGE n I
(MISSING
VIEW B CORNER~
13
10
7~ I Ur
14
1 16
5 14
VIEW B TYPE 1 NOZZLE
ANTI-ROTATION SLOT
FOR INTERSTAGE SEAL RIVET
i. Outer Band Support
2. Outer Band I
3. Partition
4. Inner Band
5. Inner Band Flange
6. Inner Band Seal
7. End Shield I TYPE 1A NOZZLE
8. Brazed Joint
ANTI-ROTATION SLOTS
9. Expansion Slot FOR INTERSTAGE SEAL RIVETS
1O. Axial Crack Partition
Leading Edge I h~ s
11 Axial Crack Partition
Trailing Edge
12. Radial Crack- Partition
13. Axial Crack Inner
and Outer Band
14. Partition Brazed 0 TYPE II NOZZLE 5
Joint Crack
MOUNTING BOLT HOLES
15. Circumferential Crack
FOR I TAGE SEAL
16. Buckling or Distortion
NOTE: TYPE 1A AND TYPE II NOZZLES HAVE A DIFFUSED
METALLIC COATING (MDC 1) OF´•l THE GAS PAS-
SAGE SURFACE OF THE PARTITIONS, INNER BAND,
AND OUTER BAND.
BC-0307
Second-Stage Turbine Nozzle
Figure 202
Figure 203
DELETED
72-52-0 Sept 1/76
Page 206
G EW ERAL ~B ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check _
Maximum Serviceable Limits- Remarks
(f) Outer band expan- One axial crack per expansion
sion slot (9) slot, 1/2 inch long max and
cracks (Type LA does not extend into partition
and Type II joint.
nozzles only),
(4) Inner band (4) for:
(a) Missing corner. Any amount up to 0.200 inch
from apex of corner measured
along either edge.
(b) Dents. Any amount up to 0.030 inch
deep, and no cracks.
(5) Inner band flange (5) for:
(a) Fretting and pit- Any amount, if the thickness
ting (CJ610-1, is not less than 0.040 inch.
-4, -5 and -6 Thickness as low as 0.030 inch
only), is allowed if no more than 15
percent of any 60 degree seg-
ment is affected.
(6) Outer band (2) for:
(a) Dents. Any amount, 0.020 inch deep. Remove high
metal.
(b) Bulged sections No visual distortion. Repair per para-
(CJ610-1, -4, graph 4,D.
-5, and -6 only).
(c) Braze void at Length 0.22 inch, width 0.06 Repair per para-
corner of frame inch. See Note and figure graph 4.D1.
stop hole. 203B.
NOTE: A braze void located at the corner of the frame stop hole
on the forward side of the second stage nozzle (specifically
the 0.08-0.06 inch chamber) is inherent in the design. When
measured in the direction of arrow (figure 203B) and does
not exceed 0.22 inch in length, or 0.06 inch in width, the
void is acceptable.
(d) Cracks emanating Not serviceable. Repair per para-
from antirotation graph 4.D1.
bolt slots.
(7) Inner band seal (6) for:
72-52-0
I Mar 30/84
Page 206A
Gf W fRAi f if CT R IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspect ion/Check Maximum Serviceable Limits Remarks
(a) Cracks. Not serviceable.
(b) Missing Seal. Not serviceable.
(8) Nozzle end shield Any amount, providing there
d7) for dents, are no cracks in the brazeq
nicks, and or welded joint or in the
scratches. end shield.
3A. Measuring Leading Edge Thickness of Partitions on Second-Stage Turbine Nozzle.
(See figure 202A.)
A. Place nozzle on flat surface with leading edge of partition facing up.
B. Open jaws of gage 2106198 or equivalent. Insert smaller probe into
partition opening on outside diameter of nozzle until partition opening
and scribed line (1.8 inches) on lower jaw of gage are aligned.
C. Release pressure on gage and allow probes to contact inner and outer
surface of leading edge of partition.
D. Move gage radially outward along leading edge, and read minimum thickness
on dial indicator of gage,
E. Repeat steps A through D for remaining nozzle partitions.
F. Open jaws of gage and insert smaller probes into partition opening to a
depth of 0.250 inch.
G. Repeat steps C and D.
H. Repeat steps F and G for remaining nozzle partitions.
4. Repair.
NOTE: Lubricate edges of shroud and stage 2 nozzle with Ease-Off 990
(Texacone Co., Box 4236, Dallas, Texas).
A. Replacement of first-stage shrouds. (See figure 201.)
NOTE: On CJ610-1 and -4 engines, all first-stage shroud segments may
I be replaced. On CJ610-5, -6, -8, -8A, and -9 engines, shrouds
are machined at assembly and cannot be replaced according to
this manual.
72-52-0 Dec 31/91
Page 206B
GENERAL ~g ELECTRIC
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
1.800 INCHES
0.250 INCH
STAGE 2 NOZZLE
LEADING EDGE
PARTITION
SCRIBED LINE
THICKNESS GAGE
PARTITION OPENING BC-O447
Measuring Second-Stage Nozzle Partititon Leading Edge
Figure 202A
Mar 30/84 72-52-0
Page 207
eEnEa L E Lr crR Ic
CJ6I0 TURBOJET
MAINTENANCE MANUAL SEI-186
CAUTION: PRE-GROUND SHROUDS MUST BE USED AND ASSEMBLY CLEARANCES MUST
BE MET.
(1) Removal.
(a) Soak shroud tracks with penetrating oil or engine oil to facili-
tate removal.
(b) Slide shroud segments (il and 12) from the casing half.
(2) Assembly,
(a) Slide shroud segments into the casing half.
(b) Shrouds must be installed so they interlock at the horizontal
split line when the casing halves are assembled.
B. Replacement of Second-Stage Shrouds (CJ610-1, -4, -5 and -6 only).
NOTE: All CJ610-1, -4, -5 and -6 second-stage shroud segments may be
replaced provided assembly clearances are met. Shrouds on CJ610-8
and -9 engines are ground at assembly and cannot be replaced per
this manual.
(1) Removal.
(a) Soak shroud tracks with penetrating oil or engine oil to facili-
tate removal.
(b) Slide shroud segments (5 and 6) from the casing half.
(2) Assembly.
(a) Slide shroud segments (5 and 6) into the casing half.
NOTE: Every other shroud segment is a locking segment.
(b) Shrouds must be installed so that the shroud anti-rotation tabs
mate with the slots at the horizontal split line when the casing
halves are assembled. Be sure the clearance between shrouds at
the horizontal split line is at least 0.020 inch across the en-
tire shroud ends, and the shroud ends are flush with the hori-
zontal split line. Bench the shroud ends as required to obtain
this clearance. The clearance between shrouds at the 6 and 12
o’clock positions shall be 0.100-0.250 inch.
72-52-0 Mar 30/84
Page 208
CEN~RAI ~P ELE CTRIC
CJ610 TURBOJET
SEI-186 RIA~AL
C, Replacement of Second-Stage Nozzle, (~ee figure 201,)
(1) Removal.
(a) Remove the anti-rotation bolt (10). Rectangular headed bolt
marked Ityll On shank, is not reusable. A bolt marked IIAll must
pass inspection before reuse. An oval headed bolt (not marked)
(used on CJ610-8, and -9 engines) must pass inspection before reuse.
(b) Remove the nozzle half (7) by sliding it from the turbine case
(1), It may be necessary to soak the tracks with penetrating
oil or engine oil to facilitate removal.
(2) Assembly,
(a) Lubricate the edges of the outer ring: of the nozzle Hith Fel Pio C-3.
(b) Slide nozzle half into turbine case. If necessary, bench the
nozzle half to obtain a slide fit.
(c) Install the anti-rntation bolt (10) into the frame stop of the
nozzle half,
SOTE: Lubrication of threads on anti-rotation boi~s no~ ~e-
quired.
(d) Hold nozzle half in the extreme aft position. Secure the bolts
to the turbine casing with nuts (8). On CJ610-1, -4, -5 and -6
engines, also use (9). Washer must be installed H~ith
recessed face against turbine casing. Torque the nut to net
torque of 40 Ib inches; loosen nut and retorque to net torque of
20-40 Ib inches tall models).
NOTE: Net torque equals gross torque minus run-on torque.
r/
SECOND-STAGE
SEALING SHROUD
UPPER-HALF
TURBINE CASING
2 Z
0.100-0.250 INCr
CLEARAHCE
CLEARANtE
b
I ji
SECOND-STAGE SHROUD
SEE DETAIL A
O’CLOtK POS:TIDN
ji LOWER-HALF
ilJCTURBINE CASING
Second-Stage Turbine Shrouds Installation CJ610-1, -4, -5, and -6
Figure 203A
72-52-0
Mar 30/84 Page 209
GfW ERAL ~P E LE CIR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(3) If only one half of the nozzle is serviceable, proceed as follows:
(a) Replace the faulty nozzle half with a like serviceable half hav-
ing the same part number. (Serial number will be different.)
When matching nozzle halves, the exit area for the replacement
half must fall within the following limits:
Nozzle Half Part No. Nozzle Half Area Limits
On CJ610-1, -4, -5, -6:
37R601096 (Type I) 37.200 37.600 sq. in. Am"
1 6010T32 (Type IA) 36.615 37.352 sq. in. Am*
On CJ610-8, -9:
6006T90 (Type II) 35.368 35.723 sq, in. Amk
6028Ti9 (Type II) 35.589 36.30: sq. in. Am"
"Am Area, mechanical (measured by gage).
Trial assemble the halves in a casing and check the outer band
gaps. Gaps must be within 0.100-0.200 inch and equal to each
other within 0.010 inch. If gaps are too small, bench material
equally from all four ends (both ends of bothhalves) or try
another half. (Do not mix nozzles of different part numbers.)
D. Repair of Second-Stage Nozzle Bulged Outer Band.
(1) Cold work the bulged section of the outer band to its original con-
tour by tapping a light hammer.
(2) Drill a 0,080 inch diameter hole in the reworked area in the location
shown in figure 204.
NOTE: Exercise care to prevent chips from entering the hole. It may
be helpful to remove chips before breaking through the outer
band while drilling.
(3) Spot fluorescent penetrant-inspect the reworked area per Section
72-03-1.
D1. Second-Stage Nozzle Weld-Repair. Weld per 72-02-4 using the follow-
ing information.
(1) Grind out welding. Whenever possible, grind out 50%
cracks before
of crack side, weld and repeat procedure for other
depth on one
side. Before attempting to repair-weld cracks containing braze filler
material, remove as much of the braze material as possible in areas
to be repair-welded to minimize weld contamination.
72-52-0
Mar 30/84
Page 210
EL~crRle
CJ610 TURBOJET
MAINTENANCE MANUAL
SEI-186
CJ61012910-E2
Braze Void at Frame Stop Hole
Figure 203B
(2) Weld using the filler specified in paragraph (8).
NOTE: Type IA and Type II nozzles have a aluminide diffusion coating
on gas passage surfaces of the partitions, inner band and outer
band. Difficulty may be encountered when welding in these areas
due to contamination of the weld by the coating; so when repair is
required, remove the coating in the affected area with a carbide
burring tool.and 60-grit sanding pads. Type II nozzle partitions
made of Mar-M-509 cast material does not have or require any coating.
CAUTION: DO NOT REMOVE MORE COATING THAN THAT WHICH IS NECESSARY.
DO NOT UNDERCUT PARENT METAL MORE THAN THAT WHICH IS
REQUIRED TO PREPARE THE WELD AREA.
(3) Keep amperages at a minimum to reduce shrinkage.
(4) Back up repair welds in the bands with copper to maintain alignments.
If area is inaccessible, use inert gas backing.
(5) Do not weld in one area so as to overheat the nozzle. Cool with dry
ice or weld in opposite sections.
sept 1/76 72-52-0
Page 210A
G EWfRAL ~D ELLCTRIC
CJ610 TURBOJET
MAINTENANCE MAM~AL SEI-186
(6) Bench after welding to remove all excess material. Use small-diameter
or pointed files to work into corners. Maintain smooth surfaces where
possible. Try to maintain the nozzle area. Restrictions in the noz-
sie area are undesirable. Repair welding is to be kept to a minimum.
NOTE: It is not necessary to recoat areas on Type IA and Type II
nozzles where the coating had been removed for weld repair.
(7) Trial assemble nozzle into casing half.
(8) The welding rod and part material is as follows:
NOTE: When welding L605 to Rene 41 material, use Hastelloy X
(AMS 5798) welding rod.
Part Nomenclature Part Material Welding Rod Process
(1) Partitions
(a) Type I Nozzle AMS 5537 (1-605) AMS 5796 (1-605) Inert are.
(b) Type IA Nozzle AMS 5545 (Rene 41) AMS 5798 Inert are.
(MDC-1 or CO-DEP- (Hastelloy X)
B-l coated)
(c) Type II Nozzle AMS 5545 (Rene 41) AMS 5798 Inert are.
(MDC-1 or CO-DEP- (Hastelloy X)
B-l coated)
I MAR-M-509 AMS 5796 (L-605) Inert are.
(2) Inner band
(a) Type i Nozzle AMS 5537 (L-605) AMS 5796 (1-605) Inert are.
(b) Type IA Nozzle AMS 5537 (L-605) AMS 5796 (1-605) Inert are.
(MDC-1 or CO-DEP or AMS 5798
B-l coated) (Hastelloy X)
(c) Type II Nozzle AMS 5537 (1-605) AMS 5796 (L-605) Inert are.
(MDC-1 or CO-DEP or AMS 5798
B-l coated) (Hastelloy X)
(3) Inner Band Seal AMS 5537 (1-605) AMS 5796 (1-605) Inert are.
(4) Outer Band
(a) Type I Nozzle AMS 5759 (L-605) AMS 5796 (1-605) Inert are.
72-52-0 Sept 1/76
Page 210B
GEIERAL ELECtRIC
CJ610 TURBO3ET
SEI-186 MAINTENANCE MANUAL
0.ORO DIA HOLE THRU
~UTER BAHD
0.520
0.460
--r-
YEHT HOLE LOCATION C)6\06W6-\-F2
Second-Stage Turbine Nozzle Outer Band Repair
Figure 204
(a) Remove honeycomb, required,
as in the area of the cracks up to a
limit of 80 cells per segment. If number of damaged or missing
cells exceeds 80, the shroud must be replaced per paragraph 4.B.
(CJ610-1, -4, -5, and -6 only). Shrouds on CJ610-8 and -9 en-
gines must be replaced per overhaul manual.
(b) Weld the crack per 72-02-4 using the following data.
NOTE: Weld bead should not be more than 0.025 inch above band
parent metal ID.
Part Nomenclature Part Material Welding Rod Process
Band AMS 5536 AMS 5798 Inert are
(2) Deleted.
F. Replacement of Interstage Seal Segments. (CJ610-8 and -9)
(1) Removal.
(a) Break lockwire and remove the 3 screws holding segment to nozzle.
NOTE: Match-mark the to facilitate re-installation in
segments
the same positions.
(b) Remove segment
72-52-0
Page 211
sept 1/76
GEIOIALQ ELECIIIC
66610 TURBOJeT
MAINTENANCE MANUAL SEI-186
(2) Assembly.
NOTE: Check match-marks on segments to re-align in same positions.
(a) Position segment on nozzle inner flange.
CAUTION: POSITION SEGMENT WITH THICK FLANGE FORWARD (SEE FIGURE
201, 72-53-0.)
(b) Install 3 screws, nuts, and washers.
(c) Torque screws to 7-9 Ib-in. and lockwire.
NOTE: Lockwire the 3 screws of each segment together. Do not
lockwire across segment end gaps.
(d) Check gap between segment ends. Gap must be a minimum 09 0.025
inch. Bench end of segment if required.
72-52-0
I Pa@le 212 sept 1/76
GENERAL B~ ELECTRIC~--
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
TURBINE ROTOR ASSEMBLY MAINTENANCE PRACTICES
i. General. This section covers the maintenance practices that can be performed on
the turbine rotor for either the scheduled, hot section inspection, or unsched-
uled repair.
2. Removal/Installation. Refer to 72-50 for this procedure.
CAUTION: TURBINE BLADE FAILURE WILL RESULT IN TURBINE ROTOR UNBALANCE AND CAN CAUSE THE
INNER COMBUSTION CASING/MAINFRAME BOLTS TO FAIL. WHENEVER INSPECTION REVEALS
ANY~BLADES HAVE FAILED, REPLACE ALL INNER COMBUSTION CASING/MAINFRAME BOLTS.
3. Ias~ection/Check. (See figure 201). Visually inspect the turbine rotor assem-
bly. When serviceable limits are exceeded, the rotor may be repaired in accor-
dance with the Overhaul Manual.
Inspection/Check Maximum Serviceable Limits Remarks
CAUTION: USED, SERVICEABLE BLADES CAN BE INSTALLED IN ENGINES OTHER THAN THE ENGINE
FROM WHICH THEY WERE REMOVED, WITH THE FOLLOWING RESTRICTIONS:
CONVENTIONALLY CAST R80 AND R100 MATERIAL BLADES REMOVED FROM CJ610-9 EN-
GINES MUST BE REINSTALLED BACK INTO THE ENGINE FROM WHICH THEY WERE RE-
MOVED. THE BLADE PART NUMBERS ARE 5008T30P01. 5039T11P01, AND 6009T97P01.
USED, SERVICEABLE BLADES MAY BE MOVED FROM ENGINE TO ENGINE ONLY IN COM-
PLETE SETS. IF A SET IS INCOMPLETE, IT SHOULD BE FILLED UP WITH NEW
BLADES.
THE BLADE TIME, PART NUMBER, HEAT LOT, AND ENGINE OR ORIGIN MUST BE ENTERED
IN THE APPROPRIATE SECTION OF THE ENGINE LOG BOOK.
A. Turbine blades (figure 202).
72-53-0
I Dec 31/95 Page 201
~B ELECTRle
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
12
I I- IIB 1111111111 13
CJ610-1. -4, -5 AND -6 CJ610-8 AND -F
11
CJ610-8 AND -9 CJ610-1, -5 AND -6
CJ610-T, -4,
-5 AND -6
CJ610-8 AND -9
17
6
7
18
16
15
1. FIRST-STAGE WHEEL 8. FIRST-STAGE BAFFLE 15. INNER ROTARY SEAL
2. SECOND-STAGE WHEEL 9. SECOND-STAGE BAFFLE 16. TORQUE RING
3. DOVETAIL SERRATION 10. LOCKING STRIP 17. NO. J BEARING LOCKNUT
4. DOVETAIL EDGES 11. INTERSTAGE SEAL 18. NO. 3 SEAL RUNNER
5. FIRST-STAGE WHEEL SHAFT 12. INTERSTAGE SEAL OUTER BAFFLE 19. TURBINE LOCKNUT
6. ROTOR BORE AND PULLER GROOVE 13. INTERSTAGE SEAL INNER BAFFLE 20. NO. 3 BEARING INNER RACE
7. RIVETS 14. OUTER ROTARY SEAL
CJ610-6!22-1-A2A
Turbine Rotor Assembly
Figure 201
72-53-0
Mar 30/84
Page 202
GENERAL ELECTRIC--~-
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
WARNING: PENETRANT METHOD OF INSPECTION
PROLONGED OR REPEATED INHALATION OF POWDERS AND VAPORS OF CLEANING
SOLVENTS, DEVELOPERS, AND EMULSIFIERS USED IN FLUORESCENT PENETRANT
INSPECTION CAN IRRITATE MUCOUS MEMBRANE AREASOF THE BODY.
CONTINUAL EXPOSURE TO PENETRANT INSPECTION MATERIALS CAN IRRITATE THE
SKIN. DIRECT EXPOSURE OF EYES TO BLACK LIGHT AND PROLONGED EXPOSURE OF
SKIN TO BLACK LIGHT CAN INFLAME AND DAMAGE EYES AND SKIN.
WEAR NEOPRENE GLOVES WHEN HANDLING PENETRANT INSPECTION MATERIALS.
KEEP INSIDES OF GLOVES CLEAN.
STORE ALL PRESSURIZED SPRAY CANS CONTAINING PENETRANTS. DEVELOPERS,
AND EMULSIFIERS IN A COOL, DRY AREA PROTECTED FROM DIRECT SUNLIGHT,
HEAT, AND OPEN FLAMES. TEMPERATURES HIGHER THAN 1200F (490C) MAY CAUSE
PRESSURIZED CAN TO BURST AND CAUSE INJURY.
IF DIRECT EYE CONTACT WITH BLACK LIGHT CAUSES EYE PROBLEMS, IMMEDI-
ATELY GET MEDICAL HELP.
WHEN USING BLACK LIGHT FOR FLUORESCENT INSPECTIONS, WEAR SAFETY
GLASSES.
CAUTION: REPLACE THE ENTIRE STAGE OF BLADING IF ONE OR MORE BLADES IS CRACKED.
IF IT CAN BE DETERMINED POSITIVELY THAT THE CRACKS ARE DUE TO FAULTY
PROCESSING OR FOD, THEN ONLY THE DAMAGED BLADES NEED TO BE REPLACED.
(1) Overall blade for:
(a)Cracks. Not serviceable. Remove FOD cracks
only in non-critical
areas on leading and
trailing edges. Blend
per paragraph 4.D.
and validate by
fluorescent-penetrant
inspection after
blending.
72-53-0
Dec 31/95 Page 202A
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINT~NANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(b) Bends, twists, Leading and trailing edges Replace blade.
and bowing within 0.046 inch from true
(see figure nominal shape of blade.
201A)
(c)Tip rub. Tip rub and scoring allowed Remove high metal
without high metal. up to 0.020 inch
from tip.
(d) First-stage blade See maximum warp angle Replace blades.
tip chord warp limits specified in figure.
angle (see fig-
ure 202A)
NOTES: 1. Inspection of all in the first-stage turbine wheel
blades
assembly las shown figure 202A) is necessary only on en-
in
gines that have performance problems.
2. Inspection of the warp angle must be made with blades in
stalled in the first-stage turbine wheel or equivalent.
(2) Airfoil for:
(a) Nicks, pits, Any number 0.010 inch deep. Blend per para-
dents, or graph 4.D.
scratches in
critical areas.
(b) Nicks, pits, Any number 0.020 inch deep. Blend per para-
dents, or graph 4.D.
scratches in
minor areas.
(c) Corrosion (swell- Not serviceable. On leading and
ing, flaking, trailing edges
chipping, etc.). only, remove
corrosion to
bright metal by
blending per
paragraph 4.D.
(d) Hot environmental
attack (hot gas
corrosion on
diffusion-coated
blades).
72-53-0
Page 202B Dec 31/95
GENERAL ~B ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
ILIEUgSTILCE
1 FOR BOWING. RWOVE 2 WORST BLADES IN
4 MAXIM]H WIDE AM) 0.046 IN~ THICK.
~NCII
d
EACH STAGE AND INSPECT THEN, ONEAT A WIRE TIIICRNESS GAGE THAT IS 0.046 INCH
TIME. I THICK IIAY BE USED AS AN ALTERNATE.
PIILCE ~LME ON L PUT SUBPICE SO TBBT
2 CONCAVE SIDE OF BLADE IS FACING UP. 5 BLADE AMD FLAT SUBFACE. IP GAGE
HOLD BLADE IN PLACE WITH FINGEB- BLADE IS MUD
PRESSURE. I SHALL BE BEPLACED.
~-1 ~c1/32
INCH
HIN
t(EPE~U PBOC~DURE WE SECOND BLdDE.
6
3 BLADE PIATWBn SHALL EXTENT) AT LEAST
1132 UICH BEYOWD BIOE OP FIAT S~eE
~7 IP ETTBgB 8Id9h IH I SIIGE TS Om-OP-
LIMITS, BPWIVE BI~U)ES LN TBAT
SO THAT BEADING WILL NQT BE AFFECTED I STAGE AND INSPECT TBPW, USING THIS
BY PLATPO%H BAILIIIS. I PBOCEWBE.
000CF7-890402
Bowing of Turbine Blades Inspection
Figure 201A
72-53-0
Dec 31/95 Page 2028.1
GENERAL ELECTRIC------
CJ61 6 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
1 All blades
identified as
Hp, HR, HS, HT,
and HW.
a Shaded areas Any amount of discoloration
only. (See with no surface roughness,
figure 2021.) blistering, or separation
of airfoil surface.
b Unshaded Any amount of discoloration,
areas. (See surface roughness, or missing
figure 202B.) coating with
no blistering or
separation of airfoil surface.
2 All other Any amount of discoloration,
areas. (See surface roughness,
or missing
figure 2021.) coating with no blistering or
separation of airfoil surface.
(3) Visible area of dovetail for nicks, pits, dents, and scratches in:
(a) Critical area. Any number 0.005 inch Replace blade.
after removal of high metal.
72-53-0
I Page 202B.2 Dec 31/95
6EI0)6LQ IL00fllC
CJ610 TURBOJET
SEI-186 MAINTENANCE MAN~AL
CONVEX SIDE
O "’Jo
0.060 INCH
0.060 INCH
AI Ir 1 A
O.lo0 INCH
CONCAVE SIDE
0.1CO INCH
1 INCH STAGE 1
4
LOCATION OF CRITICAL AREAS THRU SECTION A-A
0.10
INCH
CONVEX SIDE
CONCAVE SIDE CONVEX SIDE ~EDCE TO EDGE
STAGE 1
0.100 INCH
0.100 INCH CONtAVE SIDE
STAGE 2
LOCATION OF CRITICAL AREAS THRU SECTION B-8
CONVEX SIDE
0.060 INCH
0.060 INCH
0.100 INCH
0.100 INCH
C
2INCH CONCAYE SIDE
STltE2
r 1
LOCATION OF CRITICAL AREAS THRU SECTION C-t
B L~ B
INCH
CRITICAL AREA
CONCAVE SIDE CONVEX SIDE I j MINOR AREA (INCLUDES ENDS AND BDTTOn
OF DOVETAIL AND EDGE OF PLATFORMI
STAGE 2
NOTE THESE AREAS DO NOT DEFINE CHORD (BLENDINt) LIMITS
CJ610-3227-I-*?*
Turbine Blade Inspection Areas
Figure 202
72-53-0
I Dec 31/91
Page 202C
6 EY CRIL ELEETI1IE
CJ610 TURBOJET
~INTENANCE MANLIAL SEI-186
STRAIGHT EDGE~ ~--BLOCK
-t
0.225REF.
BLADE
WARP ANGLE
BLADE --u I
TO BE
MEASURED
I~-- TIP
CHORD
LEADING EDGE LINE
VIEW TN DIRECTION OF ARROW
FIRST-STAGE BLADE TIP CHORD
FIRST-STAGE APPLICABLE
BLADE PART NUMBER MAXIMUM WARP ANGLE MARGINAL WARP ANGLE NOTES
5008T30P01 58" 1 THKU 4
5039TllP01 58" 1 THRU 4
6009T97P01 610 1 THRU 4
6009T97P03 61" 1 THRU 4
ALL OTHER 55" 53" 1 SHRU 5
PART NUMBERS
1. MEASURE TIP CHORD WARP ANGLE WITH BLADES INSTALLED IN THE
FIRST-STAGE TURBINE WHEEL OR EQUIVALENT.
2. DO NOT MEASURE A BLADE IF DEFECTS HAVE BEEN BLENDED OUT OF THE
LEADING AND/OR TRAILING EDGE AT THE TIP CHORD.
3 MAKE SURE THAT BLOCK RESTS ON BLADES HAVING THEIR ORIGINAL
TRAILING EDGE CONTOUR.
4. REPLACE BLADES IF TIP CHORD EXCEEDS MAXIMUM WARP ANGLE LIMIT.
5. NO MORE THAN 25 BLADES IN A WHEEL ASSEMBLY SHALL BE IN EXCESS OF
THE MARGINAL WARP ANGLE LIMIT.
1 nLL DIMENSIONS I
I IRE IN INCHES I
000CJF-01990P
Inspection of First-Stage Turbine Blade Tip Chord Warp Angle
Figure 202A
72-53-0 Dec 31/91
Page 20211
CEIERAL ELECfRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
0.4 MAX
TYPICAL I 1 -0.5 EV\X
t
t ~F
0.3 MAX
0.2 MAX
0.8 MAX i -1 0.6 HAX
t 1 i ~7 t -ftZ2J L~3-t
CONCAVE CONVEX
CDNCAVE CONVEX
STAGE 1
STAGE 2
ALL DIMENSIONS
CDATED AREA ARE IN INCHES
BE-4574
Turbine Blades Inspecton for Hot Gas Corrosion
Figure 202B
InsPection /Check Maximum Serviceable limits Remarks
(b) Minor area. Any number 0.010 inch deep Replce blade.
after removal of high metal.
(4) Blade tips for Within 0.025 of true position.
curled corners.
(5) Platform, shank, Any amount of discoloration Replace blades.
and dovetail for or surface roughness with no
hot gas corrosion blistering, or separation of
and sulfidation parent metal.
(diffusion coated
blades).
Dec 31191 72-53-0
Page 203
GEWERAL ~g ELfCtRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection /Check Maximum Serviceable Limits Remarks
B. Baffles for:
CAUTION: THE TURBINE ROTOR BAFFLES USED ON CJ610-1, -4, -5, AND -6
j FIRST-STAGE TURBINE
-5, AND -6
DISASSEMBLED.
WHEELS, AM) THE BAFFLES USED ON CJ61O-1, -4,
SECOND-STAGE WHEELS MUST BE REPLACED WHENEVER THEY ARE
ALL OTHER BAFFLES MUST BE FLUORESCENT
PENETRANT-INSPECTED.
(1) Cracks in first- Not serviceable. Replace all
stage (8, figure baffles in stage
201). and balance the
rotor if one
baffle is found
cracked.
(2) Cracks in second- Not serviceable. Replace all
stage (9, figure baffles in stage
201). and balance the
rotor if one
baffle is found
cracked.
C. Locking strips (10, figure 201) for:
CAUTION: LOCKING STRIPS MOST BE REPLACED WHENEVER THE TAB IS UNBENT. DO
NOT BEND THE TAB MORE THAN ONCE.
(1) Cracks at radius Not serviceable. Replace locking
of bend. strips per
paragraph 4.B.
1 (2) Axial looseness. 0.010 inch. Replace locking
strips per
paragraph 45.
D. Inner labyrinth seal Not serviceable. Replace rivet.
for missing or loose
rivets (15, figure
201).
E. Inner rotary seal (15, figure 201) and outer rotary seal (14) for:
(1) Cracks. Not serviceable.
72-53-0 Dec 31/91
Page 204
GEIERAL~ LLECtRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
(2) Nicks and dents Any number, 0.005 inch deep; Blend to smooth
on seal teeth. A maximum of 6 per tooth, not contour removing
to exceed 0.030 inch deep. all sharp edges
A maximum of 6 per seal, nov and high metal.
to exceed 0.060 inch deep.
However, the total cumulative
length of all dents, nicks,
and blends per teeth shall
not exceed 10% of the circum-
ference of the seal. There
shall be no high metal or
sharp edges.
F. No. 3 bearing locknut Not serviceable.
(17, figure 201) and
turbine locknut (19)
for cracks.
G. No. 3 bearing inner race (20, figure 201).
NOTE: Refer to 72-02-3 for inspection.
H. lCnterstage seal (11, Detail A, figure 201) for:
(1) CJ610-1, -4, -5,
and -6 seal:
(a) Missing rivets. Not serviceable.
(b) Worn rivets. Any amount, provided the
shank diameter is not below
0.070 inch at any one
point.
(c) Cracks in seal Not serviceable.
supports.
(d) Outer and inner
baffles (12, 13,
figure 201) for:
1 Separation Not serviceable.
(broken away
from rivets).
1 Dec 31/91 72-53-0
Page 205
GEWLRAL ~g ELEC’IRIC
CJGIO TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
2Warpase Any amount to rear; 0.030
and dents. inch forward.
3 Cracks. Not serviceable.
(e) Outer baffle for Not serviceable.
burned out sec-
tions (12, fig-
ure 201).
(2) CJ610-8 and -9 seal:
(a) Missing honey- 10 percent in any one Replace segment.
comb. segment.
i (b) Grooves in Any 1/8 inch wide by
honeycomb. 0.070 inch deep with a minimum
thickness of honeycomb wall
between any 2 grooves of 1/32
inch, measured at 1/2 of the
groove depth. No rubs allowed
into parent metal of seal sup-
port.
(c) Broken Not serviceable. Re-safety bolts
lockwire. per 72-52-0.
I, No. 3 bearing carbon seal runner (18, figure 201)
NOTE: Refer to 72-02-2 for inspection.
J. Turbine wheels: (1,2, figure 201)
(1) Cracks in any area, Not serviceable.
(2) Dovetails slots for: (if blades are removed)
(a) Scratches. Any amount that can not be Replace wheel.
felt with a 0.030 inch
radius scribe.
(b) Nicks, dents, Not serviceable.
or mars.
(c) Wear or galling. Slight wear or galling,
uniform throughout full
length of dovetail.
72-53-0 Dec 1/77
Page 206
GDNERAL~ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANLTAL
Inspection /Check Maximum Serviceable Limits Remarks
(d) Dovetail edges Any number 0.005 inch deep. Any defect can be
for scratches, removed by increas-
nicks, and dents. ing the edge
radius up to 0.040
inch.
(3) First-stage wheel shaft (5, figure 201) for:
(a) Scratches, nicks, Any number, 0.015 inch, Defects up to 0.050
and dents in bore any length after removal of inch may be blended
and puller groove. high metal. out.
(b) Threads for dam- Not serviceable. One complete defec-
age. tive thread can be
removed and the
thread chased.
(c) Spline, lands, Any number, 0.010 inch deep, Defects up to 0.050
and journals for any length after removal of inch may be blended
nicks, scratches, high metal, out.
and dents.
I Dec 31/91 72-53-0
Page 206A/206B
GIWERIL~nECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
Inspection /Check Maximum Serviceable Limits Remarks
K. Visible areas of torque
ring (16, figure 201)for:
(1) Cracks, Not serviceable.
(2) Labyrinth seal Any number, 0.005 inch deep. Blend to a smooth
teeth for nicks A maximum of tooth, not
6 per contour,removing
and dents, to exceed 0.030 inch deep. all sharp edges and
A maximum of 6 per seal, not high metal.
to exceed 0.060 inch deep.
However, the total cumulative
length of all dents, nicks,
and blends per tooth shall
not exceed 10% of the seal.
There shall be no high metal
or sharp edges.
4. Repairs.
A. Turbine Blade Replacement. (See figure 203.)
CAUTION: USED, SERVICEABLE BLADES CAN BE INSTALLED IN ENGINES OTHER
THAN THE ENGINE FROM WHICH THEY WERE REMOVED, WITH THE FOLLOWING
RESTRICTIONS:
CONVENTIONALLY CAST R8O AND R1OO MATERIAL BLADES REMOVED FROM
CJ61O-9 ENGINES MUST BE REINSTALLED BACK INTO THE ENGINE FROM
WHICH THEY WERE REMOVED. THE BLADE PART NUMBERS ARE
5008T3OP01, 5039TllP01, AND 6009T97PO1.
USED, SERVICEABLE BLADES MAY BE MOVED FROM ENGINE TO ENGINE
ONLY IN COMPLETE SETS. IF A SET IS INCOMPLETE, IT SHOULD BE
FILLED UP WITH NEW BLADES.
THE BLADE TIME, PART NUMBER, HEAT LOT, AND ENGINE OF ORIGIN
MUST BE ENTERD IN THE APPROPRIATE SECTION OF THE ENGINE LOG
BOOK.
Whenever are replaced,
tubine blades the tip clearance checks
specified 72-50, paragraph 2.6., must be made. Also, record
in
the blade marking on the dovetail base except for the engine
I project letter and the blade moment weight.
number of blades with the same marking.
Also, record the
Record the operating
time for each group of blades (see figure 203A for sample record
form). Blades will assume the operating time of their respective
Dec 31/91 72-53-0
Page 207
GEWORAL~ ELECtRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
turbine wheels. engine buildup records must be searched to provide
Previous
as accurate a blade time as possible. For example, the respective turbine
wheels may have been replaced and the blades retained and vice versa. The
total actual blade operating time thus determined must be entered in the
engine log book.
Example of what must be recorded:
Marking on dovetail base (typical): BT H15BP 190
Record only this group: m15BP
NOTE i: On the CJ610-8 and -9 engines, blade
tips are ground after in-
stallation in the turbine wheel. Replacement blades may be
ground to the length of adjacent blades, prior to installation,
using holding fixture 205377, or equivalent.
NOTE 2: Blades which have been replaced with new ones and are still
serviceable must have their time recorded and attached to the
blade.
(1) Remove either the first- or second-stage turbine blades as follows:
(a) Straighten the tab of the locking strip. Forward tab on first-
stage, aft tab on second.
CAUTION: DO NOT USE SHARP TOOL TO STRAIGHTEN THE TABS.
(b) Remove the baffles, blade and locking strip.
(2) Install replacement blade in either the first- or second-stage turbine
wheel as follows: (Selected per paragraph 4.B.)
(a) Insert locking strip in the dovetails on the rim of the wheel.
the
On the first-stage the pre-bent tab end of the strip goes on the aft
side of the wheel, on the second-stage the pre-bent tab goes on the
forward side.
(b) Assemble the turbine blade in the dovetail slot and install the
baffle to the left side of the turbine blade shank,
(c) Check the blade for proper looseness by pushing circumferentially
on the blade tip. There must be perceptible motion.
(d) Bend the unbent tab of the
locking strip radially outward to secure
the turbine blade. first-stage tads, on CJ610-1, -4, -5 and -6
Bend
engines, using tool 2C5302G1; on CJ610-8 and -9 engines use tool
2C5302G2. Bend second-stage tabs, on CJ610-1, -4, -5 and -6 engines,
using tool 2C5301G1; on CJ610-8 and -9 engines, use tool 2C5301G2.
72-53-0
Dec 1/77
Page 208
GEWPRAL~ ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
BLADE
BLADE
SECOND
BAFFLE STAGE
FIRST
STAGE LOCKING STRIP
LOCKING STRIP
.I
WHEEL -´•L
WHEEL
UL10d01M´•CI
Turbine Blade Replacement
Figure 203
(e) Apply pressure against the pre-bent tab of the lockstrip to hold
it snug to the aft side of the turbine wheel. Check the space
between the bent tab and the wheel face with a 0.005 inch shim.
If the space is greater than 0.005 inch, bend the tab further by
striking the anvil head of the bending pliers with a hard fiber
mallet.
CAUTION: IF IT IS NECESSARY TO UNBEND THE LOCKSTRIP TAB, RE-
PI;ACE THE LOCKSTRIP. THE END TABS OF LOCKSTRIPS
ARE NOT TO BE FULLY BENT MORE THAN ONCE.
Dec 31/91 72-53-0
Page 208A
(pcn
lu
k, 1 Ist. STAGE WHEEL P/N S/N TSN CSN Note: This form to accompany turbine blades. E~IGINE MODEL
oo Replacement turbine blades must not ENGINE S/N
oo 2nd. STAGE WHEEL P/N S/N TSN CSN exceed the time (hrs) of the highest ENGINE TSN TSO
W
timed blade listed below:
IST STAGE AT AL 1ST STAGEAT BUILD-UP STAGE AT
BLADE MARKING NO. TIME BLADE MARKING .ITIME BLADE MARKING NO. TIME BLADE MARKING NO. TIME
C
Q)-
;P
m~
O
TOTAL MUST 55 t
TOTAL MUST 75 TOTAL MUST 55
TOTAL MUST 75 m
NOTE: BLADES WITH THE SAME MARKING SHALL ASSUME THE TIME OF THE HIGHEST TIME
BLADES OF THAT GROUP.
REMARKS:
Disassembly Insp. &Date
Assembly Insp. &Date
ENGINE MODEL CODE TURBINE BLADES CODE TURBINE BLADES
CJ61O-1 BS 5000T1 4P01
CJ61O-1, -4, BT 5002T1 OPO1 BG 37E501 526P1 01
-5, -6 BH 37E501 526P1 02
HJ 5002T1 0PO3 HK 37E501 526P1 03
CJ610-1 BJ 634E579P03
CJ610-8, -9 HE 5008T30P01 HC 5008T31 P01
CJ61 0-8, -9 HT 5039T11PO1 BC-O114-3
Ho 6oosrs7Pol HR 6009r98P01
cJslo-sn
ii I L
~I
oW
Turbine Wheel Blade Poeition and Time Record-Sample Form
oo
-41
ex, Figure 203A o\
GIYtl~L IltCtliC
CJ610 TU:RBOJET
SEI-186 ,MAlNTFNANCE MANUAL
ENGINE PROJECT BLADE PART NO. BLADE
STAGE CODE LETTER CODE LETTER PART NO.
1 B J 634E579P03
1 B T 5002T10PO1
1 B S 5000T14P01
1 H J 5002T1OPO3
1 H B 5068T30P01
1 H T 5039TllPO1
1 H
r~P P
G
6009T97P01
37E501 526P10l
2 B H 37E501526P1O2
2 H K 37E501526P103
2 H C 5008T31 PO1
2 H R 6009T98PO1
CONCAVE SIDE
CONVEX SIDE
ALTERNATE LOCATIONS OF
MOMENT WEIGHT NUMBERS
*´•ri
COATING LOT IDENTIFICATION
NUMBER (IF APPLICABLE)
ENGINE PROJECT (LETTER)JIII~I I
PART NUMBER (LETTER) MOMENT WEIGHT
CASTING OR FORGING VENDOR(1 OR 2 LETTERS
MACHINING VENDOR (1 OR 2 NUMBERS)
HEAT NUMBER---J I J
HEAT TREAT LOT
BC-0116-3
Turbine Blade Code Identification and Marking Locations
Figure 204
Dec 30/78 72-53-0
Page 208C/208D
GEWERAL f LE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
B. Methods of Blade Substitution.
I NOTE: First-stage turbine
interchangeable and
blades
may be used
Pt No. 5008T30 and 5039T11
in mixed lots.
are
(1) The moment-weighted turbine blade numbers run in 1 gram-inch incre-
ments from 175 to for the first-stage
225 turbine wheel and from
265 to 330 for the second-stage wheel. The moment weight is stamped
on the base of the blade dovetail (see figure 204).
(2) Replace blades using Method one. If a replacement blade of the same
moment weight is not available use Method ’I~o or Three.
(3) Replacement Method One.
(a) Replace each blade with one of the same moment weight number, if
available. A maximum of 10 blades may be replaced using this
method.
(4) Replacement Method Two. (See figure 205.)
(a) Remove the damaged blade and one adjacent on each side.
(b) Total the moment weight numbers and select 3 replacement blades
having the same total moment weight.
(c) Install the 3 replacement blades in the dovetail slots, retaining
the respective weights
Same same inthe the relative location in
wheel those removed (the heaviest replacement blade replacing
as
the heaviest blade in the group of 3 removed). A maximum of 3
sets may be replaced using this method.
(d) If the two adjacent blades of each set removed are still service-
able, identify them by inking the engine model and part number on
Sept 1/76 72-53-0
Page 209
OEY ERIL aD
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
-7
c---
,I
I
,1
REPLACEMENT METHOD TWO REPLACEMENT METHOD THREE
MOMENT WEIGHT NO. MOMENT WEIGHT NO.
BLADE NO. BEFORE REPAIR AFTER REPAIR BLADE NO. BEFORE REPAIR AFTER REPAIR
)80 187 1 280 LIGHT 281
2 *195 190 2 285 284
3 205 203 3 ’310 HEAVY 308
TOTAL 580 580 4 305 304
5 ’290 293
TOTAL 1470 1470
IN REPLACEMENT METHOD TWO AND THREE, 1T IS ASSUMED THAT CERTAIN BLADES, MARKED ARE NOT AVAILABLE
(IN LH COLUMN) AND ARE REPLACED BY THE AVAILABLE SPARES INDICATED IN THE RH COLUMN.
CJ610´•6110´•0´•B?
Blade Replacement Methods
Figure 205
72-53-0 April 15/68
Page 210
G EW EIAL ~b ELLCTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
the convex side of the airfoil, using semi-permanent black ink
("Easy-mark" No. 2120, Easymark Ink Co,, Lowell, Mass.) or equiv-
alent and return them to stock for re-use.
(5) Replacement Method Three. (See figure 205.)
(a) Remove the damaged blade and the two adjacent blades on either
side; a total of five blades.
(b) Total the moment weight numbers, and select 5 replacement blades
having the same total moment weight.
(c) Install replacement blades in the dovetail slots, retain-
the 5
ing the respective weights in the same relative location in
same
the wheel as those removed (the heaviest replacement blade re-
placing the heaviest blade in the group of 5 removed).
(d) If any of the adjacent removed blades are serviceable, return
them to stock for re-use as outlined in method two.
(e) A maximum of 1 set may be replaced using this method.
C. Replacement of No. 3 Bearing Inner Race and Seal Race.
NOTE: The inner and outer bearing races are matched sets and are not to
be separated, if one race is replaced, the other must also be re-
placed. Make certain replacements are a set. This replacement
is accomplished with the turbine rotor removed.
(1) Removal.
(a) Place the turbine rotor in stand, 205303, with the front end
facing up.
(b) Remove the No. 3 bearing locknut by straightening the tab on the
lockwasher and using spanner wrench, 205304.
(c) Remove the inner race and seal runner using puller, 205306.
NOTE: The bearing race and seal runner are removed at the same
time since the pulling surface is on the forward side of
the seal runner.
(2) Installation.
(a) Measure the distance from the first-stage turbine wheel shaft
hub to the seal stop shoulder. Record reading.
April 15/68 72-53-0
Page 211
GEWERALb ELECTRIC
81810 TURBOJET
MAINTENANCE MANUAL SEI-186
(b~ Measure the height of the seal runner from the counterbore to
the top of the seal runner. Measure the bearing race height.
Add the two together and record.
(c) Coat the inside diameter of the races with engine oil.
(d) Wrap both races in aluminum foil, place them in an oven, and
heat for 20 minutes at 2500F (1210C).
(e) Assemble the heated races onto the shaft. Seat the races
against the shaft and hold with inner race holder of the fixture
2C5303.
(f) After the parts have returned to room temperature, measure the
distance from the end of the shaft to the seal race in four
equally spaced places. The average of these readings must be
within f 0.001 inch of the difference between the readings taken
in step (a) and (b).
(g) Position the turbine rotor locking devise of the fixture, 2C5303
to keep rotor from turning.
(h) Assemble the lockwasher and locknut onto the shaft.
NOTE: Lubricate the threads of the shaft with engine oil.
(i) Tighten the nut, using spanner wrench, 2C5304, to 150-170 Ib-in.
Align the locknut and thelockwasher tab by increasing torque
from the minimum value. Bend the tab of the lockwasher into the
locknut slot.
D. Turbine Blade Airfoil Blending Procedure.
N(TrE: Blending is done to remove the stress concentration of nicks,
pits, scratches, etc., to prevent blade failure. The removal of
high metal, and radiusing of the leading edge is done to restore
the airfoil to nearly its original aerodynamic shape. All blend-
ing should be done with a minimum of 1/4 in. radius. Blending
close to the tip should be
straight out so as to leave a
extended
narrow projection corner. at the
the benching to remove two If
separate defects runs together, round over the point between them.
Any blending near platform-to-airfoil radii must be such as to
maintain the same smooth transition
shape as on new parts. The
of the airfoil
leading edge very important is engine to maintain
performance, They are not knife edges, but carefully radiused
edges whose shape shall be maintained in the blended area. (See
figure 206.)
72-53-0 Sept. 15/69
Page 212
CLNERALiS~I LLECTRIC
CJ610 TURBOJET
SEI-186 MAIW~ENANCE MANUAL
RAD.
I
CORRECT INCORRECT
CT)(´•)IP7-O-r2
Typical Leading Edge After Rlentling
Figure 206
(1) Rough blend the damaged area with a file, emery clotti oi´• cgctivnlcnl
tool
(2) Finish blend the final .003-.005 inch with fine emery pape~, a fine
stone or equivalent tool. Always finish blend in a length~lise tlii´•c~´•-
tion, removing all evidence of crosswise marks that may have been
made during rough blending. The final finish of the rewo~ketl ai´•c;~
shall be as smooth as the undamaged area,
(3) The amount of repair is controlled by the mininn~m chord widlli. (Sce
figure 207 or 208,) The total reduction in chord may be taken (,II
either edge or divided between the edges at any given location. Tile
tip chamfer shown allows a further reduction in cliord at the lip oti-
ly, The minimum chords between points specified are proportional.
Allowable depths of rework, shown in parentheses, are for convenience
only, In the event of doubt: or disagreement between depth and min
chord, the min chord is the referee method,
CAUTION: BLENDING IS TO BE DONE ON LEADING AND EDGES ONL~.
BLENDING IS NOT ALLOWED ON AIRFOIL SURFACES.
N(YTE: The indicated minimum chord limits are not to be taken as
permission to machine the entire edge off.
(4) Fluorescent-penetrant inspect per 72-03-1.
72-53-0
Sept, 15/69 Page 2L3
GEW ERAL 4~ ELLC’IAIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
ROUND OVER POINT
SMOOTH RADIUS
NO OVERHANG ALLOWED
NPICAL BLENDING
1/4 INCH RADIUS MINIMUM
SMOOTH RADIUS
0.7
MIN
3/8 MAX I
L?
0.5
MIN _rl
3/8
ri~JT
MAX
ALLOWABLE TIP CHAMFER
1/2 MAX
f
1/2 MAX
MINIMUM CHORD
(0.040)
MINIMUM CHORD r
"r (0.040) (0. 040)
0.740 39/16 (0. 040)
21/8
1 7/8
t
(0.040)
(0.030) \--0.760
0.740
3
2
1/4
1/2
i (0. 030)
(0. 030)
15/8r
1 3/8
f-
7-
(0´•030)
(0.020)
--l).lBO
0. 800
129/32
f (0´•030) O.Pb0
1 5/32 (0.020) 0.820 T
T
15/8 (0.020) 0.970
29/32 (0.020) 0.840
f
1 9/32 (0.020) 0.990
T
(0.020) 1.000
FIGURES IN PARENTHESES ARE
APPROXIMATE REWORK DEPTHS
13/32r
STAGE 1 STAGE 2
cwla,lr~-*u
Turbine Blade Chord Limits CJ610-1, -4, -5, -6
Figure 207
72-53-0
Page 214 Sept. 15/69
GLWEIII9 LLICIRIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
ROUND OVER POINT
SMOOTH RADIUS
NO OVERHANG ALLOWED
TYPICAL BLENDING
1/4 INCH RADIUS MINIMUM
SMOOTH RADIUS
8/8
MIN.MIN.
1/2 MAX.
7/16 MAX. MAX.
7/16 MAX.
7/1
(0.04) 1.06
(0.04) 1----0.78 1
(0.04) 1.04
3-7/1
(0.03) 1---1.02
(0.04) 1 3-1/1
0.78
2-1/4
(0.03) (--------0.80 i (0.02) 1 1.02
1-21/32
(0. 02) 0. 82 2-1
1-7/1
(0.02) 0.84
(0.02) 1.04
1-3/32 (0.02) 0.86
1-5/8
(0. 02) 1---1.06
~s i 1 1-5/1
(0.02) 1 -1.08
31/32
1ST STAGE TURBINE BLADE
2ND STAGE TURBINE BLADE
CF1003111-I´•*U
Turbine Blade Chord Limits CJ610-8 and -9
Figure 208
72-53-0
Sept. 15/69 Page 215
GEIYERIL~ ELECTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
ACCESSORY DRIVE SECTION DESCRIPTION AND OPERATION
i. General.
This section (figure 1) consists of the accessory power-takeoff drive assembly
located within the compressor rear frame; transfer gearbox located on the
bottom of the mainframe; and an accessory gearbox located on the compressor
front frame. The horizontal drive shaft and cover connects the transfer gearbox
to the accessory gearbox. The accessories are mounted on the pads of the
accessory gearbox and transfer gearbox.
On some engines the accessory gearbox is mounted on the mainframe and the
I transfer gearbox and horizontal drive shaft are not used.
2. Description.
A. Accessory Power-Takeoff (PTO).
(1) The accessory power-takeoff drive assembly is located within the
mainframe. Its purpose is to transmit power from the engine drive
shaft to the engine accessories. This assembly consists of a housing
which houses and supports the gears and their related components.
It is secured at the forward end by bolts which pass through the No. 2
bearing support to the carbon seal support. At the aft end, it is
supported by a collar which rests on the mainframe inner shell.
(2) The engine drive shaft passes through the power-takeoff assembly,
through the driver shaftgear, and mates with the internal splines on
the aft end of the driver shaftgear. The ball bearing and housing
assembly supports the forward end of the shaftgear where it enters
the PTO housing. The driven shaftgear is centrally located in the
six o’clock position of the PTO housing. It is supported by a roller
bearing at the gear end and by a ball bearing at the other end. The
lube-IN line enters the PTO at the eight o’clock position, and is
routed through lines which connect to the oil nozzles. These nozzles
spray oil to the No. 3 bearing, No. 2 bearing, the shaftgear
ball bearing, and the contact point between the 2 bevel gears. A
second connection eight o’clock location is for the PTO sump
at the
return. The 2 connections at the four o’clock position are for the
No. 3 bearing sump scavenge line and the PTO sump vent line. All
free oil in the PTO housing drains into the transfer gearbox, which
acts as a sump.
(3) An insulation blanket covering the exterior of the PTO prevents the
assembly from being overheated.
Sep 1/75´• 72-60
Page 1
OE0EI8L E ~E cr II I c
CJ810 TURBOJET
MAINTENANCE MANUAL SEI-186
I:’
ri
L; bi
~a
D
1
I ~Y’ :14
~a:
c :´•i~
_i
C CJ 61 0-4. -6. -8
[tJ610-1 5 -9
BC-0241
Accessory Drive Section
Figure 1
72-60
Sept 1/76
Page 2
GEIERAL ~b E LE CTR IC
CJ610 TURBOJET
SEI-186 KAINTENANCE MANUAL
Transfer Gearbox (C3610-1, -5, -9 engines only). The transfer gearbox,
I mounted on an adapter at the bottom of the mainframe, consists of a
beveled gear train enclosed in a casing. The gearbox, powered by the
engine power takeoff assembly through the radial drive shaft, powers
the accessory gearbox through the horizontal drive shaft. It also
provides power to the accessory (if installed) mounted on Its rear pad.
Accessory Gearbox. The accessory gearbox, mounted on a bracket under
I the front frame on CJ6PO-1, -5, and -9 engines or under the mainframe
on CJ610-4, -6 and -8 engines, consists of a gear train enclosed within
a casing and cover. The gear train is powered by the transfer gearbox
through the horizontal drive shaft if installed under the front frame,
or by the engine power takeoff assembly through the radial drive shaft
if installed under the mainframe. The fuel pump, oil pump, and over-
speed governor are mounted on pads on the accessory gearbox. Two
other pads are available for customer use.
D. Horizontal Drive Shaft and Cover (CJ610-1, -5 and -9 engines only).
The horizontal drive shaft (enclosed in a cover) is splined at both
ends and transmits power from the transfer gearbox to the accessory
gearbox.
72-60
Sep 1/75
Page 3
GENERAL ELECTRIC-------
C3610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
TRANSFER GEARBOX MAINTENANCE PRACTICES
i. General. The maintenance of the transfer gearbox is limited to the external
section except for carbon seal. If a problem concerning the interior of the
gearbox arises the gearbox must be replaced.
2. R_emoval/Installation. (C3610-1. -5, and -9)
A. Removal.
(1) Rem.ove the horizontal drive shaft per 72-63-0.
(2) Remove the 4 nuts that secure the transfer gearbox to the mainframe
adapter.
(3) Carefully lower the transfer gearbox until it is free. Remove the gear-
box and the radial drive shaft.
CAUTION: DO NOT DROP THE RADIAL DRIVE SHAFT. DO NOT ATTEMPT TO ROTATE THE
GEARBOX TO FREE IT FROM THE MOUNTING ADAPTER DURING REMOVAL AS IT
IS POSITIONED BY A TIGHT-FITTING DOWEL PIN.
(4) Remove guide cover, shaft sheild guide and O-ring from the axis A hous-
ing (input drive). Discard the O-ring.
B. Installation.
(1) Install a new O-ring in the bore of the transfer gearbox axis A housing
(input drive). Assemble shaft shield guide and guide cover over bearing
housing.
NOTE: The guide is a hand press fit and the cover fits over the guide.
(2) Lubricate both splined ends of the radial drive shaft with engine oil.
Install the radial drive shaft and carefully position the transfer gear-
box on the mainframe adapter. Secure the gearbox with 4 nuts.’ Torque
the nuts to 10-30 Ib-in.
(3) Check the alignment runout of the transfer gearbox with the accessory
gearbox per section 72-64-0.
(4) Remove the alignment fixture.
(5) Replace the horizontal drive shaft per 72-63-0.
72-62-0
Sep 1/75 Page 201
GENERAL ELECTRIC------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAZ,
3. Insoectio_n(Checks. When serviceable limits are exceeded, the parts may be re-
paired in accordance with the overhaul manual.
Inspection/Check Maximum Serviceable Limits Remarks
A. Visually inspect the transfer gearbox for:
(1) Cracks. None allowed.
(2) Nicks and scratches. Any number, 0.030 inch deep.
(3) Evidence of leakage None allowed.
between cover and
case.
(4) Evidence of leakage See operating limits, Replace seal per
at rear pad. Adjustment/Test, 72-00. paragraph 4.A.
B. At every exposure of transfer gearbox Axis B gearshaft forward and aft female
splines, clean thoroughly with a suitable solvent and using a bright light
visually inspect splines for:
NOTE: Deleted.
(1)Wear at contact 0.005 inch. (Approx. If within Service-
area. estimate can be made by able Limits lubri-
visually comparing wear cate spline with
aft
at contact point with a lubricant specified
piece of 0,005 inch shim in Section 72-01-1:
stock. lubricate forward
spline with engine
oil.
NOTE: Replacement of the transfer gearbox axis B gearshaft for forward end
spline excessive wear also requires replacement of the horizontal
drive shaft.
72-62-0
Page 202 Dec 31/95
GEWERAL~ ELTCTRIC
CJ610 TURBOJET
SEI-18S MAINTENANCE MANUAL
14. Repair.
ar
A. Rubbing Seal Replacement. (CJ610-1, -5, and -9)
NOTE: For special tools use kits (Part Nos. 205334 and 2C5333).
(1) Remove the mounted accessory per the applicable paragraph.
(2) Bend the locking tabs away from the bolt heads. Discard the locking
tabs.
CAUTION: REMOVE ONE RETAINING BOLT AT A TIME AND REPLACE WITH RE-
TAINING PIN FROM TOOL KIT 205333 BEFORE PROCEEDING TO THE
NEXT BOLT. IF ALL 3 RETAINING BOLTS ARE REMOVED WITHOUT
THE USE OF RETAINING PINS, THE BEARING RETAINER INSIDE THE
GEARBOX WILL BE DISILOCATED REQUIRING REMOVAL AND DISAS-
SEMBLY OF THE GEARBOX TO PROPERLY ASSEMBLE THE BEARING RE-
TAINER.
(3) Remove one ofretaining bolts and install a retaining pin from
the
tool kit its place. Remove the second retaining bolt and
205333 in
install a retaining pin in its place. Remove the third retaining
bolt and install a retaining pin in its place. (By replacing retain-
ing bolts with retaining pins the bearing retainer inside the gearbox
will be held in position.)
(4) Remove the seal housing with puller, 205333.
(5) Remove the O-ring; using the pusher, 205334, remove the rubbing seal
from the seal housing.
(6) Remove the O-rings from the 3 bolt holes.
(7) Remove the mating ring and packing from the shaft.
Sep 1/75 72-62-0
Page 203
GCIEIAL~ ELtCTIIC
CJB10 TURIOJLT
MAINTENANCE MANUAL SEI-186
(8) Replace defective part.
(9) Insert the mating ring packing into the mating ring.
CAUTION: USE EXTREME CARE WHEN HANDLING THE MATING RING. DO NOT
ALLOW THE RUBBING FACE TO BE DAMAGED.
(10) Insert a seal guide, 205336, into the bore of the gearshaft.
(11) Assemble the mating ring and packing to the gearshaft, seating the
mating ring (packing side) against the shaft shoulder, using inserter,
2C5335.
NOTE: Some mating rings have 2 tabs. These tabs must be aligned
with slots in the spanner nut.
(12) Assemble the three O-rings to the 3 bolt hole O-ring grooves.
(13) Lubricate the OD of the rubbing seal with engine oil and assemble it
to the seal housing with the pusher, 2C5334.
CAUTION: BE CAREFUL WHEN HANDLING RUBBING SEALS. THE CARBON SUR-
FACES ARE EXTREMELY BRITTLE AND EASILY DAMAGED.
(14) Assemble the O-ring to the seal housing.
(15) Lubricate the OD of the seal housing with engine oil and assemble it
to the gearbox housing. Use tool, 2C5334.
(16) Bend the washer tabs approximately 30 degrees. Lubricate the bolts
with oil. Replace the retaining pins with the bolts and tab washers.
Torque the bolts to 25-35 Ib-in. Bend the tabs to secure the bolts.
NOTE: Bend one tab on washer to meet best aligned side of hex bolt.
Sep 1/75
204
GCWERAL~LLP CTIIIC
C4618 TURBOJEV
SEI-186 MAINTENANCE MANUAL
HORI ZONTAL DRIVE SHAFT AND COVERS MAINTENANCE PRACTICES
Gene r al The d r iv e sha f t is ina c c e s s ib 1 e wi thou t removing the ov e r s p e e d
governor from the accessory gearbox.
Remova 1 In s t alla t ion Se e f i gur e 2O 1 CJ 6 1 0- 1 5 and 9
A. Removal.
1 Remove the a i re raf t hydr aul i c pump per the air c r af t manua 1
2 Remove the ov e r sp e e d governor f r om the middle front pad of the
accesso ry gearbox per Section 73-2 2-0.
NOTE: The thread in the plug (4) is 1/4-28. Thread abolt: of
c onv en i en t length into the p lug f or ease of removal and
r ep la c emen t
3 Remove t he ing ring
r e t a in 3 p lug 4 O-r ing 5 and
second reta ining ing 3) r f rom the overspeed governor spl ine
bore Th i s exp o s es the end o f the hor i ton t al dr ive sha f t 13
4 The sp 1 ine s o f the d r iv e sha f t 1 3) mu s t be r e a s s emb le d to the
s ame ma t ing s pline in the ac c e s so ry and t r an s f e r gearbox f r om
wh i ch it was r emoved Ma t c h-ma rk d r ive sha f t 13 and ma t ing
splines as follows:
CAUTION 1 DO NOT USE PUNCH TO MATCH-MARK TEE PART S THE
FORCE REQUIRED COULD DAMAGE THE GEARBOX BEARING S
2. DO NOT PLACE MATCH-MARK ON CONTACT SURFACE OF
SPLINE
NOTE Gear s ha f t s and drive sha f t are made of hardened ma t er i a 1´•
and will require use of adiamond file or rotary burr for
ma t ch-marking
(a Rot a t e the c ompr e s s o r ro t or un t ii one of the s pi ine t eeth
of the ace esso ry gearbox axis Bgear shaft fo rwa rd spline
is located at the 6 o’clock position.
(b P lace a ma t chma rk on the crown t ip o f the axis B gear-
shaf t s p 1 in e too th and al s o on the f o rwar d end or chamf er
of the drive shaft (13) bore. Do not mark the aft end of
the dr ive sha f t 13
Sep 1/75 72-63-0
Page 201
oEIEIAL~ ELOetlllG
C J 61 O t C~ R IB OJ IFI. V
MAINTENANCE MANUAL SEI-186
(c) Make certain the matchmarks on the accessory gearbox axis B gear-
sha f t and d r iv e a ha f t 13 are at era c t ly 6 o c lo ck p o s i t i on and
then ma t ch-ma rk the t ran s f er gearbox axis B g ear shaf t a f t 9 pline
(customer PTO/hydraulic pump). The transfer gearbox axis B gear-
sha f t will no t nec e s s ar i ly have a spline tooth lo ca t ed at the 6
lo cZc p o s i t ion 90 pla c e the ma t chmark
c on the end of the axis B
gear shaf t out er d lame t e r at era c t ly 6 o c lo c k
(5) Remove the clamp, drain valve and tubes from the drive shaft cover (7)
6 Remove 2 snaps ing s 6 from the drive sha f t cover 7
(7 Remove the 4 nu t s and wa sher s t ha t s ec ur e the flang ed cover (9 to the
transf er gearbox. Slide the flanged cover (9) and drive shaft cover (7)
forward as far as each will go.
8 Slid e the dr ive sha f t 13 forward and remove it by pulling it
forward through the a c c e 9 s o ry g ea rb ox
(9) Remove the drive shaft cover (7) and tr ans fer gearbox flanged
cover (9) Remove and d i s c ard t hr e e O- r ing s (8 and 1 0)
(10) Remove the accessory gearbox oil jet cover (12). Discard the
O- r ing s 1 O and 1 1
B. Ins tallat ion
1 As s emb le a c c e s so ry gearbox oil j et cover 12 wi th new 0- r ing s 1 O and
11 Torque the nu t s to 6 0- 9 O ib in
NOTE: For ease of ass emb ly it is recommended that clear plastic tem-
plat es be lo c al ly -anu f ac t ur ed to fit the
tud p at t e rn o f the
s
overspeed governor pad on the accessory gearbox and the cust omer
P TO hyd r aul i c pump pad on the t r an s f er g earb ox Sc r ib e a 1 ine on
the templates at the 60’ do ck position as an aid for 1 ining up
the matchmarks at exactly 6 o’clock.
(2) Ro tat e the ac ce ss ory gearbox axis B gear shaf t and tr ans fer gearbox axis
B gear sha f t un t ii the ma t c hmar ks on the end o f gear sha f t s are at
exactly 6 o’clock.
(3 Lubr i c a t e bo th splined end s o f the horizontal dr ive shaf t 1 3) wi t h
eng ine o ii P o s i t ion the mat c hmark on the f orward end o f the d r ive
sha f t a t 6 o do ck and in s er t the dr ive sha f t through the mid d le f ron t
spline bore o f the ac c e s s o ry gearbox so that app roxima t ely a 3 inch
length of the shaft is visible at the rear of the gearbox.
(4) Ins t all 2 new O-r ings (8) on the dr ive shaf t c over (7 then as semble
the cover loo s e ly over t he dr ive sha f t 13 and into the a c c e s s o ry
gearbox oil jet cover (12) as far as it will go.
72-63-0
Sep 1/75
Page 202
GEWLIAL ~sp E;L~C1R le
CJ 610´•. TW:R BO~ ET
SEI-186 MAINTENANCE MANUAL
5 In s t al 1 a new 0- r in g 10 on the t r ans f e r gearbox f 1 an g ed cover (9)
Hang the f lang ed c over lo o s e ly on the d r iv e shaf t cover 7
(6) Move drive shaft (13) toward the rear and align the matchmark on the
forward end of the d r iv e sha f t with the ma t chmar k on the f o rwar d end
of accessory gearbox axis B gearshaft. With all 3 matchmarks (drive
shaft, accessory gearbox axis B gearshaft and transfer gearbox axis B
(a f t end) gear sha f t aligned at 6 o c lo ck po s i t ion engage and seat
d r iv e shaf t 13 in t o t r an s f er gearbox sp 1 ine Ensure tha t al 1 3
matchmarks are al igned at 6 o c lo ck p o s i t ion
7 Po s i t ion and s ec ur e the f 1 ang ed cover 9 to the t rans f er gearbox pad
wi t h 4 nut s and wa s her s Torque the nut s to 6 0- 9 O Ib- in
(8) Po s it ion the dr ive shaf t cover (7 between the 2 covers (9 and 1 2) and
in s tall the 2 snap r ing s (6) us ing t ool 2 C 5 3 2 5
9 Connect and t i gh ten:´• the left and right man i fo id drain tub es (2 6 f igur e 2
S ec t ion 7 3- 00) to the fuel mani f old tees (2 5) Ins t all the clamp on the
drive shaf t cover and t i ght en the bolt to secure the drain valve 27
Connect and tighten the hose to the drain valve.
1 0) Ins t all ing r ing 3
re t a in f igur e 2 01 O- r ing 5 p lug 4 and
second retaining ring (3) in the middle front gearbox spline bore.
(11) Rep lace the overspeed governor per Section 73-2 2-0.
14
1
10
ii ii I II 11
O
13 6\
7 8
10
12
O i. Accessory Gearbox 8. O-Rlng
2. Transfer Gearbox 9. Flanged Cover 2
3. Retaining Ring 10. O-Ring
4. Plug 11. O-Ring
5. O-Ring 12. Oil Jet Cover
6. Snap Ring 13. Horizontal Drive Shaft
7. Drive Shaft Cover 14. Oil Passage
BC-0208-1
Ac ce s s ory Drive Components
Pi gur e 2 01
Sept 1/76 72- 63-0
Page 203
GEWEIAL O~ ELECtllC
CJ610 TURBOJeT
MAINTENANCE MANUAL, SEI-186
3. Inspection/Checks. When serviceable limits are exceeded, the parts may be
repaired in accordance with the overhaul manual.
Inspection/Checks Maximum Serviceable Limits Remarks
A. At every exposure of drive shaft, clean
thoroughly with a suitable solvent and
using a bright light visually inspect for:
(1) Cracks. None allowed.
(2) Nicks and scratches. Any number, 0.030 inch deep.
(3) Spline wear at con- 0.005 inch. Approxl Replace drive shaft
tact area. estimate can be made by if maxim~m service-
visually comparing wear at able Limits are
contact point with a piece exceeded,
of 0.005 inch shim stock.)
NOTE: Replacement of the h6rizontal drive shaft for excessive spline wear also
requires replacement of the female spline which mated with the worn end
of the drive shaft.
B. Visually inspect the flanged cover, oil
jet cover, and drive shaft cover for:
(1) Cracks. None allowed.
(2) Oil passage blockage None allowed. Check by blowing air
at every exposure of or smoke or
oil jet cover. oil through tlir. oil
passage. Cleriii as
req~ired to fret: th~i
oil passage openin~
or replace cover.
72163-0
sept 1/76
Page 204
GIEIEIAL~ ELECtllC -c~-----
CJ610
SEI-186 MAINTENANCE MANUAL
ACCESSORY DRIVE GEARBOX MAINTENANCE PRACTICES
1. General. The maintenance of the accessory drive gearbox is limited to the
external section except for carbon seals. If a problem concerning the in-
terior of the gearbox arises the gearbox must be replaced.
2. Removal/ Installation. (CJ610-I, -5, and -9)
I NOTE: Whenever front
(see Section
frame is removed, gearbox bracket must be aligned
72-30) prior to installation of the accessory gearbox.
A, Removal.
(1) aemovethe following components per the referenced pai~agraphs:
(a) Starter (refer to the Aircraft Maintenance Manual).
(b) Customer component that is mounted on the accessory gearbox
(refer to the Aircraft Maintenance Manual).
(c) Fuel pump and control (73-13-0).
(d) Overspeed governor (73-22-0),
(e) Horizontal drive shaft (72163-0).
(f) Lube pump and oil tank (79-21-0).
(2) Disconnect 2 lube supply and 4 scavenge lines from the fittings on
theaccessory gearbox. (On engines with center vent~ remove the
vent line from the fitting on the accessory gearbox.) Note the
locations of clamps and brackets.
NOTE: The front frame sump scavenge line may be iemoved more easily
after the accessory gearbox mounting nuts have.been removed.
(3) Remove the 4 accessory gearbox mounting nuts, and carefully remove
the accessory gearbox and laminated shims, Use tjrenches~2C5315 and
2C5316.
NOTE: Disconnect the front frame sump scavenge line as the gearbox
is being removed.
CAUTION: THE LAMINATED SHIMS ARE USED TO ALIGN TfIE ACCESSORY GEAR-
BOX WITH THE TRANSFER GEARBOX. BE SURE THE SHTMS ARE
MARKED SO THAT THEY WILL BE IN TEiE SAME LOCATION WHEN THE
ACCESSORY GEARBOX IS REPLACED.
Sept 1/76 72-64-0
Page 201
GEIEIIAL O~B ELCCTIIG
CJ610´• TURBOJET
MAINTENANCE MANUAL SEI-186
(4) Remove the horizontal drive shaft end cap from the rear middle pad of
the accessory gearbox. Discard two O-rings.
NOTE: The accessory gearbox mounting bracket was not removed or in-
stalled. If removal is necessary refer to 72-30, Maintenance
Practices.
B. Installation. (Using gage 2C5324.) The purpose of the following procedure
is to install the accessory gearbox so that its middle splined shaft axis
is parallel to and concentric with the splined shaft axis of the transfer
gearbox. Use alignment gage 2C5324 only to perform this alignment. Ihe
gage shall be equipped with the special eccentric ring as shown in fi~ure
201. The eccentric ring is designed with the center mounting hole drilled
0.020 inch off-center. This eliminates the need for use of any thermal
compensating shims under the transfer gearbox. It is necessary to set the
low point of the eccentric at exactly 6 o’clock position.
NOTES: I. In normal operation, the mainframe of the engine grows
0.020 inch more than the front frame because of thermal
expansion. The alignment is set to provide proper align-
ment in the hot or running condition.
2. Since the alignment inspection and adjustment is made with
the engine cold the transfer gearbox is 0.020 inch closer
to the engine‘ center line than is the accessory gearbox.
The purpose of drilling the ID of the eccentric ting off-
center 0.020 is to move apparent location of the acces-
the
sory~gearbox female spline 0.020 inch closer to the engine
center line. This would place both the accessory gearbox
apparent Spline and the transfer gearbox spline at the same
distance from the engine center line. In this position the
ideal alignment is to have a TIR of zero.
3. To allow for some variation, the limits of alignment are
established to allow the accessory gearbox spline to be
within 0.012 inch of the transfer gearbox spline. This
0.012 inch can be in any 3600 direction. Since a dial
indicator reads twice the displacement, the align-
ideal
ment is 0.000 TIR and the max allowable misalignment is
2 x 0.012 inch 0.024 inch TIR.
72-64-0 Sep 1/75
Page 202
C E W EIAL ~Bb t Lt CT I I C
CJ610 TURBOJLT
SEI-186 MAINTENANCE MANUAL
1 Conne c t the f r on t frame scavenge hose
sump and secure the ac c e s s o ry
gearbox and shlms to the moun t ing bracket with 4 nu t s Torque the
nu t s to 2 2 0- 2 3 5 ib- in
NOTE: On initial installation of the accessory gearbox, the use of
0. 035 inch shims on the rear studs and 0.040 inch shims on
the front studs is recommended as ast arting point.
2 In s t all the alignment gage as f ollows Se e f i gur e 2O 1
(a) With the tr ansf er gearbox in its normal installed configuration
i e no the rma 1 c omp ens a t ing s h ims ins t a 11 the shor t arbor o f
the 2 C5 3 2 4 gage in t o the t rans f er gearbox by backing o ff the
spreader s c r ew Ins er t the arbo r un t ii it bo t t oms aga ins t s e a I
p lug and s e cure in p lac e by exp and ing the s lo t t ed end u s ing the
spreader screw and a3/16 inch Alien scr ew.
(b Ins t all the long arbor o f the 2C5324 gage in t o the ac c e s s o ry
gearbox axis-B female
spline by backing off the spreader screw
in the arbor. Insert the long arbor into the accessory gearbox
unt ii it seat s Secure in p la ce by exp and ing the s lo t t ed end
using the spreader screw and a3/16 inch Alien wrench. Install
the ecc entric ring by placing it on the stub shaft of the long
arbor and secure by tight ening the setscr ew.
CAUTION: WHEN USING THE ECCENTRIC RING DO NOT INSTALL THE
0. 020 INCH THERMAL COMPENSATING SHIMS UNDER THE
TRANSFER GEARBOX.
(c) Ins tall the d ial ind ic a t or to the po s t on the shor t arbo r ins t alled
in the transfer gearbox. Adjust the ball of the indicator so that
it contacts the 60’ clock position on the OD of the 1.50 inch
d lame t er e c c en t r i c r ing in s t alled on the s tub shaf t o f the long
arbor.
Sep 1/75 72-64-0
Page 203
GEWLRAL~ELECTIIC
CJ6~0 TURBOJET
MAINTENILNCE MANUAL SEI-186
(d) With the ball of the dial indicator contacting the OD of the
ecc entric ring the 60’ do ck position rotate the ac cesso ry
at
gearbox arbor inc iud ing the e c c en t r ic r ing and ob s e rye the runo u t
The runout should be twice the off set of 0.020 and give a TIR
(Total Indicator Reading) of 0.040 inch. Bec ause of tele rance in
the t ool and the s pline the re ad ing may no t be exac t ly O 04 O
The re ad ing s can be var led
slight ly by removing the long arbor
from the accessory gearbox and reinstalling it rotated 90", 18 00
or 2 7 00 r ela t iv e t o its o r i g inal po s i t ion in the f ema le s p 1 ine
The long arbor should be rotated to these different locations until
the TIR of the ecc entric is 0. 038 0.042 inch.
(e) Once the long arbor is located in the proper position relative to
the female spline locate the minimum runout at exac try 60’ do ck
position by placing the dial indicator at 60’ do ck position and
ro ta t ing the a c c e s s ory gearbox f ema le spline in clud ing the ion g
arbo r and o b se rving the runou t The minimum runou t shall be lo ca t ed
at 60’ clock position. The arbor should be marked with afelt tip
mar ke r or e qu ivalen t at the 6 o c lock p o s i t i on
NOTE S 1 The 6 o clock mark shall be checked p er iod i c ally t o
ensure that it has not rotated off the 60’ clock posi-
t ion It mu s t remain in this p o s i t ion for t he ent ire
alignment procedure.
2 The f ac e of the e c c en t r ic r ing has a (Ver t ic al
Top s t amp ed at the po in t o f maximum e c c en t r ic i ty
This stamp should be at 12 o’ clock position as across
check.
3 Check d i s p la c emen t of spl ine s as f ol lows See f i gu r e 2O 1
(a) With the match mark on the long arbor located at 60’ do ck and the
ball o f the indi ca tor cent ac t ing the OD o f ecc entr ic r ing, rotat e
the t ran s f er gearbox spline and sho r t arbor and no te the ind i c a t or
read ing as the ind icat or is ro tat ed 3 600 The TIR (To tal Ind icator
Re ad ing mu s t no t exceed O 024 inch
72-64-0
Sep 1/75
Page 204
OEWEIILQ ELEC~IIE
CJ610 TURIOJLT
SEI-186 MAINTENANCE MANUAL
(4) Check face alignment runout as follows: (See figure 202.)
(a) Place the ball of the dial indicator the
face of the long
against
arbor. The ball should be located approximately 1-1/2 inch from
the center of the arbor. The transfer gearbox spline should be
rotated and the indicator readings noted as the indicator rotates
through 3600 The max allowable face runout is 0.006 TIR.
(5) Alignment Procedure.
(a) Install and adjust the alignment gage per paragraph (2).
NOTE: The sequence of adjustments be performed in any order
can
convenient to the operator. Experience has shown that the
following sequence will often reduce the time required.
(b) Record the face runout from 12 o’clock to 6 o’clock position
and add or subtract shims necessary on the front studs of
as
the accessory gearbox to reduce the 12 o’clock to 6 o’clock
runout to as close to zero as possible.
(c) The low point of the eccentric ring is to remain located at
6 o’clock position at all times. Record the eccentric ring
runout from 12 o’clock to 6 o’clock position. Add or subtract
equal amounts of shims to all four accessory gearbox studs to
reduce the runout to as close to zero as possible.
(d) Record the eccentric ring runout from 9 o’clock to 3 o’clock
position. Loosen the four nuts on the accessory gearbox studs
and move the accessory gearbox laterally toward 9 or 3 o’clock
to reduce the runout to as close to zero as possible. Retorque
the four nuts to 220-235 Ib-in.
Sep 1/75 72-64-0
Page 205
SEIEIAL ~B ELTCt~le
eJ610 tURIBdET
MAINTENANCE MANUAL SEI-186
(e) Record the face runout from 9 to 3 o’clock position and loosen
the four nuts the accessory gearbox and rotate the gearbox
on
about its vertical axis. This will effect both the face runout
and the eccentric ring runout. Adjust to obtain the minimum
runout. Retorque the four nuts to 220-235 Ib-fn.
(f) Loosen 4 nuts holding the transfer gearbox and rotate the
the
transfer gearbox about the vertical axis. The transfer gearbox
is located by a pin between the two rear studs. The amount of
rotation should be limited to the amount of play between the
locating pin and its hole. Do not force the box beyond this
point. The usB of this adjustment will change the 9 to 3 o’clock
readings on both the face readings and the eccentric ring
readings. Retorque the four nuts to 60-90 Ib-in.
NOTES: 1. The use of steps (d), (e), and (f) used in combination is
normally sufficient to bring the alignment within
limits.
2. There are three additional adjustments but they are
not normally required. One is to loosen the bolts
holding the accessory gearbox bracket to the front
frame and move the bracket right or left within the
tolerance of the bolt diameter and the hole diameter.
The second is to loosen the bolts holding the com-
pressor casings to the mainframe. The compressor
casing, front frame and accessory gearbox bracket,
can then be rotated right or left about the engine
center line within the limits of the tolerance of
the bolt OD and the mainframe hole ID. The third,
and seldom used, adjustment is to put unequal shims
between the left hand studs and the right hand studs
of the accessory gearbox.
3. After all adjustments have been made and all mounting
bolts have been torqued a final check of both the
face runout and the eccentric ring runout is required.
Recheck the low point of the eccentric ring to be cer-
tain it is still at 6 o’clock. The final limits are
not to exceed the following:
a. Face Fun Out 0.006 inch TIR maximum
b. Eccentric Ring Run Out 0.024 inch TIR maximum
72-64-0 Sep 1/75
Page 206
OIW11I10 ILICIIIC
CJ616 TURBOJ-ET
SEI-186 MALNTENANCE MANUAL
ECCENTRIC RING DETAILS
USING STEEL STAMP, MARK
IN 1/8 INCH HIGH LETTERS~ SCRIBE HORIZONTAL
AND YERTICAL CENTER
LINES of OD ~N TH
FACE.
0.3101
0.300
V. I T.
0.015
0.005
CHAM 25"
1.52
DIA
1.50
0.0205
0.0195
0.980
OIA
0.975
THREAD FOR NO. 5 0.140
SETSCREW.
NOTES: 1~ LOCATE 0.975 0.980 INCH DIAMETER WITHIN
0.001 INCH OF TRUE CENTER LINE HORIZONTAL.
2. INSTALL NO. 5 METAL SETSCREW IN THREADED
HOLE
3. ENLARGE 0.975 0.980 INCH DIAMETER AS
NECESSARY TO PROYIDE A SLIP FIT ON STUB
SHAFT OF LONG ARBOR OF TOOL P/N 205324.
ALL DIMENSIONS
LONG AREININCHES
ARBOR
(2C5324-6) DISPLACEMENT
0.024 TIR MAX.
POST SEAL PLUG
(2C5324-3)
ACCESSORYGEARBOX
Ila(--~b
TRANSFER GEARBOX
ECCENTRIC
RING
SHORT
ARBOR
SPREADER
SCREW (2C5324-53
PARALLEL WITHIN
~I
0.006 TIR
ENGINE SIDE VIEW
OC-022R
Accessory Gearbox Transfer Gearbox Spline Displacement
Figure 201
72-64-0
Sep 1/75
Page 206A
GEWERAL~ ELECTIIC
CJ610 7URBOJET
MAINTENANCE MANUAL SEI-186
(6) Remove alignment gage 2C5324,
(7) Replace the accessory gearbox end cap and 2 new O-rings on the rear
middle pad. Secure it with 4 nuts and washers. Torque the nuts to
60-90 Ib-in. Secure the bracket on the upper left mounting stud also.
(8) Connect the 2 lube lines and the 3 remaining scavenge lines (with
new O-rings installed where used) to the fittings on the accessory
gearbox. Assemble clamps and brackets in locations previously noted.
(9) Install the following components per the referenced paragraphs:
(a) Lube pump and oil tank (79-21-0).
(b) Horizontal drive shaft (72-63-0).
(c) Fuel pump and control (73-13-0).
(d) Overspeed governor (73-22-0).
(e) Starter (refer to the Aircraft Maintenance Manual).
(f) Customer component that is mounted on the accessory gearbox
(refer to Aircraft Maintenance Manual).
B1. Deleted.
3. Removal/Installation. (CJ610-4, -6,and -8)
I NOTE: Deleted.
A. Removal.
(1) Remove the following components per the referenced paragraphs:
(a) Starter (refer to the Aircraft Maintenance Manual).
(b) Customer component that is mounted on the accessory gearbox
(refer to the Aircraft Maintenance Manual).
(c) Fuel pump and control (73-13-0).
(d) Overspeed governor (73-22-0).
(e) Lube pump and oil tank (79-21-0).
(2) Disconnect 1 vent line, 2 lube supply lines and 1 scavenge line from
the fittings on the accessory gearbox. Note the locations of clamps
and brackets.
72-64-0 Dec 1/77
Page 206B
OEWIRAL ~b ELt~rllC
CJ810 TUReOJEi
SEI-186 MAINTENANCE MANUAL
ACCESSORY GEARBOX
LONG
ARBOR APPROX. 1-1/2
(2C5324-6)
ECCENTRIC
RING
SPREADER
SCREW PARALLEL
POST
WITHIN 0.006 TIR
(2(35324-3)
SPREADER
SHORT SCREW
ARBOR
(2C5324-5
TRANSFER~GEARBOX ~7 -J--SERL. P~UG
ALL DIMENS(ONS EHGINE TOP VIEW
AREININCHES
BC-0229
Accessory Gearbox Transfer Gearbox Face Alignment
Figure 202
Sep 1/75 ´•72-64-0
Page 206C/206D
GEWERAL~ELE eTIIG
CJ610
SEI-186 MAINTENANCE MANUAL
(3) Us ing wrenche s (2 C5 31 5 and 2C5 31 6) remove the 4 acce s sory gearbox
mount ing nut s and c ar e ful ly remove the ac c e s s o ry gearbox
NOTE Do no t use a un iv e r s al adap t e r and s o c ke t wr en c h Due to the
1 imi t e d working space in this ar ea us ing the s e t o ols can
cause damage to the fuel manifolds.
(4) Remove the radial drive shaf t (3 figure 203) from the por t at the
6 o do c k po s i t ion on the ma inf r ame
NOTE: When removing the gearbox be sure that the radial drive shaft
does no t f al 1 ou t and be c ome d ama g e d
5 Remove the gu id e cover 13 f i gu r e 203 sha f t sh i e id gu id e 14
f i gure 2 03 and O- r in g 12 f igure 2O3 f rom the ax i s "A" bear ing
hous ing.
6) Remove the 4 sh ims 4 f igure 2 O3 f r om the mo un t in g s tud s Re t a in
the shims for use in ass emb ly.
B. Ins tallation.
1 Lubr ica t e bo t h splines of the rad ial dr ive shaf t (3 f fgure 2 0 3)
with alight coat of oil. Ass emb le the shaft to the gearbox (2,
figure 203)
NOTE: Be sure the radial drive shaft shield, at the gearbow end, is
round and fr ee from nicks and dent s If nece s s ary Ii gh t
polishing is allowed on the end radius of the shield.
(2) Ins tail a new O-r ing 12 f igure 203) in the groove in the axi s "A"
bear ing on the gearbox As semble the shaf t sh ield gu id e 14 f igure
2 03 over the bear ing hous ing The sha f t shield guid e is a p re s s
fit (by hand In s t ail t he gu id e cover 13 f i gur e 2O3 over the
sha f t sh i eld gu id e snap p ing i t in t o p lac e
(3)Install a shim (4, figure 203) over each of the studs in the molant´•-´•
ing bosses of the gearbox.
(4) As s emb le 2 new O-r ings (6 f igur e 2 03) to the r igh t -hand 9 cavenge
tube and 2 new 0- r ing s 9 f i guar e 2 03 to the le f t hand sc average
t ube Ins t al 1 the tubes (5 8 f i gur e 2O3 in the s c aveng e poe t s in
the gearbox casing.
Sep 1/75 72-64-0
Page 207
ELaCtllC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
1;:
3-O 10 ~cp
Ids
12-c~ 1 LOC KN UT 8. LE FT-HAND SCAVE NG E TUBE
i 2.
3.
GEARBOX
RA D IA L D RIVE S HA FT
9.
10.
O-RING
CAP
´•-i i 4. SHIM 11. MA INF RAME
6. O-RING 13. GUIDE COVER
7. CAP 14. SHAFT SHIELD GUIDE
CJ610-6091-0´•D?
Installation of CJ610-4, -6 and -8 Gearbox
Figure 203
5 Ca re fully p o s i t i on the gearbox 2 f i gur e 203 on the gearbox b r a c k-
ets; at the same time align the radial drive shaf t (3, figure 203)
and the 2 scavenge tubes. If neces sary, loosen the bolts that
secure the se rv i c e tube s to the ma inf rame to align the scavenge
tub e s Slowly turn the engine ro t o r by hand t o engage the r ad ial
drive shaft spline in the PTO.
NOTE This is a 2-man op er a t i on S up p o r t the gearbox a t al 1 t ime s
un t ii it is s ecur ed t o the b rac ke t s wi t h the 4 lo cknu t s Be
careful no t to d ama g e the O-r ing s or sha f t shi eld guide when
al ign ing the gearb ox
6 Secure the gearbox and shims to the moun t ing br ac ke t wi th 4 nu t s
Torque the nu t s to 2 2 0- 2 3 5 ib- in
7 C onn e c t the 1 vent line 2 lube supp ly 1 ine s and 1 s c av eng e 1 in e
(with new O-r ing s in s t aile d where u s ed) to the f i t t ing s on the ac-
ees sory gearbox. As s emb le c lamp s and br ac ke t s in lo c a t i ons pre-
viously noted.
7 2- 64- 0 1
Sep 75
Page 208
c fr EIAL ~B r LL Et I IC
CJ610 TURSOJET
SEI-186 MAINTENANCE MANUAL
(8)Install the following components per the re ference paragr aphs:
(a) Lube pump and oil tank (7 9-21-0).
(b) Overspeed governor (7 3-2 2-0)
(c) Fuel pump and control(7 3-13-0)
(d Cus t omer component tha t is moun t ed on the acces s ory gearbox
(re f e r to Aircraf t Maintenance Manu al
e S tar t er (re f er to the Aircraf t Ma in t enan c e~ Manua 1
4 Ins pe c t ion Che c ks When serviceable limi t s are exe e e d e d t he part s may be re-
paired in a c co r d an c e wit h the Overhaul Manu a 1
Ins pe c t i on Che c k Maximum S erv ic e able L im i t s Remarks
A. Visually inspect the accessory gearbox for:
(1) Crac ks. None allowed.
2 Nicks and sc rat che s Any number 0 03 0 inch deep
(3) Evidence of leakage None allowed.
between cover and
case.
(4 Evidence of s eal S ee Ope rat ing L imi t s Re pla ce seal per
leakage at pad s Ad j us tment Te s t 7 2- 00 paragraph 5 A. or
5. B.
5 St r ipp ed t hr ead s One full entrance thr ead Sub s t i t u t e mod if led
in drain plug plug for drain plug
ho les. per paragraph 5. C.
I Sep 1/75 72-64-0
Page 209
GENERAL ELECTRIC-------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
B. At every exposure (accessories removed) of accessory gearbox female splines,
clean thoroughly with a suitable solvent and using a bright light visually in-
spect splines for:
NOTE: Deleted
(1) Wear at: contact Approx. estimates can be
area. made by visually comparing
wear at contact points with
pieces of shim stock sized
to the limits below,
Axis B fwd (OSG). 0.007 inch. If within Service-
able Limits lubri-
Axis B aft (Horiz. cate splines as
Drive follows:
Shaft)
(CJ610-1.-5.-9 only), CJ610-1, -5, -9:
lubricate all
splines except axis
B aft, with lubri-
cant specified in
Section 72-01-1.
Lubricate axis B
aft spline with
engine oil.
NOTE: Replacement of the accessory gearbox CJ610-1, -5, -9 axis B gearshaft
for aft end spline excessive wear also requires replacement of the
horizontal drive shaft,
Axis B aft (Customer PTO/ 0.007 inch. CJ610-4, -6, -8:
Hyd. Pump), lubricate all
(CJ610-4, -6, -8 only), splines with lubri-
cant specified in
Section 72-01-1.
Axis C fwd (Customer PTO). 0.006 inch.
Axis C aft (Starter-Gen.). 0.008 inch.
Axis D fwd (Fuel Pump). 0.006 inch.
72-64-0
Page 210 Dec 31/95
GE#EAAL 4~ ELECIIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
5. Repair.
A. Rubbing Seal Replacement. Axis C’ forward and aft, axis B forward
(overspeed governor), axis D forward (fuel pump/main fuel control).
NOTE: For special tools, use kits (Part Numbers 205333 and 205334).
(1) Remove the mounted accessory per the applicable paragraph.
(2) Remove the seal housing retainer nuts.
(3) Remove the sealhousing with the puller.
NOTE: Axis D and B forward have combination seal and bearing
housings. When the housing is removed the entire axis D
ball bearing may be removed at the same time. The bearing
must be disassembled from the housing before removing the
seal. When the axis B housing is removed, the bearing outer
race may come out with the housing and must be pressed out of
the housing before the seal is disassembled.
(4) Remove the O-ring, then remove the rubbing seal from the seal housing
with the pusher.
(5) Remove the mating ring and packing ring.
(6) Replace defective part.
(7) Insert the mating ring packing into the mating ring.
CAUTION: USE EXTREME CARE WHEN HANDLING THE MATING RING. DO NOT
ALLOW THE RUBBING FACE TO BE DAMAGED.
I (8) Assemble mating ring and packing to the gearshaft, seating
the
mating ring (packing side) against the bearing face.
the
(9) Assemble the O-ring to the O-ring groove in either the seal housing
or gearbox casing.
CAUTION: O-RING MUST BE INSTALLED IN FIRST (FORWARD) AXIS-B PORT
RECESS IN COVER ASSEMBLY.
(10) Lubricate the OD of the rubbing seal with engine oil and assemble it
to the seal housing.
Sep 1/75 72-64-0
Page 211
GLnEa r re c~lle
CJB10 tURBQJet
MAINTENANCE MANUAL SEI-186
(11) Lubricate the OD of the seal housing with engine oil and assemble it
to the gear shaft, mounting studs, and seal housing bore in the gear-
box casing with the pusher.
CAUTION: BE CAREFUL WHEN HANDLING RUBBING SEALS. THE CARBON SUR-
FACES ARE EXTREMELY BRITTLE AND EASILY DAMAGED.
(12) Lubricate the studs with engine oil. Secure the seal housing with
nuts; torque them to 10-15 Ib-in.
B. Rubbing Seal Replacement, Axis "B" Aft. (CJ610-4, -6, and -8)
NOTE: For special tools use kits (Part Numbers 2C5334 and 2C5333).
(1) Remove the mounted accessory per the applicable paragraph.
(2) Bend the locking tabs away from the bolt heads. Discard the locking
tabs.
CAUTION: REMOVE ONE RETAINING BOLT AT A TIME AND REPLACE WITH RE-
TAINING PIN FROM TOOL KIT 2C5333 BEFORE PROCEEDING TO THE
NEXT BOLT. IF ALL 3 RETAINING BOLTS ARE REMOVED WITHOUT
THE USE OF RETAINING PINS, THE BEARING RETAINER INSIDE THE
GEARBOX WILL BE DISLOCATED REQUIRING REMOVAL AND DISASSEM-
BLY OF THE GEARBOX TO PROPERLY ASSEMBLE THE BEARING RETAIN-
ER.
(3) Remove one retaining bolts and install a retaining pin from
of the
tool kit its place. Remove the second retaining bolt and
2C5333 in
install a retaining pin in its place. Remove the third retaining
bolt and install a retaining pin in itsplace. (By replacing retain-
ing bolts with retaining pins the bearing retainer inside the gearbox
will be held in position.)
(4) Remove the seal housing with the puller 2C5333.
(5) Remove the O-ring; using the pusher 2C5334, remove the rubbing seal
from the seal housing.
(6) Remove the O-rings from the 3 bolt holes.
(7) Remove the mating ring and packing from the shaft.
(8) Replace defective part.
I 72-64-0
Page 212
Sep 1/75
GEnrRAL~p Ltcrlle
CJ610 TUROOJET
SEI-186 MAINTENANCE MANUAL
9 Insert the ma t ing r ing packing in t o the ma t in g r ing
CAUTION: USE EXTREME CARE WHEN HANDLING THE MATING RING. DO NOT
ALLOW THE RUBBING FACE TO BE DAMAGED.
10) Insert a seal guide 2C5336 into the bore of the gea r s ha f t
11 As s emb le the ma t in g r in g and packing to the g ear sha f t seat ing the
ma t ing r ing (packing s id e) ag a ins t the shaf t should er us ing ins e r
ter 2C5335.
NOTE Some ma t ing rings have 2 tabs These tabs mu s t be al i gned
wi t h slo t s in the spanner nu t
12 As s emb le the three O- r ing s to the 3 bolt ho le O-ring grooves
(13) Lubricate the OD of the rubbing seal with engine oil and ass emble it
to the seal housing with the pusher 2C5334.
CAUTION BE CAREFUL WHEN HANDLING RUBBING SEAL S THE CARBON SUR-
FACES ARE EXTREMELY BRITTLE AND EASILY DAMAGED.
14) As semb le the O-ring to the seal hou s ing
(15) Lubricate the OD of the seal housing with engine oil and ass emb le it
to the gearbox hou s in g Use t oo 1 2 C5 3 34
1 6) Bend the washer tab s approxi.mately 3 O de gr e e s Lubr i c a t e the b olt s
with o ii Rep la ce the retaining p in s with the b olt s and tab wa sher s
Torque the bolt s to 2 5- 35 ib- in. Bend the tabs to secure the bolt s
Use new tab washers.
NOTE: Bend one tab on washer to meet best aligned side of hex bolt.
Sep 1/75 72-64 -O
Page 213
Gi I i IAL i Lt CT a i C
CJBIO tU’19~C)3aT
MAINTENANCE MANUAL SEI-186
-cl .470
-I CHAMFER0.062 X 450
APPROX.
--´•-´•I
MAKE FROM
MS 9571~4
CJ610~6119´•0´•G?
Replacement Plug
Figure 204
C. Substituting Modified Plug for Drain Plug.
CAUTION: THIS REPAIR IS LIMITED TO 300 HOURS OF SERVICE AND MUST BE
ENTERED IN THE ENGINE LOG BOOK.
(1) Clean drain hole to make sure it is free of foreign material.
(2) Fabricate a replacement plug per figure 204.
(3) Install O-ring onto the replacement plug and install plug into gear-
box. Tighten plug to 60-80 Ib-in. of torque and lockwire.
72-64-0
Sep 1/75
Page 214
C H A PT E R
ENGINE FUEL
AND CONTROL
CEWERIL~ ELECIRIE
CJ610 TURBOJET
SEI-186 MAINTENANCE MANLTAL
CHAPTER 73 FUEL AND CONTROL SYSTE~-
TABLE OF CONTENTS
Page
73-00 FUEL AND CONTROL SYSTEM
Description and Operation 1
Troubleshooting 101
Maintenance Practices 201
73-11-0 Fuel Heater (Airframe Furnished)
Fuel Filter Low Pressure (Airframe Furnished)
73-12-0 Fuel Flowmeter (Airframe Furnished)
Maintenance Practices 201
73-13-0 Fuel Pump
Maintenace Practices 201
73-14-0 Fuel Filter O.S.G. Servo
Maintenance Practices 201
73-15-0 Fuel Pressurizing Valve (CJ610-1, -5 and -9 Engines)
Maintenance Practices 201
73-16-0 Fuel Drain Valve (CJ610 -1, -5 and -9 Engines)
Maintenance Practices 201
73-17-0 Fuel Pressurizing and Drain Valve (CJ610-4, -6, -8 and -8A
Engines) Maintenance Practices 201
73-18-0 Fuel Nozzles
Maintenance Practices 201
73-19-0 Fuel Manifolds
Maintenance Practices 201
73-20 FUEL CONTROLLING
73-21-0 Fuel Control
Maintenance Practices 201
73-22-0 Overspeed Governor
Maintenance Practices 201
73-23-0 CDP Line to Fuel Control
Maintenance Practices 201
73-24-0 CDP Line to Aspirator
Maintenance Practices 201
73-25-0 Variable Geometry Actuator Lines
Maintenance Practices 201
Dec 31/91 73
Page 1
GENERAL ELECTRIC-´•-------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
CHAPTER 73- FUEL AND CONTROL SYSTEM
LIST OF EFFFCTIVEPAGES
CHAPTER/ CKAPTER/
SECTION PAGE DATE SECTION PAGE DATE
73 *I Dec 31/95 73-29-0 *201 thru 203 Dec 31/95
Contents 1 Dec 31/91 73-21-0 201 Mar 30/67
202 Apr 15/68
73-00 1‘’ Dec 30/78 *202A/202B Dec 31/95
2 Mar 30/67 *203 Dec 31/95
3 Jan 15/69 204 thru 205 Sep 1/75
4 Sep 15/69
5 Apr 15/68 73-22-0 *201 thru 203 Dec 31/95
6 Jan 15/69
7 Dec 30/78 73-23-0 *201 thru 202 Dec 31/95
8 Sep 15/69
73-24-0 *201 thru 202 Dec 31/95
101 Nov 15/67
73-25-0 *201 thru 203 Dec 31/95
*201 thru 202 Dec 31/95
*202A/202B Dec 31/95
203 thru 204 Mar 30/84
*205 thru 207 Dec 31/95
73-12-0 *201 thru 203 Dec 31/95
73-13-0 *201 thru 202 Dec 31/95
*202A/202B Dec 31/95
*203 Dec 31/95
204 Mar 30/84
205 thru 207 Sep 1/76
208 thru 209 Nov 1/80
73-14-0 *201 thru 203 Dec 31/95
73-15-0 *201 thru 202 Dec 31/95
73-16-0 *201 thru 202 Dec 31/95
73-17-0 *201 thru 202 Dec 31/95
73-18-0 201 Dec 31/91
202 Mar 30/67
*202A/202B Dec 31/95
*203 thru 211 Dec 31/95
*Asterisk indicates pages added, changed. or deleted by this revision.
73
Dec 31/95 I
o EW ERA L;~ E LECTR IC
CJB10 TURBOJET
SEI-186 MAINTENANCEMANUAL
ENGINE FUEL SYSTEM DESCRIPTION
i. General. The fuel system is a to provide
hydro-mechanical system designed
the proper amount of fuel to engine for optimum performance throughout
the
the operating range. It also provides fuel for operation of the engine
variable geometry, to lubricate and operate servos In the fuel control and
overspeed governor, and as a coolant for engine lube oil.
2. Description. The major components of the system include the fuel pump, the
fuel control, the overspeed governor, the O.S.G. servo filter, the fuel
flowmeter (airframe furnished),the oil cooler, the fuel pressurizing valve,
two fuel manifolds, twelve fuel nozzles, the manifold drain valve and two
variable geometry actuators. (Maintenance of the actuators is covered in
Section 75-00.) Figure 1 is a schematic of the fuel system showing the re-
lation of the components in the flow path.
A. Fuel Pump.
The fuel pump is
on the right hand drive pad of the accessory
mounted
gearbox. dual-element, self-lubricating pump, consisting of a
It is a
low pressure or boost stage, a high: pressure stage, a fuel screen, a: re-
lief valve and high and low pressure taps. Its primary purpose is to
supply high pressure fuel to the fuel control. Its secondary purpose is
to supply high pressure fuel to the overspeed governor servos.
B. Fuel Control.
The fuel control is mounted on the fuel pump. The control is a hydro-
mechanical unitthat regulates the power output of the basic
selects and
engine, maintaining its operation within,anenvelope of safe operating
limits by performing the followingspecific functions:
(1) It establishes maximum,safe, fuel flowlimits for all operating
conditions, including automatic-start-ing,
(2)~It regulates engine speed by metering fuel to the combustion section.
(3) It automatically alters the fuel schedules to m$intain the desired
power setting as operating temperatures and pressures change.
(4) It regulates fuel flow to simultaneously positionthe variable vanes
and bleed valves to a defined scheduleduring transient and steady-
state operation.
(5) It provides the proper minimum fuel flow for
infllght engine start-
ing, and for prevention combustor flameouts due to lean fuel-air
of
mixtures during deceleration.
Mar. 30/67 73-00
Page 1
2:
b iNrET GUIDE VANE a~D
3
E
BLEED VAIVE ACTUATORS i2´•
FUEL HEATER COMau sT:o~
CHAMBER
PRESSUR-
IZING
Y~ VALVE
~II I
JI I I ACTUATOR
L~S
y,r’
RELIEF
VALVE
7
SERVO
CI 25r 1
OIL
I FILTER I 200 MESH COOLER
BYPASSSTOP
L SCREEN
BL VALVE COCK
cr C
I II II I III II I I I II r 1 I I I I 1 I 1
r OVERSPEED
rc~
mi r m .II in I 1 ~1 rr 1 GOVERNOR
~L,,-J 5 Oi
m
J
99,
co
Et
1 FUEL INLET
t200 MESH
SCREEN lor
MAIN
NG
L
FLOWMETER
cl
C r:
;5
m PRESSURE m
O FILTER VALVE O)
BO OST
SENSING
ELEMENT GEAR DRAIN O
1.S.t. LINE
ELEMENT VALVE t
DRAIN m
I II I I II TO SERVOS I I II I r I ir
FILTER401* MANIFOLD
MAIN PUMP 1 )5 IB] MAIN CONTROL DRAIN
COMBUSTION
CHAMBER
CONTROL AND PUMP DRAIN DRAIN
BYPASS FLOW
LOW PRESSURE 8, DRAIN
HIGH PRESSURE
DASH LINES INDICATE AIRFRAME EQUIPMENT
cr im
n
W
9 I
A2 A
d) CJ610-6070-0- 1
GL:W ERAL ELECTRIC
CJ61_0 -TURBOJET
SEI-186 MAINTENANCE MANUAL
(6) It provides a positive fuel Shut offvalve.
C. Overspeed Governor.
The overspeed governor is mounted on the forward center pad of;the ac-
cessory gearbox. It is an isochronous, hydro-mechanical, self-contained
unit placed in series with the fuel control. Its purpose istooverride
the fuel control if the engine overspeeds. Under normal operating con-
ditions all fuel passes through: the governor unhindered. But if an
overspeedoccurs, the governor cuts in and maintains a constant engine
speed by metering the flow through.it´•and bypassing the excess fuel to
the fuel pump inlet.
D. Fuel Filter Overspeed Governor Servo.
The O.S1G. servo filter is externally mounted on a bracket attached to
the overspeed governor. It is a high pressure filter mounted.in the
overspeed governor servo fuel supply line to protect the servo mechanism
from contamination.
NOTE: There are three additional filters in the fuel system: The low
pressure filter (airframe furnished), the fuel pump filter inter-
nally installed in the fuel pump, and the fuel control filter in-
ternally installed in the fuel control.
E. Fuel Flowmeter. (Airframe furnished)
The fuel flowmeter is-installed in the fuel line between the overspeed
governor and the oil cooler.: It measures engine fuel flowto´•the fuel
manifolds.
F. Oil Cooler.
The oil cooler is recessed in the oil tank which is mounted at the 4
o’clock position on the compressor stater casing. It receives fuel from
the flowmeter and discharges fuel to the.pressurizing valve. It uses
fuel flowto cool lube oil from the oil tank. For´• further details refer
to Section 79-23-0.
I G. Fuel Pressurizing Valve. (CJ610-1, -5 and -9 engines)
The fuel pressuriziuig valve is bolted to the forwardside of the oil
cooler. It maintains a back pressure on the fuel control to ensure
proper fuel pressure on the control servos and the variable geometry
servos during low fuel flow conditions.
Jan. 15/69 ’73-00
age-3
GEIIRAL $B tLECTRIC
CJB~O TURBOJET
MAINTENANCE MANUAL SEI-186
H. Fuel Drain Valve. (CJ610-1, -5 and -9 engines)
The fuel drain valve is clamped to the accessory gearbox driveshaft
cover. It permits draining of the fuel nozzles and fuel manifolds at
engine shutdown.
I. Fuel Pressurizing and Drain Valve. (CJ610-4, -6 and -8 engines)
The fuel pressurizing and drain (P and D) valve is bolted to a boss at
the 6 o’clock position on the compressor casing. It performs the func-
tions of both the fuel pressurizing valve and fuel drain valve on the
CJ610-4, -6 and -8 engines.
J. Fuel Manifolds.
The 2 fuel manifolds are secured with clamps to the flange of the
front
mainframe. They receive metered fuel from the pressurizing valve and
distribute fuel to the fuel nozzles.
K. Fuel Nozzles.
Twelve fuel nozzles are bolted to equally spaced pads around the main-
frame. The fuel nozzles provide the correct spray pattern of metered
fuel flow to the combustion chamber for the entire operating range of
the engine. The fuel nozzles incorporate a flow divider, a primary and
secondary flow passage, spin
and an air shrouded chamber orifice. Dur-
ing starting, low-pressure primary passage sprays toward the
fuel In the
igniter tip for ignition. At higher speeds, the increased fuel pressure
opens the flow divider. This allows the fuel to flow Into the secondary
passage, into the spin chamber where it merges with the primary fuel
spray, and then into the mid-annulus of the combustion liner. The air
shroud sweeps air across the nozzle orifice to prevent carbon buildup.
L. The 2 variable geometry actuators are located at 2 and 8 o’clock on the
compressor stater casing. The actuators position the variable vanes and
the bleed valves as scheduled by the fuel control. Synchronizing cables
ensure that the 2 actuators move in unison. (Maintenance of the actua-
tors is covered in Section 75-00.)
3. System Control Signals. To provide proper engine operation, signals repre-
senting the pilot’s requirements and the engine operating conditions are Tcd
to the fuel control. The following is a list of the signals and their func-
tions.
73-00 Sept. 15/69
Page 4
6EWERAL O CLECTIIC
CJ610 TURBOJe7
SEI-186 MAINTENANCE MANUAL
Signal Function
Throttle Position Fed to control through aircraft linkage and
represents the pilot’s demand for a specific
rpm.
Engine Speed Sensed through engine-driven flyweight gov-
ernor in the fuel control. It is used to
determine fuel flow to the engine and vari-
able geometry position.
Compressor Discharge Indicates the amount of air available for
Pressure (CDP) combustion. It is used in conjunction with
other parameters to determine acceleration
schedule and is the controlling parameter in
setting the deceleration schedule.
Compressor Inlet Indicates temperature of inlet air. It is
Temperature (CIT) used to determine acceleration and variable
geometry positioning schedules.
Variable Geometry Indicates position of inlet guide vanes and
Feedback bleed valves. This is compared with desired
vane and valve position to determine fuel
pressure to the variable geometry actuators.
4. Deleted.
I April 15/68 73-00
Page 5
~1-1
P, W
09 1 2
cD O
O
Q, I I 1Q ii i 1 37
I I~P
3 i iu
20
Ij 4
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I 22
E
r 19
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r
8
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40 36 j~tPi \\,23
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r
38 Is 53 JO 28 C o
(D
18 17 16 15 14 12 11 10 34 32 11 31 29 27 26 1P~
cn m~D"
RIGHTHA N D 51DE LEFT HANDSIDE
0:
39 11 21 i. FEEDBACK CABLE CONDUI~ 21 FUEL MANIFO LD 211
35 2. ACTUATOR HO SE FITTI N G 22. ENGINE MOUNI
r -I
3. ACTUATOR HOSE FITTING 23. FUEL NOZZLE
m I 117 1 1 4. ACT UATOR H OS E 24. FUEL MANIFOLD FITTING
29 5. VENT LINE 25. T-FITTING
33 31 32
oq
r´• j 6. CLAMP 26. MANIFOLD DRAIN TUBE
21 7´• ACTUATOR HOSE FITTI N G 2 7. DRA IN VA LVE
ii I I I ~M _I 1 8. acT uATO a H os E FITTI N G 28. S HA F: COVE R
9. FUEL FLOWMETER 29. TUBE, CDP T3 FLEL CONTROL
10. HOSE, FLOWMETER TO OIL COOLER 30. CCAMP
28 1!. HOSE, FUEL CONTROL TO O/S GOVERNOR 31. OVERSPEED GOVERNOR
12. C IA MP 32. HOSE, FUEL PUMP TO FUEL FILTER
13. TUBE, CDP TO ASPIRATOR 33. TUBE, FUEL FILTER TO 0/5 GOVERNOR
14. HOSE, FUEL PUMP 10 PRESSURIZING VALVE 34. FUEL FILTER
15. PRESSURIZING VALVE 35. TUBE, O/S GOVERNOR TO FLOWMETER
G I IO
16. SCREW 36. HOSE, 0/5 GOV, TO PUMP INLET
FJ I ~-----I I 1 17. HOSE, PRESSURIZING VALVE TO DRAIN ADAPTER
r I I VALVE 37. ACTUATOR HOSE FITTING UJ
I’o L..i 11
1 8. O IL C 00 LE R 38. HOSE, FUEL CONTROL TO DRA\N TEE I F:
r
19. BOLT 39. NUT
U1
20. BOLT r
40. FUEL CONTROL
(r, BOTTOM VIEW a,
CJ610-6073-3~A2A 0~
cn
t~
00 1 24 m
H
w r
oo
o
2 23
~t I L I i I i I I 1 8
09
p
4 20
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6 21
iii
o" ~FS ,5 ii 1 00 o--‘ttt----22
;ooo~li Y1 ~iv_q ~.aoo,
7 11 I illll 1~3
io 2
I O
4 is t
a,
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I r
RIWT H*HD IIDE
j( JiiW I Oi
40 LEFT nAND SIDE
35 CT:
9 18 7 38 31 41 13 12 11 25 32 34
2 ,f~bl 36 32 33 35 31 14 26
M
;I O
c
i. FEEDBACK CABLE CONDUIT 21. FUEI MANIFOLD I ~I
2. ACTUATOR HOSE FITTING 22. EN GI N E MOUNT I 60
3. FLOWMETER ELBOW 23. FUEL NOZZLE I II
4. ACTUATORHOSE 24. FUEL MANIFOLD FITSING
5. VENT LINE 25. TUBE FITTING
6
31 1 6´• CLAMP 26. TUBE P AND D VAL\/E TO MANIFOLD
7. FLOWMETER BASE CONNECTOR 27. PRESSURIZING AND DRAIN VALVE
;C-
8. ACTUATOR TUBE FITTING 28. ACTU ATOR TUB ES
9. FUEL FLOWMETER 29. TUBE. CDP TO FUEL CONTROL
io. TEE FITTING 30. TUBE FITTING
11. HOSE. FUEL CONTROL TO O 5 GOVERNOR 31. OVE RSP E E D GOVE RN OR
32~1 lr 1 12´• CLAMP 32. HOSE. FUEL PUMP TO FUEL FILTER
13. TUBE. CDP TO ASPIRATOR 33. HOSE. FUEL FILTER TO O 5 GOVERNOR
14. HOSE. FUEL PUMP TO P 8 D VALVE 34. FUEL FILTER
M 15. CLAMP 35. HOSE, O J GOVERNOR TO FLOWMETER
16. TUBE. NO. BEARING SCAVENGE 36. HOSE. O J GOVERNOR TO PUMP INLET AC."PTER
1 37. HOSE, OIL COOLER TO P AND D VALVE
17. TEE FITTING
18. O1L COOL ER 38. HOSE. FUEL CONTROL TO DRAIN TEE
BOLT
BOTTOM VIEW 1 15( 1 I 1
19
20. BDL7
40.39. NUTFUEL tONTROI J
41. CLAMP BC-0383
’d 12 14 41 is 37
01
09 L3
00
o Fuel System CJ 610-4 6 and -8 Engines
Figure 3
GIYEIIII~BELIeflllC---
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
COMBUSTION CASING DRAIN
DRAIN VALVE
OVERSPEED GOVERNOR DRAIN
HIGH PRESSURE FILTER
FUEL CONTROL FILTER
FUEL PUMP FILTER FUEL PUMP DRAIN TEE
CJ610-1, -5 AND -9 BOTTOM VIEW
OVERSPEED GOVERNOR DRAIN
a I
COMBUSTION CASING DRAIN
PRESSURIZING VALVE DRAIN
HIGH PRESSURE FILTER
FUEL CONTROL FILTER FUEL PUMP FILTER
FUEL PUMP DRAIN TEf
CJ610-4, -6 AND -8 BOTTOM VIEW
CJ610-61131-*ZA
Fuel System Filters and Drains
Figure 4
73-00 Sept. 15/69
Page 8
OEW ERAL B% ELECTRIS
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
FUEL AND CONTROL SYSTEM TROUBLE-SHOOTING
i. General. Visual checks are important when trouble-shooting the fuel and
control system, because small defects in mechanical, hydraulic or pneumatic
signal lines can affect the fuel flow schedule. A mistaken notion that the
fuel control must be changed later becomes a disappointment when the engine
is run-up, and the malfunction persists despite the new fuel control. Per-
form operational checks whenever possible, to identify all available symp-
toms of the malfunction. The test facilities, spare parts on hand, type of
malfunction and the importance of timeusually determine how much testing
and investigation precedes the decision to replace a component. An obvious
symptom, such as a pressurizing and drain valve that does not drain at shut-
down, requires little testing or analysis before the "fix" is established.
Acceleration problems are in a more difficult category, and special tests
are almost a necessity.
Trouble-Shooting information is furnished Tn Chapter 72-00.
Nov. 15/67 73-00
Page 101
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MA~NTENANCE MANUAL
FUEL AND CONTROL SYSTEM MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
i. General. The information presented under system maintenance applies to the
system as a whole. Maintenance information which applies to an individual com-
ponent is presented as part of the maintenance information for that component.
2. Removal/Installation. Most external lines can be removed and replaced by em-
ploying ormal maintenance procedures. When replacing lines, install new clamps
where necessary.
CAUTION: 1. WHEN REASSEMBLING ANY UNIT IN THIS SECTION, LUBRICATION COMPOUNDS MUST BE
APPLIED IN ACCORDANCE WITH RECOMMENDED PROCEDURES.
2. ANY SELF-LOCKING NUT IS REUSABLE PROVIDING BOLT OF PROPER SIZE CAN-
NOT BE SCREWS THROUGH BY HAND.
3. ALL O-RINGS MUST BE DISCARDED AND REPLACED WITH NEW ONES.
4, ALL COMPONENTS MUST BE LOCKWIRED IN ACCORDANCE WITH 72-01-2.
5. ALL COMPONENTS MUST BE TORQUED IN ACCORDANCE WITH 72--01-3.
3. Adiustment/Test. The only adjustment that can be made on the fuel system is on
the fuel control; therefore, all adjustments are in 73-21-0.
73-00
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4. Insoection/Check. Inspect the following items during periodic inspections of
the engine.
A. Secureness of all studs, bolts, stand-off brackets or braces to which acces-
sories are fastened.
B. Accessories for leakage and/or cracking of mounting pads.
C. Lines and connection for leaks and/or evidence of wear per 72-02-1.
D. Clamping of lines for secureness per 72-02-1.
E. Throttle linkage for binding or excessive resistance.
5. Repairs.
A. Tighten or replace fittings as necessary to stop leaks.
B. Tighten bolts, brackets, and fasteners which secure the accessories to the
engine.
C. Remove and replace accessories with cracks in mounting pads.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
D. Remove replace leaking and/or chafed lines.
and If fire-sleeve is worn,
remove line from the engine, loosen the clamp on each end of the line,
the
and remove the covering. Check the line. If no damage is evident, install
new covering (72-02-1), and tighten clamps. Install the line on the engine,
torque connector nut, and lockwire.
CAUTION: DO NOT ATTEMPT TO STOP LEAKS AT THE END FITTINGS OF HOSES BY TIGHTENING THE
HEX FITTINGS THAT SECURE THE END FITTING TO THE HOSE.
E. If leaks result from cross threading or other damage to accessories, replace
the accessory. Refer to maintenance instructions on the component to which
the damage occurred.
73-00
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6, Servicinn.
A. Approved fuels. Use JP-4, conforming to G.E. Specifica-
JP-5, or JP-8 fuels
tion D50TF2, MIL-T-5624, or I lists engine fuels conform-
MIL-T-83133. Table
ing to GE Aircraft Engines Specification D50TF2, Class A, and are approved
for use in GE Aircraft Engines, CJ610 series.
NOTE 1: Mixing of fuel types is allowed if density knob on the fuel control
is properly set (73-21-0).
NOTE 2r Two configurations (Type A and Type B) exist for the fuel density
setting (73-21-0, figure 201A), The JP-5 setting on Type A is
equivalent to the -3 setting on Type B, The JP-4 setting on Type A
is equivalent to the -2 setting on Type B. JP-8 fuel uses the same
setting as JP-5 fuel.
TABLE I
APPROVED FUEL LIST
Density
Setting
Company Product Name Type A/B
1. American Oil Company American Jet Fuel Type A JP-5/-3
American Jet Fuel Type A-i JP-5/-3
2. Atlantic-Richfield ArcojetA JP-5/-3
Arcojet A-i JP-5/-3
Arcojet B JP-4/-2
3. British Petroleum BP A.T.K. JP-5/-3
Co., Ltd. BP A.T.G. JP-4/-2
BP AVCAT 48 JP-5/-3
73-00
Dec 31/95 Page 202A/202B
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SEI-186 MAINTENANCE MANUAL
TABLE I
APPROVED FUEL LIST (Cont)
Density
Setting
Company Product Name Type A/B
4. California Texas Caltex Jet A-i JP-5/-3
Caltex Jet B JP-4/-2
5. Cities Service Oil Co. Turbine Type A JP-5/-3
6. Continental Oil Co. Conoco Jet-40 JP-5/-3
Conoco Jet-50 JP-5/-3
Conoco Jet-60 JP-5/-3
Conoco JP-4 3P-4/-2
7. Empire State SMC JP-5/-3
8. Esso International Esso Turbo Fuel A-i JP-5/-3
Esso Turbo Fuel A JP-5/-3
Esso Turbo Fuel B JP-4/-7
9. Gulf Oil Corp. Gulf Jet A JP-5/-3
Gulf Jet A-i JP-5/-3
10. Humble Oil and Esso Turbo Fuel A-i JP-5/-3
Refining Co. Enco Turbine Fuel A-i JP-5/-3
Esso Turbo Fuel A JP-5/-3
Enco Turbo Fuel A JP-5/-3
Esso Turbo Fuel B JP-4/-2
Enco Turbo Fuel B JP-4/-2
Esso Turbo Fuel 5 JP-5/-3
Enco Turbo Fuel 5 JP-5/-3
11. Mobil Oil Co. Mobil Jet A JP-5/-3
Mobil Jet A-i JP-5/-3
Mobil Jet B JP-4/-2
Mobil Jet 4 JP-4/-2
Mobil Jet 5 JP-5/-3
11A Murphy Oil Co. Murphy Jet A JP-5/-3
12. Phillips Petroleum Co. Philjet A-50 JP-5/-3
Philjet JP-4 JP-4/-2
13. Pure Oil Co. Purejet Turbine Fuel Type A JP-5/-3
Purejet Turbine Fuel Type A-i JP-5/-3
14. Shell Oil Co. Aeroshell Turbine Fuel JP-4 JP-4/-2
Aeroshell Turbine Fuel 640 JP-5/-3
Aeroshell Turbine Fuel 650 JP-5/-3
Shell Jet A JP-5/-3
15. Sinclair Refining Co. Sinclair Superjet Fuel JP-5/-3
73-00
Mar 30/84
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MAINTENANCE MANUAL SEI-186
TABLE I
APPROVED FUEL LIST (Cont)
Density
Setting
Company Product Name ’Type A/B
16. Chevron Oil Co. Chevron Jet Fuel A-i JP-5/-3
Chevron Turbine Fuel B JP-4/-2
17. Standard Oil Co. Standard JF A JP-5/-3
(Kentucky) Standard JF A-i JP-5/-3
18. Standard Oil Co. Jet A Kerosene JP-5/-3
(Ohio) Jet A-i Kerosene JP-5/-3
19. Standard Oil Co. St.andard Turbine Fuel A-1 JP-5/-3
(Texas) Standard Turbine Fuel B JP-4/-2
20. Texaco, Incorporated Texaco Avjet A JP-5/-3
Texaco Avjer A-i 3P-5/-3
Texaco Avjet B JP-4/-2
21. Union Oil Co. of 76 Turbine Fuel JP-5/-3
California Union JP-4 JP-4/-2
Industry/Government Specification
22. Air Total Turbine Fuel, 1 and 1A JP-5/-3
ASTM Jet A Aircraft Turbine Fuel JP-5/-3
ASTM Jet B Aircraft Turbine Fuel 3P-4/-2
ASTM Jet A-i JP-5/-3
23. British Fuel D ENG. R.D. 2482, AVTUR 40 JP-5/-3
British Fuel D ENG. R.D. 2486, AVTAG JP-4/-2
British Fuel D ENG. R.D. 2494, AVTUR 50 3P-5/-3
British Fuel D ENG. R.D. 2498, AVCAT 48 JP-5/-3
British Fuel D ENG. R.D. 2488, AVCAT JP-5/-3
24. Canadian Fuel 3-GP-22 ;TP-4/-2
Canadian Fuel 3-GP-23 3P-5/-3
Canadian Fuel 3-GP-24 JP-5/-3
25. France Air 3404/B JP-5/-3
France Air 3405-C JP-5/-3
France Air 3407/B 32-4/-2
26. Germany TL 9130-006 JP-4/-2
Germany TL 9130-007 JP-5/-3
73-00
Mar 30/84
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TABLE I
APPROVED FUEL LIST
Density
Setting
Company Product Name Type A/B
27. MIL-T-5624G JP-4 JP-4/-2
MIL-T-5624G JP-5 JP-5/-3
MIL-T-83133 JP-8 JP-5/-3
28. NATO F-30 (Jet A) JP-5/-3
NATO F-34 (Jet A-i) JP-5/-3
NATO F-35 (Jet A-1) JP-5/-3
NATO F-40 (JP-4) JP-4/-2
NATO F-42 (JP-5) JP-5/-3
NATO F-44 (JP-5) JP-5/-3
NATO F-45 (JP-4) JP-4/-2
29. Romania 3754/73 (CS-3) JP-5/-3
30. USSR GOST 10227 (TS-1) JP-5/-3
USSR COST 12308 (T-7) JP-5/-3
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B. Use of aviation gasoline.
WARNING: AVIATION GASOLINE MIL-G-5572
FLAMMABLE DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES, NEAR
ELECTRICAL SPARKS, OR ON VERY HOT SURFACES.
USE ONLY WITH ADEQUATE VENTILATION. BE CAREFUL NOT TO BREATHE
VAPORS.
DO NOT SMOKE WHEN USING IT.
DO NOT TAKE INTERNALLY. DO NOT GET IN EYES, ON SKIN, OR ON CLOTH-
ING.
STORE IN APPROVED METAL SAFETY CONTAINERS.
CAUTION: ENGINE OPERATING TIME USING AVIATION GASOLINE IS LIMITED TO 25
HOURS DURING ANY ONE OVERHAUL PERIOD. OPERATING TIME WITH AVIATION
GASOLINE MUST BE RECORDED WHEN THE MIXTURE CONTAINS MORE THAN 50
PERCENT OF AVIATION GASOLINE BY VOLUME.
REFER TO AIRCRAFT FAA-APPROVED FLIGHT MANUAL FOR ALTITUDE RESTRIC-
TIONS WHEN USING AVIATION GASOLINE FUEL.
(1) Use aviation gasoline as an EMERGENCY fuel only, when Jp-4, JP-5, and
JP-8 fuels are not available.
(2) When aviation gasoline is used, the following conditions shall apply:
(a) The lowest octane fuel available shall be used.
(b) Adjust the fuel density knob (73-21-0).
C. Additives.
(1) Anti-icing.
Phillips PFA-55MB (Phillips Petroleum Co., 758 Adams Bldg.,
Bartlesville, OK 74004) and Methyl Cellosolve (Union Carbide Corp., Old
Ridgebury Rd., Danbury, CT 06817) are approved for use in the fuels
contained in the Approved Fuel List (table I) at a concentration not in
excess of 0.15 percent by volume.
73-00
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(2) Fuel Leak Detection.
WARNING: OIL AND JET FUEL DYES
FLAMMABLE KEEP AWAY FROM HEAT, SPARKS, AND OPEN FLAME.
USE IT IN A WELL-VENTILATED AREA. AVOID PROLONGED OR REPEATED
BREATHING OF VAPORS.
WEAR RUBBER GLOVES AND CHEMICAL GOGGLES.
FLUSH SKIN WITH WATER AND SEEK MEDICAL ATTENTION IF SOLUTION
CONTACTS SKIN.
STORE IN APPROVED METAL SAFETY CONTAINER.
Automate Yellow 662 (Morton Chemical Co., 335 McClean Blvd., Patterson,
N.J. 07504) is approved for fuel leak detection at a concentration of
1.6 ounces for every 100 US gallons.
73-00
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MAINTENANCE MANUAL
FUEL FLOWMETER MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMO UNTS OF ASBESTOS WHEN WORK-
ING WITH THIS ENGINE THE FOLL OWING PREC AUT IONS MUST BE RTG-
IDLY ADHERED TO:
BEFORE ANY MAINT ENANCE ACTIVITIES ARE UNDERT AKEN, REVIEW THE
ILLUST RATED PARTS BREA KDOWN/C ATALOG INDEX TO DETE RMINE IF THE
HARD WARE TO BE WO REED ON OR USED CONTAINS ASBESTOS
WHENE VER MEC MANIC AL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERT AL
BUILD-UP ON PARTS THAT CON TAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN. AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDL ING. REPLACING OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NAT I ONAL ENVIRO NMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDL ING ASBESTOS-CONTAINING HARDWARE.
1 Gene r al The fuel fl owmet e r is an ai r fr ame furnishe d pa rt The following main
t en anc e p r o c e dur e a ap ply to GE Air c r aft .En g in e a fl owme t e r P N 3 7 E 5 O 1 5 O 4 GO O 1
Re fe r to the Air c ra ft Manual if a d iffe r ent flowmet e r is in stalle d
2. Removal/Installation.
WARNING AS BE STO S
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CO NTA INS AS BES TOS,
WH I CH IS HI GHLY TOXI C TO S KIN EYE S AND RE S P I RAT ORY TRACT READ GEN-
ERAL I NF ORMAT I ON BEFORE PROCE ED ING AND ADHERE TO ALL S I TE SAFETY AND
ENV I RONME NTAL C ONT ROL S CONCERNING AS BE S TO S OTHERW I S E PERS ONAL INJURY
MAY RE S ULT
A. Remo val
1 Remove the CJ 6 1 O 1 5 and 9 fuel flowme t e r as follows Se e 73 OO
figure 2)
NOTE: For removal of the CJ610-4, -6, -8, and -8A fuel flowmeter, see
st ep A (2)
(a) Disc onnect the fuellines (10, 35) from the flowmeter (9)
(b) Disconnect the electrical connector.
(c) Remove 4bolts; remove the flowmeter from the brac ket.
73-12-0
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MAINTENANCE MANUAL
(2) Remove the CJ610-4, -6, -8, and -8A fuel flowmeter as follows: (See 73-
-00, figure 3).
(a) Disconnect the electrical lead at the flowmeter; remove the O-ring
from the connector, if necessary.
(b) Disconnect the governor-to-flowmeter fuel hose (35) at the
flowmeter (9).
(c) Remove the 4 screws that secure the flowmeter to the flowmeter base
connector (7); remove the flowmeter (9) and the O-ring.
(d) Remove the 4 screws that secure the flowmeter elbow (3); remove the
elbow and O-ring.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Install the CJ61O-1, -5, and -9 fuel flowmeter as follows: (See 73-00,
figure 2).
NOTE: For installation of the CJ61O-4, -6, -8 and -8A fuel flowmeter,
see step b.(2).
(a) Secure the flowmeter (9) to the brackets with 4 bolts. Torque the
bolts to 12-14 Ib-in. and lockwire.
CAUTION: BE SURE THERE IS CLEARANCE BETWEEN THE TUBE (35) AND ANY OTHER
LINES, HOSES, OR ENGINE PARTS.
NOTE: Position the flowmeter so that, while looking at it from the front
of the engine, the electrical connector is at the right and behind
the fuel inlet connector.
(b) Connect the fuel line (10, 35) to the flowmeter connectors. Torque
the nuts to 650-700 Ib-in.
(c) Connect the electricl connector to the flowmeter.
73-12-0
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(2) Install the CJ610-4, -6, -8, and -8A fuel flowmeter as follows: (See
73-00, figure 3).
(a) Install the O-ring onto the flowmeter elbow (3), place the elbow on
top of the flowmeter (9), and secure it with 4 screws. Torque the
screws to 14-18 Ib-in. and lockwire.
(b) Install the O-ring onto the boss of the flowmeter base connector
(7).
(c Position the flowmeter (9) on the boss of the flowmeter connector
and secure it with the 4 screws. Torque the screws to 14-18 Ib-in.
and lockwire.
(d) Connect the coupling nut of the governor-to-flowmeter fuel hose
(35) to the fitting at the top of the flowmeter. Torque the cou-
pling nut to 200-350 Ib-in.
(e) Install the O-ring in the connector of the electrical lead, if
necessary, and secure the lead to the flowmeter connector. Tighten
the connector finger-tight and lockwire.
73-12-0
IDec 31/95 Page 203
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FUEL PUMP MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
I. General. Maintenance of the fuel pump consists of Removal/Installation Inspec-
tion/Check and cleaning of the fuel pump filter.
2. Removal/Installation. (See 73-00, figures 2, 3.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
NOTE: It is recommended that the fuel pump and fuel control be removed as an
assembly and that further disassembly be accomplished on the bench.
(1) Disconnect the 2 variable geometry actuator hoses (4) from the fittings
at the top of the fuel control.
(2) Disconnect, at the pressurizing valve (or P and D valve, as applicable)
the hose (14) that runs to the fuel pump.
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(3) Disconnect, at the fuel control, the P3 tube (29) that runs from the
mainframe pad to the fitting on the rear of the fuel control.
(4) Disconnect, at the fuel control aspirator elbow, the tube (13) that runs
from the aspirator to the mainframe pad at 4 o’clock.
(5) Free the fuel control feedback cable (1) as follows:
(a) Remove the 2 screws at the fuel control mounting pad that hold the
feedback cable conduit bracket.
(b) Disconnect the feedback cable from the fuel control feedback lever
by removing the spring clip and pin.
(6) Disconnect the high-pressure fuel filter lines (32, 33) at the fuel pump
and overspeed governor (31). (It is not necessary to remove the filter
and clamp from the overspeed governor.)
(7) Disconnect, at the fuel pump inlet adapter, the line (36) from the
overspeed governor.
CAUTIION; DO NOT DISCONNECT (OR APPLY TORQUE TO) THE COUPLING NUT THAT CON-
NECTS THIS LINE TO THE FLANGED ELBOW FITTING WHEN THE ELBOW IS
ATTACHED TO THE FUEL CONTROL. IF IT ISNECESSARY TO DISCONNECT
THIS LINE FROM THE ELBOW FITTING, THE ELBOW MUST FIRST BE REMOVED
FROM THE FUEL CONTROL.
(8) Disconnect, at the overspeed governor, the line (11) that runs from the
aft side of the fuel control to the’governor.
(9) On CJ610-4, -6 and -8 engines with center-vent lube system, perform the
following: (See 73-00, figure 3.)
(a) Disconnect the clamps (12 and 15) that secure the No. 1 bearing
scavenge tube (16).
(b) Disconnect the No. 1 bearing scavenge tube (16) at the 6 o’clock
fitting of the front frame; and at the fitting on the left hand
side of the accessory gearbox. Remove the tube.
(c) Disconnect the No. 1 bearing vent tube (5) at the 2 o’clock fitting
on the front frame; and at the aft center fitting on the accessory
gearbox. Disconnect the clamps and remove the vent tube.
(10) Remove the 4 nuts and washers that attach the fuel pump to the accessory
gearbox. (Support the assembly while removing the nuts.)
(11) Slowly move the pump and control assembly forward to remove it from the
gearbox.
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MAINTENANCE MAMJAL
CAUTION: DO NOT REST THE PUMP ON THE DRIVE SHAFT AT ANY TIME. (THIS PRE-
VENTS THE POSSIBILITY OF CARBON SEAL DAMAGE.)
NOTE: Cap all openings with suitable protective covers.
(12) With the pump and control assembly on a bench, disconnect all lines.
(It is not necessary to disconnect the lines unless a line, the
pump or
fuel control require replacement.) If it is necessary to disconnect the
fuel discharge hose from the flanged elbow fitting, the elbow must first
be removed from the fuel control.
CAUTION: IF THE FUEL PUMP DOES NOT SEPARATE FROM THE FUEL CONTROL BECAUSE OF
THE SNUG FIT OF THE MATING SURFACE DOWEL PINS, GENTLY TAP THE STUDS
WITH A NONMETALLIC HAMMER. DO NOT PRY APART WITH A SCREWDRIVER OR
OTHER SHARP INSTRUMENT BECAUSE OF THE POSSIBILITY OF DAMAGING THE
MATING SURFACES.
(13) Remove 4 nuts and washers and separate the fuel pump from the fuel con-
trol.
(14) Discard the three O-rings and install protective covers over all open-
ings.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE PIAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Install 3O-rings:
new one on the fuel pump, and two on the fuel con-
trol mounting pad.
CAUTION: BE SURE THE TEETH OF THE GEAR IN THE FUEL CONTROL MESH PROPERLY
WITH THE TEETH OF THE GEAR IN THE FUEL PUMP BEFORE TORQUING THE
NUTS.
(2) Align the two holes in the control with the two dowel pins on the pump
pad. Install the control on the pump and secure it with four nuts and
washers. (Use caution not to pinch the O-rings.) Torque the nuts to
50-60 Ib-in.
73-13-0
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MAINTENANCE MANUAZ,
(3) Reinstall any hoses that were removed in step A.(12):
(a) Install the fuel control discharge hose (11) by removing the
flanged elbow fitting from the fuel control. Connect the hose
coupling nut to the elbow. Torque to 710-770 Ib-in. Using a new
O-ring between the elbow and the fuel control, attach the hose and
elbow to the fuel control. Torque the 3 screws to 24-27 Ib-in. and
lockwire.
(b) Install the small hose (14) on fuel pump elbow fitting. Tighten to
standard torque.
(c) Install the small hose (38) from fuel pump drain tee to aft side of
fuel control. Tighten to standard torque.
(4) Lubricate the spline of the fuel pump shaft with Plastilube Moly No. 3
(Thiem Automotive Div., 5151 Denison Ave., Cleveland, OH, 44102) or
approved equivalent. Install the fuel control and pump assembly with a
new gasket on the pad of the accessory gearbox. Secure it with 4 nuts
and washers. Torque the nuts to 60-90 Ib-in.
(5) Connect, at the overspeed governor (31), the large hose (11) from the
rear of the fuel control and tighten to standard torque.
(6) Connect the high pressure fuel filter lines (32, 33) to the fuel pump
and overspeed governor and tighten to standard torque.
(7) Connect, at the fuel pump inlet adapter, the hose (36) from the
overspeed governor. Tighten to standard torque.
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MAINTENANCE MANUAL
(8) Install the No. 1 bearing vent and scavenge tubes (5 and 16, 73-00,
figure 3) if applicable, and tighten the fittings to standard torque.
Install the tube clamps (12, 15) and tighten the’clamp nuts to 24-27
Ib in.
(9) Secure the feedback cable conduit bracket to the Yuel control pad
with 2 screws. Torque the screws to 10-12 Ib in. and lock-wire,
(10) Connect the feedback cable to the fuel control feedback lever with
the spring clip and pin.
I TUBE (L3),VASELINE ~UST NOT BE USED FOR LUBRICATION FJ~IEN WSTALLING
(11) Connect, at the fuel control aspirator elbow, the tube (13) that runs
from the aspirator to the mainframe pad at 4 o’clock. Tighten to
standard torque.
(12) Connect the tube (29) from the mainframe pad to the fitting on the
rear of the fuelcontrol. Tighten to standard torque.
(13) Connect, at the pressurizing valve, the hose (14) from the fuel
pump. Tighten to standard torque.
(14) Connect the 2 variable geomi~ry acutator tubes to the fuel control
ports and torque per 73-25-00.
(15) Adjust the feedback cable per section 75-00.
(16) Perform the checks required after a fuel control change per figure
503, section 72-00.
3. Inspection/Check. When serviceable limits are exceeded, the fuel pump may
5e repaired in accordance with the accessory overhaul manual (SEI-154). Vis-
ually inspect the following areas.
Inspection /Check Maximum Serviceable Limits Remarks
A. Inlet flange for 0.020 inch movement when Replace pimp.
loose studs measured at end of stud.
B. Any evidence of Not serviceable. Replace pump.
leakage
C, External spline 0.4761 inch diameter over
wear (if qoted 0.080 inch diameter pins,
visually)
73-13-0 Mar 30/84
fage 204
0 E IERAL 0 LL CTR IC
C3610 TURSOJE7
SEI-186 MAlNTENANCE MANUAL
i~i´•9,
L-2
CJ610-60811DZ
Fuel ~ump Filter
Figure 201
4, Cleaning of Fuel Pump Filter, (S’ee figure 201,)
A, Removal,
(1) Remove the´•plug and spring assembly (1), O-ring (2’) and filter (3)
from the bottbm of the fuel pump housing,
1/7673-13-0
~LECtllC
CJ610 TURICIOJCT
MAINTENANCE MANUAL SEI-186
B. Cleaning.
(1) Ultrasonic Procedure. This process is the recolmnended method for
cleaning the filter.
WARNING: TRICHLOROETHANE VAPORS ARE HARMFUL DO NOT USE NEAR OPEN
FLAMES OR ON VERY HOT SURFACES.
DO NOT USE NEAR WELDING AREAS, A SOURC$ OF CONCENTRATED
ULTRAVIOLET RAYS. INTENSE ULTRAVIOLET RAYS CAN CAUSE THE
FORMATION OF PHOSGENE GAS, WHICH IS INJURIOUS TO THE LUNGS.
USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR
REPEATED BREATHING OF VAPORS.
AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. WEAR APPROVED
GLOVES AND GOGGLES (OR FACE SHIELD) WHEN HANDLING AND WASH
HANDS THOROUGHLY AFTER HANDLING.
DO NOT TAKE INTERNALLY.
DO NOT SMOKE WHEN USING IT.
STORE IN APPROVED METAL SAFETY CONTAINERS.
(a) Pour trichloroethane, or an equivalent cleaner, into the cleaning
tank of a Blackstone Model 562 Ultrasonic Cleaner (Blackstone
Ultrasonics Inc., Sheffield, Pa. 16347), or equivalent, to a depth
of approximately 3 inches.
(b) Connect the cleaner to a suitable power source and, with the
cleaner switches in the OFF or normal position, allow the cleaner
t6 warm up for approximately 15 seconds.
(c) Place the filter (3, figure 201) in the cleaner tank and turn the
cleaner on for the desired length of (approximately 12
time
minutes), adjusting the cleaner for maximum surface agitation.
(d) Shut off the cleaner, remove the filter, and cover the tank to
prevent the contamination of the cleaning fluid.
73-13-0
Sept 1/76
Page 206
oiwii~L´• Ertcrnic
CJ016 TUR~OJET
MAINTENANCE MANUAL SEI-186
(2) Alternate Procedure. When ultrasonic cleaning equipment is not
available, the filter should be cleaned as follows:
WARNING: CLEANING) OPERATION SHALL BE: PERFORMED IN AN APPROVED
CLEANING CABINET OR WELL VENTILATED AREA. PRECAUTIONS
SHALL BE EXERCISED TO PREVENT INHALATION OF VAPOR EMITTED
BY VOLATILE CLEANING MATERIALS, AND TO MINIMIZE DANGER OF
EXPLOSION AND FIRE HAZARDS.
I (a) Cleanthe filter by inrmereing it in carbon tetrachloride,
trichloroetbane, kerosene, or equivalent. While continually
agitating the filter, use a suitably contoured soft bristle
brush to dislodge contaminants.
NOTE: Only clean, filtered solvents should be used. Assure
that containers used duringthe cleaning procedure are
clean and free from contaminants.
(b) Blow it out with filtered compressed air and be sure no dirt
particles have collected in the filter.
(c) Visually inspect the filter using a magnifying glass (10X mini-
mum) and a strong light. If the Filter is not completely clean,
repeat steps (a) and (b).
C. Replacement.
(1) Install a new O-ring (2) on the plug and spring assembly (1).
(2) Apply petrolatum to the filter (3)’to hold it in position until the
spring is installed and insert the filter, closed end out, into the
fuel pump.
CAUTION: BE SURE THAT THE: FIITER IS SEATED. THE END OF THE FILTER
8HOULD BE APPROXIMATELY 1/2 INCH INSIDE THE CASTING AND 5
ORMORE THREADS SHOULD BE VISIBLE.
(3) Install the plug and spring assembly (1) and maintain the filter
position with the spring.
(4) Torque the plug to 20-30 Ib-in. and lockwire.
CAUTION: IF IT IS NOT POSSIBLE TO TURN THE PLUG 2 COMPLETE TURNS
WITH THE FINGERS, THE FILTER HAS DROPPED OUT OF POSITION
AND FURTHER TIGHTENING WILL COLLAPSE IT. REMOVE THE PLUG
AND RESEAT THE FILTER.
73-13-0
Sept 1/76 Page 207
eltrlnAL´• ILIC1IIE
C3610 TUR´•OJaT
MASNTENANCE MANUAL SEI-186
5. Replacement of Fuel Pump High-Pressure Relief Valve Cover.
A. Remova i.
(1) Remove 1 of 3 screws (I f igure 20 2) and washer (2) which retain
relief valve cover (3)
2 Get a longer screw (AN50 OAl O 28 or AN 50 OA 1 0 3 2) and run a nut
well up onto the thread, Install screw into cover. Run nut
down onto cover.
(3) Replace other 2 screws by repeating steps (1) and (2)
(4) After rep lac ing all 3 screws back o f f nuts sequentially
2 t urn s a t a t ime until all camp r e s a lye force on rel ie f
valve spring (6) is rel ieved.
(5) Remove screws nut s and relief valve cover (3)
NOTE: When removing cover (3) note the number and posit: ion
of shims (5) located under the cover.
(6) Remove shims (5) Remove and discard o-ring (4)
B. Replacement.
(1) Inspect a-ring groove on relief valve cover (3, figure 202) for
nicks or burr a Repair any def ects
(2) Install shims (5) Use the same quantity and position as
noted during removal.
(3) Install a-ring (4) on to cover (3)
(4) Install cover (3) Use 3 screws (1) and washers (2) Turn
screws a equent ial ly 2 turns at a t ime until they are snug
(5) Torque screws (1) to 20-30 ib in.
73-13-0 Nov 1/80
Page 208
IIIIIIL rLlOtll(
CJ6~0 TU~´•OJLT
881-186 MAINTEUANCE MANUAL
1. MACH INE SCREW
6. SPRING
2. WASHER
7. RELIEF VALVE
3. FUEL PUMP RELIEF VALVE COVER
8. SLEE VE
4. O-RING
9. O-RING
5. SHIM
10 FU E L PUMP
o
r li~
3 ´•11-
t 6t 7
8 to
BC-0417
Fuel Pump High-Pressure Relief Valve
Figure 202
Nov 1/80 73-13-0
Page 209
GENERAL ELECTRIC-------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
FUEL FILTER. O.S.G. SERVO MAINTENANCE PRAC_TICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. Gen_eral. Maintenance of the fuel filter consists of Removal/Installation and
Cleaning.
2. Removal/Installation. (See figure 201.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Disconnect the fuel lines from the high-pressure filter housing which is
located on a bracket attached to the overspeed governor. (Clamp is
attached to OSG to flowmeter fuel tube on CJ610-4, -6 and -8 engines.)
(2) Remove the filter housing and clamp from the mounting bracket.
(3) Remove the plug (5) and filter (3) from the housing (1).
73-14-0
Dec 31/95 Page 201
GENERAL ELECtRIC-------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAZ INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Install 2 new O-rings (2, 4) on the filter plug and filter~element.
(2) Install the filter (3) and plug (5) in the housing (1). Torque the plug
to 90-110 Ib-in. and lockwire.
(3) Install the filter housing and clamp on the mounting bracket. (The
largest OD of the filter housing should be forward of the clamp.)
(4) Connect the fuel lines to the filter housing.
3. Cleaning.
A. Ultrasonic Procedure. (Refer to Accessory Overhaul Manual, SEI-154, for
ultrasonic cleaning process.) This process is the recommended method for
cleaning the filter.
B. Alternate Procedure. When ultrasonic cleaning equipment is not available,
the filter should be cleaned as follows:
73-14-0
Page 202 Dec 31/95
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
WARNING: TRICHLOROETHANE, 0-T-620
DO NOT USE NEAR OPEN FLAMES, WELDING AREAS, OR ON VERY HOT SUR-
FACES. DO NOT SMOKE WHEN USING IT. HEAT AND FLAMES CAN CAUSE THE
FORMATION OF PHOSGENE GAS WHICH IS INJURIOUS TO THE LUNGS.
REPEATED OR PROLONGED CONTACT WITH LI4UID OR INHALATION OF VAPOR
CAN CAUSE SKIN AND EYE IRRITATION, DERMATITIS, NARCOTIC EFFECTS,
AND HEART DAMAGE.
AFTER PROLONGED SKIN CONTACT, WASH CONTACTED AREA WITH SOAP AND
WATER. REMOVE CONTAMINATED CLOTHING. IF VAPORS CAUSE IRRITATION, GO
TO FRESH ATR. GET MEDICAL ATTENTION FOR OVEREXPOSURE OF SKIN AND
EYES.
WHEN HANDLING LI4UID IN VAPOR-DEGREASING TANK WITH HINGED COVER AND
AIR EXHAUST, OR AT AIR-EXHAUSTED WORKBENCH, WEAR APPROVED GLOVES
AND GOGGLES.
WHEN HANDLING LIQUID AT OPEN, UNEXHAUSTED WORKBENCH, WEAR APPROVED
RESPIRATOR, GLOVES, AND GOGGLES.
DISPOSE OF
LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(1) Clean the filter by immersing it in carbon tetrachloride,
element
trichloroethane, kerosene or equivalent. While continually agitating
the filter, use a suitably contoured soft bristle brush to dislodge
contaminants from the filter convolutions.
NOTE: Only clean, filtered solvents should be used. Assure that con-
tainers used during the cleaning procedure are clean and free from
contaminants.
(2) Blow it out with filtered compressed air and be sure no dirt particles
have collected in the filter.
CAUTION: DO NOT ATTEMPT TO PROBE THE FILTER CONVOLUTIONS WITH A SHARP
TOOL AS THIS MAY DAMAGE THE FILTER AND RENDER THE FILTER NOT
SERVICEABLE.
(3) Visually inspect the filter using a magnifying glass (10X minimum) and a
strong light. If the filter is not completely clean, repeat steps (1)
and (2).
NOTE: If some dark colored stains remain at the bottom of the convolu-
tions, these are not harmful, and the filter is serviceable. If
any doubt exists as to the cleanliness of the filter, repeat the
cleaning procedure.
73-14-0
Dec 31/95 Page 203
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUA~
FUEL PRESSURIZING VALVE MAINTENANCE PRACTICES
(CJ610-1, -5, and -9 Engines)
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. Maintenance of the fuel pressurizing valve is limited to Removal/
Installation.
2. Removal/Installation (See 73-00, figure 2.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Disconnect 4 hoses from the fittings of the pressurizing valve (15).
(2) Remove 2 screws (16) and washers and remove the pressurizing valve from
the oil cooler (18).
73-15-0
Dec 31/95 Page 201
GENERAL ELECTRIC-------
CJ61 6 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
B. Installation.
(1) Install a new O-ring on the OD of the pressurizing valve (15). Secure
the valve to the upper port of the oil cooler (18) with 2 screws and
washers. Torque the screws to 7-9 Ib-in. and lockwire.
(2) Connect the 4 hoses to the pressurizing valve and tighten to standard
torque values.
73-15-0
1 Phge 202 Dec 31(95
GENERAL ELECTRIC--~--
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUA~
FUEL DRAIN VALVE MAINTENANCE PRACTICES
(CJ610-1, -5 and -9 Engines)
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW TKE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. Maintenance of the fuel drain valve consists of Removal/Installation
2. Removal/I4stallation. (See 73-00, figure 2.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Disconnect the left- and right-hand manifold drain tubes (26) from the
drain valve (27).
(2) Disconnect, at the drain valve, the hose (17) that connects the fuel
pressurizing valve to the drain valve.
(3) Remove the drain valve and clamp.
73-16-0
Dec 31/95 Page 201
GENERAL ELECTRIC-------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS.
WHICH IS HIGHLY TOXIC TO SKIN. EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING. AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE. PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Wrap the clamp around the body of the manifold drain valve~(27). Secure
the clamp and valve loosely to the clamp on the accessory gearbox drive
shaft cover (28) with a bolt and nut.
NOTE: The unthreaded projection on the valve should be positioned at the
rear of the clamp, and the drain should be in the 6 o’clock posi-
tion.
(2) Connect the hose (17) leading from the bottom of the pressurizing valve
to the threaded fitting on the front of the drain valve. Torque the
hose nut to 70-100 Ib-in.
(3) Connect the left- and right-hand manifold drain tubes (26) to the drain
valve (27). Torque the nuts to 135-150 Ib-in.
(4) Tighten the clamps with the nut and bolt. Torque the clamp bolt to 20-
25 Ib-in.
73-16-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
FUEL PRESSURIZING AND DRAIN VALVE MAINTENANCE PRACTICES
(CJ610-4, -6, -8, and -8A Engines)
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
IL-LUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. Maintenance of the pressurzing and drain valve consists of Removal/
Installation and Inspection/Check.
2. Removal/Installation. (See 73-00, figure 3.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Disconnect the left- and right-hand fuel manifolds (21) from the P and D
valve (27).
(2) Disconnect, at the valve, the hose (37) connecting the oil cooler to the
valve.
(3) Disconnect, at the valve, the hose (14) connecting the fuel pump to the
valve.
(4) Remove the 3 bolts (39) that secure the P and D valve to the compressor
casing; remove the valve (27).
73-17-0
Dec 31/95 Page 201
GENERAL ELECTRIC-------
CJ610 TU R B OJ ET
SEI-186
MAINTENANCE MANUAL
WARN ING AS BE S TO S
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS
WHICH IS HIGHLY TOXIC TO SKIN EYE S AND RE S P I RATORY TRACT READ GEN
ERAL INFO RMAT I ON BEFORE PROC EEDING. AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBE S T O S OTHERWISE. PERSONAL INJURY
MAY RE S ULT
B. Inst allation.
(1) Se c´•u re the pressurizing and drain valve to the compressor casing with 3
bolts. Torque the bolts to 24-27 ib-in.
(2) Co nnect the hose (14) from the fuel pump to the valve. Torque the cou-
pling nut to 90-100 ib-in.
(3) Co nnect the hose (37) from the oil cooler to the valve. Torque the
coupling nut to 650-770 ib-in.
(4) Co nnect the le ft- and right-h and fuel manifolds to the valve. Tor que
the nuts to 70-100 ib-in.
3. Insoection/Che ck. When service able 1 imits are exceeded, the valve may he re-
paired in accor dance with the accesssory overhaul manual SEI-154. Visually
inspect the following areas:
In s p e c t ion Check Maximum Se rvic eable Limits Remarks
Housing for:
Exterior wear or None allowed de eper than
chafing. 0. 010 inch. Nicks not
deeper than 0.060 inch
allowed around boltholes.
Burrs and sharp None allowed. Blend sharp edges
edges. and remove burrs
73-17-0
Page 202 Dec 31/95
GENERAL~ELL CTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MAMJ~L
FIJEL NOZZLES MAINTENANCE PRACTICES
1 Gene r al Ma int enan c e of the fuel no ttl es c ons i s t s of R emoval/ Ins t al la t i on
and Inspection/Check.
2 R emoval/ Ins t allat i on Se e 73-00 figures 2 and 3
NOTE I t may be ne c e s s a ry to remove the engine mount ing pads to replace
I the no z ties adj a cent to the pads On CJ 610 -4 6 -8 and -8A
eng ines the ace esso ry gearbox mus t be removed per 7 2-6 4-0 to
replace the 4 lower no zzles
A. Removal.
1 D i s conne c t the fuel mani fold fi t t ing 24 from the fuel no z tie 23
2 Us e tool 2 C5322 to remove the 4 bolts (2 O that s e cure the no z tie
to the mainframe pad Apply p ene t rat ing o i1 if the bolt s s e i ze
3) Remove the no z tie by p ivo t ing the forward edge o f the mount ing
flange radially outward and to the rear.
B Ins tallat ion
1) Ins ert the fuel no ttl e (2 3 through the mainframe opening wi th the
nozzle ori fi ce facing to the rear making sure the no z tie tip is
ext end ing into the combus t i on 1 ine r no zzle fer rul e
CAUTI ON: DO NOT HANDLE THE NOZZLE TIP. FINGERPRINTS ALONE MIIY BE
ENOUGH TO DISTORT THE NOZZLE SPRAY PATTERN.
2 Lub ri cat e the 4 bolt s 2O wi th E as e-O ff 9 9 O (T exac one Co Box
1 42 3 6 Dallas T eras) S e cure the no ttl e to the mainframe wi th
bolt s t o r qu e to 16 -1 9 ib- in and lo ckwi r e
3) Connect the fu el mani fold fi t t ing (2 4) to the fuel no ttl e (2 3
j Tor qu e it to 140-160 ib-in.
3 Inso e ct i on/ Che ck When s erv i c eab le 1 imi t s are exe e ed ed the fuel no z ties
may be repaired in acco rdance with the Accessory Overhaul manual. Visually
insp ect the following areas.
Dec 31/91 73-18-0
Page 201
G LN E RAL f LE CT R I C
cJslov TURBOjET
MAINTENANCE NIANUAZ, SEI-186
Ins pec t i on/ Che c k Maximum Se rvi c ea hi e Limit s Remarks
A. Nozzle housing for:
1 Evidence of Not s e lyv i cea ble Rep 1 ac e no zz le
leakage
(2) Cracks Not se rvic eab;le. Replace nozzle.
(3) Damaged threads Not servi ceable
B. No ttl e ti p s and orifi ce for:
(1) Carbon buildup Any amount if it does not
i nt e rf e re with the spray
pattern or close
any of
the ai r shroud annulu s
(2 Ni c ks s c ra t c he s Any amount if it does not
interf ere wi th s pray
pat te rn
C. Air shroud for Any amount, 0.010 inch
wear deep after removal of
high metal.
73-18-0 Mar. 30/67
Page 202
GENERAL ELECTRIC------
CJ6 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
Flow and Sr,rav Test
A. Equipment and Material.
WARNING: CALIBRATING FLUID MIL-C-7024
COMB U S T I B LE DO NOT USE NEAR OPEN FLAME S NEAR WE L D I NG AREAS OR ON
HOT SURFACES.
PROLONGED CONTACT WITH SKIN MAY CAUSE IRRITAT I ON. PROLONGED I NHALAT ION
OF VAPOR CAN CAUSE DIZZINESS, HEADAC HE AND INTOXI CAT ION.
IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AFFEC TED AREA WITH
SOAP AND WATER IF LIQUID C ONTA CT S EYE S FLUSH EYES THOROUGHLY WITH
WATER REMOVE S OLVENT SATURATED CLOTHING IF VAP OR S CAUSE L I GHT
HEADEDNE S S GO TO F RE S H AIR rF LIQUID IS S WALL OWE D DO NOT TRY TO
VOMIT. GET ME D I CAL ATTENT ION
WHEN HEATED, HOT FLUID MAY CAUSE BURNS. AVO ID CONTACT WITH HOT FLUID.
IF SKIN CONTACTS HOT FLUID, FLUSH AFFECTED AREA WITH COLD WATER FOR 10
MI NUTE S SEEK ME D I CAL HELP I MMED IATELY
WHEN HANDLING OR WHEN APPLYING LI QU I D AT AN A IR EXHAU S TED WO RKBEN C H
WEAR APPROVED GL OVE S AND GO GGLE S OR FACE S H IELD
WHEN HANDL ING OR WHEN APPLYING L I QU I D AT AN UNEXHAU S TED WORKBENCH
WEAR APPROVED GL OVE S GOGGLE S OR FACE SHIELD AND APPROVED RE S P IRA
TOR.
DISPOSE OF LI4UID-SOAKED RAGS IN APPROVED METAL CONTAINER.
1 Us e c al ib ra t in 8 fluid M IL C 7 O 2 4A Type II. Ma in t a in t emp e r a tur e at
nozzle at 78" to 82" F (25.560 to 27.780 C)
(2) Pr ovide atest st and cap able of supplying 600 psig fuel pressure at the
fuel no z tie and a t emp e r atu r e c o nt r ol to p rov id e a fuel t emp e r a t ur e at
the nozzle within the 1 imitations specified in step (1)
3 Pr ov i d e a me a s ur in 8 c ap ah ility o f +1 ps i8 and el% of fuel f i ow r at e
4 C onn e c t the me a s u r i ng t the s ide p o rt o f the fuel f it t in g adapter
gage o
P/N 5232270-F3 (3 figure 201) and the inlet fuel pressure line to the
end port of the ad apter.
73-18-0
Dec 31/95 Page 20 2A/202B
GENERAL ELECTRIC------
CJ610 TURSOJET
SEI-186
MAINTENANCE MANUAZ.
wt
i. Adjusting Htenth (5232270-F1)
2. Stand Pfpe Adapter (5232270-F2)
3. Fuel Fitting Adapter (523221~F3)
4. Special Socket (523227~-F4)
~PLE: Tool Vendor is Dfesel Equipolent Div., GHC.
000W6-Sgg700
Special Tools
Figure 201
73-18-0
Dec 31/95 203
Page
GENERAL ELECTRIC-------
cJsl 6TUR BOJ ET
SEI-186
MAINTENANCE MANUt~L
B. Test Procedure.
(1) Refer to the fuel nozzle performance specifications.
(2) Refer to SEI-154, 73-16-1 (Troubleshooting), paragraph 9 and table 5 in
conjunction with the tests specified.
Fuel Nozzle Performance Specifications
Pressure Low Average High Flow Spray
Drop Flow Limit Flow Limit Flow Limit Hysteresis Angle
(psig) (Ib/hr) (Ib/hr) (Ib/hr) (Degrees)
100 24.26 25.4 26.54 0.5% 72 to 98
135 45.68 48.6 51.52 72 to 98
400 259.76 272.0 284.24 1.0 PPH 84 to 98
Flow tests to be conducted by increasing pressures from low pressure to the next
higher pressure.
Hysteresis must be checked when increasing and decreasing pressure.
*Flow shall be within 4 Ib/hr of the reading at the previous 135 psig increasing
test point and must be within flow limits.
(3) Flow and spray test nozzles as follows:
(a) With the assembly installed in the stand pipe adapter
fuel nozzle
5232270-F2 figure 201), connect and securely tighten fuel fit-
(2,
ting adapter 5232270-F3 (3, figure 201) to the threaded inlet of
the fuel nozzle assembly.
(b) Connect two suitable flexible hoses with connections to fit the
side and end ports of the adapter and of sufficient length to con-
nect to the measuring gage and the fuel pressure source. Provide a
suitable reservoir to catch fuel spray.
CAUTION: FLEXIBLE HOSES AND CONNECTORS WITHIN THE TEST SETUP MUST BE
CAPABLE OF WITHSTANDING FUEL PRESSURES OF MORE THAN 600 PSIG.
(c) With the line pressure set and maintained at 135 psig by means of
the test throt~ling mechanism, adjust the
stand nozzle flow rate to
the applicable limits by rotating the adjusting screw (9, figure
202) clockwise to reduce the flow and counterclockwise to increase
the flow.
73-18-0
Page 204 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU RE OJ ET
SEI-186
MAINTENANCE MANUAZ~
3
6
1
\r
21\15
17
8
819 II
i. Protective Plug Cap 12. Valve and Valve Guide Assembly
2. Protective Cap 13. Valve Retaining Pin
3. Cap 14. netering Valve
f
4. Cap Gasket 15. Valve Gage
5. Spring 16. Valve Cage Seal
6. Valve Cage Assembly 17. Filter
7. Lockscrew Retainer 18. Spray Tip Nut Assembly
8. Lockscrew 19. Inner Spray Tip Assembly
9. Adjusting Screw 20. Spacer
10. Valve Spring 21. Body Subassembly
11. Valve Spring Shaft
Hatched parts. Hust be replaced as a set.
000CJ6-8908M)
Fuel Nozzle Assembly Exploded View
Figure 202
73-18-0
Dec 31/95 Page 205
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
(d) Secure the adjusting screw in position by tightening the lockscrew
(8) against adjusting screw (9) to a torque value of 10-15
the
Ib-in. This is accomplished by using the 5/32-inch Alien wrench
portion of adjusting wrench 5232270-F1 (1, figure 201) while main-
taining the position of the adjusting screw with the 1/16-inch
Alien wrench portion of the adjusting wrench.
CAUTION: SINCE AT THIS POINT, FUEL FLOW WILL OCCUR THROUGH THE
METERING VALVE, IT WILL BE MORE CONVENIENT TO INSERT THE
ADJUSTING WRENCH IN POSITION PRIOR TO SETTING THE LINE
PRESSURE AND MAINTAIN THE WRENCH IN POSITION UNTIL ADJUST-
MENT HAS BEEN COMPLETED.
REMOVAL OF THE WRENCH WHILE THE LINE PRESSURE IS APPLIED
WILL ALLOW EXCESSIVE FUEL TO FLOW THROUGH THE 1/16-TNCH
ALLEN WRENCH SOCKET OF THE ADJUSTING SCREW (9, FIGURE 202)
THIS WILL CAUSE AN INCORRECT READING.
BE CAREFUL WHEN INSTALLING THE WRENCH INTO OPERATING
POSITION. IF THE WRENCH IS INSERTED TOO FAR INTO THE
ADJUSTING SCREW (9), IT MAY CAUSE THE END OF THE 1/16-INCH
ALLEN WRENCH TO STRIKE THE VALVE SPRING SHAFT (11) AND
INTERFERE WITH NORMAL MOVEMENT OF THE VALVE.
(e) Install cap (3) and used cap gasket (4). Tighten cap to a torque
value of 120-140 Ib-in. with a 17/32-inch socket wrench and a
torque wrench.
(f) Reset line pressure at 135 psig and recheck flow rate. If the flow
does not fall within the specified limits, readjust as necessary.
as instructed in steps (c) and (d).
(g) Decrease line to zero psig,
pressure then increase to 100 psig,
then to 135 and
finally to 400 psig.
psig, Read the flow rate and
spray angle at each point. Flow rate and spray angle must fall
within the limits specified in table 2. Measure spray angle as
shown in figure 203.
(h) Reduce line to 135 psig,
pressure taking care not to reduce pres-
sure below psig during operation, and read flow rate.
135 Flow
must be within 4 Ib/hr of reading previously obtained at 135 psig
and must be within flow limits.
(i) Starting at zero psig, slowly increase line pressure to 400 psig,
while viewing the spray under a strong light and slowly rotating
the nozzle tip. There shall be no high contrast streaks. Minor,
random streaking is allowable but streaks must flare into a uniform
spray (see figure 204, sheets 1 and 2). The spray should not pul-
sate or abruptly change spray angle during transient operation.
Spray cone skewness shall be within 2 degrees of the nozzle axis.
73-18-0
Page 206 Dec 31/95
GENERAL ~ELECTRIC------
CJ610 TURBOJET
SEI-186
MANUAL
1/2 ~NCH
PORTION OF
SPRAY
E VA LUA TE13
PROTRACTOR BL~ADES
(PARA~LEL TO STIIAICHT
PORTIONS OF SPRAY
FUEL
WITHTN 1/2 INCW I!
OF ORIFICE NOZZLE
J bo i~n
:ss~x
5f"5
Sr
’:’f;"’
ii´•´•´•
~ANULC
k :L´•.´•´•´• ~:X
if
´•tijP:i´•i iji
´•5x: :;´•:´•:´•I´•
i:.: .´•x
´•:´•:;:0:´•:.:.::’´• ´•.’´•:´•X´•:´•:´•
r´•;,
i
i: ´•´•.´•´•: :i.1
~:::i:ir
:´•.,´•,..;.I
i~1
::lt,:
1~’0
~fi:
i
:jj:.ji::::i.i
-:;:;s~ ::::~1:I:::
i :,,,i
´•c"
IinI i: : :i´I•‘.´•´:´••::´•:´:•:´t•t5i: :I;´•´•‘´•i.
:::::::::i
rmii´•1´•:´•:.
34577A
BB-02J7-1
Spray Angle Measurement
Figure 203
73-18-0
Dec 31/95 Page 207
GENERAL ELECTRIC--------
CJ 61 6 TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
4-
135 PSIt FLOW CHECK
SPRAY PUALITY DEVIATIONS
AS SHOWN ARE ACtEPTAB LE
4.L7
400 PS1G FLOW CHECK 400 PSIG FLOW CHECK
SPRAY QWALITY OEVIATIDNS SPRAY PUALITY DEVIATIONS
AS SHOWN ARE ACCEPTABLE AS SHOWN ARE ACCEPTABLE
345774
88-0243-2
Fuel Nozzle Spray Cone Limits (Sheet 1 of 2)
Figure 204
73-18-0
Page 208 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
I
MAfNT~%E MANUAL
i::
I i~
;.´•.´•::´•n
::4;
SPRAY HInllG SHROUD
SPRAY ANGLE IOT AUWED
SPRAY ANGLE ACCEPTABLE
NON-UNIFORN SPRAY (HAIRLIILE STRUKS)
AC~EPILgLE
SPRAY ANGLE AND UNIFORn nou
ACCEPTABLE
i’=X I
a-:
:j 3:
NON-UNIFORn SPRAY (HEIIVY STREAKS) n~N-vrIFan SPRAY (voID]
NOT ALLOVED I NOT ALLOVED
8-)669-1
Fuel Nozzle Spray Cone Limits (Sheet 2 of 2)
Figure 204
73-18-0
Dec 31/95 Page 209
GENERAL 4~ ELECTRIC--~--
CJ61 O TU RBOJ ET
SEI-’L86
MAINTENANCE MANUAL
(j) Increase line pressure to 600 psig and check for leakage at split
line between spray tip nut assembly (18, figure 202) and body sub-
assembly (21), and at cap gasket (4) seal.
C. Remove fuel nozzle pipe adapter (2, figure 201)
from stand and install pro-
tective cap (2, figure 202) on spray tip nut assembly (18) and protective cap
(1) on threaded inlet fitting of body subassembly (21).
D. Weld the spray tip nut assembly (18) to the body subassembly (21) as follows:
NOTE: Only Class A welders qualified per Specification MIL-T-SO?1C are autho-
rized to accomplish thisprocedure.
(1) Mark the body subassembly (21) as shown in figure 205. Do not mark on
machined surface. Marking of the body subassembly aids in location of
spray tip nut weld.
(2) Locally clean the area where spray tip nut assembly (18) is to be welded
to body subassembly.
NOTE: This is a fusion type weld. Do not use filler material.
(3) Using a gas shielded tungsten are adjusted to approximately 60 amps DC
straight polarity, weld one tab of the spray tip nut to the body subas-
sembly. (See figure 205 for optimum and alternate weld locations.)
(4) Test the integrity of the weld by inspecting the weld joint using a 10X
glass. The joint must be free of cracks and must appear fused (melted
and flowed together) and the length of perimeter of the joint must not
be less than 0.40 inch.
73-18-0
Page 210 Dec 31/95
GENERAL &5~ ELECTRIC------
CJ 61 6 TU R B OJ ET
SEI-186
MAINTENANCE MANUAL
DO NOf WELD WITHIN 1S´• OF CEN~ER-
LINE OF FLOW PASSAGES.
WELD ONE CORNER ONLY
IS´•
A. O’T’MUM LOC*TIONS FOR
WELD (USE ONE CORNER)
SEC TION A-A
ALTERNA TE LOCATIONS
FOR WELD (FUTURE USE)
rV\RKING LOCATION
(USE VIBRO PEEN OR EOUIVALEKI)
MACHINED SURFACE
CENTERLINE THRWGH
FLOW PASSAGES
000W&8909M)
Spray Tip Nut Weld Locations
Figure 205
73-18-0
Dec 31/95 Page 211
GENERAL ELECTRIC~----
CJG1OTURBOJET
SEI-186
MAINTENANCE MANUAL
FUEL MAN IFOLDS MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS WHEN WO RK
ING WITH THIS ENGINE THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
B E F O RE AN Y MA I NT E NAN C E ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUST RATED PARTS BREAKDOWN/CATALOG INDEX TO DETE RMINE IF TH E
HARD WARE TO BE WORKED ON OR USED CONTAINS ASBESTOS
WHEN EVER ME CHANI CAL REMO VAL OF MATER IAL S U CH AS MACH I N I NG
GRINDING, BUFFING DRILLING, SANDING OR ANY TYPE OF MATERIAL
BU I LD UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, AP P RO
PRIATE PERSO NAL PROTECTIVE E4UIPMENT MUST BE WO RN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CO NTAINING MATERIAL MUST BE COMPLIED WITH.
BEFO RE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CO NTAIN-
ING HARDWARE APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHE RED TO
FOR HANDLING ASBESTOS CONTAINING HA RD WA RE
1 Gene r al Ma in t en an c e o f th e fue 1 mani f o 1 d s c on s i a t in g o f Remo val In a t al lat i o n
and Inspection/Check, is covered in the following paragraphs.
2 Remo val In s t allat i o n Se e 73 OO figur e s 2 and 3
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS AS BE S TO S
WH I CH IS II I GHLY TOXI C TO S KIN EYE S AND RE S P IRATORY TRACT READ GEN
ERAL I NFO RMAT I ON BEFORE PROC EED ING. AND ADHERE TO ALL SITE SAFETY AND
ENV I RONMENTAL C ONTROL S CONCERNING ASBESTOS OTHERWI SE PERS ONAL INJURY
MAY RE S ULT
A. Removal.
(1) Remove the engine mount (22) from the mainframe flanges.
2 D i a c onn e c t the fu el man i f ol d f it t in g s 24 fr om the fu el no z z 1es 23
3 D i s c o nn e c t th e fuel manif ol d 21 f r om the T fi t t in g 25 f i gur e 2 or
f r om the P p r e a s ur i z in g) an d D d r a in valve 27 f i gu r e 3 as ap pli
cable.
4) Remo ve th e manifold and manif old clamp s
73-19-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
I. TUBING
2. FITTINGS
q 3. BW\ZED JOINTS
4. SADDLE
oalwo69oD2
Fuel Manifolds
Figure 201
WARNT_NG: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
CAUTION: IMPROPER LOCK-WIRING OF THE MANIFOLD AND T-FITTING CAN RESULT IN
OIL TANK DAMAGE. REFER TO SECTION 72-01-2 FOR PROPER LOCK-WIRING
PROCEDURES.
(1) Connect the fuel manifold fittings (24) to the fuel nozzles (23).
Torque to 140-160 Ib-in. and lockwire.
(2) Connect the manifold (21~ to the T-fitting (25, figure 2) or to the P
and D valve (27, figure 3), as applicable. Torque to 270-300 Ib-in.
(3) Secure the manifold clamps to the brackets. Torque the clamp bolts to
20-25 Ib-in.
(4) Secure the main engine mount (22) to the mainframe flanges. Torque the
bolts to 44-48 Ib-in. and lockwire.
73-19-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
3 Inso ect ion! Che ck When s ervic eable 1 imit s are exe ee d ed the manifold may be
repair ed in ac cord ane e with the Ove rhaul Manual Vi sually insp ect the following
areas. (See figure 201)
In s p e c t i on i C h e c k Maximum Se rv i c eab le L imi t s Rema r k s
A. Tub e s fo r
(1) Crac ks. Not service able. Replace fue 1 mani-
fold.
(2) Nicks or Not se rvice able if there Blend. Do not de-
scr at che s is mea s ur eable depth c r ea s e t ub e d iam
eter more than
0. 005 inch. Blend
al on g axi s o f tub e
3 Dent s Twe lye la r g e t uh e d ent s
0.020 inch in depth, One
small tub e dent 0 010 in ch
in depth. No sharp edges.
(4) Disto rtion. Any amount, if fittings line
up with noz tie the t ub e s
are not collapsed, and there
is no inter fer ence with other
pa rts of the engine.
5 Chaf ing Any amo un t O O 0 3 inch b el ow
adjac ent non-defective sur-
face.
B. The fittings for:
1 Bur r s Not s e rv i c e ah 1 e Remove by wo rk ing
threads with lapping
c omp ound F lush
with cleaning sol-
vent.
(2) Stripped thre ads. Not service able.
C Bra z e d j o int s fo r Not se rvi c e able
cracks.
D. Co ntact or inter- 0. 060 inch minimum clear-
ference between ance with adjacent parts.
tubing ass emb ly
and adjacent parts.
CAUTION: BE SURE THAT ALL FO RE I GN MATERIAL IS REMOVED FROM MAN IFOLD.
73-19-0
Dec 31195 Rage 203
G E W ERAL D LE eT R IC
CJGIO TURBOJET
SEI-186 MAINTENANCE MANUAL
FUEL CONTROL MAINTENANCE PRACTICES
i. General. Maintenance of the fuel control consists of Removal/Installation
Adjustment/Test and cleaning of the control filter.
2. Remaval/Installation.
A. Removal. Remove the fuel control per 73-13-0.
B. Installation. Install the fuel control per 73-13-0.
3. Adj ustment/Test
Three field adjustments are allowed on the fuel control:
Idle Speed Adjustment.
Maximum Speed Adjustment.
Fuel Density Adjustment.
These adjustments can be made from outside the fuel control with the control
installed on the engine.
A. Idle Speed Adjustment. (See figure 201.)
WARNING: DO NOT ADJUST IDLE SPEED WHEN THE ENGINE IS OPERATING ABOVE
IDLE.
(1) The adjusting screw at the bottom right-hand side of the
is located
fuel control. To speed turn the IDLE adjusting screw
increase
clockwise; to decrease speed turn it counterclockwise. One click of
the adjusting screw will change engine speed approximately 55 rpm.
NOTE: Adjustment clicks are sensed
by touch and can easily be de-
tected after limited experience.
NOTE: To eliminate the effect backlash, preload the internal
of
linkage of the fuel control by completing all adjustments of
idle speed in a counterclockwise direction with 5 clicks.
For example: (1) To increase engine speed 1 click, turn the
adjusting screw 6 clicks clockwise, then 5 clicks counter-
clockwise. (2) To decrease engine speed 1 click, turn the
adjusting screw 4 clicks clockwise, then 5 clicks counter-
clockwise.
Mar. 30/67 73-21-0
Page 201
GEW ERAL ELECTRIC
CJ610 TORBOJET
MAINTENANCE MANUAL SEI-186
I, I!
o n
FUEL DENSITY
ADJUSTMENT
10
MAX. AND IDLE
SPEED ADJUSTMENT
CJ610-6071-0-D2
Fuel Control Adjustments
Figure 201
(2) Adjust idle speed after the engine has operated at maximum speed for
at least 3 minutes. Set speed per 72-00, Adjustment/Test. Recheck
maximum speed whenever idle speed has been adjusted.
B. Maximum Speed Adjustment. (See figure 201.)
WARNING: DO NOT ADJUST MAXIMUM SPEED WITH THE ENGINE OPERATING ABOVE
IDLE. REDUCE ENGINE SPEED TO IDLE OR SHUT THE ENGINE DOWN,
MAKE THE ADJUSTMENT, THEN RUN THE ENGINE UP TO CHECK THE AD-
JUSTMENT.
(1) The adjusting screw is located at the bottom right-hand side of the
fuel control. To increase speed, turn the MAX adjusting screw
clockwise; to decrease speed turn it counterclockwise. One click of
the adjusting screw will change engine speed approximately 30 rpm.
NOTE: Adjustment clicks are sensed by touch and can easily be de-
tected after limited experience.
73-21-0 April 15/68
Page 202
GENERAL ELECTRIC--------
CJ610 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
NOTE: To eliminate the effect of backlash, preload the internal
linkage of the fuel control by completing all adjustments of
maximum speed in a counterclockwise direction with 5 clicks,
For example: (1) To increase engine speed 1 click, turn the
adjusting screw 6 clicks clockwise, then 5 clicks counter-
clockwise. (2) To decrease engine speed 1 click, turn the
adjusting screw 4 clicks clockwise, then 5 clicks counter-
clockwise.
(2) Adjustment of maximum speed affects idle speed. Recheck idle speed
after every maximum speed adjustment.
C. Fuel Density Adjustment. (See figures 201 and 201A.)
CAUTION: THE ADJUSTMENT KNOB MUST BE SEATED IN ITS POSITIONING DETENT FOR
SATISFACTORY OPERATION.
(1) A fuel density adjustment on the front of the fuel control allows the
fuel control to compensate fuels
varying densities.
for of
It meters
more or less fuel to the combustion area depending on the density of the
fuel. The engine will operate satisfactorily with a mixture of approved
fuels provided that the density adjustment on the fuel control is set to
correspond to the fuel that is the larger part of the mixture. To make
an adjustment, push the knob in, rotate it to the desired setting, and
release pressure. If necessary, jiggle the knob until it locks.
CAUTION: ENGINE OPERATING TIME USING AVIATION GASOLINE IS LIMITED TO 25
HOURS DURING ANY ONE OVERHAUL PERIOD. OPERATING TIME WITH AVIATION
GASOLINE MUST BE RECORDED WHEN THE MIXTURE CONTAINS MORE THAN 50%
OF AVIATION GASOLINE BY VOLUME.
(2) The fuel control density knob (see figure 201A) is to be set according
to the following table depending upon the type of fuel control used and
the mixture of aviation gasoline and JP-4, JP-5, or Jp-8 fuel.
Percent by Volume Density Knob Setting
of Density Setting Equivalents
Aviation Gasoline Ifieure 201A. Tepe A) (fiaure 201A. T~oe B)
I Below 20% JP-4, jp-5, or JP-8 -2 or -3
20-35% .75 -1
35-50% .72 11.
Above 50% .69 +1
NOTE: Density knob adjustment must be restricted to plus or minus 1 click from
setting specified for type of fuel being used.
73-21-0
Dec ~li95 Page 202A/202B
GENERAL ELECTRIC--------
CJ610 TURBOJET
SEI-186
MALNTENANCE MANUAI,
O
o~c> A)
O
INDEX
PIN
P I o po
co I~e;B 3 o
"9
ao:
~C
d
9 o;B~O
Bs, 9-
dr
INDEXb~N"EXr
TYPE A NPE 8
-3 -2 -1 a +1
-5 -4
T/PEB I -I 1 I I I
JP-5
1AYGASI
AV GAS
(Icr
JFF A. A-i, OR
A, A-i, JP-8
OR IP-B
IJP4 OR JFlB(
JP-4 OR IET B
MPEA I -I I I I
0.813 0.78 0.75 0.72 0.69
0.86
JP-5 6 iP-4
FUEL DENSIN ADJUSTMENT
BC-80841
Fuel Density Adjustment
Figure 201A
73-21-0
31/95 Page 203
Dec
fLESTIIE
C3610 TURBOJET
MAINTENANCE MANUAL SEI-186
4. Cleaning of Fuel Control Filter. (See figure 202.)
A. Removal.
(1) Remove the plug (4), O-ring (3), spring (2) and filter (1) from the
front of the fuel control housing.
NOTE: Do not remove the second filter located behind the retaining
ring.
B. Cleaning.
(1) Ultrasonic Procedure. (Refer to Accessory Overhaul Manual, SEI-154,
for ultrasonic cleaning procedure.) This is the recommended method
for cleaning the filter.
(2) AUternate Procedure. When ultrasonic cleaning equipment is not
available, the filter should be cleaned as follows:
WARNING: CLEANING OPERATION SHALL BE PERFORMED IN AN APPROVED
CLEANING CABINET OR WELL VENTILATED AREA. PRECAUTIONS
SHALL BE EXERCISED TO PREVENT INHALATION OF VAPOR EMITTED
BY VOLATILE CLEANING MATERIALS, AND TO MINIMIZE DANGER OF
EXPLOSION AND FIRE HAZARDS.
(a) Clean the filter element by immersing it in carbon tetrachloride,
trichloroethylene, kerosene or equivalent. While continually
agitating the filter, use a suitably contoured soft bristle
brush to dislodge contaminants.
NOTE: Only clean, filtered solvents should be used. Assure
that containers used during the cleaning procedure are
clean and free from contaminants.
(b) Blow it out with filtered compressed air and be sure no dirt
particles have collected in the filter.
(c) Visually inspect the filter using a magnifying glass (10X mini-
mum) and a strong light. If the filter is not completely clean,
repeat steps (a) and (b).
C. Installation.
(1) Install a new O-ring (3) on the plug (4).
(2) Install the filter (1), spring (2) and plug (4) in the fuel control
housing. Torque the plug to 60-80 Ib-in. and lockwire.
I 73-21-0
Page 204
Sep 1/75
CEWLRAL~ELE CTIIC
CJGIO TURBOJET
SEI-186 MAINTENANCE MANUAL
’8
i~:´•.....
I:
-:B
i
c.---
:I i
i. I
CJ610´•6083´•0´•E2
Fuel Control Filter
Figure 202
I Sep 1/75 73-21-0
Page 205
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
OVERSPEED GOVERNOR MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRTATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. Maintenance of the overspeed governor consists of Removal/Installation
and Inspection/Check.
Removal/Installation. (See 73-00, figures 2 and 3).
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Remove the hose (36) that connects the overspeed governor (31) to the
fuel pump adapter.
(2) Remove the tube (35) that connects the overspeed governor to the fuel
flowmeter (9).
(3) Disconnect, at the overspeed governor, the hose (11) that leads to the
fitting at the rear of the fuel control.
(4) Remove the 2 tubes (32, 33) that connect the high-pressure filter to the
fuel pump and to the overspeed governor.
73-22-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
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SEI-186
MAINTENANCE MANUAL
(5) Disconnect the drain line (if attached).
(6) Remove the high-pressure filter (34) per 73-14-0. Remove the clamp from
the bracket on the overspeed governor. (Clamp is attached to overspeed
governor to fuel control tube on C3610-4, -6, -8 and -8A engines.)
(7) Remove the 6 nuts (39) and washers that attach the overspeed governor
(31) to the front middle pad of the accessory gearbox and carefully
remove the governor and gasket.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Lubricate the spline of the overspeed governor shaft with Plastilube
Moly No. 3 (Thiem Automotive Div., 5151 Denison Ave., Cleveland, OH,
44102) or equivalent. Secure the overspeed governor (31) and a new
gasket to the front middle pad of the accessory gearbox with 6 nuts (39)
and washers. Torque the nuts to 25-35 Ib-in.
NOTE: Viewed facing the gearbox, the drain fitting should be in approxi-
mately the 5 o’clock position.
(2) Secure the high-pressure filter (34) and clamp to the bracket on the
overspeed governor (31). (The largest OD of the filter housing should
be forward of the clamp.)
(3) Connect the high-pressure filter to the overspeed governor and to the
fuel pump with 2 tubes (32, 33).
(4) Connect to the overspeed governor (31) the large hose (11) that is at-
tached to the rear of the fuel control. Tighten to standard torque.
CAUTION: BE SURE THERE IS CLEARANCE BETWEEN THE TUBE (35) AND ANY OTHER
LINES, HOSES, OR ENGINE PARTS.
(5) Install the tube (35) that connects the overspeed governor to the fuel
flowmeter. Tighten to standard torque.
73-22-0
Page 202 Dec 31/95
GENERAL ELECTRIC---
CJ610 TU RBOJ ET
SEI-186
~ALNTENANCE MANUAL
(6) Install the hose (36) that connects the overspeed governor to the fuel
pump inlet adapter. Tighten to standard torque.
NOTE: Position the overspeed governor lever arm up for normal operation;
position it down for test.
3. Inspection/Check.
A. Visually inspect the overspeed governor for evidence of external leakage and
replace governor if evidence of leakage exists.
B. Check the overspeed governor for excessive internal leakage, if suspected, as
follows:
(1) Disconnect the OSG bypass line at the fuel inlet manifold and run the
line into a bucket or other container. Cap the fuel inlet manifold
connection.
CAUTION: MAKE SURE THE IGNITION SWITCH IS OFF DURING MOTORING.
(2) Engage the starter and bring engine speed up to the maximum speed
starter is capable of producing. Advance the throttle to IDLE (without
ignition) and measure the quantity of fuel discharged from the overspeed
governor bypass line in 30 seconds. (Do not exceed maximum starter
operating time per duty cycle.)
(3) The maximum allowable bypass flow is 80 pph or about 370 cc (or 0.8 pts)
per 30 seconds. If the bypass flow is more than 370 cc per 30 seconds,
replace the overspeed governor.
(4) STOPCOCK the throttle disengage starter motor.
and After compressor
rotor has stopped rotating, allow starter to cool for 3 minutes. Then
motor the engine for 30 seconds to clean the engine of fuel.
(5) Reconnect the overspeed governor bypass line to the fuel inlet manifold.
73-22-0
I Dec 31/95 Page 203
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
CDP LINE TO FUEL CONTROL MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWNJCATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. On CJ610-1, -5 and -9 engines, the flanged end of the CDP (P3) line is
secured to the mainframe at the 8 o’clock position. On CJ610-4, -6 and -8 en-
gines, the flanged end of the line is secured to the compressor rear frame at
the 4 o’clock position. Maintenance of the CDP line consists of Removal/Instal-
lation and Inspection/Check.
2. Removal/Installation. (See 73-00, figures 2, 3.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Remove the 2 bolts that secure the flanged end of the tube (29) to the
mainrrme.
(2) Disconnect the tube at the fuel control.
(3) On FJ610-1, -5 and -9 engines, remove the clamp (30, 73-00, figure 2)
that secures tube to the synchronizing cable conduit on the left side of
the engine and remove the CDP tube.
73-23-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) As.semble the CDP tube (29) to the aft fitting on the fuel contol.
(2) Lubricate the 2 tube flange bolts with Fel-Pro C-5 (Felt Products Mfg.
Co., 7450 N. McCormick, Skokie, Illinois) or equivalent. Use a new
gasket and secure the flanged end of the tube to the mainframe with the
bolts. Torque to 24-27 Ib-in. and lockwire.
(3) Torque the tube coupling nut at the fuel control to 90-100 Ib-in.
(4) On the CJ610-1, -5 and -9 engines, install the clamp (30). Torque the
clamp nut to 24-27 Ib-in.
3. Inspection/Check. Inspect the CDP line per 72-02-1.
73-23-0
Page 202 Dec 31/95
GENERAL ELECTRIC~--
CJ 61 O T U R B OJ ET
SEI-186
MAINTENAN%E MANUAL
CDP L I NE TO AS P I RAT OR MA I NT ENAN C E PRACT I CE S
WA RN ING: ASBESTOS
THIS ENGINE MAY CON TAIN SMALL AMOUNTS OF ASBESTOS WHEN WORK-
ING WITH THIS ENGINE, THE FOLL OWING PREC AUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFO RE ANY MA INTENANCE ACTIVITIES ARE UNDERT AKEN, REVIEW THE
ILLUST RATED PARTS BREA KDOWN/C ATALOG INDEX TO DETE RMINE IF TKE
HARD WARE TO BE WORKED ON OR USED CONTAINS ASBESTOS
WHENE VER MEC MANIC AL REMO VAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN AND NA-
TION AL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BE FO RE HANDL ING RE PLAC ING OR D I S P O S I NG OF AS BE S TO S C ONTAI N
ING HARDWARE APPROPRIATE PERSO NAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARD WARE.
1 Ge n er al Ma int enan c e o f the CDP line to T2 a s p irato r is 1 imit e d to Removal
Installation. This info rmation is given in the following paragr aphs.
WARNING AS BE S TO S
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS AS BE S T O S
WH I CH IS HI GHLY TOXI C TO SKIN EYE S AND RE S P I RATORY TRACT READ GEN-
ERAL I NF ORMAT I ON BEFORE PRO CEED ING AND ADHERE TO ALL S I TE SAFETY AND
ENV I RONMENTAL CONTROL S C ON CE RN I NG A S BE S TO S O THE RWI S E PERS ONAL INJURY
MAY RE S ULT
2. Removal/Installation.
A. Removal.
1 Remove th e CJ 6 1 O 1 5 and 9 T2 as p irato r a ir t ub e as follows Se e
73-00, figure 2)
NOTE: For removal of the CJ610-4, -6, -8, and -8A aspir ator line, see
st ep A. (2)
(a) Remove the 2 b olt s 19 that s e cu r e the as p i r at o r tub e flange to
the mainfr ame at the 4 o’ do ck position. Discard the gas ket.
(b) Loosen the tube coupling nut at the sensor eductor on the front of
the fuel control.
(c) Remove the clamp (12) that secures the tube to the flowmeter oil
co ol e r fuel 1 ine and r emo v e th e a ir t uh e 13
73-24-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
(2) Remove the CJ610-4, -6, -8, and -8A T2 aspirator air tube as follows:
(See 73-00, figure 3).
(a) Loosen the tube coupling nuts at the connector pad (19) on the
mainframe and at the sensor eductor (25) on the fuel control and
remove the tube (13).
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Install the CJ610-1, -5 and -9 T2 aspirator air tube as follows: (See
73-00, figure 2).
NOTE: For installation of the CJ610-4, -6, -8, and -8A aspirator air
tube, see step B.(2).
(a) Assemble the air tube (13) to the fitting on the sensor eductor.
(b) Lubricate the 2 tube flange bolts
(19) with Ease-Off 990 (Texacone
Co., Box 4236, Dallas, Texas). Use a new gasket and secure the
flanged end of the tube (13) to the mainframe with the bolts.
Torque to 24-27 Ib-in. and lockwire.
NOTE: To eliminate unnecessary stresses in the P3 line, make sure
that the bolt holes in the P3 line flange are properly
aligned with the holes in the mainframe. If the holes are
not aligned, determine the cause of
misalignment and, if
necessary re-form the line for proper alignment before in-
stalling the bolts.
(c) Torque the connecting nut at the eductor to 75-125 Ib-in.
(d) Install the clamp (12) and torque the clamp bolt to 24-27 Ib-in.
(2) Install the CJ610-4, -7 and -8 aspirator air tube as follows: (See 73-
0O, figure 3.)
(a) Install and connect the aspirator tube (13) to the connector pad on
the mainframe. Connect the other end (25) to the sensor eductor.
(b) Torque both fittings to 180-200 Ib-in.
3. Inspection/Check. Inspect the CDP to aspirator line per 72-02-1.
73-24-0
Page 202 Dec 31/95
GENERAL ELECTRIC--------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
VARIABLE GEOMETRY ACTUATOR LINES MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONA~ ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. Maintenance of the actuator lines consists of Removal/Installation.
Whenperforming maintenance on the actuator lines use the following procedures.
2. Removal/Installation.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Remove the CJ610-1, -5 and -9 V.G. actuator lines as follows: (See 73-
00, figure 2.)
NOTE: For removal of the CJ610-4, -6 and -8 V.G. actuator lines, see
step A.(2).
(a) Disconnect the
attaching hose clamps (6) at the 3, 9, 11 and 12
o’clock positions.
73-25-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ61 OtU RBOJET
SEI-186
MAINTENANCE MANUAL
(b) Loosen the coupling nuts (7, 8) at the control and the coupling
nuts (2, 3, 37) at the actuators and remove the actuator lines (4).
NOTE: On actuator systems equipped with drain lines, remove the
drain lines.
(2) Remove the CJ610-4, -6 and -8 V,G. actuator lines as follows: (See 73-
OO, figure 3.)
(a) Disconnect the attaching hose clamps (6) at the 3 and 6 o’clock
positions.
(b) Loosen the hosecoupling nuts connected to the tee fittings (10,
17) and the coupling nuts (2) at the actuators and remove the ac-
tuator lines (4).
(c) Loosen the coupling nuts on the fuel tubes (28) at the fuel control
and remove the tubes and tee fittings (10, 17).
NOTE: On actuator systems equipped with drain lines, remove the
drain lines.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Installation.
(1) Install the CJ610-1, -5 and -9 V.G. actuator lines as follows: (See 73-
0O, figure 2.)
NOTE: For installation of the CJ61O-4, -6 and -8 V.G. actuator lines,
see step B(2).
(a) Install the fuel hose between the forward port (3) on the actuator
and the fitting (7) on the fuel control. Torque the coupling nuts
to 70-100 Ib-in.
(b) Install the fuel hose between the aft port (37) on the actuator and
the fitting (7) on the fuel control. Torque the coupling nuts to
70-100 Ib-in.
(c) Install the fuel hose between the 2 forward ports of the actuators.
Torque the coupling nuts to 70-100 Ib-in.
73-25-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
(d) Install the fuel hose between the 2 aft ports of the actuators.
Torque the coupling nuts to 10-130 Ib-in.
NOTE: On actuator systems equipped with drain lines, install the
drain lines and tighten the coupling nuts to standard torque,
(e) Connect the hose clamps (6) at the 3, 9, 11 and 12 o’clock posi-
tions. Torque the clamp bolts to24-27 Ib-in.
(2) Install the CJ610-4, -6 and -8 V.G. actuator lines as follows: (See 73-
00, figure 3.)
(a) Connect the 2 fuel tubes (28) to the fuel control.
(b) Connect the 2 tee fittings (10, 17) to the fuel tubes.
(c) Install the 2 fuel lines (4) between the tee fittings and the ac-
tuator at the 2 o’clock position.
(d) Install the 2 fuel lines between the tee fittings and the acutator
at the 8 o’clock position.
NOTE: On actuator systems equipped with drain lines, install the
drain lines and tighten the coupling nuts to standard torque.
(e) Torque the tube coupling nut at the fuel control forward port (30)
to 135-150 Ib-in. Torque the 3 coupling nuts at the tee fitting
(10) to 160-165 Ib-in.
(f) Torque the tube coupling nut at the fuel control aft port (8) to
180-250 Ib-in. Torque the 3 coupling nuts at the tee fitting (17)
to 210-220 Ib-in.
(g) Torque the hose coupling nuts (2) at the actuators to 135-150 Ib-
in.
(h) Connect the hose clamps (6) at the 3 and 6 o’clock positions.
Torque the clamp bolts to 24-27 Ib-in.
3. Inspection/Check. Inspect the actuator lines per 72-02-1.
73-25-0
(Dec 31/95 Page 203
C H A PT E R
AIR
GEN LRAL~ ILIeTIIIC
CJ610 TURBOJET
SEI-186 MA I NTENANCE MAMJAL
CHAPTER 75 AIR SYSTEM
TABLE OF CONTENTS
Pa ge
75-00 AIR SYSTEM
De scri pt ion and Ope ra t i on 1
Trouble shooting 101
Ma int enance Prac t i ce s 201
Adj u s tmen t o f Va ri abl e Geomet ry Sy s t em 2 02
Bleed Valve Adjustment 203
Vari abl e Vane Ze ro Po s i t i on Se t ti ng 2 06
Variable Vane Adjustment 206
Fuel Cent rol Feedback Ca bl e Adj us tment 2 07
Synchronizing Cable Adjustment 207
75-10 ANT I-ICING
75-11-0 Anti-Icing Valve
Ma intenance Pra c t i c e s 2 01
75-12-0 Anti-Icing Air Tube
Ma in t enanc e Pract i ce s 201
75-20 COOL I NG AIR
75 2 1- 0 E i ght h- St a ge Lea ka ge Air Tube s
Maintenance Practices 201
75 30 COhl PRE S SOR CONTROL
75 31-0 Vari a bl e Geomet ry Actuators
Maint enance Practices 201
75-32-0 Air Bleed Valve
Ma i nt enane e Prac t i c e s 201
75-33-0 Feedback Cable
Maint enance Practices 201
Ma r 30/84 75
Pa ge 1
GENERAL ELECTRIC------
CJ61 OTURBOJET
SEI-186
MAINTENANCE MANUAL
CHAPTER 75 AIR
LISTOF EFFECTIVE_PACES
CKAPTER/
SECTION PAGE DATE
75 *I Dec 31/95
Contents 1 Mar 30/84
75-00 i Mar 30/84
2 thru 5 Mar 30/67
101 Nov 15/67
201 Mar 30/67
202 thru 204 Dec 30/78
*205 Dec 31/95
206 thru 209 Dec 30/78
75-11-0 201 thru 203 Mar 30/67
75-12-0 201 Dec 31/91
202 Mar 30/67
75-21-0 *201 tbru 202 Dec 31/95
*202A thru 202B Dec 31/95
*203 thru 206 Dec 31/95
75-31-0 201 thru 205 Mar 30/67
75-32-0 *201 thru 202 Dec 31/95
*202A thru 202B Dec 31/95
*202C/202D Dec 31/95
203 Nov 15/72
204 thru 205 Jun 1/71
75-33-0 201 thru 202 Mar 30/67
203 May 15/70
*Asterisk indicates pages added, changed, or deleted by this revision.
75
Dec 31/95 I
G NERAL E LE CTR IC
CJ610 TURBOJET
SEI-186 XWINTENANCE ~ANUAL
AIR SYSTEM DESCRIPTION AND OPERATION
i. General. The engine air systems consist of a primary and bleed air systems.
2. Air System Components.
A. Anti-icing Valve.
The electrically energized anti-icing air valve controls the ON-OFF flow
of anti-icing air to the front frame. A fail-safe feature in the valve
assures air flow in the event of electrical power failure. The valve is
lorate~ at the 10 o’clock position on the front frame.
B. Compressor Bleed Valves.
The amount of
being bled from the third, fourth and fifth stages of
air
the compressor controlled by two bleed valves which are mounted at
is
three and nine o’clock on the compressor ca~ing. Each valve has six
openings or two for each stage. Each valve is
operated by a single
pushrod which moves two camplates in opposite directions inside the
valve. camplate moves three gates which slide across
Each valve
ports, opening or closing the bleed valve. The pushrod travels forward
or aft in a direction parallel to the engine centerline. A rod end
which threads onto each pushrod is connected by means of a clevis pin to
a third arm on the bellcrank link.
C. Variable Vane Actuators.
The two actuators are operated by high pressure fuel, which is scheduled
by the variable geometry servo in the main fuel control, and is intro-
duced to either side of a piston inside the actuator, causing a shaft,
nhich is attached to the
piston, to either extend or retract. This
shaft is connected, through linkage, to one arm on a master bellcrank
link. There are two bellcrank links, one mounted and pivoting about a
clevis pin on each actuator bracket. Each link has five arms, one of
which is attached to the actuator piston shaft as described above.
Another arm on each bellcrank is connected to the inlet guide vane ac-
tuator ring at three and nine o’clock.
3. Operation.
A. Engine Combustion Air Flow.
The combustion air is directly associated with combustion and thrust.
The variable vanes in the front frame annulus guide the air into the
compressor for optimum airflow. The air passes through the compressor
Mar 30/84 75-00
Page 1
GEWIAAL E Lt CTR IC
CJ610 TURBOJET
MAINTENAhTCE MANUAL SE1-186
and is diffused in the mainframe. It is then mixed with fuel in the
combustor and ignited. The combustion gases then pass through the tur-
bine where the greater portion of available energy is used to drive the
engine compressor, and the rest passes through the exhaust cone and tail-
pipe to provide thrust.
B. Engine Cooling and Pressurizing Air Flow. (See figure i.)
Compressor discharge air which leaks across the eighth stage compressor
air seal is used to pressurize the number one and number two carbon
seals and the
system. lube As the forward
air leaves the seal it moves
along the bearing housing
number two and seal support and pressurizes
the number t~-o carbon seal. Seal leakage air also passes through holes,
located in the compressor drive shaft mounting flange between the mount-
ing bolts, into the rotor. It moves forward through the rotor anu ou~
through holes in the forward compressor shaft and pressurizes the number
one carbon seal. The lube system itself is pressurized by this same ail
which leaks across the carbon seals. The pressure of the seal leakage
air is controlled by two poppet valves which are mounted on the ~nd
ten o’clock mainframe strut pads. Excess eighth stage seal leakage air,
which passes through the poppet valves, is dumped overboard or ducted
aft to the exhaust cone. (Refer to 79-41-0 for poppet valve maintenance
practices.)
Compressor discharge air that is not mixed into the fuel-air charge is
used for cooling engine components in the combustion and turbine sec-
tions. This is necessary because of the high temperature generated by
the burning process which is centered in the combustion section. Tem-
peratures are so high that without provisions for cooling air, the life
of the components in the combustion and turbine sections would be ex-
tremel?l Cooling of the inner walls of the combustion liner i
short.
accomplished by a pattern of louvers cut in the inner and outer liner
shells. These perforations direct the flow of secondary combustion air
or cooling air through the liner and along the liner inner skin to keep
the flame away from both liner walls. The air flowing between the com-
bustion liner and the outer combustion casing, cools the outer wall of
the liner, and then passes inward through a series of holes in the aft
outer flange of the liner. A portion of this air then flows outward
through radial holes in the first stage turbine nozzle outer band and
aft to cool the turbine casing and first stage turbine shroud at which
point it re-enters the main gas stream. The remainder of the air flows
through the hollow partitions in the first stage turbine nozzle, into
the inner band of the nozzle, and is expelled aftward, through slots in
the inner band, against the shanks of the first stage turbine blades.
Some of the air, as it passes through the partitions, is expelled
through small slots in the concave surface and cools the trailing edges
of the partitions.
75-00 Mar. 30/67
Page 2
GEN ERAL ~s ELECTRIC
CJ610 TURBOJET
SE I-186 MA I NTENANCE MANUAL
J*t7
~3 o
Al
~Zk, DETAIL A
DETAIL 6
DETAIL 6
CJ610-6025-0´•A?A
Ai r Flow
Engine Cooling and Pre s suri zing
Figure 1 75-00
Mar. 30/67
Page 3
GEWERAL O~ ELECTAIC
CJB10 TURBOJET
MAINTENANCE MANUAL SEI-186
Secondary combustion air which flows between and cools the combustion
liner and the inner combustion casing is directed into the balance pis-
ton chamber. This chamber is located just forward of the first stage
turbine wheel. The air enters the chamber through a series of holes
spaced between the bolt holes in the rear flange of the inner combustion
casing. It pressurizes the chamber and acts on the forward face of the
first stage turbine wheel, utilizing the wheel as a piston. This action
offsets the forward thrust of thecompressor rotor, reducing the thrust
loading on the number two bearing. Balance piston air leaves the cham-
ber through twelve holes in the first stage turbine wheel. These holes
are located between the first stage turbine wheel-torque ring bolt holes.
Six of the holes bleed air back toward the second stage turbine wheel
cooling theaft side-of the first stage wheel, the inner diameter of the
torque ring and the forward face of the second stage wheel, cooling the
aft side of this wheel, and re-enters the main gas stream. The other
six holes in the first stageturbine wheel direct air to a chamber form-
ed by the aft side of the first stage wheel and the baffle ring which is
integral with the torque ring. A series of axial holes in the baffle
ring allows the air to continue aft, through the turbine interstage seal
and onto the second stage blades shanks and turbine wheel outer rim.
Some of the air that passes through the baffle ring moves outward past
the baffle on the stationary half of the interstage seal and cools the
aft side of the first stage wheel outer rim and the blades shanks.
Air also leaves the balance piston chamber through the inner forward
turbine labyrinth seal into a chamber at the root of the turbine forward
shaft. point it pressurizes the number three carbon seal and
At this
passes aft through holes in the first stage turbine wheel. It combines
with air between the two turbine wheels and aids in cooling this area
and then passes through the bore of the second stage wheel and out into
the main gas stream.
Some of the compressor-discharge air may be bled off through four main-
frame ports for airframe use.
C. Anti-icing Air Flow. (See figure 2.)
Anti-icing airflow is controlled by an electrically operated valve
which is mounted on the aft side of the manifold on the front frame at
the o’clock position.
10 Compressor discharge air is bled from the
eleven o’clock bleed port on the mainframe and ducted forward, through
the anti-icing valve, into the manifold. Some of this air passes aft
through slots cut in each of the IGV supporting bosses, through the hol-
lowed out vane stemsand into the hollow IGV’s. Inside the IGV’s the
air flows radially inward, around baffles, then outward through holes in
the outboard ends of the vanes and into the airstream. The rest of the
75-00 Mar. 30/67
Page 4
eLwrR~L ELEErRle
CJ610 TURBOJET
SE I-186 MA I NTENANCE MANUAL
an t i i i c i ng ai r pa s s e s through the s t ru t s into the i nn e r hub Aport ion
of thi s air is di rect ed fo rwa rd into the bu lie tnose whi ch has two skins
through a ho le at the fo rwa rd end of the 1 nner skin, then aft between
the two skins and out through radial ho les at the aft end of the outer
skin. The remainder of the air in the inner hub passes aft through In-
t e rna 1 pa s s a ge s and in t o the double s ki nne d IGV shroud and s ea I. This
air anti-ices the shroud ring and then passes out into the air st ream
t hrough ra di a I ho le s at the af t end of the shroud
D Comp re s s o r Bleed Air
The ai r pi ed f rom the comp re s s o r at the thi rd f ourth and f i fth s ta ge s
is me t e re d ove rboa rd as s c he du 1 e d by the ma i n fue I control to ma i n ta in
ai rf 1 ow s t abi 1 i t y wi thin the c omp re s s o r and to prevent c omp re s sor a ta 1 1s
FRONT FRAME ANTICICING
AIR MA N I FOL D
c
INLET
INLET
VA RI A BL E VA NE
BULLET NOSE II I IrmG- SHROUD
VIEW FORWARD LOOKING AFT
CJ610´•6026´•0´•D2
Anti-icing Air Flow
Figure 2
Mar. 30/67 75- 00
Page 5
G E N E RA L ~b E LE CTR IC
CJC~IO TURBOJET
SEI-186 MAINTENANCE MANUAL
AIR SYSTEM TROUBLE-SHOOTING
i. General. The air system trouble-shooting must be accomplished in a system-
atic manner based on all available information. External air leaks may be
found by inspection (discoloration around connecting parts) or during
visual
engine coastdown. A thorough knowledge of the engine air system, applied
with logical reasoning, should solve any problems which may occur.
Trouble-Shooting information is furnished in Chapter 72-00.
Nov. 15/67 75-00
Page 101
00N ERAL ELECTRIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
AIR SYSTEM MAINTENANCE PRACTICES
i, General, The following maintenance practices are the adjustments that can
be made to the air system, For removal and replacement, refer to the indi-
vidual component section.
A, Inspect the parts of the variable geometry system for wear per figure
201 before disconnecting or removing any of them, Measure the amount of
free movement (turning) or looseness of the variable vanes and the
amount of axial play in the bleed valve clevis,
i. MANUALLY POSITION VARIABLE VANES TO THE FULL OPEN POSITION. 1. BELLCRANK
2. YOKE
2. USING FIRM HAND PRESSURE, TO TURN THE VARIABLE VANE, TAKE UP 3. ACTUATOR CYLINDER
THE SLACK FIRST IN ONE DIRECTION AND THEN IN THE OTHER. EXCESSIVE 4. ACTUATOR PISTON ROD
PRESSURE CAN MOVE THE ACTUATOR AND THE MEASUREMENT WILL BE 5. VARIABLEVANE
MEANINGLESS. CAREFULLY MEASURE FREE TURNING MOTION (LOOSENESS) 6. BLEEDVALVE
OF THE SYSTEM USING A DIAL INDICATOR OR A THIN SCALE HELD FIRMLY 7. BLEED VALVE CLEVIS OR ROD END
INSERTED BETWEEN THE OUTSIDE END OF THE VARIABLE VANE AND HELD 8. FEEDBACK CABLE
FIRMLY AGAINST THE FRONT FRAME CASING. MAKE THE MEASUREMENTS 9. SYNCHRONIZATION CABLE
OF VARIABLE VANES NEAREST TO THE 3 AND 9 O’CLOCK POSITION, THE 10. ACTUATORRING
MEASUREMENT SHOULD BE MADE AT THE OUTSIDE TRAILING EDGE OF THE Il. LEVERS
VARIABLE VANE,
9 Ip_._ ~t
3, MEASURE THE AXIAL PLY OF THE BLEED VALVE CLEVIS USING t~
A DIAL INDICATOR OR A SCALE.
Ji
i
7 ji, I
6 8
SERVICEABLE LIMIT
Q
I::: MEASUREMENT POINT
0.020 INCH MAX --7L-LJ b
SERVICEABLELIMIT tS--
i´•´•´•´•i
c i6:i i 5
0.050 INCH MAX
I SERVICEABLE LIMIT
c161oao~z-o´•cz
Variable Geometry System Inspection
Figure 201
Mar. 30/67 75-00
Page 201
G E W E RA L L LE CTR IC
CJB10 TURBOJET
MAINTENANCE MANUAL SE1-18~
(1) If the free motion of the variable vane is less than 0.05 inch total
and the axial play in the bleed valve clevis is less than 0.020 inch,
the variable geometry system is serviceable and no additional inspec-
tion is required.
(2) If the free motion of the variable vane exceeds 0.05 inch total and/
or the axial play 0.020 inch, inspect
in the bleed valve clevis exceeds
and replace parts only as required to bring the system looseness and
clevis play within serviceable limits. Reassemble the system and again
measure the free motion In the system and the clevis axial play. In-
spect and replace parts in the following order:
(a) The bellcranks of both actuators for wear in the bearing and
pivot shaft.
(b) The actuator ring for wear in ring pivot pin holes and the lug
pin holes.
(c) The levers for wear in the square holes.
(3) If the free motion in the system is not corrected by the above, the
front frame assembly must be removed and replaced as instructed in
72-30, Maintenance Practices.
2. Adjustment/Test.
A. Initial Bleed Valve Adjustment. (See figure 202.)
(L) Disconnect the synchronizing cables (12), the feedback cable (9) and
the bleed valves (2) from the-actuator bellcranks (5).
NOTE: On engines the pin (head next to compressor casing) for
some
the synchronizing cable cannot be removed until the actuator
is removed. For this configuration, remove the outer syn-
chronizing cable.
(2) Set and maintain the actuators (1) in the fully extended position.
Take the linkage backlash out in the direction of retracting the
actuator.
(3) Close the bleed valve gates (6) against their stops, fully extending
the operating arm (3) to remove the backlash.
(4) Adjust the rod end (4) and insert the clevis pin (17) through the rod
end and the bellcrank (5) arm to make sure that the parts are properly
aligned.
75-00 Dec 30/78
Page 202
GEIIERIL 6L6CTAIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
ACTUATOR
2. BLEED VALVE
3. BLEED VALVE OPERATING ARM
EXTEND ACTUATOR
4. ROD-END OR CLEVIS END
5. ACTUATOR BELLCRANK
12
6. BLEED VALVE GATE
1
7. VARIABLE VANE ACTUATOR RING
8. ADJUSTABLE LINK ~PO
9. FEEDBACK CABLE AND CONDUIT
10. NUT
11. NUT 5ir B
SYNCHRONIZING CABLE
14
.21TUN
13. HEX TURNBUCKLE NUT
14. JAM
CLOSE BLEED
VALVE GATE
15. JAM NUT
WASHER (SHIM) 3
.61NIPRETOC
17. CLEVIS PIN
18.
19. PIN I 6e/ I U B
20. WASHER I i
I-GUL
Q
I C,
NUTS ,11
LOCKWIRE r
SUPPORT
1SY
T~ VIEW IN DIRECTION OF ARROW C
NUT,IO 20
(WITH PARTIAL CUTAWAY)
VIEW IN DIRECTION OF ARROW A
VIEW IN DIRECTION OF ARROW A
t o.oos To 1,6 1 5
0.005TO 0.015 1
0.015 INCH
BLEED VAL
BLEED VALVE
V~l ~Eiid ;4k~M ROD-END BELLCRANK ARM
0.005 TO 0.005 TO
0.015 INCH 0.015 INCH 17’16
WA~HER I~11
(OPTIONAL)
SECTION B-B SECTION II-II
CJd10-6041´•0´•AZ~
Bleed Valve and Variable Vane Adjustnents
Figure 202
Dec 30/78 75-00
Page 203
GEILRAL ~D ELECTIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(5) Remove the clevis pin and rotate (counterclockwise) the rod end one
turn away from the valve. Insert the clevis pin through the rod end
and the bellcrank arm. Check to ensure that the valve gates no longer
bottom against their stops.
NOTE: The gates should be fully-closed. No visual opening of gates
should exist.
(6) Move the actuator piston by hand to Its fully retracted position,
with l.inkag’e backlash taken out in the direction of extending the
actuator. (The bleed valve is now open.)
(7) Check the position of the bleed valve gates. They should not protrude
more 1/16
than inch into the bleed valve opening. If the gates pro-
trude into the bleed valve opening more than 1/16 inch, remove the
clevis pin and rotate (counterclockwise) the ro~ end 1/2 turn.
(8) Repeat step (7) until the 1/16 inch dimension is met.
(9) Move the actuator piston by hand to its fully extended position (valve
gates closed) and check to ensure that no visual opening exists.
(10) Move the actuator piston by hand to its fully retracted position
(valve gates open).
(11) Remove the clevis pin and check to ensure that the valve gates can be
opened further. If the valve gates cannot be opened further, make
the following inspection checks:
(a) Actuator travel at the valve connection points is within limits
of 1.64 to 1.66 inches.
(b) The valve operating arm (3) has a full travel of 1.73 inches
(minimum).
(12) Replace the actuator if it is out of dimensional limits. If the valve
gates do not open or operate properly, check the valve for proper as-
sembly and replace it If it cannot be made to operate within limits.
(13) Shim each side of the actuator bellcrank arm that is connected to the
bleed valve rod end. Insert the shims (16) to obtain a clearance of
0,005 to 0.015 inch between the shim and the inside surface of the
rod end. Be sure not to apply a side load to the bleed valve operat-
ing arm by shimming. Connect the bellcrank arm to the: rod end with
the clevis pin, 2 washers and cotterpin. Torque the jam nut against
the rod end to 95-125 Ib-in. Be sure the operating arm is not twisted
in its slot so that opposing corners can rub.
75-00 Dec 30/78
Page 204
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAIP~ENANCE MANUAL
NOTE: Install one washer under the head of the clevis pin and one under the
cotterpin. The axial movement of the clevis pin shall not exceed 0.022
inch.
(14) Inspect the valve gates for full closing as follows:
(a) Fully close the bleed valve. The openings must be completely cov-
ered. Apply finger pressure down on the upper gates and up on the
lower gates to remove all play.
(b~ Visually inspect with a good light to ensure that no gaps or cracks
exist between the gate and bleed valve opening. Attempt to insert
a strip of shim stock 0.001 inch thick between the top and bottom
of the gate and the valve port. Attempt to insert the shim perpen-
dicular to the gate along the entire edge including the corners.
Replace the valve if the shim can be inserted.
(15) Deleted.
B. Initial Variable Vane Adjustment. (See figure 202.)
(1) Set the variable vanes in the zero-degree position (full open)
(2) Extend each actuator (1) until it reaches its stop. Remove all backlash
as described in paragraph A.
(3) Centralize the variable vane actuator ring (7) by moving it radially
until the gaps between the ring and the front frame are approximately
equal at the 6 and 12 o’clock positions.
(4) Adjust adjustable link (8) (turnbuckle) so that the clevis pins can
the
be through the variable vane actuator ring lug and the ball
inserted
joint of the adjustable link. Connect each adjustable link to each of
the actuator ring lugs with a clevis pin, washer and cotterpin. The
head of the clevis pin faces aft and the washer is installed under the
cotterpin. Bend the cotter pins that secure the adjustable lir;k clevis
pins at each actuator bellcrank and at the actuator ring lugs. Torque
the adjustable link jam nut to 6-8 Ib-in.
(5) Loosen the 2 bolts that secure the upper and lower actuating ring halves
together one full turn.
NOTE: Disregard steps (1) and (3) on engines without actuating ring
plastic support buttons.
(6) Secure an alignment clamp, 2C5374, to each of the three oversize struts
I (located
the arrow
at
on
the
the
2, 6, and 10
body pointing toward
o’clock positions)
the bulletnose,
on the front
as shown
frame,
in
with
figure
203. Tighten the wing nuts fingertight.
75-00
Dec 31/95 Page 205
6 EW ENAL ELfCTIIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-ls6
SECURE A CLAMP TO VARIABLE VANE AT EACH
OF THE OVERSIZE STRUTS WITH RADIUSED EDGE OF
CLAMP UP AGAINST FRONT FRAME INNER CASING.
FRONT FRAME
INNER CRSI
j ´•
g
I/jj
RADIUSED EDGE
OF CLAMP 3 CLAMPS
2[35374
WING
NUT
~----L OVERSIZE
’IZ
1 STRUT e
t
I/ ii-
VARIABLE
7r VANE
8C-0223
Setting Variable Vanes to Zero Position
Figure 203
75-00 Dec 30/78
Page 206
GLNERILQ ELLCTRIG
CJ610 TURBOJ~T
SEI-186 MAINTENANCE MANUAL
(7) Tighten the 2 bolts, that were loosened in step (5) to 28-321b-in.
The vanes are now at the "zero degree" (full open) position.
NOTE: Check the scribe line on the actuating ring for alignment
with the longest line (00 line) of the five lines on the
front frame. If they do not align, paint dykem (blue) or
equivalent on the actuating ring and rescribe actuating
ring using alignment gage 2C5356 as a guide.
(8) Set and maintain the actuators in the full extended position. Remove
backlash by exerting fingertip pressure against the bellcrank arm in
direction of actuator retraction.
(9) Adjust the length of the adjustable links (8, figure 202) so they can
be connected to the variable vane actuator ring lug without changing
the "zero degree" setting. Secure using a clevis pin, washer and
cotter pin.
(10) Torque the adjustable link jam nut to 6-8 Ib-in.
(1L) Remove the 3 alignment clamps,2CS374´•.
(12) Manually retract the actuators, then move to the fully extended posi-
tion and check alignment of t~e scribe lines for "zero degree" posi-
tion. If lines do not align, repeat adjusting procedure.
C. Initial Fuel Control Feedback Cable Adjustment, (See figure 202.)
NOTE: Final adjustment is performed during engine runup per paragraph E.
(1) The feedback cable and conduit (9) must be connected and fastened at
the main fuel control for this adjustment.
(2) Extend the actuators (I) until the stop is reached. (The bleed
valves (2) should be in a full-closed position.)
(3) Loosen nut (10) and the 2 nuts (11) or remove pin (19). Bend the
conduit mounting bracket, if necessary, to ensure that the feedback
cable moves freely through the support lug at: the actuator bellcrank
(5). Final
alignment satisfactory when the cable contin-
is considered
ues to move freely through the lug, regardless of the bleed valve posi-
tion (either in the full-open or the full-closed position). Return the
bleed valves to the full-closed position After alignment is completed.
(4) Pull the feedback cable to bring the variable geometry feedback arm
ton the fuel control) against its stop and tighten nut (10) or in-
stall pin (19).
Dec 30/78 75-00
Page 207
GEAERAL ~D E LE CI R IC
CJ610 TURBOJET
MAINTENANCE MANUAL SE 2-186
(5) Loosen nut (10) exactly 2 turns or remove pin (19) and turn rod-end
counterclockwise 2 full turns.
(6) Secure the assenibly by ins tal ling pin (19) and washer (20) or torquinl:
the 2 nu t s (11) to 6-8- Ib-in Lo ckwire
D Syn chr oni z ing Cable Ad3 us tment See figure 202
(1) Connect loos ely the 2 synchronizing cab les (12 to the clevis p in s
in each of the actuator bellcranks (5) with a cotter pin.
NOTE: On some bellc’rank configurations, washers are used with the
cotter p in On thes e conf igurat ions in a t all the washer
under the cotter pin and bend the cotter pin.
(2) Maintain the 2 actuators (1) in an extended position (the bleed valves
should be fully-closed) Take the slack out of the linkage in the
direction of opening the bleed valve (2)
(3) Re cord the sc tuator p is ton rod po s i tlon of both a c tuators
(4) T igh t en the hex turnbuckle nut 13 f ing er- t ight to take the slack out
of the synchronizing cable and place it in tension. Pre-load the
cable by tightening the hex turnbuckle 1/4 to 1/3 turn. Be sure to
res train the cable from turning with the t urnb uckle
(5 Ensure the ends of the cab le and clevis end are p rop er ly engaged by
checking inspection ho le s in the turnbuckles Ho id the hext turn-
buckle nut s agains t r o t a t ion and a e cur e them by torquing the i am nu t a
(14) Torque the sheet metal type lo cknut (no t free runn ing) to 6-8
Ib-in. If the new free running lo cknut 18 us ed torque to 2 5- 3 O ib-in
Lockwire the j am nu ts
(6) Check the actuator rod pos ition The measurement must fall wi thin
+0. 015 inch of the original valve position in step (3)
(7) Check the bleed valve lag by comparing the size of the openings of the
gates 6) of one bleed valve with the o th er The d i f 5 er en ce between
the sizes of b le ed valve gat e openings mus t no t exceed 1/16 inch
E Final Adj us tmen t of Variable Geomet ry Sys tem (S ee f igure 202
NOTE: See 72-00, figure 505 for proper schedule.
(1) If the p lo tt ed points on the bleed valve op era t ing schedule in 7 2-00
Ad3 us tment /Tes t are out of limit s p roceed with the following
75-00 nec 30/78
Page 208
GEIEIAL ELECI~IC
CJ610 TURBOJtT
SEI-186 MAINTENANCE MANUAL
(2) If both recorded points limit, increase the.
fall above the maximum
effective length (where it con-
of the fuel control feedback cable
nects to the right-hand actuator bellcrank) by one of the following,
depending on feedback cable configuration.
(a) Back off adjusting nut (10) and tighten locking nuts (11).
Torque nuts to 6-8 Ib-in. and lockwire.
(b) Remove pin 119) and turn rod-end to increase the length of the
cable. Install pin, washer and lockwire.
(c) Recheck and adjust until points fall within limits of 72-00,
Adjustment/Test.
(3) If both recorded points fall below the minimum limits, decrease the
effective length of the fuel control feedback cable (where it con-
nects to the right-hand actuator bellcrank) by one of the following,
depending on feedback cable configuration.
CAUTION: USE CARE WHEN REDUCING THE EFFECTIVE LENGTH OF THE
FEEDBACK CABLE. IF CABLE IS TOO SHORT, IT WILL
BOTTOM AGAINST THE STOP IN THE FUEL CONTROL WHEN
ACTUATOR IS FULLY EXTENDED. WITH ACTUATOR FULLY
EXTENDED A SMALL AMOUNT (0.015 INCH) OF SPRING
LOADED END PLAY SHOULD BE EVIDENT TN THE CABLE.
(a) Back off locking nuts (11) and tighten adjusting nut (10). Torque
nuts to 6-8 Ib-in. and lockwire.
(b) Remove pin (19) and turn rod-end to decrease the length of the
cable. Install pin, washer and lockwire.
(c) Recheck and adjust until points fall within limits of 72-00,
Adjustment/Test,
Dec 30/78 75-00
Page 209
CEW ERAL Q E LE CT R IC
CJ610 TURBOJET
SE1;186 MAINTENANCE MANUAL
ANTI-ICING VALVE NLA I NTENANCE PRACT ICES
Gene ra I The f ollowi ng to be used when perf orming ma i nt e-
1 pro ce dure s are
nance on the an t i i c ing va lye
2. Removal/Installation.
A. Remo vs 1
(1) Disc onnect the electrical lead from the anti-icing va lye.
(2) Remove the bo its (1, figure 201) that se cures the clamp (2, figure
201) to the bracket (3, figure 201).
NOTE Some engines may not have thi s clamp installed on the engine
3 Di s connec t the tube 4 f i gu re 2 01) f rom the rear pad of the an t i
icing valve by removing the bo Its (5, figure 201)
4) Remove the bolt s (6 f i gure 2 01 and nut s (7 f i gure 20 1) t ha t se-
cure the rear of the anti-icing valve. Remove the spacer (8, figure
201) and any shims that are used.
(5) Remove the bolts (9, figure 201) that secure the anti-icing valve to
the ant i i c ing man i f old Use t ool 205 32 2 for the i ns i de bo It
6 Remove the ant i i cing valve and di s ca rd the ga a ke t
B. Ins tallation.
pad and a s s emb le
1 Place a new ga s ke t on the ant i i c i ng valve f rent
the va lye to the manifold. Se cure with bolts (9, fi’ gure 201) Use
tool 205 32 2 for the i n s i de bo it Do not t i ght en the bolt s a t thi s
time.
201) the valve and front frame
(2) Place spacer (8, figure
the between
rear flang e Use shims as requ i red to f i 12 any gap be twe en spacer
and valve Secure the valve and spacer wi th bo it s and nut s (6 and 7
fi gure 201) Do not tighten nut s at thi s time.
3 Place a new ga sket on the ant i- i cing va 1 ve rear pad and conn ec t tube
(4, figure 201) to valve. Secure with bo its (5, figure 201) Do
not t i g ht en bo it s at thi s t ime
7 5 -11- O
Ma r 30/67
Page 201
G E W E RA L ~B E LE CT R IC
CJB10 TURBOJET
MA I NTENANCE MANUAL SEI-186
(4) Install´• clamp (3, figure 201) over the valve. Secure to brac ket (3,
i i gu re 2 01 wi th bo it s 1 ii gu re 2 01 To rque t he bolt s to 24 27
Ib-in and loc kwi re
(5 To rque holt s (9 f i gure 2 01 to 2 0- 2 5 ib- i n an d loc kwi re
(6 To rcjue nut s (7 i i gu re 2 01 to 35 40 1 b- i n
(7 To rqu e bolt s 5 i i gu re 2 01 to 20 25 ib- i n and loc kw i re
3 2~
7 U-’ a
a Ir 4
5 1 111 1 T~j´•
~I loWe
cJs IO-~04J-0-CZ
An t i i c i ng Va lye Remo va 1
Figure 201
75-11-0 Mar. 30/67
Page 202
O E I ERAL E LE CTR IC
CJ610 TURBOJET
SE I-186 MAINTENANCE MANUAL
3 In s p e c t i on/ Che c k s Whe re s e rvi c eabl e 1 imi t s a re exe e e d e d pa rt s may be re-
pa i red in a c co rdane e wi t h Overhaul Manua 1 in s t ru c t i on s
Ins p e c t i on/ Che c k Maximum Se rvi ceabl e Limit s Co r re c t i ve Act i on
A. Cracks Not se rvic eable. Replace valve.
B. Damaged threads One full thread, cumu lative
or c on t inuou s maybe mi s s ing
af ter cha s i ng
C flee t ri cal connec- Not s e rv i c ea ble Rep la c e valve
tor for broken pins
75-11-0
Mar. 30/67
Page 203
GEWERAL~ELE eTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE IMANUAZ,
ANT I-ICING TUBE MAI NTENANCE. PRACTI CES
1 Gener al The followi ng procedures are to be used when performing maintenance
on the anti-icing air tube.
2. Removal/Instal lation.
A. Removal.
1 Di s c o nne c t the tube 1 f i gure 201 from the rear pad of the anti-
icing valve (2, figure 201)
(2) Loosen air tube clamps (3, figure 201)
3) Remove air tube from ho se (4, f i gure 201 Di sc ard ga she t f rom
an ti-icing valve end.
(4) Remove tee (5, f i gure 201) by removi ng the bol t s securing i t to the
mainf rame Di scard ga ske t
B. Inst allation.
(1) Ins t all tee (5 f igure 201) and new gasket on mainframe pad. Secure
with bolts. lubricatedwith Ease-Off 990 Texacone Co. Box 4236, Dallas,
T eras T o rque bolts to 16-19 ib- in. and 10 ckwi r e
1 3 f 3 g
00
Anti-I cing Air Tube Removal
Figure 201
Dec 31/91 75-12-0
Page 201
GENERAL ~B ELPCTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(2) Install air tube into hose (4, figure 201).
(3) Secure the anti-icing tube (1, figure 201) and a new gasket to the
rear pad of the anti-icing valve with bolts. Torque the bolts to
20-25 Ib-in. and lockwire.
(4) Tighten clamps (3, figure 201) to 30-40 Ib-in. and lockwire.
3. Inspection/Check. Where serviceable limits are exceeded, parts may be re-
paired in accordance with Overhaul Manual instructions.
Inspection/Check Maximum Serviceable Limits Corrective Action
A. Tube for splits Not serviceable. Replace tube.
or cracks.
B. Nicks, chafing or 0.005 inch deep after re-
scratches, moval of high metal.
C. Dents. Not over lj5 of tube diam-
eter, if the dent is not on
the heel of a sharply-bent
radius.
D. Flatness or out- Not over 1/4 of the tube
of-roundness. diameter.
E. Tube bolt flange Not to exceed 0.005 inch Lap or reface to
for flatness. provided 3/4 of flange within 0.005 inch
thickness remains after flatness or replace
refacing. tube.
75-12-0 Mar. 30/67
Page 202
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
EIGHTH-STAGE LEAKAGE AIR DUCT MAINTENANCE PRACTICES
WARNIN_G: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
i. General. The following procedures are to be used when performing maintenance
on the air duct.
2. Removal/Installation.
WAR_N_ING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
A. Removal.
(1) Remove the nuts securing the leakage air duct (1, figure 201) to the
exhaust casing.
(2) Remove the bolts securing the elbow (2, figure 201) to the mainframe.
(3) Remove the tube from the engine and separate the elbow from the duct.
Discard gaskets (3 and 4, figure 201).
NOTE: When the elbow is removed the 8th-stage leakage air valve is ex-
posed the should be inspected in accordance with 79-41-0.
75-21-0
Dec 31/95 Page 201
GENERAL ELECTRIC--------
CJ61 O TU R B OJ ET
SEI-186
MAINTENANCE MANUAZ,
5 11
i. Air Duct
2. Elbow
3. Gasket
4. Gasket
5. Piston Ring
G~P c
CJ610-6045-1-E2
Eighth Stage Le aka ge Ai r Tub e Removal
Figure 201
WARNING AS BE STO S
THE FOLLOWI NG PROCEDURE MAY INVOLVE A PART THAT CONTAIN S AS BE S TO S
WH I CH IS HI GHLY TOX I C TO SKIN EYE S AND RE S P I RATORY TRACT READ GEN-
ERAL I NF ORMAT I ON BEFORE PROCEED ING AND ADHERE TO ALL S ITE SAFETY AND
ENVIRONMENTAL CONTROL S CONCERNING AS BE S TO S OTHERWI S E PERS ONAL INJURY
MAY RE SULT
B. Inst allation.
1 P1 a c e new ga sket s 3 and 4 fi gur e 2O1 on ma inf r ame and exh au a t caa in g
In s p e c t p i s t on r ing 5 fi gu r e 2O1 and r epla c e if d ama ge d
(2) Ass emb le the air duct (1 figure 201) into the elbow (2, figure 201)
(3) Place the tube on the engine with the elbow on the mainframe and duct on
exhaust casing.
75-21-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
WARNING: EASE OFF 990 ANTISEIZE COMPOUND
OVEREXPOSURE CAN LEAD TO CHRONIC HEALTH HAZARDS SUCH AS SEVERE DAM-
AGE TO BLOOD FORMING, NERVOUS, URINARY, AND ~EPRODUCTIVE SYSTEMS.
INHALATION MAY CAUSE IRRITATION OR BURNING OF RESPIRATORY SYSTEM.
CONTACT WITH EYES/FACE/SKIN MAY CAUSE IRRITATION OR BURNING.
INGESTION MAY CAUSE IRRITATION OR BURNING OF DIGESTIVE SYSTEM.
PERSONAL PROTECTIVE EQUIPMENT REQUIRED WHEN HANDLING OR USING THIS
MATERIAL
(4) Torque the bolts, lubricated with Ease Off 990 (Texacone Co., Box 4236,
Dallas, Texas), that secure the elbow, to 16-19 Ib-in. and lock-wire.
Torque the nuts that secure the duct to 16-19 Ib-in.
C. Replacement of Ferrule on Leakage Air Duct.
(1) Machine off old ferrule in area shown per figure 202. Using a horizon-
tal miller or equivalent with a slitting saw, remove ferrule end.
(2) Locally manufacture an alignment rod per figure 203.
(3) Locally manufacture a new ferrule per figure 204.
(4) Assemble and line up new ferrule with duct and inspect the 16.600-16.640
inch dimension in figure 202. If total length is greater, remove mate-
rial from the tapered end of the ferrule so the length is within speci-
fied limits.
(5) "V" prep ferrule weld joint (figure 205) and vapor degrease.
(6) Assemble alignment rod, ferrule, and duct per figure 205.
75-21-0
Dec 31/95 Page 202A
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
WARNING: GENERAL WELDING
DO NOT LET FLAMMABLE SOLVENTS SUCH AS ACETONE AND METHYL ETHYL KE-
TONE CONTACT HEATED WELDED PARTS.
CONTACT WITH FUMES MAY CAUSE SKIN IRRITATION, DERMATITIS, AND EYE
IRRITATION. REPEATED INHALATION OF FUMES CAN CAUSE COUGHING, WHEEZ-
ING, AND PERMANENT LUNG DAMAGE.
IF FUMES CAUSE IRRITATION, GO TO FRESH AIR. IF COUGKING OR WHEEZING
PERSISTS, GET MEDICAL ATTENTION.
WELDING SHOULD ONLY BE DONE IN AN AIR-EXHAUSTED ENCLOSED OR SHIELDED
WORK AREA.
CONTACT WITH ULTRAVIOLET RAYS MAY CAUSE FATIGUE, NAUSEA, AND FEVER.
REPEATED CONTACT MAY CAUSE PERMANENT SKIN AND TISSUE DAMAGE.
COVER ALL EXPOSED SKIN TO AVOID REDDENING OF SKIN. IF REDDENING OF
SKIN OCCURS AFTER REPEATED USE OF WELDING MACHINE, GET MEDICAL AT-
TENTION.
ONLY EXPERIENCED TRAINED PERSONNEL SHOULD USE WELDING MACHINES. WHEN
USING EQUIPMENT, FOLLOW APPROVED SAFETY PROCEDURES FOR SHIELDING AND
PERSONAL PROTECTIVE EQUIPMENT.
(7) Tack weld ferrule to duct at four approximately equally spaced locations
to hold in position. (See weld data, table 201).
(8) Remove alignment rod.
(9) Gas-back the air leakage duct with argon (5-10 cu ft/hr).
(a) Place a gas tube in the flange endof the duct and seal with alumi-
num tape.
(b) Seal ferrule end of tube with aluminum tape.
(c) Purge duct vent ferrule end with a small hole to allow purge gases
to escape.
(10) Clean weld area prior to welding. Weld ferrule using argon torch gas
(8-14 cu ft/hr), tungsten electrode 0.062 diameter, filler material AMS
5786 (Hastelloy W) 0.035 inch diameter, and a current of 25-35 amps DC
straight polarity (reference weld data table 201).
75-21-0
Page 202B Dec 31/95
GENERAL ELECTRIC------
CJ610 TU RBOJET
SEI-186
MAINTENANCE MANUA~
WARNING: PENETRANT METHOD OF INSPECTION
PROLONGED OR REPEATED INHALATION OF POWDERS AND VAPORS OF CLEANING
SOLVENTS, DEVELOPERS, AND EMULSIFIERS USED IN FLUORESCENT PENETRANT
INSPECTION CAN IRRITATE MUCOUS MEMBRANE AREAS OF THE BODY.
CONTINUAL EXPOSURE TO PENETRANT INSPECTION MATERIALS CAN IRRITATE
THE SKIN. DIRECT EXPOSURE OF EYES TO BLACK LIGHT AND PROLONGED
EXPOSURE OF SKIN TO BLACK LIGHT CAN INFLAME AND DAMAGE EYES AND
SKIN.
WEAR NEOPRENE GLOVES WHEN HANDLING PENETRANT INSPECTION MATERIALS.
KEEP INSIDES OF GLOVES CLEAN.
STORE ALL PRESSURIZED SPRAY CANS CONTAINING PENETRANTS. DEVELOPERS,
AND EMULSIFIERS IN A COOL, DRY AREA PROTECTED FROM DIRECT SUNLIGHT,
HEAT, AND OPEN FLAMES. TEMPERATURES HIGHER THAN 1200F (490C) MAY
CAUSE PRESSURIZED CAN TO BURST AND CAUSE INJURY.
IF DIRECT EYE CONTACT WITH BLACK LIGHT CAUSES EYE PROBLEMS, IMMEDI-
ATELY GET MEDICAL HELP.
WHEN USING BLACK LIGHT FOR FLUORESCENT INSPECTIONS, WEAR SAFETY
GLASSES.
(11) Fluorescent-penetrant inspect. No cracks allowed.
(12) Inspect 16.600-16.640 dimension per figure 202.
3. Ins_Dection/Check. Where serviceable limits are exceeded, parts may be repaired
in accordance with Overhaul Manual instructions.
Inspection/Check Maximum Serviceable Limits Remarks
A. Visually inspect the duct (1, figure 201) for:
(1)Cracks. Not serviceable. Replace duct.
(2)Dents. One dent, 1/4 inch deep
and 1/2 inch diameter, if
the dent is 1/2 inch away
from welded area.
B. Visually inspect the elbow (2, figure 201) for:
(1)Cracks. Not serviceable. Replace elbow.
(2) Dents. Three dents, 1/8 inch
deep, or one dent 1/4 inch
deep.
C. Inspect ring land OD (ferrule, figure 202) for:
Wear. 1.356 inch minimum diameter Replace duct.
(0.008 inch wear).
75-21-0
Dec 31/95 Page 203
GENERAL ELECIRI~-------
CJ 81 OtU R B OJ ET
SEI-186
MAINTENANCE MANUAL
16.600-16.640
NfW WELD JOINT
-I ,I-
0.895-0.900
FERRULE
ALL DIMENSIONS
ARE IN INCH ES
000CF7-895000
Eighth-Stage Air Leakage Duct
Figure 202
t
1.067 1.40
f DIA DIA
1.062 1.38
I
2.10 1 1.260
2.00 1 11250
I ALL DIMENSIONS
ARE IN INCHES I MATERIAL: SAE 1010-1025
(machine steel)
000CF7-895100
Alignment Rod
Figure 203
75-21-0
Pa ge 2 04
De c 3 1 i95
GENERAL ELECTRIC------
CJ 61 O TU R B OJ ET
SEI-186
MAINTENANCE MANUAL
MATE R IA L: AM S 5 6 4 5 0.02-0.04 C HAM FE R 1-- 0.005-0.015 R
4’40’
3’20’
1 .0 7-1 .11
1.3 64-1.368
DIA
DIA D
1.17 5-1.180
N OTES: DIA B
1
D IAM ETRAL R U N O UT OF
DIAMETERS BTO D, NOT
1
TO EXCEED 0. 002 INCH FIR
0.03
T 0. 058-0. 068
2. 12 5 S U RFAC E FINISH 0.15 0-0.15 5
BLEN D
U N LESS OTn ERWISE SPECIFI ED 63 I I 1 63
0.189-0.191
3. REMOVE SHARP EDG ES
0.50-0.52
4. ALL DIMENSIONS
0.895-0.900 --e
ARE IN INCH ES 000CF7-B95200-02
Fe rr ule D imen a i on s
Figure 204
"V" PREP JOINT
ALIGNMENT RO D
FERRULE
0.03 0-0.040 INCH
WELD JOINT
000CF7-895300
Ass emb ly of Fer rule
Figure 205
75-21-0
Dec 31j95 Page 205
rd
P, ul
TABLE 201
co h,
o TIG WELD DATA
NOTE:
1. Read welding inst ructions before using this table.
i r wel d s fo r c r a c ks un le s s ot h e rwi s e not ed
2 F1 uo r e s c ent p en et r ant in s p e c t all repa
3. Use a 1/16 inch diameter, pointed. 1 percent thoriated tungsten electrode.
4. Use 1/32 1/16 inch diameter filler wire 1/32 inch preferred for most repairs.
Mat e r ial s Ma ch ine To r ch Ga s Backup Ga s
To Be Filler Wire Current Flow Flow Weld
It em C omp o n ent To Be W eld e d Weld e d Mat e r i al tamp e r e s cu ft h r) cu ft hr Co n t o ur
Stage 8 AMS 5645 25-35 DC Argon Argon Reinforced
201-1 Duct, Leakage
AMS 5570 8-14 5-10
Straight
OR
Polarity Q) a
AMS 5786
(Hastelloy W) ~e
0.035 inch dia. em
W ma
oP
ci
mi
~I
n vl
w H
03
~D
VI
GEl EIAL ~b fLTCTRIC
CJS10 TUFPsOJET
SEI-186 MAINTENANCE MANUAL
VARIABLE GEOMETRY ACTUATORS MAINTENANCE PRACTICES
1. Genera i. The following procedures are to be used when performing mainte-
nance on the variable geometry actuators.
2. Removal/InstaLlation. (See figure 201.)
NOTE: The procedures in this paragraph apply to both the left and right-
hand actuators except where otherwise noted.
A. Removal.
(1) Disconnect the hoses at the actuator housing (1). Move the actuator
piston forward to the retracted position.
(2) Remove the cotterpins, washers, and clevis pins that secure the ac-
tuator to the bleed valve rod end (2) and to the synchronixing cable
(3).
NOTE: On some engines (head of pin next to compressor casing) the
clevi´•s pin cannot be removed until the actuator is removed
from its mount.
(3) Remove,.at the variable vane actuator ring, the:cotteypin, washer,
and clevis pin that secure the turnbuckle to the actuator ring (4).
I.VARIAB~E GEOMETRY ACTUATOR
2. BLEED VALVE ROD END
4 3. SYNCHRONIZING CABLE
TURNBUCKLE
C~U ´•1:5.
.4REHSAW
.6NIP
7. NUT
8. MOUNTING BOLTS
5 DETAIL. ~L
CJ61060460-F2
Variable Geometry Actuator Removal
Figure 201
Mar. 30/67 75-31-0
Page :201
OE#fRAL O~ ELLCTRIC
cJeid TURBOJET
MA I NTENANC E MANUAL SE I 18 6
(4) For the right-hand act uator only, do the following:
(a) Remove the pin (5) and was her (6) or the nut (7) (depending on
f e e dba c k cabl e c on f i gu ra t i on) f rom the end o f t he fuel co nt ro 1
feedback cable at the actuator bellcrank lug.
NOTE If n ec e s sa ry d i s c onne c t the feedback cabl e c on du i t
clamp s to a 1 1 ow removal of the f eedba c k ca ble f rom the
belie rank lug.
(5 Remove the 2 bo it s t ha t secure t he a c tua tor mount to t he bos s e s on
the comp re s s o r c a s i ng
(6 Remove t he 2 nu t s and bo 1 t s t ha t s e cu re the ac t ua t o r to t he forward
flange of t he compre s sor cas ing
(7 Remove the a c tua t o r 1
B. Ins tallation.
(1) Secure the vari able geomet ry actuator t oge t he r wi t h the a s s em-
bl ed tu rnbuc kle to the f o rwa rd flange of the c ompre s s o r ca s i n g wi t h
2 bo 1 t s and nu t s Torque the bo 1 t s to 35 40 Ib- i n
NOTE On some model eng ine s (hea d of p i n next t o c omp re s s o r ca s i n g)
befo re se curing the act uator, insert the clevis pin to se cure
one end of the synchronizing cable.
(2 Secure the actuator moun t to the bo s s e s on the c ompre s s o r ca s ing
wi t h 2 bo it s (8 To rque the bolt s to 24 27 ib- i n (The 2 rea r
bo 1 t s s e cu re the sync hroni zi n g cable c lamps a 1so
NOTE For the ri ght hand actuator only t he s t and- o f f b ra c ke t for
the i gni t e r plug lea d s and f e ed ba c k cabl e are secured by t he
top, rear bo it.
(3) Adj u s t and connect t he ac tua t o r to the ble ed valve s ync hroni zing
ca ble and va ri abl e vane ac tua t o r ring pe r 75 00 Ma i nt enan c e
Practices
4) If the ri ght hand a c tua t o r is beln g repla c ed conn ec t the f e ed ba c k
cable as follows:
(a Cy c 1 e the va r i a bl e ge ome t ry f e e dba c k c a bl e and c he c k for f re e dom
of movement.
75-31-0 Mar. 30/67
Page 202
OBW ERAL BP EueTRls
CJB10 TUFP~O;JET
‘SEI-186 MAINTENANCE MANUAL
(b)Adjust the feedback cable to the actuator per 75-00, Maintenance
Practices.
(5) Connect the hoses to the variable geometry actuator fittings. Torque
as specified in 73-25-0.
3. Inspection/Check. Where serviceable limits are exceeded, parts may be re-
paired in accordance with Overhaul Manual instructions.
Inspection/Check Maximum Serviceable Limits Remarks
Former Present
Configuration Configuration
A. Visually inspect the bellcranks for:
(1) Loose bearings Not serviceable.
(2) Bleed valve arm 0.195 inch ID 0.195´•inch ID.
bearing wear
(1, figure 202)
(3) Variable vane 0.134 inch ID 0.195 inch ID.
arm bearing wear
(2, figure 202)
(4) Synchronizing 0.195 inch ID 0.195 inch ID.
cable arm bear-
ing wear (3,
figure 202)
(5) Actuator arm 0.195 inch ID 0.195 inch ID.
bearing wear
(4, figure 202)
(6) Center pivot 0.255 inch ID 0.380 inch ID.
bearing wear
(5, figure 202)
(7) Feedback´•:-:oable 0.255 inch ID.
arm hole wear
(6, figure 202)
(8) Feedback cable Block must be free to rotate
block for stick- 360 degrees when lockwire is
ing (7, figure removed.
202)
Mar. 30/67 75-31-0
Page 203
oEWER A:L ELSCTRIC
CJ610 TURBOJET
MA I NTENANCE MANUAL SEI 186
In s pe c t i on/ Check Maximum Se rvi ceab I e Llmi t s Remarks
Former Present
Conf i gurat ion Conf i gu ra t i on
B Vi s ua 1 ly in s pe c t the ac tuat o r brac ke t for:
1 Loo se or mi s s ing Not se rvi cea ble
rivets or collars
(8, 9, figure 202)
in the be lie rank
p i vo t s ha f t
(2) Wear on bellcrank 0.245 inch 0.369 inch
p i vot sha f t 10 minimum OD minimum OD
figure 202)
3 Mo un t i n g bo 1 t 0 225 inch 0 2 30 inch
ho les for wear maximum ID maximum ID.
(11, figure 202)
(4) Bend s or c ra c ks No t s e rv i cea ble
C. Act uator body for One full thread, continuous
damaged threads or cumu lative may be mis-
s ing af ter cha s i ng
D. Visually inspect the actuator shaft for:
(1) Dents, nicks and 0.001 inch deep after re-
s c ra t che s in a re a moval of al 1 hi gh me tal
of shaft seal
(2 Flaking chrome Not se rv i c ea ble
plate
(3) Yoke for wear 0.005 inch deep after re-
12 f i gu re 2 02 mo va 1 of hi gh met al
E. The pins used at Not se rvic eable. Replace pin.
connecting points
figure 202)
for wear
75 -31-0 Mar. 30/67
Page 204
OEWERAL ELECTRIC
CJ610 TUFPLSOJET
SEI-186 MAINTENANCE MANUAL
PRISLNT CONFIGURATION
11
SECTION ~-b
t’~B
FORMIR CONFIGURATION
12 4
I I a
i,
3
j!
2
10
SECTION kA
o.25o
0.220~
_1 i
CJ610d053-0´•C~Z*
Variable Geometry Actuator Inspection
Figure 202 75-31-0
Mar. 30/67
Page 205
GENERAL ELECTRIC------
CJ610 TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
AIR BLEED VALVE MAINTENANCE PRACTICES
WARNING: ASBESTOS
THIS ENGINE MAY CONTAIN SMALL AMOUNTS OF ASBESTOS. WHEN WORK-
ING WITH THIS ENGINE, THE FOLLOWING PRECAUTIONS MUST BE RIG-
IDLY ADHERED TO:
BEFORE ANY MAINTENANCE ACTIVITIES ARE UNDERTAKEN, REVIEW THE
ILLUSTRATED PARTS BREAKDOWN/CATALOG INDEX TO DETERMINE IF THE
HARDWARE TO BE WORKED ON OR USED CONTAINS ASBESTOS.
WHENEVER MECHANICAL REMOVAL OF MATERIAL, SUCH AS MACHINING,
GRINDING, BUFFING, DRILLING, SANDING OR ANY TYPE OF MATERIAL
BUILD-UP ON PARTS THAT CONTAIN ASBESTOS IS NECESSARY, APPRO-
PRIATE PERSONAL PROTECTIVE EQUIPMENT MUST BE WORN, AND NA-
TIONAL ENVIRONMENTAL CONTROLS REQUIRED FOR THE HANDLING OF
ASBESTOS-CONTAINING MATERIAL MUST BE COMPLIED WITH.
BEFORE HANDLING, REPLACING, OR DISPOSING OF ASBESTOS-CONTAIN-
ING HARDWARE, APPROPRIATE PERSONAL PROTECTIVE EQUIPMENT AND
NATIONAL ENVIRONMENTAL CONTROLS MUST BE STRICTLY ADHERED TO
FOR HANDLING ASBESTOS-CONTAINING HARDWARE.
1. General. The followingprocedures are to be used when performing maintenance on
the bleed valve.
2. Removal/Installation. (See figure 201.)
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
NOTE: The procedures in this paragraph apply to both the right- and left- hand
bleed valves except where otherwise noted.
A. Removal.
(1) Disconnect the actuator fuel lines (1) from the top of the fuel control
to relieve hydraulic pressure. Position the actuator pistons in the
fully extended position (2).
(2) Remove the clevis pin that secures the bleed valve (3) rod end to the
actuator bellcrank (4).
75-32-0
Dec 31/95 Page 201
GENERAL ELECTRIC-------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
i. Fuel Line I ./i ~--4
2. Actuator
o
3, Bleed Valve
4. 8ellcrank
5. Screw
i3
6. Screw
7. Feedback Cable
CJ610-6054-1-E2
Bleed Valve Removal
Figure 201
(3) Remove the bleed valve and gaskets from the compressor casing mounting
pad by removing the screws (5 and 6) securing the valve to the casing.
Discard gaskets.
The channel nut holders are also held by the screws.
WARNING: ASBESTOS
THE FOLLOWING PROCEDURE MAY INVOLVE A PART THAT CONTAINS ASBESTOS,
WHICH IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. READ GEN-
ERAL INFORMATION BEFORE PROCEEDING, AND ADHERE TO ALL SITE SAFETY AND
ENVIRONMENTAL CONTROLS CONCERNING ASBESTOS. OTHERWISE, PERSONAL INJURY
MAY RESULT.
B. Replacement.
(1) Install 2 new gaskets and the bleed valve (3) on the compressor casing
mounting pad.
(2) Secure the bleed valve with screws (6) and 4 channel-nut holders.
Torque the screws to 25-30 Ib-in.
(3) Secure the bleed valve with screws (5) tin the tapped holes in the com-
pressor casing). Torque the screws to 25-30 Ib-in. and lockwire them.
75-32-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAPNTENANCE MANUAL
(4) Adjust the bleed valve per 75-00, Maintenance Practices.
NOTE: If the right-hand bleed valve is being installed, adjust the fuel
control feedback cable (7) per 75-00, Maintenance Practices.
(5) Connect the actuator hoses (1) to the fuel control fitting per 73-25-0.
(6) Check the variable geometry system per 75-00, Maintenance Practices.
3. Inspection/Check. Where serviceable limits are exceeded, parts may be repaired
in accordance with Overhaul Manual instructions.
Inspection/Check Maximum Serviceable Limits Remarks
A. Visually inspect the Not serviceable.
upstream and down-
Stream cases for
cracks.
B. Visually inspect the cover or nameplate for:
(1) Cracks. Not serviceable.
(2) Loose or missing Not serviceable. Replace drive screw
drive screws. per paragraph 4.
C. Visually inspect the Not serviceable.
gates for cracks.
D. Visually inspect the pushrod for:
(1) Cracks. Not serviceable.
(2) Bent. Not serviceable.
(3) Damaged threads. One full thread within
first ten threads, pro-
vided remaining threads
are free of damage.
E. Visually inspect the Not serviceable.
camplate for cracks.
75-32-0
Dec 31/95 Page 202A
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
Inspection/Check Maximum Serviceable Limits Remarks
F. Roller and roller pin inspection.
(1) Visually inspect rollers, using a 10x glass for:
(a) Transverse Not serviceable.
surface wear.
(b) Circumferential Not serviceable.
sur’Eace wear.
(c) Flat spots. Not serviceable.
(d) Chips or cracks. Not serviceable.
(2) Deleted.
G. Visually inspect the bleed valve rod-end or clevis for:
(1) Damaged threads. Twenty-five percent of
threads may be missing
after chasing.
(2) Wear in rod-end 0.192 inch maximum width Replace rod-end or
or clevis hole. (axial direction). clevis.
H. Fluorescent penetrant- Not serviceable. Replace pushrod
inspect the pushrod assembly.
assembly for cracks.
Roller Inspection
Figure 201A Deleted.
75-32-0
I Page 202B Dec 31/95
GENERAL ELECTRIC------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE
4. Aoor oved Reoairs.
A. Rep a i r o f Loo s e o r Mi s s ing Dr ive Sc r ew s
(1) Separate the up stream case from the down stream case. Keep the bleed
valve components with the case that is not being repaired Refer to
paragraph 5 for disass emb ly procedure.
2 Remove lo o s e d r iv e s c r ew s
(3) Op.en up drive screw hole with a No. 38 drill(0.l0l5 inch)
(4) Drill hole in co ver and nameplate (or just cover) with aNo. 32 drill
(0.116 inch)
(5) Remove all burrs and chips.
6 In s t all ove r s ize d r iv e s c r ew Dr ive s c r ews in the d own s t r e am case mu s t
have their heads benched until they are 0. 025-0. 030 inch in height.
75-32-0
I Dec 31/95 Page 2 O 2C 20 2D
O tW EIAL O ELLCTRIC
TURBOJET
SEIi186
MA~NTENANCE MANUAL
5. Lub ri ca t ion. (See figure 202.) During disassembly, inspect per paragraph 3.
A. Disassemble the bleed valve, except for items 2 and 3, in the
J ´•sequence established by the item numbers of, figure 202,
NOTE i: Loctite applied to the screws (1) when they were
compound was
ins tailed. Thereforei they’ may be difficult tb remove. If
difficultyis encountered removing screws, apply heat, 3000F
max., to screw area of downstream case´•(4) to soften the Loctitel
Be careful not to damage the slots in the screws when removing
them
NOTE 2: During disassembly of gates, note position and stages they were
remdv~edrfrom, to assure correct:assemljly.
:B. Us-ing a moly disulphide spray, lubricate,the rollers,.gates, camplate
I assemblies, cam riding surfaces, gate riding´• surfaces, roller slots and
push rod assembly to a thickness of approximately0.0005 inch.
C. Iss’emble, the:bleed valve as follows: (See figure 202.)
(1) Place the upstream (inboard) case assembly (16) on a clean surface,
with the mounting surface down and the pushrod groove to the left.
(2) Insert 0.618 inch diameter roller (14) in´•theleft-hand vertical
slot, and place one of the three 0.455 inch diameter rollers (7)
in the right-hand vertical:slot.
(3) Assemble one camplate assembly (8) so that the pins fit into the
holes of the2 rollers which were assembled in paragraph2.
(4):- Assemble the slide bar assembly (15) on the upstream case by in-
serting the slide bar pins in,the holes of the upstream case.
(5)’ Insert a second 0.455 inch diameter roller (7) in the center
(horizontal) groove of the upstream case.
(6)’ Place one of the two 0.499 inch diameter;rollers (123 on topof
roller-(7) assembled inparagraph (5), Line up the holes of the
two rollers. Roller (12) is now located in the camplate slot.
(7) Assemble the pushrod assembly (13) so that pin facing down will
the
fit into the two rollers that were assembled in paragraphs (5) and
(6). The shank fits into the pushrod insert (13A) with the offset
down,
Nov, 15/72 1 75-32-0
Page 203
eEWLIAL1OLLE CTl!e
CJ610 7URBOJET
MAINTENANCE MANUAL SEI-186
(8) Place second 0.499 inch diameter roller (12) and then the third
0.455 inch diameter roller (7) on the pin of the pushrod ass embly.
(9) As s emb le one aet of gates (9 10 and 11) so that the lips (gr ooves
are down and engage the camp late as s emb ly As s emb le a second set
o f gates (9 10 j and 1 1) wi th the lips (g r o ov e s up
NOTE: To equalize gate we ar turn gates over from their p revious ly
installed position in each st age.
CAUT ION THE GATE S ARE NOT INTERCHANGEABLE BETWEEN S TAGE 8
(10) As s emb le the s e c ond c amp late (8) (wi th p ins up) engage the lips
to
of the free" .s e t of gates Place p in of the pushrod in the s lo t
of the camplate.
(11) Place O 5 7 8 inch d lame te r roller (5) on the le f t-hand pin of the
camp lat e as s emb ly Place O 39 3 inch diameter roller (6) on the
right-hand pin of the camplate.
(12) Ins t all downs tream cas e so that ins tailed rollers are in their
proper slots.
13) Af t e r as s emb ly actuate the pushrod by hand a minimum of 10 cycles
to remove exces s lub r i c an t from working parts
14 Remove d owns t r e am c as e and carefully r emove: exe e s a lub r i c an t
15 As s emb le the ´•d own s t r e am and up a tream c as e as a emb lies again and
s e cure using 4 a cr ews 1) af t er app ly ing one drop of Lo ct i t e
Grade H Mill t ary 8 pe c i f i c at i on MIL-P-1126 8D or equ ivalen t to
the thre ads. Tighten the screws to a torque value of 7 to 9 ib-in.
16 To as sur e co rr e c t as s emb ly check fo r b ind ing or internal p ie ce
part hangup by operating push ass emb ly to the full open and
the rod
dos ed positions. The force to act uate the push rod shall not
;exceed 0.25 pound.
75-32-0 June
page 204
OEWIUL~ILIEIIIC----
CJ610 TURBOJeT
SEI-186 MAINTENANCE MANUA~
LEGEND
I i. SCREW
2. NAMEPLATE AND COVER
1 3. DRIVESCREW
;117 1 4. CASE (DOWNSTREAM)
5. ROLLER
6. ROLLER
is 7. ROLLER
´•p
8. tAMPLATE
9. GATE
j15~\7 10.
11.
GATE
GATE
12. ROLLER
7\\ 13. PUSHROD
‘B
iaA. INSERT
14. ROLLER
15. SLIDE BAR
16. tASE(UPSTREAM)
~175 13 ‘~c12
12
1
´•´•i~ h
C1 q
7
t~J
11
10 d
9
B 3
~---2
--~na
4 "ILJi
J
C
tJ6 10-6002- I-CZ
Bleed Valve
Figure 202
June 1/71 75-32-0
Page 205
OIIEIAL ELECTAIC
CJB10 TURBOJLT
SEI-186 MAINTENANCE MANUAL
FEEDBACK CABLE MAINTENANCE PRACTICES
i. General. The following procedures are to be used when performing mainte-
nance: -on thefeedback cable.
j-;: I::Removai/Installa tion. (See figure 201.)
A. Removal.
(1) Disconnect the feedback cable from the fuel control by removing the
pin (i) and clip (2) and the screws securing the cable housing to
the control.
MOTE: To aCcomplish this enginesit may be easier if the
on some
fuelcontrol (ref. 73-13-0).
is removed If the control is
removed it must be supported during removal to prevent damag-
ing the feedback cable and other attaching lines.
(2)-:lgiseonnect ;the feedback cable frofi the bellcrank byremoving the pin
(3) andwasher (4).
NOTE: On some engines the cable end is connected by nuts (5) and
(6).
(3) Remove the feedback cable by removing the nuts and bolts securing
the cable brackets to the engine.
B. Installation.
(1) Install the feedback cable on the engine and secure the cable brack-
ets with bolts and nuts.
~C2)’ Connect the bellcrank end to the bellcrank. Secure-with pin (3) and
washer (4) or with nuts (5) and (6), depending on cable configura-
tion. Lockwire.
(3) Connect the fuel control end to the control and secure withpin(l)
and clip (2). Secure the cable housing to the control with screws.
Torque and lockwire the screws.
NOTE: If the fuel control was removed, install the feedback cable
on the control before installing the fuel control on the
engine.
(4) Adjust the cable per 75-00, Maintenance Practices.
Mar. 30/67 75-33-0
Page 201
CJB10 ´•TURBOJET
MA I NTENANCE MANUAL i
SEI-186
5
Lr; 00
CJ(ID4011´•O´•D?
Feedback Ca bl e Remo va 1
Figure 201
3 Ins pe c t i on/ Che c k Where s e rv i c e abl e 1 i mi t s a re exceeded Pa rt s may be re-
pal red in acco rdanc e wi th Ove rhau 1 Ma nua 1 i n s t ru c t i on s
I n s pec t i on/ Chec k Maxi mumSe rv i c ea ble L imi t s Rema rks
A. Visual check
(1) Feedback cable for:
a Ki nks Mi no r kinks t ha t do not
interf ere wi th cable
actuation.
(b) Bend s Not s e rvi c ea bl e
(c) The rod end ho le 0.127 inch diameter.
(at fuel control)
for wear
75-33-0 Mar. 30/67
Page 202
GEIEIAL EL1CTRIC
CJ810 TURBOJET
SE I-186 MA I NTENANCE MANUAL
Ins p e c t i on/ Che c k Maximum Se rv i c eabl e Limit s Remarks
Remove hi gh me t al
(d) Rod end ho le Not s e rv i c ea ble
pic kup, ga iling
or burrs
e Bra c ke t loo s ene s s Not s e rv i c eable
I (f) Binding. 2.5 ib pull to move cable
through travel range.
(g) Bent rod end Any amount provided bent
connector section does not affect
ass embl y o f ca bl e
(h) dracks on threaded Not se rvic eable. Replace cable.
section
(2 Peed ba c k cable condu i t for
(a Ni c ks and c ha f i ng Any amount as long as
nicked or chafed area is
not through tube wa 11
and cable binding is not
a p pa re nt
(b) Dents Not over 1/5 of the tube
diameter and cable does
not bind.
75-3 3-0
May 15/70
Page 203
C H A PT E R
ENGINE
INDIC AT ING
GEWERALS ELECt~lC
C3610 TURBOJET
~-186 MAINTENANCE MANUAL
CHA~PTER 77 ENGINE INDTCATINC; SYSTEM
TADLE OF CONTENTS
Page
77-00 ENGINE INDICATING
Description and Operation 1
Troubleshooting 101
77-10 POWER~(Table of Contents Only)
77-11-0 Pressure Ratio Probes and Manifold
Maintenance Practices 201
77-20 TEMPERATURE (Table of Contents Only)
77-21’-0 TheMnocouple Harness and Engine
Temperature Protector
Maintenance Practices 201
L5/73 77
Page 1
CJ610 TURBOJET ENGINES
GEAircraftEnQines MAINTENANCE MANUAL
REVISION NO. 21, DATED JUL 15/99
CHAPTER/SECTION DESCRIPTION OF CHANGE PAGE (S)
77-21-0, Relocated the NOTE before step F.(1), 203
MAINTENANCE and revised the corrective action
PRACTICES column of item F.(1) in para 3
77-21-0, Revised the corrective action column 204
MAINTENANCE of item F.(2)(a) in para 3
PRACTICES
77-21-0, Relocated the NOTE before step 204
MAINTENANCE F.(2)(b), and revised the corrective
PRACTICES action column of item F.(2)(b) in
para 3
HIGHLIGHTS
Jul 15/99 77
Page 1 of 1
CJ610 TURBOJET ENGINES
GEAircraftEn9ines MAINTENANCE MANUAL
CHAPTER 77 ENGINE INDICATING SYSTEM
LIST OF EFFECTTVE PAGES
CHAPTER/
SECTION PAGE DATE
List of
Effective
Pages *I Jul 15/99
Contents 1 Nov 15/73
77-00 1 thru 2 Nov 15/73
101 Nov 15/67
77-11-0 201 thru 204 Dec 31/91
77-21-0 201 Dec 31/91
202 Dec 30/78
*203 thru 204 Jul 15/99
Asterisk indicates pages added, changed, or deleted by this revision.
77
Jul 15/99 I
GEWEIIAL~ ELECIIIC
CJ610 TURSOJET
SEI-186 MAINTENANCE MANUAL
ENGINE INDICATING SYSTEM DESCRIPTION AND OPERATION
i. General.
A. The engine furnished indicating system consists of an 8 probe thermo-
couple harness for indicating exhaust gas, temperature and 2 exhaust gas
pressure sensing probes.
NOTE: CJ6LO-9 engines used on Israel Aircraft Industries (I.A.I.) air-
I craft, includes an engine temperature protector (ETP). The ETP
consists of a resistor installed in series in the thermocouple
harness circuit to more accurately indicate the actual average
exhaust gas temperature.
B. The airframe indicating system consists of one tachometer gen-
furnished
erator, located at aft end of oil tank, and a fuel flow indicator. Op-
tional airframe equipment consists of oil pressure and- anti-icing tem-
perature indicating leads and indicators.
2. Description.
A. Thermocouples.
The thermocouple harness consists of 8 probes containing chromel-alumel
thermocouples arranged in the front of a single integral harness and
lead assembly to monitor turbine exhaust temperature. The harness is
mounted on the exhaust cone with the thermocouple probes projecting into
the gas stream, through the exhaust casing and the lead extending for-
ward and terminating in an electrical connector.
B. Tachometer Generator.
The engine speed Indicating equipment consists of the tachometer gener-
ator (airframe-furnished). It is mounted on 4 studs on the rear of the
lubrication pump that extends through an aft mounting pad of the oil
tank.
C. Pressure Probes.
The 2 pressure probes (Pt5) are mounted at 6 and 12 o’clock on the ex-
haust’cone and connect to a common manifold.
Nov. 15/73 77-OF
Page 1
o rn EIAL EIEGTRIC
CJ6I0 TURBOJET
MAINTENANCE MANUAL SEI-186
3. Operation.
A. Thermocouple.
The thermocouples are mounted on the exhaust cone and are wired in par-
allel and geometrically balanced. When the junctions are exposed to the
exhaust gases, a voltage is produced (between the 2 dissimilar metals).
The net millivolt output of the thermocouples is the arithmetical aver-
age of their individual voltages and varies directly with the exhaust
gas temperature. The resultant temperature is shown on an indicator
mounted in the aircraftcockpit.
B. Tachometer Generator.
The frequency output of the tachometer generator is proportional to en-
gine speed. This resulting electrical signal is transmitted through an
airframe-furnished electrical lead to the cockpit tachometer indicator.
C. Pressure Probes.
The 2 pressure probes (Pt5) are optional equipment, extend into the ex-
haust gas stream and connect to a common manifold located at the aft end
of the exhaust cone. The airframe pressure indicating system connects
to this manifold and the resultant aircraft cockpit indicator reading is
the engine pressure ratio (Pt5/Pt2)´•
77-00 Nov. 15/73
Page 2
GEWERAL Q ELICtllC
CJ610 TURBOJhT
SEI-186 MAINTENANCE MANUAL
ENGINE INDICATING SYSTEM TROUBLE-SHOOTING
i. General.
If trouble occurs inindicating system, it is important to be sure that
the
all connections
are secure and correctly made. Because the system consists
of only one engine-furnished component, establish whether the malfunction is
an airframe or an engine fault is relatively simple.
Trouble-Shooting information is furnished in Chapter 72-00.
15/67 77-00
Nov.
Page 101
GEWERAL~ELE CTR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
ENGINE PRESSURE RATIO PROBES AND MANIFOLD MAINTENANCE PRACTICES
i. General.
The pressure probes and manifold are optional equipment. The maintenance is
to be limited to that as stated.
2. Removal/Installation. (See figure 201).
A. Removal.
(1) Disconnect exhaust pressure probe (1) from the manifold.
NOTE: If manifold is to be removed, disconnect both pressure probes.
(2) Remove brackets (4), bolts (2), and nuts (3) from probes (1).
(3) Remove brackets (4), bolts (5), and nuts (6) from exhaust cone aft
flange.
(4) Remove probes and probe hex nuts from exhaust cone bosses.
(5) Record probe part number to ensure correct probe reinstallation.
B. Installation.
(1) Check probe part number to verify it is the same part number of the
probes removed in step A.(5).
(2) Place probe (1) in the boss on the exhaust cone. Make sure the pin
on probe is aligned with the slot in the boss.
(3) Lubricate the threads of the probe and the hex nut with anti-seize
compound, unflavored milk of magnesia, or equivalent.
(4) Align the probe with the manifold tube nut. Tighten the manifold
nuts to 40-50 Ib-in. and lockwire.
(5) Tighten the probe hex nuts to the e~haust cone boss to 40-50 Ib-in.
and lockwire to thermocouple nut.
(6) Install brackets (4) to probes (I) with bolts (2) and nuts (3).
(7) Fasten brackets (4) to eirhaust cone aft flange using bolts (5) and
nuts (6).
Dec 31/91 77-11-0
Page 201
GEWEII~LQE L6EtiliC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
2 1
B
i. EXHAUST PRESSURE PROBE
2. BOLT
3. NUT
4. BRACKET 1
5. BOLT
6. NUT
8C-0357
Exhaust Pressure Probe Mounting
Figure 201
77-11-0
Dec 31/91
Page 202
6 L W ER6L E Lf CT R IC
CJ610 TURBBJET
SEI-186 MAINTENANCE MANUAL
3 Ins D e ct i on/ Che ck S ee figure 202 Check probes fo r the following de fe c ts
Ins p e ct i on/ Check Maximum Se rv i c e ah le L imi t s Co rr e c t ive Act i on
A. Ob s t ru c t i ons in No t s erv i c eab 1 e Remove obs t ruc t i ons
ho les D and X.
B Bent or d i s t o rt ed Not s e rvi c e ah le St rai ght en and ex-
amine very closely
for cracks.
C Cracks No t s e rv i ceabl e Replac e pr oh e
D Mi s s ing al ignment No t s e rvi c eable Replace p r ob e
pin located in
collar.
WARNING: COMPRESSED AIR WHEN USING CO~IPRESSED AIR FOR ANY COOLING, CLEAN-
ING, OR DRYING OPERATION DO NOT EXCEED 3 O PS IG AT THE NOZ ZLE
EYES CAN BE PERMANENTLY DAMAGED BY CONTACT WITH LIQUID OR LARGE
PART I CLE S PROPELLED BY COMPRESSED AIR. INHALATION OF AIR-BLOWN
PARTI CLE S OR S OLVE NT VAPOR CAN DAMAGE LUNGS
WHEN USING AIR FOR CLEANING AT AN AIR-EXHAUSTED WORKBENCH, WEAR
APPROVED GOGGLES OR FACE SHIELD,
WHEN USING AIR FOR CLEANING AT AN UNEXIIAUSTED WORKBENCH, WEAR
APPROVED RESPIRATOR AND GOGGLE S
4 C 1 e an i na If the probe i s cl o gg ed i t can b e cl e ane d by pass ing a cl eaning
wi re through the sensing ho les (O 029-0 033 inch diamet er) and then applying
c omp r e s s ed air The mani fo id can also b e cleaned by app lying comp r e s s ed a i r
NOTE Be fo r e apply ing comp r es s ed air d i s c onne c t the mani fold from the ai r-
frame conne c t o r
5 ReDa i rs No repai r p e rmi t t ed o ther than tho s e sp e c i f i ed in paragraph 3
Dec 31/91 77-11-0
Pagd203
ELECIIIE
cJsio TURSdJET
MAINTENANCE MANUAL SEI-186
O HOLE X
ONE HOLE
THRU ONE
WALL
4.01
3.99
HOLE A
HOLE D 7880
ONE WALL
HOLE D
ONE HOLE
PLUG WELD PN 110,
113 OILY
FILLER MATERIAL:AMS 5680
ASSY IDENT NO HOLE D HOLE A HDtE X
3704017399108 OPEN 0.031
370401 739P110 PLUG WELD 0.080
3704017399111 O. 020 PLUG WELD O. 080
37D401739P112 0.035 PLUG WELD 0.080
3704017399113 0.045 PLUG WELD 0.080
37D401739P1~4 0.020 OPEN 0.031
37D401739P115 0.035 OPEN 0.031
ALL DIMENSIONS 370401739P116 0. 045 OPEN 0,031
AREININCHES
50-0464
Pressure Probe
Figure 202
77-11-0 Dec 31/91
Page 204
6 EW ERAL ~g ELECtRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MP;NUAL
THERMOCOUPLE ZLARNESS AND ENGINE TEMPERATURE
PROTECTOR MAINTENANCE PRACTICES
i. General. The thermocouple. harness, probes, and engine temperature protector
(ETP) are covered in this:section and the remainder of the indicating system
is covered in the Aircraft Manual.
NOTE: The ETP is installed on engines used on
CJ610-9 Commodore Jet Model
1123 (Reference Service Bulletin 77-2)
aircraft and Hansa Model 320
aircraft (Reference Service Bulletin 77-1).
Ih_ (2
,o
1) I "1) i~
i. EXHAUST PRESSURE PROBES I 1,
2. THERMOCOUPLE HARNESS CONNECTOR 4 3´•
3. THERMOCOUPLE HARNESS
4. EXHAUST CONE
5. NUTS-THERMOCOUPLE TO MOUNTING BOSS \a
Thermocouple Karness
Figure 201
DEC 31/91 77-21-0
Page 201
G6WERAL ELECfRIC
CJ610 TURBOJET
MAINTENANCE MANUAI, SEI-186
2. Removal /Installation Thermocouple Harness. (See figure 201.)
A. Removal.
(1) Disconnect the harness connector (2) from the bracket.
(2) Disconnect the harness (3) and clamps from the standoff brackets.
(3) Disconnect the nuts (5) from the mounting bosses on the exhaust
cone (4). Remove the harness.
B. Installation,
(1) Lubricate the threads of the 8 thermocouple bosses with unflavored
milk of magnesia.
(2) Install the thermocouples in the mounting bosses. Torque the nuts
(5) to 40-50 Ib-in. and lockwire.
NOT~: Do not allow anti-seize compound to get on the thermocoupl;e
elements. Do not damage the tips when inserting them into
the bosses.
(3) Clamp the harness (3) to the brackets. Tighten the clamp nuts to
standard torque value.
(4) Secure the harness connector (2) to the mounting bracket. Torque
the screws to 8-10 Ib-in. and lockwire them.
NOTE: Before running engine, check the aircraft/engine EGT indicat-
ing system for correct circuit resistance. Refer to appro-
priate aircraft manual for procedure.
1 77-21-0 Dec 30/78
Page 202
CJ610 TURBOJET ENGINES
GEAimaftEn~sines FIAINTENANCE MANUAL
3. Inspection Limits. (Installed on the engine.)
Inspection/Check Maximum Serviceable Limits Corrective Action
A. Rigid tubing Not serviceable. Replace the harness.
for cracks.
B. Hot junctions
for:
(1) Erosion or 1/2 of the original Replace the harness.
burning, diameter.
(2) Carbon Not serviceable. Remove the carbon.
buildup.
(3) Broken loops. One broken loop Replace the harness.
per harness.
C. Harness for 1200 ohms minimum. Replace the harness.
insulation
resistance
(lead-to-ground)
D. No indication when One per harness Replace the harness.
local heat is applied (including broken
to an individual probe loop)
(use a clean heat
source)
E. Harness for continuity 0.525-0.645 ohm. Replace the harness.
resistance.
F. Engine temperature
protector (ETP) for
resistance:
NOTE: Resistance of the ETP checked by disconnecting both the
is
connectors to the shorting across pins A and B on the
ETP,
input connector (from the thermocouple harness), and measuring
the resistance across pins A and B on the output connector
(to the aircraft Tg meter) with a Wheatstone Bridge.
(1) CJ610-9 engines i-0.1 ohm of the resistance Replace the ETP with
installed on value stamped on the ETP one that has the
Commodore Jet nameplate. same resistance
Model 1123 value as the ETP
aircraft, being replaced, as
stamped on the metal
ETP nameplate and
recorded in the
engine log book.
77-21-0
Jul 15/99 Page 203
CJ61 O TU R BOJ ET ENG I N ES
GE Aircraft En~sines MAINTENANCE ANUAL
In spe c t i on Che c k Maximum Se rvi c eable L imi t s Correc t ive Ac t i on
(2)CJ610-9 engines
installed on
Hansa 320 aircraft:
(a) Input circuit 500 ohms minimum when Rep lace the ETP with
be twe en pins measured at 7 5 OF 1 50F one t ha t ha s the
A and B of the same resistance
2 50C 8 3 OC
input connector) value as the ETP
being replaced, as
stamped on the metal
ETP nameplate and
r e c or de d in the
engine log book.
NOTE: Re s i s tance o f the ETP outpu t c i rcui t is chec ked wh ile c onnec t ed
to the eng i ne t he rmo c ouple ha rne s s or a sui t able re s i s t an c e
(0.6 ohm +58) can be used acress te rminals A and Bof the input
connector.
b Ou tpu t c i rcu i t 100 ohms maximum Repla c e the ETP wi th
(between pins A one that has the
and B of the same resistance
t r im- box ou tpu t value as the ETP
connector). being replaced, as
stamped on the metal
ETP nameplate and
recorded in the
engine log book.
77-21-0
Page 204 Jul 15/99
C H A PT E R
EXHAU ST
OEW ERAL E LE CI R IC
CJ610 TURBOJET
SE I-186 MAINTENANCE MANUAL
CHAPTER 78 EXHAUST SECT ION
TABLE OF CONTENTS
Page
78 -00 EXHAUST SECTION
Dese ription 1
78-10 COLLECTOR SYSTEM (Table of Cent ents On ly)
78-11-0 Exhaust Cone Ass embly
Ma intenance Practices 201
Mar 30/84 78
Page 1
G E 13 E R A L L LE CT R IC
CJGIO TURBOJET
MAINTENANCE MANUAL
SEI-186
CHAPTER 78 EXHAUST SECTION
LIST OF EFFECTIVE PAGES
CHAPTER/
SECTION PAGE DATE
78 *I Dec 31/91
78 Contents 1 Mar 30/84
78-00 1 thru 2 Apr 15/68
78-11-0 201 thru 202 Sep 15/69
203 Apr 15/68
204 thru 205 Mar 30/84
206 thru 207 Oct 15/70
~Asterisk indicates pages added, changed, or deleted by this revision.
78
Dec 31/91
OIIIRIL´•LLLCTIIIC~
CJ810 TURBOJIET
SEI-186 MAINTENANCE MANUAL
EXHAUST SECTION DESCRIPTION
CENTERBODY SUPPORT
OUTER CASING
CENTERBODY
BAPFLL ~j;
THERMOCOUPLE BOSS
ooO
CJ610 6003´•1-C2
Exhaust Section
Figure 1
i. General. The exhaust section consists of an outer casing, centerbody, and
struts. The primary functions of the exhaust section are to confine and
direct the flow of turbine exhaust gases and support the engine tailpipe.
April 15/68 78-00
Page 1
GEW ERAL O~B ELLCTRIC:´•------
CJB10 TURBOJET
MA I NTENANCE MANUAL SEI-186
2 De scription
A. Ou te r Ca s i ng The s t eel outer cas i ng ha s ei ght bo s s e s to admi t the ex-
haus t ga s the rmoc ouple s and two bo s s e s f or mount i ng the e xh au s t ga s total
pres sure sensing probes. Four pads serve as moun ts for the center body
support s Some cone s al s o have two p ad s for admi t t i ng e i ghth- s tage leak-
age a ir The Forward edge is f 1 ange d for mou n t i ng to t he tu r b i ne c as i ng
the af t edge i s fla nge d for at t ac hi ng a cu s tome r fu mi shed t a i 1 p i pe and
jet nozzle as sembly.
B. Centerbody. The front of the steel centerbody is a baffle which keeps
the second- s tage tu rbi ne wheel f rom ove the a t i ng by p re ven t i ng the ha t
e xhau s t ga s e s f rom flowi ng sc ro s s the rear f ace of the whee 1 The cane
shell has four reinforced openings to admi t the struts. Aslight de ar-
ance between the shel 1 and the s t ru t al 1 ow s i nd e pe nden t e xpa n s ion of
either part.
C S tru t s The four s teel s t ru t s are wel de d t a ge t he r at the mi ddl e of the
centerbody and are supported at their ou ter ends by the center body sup-
port s The s e suppo r t s are bo ited to pad s on the ou ter c a s i ng and pro-
trude into the ends of the s t rut s Thi s pe rmi t s expan s ion and contrac-
t i on of the s t ru t s throughout t he tempe r a tu re range and al so p ro vi de s for
I removal of the centerbody.
78-00 Aprill5 /68
Page 2
(PICIAL LLECTIIC
cJeio TURBOJET
SEI-186 MAINTENANCE MANUAL
EXHAUST CONE ASSEMBLY MAINTENANCE PRACTICES
i. Gene ral :Only the external area of the exhaust cone and those areas seen
through the tailpipe are inspected unless the cone is removed from the en-
gine.
2. Removal/Installation.
NOTE: The tailpipe must be removed before the exhaust cone can be removed.
A. Removal of Exhaust Cone and Attached Parts. Remove the exhaust cone
and attached parts as follows:
(1) Disconnect the thermocouple harness connector by removing the 4
screws that attach the connector to the connector support bracket.
(2) Remove the nuts and bolts that attach the 8 thermocouple harness
clamps to the brackets.
(3) On CJ610-5 and -6 engines remove the 2 leakage air ducts by removing
4 nuts from each flange at the exhaust cone. Pull the ducts from
the elbows.
(4) Remove the nuts and bolts that attach the exhaust cone to the tur-
bine casing. Note the location of the 8 thermocouple harness brack-
ets and the engine aft lifting lub. Match-mark the exhaust cone
with the turbine casing. Remove the exhaust cone and the attached
parts.
B. Installation of Exhaust Cone and Attached Parts. Install exhaust cone
and attached parts as follows:
NOTE: Assemble pressure probes and manifold according to 77-11-0.
(1) Position the exhaust cone on the turbine casing.
I (2) Install the
See.Section72-50,
vertical flange bolts, lugs, brackets
figure 205, for assembly notes
and
and
locknuts.
torques.
(a) Insert the 2 long bolts for the engine installation lug.
(b) Insert the long bolts for the thermocouple brackets. Use a
washer between the forward side of the flanffe and the bracket.
The offsets of the bracket face forward.
(c) Insert the remaining bolts.
´•’’:Sept. 15/69 78-11-0
Page 201
G EN ERAL ~B E LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(3) Assemble the locknuts. Tighten the bolts so that the flanges are
pulled together evenly, and torque all the bolts.
(4) Attach the thermocouple harness clamps to the brackets with bolts
and locknuts.
(5) Assemble the harness connector to the bracket.
(6) On CJ610-5 and -6 engines install the 2 leakage air ducts as follows:
(a) Slide the ducts into the elbows.
(b) Place gaskets and ducts on flange bolts.
(c) Install 8 nuts onto flange bolts and torque.
(7) Axial clearances exhaust cone to second-stage turbine wheel.
NOTE: Exhaust cone axial clearances must be determined when any
affected parts are replaced. Determine clearances as follows:
I (See figure 201.)
(a) Place wax in 4 equally spaced places in the´•turbine wheel throat,
the locking strips and the blade platforms.
(b) Attach the exhaust cone to the turbine casing using 4 bolts and
locknuts equally spaced around the flange.
(c) Remove the exhaust cone.
(d) Measure the thickness of each piece of wax at the point of im-
pression. Record these dimensions as the clearances.; Dimen-
sions i, 2 and 3 (figure 201) must be met.
(e) Remove all traces of wax from the engine.
I (f) Install cone per paragraphs 2.8.(1) through Z.B.(6).
3. -Inspection Check. Visually inspect the exhaust cone assembly as follows:
Where serviceable limits are exceeded parts may be replaced In accordance
with the Overhaul Manual.
78-11-0 Sept. 15/69
Page 202
OENIR~L O ILIC1RIC
CJ610 TURBOJET
SE I-186 MA TNTENANCE MANUAL
CENTERBODY
I--s
SECON D-S TAG E
TURBINE WHEEL
DIR.
REF. MIN. MAX.
MEAS.
1 0.210
2 A 0.210
9 A 0.210
CJ61060801-82
Exhaust Cone Clea rances
Figure 201
78-11-0
April 15/68
Page 203
GLWIRAL C LE CtRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
Inspection/Check Maximum Serviceable Limits Remarks
A. The outer casing for:
(1) Cracks in parent (a) Two cracks 1/4 inch long,
material. separated by a minimum
of 1/2 inch.
(b) Ten 1/8
cracks inch long,
separated by a minimum
of 1/4 inch.
(2) Weld cracks. (a) Ttro cracks1/4 inch long,
separated by a minimum
of 1/2 inch.
(b) Ten cracks 1/8 inch long,
separated by a minimum of
1/2 inch.
(3) Dents. 3/16 inch deep with a minimum
radius of 8 times the depth.
B. The outer casing bosses for:
(1) Cracks Not serviceable.
(2) Damaged threads One full thread with no
metal beyond thread contour.
C. The boss doublers for:
(1) Cracks Not serviceable.
(2) Missing or loose Not serviceable. Replace rivets.
rivets
NOTE: The following items are to be inspected if the exhaust cone assembly
is removed from the engine.
iD. The flanges for:
(1) Cracks Not serviceable.
(2) Nicks, scratches Any number, 0.020 inch deep
and burrs with no high metal and
across no more than 3/4 of
a mating or sealing surface.
78-11-0
Page 204 Mar 30/84
666 LRIL 9~ EtECIAIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
InspectionlCheck Maximum Serviceable Limits
Remarks
E. The centerbody for:
(1) Cracks Not serviceable.
(2) Dents Any number, 3/16 inch deep
with a minimum radius of 8
times the depth.
F. The struts for:
(1) Cracks Not serviceable.
(2) Dents Any number, 3/16 inch deep
with a minimum radius of 8
times the depth.
G. The struts and strut Any amount if struts are not
Collars for wear worn through (use a bright
light inside strut to check).
H. The cover for:
(1) Cracks Not serviceable.
(2) Bulging Any amount not closer than
.210 inch to aft face of
second-stage turbine wheel.
I. Intersection of Not serviceable.
strut cover and
exhaust cone weld
area for cracks
J. Cracks at junction Not serviceable Replace exhaust
of outer casing cone.
boss with doubler
K, Centerbody support See following note and
to centerbody support figure 203
flange alignment
NOTE: Inspection may be made with exhaust assembled on engine. Remove
bolts, nuts and washers from 2 adjacent centerbody support flanges,
Do not remove the centerbody supports. Permit the struts and
supports to take a relaxed position. Measure dimensions X and Z,
figure 203, Replace exhaust cone assembly if X dimension is
greater than 3/16 inch, or if Z is greater than 0.940 inch, on
either support flange.
78-11-0
JMar 30/84
Page 205
orn rnii a~ ELICrRIC
CJ610 TURBOJET
MAINTENANCE MANUAL
SEI-186
1/811 DIA. ROD
WELD
MATERIAL AMS5680 OR 12"
347 STAINLESS STEEL
1/2" DIA. ROD
c~clclvl.arl
Pulling Tool
Figure 202
li-"
CEN;ERBODY I I~-o i´•b
SUPPORT
FLANGE
--41 1 ;I FWD
____ilb:
CENTERBODY
SUPPORT
i REF.
f SIJPPORT
CJ~IO´•6127 O D2
Centerbody Support Flange Alignment
Figure 203
78-11-0 Oct. 15/70
Page 206
GEYI~AL ELEeTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL
SE1-186
4. Approved Repair.
A. Centerbody Dent Repair. This procedure may be used to remove dents in
the portion of the centerbody aft of the circumferential weld. Remove
dents in this area as follows:
(1) Locally manufacture pulling tool as shown in figure 202.
(2) Clean oxides from the center of dent and tack weld the 1/8 inch di-
ameter rod of the pulling tool to the center of the dent. Use gas
backup.
(3) Use an oxy-acetylene torch and heat the dent area to a cherry red
using a circular motion. Do not hold the torch too long in one spot.
(4) While continuing to play the torch over the dent area, use the rod
T-handle and pull on rod to remove dent.
(5) Cut off rod close to weld and blend dent area to original contour.
Do not undercut parent metal.
(6) Fluorescent-penetrant inspect the repaired area. No cracks allowed.
I Oct. 15/70 78-11-0
Page 207
C H A PT E R
OIL
6 EW ER L I LICfl~C
CJ610 TUReoJET
SEI-186 MAINTENANCE MANUAL
CHAPTER 79 LUBRICATION SYSTEM
TABLE OF CONTENTS
Page
79-00 LUBRICATION SYSTEM
Des crip tion and Operations 1
Troubleshooting i
101
Maintenance Practices 201
Servi cing 201
I n spa c ti on/Che ck s 207
79-10 STORAGE (Table of Conte nts Only)
79-11-0 Oil Tank
Maintenance Prac t i ce a 201
79-12-0 Oi 1 Tank Relief Va lye
Maintenance Pract, ices 201
79-20 DISTRII3UTION (Table of Cent ent s On ly)
79-21-0 Lube and Scavenge Pump
Maintenance Practices 201
79-22-0 Oi 1 Filter
Maintenance Practices 201
79-23-0 Oi 1 Cooler
Maintenance Practices 201
79-40 SUMP PRESSURIZING AM) VENT SYSTEM (Table of Cent ent s On ly)
79-41-0 Eighth-Stage Air Leakage Valves
Maintenance Prac ti ces 201
79-42-0 Oi 1 Tank Check Va lyes
Maintenance Practices 201
79-43-0 Oi 1 Manifold Check Va lye
Ma i nt enanc e Pract i ce s 201
79
Dec 30/78
Page 1
GENERAL ELEMRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
CHAPTER 79 LUBRICATION SYSTEM
ZIST OE EFFECT~VE PAGES
CHAPTER/ CHAPTER/
SECTION PAGE DATE SECTION PAGE DATE
79 *I Dec 31/95 79-41-0 201 Jan 15/69
202 Dec 31/91
Contents 1 Dec 30/78 203 Jan 15/69
79-00 1 Mar 30/84 79-42-0 201 thru 202 Mar 30/67
2 May 15/70
2A/2B Sep 15/69 79-43-0 i01 thru 202 Mar 30/67
3 Sep 15/69
4 May 15/70
4A/4B Sep 15/69
5 thru 7 Mar 30/67
101 Nov 15/67
201 thru 202 Dec 31/91
202A/202B Dec 31/91
203 thru 204 Dec 1/79
205 Jan 15/69
206 Dec 1/79
206A/206B Dec 1/79
207 thru 208 Nov 15/72
79-11-0 201 May 15/70
79-12-0 201 Jan 15/69
79-23-0 201 thru 202 Jan 15/69
202A/202B Nov 15/73
203 Nov 15/73
204 thru 208 Jan 15/69
209 May 15/70
210 Mar 30/67
211 thru 214 Apr 15/68
215 May 15/70
216 Oct 15/70
*217 thru 218 Dec 31/95
79-22-0 201 thru 203 Jan 15/69
204 thru 205 Nov 15/73
79-23-0 201 thru 202 Jan 15/69
203 Mar 30/67
*Asterisk indicates pages added. changed, or deleted by this revision.
79
Dec 31/95 I
666 ERAL EIECTR 16
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
LUBRICATION SYSTEM DESCRIPTION AND OPERATION
i. General.
The engine has pressurized closed-circuit lube system designed to furnish
a
oil to
parts which
require lubrication during engine operation. After oil
has been supplied to these parts it flows to the sumps where it is recovered
and recirculated throughout the system. All system components are engine-
furnished and engine-mounted. The main components of the lube system In-
dude:
Lube Scavenge pump-mounted
and on the rear right-hand pad of the acces-
sory gearbox.
Oil Tank secured to the lube and scavenge pump.
Oil Cooler mounted on the oil tank.
Oil Filter contained within the lube and scavenge pump casing.
2. Operation.
A. Lubrication. The pressure element of the lube pump pumps oil from the
tank, through the oil cooler, throug’h the oil filter and into the acces-
sory gearbox. Part of the oil services the gearbox; the remainder Glows
through the gearbox to 2 outlet ports on the left-side of the gearbox.
Oil then flows port through an external line to the front sump.
from one
Oil flows port through an external line to the main sump.
from the other
This line services, through internal tubing, the internal bearings,
seals and gears of the engine. The five scavenge elements of the lube
and scavenge pump pick up the oil which collects in the engine sumps and
returns it to the oil tank.
B. Sump Pressurizing, The pressurizing system conducts air through pas-
sages in the engine components to pressurize the oil seals and the en-
gine lube system.
Compressor-discharge leakage air flows across the compressor eiffhth-
stage air seal and pressurizes the No. 2 bearing carbon seal. Part of
this air circulates through the compressor rotor interior and fourth-
stage air duct to pressurize the No. 1 bearing carbon seal. Air leakage
across the carbon seals enters the lube sumps where it is scavenged with
the oil to, the lube tank or vented overboard through the center vent.
Mar 30/84 79-00
Page 1
DEWERAL~B) IIEETRIC------
CJGIO TURBOJET
MAINTENANCE MANUAL SEI-186
Part of the combustor cooling air flows into the balancepiston chamber
through holes in the aft flange of the inner combustion casing. The air
then flows through the turbine wheel inner labyrinth seal to pressurize
the No. 3 bearing carbon seal. Air leakage across the carbon seal en-
ters the lube sump where it is scavenged with the lube oil to the lube
tank.
FRONT FRAME OIL INLET
MA~IN SUMP VENT
FRONT FRAME SUMP VENT
CHECK
VALVES
OIL
TANK
t OVERBOARD VENT
RELIEF VALVE
DWELL CHAMBER
OVERBOARD
II FRONT NO. 283
SEAL DRAIN NO. 3 BEARING SCAVENGE
LUBE AND FRAME BEARING
SCAVENGE SUMP IOIL INLET
PUMP W DRIVE END
NO.2SUMPAND
P.T.O.
615141312 1
SCAVENGE
POWER TRANSFER GEARBOX
ACCESSORY
RELIEF VALVE Ej GEARBOX
BYPASS ACCESjoRY TRANSFER GEARBOX SCAVENGE
OILFILTER GEARBOX
VALVE
SCAVENGE
sv~Ass ~11 VENT SERVICE SCAVENGE
OILCOOLER VALVE
cJs~o-aosz-I-cz
Lubrication System CJB10-l (Non-Center Vent)
Figure 1
79r00 May 15/70
Page 2
OIYFI~LOILteTIIIC
CJ6I0 TURBOJET
SEI-186 MAINTENANCE MANUAL
MAIN SUMP VENT
FRONT FRAME SUMP VENT
OVERBOARD VENT
FRONT FRAME OIL INLET
RELIEF VALVE
OVERBOARD
OIL TANK SEAL DRAIN
CHECK
VALVES j ~J\LfDWELL
CHAMBER
FRONT FRAME
SUMP SCAVENGE L~JI a CY I N´•´• 3 BEARING SCAVENGE
DRIVE END
N0.2SUMPAND
PTOSCAVENGE L~-J
LUBE AND SCAVENGE NO. 2 AND 3 BEARING
s i 1 3 2 1 OILINLET
PUMP
ACCESSORY GEARBOX
RELIEF VALVE
ACCESSORY GEARBOX SCAVENGE
O1L FILTER
BYPASS VALVE
BYPASS VALVE
I~ VENT SERVICE E~IJSCAVENGE
OIL COOLER
CJ610-6121´•0-C2
Lubrication System CJ610-4 (Non-Center Vent)
Figure 1A
79-00
Sept. 15/69 Page 2A/2B
GEW ERAL~ ELECTIIC--------
CJB1Q TURB03E-T
SEI-186 MAINTENANCE MANUAL
C. Sump Vent System (Non-Center Vent). See figures 1 and 1A.
ThB sump vent is designed to maintain a controlled positive pres-
system
sure in the front
bearing sump, main sump, gear case, and oil tank. The
purpose of maintaining a positive pressure (above ambient) is to make
the tube system insensitive to altitude. Controlled carbon seal leakage
for the system is the source of pressurizing air which is normally re-
circulated exceptfor excessive air which is vented out of the system
through the tank~relief valve.
The scavenge pumpsextract an air-oil mixture from the sumps and return
it to the oil tank where the air is separated andcarrled to the air
chamber of the tank. From the air chamber, theair iB directed to the
forward and main sumps. Under normal conditions, air is forced to flow
from the tank to the sumps because the displacement of the scavenge
pumps is greater than the combined carbon seal air leakage and oil flow
from the oil supplypump, and hence would tend to evacuate the sumps if
air were not allowedto return to the sumps. If a malfunction occurs in
either sump, air may flow fromthe´• sump to the tank and’i8 handled as
referred to later in this description. Any excess of air not required
to maintain equilibrium in the system:is vented overboard, through the
vent relief valve located on the t~tnk. The’functions of’the valves in
the system are as follows:
(1) One check.valve only allows flow away from’the air chamber of the
tank. It is a swing or flapper type check valve used to allow the
normal air flow to return from the tank to the sumps and yet check
or prevent any back flow-of oilfrom: the sumps to the air chamber
during maneuvers of malfunction such as excessive pressure in the
sumps.
(2) The other check valve allows air from the sumps in excess of scav-
enge pump capacity to flow directly into the oil tank and be vented
overboard. This valve in the check direction (away from the tank)
does not permit oil to drain from the ank to the sumps during ma-
neuvers or in the event of overservlcing.
(3) Overboard Vent Relief Valve. The pressure relief valve is used to
control system pressure leeel to 2.0-3.0 psi above ambient.
the Ex-
cessive pressure buildup resulting from excessive air leakage into
the system is prevented by this valve. The calve has a small vent
orifice to allow depressurization of the pressure system at shut-
down.
Sept. 15/69 79-00
Page 3
GellEIALOallCTRIC´•---
eJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
FRONT FRAME SUMP VENT
BTH-STAGE LEAKAGE
AIR BLEED HOLE
FRONT FRAME
TURBINE ROTOR
SUMP VENT FRONT FRAME’
OVERBOARD VENT 011 INLET LOCKNUT VENT HOLES
RELIEF VALVE \11 I PTO DRIVER SHAFTGEAR
VENT HOLES
DWELL CHAMBER
01L
TANK OVERBOARD L~" U\(I C/r~
SEAL DRAIN El~n
FRONT FRAME COMPRESSOR’I II1YW-I ICOMPRESSOR ROTOR
LUBE AND ROTOR DRIVESHAFT
SUMP SCAVENGE
SCAVENGE DRIVESHAFT
PLUG VENT HOLES
PUMP DRIVE
NO. 2 SUMP AND PTO
END
SCAVENGE
514131211#] IZ,,~,,,,,,,,,,,,
OIL INLET
NO. 3 BEARING SCAVENGE
f
ACCESSORY
RELIEF VALVE POWER
I a a.,nRBOx
TRANSFER GEARBOX
OIL FILTER
BYPASS VALVE ACCESSORY
GEARBOX POWER
SCAVENGE \TRANSFER
GEARBOX
SCAVENGE
OILCOOLER I MAIN SUMP PRESSURE REFERENCE CINE
OIL PRESSURE TRANSDUCER
BYPASS VALVE
VENT SERVICE ~J SCAVENGE
CJ610-6125-1´•CZ
Lubrication System CJ610-1, -5, and -9 (Center Vent)
Figure 2
D. Sump Vent System (Center Vent). See figures 2 and 2A.
The center vent system makes use of internal venting in the main sump
through holes drilled in the compressor drive shaft. The forward end of
the drive plugged
shaft prevent compressor discharge leakage
Is to air
from overpressurizing the main sump. Holes are also drilled in the tur-
bine locknut (which screws into the aft end of the compressor shaft) to
complete the airflow path out of the main sump and overboard via the
turbine exhaust.
79-00 May 15/70
page 4
ELICIRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
FRONT FRAME SUMP VENT
OVERBOARD VENT RELIEF VALVE
3TH STAGE LEAKAGE AIR BLEED HOLE
FRONT FRAME OIL INLET
PTO DRIVER SHAFTGEAR VENT HOLES
DWELL CHAMBER COMPRESSOR ROTOR DRIVESHAFT
OIL TANK VENT HOLES
e=la n
FRONT FRAME~
SUMP OVERBOAR
SCAVENGE SEAL TURBINE ROTOR
DRAI
COMPRESSOR
ROTOR LOCKNUT VENT HOLES
DRIVE END IDRIVESHAFT PLUG
NO. 3 BEARING SCAVENGE
LUBE AND NO. 2 SUMP AND
PTO SCAVENGE NO. 2 AND 3 BEARING
SCAVENGE PUMP
6 5 4 3 2 1FII OIL INLETM-´•´•LLLIIT´•TTT
ACCESSORY GEARBOX
FILTER ACCESSORY
RELIEF VALVE GEARBOX SCAVENGE
BYPASS
MAIN SUMP PRESSURE REFERENCE LINE
BYPASS VALVE -~wall C
OIL COOLER
VENT SERV)CE SCAVENGE
PRESSURE
TRANSDUCER
CJ6106051-1-CZ
Lubrication System CJG10-q, -6, and -8 (Center Vent)
Figure 2A
79-00
Sept. 15/69 Page 4A/4B
GESS1RAL ~B LLLCtR´•IC
CJ610 TURBOJ ET
SE I-186 MAINTENANCE MANUAL
To vent the fo rwa rd sump through the comp re s sor s ha f t it i s ne c e s s a ry t o
c onn ec t the f o rwa r d sump vent 1 ine ext e rna 1 ly to the ac c e s s o ry gearbox
instead of the oil tank. Vent air then flows from the forward sump to
t he gea rbox through the gea rbox axi s I’A" ra d i al drive s ha f t into the
main sump, and then ove rboard through the compre ssor drive shaft Thi s
s y s t em i nc rea s e s the vent c a pac ity o f the f o rwa rd sump
The cen te r vent s y s t em el imi na t e s the oi 1 tank che c k valv e as we 11 a s
the ma in sump vent ii ne and ena ble s the oi 1 tank to ope ra t e i nde pend-
ent ly of t he engine sump s The re f o re the oi 1 t ank ope ra t i n g p re s su re
is increased by changing the tank relief valve cracking pressure. The
i n c rea s ed tank p re s su re suppre s s e s t he fo rma t i on of vapo r in t he lube
pump p re s su re inl e t supply t hu s el i mi na t i ng c av i t a t i on and imp rov i ng
pump pe r f o rmance at a itl tud e This reduce s the t end enc y for o i1 pre s
sure to drop off at high altitude.
3 Lu b r i c a t i on S y s t em Compon en t s
A. Lube and Scavenge Pump.
The combined lube and scavenge pump is a positive displac ement pump con-
si st ing of six gui ded- vane type pump element s mounted along a common
d r i ve s ha f t and conta ined wi t hi n a c ommon hou s i n g The pump e lement s
that se rvice the ma in engine sump are 3 GPM scavenge elements. The ele-
ment s that se rvi ce the gearbox and No 1 bea ri ng sump a re 1 GPM elemen t s
The pre s sure el emen t is a 2 5 GPM e operat ing el ement s of
1 emen t The
the pump extend aft into the oil tank from the pump flange on which the
oil tank is mounted.
The oil pa s se s between t he pump and the gearbox through s ix o ii po rt s on
the pump moun t ing f lange whi ch mate wi th s i x port s on the lube pump
mounting pad on the gearbox. All scavenge oil from the pump is dis-
charged into the oil tank dwe 11 chamber. Lube oil from the oil tank en-
ters the pre s sure el eme n t through a pen du lum- t y pe swi ve 1 pi c kup tube
t ha t extends out f ro m the af t ri g ht ha nd s ide of the pump body It i s
deli vered by the pre s sure e lement d i re c t ly to t he oi 1 coole r through
t he oi 1 fi 1 te r into the gea rbox where it is di s t r i but ed t hrou ghou t the
syst em.
A pres sure reli ef valve mount e d in pa ra ilel wi th the lube di s char ge pa s-
s a ge is inc luded to prevent dama ge that mi ght re suit f rom exce s s i ve o i1
s sure due to co id start ing or re s t r i c t i on o f no rma 1 o 11 f 1 ow The
pre
relief valve is factory adjusted to open at a pressure diffe rential or
85-95 psi (115-125 on center-vent syst ems) ac ross the valve If thi s
pre s sure di ff erent i al is reached the re ii e f valve open s and o ii f rom
the pressure element is disc har ged dir ectly into the oil tank.
Mar. 30/67 79- 00
Page 5
OEWERAL O~ ELE etR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
B. Oil Filter.
The oil filter assembly is mounted in the sump housing. It is a full-
flow, in-line type filter with a corrosion resistant screen element of
corrugated steel. The screen filters out oil contaminants over 40 mi-
crons in size, and is removable for cleaning. A filter bypass valve is
included in the core of the filter element. If the pressure difference
between oil entering the filter and oil leaving the filter exceeds 21-23
psi, the valve opens to permit a direct flow of oil through the unit
without´• filtration.
C. Oil Cooler.
The oil cooler liquid-to-liquid type heat exchanger mounted on the
is a
oil mounting flange and against the right-hand side of the oil
tank
tank. It consists of numerous longitudinal passages arranged in a
honeycomb pattern. Both fuel and oil flow simultaneously through ad-
joining passages and an exchange of heat occurs between hot engine oil
and cool fuel. Oil enters and leaves the cooler through ports located
in the housing for the pressure bypass valve. When the pressure across
the valve exceeds 16-24 psi due to clogging, the valve will open and the
oil will bypass the heat exchanging elements.
D. Oil Tank.
The oil tank is mounted on the aft flange of the lube and scavenge pump.
There are both steel and aluminum tanks in service. Included within the
oil tank is an air chamber (isolated from the remainder of the oil tank),
a dwell chamber and a system of vent tubes. The oil tank filling port
is located on the aft face and the oil level is indicated by a dip-stick
graduated in pints (to be added). Oil that overflows during filling is
collected in a scupper and drained overboard through a scupper drain
port. A vent relief valve boss, a remote fill vent boss, and a series
of check valve boss are located on the top or front of the oil tank.
The lube and scavenge pump mounting flange, oil cooler mounting flange,
and the oil tank drain boss are located on the forward face. A remote
filling boss is located on the aft side of the oil tank. Beneath the
oil tank is a deep well which forms a recess for the tachometer-genera-
tor-alternator unit which is driven from the rear pad of the lube and
scavenge pump. ´•The dwell chamber in the tank is adequate to limit the
volume of entrained air to a maximum of 50/0. The tank capacity is 4.0
quarts total with approximately 3.0 quarts usable.
79-00 Mar. 30/67
Page 6
GEWLRAL O~ ELLCTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
E E i ght h- St ag e Ai r Leakage Va lye s
The e i ght h- s ta ge a i r leakage valve s a re loca t e d a t t he 2 and 10 o do c k
mai nf rame Thes e valve s mai nta in ont rol led sump pre s
po s i t i on on the a c
ble ed i ng- o i i ei ai r 1 ea kage when the p re s su r e e re e e d s
sure by ght h- s t a ge
t he ne c e s sa ry value
79- 00
Mar. 30/67
Pa ge 7
G EW ERAL B~ ELICTRIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
LUBRICATION SYSTEM TROUBLE-SHOOTING
i. General. A malfunction within the lube system Is usually quite obvious.
Either the cockpit pressure indicator will display an abnormal reading or
visual observation will establish the need for corrective action. The lu-
brication system complex, so little trouble may be anticipated in
is not
operation or service by the engine mechanic. Beyond obvious leaks the cock-
pit indicators provide the first symptoms of a system malfunction. Readings
other than normal suggest the nature of the malfunction, but cannot isolate
the cause. Various troubles may create similar indications; however, ex-
perience and forethought will indicate the most probable causes.
I Trouble-Shooting information is furnished in Chapter 72-00.
Nov. 15/67 79-00
Page 101
OLWERAL~ELECTRIC-----
CJ610 TURBOJET
SEI-186 MAINTENANCE MANLTAL
LUBRICATION SYSTEM MAINTENANCE PRACTICES
i. General. ´•The information presented under system maintenance applies to the
system as a whole. Maintenance fnfomration which applies to an individual
component is presented as.part of the maintenance information for that
component.
WARNING: LUBRICATING OIL IF OIL IS DECOMPOSED BY HEAT, TOXIC GASES ARE
RELEASED
PROLONGED CONTACT WITH LIQUID OR MIST MAY CAUSE DERMATITIS AND
IRRITATION.
IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AREA WITH SOAP
AND WATER. IF SOLUTION CONTACTS EYES, FLUSH EYES WITH WATER
IMMEDIATELY. REMOVE SATURATED CLOTHING,
IF OIL IS SWALLOWED, DO NOT TRY TO VOMIT. GET IMMEDIATE MEDICAL
ATTENTION.
WHEN HANDLING LIQUID, WEAR RUBBER GLOVES. IF PROLONGED CONTACT
WITH MIST IS LIKELY, WEAR APPROVED RESPIRATOR.
CAUTION: SILICONE OR SILICONE BASED OIL OR GREASE SHALL NOT BE USED ON
LUBE SYSTEM COMPONENTS. SMALL AMOUNTS (SUCH AS THAT USED TO HOLD
O-RINGS DURING ASSEMBLY) WILL CONTAMINATE THE OIL SYSTEM.
SILICONE CONTAMINATION WILL CAUSE THE ENGINE OIL TO FOAM, THEREBY
RESULTING IN OIL LOSS THROUGH THE OVERBOARD VENT, IN LOSS OF OIL
PRESSURE, AND ULTIMATELY IN DAMAGE TO THE ENGINE.
2. Servicing.
A. Approved Oils/Operating Requirements.
(1) Approved oils. The following list of lubricating oils is approved
for use in GE Aircraft Engines, CJ610 series and supersedes and
cancels all previous information on this subject.
CAUTION: THE INTERMIXING OF DIFFERENT APPROVED BRANDS OF TYPE 2 OR
OF TYPE 1 OILS IS AUTHORIZED; HOWEVER, INTERMIXING OF OIL
TYPES SHOULD BE AVOIDED. IF INTERMIXING OF OIL TYPES HAS
OCCURRED, THE OIL SYSTEM MOST BE DRAINED, FLUSHED PER
PARAGRAPH 2.E. AND REFILLED IMMEDIATELY.
Dec 31/91 79-00
Page 201
G E R E RAL ~B E LE CTR I C
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
I (a) Type 1 Oils (Conforming to GE Ai rcraft Eng ines S p e c i fi c a t i on
D50TF1 current revision)
NOTE Type 1 oils should b e used in expected cold c limat es
-180 to -5 40 C (Oo to -650F)
engine op er- For best
ation, is recommended
it that engine oil be heated to
-18"0 (OOF) or above when in cold climat es.
12389 Turbo Oil Humble Oil d Refining Company
2 RM 184A Mobil Oil Company
3 Shell Aircraft Oil 307 Shell Oil Company
I (b) Type 2 Oils: (Canforming to GE Air craft Engines Spec i fi cat i on
D50TF1 current revis ion) See Table I
(2) Oil approval.
Op e ra t o rs de s i r i ng to use an o ii no t included in the ii s t s of approved
I o ils mus t obtain sp ec i fi c approval from GE A i r cr a ft Eng ines pr i o r to
its us e Approval will be grant ed upon submi s s i on by the op e rat o r or
the o ii company involved o f vali d evidence demons t rat ing that the
par t i cu lar o ii c onfo rms to the r equi r ement s o f GE Ai rcra ft Eng ines
I S pe c i fi cat i on D5 OTF1 or r evi s i ons thereto
79-00 Dec 31/91
Page 202
OEIIIRIL~ELICTRle
CJGIO TURBOJET
SEI-186 MAINTENANCE MANLTAL
TABLE I
TYPE 2 APPROVED OIL LIST
Brand Name Oil~ Company
i. AeroShell Turbine Oil 500 Shell Oil Company
2. AeroShell Turbine Oil 555 Shell Oil Company
1 3. AeroShell Turbine Oil 560 Shell Oil Company
4. AVTUR Oil Synthetic Dillons Chemical Company
5. Castrol 205 Stauffer Chemical Company
Castrol, Ltd.
6. Caltex RPM Jet Engine Oil 5 Caltex Petroleum Corporation
7. Caltex 7388 Caltex Petroleum corporation
8. Chevron Jet Engine Oil 5 Chevron International Oil Company
9. Enco Turbo Oil 2380 Humble Oil 6( Refining Company
1O. Esso Turbo Oil 2380 Humble Oil 8 Refining Company
11. Mobil~Jet Engine Oil II Mobil Oil Company
12. Mobil Oil 254 Mobil Oil Company
13. Royco Turbine Oil 560 Royal Lubricants
14. Sinclair Turbo-S Type 2 Sinclair Refining Company
15. Stauffer Jet II Stauffer Chemical Company
16. Texaco SATO 7388 Texaco, Incorporated
17. Texaco Starjet 5 Texaco, Incorporated
18. Caltex Starjet 5 Caltex Petroleum Corporation
19. E~oron Turbo Oil 2380 Exxon Company
NOTE: i. Stauffer Jet II, AVTUR Oil Synthetic, and Castrol 205 are
identical oils.
2. Texaco SATO 7388 and Caltex 7388 are identical oils.
3. Chevron Jet Engine Oil 5 and Caltex RPM Jet Engine Oil 5 are
identical oils.
4. Enco Turbo Oil 2380, Esso Turbo Oil 2380, and Exxon Turbo Oil
2380 are identical oils.
5. Texaco Starjet 5 and Caltex Starjet 5 are identical oils.
I 6. Aeroshell
identical oils.
Turbine Oil 560 and Royco Turbine Oil 560 are
Dec 31/91 79-00
Page 202A/2O2B
GENLRAL~ ELICTRIC
CJGIO TURBOJET
SEI-186 MAINTENANCE MANUAL
(3) Operating Requirements.
(a) Replace Type 1 oils with Type 2 at first opportunity using pro-
cedure outlined in following paragraph E.
(b) Change Type 2 engine operating time intervals outlined
oils at
in Table 601, 72-00.
SectionThe engine lubrication system
should be serviced with the approved oils. Type 2 oils should
be used in this engine because they are capable of withstanding
higher operating temperatures than Type 1 oils. Type 2 oils
also have improved anticoking characteristics. Use of Type 1
oil is limited to those occasions when Type 2 oil is unavailable.
B. Oil Servicing During Postflight Inspection.
The oil level should immediately following engine shutdown
be checked
because some oil will seep from the tank into the gearbox while the
engine is inoperative. After an engine shutdown or during a postflight
inspection, immediately check and add oil, if required as follows:
(1) Remove the oil tank filler cap.
(2) Check oil level on the dipstick.
I CAUTION: USE THE SAME TYPE OIL THAT IS AZ~READY IN THE OIL SYSTEM.
(3) If required, add oil until the oil level in the tank is at the full
mark (4 quarts) or slightly below.
All approved oils which in 1 quart less containers
NOT~: ready for use
come
and have been filtered to
or
10 microns. Bulk oil
are
must be filtered through a 10 micron paper or metallic filter.
Paper filter shall be used only when the oil is at ambient tem-
perature. Metallic filters can be used at ambient or elevated
temperatures.
(4) Install the filler cap and lock it.
C. 011 Servicing During Preflight Inspection.
After an engine has been inoperative (or during a preflight inspection),
to avoid over-filling the system check and add oil, if required, as
follows:
(1) Remove the oil tank filler cap.
(2) Check the oil level on the dipstick.
Dec 1/79 79-00
Page 203
G E W E RAL E LE CII IC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
1 USE THE
SYSTEM.
SAME OIL TYPE THAT IS ALREADY IN THE OIL
NOTE: All approved oils which come in 1 quart or less containers are
ready for use and have been filtered to 10 microns. Bulk oil
must be filtered through a 10 micron paper or metallic filter.
Paper filter shall be used only when the oil is at ambient
temperature. Metallic filters can be used at ambient or elevated
temperatures.
(a) If the oil (but still visible on the dipstick) motor
level is low
the engine for 30 seconds, recheck the oil level and add oil as
required. Install filler cap and lock it.
(b) If there is NO oil level indication on the dipstick add oil until
there is an indication on the dipstick. Motor the engine 30
for
seconds, recheck the oil level and add oil as required. Install
filler cap and lock it.
D. Oil Changes Using Same Type of Approved Oil.
The procedure in this paragraph is used only to change oil when the
lube system is to be refilled with the same type of approved oil that
is presently being used in the lube system. If the lube system is
to be refilled with a different type of oil, if oil types have been mixed
or if an unapproved used, the lube system should be drained,
oil has been
flushed and the filter checked per paragraph 2.E. Change the oil as
follows:
(1) Remove the oil tank filler cap.
(2) Remove the drain plugs from the oil tank, accessory gearbox and
transfer gearbox. (See figure 201.) Catch the draining oil in a clean
container that will hold 4 or more quarts.
79-00
Dec 1/79
Page 204
OIW ERAL ILEETAIC
CJslo TURB03ET
SEI-186 MAINTENANCE MANUAL
TRANSFER GEARBOX MAGNETIC DRAIN PLUG
AdcEsSORvGEARBOX MAGNETIC
DRAIN PLUGS
G]j
I’ ~xS4 PI I I Iro
OIL TANK DRAIN PLUG
OIL FILTER
CJ610-1, -5, AND -9 BOTTOM VIEW
o~?
ll,L~l
OIL TANK DRAIN PLUG
OIL FILTER
ACCESSORY GEARBOX MAGNETIC
DRAIN PLUGS
CJb10-4, -6, AND -8 BOTTOM VIEW
CJ610-6112 2-AZn
Location of Oil Drain Plugs and Filter
Figure 201
Jan. 15/69 79-00
Page 205
GENERAL O~ E LE CTR IC
CJ610 TURBOJET
MAINTENANCE MANUAL SE1-186
(3) Remove the oil filter per 79-22-0.
(4) Inspect the magnetic drain plugs, filter, and drained oil for metal-
lic particles. If metallic particles are present, examine the parti-
cles per paragraph 3.A.
(5) Clean the oil filter per 79-22-0.
WARNING: VAPORS ARE HARMFUL DO NOT USE NEAR OPEN FLAMES, OR ON VERY
HOT SURFACES. DO NOT USE NEAR WELDING AREAS, A SOURCE OF
CONCENTRATED ULTRAVIOLET RAYS. INTENSE ULTRAVIOLET RAYS CAN
CAUSE THE FORMATION OF PHOSGENE GAS, WHICH IS INJURIOUS TO
THE LUNGS. USE ONLY WITH ADEQUATE VENTILATION, AVOID
PROLONGED OR REPEATED BREATHING OF VAPORS. AVOID PROLONGED
OR REPEATED CONTACT WITH SKIN. WEAR APPROVED GLOVES AND
GOGGLES (OR FACE SHIELD) WHEN HANDLING AND WASH HANDS
TIIOROUGHLY AFTER HANDLING. DO NOT TAKE INTERNALLY. DO NOT
SMOKE WHEN USING IT. SOTRE IN APPROVED METAL SAFETY CONTAINERS.
(6) Clean the drain plugs with a suitable solvent, such as: carbon
tetrachloride, trichloroethane or kerosene.
(7) Using new O-rlngs on the drain plugs and filter, install the plugs
and filter to the
torque values specified in the Engine Torque Chart
in Section 72-01-3.
(8) Using the same type of oil that was in the lube system,
fill the oil tank (passing the oil through a l0-micron filter) to
the "FULL" mark, or slightly below, (4 quarts) on the dipstick.
Install the filler cap and lock it.
NOTE: The engine will require additional oil after the first run, to
bring the level to the "FULL" mark on the dipstick because a
small amount of oil remains in the sumps and oil lines after
engine shutdown.
E. Oil Changes (Draining and Flushing Lube System).
This procedure is used for changing the oil when the 1ube system will NOT
be refilled with the same type of oil. This procedur´•e should also
be used as soon as possible after oil types have been mixed or after
an unapproved oil has been used. Drain and flush lube system and check
oil filter as follows:
(1) Drain oil; inspect plugs and filter; clean and install plugs and
filter per paragraph 2.D., steps (1) through (7).
(2) Using an approved oil, fill the oil tank (passing the oil through a
I0-micron filter) to the "FULL" mark, or slightly below, (4 quarts)
on the dipstick. Install the filler cap and lock it.
79-00
Dec 1/79
Page 206
GE6ERAL B~ E LE CTR IC
CJ610 TURBOJET
SEI-L86 MAINTENANCE MANUAL
(3) Operate the engine for 5 minutes.
(4) Drain oil tank and gearboxes. Install plugs per paragraph 2.D.(7).
(5) Refill oil tank with the same type of oil used in step
(2).
(6) Attach a metal tag or other suitable device to the oil tank filler
that designates the type of oil being used in the system.
I cap
79-00
Dec 1/79
Fage 206A/206B
GEWERAL O~ E LC CTI It ------T
eJsiou TURBOJET
SEI-186 MAINTENANCE MANUAL
(7) .After the engine has been operated in service for 15-35 hours, check
the oil~filter and clean if necessary.
NOTE: It isimportant to establish a written record sf: findings
duringa filter inspection.’ This´•will allow detection of a
build-up of contamination during subsequent~ilterinspections.
3. Inspection~Checks.
A. Metallic Particle Check.
The engine is an~ Qsse~inbled with close tolerances. Therefore,
nietailic particles in the lubricatidn system are Cause for investigation.
Accumulation of particles may result from different causes, good judgment
must be used before: continuing to operate~ the einginei A review of pre-
vious filter inspection records and’findings should be made.
When filter contamination by metal pa?ticles is ´•les~ than ten percent of
the total area, but sufficient to be easily observed by the naked eye, the
recommendations listed below are applicable. If contamination is greater
than ‘ten ‘percent’, (larger metal. cl;ips, curls, heavily’loaded, partially
dr completely filled valleys betwee~ pleats in filter) DO NOT-OPERATE
ENGSNE’ until the; sdurce Of metal particle generation Is defined and
coYrected.
NOTE: A light deposit of minute silver particles may be found on the
filter during the early stages of engine operation and is consider-
ed normal. Silver particles can be generated from the normal
seating of engine bearing cages that are silver plated during
manufacture. In addition, a light accumulation of oxide "fuzz"
(fine light particles) on the magnetic plugs may also be considered
normal.
(1) Deleted
(2) If metallic (magnetic and/or non-magnetic) particles are found in the
filter oil, or they may have been externally introduced or caused by
wear of
engine rotating parts. These contaminants could contribute
to faulty lube system operation and may damage lube system components
or bearings. Contaminants may be in the form of metal curls, chips,
flakes, etc. In either case proceed as follows:
(a) Drain oil from tank andgearbox(es).
(b) Clean and reinstall the filter and magnetic drain plugs per
paragraph 2.D.(7).
(c) Re-service with approved oil.
(d) Run engine for 10 minutes at 85% RPM and then check filter.
Nov. 15/72 79-00
Page 207
BElflAL tltCTIIC
CJB10 TURIOJLT
MAINTENANCE MANUAL SEI-186
(e) If filter is significantly contaminated DO NOT OPERATE THE ENGINE
and DO NOT CLEAN THE OIL FILTER un t ii a cau s e for contamination can
be det ermined This may require removal disassembly and cleaning of
engine An analysis o f f ilt e r c ont aminan t s may be he ip fu 1 in de t e rmin-
ing source of con taminant a
f) If filter is a ign i f i c an t ly cleaner than bef ore re c le an and re ins tall
f ilt er Drain all o ii from eng ine and re-service wi th approved o ii
(g) Cent inue to operate engine normal ly for two hour s During this period
monitor oil temperature and o ii pressure fo r s igni f i cant chang es
Check filter and magnetic drain plug after this time. Record findings.
(h) If cent aminant s are found in ex c es s of minut e quant it ies DO NOT
OPERATE THE ENGINE and DO NOT CLEAN THE OIL FILTER until a cause for
cent aminat ion can be de t ermined This may require removal disassem-
bly and cleaning of eng ine An analys i s of filt e r cent aminant s may
be helpful in determining s ourc e of contaminants
i) If cont:aminan t s are not f oun d continue to operate eng in e no rmal ly and
repeat s t ep (g) every five hours for at 1 eas t four t ime s DO NOT
CLEAN FILTER. Record findings. Resume normal filter inspection
periods when satisfied system is clean and not generating additional
con t aminan t s
79-00 Nov. 15/72
Fag e 2 08
oLIEI~L LLECTRIC
CJ610 TURsSOJe7
SEI-186 MAINTENANCE MANUAL
OIL TANK MAINTENANCE PRACTICES
i. General. The maintenance practices for the oil tank are concerned with the
Removal/Installation and Inspection/Check and Cleaning of the component.
2. Servicing. (Refer to 79-00, Servicing.)
3. Removal/Installation.
NOTE: The oil tank, lube pump andgenerator are mounted in tan-
tachometer
dem. The removal of the simplified if all three units are
tank is
removed as an assembly and then separated. (Refer to 79-21-0.)
4. Inspection/Check.
Inspection/Check Maximum Serviceable Limits Corrective Action
A. Dents on corners Any number, 1/8 inch deep. Replace tank.
B. Dents on flat Any number, 1/4 inch deep. Replace tank.
surfaces
C. Sharp dents or None allowed. Replace tank.
creases
D. Leaks None allowed. Replace tank.
5. Cleaning.
If required the oil tank can be cleaned after it has been removed from the
engine.
A. Remove the oil tank from the engine.
B. Slosh the oil tank with a solvent, such as carbon tetrachloride or tri-
chloroethylene, until all dirt and contamination is removed.
NOTE: A discoloration may remain on the inside surface of the oil tank.
This is normal and allowable.
WARNING: THESE SOLVENTS ARE TOXIC AND SHOULD BE USED WITH ADEQUATE VEN-
I TILATION. AVOID PROLONGED BREATHING OF VAPORS.
PROLONGED CONTACT WITH THE SKIN WILL REMOVE
SEVERE DERMATITIS.
REPEATED OR
SKIN OILS AND CAUSE
C. Inspect inside of tank with a light and dental mirror for evidence of
contamination. Clean as necessary.
May 15/70 79-11-0
Page 201
G E W LRAL O~ 1 Lt STR IC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
OIL TANK RELIEF VALVE MAINTENANCE PRACTICES
i. General. The maintenance of the valve consists of the removal and replace-
ment of defective valves.
2. Removal/Installation. (CJ610-1, -5 and -9)
NOTE: Disconnect any aircraft line connected to the valve.
A. Removal.
(1) Remove the lockwire securing the valve to the side of the tank.
(2) Remove the valve by threading the valve from the tank.
(3) Remove and discard O-ring from the valve.
B. Installation.
(1) Install a new O-ring on to the valve.
(2) Assemble the valve to the oil tank.
(3) Tighten valve to 90-110 Ib-in. and lockwire.
NOTE: Connect any aircraft lines that were removed.
3. Removal/Installatlon. (CJ610-4, -6 and -8)
A. Removal.
NOTE: Disconnect any aircraft line connected to the valtre.
(1) Remove the lockwire securing the valve to the top of the tank.
(2) Remove the valve by threading the valve from the tank.
(3) Remove and discard the O-ring.
B. ~nstallation.
(1) Install a new O-ring on to the valve.
(2) Assemble the valve to the tank.
(3) Tighten the valve to 90-110 Ib-in. and lockwire.
Jan. 15/69 79-12-0
Page 201
GE nERAL E LE CTR IC
-_-
CJ610 TURBOJET
SE I-186 MAINTENANCE MANUAL
LURE AM) SCAVENGE PUMP MA I NTENANCE PRACT ICES
t he ma i nte nanc e that be pe r-
1 Gene ral The i ol lowing p re c edu re s cover may
i o rme d on the pump
1 a. Removal/Instal lation. (CJ61 0-1, -5 and -9 only)
NOTE: Refer to figure 201.
A. Removal.
(1) Drain the lu bri cation tank by removing the tank drain plug.
(2) Dis connect the 2 vent lines from the oil tank check valves. (On en-
g ine s wi thou t center vent on ly:.
(3) Remove the oil cooler and fuel-p re s suri zi ng valve as fo ilows
(a) Remove the tube (1) that runs from’ the ma inf rame pad (at 4
o c loc k) to the fue 1 c on t rol c ompre s a o r inlet t empe ra tu re a spi i
rater.
(b) Di sconnect 4 lines from the fuel- pres surizing valve
(c) Remove t he tube that runs i rom the fuel i 1 owme t e r to the oi 1
cooler
(d) Remove the 2 be its that se cure the oil cooler to the oil tank.
Remove the oi 1 coole r- fuel pre s su ri zing valve ass emb ly
(e) Remove three O-rings and the O-ring adapter from the oil cooler
po rt s
4 Di s co nn e c t the i1 t ra n s duc e r 1 i ne at the lube pump o i1
o pres su re
filter ports (if applicable)
(5) Remove the lube oil tank and tachometer from the accesso ry
pump,
gearbox as follows:
a Remove 3 mount i n g nu t s and wa s he r s at the gearbox pad
(b) Ca re ful ly move t he lube pump af t unt i 1 it clea r s t he 3 mount i ng
studs on the a c c e s s o ry gea rbox Remove s e ven O- ri n gs
CAUTION: PROTECT THE LUBE PUMP AND ACCESSORY GEARBOX FROM DAM-
AGE AND CONTAMINATION.
79-21-0
Jan. 15/69
Page 201
6E I tIAC O t Lt Ctl IC
CJ810 TURCIOJET
MAINTENANCE MANUAL SEI-186
~´•1 C
P
OIL COOL´•ER
OIL TANI<
2
PRESSURIZING VALVE
CJ610-6092-0-C2
Lube and Scavenge Pump Removal/Installation
(CJ610-1, -5 and -9 Engines)
Figure 201
(6) Separate the lube pump, oil tank, and tachometer-generator as fol-
lows:
(a) Remove 4 nuts and washers and remove the airframe tachometer-
generator.
(b) Remove washers, and separate the lube pump from the
bolts and
oil tank. Remove two O-rings from the grooves in the face of
the oil tank, and one 0-ring from the groove in the aft OD of
the lube pump.
79-21-0 Jan. 151/69
Page 202
GEICIA:L
CJB10 TURLIOJBT
SEI-186 MAINTENANCE MANUAL
B. Installation.
NOTE: Prior to installation, prime the elements of the lube and
scavenge pump with engine oil by filling all of the inlet and
outlet ports and then rotating the drive gear by hand.
(1) Install 1 O-ring in the groove in the aft OD of the lube pump
new
and 2 new O-rings in the grooves in the forward face of the oil
tank. Use O-ring lubricant and holding grease A.1 or A.2 of
Section 72-01-1.
Nov. 15/73 79-21-0
Page 202A/202B
GEW LRAL O~ ELICTRIC
CJ810 TURBOJET
SEI-186 MA I NTENANCE MANUAL
the lube t i c al ly i nto ii t ank and v i su al 1 y
(2) Carefull y insert pump ve r o
check all gnmen t Secure and oi 1 t ank to ge the r wi th 2 oppo s i t e
pump
bolts and was hers and tighten to 24-27 ib-in. to seat pump. Install
r em ai n i 13 bol t s and t i ghten to 2 4 2 7 1 b- i n and lockwi re al 1 bol t s
ng
NOTE: Some earlier configuration pumps and tanks have only 13 bo it
ho le s When e i the r t ank s or pump s are in te re ha nge d 2 bo 1 t s
may be omi t ted and the ho le s lef t open.
3) Check ~the lube oi 1 t ank a s s embl y for f ree movement of pi ok-up
pump
tube as f ol 1 ow s
(a) Dis connect and restrict the movement of the oil tank filler cap
and chain;
upri ght wi th the in the 12 clock
(b) Hand-hold the suba s s embly pump o
position.
tilt the oil tank back and forth, check for audible free
Gently
move men t f rom s t op- t o s to p of the lube p i c k-u p tu be
NOTE If unab le to sub s t an t i at e the f ree mo vemen t remove t he
lube and check for hang-up. Repeat until free move-
pump
ment is obtained.
(4 Ins t all the a i rfr ame t achome t er-g ene rat o r on the 4 s tud s that pro-
trude through the rear of the oil. tank. Secure it with nu ts and
washers Tighten the nu t s to 28 -3 5 ib in
5) Ins tall 7 new 0- r ing s in the g roo ve s on the f ace o f the lub e pump
0-ring lub ri can t and hold ing g re a s e A. 1 or A. 2
moun t ing flang e Us e
of Se c t ion 7 2;01-1 Ins t all the lub e pump oii tank and t achomet e r
of the g e arb ox and secure it wi th
on the r igh t r e ar pad ac ce s so ry
th e nu ts and wa ah er s T igh t en the nu t s to 12 0-15 0 Ib- in
ii t r an s du c e r 1 in e to the lube T igh t en
6) Conne c t the o p r e s su r e pump
to30-50 ib-in.
7 Ins t all the o ii c oo ler- fuel- p re s sur i z ing v alve as s emb ly as f o ilows
a) As s emb le 2 new 0-rings on the O-r ing ad ap t e r and 1 new O-r ing on
the o 11 luhe-OUT por t
c o ol e r Ins t all the 0-ring ad ap t er in the
lube-IN port: of the oil cooler.
(b Align lub e- IN and lub e-OUT po r t s of the o ii c o o ler t o the
the
the lub e pump and ins t all the oil c ooler
in S e cu re the
po r ts
oil cooler to the front face of the oil tank with 2bolts.
Tighten the bolts to 24-27 ib-in. and lo ckwire them.
Nov, 15/73 79121-0
Page 203
,errll~r ELICTIIC
CJ~10 TURIOJeT
MA I NTENANCE MANUAL SEI-1 86
(e Connec t 4 ho se s to the fuel p re s sur i zi ng valv e
(d) Ins t al 1 1 new O- r i ng and i n s t al 1 the fuel tube (2 t ha t c onnec ts
the f 1 owme t e r to the oi 1 coo le r T1 ghten the 2 s c r ew s to 24 27
Ib- i n and loc kwi re them
(8 In s tal 1the tube 1 (wi t h a new ga s ke t t ha t runs f rom t he main-
frame pad (at 40’ doe k) to the fuel cent rol compressor inlet tem-
pe ra ture a spi ra to r Ti ghten the 2 s c rews to 2 4 27 ib- i n and loc k-
wi re them Adj u s t and ti ghten t he support clamp s
(9) Connect the 2 vent lines to the oil tank check va lyes (On engines
wi t hou t c ent er vent onl y
10) Re s e rv i c e the lu br i c a t ion sy s t em per 7 9 00 Ma i nt enanc e Prac t i c e s
paragraph 2.D.
CAUT ION WHEN RE PLAC ING THE LUBE PUMP BE SURE THE LUBE F I LTER IS
INSTALLED.
9. Removal/Instal lation. (CJB1 O-, -6 and .-8 only)
NOTE: Refer to figure 202.
NOTE On CJ6 10- 4 engine s wi thout c ent e r vent i ng d i s conne c t the 2 vent
1 ine s f rom the o i1 tank 3 way che c k va lye
A. Remo va 1
(1) Drain the oil tank by removing the tank drain plug.
2 Di sc onne c t t he elec t r i cal lea d s at the f lowme t e r and t a chome t e r-
generator
3) Di s c onnec t at the i 1 owme t e r the governor to i lowme t e r ho s e 1
(4) Remove the 4 screws that secure the f lowme t e r to the f 1 owme t e r ba s e
connec tor remove the i lowmet e r and 0- ri ng
5 Remove the 2 loc knu t s and bo 1 t s that secure the f 1 ange d end s of the
oi 1 coole r- t o p re s suri zing and d rai n valve ho s e and t he tube (2)
Se pa ra t e the ho s e f rom the tube Remove the O- ri ng
(6) Remove the 2 screws (3) that secure the oil coole r-to-press urizing
and dra in va lye tube to the oil cooler Remove t he tube and O- ring
79-21-0 Jan. 15/69
Page 204
GEWERAL~f L,ECTRIC
CJ610 TU’eP BOJ ET
8EI-186 MAINTENANCE MANUAL
O O
1
O O
~I
I i-d
I I\I NU
O1L COOLER
O1L TANK
FLOW METER
cJa10-~093-0-C2
Lube and Sc av en~e Pump Remov al In s t al 1 a t i o n
(C J61 0- 4 6 and 8 Engine s
Figure 202
(7 Remove the 2 sc rews 4 that secure the flo wme t e r ed nne c t o r to the
oi 1 coole r remov e the fl o wme t er co nne c t o r and r emov e the 0- r i ng
(8) Remove the oil coo ler as follows:
a Remove the 2 bol t s t h at secure t he o i1 c o ole r to t he o i1 t ank
Remove the oil cooler.
(b Remo v e three O- r i n g s and the 0- r i ng ad ap t er from the o i1 coo 1 er
po rt s
Jan. 15/69 79-21-0
Page 205
G E W E II A L i~ E:L.E CT R:l C
eJeld: +uwBOJET
MAINTENANCE MANUAL SEI-186
(9 Di sconnect the o ii p re s sure t r an sducer ii ne at the 1 ube pump (i f
necess ary.
(1 O Remove the 1 ube pump from the ac ce s s o ry ge arbo x as fol lo ws
(a Remove 3 mount i ng nut s and wa sher s at; the ge arbor p ad
(b C aref ul ly move tbelube pUmp and tanlt assembly aft until the
pump cl e ar s t he 3 mount i ng s t ud a on the acces sory go arbo r Re-
mov e seven O- r i ng s
CAUT ION: PROTECT THE LUBE PUMP AND ACCE SSORY GEARBOX FROM DAM-
AGE AND CONTAMINATION.
(11 Sep ar a t e t he 1 ube pump 1
oi 1 t Pnk and al t ernat o r- t achomet e r gen er at o r
as follows:
(a Remove 4 nut s and washer s and remove the t achome t er- gene r at o r
(b Remove 13 bo 1 t s and wa she r s and s ep ar a t e the 1 ube pump from the
oi 1 t ank Remo v e two 0- r i ng s from the grooves in the f sc e bf
the o ii t ank and one OI r i ng from t he gro ov e in t he af t OD of
the 1 ube pump.
B. Inst al lation.
NOTE Pri o r to i ns t al 1 at i o n pri me t he el ement s o f the 1 ube and s c av enge
pum~ wi th engi ne o ii by filli ng al 1 of the i nle t and outlet port s
and: th en rot at i ng the d riv e ge ar by ha nd
(1 Inst al 1 1 new 0- ri ng in the groove in the af t OD of the 1 ube pump
and 2 new O- ri ng s in the groov e s in the fo rward f ace of the o i1 t ank
(2 Care f u1 1 y i ns er t the 1 ub e pump v e rt i c al 1 y into o i1 t ank and v i sual 1 y
check al i gnment Secure pump and oil t ank t ogether wi th 2 oppo s i t e
bo 1 t s and wa sh e r s and t i gh t en to 2 4- 2 7 1 b- i n to s e at p ump In s t al 1
rem ai n i n g 13 bo 1 t s and t i ght en to 2 4- 2 7 1 b- i n and 1 o c kwi r e al 1 bo 1 t s
Be sure to as semble the bracket wh i oh suppo rt s the lube pump- t o-
t rans ducer ho se at the si x o clock po s i t i on
(3 Check the 1 ube pump- o ii t ank ass embly fo r free mov eme n t o f t he pi ck-
up tube as fo ilows:
(a Di sc o nne c t and re s t ri c t the mo v eme nt o f the o i1 t ank fi 1 1 er c ap
and chain.
(b Hand- hol d the s uh a s s emb 1 y up ri gh t wi t h the pump in the 12 o c 1 ock
position.
79-21-0 Jan. 15/69
Page 206
~LIb;RIC
CJ6:10: TURBOJET
SE1-186 MAINTENANCE MANUAL
(c) Gently tilt the oil tank back and forth, check for audible free
movement from stop to stop of the tube pump pickup tube.
NOTE: If unable to substantiate the audible free movement, re-
move the lube pump from the oil tank, check for "hangup",
then reassemble. Repeat audible free movement check.
(d) Tighten the bolts to 24-27 Ib-in. and lockwire them.
(4) Install the tachometer-generator on the 4 studs that protrude through
the rear of the oiltank. Secure it with nuts and washers. Tighten
the nuts to 28-35 Ib-in.
(5) Install 7 new O-rings in the grooves on the face of the lube pump
mounting flange. Install the lube pump on the right, rear pad of
the accessory gearbox and secure Itwith 3 nuts and washers. Tighten
the nuts to 120-150 Ib-in.
CAUTION: DO NOT FORCE THE SEATING OF THE LUBE PUMP ON THE GEARBOX
MATING FLANGE. IF NECESSARY, ROTATE THE ROTOR TO ASSIST
IN MESHING THE LUBE PUMP INTERNAL GEAR WITH THE GEARBOX
MATING GEARSHAFT.
(6) Connect the fitting to the lube pump-to-transducer hose to the lube
pump las applicable).
(7)Install the oil cooleras follows:
(a) Assemble 2 new O-rings on the O-ring adapter and 1 new O-ring on
the oil cooler lube-OUT port. Install the O-ring adapter in the
lube-IN port of the ail cooler.
(b) Align the lube-IN and lube-OUT ports of the oil cooler to the
ports in the lube pump and Install the oil cooler. Secure the
oil cooler to the front of the oil tank with 2 bolts. Tighten
the bolts to 24-27 Ib-in. and lockwire them.
(8) Install the O-ring onto the fuel-OUT port boss of the flowmeter con-
nector.
(9) Position the flowmeter connector on the oil cooler with the fuel-OUT.
port boss inserted into the lower port of the oil cooler. Assemble:;
2 screws (4) through the 2.lower holes of the flowmeter connector.
Tighten the screws to 14-181b-in.
(10) Install the O-ring to the boss at the connector of the oil-cooler-to-
pressurizing and drain valve fuel tube.
I Jan. 15/69 79-21-0
page 207
GEWE RAL~E L16TRIC-------
CJB10 TURBO JET
MA I NTENANC E MANUAL SE I- 1 86
1 1) Po s i t i on the tube wi t h t he bo s s i n s e rt e d through t he top po rt in t he
f 1 owme t e r conn ec t or and into the oi 1 coole r fuel -OUT po rt S ecu re
t he tube to the o 11 cooler Wi th the 2 s c rews (3) Ti ghten t he s ore Vr S
to 14 -18 ib- i n and loc kwi re them t o t he 2 s c rews that s ecure t he
f 1 owme t e r c onne c tor
12 In s t a 1 1 the O- r i ng into the groove in t he f 1 an ge d f i t t i ng o f the
t u be Po s i t i on the f 1 an ge d end of the oi 1 c ool e r to p r e s s ur i z i n g
and d ra i n valve ho s e on the tube f lan ge S e cu re the flan ge s o f t he
tube and ho se wi t h the 2 bo it s and loc knut s Ti ght en the bolt s to
20 -25 ib-in.
1 3) In s t al 1 the O- r ing to the bo s s on the f 1 owme t e r co nn ec tor Po s i t i on
the f 1 owme t e r on the bo s a of the fl owme t e r conn e c to r and secure it
wi t h t he 4 s c rews Ti gh t en to 1 4- 18 1 b- i n and lo c kw i re them
14) Conne c t the coupli ng nut 1) of the gov e mo r to f 1 owmet e r fuel ho s e
to the f i t t i ng at the top of the flowme t e r Ti ght en t he c oupl i n g
nut to 20 0-350 ib-in.
CAUT I ON: HOLD THE FLOWMETE R F I TT I NG W ITH A WRENCH TO PREVENT DAM-
AGE TO THE FITTING WHEN TIGHTEN I NG THE COUPL ING NUT.
(15) In st all t he O- rin g i nto t he elec t r i cal c onne c t o r at the f 1 owmet e r
if necessa ry; secure the lead to the flowmeter. Tighten the connec-
tor f i n ge rt i ght (a p p ro xi ma t e ly 10- 1 5 1 b- i n and 1 o c kwi re
N(YTE Do not lubr i c a t e the O- ri ng
16 Ins tall O- rings if ne c e s s a ry to t he elec t r i c al c onne c t o r s tha t
at tach to the al t e ma t o r t a chome t e r ge ne ra t o r T i ght en the conn e c
tors f i nge rt i ght (a pp rox ima t ely 10- 15 ib- i n and lo c kwi re
(17) Rese rvice the lubrication system per Se rvicing, 79- 00.
CAUT ION WHEN RE PLAC I NG THE LUBE PUMP BE SURE THE LUBE F I LTER IS
INSTALLED
4 Ins p c t i o n/ Che c k
Check the lube pump whi le i n s t a lie d for lea ka ge No le aka ge a 1 1 owabl e
If lea ka ge is f rom lube pump- ta chomet e r generator drive sha f t s eal replac e
sea 1 per repai r pa ra g ra ph If le a ka ge is f r om non repa i rabl e area re pla c e
pump.
79-21-0 Jan. 15 /69
Page 208
0911RIL O tLLCtRIC
cJeio TURBOSET
SEI-186 MAINTENANCE MANUAL
Approved Repair.
A. Replacement Procedure for Lube Pump Tachometer-Generator Drive Shaft
Plain Encased Lip Seal (Without Removing Lube Pump from Engine). (See
figure 203.)
(1) Drain the oil from the oil tank.
(2) Disconnect the electrical leads from the tachometer-generator. Re-
move the 4 nuts and washers, then remove the tachometer-generator
from the lube pump.
(3) Remove the retainer ring, using a small screw driver or scriber. Be
careful not to scratch or damage the surface of the seal retainer or
the lube pump bore. CareSullylift out the shims and flat washer.
Note the thickness of the shims, the same amount of shimming that is
removed must be reinstalled at assembly. (See figure 204.)
NOTE: Inspect the pump housing bore at the retainer ring groove and
bench out any nicks, dents, etc.
(4) Lubricate the counterbore at the threaded end of puller 205331. In-
sert the threaded end into the rubber of the seal and turn the puller
1 or 2 turns toengage seal.
clockwise Do not pull seal at this
time. (See figure 205.)
NOTE: Do not remove the large O-ring until after the puller is en-
gaged. This is to keep the seal retainer from rotating with
the puller. If O-ring does not prevent rotation insert a
small screwdriver or scriber into O-ring to’ p;revent rotation.
TACH;GENERATOR
OILT*NK *~TLOOKINt
_LOCATION.: FORWARD
j
AFT END OF
LURE PUMP
C1610-6097-0-FZ
Replacement of Lube-Pump Seal
Figure 203
May 15/70 79-21-0
Page 209
GEIERAL ELLCfRIC:-~----
c3eio TURE~Or)ET
MAINTENANCE MANUAL SEI-186
SHIMS
´•~´•ri
PUMPBORE
FLATWASHER
SEAL
LUBEPUMPROTOR
C161Q60P8-0-E2
Seal Retainer
Figure 204
PULLER
-*c-rrr: jZ
ii~:
SEAL
SEAL SEAL-RETAINER
PUMP RO’IOR
C161(1´•6099-0-E?
Seal Puller Installed
Figure 205
79-21-0
Mar. 30/67
Page 210
G EW LIIAL BE ELECTRIC
CJB1Q TURBOJET
SEI-L86 MAINTENANCE MANUAL
(5) After the puller is engaged, use a small scriber or equivalent tool
to remove the large O-ring from in front of the seal retainer. Make
sure the seal retainer does not move outward with the O-ring.
CAUTION: AFTER THE O-RING IS REMOVED, BE CERTAIN THAT THE PUMP ROTOR
DOES NOT MOVE OUTWARD WITH THE SEAL AND RETAINER ASSEMBLY
AS THIS WILL UNSTACK THE PUMP. IF THIS SHOULD HAPPEN, THE
LUBE PUMP MUST BE REPLACED.
(6) Push the plunger towards the threaded end of the puller with the
small T-handle and hold it in this position. The plunger should en-
gage in the bottom of the female square in the lube pump drive shaft
and hold the internal parts of the pump in placeduring the removal
of the seal retainer and the seal.
(7) While holding the small T-handle pull the large T-handle
in, out to
remove the seal retainer and the seal. (See figure 206.)
CAUTION: IF ANY INTERNAL PARTS.OF THE LUBE PUMP ARE INADVERTENTLY
REMOVED (EXCEPT BEARING AND SPRING TENSION WASHER), MIS-
PLACED OR DAMAGED DURING REMOVAL OF THE SEAL RETAINER AND
THE SEAL, THE LUBE PUMP MUST BE REPLACED.
PULL OUT
PULLER
HOLD IN
HANDLE
SEAL-SEAL RETAINER
SPRING TENSION WASHERS
clsla.sloo.o.D?
Removing the Seal
Figure 206
April 15/68 79-21-0
Page 211
OEWEIAL ILECTRIC
CJ810 TURBOJET
MA I NTENANCE MANUAL SEI-186
NOTE Re i n s t al 1 beari ng and s pr i ng washer if remove d, mak i ng sure
the he ywa y s on beari ng and pump rotor are al i gne d
(8) I n ser t the gu i de (1 f i gure 206A) i nto base (2) P1 ace seal re tainer
and seal ass embl y onto gu ide (1) wi th slotted side of seal retainer
f sc i ng up Po s i t i on dr i ve r 3) on top of seal re t a i ne r
(9) Using an arbor press, push seal re tainer down to separate it from the
seal. Remove the seal, gu ide (1), and seal retainer from the base
(2).
(10) Remove the square seal O- ri ng from the i n s id e d i ame t e r groove of the
seal retainer.
11 In s t al 1 a new s qu a r e seal O ri ng into the g r oo ve on t he in s ide di ame
ter of the s eal re tainer
12) Place the new seal (me t al surf ace down) i n to the base 2 f i gure 20 7)
and us i ng pe t rola tum or e qu i val en t lu br i c a te the ou t s i de di ame ter of
the seal I n se r t the gu i de (1 through the i n s i de d i ame te r of the
seal and into the pilot hole of the base (2) of 205331.
13 Lu bri ca te the i n s i de di ame t e r of the seal re tainer and s guar e se al
O-ring. Install the seal retainer (slotted side up) onto the guide
1 Po s i t i on dri ve r 3) on top of seal re t a i ne r
ARBOR PRE SS
i. GUIDE
2. BASE
g~ 3. DRIVER
S L O TTE D E N D
THIS END UP
STAMPE D CJ610-1 AN
SEAL RETAINER
:iilliiiiiiIi~i2i
CJ610-6101)´•0´•E2
Removal of Seal from Seal Retainer
Figure 206A
79-21-0 Aprill5 /68
Page 212
Os 11 IR~L 4~ LICTRIC
CJ 610 ’6 U R BOJ E T
SEI-186 MA I NTENANCE MANUAL
ARBOR PRESS
I. GUIDE
2. BA S E
3. DRIVER
THIS END UP
STAMPED CJ610-1 and -4
1
SQ UARE O-RING
SEAL RETAIN ER
NEW SEAL
PILOT HOLE
CJ610´•6101´•1-E2
Ass embly of Seal
Figure 207
14) Us i ng an arbor pre s s c are ful ly pu s h the se al re t a i ne r down ove r the
se al unt i 1 it bo t tom s in the: ba 9 e 2 Remove the seal re t a i ne r and
seal ass emb ly.
CAUTION: CHECK THE SEAL AND SEAL RE TA I NER A S SEMBL Y TO BE CERTAI N
THAT EACH END OF THE SEAL IS BELOW THE SU RFACE S OF THE
SEAL RE TA I NER THE SEAL RE TA I NE R SLOTS MUST BE OPEN AT
THE I N S I DE DI AME TER TO PERMI T O I L PA S SAGE WHEN I N STALLED
IN THE PUMP.
15 Lub r i c a te wi t h pe t rol a tum the ou t s ide di ame ter s of the s e al re t a i ne r
and the s pre ade r 1 f i gure 2 6 8) of 2C5 3 31 Po s i t ion the s pre a de r
agai n s t the lube pump ro tor as shown, pu sh se al and se al re tai ner
as sembl y over the spre ade r (1 and i nto the lube pump unt ii i t bo t-
toms against the spring tension was hers. Remove sprea der (1)
(16) Lubricate a new O-ring and install be tween the OD of the seal retain--
er and ID of the lube pump bore. Coat the was her and shims with
pe trol atum and as sembl e in to pump Work the re ta i ning ´•r i ng i nto the
pump bore and pu sh it a gal n s t the sh im s Careful 1 y center t he s hi m s
us ing a s har p po i nt e d t oo 1 around the dri ve s ha f t so that t he y wi 1 1
no t hang up in re t ai ne r groove See f igure 20 9
NOTE: If there i s no t enough room to i ns tall the re tai ni ng ri ng, the
spring was hers have become unsea ted. Remove the parts and re-
po s i tion the wa she r s
Aprill5 /68 79-21-0
Page 213
91wIIIAL IIIEIIIC
CJ~10 TURIOJeT
MAI NTENANCE nllANUAL SEI-186
SEAL AND
SEAL-RETAINER
SPRING TENSION WAS HERS ASSEMBLY
i
liji ijiji:iiliiiiii-lli ilii
1. SPREADER
CJ610-6102-1-F2
Seal Spreader Ins tailed
Figure 208
RETAINER RING GROOVE
t
LU BE PUMP BORE
DISHED
FLAT WASHER
t RETAINER RING
SHIMS
CJ610-6103-0-F2
Installation of Retainer
Fi gu re 299
(17) Ass emble the pu sher of 2C5331 over 2 of the studs in the lube pump
moun t i ng f 1 ange and agai ns t the shims then as sembl e 2 nu t s to the
studs. (See figure 2-10.)
1 8) Ti gh ten the nu t s e venl y and dri ve the pu s he ragai n s t the shims unt i 1
the ring groove is accessible.
retainer Using a sma ii scr ewdrlver,
work the retaining ring into its groove.
NOTE Use the s p ace on each s i de of the pu she r and the 2 ac ce s s
hol e s in the pusher to work the re ta i n in g ri ng i n to place
79-21-0 Apri115/68
Page 214
o e n E II A L Q E LI CIR I C
CJ81.0 TURBOJET
SEI-186 MAINTENANCE MANUAL
NUT
MOUNTING STUD
RETAINER RING
MOUNTING STUD
ACCESS HOLES
NUT
CJb10-610~-0-F2
Pushing Retainer into Place
Figure 210
(19) Remove the 2 nuts and the pusher from the lube pump.
NOTE: The retaining ring must be thoroughly checked to make certain
it is properly seated in the groove in the inside diameter of
the lube pump bore. It must be properljr seated or the per-
formance of the lube pump will be greatly reduced affecting
the, lubrication system.
(20) Assemble the tachometer-generator to the lube pump with the 4 nuts
and washers. Tighten the nuts to 28-35 Ib-in.
(21) .Connect the electrical leads to the tachometer-generator.
(22) Refill the lube tank with oil.
B. Replacement Procedure for Lube Pump Tac’hometer-Generator Drive Shaft
Carbon Seal (Without Removing Lube Pump from Engine). (See figure 211.)
(1) Drain the oil from the oil tank.
(2) Disconnect the electrical leads from the tachometer-generator. Re-
move the 4 nuts and washers, then remove the tachometer-generator
from the lube pump.
(3) Remove the retainer ring (5), using a small screw driver or scriber.
Be careful not damage the surface of the seal retainer
to scratch or
or the lube pump bore. Carefullylift out the shims (4), flat wash-
er (3), and spring washers (6).
NOTE: Retain shims and washers for reinstallation. Inspect the pump
housing bore at the retainer ring groove and bench out any
nicks, dents, etc.
May 15/70 79-21-0
Page 215
,I:r´•il, ~´•tilcrnle
cJliO~ruRioJa+
MAINTENANCE MANUAL SE I-186
O 10
CF700-6057´•0-EZ
Lube and Scavenge Pump Rear Seal Replac ement
Figure 211
4) I n s tal 1 pu lier 2C5 436 PO2 on a hou ider o f s eal re ta i ne r (8 and re-
move wi t h a s t ra i ght pull Remove O- ring (7 i rom s eal reta iner
and d i sea rd
CAUT I ON AS THE SEAL AND SEAL RETA I NE R IS REMOVED BE CE RTA I N THAT
THE PUMP ROTOR DOES NOT MOVE OUTWARD WITH THE SEAL AND
SEAL RETA I NE R ASSEMBLY AS TH IS WILL UNSTACK THE PUMP. IF
TH I S SHOULD HAPPEN THE LUBE PUMP MUST BE RE PLACED.
(5 Remove ma t ing r i ng 1 us i ng pul le r 2 C5 4 8 4 Remove O-r i ng 10 from
mat i ng r i ng a nd d i s c a rd
CAUTION: DO NOT PERMIT PUMP ROTOR TO MOVE OUTWARD WITH THE MATING
RING AS TH IS WILL UNSTACK THE PUMP AND LUBE PUMP MUST THEN
BE REPLACED.
(6) Place s eal ret a in e r (8 in gu i de 2 C5 436 PO9 and p re s s out ca rbon s e al
us ing pu s her 2C5 436 PO7
(7 Place s eal re ta i ne r (8 in ba s e 2C5 4 3 6 PO5 and po s i t ion gui de
2C5 4 36 PO9 In s tall a new carbon seal (2) i nto s eal re t a i ne r us i ng
pi lot 2 C5 4 36 PO 3
79-21-0 Oct. 15/70
Page 216
GENERAL ELECTRIC------
CJ61 O TU R BOJ ET
SEI-186
MAINTENANCE MANUAL
CAUT I ON AL I GN SLOTS ON MAT ING R ING WITH THE PINS ON THE ROTOR SHAFT.
NOTE: With the pins on the rotor shaft in the slots of the mating ring
there will be appro ximately a 1/32 inch gap be twe en the mating
ring and the bearing (9)
(8) Install anew O-ring (10) into a new or reco nditioned mating ring (1)
Lub r i c at e O r ing wi th Mob ile As s emb ly Flui d RT4 O 3 C o r an ap p r ov e d
eq uivalent and install mating ring on rotor shaft using puller 205484 as
a pusher.
WARNING: TRICHLOROETHANE 0-T-620
DO NOT USE NEAR OPEN F LAME S WELD ING AREAS OR ON VERY HOT
SURFACE S DO NOT SMOKE WHEN U S I NG IT HEAT AND F LAME S CAN
CAU SE THE F ORMAT I ON OF PHO S GENE GAS WH I CH IS I NJUR I OU S TO THE
LUNGS.
REPEATED OR PROLONGED CONTACT WITH LIQUID OR INHALATION OF
VAPOR CAN CAUSE SKIN AND EYE IRRITATION, DERMATITIS, NARCOTIC
EFFECTS, AND HEART DAMAGE.
AFTER PROLONGED SKIN CO NTACT WASH CONTACTED AREA WITH SOAP
AND WATER REMOVE C ONTAM I NATED CLOTHING. IF VA P O R S CAUSE I RR I
TAT I ON GO TO FRESH AIR GET MEDICAL AT T E N T I O N FOR OVE REXP O
SURE OF SKIN AND EYES.
WHEN HAND L ING LIQUID IN VAP O R DEGREASING TANK WITH HINGED
COVER AND AIR EXHAU S T OR AT AIR EXHAUSTED WORKBENCH, WEAR
APPROVED GL OVE S AND GO G GLE S
WHEN HAND L I NG L I QU I D AT OPEN U NE XHAU S TE D WORKBENCH WEAR
APPROVED RE S P IRATOR GL OVE S AND GO GGLE S
DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(9) Install anew O-ring (7) onto the seal retainer (8) Lubricate O-ring
wi th Mob ile As s emb ly Flu i d RT4 O 3 C o r an a pp quirove d e v ale nt In a e rt
seal retainer into guide 2C5436P10. Wipe mating ring and ca rbon seal
fa c e wi th a de an lint free cloth d amp en ed wi th de an t r i c hlo r o e thane
Mount guide onto lube pump housing until it seats against the bearing
using guide 2C5436P09 as a pusher Remove guide and pusher
1 O In s t all s p r i ng wa s he r a 6 fl at wa she r 3 and shim s 4
79-21-0
Dec 31/95 Page 217
GENERAL ELECTRID-------
CJ610 TURSOJET
SEI-186
MAINTENANCE MANUAL
CAUTION: CENTER WASHERS AND SHIMS SO THAT THEY DO NOT CATCH IN RETAINING
RING GROOVE AS STACK IS COMPRESSED.
(11) Assemble retaining ring (5) into housing bore and install pusher
2C5436P08 to compress stack and ease installation of retaining ring.
NOTE: It may be necessary to use pusher first to compress the stack of
pump rotating parts belowthe retaining ring groove.
(12) Using a small screwdriver and/or scribe, work the retaining ring into
its~ groove. Remove pusher.
(13) Assemble the tachometer-generator to the lube pump with the 4 nuts and
washers. Torque the nuts to 28-35 Ib-in.
(14) Connect the electrical leads to the tachometer-generator.
(15) Refill the lube tank with oil.
79-21-0
I Page 218 Dec 31/95
G E W ERAL Q~ f LE CTR IC ----_--
CJ63 O T U R´•e O J E T
SEI-186 MAINTENANCE MANUAL
OIL FILTER MAINTENANCE PRACTICES
i. General. The following procedures cover the maintenance procedures for the
filter.
2. Removal/Installation.
A. Removal. (See figure 201.)
(1) Cut the lockwire securing filter cap to the pump.
(2) Thread the cap out of the pump.
NOTE: A small container (approximately 1/2 pint) should be used to
catch the small amount of oil that will drain from the pump
housing.
(3) Remove the cap and the filter element from pump.
NOTE: On some filters the cap and the element are separate, on
others they are held together by a pin.
(4) Discard the O-rings.
B. Disassembly of Filter.
(1) Reusable filters.
NOTE: On filters that are pinned to the cap, the pin mustbe removed
and the cap and protective shield removed for cleaning.
(a) TypeA and B.
i. Cut the lockwire and reniove the valve seat from the.bottom of
the filter.
2. Remove the ball, valve protective shield
(Type A) from the element.
(b) Type C.
i. Remove large snapring and slide protective shield off filter
element.
2. Remove small snapring, carefully push bypass valve out from
filter element.
3. Remove O-ring from bypass valve. Discard O-ring.
Jan. 15/69 79-22-0
Page 201
OtlEI~L8 8LICTIIC
CJglO: TURIOJET
MAINTENANCE MANUAL SEI-186
LUBE PUMP CAP
2. FILTER ELEMENT
3. O-RING (CAP)
1 a. O-R\NG (FI~TER)
5. VALVE SEAT
6. BALL
7. VALVE GUIDE
8. SPRING
O
9. PROTECTIVE SHIELD is -L~I O
10. ROLL PIN
11. SNAP RING (SMALL)
12. O-RING
13. BYPASS VALVE
2
14. SNAP RING (~ARGE)
15. O-RING (FILTER CORE)
G~--1 FILTER CORE
.61GNIR
17. SNAP
L _1
TYPE D
r- 1Po oI
1I
1 to
o1~
6-´• 213
G
i
9-(
U 4,,
L__--__-~ I i--------J I L---------l
TYPE A I TYPE TYPE C C16106072-2-82
Oil Filter Removal/Installation
Figure 201
79-22-0 Jan. 15/69
Page 202
OEWERAL BgB E LL CTR IC
CJ610 TURBOJET
SE1-186 MAINTENANCE MANUAL
(2) Disposable filters.
(a) Type D.
i. Remove large snapring from filter core and discard snapring.
2. Slide filter element off filter core.
3. Discard filter element.
C. Assembly of Filter.
(1) Type A and B.
(a) Install the protective shield over the filter element (Type A).
(b) Install the spring, valve guide and ball into the filter element.
NOTE: Position the valve´•guide by´•insereing the smaller diameter
inside the spring.
(c) Install the valve seat and tighten to 30-60 Ib-in. torque value.
(d) Safet~ wire the valve seat to the element.
CAUTION: THE PIGTAIL AT THE END -OF THE WIRING SHOULD CONSIST OF
A MINIMUM OF THREE TWISTS AND MUST BE FLUSH OR:;BELOW
VALVE SEAT SURFACE (5/8 INCH HEXAGON) AND MUST BE BENT
BACK TO WITHIN THE OUTER EDGE: OF THE THREE ANTI-
ROTATION LUGS.
(e) Assemble filter element to filter cap with roll pin. Push roll
pin into cap until it is flush with cap (Type A)´•.
(2) Type C.
(a) Assemble new O-ring to bypassvalve.
(b) Push bypass valve, small end first into filter element until it
seats.
(c) Install new small snapring into grodve’in filter element to
secure bypass valve.
(d) Slide protective shield over filter element and secure with
large snapring.
NOTE: The large snapring may be reused if undamaged.
Jan. 15/69 79-22-0
Page 203
O 6 it LI A L (LL tTI I C
CJ+1~ tURIOJET
MAINTENANCE MANUAL SEI-186
(e As s embl e fil t e r el ement i nt o f ii t e r c ap us i ng rol 1 pi n Push
ro 11 pin i nto cap unt ii it i s fl ush wi th c ap
(3) Type D.
a) Sli d e new fil t e r el ement onto f ii t er co re
NOTE: Dispos able filter elements from diffe rent vendors may
diOfer slightly in appear ance and const ruction but are
physi c al 1 y and func t i o nal 1 y i nt e r oh ange a bl e
(b) Ins t all large snap ring int o gr oove in f ilte r co re t o s ecu re
i i 1 ter el eme nt
D. Inst allation,
(1 Inst all the fil t er wi th new 0- ri ng s i nt o the lube pump hou s i ng
CAUT ION: ON THE FREE CAP TYPE FILTER BE SURE THE BYPASS END OF THIi:
F I LTER GOES INTO THE HOUSING LA ST
(2 Tight en t he f ii t e r c ap to 40- 6 O 1 b- i n and 1 o c kwi r e it
3 In sp e c t i o n/Check s
If ma gn e t i c p a rt i cl es are found in the fi 1 ter refe r to In s p e c t i o n /Ch e c 1( s
79- 00
4. Cle aning.
A. Reu s abl e Fi 1 t e r s
(1) Ultra sonic Procedure. (Refer to SE I-154 for filter de aning. Thi s
me t hod o f cl e ani ng is the r ec ommend ed method for cl e ani ng the f ii t e r
(2 Al t e rnat e Pro c ed ur e When ul t ra soni c c1e ani ng e qu i pm en t is no t av ai 1
abl e the folio wi nff procedure c an be used
(a) Clean the filter body by immersing it in carbon tetra ohio ride,
t r i chi o roe t hyl e ne ke ro sene or e clui v al en t Wh i 1 e c o n t i nu al 1 y
agi t at ing the fi It er use a sui t abl y contoured sof t b ri stled
brush to di sl edge cent ami n ant s from the fi 1 t er co nv ol ut i o n s
NOTE On 1 y cl e an f i 1 t ered solv ent s sho ul d be used As sure t h at
cent ai ne r a used d uri ng cl e ani ng p ro c ed ure are cl e an and
free from cent ami nant s
79-22-0 Nov. 15173
Page 204
GEWERAL E LE CTR IC
CJ6I0 TURBOJET
SEI-186 MAINTENANCE MANUAL
WARNING: CLEANING OPERATION SHALL BE PERFORMED IN AN APPROVED
CLEANING CABINET OR WELL VENTILATED AREA. PRECAUTIONS
SHALL BE EXERCISED TO PREVENT INHALATION OF VAPOR
EMITTED BY VOLATILE CLEANING MATERIALS, AND TO MINI-
EnIZE DANGER OF EXPLOSION AND FIRE HAZARDS.
(b) Visually inspect the filter using a magnifying glass (10X mini-
mwm) and a strong light. If the filter is not completely clean,
repeat step (a), above.
NOTE: If some dark colored stains remain at the bottom of the
convolutions these are not harmful, and the filter is
serviceable. If any doubt exists as to the cleanliness
of the filter, repeat the cleaning procedure.
CAUTION: DO NOT ATTEMPT TO PROBE THE FILTER CONVOLUTIONS WITH A
SHARP TOOL, AS THIS MAY DAMAGE THE FILTER AND RENDER
THE FILTER NOT SERVICEABLE.
B. Disposable Filters.
(1) Clean the filter core per paragraph 4.A.(1) and (2).
NOTE t Disposable filters can be cleaned once and then must be
replaced at the next inspection period.
Nov. 15/73 79-22-0
Page 205
c Elf RAL ~.ELLCTR(C
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
OIL COOLER MAINTENANCE PRACTICES
i. General. The following procedures cover the maintenance that may be per-
formed on the oil cooler.
1 a. Removal/ Installation. (CJ610-1, -5 and -9 only)
NOTE: See figure 201, 79-21-0.
A. Removal.
(1) Separate the fuel-pressurizing valve from the oil cooler. Remove
and discard the O-ring.
(2) Separate the fuel inlet tube from thefront of the oil cooler. Re-
move and discard the O-ring.
(3) ’Remove the 2 bolts that secure the oil cooler to the front face of
the oil tank.
(4) Carefully lift the oil cooler up and away from the lube pump. Re-
move the O-ring adapter; remove and discard three O-rings.
B. Installation.
(1) Assemble 1 new O-ring in the groove on the OD of the lube-OUT (bot-
tom) port of the oil cooler. Assemble 2 new O-rings on the O-ring
adapter; install the O-ring adapter in the lube-IN (top) port of the
oil cooler.
(2) Carefully align the lube-IN and lube-OUT ports to the mating ports
of the lube pump.
(3) Secure the oil cooler to the forward face of the oil tank with 2
bolts. Torque the bolts to 24-27 Ib-in. and lockwire them.
(4) Install a new O-ring on the fuel-pressurieing valve. Secure the
valve Co the top port of the oil cooler with 2 screws and washers.
Torque the screws to 12-14 Ib-in. and lockwire them.
(5) Installanew O-ring on the fuel tube. Secure:the tube and clamp
bracket to the bottomport of the oil cooler with 2 screws and
washers. Torque the screws to 12-14 Ib-in. and lockwire them.
(6) Readjust the clamps that were disturbed during the oil cooler re-
moval. Torque the clamp bolts to 20-25 Ib-in.
Jan. 15/69 79-23-0
Page 201
C E W LRAI E LL CTR IC
CJ61O T U R B:0 JET
MAINTENANCE MANUAL SE I-186
Removal/ Installation. (CJ61 0-4, ~nly)
1 3. -6 a~d -8
NOTE: See figure 202, 79 -21-0.
A. Removal.
1 Di s conn e c t the ele c t r i cal lea d at t he f 1 owme t e r
(2 Di s conne c t at the f 1 owme t er the gov e rno r to f 1 owme t e r ho s e
3 Remove t he 4 s c r ew s t ha t s ecure the f 1 owme t e r to t he f lowme t e r ba s e
c onnec tor remove the f 1 owme t er and 0- ring
(4) Remove the 2 loc knut s and bo It s that s e cure the f langed ends of t he
o ii coole r- to- pre s sur i zi ng and drai n valve ho s e and t he tu be sepa-
rate the hose f rom the tube Remove the :0- ring
(5) Remove the 2 sc rews that s ecure the o ii cooler- to- pre s suri tin g and
drain valve tube to the oi 1 coole r Remove the tube and 0- r i ng
(6 Remove the 2 s c rews that secure the f 1 owme t e r c onnec t o r to the o i1
cooler remove the f lowmeter connector and remove the 0- ring
(7) Remove the oil cooler as follows:
(a) Remove the 2 bo its that se cure the oil cooler to the oil tank.
Remove the oil cooler.
(b) Remove three 0-rings and the O-ring adapter from the oil cooler
port s
B. Ins tallation.
1 A s s embl e 2 new 0- ri n gs on the 0- ri n g a da pt e r and 1 new 0- ri ng on the
oi 1 cool er lube -OUT po rt
2 Po s i t ion the 0- ring a da pt e r in t he lube- IN po rt of the oi 1 c oo 1er
ass emble the oil cooler to the lube pump and align the 2 holes in
the oil cooler mounting legs with the 2 tapped holes in the oil
tank
(3) Secure the oil cooler to the oil tank with the 2 bolts. Tor que the
bo it s to 24-27 ib-ln and loc kwi re them
(4) Install 1 new 0- ring onto the fuel out port bos s of the flowmeter
connector.
79-23-0 Jan. 15/69
Page 202
GE#ERAL ~LECTRIC
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
(5) Position the flowmeter connector on the oil cooler with the fuel-OUT
port boss inserted into the lower part of the oil cooler. Assemble
2 screws through the 2 lower holes of the flowmeter connector.
Torque the screws to 14-18 Ib-in.
(6) Install the O-ring to the boss at the connector of the oil-cooler-
to-pressurizing and drain valve fuel tube.
(7) Position the tube with the boss inserted through the top part of the
flowmeter connector and into the oil cooler fuel-OUT port. Secure
the tube to the oil cooler with the 2 screws. Torque the screws to
14-18 Ib-in. and lockwire them to the 2 screws that secure the flow-
meter connector.
(8) Install the O-ring into the groove in the flanged fitting of the
tube. Position the Planged end of the oil cooler-to-pressurizing
and drain valve hose on the tube flange. Secure the flanges of the
tube and hose with the 2 bolts and locknuts. Torque the bolts to
20-25 Ib-in.
(9) Install the O-ring to the boss on the flowmeter connector. Position
the flowmeter on the boss of the flowmeter connector and secure it
with the 4 screws. Torque to 14-18 Ib-in. and lockwire them.
(10) Connect the
coupling nut of the governor-to-flowmeter fuel hose to
the fitting theat
top of the flowmeter. Torque the coupling nut to
200-350 Ib-in.
NOTE: Hold the flowmeter fitting with a wrench to prevent damage to
the fitting when tightening the coupling nut.
(11) Install the O-ring into the electrical connector at the flowmeter,
if necessary; secure the lead to the flowmeter. Torque the connec-
tor fingertight (approximately 10-15 Ib-in.) and lockwire.
NOTE: Do not lubricate the O-ring.
Mar. 30/67 79-23-0
Page 203
6 E6 fRAL ~B E LE CT 8 IC
CJ610 TURBOJET
SEI-1 86 MAINTENANCE MANUAL
EIG~H- STAGE AIR LEAKAGE VALVES MAINTENANCE PRACTICES
-r
,:i:::::.
i
o
.rl
!.1._:...
pi
i
I; i
B i
NOTE: DUCTING NOT USED
ON CJ610-1 AND 4
I
Ail ii 1i I i ii ENGINES
CJ 61 0 -5, -6,- 8 A ND 9 8 1 I CJ6’ 0 -1 AND -4
6
2
-5
C~61040962C2
Ei ght h- St age Air Leakage Val v e s
Fi gure 2 01
1 Gener al Thi a sect ion cov ers the mai nt enance that c an be performed of these
valves
2 Remov al Inst al 1 at ion (See fi gure 2 01
A. Removal
Jan 1 5/69 79- 41- 0
Page 201
GEHERAL~ELECTRIC
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
(1) Remove the eighth-stage air leakage ducts by removing the bolts that
secure the ducts and valves to the mainframe at the 2 and 10 o’clock
position, Use penetrating oil if bolts are seized.
NOTE: On some engines the ducts for air leakage are airframe
installed.
(2) Lift the valves and gaskets from the mainframe pads.
B. Installation.
NOTE: Lubricate all attaching bolts with Ease-Off 990 (Texacone Co.,
I Box 4236, Dallas, Texas).
(1) CJ61O-1 and -4 engines.
(a) Place a new gasket (1) and valve (2) on mainframe.
NOTE: Use either "lo~urpressure" or "high-pressure" eighth-stage
air poppet (leakage) valves. There are no valve versus
compressor eighth-stage seal (single- or double-
rotor
step) compatibility restrictions for these engines.
(b) Attach with four bolts, torque to 16-19 Ib-in., and lockwire.
NOTE: The CJ61O-1 and -4 engines do not require ducting.
1 (2) CJ610-5, -6, -8, -8A, ~nd -9 engines.
(a) Place a gasket (1), poppet valve (2), gasket (3) and duct elbow
(4) on mainframe pad and retain with four bolts (5).
(b) Install two piston rings (6) (lubricate with petrolatum) on rear
duct (7) and assemble to duct elbow (4). Connect the rear leak-
age duct (7) to exhaust cone with 4 nuts and use new gasket
(8).
(c) Torque mainframe bolts (5) to 16-19 Ib-in. and exhaust cone nuts to
24-27 Ib-in. and lockwire.
CAUTION: CJ610-5 AND -6 ENGINES INCORPORATING A SINGLE STEP
EIGHTH-STAGE COMPRESSOR AIR SEAL MUST USE "HIGH-
PRESSURE" EIGHTH-STAGE AIR POPPET (LEAI(AGE) VALVES.
THE SINGLE-STEP SEAL AND "LOW-PRESSURE" VALVES ARE NOT
COMPATIBLE FOR THESE ENGINES.
CJ610-8 AND -9 ENGINES INCORPORATE A DOUBLE-STEP COM-
PRESSOR ROTOR EIGHTH-STAGE SEAL AND MUST USE "HIGH´•
PRESSURE" EIGHTH-STAGE AIR POPPET (LEAKAGE) VALVES.
79-41-0 Dec 31/91
Page 202
ELICTIIIC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
3. Inspection/Check,
Inspection/Check Maximum Serviceable Limits Remarks
A. Housing, cap and Not serviceable
valve for cracks
B. Gap between valve 0.060 inch
stem and cap
I Jan. 15/69 79-41-0
Page 203
OI.Y I IL L
O ILI CIII I C
1J 6’1 0‘ T U R a oJ E T
SE I-186 LIA I NTENANCE MANUAL
OIL TANK CHECK VALVES
(CJ610-1 Engine Non-Center Vent On ly)
1 Gene ra 1 The f ol lowing covers the ma i nt enanc e that can be pe rf o rmed on
these valves.
2. Remova 1/Ins tallation. (See figure 201.)
A. Remo va 1
1 Di s c onn e c t the vent 1 ine s f rom the va 1 ve s
(2) Thread the vs lyes out of the flttings on the oil tank.
NOTE Di scard O- ri ng s
B. Ins ta ilation.
(1) Place new O-rings on the valves and install on the fittings on the
tank Ti ght en and lo c kwi re
(2) Connect the vent lines to the valves.
3 In s pec t i on/ Check
In s p e c t i o n/C he c k Ma x i mum erv i c ea bl e L i mi t s Remarks
A, Entire va lye for Not se rvic eable.
c rac ks
B Thread s fo r One ent rance thread Clean- up and cha s e
damage thread.
C. Free movement No binding that keeps
and seating of swing seat from seating.
swing seat
79- 42-0
Ma r. 30/67
Page 201
ELLCIDIC
CJSIO TURBOJET
MA I NTENANCE MANUAL SEI-186
t=
o k~i
CHECKVALVE
CJ610´•6094´•0-DZ
Oi 1 Tank Check Va lyes
Figure 201
79-42-0 Ma r. 30/67
Page 202
OEIEIIAL8 ELICTIIC------
cJeio TU~B´•QJET
SEI-186 MAINTENANCE MANUAL
OIL MANIFOLD CHECK VALVE MAINTENANCE PRACTICES
(CJ610-4 Engine, Non-Center Vent System Only)
i
I~
iii~
g riP1I
~jig
CJ610-60950D?
Oil Manifold Check Va’lve ’Refrrovai/Installation
Figure 201
i. General, The maintenance that can be performed on this valve is given in
this section.
2. Removal/Installation. (Refer to figure 201.)
A. Removal.
(1) Disconnect the tube that connects the valve to the mainframe.
(2) Disconnect the tube that connects the valve to the front frame.
Mar. 30/67 79-43-0
Page 201
oEW LAAL E LE eTR IC _--
CJB10 TURBOJET
MA I NTENANCE MANUAL SEI-186
(3) Remove the va lye by cutting the loc kwire and removing the three
machine sc rews.
NOTE Di s ca rd the two O- rings under t he valv e
B. Ins tallation.
1 In s t al 1 two new 0- ri n g s in the po rt s in the oi 1 tank
(2) I nstall the valve on the tank and s ecure wi th t hree s c rews Ti ght en
and loc kwi re
(3) At t a ch the tube that c onnec ts the va I ve to the f rent f rame Ti ght en
and lockwire.
(4) At’tach the tube that connec t s the valve to the ma i nf rame Ti ghten
and loc kwi re
3 Ins p e c t i on/ Che c k If s e rv i c e a bl e 1 imi t s are exe e eded va lye can be ins pect ed
and re pa i re d per A c c e s s o ry Ove rha ul Manual
In s pe c t i o n/ Che c k Maximum Se rv i c ea bl e Li mi t s Remarks
A. Ass emb ly for cracks Not se rvic eable.
B Hou s i ng f 1 an ge for Any amount provi ded valve
disto rtion seats flush on tank pad.
C Thread damage One fu 11 entrance th read Clean-up and cha s e
thread
79-4 3-0 Mar. 30/67
Page 202
C H A PT E R
STARTING
c t,l E I A L E LE CT R I C
CJS10 TUR~03ET
:f 1,, MA I NTEN ANCE MANUAL,
CHA PTE Ii. 80 START ING SYSTEM
TA BI,E OF CONTENTS
Page
b0 00 9 TART ING SYSTEM
De scri pt ion a nd Ope rat i on 1
Trouble shoe ti ng 101
Main tenance Practices 201
80-10 CHANKINC (Table of Contents On ly)
80-11-0 Starter
Ma i n l;enance Prac t ice.s 201
80 20 i GN 1T ION (Tabl e o f Con t en t. a On ly
80-21-0 Ignition Excil; er
Maint enance Practices 201
80-22-0 Igni tion Leads
Ma i ntenane e Prac t i ces 201
1-23-0 Igniter Plug
Ma intenane e Prac t i ces 201
3 0/ ii 7 80
Pa ge 1
GENERAL ELECTRIC------
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
CHAPTER 80 STARTING SYSTEM
LIST OF EFFECTIVE PAGES
CHAPTER/
SECTION PAGE DATE
80 *I Dec 31/95
Contents 1 Mar 30/67
80-00 1 Mar 30/67
*2 Dec 31/95
101 Nov 15/67
201 thru 202 Mar 30/67
80-11-0 201 Dec 31/91
80-21-0 *201 thru 202 Dec 31/95
80-22-0 *201 thru 202 Dec 31/95
80-23-0 *201 thru 202 Dec 31/95
*202A/202B Dec 31/95
203 Dec 1/77
204 Jan 15/69
205 Dec 1/77
’Asterisk indicates pages added, changed. or deleted by this revision.
80
Dec 31/95 I
6EW flAL ELECIR IC
CJ610 TURBOJET
SEI-186 MAINTENANCE MANUAL
STARTING SYSTEM DESCRIKTION AM) OPERATION
i. General.
The engine starting system consists of an ignition exciter, 2 igniter leads
and the igniter plugs. These components are engine furnished, externally
mounted on the engine and are accessible for removal and replacement.
NOTE: The engine starter motor is airframe furnished.
2. Description.
A. Ignition Exciter.
The ignition exciter (a capacitor discharge ignition unit) is often re-
ferred to as a low tension, high energy device. Its 3,000 volt D.C.
output is low when compared to the 10,000 volt or 20,000 volt jet engine
ignition units. The amount of energy produced is very small, however an
intense spark is developed by the expenditure of a small amount of elec-
trical energy in an infinitesimal period of time.
B. Igniter Plugs.
The igniter plugs are self-ionizing, shunted gap type igniters designed
for relatively low voltage application. A semi-conducting material ef-
fectively shunts the radial gap by providing a conducting path between
the electrodes.
C. Igniter Leads.
The 2 igniter leads connect the ignition plugs with the ignition exciter
unit. Each end of the lead has a machanical connector for attaching to
the plugs and ignition exciter.
3. Operation.
A. General.
Ignition of the atomized fuel-air mixture is accomplished by an intense
electrical spark produced at 2 igniter plugs which are immersed in the
combustor. A dual output capacitor discharge type of ignition exciter
produces the electrical energy necessary to create the high intensity
spark igniter plugs.
at the Generally, the ignition exciter converts 28
volt D.C.moderately high potential pulsating D.C. to charge an
to a
aspirator which is discharged across the igniter plugs in a comparative-
ly short period of time. At the completion of the starting cycle spark-
ing automatically ceases and combustion is self sustaining.
Mar. 30/67 80-00
Page 1
GENERAL ELECTRIC---~-
CJ 61 O TU R BOJ ET
SEI-186
MAINTENANCE KANUAL
B. I gnition Exciter.
The r e are two ma nu fa c t u r e rs fo r i gn i t i on exe it e rs ESC El e c t r o n i c s Co r p 534
Bergen Blvd. Palisades Pa rk, NJ 07650, and the Be ndix Jet Ignition Exciter
made by Unison Industries Ltd 7575 Bay Meadows Way Jackso nville, FL 32256
(F SCM 5 9 5 01 Both makes of excite rs wo rk from a 28 volt D C input whi oh i s
supplied to the exciter from an airframe mounted battery or generator The
inte rna 1 el e c t r i c al c i r cui t s d i fie r b e tw e e n ma nu factu r e r s b ut in b o th uni t s
each time the ionization pete ntial of the sealed gap is reached the capaci-
tor wi 11 discharge across the sealed gap to the igniter plugs Table Ilists
the lea ding partic ulars of the ignition exciter.
Table I I anition Exciter Data
Input Voltage 14-30 Volts D. C.
In put Current 4.4 Amp s. Max.
No. Plugs Fired
of 2
Operating Altitude 60, 000 Feet
Ambient Operating Tempe rature Range -65" to -t-2500F
Spa rk Rate 2 O/Sec. Min at 14 Volts D. C.
Stored Energy 2. 05 Jo ules Nominal
C. Ignition Plugs.
Wh e n the i gn i t i o n uni t ou tput reac he s a pp r ox i ma t ely 8OO v olt a enou gh c u r rent
flows through the semi-cc nductor to ionize the
igniter plug air gap Once
ionization has been initiated a conducting path is provided for the output
current whi ch area across the air gap
80-00
Page 2 Dec 31/95
OEIEIAL ELECTlle
CJB10 TURBOJET
SEI-186 MAINTENANCE MANUAL
STARTING SYSTEM TROUBLE-SHOOTING
i. General.
generally easy to detect. How-
The starting (ignition) system troubles are
isolating the trouble to the individual components is sometimes more
ever,
difficult. If replacement components are available, it is normally quicker
and moreeconomical to isolate the defective component by replacing parts
component most likely to malfunction first, is
with known good parts. The
the igniter plugs, then the ignition exciter.
Trouble-Shooting information is furnished in Chapter 72-00.
80-00
Nov. 15/67
Page 101
OEW EIAL E LE eT I IC
CJB~O TURB6JET
SEI--186 MA I NTENANCE MANUAL
START ING SYSTEM MA INTENANCE PRACT I CE S
1 Gene ra 1
Ma i n t ena nc e of the s tart ing sy stem dea 1 s p r ima r i 1 y wi t h t he rout i ng and
clamping of the syst em.
WARN ING EXE RC I SE CARE WHEN HANIL I NG ANY I GN ITE R COMPONENT I N ORDER TO
AVOID CONTACT WITH THE ELE CTR I CAL OUTPUT MAKE SURE THAT THE:
I GN IT I ON UNIT AND I GN ITER PLUGS ARE GROUNDED PROPERLY BEFORE
ENE RG I 2 ING UNIT
2. Ins pection/Check.
A. Check f o r s ecu ri ty of all c omponent s bra c ke t s and bolt s
B. Che c k f o r hi gh volt a ge a re throu gh or s ho r t s indi ca t ed by burnt or
severely dis cole red cable.
C. Check for loose connections.
D. Run engine up to maximum, available sta rter speed without att empting
i gn i t i on Che c k that RPM ava i lable is no rma 1
3. Approved Repairs.
A Ti ght en anjr loo s´•e component
B Replace any component indi cat ing sho rt s
C. Tighten loose connections.
Ma r 3 0/6 7 s o- oo
Page 201
616 III r: E LE Etl IC
G3~10 TURBIOJET
MAINTENANCE MANUAL SEI-186
2 3 1
t
II
´•c´•
7"
C ;i i c’B~
r
3i
CP
1. IGNITER PLUG
2. IGNI:TER LEAD
3. CLAMPS
4. IGNITION EXCITER
5. CLAMPS
6. IGNITER LEAD
RIGHT-HAND SIDE
4 2
165
LEFT-HAND SIDE
CJ610-6077´•0*2*
Starting System
Figure 201
80-00 Mar. 30/67
Page 202
GEWERAL OLECTRIC
CJGIO TURBOJET
SE I-186 MAINTENANCE MANUAL
STARTER MAINTENANCE PRACT I CE S
i. General.
Ref er to the Ai re ra f t Maintenance Manual for starter re qui rement s and in-
s talla t i on pro cedure s
NOTE When ins t all ing the s tar t er lubr i cat e the splined shaf t wi th
grease Plas t i lub e Mo ly No 3 or Plas t i lub e No 3 GE Ai r c ra ft
Eng ines Speci fi cat i on A5 0T18 (Thi em Automo t ive’ D iv 5 15 1 Denison
Av e Cleveland OH, 44102 or approved equival ent Torque the 6
mounting nuts to 220-325 ib-in. Be sure the gasket is installed
between the gearbox and the st ar t er mount ing pad
Dec 31/91 80-11-0
Page 201
GENERAL ELECTRIC---------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
IGNITION EXCITER MAINTENANCE PRACTICES
1. Removal/Installation of Innition Exciter. (See figure 201, section 80-00.)
A. Removal.
(1) Shut off power supply before handling any leads or cables.
WARNING: DISCONNECTING IGNITION LEADS
HIGH VOLTAGE MAY BE PRESENT. CONTACT WITH CENTER CONDUCTOR OF ELEC-
TRICAL CABLE OR CENTER ELECTRODE OF IGNITER PLUG WILL CAUSE ELEC-
TRIC SHOCK IF THE BLEED RESISTORS INSIDE IGNITION UNIT HAVE FAILED.
BEFORE REMOVING IGNITER PLUG, BE SURE THAT DISCHARGE CONNECTOR IS
GROUNDED.
(2) Disconnect the igniter plug leads (2) at the ignition exciter (4).
(3) While supporting the ignition exciter to prevent if from falling, remove
the ignition exciter, isolators, and ferrules from the mounting brack-
ets.
B. Installation.
(1) Ensure that power supply is shut off. The electrical cable, when ener-
gized, becomes a high voltage hazard even if previously grounded.
(2) Install an isolator and ferrule above and below the ignition exciter
mounting brackets at the four mounting hole locations, Secure the igni-
tion exciter (4) (isolators and ferrules in place) to the brackets with
four bolts and nuts. Torque the nuts to 8-10 Ib-in.
(3) Connect the igniter plug leads (2) to the ignition exciter connectors.
Torque the nuts to 125-150 Ib-in.
80-21-0
Dec 31/95 Page 201
GENERAL ELECTRIC------
CJ610 TUR BOJ ET
SEI-186
MA~NTENANCE MANUAL
2. InsDectisn.
Inspect Maximum Serviceable Limits Corrective Action
A. The cover for:
(1) Dents. Any number, 1/8 inch deep. Replace exciter.
(2) Scratches. Any number. Not applicable.
(3)Cracks;’ Not serviceable. Replace exciter.
B. The case and support for:
(1) Dents. Any number, 1/16 inch deep. Replace exciter.
(2) Scratches. Any number. Not applicable.
3. O;oeration Duty Cycle.
Do not use the ignition exciter in excess of the following limits.
2 Min. On, 3 Min. Off
2 Min. On, 23 Min. Off
or
5 Min. On 25 Min. Off
80-21-0
1 Page 202 Dec 31/95
GENERAL ELECTRIC--------
CJ 61 O ’6 U R B OJ ET
SEI-186
MAINTENANCE MANUAL
IGNITER LEADS MAINTENANCE PRACTICES
1. Removal/Installatio n of I eniter Leads (See figure 201, section 80-00.)
A. Removal.
(1) Shut off power supply before handling starting system components or
cables.
WARN ING: DT S CONNECTING I GNIT I ON LEAD S
HIGH VOLTAGE MAY BE P RE SENT. CONTACT WITH CENTER COND U C TOR OF E LE C
TRICAL CABLE OR CENTER ELECT RODE OF I GNITER PLUG WILL CAUSE ELEC-
TRIC SHOCK IF THE BLEED RESISTORS INSIDE IGNITION UNIT HAVE FAILED.
B E F O RE RE MO V I N G IGNITER P LUG BE SURE THAT D I S CHARGE CONNECTOR IS
GROUNDED
(2) Disco nnect the igniter leads (2) at the ignition exciter (4) and igniter
plugs (1)
3 Remove th e c 1 amp s f r om the lead a nd t ake i gni t e r le a d f r om en g in e
B. Installation.
1 En su r e that p owe r s up ply i s shut o ff
2 Co at t he th r e ad s o f t he i gn i t e r plu g wi th unflav o re d milk o f ma gne s i a
Co nnect each igniter lead (2 6) to its igniter plug (1) then connect
igniter leads to the exciter (4) to pr ev ent any residual voltage in the
exciter from bec oming ahazard. Tor que connections to 125-150 ib-in.
3 In stall clamp s 3 and 5 t o r que nut s to 8 10 ib in
80-22-0
Dec 31/95 Page 201
GENERAL ELECTRIC---~
CJ61 O TU RBOJ ET
SEI-186
MAINTENANCE MANUAL
2. Inspection.
Inspect Maximum Se rvice able Limits Corrective Action
A. The braided shield- 25 broken wires or abreak Replace lead
ing for broken wires that is less than 1/4 of
the circ umference
B. Co nnectors for:
1 Lo o s e or mi s sing Not s e rvi c eable Repla c e i t em with
pin o r s o c ket th e d ama g ed
contacts. connector.
2 C rac ke d a h ell s No t s e rv i c ea bl e Re pla c e it em wi th
the damaged
CO nnector
(3) Swelling of in- Swelled not more than 0. 060 Replace ha mess
sert. inch beyond end of connec-
to r wit h no b r e ak s b e twe e n
insert holes.
C Loc kwi re hole wo rn Not s ervice able Replac e lead
through the wall.
80-22-0
I Page 202 Dec 31/95
GENERAL ELECTRIC--------
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
IGNITERPLUGS MAINTENANCE PRACTICES
1. Remo.val/Installat,ion of Igniter Pluas. (See figure 201, Section 80-00.)
A. Removal.
(1) Shut off power supply before handling cables. plugs. or leads.
WARNING: IGNITER PLUGS
BEFORE ENERGIZING THE IGNITION CIRCUIT. BE CERTAIN THAT NO
FUEL OR OIL IS PRESENT. HAVE FIRE EXTINGUISHING EQUIPMENT
PRESENT.
HIGH VOLTAGE IS PRESENT. BE CERTAIN THE IGNITION UNIT AND
PLUGS ARE GROUNDED BEFORE ENERGIZING THE CIRCUIT.
NEVER TOUCH OR MAKE CONTACT WITH THE ELECTRICAL OUTPUT CONNEC-
TOR WHEN OPERATING ANY IGNITION COMPONENT.
NEVER HOLD OR MAKE CONTACT WITH THE IGNITER PLUG WHEN ENERGIZ-
ING THE IGNITION COMPONENT.
(2) Disconnect the wire lead (2) from the igniter plug (1).
(3) Remove the igniter plug and washers (shims) from the combustion casing.
Keep the washers (shims) together for use at replacement.
~L-- t
i. CENTER ELECTRODE I f i
2. OUTER ELECTRODE
3. CERAMIC INSULATOR
4. SEMI-CONDUCTOR
Igniter Plug
Figure 201
80-23-0
Dec 31/95 Page 201
GENERAL ELECTRIC´•---~
CJ610 TUR BOJ ET
SEI-186
MAINTENANCE MANUAL
B. Installation. Use one of the following methods for installing igniter plug.
Ensure that power supply is shut off before handling cables, leads, or
starter system components.
(1) Install igniter plug using tool 2C5318 as follows: (See figure 201A,
Type I.)
(a) Insert the gage (1, figure 201A) 2C5318, into the igniter plug boss
(4) on the outer combustion casing (7)
Push down and twist the spring-loaded hook (2, figure_201A) 180
degrees (arrow on the gage denotes hook direction) so as to engage
the inner face of the igniter eyelet (5). Lock the hook in place
by tightening screw (3).
(c) Insert the igniter plug (8) into the recessed groove of the gage
body so that the electrode tip touches the top surface of the
springloaded hook (2, figure 201A)
80-23-0
Page 202 Dec 31/95
GENERAL ELECTRIC------
CJ610 TURBOJET
SEI-186
MAINTENANCE MANUAL
I
I 1F
0.010-0.015 INCH CLEARANCE
1 IZ
I. DEPTH IMMERSION GAGE
2. SPRING LOADED HOOK
3. LOCK SCREW
4. IGNITER PLUG BOSS
5. IGNITER PLUG EYELET
6. COMBUSTION LINER
TYPE I 7. COMBUSTION CASING
8, IGNITER PLUG
7
9, SHIMS
I 10; FEELER%AGE
i. UPPER THUMB KNOB
2. MIDDLE THUMB KNOB
j 3. LOWER THUMB KNOB
4. IGNITER PLUG 8058
5. IGNITER PLUG EYELET
6. COMBUSTION LINER
TYPE II COMBUSTION CASING
7.
8. PIN
1 9. BODY
Igniter Immersion Depth Check
Figure 201A
80-23-0
I Dec 31/95 Page 202A/202B
G E W ER AL L LECTR I C
CJ610 TURBOJET
SE1-186 MAINTENANCE MANUAL
(d Add shims (9 unt i 1 the c le ar ance b e t we en the top shim and the
i gni t e r sho ul d e r i s O 01 O to O 01 5 i nch Check t he cl e ar a nc e
wi th a thi ckne s s gage (10 f i gure 2 01 A)
(e Remove the i gni t er and gage
NOTE: The igniter is now shimmed to give an immersion depth of
0. 000 to 0. 015 inch. Be sure that this immersion depth
i s ma i nt ai ned The O 01 O to 0 01 5 i ne h cl e ar anc e between
the shim and the i gni t e r sho ul d e r c omp en s a t e s fo r the
r ad i al cl e ar ance that i s bui 1 t i nt o the i gni t er e yel e t
f Lub r i ca t e the th r e ad s o f the igniter p lug wi th un f lavo r e d mi ik o f
ma gne s ia Ins tall the i gni t er and torque to 2 2 5- 2 7 5 Lb in
NOTE Avo id c on tac t ing the igni t er tip or ceramic wi th the un-
f 1 av o r e d milk of magn e s i a
CAUT I ON: POS ITION THE WASHER(S) TO PERMIT PROPER IN SPECT I ON OF
I GN ITER PLUG PLUG SHOULD THREAD EA S I L Y INTO BOSS BY
HAND. ANY ADDITIONAL FORCE MAY I ND ICATE AN INT%RFER-
ENCE PROBLEM WITH SHIM NOT SEATED IN BOSS OR I GN IT ER
PLUG NOT ENGAGED IN COMBUST I ON L I NER FERRULE E I THE R
COND ITION WILL CAUSE RAPID BURN OUT OF COMBUST I ON
LINER. NOTE FIGURE 202 FOR LOCAT I ONS.
(g Connect the i gni t er le ad s to t he i gni t er plug s To rque nut to
12 5-1 50 1 b- i n
(2 Inst all i gni t er plug using tool 20538 8 as follows (See fi gure 2 01A,
Type II.
(a) Retr act the cent act foot at the lo we r end of pin (8) by tur ning
the upper t humb knob (1 ful ly do ckwi s e No t e the po si t ion o f
the index mark on the upper thumb knob
(b Insert the gage 2(=53 88 into the i gnit er plug bo ss (4) on the
outer combusti on casing (7) maki ng sure the shoulder of body (9)
i s s e at ed on the s e at i ng surf ac e i ns i de the i gni t e r pi ug bo s s
(e Ro t at e t he upper thumb knob (1 1 80 de gr ee s co unt e rcl o ckwi s e
arrow on the knob d e no t e s cent ac t foot d i re c t i o n
(d Eng ag e the c ont a c t foo t o f the pi n (8 under the inside surf ace
of the i gni t er pi ug eyei et (5 by pul 1 i ng the pi n out ward
(e Lock the p in in pi ac e by t urni ng the lo wer thumb knob (3 down
unt ii it j us t cent ac t s the body (Do no t t i ght en t hen turn the
mi ddle thumb knob (2 down j ammi ng the lo wer thumb kno b in pi ac e
De c 1 77 80- 2 3- 0
Page 203
OlslRAL~ ELICTRIE
CJ610 TURBOJET
MAINTENANCE MANUAL SEI-186
i. IGNITER PLUG
SHIM/S MAY HANG-U
3 2. OUTER COMBUSTION CASING BOSS
ON THIS CORNER
3. SHIM/S
4. OUTER COMBUSTION CASING
5 5. COMBUSTION LINER
IGNITER PLUG MAY
HANG-UP ON FERRULE
RADIUS BOTH
CORNERS SLIGHTLY
CJ610´•J1671´•F?
Igniter Plug Installation
Figure 202
This sets the gage to the depth between the seal inside the
igniter plug boss and the inner surface of the igniter plug eye-
let.
(f) Disengage the contact foot of pin by rotating the upper thumb
knob clockwise 180 degrees and remove the gage.
(g) Measure the distance between the inside surface of the Contact
foot and the seating shoulder on the body and record the dimene
sion.
(h) Measure the length from the plug tip to the seating shoulder on
the plug and record the dimension.
NOTE: This measurement to be to inner end of igniter OD. Not
center electrode.
(i) Subtract the dimension obtained in step (g) from the measured
length of the igniter plug body obtained in step (h). Select
washers to reduce this difference to 0.010-0.015 inch. (Dimen-
sion from plug tip to the washer face to be 0.010-0.015 inch
greater than dimension obtained in step g.)
NOTE: The igniter is now shimmed to give an immersion depth of
0.000 to 0.015 inch. Be sure that this immersion depth
is maintained. The 0.010 to 0.015 inch greater plug
length compensates for the radial clearance that is built
into the igniter eyelet.
80-23-0 Jan. 15/89
Page 204
GENERAL ~b E LE CTRIC
CJ610 TURBOJET
SEI-186 MA I NTENANCE MANUAL
i th unf lavo r e d milk f
(j Lub r i ca t e the th r ead s o f the igni t er p lug w o
Ins tall the igni ter and tor que to 2 2 5- 2 7 5 ib in
magne s i a
NOTE: Av old coatacting the igniter tip or ce ramic with the un-
flavored milk of magnesia.
CAUT ION POS IT I ON THE WA SHER S TO PERMIT PROPER IN SPECT I ON OF
I CN ITER PLUG PLUG SHOULD THREAD EA S I LY INTO BOSS BY
HAND. ANY ADDITIONAL FORCE MAY I ND ICATE AN INTERFER-
ENCE PROBLEM WITH SHIM NOT SEATED IN BOSS OR I GN ITER
PLUG NOT ENGAGED IN C OMBU ST I ON L I NER FE RRULE E ITHER
C OND IT I ON WILL CAUSE RAP ID BURN OUT OF COMBU ST I ON
LINER. NOTE FIGURE 202 FOR LOCAT I ONS.
(k) Connect the i gni ter 1 ead s to the i gni ter pi ugs Torque nut to
125-150 ib-in.
2. Ins pection. See figure 201.
I n s pe ct Maximum Se rvi c e able Limi t Co rre c t i ve Ac t i on
A. The ign i t er for cha f ing 0 O30 i nch deep on di ame ter Repl ace i gni t e r
B. The outer elec tr ode for Not serviceable. Replace igniter.
cr a ck s b r e akag e or
10 OS enes s
C The we id for c r ac ks No t s e r vi ce able Repl ace i gni ter
D The center e le c t r ode f or
1 Lo o s e center Not s e r v i ce abl e Repl ace i gn i te r
(2) Erosion. 0.040 below outer electro de. Replace igniter.
E. The ceramic ins ulat or for
1 Mis s ing ma t e r ia 1 25 pe r c e n t of ori gi nal area Re pi ace i gn i te r
(2) Cracks or lo os ene s s Not s e r v i c e able Repl ace i gn i t e r
De c 1 77 8 0- 2 3 0
Page 205
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