Na 03-105ab-52

THIS PUBLlCATION IS NO
• LONGER MAINTAINEO BY
NATSF ANO IS RETAINEO
FOR REFERENCE USE ONL Y
NAVAIR 03-105AB-52
TECHNICAL MAN ~ALL----------_
DEPOT MAINTENANCE M
'.
JET FUEL GAS TURBINE ENGINE STARTER

MODEL NO. JFS100-34, PART NO. 384092-1-1
384092-1-4
384092-1-7
(AIRnearch)
NOOO 19·71-C-0189
N0014D-S8-D-RE90
NOTlCE: This prlnted manual replaees the mlcrofnmed issue prevlously contalned In
cartridge 2.aQ2. The latest change Information. ehange 2 dated 15 Jyne 1989
has been Incorporated in thls Issue. This Is a complete publicatlon.
plSTRIBUTION SWEMENT C. Dlstrlbutlon authorlzed to U.S. Govemment agencies and

their contractors to protect publications requlred for offleial use or for admlnistratlve or
.,perational purposes. determlned on 15 June 1989. Other requests for thls document shall
be referred to Commanding Offlcer. Naval Alr Teehnical Servlces Faellity. 700 Robbins
Avenue, Philadelphia, PA 19111-5097.
PESTRUCTlON NOTICE - For unclassified, IImited documenta, destroy by any method that
will prevent disclosure of contents or reconstructlon of the document.
PUBlIStEO BY DlRECTION CF Tf-E COMMANDER. NAVAl AIA SYSTEMS COMMAN>
BBB3LPSBB2?2B 1 JUNE 1975

1111111111111111
t-RVAIR 03-105R3-52 PIa< LP REV
CHANGE 2 - 15 JUNE 1989
.. '!
NAVAIR 03-105AB-52
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L1ST DF EFFECTIVE PAGES
Intert lacest cbaoged paga; dispose of supeneded pages in accordance with applicable regulatioos.
,
NOTE: Da • dlaapd PQe. chIO ponioa of chIO tezc a/fecred b, chIO laresr chaA~ il indicaeed br • venieal line. or orher chan~ symbol. ia chIO ouelO'
maraln Df cbe pap. Cban.., to i1bmracions are iodicared br miaialUft poiario. hand .. Chanae- co ... irin. diaJU'&DIS are indicaced b, shllded • ..,....
Dates Df issue for original and changed pages are:

Original •••••• o .•••.•• lJWl75
Change........ 1 ••••••• 21Jul77
Change........ 2 ••••••• 15JWl89
Total number of pages in this manual is 444 consisting of the fol1owing:
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NA'\TAIR 03-105AB-52
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NAVAIR 03-l05AB-52
TABLE OF CONTENTS
Section
LIST OF ILLUSTRATIONS ••••••••••••-••••••••••••••••••••••••••••••••••••••••••• i

IJS,T OF T.ABLES . . . . . . . . . . . . . . . . . . . . . . . .. . . . • . . . •. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. v
LIST OF TECHNICAL PUBLICATION DEFICIENCYREPORTS
(TPDR) INCORPORATED ...................................................... !............................ vi
I INTRODUCTION •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1-1

1-1. General •••••••••••••••••••••••••••••••••••••••••••••••••••• 1-1
1-5. Purpose of Equipment ••••••••••••••••••••••••••••••••••••••• 1-1
II CHARACTERISTICS ••••••••••••••••••••••••••••••••••••••••••••••••••••• 2-1
2-1. Description ••••••••••••••••••••••••••••••••• ~ ••••••• :••••••• 2-1

2-28. Starter Operation •••••••••••••••••••••••••••••••••••••• ~ ••• 2-8
2-39. Leading Particulars ••••••••••••••••••••••• ~ •••• ~ •• i • • • • • • • • 2-11
III AEROSPACE GROUND EQUIPMENT MAINTENANCE (Not app1icable) ••••••••••••• 3-1
IV DEPOT MAINTENANCE ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-1
4-1. Checkout ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-1

4-3. Disassembly •••••••••••••••••••••••••••••••••••••••••••••••• 4-1
4-4. General o.................................................... 4-2
4-42. Cleaning ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-59
4-93. Inspection ••••••••••••••••••••••••••••••••••••••••••••••••• ~8A
4-108. Magnetic Particle Inspection •••••••••••••••••••••.•••••••••• 4':'73
4-110. Fluorescent Penetrant Inspection ............................ 4-73
4-366. Repair and Replacement ••••••••••••••••••••••••••••••••••••• 4-170
4-646. Tolerances and Limits •••••••••••••••••••••••••••••••••••••• 4-213
4-660. Assembly ........................................... ti I I'. • • • •• 4-220
4-733. A1ignment and Adjustment ••••••••••••• '•••••••••••••••••••••• 4-303
4-738. Testing •••••••••••••••••••••••••••••••••••••• ~.~~.~ ••••• ~ •• 4~306
4-767. Tro~b1eshooting •••••••••••••••••••••••••.•••'......... ••.• •• •• 4-341
4-769. Preservation ••••••••••••••••••••••••••••••••••••••••• '.~. • • •• 4-341
4-772. Preparation for Storage or Shipment •••••••••••••••••••••••• 4-341
V DIFFERENCE DATA SHEETS ..••.......................•.........••.• ~ .... 5-1

LIST .OF ILLUSTRATIONS
Number Title Page
1-1. Jet Fuel Gas Turbine Engine Starter ••••••••••••••••••••••••••••••••• 1-2

2-1. Location and Identification of Major Assemblies ••••••••• ~ ••••••••••• 2-2
2-2. Electrical System ••••••••••••••••• ~ ••••• '•••••••••••••••••••••••••••• 2-3
2-3. Component Location and Identification (Sheet 1 of 2) ••••••••• '••••••• 2-4
Component Location and Identification (Sheet 2 of 2) •••••••.••••••••• 2-5
2-4. Combined Starter Systems (Fuel. Electrical, Ignition. Hydraulic
Motor and Drain) •••••••••••••••••••••••••••••••••••••••••••••••••• 2-7
2-5. Lubrication System •••••••••••••••••••••••••••••••••••••••••••••••••• 2-9
Chanee2 i
NAVAIR 03·105AB-52
LIST OF ILLUSTRATIONS (CONT)
Number Tit1e Page
4-1. Disassemb1y of P1umbing and E1ectrica1 Lines and Leads

(Sheet 1 of 2) •••.••••••••••••••..••.•••••••••••••••••••..•••••••• 4-4
Disassemb1y of P1umbing and Electrica1 Lines and Leads
4-4.
(Sheet 1 Df 3) ••.•••••.•••.•..••••••••••••.•••••••••••••••••.•...• 4-17
Disassembly of Gas Generator and Accessory Drive Assemb1y
(Sheet 2 of 3) ••.•••••••••••••.••••••••••••.•.•••••••••••••••.•••. 4-19
Disassemb1y of Gas Generator and Accessory Drive Ass~b1y
(Sheet 3 of 3) •.••••.••••.•••••••••••••••••••••••••••••••.•••.••.• 4-21
4-5. Disassemb1y of Gas Generator Assemb1y (Sheet 1 of 2) •••••••••••••••• 4-26
Disassemb1y of Gas Generator Assemb1y (Sheet 2 of 2) •••••••••••••••• 4-28
4-6. Disassemb1y of Tower Shaft Housing Assembly ••••••••••••••••••••••••• 4-33
4-7. Disassemb1y of JFS Accessory Drive Assemb1y (Sheet 1 of 3) •••••••••• 4-35
Disassemb1y of JFS Accessory Drive Assemb1y (Sheet 2 of 3) •••••••••• 4-37
Disassembly of JFS Accessory Drive Assemb1y (Sheet 3 of 3) •••••••••• 4-39
4-8. Disassembly of AC-DC Permanent Magnet Generator •• ~ •••••••••••••••••• 4-42
4-9. Disassemb1y of JFS Contro1 Box Assembly (Sheet 1 of 2) •••••••••••••• 4-45
Disassembly of JFS Contro1 Box Assemb1y (Sheet 2 of 2) •••••••••••••• 4-46
4-10. Disassemb1y of Accumulator Assembly ••••••••••••••••••••••••••••••••• 4-49
4-11. Dis8ssembly of Sensitive Sw1tch Assemb1y •••••••••••••••••••••••••••• 4-51
4-12. Disassemb1y of Switch Actuating Governor Assembly (cutout) •••••••••• 4-52
4-13. Disassembly of Main Jet Fuel Starter Fue1 Contro1 Assenbly
(Sheet 1 of 2) •.••.•••.••.•••••••••••••••••••••••••••••••...••••.• 4-53
Disassemb1y of Main Jet Fue1 Starter Fue1 Contro1 Assemb1y
(Sheet 2 Df 2) .••.•....•.•.••...•....••.•.•••••••••••..•••••...••. 4-55
4-14. Disassemb1y of Hydrau1ic Motor •••••••••••••••••••••••••••••••••••••• 4-58
4-15. Inspection of Engine Starter Mounting Flange •••••••••••••••••••••••• 4-98
4-16. Inspection of Power Turbine Containment Shie1d Assemb1y ••••••••••••• 4-100
4-17. Inspection of Engine Starter Housing Assemb1y ••••••••••••••••••••••• 4-101
4-18. Inspection of Jet Fue1 Starter Exhaust Housing Assenbly ••••••••••••• 4-102
4-19. Inspection of InternaI Gear Hub ••••••••••••••••••••••••••••••••••••• 4-104
4-20. Inspection of Bearing Support ••••••••••••••••••••••••••••••••••••••• 4-105
4-21. Inspection of Pinion Spur Gear •••••••••••••••••••••••••••••••••••••• 4-106
4-22. Inspection ofAxia1 F10w Turbine Wheel Assemb1y ••••••••••••••••••••• 4-107
4-23. Inspection of Jet Fue1 Starter Therma1 Insu1ation B1anltet ••••••••••• 4-108A
4-24. Inspection of Turbine Wheel Sea1 •••••••••••••••••••••••••••••••••••• 4-109
4-25. Inspection of Resi1ient Ba11 Bearing Housing •••••••••••••••••••••••• 4-110
4-26. Inspection of Resi1ient Mount Liner ••••••••••••••••••••••••••••••••• 4-111
4-27. Inspection of Bearing Sleeve Spacer ••••••••••••••••••••••••••••••••• 4-112
4-28. Inspection of Spur Gearshaft •••••••••••••••••••••••••••••••••••••••• 4-112
4-29. Inspection of Matched P1anetary Spur Gear Set ••••••••••••••••••••••• 4-113
li Change2
M'
NAVAIR 03-105AB-52
Number Title Page
4-30. Inspection of Gear Carrier Assembly ••••••••••••••••••••••••••••••••• 4-114

4-31. Inspection of Power Turbine Stator Assemb1y ••••••••••••••••••••••••• 4-121
4-32. Inspection of Gas Generator Containment Shield Assembly ••••••••••••• ~t2ZB
4-33. Inspection of Impe11er Shroud ••••••••••••••••••••••••••••••••••••••• 4-123
4-34. Inspection of Jet Fuel Starter Housing Assemb1y ••••••••••••••••••••• 4-124
4-35. Inspection of Compressor Impe11er ••••••••••••••••••••••••••••••••••• 4-126
4-36. Inspection ofAxial Flow Turbine Whee1 Assembly ••••••••••••••••••••• ~128
4-37. Inspection of Bearing Carrier ••••••••••••••••••••••••••••••••••••••• ~128A
4-38. Inspection of Pinion Spiral Bevel Gear •••••••••••••••••••••••••••••• 4-130
4-39. Inspection of Bearing Spacer •••••••••••••••••••••••••••••••••••••••• 4-130
4-40. Inspection of First Stage Stator Assembly ••••••••••••••••••••••••••• 4-131
4-41. Inspection of Turbine Gas-Oi1 Sea1 •••••••••••••••••••••••••••••••••• 4-132
4-42. Inspection of Bearing Carrier Assemb1y •••••••••••••••••••••••••••••• 4-133
4-43. Inspection of Fuel Air Combustor Assembly ••••••••••••••••••••••••••• 4-134
4-44. Inspection of Spira1 Bevel Gear Assembly •••••••••••••••••••••••••••• 4-135
4-45. Inspection of Bearing Carrier ••••••••••••••••••••••••••••••••••••••• 4-136
4-46. Inspection of Diffuser PIate •••••••••••••••••••••••••••••••••••••••• 4-137
4-47. Inspection of Support ••••••••••••••••••••••••••••••••••••••••••••••• 4-138
4-48. Inspection of Spur Gear ••••••••••••••••••••••••••••••••••••••••••••• 4-141
4-51. Inspection of Matched Rotary Pump InternaI and ExternaI Gearset ••••• 4-143
4-52. Inspection of Pump Lubrication Cover •••••••••••••••••••••••••••••••• 4-144
4-53. Inspection of nrive Shaft ••••••••••••••••••••••••••••••••••••••••••• 4-144
4-54. Inspection of Shouldered Shaft •••••••••••••••••••••••••••••••••••••• 4-146
4-55. Inspection of Bevel-Zerol Pinion Gear ••••••••••••••••••••••••••••••• 4-146
4-56. InspectioD of Bearing Carrier ••••••••••••••••••••••••••••••••••••••• 4-148
4-57. Inspection of Bearing Carrier ••••••••••••••••••••••••••••••••••••••• 4-149
4-58. Inspection of Bevel-Zerol Gear •••••••••••••••••••••••••••••••••••••• 4-150
4-60. Inspection of C1utch Bousing Assemb1y ••••••••••••••••••••••••••••••• 4-151
4-61. Inspection of Gearbox Accessory Housing Assemb1y •••••••••••••••••••• 4-152
4-63. Inspection o-f Shouldered Shaft •••••••••••••••••••••••••••••••••••••• 4-154
4-64. Inspection of Adapter Housing Assembly •••••••••••••••••••••••••••••• 4-155
4-65. Rectifier/Regulator Module Assembly Test Setup •••••••••••••••••••••• 4-157
4-65A. Start Cycle Protection Sensor Test Setup •••••••••••••••••••••••••••• 4-158B
4-65B. Start Cycle Protection Sensor E1ectrica1 Schematic •••••••••••••••••• 4-158E
4-66. Inspection of Fue1 Metering Va1ve Body Assemb1y ••••••••••••••••••••• 4-168
4-66A. Repair of Second Stage Containment Shield Assembly ..................................... ~178B
4-67. Repair of Sensitive Switch ••••••••••••• : •••••••••••••••••••••••••••• ~180A
4-68. Balance ofAxial Flow Turbine Whee1 Assembly •••••••••••••••••••••••• 4-182
4-69. Jet Fuel Starter Branched Wiring Harness Assemb1y ••••••••••••••••••• 4-185
4-70. Repair of JFS Branched Wiring Harness Assembly (Main) ••••••••••••••• 4-188
4-71. Repair of Power Turbine Stator Assemb1y ••••••••••••••••••••••••••••• 4-189
4·71A. Repair of First Stage Containment Shield Assembly .• . . .•. . . . .•••• .. . . •.. • •• .. • . . ....... ••• 4-190
4-72. Jet Fuel Starter Housing Assembly ••••••••••••••••••••••••••••••••••• 4-'190B
4-73. Balance of InternaI Wrenching Nut ••••••••••••••••••••••••••••••••••• 4-191
4-74. Balance of Compressor ImpeIler •••••••••••••••••••••••••••••••••••••• 4-192
4-75. Balance ofAxial F10w Turbine Wbeel Assemb1y •••••••••••••••• : ••••••• 4-193.
4-76. Balance of Bearing Spâcer . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 4-194
Change2 Di
NAVAIR 03-105AB-52
Number Title Page
4-77 • Repair of First Stage Stator Assemb1y ••••••••••••••••••••••••••••••• 4-196

4-78. Balance of CIutch Shaft Assembly •••••••••••••••••••••••••••••••••••• 4-201
4-79. Gear Box Accessory Housing Assembly ••••••••••••••••••••••••••••••••• 4-202
4-79A. Breakdown of Start CycIe Protection Sensor •••••••••••••••••••••••••• 4-204A
4-79B. Breakdown of Underspeed Detector Circuit Card Assembly •••••••••••••• 4-204B
4-79C. Breakdown of Overtemp and Overspeed Sensor Network Assembly ••••••••• 4-204D
4-79D. Box Assembly 307073-1 .... ...................................................•.................. 4-204G
4-80. Repair of EIectrical Lead AssembIy •••••••••••••••••••••••••••••••••• 4-206
4-81. Power Turbine Assembly Tab1e of Limits •••••••••••••••••••••••••••••• 4-214
4-82. Gas Generator Assembly TabIe of Limits •••••••••••••••••••••••••••••• 4-215
4-83. Accessory Drive Assembly Tab1e of Limits •••••••••••••••••••••••••••• 4-216
4-83A. Shimming Fuel Control Va1ve Sleeve •••••••••••••••••••••••••••••••••• 4-232
4-84. Fuel Contro! Assembly Test Setup •••••••••••••••••••••••••••••••••••• 4-235
4-85. JFS Contro1 Box Assembly Wiring Diagram ••••••••••••••••••••••••••••• 4-249
4-86. JFS Control Box AssembIy Identification Markings •••••••••••••••••••• 4-252
4-87. Control Box Tester Control Panel •••••••••••••••••••••••••••••••••••• 4-253
4-88. AC-DC Permanent Magnet Generator Wiring Diagram ••••••••••••••••••••• 4-264
4-89. AC-DC Permanent Magnet Generator Test Setup ••••••••••••••••••••••••• 4-266
4-90. Accessory Drive Assembly Dimensions ••••••••••••••••••••••••••••••••• 4-268
4-91. Instal1ation of Switch Actuating Governor Assembly •••••••••••••••••• 4-272
4-92. Shimming and Backlash Assemb1y Setup •••••••••••••••••••••••••••••••• 4-292
4-93. Location of Nomenc1ature Markings on Gas Generator and Accessory
Drive Assembly •••••.•••••••••••••••••.•.•••.••••..•....• fi • • • • • • • • • 4-296
4-94. C1amp Coup1ing Orientation •••••••••••••••••••••••••••••••••••••••••• 4-304
4-95. Insta1lation of JFS into Test Setup (Sheet 1 of 4) •••••••••••••••••• 4-307
Insta11ation of JFS into Test Setup (Sheet 2 of 4) •••••••••••••••••• 4-309
Insta11ation of JFS into Test Setup (Sheet 3 of 4) •••••••••••••••••• 4-311
Installation of JFS into Test Setup (Sheet 4 of 4) •••••••••••••••••• 4-312
4-96. Accumu1ator Precharge Variation with Temperature •••••••••••••••••••• 4-314
4-97. Accumu1ator Working Pressure Variation with Temperature ••••••••••••• 4-315
4-98. Maximum Transient Vibration Limits •••••••••••••••••••••••••••••••••• 4-326
4-99. Turbine In1et Temperature Nomograph ••••••••••••••••••••••••••••••••• 4-333
4-100. Test Data Sheet ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-337
4-101. Test Log Sheet •••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-338
5-1. Jet Fuel Gas Turbine Engine Starter Part No. 384092-1-7 ••••••••••••• 5-4
5-2. JFS Power Turbine Assembly (Sheet 1 of 4) ••••••••••••••••••••••••••• 5-6
JFS Power Turbine Assemb1y (Sheet 2 of 4) ••••••••••••••••••••••••••• 5-8
JFS Power Turbine Assembly (Sheet 3 of 4) ••••••••••••••••••••••••••• 5-10
JFS Power Turbine Assembly (Sheet 4 of 4) ••••••••••••••••••••••••••• 5-12
5-3. Gas Generator and Accessory Drive Assembly •••••••••••••••••••••••••• 5-14
5-4. Gas Generator Assembly •••••••••••••••••••••••••••••••••••••••••••••• 5-16
5-5. JFS Control Box Assembly •••••••••••••••••••••••••••••••••••••••••••• 5-18
5-6. Main Jet Fuel Starter Fue1 Control •••••••••••••••••••••••••••••••••• 5-20
5-7. Disassembly of Plumbing and Electrical Lines and Leads
(Sheet 1 of 2) •••••••••••••••••••••••••••••••••••••••••••••••••••• 5-23
Disassembly of Plumbing and E1ectrical Lines and Leads
(Sheet 2 of 2) •••••••••••••••••••••••••••••••••.••••••••••••••••.• 5-24
iv Change2
NAVAIR 03-105AB-52
Number Title Page
5-8. Inspeetion of Gear Carrier Assembly ••••••••••••••••••••••••••••••••• 5-33

5-9. JFS Control Box Assemb1y •••••••••••••••••••••••••••••••••••••••••••• 5-40
5-10. Electrical System ••••••••••••••••••••••••••••••••••••••••••••••••••• 5-41
5-11. InstaIIation of Tube and Conneetor •••••••••••••••••••••••••••••••••• 5-44
LIST OF TABLES
Number Tit1e Page
2-1. Table of Leading Particulars •••••••••••••••••••••••••••••••••••••••• 2-11

4-1. Table of General Physieal Conditions •••••••••••••••••••••••••••••••• 4-69
4-2. Table of Inspection and Repair Proeedures ••••••••••••••••••••••••••• 4-75
4-3. Module Assemb1y Resistance Test ••••••••••••••••••••••••••••••••••••• 4-156
4-3A. Troub1eshooting TabIe for St~rt Cyc1e Protection Sensor ••••••••••••• 4-158C
4-4. !1ectrieal Lead Assembly Wiring Data •••••••••••••••••••••••••••••••• 4-207
4-5. Power Turbine Assembly Table of Limits •••••••••••••••••••••••••••••• 4-217
4-6. Gas Generator Assemb1y Tab1e of Limite •••••••••••••••••••••••••• ~ ••• 4-218
4-7. Accessory Drive Assemb1y Tab1e of Limits •••••••••••••••••••••••••••• 4-219
4-8. Troub1eshooting for Hydraulic ~otor ••••••••••••••••••••••••••••••••• 4-229
4-9. Troubleshooting for Fuel Control Assemb1y ••••••••••••••••••••••••••• 4-242
4-10. Delay Circuit Response Settings ••••••••••••••••••••••••••••••••••••• 4-257
4-11. Troubleshooting for JFS Control Box AssembIy •••••••••••••••••••••••• 4-259
4-12. Troubleshooting for Accessory Drive Assemb1y •••••••••••••••••••••••• 4-277
4-13. OsciI1ograph Data ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-316
4-14. Starter Operating Parameters •••••••••••••••••••••••••••••••••••••••• 4-324
4-15. Power Turbine Output Shaft Barometric Correction •••••••••••••••••••• 4-327
4-16. Power Turbine Output Torqup. F1ywheel Inertia Correction ••••••••••••• 4-327
4-17. Minimum A1Iowab1e Power Turbine Output Torque ••••••••••••••••••••••• 4-328
4-18. Maximum A110wable Gas Generator Speed ••••••••••••••••••••••••••••••• 4-329
4-19. Nomograph T4 Correction for Fue1 Lower Heating Value •••••••••••••••• 4-335
4-20. Maximum Allowable Turbine Inlet Temperature ••••••••••••••••••••••••• 4-335
4-21. Troubleshooting •••••••••••••••••••••••••••••••••••••••••• ; •••••••••• 4-342
5-1. Tab1e of Inspection and Repair Procedures ••••••••••••••••••••••••••• 5-28
5-2. Wiring Harness Assembly Wire Chart •••••••••••••••••••••••••••••••••• 5-31
Change2 v
NAVAIR 03-105AB-52
LIST OF TECHNICAL PUBUCATION DEFICIENCY REPORTS (TPDR) INCORPORATED
Identification NoJ
QA Seguence No, Location
NONE
vi Change2
NAVAIR 03-105AB-52
SECTION I
INTRODUCTION
1-1. GENERAL.
1-2. This pub1ication contains depot maintenance instructions for Jet Fue1 Gas
Turbine Engine Starter, Part No. 384092-1-1, 384092-1-4 and 384092-1-7, Mode1 No. I
JFS100-34, manufactured by The Garrett Corporation, AiResearch Manufacturing Company
of Arizona, P.O. Box 5217, Phoenix, Arizona 85010.
1-3. This manual is arranged in sections. Sections I through IV contain depot

leveI maintenance instructions for Starter Part No. 384092-1-1. Section V contains
difference data sheets that pertain to Starters Part No. 384092-1-4 and 384092-1-7.
I
1-4. Maintenance assurance requirements for maintenance procedures that, if 1m-
proper1y performed, cou1d cause equipment fai1ure or jeopardize ground personne1
are provided in summaries at the end of the maintenance procedure. These summaries
inc1ude checks that can be performed after the comp1etion of the procedure to verify
proper comp1iance of maintenance procedures and practices.
1-5. PURPOSE OF EQUIPMENT.

1-6. The starter (figure 1-1) provides the power to motor a gas turbine engine for
starting. In addition it generates the ae and de e1ectrica1 power for the engine
ignition system and other systems essentia1 for engine starting.
Change 1 1-1
NAVAIR 03-105-AB-52
A-12A-I79
Figure 1-1. Jet Fuel Gas Turbine Engine Starter
1-2
NAVAIR 03-105-AB-52
SECTION 11
CBARACTERISTICS
2-1. DESCRIPTION.
Refer to NAVAIR 03-l05-AB-5l, Intermediate Maintenance

Manual.
2-2. The starter (figure 2-1) is a small, compact, lightwe1ght free turbine
engine. It ia comprised of two separable and replaceable assemblie~' (a) a gas
generator and accessory drive assembly, (b) a power turbine assembly. The gas
generator and accessory drive assembly 1s comprised of two sub-assemblies: (a) a
gas generator assembly, (b) an accessory drive assembly.
2-3. The gas generator assembly utilizes jet engine fuel to generate a low pres-
sure, high temperature gas stream. It is comprised of an annular fue1-air combus-
tor assembly, gas turbine engine igniter p1ug, fuel nozz1e assemb1ies and a rotating
assembly. The rotating assembly incorporates a single-stage centrifugaI compressor
and an axial turbine.
2-4. The power turbine assembly receives the gas stream from the gas generator
assembly and converts the gas kinetic energy to mechanical energy for starting the
gas turbine engine. The power turbine assembly is comprised of a free turbine, re-
duction gear system, and a pawl-and-ratchet type engage and disengage mechanism.
The engage and disengage mechanism disconnects the starter output sbaft from the gas
turbine engine during engine operation.
2-5. The accessory drive assembly transmits power from the rotating assembly of
the gas generator assembly to a main JFS fue1 control assembly, lubrication pump and
an ac-dc permanent magnet generator. During the initial phase of starter operation,
the accessory drive assembly transmits power from a hydrau1ic motor to the rotating
assembly of the gas generator accessory, the main JFS fuel control assembly, lubri-
cation pump and ac-dc permanent magnet generator.
2-6. The e1ectric~1 power generating system (figures 2-2 and 2-3) consists of ac-
dc permanent magnet generator (PMG) that provides the de power for starter opera-
tion and the ac and de e1eetrieal power requirements for engine starting, fncluding
engine ignit1on.
2-7. The ac-dc permanent magnet generator consists of a permanently magnetized
rotor assembly which is bearing-mounted in a housing assembly and end bell assembly.
A stator assembly is mounted, within the housing assembly, to the end bel! assembly.
A spur gear, mounted on the rotor assemb1y shaft, is available for mechanical1Y,ro-
tating the rotor assembly. The voltage induced into the stator assembly by the ro-
tating permanent magnet rotor assembly is avallable as il5 volt, 400 Hz, single-
phase ac, through a radio interference filter assembly, at an e1ectrieal connector.
The stator assembly voltage is also rectified in a rectifier/regulator module assem-
bly and avaialbe as 28 vdc, through the radio fnterferenee filter assembly, at the
electr1cal connector. The rectifier/regulator module assembly also regulates the ac
2-1
N
I ~
~
N
~
o
w
,....I
o
VI
GAS GENERATOR ASSEMBlY POWER TUR81NE ASSEM8lY I
~VI
A , J..
r - ----
------F-u-E-l-N-.O~Z~Z~l~E~G~A~S-::TURBINE
--.--._--.~- -------~
r.. FUEL-AIR
ENGAGEAND
ASSEM8LY ENGINE COM8USTOR TURBINE DISENGAGE N
IGNITER PlUG ASSEM8lY MECHANISM
OUTPUT
SHAFT
ASSEMBLY
L
SWITCU
ACTUATING
GOVERNOR
ASSEMBLY
SENSITlVE
SWITCH
ASSEMBLY
REDUCTlON
GEAR
SYSTEM
/
ACCESSORY HOUSING ASSEM8LY
, f
.'
ACCESSORY DRIVE ASSEMBLY
•
Figure 2-1. Location and Identification of Major Assemblles
-
r--------------------, AC-De PERMANENT MAGNE! GENERATOR
I I .
:~
ru "GU'AT~IL0
AHA
I I
IHI
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JFS CONTROl IOX ASSEMBlY I
I EMI
FILRIt
9~CK 2 5 WINOING
I I F~F 5~---,----j
t-I L ~2 r+-
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r" D 1-0 1 4'
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, Sl!NSITIVE
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(1)
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INDICATOR (2)
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, ASSEMllY
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181-J
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TIl-te Tal-li
TEST POINT OVERSPEED ANO I

UNDERFREQUENCV
-TIl-lO' T81-12
I
~
~ Tal- 13
SENSING CIRCUIT I OVERSPEED ~
IINDICATOR
{T::~~:
ti:t ~
I
I
:fI' ~
A
MANUAL PRIME NC
SOLENOIO VAlVE
1 CIRCUIT
~
(0
ENERGIZEO AIOVE
370HZ OE-ENERGIZEO
0leI
OVEItTEMP
CIRCUIT
ENERGIZED WHEN VOLTAGE
AT T81-11S AIOVE 7 VOLTS De
T81-51 IA
GRN (AL)
r5
WHTr
'I
NOItMALlY OPEN
aELOW 370HZ GItN I I AI 1 I SOLENOIO VALVE
DE-ENElGIZED WHEN OVERSPEED C
CONOITION OR OVERTEMP
I~~ª1;~
CONOIfION OCCURS ANO
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f
~
• I (TII-1
WHEN ENGINE CUTOUT SWITCH
SUPPUES VOLTAGE TO T81-15
SENSOIt ASSEM8lY
TaI-151 1F I - -
-,_:::t
~'rl ~ : CN~IT~ ~~
CHROMEl
UNir 8
.....
o
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GItN ALUMEL THE~OCOUPLE ~
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EO Sl!NSITlVE Clt
SWITCH t.:>
ILK ASSEMIILY W-I2A-I0C8R3
Figure 2-2. Electr1eal System
a·
NAVAIR 03-10S-AB-S2
GAS GENERATOR ANO ACCESSORY

ORIVE ASSEMBlY pown TURBINE ASSEM8lY
r-------~IG~N~IT~ER~Pl~U~G~~~. . . .--------------~V~------------~~~----------~,
ElECTRICAl lEAO
ACCUMULATOR GAS TURBINE 8RACKET
ASSEMBlY ENGINE ASSEMBLY
IGNITER PLUG
/
ElECTRICAl NORMAllY OPEN IMMERSION

COUNTER SOlENOIO VAlVE THERMOCOUPlE
Figure 2-3. Component Location and Identification (Sheet 1 of 2)
and dc outputs by providing feedback, in relation to ac and dc output leveIs, to the

stator assembly back winding.
2-8. The electrical control system (figures 2-1 through 2-3) is comprised of two
sensitive switch assemblies, an immersion thermocouple and a JFS control box assem-
bly.
2-9. The sensitive switch assembly that is locatec on the accessory drive assembly
incorporates two switches; one is normally closed and the other normally open. The
switches control circuits within the JFS control box assembly and Pt1G. This sen-
sitive switch assembly is actuated by a switch actuatir..g governo r assembly \v'ben the
gas generator speed is approximately 35,000 rpm.
2-10. The sensitive swi tch assembly that is located in the pm'ler turbine assembly
is actuated by a svT1tch actuating governor assembly at approximately 3200 rpm of the
output shaft speed. It is connected to the JFS control box assembly by a w1r1ng
harness assembly and controls circuits housed within the JFS control box assembly.
2-4
• NAVAIR 03-105-AB-52
FUEL MANIFOLO ASSEMBLY
CAPACITOR OISCHARGE HIGH
FLfL NOZZLE ASSEMBLY '~~a~I~;~~~~V07GN"ION UNIT
QUlCK-RELEASE P I N ' ACCUMULATOR ASSEMBLY
"\. ELECTRICAL RECEPTACLE

'W!....-_ CONNECTOR (J1)
/
POWER TURBINE
OIL FILL ANO ~ JFS CONTROL BOX
OIL DIP STlCK ASSEMBLY
~ INOICATOR
COMPRESSOR INLET
SCREEN ASSEMBLY
MANIFOLO TO TUBE MANUAl PRIME NC
ELBOW ASSEMBLY SOLENOIO VALVE
POWER TURBINE ASSEMBLY GAS GENERATOR ANO ACCESSORY ORIVE ASSEMBLY
r~""""""~.--"""""~' r~""""""~~""""""---'
I II I
SEDIMENT STRAINER
ELEMENT ASSEMBL Y
OUTPUT
ASSEMBLY
j-\.....:n
JFS ACCESSORY ORIVE ASSEMBLY
OIL FILL ANO OIL OIP STICK
MANIFOLO TO TUBE ACCESSORY ORIVE OIL ORAIN
ELBOW ASSEMBLY ANO MAGNET/C MACHINE
THREAO PLUG
Figure 2-3. Component Location and Identification (Sheet 2 of 2)
2-5
NAVAIR 03-l05-AB-52
2-11. lhe immersion thermocouple is located on the power turbine assembly and pro-
vides a signal to the JFS control box assembly for overtemperature protection.
2-12. The JFS control box assembly is located on the gas generator assembly and
performs several starter control operations: (a) controls the operational sequenc-
ing of the starter by controlling a manual prime nc solenoid valve, a normally open
solenoid valve, and a capacitor discharge high voltage ignition unit; (b) houses
and controls an electrical counter and an indicator; (c) provides gas generator
overspeed and start overtemperature protection; (d) prevents starter operation if
the immersion thermocouple or the thermocouple circuit is open; (e) provides starter
abort control when equipped with a government furnished abort switch, and (f) pro-
vides circuit protection by incorporating fuses.
2-13. The ignition system (figures 2-2 through 2-3) is comprised of a capacitor
discharge high voltage ignition unit, gas turbine engine igniter plug and an igni-
ter plug electrical lead.
2-14. The fue1 system (figures 2-3 and 2-4) is comprised of apressure fluid fil-
ter, main JFS fuel control assembly, check valve, accumulator assembly, restricted
flow check valve, manual prime nc solenoid valve, normally open solenoid valve, fuel
manifold assembly and fuel nozzle assemblies.
2-15. The pressure fluid filter is located on the gas generator assembly and sepa-
rates foreign particles from the fuel entering the main JFS fuel control assembly.
It incorporates a 10 micron sintered bronze filter elemento
2-16. The main JFS fuel control assembly is located on the ~ccessory drive assem-
bly and is a hydromechanical type controlo The fuel control assembly and the gas
generator are a matched set. It is comprised of a gear type fuel pump, a 25 micron
strainer assembly, an acceleration limiter valve, a governo r valve and a constant
pressure differential valve. lhe fuel pump provides fuel flow to initiate and sus-
tain starter operation. The strainer assembly separates foreign particles from the
fuel entering the metering section of the fuel controlo lhe governor valve limits
gas generator speed at 100 percent by metering fuel flow to the gas generator assem-
bly. The acceleration limiter valve regulates fuel flow to the gas generator assem-
bly during starter initiation and acceleration up to governed speed. It directs
excess fuel flow back to the inlet of the fuel pump. The constant pressure differ-
ential valve maintains a constant pressure drop across the governor valve by return-
ing excess fuel to the inlet side of the pump.
2-17. The check valve prevents a reverse flow of fuel through the control when the
accumulator assembly is actuated.
2-18. The manual prime nc fuel solenoid valve is located on the gas generator as-
sembly. It controls the opening and closing of the fuel line going to the fuel
man1fold assembly. It 1s a normally closed valve that is controlled by the JFS
control box assembly. It incorporates a manually actuated PRESS TO PRL~ button
that opens the valve when actuated.
2-19. lhe normally open solenoid valve is located on the gas generator assembly.
It controls the opening and closing of the fuel manifold assembly drain line. It
2-6
NAVAIR 03-105-AB-52
._____ACCElERATlON liMITE RVALVE
COMPRESSOR
DISCHARGE
t _ _----,.._
PRESSURE INLET
MAIN JFS
FUEl CONTROl r - - - -
ASSEMBLY,
": r-
I
PRESSURE
FLUID
FILTER
FUEL
INlET
&.\~~~~lk:~~F1
.,.:It::
CONSTANT
PRESSURE
DIFFERENTIAL
VALVE \
I
I
I
.............................
l. ________________ .JI
DRAIN/
ACCUMULATOR
ASSEMBlY
A A A AA METERED FUEL FROM FUEL CONTROL

• • • • • PUMP INlET PRESSURE
-- - - - - PUMP DISCHARGE PRESSURE I I -
L __ --I "'-HYDRAULlC
MOTOR
..
F~LDRAIN
"NORMAlLY OPEN
SOLENOID VALVE
Figure 2-4. Combined Starter Systems (Fuel, Electrical,

Ignition, Hydraulic Motor, and Drain)
2-7
NAVAIR 03-l05-AB-52
is a normally open valve that is actuated closed during starter initiation by the
JFS control box assembly.
2-20. The accumulator assembly is located on the gas generator assembly and is a
hydraulically actuated fuel accumulator. It provides a premeasured quantity of fue1
to the fuel manifold assemb1y for a quick and dependable lightoff during starter
initiation.
2-21. The restricted flow check valve is located on the gas generator assemb1y.
It prevents a drop in fuel supply pressure when the hydrau1ic pressure to the accu-
mulator terminates. An orifice in the valve permits the accumulator to gradually
recharge with fuel after the termination of hydraulic pressure.
2-22. The fuel manifold assembly is located on the gas generator assembly and
directs fuel to the five fuel nozzle assemblies.
2-23. The fuel nozzle assemblies are located on the gas generator assembly and pro-
trude into the fuel-air combustor assembly. They control the fuel discharge pattern
to assure proper fue1 atomization and a contro1led f1ame pattern.
2-24. The drain system is comprised of the necessary tube assemblies and fittings
to direct drainage from the main JFS fuel control assembly, accumu1ator assembly
and normally open solenoid va1ve into one common fuel drain.
2-25. The hydraulic motor is located on the accessory drive assembly and is a
fixed-disp1acement piston-type motor. It is used to drive the starter to self-
sustaining speed. Hydraulic pressure is supp1ied by a government-furnished hydrau-
lic system.
2-26. The lubrication system (figure 2-5) of the power turbine assemb1y is inde-
pendent of the gas generator and accessory drive assembly lubrication system. It
is a wet sump splash type system lv.Lth the JFS thermal insulation blanket (figure
2-1) serving as the oi! sump.
2-27. The lubrication system (figure 2-5) of the gas generator and accessory drive
assembly is a wet sump and pressure feed system. The accessory housing assemb1y
(figure 2-1) serves as the oil sump. A positive displacement gerotor type oi1 pump
is an integral part of the accessory drive assembly. Oil is pumped from the sump
through a rep1aceable screen type sediment oil strainer element assembly. An oil
pressure relief va1ve prevents excessive oil pressure by bypassing oil from the
discharge side of the oil pump back to the oil sump. Oil flows from the oil pump
through an oil strainer assembly to the oi1 jets and then onto the bearings of the
gas generator assembly. The oi! strainer assembly is sized to trap alI particles
that are large enough to block an oil jet. Oil returns to the sump by gravityflow.
2~28. STARTER OPERATION.
2-29. The jet fuel starter start cycle is initiated by applying hydrau1ic pressure
to the hydraulic motor. The sequencing of starter operation is comp1ete1y automatic
after applying hydraulic pressure. Simultaneously, with the app1ication of hydrau-
lic pressure, the hydraulic motor accelerates the rotating assemb1y of the gas
2-8
________A______________________________ ~, , ~
GAS GENERATOR ASSEMBLY POWER TURBINE ASSEMBLY
OIL JETS OIL JETS

'"
OIL STRAINER
ASSEMBLY
OIL
PRESSURE
RELIEF
VALVE
..
JFS THERMAL INSULATlON BLANKET lEGEND
_ l i PRESSURIZED OIL ~
\.
_ _ _ Oll RETURN ~
Y
~
ACCESSORY DRIVE ASSEMBLY
o
w
....oI
V1
N
I
\D
~
V1
N
Figure 2-5. Lubrication System

,.
~~VAIR 03-105-AB-52
generator assembly, and the accumulator assembly forces a premeasured quantity of

fue1 into the fuel-air combustor assembly. The accessory drive assembly transmits
power from the gas generator rotating assemb1y to the main JFS fuel control assem-
b1yand the ac-dc permanent magnet generator (PMG). The fuel pump develops pressure
through the open governor valve and against the manual prime ne solenoid valve. The
acce1eration limiter valve opens and bypasses flow to the inlet of the pump when the
discharge pressure is approximately 70 psig, the minimum required for proper fuel
atomization. At ambient temperatures be10w 60°F when the output of the PMG reaehes
7 vdc the JFS control box assembly energizes the manual prime nc solenoid valve and
the norma1ly open solenoid valve. If the ambient temperature 1s 60°F or above,
this operation is delayed for one second after the output of the PMG reaches 7
vdc. This delay a1lows time for the airflow through the fuel-air combustor assembly
to become sufficient to support proper combustion. When the output of the P~G is
approximately 10 vdc the capacitor discharge high voltage ignition unit starts to
function and lightoff occurs. After l1ghtoff, the gas generator assembly continues
to accelerate with the assist of the hydraulic motor. Compressor discharge pressure
against the diaphragm of the acceleration limiter valve increases as the speed of
the gas generator rotat1ng assembly 1ncreases, and the fuel flow to the combustor
becomes the funct10n of compressor discharge pressure. At approximately 35,5CO rpm
gas generator speed, the sensitive switch assembly on the accessory drive assembly
is actuated. This triggers a circuit within the JFS control box assembly to ener-
gize the electrical counter, and a circuit with1n the PMG to open the low speed
windings. When the output of the PMG reaches a frequency of 360 Hz (approximately
62,000 rpm), the JFS control box assembly terminates starter ignition and completes
the ac and dc power cir:_l~its to the government-furnished simulated aircraft engine
ignit10n and starting systems ac and dc load. At this phase of the starter start
cycle, the operator manually closes the hydraulic pressure line to the hydraulic
motor. The accumulator assembly spring repositions the piston and fuel flow through
the orifice of the restricted flow check valve and gradually recharges the accu-
mulator assemb1y with fuel. As the gas generator speed nears governed speed 100
percent rpm, the centrifugaI moment acting on the governo r flyweights, in opposition
to the governo r valve spring, forces the flyweights outward and reduces the size of
the governor valve orifice. At governed 10e percent rpm gas generator speed the
governo r valve is in control of fuel flow, the acceleration limiter valve is closed,
and the force of the governo r flyweights is balanced against the governor spring.
The elapsed time required to accelerate to 100 percent gas generator speed is
approximately five seconds.
2-30. The power turbine rotates the output shaft assembly against the government-
furnished test load. ~fuen the output shaft speed reaches approximately 3ZJC rpm,
the sensitive switch assembly, located in the power turbine assembly, is actuated.
This triggers circuits within the JFS control box assembly to deactuate the start
counter, to close the manual prime nc solenoid valve, and to open the normally
open solenoid valve which terminates gas generator operation. The pawl-and-ratchet
clutch disconnects the output shaft assembly from the power turbine reduction gears.
The switch actuating governo r assembly and the output shaft assembly continue to
rotate with the test stand shaft.
2-31. OVERTEHPERATURE PROTECTION.
2-10
CONFIDENCIAUROTINA
R- 131020ZJNOV/2007
DE AENAUT
PARA ESQAVI
INFO FORAER BANSPA
GRNC
BT
ASS Controle de Ciclos e Horas do JFS ("Jet Fuel Starter"). (ETC)
CONFIDENCIAL
R-091904ZJOUT DE ESQAVI VG CONSIDERANDO AS CARACTERISTICAS DE OPERAÇÃO DO

ESQUADRÃO ET VISANDO UNIFICAR ET FACILITAR O CONTROLE DAS UNIDADES JFS VG
AUTORIZO BIPT
ALFA - ADOÇÃO ÚNICA DO "START CYCLES" COMO FATOR PARA CONTAGEM DA

"OVERHAUL LlFE" DAS UNIDADES JFS VG QUE DEVERÃO VG A PARTIR DA PRESENTE
DATA SEREM CONSIDERADAS COMO PAR CASADO PTVG
BRAVO - A MANUTENÇÃO "ON CONDITION" DA UNIDADE "CONTROL BOX" PTVG
CHARLlE - CREDITO DE 300 "START CYCLES" VG DEVENDO O "JET FUEL START" SER
SUBMETIDO A "OVERHAUL" QUANDO O CITADO LIMITE FOR ATINGIDO VG CONTANDO A
PARTIR DA PRESENTE DATA PTVG
DELTA- APOS OVERHAUL CITADO NO ITEM CHARLlE VG ADOTAR O LIMITE DE "START

CYCLES" PREVISTO NA TABELA 2-1 VG PAGINA 2-13 DA PUBLICAÇÃO NAVAIR 03-105-AB-51
PT .......... BT
NAVAIR 03-l05-AB-52
2-32. When the gas generator exhaust discharge temperature exceeds the maximum
limit, the JFS control box assembly opens the circuits to the manual prime ne sole-
noid valve and the normally open aolenoid valve and this terminates starter opera-
tion.
2-33. OPEN THERMOCOL~LE PROTECTlON.
2-34. A fail-safe feature is provided to prevent starter operation if the immersion

thermocouple or thermocouple lead ia open. lf either of these malfunctions occur,
the JFS control box aasembly opens the circuits to the manual prime nc solenoid
valve and the normally open solenoid valve to prevent or termina te starter opera-
tion.
2-35. OVERSPEED PROTECTlON.
2-36. Anytime a gas generator overspeed causes the PMG frequency to exceed 440 Hz
(approximately 76,000 rpm). the JFS control box 88sembly wi11 open the circuits to
the manual prime nc solenoid valve and the normally open solenoid valve and actuate
the overspeed indicator. The indicator ia located in the bottom of the JFS control
box assembly and shows red for overspeed and white for normal operations.
2-37. STARTER ABORT CO~ITROL.
2-38. lf the operator desires to abort starter operation, he can do so by actuating

the government-furnished abort switch. This wi11 cut off alI e1ectrica1 power from
the PMG to the starter components which terminates starter operation.
2-39. LEADING PARTICULARS.

2-40. Leading particulars are provided in table 2-1.
Table 2-1. Tab1e of Leading Particulars
General:
Overhau1 Life 700 start cycles, 1200 houra gas turbine
operating time or 5 hours of motoring time
Weight (wet) 100.0 pounds
Basic Envelope
Diameter 9 inches
Length 20 inches
2-11
NAVAIR 03-105-AB-52
Table 2-1. Table of Leading Particulars (Cont)
Duty Cycle:
Engine Starting (a) Consecutive engine start cycles shall

be limited to three and shall not ex-
ceed 60 seconds duration each
(b) The interval between start attempts

shall be at least two minutes
(c) Engine starting cycles shall be

limited to six in a one hour period
Motoring (a) Engine motoring cycles shall not

exceed five-minutes each
(b) Motoring cycles shall be limited to

one cycle of five-minutes duration or
three cycles of two-minutes or less
duration in a one hour period
Combination Motoring- Combination motoring-start cycles shall be

Start Cycles limited to a motoring cycle of two-Qinutes
duration followed by a normal starting
cycle
Output Shaft:
Shear Load 640 foot-pound (maximum)
Rotation Counterclockwise viewing output shaft

assembly
Performance:
Power Output 75.0 horsepower at sea leveI at +59°F

(l5°C)
Acceleration from Initiation of

Start Cycle to: (approximate times)
Lightoff I second
50 percent Cutout 3 seconds
Governed Speed 5 seconds
Starter Cutout 25 seconds
2-12
NAVAIR 03-l05-AB-52
Table 2-1. Table of Leading Part1culars (Cont)
Compressor D1scharge Approximately 35 PSIG at governed speed

Pressure (total):
Electr1cal System:
Power Turbine Sensitive Norma1ly closed, open at 320C +20C m!

Sritch Assembly output shaft speed
Accessory Drive Assembly Sensitive One norma11y open switch and one normally
Sw1 tch Assembly closed sw1tch. Actuates at approximately
35,000 RPM gas generator speed
AC-DC Pernament Magnet Generator:
Voltage Output 115 volts, single-phase, 400 Hz, 825 va,

28 vdc, 2.6 ampere
Operat1ng Temperature Range
Connector Pins:
A and B 115 volts, sing1e-phase, 400 nz

C and D 50 percent speed switch input
E (-) and F (+) 28 vdc
Fuse Protection Two replaceable 5-ampere fuses are incor-

porated in electrical control box
Ignition System:
Stored Coi1 Energy 2.0 jou1es
Oi1 System:
Lubricant MIL-L-7808, .UL-L-23699
Capacity Power turbine assembly, 460 cu aI
Gas generator and accessory drive assem-
bly, 320 CU (lI .
Pressure Gas generato~ and accessory drive assem-

bly oil supply system 1s approximately 30
PSIG at governed speed
Leak.age None allowed
2-13
NAVAIR 03-105-AB-52
Table 2-1. Table of Leading Particulars (Cont)
Fuel System:
Fuel MIL-T-5624, Grades JP-4 and JP-5
Pressure Fuel inlet, O to 35 PSIG
Residual Fue1 Drained automatica1ly at shutdown
Hydrau1ic MOtor:
Weight (dry) 2.37 lbs (maximum)
No Load Speed 15,000 +100 RPM
Overspeed 18,000 +100 RPM
Shaft Sea1 Leakage One drop per minute (maximum)
Outboard Shaft Sea1 Leakage One drop in five minutes (maximum)
Sta11ed Leakage 185 cubic inches per minute (maximum)
Hydraulic F1uid MIL-H-5606
2-14
NAVAIR 03-105-AB-52
SECTION 111
AEROSPACE GROUND EQUIl'MENT MAINTENAUCE

l~ot app1icab1e.
SECTION IV
DEPOT MAINTENANCE
4-1. CHECKOUT •
4-2. Perform functiona1 check of JFS in accordance with 4-750.
4-3. DISASSEMBLY.
AGE REQUlRED
ACCESSORY GEARBOX HOUSING HOLDER 289605-1

COVER RBMOVAL PULLER 289045-1
HUB AND BEARING MECHANICAL PULLER 285461-1-1

HOUSING RBMOVAL MECHANICAL PULLER 289654-1
LüG TYPE SPANNER WRENCH 281686-1
lruT TORQUING IMPELLER HOLDER 287148-1-1
PLANETARY GEAR HOLDER 285468-1-1
PORT PLATE INSTALLATION 901148-T5

SEAL REMOVAL DRIVER 285474-1-1
SEAL REMOVAL HOLDER AND DRIVER 289043-1
SHAFT LOADING HOLDING TOOL 281846-1
SHAFr BEARING REMOVAL SUPPORT 901148-T4

SOCKET WRENCH 285471-1-1
SPLINED TORQUE WRENCH ADAPTER 285481-1-1
SPLlNED TORQUE WRENCH ADAPTER 285484-1-1
3-1/4-1
NAVAIR 03-105-AB-52 ".'
AGE REQUlRED (CONT)
TORQUE WRENCH ADAPTER 287002-1-1
TURBINE HOLDER 285454-1-1
TURBINE WHEEL HOLDER 285459-1-1
TURBINE WHEEL PRESSING IlOLDER 285487-1-1
4-4 • GENERAL.
WARNING
Lubricating oi1, MIL-L-7808 and MIL-L-23699, may soften

paint or stain c10thing with which it comes in contact.
Painted surfaces on which this oil has been spi11ed
shou1d be cleaned immediate1y and saturated c10thing
shou1d be removed as soon as possib1e. Thorough1y wash
the skin since pro10nged contact with the oi1 may cause
dermatitis. Any enclosed area in which the oi1 is used
should have adequate ventilation to keep mist and fumes
at a minimum.
4-5. Obvious steps or procedures necessary to disassemb1e the starter, such as re-
mova1 of 10ckwire is omitted from the texto In general, disassemb1y shou1d be ac-
comp1ished in sequence of index numbers assigned to the individual exp10ded views.
Any variations from this sequence and any special processes or methods are specifi-
cally mentioned in the texto
4-6. Do not disassemb1e tube assemb1ies, hose assemb1ies, wiring harness assem-
b1ies, riveted assemb1ies, or staked or press-fit parts (except seals and bearings),
or remove namep1ates, modification p1ates, lubrication p1ates, decaIs, studs or
their 10ckrings or thread inserts, un1ess specifical1y required in the text or
necessary for replacement of apart. rf disassembly or removal is necessary, pro-
ceed in a manner consistent with good shop practice.
4-7. After disassemb1y, spray steel parts with oil, MIL-L-7808, or equiva1ent.
Cover alI parts with c1ean paper or suitab1e coverings un1ess c1eaning and inspec-
tion are to be accomp1ished tmmediate1y.
4-8. P1ace each part disassemb1ed on a clean work bench in the order of remova1 in
preparation for c1eaning and inspection. Keep hardware and sma11 parts together in
trays. Provide proper covering or support to protect shafts, gears, studs and pro-
jecting parts from damage.
4-2
NAVAIR 03-105-AB-52
4-9. Bearings require special care to prevent corrosion and contamination. Wrap
bearings in clean moisture-proof paper or sea1 them in p1astic bags and do not un-
wrap them until they are to be used.
4-10. REMOVAL OF STARTER FROU SHIPPING OR STORAGE CONTAlNER.

4-11. Remove starter from shipping and storage container as fo11ows:
a. Remove bands and tape that secure container cover to base and 1ift cover
straight up.
b. Remove desiccants and padding from around starter.
c. Attach suitable hoisting adapter to forward support pads (figure 2-3).
d. Connect hoisting adapter to 1ifting device capab1e of safe1y supporting

weight of starter (approximate1y 100 pounds).
e. ~~ua11y maintain starter balance while hoisting starter out of con-

tainer with 1ifting device.
CAUTION
Do not support weight of starter on output shaft or end-
load the output shaft when hand1ing starter. Damage to
internaI parts of starter may resu1t.
f. Insta11 starter into suitable maintenance stand or do11y, and disconnect

1ifting device and hoisting adapter from starter.
4-12. DRAINING LUBRICATION SYSTElI.

4-13. Drain 1ubrication systems as fo11ows:
a. Remove magnetic plug (21, figure 4-3, sheet 1) and permit alI oil to
drain from power turbine assemb1y. Reinsta11 magnetic p1ug (21) ~dth new packing
(20).
b. Remove magnetic plug (5, figure 4-7, sheet 1) and permit alI oi1 to
drain from gas generator and accessory drive assemb1y. Reinsta11 magnetic p1ug (5)
with gasket (4) and lockwire.
c. Attach warning tag to gas generator and accessory drive assemb1y and one
to power turbine assemb1y to indicate oil systems require servicing prior to opera-
tion.
tiOTE
Perform e1ectric and e1ectronic wiring procedure in

accordance with NAVAIR OI-IA-50S.
4-3
NAVAIR 03-105-AB-52
4-14. DISASSEMBLY OF PLUMBING AND ELECTRICAL LINES ANO LEADS.
4-15. Disconnect or remove parts identified in figure 4-1 as required to faci1itate

starter disassemb1y.
2 3
I
C--l
18 17 16 12 11 10 9 7 5 4
B 13 B 8
14
L ___'5_ _ -.1
22 15 REF 17 REF
I /
19 20 21 1 REF
16 REF
VIEW B- B
VIEW A-A
VlEW C- C
Figure 4-1. Disassembly of Plumbing and Electrica1

Lines and Leads (Sheet 1 of 2)
4-4
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-1
1. METAL TUBE ASSEMBLY 31. METAL TUBE ASSEMBLY

2. IGNITER PLUG ELECTRICAL LEAD 32. NUT
3. LOOP CLAMP 33. BOLT
4. OIL DRAIN ADAPTER 34. LOOP CLAMP
5. LOOP CLAMP 35. LOOP CLAMP
6. ROSE CLAMP 36. CHECK VALVE
7. BOLT 37. METAL TUBE ASSEMBLY
8. LOOP CLAMP 38. TUBE ASSEMBLY
9. FLEXIBLE ROSE 39. LOOP CLAMP
10. ELECTRICAL WIRING INSTALLATION 40. OIL FILTER ROUSING
11. JFS BRANCHED WIRING HARNESS 41. ROSE CLAMP
ASSEMBLY 42. PACKING WITR RETAINER
12. NUT 43. NU!
13. BOLT 44. MANIFOLD TO TUBE EI.BOW ASSEMBLY
14. LOOP CLAMP 45. mEL DRAIN METAL TUBE ASSEMBLY
15. LOOP CLAMP 46. ANNULAR ALUMllmM-ASBESTOS GASKET
16. JFS METAL TUBE ASSEMBLY 47. BOLT
17. JFS METAL TUTE ASSEMBLY 48. WASHER
18. FUEL MANIFOLD ASSEMBLY 49. LOOP CLAMP
19. TEE 50. FUEI. DRAIN SPECIAL TUBE ASSEMBLY
20. METAL TUBE ASSEMBLY 51. AliGLE BRACKET
21. RESTRICTED FLOW CHECK VALVE 52. NUT
22. BOLT 53. BOLT
23. ANGLE BRACKET 54. LOOP CLAMP
24. NUT 55. LOOP CLAMP
25. BOLT 56. LOOP CLAMP
26. LOOP CLAMP 57. JFS METAL TUBE ASSEMBLY
27. NU! 58. NUT
28. BOLT 59. BOLT
29. LOOP CLAMP 60. LOOP CLAMP
30. JFS METAL TUBE ASSEMBLY 61. LOOP CLAMP
4-5
NAVAIR 03-105-AB-52
32
27 33
28 34
29 30 31 35 36
38REF
48 D
49 t
44REF 51
43REF
42REF
VIEwE-E
VIEWD-D
Figure 4-1. Disassemb1y of Plumbing and E1ectrical

4-6
NAVAIR 03-105-AB-52
4-16. DISASSEMBLY OF STARTER INTO MAJOR ASSEMBLIES.
I.fOTE
Refer to figure 4-1 for p1umbing and e1ectrica1.
4-17. Disassemble starter into major assemblies as follows: (figure 4-2).
a. Remove coup1ing (1) and angine starter mounting flange (2).
b. Remove coupling (3) from exhaust flange.
c. Insta11 starter in turbine Ho1der, 285454-1-1, as fo110ws:
(1) C1amp base of turbine Holder, 285454-1-1, in bench vise.
(2) Install starter, output shaft end first, into turbine holder.
d. Remove quick refease pin (8) and uncoup1e oil fUler housing (9) from
gas generator and accessory drive assemb1y (6).
e. Disconnect e1ectrical plug connector P3 (27, figure 4-3, sheet 1) from

JFS contro1 box assembly (56, figure 4-4, sheet 2).
f. Loosen coupling (4, figure 4-2) and separate gas generator and accessory
drive assembly (6) from power turbine assembly (5).
g. Stow quick re1ease pin (8) in ho1e of oi1 fil1er housing (9).
MAINTENAUCE ASSURANCE
Check that alI opening& are covered to preclude dirt

or foreign objects from entering assemblies.
4-18. DISASSEMBLY OF MAJOR ASSEMBLIES.
4-19. DISASSEMBLY OF POWER TURBINE ASSEMBLY.
4-20. Disassemble power turbine assembly as follows: (figure 4-3).
a. Remove ident1fication plate (1, sheet 1) 1f damaged or illegible.

b. Remove output shaft retainer (3) from retainer groove and remove output
shaft assembly (2, 4). Remove packing (2) from output shaft assembly (4).
c. Engage lip of Ho1ding Tool, 281846-1, in retainer groove of drive shaft

assemb1y (82, sheet 2). Insert Spanner Wrench, 281686-1, into bore of output drive
. I assembly (82) so that slotted end of spanner wrench engages over flats of switch
actuating governor assembly (5, sheet 1). Squeeze handles of holding too1 and ro-
tate tee handle of spanner wrench counterclockwise to remove switch actuating gov-
ernor assembly (5).
4-7
NAVAl R 03-105-AB-52
Figure 4-2. Disassembly of Starter into Major Assemblies
4-8
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-2
1. CLAMP COUPLING 6. GAS GENERATOR AND ACCESSORY DR1VE

2. ENGINE STARTER MOUNTING FLANGE ASSY
3. CWIP COUPLING 7. IDENT1F1CAT10N PLATE
4. CLAMP COUPL1NG 8. QU1CK RELEASE PIN
5. JET FOEL STARTER POlaR TURBUi'E ASSY 9. 01L F1LLER HOUSING
d. Remove quick re1ease pin (6) from oi1 filler housing (10, 11).
e. Remove assembled oil dipstick (7, 8) from oil filler housing (10, 11).
Remove gasket (7) from oi1 dipstick (8).
f. Remove 1ubrication instruction p1ate (9) from oi1 fi11er housing (10, 11)
if damaged or il1egib1e.
g. Loosen hose c1amp (15), remove oi1 fi1ler housing (10, 11) from f1exib1e
hose (16) and remove hose c1amp (15).
h. Remove bo1t (12), washer (13) and c1amp (14).
i. Loosen hose clamp (17) and remove assemb1ed f1exible hose (16, 17) from
oi1 drain adapter (22). Remove hose c1amp (16) from flexible hose (17).
j. Remove assemb1ed magnetic p1ug (20, 21) from oi1 drain adapter (22) and
remove packing (20) from magnetic p1ug (21). Remove f1uid passage bolt (18),
gaskets (19) and assemb1ed oi1 drain adapter (20, 21, 22).
k. Remove bolt (24) and clamp (25).

NOTE
Perform e1ectric and electronic wiring procedures in

accordance with NAVA1R OI-IA-50S.
1. Remove electrical wiring installation (10, figure 4-1, sheet 1) as
fo110ws. Loosen c1amp screws on back she11 of connector P3 (27, figure 4-3, sheet
1). Separate connector P3 (27) to revea1 contacts. Remove alI potting compound
from back she1l contacts and wires. Heat contacts and disconnect b1ack vire from
contact B, red wire from contact D, and orange vire from contact F. Disconnect
connector P9 (26) from immersion thermocoup1e (30).
m. Remove bo1ts (32), washer (31), c1amp (34), immersion thermocoup1e (30)
and gasket (33).
n. Remove nut (35), bolt (36) and c1amp (37).
o. Remove screw (38), washer (39), plate assemb1y (40, 41), sleeving (43)
and bushing (42).
4-9
NAVAIR 03-105-AB-52
Figure 4-3. Disassemb1y of JFS Power Turbine Assemb1y

(Sheet 1 of 4)
4-10
NAVAIR 03-1D5-AB-52
~ KEY TO FIGURE 4-3

1. IDENTIF1CAT10N PLATE 26. ELECTR1CAL PLUG CONNECTOR
2. PREFORMED PACK1NG 27. ELECTR1CAL PLUG CONNECTOR
3. OUTPUT SHAFT RETAI~~ 28. DELETED
4. OUTPUT SHAFT AS SY 29. ELECTRICAL INSULATION SLEEVING
5. SWITCH ACTUATING GOVERNOR ASSY 30. ~mRSION THE~lOCOUPLE
6. QUICK RELEASE PIN 31. WASHER
7. ANNULAR ALUM1NUM-ASBESTOS GASKET 32. BOLT
8. OIL DIP STICK 33. GASKET
9. LUBR1CAT10N 1NSTRUCT10N PLATE 34. LOOP CLA}!P
10. 1NSERT 35. NUT
11. 01L F1LLER BOUSING 36. BOLT
12. BOLT 37. LOOP CLAt·fP
13. WASHER 38. SCREW
14. LOOP CLAMP 39. WASHER
15. BOSE CLAMP 40. PIN
16. FLEX1BLE BOSE 41. PLATE
17. BOSE CLAMP 42. RUBBER BUSHING
18. FLUID PASSAGE BOLT 43. ELECTRICAL INSULAT10N SLEEVING
19. ANNULAR ALUM1NUM-ASBESTOS GASKET 44. ANNULAR ALUMINUM-ASBESTOS GASKET
20. PREFORMED PACKING 45. PLUG
21. MAGNETIC PLUG 46. Ah1IDLAR ALmITNUM-ASBESTOS GASKET
22. OIL DRAIN ADAPTER 47. PLUG
23. (DELETED) 48. WARNING TAG
24. BOLT 49. WARNING TAG
25. LOOP CLAMP
4-11
,
NAVAIR 03-105-AB-52
~ J-S3
ar~ ~
.
70A
---;-;::~~--- -
Disassemb1y of JFS
Figure 4-3. (Sheet 2 of Po
4)wer Turbine Assemb1y
4-12
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-3 (CONT)
50. SCREW 68. OIL BAFFLE

51. SCREW 69. INNER HOUSING GASKET
52. RETAINING RING SEGlfENT 70. :BEARING RETAINER
53. CONTAINMENT SUPPORT ASSY 70A. WASHER
54. THEBMAL INSULATION :BATT 71. SCREW
55. POWER TURBINE CONTAINMENT 72. ANNULAR BALL lmARING
SHIELD ASSY 73. PREFORMED PACKING
56. HEAT SRIELD 73A. SBIM
57. TURBINE DIFFUSER 74. INSERT
58. SCREW 75. INSERT
59. SPECIAL WASHER 76. INSERT
60. BRACKET 77 • INSERT
61. SCREW 78. ENGINE STARTER HOUSING
62. SPECIAL WASHER 79. DRIVE SHAFT PAWL
63. INSERT 80. RIVET
64. BRACKET 81. LEAF SPRING
65. ENCASED PLAIN SEAr. 82. DRIVE SBAFT ASSY
66. :SOLT 83. NUTPLATE
66A. WASHER 84. EXHAUST HOUSING
67. RETAlNER RING
4-13
03-105-AB-52
~VAm ____________________
B
.
Turb~ne As semb1y
Figure 4-3. Disassemb1y o f 3JFS
(Sheet of Power
4)
4-14
NAVAIR 03-105-AB-52
85. RETAINER RING 104. AXIAL FLOW TURBINE WHEEL

86. RING GEAR LOCKRING 105. INSULATION COVER
87. RETAINER RING 106. SCREW
88. ANNULAR BALL BEARING 107. SEAL RETAINER
89. INTERNAL GEAR mm 108. TBERMAL INSULATION BLANKET
90. SETSCREW 109. INNER HOUSING GASKET
91. LOCK RING 110. INNER HOUSING GASKET
92. NUT 111. BELLOWS SEAL SHIM
93. SCREW 112. TURBINE WHEEL SEAL
94. INSULATOR PLATE 113. BELLOWS SEAL SHIM
95. JllSULATOR PLATE 114. SPRING SEAT
96. SENSITIVE SlITTCH ASSY 115. ANNULAR BALL BEARING
97. PIN 116. RESILIENT JW.L BEARING HOUSING
98. SWITCH ACTUATING LEVER 117. RESILIENT MOUNT LINER
99. BEARING SUPPORT 118. STRAIGHT PIN
100. STRAIGHT PIN 119. STRAIGHT PIN
101. PLAIN HEXAGON NU! 120. SPRING SEAT
102. PINION SPUR GEAR 121. COMPRESSION HELICAL SPRING
103. TUBULAR RIVET 122. BEARING SLEEVE SPACER
123. ANNULAR BALL BEARING
4-15
NAVAIR 03-105-AB-52
136
I
c
124. STRAIGRT PIN 133. RETAlNER RING
125. PLAIN HEXAGON NUT 134. ANNULAR BALL BEARING
126. SPECIAL WASHER 135. SPECIAL WASHER
127. HEADLESS SETSCREl-7 136. SEAL CARRIER
128. NEEDLE ROLLER BEARING 137. INNER HOUSING GASKET
129. SPUR GEARSHAFT 138. PIN
130. GEAR 139. INSERT
131. INTERNAL SPUR GEAR 140. INSERT
132. BEARING SPACER 141. GEAR CARRIER
Figure 4-3. Disassemb1y of JFS Power Turbine Assemb1y

(Sheet 4 of 4)
4-16
" NAVAIR 03-105-AB-52
~I
I '1
27A
Figure 4-4. Disassemb1y of Gas Generator and Accessory

Drive Assemb1y (Sheet 1 of 3)
4-17
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-4

1. IDENTIFICATION PLATE 26. SPACER
2. WARNING TAG 27. TEE
3. NU! 27A. TU:BE ASSY
4. BOLT 28. METAL TU13E ASSY
5. LOOP CLAMP 29. RESTRICTED FLOW CHECK VALVE
6. JFS METAL TUBE ASSY 30. METAL TU:BE ASSY
7. NUT 31. PREFORMED PACKING
8. :BaLT 32. NUT
9. LOOP CLAMP 33. EL:BOlv
10. SCREW 34. NUT
11. FUEL CONTROL METAL TU13E ASSY 35. :BOLT
12. GASKET 36. LOOP CLAMP
13. BOLT 37. LOOP CLAMP
14. WASHER 38. BOLT
15. FILTER BRACKET 39. ANGLE SUPPORT
16. PREFORMED PACKING 40. IGNITER PLUG ELECTRlCAL LEAD
17. NUT 41. CAPAClTOR DISCHARGE HIGH
18. FITTING VOLTAGE IGNITION UNIT
19. PRESSURE FLUID FILTER 42. BOLT
20. PACKING 43. WASHER
2I. METAL TU:BE ASSY 44. LOOP CLAMP
22. CHECK VALVE 45. GAS TURBINE ENGINE IGNITER PLUG
23. SCREW 46. BOLT
24. METAL TUBE ASSY 47. WASHER
25. PREFORMED PACKING
4-18
,
AAVAIR 03- 105-AB-52
Jl.C~{i-~
--t--'-"'t t t
90 84 85 86
~
81
Figure 4-4. f Gas Generator ) an

Dr1ve Assembly
Disassembly o (Sheet 2 of 3 4-19
. _. _.. _ - - - - - - - - - - - - - - - - -
NAVAIR 03-105-AB-52
~KEY TO FIGURE 4-4 (CONT)
48. GASKET 90. TURNBUCKLE

49. ACCUMULATOR ASSY 91. PREFORMED PACKING
50. BOLT 92. PLUG
51. WASHER 93. NUT ~
52. BOLT 94. BaLT
53. WASHER 95. LOOP CLAMP
54. INSERT 96. NUT
55. BRACKET 97. BOLT
56. JFS CONTROL BOX ASSY 98. LOOP CLAMP
57. BaLT 99. LOOP CLAMP
58. WASHER 100. ANGLE BRACKET
59. NUT 101. METAL TUBE ASSY
60. WASHER 102. FUEL DRAIN SPECIAL TUBE ASSY
61. SCREW 103. LOOP CLAMP
62. SUPPORT BRACKET 104. JFS METAL TUBE ASSY
63. BaLT 105. PREFORMED PACKING
64. WASHER 106. UNION
65. NUT 107. ANNULAR ALUMlNUM-ASBESTOS GASKET
66. WASHER 107A. THREAD SEAL PACKING WITH RETAL~ER
67. SCREW 108. FUEL DRAIN METAL TUBE ASSY
68. LOCKING KEY 109. NUT
69. NUT 110. MANIFOLD TO TUBE ELBOW ASSY
70. ROD END BEARING 111. FLUID PASSAGE BeLT
71. LOCY.ING KEY 112. ANNULAR ALUMINtm-ASBESTOS GASKET
72. NUT 113. SPECIAL FITTING
73. ROD END BEARING 114. SCREW
74. TURNBUCKLE 115. WASHER
75. NUT 116. SPECIAL WASHER
77. SCREW 118. WASHER
78. SUPPORT lmACKET 119. SPECIAL WASHER
79. BaLT 120. SPLINED STRAIGHT SHAFT
80. WASHER 121. PREFORMED PACKING
81. NUT 122. NUT
82. WASHER 123. WASHER
83. SCREW 124. LOOP CLAMP
84. LOCKING KEY 125. LOOP CLM1P
85. NUT 126. JFS BRANCHED WIRING HARNESS ASSY
86. ROD END BEARING 127. PREFORMED PACKING
87. LOCKING KEY 128. AC-DC PERMANENT }fAGNET GENERATOR
88. NUT 129. ACCESSORY DRlVE ASSY
89. ROD END BEARING 130. GAS GENERATOR ASSY
4-20
NAVAIR 03-105-AB-52
I
126 124 ~
I 120
,.-'!:~~
~r-
119 123__,$
~'22
1\
I
."
J
~
./
121--
126
B
Figure 4-4. Disassemb1y of Gas Generator and Accessory
Drive Assemb1y (Sheet 3 of 3)
4-21
NAVAIR 03-105-AB-52
p. Remove heat shie1d (56), and turbine (57) from exhaust housing (84).
q. Remove screws (58), washers (59), and bracket (60). Remove screws (61),
washers (62), and bracket assemb1y (63, 64).
r. Remove bo1ts (66), washers (66A) and sea1 (65) from engine starter hous-
ing (78).
s. Remove retaining ring (67) and oi1 baffle (68) from drive shaft assembly
(82).
t. Remove assemb1ed engine starter housing (70 through 78), and gasket (69)
from f1ange of gear carrier (141, sheet 4).
u. Remove assemb1ed p1ug (44, 45, sheet 1), and remove gasket (44) from p1ug
(45). Remove assembled p1ug (46, 47), and remove gasket (46) from p1ug (47).
NOTE
Matchmark containment support assemb1y (53) to exhaust

housing (84) for aid during reassemb1y.
v. Remove screws (50, sheet 2) and remove assembled shie1d assemb1y (51
through 55) from exhaust housing (84). Remove screws (51), retaining ring segments
(52), and separate containment support assembly (53) from assemb1ed shie1d assembly
(54, 55). Remove thermal insulation batt (54) from shie1d assemb1y (55).
NOTE
Matchmark engine starter housing (78) to exhaust hous-

10g (84) for aid during reassemb1y.
w. Remove drive shaft assembly (79 through 82) from internaI gear hub (89,
sheet 3).
x. Remove screws (71, sheet 2), bearing retainer (70) and washers (70A).
y. Remove bearing (72), shims (73A) and packing (73) from engine starter
housing (74 through 78).
NOTE
Matchmark gear carrier (141) to exhaust housing (84)

for aid during reasscmbly.
z. Remove assembled parts (85 through 141, sheets 3 -and 4) from exhaust
housing (83, 84, sheet 2), and instal1 in Turbine Whee1 Ho1der, 285457-1-1, with
turbine wheel (104, sheet 3) against contoured side of h01der.
aa. Remove retainer ring (85). Compress 10ckring (86) to disengage gear
(131, sheet 4). Allow gear (131) to slip downward.
4-22
NAVAIR 03-l05-AB-52
ab. Retract three pins in f1ange of hub of Bearing Mechanica1 Pu11er,

285461-1-1, and position pu11er over end of internaI gear hub (89, sheet 3). Align
pins of pu1ler with ho1es in internaI gear hub (89), and engage pins by pushing in-
ward. Turn hand knob of pu11er clockwise to remove assemb1ed internaI gear hub
(87, 88, 89) and lockring (86).
ac. Remove retainer ring (87) and bearing (88) from internaI gear hub (89).
ad. Position interna! spur gear (131, sheet 4) for access to setscrew (90,
sheet 3). Remove setscrew (90) and position Torque Wtench Adapter, 285469-1-1, on
10ckring (91) sothat adapter tangs engage slots of 10ckring (91). Remove 10ckring
(91) (left-hand thread). Remove assembled bearing support (92 through 99).
ae. Engage nuts (92) with Socket Wrench, 285471-1-1, remove nuts (92), screws
(93), insulator p1ates (94, 95) and sensitive switch assemb1y (96).
af. Remove pin (97) and switch actuating 1ever (98) from bearing support
(99).
ag. Remove pin (100), nut (101) and gear (102).
ah. Position assemb1ed parts (103 through 141) into Turbine Whee1 Pressing
Bo1der, 285487-1-1, so turbine whee1 (104) is down and f1ange of gear carrier (141)
rests on bo1der f1ange.
ai. Press turbine whee1 (103, 104) from bearings (115, 123).
ajo Remove insu1ation cover (105), screws (106), seal retainer (107), insu1a-
tion blanket (108), gaskets (109, 110), and shims (111).
ak. Position assemb1ed parts (112 through 141, sheets 3 and 4) into Turbine
Whee1 Pressing Ho1der, 285487-1-1, so f1ange of gear carrier (141, sheet 4) rests
on f1ange of ho1der. Press sea1 (112, sheet 3), shim (113), spring seats (114,
120), bear1ngs (115, 123), bearing housing (116), 1iner (117), pins (118, 119),
spring (121) and spacer (122) from gear carrier (141, sheet 4) with wood dowe1, 0.75
inch diameter by 6.0 inches 10ng.
a1. Insta1l P1anetary Gear He1der, 285468-1-1, in jaws ef standard bench
vise. Laver assemb1ed gear carrier (125 through 141, sheets 3 and 4) over gear
ho1der, and simu1taneous1y engage ho1der pin in ho1e of gear carrier (141, sheet 4)
and sp1ined post with teeth of gears (130, sheet 4). Remove setscrews (127).
amo Remove pins (124) using a 3/32 inch drift, nuts (125), washers (12€) and
retainer ring (133). Remove assemb1ed gear carrier (127 through 141) and a1ign gear
(131) cutout with bearing (128). Remove shaft (129), bearing (128) and gear (131).
Remove retainer rings (133), shims (135) and use Bearing Press Driver, 287156-1-1
to press out bearings (134). .
4-21. DISASSEMBLY OF GAS GENERATOR ANO ACCESSORY DRIVE ASSmmLY.
4-23
NAVAIR 03-105-AB-52
NOTE
Refer to figure 4-1 for p1umbing and e1ectrica1.
4-22. Disassemb1e gas generator and accessory drive assemb1y as fo11ows: (figure
4-4). ~
a. Remove identification p1ate (1, sheet 1) if damaged or i11egib1e.
b. Remove nut (3), bo1t (4), c1amp (5) and tube assemb1y (6).
c. Remove nut (7), bo1t (8), c1amps (9), screws (10), tube assemb1y (11)
and gasket (12).
d. Remove screws (23), tube assemb1y (24), packing (25), and spacer (26).
e. Remove tube assemb1y (21) and check va1ve (22).
f. Remove bo1ta (13), washers (14) and assemb1ed fi1ter (16 through 20).
g. Remove fi1ter bracket (15) from fi1ter (19, 20).
h. Remove assemb1ed fitting (16, 17, 18) from fi1ter (19, 20). Remove
packing (16) and nut (17) from fitting (18).
i. Remove tube assemb1y (27A) and tee (27).
j. Remove tube assemb1y (28), restricted f10w check va1ve (29) and tube
assemb1y (30).
WA]ü~ING
Fuel wi11 1eak from accumu1ator assemb1y (49) when

assemb1ed e1bow (31, 32, 33) is removed.
k. Remove assemb1ed e1bow (31, 32, 33) from accumu1ator assemb1y (49). Re-
move packing (31) and nut (32) from e1bow (33).
1. Remove nut (34), bo1t (35), c1amp (36), c1amp (37), ba1t (38), and ang1e
support (39).
m. Remove igniter 1ead (40) and disconnect e1ectrica1 connectar P8 fram

ignition unit (41).
n. Remove bo1ts (42), washers (43), c1amp (44) and ignition unit (41).
o. Remove bo1ts (46), igniter p1ug (45), washers (47) and gasket (48).
p. Disconnect tube assemb1ies (101, 104, sheet 2) from accumu1atar assemb1y

(49). Remove fuseho1der cap (29, figure 4-9, sheet 2). Remove bo1ts (50, figure
4-4, sheet 2), washers (51) and accumu1ator assembly (49). Reinstall fuseho1der
cap (29, figure 4-9, sheet 2).
4-24
NAVAIR 03-105AB-52
q. Remove bolts (52, figure 4-4, sheet 2), washers (53) and accumulator
mounting bracket (54, 55).
r. Disconnect JFS branched wire harness assemb1y e1ectrica1 connector P2

(11, figure 4-1, sheet 1) from JFS contro1 box assemb1y (56, figure 4-4, sheet 2).
Remove bolt (57), washer (58) and JFS control box assemb1y (56).
s. Disconnect JFS branched wiring hamess assembly electrical connector P6 (126, figure 4-
4, sheet 3) from ac-dc permanent magnet generator (128, figure 4-4, sheet 3). Remove nut (59, sheet 2),
washer (60) and screw (61). Remove bolt (63), washer (64), nut (65), washer (66), screw (67), bracket (62)
and assembled tumbuckle (68 through 74).
t. Remove assembled rod end bearing (68, 69, 70) from turnbuckle (74).
Straighten tabs on 10cking keys (68, 71). Remove 10cking key (68) and nut (69) from
rod end bea~ing (70).
u. Remove assemb1ed rod end bearing (71, 72, 73) from turnbuckle (74). Re-
move 10cking key (71) and nut (72) from rod end bearing (73).
v. Remove nut (75), washer (76) and screw (77). Remove bo1t (79), washer
(80), nut (81), washer (82), screw (83) and bracket (78).
w. Remove assembled rod end (84, 85, 86) from turnbuckle (90). Straighten
tabs on 10cking key (84, 87). Remove 10cking key (84) and nut (85) from rod end
(86).
x. Remove assemb1ed rod end (87, 88, 89) from turnbuckle (90). Remove
10cking key (87) and nut (88) from rod end (89).
y. Remove assemb1ed plug (91, 92). Remove packing (91) from p1ug (92).
z. Remove nut (93), bo1t (94) and c1amp (95).
aa. Remove nut (96), bo1t (97), clamp (98), c1amp (99) and tube assemb1y
(101).
ab. Remove tube assemb1y (102).
ac. Remove bo1t (23, figure 4-5, sheet~), c1amp (103, figure 4-4, sheet 2)
and tube assemb1y (104).
ad. Remove assemb1ed union (105, 106). Remove packing (105) from union
(106).
ae. Disconnect JFS branehed wiring hamess assemb1y electrieal eonnector P7 (126, figure 4-
4, sheet 3). Remove screws (114, figure 4-4, sheet 3), washers (115), washers (116), screws (117), washers
(118), washers (119), and separate assembled parta (121 through 129) from gas generator a888mbly (130),
and remove nut (122), washer (123) and clamp (124) from ac-de permanent magnet generator mounting
stud.
Change 2 4-25
NAVAIR 03-105-AB-52
Figure 4-5. Disassembly of Gas Generator Assembly (Sheet 1 of 2)
4-26
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-5
1. COMPRESSOR INLET SCREEN ASSY 28. PREFOlUfED PACKING

2. HOSE CLAMP 29. UNION
3. IMPELLER SHROUD 30. NORMALLY OPEN SOLENOID VALVE
4. FLUID PASSAGE BOLT 31. PREFO~IED PACKING
5. PACKING WITH RETAINER 32. OIL STRAINER ASSY
6. FUEL MANIFOLD ASSY 33. MACHINE SCRm1
7. PACKING WITH RETAlNER 34. SPECIAL WASHER
8. FUEL NOZZLE ASSY 35. HOUSING GASKET
9. NON-METALLIC WASHER 36. PREFORMED PACKINC
10. JFS METAL TUBE ASSY 37. TOIm SHAFT caVER
11. BOLT 38. CAP SCREW
12. BEX-THIN SELF-LOCKING NUT 39. POt-.'ER TURBINE STATOR ASSY
13. WASHER 40. GAS GENERATOR CONTAINMENT
14. BOLT SHIELD ASSY
15. SOLENOID MOUNTING BRACKET 41. SCREW
16. PREFORtIED PACKING 42. SPECIAL WASHER
17. NUT 43. SHIELD RETAlNER
18. ELBOH 44. COlITAINMENT RING INSULATOR
19. PREFO~lED PACKING 45. NUT
20. NUT 46. SPECIAL WASHER
21. TEE 47. SHROUD RETAINING RING
22. MANUAL PRniE NORMALLY CLOSED 48. SHIM
SOLENOID VALVE 49. IMPELLER SBROUD
23. BOLT 50. SHIM
24. HEX-THIN SELF-LOCKING NUT 51. BOLT
25. WASHER 52. lVASHER
26. BOLT 53. ANGLE BRACKET
27. SOLENOID MOUNTING BRACKET 54. JFS HOUSING ASSY
54A. IDENTIFlCATION PLATE
af. Remove shaft (120) and packing (121).
age Disconnect tube assemb1y (108) from union (63, figure 4-13, sheet 1).
Remove assemb1ed e1bowassemb1y (109, 110, figure 4-4, sheet 2), gaskets (107,
107A), and tube assemb1y (108). Remove nut (109) from e1bow assemb1y (110).
ah. Remove f1uid passage bo1t (111), gaskets (112) and fitting (113).
4-27
NAVAIR 03-105-AB-52
A
Figure 4-5. Disassembly of Gas Generator Assembly (Sheet 2 of 2)
4-28
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-5 (COlIT)
55. STATOR SHIM 85. TURBlNE GAS-OIL SEAL

56. PACKING 86. SHIM
57 • INTERNAL WRENCHING PLAIN NUT 87. ANNULAR RALL BEARING
58. COMPRESSOR IMPELLER 88. KEY
59. PRECISION WASHER 89. CARRIER
60. SCREW 90. COMPRESSION HELlCAL SPRING
62. PACKING WITH RETAINER 92. PREFORMED PACKING
63. IMPELLER SEAL 93. OIL TUBE ASSY
64. SEAL GASKET 94. SCREW
65. PREFOBMED PACKING 95. WASHER
66. BEARING RETAINER PLATE 96. SLEEVE BUSHING
67. PIN 97. FUEL-AIR COMBUSTOR ASSY
68. PIN 98. SCREW
69. SPINNER LOCKING SHAFT 99. SCREW
70. COMPRESSION SPRING 100. WASHER
71. PIN 101. PREFOBMED PACKING
72. AXIAL FLOW TURBINE 102. TOWER SHAFT COVER
WHEEL ASSY 103. SCREW
73. STRAIGHT PIN 104. GEAR SHIM
74. ANNULAB. BALL BEARING 105. SPECIAL WASHER
75. BEARING CARRIER 106. PLAIN HEXAGON NUT
76. CARRIER SHIM 107. PIN
77. PINION SPIRAL BEVEL GEAR 108. GEAR
78. BEARING SPACER 109. RETAINER
79. SCREW 110. ANNULAR BALL BEARING
80. SEAL BELLOWS RETAINER 111. SLEEVE SPACER
81. FIRST STAGE STATOR ASSY 112. SLEEVE SPACER
82. HEAT SHIELD 113. AlmuLAB. BALL BEARING
83. SEAL RETAUffiR 114. BEARING CARRIER
84. SHIM 115. TOWEB. SHAFT HOUSING ASSY
ai. Remove permanent magnet generator (127, 128) from accessory drive assem-
b1y (129). Remove pack1ng (127) from permanent magnet generator (128).
MAINTENANCE ASSURANCE
a. Check that 100se parts are contained to prevent

10ss, damage or contamination.
b. Check that al1 openings are covered to prec1ude

dirt or foreign objects from entering assemb1y.
4-23. DISASSEMBLY OF GAS GENERATOR ASSEMBLY.
4-24. Disassemb1e gas generator assemb1y as fo11ows: (figure 4-5).
4-29
NAVAIR 03-105-AB-52
NOTE
Do not remove screen assembly (1) from shroud (3)
except as required for repair or replacement.
a. Remove hose clamp (2, sheet 1), impe11er shroud (3), and compressor in-
1et screen assemb1y (1).
CAUTION
Do not bend fuel manifo1d assembly tube away from

manual prime s01enoid va1ve fitting. Even slight
bending may cause cracking of fue! manifold assemb!y
at nearest fuel nozzle.
b. Loosen coup1ing nut of fue1 manif01d assemb1y (6) and slide back on nut
but do not disengage tube from fitting.
c. Remove fluid passage bolts (4) and pacldngs with retainers (5). Remove
manifo1d assemb1y (6) and packings with retainers (7).
d. Remove fue1 nozz1e assemb1ies (8) and non-meta11ic washers (9).
e. Remove tube assemb1y (10), then disconnect e1ectrica1 connector P4 and

remove JFS branched wiring harness assembly (126, figure 4-4, sheet 2).
f. Remove bo1ts (11, figure 4-5, sheet 1) and assembIed parts (12 through
22).
g. Remove nuts (12), washers (13), bo1ts (14) and solenoid mounting bracket
(15).
h. Remove assemb1ed elbow (16, 17, 18). Remove packing (16) and nut (17)
from e1bow (18).
i. Remove assemb1ed ,tee (19, 20, 21) from manual prime solenoid va1ve (22).
Remove packing (19) and nut (20) from tee (21).
j. Remove bolts (23) and assemb1ed parts (24 through 30).
k. Remove nuts (24), washers (25), bo1ts (26) and solenoid mounting bracket
(27) from assembled solenoid valve (28, 29, 30).
1. Remove assemb1ed union (28, 29) from solenoid valve (30). Remove packing
(28) from union (29).
m. Remove assembled oil strainer assembly (31, 32). Remove packings (31)
from 011 strainer assembly (32).
n. Remove screws (33) and washers (34).
4-30
NAVAIR 03-105AB-52
o. Thread two bolts of cover Removal Puller, 289045-1, into threaded holes
of tower shaft cover (37). Position sleeve of puller so that puller bolts pass
through holes in bar of puller. Thread nuts onto bolts until they contact pu1ler
bar. Grasp puller bar and pull outward to remove housing gasket (35) and assembled
tower sbaft cover (36, 37). Remove pu11er from tower shaft cover (36, 37). Remove
packing (36) from tower shaft cover (37).
p. Remove screws (38), stator assemb1y (39), shie1d assembly (40), screws
(41), washers (42), shield retainers (43) and containment ring insu1ators (44).
q. Remove nuts (45), washer~ (46), shroud retaining ring (47), shim (48),
impeller shroud (49) and shim (50).
r. Remove bolts (51), washers (52) and ang1e bracket (53).
s. Clamp Housing Removal Mechanical Pu11er, 289654-1, on flange of housing

assemb1y (54). Rotate puller jackscrew to separate assemb1ed parts (57 through
115) from housing assemb1y (54). Position assembled parts (57 through 115), wbee1
assembly down, on Turbine Whee1 Holder, 285459-1-1.
t. Remove identification plate (54A) from housing assembly (54) i f damaged
or i1legible.
u. Remove shim (55, sheet 2) and packing (56).

NOTE
Rotating assembly consists of matched parts and should be kept
together. Parts are interchangeable with identical components;
however, balancing procedures are considerable more time
consuming when attempting to match parta not previously balanced
as an a8semb1y.
v. Install Nut Torquing Impe11er H01der, 287148-1-1, over b1ades of com-

pressor impeller (58). Hold compressor impeller (58) and remove nut (57) (left-
hand thread).
w. Remove impe1ler (58) and washer (5~).
x. Remove screws (60), washers (61), packings with retainers (62), fmpe11er
sesI (63), sea1 gasket (64), packing (65), and bearing retaining p1ate (66).
y. Position remaining parts (67 through 115) on suitable support so that

whee1 assemb1y (72) is down, and f1ange of tower shaft housing assemb1y (115) is
against support. Press out whee1 assemb1y (68 through 72).
z. Remove pins (67, 68), spinner locking shaft (69), spring (70), and pin
(71) from wheel assembly (72).
aa. Remove assembled bearing carrier (73, 74, 75). Remove pin (73) and
bearing (74) from bearing carrier (75).
ab. Remove shfm (76), gear (77) and bearing spacer (78).
Change 2 4-31
NAVAIR 03-105-AB-52
WARNING
Keep face away from, and do not stand in front of the

end of the tower shaft housing when sea1 be110ws re-
tainer (80) is not secured in p1ace. Persona1 injury
could resu1t if parts are forced free by the compres-
sion of spring (90).
ac. Remove screws (79), sea1 be110ws retainer (80), stator assemb1y (81),
heat shie1d (82), sea1 retainer (83), and shims (84).
ad. Remove driver from ho1der portion of Sea1 Remova1 Ho1der and Driver,
289043-1, position end of tower shaft housing assemb1y on ho1der. Insert driver
through tower shaft housing assemb1y and seat in inside diameter of bearing (87).
Exert pressure againat end of driver to press bearing (87) and sea1 (85) from tower
shaft housing assemb1y (115). Remove too1ing, and remove sea1 (85), shim (86),
bearing (87), assemb1ed bearing carrier assemb1y (88, 89), and spring (90).
ae. Remove screw (91) and assemb1ed oi1 tube assemb1y (92, 93). Remove pack-
ing (92) from oi1 tube assemb1y (93).
af. Remove screws (94), washers (95), bushings (96), combustor assemb1y (97),
and screws (98).
ag. Remove screws (99), washers (100), and assemb1ed tower shaft cover (101,
102). Remove packing (101) from tower shaft cover (102).
ah. Remove screws (103) and assemb1ed parts (106 through 114) by inserting
brass rod, 0.25 inch in diameter by 3.0 inches 10ng, through ho1e in tower shaft
housing assemb1y (115) and tapping 1ight1y.
ai. Remove shims (104) and washers (105).
ajo Unstake nut (106) with standard punch. Position Sp1ined Torque Wrench
Adapter, 285481-1-1, in internaI splines of gear (108). Hold gear (108) and remove
nut (106) with standard wrench. Remove assemb1ed gear assemb1y (107, 108).
ak. Remove retainer (109), bearing (110), spacers (111, 112) and bearing
(113) from bearing carrier (114).
aI. Remove nuts (1, figure 4-6), washers (2, 3), bo1ts (4) and washers (5).
amo Remove diffuser housing assembly (6, 7), diffuser p1ate (8) and packing
(9) from tower shaft housing assemb1y (18 through 22).
ano Remove support (10) and gasket (11) from tower shaft housing assembly
(18 through 22).
4-32
NAVAIR 03-105-AB-52
17
/ 18
rle I /' 18
/
.I
I
" 14
1. NUT 12. INSERT

2. WASHER 13. INSERT
3. WASHER 14. INSERT
4. BOLT 15. INSERT
5. WASHER 16. PLUG
6. IUSERT 17. PLUG
7. HOUSING 18. INSERT
8. DIFFUSER PLATE 19. INSERT
9. PACKING 20. INSERT
10. SUPPORT 2I. Il~SERT
lI. TOWER SHAFT HOUSING GASKET 22. TOWER SHAFT HOUSING
Figure 4-6. Disassemb1y of Tower Shaft Housing Assembly
4-33
NAVAIR 03-105-AB-52

10ss, damage, or contamination.
b. Check that alI openings are covered, to prec1ude

4-25. DISASSEMBLY OF ACCESSORY DRlVE ASSEMBLY.
4-26. Disassemb1e accessory drive assemb1y as fo110ws: (figure 4-7).
a. Remove identification p1ate (1, sheet 1) if damaged or i11egib1e.
b. Remove 1ubrication instruction p1ate (2) if damaged or i11egible.
c. Remove threaded magnet from magnetic p1ug (5), and remove packing (3)
from magnet. Remove va1ve portion of magnetic p1ug (5) and remove gasket (4) from
magnetic p1ug va1ve.
d. Remove assemb1ed dipstick (6, 7). Remove gasket (6) from dipstick (7).
e. Remove assemb1ed strainer e1ement assemb1y (8, 9). Remove gasket (8)
from strainer e1ement assemb1y (9).
f. Remove assemb1ed p1ug (10, 11). Remove packing(10) from p1ug (11).
g. Remove assemb1ed screw (12, 13). Remove gasket (12) from screw (13).
h. Remove assemb1ed p1ug (14, 15). Remove gasket (14) from plug (15). Re-
move spring (16) and ba11 (17).
i. Remove screws (19), washers (20) and assemb1ed hydrau1ic motor (18, 21
through 23). Remove packing (21) from assemb1ed hydrau1ic motor (18, 22, 23).
CAUTION
When shearing pin (22), position a suitab1e support

beneath the c1utch jaw (23) to prec1ude damage to
the hydrau1ic motor bearings.
j. Shear pin (22) at center of hydrau1ic motor shaft and remove remaining
parta of pin from ho1es in c1utch jaw (23) and hydrau1ic motor shaft. Remove c1utch
jaw (23) from hydrau1ic motor (18).
k. Remove screws (25), screws (26), washers (27), screws (28, 29, 30),
washers (31), and remove fuel contro1 assemb1y (24).
1. Remove gasket (32) and shaft (33).
4-34
NAVAIR 03-105-AB-62
Figure 4-7. Disassembly of JFS Accessory

Drive As'sembly (Sheet 1 of 3)
4-35
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-7
1. IDENTIFlCATION PLATE 20. SPECIAL WASHER

2. LUBRICATION INSTRUCTION PLATE 21. PREFORMED PACKING
3. PREFORMED PACKING 22. STRAIGHT Pln
4. ANlroLAR ALUMINUM-ASBESTOS GASKET 23. CLUTCH JAW
5. MAGNETIC MACHlNE THREAD PLUG 24. MAIN JET FUEL STARTER
6. ANNULAR ALUMINUM-ASBESTOS GASKET FUEL CONTROL
7. OIL DIP STICK 25. SCREW
8. ANNULAR ALUMINUM-ASBESTOS GASKET 26. SCREW
9. SEDIMENT STRAINER ELEMENT ASSY 27. SPECIAL WASHER
10. PREFORMED PACKING 28. SCREW
11. PLUG 29. SCREW
12. ANNULAR ALUMlNUM-ASBESTOS GASKET 30. SOCKET HEAD CAP SCREW
13. SCREW 31. SPECIAL WASHER
14. ANNULAR ALUMINUM-ASBESTOS GASKET 32. ACCESSORY HOUSING GASKET
15 • MACHINE THREAD PLUG 33. STRAIGHT SHAFT
16. COMPRESSION HELICAL SPRING 34. NUT
17. BALL 35. WASHER
18. HYDRAULIC MOTOR 36. STRAIGHT SHAFT
19. SCREW 37. PREFORMED PACKING
4-36
• NAVAIR 03-105-AB-52
A
Figure 4-7. Disassembly of JFS
1 (Sheet
Accessory
2 of 3)
Dr1ve Assemb y
4-37
NAVAIR 03-105-AB-52
~ KEY TO FIGURE 4-7 (COlIT)

38. SENSITIVE SWITCH ASSY 79. ANNULAR BALL BEARING
39. SCREW 80. SLEEVE SPACER
40. SPECIAL WASHER 81. SLEEVE SPACER
41. PREFORMED PACKING 82. ANNULAR BALL BEARING
42. SWITCH ADJUSTING SHIM 83. BEARING CARRIER
43. CONTAINMENT FLYWEIGHT SLEEVE 84. SOCKET HEAD CAP SCREW
44. STRAIGHT PIN 85. SHIM
45. GOVERNOR WEIGHT 86. HEXAGON PLAIN I{UT
46. SPECIAL WASHER 87. ANNULAR BALL BEARING
47. GOVERNOR PIN 88. COMPRESSION HELICAL SPRING
48. SPECIAL WASHER 89. SLEEVE SPACER
49. COMPRESSION HELICAL SPRING 90. SPECIAL WASHER
50. INSERT 91. RETAINER RING
51. BODY 92. BEARING CARRIER
52. SPECIAL WASHER 93. ANNULAR BALL BEARING
53. THRUST WASHER 94. BEVEL ZEROL GEAR
54. HEXAGON PLAIN NUT 95. SPUR GEAR
55. SPUR GEAR 96. MACHINE KEY
56. KEY 97. RETAINING RING
57 • HEXAGON PLAIN NUT 98. STilAIGHT PIN
5~. SPUR GEAR 99. SPECIAL WASHER
59. KEY 100. PAWL
60. SPUR GEAR 101. SOLID RIVET
61. SOCKET HEAD CAP SCREW 102. LEAF SPRING
62. RETAINER 103. LEAF SPRING
63. MATCHED ROTARY PUMP 104. PIN
INTERNAL AND EXTERNAL GEAR SET 105. PLUG
64. KEY 106. HOUSING
65. LUBRICATION PUMP COVER 107. GEARBOX ACCESSORY HOUSING ASSY
66. DRlVE SHAFT 108. SOCKET HEAD CAP SCREW
67. ANNULAR BALL BEARING 109. NUT
68. RETAINING RING 110. ANUULAR BALL BEARING
69. HELICAL COMPRESSION SPRING 111. SPECIAL WASHER
70. SLEEVE SPACER 112. COMPRESSION HELICAL SPRING
71. ANNULAR BALL BEARING 113. SLEEVE SPACER
72. SHOULDERED SHAFT 114. 1u'OOJLAR. BALL BEARING
73. SCREW 115. SPUR GEAR
74. BEARING RETAINER ASSY 116. KEY
75. SHIM 117. SHOULDERED SHAFT ASSY
76. HEXAGON PLAIN NUT 118. RETAINER RING
77. PIN 119. BEARING CARRIER
78. ZEROL PINION BEVEL GEAR 120. INSERT
121. ADAPTER HOUSING
4-38
NAVAIR 03-105-AB-52
Figure 4-7. Disassembly of JFS Accessory

Drive Assembly (Sheet 3 of 3)
4-39
NAVAIR 03-105-AB-52
m. Remove nuts (34), washers (35), ang1e bracket (100, figure 4-4, sheet 2)
and assemb1ed parts (37, 108 through 113, figure 4-7). Remove shaft (36) and pack-
ing (37).
n. Remove screws (39, sheet 2), washers (40), and assemb1ed switch assemb1y,
(38, 41, 42). Remove packing (41) and shims (42) from switch assembly (38). f
NOTE
Washers (52) are solid disks t~ich are 0.005, 0.020

and 0.050 inch thick.
o. Engage Sp1ined Torque Wrench Adapter, 285484-1-1, in internaI splines of

drive shait (66). Position Torque Wrench Adapter, 287002-1-1, over governor assem-
b1y engaging hexagonal f1ats on body (51). Ho1d drive shaft (66) stationary, and
unthread governor assemb1y (43 through 51) from drive shaft (66). Remove washers
(52, 53).
p. Remove sleeve (43), pins (44), f1yweights (45), washers (46), pin (47),
washers (48) and spring (49) from body assembly (50, 51).
q. Unstake nut (54) using standard punch. Engage Sp1ined Torque Wrench
Adapter, 287150-1-1, in internaI sp1ines of drive shaft (66). Ho1d drive shaft
(66) and remove nut (54). Remove spur gear (55) and key (56).
r. Engage Sp1ined Torque Wrench Adapter, 285484-1-1, in internaI splines of

clutch housing (106). Hold c1utch housing (106) and remove nut (57) from shaft
(72). Remove gear (58) and keys (59).
s. Unstake nut (76) with standard punch. Remove screws (73), retainer
assemb1y (74), assemb1ed parts (76 through 83), and shims (75). Engage splines of
Sp1ined Torque ~~ench Adapter, 285481-1-1, in internaI splines of gear (78). Hold
gear (78) and remove nut (76). Remove assembled gear (77, 78). Remove bearing
(79), spacers (80, 81) and bearing (82) from bearing carrier (83).
t. Unstake nut (86) using punch. Engage external1y splined portion of

Sp1ined Torque Wrench Adapter, 287150-1-1, in internaI sp1ines of clutch shaft
assembly (101 through 106) with socket portion engaging nut (86). Hold eluteh shaft
assembly (101 through 106) and remove nut (86). Remove bearing (87), spring (88),
spaeer (89), speeia1 washers (90), and assembled parts (93 through 106). Remove
gear (60). Remove retainer ring (91) from bearing earrier (92). Remove bearing
(93), gear (94), gear (95), and key (96) from assemb1ed e1uteh assemb1y (97 through
106).
u. Remova serews (84), bearing earrier (92) and shim (85) from housing as-
semb1y (107).
v. Remove bearing (67), retaining ring (68), spring (69) and spaeer (70). ~
Reinsta11 nut (57) on shaft (72) and remove shaft (72) and bearing (71) from housing
assemh1y (107). Remove nut (57) and bearing (71) from shaft (72).
w. Remove screws (61) and retainer (62). Remove assembled drive shaft (63
through 66). Remove gear set (63), key (64) and cover (65) from drive shaft (66).
4-40
NAVAIR 03-1C5-AB-52
x. Unstake nut (109) using punch. Remove screws (108, sheet 3) and assem-
bled parts (109 through 119) from adapter housing assemb1y (120, 121). Engage
Sp1ined Torque Wrench Adapter, 285484-1-1, in interna1 sp1ines of shaft assemb1y
, (117). Bo1d shaft assemb1y (117) and remove nut (109). Remove bearing (110),
washer (111), spring (112) and assemb1ed parts (113 through 117) from carrier (119).
Remove spacer (113), bearing (114), gear (115), and key (116) from shaft assemb1y
(117). Remove ring (118) from carrier (119).

10ss, damage or contamination.
b. Check that a11 openings are covered to prec1ude
4-27. DISASSEMBLY OF ACCESSORIES.
4-28. DISASSEMBLY OF AC-DC PERMANENT MAGNET GENERATOR.
4-29. Disassemb1e AC-DC Permanent Magnet Generator as fo110ws: (See figure 4-8.)
a. Remove nut (2), washer (3) and pull gear (4) from shaft of rotor assem-
b1y (25). Remove key (5).
b. Remove screws (6, 7) and cover (8).
c. Remove connector (29), nut (30), washers (31, 33), 1ug (32) and screw
(34) from end bel1 assemb1y (35, 36).
NOTE
Do not disassemb1e end be11 assemb1y unless required

by inspection.
d. Remove screws (9, 10, 12, 13) and move fi1ter assemb1y (11), module as-
semb1y (14), 1ug (32) and connector (29) out of end be11 assemb1y (35, 36) to gain
access to wiring, then unso1der wires from filter assemb1y, module assemb1y, 1ug
and connector.
e. Peel sealing compound from terminals of fi1ter assemb1y (11) and module
assemb1y (14), and from 1eads of stator assemb1y (27).
f. Pee1 encapsu1ation from connector (29) and module assembly (14) areas of
end be11 assemb1~ (35, 36).
- g. Remove disk (15) tf damaged. Remove screws (16) and housing assemb1y
(20 through 23) with parts (17 through 19) attached.
h. Remove bearing (17), washers (18) use a drift punch and arbor presa
and sea1 (19) from housing assemb1y (20 through 23).
4-41
NAVAIR 03-105AB-52
4-31. Disassemble JFS control box assembly as follows: (figure 4-9).
a. Remove identification plate (1, sheet 1) if damaged or illegible. ,

b. Remove cover assembly (6, 7) as follows.
(1) Remove screws (2), washers (3), terminal lug (4), washers (5), and
cover sssembly (6, 7).
c. Remove assembled sensor (9 through 13) as follows:
(1) Remove screws (8).
(2) Disconnect wires from terminal boards 1 and 2, and relays Kl and K2.
(3) Remove assembled sensor assembly (9 through 13).
d. Remove relay (9) from sensor assembly (13) as follows:
(1) Remove nuts (10), washers (11) and remove relay (9) and washers (12)
from sensor assembly (13). Remove washers (12) from posts of relay (9).
I
NOTE
Refer to paragraph 4-31A for disassembly of sensor (13).
e. Remove electrical counter (22) as follows:
(1) Remove screws (14), washers (15, 16), plate (17), and plate assembly
(18, 19) from JFS controI box assembly (50, sheet 2).
Push wires through grommet (23, sheet 1) and pull electrical counter
(2)
(22) and mounts (20, 21) from electrical control box (50, sheet 2) until connectors
can be exposed.
KEY TO FIGURE 4-9 t

1. IDENTIFICATION PLATE 14. SCRElol
2. SCREW 15. lolASHER
3. WASHER 16. WASHER
4. LUG TERMINAL 17. COlWTER RETAINING PLATE
5. WASHER 18. COUNTER RETAINING PLATE GASKET
6.
7.
ELECTRlCAL CONTROL SELF
ADHERING GASKET
ELECTRlCAL CONTROL COVER
19.
20.
TRANSPARENT COL~TER
RETAINING PLATE
RESILIENT-START COUNTER MOL~T
-
8. SPACER HEAD MACHlNE SCREW 21. RESILIENT START COL~TER MOu~!
9. ARMATURE RELAY 22. ELECTRICAL COUNTER
10. NUT 23. GROMMET
11. WASHER 24. TEMPERATURE SENSOR
12. WASHER 25. INSL~TION SLEEVING
13. SENSOR ASSY 26. I~DICATOR
4-44 Change 1
NAVAIR 03-105-AB-52
.,
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,'~ I
tt.~
;~ ~,
21"
...
.1.
'tt
u/~
y~
~
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co
°I
. I,
'.
19/~
18/~·
~ /'6
• ~15
17~ ~'4
Figure 4-9. Disassemb.Iy of JFS Control Box AssembIy (Sheet I of 2)
4-45
.
NAVAIR 03-105-AB-52
A
Figure 4-9. Disassembl y of JFS Control Box As semb1y (Sh eet 2 of 2)
NAVAIR 03-l05-AB-52
27. LUG TERMINAL 39. SPECIAL WASHER

28. CARTRIDGE FUSE 40. ELECTRICAL INSULATOR
29. FUSEHOLDER 41. INSULATOR
30. ELECTRICAL RECEPTACLE CONNECTOR 42. WASHER
31. ELECTRICAL RECEPTACLE CONNECTOR 43. SCREW
32. ELECTRICAL RECEPTACLE CONNECTOR 44. TRANSISTOR
33. SCREW 45. SEMICONDUCTOR MOUNTING REAT SINK
34. WASHER 46. RIVET
35. WASHER 47. NUT
36. NUT 48. RIVET
37. LUG TERMINAL 49. SELF-LOCKING NU!
38. WASHER 50. ELECTRICAL CONTROL BOX
(3) Remove mount (20, sheet I) from e1ectrical counter (22).

Slide mount (21) away from e1ectrical counter (22) until wire con-
(4)
nections are exposed. Disconnect wires from e1ectrica1 counter (22). Remove mount
(21) and e1ectrica1 counter (22).
f. Remove grommet (23) from e1ectrical countro1 box (50, sheet 2).
g. Remove temperature sensor (24, sheet I) from e1ectrical control box (50,
sheet 2).
h. Remove indicator (26, sheet 1) as fo11ows:
(1) Unthread nut of indicator (26) from indicator.

(2) Pull indicator (26) and sufficient wiring from electrical control
box (50, sheet 2) to expose connectors on indicator.
(3) S1ide insu1ation sleeving away from connectors, and disconnect
wires.
(4) Remove insu1ation sleeving (25, sheet 1) and nut of indicator (26)
from wires.
i. Disassemb1e and remove fuseholders (29, sheet 2) as fo11ows:
{l} Remove nuts and screws of fuseholders (29) that retain 1ug terminals
(27). Remove lug terminals (27) from fuseholders (29).
(2) Remove caps of fuseholders (29) and remove fuses (28).
(3) Remove locknuts of fuseho1ders (29) and remove fuseho1ders from

e1ectrica1 contro1 box (50).
j. Remove electrica1 receptac1e connectors (30, 31, 32) as fo1lows:
4-47
NAVAIR 03-105AB-52
(1) Remove retaining nuts of connectors (30, 31, 32).
(2) Remove connectors (30, 31, 32) from ho1es in e1ectrical contro1 box
(50), and disconnect wires from contacts of connectors.
k. Remove assemb1ed heat sink and transistor (36 through 45) as fol1ows:
(1) Disconnect wires from transistor (44) and 1ug terminal (37).
(2) Remove screws (33), washers (34, 35) and assemb1ed heat sink and
transistor (36 through 45).
1. Remove transistor (44) from heat sink (45) as follows:
(1) Remove nuts (36), 1ug terminal (37), washers (38, 39, 40), insulator
(41), washers (42), screws (43), and transistor (44) from heat sink (45).
Check that parts are contained to prevent loss, damage

or contamination.
4-31A. DISASSEMBLY OF START CYCLE PROTECTION SENSOR.
4-31B. Start cyc1e protection sensor (13, figure 4-9) sha11 be disassemb1ed only to
the extent required to rep1ace a defective componente Refer to REPAIR OF START
CYCLE PROTECTION SENSOR, paragraph 4-587A, for instructions covering replacement of
defective components.
4-32. DISASSEMBLY OF ACCUMULATOR ASSEMBLY.
4-33. Disassemb1e accumulator assemb1y as fo11ows: (Refer to figure 4-10.)
a. Remove assemb1ed union (1, 2) from accumulator cap (15) and remove pack-
ing (1) from union (2).
b. Remove assemb1ed union (3, 4) from accumulator cap (15) and remove pack-
i08 (3) from union (4).
c. Remove assemb1ed b1eed plug (5, 6) from accumu1ator cap (15) and remove
packing (5) from b1eed p1ug (6).
d. Separate accumu1ator cap (15) from accumu1ator housing (11) by unthread-

ing.
KEY TO FIGURE 4-10 t

1. PREFORMED PACKING 6. PLUG 11. ACCUMULATOR HOUSING
2. UNION 7. PREFORMED PACKING 12. PREFORMED PACKING
3. PREFORMED PACKING 8. PREFORMED PACKING 13. PREFORMED PACKING
4. UNION 9. ACCUMULATOR FUEL PISTON 14. ACCUMULATOR HYDRAULIC
5. PREFORMED PACKING 10. COMPRESSION HELICAL SPRING PISTO~
15. ACCUMULATOR CAP
4-48 Change 1
NAVAIR 03-105-AB-52
E-12A-lo.w
Figure 4-10. Disassemb1y of Accumulator Assembly
4-49
....•... __ .... --------------------
NAVAIR 03-I05AB-52
•
e. Remove accumulator fueI piston (9) and compression helicaI spring (10)
from accumulator housing (11). Remove packings (7 and 8) from accumulator fueI
piston (9).
f. Remove accumulator hydraulic piston (14) from accumulator cap (15). Re-
move packings (12, 13) from accumulator hydraulic piston (14).
Check that parts are contained to prevent Ioss, damage

or contamination.
4-34. DISASSEMBLY OF SENSITlVE SWITCH ASSEMBLY.
4-35. Disassemble sensitive switch assembly as fol1aws: Refer to figure 4-11.
a. Remove pin (1), washers (2) and Iever (3).
b. Remove screws (4), pins (5), washers (6), electricaI Iead assembly (7
through 10), and packing (11) from switch housing assembly (12, 13).
Check that parts are contained to prevent 10ss, damage

or contamination.
4-36. DISASSEMBLY OF SWITCH ACTUATING GOVERNOR ASS~mLY.
4-37. Disassemble switch actuating governo r assembly as follows: Refer to figure

4-12.
a. Restrain governor pin (4) sufficiently to relieve spring tension from

governo r weights (3). Remove pins (1), washers (2), governar weights (3), &overnor
pin (4), washers (5), and springs (6).

ar contamination.
4-38. DISASSEMBLY OF FUEL CONTROL ASSEMBLY.
4-19. Disassemble fuel contraI assembly as folIows: Refer to figure 4-13.
a. Remove assembled plug (1, 2, sheet 1). Remove packing (1) from plug (2).
b. Remove air passage bolt (3), gaskets (4), and fitting (5).
c. Disassemble acceleration limiter section (6 through 24) as follows:
(1) Remove nut (6) and washer (7) from screw (11).
(2) Remove screws (8), washers (9) and assembled parts (10 through 15).
4-50 Change 1
t
NAVAIR 03-10S-AB-52
..---11
1. STRAIGHT PIN 8. ELECTRlCAL RECEPTACLE COID{ECTOR

2. SPECIAL WASHER 9. FLANGE
3. SWITCH ACTUATING LEVER 10. ELECTRICAL INSULATION SLEEVING
5. STRAIGHT PIN 12. INSERT
6. SPECIAL WASHER 13. SWITCH HOUSING
7. SEUSITIVE SWITCH
Figure 4-11 •. Disassemb1y of Sensitive Switch Assemb1y
4-51
NAVAIR 03-105-A2-52
3 2
4
J 5
i 't1
~.
6 , ~
1 k.· 8
1. STRAIGHT PIN 5. SPECIAL WASHER

2. SPECIAL WASHER 6. COMPRESSION SPRING
3. GOVERNOR WEIGHT 7. HEADLESS STRAIGHT PIN
4. GOVERNOR PIN 8. GOVERNOR BODY
Figure 4-12. Disassemb1y of Switch Actuating Governor Assemb1y
4-52
NAVAIR 03-105-AB-52
Figure 4-13.
4-53
•
NAVAIR 03-105-AB-52
~KEY TO FIGURE 4-13
1. PREFORMED PACKING 49. HEXAGON PLAIN NUT

2. PLUG 50. PREFORMED PACKING
3. AIR PASSAGE BOLT 51. ADJUSTING SCREW
4. ANNULAR. ALUMINUM-ASBESTOS GASKET 52. MACHINE THREAD PLUG
5. SPECIAL FITTING 53. COMPRESSION HELICAL SPRING
6. NEEDLE LOCKING ADJUSTMENT l~T 54. METERING VALVE
7. WASHER 55. PREFORED PACKING
9. WASHER 57. PREFORMED PACKING
10. PREFORMED PACKING 58. PREFORMED PACKING
11. ADJUSTING SCREW 59. FUEL CONTROL VALVE SLEEVE
12. INSERT 60. DELETED
13. PLUG FLUID FLOW RESTRICTOR 61. SPECIAL WASHER
14. ACCELERATION LIMITER HOUSING 62. PREFORMED PACKING
15. SPRING GUIDE 63. UNION
16. HELICAL COMPRESSION SPRING 64. SCREW
17. DIAPHRAGM RETAINER 65. WASHER
19. AIR AND FUEL DIAPHRAGM 67. ENCASED PLAIN SEAL
20. DIAPHRAGM SPACER 68. RETAINING RING
21. DIAPHRAGM SPACER 69. ENCASED PLAIN SEAL
22. SHOULDER BOLT 70. SEAL HOUSING
23. FUEL CONTROL DIAPHRAGM SPACER 71. PREFORMED PACKING
24. AIR AND FUEL DIAPHRAGM 72. PREFORMED PACKING
25. BALL 73. PREFORMED PACKING
26. NEEDLE LOCKING ADJUSTMENT NUT 74. PREFORMED PACKING
27. WASHER 75. SEDIEMNT STRAINER ELEMENT ASSY
28. SCREW 76. FUEL PUMP SLEEVE BEARING
29. WASHER 77. PLUG
30. BRACKET 78. SHAFT
31. PREFORMED PACKING 79. SPUR GEAR
32. SPRING RETAINER 80. GEAR SHAFT
33. ADJUSTING SCREW 81. SPUR GEAR
34. PREFORMED PACKING 82. PUEL PUMP SLEEVE BEARING
35. PIN 83. SPRING TENSION WASHER
36. GOVERNOR COVER 84. FLAT WASHER
37. SPRING 85. PREFORMED PACKING
33. ANNULAR BALL BEARING 86. INSERT
39. METALLIC THRUST WASHER 87. INSERT
40. METERING SLEEVE 88. INSERT
41. GOVERNO R FLYWEIGHT 89. INSERT
45. GOVERNOR CAGE 93. INSERT
46. GOVERNOR VALVE ASSY 94. PLUG
47. SLEEVE BEARING 95. PLUG
97. FUEL METERING BODY
4-54
NAVAIR 03-105-AB-52
A
Figure 4-13. Disassemb1y of Main Jet Fue1 Starter Fue1 Contro1
Assemb1y (Sheet 2 of 2)
(3) Remove assemb1ed adjusting screw (10, 11) from acce1eration 1imiter
housing assemb1y (12 through 15). Remove packing (10) from adjusting screw (11).
(4) Remove sprillg guide (15), spring (16), diaphragm assemb1y (17, 18,
19), diaphragm spacer (20), diaphragm spacer (21) and assembled air and fue1
diaphragm (22, 23, 24). Remove bo1t (22) and separate spacer (23) from air and
fue1 diaphragm (24). Remove ba11 (25).
d. Disassemb1e governo r valve section (26 through 48) as fol1ows:

(1) Remove nut (26) and washer (27).
CAUTION
When removing cover assemb1y·oC35, 36), exercise care to

prevent spring (37) from being expe11ed.
(2) Remove screws (28), WBshers (29), bracket (30) and assemb1ed parts
(31 through 36).
(3) Remove assemb1ed adjusting screw (31 through 33) from cover assem-
bly (35, 36). Remove packing (31) and spring retainer (32) from adjusting screw
(33).
4-55
NAVAIR 03-105-AB-52
(4) Remove spring (37) and assemb1ed parts (38, 39, 40). Remove bearing
(38) and shim (39) from metering sleeve (40).
(5) Remove governar flyweights (41) from governar cage (45).
(6) Align slot of governar cage (45) to expose head of screw (42). Re-
move screw (42), washer (43) and assembled parts (44, 45, 46). Remove bearing using
suitab1e pu11er (44) and governar cage (45) from governar valve assembly (46).
(7) Remove sleeve bearing (47) with suitable puller. Remove packing
(48).
e. Disassemble constant differential pressure valve section (49 through 61)

as fo11ows:
(1) Remove assemb1ed parts (49 through 52) and spring (53) from fuel
metering body (97).
(2) Remove nut (49) from adjusting screw (51). Remove assemb1ed adjust-
ing screw (50, 51) from p1ug (52). Remove pacY~ng (50) from adjusting screw (51).
(3) Remove assembled fuel contraI va1ve sleeve (54 through 59) using
suitab1e ~uller. Remove metering va1ve (54) from sIeeve (59). Remove packings
(55, 56, 57, 58) from fueI contraI va1ve sIeeve (59).
NOTE
Washers (61) are blank discs.
(4) Remove washers (61).
f. Remove assembled union (62, 63). Remove packing (62) from union (63).
g. Disassemble fuel pump section (64 through 85) as follows:
(1) Remove screws (64), washers (65, 66) and assembled seaI housing
(67 through 70).
(2) ~~te collet halves of Se aI Removal Driver, 285474-1-1, together and

insert through seal (69) and position against seal (67). Expand col1et halves by
inserting wedge end of seal remova1 driver between halves. Press seal (67) from
seal housing (70).
(3) Remove retaining ring (68) and seal (69) from seal housing (70).
(4) Remove packings (71, 72, 73) and assembled strainer element assem-
bly (74, 75). Remove packing (74) from strainer element assembly (75).
4-56
NAVAIR 03-105AB-52
NOTE
Contro1 fue1 pump sleeve bearings (76) as a matched
sete Mark each bearing in such a manner that it may
be reinsta11ed in the bore from which it was removed.
(5) Remove fue1 pump sleeve bearings (76).
(6) Remove shaft assemb1y (77, 78), spur gear (79), gear shaft (80),
and spur gear (81).
NOTE
Contro1 fue1 pump sleeve bearings (82) as a matched
sete Mark each bearing in such a manner that it may
be reinsta11ed in the bore from which it was removed.
(7) Remove fue1 pump sleeve bearings (82), spring tension washers (83),
f1at washers (84) and packings (85) from body assemb1y (86 through 91, sheet 2).

or contamination.
4-40. DISASSEMBLY OF HYDRAULIC MOTOR.
4-41. Disassemb1e hydrau1ic motor as fo110ws: Refer to figure 4-14.
a. Remove assemb1ed cap (1 through 7) from housing (29).

(4), washer (6), sea1s (7) and packings (2, 3, 5) from cap (1).
Remove bushing
I
b. I.nsert Shaft Bearing Remova! Support, 901l48-T4, around outside diameter
of washer (9) and between housing (29) and bearing (8). Press bearing (8) from
shaft (18).
c. Remove assemb1ed shaft (9, 11, 12, 13, 14, 16, 17, 18) from housing
(29). Remove washer (9), retainer (11), bearing (12), piston (13), cam (14), rotor
(16) and key (17) from shaft (18).
d. Remove cam retainer (15) and pin (10) from housing (29).
e. Remove assemb1ed port p1ate (19 through 23) as fo11ows:

(1) Hand thread Port P1ate Insta11ation Too1, 901148-T5, into port
plate (19). Remove port plate (19) from housing (29).
(2) Remove retainers (20, 22) and packings (21, 23) from port plate
(19) •
Change 1 4-57
...
NAVAIR 03-105AB-52
22
E-19A-9028
Figure 4-14. Disassembly of Hydraulic Motor
4-58 Change 1
.
NAVAIR 03-l05AB-52
~ KEY TO FIGURE 4-14
1. HOUSING CAP 16. ROTOR

2. PACKING 17. KEY
3. PACKING 18. SHAFT
~I 4. BUSHING 19. PORT PLATE
5. PACKING 20. RETAINER
I 6. WASHER 21. PACKING
7. SEAL 22. RETAINER
8. BALL BEARING . 23. PACKING
9. WASHER 24. SPRING
10. PIN 25. PIN
11. BEARING RETAlNER 26. NEEDLE BEARING
12. BALL BEARING 27. NAMEPLATE
13. PISTON 28. SCRElo1
14. AUXILIARY CAM 29. HOUSING
15. CAM RETAIlmR
f. Remove spring (24), pin (25) and need1e bearing (26) from housing (29).
g. Remove namep1ate (27) if damaged or i1legib1e.

or contamination.
4-42. CLEANING.
4-43. Recognized cleaning procedures for components requires extensive facilities,

trained personne1, good shop practices and are specified in the fo110wing proce-
dures. C1eaning of components is varied and depends on the objective of inspection
to be performed or on repair required for satisfactory operation.
WARNING
C1eaning shou1d be performed in a we11-ventilated room.

Rubber gloves and protective c10thing must be worn.
Extinguishers and vat or tank covers must be on hand
in case of fire.
4-~4. Ali parts must be cleaned to remove oil, grease, dust, stains and soiled
areas. F1ange areas, pi10t diameters and sealing surfaces must be cleaned of gas-
kets and sealing compounds, if presente After cleaning, ports and orifices shquld
be capped, plugged or sealed and protected from dust o~ other contaminants by clean
paper or p1astic covers. Steel and 400 series stainless steel parts require the
application of corrosion-preventive compounds after cl~aning to prevent rust and
corrosion. (Refer to paragraph 4-87.)
4-45. Corrosion products, ~henever they appear, must be removed and the base metal
re-treated before reassembly. Heat discoloration of metal surfaces due to normal
Change 1 4-59
NAVAIR 03-105-AB-52
service temperature is not object10nab1e, however, sca1e that may come 100se and
damage the unit must be removed. Carbon res1due and combust10n products must be
removed. Paint films that are t1ghtly bonded to base metal and are otherwise
serviceab1e sha11 not be removed. However, they shall be cleaned and the top coat
touched up as requ1red.
4-46. CLEAN1NG SOLUT10NS.
4-47. SOAP CLEANING SOLUTION. !bis soap c1ean1ng solut10n removes contam1nat10n
and carbon deposits from aluminum, magnes1um and titanium parts. Prepare solut10n
as follows:
a. D1ssolve four to six ounces of detergent (Diversey 808, Diversey Chemical

Co, 1855 S Mt Prospect Rd, Des Pla1nes, 1L 60018) 1n each gal10n of water.
b. Mainta1n solut1on at 130° to 180°F (54° to 83°C) with air agitation.
4-48. RUST STR1PPER SOLUTION. Rust str1pper solut10n cleans both stee1 and stain-
1ess stee1 parts. Prepare solution as follows:
a. Mix three to five pounds of rust stripper (Oakite Products Inc, 50

Va1ley Rd, Berkley Hts, NJ 07922, or equ1va1ent) with each gallon of water.
b. Maintain solut10n at 160° to 200°F (71° to 93°C) with air ag1tat10n.
4-49. CHROM1C-N1TRIC PICKLE.
4-50. Chromic-n1tric pick1e removes corrosion frem aluminum a110ys. Prepare

pick1e as fo1lows.
a. ~ax 12.0 to 13.5 ounces of chromic ac1d flake (Cr03) and 1.0 to 1.4 p1nts
of nitric acid (UN03) with enough distilled water to make one gallon.
b. Maintain p1ckle at 180° to 200°F (83° to 93°C).
4-51. HEAVY-DUTY ALKALlNE CLEANER SOLUT10N.

4-52. Prepare heavy-duty a1kaline cleaner solution as f01lows.
a. Dissolve 5 to 10 ounces of Wyandotte F.S. Cleaner (Wyandotte Chemica1s
Corp, Alka11 Sq, Wyandotte, MI 48192, or equ1va1ent) to each ga110n of s01ution.
b. Ma1ntain solution at 190° to 210°F (88° to 99°C) during use.
4-53. HYDROFLUOR1C ACID P1CKLE.
4-54. Prepare hydrof1uoric ac1d pick1e as follows.
a. Mix 1.0 gallons of hydrof1uoric acid (48 to 52 percent HF) into 2

ga110ns of water.
4-60
..
NAVAIR 03-105-AB-52
b. Maintain pickle at room temperature in 1ead-1ined tank.
4-55. CHROMIC ACID PICKLE.
4-56. Prepare chromic acid pickle as follows:
a. Dissolve 16 ounces of chromic acid f1ake (Cr03) (Dow Chemica1 Co, S

Saginaw Rei, Mid1and, MI 48640, or equivalent) to each gallon of water.
4-57. METAL TREATMElIT SOLUTIONS.
4-58. ALUMINUM TOUCH-UP SOLUTION. This aluminum touch-up solution protects bare
spots on aluminum parts. Prepare solution as follows:
a. Dissolve four ounces of powder MIL-C-554l into a gal10n of disti11ed

water at room temperature.
b. Adjust acidity (pH) to 0.9 to 1.0 by adding chromic acid or nitric acid
to the solution.
4-59. MAGNESlml TOUCH-UP SOLUTION. This magnesium touch-up solution protects bar e
spots on magnesium parts. The solution may be used either as a dip at 160 0 to 200°F
(71 0 to 93°C) for 15 to 30 seconds as a brush-on solution at room temperature, keep-
ing the surface wet for one to two minutes. Prepare magnesium touch-up solution
as fo110ws:
a. Add 1.3 ounces chromic acid (cr03) to slightly 1ess than one gallon of
water.
b. Add 1.0 ounce calcium sulfa te (CAS04.2H20) and enough water to make one
gallon.
c. Stir vigorous1y for at 1east 15 minutes to ensure saturation of the solu-

t10n with calc1um sulfate.
4-60. GEnERAL CLEAlUNG INSTRUCTIONS.
4-61. PETROLEUM SOLVENT DEGREASING.

WARNING
Spray vapors are toxic and must not be inhaled.

Observe alI fire precautions.
a. Place solvent P-n-680, Type 11 in a dip tank or use as a spray in a

positive outside ventilated spray booth.
b. Dip, soak, agitate or spray parts to be c1eaned until oil and grease have
been removed.
4-61
•
NAVAIR 03-105AB-52
c. Remove caked grea8e or 80ft carbon deposits using a fiber bristle brush.
CAUTION
This process shaIl not be used to degrease titanium or titanium alIoy

parta. Degreasing of titanium or titanium alloy parts shall be
accomplished using Borizine-Aqua-Fax solution, hot MIL-M-7752
silicate soap solution, or in a solvent spray booth using dry cleaning
solvent P-D-680 Type n, aliphatic naphtha TT-N-95, or methyl-
ethyl-ketone (MEK) Tl'-M-261. Any ofthe above methods may be
used if available.
4-62. VAPOR DEGREASING. Vapor degreasing is the process of removing oil, grease and wax
from both ferrous and non-ferrous metaIs by placing parta in a vat or container in which solvent, 1,1,1,
trichloroethane, MIL-T-81533, has been vaporized. As the hot vapors condense on the cold metal, the
fluid condensate dissolves and removes the grease, oil or wax as it drains from the metal. Proceed as
follows:
a. Prior to vapor degreasing, heavy deposita of grease and oil shall be removed in a solvent
spray booth, by steam cleaning, or heavy duty detergent cleaning.
WARNING
1,1,1, trichloroethane, MIL-T-81533, vapors can be fatal. Use on1y

with adequate ventilation. High concentration of vapors are
anesthetic and dangerous to life. Eye initation and dizziness are
signs of inadequate ventilation and dangerous concentration. Do
not use near heat, sparks, open flame or any other source of
ignition. Avoid prolonged or repeated contact with skin.
b. Light deposits of grease and oi} shaIl be removed by vapor degreasing using inhibited
1, 1, 1, trichloroethane, MIL-T-81533, as foUows:
(1) Check that parta to be cleaned are free of residual moisture, flux, or other material
that could cause corrosion of the equipment and parts.
CAUTION
Every eft'ort should be made to keep moisture out of the vapor

degreaser as water in the presence ofhot I, I, I, trichloroethane can
cause formation of hydrochloric acid which is very corrosive to
parts and equipment.
(2) Rack parts so that alI surfaces wiIl have direct contact with the solvent vapor and so
that condensed solvent wiIl drain directly back into the boiling solvent. Small parts may be hung in the
degreaser by meana ofhooks, wired to bars, etc.
(3) Lower racked or large parta into the vapor zone using a hoist at a rate ofvertical speed
not to exceed 11 feet per minute to avoid disturbing and causing 1088 of concentrated vapor.
4-62 Change 2
•
NAVAIR 03-105AB-52
(4) Leave parts in the vapor zone until vapor ceases to condense on parta. Ifnecessary,
use a liquid spray lance to remove stubborn deposits, metal chips, or dirt. After spray lance is used,
leave parts in tbe pure vapor for 10-15 seconds prior to removal.
(5) When condensation ofvapor is complete, remove parts from the degreaser at a
vertical speed not to exceed 11 feet per minute. AlI parta shalI be dry belore removaI from the degreaser
free board.
WARNING
Care should be exercised not to introduce entrapped 1,1,1,

trichloroethane into hot alkaline solutions, used in many metal
cleaning and electroplating operations, after degreasing as these
solutions can cause the formation of toxic and explosive products
with halogenated hydrocarbons.
c. Low-alloy steel, aluminum alloy and magnesium aUoy parts which wiIl receive no ~ther
cleaning or processing within eight houn shall be preserved with lubricant-preservative, VV-L-800, or
thin layer water displacing preservative MIL-C-81309 or equivalent to prevent in-house corrosion.
4-63. GLASS BEAD PEENING. Hard carbon, paint, corrosion and scale may be removed
by glaas bead peening. Proceed as follows.
CAUTION
Do not use on critical parts (such as turbine wheels)
where peening may obscure or peen over microscopic
fatigue cracka.
a. Mask any surfaces that might be damaged by peening.
WARNING

Change2 4-62A1(4-62B blank)

iI
NAVAIR 03-l0S-AB-S2
b. Clean parts with solvent P-D-680, Type 11 or vapor degrease to remove

oil and grease contamination.
c. Peen corroded areas with 0.001 to 0.006-inch diameter glass beads untl1
corrosion products are removed.
CAUTION
Regulate air pressure to keep erosion of base metal

to a minimum.
d. Rinse surface free of glass beads. Dry part in oven at 2~~~ to 23SoF
(96° to 113°C) for one hour.
NOTE
Glaas bead peening equipment shal1 be cleaned and re-

charged with new beads after each 24-hour period of
operation.
4-64. GLASS BEAD PEENING OF LIP SEAL SURFACES.
4-6S. Type 11 glass bead peening us1ng a SO/SO mixture of garnet grit (150 grit)
and glass beads in ten times the volume of tap water that has been inhibited with
0.2S-percent sodium dichromate shal1 be used for a11 lip sea1 surfaces. The pres-
sure leveI required to Type 11 shall be adjustable between 10 and 110 psig.
4-66. ABRASlVE BLASTING. Hard carbon or lead deposits and corrosion and scale may
be removed by subjecting parts to abrasive blasting using a standard sandblast
cabinet and 120 grit sand. Proceed as follows.
CAUTION
Do not use abrasive blasting on parts that may contain

microscopic fatigue cracks or for critica1 we1ding
where blasting may increase the formation of.cracks.
a. Mask any surfaces that might be damaged by blast cleaning.
WARNING

b. Clean parts with solvent P-D-680, Type 11 ar vapor degrease to remove

oi1 and grease contamination.
c. Set b1asting equipment air pressure at 15 to 30 paig and then subject

parts to sandb1asting.
4-63
NAVAIR 03-105AB-52
CAUTION
Keep nozzle 1n mot1on to prevent blast from dwelling

on one spot.
d. Reduce air pressure as requ1red to control act10n on base metal.
4-67. STRIPPING OF PAINT FROM COMPONENTS.
4-68. Strip pa1nt from components as follows to properly prepare surfaces for re-
pa1nting.
a. Dip the part in a stripping solution. Str1pping solut1on (Kestr1p "E",

Al11ed Ke11te Products Div, R1chardson Chemical Co, 400 Mildand Ave, Detroit, MI
48203, or equivalent) is satisfactory for this method. Where d1pping 1s not
desirable or feasible, a brush-on paint str1pper may be used. Paint remover con-
forming to TT-R-25l is satisfactory for th1s method.
b. Following the stripping operation, thoroughly clean, wipe and dry the
parto
c. Magnesium parts, from which the paint has been removed in preparation for
repainting, should first be treated to prevent corrosion as described in paragraph
4-84, step h.(l) or h.(2).
4-69. STANDARD CLEANING PROCEDURES.
4-70. ELECTRICAL COMPONENTS.
4-71. Clean electrical components as follows:
a. Wipe wiring and terminaIs with lint-free cloth dampened in solvent

I P-D-680, Type 11. Blow parts with f1ltered compressed air to dry.
b. Clean electrical connectors with soft bristled brush dampened in solvent

P-D-680, Type 11. Blow parts with filtered compressed a1r to dry.
I c. Clean assembled printed wiring boards using 11nt-free cloth.

hard-to-reach areas with soft bristled brush.
4-72. PLUMBING COMPONENTS.

Clean
4-73. Clean plumbing components as follows:
a. Solvent degrease tube assemblies and f1ttings 1n accordance with para-

graph 4-61.
b. Blow parts dry with filtered air.
c. Check that internaI passages are free from obstructions.
4-74. ALUMINUM PARTS NOT CORRODED.
4-64 Change 1
NAVAIR 03-105-AB-52
4-75. Clean non-corroded aluminum parts as fo11m~s:
a. Solvent degrease surfaces in accordance with paragraph 4-61 to remove

b. Immerse parts in soap c1eaning solution (paragraph 4-47) for at 1east 5

minutes. Scrub surfaces with stiff brist1ed brush to remove surface oil. Remove
softened gaskets with too1 b1ade; scrape surface c1ean and touch up bare areas with
a1uminum touch-up solution (paragraph 4-58).
c. Rinse parts in warm tap water 80° to 110°F (27° to 43°C).
d. B10w excess water off parts, li necessary, and finish dryio.g in oven at
200° +25°F (93° +4°C) for one hour.
e. Store parts away from corrosive fumes.
4-76. ALUMINUM PARTS CORRODED.
4-77. C1ean corroded aluminum parts as fo110ws:
a. S01vent degrease surfaces in accordance with paragraph 4-61 to remove

b. Immerse parts in soap c1eaning solution (paragraph 4-47) for at 1east 5

minutes. Scrub surfaces with stiff brist1ed brush to remove 100se surface so11.
Remove softened gaskets with too1 b1ade; scrape surface c1ean.
c. Rinse parts in warm tap water at 80° to 110°F (27° to 43°C).
d. Treat parts with chromic-nitric pick1e solution (paragraph 4-49) unti1

corrosion spots are removed, usua11y 5 to 10 minutes.
e. Rinse in co1d tap water.

f. Anodize in accordance with MIL-A-8625.
g. Rinse in tap water and b10w parts dry.
h. Store parts dry and away irom cQ~;osive fumes.
4-78. MAGNESIUM PARTS NOT CORRODED.
4-79. C1ean non-corroded magnesium parts as fo11ows:
a. Solvent degrease surfaces in accordance with paragraph 4-61, or vapor de-

grease in accordance with paragraph 4-62 to remove oi1 and grease contamination.
b. Immerse parts in soap soI11tion (paragraph 4-47) or heavy duty aIka1ine

c1eaner solution (paragraph 4-51) for 10 to 15 minutes. Scrub surfaces using stlif
bristIed brush to remove Ioose so11; 1ift softened gaskets and seaIing compounds
with tool b1ade and scrape cIean.
4-65
NAVAIR 03-105-AB-52
c. Rinse in warm tap water at 80° to 110°F (27° to 43°C).
d. Touch up bare metal surfaces by brushing on Dow Treatment 19 (Dow

Corning Corp, S Saginaw Rd, Mid1and, MI 48641, or equiva1ent). Keep surfaces wet
for one to two minutes, then rinse with c1ear tap water.
e. Oven dry parts for one hour at 200° +25°F (93° +4°C) to remove a11 traces
of moisture within 8 hours.
4-80. CORRODED MAGNESIUM COMPONENTS.
4-81. REMOVAL AND PREVENTION OF LOCALIZED CORROSION FROM MAGNESIUM COMPONENTS.
4-82. Remove and treat 10ca1ized corrosion of magnesium components as fo110ws:
a. Solvent degrease in accordance with paragraph 4-61, or vapor degrease in

accordance with paragraph 4-62 to remove 011 and grease contamination.
b. Immerse parts in soap solution (paragraph 4-47) or heavy duty a1ka1ine

c1eaner solution (paragraph 4-51) for 10 to 15 minutes, and scrub surfaces using
stiff brist1ed brush to remove 100se soi1. Lift softened gaskets and sea1ing com-
pounds with too1 b1ade, and scrape c1ean.
c. Rinse in warm tap water at 80° to 110°F (27° to 43°C).
d. B10w excess water from surface of part, and oven dry for one hour at
200° +25°F (93° ±4°C) to remove a11 traces of moisture within 8 hours.
e. G1ass bead peen corroded areas in accordance with paragraph 4-63.
NOTE
01d paint coatings may be removed by the use of paint

remover and 10ca1ized corrosion may be removed by hand
finish.
f. Touch up reworked areas by brushing on Dow Treatment 19 (Dow Corning

Corp, S Saginaw Rd, Midland, MI 48641, or equiva1ent). Keep surfaces wet for one
to two minutes, then rinse with c1ear tap water.
g. Oven dry parts for one hour at 200° +25°F (93° ±4°C) within 8 hours.
4-83. REHOVAL OF CORROSION FROM MAGlffiSIUM COMPONENTS HAVING LOOSELY BONDED OR COM-
PLETELY DETERIORATED PAINT.
4-84. Remove corrosion from magnesium components having 100se1y bonded or com-
p1ete1y deteriorated paint as fo110ws:
a. Solvent degrease in accordance with paragraph 4-61, or vapor degrease in

accordance with paragraph 4-62 to remove oi1 and grease contamination.
4-66
NAVAIR 03-105-AB-52
b. Strip paint from parts in accordance with paragraph 4-63 or paragraph

4-67.
c. Immerse parts in heavy duty alka1ine c1eaner solution (paragraph 4-51)

for one to two minutes.
d. Rinse parts in c1ean tap water.
NOTE
Anodic coated parts shal1 bypass steps e. through g.
e. Immerse parts in chromic acid pick1e solution (paragraph 4-55) for one to
five minutes. Rinse parts in c1ean tap water.
f. Immerse parts in hydrof1uoric acid pick1e solution (paragraph 4-53) for

one to two minutes.
g. Rinse parts thoroughly in clean tap water.
h. Treat parts by either one of two fo11owing processes.
(1) Treat parts for 10 to 15 minutes with Type 111 dichromate treatment
in accordance with MIL-~3171.
(2) Treat parts by immersing in Dow Treatment 19 (Dow Corning Corp, S
Saginaw Rd, Mid1and, MI 48641, or equivalent) for l5 to 45 seconds, and rinsing in
c1ean tap water at 50° to 90°F (10° to 32°C).
4-85. CLEAllING DF PLAIN AND STAINLESS STEEL PARTS.
4-86. C1ean p1ain and stain1ess stee1 parts as fo110ws:
a. Solvent degrease parts in accordance with paragraph 4-61 to remove oil

and grease contamination.
b. Immerse parts in rust stripper (paragraph 4-48) for 10 minutes.
c. Remove parts from stripper, rinae and acrub with bristled bruah.
d. Immerae parta in rust stripper for an additional 5 to 20 minutes.
e. Remove parts from ruat stripper and rinse thorougbly in clean tap water
at 80° to 110°F (27° to 43°C).
f. Dry parta by blowing with c1ean, compressed air or in oven. Preserve

parts in accordance with paragraph 4-87.
4-87. PRESERVATION OF STEEL PARTS AFTER CLEANING. ,
4-67
'lo
NAVAIR 03-105AB-52
4-88. Low alloy steel parts, such as gears and sbafts, that w111 be subjected to
magnetic particle 1nspect10n w1th1n e1ght hours may be left dry unt11 1nspected.
Place in clean container.
4-89. Low alloy steel parts that w111 be subjected to magnet1c particle 1nspection
but will be held 10nger than e1ght hours prior to 1nspect1on sball be coated w1th
011 VV-K-220. Place in clean conta1ner.
4-90. Low alloy steel parts not subject to 1nspect10n and those that have completed
1nspection, shal1 be d1p coated w1th corros1on-prevent1ve compound MIL-C-15074 for
three to five minutes. Place in a clean conta1ner and store away from m01sture and
corrosive fumes.
4-91. Stainlesa ateeI and heat res1atant a110y parts, such as turb1ne wheels, shall
be kept dry and boxed for protection from physical damage.
4-92. Sta1n1ess steels of the 400 series sbal1 be d1p coated with corros1on-
preventive compound MIL-C-15074 for three to five minutes. Box in clean container.
4-92A. CHROMATE CONVERSION COATING.
4-92B. Applieation of ehromate eonversion eoating by immersion of aluminum alloy parts in

solutions of MIL-C-81706, Class lA material shall be aecomplished as follows:
a. Parts to be treated shaU be free ofheavy grease and oU deposits, soHs, and oxide deposits.
WARNING
I, 1, I, triehloroethane, MIL-T-81533, vapors can be fatal. Use only

anesthetic and dangerous to life. Eye irritation and dizziness are
b. Remove light oi1 and grease deposits by vapor degreasing in a vapor degreaser using
inhibited 1,1,1, trichloroethane in accordance with paragraph 4-62.
c . Immerse in the si1icate soap solution at 180° - 200°F for 15 minutes followed by a cold water
rinse in an overflow tank.
d. When required, parts shall have anodic coatings removed in the Smut-Go #4 solution.
e. Immerse parts in the chromate conversion coating immersion bath for 2 to 5 minutes.
f. Remove and al10w to drain thoroughly to reduce drag-out, then rinse thoroughly in cold
running water to remove any entrapped solution.
g. Rinse in the acidulated rinse bath for 15 to 30 seconds.
4-68 Change 2
NAVAIR 03-105AB-52
(1) The 0.06% chromic acid dip used in application of Military Specificstion MIL-C-
13924 Black Oxide Coatings may be used in lieu of the acidulated rinse bath if facilities for acidulated
rinse are not available.
CAUTION
When 6rst formed, the eoating is gelatinous in nature and ean

easily be removed by touching or handling. Allow the coating to dry
prior to handling or transporlation.
h. Parta in wbich there is no danger of entrapment of solution may be air driedj this may be
speeded by use of clean dry compressed air. Parta may be oven dried at temperatures not to exceed 150°F
i • Following application of chemical file treatment, parta which are to be painted

immediately shall be handled with clean cotton gloves.
4-92C. Application of chromate conversion coating touch-up to aluminum alloy shall be done as
follows:
a. Remove oil and grease deposita with solvent dampened, clean lint-free cloths from the
area to be treated
b. Remove oxide film with Scotch Bright padi wet with water, then rinse with water.
e. While still wet, apply chromate conversion coating brush-on solution keeping the area to
be treated wet with the brush-on solution for 3 to 5 minutes.
d. Rinse thoroughly with water.
4-93. INSPECTION.
AGE REQUIRED
FUEL ATOMIZER ADAPTER 285497-1-1

FUEL NOZZLE TESTER 285496-1-1
MULTIMETER, MODEL 260 Simpson E1ectric Co,
Division of American
Gage and Machine Co,
5200 W Kenzie St,
Chicago, IL 60644
I[ OHMMETER, LOW VOLTAGE AN/USM-21A
REGULATOR TEST ADAPTER 280384-4
Change2 4-68A
NAVAIR 03-105AB-52
4-94. The methods and procedures presented are recommended by the manufacturer to
facilitate repair of the jet fuel gas turbine engine starter. The information is
presented as a supplement to the knowledge acquired by competent personnel. Pro-
cesses or procedures which are considered general or common-place are omitted. ~
However, due to the precision equipment involved, it is necessary that alI instruc-
tions detailed herein be careful1y eva1uated and c10sely fo110wed. Frequent refer-
ence should be made to paragraph 4-115 during inspection, repair and replacement
procedures to determine if parts can meet minimum or maximum limits of fit toler-
ances. Lo08 life and continued efficient operation of the starter depend upon the
care and accuracy with which inspections are conducted, repairs and replacements
accomplished, and calibration performed.
4-95. GENERAL INSPECTION INSTRUCTIONS.
4-96. PROCEDURAL STEPS OF INSPECTION. Procedural steps of inspection are left en-
tire1y to the judgement of the inspector, since it is assumed that each individual
Change2
NAVAIR 03-105-AB-52
has acquainted himself with certain basic requirements and has formulated a syste~
under which he can work ~ost efficiently. However, it is suggested that require-
ments established and referred to in this section be accepted as the basis upon
which alI inspection is undertaken.
NOTE
After inspection, preserve alI steel parts in accord-

ance with paragraph 4-87.
4-97. INSPECTION RECORDS. Good shop practices include the compilation of complete
and accurate inspection records. Such records not on1y expedite r~fl)rking of the
equipment but lend assurances of a complete and thorough overhaul. It is suggested
that inspection records be based upon the requirements presented in this section
and that parts requiring rework or replacement be so tagged and 8 notation of the
disposition of these parts be entered on the inapection recorda. The asme ~ethod
is suggeated for parts requiring special treatment, such as magnetic or fluorescent
inspections, painting, cadmium plating, etc.
4-98. VISUAL INSPECTION. A visual inspection involves viewing the part for general
appearance in an effort to locate conditions which cause abnormal wear. Such con-
ditions may be any of those mentioned in table 4-1. t~enever these conditions
exist, the inspector should refer to dimensional inspection figures related to the
damaged part and decide if rework ia feasible. Where no evidence of damage or wear
is present the inspector should detemine if dimensional inspection is requiree.
After a decision has been reached, the part should be tagged accordingly and dis-
posed of in the manner utilized by the particular facility. The disposition of the
part should then be noted on inspection records. Parts which are normally replaced
at each overhaul should be given a cursory inspection, since damage to these parts
may reflect malfunction of other components in the starter. This possibility should
be considered when any part has been damaged.
Table 4-1. Table of General Physical ConditiollS
Term Definition Probable Cause
Abrasion. A roughened area. Can be defiped Foreign particles between mov-

as 1ight to heavy dependent upon inS parts.
amount of rework necessary to
restore surface.
Blistering. Raised areas indicating separation Imperfect bond with base.

of the surfaces of ball or roller Usually aggravated by presence
bearing parts. of moisture, gas heat or pres-
sure.
4-69
NAVAIR 03-l0S-AB-S2
Table 4-1. Table of General Physica1 Conditions (Cont)

--------------------------------------------------------------------------------------
Tem Definition Probab1e Cause
Brinel1ing. Indentations sometimes found on Improper asserncly or dis-

surfaces of ball or ro11er bear- assembIy techniquie, such
ing parts. as removing or installing
a roller or ball bearing
by pressure on free race.
NOTE
Bearings which do not have

full constant rotation and
are subjected to shock load-
ing have brineI1ing tenden-
cies.
Burning. Injury to surfaces by excessive Improper clearance or lack

heat. Evidenced by discolora- of lübrication due to
tion or somet~es by flow or plugged oi1 passages,
10ss of metal. etc.
Burr. A sharp projection or rouch edge. Excessive wear and careless

handling.
----------------------------------------.------.--------------------------------~------
Chafing. A rubbing action between two Improper asse~cly tech-
part:s having a limited relative niques; improper fits,
motion.
Chipping. Breaking out of small particles Careless handling of parts;

of metal. concentration cf stresses
due to shock t nid.s,
scratches, etc.
Corrosion. Breakdovn or pitting of sur- Improper surface treat-

faces by chemical action. ment, wear, or dan~ge to
treated surfaces.
4-70
NAVAIR 03-105-AB-52
Table 4-1. Table of General Physical Conditions (Cont)
Term Definition Probable Cause
Crack. A partial fa11ure. Excessive stress due to

shock, overloading, or
faulty processing; exten-
sioo of a nick or scratch;
defective material over-
heating.
Dent. Small smooth1y rounded hollow Careless handling of

in surface. parts.
Erosion. Carrying away of material by Blow-bYj flow of corroding

the flow of hot gases, grit, liquids, hot gases, or
or chemical. grit laden 011.
Flaking. Breaking away of pieces from Incomplete bondj exces-

plated or painted surfaces. sive loadj blistering.
Galling. A transfer of metal from one Severe chafing actionj

surface to another. metal particles from rel-
ative parts embedded in
opposite surfaces.
Grooving. Smooth rounded surfaces, Concentrated wearj parts

such as score marksj whose out of aligament.
sharp edges have been
polished off.
Metal Formation of high spots be-

Bu11dup. tween stationary and rotating
parts.
Nicks. A sharp indention. Careless handling, or

fine foreign particles in
unit during operation.
4-71
NAVAIR 03-l05AB-52
Table 4-1. Table of General Phys1eal Conditions (Cont)
Term Def1nition Probable Cause
Peening. Deformation of the surfaee. Repeated impaet of foreign objeet;

misalignment of rotating parto
Seoring. Deep seratehes. Presenee of foreign partieles be-

tween surfaees having relative
motion.
Seratehes. Narrow, shallow marks on Careless hand11ng, foreign par-

surfaees. tieles in unit during operation.
CAUTION
Do not use wax base penei1s for marking on high temper-

ature al10y parts. Carbons in wax peneils are detri-
mental to parts.
4-99. WELDED, BRAZED, OR SOLDERED ASs~rnLIES. Visual1y inspect alI welded, brazed,
or s01dered assemb1ies for seeurity of joints.
4-100. TUBES AND FITTINGS. Visua11y inspect alI tubes for kinks, cracks, chafing,
signs of corrosion or other damage. Inspect alI fittings for broken threads, chip-
ping and e1eanliness.
4-101. ELECTRICAL WIRING. Visually inspect alI electrical wiring and ~r~ng har-
ness for ímproper insulation and excessive corrosion. Inspect plugs and recep-
tacles for damaged contacts, bent or broken probes, burns, or other damage.
I 4-l0lA. CIRCUIT BOARD ASSEMBLIES. Visua11y inspect circuit board assemblies for
eraeks, chips, and burned or broken components. Inspect for 100se solder connec-
tions, corrosion, deterioration and other visual evidence of damage.
4-102. BRACKETS AND SUPPORTS. Visua11y inspect brackets and supports for distor-
tion and tom or elongated bolt holes.
4-103. LOOP CLM~S. Visua11y inspect loop c1amps for distortion, torn or elongated
bolt holes and missing, deteriorated or distorted insulation.
4-104. THREADED FASTENERS. Visual1y inspect bolts, screws, nuts, inserts, studs,
nut plates, ete, for corrosion, d1stortion and crossed, peened, stripped or worn
threads. Inspect studs, inserts and nut plates for security.
4-105. BEARINGS. Inspect starter ba11 and ro11er bearings in accordance with
NAVAIR 01-lA-503 and as follows.
4-72 Change 1
•
NAVAlR 03-1C5-AB-52
WARNING
Spray vapors are toxic and must not be inha1ed.

a. Rotate bearing and check for smooth operation. Wash bearing with solvent
spray, P-D-680, Type 11, if rotation is not smooth. Recheck bearing for smooth ro-
tation. Oi1 bearing with 1ubricating oi1, lITL-L-780e, after washing.
b. Visua11y inspect for rusting or fretting corrosion.
c. Visually inspect outside cylindrical surface of bearing outer ring and

bore of bearing inner ring for scores.
4-106. GEARS. Visua11y inspect gear wear patterns for abrasion, burning, chipping.
galling or other damage.
4-107. OIL REFUSE. Inspect 011 drained from the starter prior to disassembly for
evidence of excessive metal particles. lf excessive metal particles are found in-
ternaI demage to the starter should be suspected. Check magnetic drain plugs for
metal chips prior to cleaning.
4-108. }fAGNETIC PARTICLE INSPECTION.
4-109. A magnetic particle inspection of specified criticaI steel parts i8 required

at each overhaul. This inspection should be conducted in accordance w1th ~L-I-6868
but only after a c10se visual inspection of a part has revealed no defects. Th1s
procedure wi11 e1im1nate the time requ1red to perform a magnet1c inspect10n on
obviously defective parts.
4-110. FLUORESCENT PENETRANT lNSPECTlON.
4-111. A f1uorescent penetrant inspect:f.on of specified criticaI non-ferrous metal

parts is required at each overhaul. This inspection shou1d be conducted in accor-
dance with MIL-I-6866, but on1y after a c10se visual inspection of the part has re-
vealed no defects. This procedure will e11m1nate the time required to conduct fluo-
rescent penetrant inspections of obv1ously defective parts.
4-112. Ba11 bearings, oi1 and grease seals, rubber parts, packings and gaskets
that are not covered by specific inspect10n instruct10ns (paragraph 4-115) sba11 be
rep1aced at each overbau1.
4-113. Before d1scard1ng removed bear1ngs, they should be checked for roughness,
br1ne111ng and for damaged races and retainers. Evidence of ·these cond1t10ns 1n-
d1cates poss1bi1ity of addit1ona1 damage to re1ated parts, such as rotating assem-
b11es, along w1th the possibility that 1mproper fits, ·to1erances or assemb1y
procedures may exist and may be caus1ng malfunct10n within the engine.
4-114. Parts that have special gasket seal o-rings bonded into their surfaces NUSt
be replaced at each overhaul. Rep1aced parts of this type shou1d be returned to
stores for disposition.
4-73
NAVAIR 03-105-AB-52
4-115. SPECIFIC INSPECTION INSTRUCTIONS. Refer to tab1e 4-2.
4-116. IHSPECTION OF ~~JOR STARTER ASS~mLIES (figure 4-2).
4-117. Visua11y inspect c1amp coup1ing (1, 3, 4) for cracks, kinks, broken we1ds,
and damaged bo1t.
4-118. Inspect engine starter mounting f1ange (2) as fo11ows:
a. Visua11y inspect engine starter mounting flange for cracks and corro-
sion, inspect for chipped, cracked or pee1ed paint, and scratched, scored or worn
mating surfaces.
b. Dimensiona11y inspect in accordance with figure 4-15.
4-119. Inspect power turbine assemb1y (5) in accordance with paragrapr. 4-122.
4-120. Inspect gas generator and accessory drive assemb1y (6) in accordance with
paragraph 4-176.
4-121. Visua11y inspect identification p1ate (7) for security and 1egibi1ity.
4-122. INSPECTION DF PO~~R TURBINE ASSn·$LY (figure 4-3).
4-123. Visua11y inspect identification plate (1, sheet 1) for security and legi-
bi1ity.
4-124. Visual1y inspect output shaft retainer (3, sheet 1) for cracks, nicks and
distortion. Dimensiona11y inspect distance between tangs at narrowest point for
measurement within 0.70 to 0.80 incho
4-125. Inspect output shaft assembly (4) as follows:
a. Visual1y inspect output shaft assembly for nicks, chips, cracks and wear
through to base metal.
b. Dimensiona11y inspect sp1ines as follows if visual inspection reveals

base metal wear.
(1) P1ace two 0,0800 inch diameter pins in wear area of opposite Rpline
grooves on starter end of shaft. Ch~ck for minimum dimension of l.15~~ over pins.
(2) Place two 0.08ÁO inch diameter pins fn wear area of opposite spline
grooves on engine end of shaft. Check for minimum dimension of 1.3009 over pins.
c. Perform magnetic partic1e inspection in accordance with MIL-I-6868.
4-126. Inspect switch actuating governor assemb1y (5) in accordance with paragraph
4-319.
4-74
NAVAIR 03-105-AB-52
Tab1e 4-2. Tab1e of Inspection and Repair Procedures
z
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Index NOo 2 Fiaure 4-2 Jet Fue1 Gas Turbine Engine Starter AssI
1, 3, 4 C1amp Coup1ings 4-117 4-399 Stee1 17-7PH
2 Engine Starter 4-15 4-118 4-400 Aluminum

110unting Flange Alloy
7 Identification P1ate 4-121 4-403
Index no o 2 Figure 4-3 JFS Power Turbine Assy
1 Identification P1ate 4-123 4-405
3 Output Shaft Retainer 4-124 4-406 CRES 302
4 Output Shaft Assemb1y X 4-125 4-407 Steel MIL-S-

5000 (4340)
5 Switch Actuating 4-126 4-598

Governor Assemb1y
6 Quick Release Pin 4-127 4-409
8 Oil Dip Stick 4-128 4-410 Al Alloy

6061-T6
9 Lubrication Instruction 4-129 4-411

P1ate
10, l i Oi1 Fil1er nousing 4-130 4-412 Al Alloy

6061-T6
4-75
NAVAIR 03-105-AB-52
Tab1e 4-2. Tab1e of Inspection and Repair Procedures (Cont)
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::t:t.:l :;;)t.:l ~t.:l c...t.:l u::
.... c::: c..cr:: t:l0::: <
~e
t-ItI)
Q- ~- ti) - CI::- =:I
Index No., Figure 4-3 (Cont)
15, 17 Rose C1amps 4-131 4-413
16 F1exib1e Rose 4-132 4-414
18 F1uid Passage Bo1t 4-133 4-415 CRES 303
21 Magnetic P1ug 4-134 4-416
22 Oi1 Drain Adapter 4-135 4-417 CRES 347
26, 27 E1ectrica1 P1ug 4-136 4-418

Connector
30 lImnersion Thermo- 4-137 4-419

coup1e
40, 41 Switch Cover 4-138 4-420 Al alloy

Assemb1y 6061-T6
43 E1ectrica1 Insu1a- 4-139 4-421

tion Sleeving
45, 47 P1ugs 4-140 4-422
53 Containment Support 4-141 4-423 Stee1 CRES 347

Assemb1y
54 Therma1 Insu1ation 4-142 4-424

Batt
4-76
• tlAVAIR 03-105-AB-52
Table 4-2. Table of Inspection and Repair Procedures (Cont)
Z
o
.....
E-I
= - o
=
o
.....
E-Ial
00
rzlr-4
p..1
l:Z:l
j;I,,-
til O
Zr-f
..... r-f
- -.
o• o
z
~:
Z
o tIl..;t E-I
H
E-I
O ~=
~~
:ti
;~
==
rzl
p..- ~~ ~~ ..... ~
120
H= ~~ ~~
~p..
~~
p..p..
~~
~p..
~a
o
j;I"
O ~~
OE-l
HU
til
Zrzl
~U
rzl
~
~~ ~!
C,!) OE-l
..... H
~
H til
tIlllr.! E-I~ 1:Z:l~
~1:Z:l ..... rzl
f;l~
Z HI:Z:l
Ollr.! <~
~e
O~ rzl
~e 9~ ~~ ~e
~'-' ~'-' til '-' ~
Index No. , Figure 4-3 (Cont)
55 Power Turbine Con- 4-16 4-143 4-425 Titanium

tainment Shield
Assembly
56 Heat Shie1d 4-144 4-426
57 Turbine Diffuser 4-145 4-427 CRES 347
63, 64 Bracket Assembly X 4-146 4-428 AI alloy

356-T6
70 "Bearing Retainer 4-147 4-429 Stee1 1010
74 - 78 Engine Starter 4-17 4-148 4-430 AI al10y

Hcusing Assembly 356-T6
79 - 82 Engine Starter 4-149 4-431

Drive Shaft Assembly
83, 84 Exhaust llousing 4-18 X 4-150 4-432 Steel CRES 347
Assembly
86 Ring Gear Lockring 4-151 4-433
89 InternaI Gear Hub 4-19 X 4-152 4-434 Stee1 4340
91 Lock Ring 4-153 4-435 AI a110y

6061-T6
4-77
•
NAVAIR 03-105-AB-52
Z
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uo
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U
r:J
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Cl)O
z ....
........ -. -.
o o
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....o CI)~
Z
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~~
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r:J
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t~ ~~ ffiê2
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t-IZ ~~ ~~ ~<
~~ ~~ ~Il-t r:J~
...::Ir:J CI) ~
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o r:JO i-IU ~U
OC
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t-I
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CI)
Z
....:Ir:J
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~
fSr:J
Cl)f,:t; ~~
r:Jr:J
r:J~
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t-Ir:J
~~
1-Cr:J
l:
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r:Jr:J Z~ O~ U~ <f,:t; r:J
l:r:J ::Jr:J r:Jr:J ~r:J
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ti)
HCIl ...::I~ ~~ r:J~ <
~-
CQ
~- ~- CI)'-'
94 Insu1ator P1ate 4-154 4-436
96 Sensitive Switch 4-155 4-437

Assemb1y
98 Switch Actuating 4-156 4-438 CRES 347

Lever
99 Bearing Support 4-20 4-157 4-439 Stee1 4340
101, 125 Nuts 4-158 4-440
102 Pinion Spur Gear 4-21 X 4-159 4-441 Steel AMS6260
103 - 104 Axial Flow Turbine 4-22 X 4-160 4-442 Stee1, Nicke1
Whee1 Assembly Base, Cond B
105 Insu1ation Cover 4-161 4-443 CRES 347
107 Sea1 Retainer 4-162 4-444 CRES 347
108 Jet Fuel Starter 4-23 4-163 4-445 CRES 347

Therma1 Insula-
tion B1anket
112 Turbine Whee1 Seal 4-24 4-164 4-446
114, 120 Spring Seats 4-165 4-447 Stee1 4130
4-78
I
NAVAIR 03-105-AB-52
z
oI-t
~
Z o
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o J:I:1
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• o•
00 Z,...f
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~~ m~
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til
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til
~
ZJ:I:1 J:I:1
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oz
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o~ o~
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t-It-I J:I:1
t::~
til
tIl~
~~ eí~
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t-IJ:I:1
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o~ o~ <~ ~
~-
~=
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til -
~e ~
116 Resi1ient Ba11 4-25 X 4-166 4-448 Steel 4340

Bearing Housing
117 Resi1ient Mount 4-26 X 4-167 4-449 Stee1 4340

Liner
121 Compression He1ica1 4-168 4-450 CUS 11-1PH

Spring
122 Bearing S1eeve 4-27 4-169 4-451 Stee1 4130
Spacer
129 Spur Gearshaft 4-28 X 4-170 4-452 Stee1 AMS6260

130 Matched"P1anetary 4-29 X 4-111 4-453 Stee1 AMS6260
Spur Gear Set
131 Interna1 Spur Gear X 4-172 4-454
132 Bearing Spacer 4-173 4-455 Stee1 4340
134 Annu1ar Ba11 Bearing 4-114 4-456
136 - 141 Gear Carrier 4-30 4-175 4-457 Al al10y

Assemb1y 355-T6
Index No., Figure 4-4 Gas Generator and Accessory Drive Assemb1y
1 Identification ~1ate 4-177 4-459
4-79
NAVAIR 03-105-AB-52
Z
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f-<
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o
uo
r.:J,...j H ,...j O O
Z fl..1 I Z Z
O Cf.) ..;t f-<..;t f-<
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t~
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t;~
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fl..<
r.:Jfl..
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~~
Cf.) ~
Il. Z Zr::! r::! ....:I
HU er:::U
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H H
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f-<
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Zrz.. Orz.. Urz.. <rz.. r::!
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r::! r::! r::!
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/:l.cr::l
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~e <
til
C'-' rz..- tIl- er:::- CQ
Index No. z Figure 4-4 (Cont)
15 Filter Bracket 4-178 4-460 A1 a110y

6061-T6
19 Pressure F1uid Fi1ter 4-179 4-461
22 Check Va1ve 4-180 4-462 A1 a110y
29 Restricted F10w 4-181 4-463

Check Va1ve
40 Igniter P1ug 4-182 4-464

E1ectrica1 Lead
41 Capacitor Discharge 4-183 4-465

High V01tage
Ignition Unit
45 Gas Turbine Engine 4-184 4-466

Igniter P1ug
49 Accumu1ator Assemb1y 4-309 4-467
54, 55 Accumu1ator Mounting X 4-186 4-468 A1 a110y

Bracket 356-T6
56 JFS Control Box 4-292 4-469

Assemb1y
62, 78 Support Bracket X 4-190 4-472 A1 a110y

KD-1-T6
4-80
1-
NAVAIR 03-105-AB-52
~
o
1-4
E-I
lZ'õ o
o
-. -.
rz::I
1-4 "'"' Pot"'"'
E-IClO CIlO
UO Z.-I
CI:1.-1
p.,t
1-4.-1 o o
lZi lZi lZi
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o CIl..:t E-I
1-4
E-I
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== ~==
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1-4=
~~ rz::I~
U
rz::I
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p.,
CIl "'"'
~a re~ ~~ tPocj~
•
lZiO
~Pot
I-4lZi
p.,Pot
E-IPot
ª~ t1=
elI:I
!i2rz::1
~o
~
Pot rz::I
o I-4U elI:IU
~ã
uE-l UE-l
~~
00
~
1-41-4 1-4 CIl
~: == Z~ O~ u~
1-11:1:1
J'Zl
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:E:J'Zl CIl
I-4C1l
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CIl - iª :i
Index No •• Figure 4-4 (Cont)
74, 90 Turnbuck1es 4-189 4-471 Al alloy

6061
79, 73 Rod End Bearings 4-188 4-470
86, 89
92 Plug 4-191 4-473
120 Sp1ined Straight 4-192 4-474 Stee1 4340

Sbaft
126 JFS Branched 4-193 4-475

Wiring Harness
Assembly
128 AC-DC Permanent 4-194 4-476
Magnet Generator
Index No., Figure 4-5 Jet Fuel Starter Gas Generator Assy
1 Compressor Inlet 4-198 4-480 Ring-CRES 321

Screen Assy Screen-CRES
RR-C-440
2 Bose Clamp 4-199 4-481
3 Impel1er Shroud 4-200 4-482 Al a110y

356-T6
4-81
NAVAIR 03-105-AB-52
Table 4-2. Tab1e of Inspection and Repair Procedures (Cont)
z
o
~
~
z U
-. -.
o ~
~- /:l.<-
~CXl cnO
uo Z~
~,..j ~,..j o o
Z Il.< I I Z Z
o cn..::r E-<..;t E-<
~ Z Z :z: z:z:
E-< ~:z: Il.< ~Il.<
~s:
~~ ffi~
U Il.o
~~
~
~- . ~~ ~o uo
cn uo zc.:> t;~
zo
HZ ~~ ~~ ;zJ<
Il.<Il.o
~~
~~
r.zJ~
~~ E-<Il.< cn ~
~~ /:l.< Z Z~ ~ ~
o ~o
~
~u ~u
o c.:> UE-< UE-< Z OZ
H~ ~ cn ~~ ~ ~
cn~ E-<~
~~
~o::
~~
<o::
Hr.:I
~~
Hr.:I
l::
Z
r.:Ir.:I Z~ O~ urz.. <~ ~
:t:~ t.:ir.:l ~~ ~~ 1l.4~ V.
.... cn
~~ ~~ Il.<~
cr. '-'
;zJ~ <
~'-' ~'-' ~- ~
4 F1uid Passage Bo1t 4-201 4-483 CRES 17-4PH
6 Fue1 Manifo1d 4-202 4-484 CRES 347

Assemb1y
8 Fue1 Nozz1e 4-203 4-485 CRES

Assemb1y
22 Manual Prime Norma11y 4-204 4-486

CIosed Solenoid
Va1ve
15, 27 Solenoid Mounting 4-205 4-487 CRES MIL-S-

Brackets 5059
30 Norma11y Open 4-206 4-488

Solenoid Valve
32 OU Strainer 4-207 4-489 Adapter, CRES

AssembIy 302; Screen,
CRES 304
RR-W-360
37 Tower Shaft Cover 4-208 4-490 AI alloy,

QQ-A-591
4-82
1
NAVAIR 03-105-AB-52
z
o
H
E-t
Z O
-. -.
O ~
H_
E-tClO ~-
CIlO
00 ~..-l
~..-l H..-l O O
Z ~I Z Z
~:
O CIl~ E-t
H Z 1:1:1 ZI:I:I
H 1:1:1
~~ I~
E-t
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~
~~ :ziC,!)
t~ HCl
~~
~-•
~~ ~~
CIl
~~
ZO
HZ
~~ ~~ ~p..
t~ CIl Il'\~
~~
o C,!)
p..
O ~O
Z~
HO 1l'\0
O~ ~
~!
OE-t OE-t
HH H CIl
CIlr:r.t HIl'\
IZ1IZ1
~Il'\
Il'\IZ1 HIZ1
Il'\Il'\
HIZ1
~
Z
<~
Zra. Ora. Or:r.t lZ1
~~ ~e =:1 ~:1
Q- fi- CIl - ~- ~
eQ
39 Power Turbine Stator 4-31 X 4-209 4-491 Barrier,

Assemb1y HAYl:IES 25;
Ring, CRES 321
Support,
HAYNES 25;
Casting,
Incone1 713C
40 Gas Generator Con- 4-32 X 4-210 4-492 Titanium

ta1nment Shie1d
Assemb1y
43 Shie1d Retainers 4-211 4-493 A1 a110y

6061-T6
47 Shroud Retaining 4-212 4-494 CRES 321 or
Ring 347
49 Impe11er Shroud 4-33 4-213 4-495 A1 a110y

6061-T6 or
T651
54 Jet FUe1 Starter 4-34 X 4-214 4-496 Al a110y

Housing Assemb1y Ko-1-T6
54A Ident1fication P1ate 4-215 4-497
57 Interna1 Wrenching 4-216 4-498 C~ 17-4PH

P1ain Nut
4-83
1
NAVAIR 03-105-AB-52
Z
o
1-4
E-I
Z U
-. -.
o _
1-4 ~
Il.._
E-IOO 000
u o Z,....j
(;I:J,....j 1-4-1 o o
Z ~I I Z Z
o OO.;t E-I.;t E-I
1-4 Z Z :%: z:%:
E-I 1-4:%:
~~
Il.. ~Il..
U
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(;I:J
Il..-
til . ~~
UC,!)
t;~
zC,!)
1-4t-'
t;~
Ut-'
j~
1-4~ g:~
ZO
1-42: (;I:J<
..:I(;I:J
t<Il.. <
E-tll..
Il..Il..
til
Il..<
(;I:J1l..
ex:
<~ Il.. Z Zr..:l r..:I ..:I
Z::l o r..:IO, I-4U ex:u <
ot-' UE-t UE-I Z OZ E-I
1-11-1 1-4 00 ..:Ir.::! (;I:J ::.l
oo~
Z
E-Iex:
r..:Ir..:I
r.::!~
~r..:I
<~
1-4r..:1
~~
1-4r..:1
::c
~n:~ <~
Zf.I.. 0f.I.. U~ r..:I
t-'r..:I ::l~ f::Ir..:I Il..~ 00
1-1 til
~e ..:I~ Il..~ a:
r.::! <
Q- f.I..- til - a:- =:I
58 Compressor Impel1er 4-35 X 4-217 4-499 A1 a110y

C353
66 Bearing Retaining 4-218 4-500 Stee1 4340

P1ate
69 Spinner Locking 4-219 4-501 CRES 303

Shaft
70 Compression Spring 4-220 4-502 Inconel X Wire
72 Axial F10w Turbine 4-36 X 4-221 4-503

l-lheel Assemb1y
74 Annu1ar Ball Bearing 4-105 4-504
75 Bearing Carrier 4-37 4-223 4-505 Stee1 4340
77 Pinion Spiral Beve1 4-38 X 4-224 4-506 Stee1 A..\fS6260

Gear
78 Bearing Spacer 4-39 X 4-225 4-507 Steel 4340
80 Seal Be110ws Retainer 4-226 4-508 CRES 347 or

321
81 First Stage Stator· 4-40 X 4-227 4-509 Steel 4340

Assemb1y
4-84
1
NAVAIR 03-105-AB-52
Z
o
H
E-I
Z t)
~
O
H_
E-ICO
00
1Zl,...,
fl.ol
tIl~
lZl
~'""
til
Z"'"
O
H,...,
E-f~
I
O
Z
.
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-.
O
Z
H
E-I
Z
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~= ~~
= i~
~~ ~~
t)
lZl
t-IC
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~~ ~~ ~~
til
ZO
HZ
~~ ~Poc
Poc~
~~
E-I~ til
ZIZl
~O
~
lZl
O HO ~O
HH
OE-l
H
OE-f Z
:;J~
015
~
til
tIl~ E-I~ 1Zl~ ~~
HIZl
8~
IZlIZl ~1Zl HIZl
Z~ O~ O~ <~ lZl
~e ~e ~~
=e
til
~- tIl- ~
82 Heat Shie1d 4-228 4-510 CRES 347
83 Sea1 Retainer 4-229 4-511 CRES QQ-S-763

85 Turbine Gas-Oi1 Sea1 4-41 4-230 4-512
88, 89 Bearing Carrier 4-42 X 4-231 4-513 Stee1 4340

Assemb1y
90 Compression He1ica1 4-232 4-514

Spring
93 Oi1 Tube Assemb1y 4-233 4-515 CRES 347

97 Fue1-Air Combustor 4-43 X 4-234 4-516 CRES N155
Assemb1y
102 Tower Shaft Cover 4... 235 4-517 A1 a110y
356-T6
107, 108 Spira1 Beve1 Gear 4-44 X 4-236 4-518 Stee1AMS6260
Assemb1y
111, 112 Sleeve Spacers 4-237 4-519 Stee1 4340
114 Bearing Carrier 4-45 4-238 4-520 Stee1 4340
4-85
NAVAIR 03-105-AB-52
:.:
o
H
H
Z U
-. -.
O f::l
H_ Ilo_
HCO til C
UO Z..-I
r:.:1..-1 H..-I O O
Z !lo I I Z :z;
O Cf)..;t H..;t H
H Z ::z::
~~
Z::C
H H::Z:: Ilo tzlllo
U
8~ ffi~
!lo
tzl
!lo-
Cf)
ZO
. ~Q3
U~
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Z~
H~
t;~
UC
:S~
HZ ~~ ~~ r:.:1< Ilo<
~< Il<I=4 ~1=4
Cf)
~~ <1=4
1=4 ~1=4 Zr:.:1 ~ ...:l
ZO
OC UH
O f::lO
UH
HU
Z
r:t:4U
CZ
<
H
HH H Cf) r:.:1
~~
tzl
Cf)~ H~ ~~ ~c:t:: ~
Z r:.:1r:.:1 c:t::r:.:1 Hr:.:1 Hr:.:1
~r:.:1 Z~ O~ U~ <~ ~
C ~"I Or:.:1 c:r.
~~ ~tzl I=4tzl
1:\- ~e ...:l~
~-
1=4~
Cf) -
~~
~- ~
Index NO. I Figure 4-6 Tower Shaft Housing Assemblx
22 Tower Shaft Housing 4-46 4-239 4-521

Assemb1y
Index No., Figure 4-7 JFS Accessory Drive Assembly
1 Identification Plate 4-241 4-523
2 Lubrication Instruc- 4-242 4-524

tion P1ate
5 ~~gnetic Machine 4-243 4-525 Al alloy

Thread P1ug
7 Oi1 Dip Stick 4-244 4-526 Al alloy

6061-T6 or
2024-T4
9 Sedtment Strainer 4-245 4-527

E1ement Assy
16 Compression He1ical 4-246 4-528

Spring
18 Hydraulic .fotor 4-249 4-634
22 5traight Pin 4-247 4-529
23 C1utch Jaw X 4-248 4-530 Stee1 4340
4-86
...
NAVAIR 03-l05-AB-52
Z
oH
E-I
U
~
- -
~
H_
E-IOO Ilo<
000 -
t.>0 Z.-I • •
~
~.-I H.-I O
Z Ilo<I I Z
O tI)~ E-I~ E-I
~g:
H Z=
~= =
~~ I~
E-I
U
rz:I
~~ t1~ H
~~
Ilo<- C!)
~~ !~ ~~
ti) •
~i
51lo< E-I1lo<
Ilo<Ilo< ~Ilo<
~~
00
Zrz:I rz:I
~o ~
Ilo<
O HU P::U
o
~ã
C!) UE-! UE-! o~
~
HH H 00
CIlfzl E-I~ ~~ ~~
p::rz:I Hrz:I
~~
~!
Ofzl UfzI <1":1:1 rz:I
~e 9~ ~~ ~~
ti)
~- fzI- CIl -
:i
Index l~o. I Figure 4-7 (Cont)
24 Main Jet Fuel Starter 4-324 4-604

Fuel Control
Assembly
33, 36 Straight Shafts 4-251 4-533 Stee1
38 Sensitive Switch 4-253 4-594

Assembly
42 Switch Adjusting 4-252 4-534 CRES 321 or

Shims 347
43 - 51 Switch Actuating 4-254 4-536

Governor Assembly
53 Thrust Washer x 4-255 4-537 Steel MIL-S-

7420
55 Spur Gear 4-48 X 4-256 4-538 Steel 4340

58 Spur Gear 4-49 X 4-257 4-539 Steel 4340
60 Spur Gear 4-50 X 4-258 4-540 Stee1 4340
62 Retainer 4-259 4-541 Stee1 4130 or

CRES 301, 302 ,
304
4-87
1
NAVAIR 03-105-AB-52
63 Matched Rotary Pump 4-51 4-260 4-542

InternaI and Exter-
naI Gear Set
65 Lubrication Pump 4-52 4-261 4-543 AI al10y

Cover 6061-T4
66 Drive Shaft 4-53 X 4-262 4-544 Steel 4340
67, 71 Annular Ball Bearing 4-263 4-545
69 Compression Helical 4-264 4-546 CRES 302

Spring
70 Sleeve Spacer 4-265 4-547 Steel 4340
72 Shouldered Shaft 4-54 X 4-266 4-548 Steel 4340
74 Bearing Retainer Assy 4-267 4-549 CRES 347
78 Zerol Pinion Bevel 4-55 X 4-268 4-550

Gear
80, 81 Sleeve Spacers 4-269 4-551 Steel 4340
83 Bearing Carrier 4-56 4-270 4-552 AI alloy

6061-T4 or
T651
4-88
i
NAVAIR 03-105-AB-52
Z
o
1-1
E-c
o
~
-i -
rz:l
H_ Il.t_
E-ICXl CIlO
o•
00 Zr-!
1-1.-1
•
1Z1.-1
Z ~I I Z
o E-I~
i~
tIl~
~=
I-f Z ::ti
E-I I-I:X:
t.,)
rz:l
Il.t_ !j~ t1~ ~~
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~Il.t ~~
til •
::tiO
HZ S~
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til
Zrz:l rz:l
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oz ~
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~
HH H
~tl
til
E-c~
tf.I~
Z
r;lt! ~~ t.,)fr.I
HIZ1
lZ1
~~
Ofr.l <fr.I
=e
PIZ1
~e retl CIl
...:I~
~- ~- tf.I- :i
87, 93, Annu1ar Ba11 Bearings 4-271 4-553

110, 114
88, 112 Compression He1ica1 4-272 4-554 QQ-W-423

Springs
89, 113 Sleeve Spacers 4-273 4-555 Stee1 4340

92, 119 Bearing Carriers 4-57 X 4-274 4-556 CRES 17-4PH
94 Beve1 Zero1 Gear 4-58 X 4-275 4-557 AMS6260
95 Spur Gear 4-59 X 4-276 4-558 AMS6260

100 Paw1s 4-277 4-559 SAE 52100
101 - 106 C1utch Shaf t Assemb1y 4-60 4-278 4-560
107 Gearbox Accessory 4-61 4-279 4-561 Al a110y
Housing Assemb1y 356-T6
115 Spur Gear 4-62 X 4-280 4-562 AMS6260
117 Shou1dered Shaft 4-63 X 4-281 4-563 Stee1 4340

Assemb1y
120, 121 Adapter Housing 4-64 4-282 4-564 Al a110y
Assemb1y A356-T6
4-89
- - - - - - - ._- -------- -
,
NAVAIR 03-l05-AB-52
Table 4-2. Table of Inspection and Repair Precedures (Cont)
Z
o
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~
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O
1-1 _ ~
ll.o_
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C,)
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ti)O
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.
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.
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H::C
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. ~~ ~~
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~~ :3~
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ZO
HZ E:!~ t:~ ll.o<:
ll.o/l.<
~ll.o ~~
~ll.o
~~
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ll.o Z Z~ ~ ..J
Z::> O lz:IO H ~C,)
~
C,)
oH r.!) C,)~
H
C,)~
..J~
Z OZ
1-1 CIl ~ :z:I
CIl~ ~a::: ~a::: <:a::: a::: c::: l:
Z ~~ C:::~ H~ t-'~
~~ Z~ O~ C,)~ <:~ ~
~~
r.!)~ ::>~ ~~ Il.~ Cf.)
ll.o~
~e ...:la::: ~Qi:! <:
Q- ~- CIl - ~- :lO
Index No. , Figure 4-8 AC-DC Permanent Magnet Generator
4 Generator Spur Gear X 4-284 4-566
11 Sealed Radio Inter- 4-285 4-566

ference Filter
Assembly
14 Rectifier/Regulator 4-286 4-566

Module Assembly
20, 21, Generator Housing Assy X 4-287 4-567

22, 23
25 Generator Roter 4-288 4-568

Assembly
27 Generator Stator 4-289 4-568

Assembly
35 Electrical Rotating X 4-290 4-569

Equipment End Bell
Assy
Index No. I Figure 4-9 JFS Control Box Assy
1 Identification Plate 4-293 4-572
6, 7 Electrical Control 4-294 4-573 Al alloy

Cover
4-90
NAVAIR 03-105AB-52
Tab1e 4-2. Table of Inspection and Repair Procedures (Cont)
~
H
E-I
Z U
O rzl
I-l,.... p., ,....
,....
E-ICO C/) O ,....
UO
rzl ....
Zr-I
I-l .... • O
•
p.,1 {@
~
I-l
C/),q E-IJ. E-I:zt
~g:
:-. i:5::r:p., = Z=
U
;j~ ~~ ~~
~I
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§~
p.,
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HZ S~
~ p.,p., ~~
E-Ip., ~p.,
~~ ~p., C/)
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:z:
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gjo
UE-I
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Z ~~ ~
E-í
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C/)
E-I~ <:tt:
~~
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Z I-lrzl Hrzl
~~
~~
rzl
.;e
gfz.l Ufz.l <fz.I
rzlrzl
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p.,~
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Index NO. I Figure 4-9 (Cont)
9 Armature Re1ay 4-295 4-574
13
17
Start Cycle Pro-
tection Sensor
Counter Retaining
4-295A 4-587A
4-296 4-575 AI alloy

I
Plate 6061-T6
18, 19 Counter Retaining 4-297 4-576

PIa te Assemb1y
20, 21 Resi1ient Start 4-298 4-577

Counter Mounts
22 Electrical Counter 4-299 4-578
24 Temperature Sensor 4-300 4-579
26 Indicator 4-301 4-580
98 Cartridge Fuse 4-302 4-581
29 Fuseholders 4-303 4-582
30, 31, Electrica1 Receptacle 4-304 4-583

32 Connector
41 Insu1ator 4-305 4-584
44 Transistor 4-306 4-585
Change 1 4-91
NAVAIR 03-105-AB-52
Z
o
1-1
E-4
Z U
o _
-i -.
1-1 lz:l
Il.o_
E-4a:> ti) o
uo
lz:l.-l
Z.-I
1-1.-1
• o
Z Il..I I Z
o
1-1
ti) -:t E-4-:t E-4
~g:
Z = z=
E-4 1-1= ll.. lz:lll.o
U
lz:l
!j~ ~:i ~:i
1-1 C.!)
~:i
~~
ll..-
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~~ ~~
ti)
~~
20
I-IZ
~Il.o E-4ll..
ll..ll.. ~ll..
~~
ti)
Il.o Z Zlz:l lz:l ~
O C!)
O
UE-4
lz:l0
UE-4
I-IU
Z
~U
OZ ~
1-11-1 1-1 CI) ~lz:l lz:l lz:l
tI)~ E-4~ lz:l~ <~ ~tx: l:
lz:llz:l ~lz:l I-Ilz:l I-Ilz:l
~e <~
Z~ O~ U~ ~
C.!)lz:l Olz:l lz:llz:l Il.olz:l ti)
lz:l~
CI- ~e ~~
~-
Il.o~
CI) - ~- ~
Index NO. I Figure 4-9 (Cont)
45 Semiconductor Mounting 4-307 4-586

Heat Sink
46 - 50 Electrical Control 4-308 4-587 AI alloy

Box
Index NO. I Figure 4-10 Accumulator Assy
9 Accumu1ator Fue1 4-310 4-589 AI a110y

Piston 6061-T6 or
T651
10 Compression Uelical 4-311 4-590 SAE 9254
Spring
11 Accumu1ator Housing x 4-312 4-591 AI a110y
14 Accumulator Hydrau1ic 4-313 4-592 AI a110y

Piston 6061-T6 or
T651
15 Accumulator Cap x 4-314 4-593 AI alloy
356-T6
Index No., Figure 4-11 Sensitive Switch Assemb1y
3 Switch Actuating 4-317 4-596 CRES 321 or

Lever 347
4-92
,
NAVAIR 03-105-AB-52
~
1-1
E-I
o
oZ
~
1-1_
E-ICO
uo
J:r:I..-I
~I
JZ:I
Ilot-
til o
Z..-I
1-1..-1
E-IJ.
-. -.
i i
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I-It,!!
~~
ij~ ~~
ti)
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~~
~~ ~~
ti)
~o ZJZ1
~
J:r:I
1-10 ~:I o
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1-11-1 1-1
~
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~~
tIllZc
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f;1~ I-I~
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til -
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Index NOo l Fi~re 4-11 (Cont)
7 - 10 E1ectrical Lead 4-316 4-595

Assemb1y
13 Sw1tch Housing 4-318 4-597 Al alloy

Assemb1y 356-T6
Index Na., Figure 4-12 Sw1tchActuating Governar Assy
3 Governor Weight 4-320 4-599 CRES 431
4 Governor Pin 4-321 4-600 Stee1 4130 or

CRES 17-4PH
6 Compression Helical 4-322 4-601 CRES 302
Spring
7, 8 Governor Body Assemb1y 4-323 4-603 Al a110y
Index No., Figure 4-13 Main Jet Fue1 Starter Fue1 Conttó1'Assy
3 Air Passage Bolt 4-325 4-605 CRES 303

11 Adjusting Screw 4-326 4-606
12 - 14 Acce1eration Limiter 4-327 4-607 AI a110y
Housing Assy 356-T6
4-93
NAVAIR 03-105-AB-52
Tab1e 4-2 .. Tab1e of Inspection and Repair Procedures (Cont)
%
o1-4
E-t
% U
o
-. -.
1-4 _ ~
j:I.,-
E-tOO ti) o
uo %.-4
~r-l
p..
t-Ir-l oZ o
Z I I Z
o1-4 ti) ~ E-t...:t E-t
Z Z ::c
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.
c:w
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zo uc zc
I-iC
t;~
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1-i:Z; ~~ fi!~ ~<:
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j:I.,<:
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~~ <:c:w E-tp.. ti) Il::
<Il::
z~
p..
o
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I-il-i I-i ti) ~~ ~ ~
tI)~ E-t~ ~c::.:: <:c::.:: c::.::1l:: ::E:
z~IZJ ~IZJ
zra..
Il::IZJ I-4IZJ I-i~
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:t1ZJ CIZJ ;:::JIZJ IZJIZJ C:WIZJ ti:
j:l.,1l:: IZJIl::
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1-4 ti) <:
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Index NO. 2 Figure 4-13 (Cont)
15 Spring Guide 4-328 4-608 MIL-S-7720
16 Compression Helical 4-329 4-609 QQ-W-423

Spring
20 Diaphragm Spacer 4-330 4-610 AI alloy A380
21 Diaphragm Spacer 4-331 4-611 AI alloy

2024-T4
23 Fuel Control Diaphragm 4-332 4-612 Al alloy

Spacer 6061-T6
32 Spring Retainer 4-333 4-613 MIL-S-7720
33 Adjusting Screw 4-334 4-614
35, 36 Governor Cover 4-335 4-615 Al alloy

Assembly 356-T6
37 Compression Helical 4-336 4-616 lU-SPAN C

Spring
38, 44 Annular Ball Bearings 4-337 4-617
40 Metering Sleeve 4-338 4-618 Nl-RESIST
41 Governor Flyweight 4-339 4-619 Steel 1020 or

MIL-S-22141
4-94
NAVAIR 03-105-AB-52
z
o
1-4
E-!
Z t,)
z
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1-4 _
E-! co
t,)o
1:r:I ....
fàJ.
l:r:I
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z ....
1-4 ....
-. -.
zo o
o
1-4
E-!
t,)
l:r:I
p..-
~=
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s~ !~ ~~ ~~
til •
zo
I-4Z
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=p..
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lndex No. , Figure 4-13 (Cont)
45 Governor Cage 4-340 4-620 SAE D2

46 Governor Valve X 4-341 4-621 QQ-S-763
Assemb1y
47 Bearing Sleeve 4-342 4-622
51 Adjusting Screw 4-343 4-623 CRES 303

52 Machine Thread Plug 4-344 4-624 CRES 303
53 Compression He1ica1 4-345 4-625 CRES 17-7PH
Spring
54 Meteririg Valve 4-346 4-626 QQ-S-763
59 Fue1 Contro1 Va1ve 4-347 4-627 QQ-S-763
S1eeve
70 Sea1 Housing 4-348 4-628 Al alloy
356-T6
76, 82 Fue1 Pump Sleeve 4-349 4-629
Bearing
77, 78 Pump Drive Shaft 4-350 4-630 QQ-S-763

Assembly
79, 81 Spur Gears X 4-351 4-631 AMS6260
4-95
NAVAIR 03-105AB-52
Tab1e 4-2. Table of Inspection and Repair Procedures (Cont)
z
o
H
H
-.
Z U
O tzl
Z
H_
t~
tzl,....j
r:l.tl
r:t.._
000
Z,....j
H,....j
I
O
Z
-.
O
Z
O oo.;:t H.;:t H
H Z ::r:: Z::r::
ttzl H::r::
~ ~= ~~
tzlr:t..
r:I.t- ~;2
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t~ Ht!I
ffi;2
Ut!I
~~
Zt!I
00
:2:0• :3;2
HZ ~~ ~~ r:t..<
~r:I.t < r:t..r:I.t
00
tzlr:t..
~rz:I ~r:t.. Ztzl
~
tzl
~8 :àH
r:l.t
0 tzlO HU ~U
UH UH
~~
0:2:
HH H 00 rz:I tzl
oo~
Z
H~ rz:I~
~tzl Htzl
~~
Htzl
x:
~~ O~ U~ <~ J:LI
~n~~ Crz:I ::Jtzl J:LIJ:LI r:t..J:LI 00
HOO J:LIa:
~e
...J~ r:I.t~
Q- ~- 00 - clt"'" ~
80 Gear Shaft 4-352 4-632 CRES 440C or

440F
I 86 - 97 Fuei Metering Va1ve 4-353 4-633 AI a110y

Body 356-T6
Index No. , Figure 4-14 Hydraulic Motor
1 Housing Cap 4-355 4-635 Al a110y

2024-T4
11 Bearing Retainer 4-356 4-636 AI al10y

2024-T4
13 Pistons 4-357 4-637 Steel 52100
14 Auxiliary Cam X 4-358 4-638 Steel 52100
15 Cam Reta1ner 4-359 4-639 Al al10y

A850-T5
16 Rotor 4-360 4-640 AI alloy

B850-T5
18 Shaft 4-361 4-641 Steel 3310

or 9310
19 Port P1ate 4-362 4-642 Nitralloy

135M
4-96 Change 2
-. NAVAIR 03-105AB-52
~
H
~
~
-
O
rz:I
!-I- t:lc-
E-Ico ti) O
00
e::l '""'• o•
20
o
rz:Ir-I
t:lcl
tI).,:t ~J.
i ~2O
!-I
~= ~= = 20=
S~ ~~
~
o
rz:I
~~ rz:I~
~~
t:lc-
~~ ~~ ~~
ti) •
~i
~~ ~t:lc
t:lct:lc
rgrz:l
~~
it:lc rz:I
i
t:lc
o~ @3~
!-lO
o~
~~
z ~~
ti)
~=
o~
s~
t,.)~ ~i
~e
.:::1- lã ~~
fi- ~~
C/l-
~~
lli:\-
rz:I
ti)
-<
llQ
24 Spring 4-363 4-643
27 Name P1ate 4-364 4-644
29 Housing 4-365 4-645
4-127. Visua11y inspect quick re1ease pin (6) for ba11 10ck operation and inspect
body of pin for nicks and burrs.
4-128. Visua11y inspect oi1 dip stick (8) for damaged threads, rounded wrenching
f1ats, wom 10ckwire ho1es and bent or broken gaging probe.
4-129. Visua11y inspect 1ubrication instruction p1ate (9) for security and 1egi-
bi1ity.
4-130. Visua11y inspect oi1 fi11er housing (10, 11) for distortion, dents, cracks,
and tom or worn 10ckwire ho1es. Inspect insert (10) for security and damaged
threads.
4-131. Visua11y inspect hose c1amps (15, 17) for distortion and cracks and inspect
strap for tom or wom slots, and gear for damaged or wom teeth.
4-132. Visua11y inspect f1exib1e hose (16) for chafes, tears and deterioration.
4-133. Visua11y inspect f1uid passage bo1t (18) for damaged threads and inspect
f1uid passages for dirt or other foreign matter.
Change 1 4-97
.
NAVAIR 03-105-AB-52
1
DIAC
DIAA
I
SURFACE 8 SHALL 8E NORMAL TO DIAMETER A WITHIN C.CCI
INCH TOTAL INDICATOR READING
SURFACE D SHAL l 8E PARA L LEL TO SURFACE 8 ''''ITHIN O. CCI

INCH TOTAL INDICATOR READING
A C
6.296 TO 4.120 TO
6.298 IN. 4. i221N.
1-12A-895
Figure 4-15. Inspection of Engine Starter Mounting Flange
4-134. Visua11y inspect magnetic p1ug (21) for rounàed wrenching f1ats, torn,
10ckwire ho1es, security of magnet and damaged threads.
4-135. Visually inspect oil drain adapter (22) for distortion, cracks, dents,
chafes, and damaged threads.
4-136. Visually inspect electrical p1ug connectors (26, 27) for cracks in housing
and back she11, damaged threads, and broken, burned ar corroded sockets.
4-137. Inspect immersion thermocouple (30) as fo110ws:
a. Visua11y inspect housing for bent probe, distortion, dents and cracks.
b. Visua11y inspect connc~tor for bent, broken or corroded pins.
c. Check for continuity between pins A and C.
NOTE
If infinity readingÉ not obtained preheat thermo-

coup1e to 200°F (9.3°C) for four hours and retest.
4-98
NAVAIR 03-105AB-52
d. Check for resistance reading of infinity between grotm.d and pins A and
c.
~ 4-138. Inspect switch cover assemb1y (40, 41) as follows:
a. Visua11y inspect pin (40) for security, burred edges, and distortion.
b. Visua11y inspect p1ate (41) for distortion, and cracks.
4-139. Visua11y inspect e1ectrical insulation sleev1ng (43) for cuts, chafes,
resi1ience and distortion.
4-140. Visua11y inspect p1ugs (45, 47) for rotm.ded wrenching f1ats, cracks and
damaged threads.
4-141. Inspect containment support assemb1y (53, sheet 2) as fo11ows:
a. VisualJy inspect containment support assembly for cracks and cOlTosion. Cracks
running radially outward from the bolt holes are acceptable provided they have not progressed into the
non-machined area and that the crack has been stop drilled 0.050 to 0.063 inch diameter. One crack per
I
hole acceptable.
b. Visua11y inspect a1ignment pin for security, burred edges, and dis-
tortion.
c. Dimensiona11y inspect outer diameter of containment support for measure-
ment within 8.537 to 8.539 inches.
4-142. Visua11y inspect thermal insulation batt (54) for deformation and shredding.
4-143. Inspect power turbine containment shie1d assemb1y (55) as fo11ows:
a. Visua11y inspect containment shie1d assemb1y for cracks, distortion,

and heat damage.
b. Visually inspect pins and segments for security.
NOTE
Diameter B of the containment shield 1s segmented, take
readings as required to ensure that diameter B is within
1imits.
c. Dimensiona11y inspect containment shie1d assemb1y in accordance with

figure 4-16.
d. When inspecting the power turbine containment shield assembly in accordance with
figure 4-16, A and B diameters of7.235-7.250 inches and 6.350-6.354 inches, respectively, shall be used.
e. Power turbine containment shield assemblies which fail to meet the B diameter
requirements specified in paragraph d above may be repaired in accordance with the following
procedures:
Change 2 4-98A
..
NAVAIR 03-105AB-52
(1) Containment shield assemblies on which the B diameter is undersize andlor out-of-
round, including wheel rub damage, shaU be repaired as follows:
NOTE
Parta must be machined dry to avoid contamination of parent
metal.
(a) Grind the B diameter surface the minimum amount necessary to obtain the
dimensional requirements ensuring that the concentricity and normality requirements of the figure
listed in paragraph d above is maintained. One hundred percent clean-up of B diameter surface is not
required. Deburr machined edges 0.005 to 0.025 incho
(b) Visual1y inspect ground surfaces for cracks. Presence of cracks sha]] be cause
for rejection.
(c) Thoroughly clean to remove alI contamination. Hot water rinse and air blow or
bake dry.
(2) Containment shield assemblies which are oversize on B diameter surface shall be
repaired in accordance with the procedures specified in paragraph (1) except for the following
deviations:
(a) Measure diameter B after clean-up of segments. When B diameter is between

6.374 and 6.413 inches, rebuild the segment sunace using paragraph 1 below. When this dimension is
between 6.414 and 6.444 inches, rebuild the segment surface using paragraph Z below. When this
dimension exceeds 6.445 inches, replace segments per paragraph 4-425.
(b) Build-up segmented inner surfaces on each containment shield 88sembly a

minimum of 0.015 inch thickness to obtain a maximum I.D. of 6.320 inches as follows:
.1 Apply Mete0 443 material or equivalent by plasma spray, using Mete0

procedure No. P443-10. Mask the support ring ofTitanium to protect it from glass beads or grit during
cleaning and from overspray during spray application. The segmented ends and sides must be free
from plasma spray.
2 Ensure part is cleaned for welding. Apply L-605 weld rod to the segment to
dimensions in paragraph (b) above. Apply weld to the inner face of segments on]y, taking care to mask
the Titanium support ring from weld spatter and to keep segment end gaps open.
(c) Machinelgrind the sprayed/welded diameter to 6.350-6.352 inches ensuring that

the concentricity and normality requirements of the figure listed in paragraph d above are maintained.
Trim segmented ends to maintain c]earance gap of 0.03 to 0.09 inch wide by 0.09 to 0.095 inch deep (six
places). Deburr machined edges 0.005 to 0.025 incho
(d) Stress relieve the containment shield assembly in ao oven preheated to 1075°F to
1125°F for a time period of one to two hours, followed by air cooling after removal from oven.
(e) Visual1y inspect the machined surface for surface cracks. Presence of cracks is
cause for rejection.
4-98B Change 2
• NAVAIR 03-105AB-52
4-144. Visua11y inspect heat shie1d (56) for deformation and shredding.
4-145. Visua11y inspect turbine diffuser (57) for distortion and cracks.
4-146. Inspect bracket assemb1y (6~ 64) as fo11ows:

a. Visua11y inspect bracket (64) for cracks and deformation.
b. Visually inspect 1nsert (63) for security and damaged threads.
Change2 4-99
•
NAVAIR 03-105AB-52
~
- •"
oIAA DI A8
SURFACEC-./' /
OIAMETER B SHAL L 8E CONCENTRIC WITH DIAMETER A WITHIN

0.002 INCH TOTAL INDICATOR REAOING ANO NORMAL TO
SURFACE C WITHIN 0.001 INCH TOTAL INDICAl'OR REAOING.
A B
7.235 TO 6.350 TO
7.250 IN. 6.354 IN. 1-12A-863
Figure 4-16. Inspection of Power Turbine Containment Shie1d Assembly
c. Perform'f1uorescent penetrant inspection in accordance with MIL-I-6866.
4-147. Visua11y inspect bearing retainer (70) for distortion and cracks.
4-148. Inspect engine starter housing assemb1y (74 through 78) as fo11ows:
a. Visua11y inspect housing (78) for dents, cracks and corrosion and in-
spect paint for chipping, cracking and pee1ing.
b. Dimensiona11y inspect housing (78) in accordance with figure 4-17.
c. Visua11y inspect inserts (74 through 77, figuré 4-3) for security and
damaged threads.
4-149. Visual1y inspect engine starter drive shaft assembly (79 through 82) for
cracked or chi~ped drive shaft paw1s (79), loose rivets (80), broken springs (81)
or worn shaft (82).
4-100 Change2
•
UAVAIR 03-105-AB-52
.,...._ _ _ SU_~A~
r-
OIAB
DIA E
DIA C
SURfACE A SHALL BE NORMAL TO OIAMETER F WITHIN 0.001

INCH TOTAL INDICATOR READING.
OIAMETER B SHALL BE NORMAL TO SURFACE O WITHIN 0.001

DIAMETER C SHAL L BE CONCENTRIC WITH DIAMETER BWITHIN

0.002 INCH TOTAL INDICATOR REAOING.
OIAA'.ETER E SHAL L BE CONCENTRIC WITH OIAMETER BWITHIN

G.OOl INCH TOTAL INDICATOR REAOING.
DIAA'.ETEII. f SHAL L BE CONCENTRIC WlTH OIAMETER BWITHIN

0.001 INCH TOTAL INDICATOR RfADING.
B C E F
5.559 TO 8.570 TO 6.300 TO 2.448 TO

5.561 IN. 6.572 IN. 6.302 IN. 2.451 IN.
Figure 4-17. Inspection of Engine Starter Housing Assembly
4-150. Inspect exhaust housing assemb1y (83, 84) as fol1ol-1S:
a. Visually inspect ~laust housing (84) for cracks and corrosion paying
particular attention to f1anges and we1ded joints.
b. Visua11y inspect threaded bores of exhaust housing (84) for damaged

threads.
4-101
•
NAVAIR 03-10SAB-S2
c. Visua11y inspect insu1ation of exhaust housing (84) for integrity and

security.
d. Visua11y inspect nutp1ates (83) for security and damaged threads.
e. Dimensiona11y inspect exhaust housing (84) witb surface D and diameter

E in restrained position. Refer to figure 4-18.
.
LJtJ
, ~
~
6)
DIA D~
DI AA <O
,
\-~
/~ ,;
SURFA CE B "'-SURFACE C
j
SURFACE B SHAll BE PARALlEl TO SURFACE C WITHIN 0.004 INCH,
OIAMETER A SHAll BE CONCENTRlC WlTH OIAMfTER D WITHIN

O.OO4INCH TOTAllNOICATOR REAOING,
A D
8.540 TO 8,573 TO
8.542 IN, 8,575 IN,
1-12A-933
Figure 4-18. Inspection of Jet Fuel Starter Exhaust Housing Assembly
4-102 Change2
•
NAVAIR 03-105AB-52
f. Visually inspect using 10-power magnificafion and white Iight. I

4-151. Inspect ring gear lockring (86, figure 4-3, sheet 3) as fo11ows:
a. Visua11y inspect lockring (86) for cracks and distortion.

b. Dimensionally inspect for free ring diameter within 4.70 to 4.75 inches.
4-152. Inspect internaI gear hub (89) as fo11ows:
a. Visua11y inspect teeth and sp1ines of internaI gear hub (89) for cracks,
chips, and evidence of abnorma1 wear.
b. Dimensional1y inspect interna! gear hub (89) in accordance with figure
4-19.
c. Perform magnetic partic1e 1nspection in accordance with MIL-I-6868.
4-153. Visua11y inspect lock ring (91, figure 4-3) for damaged threads, burred or
rounded wrenching slots, distortion and cracks.
4-154. Visua11y inspect insulator pIa te (94) for distortion and cracks.
4-155. Inspect sensitive switch assemb1y (96) as fo11ows:
a. Visua11y inspect wire insulation for chafes, cracks and deterioration.
b. Inspect wires for continuity with multimeter.
c. Check for continuity across normal1y c10sed contacts of switch by con-

necting meter 1eads to b1ack and red wires. Actuate switch and check that circuit
opens.
d. Check for open circuit at norma11y open contacts of switch by connect-
fug meter leads to black and orange wires. Actuate switch and check for cont1nuity.
4-156. Inspect switch actuating 1ever (98) for distortion, cracks and worn pin
bole.
4-157. Inspect bearing support (99) as follóws:
a. Visua11y.inspect bearing support for scratching or scoring of bearing
surfaces.
b. Dimensiona11y inspect bearing support in a~cordance with figure 4-20.
4-158. Visua11y inspect nuts (101, 125, figure 4-3) for rounded wrenching f1ats,
damaged threads, elongated pin ho1es and cracks.
4-159. Inspect pinion spur gear (102) as fo11ows:
Change 2 4-103
NAVAIR 03-105-AB-52
rI}
-
1
oIAA
j ..6.
./-
H. --
SU RFACEBJ
ii
SURFACE B SHAL L BE NORMAL TO DIAMETER A WITHIN O.. 001
1.8500 TO
1.. 8505 IN.
Figure 4-19. lnspection of Interna1 Gear Hub
a. Visua11y inspect that gear teeth are free of surface defects.
b. Visual1y inspect gear teeth for chipping, and cracks.
c. Visually inspect splines for wear.
d. Dimensional1y inspect splines as fol1ows if visual inspection revea1s

sp1ine wear.
(1) P1ace two O.0450-diameter pins in wear area of t,-,o opposite spline
grooves.
(2) Check for maximum dimension of 0.3919 inch between pins.
e. Dimens1ona11y inspect spur gear (102) in accordance with figure 4-21.
f. Perform magnetic partic1e inspection in accordance with MIL-I-6868.
4-104
NAVAlR 03-l05-AB-52
,,..--n.olDIA C
l
SURFACE B
DIAMETER A SHAL L BE CONCENTRIC WITH DIAMETER C WITHIN

0.0005 INCH TOTAL INDICATOR READING.
DIAMETER A SHAL L BE NORMAL TO SURFACE BWITHIN 0.0005

DIAMETER C SHALL BE NORMAL TO SURFACE BWITHIN 0.001

A C
1.9193 TO 0.9838 TO
1.9196 IN. 0.9842 IN.
Figure 4-20. Inspection of Bearing Support
4-160. Inspect turbine whee1 assemb1y (103, 104, figure 4-3) as fo11ows:
a. Visually inspect tubu1ar rivets (103) for security.
b. Visually inspect each b1ade of whee1 assemb1y, using strong 1ight and
magnifying g1ass for nicks, cracks, scratches and evidence of scoring or abrasion.
c. Visua11y inspect tbreads for damage.
d. Visua11y inspect splines for wear. Dimensionally inspect splines as

follows if wear is evidente
(1) P1ace two 0.0600-inch diameter pins in wear area of opposite spline
grooves.
(2) Check for minimum dimension of 0.5249-inch across pins.
4-105
NAVAIR 03-105-AB-52
SURFACE A SURFACE B
,j
tc
DIA
SURFACE A SHAlL BE PARALLEL TO SURFACE B WITHIN 0.0005

DIAMETER C SHALL BE NORMAl TO SURFACE B WITHIN 0.0005

C
0••803 TO
0••807 IN.
Figure 4-21. Inspection of Pinion Spur Gear
NOTE
New turbine whee1 assemb1ies sba11 conform to dimensions
spec1fied in figure 4-21. In-service turbine whee1 as-
semb1ies are permitted a11owab1e variation.
e. Dimensiona11y inspect turbine whee1 (104) in accordance with figure

4-22.
f. Perform f1uorescent penetrant inspection in accordance with MIL-I-6866,

type I, method B.
g. Check balance turbine whee1 assemb1y in accordance with paragraph 4-442,

step c.
4-161. Visually inspect insu1ation cover (105, figure 4-3) fo~ distortion and
cracks.
4-162. Visual1y inspect sea1 retainer (107) for distortion and cracks.
4-163. Inspect jet fue1 starter thermal insu1ation blanket (108) as fo11ows:
4-106
, NAVAIR 03-105AB-52
DIA C SPLlNE E
DIA A
DIA O
OIAMETER A SHAL L 8E CONCENTRlC WITH OIAMETER C WITHIN

SUlFACE 8 SHALL 8E NORMAL TO DIAMETER C WITHIN 0.0003
DIAMETER D SHAL L 8E CONCENTlIC WITH DIAMETER C WITHIN

SPLINE E SHALL 8E MEASURED OVER 0.0600 DIAMETER PINS.
A C D E
6.285 TO 0.6693 TO 0.4804 TO 0.5249 IN. MIN.

6.287 IN. 0.6695 IN. 0.4806 IN. 0.52604 IN. MAX IEF
ALLOWABLE VARIATlON
6.291 IN.
MAX
1-12A-934
Figure 4-22. Inspection ofAxial Flow Turbine Wheel Assembly
Change 2 4-107
•
NAVAIR 03-I05AB-52
a. Visually inspect thermal insulation blanket for distortion or damage

affecting 1nsulation.
b. Restrain thermal insulation blanket and dimensionally inspect in accord-

ance with figure 4-23.
e. Restore surl'ace A (figure 4-23) within inspection limits and repair crack(s) near the sma11
end as follows:
(1) Place a 3 1/2 inch diameter by 1/2 inch minimum thickness solid steel backing block
on the platen of a hydraulie press.
NOTE
The steel bloek must have a 65 micro-inch finish or better on both

sides and the sides shall be parallel within 0.010 inch TIR. A
similar block or a 3 lJ4 inch diameter solid ram is required for
applying force.
(2) Center the subject thermal insulation blanket on the base block and cent.er the
bydraulie ram with its facing block inside the subject part while applying an approximate force of 2,000
pounds.
(3) Ensure that the blocks are centered, then slowly increase force to 5 tons (10,000
pounds).
(4) Remove and inspect. Parts must be within inspection limits of figure 4-23.
(5) Repair crack(s) in the outer shell (0.010 inch thick) as follows:
(a) Areas adjacent to crack(s) shaU be cIeaned by wire brushing and/or lightly
blasting with number 13 gIass beads.
(b) Visually inspect and mark adjacent to the crack(s).
(c) Stop drill the crack(s) using a 0.050 inch diameter drill.
(d) Fabricate a repair patch of stainless steel foil (0.005 inch to 0.010 inch thick) such
that the eraeked area ia ful1y eovered and approximately 1 ineh of patch material rests on uncracked
base material around the craek. Patch material shall be 321, 347, or 348 stainless steel.
(e) Attach the repair patch to the outer sheU (which is 347 stainless steel) by spot
welding in aceordanee with MIL-W-6858 around the entire eircumference ofthe patch at weld intervals
no greater tban 0.050 incho
(6) Areas of prior welding (inner-to-outer shell eonnection points) that exhibit cracking
shaIl be repaired by heliarc welding per MIL-W-8611 using Hastelloy W or 347 stainless steeI finer rodo
These re-welded areas may also be covered by the patches which repair adjoining cracked areas.
(7) Fluorescent penetrant inspect in aecordance with MIL-I-6866 and NAVAIR 01-IA-I6.
4-108 Change2
NAVAIR 03-105AB-52
_-SURFACEB
.--SURFACE A
SURFACE A SHALL BE PARALLEL TO SURfACE BWITHIN 0.010

SURFACE B SHALL BE FLATWITHIN 0.010 INCH TOTAL.
1-12A-885
Figure 4-23. Inspection of Jet luel Starter Thermal Insulation Blanket
4-1640 Inspect turbine whee1 seal (112, figure 4-3) as fo11ows:
NOTE
Ensure that cIeanliness is maintained at alI times.
a. Careful1y remove the seal ftom the power turbine assembly and inspect for evidence of
leakage past the carbon element and the rotor face.
b. VisuaUy inspect carbon face for cracks, scratches, nicks, pits, and chips.
(1) Cracks are not permitted.
(2) Pits larger than 0.020 inch in diameter or 0.020 inch in depth are not pennitted.
(3) No more than four pits are permitted on Beal Burface.
(4) Nicks shalI not extend, either individuaIly or collectiveIy, &er088 more than 10
percent of sealing surface.
(5) Scratches in sealing Burface shalI not exceed a depth ofO.0005 inch, a width ofO.OOO5
inch, or a lengtlt that traveraes a radial band equal to 30 percent of sealing surface.
Change2
•
NAVAIR 03-105AB-52
(6) Defects on edges of carbon ring shall be no larger than 0.020 incho
(7) Totallength of defects on edges of carbon ring shall not exceed 0.500 incho
(8) Seals exceeding these limita shall be replaced.
c. Inspect seal rotor as folIows:
(1) Visually inspect rotor face for coke and vamish deposits. No measurable quantity is
permitted. Metal discoloration is permitted.
(2) Inspect alI areas for cracks, scoring, grooving, and scratches using 20-power
magnification.
(a) Cracks are not permitted.
(b) Sealing surface shall be free of defects.
(c) Clamping surface on back side shall have a finish of AA16 or better. Raised
metal or radial scratches visible with 20-power magnification are not permitted. Circumferential
scratches deeper than 0.001 inch are not permitted.
(d) Scoring and raised metal are not pennitted on ID. Stone to remove high metal.
d. SeaIs which exhibit no Ieakage indications or other visible damage shall be used as is
subsequent to cleaning and testing as foIlows:
WARNING
1, 1, 1, trichloroethane, MllrT-81533, vapors can be fatal. Use only

(1) Clean the seal by the ultrasonic cleaner process using I, I, I, trichloroethane, MIL-T-
81533.
(2) Clean the mating face of the carbon element and the rotor face witb a line-free wiper
(Kimberly Clark Type 900-S, Neenah, Wisconsin, or equivalent) saturated with a solvent (MllrT-
81533). When cleaning the retor, place wiper on a flat surface and rotate retor in a figure eight motion
untiI residue ceases to be transferred to the wiper.
e. Static test the seaI in a leak test fixture prior to installation into the power turbine
assembly. Connect seal test fixture to an air pressure source regulated at 34 to 36 PSIG, with a flow
measuring device capable of checking air leakage not exceeding 0.03 pounds per minute. Should
leakage exceed 0.03 pounds per minute, the seal is defective.
4-108B Change2
NAVAIR 03-105AB-52
f. Visually inspect seal bellows for resilience and for damage.
g. Dimensionally inspect seal housing and rotor in aeeordanes with figure 4-24.
, 4-24.
4-165. Visua11y inspect spring seats (114, 120, figure 4-3) for distortion and
evidence of wear. Dimensionally inspect spring seats for flatness within 0.005
!nch if visual !nspection revea1s distortion.
4-166. Inspect resi1ient bal1 bearing housing (116) as fol1ows:
a. Visually inspect resilient ba11 bearing housing for cracks, nicks,
scratches, scoring and corrosion.
SURfACE a I....--/SURfACE c
r OPERAllNG
_ RANGE !JJJZ.4-
0.157
DIM. A
SURFACE aSHALL BE PARALLEL WlTH SURFACE C WlTHIN 0.0002 INCH.

SURFACE o SHALL BE PARALLEL WlTH SURfACE E WITHIN 0.003 INCH.
SURfACE a OF ROTOR ANO SEAL SHALL BE FLAT WITHIN THREE HELlUM LlGHT IANOS.
0.225 TO
0.227 IN.
1-12A-931Rl
Figure 4-24. Inspection of Turbine Wheel Seal
•
I~VAIR 03-l05-AB-52
b. Dimensional1y inspect resi1ient ball bearing housing in accordance with

figure 4-25.
4-167. Inspect resilient mount 1iner (117, figure 4-3) as fol1ows:
a. Visually inspect resilient mount liner for cracks, nicks, scratches,

scoring, and corrosion.
b. Dimensionally inspect resilient mount liner in accordance with figure

4-26.
4-168. Inspect compression helica1 spring (121, figure 4-3) as fol1ows:
a. Visua11y inspect spring for cracks and corrosion.
b. Load spring with standard compression type spring tester, and compress
spring to 0.93 incho Check that 10ad is within 25 +2.5 pounàs.
~---~~-----t-+---DIA B
DIAA
DIAMETER B SHALL 8E CONCENTRIC WITH DIAMmR A WlTHIN

A B
1.6038 TO 1.3774 TO
1.~lIN. 1.3778 IN.
Figure 4-25. Inspection of Resilient Ba1l Bearing Housing
4-110
l~VAIR 03-105-AB-52
DIA B
DIM. c .1. .1
DIAMETER B SHALL BE CONCENTRIC WITH DIAMETER A WITHIN
A B C
2.0375 TO 1.6037 TO 0.3940 TO

2.0379 IN. 1.6041 IN. 0.3945 IN.
Figure 4-26. Inspection of Resi1ient Uount Liner
4-169. Inspect bearing s1eeve spacer (122) as fo11ows:
a. Visua11y inspect bearing s1eeve spacer for cracks and corrosion.
b. Dimensiona11y inspect bearing s1eeve spacer in accordance l1ith figure

4-27.
4-170. Inspect spur gearshafts (129, figure 4-3, sheet 4) as fo11ows:
a. Visua11y inspect gear teeth and sp1ines for cracks, chipping and evi-
dence of abnorma1 wear. Check tbat teeth sp1ines are free of surface defects.
b. Inspect threads for damage.
c. Dimensiona11y inspect spur gearsbafts in accordance t..rith figure 4-28.
d. Perform magnetic partic1e inspection in accordance with MIL-I-6868.
4-171. Inspect matched p1anetary spur gear set (130, figure 4-3) as fo11ows:
4-111
- -----------------------------
NAVAIR 03-105-AB-52
'URfACE A l
............ iDIM.Sl
_____ 'URfACE C
DIAD
1
!
SURFACE A SHALL SE NORMAL TO OIAMETER O WITHIN 0.002 INCH.
SURFACE C SHALL SE PARALLEL WITH SURFACE A WITHIN 0.0002 INCH.
S O
0.930 TO 0.673 TO
0.932 IN. 0.677 IN.
Figure 4-27. Inspection of Bearing S1eeve Spacer
DIAD
DIAMETER B SHAL L BE CONCENTRIC WITH DIAMETER A WITHIN

SURFACE C SHAL L BE NORMAL TO DIAMETER A WITHIN 0.0005

A 8 o
0.471«; ro 0.7699 TO 0.4370 TO
0.4721 IN. 0.7702 IN. 0.4375 IN.
Figure 4-28. Inspection of Spur Gearshaft
4-112
..
NAVAIR 03-105-AB-52
a. Visually inspect gear teeth and sp1ines for craclcs, chipping and evi-
dence of abnormal wear. Check that teeth and splines are free of surface defects.
b. Dimensiona11y inspect sp1ine as fo11ows if wear is indicated.

(1) Place two 0.1050 inch diameter pins in wear area of opposite sp1ine
grooves.
(2) Inspect for maximum diameter of 0.6034 inch between pins.

c. Dimensional1y insepct gear set in accordance with figure 4-29.
d. Perform magnetic particle inspection in accordance with MIL-I-6868.
4-172. Inspect internaI spur gear (131, figure 4-3) as fo11ows:
a. Visual1y inspect gear teeth and sp1ines for cracks, chips and abnorma1
wear. Check that teeth and sp1ines are free of surface defects.
b. Perform magnetic partic1e inspection in accordance with MIL-I-6868.

4-173. Visua11y inspect bearing spacer (132) for distortion, cracks, corrosion,
nicks, and burrs. .
4-174. Inspect annular ba11 bearing (134) in accordance with paragraph 4-105.
4-175. Inspect gear carrier assemb1y (136 through 141) as follows:
a. Visua11y inspect sea1 carrier (136) for scratches, scoring, wear and
security.
SURFACfA SURFACE B
SURFACE A SHALL BE PARALLEL TO SURFACE B WITHIN 0.0005

Figure 4-29. Inspection of Matched Planetary Spur Gear Set
4-113
HAVAIR 03-105-AB-52
b. Visua11y inspect pin (138) for distortion, burred edges, and security.
c. Visua11y inspect inserts (139, 140) for security and damaged threads.
d. Visua11y inspect gear carrier (141) for cracks and corrosion. Inspect f
gearshaft bores in gear carrier for scratches, scoring and wear.
e. Dimensiona11y insepct gear carrier assemb1y in accordance with figure

4-30.
4-176. INSPECTION OF GAS GENERATOR AlID ACCESSORY DRlVE ASSEMBLY (figure 4-4).
4-177. Visua11y inspect identification p1ate (1, sheet 1) for security and 1egi-
bi1ity.
DIA B
t
DIAC DIA F
SURFACE G
/
OIAMETER 8 ANO C SHAL L BE CONCENTRIC WITH OIAMETER F
WITHIN 0.002 INCH TOTAL INOICATOR REAOING.
OIAMETER O ANO E SHAL L BE CONCENTRIC WITH OIAMETER F

WITHIN 0.001 INCH TOTAL INOICATOR REAOING.
A B C O E F
1.2597 TO
2.1428 TO 2.0380 TO 1.3781 TO 1.9195 TO 8.570 TO
1.2602 IN.
2.1438 IN. 2.0385 IN, 1.3785 IN. 1.9198 IN, 8.572 IN.
3 PLACES
Figure 4-30. Inspection of Gear Carrier Assemb1y
4-114
NAVAIR 03-105-AB-52
4-178. Visua11y inspect filter bracket (15) for cracl(B, distortion, and torn or
worn mounting ho1es.
4-179. Inspect pressure f1uid filter (19) as fo11ows:
a. Visua11y inspect filter e1ement for security to end cap and c1eanliness.
b. Visua11y inspect filter end cap for rounded wrenching f1ats and damaged
threads.
c. Visua11y inspect fi1ter housing for rounded wrenching f1ats, damaged

threads, and nicked, chipped, or cracked sea1ing surface of housing fitting.
d. Back pressure f1ush pressure f1uid filter.
4-180. Inspect check va1ve (22) as fo11ows:
a. Visua11y inspect check va1ve for rounded wrenching f1ats, damaged

threads, and nickeã, chipped or cracked sea1ing surfaces on fittings.
b. F10w check, check va1ve as fo11ows:
(1) Insta11 va1ve in test setup capab1e of providing fue1 (MIL-C-7024A,

Type 11) at pressure from zero to 500 psig.
(2) Slow1y increase pressure to inlet of check va1ve from zero psig
unti1 va1ve cracks open. Clleck for pressure within 0.5 and 1.0 psig. Decrease
pressure to zero psig.
(3) Disconnect check valve from test setup and reconnect with pressure
1ine to out1et of check va1ve.
(4) Increase pressure on va1ve out1et to 2.0 psig. Check maximum 1eak-
age, which sba11 not exceed 10cc per minute.
(5) Increase pressure on va1ve out1et to 500 psig, and check for check-
ing operation in non-f1ow direction.
(6) Decrease pressure to zero and remove va1ve from test setup.
4-181. Inspect restricted flow check valve (29) as fo11ows:
a. Visua11y inspect restricted f10w check va1ve housing for rounded wrench-
ing f1ats, damaged threads, and nicked, chipped or cracked sea1ing surfaces on
fittings.
b. Instal1 restricted f10w check va1ve in test setup capab1e of providing

fue1 (MIL-C-7024A, Type 11) at pressure of 200 psig with 150 pph f1ow, 250 psig at
zero flow, and capable of monitoring differential pressure across valve.
4-115
•
NAVAIR 03-l05-AB-52
c. Increase pressure slowly on in1et of valve from zero until va1ve cracks
open. Check maximum cracking pressure which shal1 not exceed 1.0 psig.
d. Increase f10w through va1ve to 120 pph and check maximum pressure drop
across va1ve which sba11 not exceed 10 psig. Decrease pressure to zero psig.
e. Disconnect restricted f10w check va1ve from test setup and reconnect
pressure 1ine to out1et of valve.
f. Increase pressure on va1ve out1et to 250 psig. Check for fuel flow
within 4.5 to 9.0 cubic inches per minute. Decrease pressure to zero psig and dis-
connect va1ve from test setup.
4-182. Inspect igniter p1ug e1ectrica1 1ead (40) as fo110ws:
a. Visua11y inspect igniter 1ead iIlsu1ator terminaIs for cracks and dis-
tortion.
b. Visual1y inspect connectors for rounded wrenching f1ats and damaged

threads.
c. Visua11y inspect si1icone grommets within igniter p1ug e1ectrica1 1ead

for cuts and crushed edges.
d. Visual1y inspect outer shie1ding for chafes, cuts, and separation from
connectors.
4-183. Inspect capacitor discharge high voltage ignition unit (41) as fol1ows:
a. Visua11y inspect ignition unit case for dents and cracks.
b. Visually inspect mounting bracket for secur1ty, d1stort10n, and tom

holes.
c. Visua11y inspect warning, input connector and identification tags for

security and 1egibi11ty.
d. Visua11y inspect connectors for bent, broken, burned or contacts and for
damaged threads.
e. Perform operational check of ignition unit as follows:
WARNING
The output voltage of the ignition unit is approxi-

mate1y 18,000 volts. Precautions sha1l be taken to
protect personnel from e1ectrica1 shock. The require-
ments of alI app1icab1e ground safety regu1ations
and manuaIs sba11 be comp1ied with.
4-116
NAVAIR 03-l05-AB-52
(1) Connect ignition unit into test setup with igniter p1ug e1ectrica1
1ead (40) and igniter p1ug (45). Connect 1ead from test setup to input connector of
ignition unit in accordance with tag on ignition unit case.
(2) Apply 10 volts dc to ignition unit input connector and check igni-
ter plug firing rate for minimum of one spark per second.
4-184. 1nspect gas turbine engine igniter p1ug (45) as follows:
a. VisuaIly inspect ceramic insulation of plug for cracks and chipping.

b. Visua11y inspect electrode for excessive burning or damage.
c. VisuaIly inspect connector for bent, broken, or burned contact.
d. Visually inspect housing for cracks, and mounting bracket for security
and distortion.
e. Check igniter pIug for operation as follows:

WAmUNG
Output voltage of ignition unit is approximately

18,000 volts. Precautions shall be taken to protect
personne1 from danger of electrical shock. The re-
quirements of alI applicable ground safety regula-
tions and manuaIs shall be complied with.
(1) Connect igniter plug to test setup comprised of ignition unit (41),
igniter pIug eIectrical Iead (40) and dc power source to ignition unit.
(2) Apply 10 volts dc to ignition unit and observe that igniter plug
fires consistently.
4-185. 1nspect accumulator assembly (49, sheet 2) in accordance with paragraph

4-309.
4-186. 1nspect accumu1ator mounting bracket (54, 55) as fo11ows:
a. Visua11y inspect bracket (55) for nicks, burrs and distortion.
b. Visually inspect inserts (54) for security and damaged threads.
c. Fluorescent penetrant inspect accumulator mounting bracket in accordance

with MIL-1-6866, type I, method A.
4-187. 1nspect JFS control box assemb1y (56) in accordance with paragraph 4-292.
4-188. Inspect rod end bearings (70, 73, 86, 89, sheet 2) as fo11ows:
a. Visually inspect bearings for wear, burrs, nicks and corrosion.
4-117
NAVAIR 03-l05-AB-52
b. Visually inspect shanks of rod end bearings for distortion and damaged
threads.
4-189. Inspect turnbuck1es (74, 90, sheet 2) as follows:
a. Visually inspect end plugs of turnbuckles for rounded wrenching flats,

damaged threads and security.
b. Visually inspect turnbuckle tubes for distortion, dents and cracks.
4-190. Visually inspect support brackets (62, 78, sheet 2) for distortion, e1on-
gated bolt holes, burrs, and nicks. Fluorescent penetrant inspect in accordance
with MIL-I-6866, type I, method A.
4-191. Visually inspect p1ug (92, sheet 2) for rounded wrenching f1ats, damaged
threads and torn lockwire holes.
4-192. Inspect shaft (120, sheet 3) as follows:
a. Visually inspect shaft for distortion, and shaft splines for nicks,
cracks and chips.
b. Visually inspect splines for wear.
c. Dimensional1y inspect splines as follows if flash copper p1ating is

worn through.
(1) Place two 0.0600 inch diameter pins in wear area of opposite
spl1ne grooves.
(2) Inspect for minimum dimension across pins of not 1ess than 0.3981
incho
4-193. Inspect wiring harness assemb1y (126) as follows:
a. Visual1y inspect identification straps for security and 1egibi1ity.
b. Visually inspect teflon coated fiberg1ass cord braid covering for

chafes, cuts, and fraying.
c. Visually inspect electrica1 connectors for torn, cut or deteriorated

insulation, and burned, broken or loose contacts, and damaged threads.
d. Perform continuity check using figure 4-70 as a guide.
4-194. Inspect permanent magnet generator (128, figure 4-4, sheet 3) in accordance
with paragraph 4-283.
4-195. Inspect accessory drive assemb1y (129) in accordance with paragraph 4-240.
4-196. Inspect gas generator assem~ly (130) in accordance with paragraph 4-197.
4-118
NAVAIR 03-105-AB-52
4-197. nISPECTION OF GAS GENERATOR ASSEMBLY (figure 4-5).
4-19ü. Inspect compressor in1et screen (1, sheet 1) as fol10ws:
a. Visual1y inspect screen ring for distortion, cracks and cracked we1d.
b. Visua11y inspect wire mesh for distortion of wires, broken wires and
cracked braze joints. Check for separation of mesh from ring.
4-199. Visua11y inspect hose c1amp (2) for distortion, cracks, and damaged b01t
threads. Inspect hose c1amp nut for damaged threads and rounded wrenching f1ats.
4-200. Visually inspect tmpe11er shroud (3) for cracks, distortion and cracked or
chipped paint.
4-201. Visua11y inspect f1uid passage bo1t (4) for cracks and corrosion. Inspect
f1uid passages for dirt or other foreign matter. Inspect wrenching f1ats for
rounded edges, and threads for damage.
4-202. Inspect fue1 manifo1d assemb1y (6) as fo110ws:
a. Visually inspect manifold for distortion, dents, and corrosion. Inspect

sealing surfaces of bosses for nicks and scratches.
b. Perform dye penetrant inspection per MIL-I-6866 to brazed joints at tee

connection of supp1y 1ine to manifo1d ring and both direct1y adjacent joints on
manifo1d ring at fue1 nozz1es.
c. Pressure test fue1 manif01d assemb1y as fo11ows:
(1) Connect contro1 source of air pressure, zero to 500 psig, to inlet
of manifo1d.
(2) B10ck alI out1ets from manifo1d.

(3) App1y 500 psig air pressure to manifo1d and c10se air supp1y to in-
1et of manifo1d.
(4) Inspect manifo1d pressure reading after one minute for indication
of 500 psig. Leakage, as noted by 10ss of ~ressure is not acceptab1e.
4-203. Inspect fue1 nozz1e assemb1ies (8) as f0110ws:
a. Visua11y inspect fue1 nozz1e assemb1y for corrosion, wear, cracks and
heat damage; inspect threads for stripped, crossed or worn threads.
b. Perform functiona1 test of fue1 nozz1e assemb1y using suitab1e test
setup. Install Adapter 280384-4, in fuel nozz1e assemb1y; insta11 assemb1ed items
in Tester, 285496-1-1, using Adapter, 285497-1-1. Provide a f10w of ca1ibrating
f1uid per MIL-C-7024B, type 11 at suitab1e pressures, flows up to 50 pounds per
hour, and at a temperature of 60° to 80°F (16° to 27°C).
4-119
•
NAVAIR 03-105-AB-52
c. Measure the spray angle at fuel inlet pressures of 25 and 200 psig.
Spray angle shall be 55 to 60 degrees measured at a distance of one inch from the
spray apex.
d. Measure the flow at 200 psig inlet fuel pressure. The flow shall be 20
+0.5 pounds per hour.
e. Check the fuel spray quality. The fuel spray shall be in the form of a
fully developed cone of finely divided droplets with no solid streaks, disconti-
nuities, bubbling or spitting over the range of fuel pressures from 15 to 400 psig.
4-204. Inspect manual prime norma11y c10sed solenoid va1ve (22) as follows:
a. Insta11 valve in test setup that will indicate flow of fuel (MIL-C-
7024B, type 11) through valve.
b. De-energize vaIve solenoid and apply 50 +2 psig fue1 pressure to valve

inlet.
c. App1y 10 volts dc (maximum) to valve solenoid and check that valve opens
by observing fIow indication.
d. De-energize va1ve solenoid and apply 600 +10 psig to va1ve inlet.
e. Apply 30 volts dc to va1ve solenoid. Check that va1ve opens.
f. Slowly reduee solenoid voltage to 10 volts de and cheek that solenoid

does not drop out.
g. Reduce pressure to zero and de-energize valve solenoid. Apply 50 +2

psig to valve in1et, and check that valve interna1 1eakage does not exceed five cc
per hour.
h. Reduee pressure to zero and remove valve from test setup.
4-205. Inspect solenoid mounting brackets (15, 27) for distortion and cracks.
4-206. Inspect normally open solenoid valve (30) as follows:
a. Install valve in test setup that wil1 indicate flow of fuel (MIL-C-
7024A, type 11) through valve.
b. De-energize solenoid of valve and apply 50 +2 psig fuel pressure to

va1ve inlet.
c. Apply 10 volts de (maximum) to valve solenoid. Check that valve eloses

by observing termination of fuel flow.
d. Apply 400 +5 psig fuel pressure to va1ve inlet and hold for five
minutes.
4-120
NAVAIR 03-105-AB-52
e. De-energ1ze solenoid of valve and check that valve opens within 0.5
seconds. Reduce pressure at valve inlet to zero.
f. Energize valve solenoid and apply 300 psig fue1 pressure to inlet of
valve, and check that interna! leakage through valve does not exceed five cc per
hour.
4-207. Inspect 011 strainer assemb1y (32) as fol10ws:
a. V1sua11y inspect mesh screen for rips, tears, d1stortion and c1eanliness.
b. Visua11y inspect braze between screen and adapter for cra('l•.s.
4-208. Visua11y inspect tower shaft cover (37) for cracks ~~ distortion.
4-209. Inspect power turbine stator assemb1y (39) as f0110ws:
a. V1sually inspect stator assembly for cracks and foreign object damage.
b. Dimensiona11y inspect power turbine stator assemb1y in accordance with

figure 4-31.
DIAA
6.315 TO
6.320 IN.
Figure 4-31. Inspection of Power Turbine Stator Assembly
4-121
..
NAVAIR 03-105AB-52
c. Perform fluorescent penetrant inspection in accordance with MIL-I-6866,

type I, method A.
4-210. Inspect gas generator containment shield assemb1y (40, figure 4-5) as
follows:
a. Visua11y inspect shie1d assemb1y for cracks, distortion and heat damage.
b. Inspect pins and segments for security.
c. Dimensiona11y inspect gas generator containment shie1d assembly in

accordance with figure 4-32.
d. When inspecting the gas generator containment shield assembly in accordance with
figure 4-32, B and C diameters of 4.703-4.707 inches and 6.311-6.315 inches, respectively, shall be used.
e. Gas generator containment shield assemblies which fail to meet the B and C diamete:-
requirements specified in paragraph d above may be repaired in accordance with the following
procedures:
(1) Containment shield assemblies on which the B diameter is undersize aml/or out-of·
l'ound, including wheel rub damage, sha)) be repaired as follows:
NOTE
Part must be machined dry to avoid contamination of panmt metal.
(a) Grind the B diameter surface the minimum amount necessary to obtain the
dimensional requirements ensuring that the concentricity and normality requirements of figures
listed in pal'agraph d above are maintained. One hundred percent clean-up of' B diameter surface is not
required. Deburr machined edges 0.005 to 0.025 incho
(b) VisuaUy inspect ground surfaces for cracks. Presence of cracks shall be cause
for rejection.
(c) Thoroughly clean to remove a11 contamination. Hot water rinse and aiT blow or
bake dry.
(2) Containment shield assemblies which are oversize on B diameter surface shall be
repaired in accordance with the procedures specified in paragraph (1) except for the following
deviations:
(a) Measure diameter B after clean-up of segments. When B diameter is between

4.714 and 4.743 inches, rebuild the segment surface using paragraph 1 below. Wben this dimension is
between 4.744 and 4.790 inches, rebuild the segment surface using paragraph 2 below. When this
dimension exceeds 4.791 inches, replace segments in aceordance with paragraph 4·492.
(b) Build-up segmented inner surfaces on each containrnent shield assernbJy a

minimum 01 0.010 inch thickness to obtain a maximum I.D. of 4.694 inches as follows:
4-122 Change 2
NAVAIR 03-105AB-52
1 Apply Mete0 443 material or equivalent by plasma spray using Mete0

procedure No. P443-10. Mask the support ring ofTitanium to protect it from glass heads or grit during
cleaning and from overspray during spray application. The segmented ends and sides must be free
from plasma spray.
2 Ensure part is cleaned for welding. Apply L-605 weld rod to the segment to
dimensions in paragraph (b) above. Apply weld to the inner face of segmenta only, taking care to mask
the Titanium support ring from weld spatter and to keep segment end gaps open.
(c) Machinelgrind the sprayedlwelded diameter to 4.703-4.705 inches ensuring that

the concentricity and normality requirements of figures listed in paragraph d above cl~ .uaintained.
Trim segmented ends to maintain clearance gap of 0.03 to 0.09 inch wide by 0.09 to 0.095 inch deep (six
places). Deburr machined edges 0.005 to 0.025 incho
(d) Stress relieve the containment shield assembly in an oven preheated to 1075°F to
1125°F for a time period of one to two hours, foIlowed by air cooling after removal from oven.
(e) Visual1y inspect the machined surface for surface cracks. Presence of cracks is
cause for rejection.
(3) Containment shield assemblies which are oversize on the diameter (not to exceed
6.320 inches) shaIl be machined the minimum amount necessary to obtain the required dimension
ensuring that the applicable concentricity and normality requirements of figures listed in paragraph d
above are maintained. One hundred percent surface clean-up is not required.
(4) Containment shield assemblies which are undersize or out-of-round on C diameter

shaIl be machined minimum amount required to eft'ect one hundred percent clean-up, but not to falI
below 6.281 inches diameter, and processed as folIows:
(a) Mask as required and grit blast the surface to he plasma sprayed with meteolite
C.
(b) Preheat to 2500F-4000F.
(c) Utilizing Mete0 P90F-I0 parameters, plasma spray sufticiently to allow for
fmish machining (6.3li inches diameter minimum).
(d) Grind to 6.311-6.313 inches diameter. Deburr 0.025 inch maximum.
Change2 4-122A
NAVAIR 03-105AB-52
SURfACEA
.PL
?li
~~
DIAB DIA c
g~
DIAMETER B SHAL L SE CONCENTRIC WITH DIAMETER C WITHIN 0.002

INCH TOTAL INDICATOR READING AND SHAL L BE NORMAL TO SUR-
fACE A WITHIN 0.001 INCH TOTAL INDICATOR READING.
B C
".703 TO 6.311 TO
4.707 IN. 6.315 IN.
1-12A-899
Figure 4-32. Inspection of Gas Generator Conta1nment Sh1eld Assembly
4-122B Change2
NAVAIR 03-105AB-52
f. Perform f1uorescent penetrant inspection in accordance with MIL-I-6866, type 1, method B.
4-211. Visua11y inspect shield retainers (43, figure 4-5) for distortion and cracks.
4-212. Visua11y inspect shroud retaining ring (47) for corrosion, cracks, and dis-
tortion.
4-213. Inspect impe11er shroud (49) as fo11ows:
a. Visually inspect shroud for cracks, corrosion, and for evidence of rubbing. I
b. Dimensiona11y inspect impe11er shroud in accordance with figure 4-33.
4-214. Inspect jet fue1 starter JFS housing assemb1y (54, figure 4-5) as fo11ows:
a. Visua11y tnspect housing for dents, cracks and corrosion. Inspeçt

adapter and inserts for security and damaged threads.
DIAS
SURFACE A SHAL L SE FLAT WITHIN 0.001 INCH.

DIAMETER B SHALL BE NORMAL TO SURfACE A WITHIN 0.001
4.556 TO
4.558 IN.
Figure 4-33. Inspection of lmpe11er Shroud

NAVAIR 03-105AB-52
b. Dimensionally inspect housing assembly in accordance with figure 4-34.
c. Perform fluorescent inspection of alI exposed (unpainted) surfaces in accordance with
I
MIL-I-6866, type I, method C.
d. Ifpaint coating is removed for any reason, perform fluorescent penetrant inspection of
entire housing in accordance with MIL-I-6866, type I, method B.
DIA C DIA O
OIAMETER A SHALL BE CIRCULAR WlTH RESPECT TO OIAMETER C WITHIN 0.005 INCH

TOTAL INOICATOR REAOING.
SURFACE B RÚNOUT SHALL BE WITHIN 0.002 INCH TOTAL INOIACTOR REAOING WITH
RESPECT TO OIAMETER A, ANO SHALL BE PARALLEL WITH SURFACE E WITHIN 0.002 INCH,
DIAMETER D SHALL BE CIRCULAR WITH RESPECT TO DIAMETER A AND SURFACE 8 WITHIN

SURFACE E RUNOUT SHALL BE WITHIN 0.002 INCH TOTAL INDICATOR READING \'11TH
RESPECT TO OIAMETER D.
A C o E
8.538 TO 7.861 TO 7.874 TO 8.782 TO

8.539 IN. 7.876 IN. 7.890 IN. 8.mlN. 1-12A-938Rl
Figure 4-34. lnspection of Jet Fuel Starter Housing Assembly
4-124 Change2
,
NAVAIR 03-105AB-52
4-215. Visually inspect identification plate (54A, figure 4-5) for security and
legibUity.
4-216. Visually inspect internaI wrenching plain nut (57, sheet 2) for cracks,
rounded internal wrenching points, and damaged threads. Check balance nut in accor-
dance with'paragraph 4-498.
4-217. Inspect compressor impeller (58) as follows:
a. Visually inspect each blade of impeller for n1cks, cracks, scratches,

corrosion, erosion and for evidence of scoring or rubbing on edges of blades while
us1ng a strong light and magnifying glass.
NOTE
Refer to figure 4-74 for information regarding areas
of impeller from which metal may have been removed
for dynamic balancing purposes.
b. V1sually 1nspect splines for cracks, n1cks, and evidence of wear. Di-
mensionally inspect splines as follows 1f wear 1s 1ndicated.
(1) Place two 0.0600 inch diameter pins in wear area of opposite
splines.
(2) Inspect for maximum diameter between pins of not more than 0.4377
inch.
c. Dimensionally inspect impeller in accordance with figure 4-35.
d. Fluorescent penetrant inspect in accordance with MIL-1-6866, type l,

method A.
e. Check balance impeller in accordance with paragraph 4-499, step d.

4-217A Inspect impeller seal (63) as follows:
NOTE
Ensure that cleanliness is maintained at alI times.
a. Carefully remove the seal from the gas generator assembly and inspect for evidence of
leakage past the carbon element and the rotor face.
b. Visually inspect carbon face for cracks, scratches, nicks, pits and chips.
(1) Cracks are not permitted.
(2) Pits larger than 0.020 inch in diameter or 0.020 inch in depth are not permitted.
(3) No more than four pits are permitted on seal surface.
Cbange2
.
NAVAIR 03-105AB-52
(4) Nicks shaIl not extend, either individuaIly or collectively, across more than 10
percent of sealing surface.
(5) Scratches in sealing surface ahall not exceed a depth ofO.0005 inch, a width ofO.0005
inch, or a length that traverses a radial band equal to 30 percent of sealing surface.
(6) Defects on edgea of carbon ring shall not be larger than 0.020 incho
(7) Totallength of defects on edges of carbon ring shaIl not exceed 0.500 incho
(8) SeaIs exceeding these limits shal) be replaced.
c. Visually inspect rotor face for coke and vamish deposits. No measurable quantity is
permitted. Metal discoloration is permitted.
d. Seals which exhibit no leakage indications or other visible damages shaIl be used as ia
subsequent to cleaning and testing as follows:
WARNING
1, 1, 1, trichloroethane, MIL-T-81533, vapors can be fatal. Use only

with adequate ventilation. High concentration ofvapors are
anesthetic and dangerous to Iife. Eye irritation and dizziness are
(1) Clean the seal by the ultrasonic cleaner process using 1, 1, 1, trichloroethane, MIL-T-
81533.
(2) Clean the mating face ofthe carbon element and the rotor face with a lint-free wiper
(Kimberly Clark Type 900-S, Neenah, Wisconsin, or equivalent) saturated with a solvent <MIL-T-81533
or equivalent). When cleaning the rotor, place wiper on a flat surface and rotate rotor in a figure eight
motion untf residue ceases to be transferred to the wiper.
e. Static test the seal (rotor included with a rubber stopper simulating the shaft) in a vacuum
leak test fixture prior to installation into the gas generator assembly. The seal must be placed such that
the vacuum is drawing the rotor against the carbon face. Restrain the rotor to the minimum operating
range (0.246 inch) per the applicable parts drawing. Ensure the free dimension of the carbon face from
the sheIl is within the operating range (0.276/0.246 inch). Connect seal test finure to a ~anometer which
is connected to a vacuum system. Observe that the minimum manometer negative pressure is above 26
inches Hg and close valve to vacuum system. Check manometer and observe that negative pressure
does not decay more than 0.500 inch below 26 inches in 30 seconds. Ir nega tive pressure decays from 26
inches to less than 25.5 inches in 30 seconds, the seal is defective.
f. Damaged, wom, or leaking seal assemblies shall be replaced with a new seal assembly or
further processed as follows:
4-124B Chang&2
I
•
NAVAIR 03-105AB-52
WARNING

anesthetic and dangerous to lire. Eye irritation and dizziness are
(1) Clean the seal assembly carbon element with the vapor degreasing process in
paragraph 4-62. After vapor degreasing, immerse seaIs in MIL-C-14460 corrosion removing compound
at 190 - 2100F until clean. Rinse and air dry.
(2) Lap the rotor face on the rotating lapping machine to provide flatness requirement
within three helium light bands. 8houlder on rotor shaIl be paraUel to rotor face within 0.0002 incho
Prior to checking fIatness, clean in accordance with paragraph d.
NOTE
The foIlowing steps apply to seaIs without a tack welded carbon

element retainer. If retainer is tack welded go to paragraph (7).
(3) Carefully PIY out the carbon element retainer using a seribe or other suitable tool
ensuring retainer is not damaged. Start by prying at the anti-rotation slots and graduaUy working
around until retainer is removed.
(4) Remove carbon element, o-ring packing, washer and wave spring.
(5) Place a new emery polishing paper grit 4/0 on a flat surface and hand lap the mating
face of the carbon element to remove scratches and nieks. Use a flgUl'e eight lapping motion. Provide
flatness requirement within three helium ligbt bands using a new three micron lapping filmo Prior to
cheeking fIatness, clean in accordance with paragraph d.
(6) Reassemble seal in reverse order of disassembly and as follows.
(a) Lubricate new o-ring packing, 89413-125, or equivaIent with engine oil, MIL-L-
23699 and instaIl in groove in carbon element (acceptable equivalent o-ring packings are MS938R-125,
NAS 1593-125, MB3248/2/125, ST 3001-125, R149P125, R1309P125 and 77-545-2-125).
(b) Install wave spring in seal shell and instaII washer on top or wave spring.
(c) Install carbon element with o-ring packing in seal shell.
(d) Press carbon element retainer in seaI shell to bottom exercising caution to align
anti-rotation tabs in retainer with anti-rotation slots.
(7) Test the seaI assembly in accordance with paragraph (5) above. SeaIs that still do not
pass the leakage requirements shaIl be replaced. Seal8 with tack welded carbon element retainer shall
be retained for future repair evaluation ifsufticient quantity generates.
Change2 4-124(")(4-124D blank)

l
NAVAIR 03-105AB-52
4-218. Visually inspect bearing retaining ring plate (66, figure 4-5) for cracks
and distortion.
4-219. Visually inspect spinner lockring sbaft (69) for wear through of dry-film
lubricant, worn or eIongated pin holes, burrs, nicks and cracks •
.
4-220. Inspect compression spring (70) as follows:
a. Visually inspect spring for cracks and corrosion. Check alignment of

coils by rolling spring across a smooth, flat surface; spring must roll smoothly
and in a straight line.
b. Using a standard compression-type spring tester, check spring compres-

sion. Load required to compress spring to Iength of 1.20 inches must be 0.060
+0.06 pounds.
Change 2 4-125
NAVAlR 03-105-AB-52
DIAA
t
SURFACE B SURFACE o
SURFACE B SHALL BE PARALLEL TO SURFACE O WITHIN 0.0002 INCH

TOTAL INDICATOR READING.
SURFACE O SHALl BE NORMAL TO DIAMETER E WITHIN 0.0002 INCH

DIAMETER E SHAL L SE CONCENTRIC WITH DIAMETER A WITHIN 0.006

A C E
0.984 TO 2.412 TO 0.5852 TO

0.996 IN. 2.422 IN. 0.5855 IN.
Figure 4-35. Inspection of Compressor Impe11er
4-221. Inspect axial f10w turbine whee1 assemb1y (72) as fo11ows:
a. Visua11y inspect each b1ade of whee1 assembly for nicks, cracks,

scratches, and evidence of scoring or abrasion using strong 1ight and magnifying
glass.
b. Inspect threads for stripped, crossed or worn threads.
c. Visua11y inspect sp1ines for wear; if copper plating is worn through,

dimensionally inspect as fo11ows:
(1) P1ace two 0.0800 inch diameter pins in ",ear area of opposite sp1ine
grooves.
(2) Inspect for minimum measurement across pins of not 1ess than 0.6138
incho
d. Visual1y inspect serrations for wear. Dimensiona11y inspect as fo11ows

if copper p1ating i8 worn through.
4-126
1
NAVAIR 03-105AB-52
(1) Place two 0.0400 incb diameter pins in wear area of opposite serra-
tions.
(2) lnspect for minimum measurement across pins of not less than 0.6893
incho
NOTE
New turbine wheel assemblies sball meet specified di-

mensions. Only in-service wbeel assembies are per-
mitted allowable variation.
e. The wheel assembly maU be replaced if diameter E figure 4-36 exceeds 4.652 inches. [
f. Perform fluorescent penetrant inspect10n in accordance with MIL-I-6866,

type l, method B.
g. Check balance of wheel assembly in accordance with paragraph 4-503, step

c.
4-222. lnspect annular ball bearing (74, figure 4-5) in accordance with paragraph
4-105.
4-223. Inspect bearing carrier (75) as follows:
a. Visually inspect bearing carrier for cracks, nicks, scratches and corro-
sion.
b. Dimensionally inspect bearing carrier in accordance with figure 4-37.
4-224. lnspect pinion spiral beve1 gear (77, figure 4-5) as follows:
a. Visually inspect pinion spiral beve1 gear for cracks, chipping, or wear
of teeth, and scratches or scores on bearing surfaces.
b. Dimensionally inspect in accordance with figure 4-38.

c. Perform magnetic particle inspection in accordance w1th MlL-l-6868.
4-225. Inspect bearing spacer (78, figure 4-5) as follows:
a. Visually inspect bearing spacer for scratching or scoring of bearing

surfaces.
b. Dimensionally inspect bearing spacer in accordance with fi~ure 4-39~
c. In addition to the dimensional requirements, measure the axial dimension of the bearing
spacer. This dimension shall be 4.769/4.765 inches. Also measure inside diameters.
L
Change2 4-126A/(4-126B blank)

I
I
I
I
I
I
I
I
NAVAIR 03-105AB-52
d. Bearing spacers less than 4.765 inches axially, or I.D. of small bore more than 0.6602 inch
or large bore more than 0.6699 inch shall be repaired as follows:
NOTE
The exact measurement of the bearing spacers sbaIl be properly

recorded to ensure that plating may be applied which will a110w for
final machining.
(1) Grind axial face, if reguired, to ensure surfaces are sguare. If inside diameters are
oversize, grind smaU bore to 0.666 inch, and large bore to 0.675 incho Identify surfaces that require
chromium plate.
(2) Magnetic partide inspect.
(3) Mask, and chromium plate axial faces per reference (a) to ensure an after plate
length greater than 4.772 inches. One or both faces may be plated to obtain the after plate length.
Chromium plate inside diameters approximately 0.010 inch over (mish print dimension (smaU bore
0.650 inch, large bore 0.659 inch.).
(4) Embrittlement relieve by baking at 375°F <±25°F) for three hours.
(5) Grind axial face and/or inside diameters to fmish dimensions per Drawing No.
(99193) 364333. Remove alI rough edges.
e. Perform magnetic particle inspection in accordance with MIL-I-6868.
f. Check balance or bearing spacer in accordance with paragraph 4-507, step b.
Change 2 4-127
NAVAIR 03-105AB-52
SURFACE F
SPLlNES
"
OIAA
~ ~
OIAC
j -~
1I -1 DIA E
DIA B
t
1
DIA O
_J
OIAMETER A ANO C SHALL BE CONCENTRIC WlTH DIAMETERS B ANO O WITHIN
DIAMETERS B AND O SHALl BE ROUND WITHIN 0.0001 INCH TOTAL INOICATOR

READING.
DIAMETER E SHALL BE CONCENTRIC WITH OIAMETEP. O WITHIN 0.001 INCH TOTAL

INDICATOR REAOING.
A B C O E
0.5850 TO 0.5906 TO 0.6595 TO 0.6693 TO ".647 TO

0.5852 IN. 0.5908 IN. 0.6598 IN. 0.6695 IN. 4.652 IN.
ALLOWABLE VARIATlON
".643
IN. MlN
1-12A-939Rl
Figure 4-36. Inspection ofAxial Flow Turbine Wheel Assembly
4-226. Visually inspect bellows seal retainer (80, figure 4-5) for distortion,
cracks and corrosion.
4-227. Inspect first stage stator assembly (81) as follows:
a. Visually inspect nozzle for cracks, vane erosion and foreign object
damage.
4-128 Change 2
NAVAIR 03-105AB-52
DIAA
I
SURFACE B-./
SURFACE BSHALL 8E NORMAL TO DIAMETER A WITHIN 0.0005

1.3780 TO
1.3783 IN. I-12A-861
Figure 4-37. Inspection of Bearing Carrier
NOTE
Circumferential cracks in weld joint between nozzle and ring
(weld areas 2 and 4, figure 4-77) are permissible up to 1.000 inch
separated by a minimum of 0.500 inch provided crack is not in
parent material
b~ Dimensionally inspect first stage stator assembly in accordance with

figure 4-40.
c. Perform fluorescent penetrant inspection in accordance with MIL-I-6866,
type I, method A.
4-228. Visually inspect heat shield (82,.L1gure 4-5) for cracks, distortion and
corrosion.
4-229. Visually inspect seal retatner (83) for cracks, distortion and corrosion.
NOTE
Ensure that cleanliness is maintained at alI times.
a. CarefuIIy remove the seal from the gas generator assemb1y and inspect for any evidence of
leakage past the catbon element and the rotor face.
4-128A
NAVAIR 03-105AB-52
b. SeaIs which exhibit no leakage indications or other visible damages sha]] be used as ia
subsequent to cleaning and testing as follows:
WARNING

anesthetic and dangeroua to life. Eye irritation and dizziness are
not use near heat, sparks, open fiame or any other source of
(1) Clean the seaI by the ultrasonic cleaner process using trichloroethane, MIL-T-81533.
(2) Clean the mating face ofthe carbon element and the rotor face with a lint-free wiper
(Kimberly Clark Type 900-S, Neenah, Wisconsin, or equivalent) saturated with a solvent (MIL-T-81533
or equivalent). PIace wiper on a flat surface and rotate the seaI and rotor individual1y in a figure eight
motion until residue ceases to be transferred to the wiper.
c. Static test the seaI (rotor inc1uded) in a vacuum Ieak test fixture prior to installation into
the gas generator assembly. Connect seal test fixture to a manometer which is connected to a vacuum
system. Observe that minimum manometer negative pressure is above 26 inches Hg. and close valve to
vacuum system. Check manometer and observe that negative pressure does not decay more than 0.5
inch below 26 inches in 30 seconds. If negative pressure decays from 26 inches to less than 25.5 inches in
30 seconds, the seal is defective.
d. Damaged, wom, or leaking seal assemblies shall be replaced with a new seal assembly ir
available or further processed as follows:
WARNING
I, 1, 1, trichloroethane, MIL-T-81533, vapors can be fatal. Use only

with adequate. ventilation. High concentration of vapors are
not use near heat, sparks, open fiame or any other source of
(1) Clean the seal assembly carbon element with the vapor degreasing process in
paragraph 4-62.
(2) Lap the rotor face on the rotating lapping machine to provi de fiatness requirement
within three helium 1ight bands.
4-128B Change2
ti
NAVAIR 03-105AB-52
(3) Place an emery polishing paper grit 4/0 on a flat surface and hand lap the mating
face of the carbon element to remove scratches and nicks. Use a figure eight lapping motion. Provide
flatness requirement within three helium light bands using three (3) micron lapping film.
(4) Prior to checking flatness, clean in accordance with paragraph b.
e. Test the seal assembly in accordance with paragraph c above.
4-229A Inspect carbon face.
4-230. Inspect turbine gas-oil seal (85) as follows:
a. V1sually inspect sealing surfaces of rotor and carbon for scratches,

cracks, ch1ps and nicks.
b. Dimensionally inspect seal and rotor in accordance with figure 4-41.
4-231. Inspect bearing carrier assembly (88, 89, figure 4-5) as follows:
a. V1sually inspect key (88) for burrs, nicks, and secur1ty.
Change 2 4-129
NAVAIR 03-105AB-52 •
SURFACE B
SURFACE A SHALL BE NORMAL TO OIAMETER C WlTHIN 0.0002 INCH TOTAL

INOICATOR REAOING.
SURFACE a SHALL BE PARALLEL TO SURFACE A WITHIN 0.0001 INCH TOTAL

INOICATOR REAOING.
0.6600 TO
0.6605 IN. 1-12A-906 RI
Figure 4-38. Inspection of Pi~ion Spiral Bevel Gear
t
oIAA
f
DIA B
t
DIA E DIA F
f
I ~ i 1
SURFACE c-" DlUG • ' - SURFACE D·
CIRCUI,AR RUNOUT OF SURFACE C SHAU. NOT ElE MORE THAN 0.0001

INCH TOTAL INDICATOR AEADlNG WllH RESPECT TO DlAMETER B.
SURFACE oSHALL BE PARALLEL TO SURFACE C WlTHN 0.0002
INCH TOTAL INDICATOR FIEADING.
RUNOUT OF DIAMETER E SHALL NOT SE MORE THAN O.OOO5INCH
TOTAL INOICATOR READlNG WllH RESPeCT TO DlAMETER B.
CIRCUlAR RUNOUT OF SURFACE OSHAU. NOT BE MORE THAN 0.0001 INCH
TOTAL INDlCATOR READlNG WlTH RESPECT TO DIAMETER E.
A B E F G
0.79 TO 0.6599 TO 0.6696 TO 0.85 TO ".769 TO

0.81 IN. 0.6602 IN. 0.6699 IN. O.B71N. 4.765 IN.
1-12A-9OQ
Figure 4-39. Inspection of Bearing Spacer
4-130 Change 2
r~VAIR 03-105-AB-52
-- SURFACE E
- /
L
SURFACE o
r-....
i'.
DIAA DIAB DIA C
]0
=
-
SURFACE E SHALL BE PARALLEL TO SURFACE O WITHIN 0.002 INCH TOTAL INOICATOR REAOING.
SURFACE D SHALL BE NORMAL TO DIAMETER B WITHIN 0.005 INCH TOTAL INDICATOR READING.
OIAMETERS BANO C SHALL BE CIRCULAR WITHIN O.OO3INCH TOTAL INOICATOR REAOING.
A B C
4.890 TO 3.395 TO 3.231 TO

4.895 IN. 3.400 IN. 3.235 IN.
Figure 4-40. Inspection of First Stage Stator Assembly
4-131
NAVAIR 03-105-AB-52
SURFACE B---' i I-SURFACEC

I
I
I I
DIA O
DIAA·
SURFACE B SHAlL SE PARALlEl TO SURFACE C WITHIN 0.0002 INCH Al\iD i'OOIlMAL

TO OIAMETER A WITHIN 0.0002 INCH.
SURFACE C OF ROTOR ANO SEAl SHALL SE FlAT WITHIN THREE HELlUM lIGHT SANDS.
A D
0.6697 TO 2.0905 TO
0.6700 IN. 2.0910 IN.
Figure 4-41. Inspection of Turbine Gas-Oi1 Sea1
4-132
NAVAIR 03-105-AB-52
b. Visually inspect carrier (89) for cracks, burrs, nicks, corrosion, and
distortion.
c. Visually inspect carrier (89) in accordance lv.lth figure 4-42.
4-232. Inspect compression helical spring (90, figure 4-5) as follows:
a. Visually inspect spring for cracks and corrosion. Check alignment of

coils by rolling spring across a smooth, flat surface; spring must rol1 smooth1y and
in a straight line.
b. Using a standard compression-type spring tester, check spring compres-

sion. Load required to compress spring to length of 0.75 inch must be 100.0 +10.0
pounds.
4-233. Visually inspect oil tube assembly (93) for distortion, cracks and obstruc-
tions.
4-234. Inspect fuel-air combustor assembly (97) as follows:
f
l DIA B
J
DIAA
DIAMETER A SHALL BE CONCENTRIC WlTH DIAMETER BVIITHIN 0.0005 INCH

SURFACE C SHALL BE NORMAl. TO DIAMETER B WITHIN 0.0005 INCH TOTAL

INDICATOR READING.
A B
1.8994 TO 1.5748 TO
1.8997 IN. 1.5751 IN.
Figure 4-42. Inspection of Bearing Carrier Assembly
4-133
NAVAIR 03-105AB-52
4. Visually inspect fuel-air combustor assembly for cracks, buckling,

broken welds, or erosion; check for missing vanes. Inspect seals for wear or dis-
tortion. Inspect grommets for wear and free movement.
b. Fluorescent penetrant inspect in accordance with MIL-I-6866, type r,

method A.
c. Dimensionally inspect seals in accordance with figure 4-43.
4-235. Inspect tower sbaft cover (102, figure 4-5) for distortion, cracks, nicks
and burrs.
o
o
o
-
:-0
C>
o
-
COlO
O
O
-t 1
DIA C
_I
o 00
o
DIA A
C>
o
C>
C>
:0
::
o
• O
O
e
A C
4.897 TO 3.214 TO
4.927 IN. 3.230 IN.
1-12A-857Rl
Figure 4-43. Inspection of Fuel-Air Combustor Assembly
4-134 Change 2
ltAVAIR 03-l05-AB-52
4-236. Inspect spiral beve1 gear assembly (107, 108) as follows:
a. Visually inspect spiral beve1 gear assembly for cracks, chipping or ab-
normal wearing of teeth, and scratching or scoring of hub surfaces. Inspect tbreads
for stipped, crossed or worn tbreads; inspect pin (107) for security.
b. Visua1ly inspect sp11nes for wear; 1f wear is indicated, dimensiona11y

inspect. Spline measured over 0.0540 inch diameter pins must not be more than
0.2371 incho
c. Dimensionally inspect spiral bevel gear assembly in accordance with

figure 4-44.
d. Perform magnetic partic1e inspection in accordance with MIL-I-6868.
4-237. Inspect sleeve spacers (111, 112, figure 4-5) as fo11ows:
a. Visua11y inspect spacers for distortion, nicks, and burrs.
b. Dimensiona11y inspect spacers for 1ength within 0.1800 to 0.1802 incho
4-238. Inspect bearing carrier (114) as fo11ows:
SURfACE BSHAL L BE NORMAL TO DIAMETER A WITHIN 0.0005

INCH TOTAL INDICATOR READING,
0•.4720 TO
0.4723 IN.
Figure 4-44. Inspection of Spira1 Bevel Gear Assembly
4-135
NAVAIR 03-105-AB-52
a. Visua11y inspect bearing surfaces for scratches or scoring.
b. Dimensiona11y inspect bearing carrier in accordance with figure 4-45.
4-239. Inspect tower shaft housing assemb1y (figure 4-6) as fo11ows:
a. Inspect diffuser housing assemb1y (6, 7) as fo11ows:
(1) Visua11y inspect inserts (6) for damaged threads and security.
(2) Visua11y inspect housing (7) for cracks, corrosion, and for chip-
ping or pee1ing of paint.
b. Inspect diffuser p1ate (8) as fol1ows:
(1) Visua1ly inspect diffuser p1ate for cracks, corrosion and nicked or
broken vanes.
(2) Dimensionally inspect diffuser p1ate in accordance with figure

4-46.
c. Inspect support (la, figure 4-6) as fo11ows:
(1) Visua11y inspect support for cracks, corrosion, and scratching or

acoring of bearing aurfaces.
SURFACE A
t
DIA B
t
DIA C
1 1
SURFACE A SHAlL BE NORMAL TO DIAMETER C WITHIN 0.001

DIAMETER B SHAll BE CONCENTRIC WITH DIAMETER C WITHIN

SURFACE o SHALl SE NORMAL TO DIAMETER BWITHIN 0.0003

B C
1.3211 TO 1.1025 TO
1.3213 IN. 1.1028 IN.
4-136
r
NAVAIR 03-105-AB-52
SURFACE A~I==
DIA B DIAC
~~-----......
SURFACE A SHAL L BE STRAIGHT WITHIN 0.002 INCH TOTAL

INDICATOR READING.
DIAMETER C SHAL L BE CONCENTRIC WITH DIAMETER 8 WITHIN

0.001 TOTAL INDICATOR READING.
B C
3.099T0 7.001 TO
3.101 IN. 7.003 IN.
Figure 4-46. Inspection of Diffuser P1ate
(2) Dimensiona1ly inspect support in accordance with figure 4-47.
d. Visua11y inspect inserts (12, 13, 14, 15, figure 4-6) for security and
damaged threads.
e. Visua11y inspect p1ugs (16, 17) for security.
f. Visua11y--inspect tower shaft housing (18 through 22) for cracks, corro-
sion, and for loose or damaged inserts.
g. Pressure test gasket (11) as fol1ows:
(1) Provide suitab1e source of air pressure to supp1y 30 pai pressure.
(2) C1amp Pressure Test Fixture, 287082-1-1, over flange of housing

(22).
(3) Connect preasure line to fitting on fixture and apply 30 psig pres-
aure.
(4) Check that leakage across gasket (11) does not exceed 5 cc/mino
4-137
NAVAIR 03-l05-AB-52
n
DIA B
1
DIA C
I I
SURFACE A SHALL BE NORMAL TO DIAMETER B WITHIN 0.002
B C
2.0042 TO 2.0880 TO
2.0048 IN. 2.0890 IN.
Figure 4-47. Inspection of Support
4-240. INSPECTION OF ACCESSORY DRIVE ASSEMBLY (figure 4-7).
4-241. Visually inspect identification plate (1, sheet 1) for security and legi-
bility.
4-242. Visually inspect lubrication instruction plate (2) for security and legi-
bility.
4-243. Inspect magnetic machine thread plug (5) as follows:
a. Visually inspect magnet for rounded t~enching flats, damaged threads,

and torn lockwire holes.
b. Check for closing operation of valve when magnet is removed.
c. Visually inspect body for rounded wrenching flats, damaged threads, and
torn lockwire holes.
4-244. Visually inspect oil dip stick (7) for damaged threads, rounded wrenching
flats, torn lockwire holes and bent or broken gauging probe.
4-245. V1sually inspect sediment strainer element assembly (9) for cleanliness and
collapsed or torn screen. Inspect for separation of magnet or plug from screen.
4-246. Inspect compression helical spring (16) as follows:
4-138
NAVAIR 03-105-AB-52
a. Check spring coi1s for a1ignment. Rol1 spring across smooth, f1at sur-
face and check for smooth, straight, rol1ing action.
b. Check spriug teusion as follows:
(1) Compress spring to length of 0.48 incho
(2) Check for spring 10ad witbin 0.85 +0.09 pound.
4-247. Visual1y inspect pin (22) for security.
4-248. Iuspect c1utch jaw (23) as fo11ows:
a. Visually check for nicked, cracked or broken splines and teeth.
b. Visually inspect splines for wear, and dimensionally inspect splines as

fo11ows if visual inspection reveals wear.
(1) Place two 0.0600 inch diameter pins in wear area of opposite spline
grooves.
(2) Check that maximum dimension between pins does not exceed 0.2711
incho
c. Perform magnetic particle inspection in accordance with MIL-I-6868.
4-249. Inspect hydraulic motor (18) in accordance with paragraph 4-354.
4-250. Inspect fuel control assembly (24) in accordance with paragraph 4-324.
4-251. Inspect shafts (33, 36) as fo11ows:
a. Visually inspect shaft for cracked, chipped, or nicked splines. Inspect

shaft for corrosion and wear through of flash copper plating.
b. Dimensionally inspect splines as follows if wear is evidente

(1) Place two 0.0400 inch diameter pins in opposite apline groovea.
(2) Inspect for minimum measur~ent over pins of not 1ess than 0.2831
incho
4-252. Visually inspect switch adjusting shims (42, sheet 2) for distortion, folda,
tears, and burrs.
4-253. Inspect sensitive switch assembly (38) in accordance with paragraph 4-315.
4-254. Inspect switch actuating governor assembly (43 through 51) as follows:
a. Visua11y inspect f1yweight containment sleeve (43) for cracks and dis-
tortion.
4-139
NAVAIR 03-105-AB-52
b. Visua11y inspect f1yweights (45) for nicks, scratches and cracks.
c. Visua11y inspect governor pin (47) for scratches, nicks and burrs.
d. Check compression spring (49) as fo11ows:
(1) Visua11y inspect spring for cracks and corrosion.
(2) Check a1ignment of spring coils. Ro11 spring across smooth, f1at
surface, and check that spring ro11s straight and smooth.
(3) Compress spring to 10ad 1ength and check spring load as fo11ows:
Part Number Load Length Load
364702-1 0.490 inch 0.625 +0.025 pound
364703-1 0.490 inch 0.575 +0.025 pound
364332-1 0.490 inch 0.500 +0.050 pound
e. Inspect body assemb1y (50, 51) as fo11ows:
(1) Visua11y inspect insert (50) for security and damaged threads.
(2) Visua11y inspect body assemb1y (51) for nicks and burrs.
4-255. Inspect thrust washer (53) as fo11ows:
a. Inspect thrust surfaces for finish of AAB or better.
b. Dimensiona11y inspect washer for thickness within 0.061 to 0.063 incho
c. Perform magnetic partic1e inspection in accordance with MIL-l-686B.
4-256. Inspect spur gear (55) as fo11ows:
a. Visua11y check gear teeth for cracks, chipping, surface defects, and
wear.
b. Dimensiona11y inspect gear in accordance with figure 4-4B.
c. Perform magnetic partic1e inspection in accordance with MIL-l-686B.
4-257. Inspect spur gear (58, figure 4-7) as fo11ows:
a. Visual1y inspect gear teeth for cracks, chipping, surface defects and
wear.
b. Dimensional1y inspect gear in accordance with figure 4-49.
4-140
•
NAVAIR 03-105-AB-52
~--'-
r DIAB
DIAMETER B SHAL L BE NORMAL TO SURFACE A WITHIN 0.0005 INCH

I B
Figure 4-48. Inspection of Spur Gear
SURFACE A
DIAC
SURFACE A SHALL BE PARALLEL TO SURFACE BWITHIN 0.0005

SURFACE B SHALL BE NORMAL TO DIAMETER C WITHIN 0.0005

c
0.3125 TO
0.3130 IN.
Fi~re 4-49. Inspection of Spur Gear
4-141
NAVAIR 03-105-AB-52
4-258. Ispect spur gear (60, figure 4-7) as follows:
a. Visually inspect gear teeth for cracks, chipping; surface defects and
wear.
b. Dimensionally inspect gear in accordance with figure 4-50.
4-259. Visually inspect retainer (62, figure 4-7) for distortion, cracks, burrs
and corrosion.
4-260. Inspect matched rotary pump internaI and externaI gear set (3) as follows:
a. Visually inspect gear set for scratching, scoring and wear.
b. Dimensionally inspect gear set in accordance with figure 4-51.
rOIAB
F I - -....
t
lSURfACEA
OIAMETER B SHAL L BE NORMAL TO SURfACE A WITHIN 0.0005 INCH

TOTAL INOICATOR READING.
0.3125 TO
0.3130 IN.
4-142
NAVAIR 03-105AB-52
-, ,IM.S
DIA A r----,i
DIA C
1~1--.1
OIM. o
SURFACES INOICATED BY DIMENSION BSHALL BE NORMAL
TO OIAMETER A WITHIN 0.0005 INCH TOTAL INOICATOR
REAOING.
SURFACES INOICATEO BY OIMENSION O SHALL SE NORMAL TO
OIAMETER A WJTHIN 0.0005 INCH TOTAL INOICATOR REAOING.
A B C O
0.3125 TO 0.2515 TO 1.4990 TO 0.2495 TO

0.2525 IN. 1.4995 IN. 0.2500 IN. 1-12A-860
0.3130 IN.
Figure 4-5l. Inspection of Matched Rotary Pump Internal and

External Gear Set
4-261. Inspect 1ubrication pump caver (65, figure 4-7) as fo1lows:
a. Visual~y inspect cover for scratching, scoring and wear.
b. Dimensionally inspect cover in accordance with figure 4-52.

4-262. Inspect drive shaft (66, figure 4-7) as fo1lows:
a •. Visua11y inspect shaft for cracks, nicks, scratches, scores, corrosion,
and damaged threads. Inspect shaft splines for nicks, cracks and breaks.
b. Visually inspect splines for wear. Dimensionally inspect splines as

follows if wear is·indicated.
(l) Place two 0.0300 inch diameter pins in wear area of opposite
sp1ine grooves.
(2) Inspect for maximum dimension between pins of not more than 0.1979
inch.
c. Dfmensionally inspect drive sbaft in accordance with figure 4-53.
4-263. Inspect annular ball bearings (67, 7l, figure 4-7) in accordance with para-
graph 4-l05.
Cbange 2 4-143
.... _-_._------------
NAVAIR 03-105-AB-52
SURFACE A "'I I
I
DIA B
D~E
DIA O
l
I t
OIAMETER B SHALL BE NORMAL TO SURFACE A WITHIN 0.0005 INCH TOTAL /NO/CATOR

REAOING.
OIAMETER O SHALL BE CONCENTRIC WITH O/AMETER 8 WITH/N 0.0005 INCH TOTAL

INOICATOR REAOING.
SURFACE C SHALL BE PARALLEL TO SURFACE A W/TH/N 0.0005 /NCH TOTAL INOICATOR

REAOING.
B O E
1.4990 TO 0.3125 TO 0.323 TO

1.4995 IN. 0.3130 IN. 0.333 IN.
Figure 4-52. Inspection of Pump Lubrication Cover
~
OIAA OIAC
t t
OIAMETER A SHALL BE CONCENTRIC WITH OIAMETER B WITHIN 0.0005
INCH TOTAL INOICATOR REAOING.
DIAMETER C SHALL BE CONCENTRIC WITH OIAMETER B WITHIN 0.0005

INCH TOTAL INOICATOR REAOING.
A B C
0.2485 TO 0.3115 TO 0.4\15 TO
0.2490 IN. 0.3120 IN. 0.4120 IN.
Figure 4-5~. Inspection of Drive Shaft
4-144
liAVAIR 03-105-AB-52
4-264. Inspect he11cal compress1on spring (69) as follows:
a. Visually inspect springs for cracks and corrosion.
b. Check al1gnment of spring col1s. RoII spring across smooth, flat sur-
face and check that spring roIIs stra1ght and smooth.
c. Check spring tension as fol1ows:
(1) Compress spring to 0.70 inch.
(2) Check for spring load within 23.5 +2.0 pounds.
4-265. Inspect sleeve spacer (70) as follows:

a. V1sually inspect sleeve spacer for d1stortion, cracks and burrs.
b. DimensionaIly inspect for spacer Iength within 0.595 to 0.605 inch.
4-266. Inspect shouldered shaft (72) as follows:
a. VisuaIly inspect shouldered shaft for scratches, scoring, corrosion and

damaged threads.
b. Dimensionally inspect shouldered shaft in accordance with figure 4-54.
4-267. Inspect bearing retainer assembly (74, figure 4-7) as follows:
a. Visually inspect flange for cracks, distortion, corrosion, nicks and

burrs.
b •. Visually inspect pin for security, d1stortion, and burred edges.
4-268. Inspect zerol pinion beve1 gear (78) as follows:
a. Visual1y inspect gear teeth for cracks, chips and wear.
b. Visually inspect splines for n~~~, cracks and breaks.

c. Visually inspect for damaged threads.
d. Dimensionally inspect gear in accordance with figure 4-55.
e. Perform magnetic particle inspection in accordance with MIL-I-6868.
4-269. Inspect sleeve spacers (80, 81, figure 4-7) as follows:
a. Visually inspect sleeve spacers for distortion, cracks and corrosion.
4-145
NAVAIR 03-105-AB-52
SURFACE D--......'
L I
DIAMETER B SHAL L BE SYMMETRICAL TO DIAMETER A WITHIN

DIAMETER C SHAL L BE CONCENTRIC WITH DIAMETER A WITHIN

SURFACE D SHALL BE NORMAL TO DIAMETER A WITHIN 0.0005

INCH TOTALINDICATOR READING.
A B C
0.3932 TO 0.0635 TO 0.3115 TO

0.3936 IN. 0.0655 IN. 0.3120 IN.
Figure 4-54. Inspection of Shouldered Shaft
t
DIA B
l
SURFACE A SHALL BE NORMAL TO DIAMETER BWITHIN 0.0005

0.4720 TO
0.4723 IN.
Figure 4-55. Inspect10n of Bevel-Zerol Pinion Gear
4-146
NAVAIR 03-105-AB-52
b. Dimensional1y inspect 1ength of sleeve spacers for measurement within

0.1800 to 0.1802 incho
c. lf pin (77) is damaged or loose, remove pin using Pin Pressing Ho1der
287153-1-1 and a punch. lnstall new pin using ho1der and a punch.
, 4-270. lnspect bearing carrier (83) as fo11ows:
a. Visua11y inspect carrier for cracks, burrs, and corrosion.
b. DimeIl$ional1y inspect carrier in accordance with figure 4-56.
4-271. Ispect annu1ar ball bearings (87, 93, 110, 114, figure 4-7, sheet 2 and 3)
in accordance with paragraph 4-105.
4-272. lnspect compression helical springs (88, 112) as fo11ows:
a. Visua1ly inspect springs for cracks and corrosion.
b. Check a1ignment of spring coils. Ro11 springs across smooth, f1at sur-
face and check that springs ro1l stra1ght and smooth.
c. Check spring tension as fo11ows:
(1) Compress spring to 0.270 incho
(2) Check for load with1n 15 +1.5 pounds.
4-273. lnspect sleeve spacers (89, sheet 2; 113, sheet 3) as fol1ows:
a. Visua11y inspect sleeve spacers for cracks, distortion and burrs.
b. Dimensiona11y inspect sleeve spacers for 1ength with1n 0.327 to 0.337

incho
4-274. Inspect bearing carriers (92, 119) as fo11ows:
a. Visua11y inspect bearing carrier for cracks, nicks, scores, burrs,

scratches and corrosion.
b. Dimensionally inspect bearing carrier in accordance with figure 4-57.
c. Perform magnetic partic1e inspection in accordance with MIL-l-6868.
4-275. lnspect bevel-zerol gear (94, figure 4-7, sheet 2) as fo11ows:
a. Visua11y inspect gear teeth for cracks, chips, surface defects, and
wear.
b. Dimensionally inspect bevel-zerol gear in accordance with figure 4-58.
4-147
•
NAVAIR 03-10S-AB-52
ir
,
SURFACE C
I
DIA O
OIAMETER A SHAll 8E CONCENTRIC WITH OIAMETER O WITHIN

0.0003 INCH TOTAL INOICATOR REAOING.
SURFACES 8 ANO C SHAll SE NORMAL TO OIAMETER O WITHIN

O.OOO3INCH TOTAL INOICATOR READING.
A o
1.2495 TO 1.1024 TO
1.2499 IN. 1.1028 IN.
Figure 4-56. Inspection of Bearing'Carrier
4-276. Inspect spur gear (95, figure 4-7) as fol1ows:
a. Visua11y inspect gear teeth for cracks, chips, surface defects and
wear.
b. Dimensionally inspect spur gear in accordance with figure 4-59.
4-277. Inspect pawls (100, figure 4-7) for nicks, cracks, chips, and wear.
4-278. Inspect c1utch shaft asse::lb1y (101 through 106) as fo11ows:
a. Visua11y inspect rivets (101) for security.
b. Visua11y inspect leaf springs (102, 103) for cracks, distortion and
wear.
c. Inspect pin (104) and p1ug (105) for security.
4-148
liAVAIR 03-105-AB-52
r
t
T DL
DIAMETER A SHAL L BE CONCENTRIC WlTH DIAMETER BWITHIN
SURFACf C SHALL BE NORMAL TO DIAMETER A WITHIN 0.0005
A B
1.1595 TO 1.0238 TO
1.1597 IN. 1.0243 IN.
d. V1sua11y 1nspect c1utch housing (106) as fo11ows:
(1) Inspect housing for cracks, scratches and scores.
(2) Inspect for damaged threads.
(3) Visually inspect splines for cracks, chips, breaks and wear.
e. D1mens1onal1y inspect splines as follows ti visual inspection reveals

wear.
(1) P1àce two 0.0300 inch diameter pins in opposite sp11ne grooves.
(2) Inspect for max1mum d1mension between pins of not more than 0.1979
incho
f. D1mens1ona11y inspect clutch housing assemb1y (106) in accordance with

figure 4-60.
g. Perform check balance of clutch shaft assembly in accordance with para-

graph 4-560, step d.
4-279. Inspect gearbox accessory housing assembly (107, figure 4-7) as fo1lows:
a. Visually inspect housing for cracks and corrosion. Inspect bores in

housing for chips, cracks, scratches, scores and wear.
4-149
,
NAVAIR 03-105-AB-52
SURFACE B
SURFACE C
DIAA
Lt-----II
SURFACE B SHALL BE PARALLEL TO SURFACE C WlTHIN 0.0005 INCH

RUNQUT OF SURFACE C SHALL NOT EXCEED 0.0003 lNCH TOTAL INDICATOR

READING WITH RESPECT TO DIAMETER A.
0.4217 TO
0.4222 IN.
Figure 4-58. Inspection of Beve1-Zero1 Gear
b. Visual1y inspect inserts (1, 2, 3, 4, 7, 8, 10, 11, figure 4-79) for

security and damaged threads.
c. Visua11y inspect pins (5, 6, 13) for burred edges, distortion and
security.
d. Visua11y insepct p1ugs (9, 14) for security.
e. Visua11y inspect studs (12) for damaged threads and security.
f. Dimensional1y inspect housing (15) in accordance with figure 4-61.
4-280. Inspect spur gear (115, figure 4-7, sheet 3) as fo11ows:
4-150
NAVAIR 03-105-AB-52
SURFACE B
,
OIAA
SURFACE C SHALl BE PARALLEL TO SURFACE BWITHIN O.OOO3INCH

TOTAL INOICATO\ READING.
RUNOUT OF SURFACE B SHAL L BE WITHIN 0.0003 INCH TOTAL INDICATOR

READING WITH RESPECT TO DIAMETER A.
0.4217 TO
0.4222 IN.
RUNOUT OF SURFACE C SHALL NOt.EXCEED 0.0005 INCH TOTAL INDICATOR

READING WITH RESPECT TO DIAMETER A ANO OIAMETER B.
A B
0.4212 TO 0.3932 TO
0.4215 IN. 0.3936 IN.
Figure 4-60. Inspection of Clutch Housing Assembly
4-151
I
NAVAIR 03-105-AB-52
+
--+-- OIAF
+
......... SURFACE E
SECTION C-C SECT/ON B-B
D/A A
! ~ +
:;===t~:í3l=J~=:i:=t:QOIk'A BD/A C
t t l
SECT/ON A-A
OIAMETER A SHALL BE CONCENTRIC WITH OIAMETER C WITH/N 0.001

/NCH TOTAL INOICATOR REAOING.
OIAMETER F SHALL BE NORMAL TO SURFACE E WITHIN 0.001 INCH

TOTAL INO/CATOR REAOING.
SURFACE H SHALL BE NORMAL TO OIAMETER G WITHIN 0.0005 INCH

TOTAL /NO/CATOR REAOING ANO PARAlLEL TO SURFACE E WITHIN
0.001 INCH TOTAllNOICATOR REAOING.
A B C O F G
0.3123 TO 0.323 TO 1.4998 TO 1.2498 TO 1.0235 TO 1.1597 TO

0.3130 IN. 0.333 IN. 1.5005 IN. 1.2505 IN. 1.0242 IN. 1.1604 IN.
Figure 4-61. Inspection of Gearbox Accessory Housing Assemb1y
4-152
NAVAIR 03-105-AB-52
a. Visual1y inspect gear teeth for cracks, chips, breaks, surface defects,
and wear.
b. D:lmensiona11y inspect spur gear in accordance with figure 4-62.

4-281. Inspect shouldered shaft assembly (117, figure 4-7) as follows:
a. Visually inspect shouldered shaft assembly for scratches, scores, corro-

sion, and damaged threads.
b. Visually inspect internaI pIug for security.
c. VisuaIIy inspect internal spl1nes for cracks, breaks, chips, and wear.
d. D:lmensionally inspect splines as follows if visual inspection revea1s

wear.
(1) P1ace two 0.0300 inch diameter pins in wear area of opposite sp1ine
grooves.
(2) Inspect for max:lmum d:lmension between pins of not more tban 0.1979
incho
t
DIAA
1
J
SURFACE C SHALL BE PARALLEL TO SURFACE BWlTHIN
RUNOUT OF SURFACE B SHALL BE WITHIN 0.0003 INCH TOTAL

INDICATOR READING WlTH RESPECT TO DIAMETER A.
0.4217 TO
0.4222 IN.
4-153
,
NAVAIR 03-105-AB-52
e. Dimensional1y inspect shou1dered shaft assemb1y in accordance with

figure 4-63.
f. Perform magnetic partic1e inspection in accordance with MIL-I-6868.
4-282. Inspect adapter housing assemb1y (120, 121, figure 4-7) as fo11ows:
a. Visua11y inspect housing assemb1y for cracks and corrosion.
b. Visua11y inspect paint for chipping and f1aking.
c. Visua11y inspect bores in housing (121) for cracks, scratches, scores,

and wear.
d. Visua11y inspect inserts (120) for security and damaged threads.
e. Dimensiona11y inspect housing assemb1y in accordance with figure 4-64.
4-283. INSPECTION OF AC-DC PERMANENT MAGNET GENERATOR COMPONENTS (figure 4-8).
n
I
~-------J
I-f\
y . - P
.~
DIA B
1c
:>IA
SURFACE O
I I
Y U~SURFACEA c - - - - - -)".........
s
SURFACE E
I
SURFACE A RUNOUT SHALL NOT EXCEEO 0.0005 INCH TOTAL INDICATOR REAOING
WITH RESPECT TO SURFACES DANO E.
OIAMETERS BAND C RUNOUT SHALL NOT EXCEED 0.0005 INCH TOTAL INDICATOR
READING WlTH RESPECT TO SURFACES DANO E.
8 C
0.3932 TO 0.4212 TO
0.3936 IN. 0.4215 IN.
Figure 4-63. Inspection of Shouldered Shaft
4-154
NAVAIR 03-105-AB-52
SURFACEO-
-SURFACEF
-SURFACEE
I
.JIAA
I
OIAMETER B RUNOUT SHALL NOT EXCEEO O.OOIINCH TOTAL INOICATOR READING
WITH RESPECT TO SURFACE E ANO OIAMETER C.
SURFACE O SHALL BE PARALLEL WlTH SURFACE E WlTHIN 0.001 INCH.
SURFACE F SHALL BE PARALLEL WlTH SURFACE O WlTHIN 0.001 INCH.
A B C
2.2600 TO 1.1600 TO 2.3110 TO

2.2610 IN. 1.1605 IN. 2.3120 IN.
Figure 4-64. Inspection of Adapter Housing Assembly
4-284. VisuaIIy inspect generator spur gear (4) teeth for cracks, chips, surface
defects and wear.
4-285. VisuaI1y insepct fi1ter assemb1y (11); there must be no loose or broken ter-
minaIs, cracks in solder joints, or leakage of potting compound. AppIy a test vo1t-
age of 230 vac, 400 Hz, between terminaIs A, B, 1, and 2 and case for 15 seconds;
there must be no indication of insu1ation breakdown. Apply a test voltage of 56 vdc
between terminals D, F, 7, and 8 and case for 15 seconds; there must be no indica-
tion of insulation breakdown.
4-286. VisuaIIy inspect module assembly (14); there must be no Ioose or broken ter-
minaIs, cracks in solder joints, or 1eakage of potting compound. Test module
assemb1y as fol1ows:
4-155
,.
NAVAIR 03-l05-AB-52
a. Using an obmmeter, perform resistance test in accordance with table

4-3.
b. With power sources set to zero volts, connect module assembly to a test
setup as shown in figure 4-65.
Table 4-3. Module Assembly Resistance Test
Resistance Indication ~OHMS~

Reverse
Ohmmeter Ohmmeter Leads
Scale +Lead -Lead Min Max Min Max
RXlOO El E2 250 350 250 350
RXlOK El Heatsink 5 Meg Infinity 5 Meg Infinity
BXlOK El E3 5 Meg Infinity 5 Meg Infinity
RXlOK El E4 5 Meg Infinity 5 Meg Infinity
RXlOK El E5 5 Ueg Infinity 5 Meg Infinity
RXIOK El E6 5 Meg Infinity 5 Meg Infinity
RXlOK El E7 5 Meg Infinity 5 Meg Infinity
R.XlOK El E8 5 Meg Infinity 5 Meg Infinity
RXIOK El E9 5 Meg Infinity 5 Meg Infinity
RXl E3 E8 5 30 1 Meg Infinity
RXl E3 E9 5 Meg Infinity 5 30
RXl E5 E9 5 Heg Infinity 5 30
RXl EB E7 400 600 400 600
4-156
i
NAVAIR 03-l05-AB-52
INPUT E6
OSClllOSCOPE
COM 8 OHM 7SW
~,
E8
<10 VOC +
VARIASLE
POWER
IN 4719
~
/
OTO<oIIDC
VOlTMETER
SOURCE
- E9
RECTIFIERI
--L REGULATOR
"---- S 3 - E7 MODULE
ASSEM8lY
EI
E2
E3
~
.A" S2
~
125 VAC I
<100 HZ
VARIASLE OTO 125 VAr;
I, 2 I .I!
: 11 3
2T E4
POWER VOlTMETER I
: 11
SOURCE ,I
I
I 2
• 1\
11
4 ES
SI
PART NO. 11599
HADlEY lOS ANGELES, CALlF 90037
Figure 4-65. Rectifier/Regulator Module Assembly Test Setup
c. Set test setup switches 1 and 2 to position 2.
d. Set oscil1oscope sensitivity to 10 volts per centimeter and sweep to

100 microseconds per centimeter.
CAUTION
Do not exceed an output of 40 vdc on dc power source.
e. Increase dc power source until oscilloscope trace indicates regu1ator

pulses; as dc voltage is increased, regulator pulses must first appear between 31
and 31.5 vdc. If required, adjust module assembly variable resistor R5 to obtain
specified resu1ts.
f. Set dc power source to 25 vdc.
CAUTION
Do not exceed an output of 125 vac on ac power source.
g. Increase ac power source until oscilloscope trace indicates regulator

pulses; as ac voltage is increased, regu1ator pulses must first appear between 114
and 116 vac. lf required,.adjust module assemb1y variab1e resistor R2 to obta1n
specified results.
4-157
I
NAVAIR 03-105AB-52
h. Set de and ae power sourees to zero volts.
i. Set test setup switeh SI to position 1.
j. Set ae power souree to 80 vaej de voltmeter must 1nd1eate 23 to 27 vdc.
k. Set ae power source to zero volts and set test setup sw1teh S2 to posi-
tion 1.
1. Set ae power source to 80 vae; de vo1tmeter must 1nd1eate 23 to 27 vde.
m. Press test setup sw1tch 53; observe operat10n of module assemb1y re1ay
by sound and variat10n of de voltmeter ind1eation.
n. Set de and ae power sourees to zero and remove module assembly from test
setup.
o. Seal module assembIy adjustment holes for variable resistors R2 and R5

with seaIing compound (RTV-732, Dow Corn1ng Corp, 5. 5aginaw Road, Midland, Ml
48640, or equiva1ent; no known Government specification).
4-287. Inspect housing assembly (20 through 24, figure 4-8) as follows:
a. Visually inspeet hous1ng for cracks and corrosion.
b. Visually inspeet bores for cracks, scratches, scores and wear.
e. Dimensionally inspeet 1nside diameter of insert (20); d1ameter shall

Dot exeeed 1.2605 inches.
d. Visually inspect ring (21) andstud (22) for security of installat10n.
e. Visually inspect housing for damaged threads.
,-288. Dimensionally 1nspect bear1ng diameters of rotor assembly (25); d1ameter for
,earing (17) shall not be less than 0.5903 1nch and diameter for bearing (24) sball
,ot be less than 0.4721 incho
-289. Inspect stator assembly (27) as follows:
a. Check resist&nce of stator assembly windings; resist&nee must be 0.97 to 1.19 ohms
>etween red and green leads, 2.03 to 2.49 ohms between black and white leads, 0.16 to 0.19 ohms between
~ay and black leada, and 7.30 to 8.92 ohms between blue and yellow leads. When measuring
'esistance ofles8 than 2.0 obms, use low voltage ohmmeter, AN/USM-2IA.
b. Perform insulat10n res1stanee test between core of stator assembly and

d, gray, and blue leads {tied together)j insulation res1stance must be a minimum
2000 megohms at 2000 vdc.
e. Perform dielectric test by applying 1000 vac, 60 Hz, for one minute be-
een core of stator aS8emb1y and red, black, and blue leads (t1ed together); there
st be no indication of dieletric breakdown.
)8 Change2
i
NAVAIR 03-105AB-52
4-290. Inspect electrical rotating equipment end bell assembly (35, 36) as follows:
a. Dimensionally inspect inside diameter of insert (35); diameter sha1l not

exceed 1.1031 inches.
b. Visually inspect machined end bell (36) for cracks and corrosfon.
4-291. INSPECTION OF STARTER COMPONENTS.
4-292. INSPECTION OF JFS CONTROL BOX ASSEMBLY (figure 4-9).

4-293.Visually inspect identification plate (1, sheet 1) for securi~· and legi-
bility.
4-294. Inspect electrical control cover assembly (6, 7) as follol~:
a. Visually inspect gasket (6) for deterioration, distortion, security,

cuts and tears.
b. Visually inspect cover (7) for distortion, cracks and corrosion.
4-295. Inspect armature relay (9) as follows:
a. Visually inspect relay case for dents and distortion.
b. Visually inspect for loose, burned, bent or broken terminaIs.
c. Functionally check relay as follows:
(1) Connect positive lead of variable voltage dc power supply, zero to

12 volts dc, to terminal I of relay; connect negative lead to terminal 2.
(2) Check for. continuity between terminaIs 4 and 5, and 7 and 8, with
relay de-energized.
(3) Gradually increase voltage to relay coil and check that maximum
voltage to pull-in relay ia not more than 13.0 volts.
(4) Check for continuity between terminaIs 3 and 4, and 6 and 7, with
relay energized.
(5) Slowly decrease voltage and check that minimum voltage at relay
dropout is not less than 2.0 volts.
(6) Disconnect alI test leads from relay.
4-295A. Inspect start cycle protection sensor (13) in accordance with general in-
spection instructions for circuit board assemblies in paragraph 4-10lA, and func-
tionally check sensor using the follow1ng instructions. Troubleshoot sensor in
accordance with paragraph 4-295B if sensor fails to function as specified.
a. Install sensor.in test setup shown in figure 4-65A.
Change 1 4-158A
,
NAVAIR 03-105AB-52
b. Slowly inerease the 28 vde power supp1y from O volts unti1 re1ay Kl pulls
in; de vo1tmeter indieation must be 7 +1.0 vde.
e. Slow1y deerease the 28 vde power supp1y v01tage unti1 re1ay Kl drops out;
de voltmeter indieation must be 7 +1.0 vde.
d. Set 28 vde power supply so that de voltmeter indieation is 28 +2 vde.

Set ae power supply so that ae vo1tmeter indieation is 115 +1.0 vde, and frequeney
eounter indieation is 400 Hz.
e. Inerease the temperature setting on temperature thermoeouple simu1ator

unti1 overtemperature eireuit trips. Simulated temperature must be 1900°F +20 o F.
f. Depress reset switeh to reset relay.
g. Remove a 1ead of the thermoeoup1e from sensor; re1ay Kl rnust drop out.
Replaee thermoeouple 1ead; relay Kl must not pull in.
h. Depress reset switeh to reset relay.
EXTERNALLV MOUNTED
~---------. , . - - -.....28VOC
: I
I
I I
I I
I 2N3716
I __ ...JI
RESET '--
De
POWER
SUPPLV
D-30V "'-~~f--,
SIMULA-
TOR
NETWORK
ASSEMBlV
SENSOR
~SSEMBlV
ICE BATH
AC
S~P~ ~--.---~--------~
D-115V
RMS
0-440 HZ
T-IJ·,,.
Figure 4-65A. Start Cye1e Proteetion Sensor Test Setup
4-l58B Change 1
NAVAIR 03-105AB-52
i. Slowly inerease frequeney of ae power supp1y until relay II drops out.

Indication on frequency counter when overspeed circuit trips must be 436 +4 Hz.
Measure the de voltage at terminal 12 of network assembly; de voltage mustbe 24
+4 vde through a 1200 ohm load.
j. Set frequeney of ae power suppIy to zero; relay Il must not pull in.
Depress reset switeh to reset reIay.
k. Set frequeney of ae power supply to 400 Hz. While monitoring the volt-
age at pin 6 of the eireuit eard assembIy, sIow1y deerease the frequeney of ae
power supp1y unti1 the vo1tage at pin 6 ehanges from 28 vde to O vde +4 vde. Fre-
queney eounter indieation must be 370 +8 Hz.
1. Slowly increase frequeney of ae power supp1y until the vo1tage at pin 6

ehanges to 28 +4 vde. Frequeney eounter indieation must be 370 +8 Hz.
m. Depress the reset switeh to reset relay KI.
n. Deerease de power supply voltage to O. Slowly inerease de power supply

to 8 vde +0, -0.5 vdc; relay K1 must pull in.
o. Inerease de power supply setting to 18 +1.0 vde. Set ae power supply

frequeney to 60 +3 Hz.
p. Inerease the temperature setting on thermoeouple simu1ator until the

overtemp eireuit trips. Thermoeouple simulator setting must be 1900 +30°F.
q. Depress the reset switeh to reset reIay KI.
r. Depress the primary cutout switeh; reIay Il must drop out and not pu11
in when eutout switch is re1eased.
s. Set ae power supp1y and de power supp1y to off.
t. Connect 560 ohm +1 percent resistor between pins 12 and 13 of underspeed

detector cireuit eard assembIy.
u. Monitor vo1tage between pin 16 (+) of overtemp and overspeed sensor

network assemb1y and ground using osei110seope.
v. Turn on de power. Vo1tage at pin 16 sha1l stay at 12 +2 vde for one

+0.1 see then go to 2 +2 vde.
w. Turn off de power. Rep1aee 560 ohm resistor with 470 ohm +1 pereent
resistor.
x. Turn on de power. Voltage at pin 16 sha11 go to or stay at 2 +2 vde

within 0.1 see.
y. Turn off de power and diseonneet sensor assembly from test setup.
Change I 4-158C
•
NAVAIR 03-l0SAB-S2
4-295B. Troubleshooting. Refer to table 4-3A for aid in troubleshooting. See

figure 4-65B for a schematic of the sensor.
Table 4-3A. Troubleshooting Table for Start Cycle Protection Sensor
Trouble Probable Cause Remedy
Relay Kl does not pull Relay defective. Replace defective relay.

in.
Component on network as- Isolate and replace defective

sembly or on circuit componente
card assembly defective.
Printed circuit board Replace defective network or

defective. circuit card assembly.
Voltage at which relay Relay defective. Replace defective relay.

K1 pulls in ia not as
specified.
Component on network as- Replace defective componente
sembly or on circuit
card assembly defective.
Voltage at which relay Relay Kl defective. Replace defective relay.

K1 drops out is not
as specified.
Trip point of temper- Circuit out of calibra- Calibrate circuit in accor-

ature is not as tion. dance with instructions in
specified. paragraph 4-S74C and retest.
Overtemp circuit will Component defective. Isolate and replace defective

not calibrate. componente
Overspeed circuit trip Calibration not correct Calibrate overspeed circuit

point not as specified. on overspeed circuito in accordance with instruc-
tions in paragraph 4-574C.
4-l5SD Change 1
':
UAVi\IR 03-10SAB-52
r- -- -- -- - -
I
- - - - I
ff -h
n- - -- - -
- 4 t
--R52 -100
~ 1%,3W
-------,
I
I ROOl
1xf't\L ~~:" ),~~~' ,~)~,
I I IN645 U6 ~ ~16
;~"7 ~
~~~, <>.
-
, .-
, -- -- - -.--:::------,:1
-----
....
2
o
3
o
:
CR3 2
[I . -
68.IK I - 4 VR10 R50
I I I; ~/~~% '!.IO%,1 . ~ ~;t-015- ~~907A COLaR DOT / ' o o
1"28 voe <p

1U ±I%
3W
I I I,___-, R"
li.
40.2K
R45 R-48,ISI <
~ ;-t;1~ -/
9001
13
12 •
':l
IN964B 3.3K
51
~IK
~ '---'-~-"-5-
~53
6---W-+--:-l
;.32K VR12 OIAGRAM A
1
DIAGRAM 8
4
2 (1 1/;;:;9
I R4
1"_IKI~o r----, VR5 I I
'--_-4!:1.0% R47,II
I/aw +
CRI4
...;.! r--t----+---'I.96K
I R55 L!2. ±O,I %
I / l0W
lN746A
CR24
VIEWED FROM LEAD SIDE VIEWED FROM PIN SIDE
I ~~ ~ : ~01~~3'~~~+ ~_ 1 _ _ _. a·~--~3~4~,7~M~~~~~_~5~o/,L04-~-----~t::::~~_~~~~i~~~+_~~_~_~~~~=~=====~_~
COLOR DOT
VRI7~MI-r~_L_I_~:~_I_~~ ~_3 W~ ~~===::=~~~A~=;;=;;=-~~B=~~~c_-_~_nl Afl-~~I ~K ~K ~L____----'

(FARSIOE)
I IN302c ·_ ____ __ __ :,Ir~ ±O.I % ~ !: O.I % 2
I .,. I
Rll L-----+----t---+------~_+-.....,r--_1t__t__1t_- àI( 9 t..:~~R~J l(IOW l/IOW .

3
o
2
o
o
:;.
I lOO±5%
+hC3::---I;;;/2:v.W;:~----......,.
.... IC~5:-+--~----1------t--t---t-----' : r--< R58
I1 A - - - -~ . o o
. ,'~ I "
~~ 65J-033-9~;'~ 'I~5~ L - g~1 :!I / 0.1%~~
511 I J 2 X2
GND Q>' ---+-f--r--t-------t-+-.- A'L(
'Y"
5
IOW 1- - - -
OIAGRAM C
o
4
o
3
' '- ~~I L _ _ _ ~L11_
e
VIEWED FROM PIN SI DE DIAGRAM o
I Ra RI? RI6 ~ R21
1
CI
499
.10.1 %
3.74K
iO.I %
732
!1 %
R
19
IK
iO.l %
R25 R42
,-
3A 0---0.- I
--,
VIEWED FROM PIN SIDE
CIO R34
I 3.3
ljO%
l/aw ....-=,.-I..,/ 8W
+ RIO R13 P l(8W
RI7 ~
I / aw
3.3
1 10% +
IOMEG ....
CR5
6.2K
R37
6,7K
CI4
0.22
+ 07
t7 2N2907A
?lO
1/2W
,
I A'f-t
.~
i
'. i A I SELECT ONE (1) RESISTOR FROM lHE INDICATED CALIBRATlON
ASSORTMENT, S9546-103 THRU 154 IF REO'O
I RI
1081<
R9,~C~10K
23007
lK
+0 . 1% lW
1/aw ' 5%
500
IW
RJ5
't
CRI I 653-033-~3'"
VR9 b -I.. I
JB <>---':'1
~ 2B
I
I
SELECT ONE lI) RESISTOR FROM THE INDICATED CALl8RATlON
ASSORTMENT, 59546-512 lHRU 223 IF REO'O
15% t--i------' r-;--,R2" 1~ RELAY(+) I B , I ,
I R14 RIa CR20 CR11 2.2K
R3a R39 ~ ~--~--~7 I I PROVISIONAL COMPONENT.
I R5
249K
:! 0.1 %
249K
<0.1 %
,~
h
j~ 05 12K 3_3K DJF) CR12
'I ,
t a-. 7 XII
4. 991< 1/ 6W l / aw VR6 \.!!; lN645 SELECT ONE (I) RESISTOR FROM THE INDICATEO CALlBRATlON
J
±0'~1' L8W ~;1-01;::___~')-..l~~..!.6+...;._+__+-+_I"1N~7~,0*A.J
Jfi!\.X21 ASSORTMENT, S9547-434 THRU -205 OR Rn MAY NOT SE REOUI RED
THERMO HROMELt 2 R36 + CI3
6.6
R40 ~'------{,="I I K1 I 1
12K R43
COUPlE ALUMEl's')t-t-_;;;4.,,99.;.:K:.:-_ _ _ _ _ _ _ _ _ _ _-+_ J~'01
_+-----+~ (725) 6'~ :. 35V
2K
2K
.....t---.1r-+L ) RE LA Y (-) L2.4rlJ_!?:Jl
I SELECT ONE (I) RESISTOR FROM lHE INDICATED CALlBRATlON
.\V '0.1% ~ 09 ._.. ..J ASSORTMENT, $.9546-222 THRU -103 •
~ 1/ 8W R23, 40.2\( 4 R31 r- OIAGRAM E
~ ! I')C ,
l / aw 5 1 MEG C!f L-----;-----I--~K VIEW':O FROM TOP SIOE
1 CRI
R20
l R22 R27
r,,;.;~;""'I--....--"--t--t----t-l
+ 5%
-
CRIO, " R41
L----+--{L
SELECT ONE (I ) RESI5TOP. FROM lHE INDICATED CALlSRATION
ASSORTMENT 59547-394 THRU -305 IF REO'D
OI
l.aK,I / 2W
%. 653-023-9010 l00K A 10K;-, r~ PRIMAR'· • ' IT · OUT SWITCH 6• PIN NUMBERS FOR UI, U2, U3, TI, T2 & Kl ARE FOR REF ONLY·
:!: 0.1 % Ln. R24 IW, ~ I I LAST ~EF OESIGNATI ON UI, U2 & U4 REFER TO OIAGRAM A, TI REFER TO DIAGRAM S,
r.\. c,.R2 I / aw 39K '5% 7
R32
2.2K 06 4 USEO NOT USED T2 REFER TO DIAGRAM O, KI REFER TO OIAGRAM C, U3 REFER TO
~)f--if--*
1
r----I
653-023-9010 r - ---, RI5
0jp
t---,..."""". . . . ~~+--~3 J2
R26 R30 431-00~
8 CR8
~ a ) 2N29i 'A
I .. 1
I R65
DIAGRAM E, FOR RELATlVE LOCATlON OF PINS.
l~
~
~
R2,l1K,IW I, 13 4,3K C7 + IK 15K29101

6 ~ C15 CR13 ~ C20 5. ALL TRANSISTORS ARE 2N2222A.
1, VR2 " C2 I • ~. I C4 ~- C6 1.0 l?(741)4 R33 10 + lN4DQ4 I CR27 CR4
AC INPUT IN3022a ~. I\. I _ .. I .047 5.1 K 20V I VR13
4. ALL DIObES ARE 1N457.
/ --'
I VR3 l ' L1là r :t10% 15000pf 5 L,.
Ifi\. 1N3022B . J I : ~~-o-I OO~D'-1-V_+-_",
.......!;1 ±5% CI1 +
OVERSPEf D INDICATOR 010 Q2 3. ALL CAPACITOR VALUES ARE IN MICROFARADS, ::: 2()'% , 5OV_
'4'"1 RJ, 111<, lW 21 TI

~.'1417a-2.J
14 500V
ca +
0.22
R26 C12 -.
CR9 ~. VRa ~
IN75aA .' I T2
KI
2. ALL RESISTOR VAlUES ARE IN OHMS, :!: 2% , 1/4W.
....
I
Q4 68,1 K 47
1,0 U4 I. PARTIA L REFERENCE OESIGNATlONS ARE SHOWN, FOR COMPLETE
I 2N2907A 10.1%
I/aw
20V ~VR7
1 N750A DESIGNATlON PREFIX WITH UNIT AND/ OR ASSEMBl Y DESIGNATlON.
L -- --- --- --- --- --- -- -- --- --- -- - - - - - - -- - - - - - ~ W-19A- 1376
Figure 4-65B. Start Cycle Protection Sensor Electrical Schematic
Change 1 4-1S8E/(4-158F blank)

r
•
NAVAIR 03-105AB-52
Tab1e 4-3A. Troub1eshooting Tab1e for Start Cyc1e Protection Sensor (Cont)
Troub1e Probab1e Cause Remedy
Overspeed circuit wi11 Component defective. Iso1ate and rep1ace defective

not calibra te. componente
Underspeed trip point Underspeed circuit out Ca1ibrate underspeed circuit

not as specified. of ca1ibration. in accordance with instruc-
tions in paragraph 4-574C.
Underspeed circuit Component defective. Iso1ate and rep1ace defective

wi11 not ca1ibrate. componente
Delay circuit fai1s Delay circuit out of Ca1ibrate de1ay circuit in

to respond within Calibration. accordance with instructions
limits. in paragraph 4-581C.
De1ay circuit wi11 not Component defective. Iso1ate and replace defective
calibra te. componente
4-296. Visua11y inspect counter retaining p1ate (17) for corrosion and distortion.
4-297. Inspect counter retaining assemb1y (18, 19) as fo11ows:
a. Visua11y inspect gasket (18) for cuts, distortion, deterioration and

security to p1ate (19).
Change 1 4-159
•
RAVAIR 03-105-AB-52
b. Visually inspect retaining plate (19) for translucence, cracks and dis-
tortion.
4-298. Visually inspect resi1ient start counter mounts (20, 21) for tears, shred- ~
ding, deteriorat1on and resilience. ~
4-299. Visually inspect electrical counter (22) as follaws:
a. Visually inspect dia1 for legibility and alignment of number wheels.
b. Visually 1nspect case for corrosion, dents and distortion.
c. Visual1y inspect for burned, bent, corroded, or broken contacts.
d. Funct10nally check counter as follows:
(1) Ground counter case electrically, and connect positive lead of

10 volt dc power supply to pin 1 of counter; connect nega tive lead to pio 2.
(2) Apply 10 volts dc to counter and observe that start count increases
byone.
(3) Disconnect test leads from counter.
4-300. Inspect temperature senso r (24) as follows:
a. Visually inspect sensor leads for chafed, cracked or deteriorated 1n-

sulation.
b. Visually inspect sensor case for cracks.
c. Inspect sensor for res1stance of 500 ohms +1 percent at 70°F (21°C)

with multfmeter.
4-301. Inspect indicator (26) as follows:
a. Visually inspect case for cracks and damaged threads.
b. Visual1y inspect contacts for corrosion and security.
c. Functional1y check indicator as follows:
(1) Connect positive lead of 28 volt dc pawer supp1y to terminal 1 of

indicator; connect nega tive 1ead to terminal 2.
(2) Apply 28 volts de to indieator and ebeek for red indieation in dis-4
p1ay area.
(3) Disconnect test 1eads from indicator and reconnect as follows.

Connect positive lead to terminal 4 and negative lead to terminal 3.
4-160
NAVAIR 03-l05-AB-52
(4) Apply 28 volts dc to indicator and check for white indication in

display area.
(5) Disconnect test leads from indicator.
4-302. Inspect fuses (28, sheet 2) aa follows:
a. Visually inspect end caps for corrosion and security.
b. Visua11y inspect tube for cracks.

c. Visua1ly inspect fuse wire for continuity.
4-303. Inspect fuseholders (29) as follows:
a. Visually inspect fuseholder cap for cracked insulation, dirty or cor-

roded contacts, and damaged threads.
b. Visually inspect body for c.l:'!lcks, loose, burned, bent or corroded con-
tacts and terminals, and damaged tbreads.
4-304. Inspect electrica1 receptac1p. connector (30, 31, 32) as follows:

a. Visually inspect for bent: burned, corroded, or broken pins and ter-
minals.
b. Visually inspect insulation for distortion, tears, and deterioration.
c. Visua1ly inspect housing for cracks and damaged tbreads.

4-305. Visual1y inspect insulator (41) for cracks and distortion.
4-306. Inspect transistor (44) as follows:
a. Visua11y inspect housing for dents, distorted mounting flange and for
loose, bent or corroded terminals.
b. Functionally test transistor using transistor test sete
4-307. Visually inspect heat sink (45) for cracks, corrosion and damaged tbreads.
4-308. Inspect electrical contro1 box assemb1y (46 through 50) as follows:
a. Visua11y inspect nuts (47, 49) for security and damaged tbreads.
b. Visually inspect e1ectrica1 control box (50) for distortion, cracks,

corrosion, and for security of mounting bracket.
4-309. INSPECTION OF ACCUMULATOR ASSEMBLY (figure 4-10).

4-310. Inspect accumulator fuel piston (9) as fol1ows:
4-161
NAVAIR OJ-IOj-AB-52
a. Visua11y inspect piston for scratches, corrosion and wear.
b. Visual1y inspect packing grooves for burred, chipped or eroded edges.
4-311. lnspect compression helical spring (10) as fo11ows:
a. Visua11y inspect spring for cracks ano corrosion.
b. Check a1ignment of spring coi1s. Rol1 spring across smooth, f1at sur-
face and check that spring ro11s straight and smooth.
c. Check spring tension as fo11ows:
4-312. lnspect accumu1ator housing (11) as fo11ows:
a. Visua11y inspect threads for damage and wear through of dry-filc 1ubri-
canto
b. Visually inspect housing for cracks, torn lockwire ho1es, and corrosion.
c. lnspect sea1ing surface for scratches, scores and wear.
d. Perform f1uorescent penetrant inspection in accordance l'Iith HIL-1-6866,

type 1, method A.
4-313. lnspect accumulator hydrau1ic piston (14) as follows:
a. Visually inspect piston for scratches, corrosion, cracks and wear.
b. Visua1ly inspect packing grooves for burred, chipped or eroded edges.
4-314. lnspect accumu1ator cap (15) as fol1ows:
a. Visually inspect alI threads for damage.
b. Visua1ly inspect cap for cracks, corrosion and torn lockwire ào1es.
c. Visual1y inspect sealing surface for scratches, scores and wear.
d. Perform fluorescent penetrant inspection in accordance with MIL-l-6866,

type I, method A.
4-315. lNSPECTlON OF SENSlTlVE SWlTCH ASSEMBLY (figure 4-11).·
4-316. lnspect e1ectrical 1ead assemb1y (7 through 10) as fo11ows:
a. Inspect e1ectrical connector (8, 9) as follows:
4-162
NAVAIR 03-105AB-52
(1) V1sua11y 1nspect for bent, broken, burned or corroded p1ns and
termina1s.
, (2) V1sua11y inspect for torn, distorted or deteriorated insu1at1on.
(3) Visually inspect connector housing for cracks, distortion, damaged

threads, and secur1ty to f1ange (9).
(4) V1sua11y inspect flange (9) for cracks and d1stort1on.
b. Inspect 1nsu1at1on sleeving (10) for d1stort1on and secur1ty.
c. Vsua11y 1nspect insu1ation of wires for cracks, chafing and deteriora-
tion.
d. Visua1ly inspect soldered connections for security.
e. Visua11y inspect housing of switches (7) for cracks.
f. Actuate switches and check for 'mechanica1 binding.

g. Functiona11y check 1ead assemb1y as fo11ows:
(1) Check for continuity between pins B-F and A-D of connector.
(2) Check for open cir~uit between pins C-F and E-D.
(3) Actuate switches and check for reversa1 of operation.

h. Cheek insulation between alI conductor pins and case ground at 500 volts RMS at 60 Hz.
Check insulation between connector pin groups B, C, F and A, E, D at 500 volts RMS at 60 Hz. No arcing
l
or breakdown between pin and case ground or between pin groups is permitted.
4-317. Visua11y inspect switch actuating 1ever (3) for distortion and cracks.
4-318. Inspect switch housing assemb1y (13) as fo11ows:

a. V1sua11y inspect hous1ng for cracks, dents, nicks, and for damaged
threads.
b. Visual1y inspect paint for chipp1ng, f1aking and peeling.
4-319. INSPECTION OF SWITCH ACTUATING GOVERNOR ASSEMBLY (figure 4-12).

4-320. Visua11y inspect governor weights (3) for n1cks, cracks and scratches.
4-321. Visua11y inspect governor pin (4) for scratches, nicks, burrs and wear.
4-322. Inspect compression spring (6) as fo1lows:
a. Visually inspeet spring for craeks and eorrosion.
b. Check alignment of spring coils. Ro1l spring aeross smooth, f1at sur-
face and check that spr1ng rolls straight and smooth.
Change 2 4-163
NAVAIR 03-105-AB-52
c. Check apring tension as follows:
(1) Compress spring to length of 0.490 incho
(2) Check for spring load within 0.575 +0.025 pound.
4-323. Inspect governor body assembly (7, 8) as follows:
a. Visually inspect pin (7) for security.
b. Visually inspect governor body for stripped, crossed or peened threads.

Inspect for rounded wrenching f lata. Inspect machined surfaces for scratches, nicks
and burra.
4-324. INSPECTION DF MAIN JET FUEL STARTER FUEL CONTROL ASSEMBLY (figure 4-13).
4-325. VisuaIly inspect air passage bolt (3, sheet 1) for dirt or other foreign
objects in air passage. Inspect bolt for cracks, damaged threads and rounded
wrenching f1ats.
4-326. Visua1ly inspect adjusting screw (11) for distortion, rounded wrenching
socket, damaged threads, and nicks and burrs.
4-327. Inspect acceleration Iimiter housing assembly (12, 13, 14) as fol1ows:
a. Visua1Iy inspect insert (12) for security and damaged threads.
b. Visually inspect restrictor (13) for obstructed orifice and for security.
c. Visually inspect housing (14) for cracks and housing mating flange for
nicks, burrs and distortion. Inspect housing for damaged threads.
4-328. Visually inspect spring guide (15) for cracks, distortion and wear.
4-329. Inspect compression he1ical spring (16) as fo1lows:
a. Visua1Iy inspect spring for cracks and corrosion.
b. Check alignment of spring coils. Rol1 spring across smooth, f1at sur-
face and check that spring ro11s straight and smooth.
c. Check spring tension as fo1lows:
4-330. VisuaI1y inspect diaphragm spacer (20) for cracks, distortion and for nicks
and burra on mating flanges.
4-331. Visually inspect diaphragm spacer (21) for cracks, distortion and for nicks
and burrs on mating flanges.
4-164
NAVAIR 03-105-AB-52
4-332. Visually inspect fuel control diaphragm spacer (23) for damaged threads and
for nicks or burrs on ball seat.
4-333. Visually inspect spring retainer (32) for cracks, distortion, wear and
damaged threads.
4-334. Visua1ly inspect adjusting screw (33) for damaged threads, distortion, and
for nicks, burrs and scratches on bearing surfaces.
4-335. Inspect governor cover assemb1y (35, 36) as fo11ows:
a. Visually inspect pin (35) for distortion and security.
b. Visua1ly inspect caver for distortion and cracks.
c. Visual1y inspect cover mounting f1ange for nicks and burrs.
4-336. Inspect compression helica1 spring (37) as fo11ows:
b. Check a1ignment of spring coils. Ro11 spring across smooth, flat sur-
face and check that spring rolls straight and smooth.
c. Check spring tension as follows:
(1) Compress spring to 0.850 inch.
4-337. Inspect annular ball bearings (38, 44) in accordance with paragraph 4-105.
4-338. Inspect metering sleeve (40) as fo1lows:
a. Visua11y inspect sleeve for scratches, nicks and burrs.

b. Check sleeve for smooth fit over governor va1ve assemb1y (46).
c. Dimensionally inspect for minimum diameter of not lesa than 0.4993 inch
at journa1 for bearing (38).
4-339. Visually inspect governor f1yweights (41) for cracks, nicks and diatortion.
Inspect pivot v-grooves for scratches, nicks, burrs and wear.
4-340. Inspect governar cage (45) as fo11ows:
a. Visual1y inspect cage for nicks, burrs, scratches, cracks and distor-
tion.
b. Visua11y inapect f1yweight pivots for nicks, burra, scratches and wear.
4-165
.
NAVAIR 03-105-AB-52
c. Dimensionally inspect for maximum diameter of not more than 0.4359 inch
at bore for governor valve assecbly (46).
4-341. Inspect governor valve assembly (46) as follows:
a. Visua11y inspect for security of plug in valve bore.
b. Visually inspect valve for nicks, burrs, cracks and scratches.
c. Dimensionally inspect for minimum diameter of not less than 0.4364 inch
at mating surface for governo r cage (45).
d. Dimensionally inspect for minimum diameter of not less than 0.4999 inch
at journal for bearing (44).
e. Perform magnetic particle inspection in accordance with MIL-l-6868.
4-342. Inspect sleeve bear1ng (47) as follows:
a. Vsually 1nspect for nicks, scratches, burrs and cracks.
b. Dimens10nally inspect that inside d1ameter of sleeve bearing 1s 0.3753

to 0.3758 incho
4-343. V1sually inspect adjusting screw (51) for nicks, scratches, burrs, cracks,
distortion and damaged threads.
4-344. V1sually inspect machine thread plug (52) for damaged threads and for
rounded wrenching flats.
4-345. Inspect compression helical spring (53) as follows:
a. Visually 1nspect spring for cracks and corrosion.
b. Check a1ignment of spring coils. Roll spring across smooth, flat sur-
faces and check that spring rolls straight and smooth.
c. Check spring tension as follows:
(2) Check for spring load w1th1n 1.20 +0.10 pound.
4-346. V1sually inspect meter1ng valve (54) for nicks, scratches or burrs and
smooth s11ding f1t within fuel control va1ve sleeve (59). Check alI passages of
valve for c1eanliness and freedom from obstructions.
4-347. Visua1ly inspect fuel contro1 valve sleeve (59) for nicks, scratches or
burrs. Check alI passages of sleeve for cleanliness and freedom from obstructions.
4-348. Inspect seal hous1ng (70) as follows:
4-166
•
NAVAIR 03-105-AB-52
a. Visua11y inspect housing for cracks, nicks and burrs.
b. Visua11y inspect alI paasages for c1eanlinesa and freedom from obstruc-
tions.
c. Visua11y inspect mating f1anges of housing for burrs and nicks.
4-349. Visua11y inspect fue1 pump sleeve bearings (76, 82) for nicks and scores.
Check security of seating of viton sea1 on outside.
4-350. Inspect pump drive shaft assemh1y (77, 78) as fo11ows:
a. Visua11y inspect p1ug (77) for security.
b. Visua11y inspect shaft sp1ines for chips, nicks and breaks.
c. Dimensiona11y inspect splines as follows:
(1) P1ace two 0.030 inch diameter pins in wear area of opposite sp1ine
grooves.
(2) lnspect for maximum dimension of not more than 0.1979 inch between
pins.
4-351. Inspect spur gears (79, 81) as fo11ows:

a. Visua11y inspect gears for broken, chipped or cracked teeth.
b. Check teeth for excessive wear by p1acing a 0.0864 inch diameter pin in
either space adjacent to the tooth which is diametrica11y opposite the first pino
Measure across the outside of these two pins. Repeat at 90 degrees for a second
reading. A measurement of 1ess than 0.8135 inch is cause for rejection of the
gear.
c. Perform magnetic partic1e inspection in accordance with MIL-l-6868.

4-352. Visua11y inspect gear shaft (80) for cracks, wear, nicks and burrs.
4-353. Inspect fue1 metering va1ve body assemh1y (86 through 97, sheet 2) as
fo11ows:
a. Visua11y inspect mating f1anges of body assemb1y (97) for nicks and
burrs.
b. Visual1y check alI passages in body for c1eanlines8 and for freedom from
obstructions.
c. Visua11y inspect inserta (86 through 93) for security and damaged
threads.
d. Visually inspect plugs (94, 95, 96) for security.
4-167
NAVAIR 03-10SAB-52
e. Dimensionally inspect body (97) in accordance with figure 4-66.
(_ f. Inspect bores ofbody (97) for scoring or damage from contact with spur gears (79, 81).
4-354. INSPECTION OF HYDRAULIC MOTOR (figure 4-14).
4-355. Inspect housing cap (1) as follaws:
a. Visually inspect cap for corrosion, nicks, burrs and cracks.
b. Visually inspect threads for crossed, stripped, ga11ed or worn threads.
c. Dimensionally check that inside diameter of cap bearing mating surface

ia within 1.4568 to 1.4573 inches.
4-356. Visual1y inspect bearing retainer (11) for corrosion, nicks, burrs and
cracks.
4-357. Inspect pistons (13) as fol1ows:
SURFACE C
DIAMETER A SHAll BE CONCENTRIC WITH DIAMETER B WITHIN 0.0005 INCH TOTAL INDICATOR
READING.
DIAMETER B SHALL BE NORMAL TO SURFACE C WITHIN 0.0005 INCH TOTAL INDICATOR

READING.
A B
0 •.3754 TO 0.7998 TO
0.3770 IN. 0.1KlO3 IN.
1-12A-9()'(R1
Figure 4-66. Inspection of Fue1 Metering Valve Body Assembly
4-168 Change2
I
NAVAIR 03-105AB-52
a. Visua11y inspect pistons for scoring, corrosion, nicks, burrs and

cracks.
, b. Dimensiona11y check that pistons body diameter is within 0.2497 to

0.2498 inch.
4-358. Inspect auxi1iary cam (14) as follows:
a. Visua11y inspect cam for corrosion, deformation, nicks, burrs and

cracks.
b. Magnetic partic1e inspect in accordance with MIL-I-6868.
4-359. Visua11y inspect cam retainer (15) for corrosion, nicks, burrs and cracks.
4-360. Inspect rotor (16) as fol1ows:
a. Visua11y inspect rotor for corrosion, nicl~, burrs and cracks.
b. Dimensiona11y check that diameter of rotor piston ho1es is within 0.2503

to 0.2505 inch.
c. Dimensiona11y check that surface of rotor that mates with port p1ate
(19) is f1at within one he1ium 1ight band.
d. Dimensiona11y inspect internaI keyway. Measurement of keyway width

sha11 not exceed 0.1280 inch.
4-361. Inspect shaft (18) as fo11ows:
a. Visua11y inspect shaft for corrosion, nicks, burrs and cracks.
b. Visua11y inspect externaI sp1ines for cracks, chips, nicks and wear.
c. Dimensiona11y inspect externaI sp1ines on output end of shaft by measur-

ing across two 0.080 inch diameter pins set in sp1ine grooves across sp1ine diameter.
Measurement sha11 not be 1ess than 0.4317 inch.
4-362. Inspect port p1ate (19) as fo110ws:
a. Visually inspect plate for corrosion, nicl~, burrs and cracl~.
b. Dimensiona11y check that surface of p1ate that mates with rotor (14)
is f1at within one he1ium 1ight band.
4-363. Inspect spring (24) as follows:
b. Check spring for deformation by ro11ing spring across smooth, f1at sur-
face; observe that spring ro11s straight and smooth.
Change 1 4-169
NAVAIR 03-105AB-52
Co Check spr1ng tens10n as fo11ows:
(1) Compress spring to 0 0 687 incho
(2) Check for spr1ng load within 7.8 +2 pounds o
4-364. Visua11y 1nspect name plate (27) for security and 1egibi1ity.
4-3650 Inspect housing (29) as fo11ows:
a. Visually inspect hous1ng (29) for cracks, wear, nicks, burrs and cor-
rosiono
ho Visua11y inspect housing paint for pee1ing, flaking and chipso
Co Visual1y inspect housing threaded surfaces for crossed, stripped,

gal1ed or worn threadso
4-3660 REPAIR AND REPLACEMENTo

AGE REQUIRED
BALANCING ARBOR SET 285476-1-1
BALANCING ARBOR SE! 287447-1-1
BALANCING SUPPORT INSERT 256377-1
I
CUTTER WHEEL, ABRASIVE
CUTTlNG MANDREL, VANE RING
PIN INSTALLING HOLDER 287944-1
PIN PRESSING HOLDER 287153-1-1
PIN REMOVING HOLDER AND DRlVER 287945-1
PNEUMATIC TOOL RIVET SET
PNEUMATIC TOOL RIVET SET 287735-1
I RESTRAINING FIXTURE
ROTATING ASSEMBLY BALANCING SUPPORT INSERT 256377-8
TURBINE WHEEL BALANCING ADAPTER 281373
TURBINE WHEEL BALANCING ADAPTER 285475-1-1
I. WELDING FIXTURE
4-170 Change2
NAVAIR 03-105AB-52
4-367. GENERAL
4-368. The methods and procedures outlined in this section are recommended by the
manufacturer to facilita te overhaul of the jet fuel gas turbine engine starter.
The information is presented as a supplement to the knowledge acquired by competent
personnel engaged in the overhaul activities of organized depotso Processes or pro-
cedures which are considered general or commonplace are omitted. However, due to
Change2 4-170Af(4-170B blank)

I
I
NAVAIR 03-105-AB-52
the precision equipment involved, it is necessary that alI instructions be careful1y

evaluated and stringently followed. Long life and continued efficient operation of
the jet fue1 gas turbine engine starter depend upon the care and accuracy with which
repairs and replacements are accomplished.
4-369. GENERAL REPAIR ANO REPLACEMENT INSTRUCTIONS.
4-370. MAGNESIUM AND ALUMINUM PARTS. Burrs, nicks, scratches, and galling should
be smoothed out with abrasive cloth (P-C-45l) and 011. lf paint is excessive1y
flaked, chipped or scratched, the part should be complete1y repainted. (Refer to
paragraphs 4-378 or 4-379.) Corrosion should be removed from magnesium parts as
described in paragraph 4-371 and from alum1num parts-as described in ~~~agraph 4-372.
WARNING
Whenever magnesium parts are reworked, care must be

exercised to remove alI dust, fittings, turnings, and
shavings as they are formed. Magnesium in these forms
is high1y inflammable and under certain conditions,
explosive.
4-371. Areas on magnesium parts wh1ch have corroded or where the original surface
treatment is no 1anger effective shou1d be treated as fo11ows:
a. Thorough1y c1ean the part to be treated and remove any paint as de-
scribed in paragraph 4-377.
b. Where close tolerance& are not required -remove any corrosion with a
wire brush or abrasive paper.
c. Where close tolerances must be observed swab or brush the defective sur-
face with a hat chromic acid solution at 180° to 200°' (82° to 93°C) containing
1-1/2 pounds of chromic acid (chromic trioxide) (o-C-303) and enough water to make
one gallan of so1ution. Do not allow this solution to contact any copper inserts.
WARNlNG
Due to the action of chromium trioxide in water, it ia
recommended that it be added to on1y 1/2 gallon of
water and allowed to dissolve before adding additional
water to make one gallon. Personnel should wear pro-
tective covering at alI times.
d. After treating defective surface, rinse parts thoroughly in co1d water

and then in hot water, drain and dry with compressed air.
e. Spot treat magnesium areas cleaned of corrosion or where original sur-

face treatment is not effective by brushing on a chrome-pickling solution in accord-
ance with MIL-M-3l7l, type I, conta1ning 1/2 pound of sodium dichromate solution
(Na207.H20), 1-1/2 pints of nitric acid (HN03-SPGR 1.42) and enough water to make
one gallan of sa1ution. Mix the abave 1nsredients in an acid-resistant cantainer
as fo110ws:
4-171
t
NAVAIR 03-105AB-52
(1) Pour approximately three quarts of water in the container and then
add the sodium dichromate.
(2) When the dichromate is completely dissolved slowly add the nitric
acid and then enough water to make one gallon of solution.
(3) Stir until thoroughly mixed.
WAIUUNG
Personnel should wear protective covering at alI times_
f. Maintain the chrome--pick1ing solution at a temperature of 21° to 32°C

(70° to 90°F); do not allow so1ution to remain on the treated surface for longer
than 15 seconds. Follow application immediately with a cold water rinse; then
rinse with hot water and dry thoroughly.
g. Repaint parts as required in accordance with paragraphs 4-378 or 4-379.
4-372. Areas on aluminum parts which have corroded or where the original surface
treatment is no Ionger effective should be treated as follows:
a. Clean and remove any paint as described in paragraph 4-377.
b. Where close tolerances are not required, remove any corrosion with a
wire brush or abrasive paper (P-P-lOI).
c. Where close tolerances must be observed, swab oro brush the surface with
a hot chromic acid solution as described in paragraph 4-55.
d. Spot-treat areas on aluminum parts cleaned of corrosion, or where original surfaee

treatment ia not effective, in aeeordanee with MIL-C-5541-1, using MIL-C-81706, elass lA material.
e. Reanodize a1uminum parts if necessary, in accordance with MIL-A-8625.
4-373. STEEL PARTS.
4-374. Burrs and minor galling, pitting, or scratches should be smoothed out with
abrasive cloth (P-C-458) or with a fine stone. Remove corrosion on steel parts as
follows:
a. Soak in rust stripper solution (one gallon of water mixed with 3 to 5

pounds of Oak1te Rust Stripper, Oak1te Products, Inc, 50 Va11ey Rd, Berk1ey Rts,
NJ 07922, or equivalent), heated to 71° to 83°C (160° to 180°F) with air agitation
for 15 to 30 minutes.
b. Remove part from stripper solution, rinse with c1ean water, and brush
with a stiff brush.
4-172 Change 2
i
NAVAIR 03-105AB-52
c. Repeat cleaning operation until alI surfaces are free of deposits.
d. Rinse thorough1y with c1ean water and dry with filtered compresaed air
or wipe dry with a clean, lint-free cloth.
4-375. Steel parta which have been cadmium plated (except those considered to be
stock parts such as bolts, nuts, washers, etc) should be replated, if necessary.
No base metal should be visible on plated surfaces. lf the plating is pitted,
cracked, or worn, replate the part in accordance with methods outlined in QQ-P-416.
Remove alI plating prior to rep1ating by soaking the part in a 10- to :J-percent
solution of ammonium nitrate.
4-376. PAlNTlNG.
4-377. Before parts are repainted at overhaul, their surfaces must be properly pre-
pared to receive the paint as follows:
a. To remove paint, immerse part in MIL-R-81835 hot tank stripper for 30 minutes. Where
immersion is not feasible, brush on MIL-R-81294 mild stripper.
I
b. Following the stripping operation, thorough1y clean, wipe, and dry the
parto
c. Magnesium parts, from which the paint has been removed in preparation
for repainting, should first be treated to prevent corrosion as described in para-
graph 4-371.
4-378. Parte may be repainted as follows:
a. Plug alI holes and mask alI areas not to be painted. Thorougbly clean
and dry the surfaces to be painted.
b. Apply one coat ofzinc chromate primer (TI'-P-1757) and allow to dry, then apply NO coats (
ofblack enamel ('M'-E-489, class B). Paints m~y be applied with a spray gnu or a brush.
4-379. ALTERNATE PAINTlNG METHOD.
a. Plug alI holes and mask alI areas not to be painted. Thorough1y clean
and dry surfaces to be painted.
b. Apply one coat of MIL-P-2337 to a dry film thickness (DFT) of 0.6 - 0.9 mils. Allow to &ir-
ar
dry for 1 hour. Apply two coats of gloss black MIL-C-83286 to a DFT 1.7-2.3 mils, thus requiring a total
DFT of 2.3-3.2 mils of primer and top coat.
I
Change 2 4-173
NAVAlR 03-105-AB-52
4-380. DRY-FlLM LUBRlCATlON.
4-381. Dry-film 1ubrieation may be required for speeified parts at overhaul. The
surfaee of these parts should be visua11y inspeeted for erosion, eorrosion, or
damage to finish. lf base metal is visib1e, or if the finish is bad1y nieked or
scratehed, the parts shou1d be replaeed or the surfaee restored in aecordanee with f
reeommendations of the manufaeturer (types I and IV, Drilube Co, 723 W Broadway,
G1endale, CA 91204; types I, 11, IV, and V, E1ectrofilm Ine, 7116-21 Laurel Canyon
B1vd, Ho11ywood, CA 91605, or equiva1ent).
4-382. EXPANSION OF PARTS BY HEAT.
4-383. When removing or installing tight fitting parts, it is sometimes neeessary

to heat the surrounding metal to faeilitate the operation. The most desirable
method to accomplish this is by oven heating to the proper temperature; heating
the part with a torch is satisfactory if the toreh is hand1ed properly. A soft
f1ame gas torch shou1d be used and f1ame app1ied over the entire area surrounding
the part to be removed. The f1ame must not be he1d toe long in one spot.
4-384. Except where otherwise specified, magnesium parts must be kept be10w 120°C
(248°F) and aluminum parts below 150°C (302°F).
4-385. WELDED, BRAZED, OR SOLDERED ASSEMBLlES.
4-386. If inspection reveals a damaged or broken welded, brazed, or soldered joint,

the damage may be repaired using good shop practiee.
4-387. ROSAN STUDS, INSERTS, AND LOCKRINGS.
4-388. If inspeetion revea1s a damaged stud or insert, the damaged parts may be re-
placed as follows:
a. Remove insert by drilling to a depth equal to the thickness of the loek-

ring with a drill equal in diameter to that of the serrations between the lockring
and inserto Then remove the insert with an "easy-out" to oI.
b. Remove stud by milling to a depth equal to the thickness of the lockring

with a hollow mill equal in outside diameter to that of the serrations between lock-
ring and stud, then remove the stud.
e. For further instructions and use of oversize studs, inserts, and loek-
rings, refer to the manufacturer (Rosan Ine, 2901 W Coast Highway, Newport Beach,
CA 92663).
4-389. HELI-COlL INSERTS.
4-390. Damaged or improper1y instal1ed He1i-Coil inserts may be removed with He1i- •
Coi! extracting tools. Refer to MS33537. ~
4-391. BEARINGS, RUBBER PARTS, PACKINGS, AND GASKETS.
4-174
NAVAIR 03-l05-AB-52
4-392. AlI oil and grease seals, rubber parts, packings, and gaskets must be re-
placed at each overhaul unless otherwise specified. The same type of material must
be used in replacing rubber parts and packings.
, 4-393. Parts that have special gasket seal o-rings bonded into their surfaces must
be replaced at each overhaul. Replaced parts of this type should be returned to
stores for disposition.
4-394. BALANCING PROCEDURES.
4-395. The balance of the rotating assemblies must be extreme1y accurate due to the
high operating speeds and temperatures to which they are subjected. Balancing pro-
cedures must be carefully performed and balancing equipment must be carefu11y
checked throughout the balancing operations. Upon completion of balancing pro-
cedures, as applicable, the components of each rotating assemb1y must be stored in
clean, dry, dust-free containers and, if to be stored for some time, protected
against corrosion in accordance with MIL-P-116.
NOTE
A standard balancing machine (Giddings and Lewis Inc,

142 Boty St, DuLac, WI 54935, or equivalent) must be
used to perform balancing operations.
CAUTION
Rotating assemblies consist of matched parts and as
such should be kept together. Parts are interchange-
able with identical components, however, balancing
procedures are considerably more time consuming when
attempting to match parts not previously balanced as
an assembly.
4-396. DETAILED REPAIR INSTRUCTIONS.

4-397. Table 4-2 lists the repair requirements for the jet fuel starter. Compo-
nents requiring balance, rework or repair are so noted by reference to appropriate
figures or paragraphs inserted in the applicable columns.
NOTE
Before discarding any part which does not meet dimen-
sional inspection requirements, refer to paragraph
4-646 to determine i f part can meet mintmum or maxi-
DUm Iimits of fit tolerances with mating parts. Refer
to applicable repair and replacement instructions to
determine if repair is feasible.
4-398. REPAIR OR REPLACEMENT OF MAJOR STARTER ASSEMBLIES (figure 4-2).
4-399. Rep1ace clamp coupling (1, 3, 4) if inspection revea1s damage.
4-175
NAVAIR 03-105-AB-52
4-400. Repair or rep1ace engine starter mounting flange (2) as follows:
a. Remove corrosion from engine starter mounting flange in accordance with

paragraph 4-372, repaint defective painted surfaces in accordance with paragraph
4-378.
b. lf flange is cracked or fai1s to meet dimensional inspection require-

ments, rep1ace engine starter mounting flange.
4-401. Repair power turbine assembly (5, figure 4-2) in accordance with paragraph
4-404.
4-402. Repair gas generator and accessory drive assemb1y (6) in accordance with
paragraph 4-458.
4-403. Rep1ace identification p1ate (7) if plate is damaged or i1legible.
4-404. REPAIR OF POWER TURBINE ASSElffiLY (figure 4-3).
4-405. Rep1ace identification p1ate (1, sheet 1) if damage or illegibility is evi-

denced by inspection.
4-406. Replace output shaft retainer (3) if inspection requirements are not meto
4-407. Repair or rep1ace output shaft assembly (4) as fo1lows:
a. Remove minor nicks or burrs in accordance with paragraph 4-374.
b. rf base metal is visib1e through dry-fi1m 1ubricant, renew lubricant alI

over in accordance with paragraph 4-380, using type I lubricant. Apply lubricant
0.0001 to 0.0003 inch thick.
c. rf output shaft assemb1y fai1s to meet dimensional requirements, re-
p1ace shaft assem~ly.
4-408. Repair switch actuating governor (5) in accordance with paragraph 4-598.
4-409. Repair or rep1ace quick re1ease pin (6) as follows:
a. Remove minor nicks or burrs in accordance with paragraph 4-374.
b. Rep1ace quick re1ease pin if operation of ball lock is not satisfactory.
4-410. Rep1ace oil dip stick (8) if inspection reveals damage.
4-411. Rep1ace damaged or illegible 1ubrication instruction plate (9).
4-412. Repair or rep1ace oil fi11er housing (10, 11) as fo110ws:
a. rf anodized surfaces are worn through, reanodize housing (11) in accord-

4-176
,
NAVAIR 03-105-AB-52
b. lf insert (10) is damaged rep1ace in accordance with paragraph 4-387.
c. Rep1ace oi! fi11er housing (10, 11) if inspection revea1s damage.
, 4-413.
4-414.
Rep1ace c1amps (15, 17) if inspection revea1s damage.
Rep1ace f1exib1e hose (16) if inspection revea1s damage.
4-415. Repair or rep1ace f1uid passage bo1t (18) as fo11ows:
a. lf inspection of f1uid passage revea1s foreign matter, c1ean using

standard procedures. lf cleaning is unsuccessful, rep1ace bolt.
b. Rep1ace bo1t if inspection revea1s damage.
4-416. Rep1ace magnetic p1ug (21) if inspection revea1s damage.
4-417. Rep1ace oi! drain adapter (22) if inspection revea1s damage.
4-418. Repair e1ectrical wiring insta11ation (10, figure 4-1) in accordance with
NAVAlR 01-lA-505 and as fo1lows:
a. Disassemb1e e1ectrical connectors P3 (27, figure 4-3) and P9 (26) for

repair or rep1acement as fo11ows:
(1) Disassemb1e e1ectrica1 connector by 100sening clamp screws on back
shell of connector.
(2) Separate connector and slide back insulation sleeving (29) as re-
quired to expose contacts.
(3) Remove alI potting compound from back she11, contacts and wires.
(4) Heat contacts to melt so1der and disconnect wires as necessary.
b. Repair loose wire connections as follows:
(1) Disassemb1e affected electrica1 connector in accordance with step

a.
(2) Repair loose connection by so1dering using so1dsr SB5, per

QQ-S-571.
(3) Assemble e1ectrical connector in accordance with step d.
c. Replace damaged wires as fo1lows:
(1) Disassemble electrical connectors and disconnect wire in accordsnce

with step a.
(2) Pu11 wire from insulation sleeve.
4-177
NAVAIR 03-105-AB-52
(3) Measure and cut replacement wires to 1ength of 8.5 inches.
(4) lnsert replacement wires through insu1ation sleeve and back shells
of connectors.
(5) Assemble e1ectrical connectors in accordance with step d.
d. Assemb1e electrical connectors P3 (27) and P9 (26).
(1) Connect green wire, MB138l-l-2D-5, between contact A of connector

P3 and contact A of connector P9 (26). Connect white wire, M8l38l-l-20-9, between
contact C of connector P3 (27) and contact C of connector P9 (26).
(2) Solder wires to contacts using solder SB5, per QQ-S-57l.
NOTE
Do not apply potting compound to connector P3; addi-
tiona1 wiring connections are to be made during final
assemb1y.
(3) App1y potting compound, MlL-S-23586, (RTV8lll, General Electric Co,

Silicone Products Division, Waterford, NY, or equivalent) to connector.
(4) Assemble connector and secure with clamp screws.
4-419. Rep1ace immersion thermocouple (30) if inspection requirements are not meto
4-420. Repair or rep1ace switch cover assembly (40, 41) as follows:
a. Rep1ace loose or damaged pin (40) by cutting off flush with cover (41)
and drilling old pin out to a maximum diameter of 0.129 incho Clean hole with
solvent, Specification P-D-680. Apply an even coat of primer (Cati-Coat E42GP22
and catalyst reducer V66KP46, Sherwin-Williams Co, Main Store 2312 N. 16th ST,
Phoenix, AZ 85106), mixed equal by volume, and install pin, pin shall protrude 0.21
to 0.25 inch, swage in place.
b. lf paint on plate (41) is damaged, mask off pin (40) and repaint in
accordance with paragraph 4-379.
c. lf plate (41) is cracked, dented, distorted, or shows evidence of

elongated holes, replace cover.
4-421. Replace sleeving (43) if inspection reveals damage.
4-422. Replace plugs (45, 47) if iuspection reveals damage.
4-423. Repair or replace containment support assembly (53, sheet 2) as follows:
a. Remove corrosion from support assembly in accordance with paragraph

4-373.
4-178
NAVAIR 03-105AB-52
b. Replace support assembly if inspection requirements are not mete
4-424. Replace thermal insulation batt (54) tf inspection reveals damage.
4-425. Repair or replaee second stage containment shield assembly (55) as follows:
a. Machine the ring (1) in an axial direction to the bottom of the existing weld. Remove the
remainder or the ring and the pins from the assemb1y and discard.
b. Remove the segment set (2) and support set (4) in (99193) 363950-1 assemb1y.
CAUTlON
Eaeh set is matched and must not be broken during processing.
c. The shield surface A (figure 4-66A) which mates with the ring shall be cleaned up by
machining up to a maximum diameter or 7.040 inches. The surface finish shall be 64 micro inches or
better.
d. Glass bead blast the segment set to remove surface oxides.
e. Remove the silver plating from the support set in (99193) 363950-1 assemblies then replate to a
thiekness orO.OOl to 0.003 ineh per speeification QQ-S-363.
f. In aeeordance with Drawing No. (96916) lC2986, manufacture a replacement ring. Prior to
installation, machine ring surface A, (figure 4-66A), to eft'eet a shrink fit of 0.0005-0.003 incho Machine
aurfaee B 80 that the segment set ia secure with 0.0000 elearance and surfaee B has a maximum or 0.005
inch elearance from the edge of the shield (5).
g. Obtain sa new pins, MSl71444.
NOTE
Ensure gap at end of segments are approximately equal and no

more"than 0.090 incho
h. Clean the mating surface of the shield and ring of alI contaminants including
fingerprints, and instalI the ring and aSBociated item into the shield in accordance with figure 4-66A,
ensuring that no further contamination occurs.
i. Eleetron beam weld the ringto the shield. FuIl weld penetration ofthejoint to adepth of
0.205 inch ia required. See Drawing No. (99193) 363950.
j. Stress relieve the weld at llOOOF ± 250 for one hour and air 0001.
k. Final machine the part to the dimensions of Drawing No. (99193) 363950.
I . Fluorescent penetrant inspeet the weld joint in aecordance with the latest revision of MIL-
1-6866, type I, method B.
Change2 4-178A
t
NAVAlR 03-105AB-52
1. RING 3
2. SEGMENT SET
3. PIN
oi. SUPPORT SET
5. SHIELD
__J----------[IIMD--------~
A B C O
7.0215 TO 6.635 TO 1.al8T0 2.193 TO
7.0400 IN. 6.625 IN. 1.898 IN. 2.183 IN.
Figure 4-66A Repair of Second Stage Containrnent Shield Assernbly
4-426. Replace heat shield (56) if inspection reveals damage.
4-427. Replace turbine diffuser (57) if damage is revealed by inspection.
4-428. Repair or replace bracket assembly (63, 64) as follows:
a. lf insert (63) is loose or damaged, replace in accordance with paragraph

4-387.
b. Replace bracket (64) if inspection reveals damage other than that speci-
fied in preceding step a.
4-429. Replace retainer (70) if inspection reveals damage.
4-430. Repair or replace engine starter housing assembly (74 through 78) as follows:
a. Remove corrosion in accordance with paragraph 4-372.
b. Repaint damaged or worn painted surfaces in accordance with paragraph
4-178B Change2
NAVAIR 03-105AB-52
4-379.
c. Replace damaged inserts (74, 75, 76, 77) in accordance with paragraph
4-387.
d. Keplace housing (78) if visual inspection reveals cracks or if dimen-

sional requirements are not meto
4-431. Repair or rep1ace engine starter drive shaft assembly (79 through 82) as
follows:
a. Replace pawls (79) 1f inspection revea1s damage.
b. Rep1ace loose or damaged rivets (80) or spring assemblies (81) by center

dri1ling bead of rivet (80). Using an appropriate sized drift dis10dge rivets and
assembly from shaft (82). Rivet holes sball not exceed 0.101 inch in diameter and
shal1 not show evidence of elongation. Using Pneumatic Tool Rivet Set, 285464-1-1
install new springs and rivet.
c. Replace shaft assembly (79 through 82) if inspection reveals wear or

damage.
4-432. Repair or replace exhaust housing assembly (83, 84) as follows:
WARNING

anesthetic and dangerous to lüe. Eye irritation and dizziness are
a. Vapor degrease for one hour using MIL-C-81533.
b. Glass bead blast using MIL-G-9904, Size 13 glass beads, at 30 P.S.I.G.
c. Thoroughly air blast emaust housing assembly after glass bead blasting.
d. Wire brush area to be welded using wire brush with similar composition as material being
welded. Hand brush where necessarv.
e. Cracks in liner materialless than one inch in length shall be stop drilled using 1/32 inch
driIl bit patched using 0.006 to O.OOS inch thick 347 CRES sheet stock per AMS 5512 or equivalent. Patcb
size shall exceed crack Iength and width by 0.500 incho Patch shall have rounded comers.
f. Resistance spot weld patches in accordance witb MIL-W-6858. Weld spacing shall not
ex:ceed 1/8 incho
Change2 4-178C'J(4-178D blank)

NAVAIR 03-105AB-52
g. Do not overlap patches. If crack is located in an area where overlapping could occur,
remove any existing patches and replace with one patch or liner segment where nece~sary.
h. Cracks exceeding one inch in length anel/or 0.500 inch in circumference require
replacement of the individualliner segmente Liner segment shall be resistance spot welded in
accordance with MIL-W-6858. Weld spacing shaIl not exceed 0.125 incho
i. Ifweld repair ia not feasible or possible due to pre-existing condition ofthe material. e.g.,
inadequate surface for welding, part shall be forwarded to the Material Review Board (MRB) for
disposition.
j . Exhaust housing assembly shall be visually inspected for acceptance/non-acceptance in

accordance with MIL-I-6866.
4-433. Replace ring gear lockring (86, sheet 3) if visual and dimensional inspec-
tion requirements are not mete
4-434. Replace internal gear hub (89) if inspection requirements are not mete
4-435. Replace lock ring (91) if inspection revea1s damage.

4-436. Replace insulator p1ate (94) if inspection reveals damage.
4-437. Repair or replace sensitive switch assembly (96) as follows:
NOTE
Perform electric and e1ectronic wiring procedures in

accordance vith NAVAlR OI-IA-50S.
a. Replace damaged wires by removing potting compound and unsoldering old
wires. Obtain 36 inch lengths of M8l38l/l-2o-0, M8l38l/l-2o-2 and M8l381/l-2o-3
wire; strip 0.25 inch of insulation from one end of vires. Solder M8138l/1-2o-0
wire to switch COMMON terminal, M8l38l/l-20-2 vire to NORMALLY OPEN terminal and
M8138l/1-20-3 vire to NORMALLY CLOSEO terminal; soldering sball be in accordance
with MIL-STD-454, REQ. 5; solder sha1l conform to QQ-S-57l, composition Sn60.
C1uster vires together as shown in figure 4-67, dimension B. Apply compound
(Epoxylite 203, and Catalyst No. 1, Epoxy1ite Corp, 1428 Santa Anita Ave, P.O. Box
3397, El Monte, CA 91733) in accordance with figure 4-67, dimension A.
b. Replace switch assembly if inspection reveals damage other than speci-

fied in preceding step a.
4-438. Replace svitch actuating lever (98, figure 4-3) if inspection revea1s
damage.
4-439. Rep1acebearing support (99), if inspection reveals damage.
Change 2 4-1'19
NAVAIR 03-105AB-52
4-440. Rep1ace nuts (101, 125) ii inspection revea1s damage •
. 4-441. Rep1ace pinion spur gear (102) ii 1nspection revea1s damage.
4-442. Repair or rep1ace turbine whee1 assemb1y (103, 104) as fo11ows:
a. Remove minor nicks and scratches from blades of whee1 with abrasive
c10th (P-C-458) or with a fine stone (No. AF-3-JB, Carborundum Co, P.O. Box 403,
Niagara Fa11e, NY 14302, or equivalent).
b. If wheel is cracked, replaee the wheel assembly. Ir diameter A, figure 4-22, (over blade
tips) exceeds 6.291 inches, it may be machined by grinding O.D. to within specified limits of reference
(a) BB diameter (6.287 to 6.290 inches), up to a maximum removaI of 0.012 inch during the lifetime or the
wheeI.
c. Each rework removal of metal from the blade tip diameter shall be acid etched on the outer
bulged portion of the wheel hub (see note 11, Detail E, Zone G5 of Drawing No. (99193) 363280). At the
second and succeeding rework cyc1es, the former rem oval figure shall be added to the current removal
figure and the totalsum ofthe material removed from diameter A is to be etched next to the former entry
and the former entry is to be marked through by the same acid etch processo
NOTE
When the total material removed from diameter A exceeds 0.012

inch, the wheel assembly shaU be replaced.
d. Shaft diameters C and D, figure 4-22, may be repaired by grinding shaft 0.000 to 0.005 inch
under size, replating in accordance with Federal Specification QQ-P-416, using hard chrome plate, QQ-
C-320, to a thickness of 0.010 incho Regrind to dimensionallimits specified in figure 4-22.
e. Using Turbine Wheel Balancing Adapter, 281373, balance turbine wheel assembly on
diameter B, figure 4-68, to an accuracy of 0.0034 ounce-inches in planes M and L, observing aI10wable
material removal areas.
f. Replace turbine wheel assembly if any damage ot.her than specified in paragraphs a
through d is revealed by inspection.
4-180 Change 2
NAVAIR 03-105AB-52
NORMALLY OPEN
A B
0.12 TO 0.25 IN.

0.17 IN. MIN
1-12A-945
Figure 4-67. Repair of Sensitive Switch
4-443. Replace insulation cover (105, figure 4-3) if inspection reveals damage.
a. Placa a 3.250 inch diameter by 0.500 inch minimum thickness solid steeI backing bIock on
the pIaten of a hydraulic press.
NOTE
The steeI block must have a 65 micro-inch finish or better on both
sides and the sides shall be paralIeI within 0.010 inch TIR. A
similar block or a 3.250 inch diameter solid ram is required for
appIying force.
b. Center the subject thermal insulation blanket on the base block and center the hydraulic
ram with its facing bIock inside the subject part while appIying an approximate force of 2,000 pounds.
c. Ensure that the blocks are centered., then sIowIy increase force to 5 tons (10,000 pounds).
d. Remove and reinspect. Parta must be within inspection limits of figure 4-23.
Change2 4-18OA
,
NAVAIR 03-105AB-52
e. Repair crack(s) in the outer shell (0.010 inch thick) as follows:
(1) Areas acljacent to crack(s) shall be cleaned by wire brushing andlor lightly blasting
with number 13 glass beads.
(2) Visually inspect and mark acljacent to the crack(s).
(3) Stop drill the crack(s) using a 0.050 inch diameter drill.
(4) Fabricate a repair patch ofstainless steeI foil (0.005 inch to 0.010jnch thick) such that
the cracked area is fully covered and approximately 0.250 inch of patch material resta on uncracked
base material around the crack. Patch material shall be 321, 347, or 348 stainless steeI.
(5) Attach the repair patch to the outer shell (which ia 347 stainless steel) by spot welding
in accordance with MIL-W-6858 around the entire circumference ofthe patch at weld intervals no
greater than 0.050 incho
f. Areas of prior welding (inner-to-outer shell connection pointa) that exhibit cracking shall
be repaired by heliarc welding per MIL-W-8611, using HasteIloy W or 347 stainIess steeI filIer rodo
These re-welded areas may also be covered by the patches which repair adjoining cracked areas.
g. Fluorescent penetrant inspect in accordance with MIL-I-6866 and NAVAIR 01-IA-16. No

cracks are acceptabIe.
4-444. Replace seal retainer (107) if inspection reveals damage.
4-445. Replace thermal insulation b1anket (108) if inspection revea1s damage.
4-446. Replace turbine whee1 seal assemb1y (112) 1f 1nspect1on reveals damage.
a. Damaged, wom, or leaking seal assemblies shaIl be replaced with a new seal assembIy or
further processed as follows:
(1) Clean the seal assembly carbon element with the vapor degreasing process found in
paragraph 4-62.
(2) Depress carbon fuJly. Keep sealing surface parallel to back of seal during this
operation.
(3) Slowly release load on carbono Roughness of seal operation is pennissible as long as
. carbon does not stick and hold when load is released.
(4) Expand Beal bellows utilizing apeeial tool until carbon face extends slightly beyond
seal shell. Retain in this position with special tool. Place a new emery polishing paper grit 4/0 on a flat
surface and hand lap the mating face ofthe carbon element to remove scratches and nicks. Use a figure
eight lapping motion. Provide flatness requirement within three helium light bands using a new three
micron lapping filmo Prior to checking fiatness, clean per paragraph 4-164.d. Remove specia) tooling
and alIow carbon element to retum to normal operating position.
4-180B Change2
NAVAIR 03-105AB-52
(5) Repeat paragraphs (2) and (3).
(6) Refer to figure 4-24. Spring load maU be 6.5 pounds maximum at 0.187 operating
length and 0.2 pounds minimum at 0.157 operating length.
(7) Lap the rotor face on the rotating lapping machine to provide ftatness requirement
within three helium light bands. Shoulder on rotor shall be parallel to rotor face within 0.0002 incho
Prior to checking flatness, clean per paragraph 4-164d.
(8) Test the seal assembly per paragraph 4-1648. Sea1s that still do not par;o the leakage
requirements shall be replaced.
4-447. Replace spring seats (114, 120) if visual or dimensional inspection require-
ments are not mete
Change2 4-181
NAVAIR 03-105-AB-52
REMOVE MATERIAL FROM HERE FOR

BALANCING. DO NOT EXCEEO
/ SHADEO AREAS.
ALL PLACES WHERE MATERIAL IS REMOVE0

MUST FAIR SMOOTHLY. ALL CORNERS
0.015 INCH RAOIUS MINIMUM. FINISH 63,7
v
Figure 4-68. Balance ofAxial F10w Turbine Whee1 Assemb1y
4-448. Repair or rep1ace resilient ba11 bearing housing (116) as fo11ows:
a. Remove corrosion from housing in accordance with paragraph 4-374.
b. Rep1ace housing if inspection requirements are not meto
4-449. Repair or rep1ace resi1ient mount 1iner (117) as fo11ows:
b. Rep1ace liner if inspection requirements are not meto
4-450. Rep1ace compression helical spring (121) if inspection requirements are nol
meto
4-451. Repair or rep1ace bearing sleeve spacer (122) as fo11ows:
4-182
NAVAIR 03-105-AB-52
a. Remove corrosion from spacer in accordance with paragraph 4-374.
b. Rep1ace spacer if inspection requirementa are not mete
4-452. Rep1ace spur gearshafts (129) if inspection requirements are not meto
4-453. Rep1ace matched p1anetary spur gear set (130) if any inspection requirement
is not meto
4-454. Rep1ace internaI spur gear (131) if any inspection requirement is not meto
4-455. Repair or rep1ace bearing spacer (132) as fo1Iows:
a. Remove corrosion from spacer in accordance with paragraph 4-374.
b. Rep1ace spacer i f inspection requirements are not meto
4-456. Rep1ace bearing (134) if any inspection requirement ia not meto
4-457. Repair or rep1ace gear carrier assemb1y (136 through 141) as fo11ows:
a. RepIace gasket (137) if pressure check at inspection revea1s defective

gasket.
b. Rep1ace pin (138) if required by removing old pin and instal1ing new
pin as fo11ows:
(1) C1ean pin (138) and pin ho1e in gear carrier (141) with so1vent
(Dowc1ene EC, Dow Chemical Co, Mid1and, MI 48640, or equiva1ent).
(2) App1y coat of wet primer (equa1 parta Sherwin-Wi11iama Cati-Coat

Primer E42GP22 and Cata1yst Reducer V66KP46, Sherwin-Wi11iams Co, Main Store, 2312
N. 16th St, Phoenix, AZ 85016, or equiva1ent) evenly to outer diameter of pin; do
not dip-coat pin or coat ho1e.
(3) Press pin to bottom of ho1e whi1e primer ia wet.
(4) Cure for 4 to 6 hours at room temperature or for 2 houra at 180 0
4-458. REPAIR OF GAS GENERATOR ANO ACCESSORY DRIVE ASSEMBLY (figure 4-4).
4-459. Rep1ace identification p1ate (1) if inspection requirementa are not meto
4-460. Rep1ace fi1ter bracket (15) if inspection revea1s damage.
4-461. Rep1ace pressure f1uid fi1ter (19) if any insp'ection requirements are not
meto C1ean dirty fiIter by back fIushing.
4-462. Rep1ace check va1ve (22) if any inspection requirements are not mete
4-183
•
NAVAIR 08-105AB-52
4-463. Replace restricted flow check valve (29) if any inspection requirement i8
not mete
4-464. Replace igniter plug electrical lead (40) if inspection reveals damage.
4-465. Replace capacitor discharge high voltage ignition unit (41) if inspection
requirements are not mete
a. Reinforce existing bracket by welding a 0.060 inch thick aluminum plate (6061-T6 or
equivalent) 2.500 inches wide by 4.000 inches long centrally located and positioned apPl'oximately 0.250
inch from igniter connector side of the unit.
NOTE
Remove paint from ignition unit as required to expose bare metal in
area to be welded.
b. Weld plate in accordance with MIL-W-8604.
c. Provide four slots in plate in accordance with Drawing No. (99193) 369963.
d. Complete processing in accordance with requirements of the aft'ected publication.
4-466. Replace igniter plug (45) if inspection requirements are not meto
4-467. Repair or replace accumulator assembly (49) in accordance with paragraph

4-588.
4-468. Repair or replace accumulator mounting bracket (54, 55) as follows:
a. Replace insert (54) in accordance with paragraph 4-387, if damage is

revealed at inspection.
b. Remove mino r nicks and burrs in accordance with paragraph 4-373.

c. Replace bracket (55) if inspection requirements are not mete
4-469. Repair or replace JFS contro1 box assemb1y (56) in accordance with para-
graph 4-571.
4-470. Replace rod end bearings (70, 73, 86, 89) if inspection reveals damage.
4-471. Replace turnbuckles (74, 90) if damage is revealed at inspection.
4-472. Repair or replace support brackets (62, 78) as follows:
a. Remove burrs using a fine stone (AF-3-JB, Carborundum Co, N1agara Fal1s,
NY, ar equivalent). Reanodize brackets in accordance with paragraph 4-372, with
type 11, class I treatment.
4-184 Change 2
i
NAVAIR 03·105AB·52
b. Rep1ace support brackets if any defect other than corrosion i8 revea1ed.

4-473. Rep1ace p1ug (92) i f inspection revea1s damage.
4-474. Replace shaft (120) if any inspection requirement ia not meto
nOTE
accordance with NAVAIR Ol-lA-SOS.
4-475. Repair JFS branched wiring barness assemb1y (ll, figure 4-1) as follows:
Refer to figure 4-69.
a. Disassemb1e electrical connectors (2, 3, 4, 5, 6, 7) as follows:

I
I
I
I
I
I
NAVAIR 03-l0S-AB-S2
___ 2
3
/
1
/
~1 ".....,4
1. IDENTIFICATION
STP.AP
/5 2. CON!lECTOR (P2)
3. CONNECTOR (P8)
4. CONNECTOR (P4)
\ 5.
6.
CO!1NECTOR
CONNECTOR
(P5)
(P7)
7. CONNECTOR (P6)
I
1
........-1
Figure 4-69. Jet Fuel Starter Branched Wiring Harness Assembly
4-185
NAVAIR 03-105-AB-52
(1) Disassemb1e e1ectrica1 connector by loosening clamp screws on back

shell of connector.
(2) Separate connector and slide back braided fiberglass insulation as

required to expose contacts.
(3) Remove alI potting compound from back shell, contacts and wires.
(4) Heat contacts to melt solder and disconnect wires as necessary.
b. Repair loose wire connections as fo11ows:
(1) Disassemble affected e1ectrical connector in accordance with step

a.
(2) Repair loose connection by soldering using solder SB5, per QQ-S-571.
(3) Assemble electrical connector in accordance with step c.
c. Assemb1e electrical connectors (2, 3, 4, 5, 6, 7) as follows:
(1) Insert wire through back shel1 of connector.
(2) Connect wires to connectors in accordance with figure 4-70.
(3) Solder wires to contacts using solder SB5, per QQ-S-571.
d. Rep1ace damaged identification straps (1, figure 4-69).
e. Perform continuity check using figure 4-70 as a guide.
4-476. Repair permanent magnet generator (128, figure 4-4, sheet 3) in accordance
4-477. Repair or replace accessory drive assemb1y (129) in accordance with para-
graph 4-522.
4-478. Repair or replace gas generator assemb1y (130) in accordance with paragraph
4-479.
4-479. REPAIR JET FUEL STARTER GAS GENERATOR ASSEMBLY (figure 4-5).
4-480. Replace screen assemb1y (1, sheet 1) if inspection requirements are not meto
4-481. Rep1ace c1amp (2) if inspection revea1s damage.
4-482. Repair or rep1ace impe11er shroud (3) as follows:

\
a. If paint reveals damage, repaint in accordance with paragraph 4-379.
b. Replace shroud if inspection reveals damage other than defective paint.
4-186
i
NAVAIR 03-l05-AB-52
4-483. lf inspection of fluid passage bolt (4) reveals blockage of bores, clean
) bores using standard cleaning procedures. Replace bolt if clesning efforts are not
successful or other damage is evidente
4-484. Repair or replace fue1 manifold assembly (6) as follows:
a. Remove corrosion fram fuel manifold assembly in accordance with para-

graph 4-373.
b. Remove minor nicks and burrs from face of bosses using abrasive cloth,
P-C-458.
c. rf dye penetrant inspection of fue1 manifold reveals cracks, braze per

MIL-B-7883. Pressure check after brazing in accordance with paragraph 4-202, step
c.
d. Replace fuel manifold assembly if inspection reveals damage beyond re-

pair limits.
4-485. Repair or replace fuel nozzle assemblies (8) as follows:
a. Remove carbon and cambust10n products with a soft bristled brush,

clean air assist ports with 80ft wire. Remove corrosion in accordance with para-
graph 4-373.
b. Replace nozzle assembl1es if damage other tban corrosion or if func-

) tional test requirements are not meto
4-486. Replace manual prime normally closed solenoid valve (22) if inspection
requirements are not meto
4-487. Replace so1eno1d mounting bracke~s (15, 27) if inspection reveals damage.
4-488. Replace normally open solenoid valve (30), if inspection reveals damage.
4-489. Replace oi! strainer assembly (32) i f inspection reveals damage and ff no
damage is evident, clean in accordance with standard procedures.
4-490. Replace tower shaft cover (37) if inspection reveals damage.
4-491. Repair or replace power turb1ne stator assembly (39) as follow:
a. Remove corrosion and combustion products in accordance with paragraph

4-373.
b. Repair minor vane damage and cracks not exc~eding 1/32 inch by smooth-
ing with a rotary file, smooth and blend filed surfaces using abrasive paper
J (P-P-lOl, 180 grit or equivalent).
c. Repair cracks in stator assembly by welding in accordance with figure

4-71.
4-187
~
~ ~
00
~
00
P8
~
o
w
P4 ....J
o
LENGTH V1
~
11.00 INCHES
V1
N
LENGTH
9.75 INCHES
LENGTH
13.25 INCHES
N WHT MBI381/1-20-9
H YEL MB1381/1-20-4
J GRN M81381/1-20-5
K WHT MBI381/1-20-9
LENGTtI
l GRN MB I 381/1-20-5 24.75 INCtiES
P2
M WIIT
IA
B
O WHT
C
WHT-RED
WHf-Bl.K
VIO
MBI381/1-20-9
MBI381/1-2o-92
MB 138 l/1-20-90
MBI381/1-2o-9
MBI38I/I-20-7
--------------------------~~ :
F
Pó
E Bl.U MB1381/1-20-ó MBI381/1-20-95 WHT-GRN C

F BLK MBI38I/I-20-0 MBI381/1-20-9ó WHT-BLU O
~
LENGHl
24. "5 INCHES
LENGTtt
1.63 INCitES
F A 8 C D E
P7
... ,.. Figure 4-70.

,.
Repair of JFS Branched Wiring Harness Assembly (Main)
, ""
j
NAVAIR 03-105AB-52
1-12A-887
NOTES:
A. WELD AREA 1 USING INCONEL 92 FILLER. ROD

B. WELD AREA 2 (TYPlCAL) PER MIL-W-86ll. USE WELD-
ING ROD PER. MIL-R-S03l.
Figure 4-71. Repair of Power Turbine Stator Assembly
NOTE
Weld repair on vane surfaces ia not permitted.

d. Replace stator assembly 1f inspection reveals damage beyond repair
limits.
4-492. Repair or replac~ First Stage containment shield assembly (40, figure 4-5) as foUows:
a. Machine ring (1, figure 4-71A) in an axial direction to the·bottom ofthe existing weld.
Remove the remainder of the ring and pins (6) from the assembly and discard.
b. Remove the segment set (5) and support set (2) respectively, in 363944-1 assembly or
segment set (5) and insulation (3) respectively, in 363944-2 assembly.
CAUTION
Each set is matched and must not be broken during processing.
c. The shield surface A (figure 4-71A) which mates with the ring shaU be cleaned up by
machining up to a maximum diameter of 5.525 inches. The surface finish ahall be 64 micro inches or
better.
Change 2 4-189
•
NAVAIR 03-105AB-52
DIA A
~~.l
SURFACEB
6 5
1. RING 4. SHlELD
2. SUPPORT ser 5. SEGMENT ser
3. INSULATION 6. PlN
A
5.506 TO
5.525 IN.
Figure 4-71A Repair ofFirst Stage Containment Shield Assembly
d. Examine the insulation in 363944-2 assemblies for further usability and replace as
necessary per Drawing No. (99193) 363944.
e. Glass bead blast the segment set to remove surface oxides.
f. Remove the silver plating from the support set in 363944-1 assemblies then replate to a
thicknes8 of 0.001 to 0.003 inch per specification QQ-S-363.
g. In accordance with Drawing No. (96916) lC2391, manufacture a replacement ring. Prior to
installation, machine ring surface A to eft'ect a shrink fit of 0.0005 to 0.003 incho Machine 8urface B 80
that the segment set is secure with 0.0000 clearance and surface B has a maximum or 0.005 inch
clearance from the edge of shield (4).
h. Obtain six new pins, MS171437.
i. Clean the mating surfaces of the shield and ring oí alI contaminants ineluding
fingerprints, and instaU the ring and assoeiated items into the shield, ensuring that no further
contamination occurs.
j . Electron beam weld the ring to the shield. Full weld penetration of the join t to a depth or
0.115 inch is required.
4-190 Change2
NAVAIR 03-105AB-52
k. Stress relieve the weld at llOO°F ±25° for one hour and &ir cool
1. Final maehine the part to the dimensions in Drawing No. (99193) 363944.
m. Fluorescent penetrant inspect the weldjoint in aecordance with the latest revision ofMIL-
1-6866, type I, method B.
n. Replace eontainment shield assembly (55, figure 4-3) Ü any of the above limits are
exeeeded.
4-493. Replace shie1d retainers (43) if inspection revea1s damage.

4-494. Repair or replace shroud retaining ring (47) as follows:
b. Replace ring if inspection requirements are not mete
4-495. Repair or replace impeller shroud (~9) as follows:
a. If paint is present, remove inaccordanee with paragraph 4-377(a).
b. Ifwear is confined to minor nieks, dents, and abrasions on less than 10% ofthe total
surfaee area, touch up bare spots in aecordanee with MIL-C-5541 ehromate corrosion eoating. If wear
exceeds 10%, reapply hard anodize in accordance with MIL-C-8625, type m
(paragraph 4-372).
e. RepIaee shroud if damage other than that described in preceding steps is revealed at
inspeetion.
Change2
NAVAIR 03-105AB-52
4-496. Repair or rep1ace jet fue1 starter housing assemb1y (54, figure 4-5) as
fó110ws:
a. Rep1ace damaged adapter (2, figure 4-72) and insta11 new packing (1) if
adapter is rep1aced.
b. Rep1ace 100se or damaged restrictor (3) by removing adapter (2), packing
(1) and restrictor. Press in new restrictor to bottom, swage in pIace. InstaII new
packing and adapter.
6 5-~
'.)9-.
1. PREFORMED
PACKING"
2. TtmE TO BOSS
ADAPTER ASSY
3. RESTRICTOR
7 4. INSERT
5. INSERT
6. INSERT
5 7. INSERT
8. INSERT
9. HOUSING
E-12A-I051
Figure 4-72. Jet Fue1 Starter Housing AssembIy
c. Rep1ace 100se or damaged inserts (4, 5, 6, 7, 8) in accordance with

paragraph 4-387.
d. lf paint ia worn or damaged, atr1p painted surfaces in accordance with

paragraph 4-377. AppIy a coat of primer (E42GP20, Sherwin-WiII1ams Co, Main Store,
2312 N. 16th St, Phoenix, AZ 85106, or equ1va1ent). Cure for one hour at 150° to
175°F. Apply a final coat of paint (V78VP2, Sherw1n-Wil1iams Co, Main Store, 2312
N. 16th St, Phoenix, AZ 85016, or equiva1ent), mixed with 12 ounces of a1uminum
paste. Air dry for four hours. Do not paint mating f1anges.
4-190B Change2
NAVAIR 03-105AB-52
e. Renew worn or damaged anodized coating in accordance with paragraph

4-372.
f. Housing assemblies which fail to meet the dimensional requirements specified in figure
4-34 or exbibit corrosion damage on diameters A or D not to exceed 10% of wall tbickness may be
repaired in accordance witb tbe following procedures.
(1) Housing assemblies which are undersize on the A diameter, oversize on tbe D
diameter, or damaged on surface B shall be built-up by metal spray procedures as follows:
(a) Machine A diameter to 8.493 to 8.495 inches and D diameter to 7.900 to 7.910
inches concentric to centerIine within .002 inch T.I.R.
(b) Prepare the applicable surface for metal spraying by suitably maaking the
internaI parts oftbe cylinder and tbe end face with sheet metal and grit blasting tbe surface to be sprayed
with Metcolite C.
(c) Apply a bond coat ofMetco 450 to a deptb ofO.003-0.005 inches and build diameter
D surface to an inside diameter of 7.8970 inches and diameter A to 8.560 inches with Mete0 SF
aluminum wire, assuring a total metal spray thickness necessary for subsequent finish machining.
g. Finish machine the housing to dimensions or Drawing No. (99193) 364793 as follows:
(1) Machine tbe applicable metal spray areas by applicable procedures.
(2) Machine diameters A, D, and surface B or figure 4-34 as necessary to bold

dimensions, runout, parallelism, perpendicu1arity, and concentrieity required by Drawing No. (99193)
364793.
h. COl'l'Osion pitting of internaI surface can be removed by grinding to a limit of 10 percent
los8 ofwall thickness. Apply chromate conversion coating per MIL-C-5541, using MIL-C-81706, cIass IA
materiaIs in accordance with reference (e), to alI exposed metal surfaces. AppIy a coat olheat resistant
aluminum paint, 'lT-P-28 to tbe applicable surfaces as noted in Drawing No. (99193) 364793. Cure paint
coat by baking one bour at 1500 to 175°F.
i . Perform f1uorescent penetrant inspection as outlined in paragraph 4-214.c of the aft'ected

publication only on diameters A and D, and the 2.435 inch diameter bore. AlI other areas are painted
with heat resistant paint which preventa reliable inspection results with either the paint on 01' with the
paint chemically removed.
4-497. Replaee identifieation plate (54A, figure 4-5) if inspeetion requirements

are not meto
4-498. Repair or replaee internal plain wrenehing nut (57, sheet 2) as foilows:
a. Replaee nut if damage ia revealed at inspeetion.
b. Statieally balance nut on diameter B, figure 4-73 and surface A using

suitable balance machine and adapter. Unbalanee in plane L ahall not exceed 0.0004
ounce-inch. Remova1 of material sha11 not exceed limit shown in figure 4-73.
Change2 4-19OC'I(4-190D blank)

I
I
I
I
..
NAVAIR 03-105AB-52
REMOVE MATERIAL
HERE FOR 8ALANCING
0.030 MAX DEPTH ~
__ r.2::::t=~-...;
I DIA 8
FINISH ALL OVER 1~
1-12A-914
Figure 4-73. Balance of InternaI Wrenching Nut
4-499. 'Repair or replace compressor impeller (58. figure 4-5) as follows:
Change 2 4-191
NAVAIR 03-105-AB-52
a. Remove nicks or scratches not exceeding 0.020 inch from blade surfaces
with abraaive paper (P-P-I01, 400 grit or equivalent).
b. Remove corrosion in accordance with paragraph 4-372.
c. Rep1ace impeller if damage other than mino r scratches or nicks and

corrosion ia revealed at inspection.
d. Using Rotating Assembly Ba1ancing Support Insert, 256377-8, and Ba1anc-

ing Arbor Set, 285476-1-1, balance impeller on diameter B, figure 4-74 to an accu-
racy of 0.0006 ounce-inches in plane L and an accuracy of 0.0004 ounce-inches in
plane M. Remove material from primary balance region by drilling ho1es 0.120 inch
diameter maximum and 0.250 inch in depth maximum, spaced at least 0.06 inch apart
and centered between hub outside diameter and major diameter of sp1ine; deburr.
CAUTION
Remove material from secondary balance region only if

balance cannot be obtained from primary region. Remove
no more than 0.003 inch from convex side of each b1ade.
PLANEL~ ~PLANEM
SECONOARV BALANCE REGION

I
I
I
:r REMOVE MATERIAL FROM HERE FOR BALANCING.
DO NOT REMOVE MATERIAL BElOW i' REFERENCE
LINE. FINISH TO 63}
DIA B
-t
PRIMARV BALANCE REGION.--/
ALL PLACES FROM WHICH MATERIAL WAS

REMOVE0 MUST FAIR SMOOTHL V ANO LEAVE
NO CORNERS SHARPER THAN 0.015 IN. R.
Figure 4-74. Balance of Compressor Impe1ler
4-192
NAVAIR 03-105AB-52
e. rf required renew anodized finish on surfaee B, figure 4-35, in aeçord-

anee with MIL-A-8625, type r, elass C. Remainder of part shall reeeive chemical
film treatment per MrL-L-554l.
~ 4-500. Replace bearing retaining plate (66, figure 4-5) if inspection reveals
damage.
4-501. Repair spinner .lockring sbaft (69) as follows:
a. Renew worn dry-film lubricant in aeeordanee with paragraph 4-380. Apply
lubrieant 0.0003 to 0.0005 ineh thiek.
b. Remove minor burrs with abrasive cloth (P~-458).
c. rf damage other tban worn lubricant, and minor nicks and burrs is
revealed at inspection, replace sbaft.
4-502. Replace compressian spring (70) if any inspeetion requirement i8 not meto
4-503. Repair ar replaee axial f10w turbine'whee1 assemb1y (72) as fo11ows:

a. Remove minor nieks and scratches from b1ades with abrasive cloth
(P-C-458) or a fine stone (AF-3-JB, Carborundum Co, P.O. Box 403, Niagara Falls,
NY 14302 or equivalent). AlI repaired areas sball fair smoothly.
b. Inspect the turbine end bearingjournal as specified in paragraph 4-221 and figure 4-36 of
the aft'ected publication.
c. Grind damaged diameter a minimum amount to remove damage, maintaining

concentricity requirements and not to exeeed tbe minimum. outside diameter as indicated by figure
.4-36.
d. SUbject shafts which exhibit damage or falI below minimum. diameter on the turbine end
bearing joumal may be further processed as tollows:
(1) Grind the applicable diameter(s), B, C, or D, offigure 4-36, a minimum amount to

remove ali damage. If damage is not removed completely when ground to tbe following specified
limits, the shaft shall be rejected. .
Diameter B - 0.5846 inch

Diameter C - 0.6535 inch
Diameter D - 0.6633 inch
(2) Perform magnetic particle inspection in accordanee witb MIL-I-6868.
(3) Shot-peen the aft'ected diameter with 330 ateeI shot (MlL.S-851) to an intensity of
10A2 - 1M2. Ensure that alI areas not requmng shot-peening are suitably masked.
(4) Chromium plate to a sufticient tbickness to pemllt machining ofplated diameter to

requirements of figure 4-36 of the aft'ected publication.

NAVAIR 03-105AB-52
(5) Bake shaft at 375° ±25°F for three houra immediately after plating.
(6) Grind the plated surface to within the dimensions indicated for diameter(s) B, C, or
D, oftigure 4-36.
(7) Perf'orm magnetic partic1e inspection in accordance with MIL-I-6866. No cracks

mayexist.
e. Replace turbine wheel assembly if damage other than minor nicks and scratches are
revealed at inspection;
f. Using Turbine Wheel Balancing Adapter, 285475-1-1, balance turbine wheel assembly on
diameters B and E (figure 4-75) t.o an accuracy of 0.0023 ounce-inches in plane R.
DIA E . / ' MATERIAL MAY BE

~ REMOVED FROM RINGS
FOR BALANCING.
REMOVE EQUAL
AMOUNTS FROM EACH
SIDE Cf BALANCE R1NG.
""PLANE R
FINISH ALL OVER 1'J!j.:[

1-12A-913R1
Figure 4-75. Balance ofAxial Flow Turbine Wheel Assembly

I
NAVAIR 03-105AB-52
4-504. Replace annular ball bearing (74, figure 4-5) if inspection requirements
are not meto
4-505. Repair or replace bearing carrier (75) as follows:
b. Replace carrier if dimensional and visual inspection requirements are

not meto
4-506. Replace pinion spiral bevel gear (77) if any inspection requirement is not
meto
4-507. Repair or replace bearing 8pacer (78) as follows:

a. Burrs and minor galling, pitting, or seratches on surfaces C and D, (figure 4-39) sha]] be
I smoothed out with abrasive cloth, (P-C-458), or with a fine stone. Surface finish of AA125 is required.
Surfaces C and D must be paraIlel within 0.0002 inch TIR.
b. Replace spacer if any inspection requirement is not meto
c. Balance spacer on diameters A and B (figure 4-76) to an accuracy orO.0005 ounce-inehes

in plane L and in plane M. Aner balancing perform magnetie parti ele inspection in aeeordance with
MIL-I-6868.
4-508. Repair or replace bellows seal retainer (80, figure 4-5) as follows:
b. RepIace retainer, if damage other than corrosion i8 revealed by inspec-

tion.
REMOVE MATERIAL FROM

HERE FOR BALANC/NG.
0.020 MAX DEPTH
t
DIA A
t
DIA 8
f i
PLANE L PLANE M
FINISH AL L OVER "J5O.]" 1-12A-911
Figure 4-76. Balance of Bearing Spacer
4-194 Change 2
i
NAVAIR 03-105AB-52
4-509. Repair or rep1ace first stage stator assemb1y (81) as fo11ows:
a. Remove corrosion and combustion residue in accordance with paragraph

4-373.
b. Repair minor vane damage and cracks not exceeding 1/32 inch by reworking
with a rotary file. Smooth and b1end reworked surfaces. Remove file marks with
sandpaper, 180 grit or equiva1ent.
c. Repair cracks in stator assemb1y by welding as shown in figure 4-77.
NOTE
We1d repair of vane surfaces ia not permitted.
d. Clean by vapor degreasing to remove alI oil, grease, and carbon deposita as detailed in
paragraph 4-62.
e. Inspect the subject stator assembly in accordance with paragraph 4-227.
f. Dimensional discrepancies due to erosion or wear on surfaces A, B, or C (figure 4-40) can

be repaired by the following metal spray procedures:
(1) Clean in accordance with paragraph d above.
(2) Suitably mask adjacent areas not designated for metal spray.
(3) Bake at 325°F to 350°F for one hour within one hour of grit blasting operation.
(4) Grit blast the discrepant area utilizing Metcolite C or equivalent, using pressure of 60
psig to minimize damage from blasting.
(5) Apply the metal spray material using Mete0 460 (bond ooat) for the complete coating
thickness required.
NOTE
Base Metal is Inconel 713C.
(6) Parameters for metal spray thickness are as follows:
(a) Build A dimension to 4.91014.926 inches outside diameter. This a1lows 0.012 to
0.015 inch thickness for machining.
(b) Build B dimension to 3.41513.430 inches outside diameter. This allows 0.010 to
0.015 inch thickness for finish machining.
(c) Build C dimension to 3.21113.206 inches inside diametar. This allows 0.016 to
0.010 inch thickness for finish machining.
(7)' Finish machine the subject stator a&sembly to dimensions given in figure 4-40.
g. Replace stator assembly ir damage exceeds repair limits or if dimensional inspection

limits are not mel
Change2 4-l94A
NAVAIR 03-105AB-52
4-509A Stator assemblies with unacceptable vanes shall be processed as foIlows:
a. Position stator assembly in a lathe with chucks clamping on the O.D. over the bolt hole
bosses.
b. Remove entire vane ring assembly and the inner mounting flange by cutting on areas 2 ~
and 4 (see figure 4-40 and 4-77) with a smaU point cutting too1. This will minimize reweld area.
c. Remove the damaged section of the vane ring assembly (minimum segment of two vanes)
with a high speed abrasive cut-oft' whee1. Adjust the cut-oft' wheel angle and the vane ring assembly to
avoid hitting any vanes in the cutting processo
d. Designate a stator 88sembly for cannibalization ofthe vane ring assembly. Repeat
paragraphs 0., b, and c above except remove a segment ofgood vanes to match the section ofremoved
damaged vanes, a1lowing the good vane segment to be a Iittle larger than the removed damaged section
(allow for clltting wheel width).
e. Position vane ring assembly and the replacement vane segment in a vane ring holding
fixture. Use spacers to ensure proper vane spacing. Grind ends ofreplacement vane segment, as
required, to provide correct vane spacing with the entire assembly in a constrained position meeting the
dimensions of Drawing No. (99193) 364560.
f. Weld replacement vane segment to vane ring assembly using Ineonel 92 filler rodo Weld
only on the outside and inner diameters ofthe vane ring assembly. Do not weld on the in si de vane
spaces. The edges to be welded may be beveled to assure good weld penetration.
g. Grind dress the welded areas to conform to the original curvature on the I.D. and 0.0.
surfaces.
h. Perform fluorescent penetrant inspeetion in aecordance with MIL-I-6866, type I. method A
NOTE
The four (4) notches in the vane ring assembly must match the four
(4) impingement nozzle tubes (JFSl00-13A, 364697-1 only).
i. InstaU the vane Ting assembly in the stator assembly housing and position the inner
mounting flange using a restraining fixture to meet the rotational and the dimensional requirements
of1igures 4-77.4-40 and 5-63 as applicable. Weld areas 2 and 4 offigure 4-77 (1) for the 364560-1 (JFSlOO-
34) and weld areas 4 and 6 offigure 5-63 for the 364697-1 (JFS100-13A). and grind dress as required.
j. Repeat paragraph h above.
4-510. Repair or replace heat shield (82, figure 4-5) as follows:
b. Replace heat shie1d if damage other than corrosion ia revea1ed at 1n-

spection.
4-194B Change2
.
NAVAIR 03-105AB-52
4-511. Repair or rep1ace seal retainer (83) as fo11ows:
b. Rep1ace retainer if damage other than corrosion is revealed at inspec-

tion.
4-512. Replace turbine gas oil seal (85) if any inspection requirement is not meto
4-513. Repa1r or replace bear1ng carr1er (88, 89) as fol1ows:
a. lf damage is evident, remove key (88) and install new key and stake
carrier (89) on both sides of key.
c. Replace carrier assembly if damage other than that described in pre-

ceding steps a and b 1s ev1dent.
4-514. Rep1ace compress1on he11ca1 spring (90) 1f 1nspect1on requ1rements are not
meto
4-515. Replace oil tube assembly (93) if inspection requirements are not meto
4-516. Repair or replace fuel-air combustor (97) as follows:
a. When processing: fuel-air combustor assemblies with cracks or broken welded jOint8
repair as follows:
(1) Reweld broken fusion welded joints in accordanee with MIL-W-8611A using N-155
filIer material (MIL-R-5031. elass 9).
b. Weld surface craeks using base material rod in accordance with MIL-R-5031. elass 9.
Weld in accordance with instructions in MIL-W-8611A
c. Mer welding, stress-relieve at 12000 F ±25°F for one hours. Air cool after stress-relieving.
d. If inspection disclo&es any crack or weld defect that can not be repaired in accordance with
paragraph a or b above. discard the fuel-air combustor assembly.
Change 2 4-195
NAVAIR 03-105-AB-52
NOTES:
A, WELD AREAS I ANO 5 USING HASTELLOY- W FILLER ROD,

8, WELD AREAS 2 ANO 4 USING INCONEL 92 FlllER ROD.
C, WELD AREAS 3 ANO 6 PER SPECIFICATlON MlL- W-6858 CLASS B.
Figure 4-77. Repair of First Stage Stator Assembly
4-517. Replace tower shaft cover (102) if inspection requirements are not meto
4-518. Rep1ace spira1 beve1 gear assembly (107, 108) if any inspection requirement
is not meto
4-519. Replace sleeve spacers (111, 112) if inspection requirements are not meto
4-520. Replace bearing carrier (114) if inspection requirements are not meto
4-196
.
NAVAIR 03-105AB-52
4-521. Repair or rep1aee tower sbaft housing assemb1y (figure 4-6) as fo11ows:
a. Repair or rep1aee àiffuser housing assemb1y (6, 7) as fo11ows:
(1) Replaee damaged inserts (6) in aeeordanee with paragraph 4-387.
(2) Remove eorrosion in aeeordanee with paragraph 4-372.

(3) Replaee housing assemb1y (7) if damage other tban that speeified
in steps (1) and (2) is revealed by inspeetion.
b. Repair or rep1aee diffuser p1ate (8) as fo110ws:
(1) Remove minor nieks from vanes of diffuser p1ate not to exeeed 1/32
ineh in depth with a fine stone (AF-3-JB, Carborundum Co, P.O. Box 403, Niagara
Fa1ls, NY 14302 or equivalent).
(3) Rep1aee diffuser p1ate if damage other than that speeified in pre-
eeding steps (1) and (2) is revea1ed at inspeetion or if dimensional requirements
are not mete
e. Repair or rep1aee support (10) as fol10ws:
(1) Rep1aee 100se or damaged p1ugs, by removing damaged or 100se plug;

insta1l new plug, swage with 60 degree eenter stake to seal.
NOTE
Gasket shall be coated on both sides per paragraph 4-670 prior to
installation.
(3) lf support 1s replaeed, insta11 new gasket (11) and repeat pressure
I
test in aeeordanee with paragraph 4-239.
(4) Rep1aee support if eraeks or damage beyond repair is revea1ed at

inspeetion.
d. Rep1aee damaged or 100se inserta (12, 13, 14, 15, 18, 19, 20, 21) in
aeeordanee with paragraph 4-387.
e. Rep1aee any part damaged beyond repair or exeeeding 1fmÍcs defined in
this paragraph.
f. Remove lube oil jet retaining screw and oil jet, 364276-1.
g. Place tower housing assembh, 364517-2, in an oven and heat at 200°F for one hour. I
Change2 4-196A/(4-196B bJank)
I
I
I
I
I
I
I
I
I
I
I
I
NAVAIR 03-105AB-52
h. Remove tower housing assembly from oven and quickly accomplish the following:
(1) Pack support fuIl of dry ice. Hold tower housing flange up and maU 8upport end
down. Tap out support using 0.375 inch diameter x 10 inch long aluminum rodo
(2) Mer support remova1, clean tower housing in accordance with paragraph 4-372.
Check for carbon deposits and remove with non-metal1ic bristle brush if necessary.
i . Install three studs approximately 3 inches long having a No. 10-32-NF thread into the
support end ofthe tower housing. These studs will act as guide pins when installing the support.
j . Place tower housing, with guide studs in place, back into oven and heat to 200°'F for one
hour. Paek new support full of dry ice and place in freezer.
k. Remove tower housing from oven and remove support from fTeeZer.
NOTE
Notches and oil drain hole in support must line up with

corresponding areas of tower housing.
I. Place support on the guide pins in the proper alignment and drop into tower housing. Wait
approximately 5 to 10 minutes and press support to 88sure that support is bottomed out.
NOTE
Press on the larger of the two inner diameters
m . Machine supporl 8mall inner diameter and bearing carner anti-rotation 810t to the
dimensions eontained in reference (b).
n. Inspeet for cracks in accordanee with MIL-I-6866 and paragraph 4-110. No eracks are
aeceptable.
O. Inspeet and pre8sure test in accordance with paragraph 4-239.
4-522. REPAIR OF JFS ACCESSORY DRIVE ASSEMBLY (figure 4-7).

4-523. Rep1aee identifieation p1ate (1, sheet 1) if inspeetion reveals damage.
4-524. Rep1aee lubrieation instruetion plate (2) if inspeetion reveals damage.
4-525. Replaee magnetie maehine thread plug (5) if any inspeetion requirement i8
Dot meto
Change 2 4-197
NAVAIR 03-105-AB-52
4-526. Rep1ace oil dip stick (7) i f any inspection requirement is not meto
4-527. Replace sediment strainer element assembly (9) ii damage other than clean-
liness is revealed at inspection. Clean element using standard cleaning procedures.
4-528. Replace compression helical spring (16) ii any inspection requirement is ~

not meto
4-529. Replace pin (22) by removing old pin, install new pin and upset at center to
secure.
4-530. Replace jaw (23) ii any inspection requirement is not meto
4-531. Repair or replace hydraulic motor (18) in accordance with paragraph 4-634.
4-532. Repair or rep1ace iuel control assembly (24) in accordance with paragraph
4-604.
4-533. Replace shafts (33, 36) 1f damage other than corrosion is revealed at in-
spection. Remove corrosion in accordance with paragraph 4-373.
4-534. Replace switch adjusting shims (42, sheet 2) ii inspection reveals damage.
4-535. Repair or replace sensitive switch assembly (38) in accordance with para-
graph 4-594.
4-536. Replace individual parts oi switch actuating governor assembly (43 through
51) ii any individual part iails to meet any inspection requirement.
4-537. Replace thrust washer (53) ii inspection requirements are not meto
4-538. Replace spur gear (55) i f any inspection requirement is not meto
4-539. Replace spur gear (58) if any inspection requirement is not meto
4-540. Replace spur gear (60) ii any inspection requirement is not meto
4-541. Remove corrosion On retainer (62) in accordance with paragraph 4-373. Re-
place retainer if any other inspection requirement is not meto
4-542. Replace matched rotary pump internaI and externaI gear set (63) if any
damage is revealed at inspection.
4-543. Rep1ace lubrication pump cover (65) ii damage is revealed at inspection.
4-544. Repair or replace drive shaft (66) as follows:
b. Remove minor nicks and burrs in accordance with paragraph 4-374.
4-198
NAVAIR 03-l05-AB-52
c. Rep1ace drive shaft if inspection reveals damage other than that speci-
fied in preceding steps a and b.
4-545. Rep1ace annu1ar ba11 bearings (67, 71) if inspection requirements are not
meto
4-546. Replace helical compression spring (69) if any inspection requ1rement 1s not
meto
4-547. Rep1ace s1eeve spacer (70) if inspection requirements are not meto
4-548. Repair or rep1ace shouldered shaft (72) as fo11ows:
b. Remove nicks or burrs in accordance with paragraph 4-374.

c. Replace shouldered shaft i f inspection reveals damage other than speci-
fied in steps a and b.
4-549. Repair or replace bearing retainer assembly (74) as follows:

b. Remove minor n1cks and burrs in accordance with paragraph 4-374.
c. Replace retainer assemb1y if damage other than specified in preceding

steps a and b is revea1ed by inspection.
4-550. Replace zerol pinion bevel gear (78) if any inspection requirement is not
meto
4-551. Rep~ir or replace sleeve spacers (80, 81) as fo11ows:
b. Rep1ace spacers if damage other than corrosion is revea1ed at damage.
4-552. Repair or replace bearing carrier (83) as follows:

b. Remove minor nicks or burrs in accordance with paragraph 4-374.
c. Replace bearing carrier if damage other than corrosion and minor nicks
and burrs is revea1ed by inspection.
4-553. Replace annu1ar ba11 bearings (87, 93, 110, 114) if inspection revea1s any
damage.
4-554. Replace compression helical springs (88, 112) if inspection requirements

are not meto
4-199
NAVAIR 03-105-AB-52
4-555. Rep1ace sleeve spacers (89, 113) if any inspection requirement is not meto
4-556. Repair or rep1ace bearing carriers (92, 119) as fo110ws:
b. Remove minor nicks and burrs from noncritica1 areas in accordance with
paragraph 4-374.
c. Rep1ace bearing carriers if damage other than corrosion and minor nicks
and burrs is revea1ed at inspection.
4-557. Rep1ace beve1 zero1 gear (94) if any inspection requirement is not meto
4-558. Rep1ace spur gear (95) if any inspection requirement is not meto
4-559. lf pins (98) or paw1s (100) are damaged, remove pins, using Pin Removing
Ho1der and Driver, 287945-1, and an arbor press, then remove washers (99) and paw1s
(100). Rep1ace paw1s (100), washers (99), and using Pin lnsta11ing Ho1der,
287944-1, and punch or drift, insta11 new pins (98).
4-560. Repair or rep1ace c1utch shaft assemb1y (101 through 106) as fo110ws:
a. Rep1ace 100se rivets (101) or worn or damaged springs (102, 103) by

center dr1l1ing rivet head and remove parts with a drift. Using Pneumatic Too1
Revet Set 287735-1, insta11 springs and secure rivet.
b. If pin (104) or p1ug (105) is 100se or damaged, remove pin and plugo
Instal1 new p1ug and using ho1es in housing (106) as a guide, drill 0.062 to 0.065
inch diameter hole through plugo Apply a coat of primer (Cati-Coat E42GP22 and
cata1yst reducer V66XP46, equal parts by volume, Sherwin-Wil1iams Co, Main Store,
2312 N. 16th St, Phoenix, AZ 85016, or equivalent) to pin, install pin in housing
and p1ug. Cure in oven at 180° to 275°F for one hour.
c. Rep1ace c1utch shaft assemb1y if damage other than specified in preced-

ing steps a and b ia revea1ed by inspection.
d. Using Balancing Support Insert, 256377-1, and Balancing Arbor Set,
287447-1-1, balance shaft assemb1y on diameter B (figure 4-78) to an accuracy of
0.0004 ounce-inches in plane M. Remove material where shown.
4-561. Repair or replace gear box accessory housing assemb1y (107, figure 4-7) as
fo1lows:
a. Rep1ace loose or damaged inserts (1, 3, 7, 8, 10, 11, figure 4-79) in

accordance with paragraph 4-387.
b. Replace loose or damaged inserta (2, 4) in accordance with paragraph

4-389.
4-200
NAVAIR 03-105-AB-52
~---,_ _ _ _ _~ DIA B
REMOVE MATERIAL HERE

FOR BALANCING. REMOVE
IN SAME RADIAL LOCATION.
Figure 4-78. Balance of Clutch Shaft Assembly
c. Rep1ace 100se or damaged pins (5, 6, 13). Ensure bole for pin (5) is
0.107 to 0.114 inch in diameter and 0.23 inch in depth maximum; hole for pin (6)
0.094 to 0.097 inch in diameter and 0.~50 to 0.280 inch deep; ho1e for pin (13)
0.062 to 0.065 inch in diameter and 0.300 to 0.320 inch deep; press new pins to
fuI1 depth.
d. Remove 100se or damaged plug (9), insta11 new p1ug and swage with 60
degree center stake to sea1.
e. Rep1ace p1ug (14) by center dri11ing a maximum of 0.116 inch in diameter

and 0.078 inch deep; remove old p1ug, instal! new p1ug and drive in tapered pin
f1ush.
f. Rep1ace damaged or chipped paint by preparing painted surfaces in ac-
cordance with paragraph 4-377. Repaint previous1y painted surfaces in accordance
g. Replace damaged or worn anodized coating using hard anodize in accord-

h. Rep1ace housing if defects other than those specified in steps a through
g are revea1ed by inspection.
4-562. Rep1ace spur gear (115, figure 4-7, sheet 3) if any defect i8 revea1ed by
inspection.
4-563. Repair or rep1ace shouldered shaft assembly (~17) as f011ows:
b. Remove minor nicks and b~rrs in accordance with paragraph 4-374.
4-201
NAVAIR 03-105-AB-52
1. INSERT 8. INSERT
2. INSERT 9. PLUG
3. INSERT 10. INSERT
4. INSERT 11. INSERT
5. PIN 12. STUD
6. PIN 13. PIN
7. INSERT 14. PLUG
15. HOUSING
Figure 4-79. Gear Box Accessory Housing Assembly
c. Rep1ace shaft assemb1y if any inspection requirement other than corro-

sion or minor nicks and burrs is not meto
4-564. Repair or replace adapter housing assembly (120, 121) as fo11ows:
b. Rep1ace damaged or loose insert (120) in accordance with paragraph 4-389.
4-202
NAVAIR 03-105AB-52
c. Repaint damaged painted surfaces after preparation in accordance with

paragraph 4-365. Repaint in accordance with paragraph 4-379.
d. Rep1ace housing assemb1y if damage other than specified in preceding
, steps a, b, and c is revea1ed by inspection.
4-565. REPAIR OF AG-DC PERMANENT MAGNET GENERATOR COMPONENTS (figure 4-8).
4-566. Replace bearings (17, 24) if required and sea1 (19) regard1ess of condition.
Replace gear (4), filter assemb1y (11) and module assemb1y (14) if inspection re-
quirements are not mete
4-567. Rep1ace insert (20) if inspection requirement ia not mete Prp~s insert from
housing (23). App1y loca1ized heat to bore of housing and coo1 insert using dry
ice. Press new insert into housing, making certain insert bottoms in housing bore.
4-568. Touch up painted surfaces of rotor assemb1y (25) and stator assemb1y (27),
as required, with one coat of primer (E42GP22, The Sherwin-Wi11iams Co, Main Store,
2312 N. 16th St, Phoenix, AZ 85016, or equiva1ent; no known Govemment specifica-
tion) and a110w to air-dry for two hours at room temperature. App1y one interior
green top-coat (Aero-Caticoat, FED-STD-595 Co1or No. 34151, The Sherwin-Wi11iams Co,
Main Store, 2312 N. 16th St, Phoenix, AZ 85016, or equiva1ent; no known Govemment
specification) and al1aw to air-dry for 18 hours at room temperature. Do not exceed
a maximum paint bui1d-up of 0.001 inCh on rotor assemb1y and 0.0008 inch on stator
assemb1y.
4-569. Rep1ace insert (35) if inspection requirement ia not mete Press insert from
end bell (36). App1y loca1ized heat to bore of end bell and cool insert using dry
ice. Press new insert into end be1l, making certain insert bottoms in end be11
bore.
4-570. REPAIR OF STARTER COMPONENTS.
4-571. REPAIR OF JFS CONTROL BOX ASSEMBLY (figure 4-9).
4-572. Replace identification p1ate (1) if any defect is revea1ed by inspection.

4-573. Replace or repair electrica1 cover assemb1y (6, 7) as fo1laws:
a. Replace gasket (6) if any defect is noted at inspection.
c. Rep1ace cover if damage other than corrosion ia noted at inspection.
4-574. Rep1ace armature re1ay (9) if any inspection requirement is not mete
4-574A. Repair start cyc1e protection sensor (13) if any inspection requirement is
not mete Refer to paragraph 4-587A.
4-575. Rep1ace counter retain1ng plate (17) if damage is revea1ed by inspection.
Change2 4-202A/(4-202B bJank)

NAVAIR 03·105AB-52
4-576. Replace counter retaining plate assembly (18, 19) as follows:
a. Replace gasket (18) if any damage is noted at inspection.
b. Rep1ace p1ate (19) if any defect is noted at inspection.
4-577. Replace resilient-start counter mounts (20, 21) if any defect ia noted at
inspection.
4-578. Replaceelectrical counter (22) if any defect is noted at inspection.
4-579. Replace temperature sensor (24) if any damage is revealed by inspection.
4-580. Replace indicator (26) if auy damage is revealed by inspection.
4-581. Replace fuses (28) if any damage ia revea1ed by inspectiono
4-582. Clean dirty or corroded fuseholder (29) contacts. Replace fuseholder if

any other damage 1s revealed by 1nspect1on.
4-583. Replace electrical receptacle connector (30, 31, 32) if damage is revealed
by inspection.
4-584. Replace insulator (41) if damage is revealed by inspection.
4-585. Replace transistor (44) if any damage is revealed by inspection.
4-5860 Replace heat s1nk (45) if any damage 1s revealed by 1nspection.
4-587. Repair or rep1ace JFScontro1 box assemb1y (46 through 50) as fo11ows:
a. Replace loose rivets (46, 48) or damaged nuts (47, 49).

c. Remove the paint finish and thoroughly cIean the portion of the box assemb1y in the
location where cracks have occurred and alao where angIe, (96916) 1B3036-1, ia to be attached to the box
assemb1y as shown in figure 4-79D.
d. Grind out alI cracks in the box assembIi: -
e. Degrease the area in the box assembIy wbicb wiIl be welded.
f. Tungsten Inert-Gas (TIG) weld the cracks in the box assembly using 5183 filler per Fed.
Spec. QQ-R-566, or ir not available, use 4043 ftI1er per Fed. Spec. QQ-R-566. Grind these welded ateu to
provide a smooth flat surface. Inspect the repaired areas for cracks using fluorescent penetrant.
g. Obtain 6061-0 aluminum alloy, QQ-A-250111, 0.071 incb thick, 1.190 inches wide, 1.620
inches long. Solution heat treat this material at 980°F for 45 minutes. Form this material into angle,
(96916) 1B3036-1, in accordance with Drawing No. (96916) 1B3036-1. Degrease the completed angle and
the box assembly.
NAVA1R 03-105AB-52
h. TIG weld all edges of angle, (96916) 1B3036-1, to the box assembly as shown in enclosure
(1). Use 5183 filIer per Fed. Spec. QQ-R-566, or ifnot available, use 4043 finer per Fed. Spec. QQ-R-566.
i. Remove the portion ofthe ang1e, (96916) 1B3036-1, which extends beyond the mounting
bracket, to make this edge ofthe angle shaped as shown in figure 4-79D. EnsuTe that the comer radius of
0.380 inch and the height ofO.160 inch minimum 0.190 inch maximum, as shown in figure 4-79D, are
obtained. TIG weld this edge of the angle to the edge of the mounting bracket. Surface finish the 0.380
inch comer radius and adjacent area to provi de no nicks or scratches in this area. Surface finish of
radius shall be 60 microinches or better.
j. Age the modified box assembly, (70210) 307073-1, to the T6 condition by heating it at 320°F
for 18 hours. Inspect the repaired areas of the box assembly for cracks using fluorescent penetrant.
k. Finish the repaired area with zinc chromate primer. Provi de final finish with acrylic
lacquer, MIL-L-81352, black coloro
I. Ensure alI applicable Drawing No. (70210) 307073 requirements are met.
4-587A. REPAIR START CYCLE PROTECTION SENSOR (13, FIGURE 4-9).
4-587B. Rep1ace seneor assemb1y parts that do not pass inspection and are damaged
beyond repair.
a. See figures 4-79A through 4-79C for aid in locating and identifyirtg
sensor aesembly components requiring replacement.
b. Make alI electrica1 connections using solder (Federal Specification

QQ-S-571, Type Sn60-W-RA-P2).
c. Inspect and functionally check sensor in accordance with paragraph

4-295A after rep1acing defective components.
4-204 Change 2
NAVAIR 03-105AB-52
1. PLATE 4. UNDERSPEED" DETECTOR CIRCUIT CARD

2. SCREW ASSY (FOR BREAKDOWN SEE FIGURE 4-79B)
3. WASHER 5. OVERTEMP AND OVERSPEED SENSOR
NETt~ORK ASSY (FOR BREAKDotolN SEE
FIGURE 4-79C)
Figure 4-79A. Breakdown of Start Cycle Protection Sensor

Change 1
NAVAIR 03-105AB-52
1. RESISTOR 13. RESISTOR 25. CAPACITOR

2. RESISTOR 14. RESISTOR 26. DIODE
3. RESISTOR 15. RESISTOR 27. WIRE
4. RESISTOR 16. RESISTOR 28. RESISTOR
5. RESISTOR 17. INSULATOR 29. RESISTOR
6. RESISTOR 18. TRANSISTOR 30. RESISTOR
7. CAPACITOR 19. RESISTOR 31. INTEGRATED CIRCUIT
8. INTEGRATED CIRCU!T 20. DIODE 32. IUSULATOR
9. RESISTOR 21. TRANSFORMER 33. INSULATOR
10. RESISTOR 22. DIODE 34. SPACER
11. RESISTOR 23. CAPACITOR 35. TERMINAL
12. RESISTOR 24. DIODE . 36. PRINTED WIRING
BOARD
Figure 4-79B. Breakdown of Underspeed Detector Circuit Card Assemb1y
4-204B Change 1
NAVAIR 03-105AB-52
4-587C. Calibrate sensor assembly circuits using the following instructions. Re-
fer to paragraph 4-295B for troubleshooting if sensor assembly will not calibrate.
a. Connect sensor to test setup shown in figure 4-65A. See figure 4-65B
for sensor eleetrieal sehematie.
b. Short pins 2 and 3 of integrated eireuit UI together. Monitor the de

voltage between pin 6 of integrated eireuit UI and de ground.
e. Set test setup de power supply to 28 +2 vde. Set test setup ae power
supply to 115 +1.0 vae and set ae power supply frequency to 400 +4 Hz.
d. Adjust resistor R29 until resistor is set halfway between the point
where OP amplifier goes to Vsat negative. Do not adjust resistor R29 at any time
for the duration of this testo
e. Set both test setup power supplies to off and remove the short from
integrated eireuit UI.
f. Tum both test setup power supplies on. Measure the de voltage across
resistors R8 and R9 (total). Adjust resistor R13 until the voltage across re-
sistors R8 and R9 is 0.183 times the voltage aeross zener diode VR4 within +0.1
vde.
g. Set both test setup power supplies to off.
h. Slowly inerease test setup de power supply voltage until relay Kl pulls
in; de voltage at whieh the relay pulls in must be 7 +1.0 vde.
i. Set test setup de power supply voltage to 28 +2 vde. Set test setup ac
power voltage to 115 ~1.0 vae and set ae power supply frequeney to 400 +4 Rz.
j. Set test setup temperature thermoeouple simulator to 2000°F. Adjust

resistor RI7 and seIeet resistor R19 from resistor assortment sueh that the maximum
temperature at whieh relay drops out is at this simulator setting.
k. Adjust resistor R17 so that, with an inereasing temperature, relay Kl
drops out at a temperature setting of 1900 +20°F.
NOTE
After relay Kl has dropped out, it is neeessary to
depress reset switeh to reset relay.
1. Set test setup ae power supply frequeney to 440 +8 Hz. Adjust resistor
R27 and select resistor R22 from resistor assortment so that-this is the maximum
frequency at whieh reIay KI drops out.
m. Adjust resistor R27 so that, when frequency is increasing, overspeed

trip point is 436 +4 Hz.
Change 1 4-204C
NAVAIR 03-105AB-52
20 7
182122 8 23 242526 2728 29
75
74
73
71
72
13
70~~~~~L-__~
69
15 ":-r~";";=~~'.J
16
55 1 54 15 7 53 52
16 8 E-12A-1S06A!
Figure 4-79C. Breakdown of Overtemp and Overspeed Sensor Network Assembly
4-204D Change 1
NAVAIR 03-105AB-52
~ KEY TO FIGURE 4-79C
1. OIOOE 26. RELAY 51. RESISTOR

RESISTOR 27. RESISTOR 52. CAPACITOR
~ 2.
3. DIODE 28. RESISTOR 53. RESISTOR
4. DIODE 29. RESISTOR 54. CAPACITOR
5. SLEEVING 30. RESISTOR 55. DIODE
6. RESISTOR 31. PROBE 56. (OELETED)
7. TRANSISTOR 32. RESISTOR 57. OIOOE
8. INSULATOR 33. RESISTOR 58. SLEEVING
10. RESISTOR 35. INTEGRATEO CIRCUIT 60. CAPACITOR
11. SEMICONDUCTOR DEVICE 36. INSULATOR 61. RESISTOR
12. RESISTOR 37. INSULATOR 62. TRANSFORMER
13. CAPACITOR 38. RESISTOR 63. SEMICONDUCTOR
14. OIODE 39. RESISTOR 64. CAPACITOR
15. TRANSISTOR 40. RESISTOR 65. RESISTOR
16. INSULATOR 41. RESISTOR 66. RESISTOR
17. CAPACITOR 42. RESISTOR 67. CAPACITOR
19. RESISTOR 44. RESISTOR 69. DI ODE
20. RESISTOR 45. RESISTOR 70. DIODE
21. RESISTOR 46. RESISTOR 71. TRANSISTOR
22. RESISTOR 47. INTEGRATED CIRCUIT 72. INSULATOR
23. RESISTOR 48. INSULATOR 73. SLEEVING
24. RESISTOR 49. INSULATOR 74. TERMINAL
25. CAPACITOR 50. SEMICONDUCTOR 75. PRINTED WIRING
OEVICE BOARD
o. Se1eet resistor R44 from the resistor assortment so that the voltage at
pin 6 of eireuit eard assemb1y wi11 ehange from 28 vde to O +4 vde when test setup
ac power supp1y frequeney deereases to 370 +4 Hz.
o. Set both test setup power supp1ies to off.
p. Connect 560 ohm +1 percent resistor between pins 12 and 13 of underspeed

detector cireuit eard assembly.
q. Monitor voltage between pio 16 (+) of overtemp and overspeed sensor
oetwork assemb1y aod grouod with osei110seope.
r. Turo 00 de power. ,Vo1 tage at pin 16 shall stay at 12 +2 vdc for ooe
+0.1 sec theo go to 2 +2 vdc.
s. Se1ect R53 resistor from assortment to obtain the ooe +0.1 sec time
de1ay.
t. Turo off de power. Rep1ace 560 ohm resistor with 470 ohm ~1 percent
resistor.
Change 1 4-204E
NAVAIR 03-l05AB-52
u. Tum on de power. Voltage at pin 16 sha11 go to or stay at 2 +2 vdc

within 0.1 seco
v. Turn off de power and disconnect sensor assemb1y from test setup.
4-587D. Perform final assemb1y instructions that fo110w.
a. Seal adjustment screws using compound (G1yptal Cement No. 1276, General
Eleetrie Co, Plasties Business Department, Plasties Ave, Pittsfield, MA).
b. After assembly, secure any loose wires to eireuit boards, using adhesive
(RTV-732, Dow Corning Corp, Midland, MI, or equivalent).
e. Touch-up any reworked areas with a polyurethane coating (No. 683-3-3

with yellow traeer, Finch Paint and Chemica1 Co, Div USM Corp, Torrance, CA, or
equivalent).
4-588. REPAIR OF ACCUMULATOR ASSEMBLY (figure 4-10).
4-589. Replace accumu1ator piston (9) if any damage is revea1ed by inspection.
4-590. Replace compression he1ica1 spring (10) if any damage is revealed by in-
speetion.
4-591. Repair or rep1ace accumu1ator housing (11) as fo110ws:
a. Remove corrosion in aceordance with paragraph 4-372.
b. Renew worn hard anodize coating in aeeordanee with paragraph 4-372,

step e.
e. Renew worn dry-fi1m lubricant 1n aecordance with paragraph 4-380.
4-204F Change 1
NAVAIR 03-105AB-52
ADD
-183036-1 ANGlE
(70210)307D73-1Ik>XASSEMBLV
PAlNT COLOR NO. 37038 A 8 C

LUSTERLESS BLACK, IN
ACCORDANCE WITH FEO 0.38 0.75 0.16 TO
STD5Q6. 0.19 IN
Figure 4-79D. BoxAssembly 307073-1
Change2 4-204GI(4-204H blank)

NAVAIR 03-105-AB-52
d. Rep1ace housing if any defect other than those specified in preceding

steps a, b, and c is revea1ed by inspectiou.
4-592. Repair or rep1ace accumu1ator hydraulic piston (14) as fo11ows:
b. Renew worn hard anodize in accordance with paragraph 4-372.
c. Rep1ace piston if damage other than corrosion or worn anodize is re-

vea1ed by inspection.
4-593. Repair or rep1ace accumulator cap (15) as fo11ows.
b. Renew worn hard anodize in accordance with paragraph 4-372.
c. Rep1ace cap if any defect other than corrosion is revealed by inspec-

tion.
4-594. REPAIR SENSITIVE SWITCH ASSEMBLY (38, figure 4-7 and figure 4-11).
NOTE
Perform e1ectric and e1ectronic wiring procedures in
accordance with NAVAIR Ol-lA-505.
4-595. Repair e1ectrica1 1ead assembly as fo11ows: Refer to figure 4-11.
a. Replace any part tbat fails to meet inspection requirements and is
damaged beyond normal shop repair.
b. Repair electrical lead assembly (7 through 10, figure 4-11) as follows:

(1) Measure and cut replacement wires as specified in table 4-4.

Refer to figure 4-80 for terminal and switch identification.
(2) Heat termina1s of switches (2), and disconnect wires as required
to repair or rep1ace parta.
(3) S1ide sleeves (1) down wires, heat contacts of connector assembly
(3), and disconnect wires as required to repair or replace parts.
(4) Install replacement sleeves (1).

(5) Rep1ace damaged sw1tches (2) as fo1lows. Strip end of wires 0.25
incho Attach wires to switch terminaIs as specified in tabIe 4-4 and 111ustrated
in figure 4-80. Solder wires to terminaIs using solder SB5, per QQ-S-571.
4-205
NAVAIR 03-105-AB-52
1. SLEEVE
2. SWITCH
3. CONNECTOR
-t
0.39 TO
0_.4~j_IN_·
____ -HH+IIr-~_~2
@@
COMMON TERMINAL
NORMALLY OPEN TERMINAL
TERMINAL~ l--~-
/
'NORMALLY CLOSED
SWITCH A SWITCH B
Figure 4-80. Repair of E1ectrica1 Lead Assemb1y
(6) Rep1ace damaged connector (3) as fo11ows. Insert wires into con-
tacts of connector as specified in tab1e 4-4 and i11ustrated in figure 4-77. Solder
wires to contacts of connector using solder SB5, per QQ-S-571.
(7) Rep1ace damaged wires as fo110ws. Cut wires to length as specified

in tab1e 4-4. Strip one end of wire 0.25 incho Attach to switch terminal and sol-
der using solder SB5, per QQ-S-571. Sl1p sleeve (1) over w1re. Insert wire into
contact of connector and solder using solder SB5, per QQ-S-571. Slide sleeve (1)
over contact of connector.
4-596. Rep1ace switch actuating 1ever (3, figure 4-10) if damage 18 revea1ed by
inspection.
4-597. Repair damaged paint to housing (13) by preparing surface in accordance with
r ~raph 4-377. Paint in accordance with paragraph 4-379.
4-~98. REPAIR OR REPLACE SWlTCH ACTUATING GOVERNOR ASSEMBLY (figure 4-12).
4-599. Replace f1yweights (3) 1f damage 1s revea1ed by inspection.
4-600. Rep1ace governor pin (4) if inspection revea1s damage.
4-206
t
NAVAIR 03-105-AB-52
Table 4-4. E1ectrica1 Lead Assemb1y Wiring Data
Connector
Wire Colar Length Pin Switch Terminal
~
Blue 1.10 to C A Norma11y Closed
1.30 in.
White-green 0.70 to A B Norr' ..l.ly Open

0.90 in.
White-orange 0.70 to B A Norma1ly Open

0.90 in.
White-blue 0.30 to D B Common

0.50 in.
B1ack 0.30 to F A Common

0.50 in.
Green 1.10 to E B Norma11y C10sed

1.30 in.
4-601. Replace compression spring (6) 1f any defect ia revea1ed by 1nspect1on.

4-602. Rep1ace pin (7) i f any defect ia revea1ed by inspection.
4-603. Rep1ace governor body asaembly (7, 8) 1f any defect to body (8) 1s revealed
by inapect1on.
4-604. REPAIR OR REPLACE FUEL CONTRaL ASS~Y (figure 4-13).
4-605. Rep1ace a1r pasaage bo1t (3, aheet 1) 1f any defect is revea1ed by inspec-
tiOh.
4-606. Rep1ace adjusting screw (11) if any defect 1s revealed by 1nspection. ,

4-607. Repair or Tep1ace acceleration limiter hous1ng assemb1y (12, 13, 14) as
fo1lows:
a. Remove minor burrs and nicks on non-mating surfaces in accordance with

paragraph 4-370.
4-207
NAVAIR 03-l05-AB-52
b. Replace damaged or loose restrictor (13) by removing restrictor and

press new restrictor to bottom and swage to secure.
c. Repaint damaged painted surface by preparing in accordance with para-

aph 4-377. Paint in accordance with paragraph 4-379.
d. Replace housing assembly if any defect other than specified in steps a

through d is revealed by inspection.
4-608. Replace spring guide (15) if any defect is revealed by inspection.
4-609. Replace compression helical spring (16) if any defect is revealed by inspec-
tion.
4-610. Replace diaphragm spacer (20) if any defect is revea1ed by inspection.
4-611. Replace diaphragm spacer (21) if any defect is revealed by inspection.
4-612. Rep1ace fuel contro1 diaphragm spacer (23) if any damage i5 revealed by in-
spection.
4-613. Rep1ace spring retainer (32) if any defect is revealed by inspection.
4-614. Replace adjusting screw (33) if any defect is revealed by inspection.
·615. Repair or rep1ace governar cover a5semb1y (35, 36) as fol1ows:
a. Replace damaged pin (35) by removing old pin; pin hole after pin re-
moval shall be 0.062 to 0.065 inch in diameter and 0.19 to 0.21 inch deep. Coat new
pin with primer (Cati-Coat E42GP20 and catalyst reducer V66KP46 equal by volume,
Sherwin-Wi11iams Co, Main Store, 2312 N. 16th St, Phoenix, AZ 85016, or equivalent).
Install pin into hole. Cure at 180° to 275°F for one hour.
b. Removeminor nicks and burrs in accordance with paragraph 4-372.
c. RepIace cover assembIy i f any defect other than that specified in pre-
ceding steps a and b is revealed by inspection.
4-616. Replace compression helica1 spring (37) if any inspection requirement i5 not
meto
4-617. Replace annular ball bearings (38, 44) if any inspection requirement is not
meto
1.-618. Repair metering sleeve (40) as follows:
a. If sleeve (40) and metering valve (46) do not have a smooth sliding fit,
po1ish outside diameter of metering valve and inside diameter of sleeve with crocus ~
cloth (P-C-458). Use crocus cloth carefully, with a rotary, longitudinal motion,
avoiding excessive metal removal.
4-208
NAVAlR 03-l05-AB-52
CAUTlON
Excessive metal removal from sleeve or metering valve

will cause leakage in governor.
b. lf any defect other than that specified in preceding paragraph a is

revealed by inspection, replace sleeve.
4-619. Replace flyweights (41) i f any defect is revealed by inspeetion.
4-620. Replace governo r cage (45) if any defect is revealed by inspeetion.
4-621. Replaee governor valve assembly (46) if any defect isrevealeà by inspec-
tion.
4-622. Replaee sleeve bearing (47) i f dimensional inspeetion requirements are not
mete Minor nicks or scratches on ends of sleeve bearing are permissable.
4-623. Replaee adjusting screw (51) if any defeet is revealed by inspection.
4-624. Replace machine thread plug (52) if any defect i8 revealed by inspection.
4-625. Replace compression helical spring (53) if any defect other than mild corro-
sion is revealed by inspection. Remove corrosion in aceordance with paragraph
4-373.
4-626. Replaee metering valve (54) if any defect is revealed by inspection.
4-627. Repair or replace fuel control valve sleeve (59) as follows:
a. Clean obstructions or foreign material from valve Bleeve passages usina

standard eleaning proeedures. If passages cannot be cleared, repIaee valve sleeve.
b. Replace valve sleeve if any defeet other than apecified in preeeding

step a is reveaIed by inspeetion.
4-628. Repair or repIace aeal housing (70) as follows:
a. Remove minor nicks or burrs on non-sealing surfaces in accordance with

paragraph 4-372.
b. Clean passages of foreign material or obstructions using atandard clean-
ing procedures. RepIaee housing i f obstructions cannot be eIeared.
c. Replaee housing i f any defeet other than those speeified in preceding
stepa a and b 1s revealed by inspect1on.
4-629. ,Repair or replace fuel pump aleeve bearing (76, 82) as follows:
4-209
NAVAIR 03-l05-AB-52
a. Check width of bearings (76); width shall be within 0.0002 inch of each
other. If width is not as specified, lap non-functional side of bearings to obtain
specified dimensiono Observe minimum allowable width of 0.2495 incho
b. Remove minor nicks and scratches from non-functional areas of bearing

(82) in accordance with paragraph 4-373.
c. Replace bearing i f any defect other than those specified in preceding

steps a and b is revealed by inspection.
4-630. Repair or replace pump drive shaft assembly (77, 78) as follows:
a. If plug (77) is loose, remove plugo Remove cured adhesive by immersing

part in stripper Enthone 5-16 to soften, then remove with methyl-ethyl-ketone.
Vapor degrease, immediately prior to bonding. Wipe degreased surface to be bonded
with methyl-ethyl-ketone. Do not allow methyl-ethyl-ketone to air-dry, wipe dry
with a clean cloth~ Apply a thin smooth coat of adhesive EA929 (Hysol Div, The
Dexter Corp, P.O. Box 831, 2850 Willow Pass Rd, Pittsburg, CA 94565) to new plug
and to plug seating area in shaft. Immediate1y install plugo Cure part for four
hours at 250°F.
b. Replace shaft assembly if any defect other than that specified in pre-
ceding step a is revealed by inspection.
-631. Replace spur gears (79, 81) if any defect is revealed by inspection.
4-632. Replace gearshaft (80) if any defect is revealed by inspection.
4-633. Repair or replace fuel metering valve body assembly (86 through 97) as
follows:
a. Remove nicks and burrs from surfaces using a fine stone (No. AF-3-JB,
Carborundum Co, Niagara Falls, NY, or equivalent).
b. Remove mild corrosion in accordance with paragraph 4-372.

c. Clean alI passages in body using standard cleaning procedures.
d. Replace damaged inserts (86 through 93, sheet 2) in accordance with

paragraph 4-387.
e. Replace loose or damaged plugs (94, 95, 96), by removing old plugo
Clean plug hole and new plug thorough1y with solvent (Dowclene EC, Dow Chemical Co,
Midland, MI 48640, or equivalent); allow solvent to evaporate. Applyan even coat
~f primer (Cati-Coat E42GP22 mixed in equal parts with catalyst reducer V66KP46,
lerwin-Williams Co, Main Store, 2312 N. 16th St, Phoenix, AZ 85016) to plugo Do
.&ot dip coat, or coat bore to receive plugo Install plug while primer is still ~
wet, swsge to hold in p!ace. ,
f. Renew worn or damage anodized coating in accordance with paragraph

4-374. Anodic coating sha!! be type I.
NAVAIR 03-105AB-52
g. Repaint damaged painted surfaces in accordance with paragraph 4-3790
h. Rep1ace body assemb1y if damaged beyond repair.
i . Bores which are scored or damaged from contact with spur gears (79, 81) and are not in
excess of 0.8030 inch should be honed or polished to blend the area and remove any high spots. Blemishes
~n area of spur gear path are acceptable.
NOTE
Do not exceed 0.8030 inch diameter when boning.
j. Treat machinedlpolished bores in accordance with paragraph 4-58.
4-634. REPAIR OR REPLACE HYDRAULIC MOTOR (figure 4-14).
4-635. Repair or replace housing cap (1) as follows:
a. Remove minor burrs and nicks in accordance with paragraph 4-370.

c. Rep1ace cap if any defect other than specified in steps a and b is re-
I vealed by inspection.
4-~360 Repair or replace bearing retainer (11) as follows:

bo Remove corrosion 1n accordance with paragraph 4-372.
Co Rep1ace bearing retainer i f any defect other than spec1fied 1n steps a
and b is revea1ed by inspection.
4-637. Replace pistons (13) if any defect ia revealed by inspection.
4-638. Repair or replace auxiliary cam (14) as follows:

c. Replace auxiliary cam if any defect other than specified in steps a an

b is revealed by inspection.
4-639. Repa1r or replace cam retainer (15) as follows:
Change 2 4-211
•
NAVAIR 03-105AB-52
NOTE
Cam retainer shall not be anodized.
ho Remove mild corrosion in accordance with paragraph 4-172 0
Co Rep1ace cam retainer if damage other than that described in preceding

steps a and b is evidento
4-640. Repair or rep1ace rotor (16) as fo11cws:

a. Remove minor hurrs and nicks on non-mating surfaces in accordance with
paragraph 4-3700
b. Remove mi1d corrosion in accordance with paragraph 4-372.
c. Lap surface of rotor that mates with port plate (19) to flatness within
one heliUM light bando
d. Replace rotor if dimensional inspection rp.quirernents are not meto
4-641. Repair or rep1ace shaft (18) as follows:
ao Remove mino r burrs, nicks and corrosion in accordance with paragraph

374.
h. Replace shaft if dimensional inspection requirements are not meto
4-642. Repair or replace port plate (19) as follows:
a. Remove minor burrs and nicks on non-mating surfaces in accordance with

paragraph 4-3700
ho Remove corrosion in accordance with paragraph 4-372.
c. Lap surface of plate that mates with rotor (16) to a flatness within one
he1ium light bando
do Rep1ace port p1ate if any defect other than specified in p~eceding steps
a, b, and C is evidento
4-6430 Rep1ace spring (24) if inspection requirements are not Met.
4-6440 Replace nameplate (27) if inspection requirements are not meto
5450 Repair or replace housing (29) as follows:
ao Remove nicks and burra in accordance with paragraph 4-370.
h. Remove corrosion in accordance with paragraph 4-372.
Co Repaint damaged painted surfaces as follows:
4-212 Change 2
• NAVAIR 03-l05AB-52
(1) Prepare surfaces for painting in accordance with paragraph 4-377.

(2) Mix equal parts (by volume) of A-4l5-66 epoxy enarnel (glos8 blaci
~ and T1178-66 converter (Andrew Brown Co, 5431 S District B1vd, Los Angeles, CA
90052).
(3) App1y one coat and cure by air-drying for 2 hours, then cure in
oven at 175 to 225°F (79 0 to 107°C) for one hour.
0
Change2 4-212A1(4-2l2B blank)

...
NAVAIR 03-l05-AB-52
d. Replace housing if any defect otber than specified in preceding steps

a, b and c is evident.
4-646. IOLERANCES AND LIMITS.
~ 4-647. TABLES.
4-648. The tabes of 1imits in this section are to be used in conjunction with
figures 4-81, 4-82 and 4-83.
4-649. REFERENCE NUMBERS.

4-650. Reference numbers on the figures indicate tbe 10cation of fits, clearances,
and parts for wbich torque valuea are apecified. A description of the limita for
these fts, c1earancea, and torques are located in tbe tables by correspondiDg re-
ference numbers.
4-651. LIMITS.
4-652. The ''MIN'' and ''MAX'' co1umns contain the overhaul fits and c1earances between
parts.
4-653. TERMS AND SYMBOLS.
4-654. The symbo1 ''L'' and "T" in tbe ''MIN'' and ''MAX'' co1umns indicate a 100se or
tight fito The term "BY SELECTION" in the ''DESCRIPTION'' co1umn indicates that the
parts must be matched by choosing units which wil1 provide tbe correct fit. The
term "FIT TO" means that grinding, fil1ing or otber fitting operation may be nec-
essary to obtain the correct fit at assembly. Unless otherw1se specified, alI fits
are diametrical.
4-65.5. The figures in tbe ''l!IN'' and ' MAX'' columns shall be interpreted as follows:
Torque in inch-pounds or foot-pounds as indicated and alI other limits in inches.
4-6.56. TORQUE APPLICATION.

4-657. The threads lIlUst be free of burrs or nicks and also must turn freely without
binding.
4-658. T1ghten alI nuts in staggered sequence to the torque setting or unti! the
parts are f1rmly seated at the sp1it l1ne. Then loosen one at a time and retighten
finger-t1ght (unti1 the shou1der of the nut just makes contact). Angular tightening
starts from this finger-tight position. Final torque applied at the first drawdown
ia not permisaible as this results in overstressing of some parts and uneven tension
in others. Refer to NAVAIR 01-LA-8 for standard torque values. Non-standard torque
va1ues are presented in tab1es 4-5, 4-6, and 4-7.
4-659. Unless otherwise specified, thread lubricants should not be applied to units
which are to be torqued. When torque figures are provided in the ''MIN'' column only,
the nut shou1d be tightened, if necessary to proper1y a1ign the locking alot. Where
torque figures are provided in the "Mm" and "MAX" columns, tbe alignment of the
4-213
NAVAIR 03-105-AB-52
17 16 13 29
~ 14
SECTION A-A
t
15
22
"
VIEW B
VIEW C
Figure 4-81. Power Turbine Assemb1y Tab1e of Limits
4-214
..
NAVAIR 03-105-AB-52
27
~
28
DETAll B
L __- - -
VIEW A-A
Figure 4-82. Gas Generator Assembly Tab1e of Limits
4-215
NAVAIR 03-10S-AB-52
Figure 4-83. Accessory Drive Assembly Tab1e of Limits
4-216
NAVAIR 03-l05-AB-52
Tab1e 4-5. Power Turbine Assembly Tab1e of Limits
Figure 4-81
Ref No. Description Min Max
~
1. Tightening Torque 5 m.-1b 8 in.-Ib
2. Tightening Torque 50 in.-1b 70 in.-lb
3. T~ghtening Torque 50 in.-lb 80 in.-lb
4. Tigbtening Torque 2 in.-1b 4 m.-lb
5. Bearing On Gearsbaft 0.0004T 0.0005L
6. Bearing On Gearshaft 0.0000 0.0006T
7. Tightening Torque 20 in.-1b 25 in.-lb
8. Bearing In Support 0.0000 0.0006T
9. Bearing In Housing 0.007lL 0.0105L
10. Tightening Torque 20 in.-1b 25 in.-1b
11~ Bearing In Support 0.0003T O.OOOSL
12. Bearing In Gearshaft 0.0004T 0.0006L
13. Gear To Gear - Back1ash 0.0005 0.0025
14. Tightening Torque 25 in.-Ib 30 in.-Ib
15. Whee1 To Shie1d 0.030 0.032
16. Bearing On Whee1 Assemb1y 0.0000 O.OO04T
17. Bearing In Inner Housing O.OOOlL 0.0008L
18. Resilient Mount To Bearing 0.0001L 0.0006T
19. Liner To Resi1ient Mount 0.0003L 0.0004T
20. Housing To Liner O.OOOlL O.OOIOL
21. Sea1 To Sea1 0.164 0.175
22. B1anket Assembly To Sea1 0.007 0.013
23. Pin Head To Liner Surface 0.0000 0.020
24. Tightening Torque 50 in.-lb 80 in.-lb
25. Bearing On Gearshaft O.OOOIL 0.0005L
26. Retaining Ring To Bearing 0.000 0.004
27. Tightening Torque 50 m.-1b 70 in.-1b
28. Tightening Torque 4 in.-lb 6 in.-1b
29. Support In lnner Housing O.OOOIL 0.0005L
30. Bearing In Housing O.OOOIT 0.0007L
31. Tightening Torque 20 m.-1b 25 in.-1b
32. Tightening Torgue 115 in.-1b 120 in.-1b
4-217
•
NAVAIR 03-105-AB-52
Tab1e 4-6. Gas Generator Assemb1y Tab1e of Limits
'ure 4-82
af No. Description Min Max
1. Tightening Torque 30 m.-1h 35 in.-1h

2. Whee1 Assemb1y To Shield Assemb1y
(a) New Parts 0.027 0.029
(b) Used Parts (test on1y or 0.023
extended use)
3. Tightening Torque 50 m.-1b 70 in.-1h
4. Housing Assemb1y To Stator Assemb1y; 0.002 0.005
Pinch
5. Shim For C1earance 4
6. Spacer To Shaft O.OOOlL 0.00071
7. Combustor Assemb1y On Stator 0.002L 0.012L
Assemb1y
8. Carrier To Bearing 0.0000 0.0005L
9. Tightening Torque 12 in.-1h 15 in.-1b
11. Tightening Torque 50 m.-1h 70 in.-1b
15. Compressor Whee1 To Inlet Shroud 0.015 0.017
16. Ring To Shroud; Pinch 0.030 0.040
18. Tightening Torque 30 m.-Ib 35 in.-1b
20. Shims To Locate Gear In Re1ation
To Gear Assemb1y
2I. Gear To Gear Assemb1y Backlash 0.002 0.004
22. Shim For Item 21.
23. Carrier To Bearing O.OOOlL 0.0007L
24. Shims For C1earance 25
25. PIate To Impel1er 0.000 0.008
27. Tightening Torque 12 in.-Ih 15 in.-Ib
28. Shim In Spotface 0.000 0.001
30. Carrier To Bearing 0.000 0.0005L
32. For Minimum CIearance Betwpen 1 Gasket 2 Gasket
Containment Ring and Impingement
Nozz1es on Stator
33. Seal Insta11ed Height 0.090 0.102
35. Seal Assemb1y To Retainer 0.000 0.003
4-218
•
NAVAIR 03-I05-AB-52
Table 4-6. Gas Generator Asaembly TabIe of Limita (Cont)
Figure 4-82
Ref No. Description
36. Spacer To Shaft O.OOOlL 0.0007

38. Tightening Torque 300 in.-lb 500 in.-Ib
39. Gear On Wheel Assembly O.0002L O.OOIOL
40. Stator To Shield O.002L 0.009L
4l. Wheel Assembly To Bearing 0.0004T O.OOOOL
42. Bearing on Gear O.OOOIT 0.0004L
Table 4-7. Accessory Drive Assembly Table of Limits
Figure 4-83
Ref No. Description Min
l. Tightening Torque 35 in.-lh 40 in.-ll

2. Shaft In Bearing 0.0002T 0.0005L
3. Tightening Torque 20 !n.-1b 25 !n.-1b
4. Tightening Torque 35 in.-lb 40 !n.-lb
5. Tightening Torque 20 in.-lb 25 in.-1b
6. Governor Assembly To Thrust Washer 0.003L 0.006L
7. Shims For Clearance 6
8. Governor To Microswitch Pinch 0.000 0.020
9. Shims For Clearance 8
10. Tightening Torque
11. Carrier In Housing 0.0003L 0.0010L
12. Bearing In Carrier 0.0002L O.OOlOL
13. Shaft In Bearing 0.0002T 0.0005L
16. Tightening Torque 12 !n.-lb 15 in.-lb
18. Tighten!ng Torque 20 in.-lb 25 in.-lb
19. Tightening Torque 5 in.-lh 8in.-lb
21. Gear Mounting Dimension 0.854 0.856
22. Shims For Dimension 21
23. Gear To Gear Backlash 0.002 0.004
24. Shims For C1earance 23
25. Gear Mounting Dimension On Clutch 0.550 0.550
Housing And Shaft Assembly
4-219
NAVAIR 03-105-AB-52
Table 4-7. Aeeessory Drive Assembly Table of Limits (Cont)
'I?;ure 4-83
lef No. Deseription Min Max

10cking s10t must be obtained without exeeeding the maximum torque. lf this is not
permissible, another nut should be used. After tightening nuts to the recommended
torque, they should not be loosened to permit insertion of lockwire or eotter pins.
NOTE
When tightening bolts and nuts, frietion torques devel-

oped from self-loeking devices must be added to bolt
and nut 10ading torques and must be determined sepa-
rately for eaeh bo1t and nut.
SOe ASSEMBLY.
AGE REQUlRED
ADAPTER PLATE MOUNT 901148-T7
BACKLA5H CHECKING GAGE 287149-1-1
BACKLASH CHECK GEAR HOLDER 287154-1-1
BALANCING MACHlNE (Mode1 13-5, Giddings and

Lewis Ine, 142 Doty St,
Fond Du Lae, WI 54935, or
equiva1ent)
BEARING AND BUSHING DRIVER 285482-1-1
BEARING AND BUSHING DRIVER 285486-1-1
BEARING ANO BUSHING DRIVER 287147-1-1
BEARING GUIDE SLEEVE 289640-1
BEARING PRESS 287157-1-1

BEARING PRESS DRIVER 287156-1-1
4-220
NAVAIR 03-105-AB-52
AGE REQUIRED (CONT)
CONTROL BOX TESTER 289680-1

COVER INSTALLING DRIVER 289044-1
DIGITAL VOLTMETER Model 2401C Hew1ett

Packard (DYMEC), or
equivalent
ELECTRONIC COUNTER (Hew1ett Packard Mode1
5214, or equ1val~~t)
ELECTRONIC COUNTER Mode1 3734A, Bew1ett
Packard, or equiva1ent)
FUEL ACCESSORIES TEST STAND 285304-1
FUEL CONTROL SPEED INCREASER ADAPTER 284763-1-1

FUEL CONTROL TEST ADAPTER 285492-1-1
GEAR POSITIONING GAGE SET 285483-1-1
GOVERNOR CALIBRATOR ADAPTER 281157
GOVERNOR CALIBRATOR ADAPTER 289679-1

GOVERNOR CALIBRATION SWITCH 281159
GOVERNOR STAKING TOOL 289046-1
JFS ACCESSORY DRIVE TESTER. 291659-1
MULTIMETER (.Mode1 260, Simpson

E1ectric Co, Division of
American Gage and Machine
Co, 5200 WKenzie St,
Chicago, IL 60644, or
equiva1ent)
NEEDLE BEARING AND SHAP'T SEAL 901148-T3
INSTALLATION TOOL
NUT STAKING TOOL 287946-1
NU! TORQUING IMPELLER HOLDER 287148-1-1
PIN INSTALLING HOLDER 287944-1
PIN PRESSING HOLDER 287153-1-1
4-221
NAVAIR 03-105-AB-52
AGE REQUlRED (CONT)
PLANETARY GEAR HOLDER 285468-1-1
PORT PLATE INSTALLATION TOOL 901148-T5
PORT PLATE o-RING AND BACK-UP RING 901146-Tl

CONDITIONER
RETAINING RING PILOT ANO DRIVER 284311-1-1
SEAL INSTALLING DRIVER 287155-1-1
SEAL INSTALLING DRIVER 281200
SEAL INSTALLING PILOT 289024-1
SEAL PRESSING DRIVER 289025-1
SEAL PRESSING DRlVER SET 285473-1-1
SHAFT BEARING PRESS INSTALLATION TOOL 901148-T2
SlIAFl' INSTALLING DRIVER. ANO HOLDER 285462-1-1
SHAFT INSTALLING DRlVER AND HOLDER. 285463-1-1
SHIM CHECKING GAGE 287151-1-1
SHIM CLEARANCE GAGE 287146-1-1
SOCKET waENCH 285471-1-1
SPEED SENSOR CALDmATOR 281007
SPLINE ADAPTER 901148-T8

SPRING COMPRESSOR 285456-1-1
SPRING :OMPRESSOR 285458-1-1

TIME INTERNAL COUNTER Mode1 3734A, Hew1ett ~
Packard, or equiva1ent
4-222
NAVAIR 03-105-AB-52
AGE REÇUIRED (CONT)
TORQUE WRENCH ADAPTER 287002-1

'IURBINE HOLDER 285454-1-1

TUImINE WHEEL HOLDER 285459-1-1
VARIABLE DC POWER SUPPLY (O to 30 vdc)
4-661. GENERAL ASSEMBLY INSTRUCTlONS.
4-662. The jet fue1 gas turbine engine starter is a precision unit which requires
fits and c1earances to be c10se1y maintained. Assemb1y of the starter shall be
performed with attention to the details out1ined in th1s manual. The highest stand-
ard of precision shop procedures shall be emp10yed throughout tbe entire reassemb1y
operation.
CAUTlON
lf any foreign particle is dropped into the starter

assemb1y, assemb1y shall be stopped until tbe foreign
partic1e is 10cated and removed even if this may cause
considerab1e disassemb1y.
4-663. For added protection to the starter, 1arge openings shall be covered with
tape and cardboard, smaI1 openings with tape or a c1ean c10th. Open tube ends shall
be capped or taped. Openings on fue1 system components sba11 not be tapedj caps
or similar coverings sha11 be used. l f the starter is to be 1eft for even a short
period in a partia11y disassembled state, alI openings sba11 be covered.
4-664. AlI parts sba11 be thorough1y c1ean before assemb1y and alI parts and sur-
faces sba1l be w1ped with a clean lint-free cloth. lf any parts were coated with
corrosion-preventive compounds, alI traces of this compound and any accumulated
foreign matter shal1 be removed.
4-665. Lubr1cate packings prior to assemb1y. Coat packings used in lubricating 011
MIL-L-7808 and MIL-L-23699 with 1ubr1cating oil MIL-L-7808 ar MIL-L-23699. Coat
packings uaed in JP4 or JP5 fue1s witb 1ubr1cãnt (HF825, Roya1 Lubr1canta Co, P.O.
Box 95 River Rd, E. Hanover, NJ 07936, or equiva1ent).
4-666. When sp1ines or gear teeth are to be mated, the surfaces aba11 be proper1y
1ubr1cated with 1ubricating oi1 O!.IL-L-7808 or MIL-L-23699).
4-667. Lockwire sba11 be insta11ed in accordance with NAVAIR 01-lA-8 or NAVAIR

OI-IA-50S as app1icab1e. Un1ess otherwise specified, 10ckwire MS20995C20 aba11 be
used.
4-223
NAVAIR 03-105AB-52
4-668. Extreme force should never be used in the assemb1y of the starter. lf dif-
ficu1ty is encountered, the starter sba11 be d1sassemb1ed and inspected for burrs
?r otber interferences. Paragraph 4-646, To1erances and Ltm1ts, sba11 be referred
, as a guide in a11 assemb1y operations invo1ving fits, c1earances, back1ashes and
_orques.
4-669. Al1 packings, gaskets and lock1ng devices requ1r1ng bending during insta11a-
tion, sba11 be repIaced whenever they are removed.
4-670. Apply aluminized paint to parts as required and in accordance with foI1owing
steps of procedure.
NOTE
Aluminized paint has a maximum pot life of two hours. Mixture

older than two bours shall not be used.
a. Apply one coat of aluminized paint (8herwin-Williams Clear Cati-Coat V40VP7 with
catalytic reducer V66KP46 1:1 mixed with 16 ounces per gallon of catalyzed mixture of extra fine
aluminum Uning powder, (Sherwin-Williams Co. Main 8tore, 2312 N. 16th St, Phoenix, AZ 85016).
I Premixed Dutch Boy aluminized paint, or equivalent, may be utilized in lieu of the specified two part
non-mixed aluminized paint.
b. Assemb1e parts whi1e pa1nt 1s wet.

4-671. Insta11 adhesive-backed metal foil ident1f1cation pIates, and lubricat10n
instruction pIates as follows:
WARNING
Methyl-ethyl-ketone and toluene are flammable. Keep away from

heat and open flame. Vapors are harmful. Use only with adequate
ventilation or respirator as specified by the Bioenvironmental
Engineer. Avoid prolonged or repeated breathing ofvapor. Avoid
contact with skin and eyes. Do not take intemally. Comply with
air pollution control rules conceming photochemically reactive
solvents.
a. CIean surface to wh1ch appl1cation 1s to be made with toluene, TT-T-548,

or metbyl-etbyl-ketone.
b. lmmerse pIate in water for approximately one minute. Remove excess
isture by bIotting witb cIoths or paper towels.
c. Carefu11y remove ce110pbane backing to avoid contact witb adbesive.
d. Apply pIate fmmediateIy, adhesive side down, and press firmly with
fingers or ro1ler.
4-224 Change 2
NAVAIR 03-105AB-52
e. App1y Nycote 7-11 (Nycote Laboratories, 15002 Delano. Van Ruys, CA

91401) over surface and extend 1/8 inch beyond periphera1 edge of p1ate 1abe1 on
deca1 to sea1 edge.
f. Cure coating at room temperature for 72 hours or for one hour at roam
temperature fo11owed by air-dry period of 12 hours at 120°F, 8 hours at 150°F, four
hours at 180°F, two houra at 220°F or 1/2 hour at 300°F.
4-672. ASSEMBLY OF COMPONENTS.
4-673. ASSEMBLY OF HYDRAULIC MOTOR.
4-674. Assemb1e hydrau1ic motor as fo11ows. Refer to figure 4-14.
Change2 4-224AI(4-224B blank)

c
NAVAIR 03-105AB-52
NOTE
AlI parts and surfaces shall be lubricated with

hydraulic fluid, MIL-H-5606. AlI packings and press
fit surfaces sha11 be coated with a thin coat of
lubricant, MIL-G-4343.
a. Press bearing (26) into housing (29) using Needle Bearing and Shaft Seal
Installation Too1, 901148-T3.
b. Press pins (25) into housing (29) until firm1y bottomed.
c. Assemble port plate (19) and spring (24) to housing (29) as fo11ows:
CAUTION
Use extreme care so as not to damage port p1ate (19)

lapped surface.
(1) Lap mating surface of port p1ate (19) as required to achieve f1at-
ness requirements described in paragraph 4-642, step c and clean.
(2) Insta11 packings (21, 23) toward inside of port p1ate (19).
(3) Insta11 retainers (20, 22) toward each end of port plate (19).
(4) Carefu11y press assemb1ed port plate (19) into Port P1ate o-Ring
and Backup Ring Cond1tioner, 901146-T1. Let stand two m1nutes or 10nger to pres-
sur1ze retainers to facilitate instal1ation into housing (29).
(5) Position spring (24) centra11y into bottom of housing (29).
NOTE
Port plate (19) shall be free within housing (29).
(6) Insert Port Plate Installation Tool, 901148-T5 into threaded in-
side diameter of port plate (19). Remove port p1ate from conditioner and insta11
in housing (29).
d. Assemb1e rotor (16) to shaft (18) as follows:

CAUTION
Use extreme care not to damage rotor (16) 1apped
surface.
(1) Lap mating surface of rotor (16) as required to achieve flatness

requirements described in paragraph 4-360 and clean.
(2) Instal1 key (17) into keys10t of shaft (18).
Change 1 4-225
NAVAIR 03-105AB-52
(3) Press shaft (18) into rotor bore until shou1der of shaft is seated
against rotor (16).
(4) Check shaft rotor bore for any displaced bronze and remove with
suitab1e burring tool.
e. Assemb1e bearing (12) to retainer (11) as fo1Iows:
CAUTION
Use extreme care not to damage bearing (12) Iapped surface.
(1) Lap mating surface of bearing thrust plate and c1ean. Mating sur-
face shal1 be flat within one he1ium light band.
(2) InstaII bearing (12), thrust p1ate first, into retainer (11). En-
sure thrust plate is fully down into bottom of retainer shoulder.
f. Assemble rotating components to shaft and rotor (from step d) as folIows:
CAUTION
Pistons (13) shaII fit freely within rotor (16).
(1) InstaII cam (14) and pistons (13).
(2) InstaII assembled bearing (12) and retainer (11) from step e.
(3) InstaII washer (9).
NOTE
Press on1y on the inner race of bearing (8).
(4) Position bearing (8) side marked "thrust here" toward splined end
of shaft. Press bearing (8) onto shaft (18) using Shaft Bearing Press Installation
TooI, 90l148-T2, until firmly against washer (9) and shoulder of shaft (18).
(5) Position cam retainer (15) in place.
g. InstaII pin (10) into pin sIot in housing (29).
h. InstaII assembled shaft (from step f) into housing (29) tal~ing care to
align pin sIot grooves of cam retainer (15) and bearing retainer (11). Verify that
pin (10) is properly positioned; if end of pin is not visible, assembly must be
repeated.
i. Assemble components to cap (1) as follows:
CAUTION
Press on metal outside diameters of sea1s (7).
4-226 Change 1
NAVAIR 03-105AB-52
(1) Insta11 packing (5) into cap (1).
CAUTION
Press on metal outside diameter of sea1s (7).
(2) Press sea1s (7) into cap (1).
(3) Assemb1e packings (2, 3) anta capo
j. Insta11 shipping p1uga into hydrau1ic motor. Poaition hydraulic motor

shaft side up and fi11 with hydraulic f1uid, MIL-H-5606.
CAUTION
Shaft (18) sha11 not be restrained when cap (1) is being

instaIIed into housing (29). To precIude damage to seals
(7), shaft (18) sha11 be a110wed to rotate with cap (1)
when the cap ia being insta11ed.
k. Coat inside diameter of sea1s (7). Insta11 cap (1) onto housing (29).
Torque cap (1) to 150 inch-pounds using cap wrench (96916) PE-A97I9 or equiva1ent.
1. Rotate shaft (18) by hand in a counterc1ockwise rotation (viewing from

shaft end). Rotation sha1l be free and even without evidence of binding. If the
ahaft does not rotate freely, the unit must be disassembled to determine cause.
m. Stake housing (29) into 1ip of cap (1) as required to mark position of
cap after assemb1y.
Verify that hydrau1ic motor is complete.

4-675. Test hydraulic motor as follows:
a. Provide test equipment and facilities as follows:
(1) Poaition Adapter P1ate Mount, 901148-T7, to Drive Pad, AND20002,

of GFE Hydrau1ic Test Stand, SANE69-l52.
(2) Insert Sp1ine Adapter, 901148-T8 into drive pad of hydraulic test
stand.
(3) Insert hydraulic motor into spIine adapter and se cure motor to
adapter p1ate mount.
(4) Connect teater to hydrau1ic motor ports marked "in" and "out".
(5) Supp1y tester with hydrau1ic f1uid, MIL-a-5606, at a temperature of
70° to 130°F (21° to 54°C).
Change 1 4-227
...
NAVAIR 03-105-AB-52
b. Perform run-in of hydraulic motor as follows:
(1) Operate motor at 4000 rpm With inlet pressure 500 psi above out1et
pressure for 5 minutes.
(2) Conduct remainder of run-in conditions in accordance with the

f0110wing schedule.
Speed Inlet Psig Time

rpm + 25 Psig Minutes
4000 1500 5
4000 3000 5
7000 1200 2
*15000 Min Req'd 1
*18000 Min Req'd 5 seconds
4000 500 5
7000 1200 5
*4000 Min Req'd 1
*7000 Min Req'd 1
*No 10ad condition (the motor is not driving a 10ad; in1et pressure is that which
is required to operate the hydrau1ic motor at the specified rpm).
c. Perform no 10ad speed test as follows:
(1) Operate hydraulic motor at 15,000 +100 rpm with no 10ad applied.
(2) Record the inlet psig and inlet flow. Inlet flow shall not exceed
10.10 gpm maximum.
d. Perform no load overspeed test as follows.
(1) Operate hydraulic motor at 18,000 +100 rpm with no load applied
for 5 seconds.
(2) Record the inlet psig.
e. Perform sampling and consumption test as follows:
(1) Operate hydraulic motor at 4000 +50 rpm with inlet pressure 3000
+25 psid above out1et presaure for one minute. Record the actua1 output torque
value and in1et flow value. Minimum output torque sha11 be 59.2 inch-pounds, and
maximum in1et flow ahall not exceed 3.46 gpm.
(2) Operate hydraulic motor at 7000 +50 rpm with in1et pressure 2500
+25 paig above out1et pressure for one minute. Record the actual output torque ~ \,
va1ue and inlet f10w values. Minimum output torque shall be 47.3 inch-pounds, and '-
maximum in1et f10w aba11 not exceed 5.30 gpm.
4-228
NAVAIR 03-l05AB-52
(3) Operate hydraulic motor at 14,000 +50 rpm with inlet pressure 1400
+25 psid above outlet pressure for one minute. Record the actual output torque
value and inlet flow value. Minimum outlet torque shal1 be 20.2 inch-pounds, and
maximum in1et f10w sha11 not exceed 10.30 gpm.
f. Perform shaft sea1 leakage test as follows:
(1) Position seal drain port at bottom of hydraulic motor and vented
to atmosphere.
(2) Operate hydrau1ic motor at 7000 +50 rpm with in1et pressure 2500
+25 psid above out1et pressure for one minute. Leakage from shaft se aI shal1 not
~xceed one drop per minute.
g. Perform stalled leakage test as fo11ows:
(1) Lock shaft into position and vent return port to atmosphere.
(2) App1y 3000 +25 psig to inlet port; leakage from return port sha11
not exceed 185 cubic inches per minute.
h. Refer to table 4-8 for aid in determining and correcting cause of

hydrau1ic motor ma1functions.
Table 4-8. Troubleshooting for Hydraulic !olotor
J Trouble Probable Cause Remedy
Shaft seal 1eaking Nicks in area of shaft (18) where Rep1ace shaft.
seal is instal1ed.
Seal (7, figure 4-14) has cuts Replace seaI.

and nicks.
High consumption Bad finish between mating sur- Replace mating sur-
(motor requiring faces of port p1ate (19) and faces.
toa much inlet f1ow) rotor (16).
4-676. ASSEMBLY OF FUEL CONTROL ASSEMBLY.
4-677. Assemb1e fuel control assembly as follows. Refer to figure 4-13.
a. Assemb1e fue1 pump section (64 through 85, sheet 1 and 2) as fol1ows:
(1) Coat inside diameter of gears (79, 81, sheet 1) and outside diam-
eter of shafts (78, 80) with lano1in (commercially available).
Change 1 4-229
•
NAVAIR 03-l05-AB-52
(2) Use shaft installing Driver and Holder, 285462-1-1. Place gear
(79) in pocket of holder. Install open end of shaft (78) into driver. Position
plug end of shaft (78) into driver. Position plug end of shaft (78) over gear (79).
Press shaft into gear until face of driver contacts face of gear.
(3) Use shaft installing Driver and Holder, 285463-1-1. Place gear ~
(81) in pocket of holder. Install slotted end of shaft (80) into driver. Position
non-slotted end of shaft (80) over gear (81). Press shaft (80) into gear until end
of shaft contacts bottom of counterbore in holder.
(4) Coat outer diameter of seals (67, 69) with compound (MIL-S-22473,
grade EV). Use Seal Pressing Driver Set, 285473-1-1, which consists of folowing;
base plate, pilot rod and driver. Place seal housing (70) on base plate. Slide
seal (69), sealing lip down, over pilot rodo Place driver over pilot rod, and press
seal (69) into housing (70). Install snap ring (68). Slide sea1 (67) over pilot
rod with sealing lip up. Place driver over pilot rod, and press sea1 (67) into
housing (70). Remove alI excess compound.
CAUTION
Seal (67) must be flush with the surrounding surface

of seal housing (70).
CAUTION
Do not force bearings (82) into body (97).
(5) Tria! fit bearings (82) into body (97, sheet 2). Lap bearing flats
using abrasive paper (P-P-IOI, No. 600 grit) as required, if insufficient clearance
between flats causes interference during trial f.it.
CAUTION
To avoid violating the maximum clearance of 0.0002
inch between the flats of assembled bearings, remove
material uniformly from each bearing a small amount
at a time and trial fit frequently. Repeat the opera-
tion until the bearings can be installed by finger
force.
(6) Install bearings (82, sheet 1) into body (97, sheet 2) and check
clearance between bearing flats for maximum of not more than 0.0002 incho
(7) Remove bearings (82, sheet 1), and install packings (85), flat
washers (84) and spring tension washers (83).
(8) Install bearings (82). Install assembled gear and shaft (78, 79)
into body (97, sheet 2) with plug end of shaft down. Install assemb!ed gear, and
shaft (80, 81, sheet 1) into body (97, sheet 2) with slotted end down. l
4-230
NAVAlR 03-I05-AB-52
CAUTION
Do not force bearings (76, sheet 1) into body (97).
(9) TriaI fit bearings (76, sheet 1) into body (97, sheet 2) with
, chamfered inside diameter toward gears (79, 81). Lap bearing flats as required
using abrasive paper (P-P-IOI, No. 600 grit) if insufficient c!earance between
flats causes interference during triaI fito
CAUTION
To avoid violating the maximum c1earance of 0.0002

inch between bearing flats when assembled, remove
material uniform1y from each bearing a amaI! amount
at a time, and triaI fit frequently. Repeat the
operation untiI the bearings can be instaIled by
finger force.
(10) InstaII bearings (76) into body (97, sheet 2) with Chamfered in-
side diameter toward gears (79, 81, sheet 1).
(11) Instal1 packing (74) in sediment strainer e1ement assembly (75)
and insta1led assemb1ed strainer e1ement assembly (74, 75) into body (97, sheet 2).
I
I
Verify proper insta1latipn of bearings (76, 82,
sheet 1).
(12) Place shank of se~l fnstalling pi1ot, 289024-1, in bore of shaft
(78). Assemble packings (71, 73) on seal housing (70) and packing (72) ou body
assemb1y (86 through 97). Plsce assemb1ed housing (67 through 71, 73) over bu11et
end of seaI installing pi1ot, and with hand pressure, press housing onto mating
surface of body (97).
(13) Install one washer (65) as illustrated, three washers (66).
Torque screws to 15.to 18 inch-pounds and lockwire.
b. Assemble packing (62) on union (63). Instal1 assembled union (62, 63)
in body assembly (96 through 97).
c. Assemb1e constant differentia1 pressure valve section (49 through 61)
as follows:
NOTE
Washers (61) are 0.005 inch thick b1ank discs.

(1) Insta11 washers (61) as required to equal total thiCkness of
washers (61) removed during disassemb1y. Temporari1y insta11 sleeve (59) in fue1
metering body (97, sheet 2). Measure dimension A, figure 4-83A as iIlustrated and
compare reading to limits. lf reading is not within limits, add or remove washers
4-231
NAVAIR 03-105-AB-52
DIM.A- FUEL CONTROL VAL VE SLEEVE
0.195 TO
0.205 IN.
Figure 4-83A. Shimming Fuel Control Valve Sleeve
as required to obtain proper dimension A measurement. Remove sleeve (59, sheet 1)

from fuel metering body after confirming that dimension A is within limits.
CAUTION
Do not insta11 packings (55, 56, 57, 58) in groove of

sleeve (59) having port opening.
(2) Install washers (61) in body (97) as required to shim sleeve (59)
to ensure adequate packing (56, 57) backup. Install packings (55, 56, 57, 58) on
sleeve (59). Install metering valve (54) in sleeve (59).
a. Verify metering valve (54) moves freely in sleeve
(59).
b. Verify installation of packings (55, 56, 57, 58).
(3) InstaIl assembled parts (54 through 59) into body (97).
(4) InstaIl spring (53, sheet 1) and pIug (52). Do not torque pIug
(52) at this time.
4-232
c
NAVAIR 03-105-AB-52
(5) Install packing (50) on adjusting screw (51) and install assembled
adjusting screw (50, 51) into plug (52). Torque plug to 140 to 150 inch-pounds.
InstaIl nut (49) on screw (50) and torque to 20 to 25 inch-pounds. Lockwire screw
(51) and nut (49) after final adjustment.
d. AssembIe governor vaIve section (26 through 48) as follows:
(1) InstaIl packing (48) in body (97, sheet 2), and instalI seal (47).
(2)Press governor cage (45) and bearing (44) on governo r valve ass~
bIy (46). InstaII fIyweights in governor cage and cbeck that fIyweights operate
freeIy.
Verify that fIyweights operate freeIy.
(3) InstaII assembIed governor vaIve assembIy (44, 45, 46, sheet 1) in
body (97, sheet 2) and secure with washer (43, sheet 1) and screw (42). Torque
screw (42) to 50 to 75 incb-ounces.
(4) Select washers (39) to position governo r metering valve 0.040

+0.005 inch open when assemhIed metering vaIve sIeeve (38, 39, 40) is installed
over governor metering valve assemhly (46). Install seIected washers (39) and
bearing (38) on governor metering vaIve sIeeve (40). InstaII assemhled metering
valve sleeve (38, 39, 40) over governor metering vaIve assembly (46).
(5) InstalI packing (31) in cover assemhIy (35, 36). InstaIl spring
retainer (32) on adjusting screw (33) and instaIl assembIed adjusting screw (32,
33) into cover assemhly (35, 36). Install washer (27) and nut (26) on adjusting
screw (33). Lockwire after final adjustment. Install packing (34) on cover
assembly (35, 36).
Verify that governo r assembly is complete.
(6) InstaIl spring (37) over metering sIeeve (40), and instalI ass~
bled cover (26 through 36) to body (97, sheet 2). Secure cover (36, sheet 1) to
body (97, sheet 2) with washers (29, sheet 1), bracket (30) and screws (28).
Iorque screws (28) to 20 to 25 inch-pounds. Lockwire screws (28) after final fuel
control adjustment.
e. AssemhIe acceleration limiter section (6 through 24) as foIIows:
(1) Instal1 ba11 (25) in body (97, sheet 2).
(2) Hold spacer (23, sheet 1) in chuck vise with 3/8 inch chuck.
Apply light coat of lubricating oil (MIL-L-7808) to shoulder of bolt (22). In-
stall diaphragm (24) with elastomer side of diaphragm toward body (97, sheet 2),
and secure with bolt (22, aheet 1). Torque bolt (22) to three to four inch-pounds.
4-233
NAVAIR 03-105-AB-52
(3)
Remove assemb1ed diaphragm (22, 23, 24) from chuck vise and insta11
in body (97). Insta11 spacers (20, 21), diaphragm assemb1y (17, 18, 19), spring
(16) and guide (15).
(4) Insta11 acce1eration 1imiter housing assemb1y (12, 13, 14) against
f1ange of diaphragm assembly (17, 18, 19). Instal1 washers (9) and screws (8).
Torque screws (8) to 15 to 18 inch-pounds.
(5) Insta1l packing (10) on adjusting screw (11), and instal1 assemb1ed
adjusting screw (10, 11) in housing (14). Insta11 washer (7) and nut (6). Tighten
nut (6) finger tight.
(6) Instal1 gaskets (4) and fitting (5) on housing (14) and secure
with air passage bo1t (3).
(7) Insta11 packing (1) on plug (2), and instaII assemb1ed plug (1, 2)
in body (97, sheet 2).
Verify that fue1 contro1 assembly is complete.
4-678. Test fueI contro1 assembly as fo1lows: Refer to figure 4-84.
a. Provide test equipment and faci1ities as fo11ows:
(1) Use Fue1 Accessories Test Stand, 285304-1, to drive fue1 control
assemb1y at variable speeds and to provide instruments to measure quantities.
(2) Mate Fue1 Contro1 Speed Increaser Adapter, 284763-1-1, direct1y to

~D20001 drive pad of fue1 accessories test stand to provide drive output of test
stand with 1.5:1 speed increase.
(3) Insta11 Fuel Control Test Adapter, 285492-1-1, over mounting studs
of Speed Increaser Adapter, 284763-1-1.
(4) Provide faci1ity service consisting of c1ean, dry-air regu1ated to

50 +1 psig and fue1 (MIL-T-5624, Grade JP-4, JP-5 or MIL-F-7024A, type 11).
(5) Connect associated p1umbing and eqúipment as shown in figure 4-84.
(6) Check that input shaft rotates counterclockwise when viewed from
shaft end.
(7) Provide a test record sheet to maintain complete and accurate
records of alI test information.
b. Perform static Ieakage check as fo110ws:
(1) Position the fueI contro1 with the drive shaft in an upright
position.
4-234
NAVAIR 03-105-AB-52
FUEl ..
SUPPlY ... -----I
12
5
l
,....------l/....--_
18
t
12 1~ II
! l
OISCHARGE OIFFERENTIAl FUElOUT

CHARGE t
10
PRESSURE
AOJUSTMENT
GOVERNOR
AOJUSTMENT
8 '\
1 OVERBOARO _ _-'--H
ORAIN
AIR ..
SUPPlY ... -~~
LlMITER
ADJUSTMENT I /
1
9
CONTROl
AlR IN
PUMP
OISCHARGE
PRESSURE
Figure 4-84. Fuel ControI AssemhIy Test Setup
4-235
NAVAIR 03-l05-AB-52
~KEY TO FIGURE 4-84
1. FUEl REGULATOR VALVE 10. AIR REGULATOR VALVE

2. FILTER 11. DISCHARGE CHAMRER
3. O TO 60 PSIG GAGE 12. O TO 50 PSIG GAGE
4. ROTOMETER 13. 1. 3 TO 1. 8 PSIG CHECK VALVE
5. O TO 50 PSID 14. FUEl SHUTOFF VALVE
6. O TO 1000 PSIG GAGE 15. 0.0292 INCH DIAMETER ORIFICE
7. FUEl CONTROl ASSEMBlY 16. BYPASS VALVE
8. O TO 60 PSIG GAGE 17. GAGE SAVER
9. AIR REGULATOR VALVE 18. O TO 160 PSIG GAGE
(2) Close shutoff va1ve (14, figure 4-84).
(3) Adjsut fuel regu1ator va1ve (1) to obtain fue1 inlet pressure of
50 +1 paig as indicated on gage (8) for 6+1 minutes. Purge air from fue1 system.
(4) Adjust air regulator va1ve (9) to obtain air in1et pressure of
50 +1 paig aa indicated on gage (3) for 3 +1 minutes.
(5) There sha11 be no co1lection of fue1 in the drive shaft (77, 78,
figure 4-13, sheet 1), no 1eakage from drive shaft sea1 (67) and mating aurfaces.
(6) There sha11 be no fue1 or air leakage from overboard drain (63).
(7) Check that vent orifice on side of acce1eration 1imiter housing

(14) is not obstructed and ensure that air f10ws from orifice.
(8) Apply a detergent solution (Leak-Tec No. 277C, American Gas and
Chemica1 Co Inc, 511 East 72nd St, P.O. Drawer B, lenox Hi11 Station, New York, NY
10021, or equiva1ent) to alI are as where air pressure is contained. Air 1eakage
shall not be great enough to readily break bubbles.
(9) Check that there is no air leakage from around acceleration

limiter adjusting screw or mating surfaces.
,(10) Adjust air and fuel regulator va1ve (1, 9, figure 4-84) to obtain
a preaaure of zero on gages (3, 8).
NOTE
Care shou1d be exercised to ansure that there is no

axial load on the pump drive ahaft at any time and
that the pump tang or ap1ine ia properly engaged with
the drive stand.
(11) Insta11 fue1 control in test stand.
c. Perform operationa1 1eakage check as fol1ows:
4-236
• NAVAIR 03-l05-AB-52
(1) There shaII be no Ieakage from the input drive shaft (77, 78,
figure 4-13, sheet 1), input drive shaft seal (67), governor adjusting screw (33),
the acceleration Iimiter adjusting screw (11), any of the mating surfaces or the
overboard drain port during any of the following tests.
NOTE
Establ1sh input settings by approaching the setpoint

from the direction indicated unless othewise indicated
in the testing sequencej approach alI air pressure
settings from an incrasing pressure direction, speed
setpoints from an increasing speed direction except
governo r maximum fueI flow and hysteresis check pointo,
governor maximum fueI flow check points from a decreas-
ing speed direction, the governor hysteresis check
points as indicated in the appropriate paragraph, and
alI fuel pump disCharge pressure settings (fuel control
run-in) from an increasing pressure direction.
d. Perform fueI controI purging run as follows:
(1) Open fueI shutoff valve (14).
(2) Adjust fuel regulator valve (1, figure 4-84) to obtain fueI inlet
pressure of 20 +5 psig as indicated on gage (3).
(3) Observe rotometer (4) for air in fuel system. lf air remains in
rotometer for one minute, operate the fueI controI at 1500 +50 rpm untiI rotometer
shows no air in fueI system.
e. Perform run-in of fuel controI assembly as follows:
(1) Operate fueI controI in accordance with the following governor

set points:
Fuel ContraI
Fuel lnlet Air lnlet Discharge Operat1ng
Pressure Fuel Control Pressure Pressure Gage Time
Gage (1) rpm Gage (8) (6) Minutes
5 +1 1200 +100 26 +1 50 +10 5 +1

5 +1 2500 +100 26 +1 150 +20 3 +1
5 +1 4700 +100 26 +1 300 +50 3 +1
(2) Adjust fueI inlet pressure by adjusting fueI regulator valve (1)
to obtain fueI discharge pressure on gage (6). Adjust manual control valve (14) to
obtain air inlet pressure on gage (8). Adjust air regula to r valve (9) as required.
f. Adjust acceleration 11miter valve cracking pressure as fo1lows. Refer

to figure 4-84.
4-237
NAVAIR 03-105-AB-52 •
(1) Vent air supp1y in1et port to atmosphere and ensure that discharge
chamber (11) pressure is O psig on gage (12).
(2) Operate the unit at 1200 +25 rpm input speed.
(3) Adjust fue1 in1et pressure regu1ator va1ve (1) to 2.0 +1.0 psig as
indicated on gage (3, figure 4-84).
(4) C10se fue1 shutoff va1ve (14). Loosen nut on screw of 1imiter
adjustment (figure 4-81) and adjust acrew to obtain cracking pressure of 70 to 75
paig on gage (6). Bo1d screw and tighten nut on 1imiter adjustment.
NOTE
If the acce1eration 1imiter cr~cking pressure cannot

be adjusted within the 1imits of 70 to 75 psig, then
contro1 may have high internaI 1eakage or 10ss of
pump capacity. Determine cause and correct.
(5) Repeat steps (1) through (4) unti1 acce1eration 1imiter cracking
pressure is within 1imits of 70 to 75 psig.
(6) Reconnect air supp1y in1et port 1ine.
g. Adjust constant differentia1 pressure va1ve as fo11ows. Refer to figure

4-84.
(1) C10se bypass va1ve (16, figure 4-84) and open shutoff va1ve (14).
NOTE
Fee1 body of fue1 contro1 for heat bui1dup.
(2) Operate the unit at the fol10wing governor set points.
Input shaft speed: 5750 +2 rpm
In1et fue1 pressure: 2.0 +1 psig on gage (3)
Contro1 air preasure to 26 ±l psig on gage (8)

11miter va1ve and dis-
charge chamber:
(3) Loosen nut on screw of governor adjustment (figure 4-84) and

adjust acrew to obtain indication of 115 to 119 pph on rotometer (4). Hold screw
and torque nut to 20 to 25 inch-pounds.
4-238
•
NAVAIR 03-I05-AB-52
NOTE
Chang1ng the d1fferent1aI pressure changes the gover-

nor set point, maximum flow and minimum flow. lf the
d1fferent1aI pressure is changed after the flow condi-
tions are set, the flow conditions shaII be checked
and reset if required.
(4) Loosen nut on screw of differentiaI pressure adjustment (figure

4-84) and adjust screw to obtain indicat10n of 45 +5.0 ps1d on gage (5). Hold screw
and torque nut to 25 to 30 1nch-pounds.
(5) Operate fueI controI for 5 +1 minutes and repeat steps (1) through
(4) untiI different1aI pressure remains witbin limits specified.
h. Perform fueI controI limiter 11nearity check as follows:
(1) Adjust air inlet supply pressure to zero as indicated on gage (8).
(2) Adjust governor speed to 200 rpm below governor set point of 5750
rpm.
(3) Slowly increase air inlet supply pressure and observe 1ncrease in
fueI pressure on gage (6).
(4) Continue to sIowly incrase air inlet pressure and observe that
fueI pressure on gage (6) increases at a continuous rate without resetting.
(5) lf indicated fueI pressure on gage (6) resets, reject fueI controI
for 11m1ter seal rework.
1. Adjust fuel control maximum fuel flow as follows:
(1) Adjust regulator (9) to obta1n ind1cation of 50 +1 psig on gage
(8) and adjust regulator valve (10) to obtain indication of 26 +I-psig on gage (12).
(2) Adjust shaft speed to 5625 +5 rpm with 1nlet fuel pressure of 2 +1
ps1g.
(3) Observe fuel flow 1ndicat10n on rotometer (4). D1scont1nue test-
log and add shims (39, figure 4-13) to reduce flow, or remove shims to increase flow
if fuel flow indication on rotometer (4, figure 4-84) i8 not within 160 to 182 pph.
(4) Recheck and readjust maximum flow until indicat10n of 160 to 182
pph is obtained, and a minimum reading of 35 psid on gage (5).
j. Check governo r calibration by repeating paragraph g; recalibrate ff re-

qu1red.
k. Adjust fuel control minimum fuel flow as follows:
4-239
NAVAIR 03-I05-AB-52
(1) Operate unit at 5750 +2 rpm with inlet fuel pressure of 2 ±l psig,
inlet air pressure and discharge chamber pressure at 26 +l psig.
NOTE
lf differential pressure exceeds 58 psid on gage (5),

check for a flow restriction in passage from differen-
tial va1ve to inlet of pump.
(2) Increase input speed to 5850 +5 rpm and observe fueI flow on rotom-
eter (4). Fue1 f10w indication sha11 not exceed 70 pph on rotometer (4), and dif-
ferentia1 pressure sha11 not exceed 58 psid on gage (5).
(3) Change governor spring (37, figure 4-13, sheet 1) if fue1 f1aw
exceeds 70 pph.
(4) Repeat steps (l) through (4) unti1 differential pressure is less
than 58 psid on gage (5, figure 4-84).
1. Check governor hysteresis as fol10ws:
(1) Check decreasing speed hysteresis as fol10ws:
(a) Operate fue1 controI at pump speed 5750 +10 rpm, air in1et
pressure of 50 +1 on gage (5), discharge chamber pressure of 26 +1 psig on gage
(12) and fueI f10w of 117 +2 pph on gage (4). Record differential pressure from
gage (5).
(b) Decrease speed to 4700 +10 and record fuel flow from rotometer
(4) and differentia1 pressure from gage (5).
NOTE
During the fol10wing check do not overshoot speed of
5750 +10 rpm or fue1 f10w of 117 +2 pph or check
sbal1 be repeated.
(c) lncrease fue1 contro1 pump speed until fuel f10w is l17 +2
pph on gage (4). Record speed and differential pressure.
(d) Record difference in speed obtained in steps (a) and (c) as

governor decreasing speed hysteresis.
(e) Operate fue1 control at speeds recorded in steps (a) and (c);
differential pressure sha11 be repeatable within +10 rpm of recorded speed.
(2) Check increasing speed hysteresis as follaws:
(a) Operate fuel control at pump speed of 5750 +10 rpm, air inlet
pressure of 50 +1 ou gage (5), discharge chamber pressure of 26 +1 psig on gage
(12) and fue1 f10w of 117 +2 pph on gage (4). Record differentiaI pressure from
gage (5).
4-240
1
NAVAIR 03-l05-AB-52
(b) Decrease speed to 5800 +10 and record fuel flow from rotometer
(4) and differential pressure form gage (5).
NOTE
, During the following check do not overshoot speed of

5750 +10 rpm or fuel flow of 117 +2 pph or check shall
be repeated.
(c) Increase fuel control pump speed untl1 fuel flow is 117 +2
pph on gage (4). Record speed and differential pressure.
(d) Record difference in speed obtained in steps (a) and (c) as
governor increasing speed hysteresis.
(e) Operate fuel control at speeds recorded in steps (a) and (c);
differential pressure shall be repeatable within +10 rpm of recorded speed.
m. Recheck acceleration limiter valve setting in accordance with paragraph

f.
(I) Lockwire as follows:
(a) Lockwire screw (51), nut (49) and one screw (28) together and
seal.
(b) Tighten nut (26) and screw (28) to a torque va1ue of 20 to 25
inch-pounds and lockwire nut (26) and one screw (28) together and seal.
(c) Lockwire remaining two screws (28) together.
(d) Lockw1re plug (2), bolt (3), nut (6) and screws (8).
Verify proper and complete lockwiring.

n. Refer to table 4-9 if fuel control cannot be adjusted to perform within
1imits.
NOTE
Use combined starter systems schematic (figure 2-4) to

supplement troubleshooting table 4-9.
o. Preserve fuel control assembly as follows.
(1) Disconnect a11 fuel and air 1ines.

(2) Connect suitable drain 1ine to fuel out connection (figure 4-84).
4-241
Tab1e 4-9. Troubleshooting for Fue1 Contro1 Assembly
t
I\) ~
~
I\) ~
Sympton Cause Method of Detection Corrective Action !;d
o
'f
f-I
Fuel 1eaks from housing Damaged packings. Inspect packings (71, Replace packings (71, 72, o
V1
~I
(70, figure 4-13, sheet 72, 73, 74, sheet 1). 73, 74).
1) to body (97, sheet
2) f1ange. V1
I\)
Fue1 leaks from around Damaged packings. Inspect packing (62) Rep1ace app1icab1e pack-
union (63) or p1ug (2). or (1). ing (62) or (1).
Fue1 1eaks from around Damaged packings. Inspect packings (31) Replace applicable pack-
adjustment screws (33) or (50). ing (31) or (50).
or (51).
Fuel 1eaks from accel- Ruptured air and Inspect diaphragm (24). Rep1ace air and fuel
eration 1imiter valve fuel diaphragm (24). diaphragm (24).
air vento
Fue1 leaks from dia- Damaged spacer (20), Inspect suspected parts Replace parts as re-
phragm spacer (20) to spacer (21), diaphragm for defects. quired.
body (97) flange. (24) or body (97,
sheet 2).
Fuel leaks from cover Damaged packing. Inspect packing (34). Rep1ace packing (34).
(36, sheet 1) to body
(97, sheet 2) flange.
Fue1 1eaks from around Loose p1ug. Inspect plug for security. Tighten plug to specified
p1ug (52, sheet 1). torque.
.,
- -
Tab1e 4-9. Troub1eshooting for Fue1 Contro1 Assemb1y (Cont)
-
Symptom Cause Method of Detection Corrective Action
Fue1 1eaks from around Damaged threads. Inspect p1ug (52) and Rep1ace p1ug (52, sheet
p1ug (52, sheet 1). body (97, sheet 2) for 1) or body (7, sheet 2)
(Cont) peened, crossed, strip- as required.
ped or worn threads.
Fue1 1eaks from inside Loose p1ug (77). Inspect p1ug (77) for Rep1ace p1ug (77).
of shaft (78). security.
Fue1 1eaks around Defective sea1s Inspect sea1s (67, 69). Rep1ace sea1s (67, 69).
shaft (78). (67, 69).
Air 1eaks between bo1t Defective gasket. Inspect gaskets (4). Rep1ace gaskets (4).
(3) and fitting (5) or
between fitting (5)
and housing (14).
Air 1eaks around Damaged packing. Inspect packing (10). Rep1ace packing (10).
adjustment screw (11).
Air 1eaks from hous- Damaged diaphragm Inspect diaphragm assem- Rep1ace diaphragm assem-
ing (14) to body (97, assemb1y (17, 18, b1y for damage and pro- b1y.
sheet 2) f1ange. 19, sheet 1). per pinch fito ~>
,.,
H
Acce1eration 1imiter Worn or damaged parts Disassemb1e and inspect Repair or rep1ace parts o
W
cannot be adjusted in acce1eration acce1eration 1imiter as required by inspec- .....I
to 1imits. 1imiter section. section. tion. o
VI
.p.
N
I $
VI
~ N
.co- Table 4-9. Troubleshooting for Fuel Control Assembly (Cont)
I
~
N
.co-
.co-
>
Symptom Cause Method of Detection Corrective Action ~
ow
~
Constant differential Worn or damaged parts Disassemble and inspect Repair or replace parts '.
v.
pressure valve cannot in constant differen- constant differential as required by inspec-
be adjusted within tial pressure section. pressure section. tion. ~
I
limits or operates ~'l
N
erratically.
Maximum fuel flow is Constant differential Check constant differ- Adjust constant differ-
low and cannot be ad- pressure valve is not ential pressure. Refer ential pressure valve in
justed to conform to operating within to paragraph 4-678, step accordance with paragraph
minimum limit. limits. g. 4-673, step g.
Pump gears (79, 81) Check for binding shaft Adjust fuel control as-
are being held away (78) at test stand sembly mounting flange on
from bearings (76) by drive adapter. test stand.
axial load on shaft
(7M).
Worn or damaged parts Disassemble and inspect Repair or replace worn or
in fuel pump section. fuel pump section. damaged parts, or free
bearings.
Worn or damaged parts Disassemble and inspect Repair or replace worn or

in governor section. governor section. damaged parts.
Minimum fuel flow Worn or damaged parts Disassemble and inspect Repair or replace damaged
cannot be adjusted to in governo r section. governor section. or worn parts.
conform to limits.
Governor hysteresis Worn or damaged parts Disassemble and inspect Repair or replace damaged
exceed maximum limits. in governor section. governor section. or worn parts.
- -
NAVAIR 03-105-AB-52
(3) Supp1y lubricating oi1 (MIL-L-608l, grade 1010) to fue1 inlet con-
nection.
, hose.
(4)
(5)
Drive assemb1y at 200 to 500 rpm until c1ear oi1 f10ws from drain
Remove fue1 control from test stand.
(6) Drain alI oi1 from assembly and cover alI openings and fittings.
4-679. ASSEMBLY OF SWITca ACTUATING GOVERNOR ASSEMBLY (cutoff).
4-680. Assemb1e switch actuating governor assemb1y as fo110ws: Refer to figure

4-12.
a. Se1ect washers (2) as required to center f1yweights (3) within 0.005-

inch and to provide 0.003 to 0.008-inch end f10at.
b. Insta11 spring (6), trial amount of shims (5), and governar pin (4) into
governo r body (7, 8).
c. Insta11 f1yweights (3) with tangs engaged in groove of governor pino

Insta11 washers (2) and pins (1).
d. C1amp vertical sides of Governor Staking Too1, 289046-1, in a standard

bench vise. Raise hand1e of staking too1 and position governor in slot of 10cating
block between anvi1s. Pu11 staking too1 hand1e down unti1 contact is made between
anvi1s and both sides of governo r body. Check a1ignment of too1 to governor body.
Stake pins (1) simu1taneous1y in alI four p1aces by exerting slight, additiona1
downward pressure on too1 hand1e.
4-681. Test switch actuating governor assemb1y as fo110ws: Refer to figure 4-12.
a. Provide test equipment as f0110ws:

(1) Use Speed Sensor Ca1ibration, 281007, to rotate governor at opera-
ting speeds and provide visual indication of governor actuation speed.
(2) Use Governor Ca1ibration Adapter, 281157, to mate governor assemb1y

to Speed Sensor Ca1ibration 281007.
(3) Use Governor Ca1ibrator Switch, 281159, to interconnect Speed

Sensor Ca1ibrator, 281007, to e1ectronic counter.
(4) Use Electronic Counter (Hew1ett Packard Mode1 5214 or equiva1ent)

to indicate speed of sensor ca1ibrator output sbaft.
b. Prepare governor assemb1y for testing as f0110ws:
(1) Attach Governor Ca1ibrator Adapter, 281157, to output shaft of

Ca1ibrator, 281007.
4-245
NAVAIR 03-105-AB-52
(2) Remove cap of Adapter, 281157, and thread governor assemb1y into
capo Reinsta11 cap with governor attached, into adapter.
(3) Attach Governor Ca1ibrator Switch, 281159, to upright support of

Ca1ibrator, 281007. Insta11 upright support on calibrator with switch plunger •
aligned with governor pin (4). ,
c. Rotate governor assembly increasing speed until weights throw out actu-
ating governor calibrator switch. Check electronic counter for indication of 3100
to 3300 rpm. Add or remove washers (5) as required to adjust throwout speed within
limits.
Verify governor assembly throwout speed.
4-682. ASSEMBLY OF SENSITIVE SWITCH ASSEMBLY.
4-683. Assemb1e power turbine assembly sensitive switch assembly as follows:

a. Insta11 packing (11) into groove of housing (13).
b. Insta11 lead assemb1y (7, 8, 9) into housing (13).
c. Position switches by insta11ing washers (6) as required between switches

(7) and housing (13). Insta11 pins (5) to retain washers (6) and switches (7).
d. Install screws (4) to secure e1ectrica1 connector of lead assemb1y (7,

8, 9).
e. Shim both s1des of lever (3) with washers (2) to estab11sh total 1ever
end play within 0.005 to 0.030 incho
f. Instal1 pin (1) to retain washers (2) and lever (3).
g. Check assemb1y for binding by manua11y actuating switches.
h. Center pins (1, 5) in housing (13) and stake each pin hole, both ends,
in four p1aces per ho1e or deform edges of ho1es to""ietain pins.
i. Fil1 each end of alI pin ho1es, approximately f1ush, with potting com~
pound (203 Epoxylite and Cata1yst No. 1, Epoxylite Corp, 1428 Santa Anita Ave, P.O.
Box 3397, South EI Monte, CA 91733).
a. Check 1ever and switches for freedom of operation.
b. Check switches for continuity between pins A-B and

E-F at connector (8).
4-246
-{
NAVAIR 03-105-AB-52
MAINTENANCE ASSURANCE (CONT)
c. Check that circuits C-B and D-F are open.
d. Actuate switch and check for reversa1 of operation.

4-684. ASSEMBLY OF ACCUMULATOR ASSEMBLY.
4-685. Assemb1e accumu1ator assemb1y as fo11ows: Refer to figure 4-10.
a. Insta11 packings (12, 13) on accumulator hydrau1ic piston (14) and in-
sta11 assemb1ed parts (12, 13,14) in accumulator cap (15).
b. Insta11 packings (7, 8) on accumulator fue1 piston (9).

c. Insta11 compression he1ical spring (10) and assemb1ed accumu1ator fue1
piston (7, 8, 9) in accumu1ator housing (11).
Verify complete and proper assemb1y of internaI parts.
d. Thread accumu1ator cap (15) on accumu1ator housing (11) and tighten.

e. Insta1l packing (5) on b1eed plug (6), and insta11 assembled b1eed p1ugs
(5, 6) in accumulator cap (15).
f. Insta11 packing (3) on union (4) and insta11 assemb1ed union (3, 4) in
accumu1ator cap (15).
g. Insta11 packing (1) on union (2) and installed unions (1, 2) in accu-
mu1ator cap (15).
4-686. ASSEMBLY OF JFS CONTROL BOX ASSEMBLY.
4-687. Assemb1e JFS contro1 box assemb1y as fo11ows: Refer to figure 4-9.
a. Assemb1e re1ay (9, sheet 1) to sensor assemb1y (13) as fo11ows:
(1) Insta11 washers (12) over mounting studs on relay (9).
(2) Assemb1e relay (9) to sensor assemb1y (13).
(3) Secure re1ay (9) to sensor assemb1y (13) with washers (11) and nuts
(10).
b. Assemb1e transistor (44, &heet 2) to heat sink (45) as fo11ows:
(1) Assemb1e insu1ator (41) and transistor (44) on heat sink (45).
(2) Insta11 washers (42) and screws (43).
4-247
NAVAIR 03-l05-AB-52
(3) Fit insulator (40) around shanks of screws (43) and within holes in
heat sink (45).
(4) Insta1l washers (39, 38) and terminal (37).
(5) Coat threads of screws (43) with 1ubricant (Parker Sealube, Parker f
Seal Co, 10567 Jefferson Blvd, Culver City, CA 96231) and install nuts (36).
NOTE

accordance with NAVAIR 01-lA-50S.
c. Solder wires to terminaIs using solder Sn60, per QQ-S-S7l, and as

fol10ws: Refer to figure 4-8S.
NOTE
Wire leads sbal1 be soldered to the terminaIs of

transistor (44) so that they are be10w the ends
of the terminaIs.
(1) Solàer wires to transistor (44, figure 4-9) and trim wire ends
below level of heat sink (4S).
(2) Install insulating sleeving (25, sheet 1) over wires for indicator
(26). Solder wires to indicator (26) including jumper, and slide sleeving (25)
over soldered terminals.
(3) Solder wires to connectors Jl, J2 and J3.
d. Assemble parts into box (50, sheet 2) as follows:
(1) App1y 1-1/2 inches of tape (A2008, Connecticut Hard Rubber Co,
407 Esst St, New Haven, CT 06509) to bottom of box directly under normal position
of transistor (44).
(2) Place assembled parts (36 through 45) inside of box (50). Align
holes in heat sink (45) with mounting holes in box (50) and, secure heat sink to
box with washers (35, 34) and screws (33).
(3) Insta11 connectors (30, 31, 32) in box (50) and se cure with nuts
(30, 31, 32) respect1ve1y.
(4) Insta11 fuseholders (29) in box (50) and se cure with fuseholder
nuts (29).
(5) Insta11 fuses (28) in fuseholders (29) and secure with fuseholder
caps.
4-248
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1 2345678 9 10 11 12 13 14 15 17 ~ J K
17(TBI-5)
12C(TB1-1)
18(TBl-4)
J3
A
8
C
TBl Kl-1 13B(Kl-l) D
16(TBI-15) F
26(TB2-12) E
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JI .1 3B(TB1-10)~
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J 2O(TBI-17)--oE ~ E
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DETAIL B
8 L
TB2 M
1 234 7 8 9 10 11 12 13 14 15 N
FI , O O O O O O O O O
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112341
OVERSPEEO
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DETAIL 8 INDICATOR COUNTER

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DETAIL A
TEMPERATURE
SENSOR TB2
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VI
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N
Figure 4-85. JFS Control Box Assembly Wiring Diagram

NAVAIR 03-105-AB-52
(6) Instal1 indicator (26, sheet 1) in box (50, sheet 2) and secure
with indicator nut. Sea1 around indicator with Loctite 49 Sealant (Loctite Corp,
Newington, CT).
(7) Coat probe of sensor (24, sheet 1) ~~th grease (DC4, Dow Corning t
Crop, ~tldland, MI 48640). Insta1l sensor (24) to ful1 depth of hole in bottom of
box (50, sheet 2). Pot end of sensor wires to bottom of box (50) with 203 Epoxylite
adhesive and 1 Epoxylite Activator (Epoxylite Corp, El Monte, CA).
(8) Route wires along bottom of box (50).
(9) Attach terminals (27) to fuse wires using standard crimping tool.
Connect terminals to fuseholders (29) with fuseholder terminal nuts and screws.
e. Connect wires as follows. Refer to figure 4-85. Solder using Sn60,

per QQ-S-57L
(1) Connect wires to terminal boards TBl and TB2.
(2) Connect wires to relays Kl and K2.
a. Check terminal board and relay wires for proper

routing in accordance with figure 4-85.
b. Check that soldered connections conform to re-

quirements of NAVAIR 01-lA-505.
(3) Insta1l grommet (23, figure 4-9, sheet 1). Insert counter wires
through grommet (23), and slide mount (21) over wires. Connect wires to counter
(22).
a. Check counter wires for proper routing in accord-

ance with figure 4-85.
b. Check that soldered connections conform to re-
quirements of NAVAIR 01-lA-505.
f. Assemb1e counter (22, figure 4-9) into box (50, sheet 2) as follows:
(1) Fit mounts (20, 21, sheet 1) over counter (22).
(2) Install counter (22) with mounts (20, 21) into box (50, sheet 2).
(3) Install plate (17, sheet 1) and plate assemb1y (18, 19) and secure
and seal with washers (16, 15) and screws (14).
g. Secure senso r assembly (13) into box (50, sheet 2) with screws (8,
sheet 1).
4-250
NAVAIR 03-l05AB-52
h. Test JFS control box assembly in accordance with paragraph 4-688.
i. Install cover assembly (6, 7) on box (50, sheet 2) and secure with
washers (5, sheet 1) terminal (4), washers (3), and screws (2). Lockwire nut of
, connector (32) to terminal (4).
NOTE
Terminal (4) shall be on top of washer (5).
j. Paini exterior surfaces as fol1ows:

CAUTION
Do not exceed 200°F when curing primer or paint.
(1) Mask connectors (30, 31, 32, sheet 2), fuseholders (29), indicator
(26, sheet 1) front face of counter (22) and 5/8 inch diameter area around hole in
bracket of box (50, sheet 2).
(2) App1y one coat of primer, MIL-C-85l4, and cure for one to four
hours.
(3) Apply one 0.04 to 0.08 inch coat of primer, MIL-P-23377.
(4) Apply one cover coat of epoxy polyamide, MIL-C-22750B, Color 37038,
air-dry for eight haurs.
k. Ink stamp identification as shown in figure 4-86 with Nycote 7-11
(Nycote Laboratories, 15002 De1ano, Van Nuys, CA 91401).
(1) Insta11 identification plate in accordance with paragraph 4-671.
4-688. Test JFS control box assembly as follows:
4-689. Prepare Control Box Tester 289680-1 for use as fo1lows:

a. Open tester and remove cab1e assemblies as fol1ows:
(I) Unlatcn and open 1id of tester case.
(2) Open inner lid and remove Cable Assemblies 292355-1, and 282223-2.
b. Connect instrumentation to tester as follows: See figure 4-87.
(1) Connect frequency counter (Hewlett Packard Model 3734A, or equiv-

alent) to 115 VAC posta on tester.
(2) Connect digital voltmeter (Hewlett Packard MOdel 240lC, or equiv-

alent) to TEMP OUT posta on teater.
Change 1 4-251
NAVAIR 03-105-AB-52
A A
L ______ .-J
OVERSPEED
©
VIEW A-A
F-12A-621
Figure 4-86. JFS Control Box Assembly Identification Markings
4-252
ON
ti
Q) Q)
D.C. POWER IN
TEST CABLE
~
~~ OFF
~1i15V®
~
f.})
@e® @ f0i
~
~.C.O OLT O
FUEL FUEL PMG CUST D.C. NO FAULT
SOL DRAIN
NORM
~~
OFF
ON
6@~~~@~
~~~
OFF OELAY-@
JFS 50 PERCENT F=&~~ DELAY~r~~TURE T.P.
ABORT
~
Figure 4-87. Control Box Tester Control Panel
(3) Connect time interval counter (Hewlett Packard Model 3734A, or

equivalent) to tester as follows:
(a) Connect GRD lead of counter to -DC volts post on tester.
(b) Connect STOP PULSE lead of counter to DELAY T.P. post on

tester.
(c) Connect START PULSE lead of counter to +DC VOLTS post on
tester.
c. Check temperature simulate circuit for calibration as follows:
(1) Measure ambient temperature (OF) at TEMP OUT posts of tester.
(2) Calculate TEMPERATURE SIMULATE dial setting by subtracting 32°'

from the ambient temperature obtained in step (1), and.add 19000F to the remainder.
4-253
NAVAIR 03-l05-AB-52
EXAMPLE
Ambient temperature 78°F

Subtract 32°F - 32°F
Remainder 46°F
Add 1900°F to remainder 1900°F
Equals TEMPERATURE SIMULATE DIAL 1946°F
setting for ambient temperature of 78°F.
NOTE
When reading the TEMPERATURE SIMULATE dial, add 1000°F

to the actual dial indicatlon. This is to account for
a 1000°F constant not indicated by the dial. For
examp1e, when setting a temperature indication of
1946°F, set the dia1 to read 946°F.
(3) Set TEMPERATURE simulate dia1 to setting obtained in step (2).
(4) Position D.C. POWER switch to on.
(5) Observe indication on digital voltmeter.
NOTE
Calibrate and/or troubleshoot temperature simu1ate

circuit in accordance with NAVAIR l7-l5AB-5 if volt-
age indication is not within 42.78 +0.04 mv.
(6) Disconnect leads of digital voltmeter from TEMP OUT posts of

tester.
(7) Position D.C. POWER switch to OFF.
d. Position ABORT switch to NORM, all other switches to OFF and counter
dials to O.
e. Connect cables to tester as follows:
(l) Connect Cab1e Assembly 292355-1 to TEST CABLE connector.
(2) Connect Cable Assembly 282223-2 to DC POWER in connector.
f. Connect tester to variable O to 30 vdc power supply as follows:
(1) Set power supply to O volts.
(2) Connect Cable Assembly, Part No. 282223-2 variab1e O to 30 vdc

power supp1y.
g. Connect Cab1e Assemb1y, Part No. 292355-1, to connectors Jl, J2 and J3

of JFS control box assembly.
4-254
NAVAIR 03-105-AB-52
4-690. Perform fault relay trip point test as fo11ows:
a. Position D.C. POWER switch to ON.
b. S1ow1y increase power supply voltage unti1 FUEL SOL, FUEL DRAIN, IGN
and NO FAULT lights il1uminate.
c. Observe vo1tage on VOLTS DC meter. Voltage sha11 indicate 7 +1 vdc.

4-691. Perform temperature setpoint test as fo11ows:
a. lncrease power supply voltage to 24 +0.5 vdc.
b. lncrease TEMPERATURE SIMULATE dial until NO FAULT, FUEL SOL and FUEL
drain lights latch off.
c. Observe indication on TEMPERATURE SIMULATE dia!. lndication sbal1 be

within 1862 to 1938°F.
d. Decrease TEMPERATURE SIMULATE dial to minimum.
e. Cycle DC POWER switch, OFF anel then ON.
f. Decrease power supply voltage to 8.0 to 8.5 vdc.
g. S1ow1y increase TEMPERATURE SIMULATE dial untU NO FAULT, FUEL SOL and
FUEL DRAIN 1ights 1atch OFF.
h. Observe indication on TEMPERATURE SIMULATE d1al. lndication shall be
within 1862 to 1938°F.
i. Position TEMPERATURE SIMULATE dial to indicate below 1500°F.
j. Cycle DC POWER switch, OFF and then ON.

k. Increase power supp1y vo1tage to 24 vdc, and observe that FUEL SOL,
FUEL DRAIN, and NO.FAULT 1ights il1uminate, test unit OVERSPEED indicator sha1l
indicate white.
4-692. Perform overspeed setpoint and overspeed indicator test as follows:

a. Slow1y increase indication on FREQUENCY SIMULATE dia1 until IGN light
extinguishes and PMG and CUST DC lights il1uminate.
b. Ovserve indication on frequency counter. Indication sbal1 be within
360 to 380 Hz.
c. Continue to increase indicator on FREQUENCY SIMULATE dial until FUEL

SOL, FUEL DRAlN, and NO FAULT lights latch OFF. Observe indication on frequency
counter. lndication sbal1 be within 435 to 439 Hz. Test unit OVERSPEED indicator
sba11 indicate rede
4-255
NAVAIR 03-105-AB-52
d. Slow1y de~rease indication on FREQUENCY SIMULATE dia1 unti1 IGN 1ight

il1uminates, and PMG and CUST DC lights extinguish. Observe indication on frequency
counter. Indication shall be within 360 to 380 Hz.
e. Cycle DC POWER switch, OFF and then to ON, and observe that FUEL SOL,
FUEL DRAIN, IGN and NO FAULT 1ights il1uminate. Test unit OVERSPEED indicator sha1! ~
indicate white.
4-693. Perform start counter test as fo11ows:
a. Observe start counter on test unit and position 50 percent switch to ON

and then to OFF.
b. Test unit start counter sball advance one count.
4-694. Perform primary cutout switch test as fo11ows:
a. Position PRIMARY CUTOUT switch to ON, and observe that FUEL SOL, FGEL
DRAIN, and NO FAULT 1ights 1atch OFF.
b. Cycle DC POWER switch, OFF and then ON, and observe that FUEL SOL, FUEL
DRAIN, and NO FAULT 1ights remain off.
c. Position PRIMARY CUTOUT switch to OFF. Cyc1e DC POWER switch, OFF and
then ON, and observe that FUEL SOL, FUEL DRAIN and NO FAULT 1ights i11uminate.
d. Slow1y decrease power supply voltage and observe that FUEL SOL, FUEL
DRAIN and NO FAULT 1ights go off at 7 +1 vdc.
4-695. Perform de1ay circuit response test as fo1lows:
a. Set FREQUENCY SIMULATE, DELAY, and TEMPERATURE SIMULATE dials to

minimum.
b. Position DC POWER switch to OFF.
c. Estab1ish power supply vo1tage at 8.0 to 8.5 vdc.
d. Measure temperature of TEMP OUT probe housing within +O.5°F.
e. Locate temperature measured in step d. in temperature co1umn of tab1e

4-10. Set DELAY dial to indicate setting shown in no de1ay column for that tem-
perature.
f. Position DC POWER switch to ON, and observe that FUEL SOL, FUEL DRAIN,
IGN and NO FAULT lights i1luminate immediately.
g. Position DC POWER switch to OFF.
h. Locate temperature measured in step d. in temperature column of table

4-10. Set DELAY dial to indicate s~tting shown in de1ay column for that temperature.
4-256
• NAVAIR 03-105-AB-52
Tab1e 4-10. De1ay Circu1t Response Settings
Temperature No Temperature No
(OF) De1ay De1ay (OF) De1ay De1ay
67 317 808 79 147 205
68 290 648 80 141 194
69 266 542 81 136 184
70 246 466 82 131 175

71 229 409 83 126 167
72 215 364 84 122 159
73 202 329 85 117 153
74 191 300 86 113 147

75 177 268 87 110 141
76 169 249 88 107 136
77 161 232 89 104 131
78 154 218 90 101 127
1. Pos1t1on DC POWER switch to ON, and observe tbat IGN 11ght 1l1uminates
fmmed1ate1y, and that 111uminat1on of FUEL SOL, FUEL DRAIN and NO FAULT 11ghts 1s
de1ayed. De1ay time sba11 be 1 +0.2 seconds.
4-696. Perform trans1ent operat1on test as follows:

a. Reduce power supp1y vo1tage to O vdc.
b. Increase power supp1y vo1tage to 30 vdc at rate of approximate1y 10
vdc/sec.
c. Observe ind1cator on DC VOLTS meter as FUEL SOL, FUEL DRAIN, IGN and
NO FAULT 1ights i11uminate. Lights sba11 i11uminate at 7 +1 vdc and remain on
throughout remainder of range.
d. Decrease power supp1y v01tage to O volts.
4-257
NAVAIR 03-l05-AB-52
4-697. Refer to table 4-11 if JFS control box assembly fails to function within
limits. See figure 2-2 for electrical schematic.
4-698. Disconnect tester from JFS control box assembly as follows:
a. Position alI tester switches to OFF and counter dials to O.
b. Decrease power supply voltage to O volts.
c. Disconnect Cable Assembly, 292355-1, from JFS control box assembly

connectors Jl, J2 and J3.
4-699. ASSEMBLY OF AC-DC PERMANENT MAGNET GENERATOR.
4-700. Assemble ac-dc permanent magnet generator as follows: Refer to figure 4-8.
a. Press bearings (17, 24) onto shaft of rotor assembly (25).
b. Install rotor assembly (25), with bearings (17, 24), in housing assembly
(20 through 23).
c. Install end bel1 assembly (35, 36) on housing assembly (20 through 23)
and secure with screws (6).
d. Check end play of rotor assembly (25) shaft in housing assembly (20
through 23) and end bell assembly (35, 36); determine the selection of washers (18)
as required to obtain end p1ay of 0.005 to 0.008 incho
e. Remove end be1l assemb1y (35, 36) and rotor assembly (25), with bearings
(17, 24), from housing assemb1y (20 through 23).
f. Apply grease (BEACON 325, Exxon Co, P.O. Box 2180, Houston, TX 77001,
or equivalent; no known Government specification) sparingly to lip of seal (19);
press sea1 to shou1der in housing assembly (20 through 23).
g. Instal1 washers (18), selected in step d, to obtain end play of 0.005

to 0.008 inch, and rotor assembly (25), with bearings (17, 24), in housing assembly
(20 through 23).
h. Use washers (28) as required to obtaia.an air gap of 0.028 inch between
stator aS8embly (27) and rotor assembly (25). Install washers (28) and stator
assembly (27) on end bel I assembly (35, 36), guiding stator assembIy Ieads through
slot in end bel1 assembly. Secure stator assembIy with screws (26).
i. Instal1 housing assembly (20 through 23), with rotor assembly (25), on
end bell assembly (35, 36) and se cure with screws (16).
j. With generator assembled thU6 far, check for correct air gap between
stator assembly (27) and rotor assembly (25), by driving generator at 5970 to 6030
rpm (199 to 201 Hz); voltage across stator assembly red and green leads must be 61
to 65 vac. Adjust selection of washers (28), as required, to obtain results
specified.
4-258
-
AO,
Table 4-11. Troubleshooting Table for JFS Control Box Assembly
Test/Symptom Cause Method of Detection Corrective Action
Fault Relay Trip Point Test.
1. Indication on De Defective start Inspect sensor in Repair sensor in accor-

VOLTS meter is not cycle protection accordance with in- dance with instructions
within limits when sensor. structions in para- in paragraph 4-587Ao
fault relay trips. graph 4-295A.
2. FUEL DRAIN and NO Defective circuit. (1) Check continuity Repair defective circuito
PAULT Iights fail from Kl-2 to J2-L.
to illuminate. AlI
other indications (2) Check continuity Repair defective circuito
are normal. from J2-D to J2-M.
3. FUEL SOL and NO Defective circuit. (1) Check continuity Repair defective circuito
FAULT Iights fail from KI-2 to J2-J.
to illum:lnate. AlI
other indications (2) Check continuity Repair defective circuito
are normal. from J2-D to J2-K.
4. IGN, FUEL SOL, FUEL Defective circuit. . Check continuity from Repair defective circuito
DRAIN and NO FAULT JI-C to J2-H and J3-B.
lights fail to
iIluminate. DC
POWER light iIIu-
minates and DC VOLTS
9 meter indicates
~
OQ
voltage. ~
>
(1)
~
r-a o
~
....
o
tN ~I
1.11
1.11 N
\O
t Tab1e 4-11. Troub1eshooting Tab1e for JFS Contro1 Box Assembly (Cont)
z
N ~
C\
o >
~
Test/Symptom Cause Method of Detection Corrective Action o
n
....'f
o
::r VI
§ yault Relay Trip Point Test (Cont)
OQ
I'D
~
VI
..... 5. DC POWER 1ight i11u- a• Defective fuse F2. Check fuse. Rep1ace defective fuse. N
minates. DC VOLTS
meter fai1s to in- b. Defective circuit. (1) Check continuity Repair defective circuit.
dicate. AlI other from J2-C to JI-E.
indicator lights
fai1 to i11uminate. (2) Check continuity Repair defcctive circuit.
from J2-D to JI-J.
6. IGN and NO FAULT a. Defective K2 Check continuity from Rep1ace defective relay.
1ights fail to i11u- relay. K2-4 to K2- 5.
minate. AlI other
indications are b. Dcfective circuit. (1) Check continuity Repair defective circuit.
normal. from JI-C to J2-H.
(2) Check continuity Repair defcctivc circuit.

from J2-D to J2-N.
7. FUEL SOL, FUEL DRAIN a. Defective circuit. (1) Check continuity Repair defectivc circuit.
and 1-10. FAULT lights from JI-C to J3-B.
fail to il1uminate.
AlI other indications (2) Check continuity Repair defcctive circuit.
are normal. from J3-D to Kl-1.
(3) Check continuity Rcpair dcfcctivc circuit.

from Kl-2 to J2-J
and J2-L.
Tempcrature Sctpoint Tcst
1. Temperature sctpoint Defcctive start cycle AddLtional iso1ntion i6 Repa1r sensor in accor-
is not withih limits. protection sensor. not rcquircd. dance with tnstructions
in paragrnph /4-.587A.
"
- -
-
Table 4-11. Troubleshooting Table for JFS ControI Box Assembly (Cont)
.
Temperature Setpoint Test (Cont)
2. NO FAULT, FUEL SOL Defective sensor. lnspect sensor in Repair sensor in accor-
and FUEL DRAlN accordance with in- dance with instructions
Iights faiI to structions in para- in paragraph 4-587A.
Iatch off. graph 4-295A.
Overspeed Setpoint and Overspeed Indicator Test.
1. Frequency is not Defective start cycle lnspect sensor in Repair sensor in accor-
within Iimits when protection sensor. accordance with in- dance with instructions
PMG and CUST DC structions in para- in paragraph 4-587A.
Iights illuminate graph 4-295A.
and lGN ligh t goes
out.
2. PMG Iight fails to a. Defective fuse Check fuse. Replace defective fuse.
ilIum1nate. AlI FI.
other conditions
normal. b. Defective circuit. (I) Check continuity Repair defective circuit.
from JI-K to K2-6.
(2) Check continuity Repair defective circuit.

from K2-7 to FI-I.
(3) Check continuity Repair defective circuit.

9
11.) from FI-2 to J2-A. ~
~ c. Defective K2 Perform continuity checks lf circuits check ok, re- ~
l:=d
I-' relay. of circuits. place K2 relay. o
~
~
o
Vt
tN ~Vt
....
0\
N
r- Table 4-11. Troubleshooting Table for JFS Control Box Assembly (Cont) ~
~
I'-.)
0\
I'-.)
~
Test/Symptom Cause Method of Detection Corrective Action o
~
~
o
9
!
(l)
Overspeed Setpoint and Overspeed Indicator Test (Cont)
~
Vt
~
3. Frequency is not Defective start cycle Inspect sensor in Repair sensor in accor- I'-.)
within limits when protection sensor. accordance with in- dance with instructions
FUEL SOL, FUEL structions in para- with paragraph 4-587A.
DRAIN, and NO FAULT graph 4-29~A.
lights latch off
and indicator shows
rede
4. Indicator fails to a. Defective dircuit. (1) Check continuity Repair defective circuit.
show red during from TBI-12 to
overspeed simula- terminal I of in-
tion. AlI other dicator.
indications are
normal. (2) Check continuity from Repair defective circuit.
terminal 2 of indi-
cator to J2-D.
b. Defective indi- Perform continuity check of If circuits indicate ok,

cator. indicator circuits. replace indicator.
5. Indicator fails to Defective circuit. Check continuity from ter- Repair defective circuit.
reset to white minal 4 of indicator to
when test is ter- Kl-2.
minated.
Defective indicator. Check continuity of indi- If circuits check ok,
cator circuits. replace indicator.
Start Counter Test.
Electrical counter a. Defective circuit. Check continuity of cir- Repair defective circuit.
fails to advance one cuits between electrical
count. counter and J2-E and J2-D.
.
- -
-
Table 4-11. Troubleshooting Table for JFS Control Box Assembly (Cont) li
Start Counter Test (Cont)
Electrical counter b. Defective elec- Check continuity of If·· circuits check ok,
fails to advance one trical counter. counter circuits. replace counter.
count. (Cont)
primary Cutout Switch Test.
FUEL SOL, FUEL DRAIN a. Defective circuit. Check continuity from Repair circuits as
an~ NO FAULT lights J3-F to TBl-15. required.
fail to latch off.
b. Defective start Inspect sensor in accor- Repair sensor in accor-
cycle protection dance with instructions dance with instructions
sensor. in paragraph 4-295A. in paragraph 4-587A.
DeIay Circuit Response Test.
Delay circuit fai1s a. Defective tem- Check temperature sensor. Replace temperature
to respond within perature sensor. sensor.
limits.
b. Defective start Inspect sensor in accor- Repair sensor in accor-
cycle protection dance with instructions dance with instructions
sensor. in paragraph 4-295A. in paragraph 4-587A.
Transient Operation Test.
w FUEL SOL, FUEL DRAIN, Defective start cycle Inspect sensor in accor- Repair sensor in accor- ~
lGN and NO FAULT lights protection sensor. dance with instructions dance with instructions ~
~ fail to remain illumi- in paragraph 4-295A. in paragraph 4-587A. H
.... nated throughout tran-
:;d
o
sient voltage range. w
I
.....
o
"t
N
~I
C\ lJ1
W N
NAVAIR 03-l05-AB-52
NOTE
Voltage variation across stator assembly (27) red and

green leads is approximately 0.5 vac per 0.001 inch
air gap between stator assembly and rotor assembly
(25). The air gap must be a minimum of 0.015 incho
k. After final selection and installation of washers (28), apply thread-

locking primer (MIL-S-22473, Grade T) and thread-locking sealant (MIL-S-22473,
Grade B) to threads of screws (26, 16) and install screws while sealant is moist.
1. Bond disk (15) to end bell assembly (35, 36) with adhesive (STABOND
C136, Stabond Co, 14010 S. Western Ave, Gardena, CA 90249, or equivalent; no known
Government specification).
i~OTE
Perform electric and electronic wiring procedures in

accordance with NAVAIR 01-lA-505.
m. Connect wires of stator assembly (27) and lead wires between filter as-
sembly (11), module assembly (14), stator assembly, and connector (29) as shcJO in
figure 4-88. Use size 22 (AWG) high temperature, Type EE, insulated electrical wire
with silver-coated conductor and extruded TFE (Teflon) insulation jacket in accord-
ance with MIL-W-16878 (NAVY), Type EE. Solder connections with solder (QQ-S-571,
Type Sn60). Use 3/l6-inch irradiated, heat-shrinkabIe, thermaIIy-stabiIized
insulation sleeving (RT876, Raychem Corp, 300 Constitution Drive, MenIo Park, CA
94025, or equivaIent) over solder parts of connector (29); expose for a few seconds
to 135°C (275°F) to accomplish shrinkage.
REO A.
RED A
RED /1
GREEN GREEN
B 3
GilEEN /2
8LUE I FILTE~
STATOR
ASSEM8LY
YELLOW
1
I VIOLET
7
ASSEM8LY
::>
'JIOLn
o
CO~NEC'!O~
BLACK
!
GRAY
I
I I
I
'.'i"lITE ""
...
9
T
ORAI\;GE C
E /."iHITE
.LJG
E
WHITE
I
I
j i
I
1
;
i
8LACt<
6 F
i!LACK
F
E3 E4 E5
J
E6 EI E2 E7
I
E9 EB
/
RECTIFIER.:REGULATOR
MODULE ASSEM8LY
w·" 2...
Figure 4-88. AC-DC Permanent Magnet Generator Wiring Diagram
4-264
•
NAVAIR 03-105AB-52
n. Install eonnector (29, figure 4-8) and screw (34), washers (31, 33), lug (32), and nut (30) in
end bell assembly (35, 36). Lockwire eonnector (29) with serew (M), using wire (MS20995C20) in
accordanee with NAVAIR 01-lA-8 and NAVAIR 01-1A-505.
o. Apply eneapsulant (DC3110, Dow Coming Corp, S. Saginaw Road, Midland, MI 486(0), or
insulating eompound MIL-I-81550, type n (Dow Coming Sylgard 182) to the three sides of end bell
I
assembly (35, 36) whieh wiIl mate with the three sides of module assembly. Apply thread-locking
. primer (MIL-S-22473, grade T) and thread-locking sealant (MIL-S-22473, grade B) to threads of serews
(12, 13) and instaIl screws while seaIant is moist.
p. Install filter assembly (11) in end bell assembly (35, 36). Apply
thread-locking primer (MIL-S-22473, Grade T) and thread-locking sea1ant (MIL-S-
22473, Grade B) to threads of screws (9, 10) and install screws wh1le sealant is
maist. Lockwire screws (9, 10) with wire (MS20995C20) in accordance with NAVAIR
01-lA-8.
q. Apply sealing compound CMIL-S-23586, type n or m, elass 2, grade A) around solder joints I.
at terminaIs 1, 2,7,8, and 9 oftilter assembly (11), around solder joints ofmodule assembly (14), and
around wires of stator assembly (27) where they pass through slot in end bell assembly (35, 36), tilling
entire slot.
r. FiIl connector (29) cavity of end beIl assembly (35, 36) to a leveI that just covers electrical
header oífilter assembly (11) that contains terminaIs A, B, D, E, and F, with encapsulant (DC3110, Dow
Coming Corp, S. Saginaw Road, Midland, MI 486(0), or insulating compound (MIL-1-81550, ty.pe II Dow
Coming Sylgard 182).
I
WARNING
Use methyl-ethyl-ketone in a well-ventilated area.
Avoid breathing fumes and skin contact. Keep away
from flame.
CAUTION
Tapped holes in end bell assembly (35, 36) must be
free of sealing compound.
s. Clean contact surfaces oí cover (8) and end bell assembly (35, 36) with methyl-ethyl-ketone
(TI'-M-261). Apply seaIing compound (MIL-S-23586, type III, class 2, grade A) liberally to mating
aurface oí end bell assembly. Install cover, squeezing excess sealing compound from joinlApply
thread-locking primer (MIL-S-22473, grade T) and thread-Iocking sealant (MIL-S-22473, grade B) to
'threads of screws (6, 7) and instaIl screws while sealant ia moist.
t. Test assembled permanent magnet generator (128, figure 4-4) as follows:

(1) Install and connect generator in a test setup as shown in figure
4-89.
Change 2 4-265
NAVAIR 03-105AB-52
GENERATOR
r--
A
~
~OTO"OVAC 1320tw.
c;: :
VOLTMETER
l00w
B
I e
I
GENERATOR
I SWITCH 3 19.3 OHM 12.9MH
DRIVE SHAFT 3SOW lA
O TO 13,200
RPM
DRIVE ,I
C
O
:l
I
I I
I E
~OTO"VDC
I
I I
:
RPM F
VOLTMETER I
SWITCH 1 190tw.
SPEED '--
COUNTER 45W
2<4 OHM
35W
SWITCH 2 12 OHM
'·17. "' 70W
Figure 4-89. AC-DC Permanent Magnet Generator Test Setup
CAUTION
Do not operate generator at 50 pereent speed with

test setup switeh 1 open for more than 5 seeonds.
Test setup switeh 1 must be elosed before increas-

ing generator speed beyond 50 pereent (6000 rpm).

test setup switeh 3 elosed for more than 45 seeonds.
(2) Open test aetup switch 1, cIose test setup switches 2 and 3, and operate generator at
minimum speed (lO percent) by driving generator at 1200 rpm (40 Hz); de voltmeter must indicate a
~. minimum of 14 vdc.
CAUTION

test setup switeh 1 open for more than 5 seeonds.
(3) Operate generator at mid-speed before switeh (50 pereent) by

driving generatorat 6000 rpm (200 Hz); de voltmeter must indieate a maximum of 38
vdc.
4-266 Change 2
•
NAVAIR 03-105AB-52
(4) Close test set-up switches 1 and 3, open test setup switch 2, and operate generator at
mid-speed (50 percent) by driving generator at 6000 rpm (200 Hz); de voltmeter must indicate a
minimum of 14 vde.
I
CAUTION
Do not operate generator at 90 percent speed with

test setup switch 3 c10sed for more than 45 seconds.
(5) Operate generator at 90 percent speed by driving gene~ator at

10,800 rpm (360 Hz); ac vo1tmeter must indicate 102 to 124 vac, and de vo1tmeter
must indica te 18 to 29 vdc.
(6) C10se test Betup switch I, open test setup switches 2 and 3, and
operate generator at 110 percent speed by driving generator at 13,200 rpm (440 Hz);
ac vo1tmeter must indicate 102 to 124 vac, and dc vo1tmeter must indicate 18 to 29
vdc.
(7) Remove permanent magnet generator from test setup.
4-700A. Touch-up painting shalI be accompIished as folIows:

a. Loose or aged paint shall be removed by scufl' sanding UBing aluminum oxide cloth (P-C-
451) or abrasive mats (MIL-A-9962).
WARNING
Aliphatic Naphtha, is flammable. Keep away fioom heat and open

flame. Vapors may be hannful. Use with adequate ventilation.
Avoid prolonged or repeated breathing ofvapor. Avoid contact with
skin and eyes. Do not take intemally. Comply with air pollution
control ruIes conceming photoehemical1y reaetive Bolvents.
b. AlI soils,lubrieants and preservatives shalI be removed using aliphatic naptha (TT-N-
95).
e . Bare metal shaU be treated with chromate eonversion coating (Alodine, Iridite, etc.) in
accordance with MIL-C-5541 UBing MIL-C-81706, class lA material.
d. Spot treat those areas requiring touch-up with (TT-P-1757) zinc chromate primer. Allow to
dry 30 minutes. Apply black lacquer (MIL-L-19537) color no. 27038 as required.
4-701. ASSEMBLY OF MAJOR ASSEMBLIES.
4-702. ASSEMBLY OF ACCESSORY DRIVE ASSEMBLY.
4-703. Assemb1e gear and bearing assemb1y (76 through 83, sheet 2) as fo11ows:
Change2 4-266A/(4-266B b1ank)

NAVAlR 03-105AB-52
a. Place gear (78) in Pin Pressing Holder, 287153-1-1, with shoulder of

gear against end of holder. tocate pin hole in shaft directly over pin evacuation
bole in holder. Press pin (77) into hole of gear (78) using standard punch or
drift, and arbor press.
b. Place assembled gear (77, 78) in micing block with shoulder of gear
against block. Rest 1/2 inch ball in bore of gear (77, 78) and measure and record
dimens!on from top of ball to shoulder of gear (Dim. D, figure 4-90).
c. Place gear (78, figure 4-7) amall end first through amall end of
carrier (83). Install bearing (82) with thrust side (large open end; ~~ward gear
(78). Instal1 spacers (80, 81) and bearing (79) with thrust side (la~ge open end)
facing away from gear (78). Insta11 nut (76). Place sp1ined Torque wrench Adapter,
285481-1-1, in interna1 sp1ines of gear (78). Engage torque wrench into adapter,
and app1y 60 to 65 inch-pounds of torque to nut (76) with standard wrench.
d. P1ace anvil of Nut Staking Too1, 287946-1, directly over slot in sbaft
of gear (78), and squeeze handles on staking too1 to stake nut (76).
e. Measure dimension E (figure 4-90) from top of 1/2 inch micing ba11 to
shimming contact surface of carrier (83, figure 4-7). Assure that parts are con-
tacting bottom of carrier (83) during measurement. Record the measurement.
Change 2 4-267
NAVAIR 03-105-AB-52
rr--o---TOWER BEVEl
PINION GEAR
_-SHIMSA
0.8552
MOUNTlNG
MICING BALL
INOEX LINE
0.550
MOUNTlNG
t+-~-OIM. G----t
j.--+-OIM. H - - - . j
OIM. F
LOWER MESH
Figure 4-90. Accessory Drive Assemb1y Dimensions
4-704. Assemb1e c1utch shaft and bearing assemb1y (86 through 106) as fo110ws:
a. Position shaft assemb1y (101 through 106) in pin insta11iog Ho1der
287944-1. P1ace paw1 (100) and washers (99) in position and press pio (98) to
bottom in shaft assemb1y (101 through 106). Insta11 ring (97) into shaft assemb1y
(101 through 106).
b. Insta11 gear (95) and gear (94) on assemb1ed parts (97 through 106).
Secure with key (96).
c. P1ace micing b10ck on a f1at p1ate, and p1ace assemb1ed parts (94
through 106) on it, shaft end down. Mark an index 1ine with vi01et marker (Mas ter
Marker, Grade 127-1/2, or equiva1ent) 00 top edge of assemb1ed parts. Take indi-
cator readings at mark and at top of micing b10ck. Subtract readings and record
difference as dfmension G. See figure 4-90.
d. Insta11 ring (91, figure 4-7) inside of carrier (92). Beve1ed side ~
of ring (91) sha11 face f1ange of carrier (92). P1ace assemb1ed parts (94 through
106) with shaft up, and install the following on the shaft: bearing (93), carrier
(92) with ring (91), spacer (89), washer (90), spring (88), bearing (87) and nut
4-268
NAVAIR 03-105-AB-52
(86). P1ace externa11y sp1ined portion of sp1ine Torque Wrench Adapter, 287150-1-1,
in interna! sp1ines of clutch shaft assembly (101 through 106) with socket portion
of too1 engaging nut (86). Engage torque wrench to adapter; hold handle on socket
portion of adapter and apply 30 to 40 inch-pounds of torque to nut (86).
e. Place anvll on Nut Staking Tool, 287946-1, directly over slot in shaft
of c1utch shaft assemb1y (101 through 106) and squeeze handles of staking too! to
stake nut (86).
f. Place assembled parts (86 through 106) upside down (nut end down) on a
three-point suspension of height blocks. Take indicator readings next to index
line of top of assembled parts and at bottom of flange. Subtract reading and record
difference as dimension H. See figure 4-90.
4-705. Insta1l gear assemblies (76 through 83 and 86 through 106, figure 4-7) as
fo!lows:
a. Use gear positioning Gage Set, 285483-1-1, which consists of one hori-
zontal gage and one vertical gage. Insert horizontal gage into assembly (107) until
shoulder of gage contacts housing assembly at position normally filled by parta (86
through 106). Measure from tip of horizontal gage to flange of housing assembly
(107) with micrometer. Record as first measurement.
b. Insert vertical gage where assembled parts (76 through 83) will go, and
position against horizontal parte Reposition both too! parts as required to assure
ful1 contact between them, both vertically and horizonta1ly. Measure and record
dimension from tip of horizontal gage to flange of housing assembly (107) with
micrometer. Record as second dimensiono Subtract second reading from first read-
ing. Add gage length (stamped on outside diameter of horizontal gage) to differ-
ence, and record result as dimension F. See figure 4-90.
c. Retain gage set in same position. Take micrometer reading from top of
housing assembly (107, figure 4-7) to top of vertical gage. Add gage length
(stamped on outside diameter of vertical gage) to measurement; record sum as dimen-
sion C. See figure 4-90.
d. Calculate thickness for shtms (B, figure 4-90) in accordance with the
following formula:· B - F+G -H - 0.5500.
a. Verify proper installation of thrust bearings,
bearings (79, 83, figure 4-7).
b. Ver1fy dimensions C, D, F, G, and H. Refer to

figure 4-90.
e. Se1ect shtms (85, figure 4-7) to equal dimension B. Insta1l shims (85)
and assembled parts (86 through 106) into housing assembly (107). Insta11 screws
(84) and torque to 12 to 15 inch-pounds.
4-269
NAVAlR 03-l05-AB-52
f. Calculate dimension A for shims (68, figure 4-7) in accordance with

following formula: A = E + 0.8552 -c -D.
g. Select shims (75) to equal dimension A. Install shims (75) and assem-
bled parta (76 through 83) into housing assembly (107). Position parts sO that gear
(78) ia meshed with gear (94) and notches in shims (75), and carrier (83) are adja-
cent to hole in housing assemb1y (107). Position retainer assembly (74) so that
pin in retainer is engaged in ho1e of carrier (83). Secure with screws (73) and
apply five to eight inch-pounds of torque to screws (73) and 10ckwire.
h. Bolt backlash check Gear Holder, 287154-1-1, to flange of housing assem-

bly (107) with fixed fingers of holder stradd1ing pin bosses located on outer diam-
eter of shaft assembly (101 through 106). Adjust hand knob on gear holder to force
movable finger tightly against outer diameter of shaft assemb1y (101 through 106).
Install Back1ash Checking Co1lett Assemb1y 288693-1 (detail of Backlash Checking
Gage Set 287149-1-1) into shaft of gear (78) and tighten secure1y.
i. Setup and zero dial indicator with indicator ball against notch on
Collett Assembly 288693-1. Manually turn Collett Assembly 288693-1 full left,
then full right. Check dia1 indicator for total indicator reading within 0.002 to
0.004 incho Add or remove shims (85) as required to obtain proper reading.
Verify backlash of 0.002 to 0.004 incho
4-706. Assemble shaft and bearing assemb1y and oil pump assemb1y (54 through 72,
figure 4-7) as follows:
a. Install bearing (71) on shaft (72) and p1ace both in housing (107).
Install spacer (70), spring (69), ring (68), and bearing (67).
b. Insta1l outer ring of gearset (63) into housing assemb1y (107).
CAUTION
Rounded end of key (64) must go into rounded end of

keyway in shaft (66).
c. Install parts as fo110ws on shaft (66), cover (65), inner rotor of

gearset (63) with index mark on ssme side as outer ring, and key (64). Insta11
assembled parts (63 through 66), retainer (62) and screws (61) into housing (107).
Apply 20 to 25 inch-pounds of torque to screws (61).
Verify marks on rotor and ring of gearset (63) are

on aame aide.
d. Instal1 gear (60) with shoulder toward bearing (67), key (59), gear
(58) and nut (57). Engage sp1ines Torque Wrench Adapter, 285484-1-1, in internaI
4-270
NAVAIR 03-l05-AB-52
splines of clutch sbaft assemb1y (101 through 106). Ho1d adapter to 10ck gear
train and app1y 35 to 40 inch-pounds of torque to nut (57).
e. P1ace anvi1 of Nut Staking Too1, 287946-1, direct1y over slot in sbaft
(72), and squeeze hand1es on staking tool to stake nut (57).
f. Install gear (55) with shoulder toward shoulder of shaft (66), key (56)
and nut (54). Engage splined Torque Wrench Adapter, 285484-1-1, in internaI sp1ines
of c1utch shaft assemb1y (101 through 106). Ho1d adapter to 10ck gear train and
app1y 35 to 40 inch-pounds of torque to nut (54).
g. P1ace anvil of Nut Staking Too1, 287946-1, direct1y over slot io shaft
(66) and squeeze handles on staking tool to stake nut (54).
4-707. Assemb1e switch actuating governo r assemb1y (43 through 51) as fo110ws:
a. Se1ect washers (46) as required to center weights within 0.005 inch

and to provide 0.003 to 0.008 inch end f10at.
b. Insta11 spring (49) trial amount of washers (48) and governor pio (47)
into body assembly (50, 51).
c. Instal1 flyweights (45) with tangs engaged in groove of governor pin

(47). Instal1 washers (46), and pins (44).
d. Insta11 sleeve (43) and position by stak1ng material around 0.095 diam-
eter holes in sleeve into 0.190 diameter ho1es in body (51).
4-708. Instal1 governor assemb1y (43 through 51) as follows:
Coat thrust washer (53) with lubricant (HF825 , Royal

Lubricants Co, P.O. Box 95 Rlver Rd, E. Hanover, NJ
07936, or equivalent) to a~d assemb1y by holdiog the
thrust washer in place.
a. Install thrust washer (53).
b. Determine requirement for washers (52) as follows:
(1) Load shaft (66) as 1ndicated in figure 4-91.
(2) Measure and record dimensions A (flange to thrust washer), B

(flange to sbaft), and C (depth of bore in governor body). Refer to figure 4-91.
(3) Compute dimension D (figure 4-91) using formula: A - B - D.
(4) Compute required thickness of washers (52, figure 4-7) uslng

formula as follows:
4-271
NAVAIR 03-105-AB-52
~DIM.A "
I-DlM. 8-r-D1M. 0-=
- 1 1 - - - 0.003 TO 0.006
.u--__ END PLAY
TORQUE WRENCH
ADAPTER 287007- 1-1
SPINDLED TORQUE
WRENCH ADAPTER
285484-1-1
Figure 4-91. Insta11ation of Switch Actuating Governor Assemb1y
c- D =Y
Y + 0.005 = total th1ckness of washers (52) required to obtain end ~

p1ay within 0.003 to 0.006 inches.
4-272
.,,.
NAVAIR 03-105-AB-52
c. Insta11 washers (52) and switch actuating governor assemb1y (43 through
51).
,
d. Insta11 sp1ined Torque Wtench Adapter, 285484-1-1, sbaft into assemb1y
(101 through 106) as i11ustrated in figure 4-91.
e. Insta11 Torque wrench Adapter, 287002-1, over switch actuating governor
assemb1y. Ho1d sp1ined Torque Wrench Adaptar, 285484-1-1, stationary to lock gear
train. Thread governor assemb1y (43 through 51, figure 4-7, sheet 3) onto sbaft
(66) unti1 it bottoms, then tighten 1/6 turn with Torque wrench Adapter, 287002-1-1.
f. Remove a11 AGE from accessory drive assemb1y.
KAINTENANCE ASSURANCE
a. Verify that spur gears (55, 58, 60, figure 4-7,

sheet 2) are proper1y insta11ed and nuts (54,
57) are torqued and staked.
b. Verify that governo r end play is within 0.003
to 0.006 inch.
4-709. InstaI1 sensitive switch assemb1y (38) as fo11ows:

a. Prepare mu1timeter to check continuity and connect 1aads to pins B and
F of connector on sensitive switch assemb1y (38).
b. Take up end p1ay by sliding switch actuating governor assemb1y (43
through 51) against thrust washer (53). Refer to figure 4-91.
c. Insta11 sensitive ~tch assemb1y (38, figure 4-7, sheet 2) with tria1
amount of shims (42). Alter thickness of shims (42) until continu~ty is indicated
on mu1timeter.
d. Disconnect mu1timeter and remove 0.020 inch of shims to assure proper
switch actuation.
a. Insta11 pack1ng (41) on sensitive switch assemb1y (38) and iusta1l in
drive assemb1y.
f. Iusta11 washers (40), screws (39), torque screws 20 to 25 inch-pounds
aud lockwire.
4-710. Insta11 parts (1 through 17) as fo11ows:
,
a. Insta11 gasket (14) on p1ug (15). Insta11 ba11 (17), spring (16), and
assemb1ed p1ug (14, 15) iuto housing assembly (107).
b. Insta11 gasket (12) on screw (13), and install assemb1ed screw (12, 13)
iuto housing assemb1y (107) and lockwire to p1ug (15).
4-273
NAVAIR 03-105-AB-52
c. Install packing (10) on plug (11) and install assemb1ed p1ug (10, 11)
1nto hous1ng assemb1y (107).
d. Instal1 gasket (8) on strainer e1ement assembly (9) and insta11 assem-
b1ed strainer element assembly (8, 9) into housing assemb1y (107) and lockwire to
plug (11). ~
e. Install gasket (6) on dip stick (7) and install assembled dip stick (6,
7) into housing assemb1y (107, sheet 2). Lockwire after servicing prior to starter
testing.
NOTE
Magnetic p1ug (5, sheet 1) consists of two parts:

magnet and valve. Packing (3) provides a seal between
the magnet and va1ve. Gasket (4) provides a seal
between the valve and housing assembly (107).
f. Install gasket (4) on valve of magnetic plug (5) and install assembled
valve (4, 5) into housing assembly (107). Install packing (3) on magnet of magnetic
plug (5), and install assemb1ed magnet (3, 5) into valve of magnetic plugo Lockwire
magnet and valve of magnetic plug (5).
a. Verify proper installation of hydraulic motor.
b. Verify proper and complete lockwiring.
4-711. Test accessory drive assembly as fol10ws:
a. Install accessory drive assembly into JFS Accessory Drive Tester,

291659-1, as fo110ws:
(1) Install blankoff plate and packing (components of 291659-1) over

adapter housing assembly mounting flange.
(2) Install manifo1d block (component of 291659-1) over zerol pinion

bevel gear flange.
CAUTION
Insure that there is no axial 10ad on drive shaft and

that drive tang is proper1y engaged.
(3) Install accessory drive assembly and gasket to tester base assem-
bly.
(4) Connect E1ectronic Counter (Mode1 52LA, Hew1ett Packard Co, Mfg
Division, 3215 Porter Dr, PaIo Alto, CA 94304, or equivalent) to monopole pickup.
4-274
NAVAIR 03-105-AB-52
(5) Connect leads of continuity indicator to sensitive switch assembly

(38, figure 4-7, sheet 2).
(6) Connect leads of continuity indicator to tester paw1 contact and

base assemb1y.
(7) Service accessory drive assembly as fo11ows:
(a) Remove JFS accessory drive oi! dip stick (figure 2-3, sheet
2) from OIL F1LL porto
(b) Service accessory drive assembly with 200 to 225 cc of lubri-

cating oi! (MIL-L-7808 or MIL-L-23699) through accessory drive assembly OIL FILL
porto
(c) Reinstall JFS accessory drive oi! dip stick.
(8) Connect tester to 110 volt power source.
b. Test oi1 pump operation as fol10ws:
(1) Accelerate tester to 6000 rpm in approximately 5 seconds. Oi1

pump sha11 indicate prime and 20 psig oi1 pressure. Shut down tester immediate1y
if there is no oi! pressure.
(2) Acce1erate tester to 5700 rpm. Oi1 pump pressure shall be steady
and 25 +5 psig.
c. Test sensitive switch assemb1y and paw1 throwout as f0110ws:
(1) Acce1erate tester slowly from O to 4000 rpm. Sensitive switch

assemb1y sha11 actuate between 2700 and 3100 rpm as indicated on continuity indica-
toro
(2) Add washers (48, figure 4-7, sheet 2) to governor (51) to raise
actuation speed. Remove washers to lower actuation speed.
(3) Ascertain that paw1 throwout does not occur prior to sensitive
switch operation as indicated on continuity tester.
d. Test pressure relief valve (14, 15, 16, figure 4-7) by closing bypass
va1ve. Valve sbal1 open at 30 to 40 psig.
e. Remove accessory drive assembly from tester as fo110ws:
(1) Drain 1ubricating oi1 from accessory drive assemb1y.
(2) Disconnect 110 volts power source from tester.
(3) Disconnect continuity indicator leads from paw1 contact and base
assembly.
4-275
NAVAIR 03-105-AB-52
(4) Disconnect continuity indicator 1eads from sensitive switch assem-

b1y.
(5) Disconnect e1ectronic counter from monopo1e pickup.
(6) Remove accessory drive assemb1y and gasket from tester base assem-
b1y.
(7) Remove manifo1d b10ck from zero1 pinion beve1 gear f1ange.
(8) Remove b1ankoff p1ate and packing from adapter housing assembly
mounting f1ange.
f. Refer to tab1e 4-12 for troub1eshooting procedures for accessory drive

assemb1y.
4-712. Assemb1e adapter assemb1y (108 through 121, sheet 3) as fo11ows:
a. Insta11 ring (118) inside carrier (119) with beve1ed side of ring
facing flange of carrier.
b. Insta11 parts on shaft (117) as fo11ows: key (116), gear (115), bear-
ing (114), spacer (113), spring (112), washer (111), carrier (119) with ring (118),
bearing (110) and nut (109).
c. Engage sp1ined Torque Wrench Adapter, 285484-1-1, in internaI sp1ines

of shaft (117). Ho1d shaft with adapter and app1y 35 to 40 inch-pounds of torque
to nut (109).
d. Position anvil of Nut Staking Too1, 287946-1, direct1y over slot in

shaft (117) and squeeze hand1es of staking tool to stake nut (109).
e. Insta11 shaft (36, sheet 1) in internaI sp1ines of shaft assemb1y (101

through 106, sheet 2).
MAIlITENANCE ASSURANCE
a. Verify that nut (109) is torqued and staked.
b. Verify insta11ation of shaft (33, sheet 1).
f. Insta11 packing (37) on housing (121, sheet 2) and insta11 housing

(121) with packing (37, sheet 1) into bore of housing assemb1y (107, sheet 2).
Secure with washers (35, sheet 1) and nuts (34). App1y 20 to 25 inch-pounds of
torque to nuts (34). Insta11 bracket (100, figure 4-4, sheet 2) on stud that is
a1igned with mounting f1ange of accessory drive assemb1y.
4-713. Insta11 fuel contro1 assemb1y (24, figure 4-7, sheet 1) as fo11ows:
a. Instal1 shaft (33) into internaI sp1ines of shaft (66), and place gasket
(32) on housing assembly (107).
4-276
-
Table 4-12. Troubleshooting Tab1e for Accessory Drive Assembly '.
No oil pressure or oil a. Improper servicing. Service accessory drive

pressure below 20 psig. assemb1y.
b. Defective pressure Remove and inspect gasket Replace defective com-

relief valve. (14, figure 4-7), plug ponents.
(15), spring (16) and
ba11 (17).
c. Defect:l.ve oU Remove and inspect gearset Replace defective com-

pump. (63), key (64), cover (65) ponents.
and shaft (66).
Sensitive switch Defective governor Remove and disassemble Replace defective spring.
actuates prior to spring (49). governor assembly (43
2700 rpm after adding through 51). Inspect
maximum amount of governor spring (49).
washers (48).
Sensitive switch a. Improper shimming Check sensitive switch Remove or insta11 shims
actuates above 3100 rpm of sensitive switch assembly for proper amount (42).
after removal of alI assemb1y. of shims (42).
washers (48).
b. Defective sensi- Remove and inspect switch Replace defective com-

tive switch assem- assemb1y for binding parts. ponents.
bly (38).
~
c. Defective governor
assembly (43
Remove and disassemble
governor assemb1y. Check
Replace defective com-
ponents.
~
1=1:1
through 51). governor assemb1y for o
W
binding parts. I
.....
o
VI
~
I
NI
~
I
VI
"" N
~
I Tab1e 4-12. Troub1eshooting Tab1e for Accessory Drive Assemb1y (Cont) ~
'"
......
00
;:
~
Symptom Cause Method of Detection Corrective Action o
w
~
o
VI
Sensitive switch d. Defective gover- 1nspect governor spring. Rep1ace defective spring.
actuates above 3100 rpm nor spring (49). ~I
after remova1 of a11 v.
washers (48). (Cont) '"
Paw1 (100) throwout Defective c1utch shaft Remove and disassemb1e Rep1ace defective spri~g.
occurs prior to sensi- assembly spring (102, c1utch shaft assemb1y
tive switch assemb1y 103). (101 through 107). 1n-
actuation. spect springs.
fJ
- -
NAVAIR 03-l05-AB-52
MAINTEUANCE ASSURANCE
Verify installation of shaft (33).
, b. Install fue1 contro1 assemb1y (24, sheet 1) on housing assemb1y (107,

sheet 2) with fuel contro1 shaft engaging shaft (33, sheet 1).
c. Insta11 washers (27, 31) and screws (25, 26, 28, 29). Apply 20 to 25
inch-pounds of torque to screws (25, 26, 28, 29).
d. Instal1 washers (31) and s~rews (30). Apply 20 to 25 inch-pounds of

torque to screws (30).
e. Lockwire screws (26) and screws (29).
4-714. Instal1 hydrau1ic motor (18) as fo11ows:
CAUTION
Restrain hydraulic motor shaft to preclude damage to
motor bearings when bending pin (22).
a. Install clutch jaw (23) on shaft of hydraulic motor (18). Instal1 pin
(22) and safety by bending pin through opening in end of hydrau1ic motor shaft using
suitable tool to prevent cuts or tool marks on pino
Verify pro per installation of starter jaw.
b. Instal1 packing (21) on hydrau1ic motor (18).
c. Install hydraulic motor (18) on fuel control assembly (24). Install
washers (20) and screws (19). Apply 50 to 70 inch-pounds of torque to screws (19)
and lockwire.
4-715. ASSEMBLY OF GAS GENERATOR ASSEMBLY.
4-716. Assemble tower shaft housing assembly figure 4-6 as fo1lows:
a. Install pack1ng (9) on diffuser plate (8) and insta11 assembled diffuser
plate (8, 9) on tower shaft housing assembly (22).
NOTE
Align diffuser plate (8) so that fuel nozzle boss hole
centered between two of the diffuser plate attaching
bolt holes will be in alignment with the center of
tower shaft housing cover (102, figure 4-5, sheet 2).
4-279
NAVAIR 03-I05-AB-52
b. InstaII diffuser housing assembly (6, 7, figure 4-6) on d1ffuser plate

and tower shaft housing assembly and secure assembly with bolts (4), washers (5),
WRshers (2, 3) and nuts (1). Apply 28 to 32 inch-pounds of torque to nuts (1).
c. Blank off assembled housing and pressure check pack1ng (9) at 30 psi.
Check that Ieakage does not exceed 10cc/min.
4-717. Determine required thickness of shims (76, figure 4-5, sheet 2) as follows:
Refer to figure 4-5 and figure 4-92.
a. Hand press bearing (74, figure 4-5) into carrier (75) with thrust side
of bearing facing carrier and instaII pin (73).
b. Use shim Checking Gage Assembly, 287146-1-1, which consists of parts as

follows: jam nut (1, figure 4-92), nut (2), sIeeve (7), baII stud (9), vertical
gage assembly (I2), adapter (13), and Gear Positioning Shaft, 288828, which is not
i11ustrateã. Parts (1, 2, 7, 13) comprise horizontal gage assembly.
c. Insert sIeeve (7) through assembled bearing and carrier (5, 6) and
assembled tooling (2, 13). InstaII jam nut (1) and tighten untiI snug to remove alI
bearing play. Loosen nut (2). Keep nut (2) Ioose untiI after tooling is installed
in housing assembly (11).
d. InstaII vertical gage assembly (12) into housing assembly (11) from
direction of arrow.
Figure 4-92. Shimming and Back1ash Assembly Setup
4-280
• NAVAIR 03-105-AB-52
*1. JAM NUT 8. MICROMETER 1 INCH AND 4 INCH

*2. NU! MIC ROD
3. SHIMS (76, figure 4-5) * 9. BALL STUD
4. SCREW (60, figure 4-5) 10. SCREW (103, figure 4-5)
5. CARRIER (75, figure 4-5) 11. HOUSING ASSEMBLY (115, figure 4-5)
6. BEARING (74, figure 4-5) *12. GAGE ASSEMBLY (vertical)
*7. SLEEVE *13. ADAPTER
*COMPONENTS OF SHIM CHECKING GAGE ASSEMBLY 287146-1-1
e. Instal1 horizontal gage (1, 2, 7, 13) a10ng with assemb1ed parts (5, 6)
into housing assemb1y (11). Secure with screws (4).
f. App1y 25 inch-pounds of torque to nut (2) using Shim Checking Adapter

Assemb1y, 288692-1, of Gage Assemb1y, 287146-1-1.
g. Measure between end of sleeve (7) and ba11 stud (9) using one inch
depth micrometer with four inch rod (8). Subtract micrometer reading p1us 4 inches
(4 inch rod) from 4.438 inches and se1ect shims (3) of thickness of equa1 remainder.
h. Loosen nut (2) using Adapter Assemb1y, 288692-1. Remove screws (4) and
horizontal gage (1, 2, 7, 13) along with assemb1ed parts (5, 6). Insta11 shims (3)
and reinsta11 horizontal gage (1, 2, 7, 13) a10ng with assemb1ed parts (5, 6) in ac-
cordance with steps e and f.
i. Measure from sleeve (7) to ba11 stud (9) for reading with1n 4.438
+0.001 inches. Reshim and recheck as required to obtain 1imits.
j. Loosen nut (2). Remove screws (4), horizontal gage (1, 2, 7, 13) a10ng
with assemb1ed parts (5, 6) and remove shims (3). Remove alI AGE from bearing and
carrier (5, 6) and from housing assemb1y (11).
4-718. Assemb1e gear and bearing assemb1y (108, sheet 1, through 114, sheet 2,
figure 4-5) as fo11ows:
a. Place gear (108) w:Lth shaft end up on work surface and position carrier
(114), f1ange end down and over shaft of gear (108). Insta11 parts onto carrier
(114) and over shaft of gear (108) as follows:
(1) Insta11 bearing (113) with thrust side up.
(2) Insta11 spacers (111, 112).

(3) Install bearing (110) w:Lth thrust side down.
4-281
..
NAVAIR 03-105-AB-52
a. Ver1fy that thrust faces of bearings (113) and

(110) faces each other.
b. Verify that pin (107) is insta11ed.
b. Secure assemb1ed parts to carrier (114) with retainer (109).
c. Secure assemb1ed parts to gear (108) with nut (106). Engage sp1ined
Torque Wrench Adapter, 285481-1-1, in internaI sp1ines of gear (108). Hold gear
with adapter, attach torque wrench to adapter and app1y 55 to 60 inch-pounds of
torque to nut (106) with a standard open end or box end wrench. Read torque on
torque wrench.
d. P1ace Nut Staking Too1, 287946-1, over nut (106) with anvi1 located
direct1y over slot in shaft of gear (108). Squeeze hand1es on too1 to stake nut.
Stake nut in two p1aces.
4-719. Determine required thickness of shims (104, figure 4-5) to estab1ish beve1
gear backlash as fo11ows:
a. Se1ect and insta11 shims (105) as required to shim spot faces within
0.0000 to 0.0010-inch of mounting surface for shims (104).
b. Insta11 assemb1ed parts (106 through 114, figure 4-5) into housing
assemb1y (115) without shims (104), and secure with screws (103). App1y 12 to 15
inch-pounds of torque to screws (103).
c. Insert gear positioning shaft of Shim C1earance Gage, 287146-1-1,

through gear (77, figure 4-5) assemb1ed bearing and carrier (5, 6, figure 4-92),
and assembled tooling (2, 13). Instal1 jam nut (1) and tighten until snug to remove
alI bearing p1ay. Loosen nut (2). Keep nut (2) loose unti1 after tooling is in-
sta11ed in housing assemb1y (11).
d. Insta11 shims (3), and horizontal gage assemb1y consisting of gear

positioning shaft and parts as assemb1ed in step c. Secure into housing assembly
(11) with screws (4).
e. App1y 25 inch-pounds of torque to nut (2) using Shim Checking Adapter

Assembly, 288692-1, of Gage Assemb1y, 287146-1-1.
f. Insert co11et portion of Backlash Checking Gage, 287149-1-1, into gear

(108, figure 4-5) and rotate tee handle c10ckwise to expand co11et. Setup and zero
standard dia1 indicator with tip against f1at spot on reference pin of gage.
g. Insert screwdriver through shaft of gear (108) between pin (107) and
wa11 of shaft. Turn screwdriver from fu11 c10ckwise to fu11 counterc1ockwise.
Check indication on dia1 indicator for total indicator reading within 0.002 to 0.004
incho
4-282
NAVAIR 03-105AB-52
h. Shim as required with shims (104) to obtain proper backlash. Recheck

and reshim as required.
i. Check gears (77, 108) for cleanliness and check backlash in four places,
90° from each other. Compare read1ngs for uniformity within 0.0005 inch total in-
dicator reading.
Verify 0.002 to 0.004 backlash.
j. Remove alI AGE. Remove assembled bearing carrier (66, 7~, 74, 75, 76)
and reta in as an assembled unit.
k. Lockwire screws (103).
1. Reinsta11 assemb1ed bearing carr1er (66, 73, 74, 75, 76). Instal1
plate (66) with recess s1de up and temporarily secure plate (66) with screws (60) to
retain assembled bearing carrier in tower sbaft housing (115).
4-720. Assemble turbine wheel assembly (67 through 72, figure 4-5) as follows:
a. InstaI! pin (68) in shaft (69).
b. Instal1 pin (71), spring (70), shaft (69) with pin (68) and piO (67).
4-721. Perform pre11m1nary assembly of rotat1ng group as followa: Refer to figure

4-5.
a. Position housing assembly (U5) on bench with dift'user end up. Using a depth micrometer,
measure from top ofbearing (74) inner raee to ftat on diftUser plate just inside of düfuser vanes. Record
this as dimension A
b. Measure from bottom of impeller (58) to flat surface at base of diffuser vanes. Record this
measurement as dimension B.
e. Subtraet dimension B from dimension A and reeord as dimension C. Measure and reeord
thickness of rotor seal (63). Subtract thickness of rotor seal from dimension C and record as dimenaion
D. Add 0.005 inch to dimension D to obtain final dimensiono Select washers (59) as required to obtain
total thiekness equal to final dimensiono This should provide 0.002 to 0.008 inch clearance between
impeller blades (58) and plate (8, figure 4(6).
d. Place wheel assembly (67 through 72, figure 4-5, sheet 2) on turbine wheel holder, 285459-1-1
in a vertical position. Insta1l rotor of seal (85) bevel side up, spacer with 0.670 inch m, LO inch O.D, and
0.470 inch width Ooeally manufactured) (alternate ba11 bearlng, 364752 with bore increased to 0.670
inch), spacer (78), gear (77), spacer with 0.5915 inch ID, 1.0 ineh OD, and 0.431 inch width Ooeally
manufactured) (alternate ball bearing 358419 with bore increased to 0.5915 ineh), rotor of seal (63) haveI
side down, washers (59) previously selected, impellers (58), and nut (57) fi11ger tight.
Change 2 4-283
.- "---------------------
illl 03-105AB-52
e. Measure to bexagon surface of shaft (69) with heigbt gage and record
.ng as first measurement.
CAUTION
Do not exceed 500 inch-pounds of torque when tighten-

10g nut (57). Torque on nut (57) sball be within 300
to 500 inch-pounds.
f. Rold impeller (58) with nut Torquing Impeller Bolder, 287149-1-1. In-
~/8 inch a11en-head wrench into nut (57) and force shaft (69) inward against
In of spring (70) unti1 hex points of sbaft (69) disengage interna! wrenching
I of nut (57). App1y 350 inch-pounds of initia1 torque to nut (57) in counter-
dse direction. Continue to torque unti1 hex end of shaft (69) is aligned
Tenching points in nut (57). Remove al1en wrench.
g. Measure to hexagon surface of shaft (69) with heigbt gage, as in step

record reading as second measurement. Subtract aecond measurement trom first
ement in step e, and check tbat difference, sbaft atretch, is within 0.012 to
inch." Increase torque and recheck as required to obta1o shaft stretch within
to 0.015 inch.
h. Check balance of assemb1ed rotating parta as fo1lows:
CAUTIQN
Rotate componente on the rotating assembly to achieve balance

within limits. Recheck balance of individual componente as
necessary should rotating balance not be achieved. Should rotating
of components and rechecking balance of the individual
components not achieve rotating assembly balance, parta then may
be rematched. As a last rasort, up to 10 percent ar material removed
for individual balance may be removed to achieve rotating
assemb1y balance.
(1) Insta11 rotating assemb1y into ba1ancing ~chine (Mode1 13-5,

~ and Lew1s Inc, 142 Doty St, Fond Du Lac, lVI 54935, or equiva1ent).
(2) Check that maximum unbalance does not exceed 0.0016 on turbine end,
)13 ounce-inch on impeller end.
Mark a1ignment of parts after balancing with blue dye (Blue Dykem,
(3)
Irp, 8501 Delport Dr, St. Lauis, MO 63114, or equivalent). Disassemb1e parts
.ing.
Assemble stationary parts to housing assemb1y (115) as follows. Refer to

-S.
!. Use Shim Check1ng Gage, 287151-1-1, which includes the fol10wing parts:
te with a hollow post and removable s~ft which has a movable ring secured
?per end. Insta11 bearing carrier assembly (89) into tower shaft housing
NAVAIR 03-105AB-52
assemb1y (115) and a1ign key (88) with slot in support in housing (115). P1ace
gage shaft in a vertical position with removab1e ring down and p1ace fo110wing parts
onto shaft: rotor of seal (85) with beve1 side up, bearing (87) with thrust side
up, spacer (78) and (77) with teeth down. Insert assemb1ed shaft into tower shaft
housing assemb1y (115). P1ace assemb1ed tower shaft housing assemb1Y'(115) onto
base p1ate of gase, 287151-1-1. Heasure drop from shaft to movab1e ring of gage.
Subtract 0.085. inch from measurement and se1ect shims (86) of total th1ckness to I
equa1 remainder. Remove alI to011ng and alI vert1ca11y stacked parts: 60, 66, 73
through 78, 85, 87 and 89. Ho1d se1ected shims (76, 86) for assemb1y.
b. Instal1 packing (92) on tube assemb1y (93). Insta1l assembled tube

assemb1y (92, 93) into housing assemb1y (115) and secure with screw (91).
c. Press bearing (87) into carrier (89) with thrust side facing inward
against shou1der of carrier. Install. spring (90) and position assemb1ed carrier
assemb1y (87, 88, 89) into housing assemb1y (115). Insta11 spring Compressor,
285456-1-1, through hous1ng assemb1y (115), spring (90), carr1er assemb1y (88, 89)
and bearing (87). Insta11 rotor of sea1 (85) over shaft of spring compressor and
insta11 c-washer of tool around shaft. Rotate hand knob of spring compressor to
pull carrier assembly (88, 89), bearing (87) and rotor of seal (85) into housing
assemb1y. Guide carrier (89) to posit10n slot in carr1er around tube assemb1y (93)
and to align key (88) with slot in housing assemb1y (115). Continue to compress
spring (90) until end.of carr1er 1s approxímate1y f1ush with recess for shims (86).
CAUTION
Do not damage sea1ing surface of rotor of sea1 (85).
Oi1 seal (85) with lubricant (MIL-L-7808 or MIL-L-
23699) prior to assemb1y.
Verify that thrust face of bearing (87) is proper1y

pos1tioned.
d. Place housing assemb1y (115), with assemb1ed parts and to011ng, in up-
right position. Instal1 previous1y se1ected shims (86). Position seal (85) over
bore in housing assemb1y (115). Place Seal Insta11ing Driver, 287155-1-1, over
seal so that outer sleeve of driver rests on housing assemb1y (115) and driver
portion cf too1 rests on outer she11 of sea1 (85). Press seal (85) into place.
Determine shims (84) re~11red for c1earance between seal (85) and retainer (83) as
fo110ws:
(1) Insta11 0.100 inch or more of sh1ms (84). Use fee1er gage to
determine c1earance between retainer (83) and tower sbaft housing assemb1y (115).
Record dimensiono
(2) Reduce shims (84) by amount of dimension recorded in step (1) to

maintain a 0.000 to 0.003 inch c1earance between sea1 (85) and inner f1ange of
retainer (83).
Change2
NAVAIR 03-I05AB-52
(3) Insta11 shims (84) and temporari1y instal1 retainer (83) and
secure with screws (79).
CAUTION
Keep face away from end of housing assemb1y (115) when
retainer (83) is removed.
dI. Blank oft' assembled tower housing assembly (115) and pressure check for leaks at seal
I (85), packing (9), and gasket (lI), figure 4-6. Provide suitable source of air pressure to supply 30 psi
pressure. Ensure leakage does not exceed IOcclmin. Remove blank off fixture.
e. Paint mating surfaces of retainer (80), stator assemb1y (81), shie1d

(82), and retainer (83) in accordance with paragraph 4-670.
f. Insta11 packing (101) on cover (102). Instal1 assemb1ed cover (101,

102) and secure with washers (100) and screws (99). App1y 12 to 15 inch-pounds of
torque to screws (99) and Iockwire.
g. Install screws (98). App1y 10ckwire to each screw (98) and 1et lockwire
hang Ioose. Insta11 combustor assembly (97) and secure with washers (95), bushings
(96) and screws (94). Apply 12 to 15 inch-pounds of torque to screws (94). Lock-
wire screws (94) with previous1y insta11ed lockwire to screws (98).
CAUTION
Do not over-torque screws (94).
h. Remove screws (79) from retainer (83) and install shield (82) and stator
assemb1y (81). Instal1 retainer (80) with painted side down, and six screws (79).
Remove Spring Compressor, 285456-1-1.
i. Determine required thickness of shims (55) as follows:
(1) Position assembled housing assembly (115) vertical with stator

assembly (81) up. Measure from flange of stator assembly (81) down to top surface
of outer flange on hous1ng assembly (115). Take add~t1onal measurement, 180 degrees
from first measurement. and check that measurements do not vary more than 0.015
incho Average measurements and record as dimension A.
(2) Place housing asse~b1y (54. sheet 1) in a vertical position on a

surface pIate with the forward end of housing down. Using inside micrometer,
measure from surface plate to Iower surface of f1ange on inside of housing assemb1y.
Record measurement as dimension B.
(3) Subtract dimens10n A from dimens10n B, and select shims (55) of

total thickness to equa1 remainder.
4-286 Change 2
NAVAIR 03-105AB-52
MAINTENANCE AS SURANCE
&. Verify requirement for shims (55).

b. Verify lockwiring of screws (79, 94, 98, 99).
iL Blank off assembled hOUSÚlg assembly (115) and pressure check for leaks. Provide a
suitable source of air pressure to supp1y 30 pai pressure. Ensure leakage does not exceed 15 ccJmin.
Remove blank off fixture.
I

NAVAIR 03-105-AB-52
j. Insta11 packing (56, sheet 2) on housing assemb1y (115). Insta11

washers (9, sheet 1), and install nozzle assemblies (8) with tips of nozz1es
centered inside of combustor ferrules. App1y 65 to 75 inch-pounds of torque to fue1
assemb1ies (8).
k. Coat shims (55, sheet 2) with primer and aluminized paint in accordance
with paragraph 4-670. Install shims (55) whi1e paint is wet, on top of stator as-
semb1y (81). Lower housing (54, sheet 1) over stator assemb1y (81, sheet 2) with
accessory bosses a1igned. Align ho1es in housing assemb1ies (54, sheet 1) and (115,
sheet 2), and press housing assemb1ies together. Insta11 bracket (53, sheet 1)
at attached bo1t ho1e in d1ffuser plate that ia located between the second and third
fue1 nozz1e bosses, washers (52) and bo1ts (51, six p1aces). App1y 50 to 70 inch-
pounds of torque to bo1ts (51). Align screw ho1es in housing assemb1y (54) with
ho1es in first stage stator assemb1y (81, sheet 2). Loosen screws (79) as required
to obtain alignment. Temporarily insta11 three short screws in holes for screws
(38, sheet 1). Apply 30 to 35 inch-pounds of torque to screws (79, sheet 2) and
lockwire.
4-723. Assemb1e rotating assemb1y to stationary assemb1y as fo11ows: Reter to

figure 4-5.
a. P1ace assemb1ed parts with aft end of housing (54, sheet 1) down and
under an arbor press. Insta11 spacer (78, sheet 2) with 1arge inside diameter down
and with balance mark a1igned with rotor of seal (63) marldng. Insert c1ean shaft
of wheel assembly (72) through parts from below into spacer (78) while aligning
balance marks of spacer (78), rotor of sea1 (63) with turbine whee1 (72) balancing
marks.
CAUTION
Center spacer (78) on sbaft of wheel assemb1y (72)

prior to pressingto avoid damage to shaft sp1ines.
b. Place assemb1ed parts on Turbine 1~ee1 Bo1der, 285459-1-1. P1ace Bear-

ing and Bushing Driver, 285482-1-1, over shaft of turbine whee1 assembly and in
contact with spacer (78). Carefu11y press shaft of wheel assembly (72) through
bearing (87). Remove bearing and bushing driver.
c. InstaI1 gear (77) with teeth engaged in gear (108) and with balance
marks a1igned with marks on spacer (78). Instal1 prese1ected shims (76), and
carrier (75) with bearing (74) and pin (73).
Ver1fy that thrust face of bearing (74) ia proper1y

positioned with thrust side down.
d. Coat rotor of sea1 (63) with 1ubricating oi1, MIL-L-7808 or MIL-L-23699.

InstaI p1ate (66) recess side up, packing (65), rotor of sea1 (63), gasket (64) and
sea1 (63). Secure with packings with retainers (62), washers (61) and screws (60).
Apply 30 to 35 inch-pounds of torque to screws (60) and lockwire. Insta11 pre-
selected washers (59).
4-287
NAVAIR 03-105-AB-52
e. P1ace shroud (49, sheet 1) over impe1Ier (58, sheet 2). Mark one blade
of impe11er (58) and corresponding Iocation on shroud (49, sheet 1) with blue dye
(Dykem Corp, 8501 De1port Dr, St. Louis, MO 63114, or equivalent). ~easure distance
between top of impel1er (58, sheet 2) and top of shroud (49, sheet 1) at dykem marks
and record as dimension C.
a. Verify measurement from top of shroud (49, sheet 1)

to impeller (58, sheet 2).
b. Verify that washers (59) are insta1Ied.
c. Verify that screws (60) are 10ckwired.
f. Heat impe1Ier (58) if necessary and instaII over turbine shaft (72) to
rest on top of spacers (59). Check for clearance of 0.000 to 0.008 inch between
10west segment on impeller and flat surface of diffuser plate (8, figure 4-6, sheet
1) 10cated adjacet to vanes. Record actua1 measurement as dimension D.
g. Measure to hexagon surface of shaft (69, figure 4-5, sheet 2) with

height gage and record reading as first measurement.
CAUTION
Do not exceed 500 inch-pounds of torque when tighten-

ing nut (57). Torque on nut (57) shal1 be within 300
to 500 inch-pounds.
h. Install nut (57). Ho1d impe11er (58) with nut torquing Impeller Holder,
287148-1-1. Insert 3/8 inch a1Ien-head wrench into nut (57) far enough to release
shaft (69) from wrenching flats of nut (57). Apply 350 inch-pounds of initial
torque, in counterclockwise direction, to nut (57). Continue to torque until shaft
(69) engages nut (57).
i. Measure to shaft (69) with height gage as in step g, and record reading
as second measurement. Subtract second measurement from first measurement in step
g, and check for 0.012 to 0.015 inch difference. Increase torque and recheck as
required to obtain shaft stretch within 0.012 to 0.015 incho
j. Insta11 shroud (49, sheet 1) and a1ign points on shroud (49) and im-
pe11er (58, sheet 2) previously marked with blue dykem. Measure from shroud to
impe11er at dykem marks and record reading as dimension D. Subtract dimension C,
taken in step e, from dimension D. Record difference as dimension E, wheeI to
shroud c1earance. Check that dimension E is within 0.015 to 0.017 incho Select
shims (50, sheet 1) as required to obtain wheeI to shroud clearance (dimension E)
within 0.015 to 0.017 incho Recheck and reshim as required.
k. Insta11 parts (45 through 50) as fo110ws:
(1) Install shims (50). and shroud (49).
4-288
NAVAIR 03-l05-AB-52
(2) Temporari1y instaII two nuts (45) to secure ring (47) to diffuser
housing.
(3) Setup diaI indicator on shroud (49).
(4) Record dial indicator reading with shroud (49) at its lowest point.
(5) Raise shroud (49) to its h1ghest point and record dial indicator
reading.
(6) Se1ect shims (48) to equa1 the difference between the readings
taken in steps (5) and (6) pIus 0.030 to 0.040 incho
(7) Remove two nuts (45) installed in step (2).
NOTE
Shims (48) se1ected in step (6) wi11 provide 0.030
to 0.040 inch pinch on ring (47).
(8) Insta11 shims (48), ring (47), washers (46) and nuts (45). App1y
20 to 25 inch-pounds of torque to nuts (45).
(9) Turn assemb1ed parts over 180 degrees.
1. Se1ect one or two insulators (44) for minimum c1earance between con-
tainment ring and impingement nozzles on stator. Coat both sides on insulator(s)
(44) with primer and a1uminized paint in accordance with paragraph 4-670. Remove
three screws temporari1y insta1led in step k and install insulator(s) (44). Coat
threads of screws (41) with jointing compound (Si1ko1ene 762, Da1ton and Co, Ltd,
Belper, Derbyshire, Eng1and). Loose1y insta11 screws (41), washers (42) and re-
tainers (43).
m. Coat gasket surface of shie1d assemb1y (40) with prtmer and a1uminized
paint in accordance with paragraph 4-670. P1ace shie1d assemb1y (40) in position.
Center shield assemb1y (40) over whee1 assemb1y (72) by insta11ing shim stack at
120 degree intervals between whee1 blade ends and inside diameter of shield assem-
b1y (40). Slide retainers (43) against f1ange of shie1d assembly (40), and apply
12 to 15 inch-pounds of torque to screws (41). Check for 0.027 to 0.029 inch c1ear-
ance between b1ade tip ends and shie1d. Remove shim stock, and coat stator contact
surface of shie1d assembly (40) with jointing compound (Si1kolene 762, Dalton and
Co, Ltd, Be1per, Derbyshire, Eng1and, or equiva1ent).
N~E
During reassemb1y fo11owing starter operation, the

mintmum c1earance between blade tip ends and shie1d
is 0.023 incho
4-289
NAVAIR 03-105-AB-S2
MAlNTENANCE ASSURANCE
Verify turbine wheel blade tip clearance.
n. Apply jointing compound (Silkolene 762, Dalton and Co, Ltd, Belper,
Derbyshire, England, or equivalent) to threads of screws (38) and to surface of f
stator assemb1y (39) that contacts flange of shield assemb1y (40). Apply primer and
aluminized paint in accordance with paragraph 4-670 to surface of stator assembly
f1ange (39) tbat contacts insulator (44). Mark slot locations on stator assemb1y
(39) with ye110w china penci1 (Berol Corp, P.O. Box 1000, Danburry, CT 06810, or
equiva1ent). Insta11 stator assembly (39) and se cure with screws (38). Apply 50
to 70 inch-pounds of torque to screws (38) and 10ckwire.
o. P1ace assemb1ed gas generator housing (54) on its side with cover (37)
bore in the up position. Insta11 pack1ng (36) on cover (37). Insta11 gasket (35)
on tower shaft housing assemb1y (115, sheet 2) base inside of cover (37, sheet 1)
bore of housing (54). App1y petr01atum, VV-P-236, to gasket (35), tower shaft hous-
ing assemb1y (115, sheet 2) boss, inside of cover (37, sheet 1) bore and on packing
and cover (37). Press assemb1ed cover (36, 37) into outer s1eeve of cover insta11-
ing Driver, 289044-1, position driver over cover bore in housing (54) and apply hand
pressure to end of driver to force cover (36, 37) into housing assembly (54). In-
sta11 washer (34) and screw (33). Apply 20 to 25 inch-pounds of torque to screws
(33). Instal1 packings (31) on oi1 strainer assembly (32) and install assembled oil
strainer assemb1y (31, 32) through cover assemb1y (37), gasket (35) and into tower
sbaft housing assembly (115, sheet 2). Hand press oil strainer assemb1y (32, sheet
1) to seat.
4-724. Assemble systems-components (1 through ~O,.figu~e 4-5, sheet 1) to gas

generator as follows:
a. Insta11 packing (28) on union (29). Insta11 assemb1ed union (28, 29) in
normally open solenoid valve (30). .
b. Secure assemb1ed normally open solenoid valve (28, 29, 30) to bracket
(27) with bolts (26), washers (25), and nuts (24).
c. Secure assemb1ed norma1ly open solenoid va1ve (24 through 30) to housing
assemb!y (54) with bolts (23). Do not tighten bo1t (23) that secures c1amp (61,
figure 4-1, sheet 2).
d. Install nut (20, figure 4-5, sheet 1) and packing (19) on tee (21). In-
staI! assemb!ed tee (19, 20, 21) in manual prime solenoid va1ve (22).
e. Install nut (17) and packing (16) on elbow (18). Install assembled
e1bow (16, 17, 18) in manual prime nc so1enoid valve (22).
f. Secure assembled manual prime nc solenoid va1ve (16 through 22) to

bracket (15) with bolts (14), washers (13) and nuts (12).
g. Place assembled gas generator assembly with in1et side up. Install
packing with retainer (7), manifold assembly (6), packing with retainer (5). Loosely
instal1 bolts (4).
4-290
NAVAIR 03-105-AB-52
CAUTION
Make eertain that fue1 manifo1d assembly nut is loosely

threaded to manual prime nc solenoid valve fitting prior
to valve insta1lation. Bending of the fue1 manifold
tube for connection after solenoid valve insta11ation
may cause cracking of the fue1 manifo1d assemb1y at
nearest fue1 nozz1e.
h. Insta11 assemb1ed manual prime nc solenoid va1ve (12 through 22) to
housing &ssemb1y(54) with bo1ts (11). Do not tighten bo1ts (11).
i. Attach fue1 manifo1d assemb1y (6) nut to manual prime ne solenoid va1ve
(22), tee (21). Do not tighten DUt.
j. Attach tube assemb1y (10) over wiring harness (126, figure 4-4, sheet
3) and between tee (21, figure 4-5, sheet 1) and union (29). Do not tighten tube
assemb1y.
k. Torque bo1ts (11) to torque value of 20 to 25 inch-pounds.
1. Torque fue1 manifo1d assemb1y (6), bo1ts (4) to a torque va1ue of 35 to

45 inch-pounds. Tighten fue1 manifo1d assemb1y nut to tee (21).
m. Tighten nuts on tube assemb1y (10) at tee (21) and union (29).
n. Insta11 shroud (3, figure 4-5, sheet 1) into shroud (49) and secure with
c1amp (2). Insta11 screen assembly (1) to shroud (3),'
4-725. ASSEMBLY OF GAS GENERATOR AND ACCESSORY DRIVE ASSEMBLY.
4-726. Assemb1e gas generator and accessory drive assemb1y as fo11ows: Refer to
figure 4-4.
NOTE
Refer to figure 4-1 for p1um.bing and e1ectrica1
insta11ation.
a. Instal1 packing (127, figure 4-4, sheet 3) on permanent magnet generator

(128). Instal1 permanent magnet generator (128) on f1ange of accessory drive assem-
b1y (129). Connect P6 of harness assemb1y connector on permanent magnet generator
(128). C1amp harness assemb1y (126) to the two inboard studs of permanent magnet
generator (128) with clamps (124, 125). Insta11 washers (123) and nuts (122).
App1y 20 to 25 inch-pounds of torque to nuts (122).
b. Instal1 packing (121) on housing assemb1y'(107, figure 4-7). Insta1l
shaft (120, figure 4-4, sheet 3) into accessory gear drive assemb1y (129).
4-291
NAVAIR 03-105-AB-52
a. Verify packing (121) is insta11ed.
b. Verify shaft (120) is insta11ed.
CAUTION
Packing (31, figure 4-5) on oi1 strainer (32) can be
damaged during insta11ation of accessory drive assem-
b1y (129, figure 4-4, sheet 3) to gas generator assem-
b1y (130). Use extreme care during this operation.
c. Position accessory drive assemb1y (129) to gas generator assembly (130).

Se1ect washers (119) to obtain 0.000 to 0.004 inch 100se fit between drive assemb1y
brackets, one located on each side of accessory drive housing, and bosses on gas
generator assemb1y prior to tightening. Insta11 se1ected washers (119), washers
(118) and screws (117). Apply 100 to 140 inch-pounds of torque to screws (117).
d. Se1ect washers (116) to obtain 0.000 to 0.004 inch 100se fit between
bosses on gas generator assembly (130) and hydrau1ic motor (18, figure 4-7) prior
to tightening. Insta11 se1ected washers (116, figure 4-4), washers (115) and '~rews
(114). App1y 50 to 70 inch-pounds of torque to screws (114).
e. Instal1 fitting (113, sheet 2) to hydraulic motor with gasket (112) on

each side, and secure with bo1t (111).
f. Install nut (109), packing with retainer (107A) and gasket (107) on
e1bowassembly (110). Instal1 gasket (107) and tube assemb1y (108) on solenoid
va1ve (drain) (30, figure 4-5), and secure with assembled elbow (107, 109, 110,
figure 4-4, sheet 2). Connect tube assemb1y (108) to union (63, figure 4-12).
g. Instal1 packing (105, figure 4-4, sheet 2) to union (106). Insta1l

assemb1ed union (105, 106) in hydrau1ic motor (18, figure 4-7).
h. Insta11 tube assemb1y (104, figure 4-4, sheet 2) over wiring harness
(126, sheet 3) and to union (106, sheet 2). C1amp tube assemb1y (104) to bo1t ,(23,
figure 4-5) that is nearest to union (29, figure 4-5), using c1amp (103, figure
4-4, sheet 2).
i. Connect tube assemb1y (102) to tube assemb1y (108) and fitting (113).
j. Connect tube assemb1y (101) to tube assemb1y (102). Secure bracket

(100) under inboard washer (35, figure 4-7) and nut (34, figure 4-7). C1amp harness
assemb1y (126, figure 4-4, sheet 2) and tube assemb1y (101) to bracket (100) with
c1amps (98) and (99) respective1y. Secure clamps to bracket (100) with bolt (97)
and nut (96). Clamp tube assemb1y (101) to bracket (53, figure'4-5) with bolt (94,
figure 4-4, sheet 2) and nut (93).
k. Insta11 packing (91) on p1ug (92) and insta1l assembled plug (91, 92)
in gas generator assemb1y (130) and 10ckwire.
4-292
NAVAIR 03-105-AB-52
1. Install nut (88), locking key (87) on rod and bearing (89), and install
assembled parts to turnbuckle (90).
m. InstaIl nut (85), locking key (84) on rod end bearing (86), and install
assembled parta to turnbuckle (90).
n. Install support bracket (78) to rod end bearing (89) using screw (83),
washer (82) and nut (8l). Torque nut (8l) 46 to 50 inch-pounds. Install assembled
parts on gas generator assembly by securing support bracket (78) with washers (80)
and bolts (79). Apply 35 to 40 inch-pounds of torque to bolts (79).
NOTE
There sball be no load on the permanent magnet genera-
tor (128, sheet 3) when the turnbuck1es (74, 90, sheet
2) are installed and torqued.
o. Center turnbuck1e (90) between rod end bearings (86, 89) and adjust to
fit lower bracket on permanent magnet generator (128, sheet 3). Install screw (77),
washer (76), nut (75), and torque 46 to 50 inch-pounds.
p. Torque turnbuckle (90) to 10 inch-pounds. Hold turnbuckle (90), and
torque nuts (85, 88) to 150 inch-pounds. Bend one tab of lock1ng key (87) to lock
nut (88), and other tab to lock turnbuck1e (90). Bend one tab of locking key (84)
to lock nut (85) and other tab to lock turnbuck1e (90).
q. Install nut (72), locking key (71) on rod end bearing (73) and install
assembled parts to turnbuckle (74).
r. Install nut (69), locking key (68) on rod end bearing (70), and install
assembled parts to turnbuck1e (74).
s. Install support bracket (62) to rod end bearing (73) uaing screw (67),
washer (66) and nut (65). Apply 46 to 50 inch-pounds of torque to nut (65). In-
stall aasembled parta on gas generator assembly by securing aupport bracket (62)
with washers (64) and baIta (63). Apply 35 to 40 inch-pounds of torque to bolts
(63).
t. Center turnbuck1e (74) between rod end bearing (70, 73) and adjust to
fit upper bracket on permanent magnet generator (128). Install screw (61), washer
(60), nut (59), and torque nut 46 to 50 inch-pounds.
u. Torque turnbuckle (74) to 10 inch-pounds. Hold turnbuck1e (74), and
torque nuts (69, 72) to 150 inch-pounds. Bend one tab of locking key (71) to hold
nut (72) and other tab to hold turnbuckle (74). Bend one tab of locking key (68)
to hold nut (69) and other tab to hold turnbuckle (74).
v. Install JFS control box assembly (56) and secure to gas generator assem-
bly (130) with washer (58) and bolt (57). Apply 35 to 40 inch-pounds of torque to
bolt (57).
4-293
NAVAIR 03-105-AB-52
w. Insta11 bracket (54, 55). Secure bracket (54, 55) and e1ectrica1 con-
trol box (56) to gas generator assemb1y with washers (53) and bolts (52). App1y
50 to 70 inch-pounds of torque to bolts (52). Connect P2 of e1ectrical harness
assemb1y (126) to e1ectricaI controI box (56).
x. Install accumulator assembly (49) to bracket (54, 55) and secure with ~
washers (51), and bolts (50). Connect tube assembly (101) to union (2, figure 4-10),
and tube assembly (104, figure 4-4, sheet 2) to union (4, figure 4-10).
y. Install gasket (48, figure 4-4, sheet 1) on igniter p1ug (45). Insta1l
assemb1ed igniter plug (45,48) in gas generator assembly (130, sheet 3) with
washers (47, sheet 1) under boss of igriiter plug (45). Secure with bolts (46).
AppIy 35 to 40 inch-pounds of torque to bo1ts (46).
z. Insta1I ignition unit (41) with washers (43) and bo1ts (42) except for
washer and bo1t nearest e1ectrica1 contro1 box (56, sheet 2). Connect P8 of wiring
harness assemb1y (126, sheet 3) to ignition unit (41, sheet 1). C1amp wiring har-
ness assemb1y (126, sheet 3) with c1amp (44, sheet 1), and washer (43) and bolt (42)
nearest e1ectrica1 contro1 box (56, sheet 2). App1y 35 to 40 inch-pounds of torque
to bolts (42, sheet 1).
aa. Connect 1ead (40) between igniter p1ug (45) and ignition unit (41).
ab. Connect P4 of wiring harness assemb1y (126, sheet 3) to manual prime

nc solenoid va1ve (22, figure 4-5) .and P5 of wiring harness assemb1y (126, figure
4-4, sheet 3) to solenoid norma11y opeen va1ve (30, figure 4-5). Insta11 support
bracket (39, figure 4-4, sheet 1) to gas generator assemb1y (130, sheet 3) with
long ang1e of support bracket facing housing (130) and with bo1ts (38, sheet 1)
through short ang1e attaching bracket to housing (130, sheet 3). Apply 20 to 25
inch-pounds of torque to bolt (38, sheet 1). C1amp wiring harness assembly (126,
sheet 3) and tube assembly (101, sheet 2) to support (39, sheet 1) with c1amp (37)
and c1amp (36) respective1y. Secure with bo1t (35) and nut (34). Apply 20 to 25
inch-pounds of torque to nut (34).
ac. Insta1l nut (32 and packing (31) on e1bow (33). Insta11 assemb1ed
elbow (31, 32, 33) in accumu1ator assembly (49, sheet 2).
ad. Connect tube assemb1y (30, sheet 1) to elbow (33). Connect va1ve (29)
to tube assemb1y (30) with arrow on va1ve pointing away from accumu1ator assembly
(49, sheet 2). Connect tube assembly (28, sheet 1) to va1ve (29). Connect tee (27)
to tube assemb1y (28). Connect tube assembIy (27A) between tee (27) and eIbow (18,
figure 4-5).
ae. Insta11 spacer (26, figure 4-4, sheet 1) and packing (25) in fueI
contro1 assemb1y (31, figure 4-7). Install tube assemb1y (24, figure 4-4), and
secure with screws (23, sheet 1). App1y 12 to 15 inch-pounds of torque to screws
(23) and lockwire.
af. Connect valve (22) to tube assemb1y (24) with arrow on vaIve (22)
pointing away from fue1 contro1 assembly. Connect tube assemb1y (21) between va1ve
(22) and tee (27).
4-294
NAVAIR 03-l05-AB-52
ag. Insta11 packing (20) over e1ement of fi1ter (19) and instaIl filter
e1ement in filter housing.
ah. Install nut (17) and packing (16) on fitting (18). InstaI1 assembled
fitting (16, 17, 18) in filter (19, 20). InstaIl bracket (15) over housing of
filter (19). Secure assemhled filter (15 through 20) to gas generator assembly
(130) with washers (14) and bolts (13). App1y 35 to 40 inch-pounds of torque to
bo1ts (15).
ai. Instal1 gasket (12), tube assemb1y (11) and secure with screws (10).
Apply 12 to 15 inch-pounds of torque to screws (10) and lockwire. Insta11 clamps
(9) ·one on tube assemb1y (24) and the other on tube assemb1y (11). Sp~~re c1amps
together with bo1t (8) and nut (7). Apply 20 to 25 inch-pounds of tor~ue to nut
(7).
ajo Insta11 tube assembly (6) and c1amp bracket on fue1 control with c1amp
(5). Secure c1amp to bracket with bolt (4) and nut (3). Apply 20 to 25 inch-
pounds of torque to nut (3).
ak. Insta11 identification plate (1) in accordance with paragraph 4-671 if

required.
aI. Ink stamp identifyingnomenc1ature in 1/8 inch 1etters as i11ustrated
in figure 4-93.
4-727. ASSEMBLY OF PO}ngR TURBINE ASSEMBLY.
4-728. Assemb1e turbine whee1, bearings, gears, and carrier (85 through 141, figure
4-3, sbeet 3 and 4) as fol1ows:
a. Coat threads of setscrews (90, 127) with 1ubricant (NV Liquid-Mo1y,

Lockrey Co, Lubricants Div, Cedar Shores, Soutbampton, NY 11968, or equiva1ent).
Insta11 setscrews (90, 127) into carrier (141), and back them out far enough to
prevent interference of further assemb1y.
b. Instal1 one ring (133) into carrier (141) in three p1aces.

c. Position carrier (141) under arbor press. Insta11 bearing (134) on
Bearing Press Driver, 287156-1-1, and position bearing assemb1ed on too1, over
bearing bore in carrier (141). Press bearing (134) into bore of carrier (141)
until shou1der of driver contacts carrier (141). Remove driver. Insta11 ring
(133). Check bearing (134) for end play within 0.000 to 0.004 incho Select shims
(135) as required to provide end p1ay within 0.000 to 0.004 incho Remove ring (133)
and bearing (134). Insta11 shims (135) in position as i11ustrated and reinsta11
bearing (134) and ring (133). Complete this step for two remaining bearings (134).
d. Insta11 spacers (132) with beve1 side toward bearing (134).
e. Position gear (131) on carrier (141). Insta11 P1anetary Gear Bo1der,

285468-1-1, in standard bench vise. Lower carrier (141) over gear ho1der. In-
stal1 gears (130) into carrier (141) and a1ign scribe mark on gears (130) with marks
4-295
NAVAIR 03-105-AB.-52
( )
--r~OIL FILL
/
OIL DRAIN .. _
fiVIEW A
Figure 4-93. Locat1on of l~omenclature Markings on Gas

Generator and Accessory Drive Assembly
4-296
NAVAIR 03-105-AB-52
on sp1ined post of p1anetary gear ho1der. Insta11 gearshafts (129) and bearings
(128) into carrier (141). Secure bear1ngs (128) iuto position by engaging setscrews
(127) into ho1es of bearings (128). App1y 2 to 4 inch-pounds of torque to setscrews
(127).
f. Position carrier (141, sheet 4), with threaded end of gearshafts (129)
up, ou P1anetary Gear Ho1der, 285468-1-1, instal1 nuts (125). Apply 50 to 80 inch-
pounds of torque to nuts (125). Check pin ho1es in nuts (125) for a1ignment with
ho1es in gearshafts (129). Se1ect washers (126) as required to reposition nuts
(125) so ho1es will a1ign when 50 to 80 inch-pounds of torque is app1ied to nuts
(125). Remove nuts (125) and insta11 washers (126), and reinsta11 nuts (125). In-
sta1l pins (124), and bend pins in center of gearshafts (129) to lock ~n place.
Use suitab1e too1 to prec1ude cuts or other damage to pins.
a. Verify uuts (125) are proper1y torqued, and pins

(124) are proper1y safetied.
b. Verify marks on gears (130) a1ign proper1y with

marks on sp1ined post of Planetary Gear Bo1der,
285468-1-1.
g. Determine required thickness of shims (113, sheet 3) and 1ength of pin

(119) as fo110ws:
(1) Insta11 seat (120) in carrier (141, sheet 4). Align pin ho1e in
seat (120, sheet 3) with pin ho1e in carrier (141, sheet 4). Insta11 one of pin
(119, sheet 3) in 1iner (117). Insta11 assemb1ed 1iner (117, 119) into carrier
(141, sheet 4) with pin (119, sheet 3) a1igned with pin ho1es in seat (12.Q) and
carrier (141, sheet 4). InstaI1 housing (116, sheet 3) into 1iner (117) with pin
slot in outer circumference aligned with pin slot in inner circumference of 1iner
(117). Engage housing (116) to 1iner (117) with pin (118).
a. Verify pin (119) aligns with holes in seat (120)

and carrier (141, sheet 4).
b. Verify pin (118, sheet 3) is proper1y insta11ed.
(2) Install bearing (115) and seat (114). Check tbat pin (119) is
f1ush to 0.020 inch be10w surface of seat (114). Rep1ace pin (119) with 10nger
or shorter pin as required.
(3) P1ace rotor of sea1 (112) against inner race of bearing (115).
Heasure from rotor of seal (112) down to seat (114). Se1ect shims (113) as required
to reduce measurement within 0.164 to 0.175 incho Place shims (113) on seat (114).
Measure from rotor of sea1 (112) down to shims (113). Rese1ect shims as required
to obtain measurement within 0.164 to 0.175 incho
4-297
NAVAIR 03-105-AB-52
(4) Remove rotor of sea1 (112), shims (113), seat (114), bearing (115),
housing (116), 1iner (117), pins (118, 119) and seat (120).
h. Stack parts as fo110ws over threaded end of Spring Compressor, 285458-

1-1, bearing (123), spacer (122), spring (121), seat (120), pins (118, 119), 1iner
(117), housing (116), bearing (115), seat (114) and rotor of sea1 (112). P1ace f
sleeve of compressor over threaded endj insta11 nut of spring compressor and com-
press spring (121) as required.
i. Insta11 parts assemb1ed OD spring compressor into carrier (141, sheet 4).
Use 0.060 diameter by 5.0 inch 10ng pin to a1ign ho1es for pin (119, sheet 3).
Insta11 shims (113). Insta11 sea1 (112) over sleeve of Spring Compressor, 285458-
1-1, then install Seal Pressing Driver, 289025-1, over sleeve. Press sea1 (112)
into carrier (141, sheet 4) with arbor press.
j. Position two gaskets (110, sheet 3) on carrier (141, sheet 4). Measure
from outer surface of top gasket (110, sheet 3) to she11 of sea1 (112). Se1ect
shims (111) of thickness to reduce dimension to within 0.007 to 0.013 incho Insta11
se1ected shims (111). Measure from outer surface of top gasket (110) to surface of
shims (111). Add or remove shims (111) as required to obtain reading of 0.007 to
0.013 incho
k. Insta11 two gaskets (109), insu1ation blanket (108), retainer (107),

and screws (106). App1y 20 to 25 inch-pounds of torque to screws (106) and 10ck-
wire. Remove Spring Compressor, 285458-1-1.
1. Insta11 insu1ation material (microquartz, 'six pounds per cubic foot

density, Johns-Manvi11e Corp, at Greenwood P1aza, Denver, CO 80217) as required in
retainer (107). InstaI1 cover (105) and secure by crimping retainer (107) in six
p1aces, approximate1y 60 degrees apart.
Verify that retainer (107) is properly crimped.
m. Instal1 whee1 assemb1y (103, 104) on Turbine Wheel Ho1der, 285457-1-1,

insta11 Bearing Guide Sleeve, 289640-1, on end of wheel assemb1y shaft. Insta11
assemb1ed carrier (106 through 141, sheet 4) over shaft of wheel assembly (103,
104, sheet 3) so that bearing (115) guides over bearing guide sleeve. P1ace Bear-
ing and Bushing Driver, 287147-1-1, on inner race of bearing (123) and press assem-
b1ed carrier (106 through 141, sheet 4)- onto shaft of whee1 assemb1y (103, 104,
sheet 3).
n. Insta11 gear (102), and a1ign scribe marks on gear (102) with scribe
marks on gears (130, sheet 4). Insta11 nut (101, sheet 3); app1y 300 to 400 inch-
pounds of torque to nut (101). Insta11 pin (100) and safety by bending pin inside
center of whee1 assemb1y shaft. Use suitab1e too1 to preclud~ cuts ar other damage
to pino
'.
4-298
ti
NAVAIR 03-l05-AB-52
MAINTENANCE AS SURANCE
Verify a1ignment of marks on gears (130, sheet 4) and

gear (102, sheet 3).
o. Install lever (98) into support (99) and secure with pin (97). Install
switch assembly (96), plates (94, 95), screws (93) and nuts (92). Apply 4 to 6 inch-
pounds of torque to nuts (92) with Socket Wrench, 285471-1-1. Insert wire of switch
assembly (96) through hole in support (99).
p. Insert wires of sw1tch assemb1y (96, sheet 3) through ho1e in gear
carrier (141, sheet 4). Insta11 assemb1ed bearing support (92 through 99, sheet 3)
into carrier (141). Install ring (91) us1ng Torque Wrench Adapter, 285469-1-1,
apply 5 to 8 inch-pounds of torque to setscrew (90).
q. Install bearing (88) into hub (89) and secure with ring (87). Insta11
lockring (86) on hub (89). Compress lockring tight against hub (89), and press
assembled hub (86 through 89) onto support (99) using Bearing Press, 287157-1-1,
insta11 ring (85).
4-729. Insta11 assemb1ed turbine wheel and carrier (85 through 141, sheet 3 and 4)
into exhaust housing (84, sheet 2) as follows:
a. Insert three pins through holes in face of sbaft assembly (82) to retain
-. ·pawis (79). Instal1 sbaft as~embly (79 through 82) over hub (89, sheet 3), and
remove pins.
b. Instal1 packing (73, sheet 2), shims (73A) and bearing (72) in housing
(78). Insta11 retainer (70), washers (70A) and screws (71). Apply 20 to 25 inch-
pounds of torque to screws (71).
c. Use Bearing and Bushing Driver, 285486-1-1, which consists of following

parts: sbaft, driver, thrust bearing, jam nut, and tee handle. Instal1 gasket
(69). Thread shaft of tool into shaft assembly (82). Place housing (78) over in-
stalled tool sbaft, and route wires of sw1tch (96, sheet 3) through slot and hole
in housing (78, sheet 2). Position driver of tool against inner race of bearing
(72).. Install remaining tool parts: thrust bearing, jam nut, and tee ~nd1e. Hold
tee handle and turn jam nut clockwise to insta11 bearing (72).
CAUTION
Bearing (72) must bottom out against shoulder of sbaft

assemb1y (79 through 82).
d. Install baffle (68). Install pilot portion of Retaining Ring Pilot and
Driver, 284311-1-1, over end of sbaft (82). Place ring (67) on end of pilot, and
position driver portion of tool on top of ring (67). Apply hand pressure on driver
portion of tool to install ring (67) into groove of sbaft (82). Remove tool1ng.
4-299
NAVAIR 03-105-AB-52
e. Coat lip and underside of seal (65) with &rease (MIL-G-3278). Install
Seal Installing Pilot, 281200, in bore of shaft (82). Place seal (65) over pilot
and install by hand pressure. Remove tool. InstaIl bolts (66) and tighten to a
,
torque value of 20 to 25 inch-pounds.
CAUTION
Do not lift assembled parts (65, sheet 2 through 141,
sheet 4) by housing (78, sheet 2).
NOTE
Use temporary match marks applied during disassembly

when aligning housings (78) and (84).
f. Coat threads of screws (58, 61) with compound (Fel-Pro C-5A, Fel-Pro
Inc, Div of Felt Products Mfg Co, 7450 N McCormick, Skokie, IL 60076, or equivalent).
Install assembled parts (65 through 141, sheet 4) into housing (84, sheet 2). In-
stall bracket (60), washers (59), and screws (58). Instal1 bracket assembly (63,
64), washers (62), and screws (61). Tighten screws to a torque value of 115 to 120
inch-pounds.
g. Insert wires of switch (96, sheet 3) through bushing (42, sheet 1),
and insert bushing in housing (78, sheet 2) until bushing bottoms out. Fill cavity
around bushing (42, sheet 1) and switch wires with sealing compound (RTV731, Dow
Corning Corp, South Saginaw Road, Midland,. MI 48640, or equivalent). Install cover
assembly (40, 41) and secure with washer (39) and screw (38). Apply 50 tO .. 7"O" inch-
pounds of torque to screws(38). Install insulA'tion sleeving over wíres from switch'"
(96, sheet 3).
·h. Install assembled parts (58 through 141, sheet 4) in Turbine Holder,
285454-1-1, assemble ring segments (52, sheet 2) into shield assembly (55). In-
stall support assembly (53) and screws (51). Do not tighten screws at this time.
NOTE
When placing assembled parts (51 through 55) into hous-
ing assembly (84), aiign temporary match marks on con-
tainment support assembly (53) and exhaust housing (84)
that were applied during disassembly. _
i. Place assembled parts (51 through 55) intohousing assembly (84). In-
stall screws (50) and tighten. Use 0.030 to 0.032 inch diameter wire to obtain gap
between blades of whee1 assembly (104, sheet 3) and shield assembly (55, sheet 2).
Apply 25 to 30 inch-pounds of torque to screws (51), and recheck gap. Loosen and
retighten screws (51) until proper ~ap is obtained. Lockwire screws in groups of
three. Then remove bolts (50) and shield assembly (55).
j. Assemble d1ffuser (57). PIace heat shield ·(56) around diffuser (57)
and housing assembly (84).
4-300
NAVAIR 03-105-AB-52
k. Insta11 insulation batt (54) and secure it with 1/2 inch wide glass
c10th electrica1 tape (Scotch No. 27, 3 M Co, 3 M Center, St. Paul, MN 55101, or
equiva1ent). Assemb1e shield assembly (55) into housing assemb1y (84) and secure
with screws (50). Recheck gap as spec!fied in step h.
Ver1fy that clearauce between blades of wheel assembly

(104, sheet 3) and shield assembly (55, sheet 2) ia
within 0.030 to 0.032 incho
4-730. Install externa11y mounted parts (1 through 47, sheet 1) to power turbine
assembly as follows:
a. Instal1 gasket (46) to plug (47), and gasket (44) to plug (45). Install
assembled plugs (46, 47) and (44, 45) into housing assembly.
b. Install clamp (37), bolt (36), and nut (35).
c. Assemble gasket (33) over thermocouple (30); WTap thermocouple probe

with micro-quartz, six pound-foot density (Jobns-Manville Sales Corp, at Greenwood
Plaza, Denver, CO 80217), and position assembled thermocouple (30, 33) on housing
assembly (84). Instal1 washer (31), clamp (34), and bolts (32).
NOTE
Perform electric and electronic w1ring procedure in
accordance with NAVAIR 01-lA-505.
d. Connect electrical plug connector (26) to thermocouple (30).
e. Loosen clamp screws ou back shell of connector (27). Separate connector

(27) to expose contacts. Check that alI potting compound bas been removed from
around contacts, wires, and back shell.
f. Insert wires from switch assemb1y (96, sheet 3) through insulation
s1eeving and back she11 of connector (27, sheet 1).
g. Solder b1ack wire to contact B, red wire to contact D, and orange wire
to contact F. Solder in accordance with Military Standard 454, requirement 5,
using SB5 solder per QQ-S-571.
h. App1y potting compound MIL-S-23586 (RTV811l, General E1ectric Co,
Sllicone Products Business Dept, Waterford, NY 12122, or equivalent) to back she11
of connector (27) to assure sealing of exposed contacts. Assemb1e connector and
secure clamp screws.
i. Install clamp (25), and bolt (24).
4-301
NAVAIR 03-105-AB-52
j. Assemb1e gaskets (19) and f1u1d passage bo1t (18) to 011 dra1n adapter
(22) and insta11 on hous1ng (78, sheet 2). Torque f1u1d passage bo1t 50 to 80 1nch-
pounds and 10ckwire.
k. Insta11 f1exib1e hose (16, sheet 1) onto 011 drain adapter (22) and
secure with hose clamp (17).
1. Assemb1e gasket (7) on 011 dipstick (8) and insta11 1nto oi1 fi11er
housing (10, 11).
m. Insta11 1ubricat1on instruction p1ate, 1f required, in accordance with

paragraph 4-671.
n. Insta11 oi1 fi11er housing (10, 11) into f1exib1e hose (16) and secure
with hose c1amp (15).
o. Insta11 quick re1ease p1n (6) into pin ho1es of oi1 f111er hous1ng (10,
11).
p. Prepare mu1timeter to check continuity, and connect mu1timeter 1eads to

pins B and D of wiring harness connector (27).
q. Coat threads of switch actuating governor assemb1y (5) with 1ubr1cant

(HF825 , Roya1 Lubr1cants Co, P.O. Box 95 R1ver Rd, E. Hanover, NJ 07936, or equiv-
a1ent). Position switch actuating governor assemb1y (5) inside of shaft assemb1y
(82, sheet 2).
r. Pos1tion shaft 10ading Ho1ding Too1, 281846-1, into shaft assemb1y (82)
so that 1ip of too1 engages retaining ring groove.
s. Position 1ug type Spanner Wrench, 281686-1, through center of shaft

10ading ho1ding too1 and into shaft assemb1y (82) unti1 slot of spanner wrench
engages f1ats on switch actuat1ng governor assemb1y (5, sheet 1).
t. Squeeze hand1es of shaft 10ading ho1d1ng too1 and pu11 outward to 10ad
shaft assemb1y (82, sheet 2).
u. Grasp tee handle of 1ug type spanner wrench and turn switch actuating
governor assembly (5, sheet 1) clockw1se unt11 continu1ty 1s ind1cated on mu1timeter.
Turn switch actuat1ng governor assemb1y (5) c10ckwise an add1tional 120 to 150
degrees.
v. Remove multimeter leads from wir1ng harness assembly connector. Remove

1ug type spanner wrench and shaft 10ading ho1d1ng too1 from shaft assemb1y.
w. Assemb1e output shaft retainer (3) and pack1ng (2) on output shaft
assemb1y (4). A11gn f1ats of governor assemb1y (5) with slot in output shaft assem- ~
b1y (4). Insta11 output shaft assemb1y (4). Lock output shaft assemb1y (4) 1nto ~
position by engaging output sbaft reta1ner (3) 1nto reta1ner groove of shaft assem-
b1y (82, sheet 2).
4-302
NAVAIR 03-105AB-52
x. Position power turbine assembly on a suitable driving fixture and rotate the units' output
shaft at 6500 ±50 rpm for ten minutes. Vary the speed up and down a few times.
y. Observe that the clutch remains disengaged at speeds above 3500 rpm and re-engages at
speeds below 2000 rpm. Ensul'e no leakage of liquids 01' gases.
z. Remove the power turbine from the test fixture.

..
NAVAIR 03-105-AB-52
4-731. ASSEMBLY OF MAJOR ASSEMBLIES INTO JET FUEL STARTER ASSEMBLY.
4-732. Assemb1e major assemb1ies into jet fue1 starter assemb1y as fo110ws: Refer
to figure 4-2.
CAUTION
Do not support weight of starter on output shaft or

end-load output shaft when handling starter. Damage
to internaI parts of starter may resulta
a. Instal1 power turbine assemb1y (5) into Turbine Ho1der, 285454-1.

b. Insta11 gas generator and accessory drive assemb1y (6) on power turbine
assemb1y (5).
c. Insta11 coupling (4) as i11ustrated in figure 4-94. Apply 100 to 120
inch-pounds of torque to nut on coupling (4).
d. Connect connector (27, figure 4-3, sheet 1) to JFS control box assembly
(56, figure 4-4, sheet 2).
e. Connect oi1 fi11er housing (11, figure 4-3, sheet 1) to bracket on gas
generator assemb1y (6, figure 4-2, sheet 1) with quick relesse pin (6, figure 4-3,
sheet 1).
f. Connect suitable lifting adapter to starter and hoist starter from

Turbine Ho1der, 285454-1.
g. Lower starter into suitab1e work stand or transportation dolly.

h. InstaIl engine starter mounting fIange (2, figure 4-2) and secure with
clamp coupling (1). Torque 100 to 120 inch-pounds.
i. Cover exhaust port and install coupling (3).

j. InstaIl a protective cover over the fmpeller air inlet adapter screen.
k. Check tbat fuel inIet fitting, oi! drain fitting and hydraulic motor
openings are plugged and closed off.
4-733. ALIGNMENT AND ADJUSTMENT.
AGE REQUIRED
SHAFT LOADING HOLDING TOOL 281846-1
LUG TYPE SPANNER WRENCH 281686-1
4-303
NAVA1R 03-10S-AB-S2
VIEW A-A
Figure 4-94. Clamp Coupling Orientation
AGE REQUlRED (CONT)
MULTIMETER Model 260 PRT (Simpson

Electric Co, Division of
American Gage and Machine
Co, 5200 W Kenzie St,
Chicago, 1L 60644, or •
equivalent) ,
4-734. Adjust power turbine assembly sensitive switch assembly as follows: Refer
to figure 4-3.
4-304
i
NAVAIR 03-105-AB-52
a. Disengage output sbaft retainer (3, sheet 1) from retainer ring groove
and remove assemb1ed output sbaft (2, 3, 4).
b. Prepare multimeter to check continuity and counect 1eads to pins B and
D of connector P3.
c. Position shaft 10ading Ho1ding Too1, 281846-1, into shaft assemb1y (82,
sheet 2) so that 1ip on too1 engages sbaft retaining ring groove.
d. Position 1ug type Spanner irench, 281686-1, through center of sbaft

10ading ho1ding tool and into sbaft (82) so slot of wrench engages f1ats on switch
actuating governor assemb1y (5, sheet 1).
e. Squeeze hand1es of sbaft 10ading ho1ding too1 and pu11 outward to 10ad
sbaft. Grasp tee hand1e of spanner wrench and adjust governo r (5) in until con-
tinuity is obtained, and then turn governo r (5) an additional 120 to 150 degrees.
f. Remove too1ing and mu1timeter.
g. Rep1ace packing (2) on output sbaft (4). Inspect output sbaft (4) and
retainer (3) in accordance with paragraphs 4-124 and 4-125. Repair or rep1ace as
required. Install assembled output shaft (2, 3, 4) with sbaft slots engaging
governo r assembIy flats. Engage retainer (3) in retainer groove.
4-735. Adjust accessory drive assemb1y sensitive switch assemb1y as fo11ows:

a. Remove screw (39, sheet 2), washers (40) and sensitive switch assemb1y
(50 percent) (38, 41, 42).
b. Remove and discard packing (41).
c. Prepare mu1timeter to check continuity and connect 1eads to pins B and F
of connectoron sensitive switch assemb1y (38).
d. Take up end p1ay by sliding switch actuating governo r assembIy (43
through 51) against thrust washer (53).
e. Install sensitive switch assemb1y (38) with trial amount of sh1ms (42).
Alter thickness of shims (42) unt1l continu1ty 1s ind1cated.
f. Disconnect mu1timeter and remove 0.020 inch of shims (42) to assure
proper switch actuat10n.
g. Install new packing (41) and selected shims (42) on sensitive switch
assembly (42) and instal1 assemb1ed switch assemb1y (38, 41, 42) to housing assemb1y
(107).
h. Insta11 W8shers (40), screws (39) and torque bolts to 20 to 25 inch-

pounds and lockwire.
4-305
- - -------------
NAVAlR 03-105-AB-52
4-736. Adjust acce1eration 1imiter va1ve cracking pressure as fo110ws: Refer to

figure 4-13.
a. Check acce1eration 1imiter va1ve cracking pressure in accordance with

procedure in paragraph 4-743.
b. Ho1d acce1eration 1imiter va1ve adjustment screw (11) and 100sen nut
(6) •
c. Turn adjustment screw (11) c10ckwise to increase cracking pressure,

counterc1ockwise to degrease pressure.
d. Ho1d adjustment screw (11) and tighten nut (6).
e. Recheck and readjust acce1eration 1imiter va1ve cracking pressure as

required. Refer to paragraph 4-743. Lockwire nut (6).
4-737. Align fue1 manifo1d (6, figure 4-5) as fo110ws:
a. Check to ensure that center of fue1 manifo1d supp1y 1ine fIare is

within 0.10 inch of the center1ine of the supp1y fitting. lf not bend manifo1d to
obtain proper a1ignment.
b. Inspect after bending in accordance with paragraph 4-202, step b.
4-738. TESTlNG.
AGE REQUlRED
Refer to paragraph 4-739 for test setup requirements.
4-739. TEST SETUP. Provide test equipment as shown in figure 4-95 and as fo11ows:
8. Provide test stand (111, sheet 4) with equipment to function as fo110ws:
(1) Mounting pad (102) to mount and support JFS test unit (101).
(2) Torque measuring system (107, 108) to monitor JFS test unit torque.
(3) F1ywhee1 (109) with total moment of- inertia of 12.5 slug ft 2 to
simulate aircraft engine 10ad.
(4) F1ywhee1 brake assemb1y to provide means of stopping test stand

rotating assemb1y.
(5) OVerrun drive assemb1y (103) capab1e of driving JFS test unit out-
put shaft at 6500 +50 rpm for 10 minutes.
(6) Disconnect assemb1y (106) to disconnect f1ywhee1 from JFS test untt
output shaft during output shaft overspeed testo
4-306
i
NAVAIR 03-105-AB-52
TO TO
NO. NO. TO TO TO
69 60 NO. NO. NO.
81 85 84
12-.ij
5
. rI,
ACVOLT
I ~-8
11-0 13-cb ~l~.

4----L1'
r AC AMP
I
15
0.-+--9
3-t----L~
2 I, I
o
DCAMP
50%
SW
""--'&"'--17
\f-ll
IIIII=~III rtD~'~1~~190l
NORM
1 ~ ~·-+--10
EXT AC ABORT
LOAD
TO NO. 77 TO NO. 76
24
\
27
HYDRAULlC SYSTEM \
'--_.....J\
30
I
\
33 t
34
JFS HYDRAULlC INITIATION SYSTEM
TO
NO.
45 39
3W;I--P. I ___ 4<: ~=C. .-=r= =1~- -oI/I: .p=42

_ _ TO NO. 45
TEST SETUP FUEL SYSTEM
Figure 4-95. Installation of JFS 1nto Test Setup (Sheet 1 of 4)

4-307
NAVAIR 03-105-AB-52

1. EXTERNAL AC LOAD SWITCH 29. HYDRAULIC PUMP
2. DC AMMETER. 30.
3. DC VOLTMETER
4. AC AMMETER.
5. AC VOLTMETER
31.
32.
HYDRAULIC CHECK VALVE
ACCUMULATOR PRECHARGE PRESSURE
GAGE
FILLER VALVE (air or nitrogen)
,
6. DC INDlCATOR LAMP 33. ACCUMULATOR
7. AC INDlCATOR LAMP 34. ACCUMULATOR PRESSURE GAGE
8. OVER TEMPERATURE SIMULATOR 35. FUEL TANK
9. 50% SWITCH INDICATOR 36. FUEL PUMP
10. ABORT SWI TCH 37. FUEL PRESSURE REGULATOR VALVE
lI. ACCESSORY GEARBOX CASE PRESSURE 38. FUEL SHUTOFF VALVE
GAGE 39. IMMERSION THERMOCOUPLE
12. SED IMENT STRAINER ELEMENT 40. FUEL FILTER
ASSEMBLY WITH PRESSURE TAP 41. FUEL INLET PRESSURE GAGE
13. FUEL CRACKING PRESSURE GAGE 42. FLOWMETER
(O to 100 paig) 43. OIL TEMPERATURE IMMERSION THERMD-
14. ACCESSORY GEARBOX OIL PRESSURE COUPLE
GAGE (O to 50 paig) 44. OIL TEMPERATURE IMMERSION THERMD-
15. RPM MONOPOLE PICKUP COUPLE
16. TEMPERATURE INDlCATOR 45. TEMPERATURE INDlCATOR
17. IMMERSION THERMOCOUPLE 46. INLET VENTURI .1 PRESSURE GAGE
18. EXBAUST DUCT 47. THERMOCOUPLE (3 req'd)
19. GAS GENERATOR SPEED INDlCATOR 48. SENSING MANIFOLD
20. HYDRAULIC RESERVOIR 49. INLET AIR SENSING DUCT
21. HYDRAULIC CHECK VALVE 50. VIBRATION PICKUP
22. HYDRAULIC FILTER 51. VIBRATION PICKUP MOUNT
23. DISCONNECT TO HYDRAULIC MOTOR 52. VIBRATION PICKUP
OUTLET 53. VIBRATION PICKUP MOUNT
24. HYDRAULIC CHECK VALVE 54. VIBRATION METER
25. DISCONNECT TO HYDRAULIC MOTOR 55. POWER TURBlNE VIBRATION PICKUP
INLET INSTALLATION POINT
26. HYDRAULIC MANUAL CONTROL VALVE 56. PLUG
27. HYDRAULIC REVERSE FLOW BALANCED 57. OIL SERVICING PORT
RELIEF VALVE (3600 to 3650 paig 58. MAGNETIC PLUG
crack preasure) 59. IMMERSION THERMOCOUPLE
28. HYDRAULIC MANUAL DISCHARGE VALVE 60. ELECTRICAL PLUG CONNECTOR P9
61. ELECTRlCAL COUNTER
4-308
NAVAlR 03-105-AB-52
TO TO TO
NO. TO NO. NO.
57 OR 100 NO. 55 6S
~ TO
NO.
72 50
51-
52
53
88
45
I
(8
~'..!I!""
'",,11.
t
!li
I I
47
81 60 59
Figure 4-95. Installation of JFS into Test Setup (Sheet 2 of 4)

4-309
NAVAIR 03-105-AB-52
..
~KEY TO FIGURE 4-95 (CONT)
62. OIL FILLER HOUSING 81. SEDIMENT STRAlNER ELEMENT
63. OIL DIP STICK ASSEMBLY
64.
65.
JFS FUEL INLET
GAS GENERATOR VIBRATION
PICKUP POINT
82.
83.
SCREW
ANNULAR ALUMlNUM ASBESTOS
GASKET
,
66. RESTRICTED FLOW CHECK VALVE 84. OIL PRESSURE SENSING PORT
67. METAL TUBE ASSEMBLY 85. FUEL CHECK VALVE OUTLET
68. ACCUMULATOR ELBOW 86. METAL TUBE ASSEMBLY (fuel)
69. ELECTRlCAL RECEPTACLE 87. OIL DIP STICK
CONNECTOR (Jl) 88. OIL DRAIN PLUG
70. FUSE FI 89. LUBRlCATION INSTRUCTION PLATES
71. INDlCATOR 90. MANIFOLD TO TUBE ELBOW ASSEMBLY
72. AIR INLET (fuel drain)
73. MANUAL PRIME NC SOLENOID 91. HYDRAULIC MOTOR INLET PORT
74. LIFTING BRACKET 92. HYDRAULIC MOTOR DISCHARGE PORT
75. JFS METAL TUBE ASSEMBLY 93. EXHAUST FLANGE
(compressor discharge pressure) 94. CLAMP COUPLING
76. MAIN JET FUEL STARTER FUEL 95. CLAMP COUPLING
CONTROL ASSEMBLY 96. ENGINE STARTER MOUNTING F1AL~E
77. OIL SERVICING PORT 97. OUTPUT SHAFT ASSEMBLY
78. PLUG 98. PLUG
79. ANNULAR ALUMINUM ASBESTOS 99. ANNULAR ALUMlNUM ASBESTOS
GASKET GASKET
80. GAS GENERATOR INSTRUMENTATION 100. OIL SERVICING PORT
PORT
4-310
NAVAIR 03-105-AB-52
66 65
69
70
73 72
Figure 4-95. Installation of JFS into Test Setup (Sheet 3 of 4)
4-311
~
~>
I
W
.....
N
~
o
W
....o
I
VI
~I
VI
N
o c::=:J c:::::l
/109
111
Figure 4-95. Instal1ation of JFS into Test Setup (Sheet 4 of 4)

..
- -
NAVAIR 03-l05-AB-52
lO!. JFS TEST UNIT 106. DISCONNECT ASSEMBLY

102. TEST STAND MOUlITING PAD 107. TORQUE INDlCATOR
103. OVERRUN DRIVE ASSEMBLY 108. TORQUE TRAl~SDUCER
104. MONOPOLE PICKUP 109. FLYWHEEL
105. COUNTER 110. LOAD BRAKE
111. TEST STAND
(7) Load brake (110) to provide a means of app1ying a variab1e 10ad to

the test stand rotating assemb1y.
(8) Speed measuring system (104, 105) to monitor output shaft speed.
WARlUNG
To prevent injury from the inadvertent re1ease of

hydraulic f1uid under high pressure, do not charge
the JFS hydrau1ic initiation system until it is
connected to the hydraulic motor.
b. Provide JFS hydraulic initiation system (20 through 34, sheet 1) tbat
dup1icates the performance of the aircraft system. It sba1l inc1ude an accumulator
equivalent to 150 in. 3 precharged to apressure at 60°1 (16°C). Refer to figure
4-96. The hydrau1ic supp1y working pressure sha11 be within the 1imits of figure
4-97.
c. Provide fuel system (35 through 42) to provide fue1 (MIL-T-5624, JP-4
or JP-5) to JFS test unit within 5 +1 psig.
d. Provide exhaust duct (18) which duplicates the performance effects of

the aircraft starter exhaust system.
e. Provide air in1et sensing duct (49, sheet 2) with be11 mouth and
venturi that dup1icates the performance effects of the aircraft starter air inlet
system. Provide sensing manifold (48) for venturi L1 pressure.
f. Provide over temperature simulator (8, sheet 1) to provide temperature
signa1 within range of 1850 to 1950°1 (1010 to l065°C) to JFS electrical control
boxe
g. Provide ABORT awitch (10) to open control circuits to JFS test unit when
unit is not operating and to provide a means of emergency shutdown of the JFS test
unit during operation.
h. Provide e1ectrica1 10ad system to dup1icat~ aircraft ignition system

and aircraft system load (igniters and 100 W 1 amp). Provide svitch (1) to dis-
connect externaI ac 10ad.
4-313
t
NAVAIR 03-105-AB-52
2200
~S\
~
2000 ~.,\
,~
STANDARD PRECHARGE
« ~\
Vi PRESSURE (59" F DAY)
A. ,~
w'
co: 1800
;:,
In
tp~S\
In ,1
w
co:
A.
In
« ,tJ:P ~\
C>
w 1600
C>
co: ,'J$J VS\
~
U
w
co:
Ao
1400
1200
THIS CURVE APPLlES TO NITROGEN AT CONSTANT VOLUME.
REAL GAS COMPRESSIBILITY EFFECTS ARE INCLUDED.
1000
-40 -20 o 20 40 60 80 100 120 140
ACCUMULATOR TEMPERATURE, °F
Figure 4-96. Accumu1ator Precharge Variation with Temperature
i. Provide instrumentation to indicate JFS test unit operating parameters

as fo11ows:
NOTE
Refer to tab1e 4-13 if an osci11ograph is used in con-

junction with the direct r~ading indicators.
(1) Timer to indicate JFS test unit starting time from zero rpm to
cutout speed.
(2) Vibration meter (Mode1 1-117, Bell and Howe1l Co, Electronics and
Instruments Group, Instruments Div, 3600 Sierra Madre Vi11a, Pasadena, CA 91109, or
equiva1ent) (54, sheet 2) and two vibration pickups (Mode1 4-125, Be11 and Howel1
Co, E1ectronics and Instruments Group, Transducer Div, 360 Sierra Madre Vi11a,
4-314
NAVAIR 03-105AB-52
(150 CUBIC INCH ACCUMLATOR PRECHARGED TO 1750 +50 PSIG AT 60 F)
(!)
Vi
Ao
UJ'
l1li:
:I
VI
VI
UJ
l1li:
Ao
(!) 3000
Z
~
l1li:
~ MAXIMUM ALLOWA6LE WORKING PRESSURE
2000
-20 o 20 60 80 100 120
AMBIENT TEMPERATURE, °F G-12A-167
Figure 4-97. Accumu1ator Working Pressure Variation with Temperature
Pasadena, CA 91109, or equiva1ent) (50, 82) to monitor gas generator assemb1y and
power turbine assemb1y vibration.
(3) Speed indicating system (15, 19) to indicate gas generator speed
within range of O to 80,000 rpm.
(4) Power turbine speed indicating system (104, 105, sheet 4) to

indicate power turbine speed within range of O to 4,000 rpm.
(5) Temperature indicating system (45, 47, sheet 2) to indicate com-
pressor inlet temperature within range of -50 to 150°F (-46 to 66 D C).
(6) Pressure gage (46) to indicate venturi ~ pressure with1n O to 50
(7) Pressure gage (11, sheet 1) to indicate accessory gearbox case

pressure with O to 30 psig. Provide sediment strainer e1ement assemb1y (12) with
fitting to tap off case pressure.
(8) Temperature indicating system (44, 45, sbeet 2) to indicate accessory gearbox oil
temperature within Oto 4000F (-18 to 2040C). I
NAVAIR 03-105-AB-52
Table 4-13. Oseillograph Data
Parameter Range Osc111ograph Speed Setting
Gas Generator Speed o to 80k rpm 20k rpm/ineh
Power Turbine Speed o to 4k rpm lk rpm/ineh
Torque (Power Turbine) o to 500 ft-lb 100 ft-lb/ineh
Fuel Inlet Pressure o to 25 psig 5 psig/ineh
Inlet Venturi ~ Pressure o to 50 in. H20 10 inehes/ineh
*Fuel Flow
Power Turbine Vibration o to 2.0 mils 0.5 mil/ineh
Gas Generator Vibration o to 2.0 mils 0.5 mil/ineh
Aeeessory Gearbox Case Pressure o to 50 psig 10 psig/ineh
Power Turbine Oil Temp. o to 300°F
Accessory Gearbox Oil Temp.
Compressor Inlet Temp.
Accessory Gearbox Oil Pressure o to 50 psig 20 psig/ineh
Turbine Discharge Temp.
Fuel Inlet Temp.
PMG Voltage, de o to 40 vdc 20 volts/ineh
AC Load Voltage o to 120V 50 V/ineh
AC Load Current o to 10A 5 A/ineh
DC Load Voltage o to 30V 10 V/inch
DC Load Current o to 2A 1 A/ineh
*Depends on flowmeter used. Choose appropriate scale and range using flowmeter
calibration curve.
4-316
f
NAVAlR 03-105-AB-52
NOTE
lf an oscillograph or recorder is used a direct read-

ing gage is also required to provide a visual indica-
tion of accessory gearbox oil pressure.
(9) Pressure gage (14, sheet 1) to indicate accessory gearbox 011 pres-
sure within O to 50 psig.
(10) Temperature indicating system (43, 45, sheet 2) to indicate power
turbine oil temperature within O to 300°F (-18 to 149°C).
(11) Temperature indicating system (16, 17, sheet 1) to indicate tur-

bine discharge temperature within O to 2000°F (-18 to 1093°C).
(12) Pressure gage (13) to indicate acceleration 1imiter cracking pres-

sure within O to 100 psig.
(13) Pressure gage (41) to indicate fue1 inlet pressure to JFS test
unit within O to 25 psig.
(14) Fuel flowmeter (42) to indicate fuel flow to JFS test unit within
O to 180 pph.
(15) Voltmeter (5) to indica te voltage of ac 10ad circuito
(16) Ammeter (4) to indicate current flow in ac 10ad circuito

(17) Vo1tmeter (3) to indicate vo1tage of dc 10ad circuito
(18) Ammeter (2) to indicate current flow in dc 10ad circuito
(19) DC and AC indicator lamps (6, 7) to indicate at externaI 10ad

switching point.
NOTE
When using an osci110graph or recorder to monitor PMG
dc vo1tage and gas generator speed, the recorded data
of these parameters will provide an indication of gas
generator and accessory drive assembly sensitive switch
assembly actuation.
(20) Provide indicating system as required to determine if the sensi-
tive switch assembly in the gas generator and accessory drive assembly actuates
before 45,000 rpm gas generator speed.
(21) Pressure gage (31) to indicate hydraulic accumu1ator precharge
pressure.
4-317
NAVAIR 03-10S-AB-52
(22) Presure gage (34) to indieate JFS hydrau1ie 1oitiation system

pressure within O to 5000 psig.
(23) Barometer to measure aetua1 ambient atmospherie pressure.
4-740. Insta11 JFS into test setup as fo110ws:
a. Visua11y inspeet starter for evidenee of damage. Repair or rejeet

starter showing evidenee of damage.
b. Loosen nut at elamp eoupl1og (95, sheet 3) and remove mounting flange
(96).
CAUTION
Do not support the weight of the JFS on the output shaft

assembly (97) or end-load the output shaft assembly when
handling the JFS. Damage to interna1 parts of the JFS
may resu1t.
e. Hoist JFS into a1ignment with test stand mounting pad (102, sheet 4)
using suitab1e adapter and hoist. Rotate test stand f1ywhee1 (109) to engage
sp1ines of output shaft assembly (97, sheet 3) with sp1ines of test stand rotating
assemb1y. Torque nut of elamp eoup1ing (95) to 100 to 120 ineh-pounds.
d. Conneet exhaust duet (18, sheet 1) to exhaust f1ange (93, sheet 3) with
e1amp eoup1ing (94). Torque nut of e1amp eoup1ing (94) to 75 ineh-pounds.
e. Insta11 in1et air sensing duet (49, sheet 2) to air in1et (72, sheet 3).
CAUTION
Fi11 hose assemb1y of pressure gage (14, sheet 1) with

1ubrieating oi1 (MIL-L-7808), prior to eonneeting to
starter. Damage to starter resu1ting from oi1 starva-
tion may oeeur if hose assemb1y is not preservieed with
oi1.
f. Remove serew (82, sheet 3) and gasket .. (83) and eonneet pressure gage
(14, sheet 1) to oi1 pressure sensing port (84, sheet 3).
g. Remove sediment strainer e1ement assemb1y (81) from aeeessory gearbox

assemb1y, and insta11 speeia1 test sediment strainer e1ement assemb1y with pressure
tap (12, sheet 1).
CAUTION
Align gear tooth at highest point. Bottom rpm monop01e

piekup (15, sheet 1) on gear tooth and baek off 3/4 turno
Tighten 10eknut on monop01e piekup.
4-318
{
NAVAIR 03-105AB-52
NOTE
Speed pickup: Hz X 16.772 • gas generator rpm.
h. Remove pJug (78, sheet 3), gasket (79) and insta11 monopo1e pickup (15,
sheet 1) into instrumentat10n port (80, sheet 3).
1. Connect e1ectr1cal system (1 through 11, sheet 1) as follows:

(1) Open ABORT sw1tch (10).
(2) Connect harness assemb1y of test setup e1ectr1ca1 system (1 through

10) to JFS contro1 box assemb1y.
WARNING
To prevent injury from the inadvertent release of

hydrau11c f1u1d under high pressure, do not attempt
to connect the JFS hydrau11c in1tiat10n system to
the hydrau1ic motor if the system is charged.
j. If JFS hydrau1ic system is ~harged open hydraulic manual discharge valve

(28, sheet 1) to dep1ete pressure.
k. Connect JFS hydrau11c in1tiat1on system pressure 1ine to hydrau11c motor

1n1et port (91, sheet 3).
1. Connect JFS hydrau11c in1tiat10n system return 11ne to hydrau11c motor
d1scharge port (92).
m. Connect test setup fue1 system to JFS fuel in1et (64).
n. Connect su1tab1e drain hose to man1fo1d to tube e1bow assemb1y (90).
o. Remove 011 dra1n p1ug (88, sheet 3) and insta11 011 temperature immer-
sion thermocoup1e (44, sheet 2).
p. Remove screws at po1nt (55) to left side of l1fting bracket (74, sheet
3). Insta1l vibration pickup mount (51, sheet 2) and vibration pickup (50) at
po1nt (57). T1ghten screws to a torque va1ue of 115 to 120 1nch-pounds.
q. Remove bolts at point (65, sheet 3). Insta11 vibration pickup mount
(53, sheet 2) and v1brat1on p1ckup (52) at p01nt (65, sheet 3). T1ghten bo1ts to
a torque va1ue of 50 to 70 inch-pounds.
Change 2 4-319
t
NAVAIR 03-l05-AB-52
4-741. SERVICING JFS LUBRICATION SYSTEM. Service JFS lubrication systems as

follows:
NOTE
Starter sba11 be in normal horizontal position when

servicing lubrication systems.
a. Remove p1ug (56, sheet 2) or (98, sheet 3). Service power turbine
assembly with 470 +15 cu.em. of 1ubricating oi1 (MIL-L-23699 or MIL-L-7808) through
oi1 servicing port (57, sheet 2) or (100, sheet 3). Insta11 thermocoup1e (43) into
servicing port in p1ace of p1ug (56, sheet 2) or (98, sheet 3) removed for servicing.
b. Remove oi1 dip stick (87) and service accessory drive assemb1y with
325 +15 cu.cm. of 1ubricating oi1 (MIL-L-7808 or MIL-L-23699) through accessory
drive assembly 01L FILL porto Reinsta1l oi1 dipstick (87) into 01L FILL porto
a. Check starter for secure mounting.
b. Check alI fue1, oi1, hydrau1ic, and e1ectrica1

connections for security.
c. Check that air in1et and exhaust ducts are free

of obstructions or foreign material.
4-742. PURGING HYDRAULIC INITIATION SYSTEM AND PRnUNG FUEL SYSTEM. Purge air
from hydraulic system, depreserve fue1 system and prime fuel system as fo110ws:
a. Disconnect tube assemb1y (67, sheet 3) from restricted f10w check va1ve
(66) and e1bow (68). Cap restricted f10w check va1ve (66) and e1bow (68).
b. Open AnORT switch (10, sheet 1) to prevent 1ightoff of JFS.
c. Check accumu1ator precharge pressure gage (31). Service accumu1ator

(33) with dry air or nitrogen as required if indication is not equiva1ent to 1750
±50 psig at 60°F. See figure 4-96.
d. Charge JFS hydraulic initiation system to working pressure within

limits of figure 4-97.
e. Operate test setup fue1 system to provide fuel to JFS fue1 in1et at
5 +1 psig.
CAUTION
Ascertain that both the power turbine assemb1y, and the

gas generator and accessory drive assemb1y are proper1y
serviced prior to motoring the starter.
4-320
[
NAVAlR 03-l05-AB-52
f. Depress PRESS TO PRIME button on manual nc solenoid valve (73, figure

4-95, sheet 3).
g. Open hydraulic manual control valve (26, sheet 1) to motor JFS and
observe fue1 flow from fuel drain hose.
h. Repeat steps d through g unti1 steady stream of fuel is observed from
fuel drain hose.
NOTE
A minimum of two motoring cycles is required to purge

the hydraulic system of air. lf only one motoring
cycle is required to prime the fuel system as indicated
by a steady stream of fuel from the fuel drain hose,
perform one additional cycle, ommitting step f, to
completely purge the hydraulic system of air.
i. Remove caps from elbow (68, sheet 3) and restricted flow check va1ve
(66). Reinstall tube aS8emb1y (67).
j. lnspect for fuel, oil and hydraulic leaks. Tighten or replace leaking
tubes or fittings.
k. Record motor time on run sheet (locally developed).
4-743. CHECKING ACCELERATlON LIMlTER CRACKING PRESSURE. Check acceleration limiter
cracking pressure as follows:
a. Remove tube assemb1y (86, sheet 3) and connect fue1 pressure gage (13,
sheet 1) to out1et of check va1ve (85, sheet 3).
b. Disconnect tube assembly (67) from restricted flow check valve (66) and
elbow (68). Cap elbow (68).
c. Disconnect tube assembly (75) at fuel control assembly (76).
d. Open ABORT switch (10, sheet 1).

e. Charge JFS hydraulic initiation system to working pressure within limits
of figure 4-97.
CAUTION
Ascertain that both the power turbine assembly and the
gas generator and accessory drive assembly are properly
serviced prior to motoring the starter.
f. Open hydraulic manual control valve (26, figure 4-95, sheet 1) to motor
JFS, and observe acceleration limiter valve cracking pressure on fue1 pressure gage
(13). Adjust cracking pressure if not with 70 to 75 psig. Refer to paragraph
4-736 for adjusting procedures.
4-321
NAVAIR 03-l05-AB-52
g. Reconnect tube assembly (75, sheet 3) to fue1 control assembly (76).
h. Remove cap from elbow (68) and reinstall tube assembly (67).
i. Disconnect fuel pressure gage (13, sheet 1) from outlet of check valve f
(85, sheet 3). Reinstall tube assembly (86).
a. Check coupling nuts on tube assemblies (7S, 86)

for security.
b. Check coupling nuts on tube assembly (67) at

fuel control assembly.
4-744. OPERATING PROCEDURES. Observe procedures tbat follows when operating JFS.
4-745. Observe the following rules of safety during functional and performance
testing of JFS.
a. Check air intake and exhaust outlet for foreign objects prior to opera-
tion.
b. Remove alI closures from starter prior to operation.
c. Check oil system prior to motoring or operating starter. Service as

required.
d. Assure that starter is properly restrained prior to operation.
e. Assure that exhaust gases are directed safely away from starter.
f. Provide safe containment of fuel drainage to preclude fires and slipping

type accidents.
g. Assure that alI personnel in test area use ear protective devices during
starter operation.
h. Assure that alI personnel are clear of exhaust outlet and planes of
turbine and compressor rotation during starter operation.
i. Abort starter operation immediately if seizing, unusual noise, smoke,

fue1 or oil leakage, or other obvious malfunctions are observed.
j. Starter operation sball not be initiated if power turbine sump tempera-

ture exceeds 160°F (+710C).
4-746. Perform normal start cycle operation as follows:
4-322
{
NAVAIR 03-lOSAB-52
NOTE
Refer to tab1e 4-14 for operating parameters, and see
figure 4-98 for maximum transient vibration 1imits.
a. Charge JFS hydraulic initiation system to working pressure within limits offigure 4-97. I
WARNING
Abort start under the fol10wing conditions: (a) no
oi1 pressure, (b) output shaft speeds exceeds 3400
rpm, (c) gas generator speed exceeds 74,800 rpm.
NOTE
To abort starter operation, open ABORT switch (10,

figure 4-95, sheet 1).
b. C10se ABORT switch (10).
c. Open hydrau1ic manual control valve (26) to initiate JFS start anê
monitor starter operating parameters. Refer to table 4-14, and see figure 4-98.
d. Close hydrualic manual control valve (26, figure 4-95, sheet 1) when
lights (6) and (7) illuminate.
NOTE
Complete entries in test data sheet, figure 4-100 and
test log sheet, figure 4-101 during testing of JFS.
4-747. RUN-IN. Perform normal start cycles in accordance with paragraph 4-746 as
required to perform checks in the following paragraphs.
4-748. Power turbine assemb1y sensitive switch assembly actuating speed check.
Check power turbine assembly sensitive switch assembly actuating speed as follows:
a. Observe that power turbine assembly sensitive switch assembly actuates at 8200 to 3500 rpm
power turbine speed.
b. Add or delete washers (5, figure 4-12) as required to adjust switch
actuation speed within 1imits.
4-749. Accessory drive assembly sensitive switch assembly actuating speed check.
Check accessory drive assemb1y sensitive switch assemb1y actuating speed as fol1ows:
NOTE
Actuation of accessory drive assembly sensitive switch
assemb1y actuation may be verified by recorded data, PMG
dc voltage.and gas generator spead.
Change2
· NAVAIR oa-l05AB-52
Table 4-14. Starter Operating Parameters
Parameter Limits
Gas Generator Speed 70,000 to 75,000 rpm
Power Turbine Cutout Speed 3200 +200 rpm
Fue1 In1et Pressure 5 +1 psig
Compressor Discharge Pressure 30 to 35 psig
Venturi Delta Pressure 20 to 30 inch H20
Fuel Flow 100 to 140 pph ref
Power Turbine Vibration (normal 0.4 mil max (steady-state)

start cycles and motoring runs)
Gas Generator Vibration (normal 0.6 mil max (steady-state)

start cycles and motoring runs)
Accessory Gearbox Case Pressure 3.0 psig max
Compressor Inlet Temp. 60° to 80°F (65-70 recommended)
Accessory Gearbox Oil Pressure 20 psig min
Turbine Discharge Temperature 0000 to 13000F refsteady-state

1600°F mo during aeeeleration
Fuel In1et Temperature Ambient (Ref)
PMG Voltage Used to determine sensitive switch assem-

bly actuation
DC Load Voltage 18 volt min
DC Load Amperes 1. O amp min
AC Load Volts 100 volts min (Simulated loads on1y)
AC Load Amperes 3.1 to 3.5 AMPS (Simulated loads only)
Acceleration rate from initiation to:
L1ghtoff 1 second
50 percent 3 seconds
Governed Speed 5 seconds
Cutout 25 to 35 seeonds
4-324 Change 2
NAVAIR 03-105-AB-52
Tab1e 4-14. Starter Operating Parameters (Cont)
Parameter Limite
Acceleration Limiter Valve Cracking 70 to 75 psig

Pressure
External electrical load Switching 62,000 rpm gas generator speed min
Point (360 Hz)
Sensitive Switch Assembly Actuation 45,000 rpm gas generator spee~ max
a. Observe that accessory drive assembly sensitive switch assemh1y actuates

before gas generator speed reaches 45,000 rpm.
b. Refer to table 4-21 1f switch actuation is not with1n limits.
4-750. JFS output power check. Check JFS output power as follows:
a. Read raw output torque at 1000 and 2000 rpm power turbine speed.
b. Correct raw output torque va1ues using the following equation:
corrected torque • raw torque X K-factor

6
NOTE
The barometer correction, 6 , is obtained from table
4-15. Knowing the test stand flywhee1 inert1a; the
K-factor is determined from table 4-16.
c. Compare corrected torque values at 1000 and 2000 rpm with mintmum
va1ues given in tab1e 4-17.
NOTE
Gas generator speed sba11 not exceed the va1ues given
in table 4-18.
d. Readjust fue1 control governor setpoint as fo11ows if corrected torque

values are lower than minimums given in table 4-17.
(1) Loosen nut (26, figure 4-13) and adjust screw (33).
(2) Ho1d screw (33) and tighten nut (26) to torque va1ue of 20 to 25
inch-pounds.
4-325
NAVAIR 03-1OSAB-52
GAS GENERATOR, RPM
POWER TURBINE OUTPUT SHAFT SPEED, RPM G-12A-I48Rl
Figure 4-98. Maximum Transient Vibration Limits
e. Repeat steps a through d until corrected torque values are within

limita of table 4-17.
4-751. Electrical aystem check. Check electrical system as follows:
4-326 Change 2
NAVAIR 03-105-AB-52
Tab1e 4-15. Power Turbine Output Shaft Barometric Correction
Barometer (in. Hg) Correction Barometer (in. Bg) Correction
~ 30.00 1.0027 28.95 0.9676

29.95 1.0010 28.90 0.9659
29.90 0.9993 28.85 0.9642
29.85 0.9977 28.80 0.9626
29.80 0.9960 28.75 0.9609
29.75 0.9943 28.70 0.9592
29.70 0.9926 28.65 0.9576
29.65 0.9910 28.60 0.9559
29.60 0.9893 28.55 0.9542
29.55 0.9876 28.50 0.9525
29.50 0.9860 28.45 0.9507
29.45 0.9843 28.40 0.9492
29.40 0.9826 28.35 0.9475
29.35 0.9809 28.30 0.9459
29.30 0.9793 28.25 0.9442
29.25 0.9776 28.20 0.9425
29.20 0.9759 28.15 0.9408
29.15 0.9743 28.10 0.9392
29.10 0.9726 28.05 0.9375
29.05 0.9709 28.00 0.9358
29.00 0.9693
For interpo1ation use 0.0034 per 0.01 in. Hg A.
Tab1e 4-16. Power Turbine Output Torque F1ywhee1 Inertia Correction
F1ywheel In~rt1a
(Slug .}'t ) K-Factor
12.5 1.058
12.85 1.056
13.0 1.054
16.5 1.044
18.15 1.040
22.15 1.033
4-327
NAVAIR 03-105-AB-52
Tab1e 4-17. Minimum Al1owab1e Power Turbine Output Torque
JFS Compressor Inlet Minimum Al1owab1e Torque*

Temperature COF) At 1000 RPM At 2000 RPM
50 296 204
52 294 202
54 291 201
56 289 199
58 287 198
60 285 197
62 283 195
64 281 193
66 279 192
68 276 190
70 274 189
72 272 187
74 270 186
76 268 184
78 266 183
80 264 181
82 261 180
84 259 179
86 257 177
88 255 176
90 253 174
92 251 173
94 248 171
96 246 170
98 244 168
100 242 167
*After correction for barometer and f1ywhee1 inertia using fol1owing formula:
Corrected torque = Raw torgue x K-factor
6
Maximum a110wable torque at 2000 rpm sha1l not exceed minimum by more than 15 lb-ft
4-328
Table 4-18. l.faximum A110wable Gas Generator Speed.
Maximum Allowable Barometer

Gas Generator Speed (rpm) (In. Bg)
74800 28.00
74850 28.50
74900 29.00
74950 29.50
75000 30.00
a. Observe that PMG frequency ia greater than 360 Hz at externaI load

switching point, when DC and AC indicator 1ights (6, and 7, figure 4-95, sbeet 1)
i1luminate. Determine PMG frequency using fol1owing equatiún.
Hz - gas generator speed

172.2
b. Observe that aircraft engine igniters arc and 100 W10ad 1amp 111umi-
nates.
c. Observe that dc current is at least 1 amp at 18 to 29 vdc.

4-752. Overtemperature shutdown check. Perform overtemperat~e shutdown check as
follows:
a. Disconnect e1ectrica1 p1ug connector P9 (60, sbeet 2). from immersion

thermocoup1e (59).
b. Connect cab1e from overtemperature simu1ator (8, sheet 1) to e1ectrica1

p1ug connector P9 (60, sheet 2).
c. Slowly increase temperature simulator setting during JFS start cycle.
d. Observe that shutdown occurs when simulator setting is within 1850 to
1950°F (1010 to 1065°C).
e. Disconnect temperature simulator (8, sheet 1) from e1ectrica1 p1ug

connector P9 (60, sheet 2), and reconnect connector P9 to immersion thermocoup1e
(59).
4-753. E1ectrical counter check. Check e1ectrica1 counter by ver!fying correct
counter operation for minimum of two starts.
4-754. OUTPUT SBAFT OVERSPEED TEST. Perform output shaft overspeed test as fo11ows:
4-329
NAVAIR 03-105AB-52
NOTE
Leakage of 1iquids or gases from the starter during

the output sbaft overspeed test, other than through
the drain hose, is cause to reject the starter.
I The following output shaft overspeed test is optional providing

paragraphs 4-730. x, y, and z have been performed:
a. Actuate disconnect assemb1y (106, sheet 4) to disconnect f1ywhee1 (109)

from JFS test unit (101).
b. Operate overrun drive assemb1y (103) to drive test stand shaft at 6500
+50 rpm for 10 minutes.
c. Observe that the starter remains disengaged. Fai1ure of the starter to

remain disengaged is cause to reject the starter.
d. Engage disconnect assemb1y (106) after comp1eting output shaft overspeed

testo
4-755. SIMULATED STARTlNG CYCLE TEST. Perform simu1ated starting cyc1e test as
fo11ows:
NOTE
lf the gas generator speed exceeds 74,800 rpm during

any start cyc1e, shutdown the JFS and check tab1e
4-18 for maximum a11owab1e gas generator speed. The
gas generator speed sbal1 be more than 66,000 rpm
but sball not exceed the maximum allowable speed
shown'in tab1e 4-18.
Leakage of 1iquids or gases from the starter during

the simu1ated starting cyc1e test, other than through
the drain hose, is cause to reject the starter.
a. Perform two normal start cycles after perfonning final power adjustments or paragraph 4-
I 750, step d. The time interval between starts shall be at least 2 minutes but not more than 5 minutes.
Record the time interval between finish or run number one and start of run number two. Record data as
follows at approximately 3000 rpm power turbine speed.
(1) JFS in1et temperature.
(2) Fue1 f1ow.
(3) Gas generator speed.
(4) lnlet venturi ~ pressure.
(5) Barometric pressure.
4-330 Change 2
NAVAIR 03-105-AB-52
NOTE
Calculations to determine turbine inlet temperature

(T4) sball be based on data obtained on second or
subsequent start cycle.
c. Determine turbine inlet temperature (T4) using figure 4-99 and table
4-19 as follows:
(1)
Enter figure 4-99 between the two lower graphs with the observed
value of JFS comp~essor in1et temperature. MOve right horizonta1ly until appro-
priate gas gemerator speed line is intersected (linear eyeball interpolation is
permitted on alI parts of figure 4-99). From the gas generator speed 1ine, read
up to compressor discharge temperature scale and write down indicated value for
later use.
(2) Return to in1tia1 point of entry on compressor inlet temperature
scaIe and read 1eft horizonta11y unti1 appropriate in1et be1lmouth venturi P 1ine
is intersected. Move up vertically to barometer REF line, which corresponds to
barometer reading of 29.92 in. Hg, sea level, standard conditions. lf barometer
reading exceeds this value, linear extension of guide lines is permitted. From
this point, dog-leg back parallel to nearest guide line to observed barometer value,
then move up and cross airf10w scale vertically. Continue moving vertically until
observed fuel flow line is encountered. Move right horizontally into turbine inIet
temperature graph until compressor discharge temperature 1ine written down earlier
is intersected. Point of intersection is turbine inlet temperature (T4) value.
Correct this va1ue for 10wer heating value of fuel using tab1e 4-19.
d. Compare calculated turbine inlet temperature (T4) to limits provided in

table 4-20. The turbine inlet temperature shall be less than the limit in table
4-20.
CAUTION
When performing motoring run, fai1ure to remove ac

e1ectrica1 load at 45 seconds may damage e1ectricaI
circuitry due to excessive current f1ow. Do not
a110w ac externaI load to r ema in after 45 seconds.
e. Perform one two-minute motoring run at 1400 +100 rpm power turbine speed
using load brake (110, figure 4-95, sheet 4) to contro1 apeado Remove externaI ac
10ad at 45 seconds. Reject starter 1f gas generator speed droop exceeds 5000 rpm.
4-756. LEAK CHECK. Perform Ieak check as fo11ows:
a. Place fue1 and lubrication system in shipping configuration.
(1) Remove thermocouple (43, figure 4-95, sheet 2) from servicing port
(57) or (100, sheet 3) as applicable. Reinstal1 gasket and plug (56, sheet 2) or
(98, sheet 3), as app1icable, into port (57, sheet 2) or (100, sheet 3).
4-331
NAVAIR 03-105-AB-52
(2) Remove monopole piekup (15, sheet 1) from instrumentation port

(80, sheet 3). Reinsta1l gasket (79) and p1ug (78) into port (80). Loekwire plug
(78).
(3) Diseonneet pressure gage (14, sheet 1) from oil pressure sensing
port (84, sheet 3). Reinsta11 gasket (83) and serew (82) into port (84). Loekwire f
screw (82).
(4) Remove speeial test sediment strainer element assembly with pres-
sure tap (12, sheet 1) from aecessory drive assembly, and reinstall gasket and
sedfment strainer e1ement (81, sheet 3). Loekw1re strainer element (81).
b. Perform normal JFS start cycle and visually inspect unit for evidence
of fue1 or oi1 1eakage. Reject unit 1f leakage is observed.
4-757. FUEL SYSTEM PRESERVATION. Perform fuel system preservation procedures as

fol10ws:
a. Disconneet tube assembly (38, figure 4-1, sheet 2) from in1et side of
manual prime ne solenoid va1ve.
b. Supply oil MIL-o-608l, grade 1010 or 1005 to JFS fuel inlet (64, figure
4-95, sheet 3).
NOTE
It may be necessary to supp1y oil to the fue1 control

assembly under a slight pressure, in order ~or the
fue1 pump to pick up the oi1.
c. Charge JFS hydrau1ic initiation system to working pressure within 1imits

of figure 4-97.
d. Open ABORT switch (10, figure 4-95, sheet 1).
e. Open hydrau1ic contro1 valve (26) to motor JFS. Purge alI fue1 from
system.
f. Drain oi1 from fue1 system unti1 on1y residual coating remains.
g. Reeonneet tube assemb1y (38, figure 4-1, sheet 2) to inlet side of

manual prime ne solenoid va1ve. Attaeh warning tag to tube assembly indieating it
was diseonnected after testing.
4-758. LUBRICATION SYSTEM PRESERVATION. Perform 1ubrieation system preservation

as fol10ws:
a. Remove magnetic plug (58, figure 4-95, sheet 2) and permit alI oi1 to
drain from power turbine assembly. Reinsta1l magnetie p1ug (58) with new packing.
4-332
RAVArR 03-105-AB-52
' .....' ....'-:'::'-'....1""'-lI,":,:'~I....I...I...I'":':I'!-'....I...I...'":'.'

::J1u.1.L.1..I.1-:.I'=1L-L.1..I.I..I.I-:.I'!::IL-L.I..I.I....I-:J'!::.&..I.... t,. '" "" 320' ,I. 1"III~
1" ,.1,,: ao
SI' 11.1." ,I, 11"" 1.1., "I., 1,1, e" I •• , ,i I tI' I. 1«' l.u,·',., .1
., 1.7& 1.70 I" 1.10 I" UO IAS 110 MO ., ., m ., ., tOe •
AIRFLOW Ll/SEC IIAIIOIIImR _ "'" _ _ DI_OE TElllfERATURE .,
~~~~~~~--~~~~~~~~--~~~~ ~
A28227
_ _ ON FOI.LOWtND _ _
lo AIR'LOW IlETUINO VIII1\Ml 1_ _T

AREA ICIUALlt.m _ 1 _ 10 CIORRm
fOR DlFFERENT IFFmM AREA. _ " _IIYID
~ER PARAMITIR AlI'OUOIIII:
. IAROINOIIOI • 1AII000000"VINTURI AREAIUJI
I. IURNER EFFICllNCY DF .., 11M _
Figure 4-99. Turbine Inlet Temperature Nomograph

4-333/(4-334 blank)
NAVAIR 03-105-AB-52
Tab1e 4-19. Nomograph T4 Correction for Fuel Lower Heat1ng Va1ue
Correction to T4
Lower Heat1ng Va1ue Ca1cu1ated From Nomograph
of Test Fuel Used Figure 4-99
18000 SUBTRACT 40.5

18100 SUBTRACT 33.6
i8200 SUBTRACT 26.8
18300 SUBTRACT 20. O
18400 SUBTRACT 13.3
18500 SUBTRACT 6.6
18600 NO CORRECTION
18700 ADD 6.5
18800 ADD 12.9
18900 ADD 19.3
19000 ADD 25.6
Tab1e 4-20. Maximum Al1owab1e Turbine Inlet Temperature
JFS
Compressor
Inlet
Temperature Maximum Al1owab1e Turbine
(OF) Inlet Temperature (Op)*
Baro. 28.00 28.50 29.00 29.50 30.00
50 1756 1753 1750 1747 1744

52 1757 1754 1751 1748 1745
54 1759 1756 1753 1750 1747
56 1761 1758 1755 1752 1749
58 1762 1759 1756 1753 1750
60 1764 1761 1758 1755 1752
62 1766 1763 1760 1757 1754

64 1768 1765 1762 1759 1756
66 1770 1767 1764 1761 1758
68 1772 1769 1766 1763 1760
70 1775 1772 1769 1766 1763
4-335
NAVAIR 03-105AB-52
Tab1e 4-20. Maximum A110wab1e Turbine Inlet Temperature (Cont)
JFS
Compressor
Inlet
Temperature Maximum A110wab1e Turbine
,
(OF) Inlet Temperature (OF)*
Baro. 28.00 28.50 29.00 29.50 30.00
72 1777 1774 1771 1768 1765

74 1779 1776 1773 1770 1767
76 1781 1778 1775 1772 1769
78 1783 1780 1777 1774 1771
80 1785 1782 1779 1776 1773
82 1887 1784 1781 1778 1775

84 1789 1786 1783 1780 1777
86 1790 1787 1784 1781 1778
88 1792 1789 1786 1783 1780
90 1793 1790 1787 1784 1781
92 1795 1792 1789 1786 1783

94 1796 1793 1790 1787 1784
96 1797 1794 1791 1788 1785
98 1799 1796 1793 1790 1787
100 1800 1797 1794 1791 1788
*Ca1cu1ated using figure 4-99, tab1e 4-19 and data taken at 3000 rpm power turbine
speed.
b. Remove thermocoup1e (44) from oi1 drain portion in accessory drive

assemb1y. Perm1t alI oi1 to drain from accessory dr1ve assemb1y. Relnsta11 gasket
and 011 dra1n p1ug (88, sheet 3). Lockwire drain plug (88).
4-759. REHOVAL OF JFS FROM TEST SETUP. Remove JFS from test setup as fo110ws:
a. Shut off test setup fue1 to JFS.
b. Open ABORT switch (10, figure 4-95, sheet 1).
r c. Deleted.
4-336 Change2
NAVAIR 03-105-AB-52
MEAS PT
SEE
MEASUREMENT FIGURE QUANnTY OPERAnNG CYCUS
4-95
1Al0METERIC PRESSURE BAROMETER IN. ligA
UNIT INLET TEMPERATURE °F
ACassORY AS Of
REQUIRED
OIL TEMl'EJATURE
AS Of
fUlalNE REQUIRED
EXHAUST GAS TEMPERATURE °F
COMPRESSOR DlSCHARGE Of
TEMPERAME
OUTPUT SHAFT SPUD (PRIMARY) RPM
GAS GENERATOR GOVERNED AS RPM
SPEED REQUIUO
INLET VENTURI ~ IN. H20
INITIAL PSIG
HYDRAULlC PRESSURE
ACCUMULATOR INITIAL TOTAL
TEMPERATURE °F
cyaETIME
SECONDS
IZERO TO CUTOFF SPEED)
1000 ACTUAL LB-FT
OUTPUT RPM CORRECTED LB-FT
TORQUE 2000 ACTUAL LB-FT
RPM CORRECTED LB-FT
INLEr FUEL PRESSURE m PSIG
GAS Hz
STEADY-$TATE GENERATOR MILS
VIIRATI~ POVlER Hz
TUR8INE MlLS
ACTUAL LB/HR
FUEl FlOYl
CORRECTED LB/HR
o- VOLTS VOLTS
u5 FREQUENCY HZ
PMG <~
ELEC- Ü CUIIlIENT AMPS
TRICAL o- VOLTAGE VOLTS
OUTPUT u5 CURRENT AMPS
ali!
Ü
STAIT COUNTER $TART
READING END
EXTERNAL LOAD S\'IITCHlNG Hz
POINTS
T.C ACT. SPEC.
RECORDING NO.
REMARK. ACCElERATION LIMITEI CRACK PRESSURE PSlG INDIVIDUAL TEST STATUS
(I) UNLESS OTHERWISE INOICATED, UNIT INLET DIELECTIIC TEST PERfORMEDD
FUEL PRESSURE SHALL BE 5.. I PSI G.
INCRfASING OVERRUNNING TEST PERFORMEDD
UM
CUTOUT SWITCH SPEED
ACTUATlON SPEEO DECREASlNG 50':. S\VITCH CHECK PERfORMEOD
RPM
SPEEO
OVERTEMPERATURE SHUTDOWN
CHECK PERfORMEOD
CERTIFIED TO IE
ACCEPTA8LE PER
TEST SPEC D REJECTED D
SIGNATURE DATE
TECHNICIAN
TECHNICIAN
SUPERVISOR
QUALITY
PRESERVATION PREFORMED IV CONTROl
UNIT ACTUAL DRY WEIGHT POUNDS GOV'T INSP
Flgure 4-100. Test Data Sheet
4-337
NAVAIR 03-105-AB-52
DATE PAGE NO.

TESTCREW TEST LOG SHEET ASSY. NO.
CELL NO. :::SER=lA:..:.L::...;.;N;.;:;O.:.,.._ _ _ __
S
T
STAlRT STO~ RUN A
TIME TIME MIN. R TIME REMARKS
T
S
TOTAL
Figure 4-101. Test Log Sheet
4-338
NAVAIR 03-l05-AB-52
WARNING
To prevent injury from the inadvertent release of

hydraulic fluid under high pressure, do not dis-
connect the JFS hydraulic initiation system frem
the hydraulic motor if the system is cbarged.
d. If JFS hydraulic initiation system is charged, open hydraulic manual

discharge valve (28) to deplete system.
CAUTION
To prevent foreign objects from entering the JFS

and test setup, cap or plug a11 hoses, fittings
and ports as disconnections are made.
e. Disconnect JFS hydraulic initiation system frem hydraulic motor inlet

port (91, sheet 3) and hydraulic motor discbarge port (92).
f. Disconnect drain hose from manifold to tube elbow assembly (90).
g. Disconnect test setup fue1 system from JFS fuel inlet (64).
h. Disconnect electrical system (1 through 10, sheet 1) from JFS control

box assembly.
i. Loosen clamp coupling (94) and remove exhaust duct (18, sheet 1) frem
exhaust flange (93, sheet 3).
j. Remove inlet air sensing duct (49, sheet 2) frem air inlet (72, sheet
3) •
k. Remove bolts at point (57, sheet 2). Remove vibration pickup (50) and
vibration pickup mount (51). Reinstall bolts.
1. Remove bo1ts at point (65, sheet 3). Remove vibration pickup (52) and
vibration pickup mount (53, sheet 2). Reinsta11 bo1ts and tighten to torque value
of 50 to 70 inch-pounds.
CAUTION
Do not support the weight of the JFS on the output sbaft

assembly (97, sheet 3) or end-load the output shaft assem-o
bly when handling the JFS. Damage to internal parts of
the JFS may resulto
m. Attach suitable hoist and adapter to JFS. Loosen clamp coupling (95,
sheet 3) and remove JFS from test stand. Install JFS into suitable work stand or
dolly.
n. Install mounting flange (96) on JFS and tighten clamp coupling (95).
4-339
NAVAIR 03-105-AB-52
4-760. LEVEL OF TESTlNG FOLLOWlNG SPEClFlC REPAlRS.
4-761. Starters rejected because of failure or malfunction should have cause of

failure of malfunction corrected and alI or part of acceptance test re-run. The
class of failure or malfunction and the point of occurrence during the acceptance
test will determine the amount of re-run required. Failures and malfunctions are
classified into three categories as follows:
a. CLASS ONE: FAILURE OF ANY ROTATING PART. Class One parts include tur-
bine whee1s, compressor impeller and associated shafts and splines, alI shafts,
gears, gas generator and power turbine sections. After repair or replacement pf
any Class One item, starter must undergo complete run-in, output shaft overspeed,
and simulated starting cycle.
b. CLASS NO: FAILURE OF FUNCTIONAL COMPONENT. Class Two parts include

sw1tch assemblies, fuel control assembly, thermostatic switch, governo r assemblies,
motor and generator. In event of a Class Two failure, the faulty component must be
removed from the starter and repaired. Before installation, the repaired component
must be tested and calibrated as specified in Section IV, or in accordance with the
applicable publication for the componente Testing of the starter may be resumed at
the point of failure if the failure occurred before the component was calibrated on
the starter, or if replacement of the component does not affect calibration of
another componente If failure occurred after calibration of the component, the test
must be resumed at the point of calibration. A component may be removed and re-
placed without recalibration if only its point of attachment is disturbed, for
example, replacement of a packing or gasket acting as seal between component and
starter. However, sufficient testing must be performed to ensure proper functioning
of the componente
c. CLASS THREE: FAILURE OF MINOR PART AND EXPENDABLE ITEMS AND PARTS.
Class Three parts include plumbing, electrical harness and fittings, igniter plugs,
gaskets, nuts, bolts, etc. Failed parts must be replaced with acceptable parts and
testing may be resumed from the point at which faiIure occurred, unless its re-
placement involves disturbing a component of a higher class. lf so, testing may be
resumed at the point at which the higher class component would be tested.
4-762. FLUlD A1~ ELECTRlCAL SUPPLY REQUlREMENTS.
4-763. Fuel MIL-T-5624 (JP-4 or JP-5) shall be used for alI testing.
4-764. Lubricating oil MIL-L-7aOa sha11 be used in power turbine assembly and
accessory drive assembly in quantities as f01lows:
a. Power turbine assembly - 470 +15 cucm.
b. Accessory drive assembly - 325 +15 cucm.
4-765. Hydraulic fluid MIL-H-5606 sball be used for start initiation.
4-766. ExternaI electrical power is not required for starter operation.
4-340
NAVAIR 03-105-AB-52
4-767. TROUBLESHOOTING.
4-768. Troubleshooting procedures are provided in table 4-21.
AGE REQUIRED
~mLTIMETER, MODEL 260PRT (Simpson Electric Co.,

Chicago, IL, or equiv-
alent)
4-769. PRESERVATION.
4-770. GENERAL PRESERVATION PROCEDURE.

CAUTION
Do not spray compressor section of starter with pre-
servative oil under any circumstances.
4-771. Preservation of the starter shall be in accordance with MIL-E-5595 and

MIL-E-5607, except the compressor section shall not be sprayed with any corrosion-
preventive compounds. No hydrocarbons or oUs should ever be introduced into the
compressor section: a possibility of uncontrolled combustion might resulto Pro-
cedure for preservation and storage of the starter should be observed as follows:
a. Preserve fuel system in accordance with paragraph 4-757.
b. Preserve lubrication system in accordance with paragraph 4-758.
c. Attach warning tag (2, figure 4-4) to gas generator and accessory drive
assembly and tag (48, figure 4-3) to power turbine assembly.
4-772. PREPARATION FOR STORAGE OR SHIPMENT.

4-773. Prepare starter for storage or shipment in accordance with NAVAIR 15-01-1
and NAVAIR 15-01-2.
4-341
~
~
I Tab1e 4-21. Troubleshooting
Ul
~
~
N

Ul
.....I
o
lJ1
1. Starter fails to a. Sheared hydraulic Remove hydraulic motor Repair hydraulic motor.
motor over during motor shaft. and check for sheared ~I
start cycle. shaft. \.ri
N
Operation of
hydraulic motor b. Defective hydrau- Inspect hydraulic motor Replace damaged clutch
is audible. lic motor clutch. clutch components. jaw, or disassemble gas
generator and accessory
drive assembly for in-
spection and repair if
clutch part other than
cIutch jaw is damaged.
2. Starter fails to a. Seizing orbinding Remove hydrauIic motor Disassemble gas generator
motor over during in gas generator or and manually rotate im- and accessory drive as-
start cycle. accessory drive peller of gas generator sembly for inspection and
Audible sign of assembly. to check for binding. repair.
hydraulic motor
operation is not b. Defective hydrau- Check hydraulic motor RepIace hydraulic motor.
evidente lic motor. for binding.
3. Starter motors a. Defective immer- Disconnect connector P9 RepIace open immersion

normally, ignition sion thermocouple. from immersion thermo- thermocouple.
is audible, starter couple. Check for con-
fails to Iightoff. tinuity across pins A
and C of immersion
thermocouple.
b. Defective elec- Disconnect connector P3 Repair electrical wiring

trical wiring from JFS control box as- installation as required.
instaIIation (P9 sembIy and ch~ck thermo-
circuits) • couple circuits between
connector P9 and connector
P3 for shorts, and for con-
___ _ _ _ ___ _____ tinuity. •
- -
-
Table 4-21. Troubleshooting (Cont)
""
Symptom Cause Method of Detection Corrective Actlon
3. Star ter mo tors c. Defectlve n.o. Fuel coming manifold to RepIace n.o. solenoid
normally, 19n1tion solenold valve. tube elbow assembly dur- valve lf voltage to
is audlble, starter lng start cycIe. valve is normal.
falls to Iightoff. Remove connector P5 and
(Continued) check voltage across pins
A and B durlng normal start
cycle. Voltage of approxl-
mately 20 vdc is normal.
d. Defectlve wirlng Low or no voltage across Repalr wirlng harness

harness assembly pins A and B. Check har- assembly as required.
ness for contlnulty.
e. Defective fuel Check accelerat10n limlter (1) Adjust cracking

control assembly. valve crack1ng pressure. pressure.
(2) Repalr fuel control

assembly as requlred if
acceleratlon limlter
valve does not respond to
adjusonent.
f. Defectlve wlring Check contlnulty of alI Repair harness assembly

harness assembly circuits between connector as required.
P4 circuits caus- P4 and connector P2.
ing manual prime
nc solenoid vaIve
to be inoperative.
~
Test permanent magnet permanent magnet
E
o
g. Defectlve permanent h~pair
c..J
magnet generator. generator. generator as required. .!.
o
I.n
h. Defective JFS con- Test JFS control box Repalr JFS control box
~
I
w trol box assembly. assembly. assembly as requlred. ~,
~ I.n
w N
~
e;~
I TabIe 4-21. Troubleshooting (Cont)
w
~
~
l:Id
Symptom Cause Method of Deteetion Correetive Aetion o
W
,....I
o
\J1
3. Starter motors 1. Defeetive manual Valve fails to open with RepIaee manual prime ne I
normally, ignition prime ne fuel sole- normal voltage applied at fuel solenoid valve. ~
I
is audible, starter noid valve. eonneetor P4. Cheek by \J1
N
fails to lightoff. removing eleetrieaI eon-
(Cont) neetor P5 from ne solenoid
valve, and performing nor-
mal start eyele. Fuel
should flow from fuel drain
if manual prime ne solenoid
valve opens.
j. Plugged fuel Remove and inspeet fuel Inspeet remaining fuel

nozzle assembly. nozzle in aIignment with nozzles, and replaee
igniter plugo nozzles that do not eon-
form to inspeetion re-
quirements.
4. Starter motors a. Open fuse F2. Check fuse F2. RepIaee fuse.
normally, faiIs to
Iightoff, ignition b. Defective igniter Test igniter plugo RepIace igniter plugo
is not audible. plugo
c. Defective ignition Test ignition unit. RepIaee ignition unit.

unit.
5. Delayed starter a. AcceIeration Check acceleration Iimiter (1) Adjust acceIeration

Iightoff. limiter vaIve out valve cracking pressure. limiter valve eracking
of adjustment. pressure.
(2) Repair fuel control

assembly if acceleration
Iimiter valve faiIs to
respond to adjustment. ~
- -
Tab1e 4-21. Troub1eshootlng (Cont)
~
5. De1ayed starter b. Defective fue1 Inspect fue1 nozz1es. Rep1ace a11 fue1 nozz1es
1ightoff. nozz1es. that fai1 to conform to
(Cont) 1imits.
6. AC indicator 1am.p a. 'Open fuse F1. Check fuse for continuity. Rep1ace open fuse (F1).
fai1s to i11uminate
at approximate1y b. Defective JFS Test JFS contro1 bOXe Repair JFS control box
62,000 rpm, gas contro1 box assemb1y.
generator speed. assemb1y.
DC load 1am.p i1-
1uminates nor-
ma11y.
7. DC indicator 1am.p Defective JFS contro1 Test JFS contro1 box Repair JFS control box
fai1s to 111uminate box assemb1y. assemb1y. assemb1y.
at approximate1y
62,000 rpm, gas
generator speed.
AC load 1am.p i1-
1uminates norma11y.
8. AC and De indicator Defectiva JFS contro1 Test e1ectrica1 contro1 Repair JFS control box
lamps fai1 to il- box assemb1y. bOXe assemb1y.
1uminate or i11u- ~
minates at frequency ~
of 360 Hz or 1ess. ~
o
w
t!.-
o
VI
f ~I
~ VI
\.n N
~
I
I.IJ
~
~>
0\
~
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.....I
o
9. Slow starter a. Restriction in Remove compressor dis- Clean or rep1ace tube as VI
acceleration. compressor discharge pressure tube and required. ~I

charge pressure check for obstructions. VI
tube assembly. N
b. Acce1eration Apply air pressure, 40 +1 Repair fuel control as-

limiter va1ve psig, to fue1 control assembly.
leaks. sembly air inlet fitting
and check for leakage.
Air leaks from overboard
vent, around adjusting
screw, cover assembly or
from cover flange.
c. Defective fuel Inspect fue1 nozzles. Replace alI fuel nozzles

nozzles. that fail to conform to
inspection requirements.
d. Defective fucl Test fuel controlo Repair fuel control as-

controlo sembly as required.
e. Defective hydrau- Test hydraulic motor. Replace hydraulic motor.

lic motor.
10. Premature starter a. Overfrequency Overspeed indicator at Disassemble Jet Fuel

cutout. (Prior to shutdown. bottom of JFS control Starter (JFS) generator/
3000 rpm output box will show rede accessory drive assembly
shaf t speed). for inspection and re-
pairo
b. Overtemperature Check hydraulic system for Correct system problem

shutdown. proper servicing and ex- and disassemble JFS gas
haust duct for obstruction. generator/accessory drive
assembly for inspection 11
and repnir.
- -
Tab1e 4-21. Troubleshooting (Cont)
...
10. Premature starter c. Output shaft Rotate power turbine wheel lf test stand rotating
cutout. (Prior to sheared. through exhaust opening. assembly does not turn
3000 rpm output Test stand rotating assem- when power turbine wheel
shaft speed). bly should turno is rotated, replace
(Cont) sheared output shaft.
d. Switch actuating Test governor. Repair governor assembly.

governor assembly
defective.
e. Sensitive switch Remove and inspect Repair or replace sensi-

assembly in power sensitive switch assembly. tive switch assembly as
turbine assembly. required.
11. Output shaft cutout a. Switch actuating Remove and inspect switch Repair switch actuating
speed is toa high. governor assembly actuating governor assem- governor assembly.
in power turbine b1y.
assembly defective.
b. Sensitive switch Remove and inspect sensi- Repair or replace sensi-

assemb1y in power tive switch assembly. tive switch assembly.
turbine assembly
defective.
12. Starter rpm "hangs Troubleshoot in ac- ~

~
up", fatis to come cordance with item
up to governed 9, stepa a through
speed. d. o
w
~
o
IJI
f ~I
~ IJI
...... N
~>
~
I
("J
~
(X)
~
("J
I
.....
o
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13. Starter smoking Gas generator rotor Check oil leveIs in power lf accessory case-oil
during or following or power turbine turbine and accessory drive leveI drops in excess of ~I
a start cycle. rotor seal defective. assemblies. 10 cucm after a start \.ri
N
cycle inspect and repair
JFS gas generatorl
accessory drive assembly.
lf power turbine oil
leveI drops in excess of
10 cucm, after a start
cycle, inspect and repair
power turbine assembly.
14. Fuel coming from N.O. solenoid valve Disconnect line from down- lf fuel is coming from
manifold to tube not closing, seal stream side of n.o. valve downstream side of n.o.
elbow assembly damaged in fuel con- and make a start-cycle to solenoid valve replace
during start cycle. trol, or limiter fuel determine if fuel is coming solenoid valve. lf fuel
diaphragm ia defective. out overboard vent line or is coming from overboard
from downstream side of drain, repair fuel con-
fuel drain solenoid. trol assembly.
15. Oil coming from Gas generator seal Disassemble JFS gas
overboard vent leaking causing exces- generator/accessory drive
during start cycle. sive pressure of fuel assembly for inspection
control shaft seal is and repair.
defective.
16. Oil coming from power Output shaft packing Remove output shaft and lf packing i8 damaged,
turbine output shaft damaged or output inspect packing and output replace packing. lf con-
seal or output shaft shaft seal defective. shaft seal. dition of packing is good,
seal area. replace output shaft seal. ~
- -
-
111
17. Overtemperature. a. Restricted air Check for obstructions in Remove obstructions and
inlet or exhaust air inlet and exhaust disassemble starter for
outlet. outlet. inspection and repair.
b. Defective fuel Disassemble starter for

control assembly. inspection and repair.
18. Overspeed. Defective PMG or JFS Test PMG and JFS control Repair PMG or JFS control
control box assembly. box assembly. box assembly as required.
Perform inspection of
starter as required.
~
I
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-
~
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1.1'1
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•
!tAVAIR 03-105AB-52
SECTION V
DIFFEREUCE DATA SllEETS
Depot maintenance instructions for jet fue1 gAS turbine engine stAT.'ters included in
this section are the sa1'le as for procedures for Jet Fue1 GAS Turbine Eng:'-ne Starter
Part no. 384092-1-1, except for specific differences noteri by Appl:'-cAble difference
data sheet. Sections I throllgh IV contain complete inst!'llctions for Jet Fuel Gas
Turbine Engine Starter Part No. 384092-1-1.
IlIDEX TO DIFFERENCE DATA SHEETS
Part Uo.
384092-1-7 5-3
384092-1-4 5-49
Change 1 5-1/ (5-2 blank)

•
NAVAIR 03-105AB-52
JET FUEL GAS TURBINE ENGINE STARTER PART NO. 384092-1-7
mE INSTRUCTIONS CONTAINED IN THE PRECEDING SECTIONS OF THIS MANUAL

APPLY EXCEPT FOR THE DIFFERENCES LISTED IN THIS DATA SHEET.
NOTE
The differences between Starter Part No. 384092-1-1 and

Part No. 384092-1-7 is comp1iance with Accessory Change
No. 469 and Accessory Change No. 499.
5-1. INTRODUCTION.
No differences.
5-2. CHARACTERISTICS.
Starter Part No. 384092-1-7 is physical1y and functiona11y similar to Starter Part
No. 384092-1-1. A breakdown describing the differences Df the assemb1ies, sub-
assemblies and components are pro~.ded in the fo11owing paragraphs.
5-3. STARTER ASSEMBLY. Differences in the starter assemb1y are as fo11ows.
NOTE
Use figure 5-1 in conjunction with figure 4-2. Refer to

paragraphs 5-4 and 5-5 for differences in power turbine
assemb1y (5, figure 4-2), and gas generator and accessory
drive assemb1y (6).
a. Harness assemb1y (10, figure 5-1) is used in p1ace Df e1ectric wiring

insta11ation (10, figure 4-1).
b. Lubrication instruction plate (11, figure 5-1) ia incorporated.

5-4. POWER TURBINE ASSEMBLY. Differences in the power turbine assemb1y are as
fol1ows.
a. P1ug (8, figure 5-2), p1ate (9), oi1 fi1ter housing (11), hose (15), and
oi1 drain adapter (20) are used in p1ace Df dipstick (8, figure 4-3), p1ate (9),
housing (11), hose (16) and adapter (22).
b. A different immersion thermocoup1e (23, figure 5-2) is used.
c. Connector (27, figure 5-2), packing (33), and tube (34) are used in
p1ace Df connectors (26 and 27, figure 4-3), cover assemb1y (40, 41), and bushing
(42).
Change 1 5-3
NAVAIR 03-105AB-52
d. Dipstick assembly (36, figure 5-2), tube assembly (37) and fitting (39)
are used in place of plug (45, figure 4-3).
e. Bracket (60, figure 4-3) does not apply.
f. A different housing assembly (79, 80, figure 5-2) i5 used.
g. Screws (86, figure 5-2) and support assembly (94) are used in place of
setscrew (90, figure 4-3), lock ring (91), and bearing support (99).
h. Insert (133, figure 5-2) i5 incorporated.
i. Pin (138, figure 4-3) does not apply.
F-12A-736
NOTE
Refer to figure 4-2 for items 1 through 7.
8. CLAMP 10. HARNESS ASSY

9. BOLT 11. PLATE
Figure 5-1. Jet Fue1 Gas Turbine Engine Starter Part ~o. 384092-1-7
5-4 Change 1
•
NAVAIR 03-10SAB-52
5-5. GAS GENERATOR AND ACCESSORY DRIVE ASSEt1BLY. Differences in the gas gener-
ator and accessory drive assembly are as follo1~.
NOTE
Use figure 5-3 in conjunction with figure 4-4. Refer

to paragraphs 5-6, 5-7 and 5-8 for differences in
accessory drive assemb1y (129, figure 4-4), gas gen-
erator assemb1y (130), and contro1 box assemh1y (56).
a. A different filter (19, 20, figure 5-3) ia used.

b. Bushing (20A) is incorporated.
5-6. GAS GENERATOR ASSEMBLY. Differences in the gas generator assemb1y are as
fo!.lows.
NOTE
Use figure 5-4 in conjunction with figure 4-5.

a. Bose assembly (6A, figt~re 5-4) and manifo1d assembly (6B) are used in
place of manifo1d assemb1y (6, figure 4-5).
b. Scuff p1ate (15A, figure 5-4) ia used in p1ace of brackets (15 and 27,
figure 4-5).
5-7. ACCESSORY DRlVE ASSmmLY. Differences in the accessory drive assemb1y are
in hydrau1ic motor (18, figure 4-7) and fue1 contro1 assemb1y (24). Refer to para-
graphs 5-9 and 5-10.
NOTE
Use figure 5-5 in conjunction with figure 4-9.

5-8. CONTROL BOX ASS~mLY. P1ate assemb1y (18, 19A, figure 5-5) is used in p1ace
of plate (17, figure 4-9), p1ate assemb1y (18, 19), mounts (20 and 21), counter
(22) and grommet (23).
5-9. FUEL CONTROL ASSEMBLY. Difference in fue1 contro1 assemb1y is the pump
drive shaft. Shaft (78A, figure 5-6) is used in place of shaft (77, 78, figure
4-13) •
5-10. HYDRAULIC MOTOR. Differences in hydrau1ic motor are as fo11ot~.
a. A different cap (1, figure 4-14), packing (5) and sea1 (7) are used.
b. Bushing (4) and washer (6) do not app1y.
Change 1 5-5
,
NAVAIR 03-105AB-52
36
~
r'--'
J
22 ..........
"'A
t'f> 43
\
35
21,
,7 I
)ft::Y
I ~
5 2,
~
. '. (;" I
"! \ 3 4
/ t,J~I.
~:: ~'>
17~~lJf;r'
v.-r-- 20
~\ ~17
J9 18 ~"""16
E-12A-1502
Figure 5-2. JFS Power Turbin.e Assembly (Sheet 1 of 4)
5-6 Change 1
I
NAVAIR 03-105AB-52
~ KEY TO FIGURE 5-2
1. IDE~ITIFICATION PLATE 22. tiASHER

2. PREFOBimD PACKING 23. nfomRSION THERMOCOUPLE
3. OUTPUT SHAFT RETAINER 24. GASKET
f
4. OUTPUT SHAFT ASSY 25. SCREt~
5. SWITCH ACTUATING GOVERNOR ASSY 26. WASHER
6. QUICK RELEASE PIN 27. ELECTRICAL PLUG CONNECTOR
7. ANNULAR ALUHlNUM-ASBESTOS 28. SLEEVING
GASYxr 29. PACKING
8. PLUG 30. LOOP CLAMP
9. LUBRICATION INSTRUCTION PLATE 31. SCREti
10. INSERT 32. tiASHER
lI. OIL FILLER HOUSING 33. PREFORMED PACKING
12. BOLT 34. TUBE
13. toJASHER 35. PACKING
14. LOOP CLAMP 36. DIPSTICK ASSY
15. HOSE 37. DIPSTICK TUBE ASSY
16. FLUID PASSAGE BOLT 38. ANNULAR ALUMItruM-ASBESTOS
17. ANNULAR ALUMINUM-ASBESTOS GASKET
GASKET 39. DIPSTICK FITTING
18. PREFORMED PACKING 40. ANNULAR ALUMINUM-ASBESTOS
19. MAGNETIC PLUG GASKET
20. OIL DRAIN ADAPTER 41. PLUG
2I. BOLT 42. WARUING TAG
43. t~ARNING TAG
Change 1 5-7
NAVAIR 03-105AB-52
~ ~ft
78 6{ /,
64 65
E-12A-1503 A
Figure 5-2. JFS Power .
Turb~ne Assembly (Sheet 2 of 4)
5-8 Change 1
NAVAIR 03-105AB-52
44. SCREl-l 62. OIL BAFFLE

45. SCREW 63. INNER BOUSING GASKET
46. RETAINING RING SE~IENT 64. BEARING RETAINER
47. CONTAINMENT SUPPORT ASSY 65. lfASHER
48. THERMAL INSULATION BATT 66. SCREW
49. POWER TURBINE CONTAINHENT 67. ANNULAR BALL BEARING
SBIELD ASSY 68. PREFORMED PACKING
50. REAT SHIELD 69. SBm
51. TURBINE DIFFUSER 70. INSERT
54. SCREtY' 73. INSERT
55. SPECIAL WASHER 74. ENGINE STARTER BOUSING
56. INSERT 75. DRIVE SHAFr PAWL
57. BRACKET 76. RIVET
58. ENCASED PLAIN SEAL 77. LEAF SPRING
59. BOLT 78. DRIVE SHAFT ASSY
60. WASHER 79. NUTPLATE
61. RETAINER RING 80. EXHAUST BOUSING
Change 1 5-9
NAVAIR 03-105AB-52
E-12A-1504
Figure 5-2. JFS Power Turbine Assemb1y (Sheet 3 o f 4)
5-10 Change 1
I
NAVAIR 03-105AB-52
81. RETAINER RING 100. INSULATION COVER

82. RING GEAR LOCKR.ING 101. SCREW
83. RETAlNER RING 102. SUL RETAINER
84. ANNULAR BALL BEARING 103. THERMAL INSULATION BLANKET
85. INTERNAL GEAR HUB 104. INNER HOUSING GASKET
86. SCREW 105. INNER HOUSING GASKET
87. NU! 106. BELLOl~S SEAL SHIM
88. SCREW 107. TURBlNE WHEEL SUL
89. INSULATOR PLATE 108. BELLOWS SEAL SHnI
90. INSULATOR PLATE 109. SPRING SEAT
91. SENSITIVE SlflTCH ASSY 110. ANNULAR BALL BEARING
92. PIN 111. RESILIENT BALL BEARING HOUSING
93. SWITCH ACTUATING LEVER 112. RESILIENT MOUNT LlNER
94. BEARING SUPPORT 113. STRAIGHT PIN
95. STRAIGHT PIN 114. STRAIGHT PIN
96. PLAIN HEXAGON NU! 115. SPRING SEAT
97. PINION SPUR GEAR 116. COMPRESSION HEtICAL SPRING
98. TUBOLAR RIVET 117. BEARING SLEEVE SPACER
99. AXIAL FLOW TURBINE WHEEL 118. ANNULAR BALL BEARING
Change 1 5-11
t
NAVAIR 03-105AB-52
---
t
135
c
E-12A--lS05
Figure 5-2. JFS Power Turbine Assemb1y (Sheet 4 of 4)
5-12 Change 1
i
NAVAIR 03-105AB-52
119. STRAIGHT PIN 128. RETAINER RING

120. PLAIN HEXAGON NUT 129. ANNULAR BALL BEARING
121. SPECIAL WASHER 130. SPECIAL WASBER
122. HEADLESS SETSCREW 131. SEAL CARRIER
123. NEEDLE ROLLER BEARING 132. INNER HOUSING GASKET
124. SPUR GEARSHAFr 133. INSERT
125. GEAR 134. INSERT
126. INTERNAL SPUR GEAR 135. INSERT
127. BEARING SPACER 136. GEAR CARRIER
Change 1 5-13
,
NAVAIR 03-105AB-52 14 13
E-19A-9026
NOTE
For continuation of figure 5-3, use sheets 2 and 3 of figure 4-4.
Figure 5-3. Gas Generator and Accessory Drive Assembly
5-14 Change 1
NAVAIR 03-105AB-52
~ KEY TO FIGURE 5-3
1. IDENTIFICATION PLATE 26. SPACER

2. WARNING TAG 27. TEE
3. NUT 27A. TUBE ASSY
4. BOLT 28. METAL TUBE ASSY
5. LOOP CLAMP 29. RESTRICTED FLOW CHECK VALVE
6. JFS METAL TUBE ASSY 30. METAL TUBE ASSY
7. NU! 31. PREFORMED PACKING
8. BOLT 32. NU!
9. LOOP CLAMP 33. ELBOW
10. SCREW 34. NUT
11. FUEL CONTROL METAL TUBE 35. BOLT
ASSY 36. LOOP CLAMP
12. GASKET 37. LOOP CLAMP
13. BOLT 38. BOLT
14. WASHER 39. ANGLE SUPPORT
15. FILTER BRACKET 40. IGNITER PLUG ELECTRICAL LEAD
16. PREFORMED PACKING 41. CAPACITOR DISCHARGE HIGH
17. NUT VOL~GE IGNITION UNIT
18. FITTING 42. BOLT
19. PRESSURE FLUID FILTER 43. tiASHER
20. PACKING 44. LOOP CLAMP
20A. BUSHING 45. GAS TURBINE ENGINE ImUTER
21. METAL TUBE ASSY PLUG
22. CHECK VALVE 46. BOLT
23. SCREW 47. WASHER
24. METAL TUBE ASSY 48. GASKET
25. PREFORMED PACKING
Change 1 5-15
NAVAIR 03-105AB-52
E-12A-1500
Figure 5-4. Gas Generator Assembly
5-16 Change 1
NAVAIR 03-105AB-52
~ KEY TO FIGURE 5-4
1. COMPRESSOR INLET SCREEN ASSY 27. SOLENOID MOmITING BRACKET

2. ROSE CLAMP 28. PREFORMED PACKING
~ 3. IMPELLER SHROUD 29. UNION
4. FLUID PASSAGE BOLT 30. NORMALLY OPEN SOLENOID VALVE
5. PACKING WITH RETAINER 31. PREFORMED PACKING
6. FUEL MANIFOLD ASSY 32. OIL STRAINER ASSY
6A. FLEXIBLE FUEL ROSE ASSY 33. MACHINE SCREW
6B. FUEL MANIFOLD ASSY 34. SPECIAL WASRER
7. PACKING WITH RETAINER 35. ROUSING GASKET
8. FUEL NOZZLE ASSY 36. PREFORMED PACKING
9. NON-METALtIC WASHER 37. TotmR SHAFT COVER
10. JFS METAL TUBE ASSY 38. CAP SCRmi
11.. BOtT 39. POWER TURBlNE STATOR ASSY
12. REX-THIN SELF-LOCKING NUT 40. GAS GENERATOR CONTAINMENT
13. WASHER SRIELD ASSY
14. BOLT 41. SCREW
15. SOLENOID MOUNTING BRACKET 42. SPECIAL WASHER
15A. SCUFF PLATE 43. SHIELD RETAINER
16. PREFORMED PACKING 44. CONTAINMENT RING INSULATOR
17. NUT 45. NUT
18. ELBOW 46. SPECIAL liASHER
19. PREFORMED PACKING 47. SHROUD RETAINING RING
20. NU! 48. SHUI
21. TEE 49. D-iPELLER SHROUD
22. MANUAL PRIME NORMALLY CLOSED 50. SHrn
SOLENOID VALVE 51. BOLT
23. BOLT 52. WASHER
24. HEX-THIN SELF-LOCKING NUT 53. ANGLE BRACKET
25. WASHER 54. JFS HOUSING ASSY
26. BOLT 54A. IDENTIFICATION PLATE
Change 1 5-17
.
NAVAIR 03-10SAB-52
,
... .....8
'~
-- '-
E-19A-9029
For continuation offigure 5-5, use sheet 2 of figure 4-9.
Figure 5-5. JFS Control Box Assembly
5-18 Change 1
NAVAIR 03-105AB-52
~ KEY TO FIGURE 5-5
, 1. IDENTIFICATION PLATE
2. SCREW
3. WASHER
15. WASHER
16. llASHER
17. COUNTER RETAINING PLATE
4. LUG TERMINAL 18. COUNTER RETAINING PLATE GASKET
5. WASHER 19. TRANSPARENT COUNTER RETAINING
6. ELECTRlCAL CONTROL SELF PLATE
ADHERING GASKET 19A. COUNTER RETAINING PLATE
7. ELECTRlCAL CONTROL COVER 20. RESILIENT-START COUNTER ~IOUNT
8. SPACER HEAD MACHINE SCREW 21. RESILIENT-START COUNTER MOUNT
9. ARMATURE RELAY 22. ELECTRlCAL COUNTER
10. NUT 23. GROMMET
11. WASHER 24. TEMPERATURE SENSOR
12. l~ASHER 25. INSULATION SLEEVING
13. SENSOR ASSY 26. INDlCATOR
14. SCREtv
Change 1 5-19
For continuation of figure 5-6, use sheet 2 of figure 4-13.
Figure 5-6. Main Jet Fue1 Starter Fue1 Contro1
5-20 Change 1
1
NAVAl R 03-105AB-52
~ KEY TO FIGURE 5-6
1. PREFORMED PACKItlG 50. PREFORMED PACKING

2. PLUG 51. ADJUSTING SCREW
3. AIR PASSAGE BOLT 52. MACHINE THRF..AD PLUG
4. ANNULAR ALUMINUM-ASBESTOS GASKET 53. COliJ?RESSION RELICAI.. SPRING
5. SPECIAL FITTING 54. METERING VALVE
6. NEEDLE LOCKING ADJUSTMENT NUT 55. PREFORMED PACKING
7. llASHER 56. PREFORMED PACKING
9. WASHER 58. PREFORHED PACKING
10. PREFORMED PACKING 59. FUEL CONTROL VALVE SLEEVE
11. ADJUSTING SCREW 60. DELETED
12. INSERT 61. SPECIAL llASHER
13. PLUG FLUID FLOW RESTRICTOR 62. PREFORMED PACKING
14. ACCELERATION LIMITER HOUSING 63. UNION
15. SPRING GUIDE 64. SCRElol
16. HELICAL COMPRESSION SPRING 65. l~SHER
18. DIAPHRAGU RETAINER 67. ENCASED PLAIN SEAL
19. AIR AND FUEL DIAPHRAGU 68. RETAINING RING
20. DIAPHRAG1 SP ACER 69. ENCASED PLAIN SEAL
2I. DIAPHRAGM SPACER 70. SEAL HOUSING
22. SHOULDER BOLT 71. PREFORMED PACKING
23. FUEL CONTROL DIAPHRAGM SPACER 72. PREFORMED PACKING
24. AIR AND mEL DIAPHRAGM 73. PREFORMED PACKING
25. BALL 74. PREFORMED PACKING
26. NEEDLE LOCKING ADJUSTMENT NUT 75. SEDIMF..NT STRAINER ELEUENT ASSY
27. WASHER 76. FUEL PUMP SLEEVE BEARING
28. SCREt-l 77. PLUG
29. l1ASHER 78. SHAFT
30. BRACKET 78A. PillfP DRIVE SHAFT
31. PREFORMED PACKING 79. SPUR GF..AR
32. SPRING RETAIl\"ER 80. GF..ARSHAFT
33. ADJUSTING SCREW 81. SPUR GEAR
34. PREFORMED PACKING 82. FUEL PUMP SLEEVE BEARING
35. PIN 83. SPRIttG TENSION l-lASHER
36. GOVERNOR COVER 84. FLAT l-lASHER
37. SPRING 85. PREFORMED PACKING
38. ANNULAR BALL BEARING ~6. INSERT
39. }mTALLIC THRUST WASHER 87. INSERT
40. METERING SLEEVE 88. IUSERT
41. GOVERNOR FLyt~EIGHT 89. INSERT
42. SCREtol 90. INSERT
43. SPECIAL l-lASHER 91. INSERI
45. GOVERNOR CAGE 93. INSERI
46. GOVERNOR VALVE ASSY 94. PLUG
47. SLEEVE BEARING 95. PLUG
49. HEXAGON PLAIN NUT 97. FUEL METERING BODY
Change 1 5-21
NAVAIR 03-105AB-52
5-11. AEROSPACE GROUND EQUIPMENT MAINTENANCE.
Not app1icable.
5-12. DEPOT MAINTENANCE.
A breakdown of the differences in maintenance instructions are provided below.
5-13. DISASSEMBLY. Differences in instructions for the disassemb1y of assemblies,

subassemb1ies and components are provided in the following paragraphs.
5-14. Disassembly of P1umbing and Electrica1 Lines and Leads. Use figure 5-7 in
p1ace of figure 4-1.
5-15. Disassemb1y of Starter into Major Assemb1ies. Instructions for disassembly

of starter into major assemb1ies are the same as in paragraph 4-17, except step e
is not app1icable. Complete instructions that fol10w in the p1ace of step e.
a. Remove bo1t (9, figure 5-1) and c1amp (8).
b. Disconnect and remove harness assemb1y (10).
c. Remove p1ate (11) from control box assembly if damaged or il1egible.
5-16. Disassembly of Power Turbine Assembly. Instructions for disassembly of

power turbine assembly are the same as in paragraph 4-20, except as fol10ws. Use
figure 5-2 in place of figure 4-3 unless otherwise noted.
a. Steps d througn o of paragraph 4-20 are not applicable. Complete in-

structions that fol10w in the place of steps d through o.
(1) Remove quick re1ease pin (6, figure 5-2) from oiI filler housing
(11) •
(2) Remove plug (8) and gasket (7). Remove gasket (7) from plug (8) •
(3) Remove Iubrication instruction p1ate (9) i f i t is damaged or

i1Iegib1e.
(4) Remove oi1 filler housing (11) from end of hose (15).
(5) Remove bolt (12), washer (13) and clamp (14). Remove hose (15)
from oi1 drain adapter.
(6) Remove p1ug (19) and packing (18). Remove packing (18) from plug
(19).
(7) Remove fluid passage bo1t (16), gaskets (17) and oi1 drain adapter
(20).
(8) Remove bo1ts (21), washer (22), thenmocouple (23) and gasket (24).
5-22 Change 1
-. NAVAIR 03-105AB-52
2 3
,
LA
17 16 12 11 10 7 5
13 8 8
8 14
L_ 15 _-.1
22 15 REF 17REF
I
/
19 20 21 1 REF
VIEW 8-8
VIEW A-A
F-19A-<I368
Figure 5-7. Disassembly of Plumbing and Electrical

Change 1 5-23
NAVAIR 03-105AB-52
32
27 33
28 34
29 30 31 35 36
48
\ 38REF
,
D
49
44REF 51
39REF 11 REF 56REF
VIEWE-E
VIEWD-D F-19A-4367
Figure 5-7. Disassembly of Plumbing and Electrical

5-24 Change 1
NAVAIR 03-105AB-52
~ KEY TO FIGURE 5-7
1. ~1ETAL TUBE ASSY 31. METAL TUBE ASSY

2. IGNITER PLUG ELECTRICAL LEAD 32. NUT
3. LOOP CLAMP 33. BOLT
4. ROSE 34. LOOP CLAMP
5. (DELETED) 35. LOOP CJ..AMP
6. (DELETED) 36. CHECK VALVE
7. BOLT 37. ~1ETAL TUBE ASSY
8. LOOP CLAMP 38. TUBE ASSY
9. FLEXIBLE HOSE 39. LOOP CWIP
10. llARNESS ASSY 40. OIL FILTER HOUSING
lI. JFS BRANCHED WIRING HARNESS 41. (DELETED)
ASSY 42. PACKING WITH RiITAIUER
12. NUT 43. NUT
13. BOLT 44. ~lIFOLD TO TUDE ELBOW ASSY
14. LOOP CLAMP 45. FUEL DRAIN METAL TURE AS SY
15. LOOP CLAMP 46. ANUULAR AJ..Ul-llHUM-ASBESTOS GASKET
16. JFS METAL TUBE ASSY 47. BOLT
17. JFS METAL TUBE ASSY 48. WASHER
18. ROSE ASSY 49. LOOP CLAME'
19. TEE 50. FUEL DRAIN SPECIAL TUBE ASSY
20. METAL TUBE ASSY 5I. ANGLE BRACKET
21. RESTRICTED FLOlv CHECK VALVE 52. NUT
22. BOLT 53. BOLT
23. ANGLE BRACRET 5i•• LOOP CLAMP
24. (DELETED) 55. LOOP CLAMP
25. (DELETED) 56. LOOP CLMIP
26. (DELETED) 57. JFS METAL TUBE ASSY
27. NUT 58. NU!
28. BOLT 59. BOI..T
29. LOOP CLMIP 60. LOOP CLAl1P
30. JFS ~IETAL TUBE ASSY 61. LOOP CI..AMP
(9) Remove scre'-1S (25), l.,ashers (26), and d1sconnect connector (27)
from wires.
(10) Remove sleeving (28) from wires. Remove pack1ng (29) and c1amp
(30) from tube (34).
(11) Remove screw (31), washer (32), and tube (34) and packing (33).
Remove packing (33) from tube (34).
(12) Remove d1pstick (36) and pack1ng (35) fr~ tube assemb1y (37).
Remove pack1ng (35) from d1pstick (36).
(13) Remove tube assembly (37).
(14) Remove f1tt1ng (39) and gasket (38).
Change 1 5-25
..
NAVAIR 03-I05AB-52
b. Referenee to braeket (60, figure 4-3) in step q is not applieable.
e. Step u is not applieable.
d. Steps ad and ae are not applieable. In their plaee, use the following
instruetions.
(1) Remove serews (86) and assembled bearing support (87 through 94).
(2) Engage nuts (87) with Soeket Wrench Part No. 285471-1-1. Remove
nuts (87), serews (88), insulator plates (89 and 90) and sensitive switeh assemb1y
(91).
5-17. Disassembly of Gas Generator and Aeeessory Drive Assembly. Instruetions for
disassembly of the gas generator and aeeessory drive assemb1y are the same as in
paragraph 4-22, exeept the following instruetions should be performed following
step e. Remove bushing (20A, figure 5-3) from filter (19).
5-18. Disassembly of Gas Generator. Instruetions for disassembly of the gas

generator are the same as in paragraph 4-24, except as follows.
a. Steps b and e are not applieable. Complete the following instruetions

in the place of steps b and e.
CAUTION
To prevent damage to fuel manifold assembly, use wreneh

to hold inlet fitting of fue1 manifold assemb1y when
disconneeting hose assemb1y from fitting.
(1) Diseonneet hose assembly (6A, figure 5-4) from manifold assemb1y
(6B).
(2) Remove fluid passage bo1ts (4) and paekings with retainers (5 and
7). Remove manifold assemb1y (6B).
(3) Diseonneet hose assembly (6A) from tee (21).
b. Steps f through k are not app1icable. Complete instruetions that follow

in the plaee of steps f through k.
(1) Remove bolts (11 and 23) and assemb1ed parts consisting of items
12 through 14, l5A through 26, and 28 through 30.
(2) Remove nuts (12), washers (13), bolts (14) and parts eonsisting of
items 16 through 22.
(3) Remove assemb1ed elbow (16, 17, 18). Remove packing (16) and nut
(17) irom elbow (18).
5-26 Change 1
NAVAIR 03-10SAB-S2
(4) Remove assemb1ed tee (19, 20, 21) from manual prime solenoid va1ve
(22). Remove packing (19) and nut (20) from tee (21).
(5) Remove nuts (24), washers (25), bolts (26) and scuff plate (ISA)
from assemb1ed solenoid va1ve (28, 29, 30).
5-19. Disassembly of JFS Control Box Assemb1y. Instructions for disassemb1y of

the JFS contro1 box assemb1y are the same as in paragraph 4-31, except steps e and
f are not app1icab1e. Complete instructions that fo11mi in p1ace of steps e and f.
Remove screws (14, figure 5-5), washers (15 and 16) and p1ate assemb1y (18, 19A).
5-20. Disassemb1y of Fue1 Contro1 Assemb1y. Instructions for the disassemb1y of

the fue1 contro1 assemb1y are the same as in paragraph 4-39, except for step g.(6).
Use instructions that fo11ow in p1ace of step g.(6). Remove shaft assemb1y (78A,
figure 5-6), spur gear (79), gearshaft (80) and spur gear (81).
5-21. Disassemb1y of Hydrau1ic MOtOl. Instructions for the disassemb1y of the

hydrau1ic motor are the same as in paragraph 4-41, except alI references to bushing
(4, figure 4-14) and washer (6) shou1d be omitted.
5-22. CLEANING. Instructions for c1eani.ng are the same.
5-23. INSPECTION. Differences in instructions for inspection are provided in the

fo11owing paragraphs.
5-24. Tab1e of Inspection and Repair Procedures. Use table 5-1 in conjunction
with tab1e 4-2. References to the fo11owing items in tab1e 4-2 are not app1icab1e.
a. Figure 4-3, items 8 through 11, 15 through 16, 17, 22, 26, 27, 30, 40,
41, 43, 45, 91 and 99.
b. Figure 4-5, items 6, 15, and 27.
c. Figure 4-9, items 17, 19, and 20 through 22.
d. Figure 4-13, items 77 and 78.
5-25. Specific Inspection Instructions. Use inspection instructions in the fo1-

lowing paragraphs in conjunction with the instructions in paragrapI~ 4-115 through
4-365. Paragraphs 4-296 through 4-299 are not app1icab1e.
5-26. Visua11y inspect wiring harness assemb1y (10, figure 5-1) as fo11ows:
a. Visua11y inspect identification straps for security and 1egibi1ity.
b. Visua11y inspect e1ectrica1 connectors as fo11ows.
(1) Check e1ectrica1 connectors for security to wiring.
(2) Check e1ectrica1 connectors for broken, burned, corroded or bent

contacts.
Change 1 5-27
NAVAIR 03-105AB-52
•
Tab1e 5-1. Tab1e of Inspection and Repair Procedures
,
Z
o
I-!
f-j
Z U
o _
I-! ~
Z
f-jCO
UO
(.:Ir-!
!lo I
!lo
(/)0
Zr-!
'"'
I-! r-!
f-j..;tI
- -
~
• C
Z
•
o (/)..;t f-j
I-!
f-j
U
Z
I-!::C
Il.
Z
~~ z~
= z=
'==c..
lz:J lz:J<
o-JI:!::: ~~ OI:!:::
t-It.!l
~~
Il.
(/) -
Ut.:i
zo•
uc zc
~~ :S~
I-!Z ~~ ~~ f:l< tl.<
~< < A..~ ~~
o-Jlz:J <Il. f-jtl. (/) I:!:::
(.:I
~~ ~o
Z~
!lo
O I-!U I:!:::U
Ot.!l Uf-j Uf-j Z OZ
I-! I-! I-! (/) "'::f;:;:! (.:I
(/)rz.. f-j~ ~I:!::: <I:!::: C::~
Z (.:If<l lX:~ I-! (.:I H~
zrz.. orz.. urz..
-
(.:1(.:1 <rz..
:=f<l Cf;:;:! O~ ~~ A..~ cr.
I-I(/)
0- ~e
...::~
rz..-
~~ ~~ <
(/) ~- r:Q
Index No. z Figure 5-1 Jet Fue1 Gas Turbine Engine Starter Assy"
10 Wiring Harness Assy 5-26 5-53
11 Lubrication P1ate 5-27 5-54
lndex No., Figure 5-2 JFS Power Turbine Assy"
8 P1ug 5-28 5-55 AI Alloy

6061-T6
10, 11 Oil Fil1er Housing x 5-29 5-56 AI Alloy

606I-T6
14, 30 Clamps 5-30 5-57
15 Hose 5-31 5-58
20 Adapter 5-32 5-59 AI Alloy

356-T6
23 Immersion 5-33 5-60

Thermocoup1e
27 Connector 5-34 5-61
28 Sleeving 5-35 5-62
34 Tube x 5-36 5-63 Steel

CRES 347
5-28 Change 1
NAVAl R 03-105AB-52
Tab1e 5-1. Table of lnspection and Repair Procedures (Cont)
z
o
1-1
~
lZi o
Z
o
1-1-
tn~
r.:!..-I
~I
lZl
~-
o
ti)
z1-1..-1
...
I
- -
o•
Z
o
Z
•
U
o
1-1
~
lZl
tI)..;t
Z
1-1::::
r.:!~
§:
t~ S~
::::
~
z::::
~~
r.:!~
uc
P-I- Oc
• ~<
:S~
~~ !~
ti)
lZiO U~
HlZi rz:Ic:( P-I<:
P-IP-I r::IP-I
~rz:I
~~
~P-I
P-I
~p::
o -
....
r::IO
ti)
Zr.:!
I-IU
~
~t)
r::I
~
oc
1-11-1
tl)rz,
§r.:!
..... r:::l
U~
1-1
~c::
r::Ir:::l
zrz,
Clr:::l
U~
ti)
rz:I~
~~
orz,
:Jf;a
=à!
I-Ir::l
urz,
r:::l::.l
O~
~~
~
1-1 r.:!
<:rz,
Ilor::l
-
~
.....
~
ti)
1-1 ti) ~~ Fie r::..~ r:::l~
r;::::-
<:
A- ",- ti)- ~
lndex No., Figure 5-2 (Cont)
36 Dipstick Assy 5-37 5-64
37 Tube Assy 5-38 5-65 Stee1

CRES 347
39 Fitting 5-39 5-66 Stee1

CRES 303
79, 80 Exhaust Housing 4-18 X 5-1+0 5-67 Steel

Assy CRES 347
94 Support 4-20 5-41 5-68 Stee1

CRES 17-7PH
131 - 136 Carrier Assy 5-30 5-42 5-69 AI Alloy
355-T6
lndex No., Figure 5- 3 Gas Generator and Accessory Dr1ve Assy
19, 20 Fi1ter 5-1.3 5-70
20A Bushing 5-44 5-71
--------------------------------------------------------------------------------
Change 1 5-29
NAVAIR 03-105AB-52
zo
1-1
E-o
Z to)
- -
o
1-1 _ ~
E-oCO Il.
u )-o
uo z .....
Z
foJ .....
/l.1
1-1 ..... o
Z
• oz•
o u)...:2" E-oJ.. E-o
1-1 Z Z = z=
E-o 1-1= <= Il. ~Il.
U
~~ ~~ rzl~
/l.
rzl
Il.
U) -
~~ zc.:;
1-10 UO
• uc
zo b~ :S~
I-IZ ~~ ~~ (oJ< /l.<
Il.Il. r::~
~rzl
cr.<
<Il. E-o~ U) CI::
~!5
/l.
o
zwo Z""
I-IU :t:u
rzl ~
00
1-11-1
UE-o
H
UE-o
U)
Z
...:ltz:
OZ
W
fSt::I
U)~ E-oCl:: t::ICI:: <CI:: 0:::11:: ~
rzltz: CI::~ I-Irzl t-I::r.:
:o?:it::l Z~ o ur.:.. <~ ::J
~w
r.:..
ow !::l~ foJt::I /l.W U)
I-IU) 1l.0:: foJO::
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~CI:: <
/:l- ~- U) '-' CI::- ~
Index No., Figure 5-4 JFS Gas Genera tor Assy
6A Hose Assy 5-45 5-72
6B Manifold Assy 5-46 5-73 Steel

CRES 347
15A Plate X 5-47. 5-74 CRES NIL-S-

5059
Index No., Figure 5-5 JFS Control Box Assy
19A Plate X 5-48 5-75 AI AlIoy

6061-T6
Index No., Figure 5-6 Main JFS Fuel Control Assy
78A Shaft 5-49 5-76 Steel

CRES 440C
5-30 Change I
NAVAIR 03-105AB-52
(3) Check e1ectrical connectors for cracks, corrosion, distortion,

nicks and burrs.
(4) Check each circuit of wiring harness assemb1y for shorta and con-
tinuity using mu1timeter. Refer to tab1e 5-2.
(
Table 5-2. Wiring Harness Assemb1y Wire Chart
Wire From To Length

Identification Part No. Location Pin Location Pin (inches)
Wh.ite S9510G95W P3 C P9 C 8.15

Green S95l0G95W P3 A P9 A 8.15
Black M8l38l/7-20-0 P3 B P10 B 8.00
Red M8138l/7-20-2 P3 D P10 D 8.00
Orange ~18138l/7-20-3 P3 F PlO F 8.00
5-27. Visual1y inspect 1ubrication plate (11) for security and legibi1ity.
5-28. Visua11y inspect p1ug (8, figure 5-2) for damaged threads, rounded wrenching
f1ats and worn lockwire boles.
5-29. Visually inspect oi1 fi11er housing (10, 11) for distortion, dents, cracks
and tom or wom lockwire ho1es. Inspect insert (10) for security and damaged
threads.
5-30. Visua1ly inspect c1amps (14, 30) for distortion and cracks.
5-31. Visua11y inspect hose (15) for chafes, tears and deterioration. Inspect
threads for damage.
5-32. Visual1y inspect adapter (20) for distortion, cracks, dents, chafes and dam-
aged threads.
5-33. Inspect immersion thermocoup1e (23) as fo1lows:
a. Visua11y inspect housing for bent probe, distortion, dents and cracks.
b. Visual1y inspect connector for bent, broken or corroded pins.
c. Check for continuity between pins A and C.
d. Check for resistance reading of infinity between ground and pins A and C.
Change 1 5-31
NAVAIR 03-l05AB-52
5-34. Visua1ly inspect connector (27) for broken, burned, corroded or bent
contacts.
5-35. Visually inspect sleeving (28) for cuts, chafes, resilience and distortion.
5-36. Visually inspect tube (34) for kinks, cracks, chafing, signs of corrosion
or other damage. Inspect for broken threads, chipping and cleanliness.
5-37. Visua11y inspect dipstick assembly (36) for security of component parts,
damaged pins and bent or broken dipstick.
5-38. Visua11y inspect tube assembly (37) for kinks, cracks, chafing, signs of
corrosion or other damage. Inspect threads for damage, chipping and cleanliness.
Inspect bracket portion for cracking along brazed area.
5-39. Visua1ly inspect fitting (39) for damaged threads, rounded wrenching flats
and bent or broken gaging probe.
5-40. Inspect exhaust housing assembly (79, 80) as fo1lows:
a. Visua1ly inspect exhaust housing assemb1y (79, 80) for cracks and cor-
rosion paying particular attention to flanges and welded joints.
b. Visually inspect threaded bores of exhaust housing assemb1y for damaged

threads.
c. Visually inspect insulation of exhaust housing assernbly (79, 80) for

integrity and security.
d. Visual1y inspect nutplates (79) for security and damage to threeds.
e. Dimensionally inspect exhaust housing assemb1y (79, 80) with Surface D

and Diameter E in restrained position. Refer to figure 4-18.
f. F1uorescent penetrant inspect in accordance with figure 4-13.
5-41. Inspect support (94, figure 5-2) as fol1ows:
a. Visually inspect support for scratching or scoring of bearing surfaces.
b. Dimensionally inspect bearing support in accordance vith figure 4-20,

except Diameter A does not app1y.
5-42. Inspect carrier assemb1y (131 through 136, figure 5-2) as fo11mls:
a. Visua11y inspect seal carrier (131) for scratches, scoring, wear and
security.
b. Visua1ly inspect inserts (133, 134, 135) for security and damaged
threads.
5-32 Change 1
NAVAIR 03-105AB-52
c. Visua11y inspect carrier (136) for cracks and corrosion. Inspect gear-
shaft bores for scratches, scoring and wear.
d. Dimensiona11y inspect gear carrier assemh1y in accordance with figure

5-8.
5-43. Visua11y inspect pressure f1uid filter (19, 20, figure 5-3) as follows:
a. Visual1y inspect filter element for security to end cap and clean1iness.
b. Visually inspect filter end cap for rounded wrenching f1ats and damaged
threads.
c. Visually inspect filter housing for rounded wrenching flats, damaged
threads, and nicked, chipped or cracked sealing surface of housing fitting.
d. Back pressure flush pressure fluid filter.
1 DIAF
T
DIA B DIA C
SURFACE G
/'
DIAMETER BAND C SHALL BE CONCENTRIC WITH DIAMETER F
WITHIN 0.OO2INCH TOTAL INDICATOR READING.
DIAMETER D AND E SHAL L BE CONCENTRIC WITH DIAMETER F

WlTHIN 0.001 INCH TOTAL INDICATOR READING.
A B C D E F
1.2597 TO 1.3781 TO 8.570 TO
2.1428 TO 2.0380 TO 2.S360TO
1.2602 IN. B.572IN.
2.1438 IN. 2.0385 IN. 1.3785 IN. 2.5367 IN.
3 PLACfS
1-19A-51<46
Figure S-S. Inspection of Gear Carrier Assembly
Change 1 5-33
NAVAIR 03-l05AB-52
5-44. Visually inspect bushing (20A) for rounded wrenching flats and damaged
tbreads.
5-45. Visually inspect hose (6A, figure 5-4) for chafes, deterioration and damaged
threads.
5-46. Visually inspect fuel manifold assembly (6B) as follows:
a. Visually inspect fuel manifold assembly (6B) for l:inks, cracks, chafing,
signs of corrosion or other physical damage.
b. Visually inspect threads for damage, chipping and cleanliness.
c. Pressure check manifold with 500 psig air pressure for one minute. No
leakage is permitted.
5-47. Visually inspect plate (15A) for cracks and distortion. Perform fluorescent
penetrant inspection in accordance with MIL-I-6866.
5-48. Visually inspect counter retaining plate (19A, figure 5-5) for cracks and
distortion. Perform fluorescent penetrant inspection in accordance with MIL-I-6866.
5-49. Visually inspect pump drive shaft (78A, figure 5-6) as follows:
a. Visually inspect security of brazed plugo
b. Visually inspect internaI splines for chips, nicks and ~reaks.
c. Dimensionally inspect internaI splines as follows:
(1) Dimensionally inspect by using adiaI indicator.
(2) Compare reading of worn sp1ine tooth and one wit~ no apparent wear.
Wear shall not exceed 0.010 incho
5-50. REPAIR AND REPLACEME~!T. Differences in instructions for repair and replace-
ment are provided in the following paragraphs.
5-51. General. General repair instructions are the same.
5-52. Detailed Repair Instructions. rsc instructions in the following paragraphs

in conjunction with paragraphs 4-396 through 4-645, and use table 5-1 in conjunc-
tion with table 4-2. Paragraphs 4-575 through 4-578 are not applicable.
5-53. Repair w1r1ng harness assembly (10, figure 5-1) in accordance with ~AVAIR
OI-IA-50S and as follows:
a. Disassemble applicable electrical connector for repair as follows:
(1) Disassemble electrical connector by loosening clamp screws on back

she1l of connector.
5-34 Change 1
• NAVAIR 03-105AB-52
(2) Separate connector and slide back insulation s1eeving as required

to expose contacts.
(3) Remove alI potting compound from back she11, contacts and wires.
(4) Beat contacts to me1t so1der and disconnect wires as necessary.
b. Repair 100se wire connections as fo11ows:
(1) Disassemb1e affected e1ectrica1 connector in accordance with

step a.
(2) Repair loose connection by soldering using solder SB5, per
qQ-S-571.
(3) Assemble electrical connector in accordance with step d.
c. Rep1ace damaged wires as fo11ows:
(1) Disassemb1e e1ectrica1'connectors and dis-connect wire in accordance

with step a.
(2) Pull wire from insulation sleeve •.
(3) Ueasure and cut rep1acement wires to 1ength specified in table 5-2.
(4) Insert rep1acement wires through insu1ation s1eeve and back she11s
of connectors.
(5) Assemble electrical connectors in accordance with step d.
d. Assemb1e electrical connectors as fo11ows:
(1) Connect wires to contacts as specified in table 5-2.
(2) Solder wires to contacts using solder SB5, per QQ-S-57l.
(3) Check pin to pin continuity using table 5-2.
(4) Apply potting compound (RTV8372, General Electric Co, Silicone

Products Division, Waterford, NY, or equivalent) to connector.
(5) Assemb1e connector and se cure with c1amp screws.
5-54. Remove and replace lubrication plate (11) as fo11ows:
a. Remove lubrication plate (11).
Change 1 5-35
-------------_._--_.
•
NAVAIR 03-l05AB-52
NOTE
Lubrication instruction plate (11) shall be installed in

a moderate temperature. Temperature below 60°F results
in poor adhesion; very warm temperatures result in
stretching of the filme
Newly painted control box asseI!lhlies shall be allm7ed to

air-cure at least 24 hours before applying the lubrication
instruction plate.
b. Remove oil, grease, and dirt from application surface with solvent,
Stoddard (Federal Specification P-D-680, Type 11). Wipe application surface with
toluene (Federal Specification TT-T-548) or methyl-ethy1-ketone and dry with c1ean,
dry cloth.
c. Wipe face of lubrication instruction p1ate and edge of 1mv friction

plastic squeegee with soft c10th.
NOTE
Lubrication instruction plate (11) consists of two matched

1abels. Install each label separateIy using the instruc-
tions that fol10w.
d. PIace lubrication instruction plate face down on clean surface, and peel
backing away from Iabels, one at a time.
e. Slide labe1 into position with notch(es) in 1abe1 a1igned with cover
screw heads. Touch labe1 on1y 1ight1y during positioning to prevent activation.
f. Tack label Iightly in place with fingers at two points on outer edge.
g. Se cure labe1 firmIy on appIication surface using 10w friction p1astic

squeegee edge. Start at center, and use over1apping strokes to work outward to
edges. Initial squeegee pressures must be very firm to avoid formation of air
pockets. l~en nearing upper edge, 1ift corners back beyond points at which 1abel
was pre-tacked to prevent wrinkles at tack points as activation proceeds.
h. Seal labe1 by tracing completely around plate edge with squeegee using
very firm pressure.
i. Repeat steps d through h for remaining label.
5-55. Replace pIug (8, figure 5-2) if inspection revea1s damage.
5-56. Repair or rep1ace oi1 fi11er housing (10, 11) as fo110ws:
8. lf anodized surfaces are worn through, reanodize in accordance with

paragraph 4-372.
5-36 Change 1
NAVAIR 03-105AB-52
b. lf insert (10) is damaged replace in accordance with paragraph 4-387.
c. Replace oil filler housing (10, 11) i f inspection reveals damage.
, 5-57.
5-58.
Replace c1amps (14, 30) if inspection reveals damage.
Rep1ace hose (15) if inspection reveals damage.
5-59. Repair or replace adapter (20) as follm~s:
a. lf anodized surfaces are worn through, reanodize in accordance with

paragraph 4-372.
b. Replace adapter (20) if inspection revea1s damage.
5-~0. Replace immersion thermocouple (23) if inspection requirements are not mete
5-61. Rep1ace connector (27) if inspection reveals damage.
5-62. Replace sleeving (28) if inspection reveals damage.
5-63. Replace tube (34) if inspection reveals damage.
5-64. Replace dipstick assembly (36) if inspection reveals damage.
5-65. Replace tube assemb1y (37) if inspection revea1s damage.
5-66. Replace fitting (39) if inspection revea1s damage.

5-67. Repair or replace e~maust housing assembly (79, 80) as follows:
a. Remove corrosion from housing assembly in accordance l~th paragraph

4-373.
b. Replace damaged nutplates (79) by resistance l~e1ding neto1 nutplates to

housing assembly per MIL-W-6858, Class B.
c. Replacehousing assembly (79, 84) if inspection reveals damage.

5-68. Replace support (94) if inspection reveals damage.
5-69. Repair or replace gear carrier assembly (131 through 136) as follm~s:
a. Replace gasket (132) if pressure check reveals darnage.
b. Replace inserts (133, 134, 135) if damaged as specified in paragraph

4-387.
Change 1 5-37
NAVAIR 03-l05AB-52
5-70. Repair or replace filter (19, 20, figure 5-3) as follows:
a. Remove and replace packing (20).
b. Replace filter (19) if inspection revea1s damage.
5-71. Replace bushing (20A) if inspection reveaIs damage.
5-72. Replace hose assembly (6A, figure 5-4) if inspection revea1s damage.
5-73. Replace fuel manifold assemb1y (6B) if inspection requirements are not meto
5-74. Replace plate (15A) if inspection reveaIs damage.
5-75. Replace plate (I9A, figure 5-5) if inspection revea1s damage.
5-76. Replace pump drive shaft (78A, figure 5-6) if inspection revea1s damage.
5-77. TOLERANCES ANO LIMITS. Tolerances and Iimits are the same.
5-78. ASSEMBLY. Differences in instructions for the assembly of components,

subassemblies, and assemblies are provided in the following paragraphs.
5-79. Assembly of Hydraulic Motor. Instructions for assembly of the hydrau1ic

motor are the same as in paragraph 4-674, except for step i. Complete instructions
as follows in place of step i.
a. InstaII packing (5, figure 4-14) into cap (1).
CAUTION
Press on metal outside diameter of seals (7).
b. Press se aIs (7) into cap (1).
c. Assemble packings (2, 3) onto capo
5-80. Assembly of Fuel Control Assembly. Instructions for assembly of the fuel
control assembly are the same as in paragraph 4-677, except steps a.(I) and a.(2)
are not applicab1e. Complete instructions that fol1ow in p1ace of steps a.(l) and
a. (2) •
a. Coat inside diameter of geqrs (79, 81, figure 5-6) and outsicle diameter
of shafts (78A, 80) with lanolin (commercially avai1ab1e).
b. Use Shaft Installing Driver and Holder Part No. 285462-1-1. Place gear
(79) in pocket of holder. InstaIl open end of shaft (78A) into driver. Position
plug end of shaft (78A) into driver. Position plug end of shaft (78A) over gear
(79). Press shaft into gear untiI face of driver contacts face of gear.
5-38 Change 1
NAVAIR 03-105AB-52
5-81. Assemb1y of JFS Contro1 Box Assembly. Instructions for assemb1y of JFS
contro1 box assemb1y are the saroe as in paragraphs 4-687 through 4-698, except as
fo11ows:
a. Use figure 5-9 in place of figure 4-85.
b. Use figure 5-10 in p1ace of figure 2-2.
c. Step e.(3), paragraph 4-687 is not applicab1e.
d. Step f, paragraph 4-687 is not app1icab1e. Use instructions that fol1ow

in p1ace of step f. Install plate assembly (18, 19A, figure 5-5), and secure and
seal with washers (15 and 16) and serews (14).
e. Paragraph 4-693 is not applicable.
f. Start eounter test item in table 4-11 is not app1ieable.
5-82. Assemb1y of Gas Generator. Instructions for assembly of the gas generator
is the saroe as in paragraphs 4-715 through 4-724, except as follows:
a. Paragraph 4-724 is not applicable. Complete instruetions as follows in

place of paragraph 4-724.
(1) Instal1 paeking (28, figure 5-4) on union (29). Install assemb1ed
union (28, 29) in normally open solenoid valve (30).
(2) Position norma11y open so1enoid va1ve (30) on scuff plate (15A),
and install two bolts (26), washers (25) and nuts (24). Do not tighten nuts (24)
at this time.
(3) InstaIl nut (20) and paeking (19) on tee (21). Install assembled
tee (19, 20, 21) in manual prime solenoid valve (22).
(4) Install nut (17) and packing (16) on e1bow (18). Insta11 assembled
elbow (16, 17, 18) in manual prime ne solenoid valve (22).
(5) Position manual prime norma11y closed so1enoid va1ve (22) on scuff
p1ate (15A), and connect tube assembly (10) to tee (21) and union (29). Seeure
manual prime normally e10sed solenoid valve (22) to seuff plate (15A) with two
bolts (14), washers (13), and nuts (12). Tighten nuts (12 and 24).
(6) Position assembled parts (10, 12 through 14, 15A through 26, and
28 through 30) on housing assembly of gas generator, and connect harness assembly
(11, figure 5-7) to manual prime normally closed solenoid va1ve (22, figure 5-4)
and normally open solenoid valve (30). Secure scuff plate (lSA) to housing asse~
b1y with bolts (11 and 23). Tighten bolts (11 and 23) to torque of 20 to 25 inch-
pounds.
Change 1 5-39
'f c;;- ~
~
o -. "",- ......... :::;- N N - ...:... - - - - - - -- -- --. -- - - _....--~ LL. a - ;:
ãi~~l<?:%~o~~Q;;~~~~l1~ ~o~1~~
t:.g,oo:::;~_=UQt::.o~~!:!:::.::J. 0.0 ........ ~O.:l:::J.
~~~~~~é~!
.:J.::J.~u~::;C::30
~
Oo.CICI"~O ................ ow .... C>..:(II:I..:(1I:I 1IlC>:X:"~ U-oOc')MM .... "CICI o
g
~
l:VJVll11I~~t;I \l1~ }IIIIII11 17(TBI-5)
12C(TB1-1)
~
I-'
o
~
1 2 3.. 5 6 7 8 9 10 11 12 13 14 15 17 A A 8 Kl- J K
L --.J 2A 18(TBI-4)
~ TBI Ktl VI
..... N
A-,
o
JI .1
.2
A .3
B
.15 TBI C
C
• 12 6•
O
E
F J)--t-
02
120 (TB1-I)--oC 08
02
9 ·,4 o
J 7. E
~
.13 8-
G ,---+-19(TBI-3)--OB Of 0j .,0 9
F
J 20(TB 1-17)--0 E '----=- ·11 H
o o.
K J
O
B
OETAll B
TB2
L
M
"
I '} 3 4 5 6 7 8 9 lO 11 12 13 14 15 78(TBI-2)--f N
FI ,
@>l-2(K2-7) OOOOOIOOOOO()lo0
~3A(TBI-l0)
DETAIl
F2 'I
A
- .....
~
I .!.
~
I
;(
OUJO
~ ~ g;
"'~
~5(J'-E) co ~ ~
~6(J2-C)
DETAIl A
_I -
'"I
a)
CICI
I
11:1 I I PART NUMBER(FAR SIDE)
B
VIEW A-A
t
lEAOS SHAll BE
BElOW TOP OF
TERMINAlS
...-co...«- ....
~
«...
N
........
<ri
u:;:;
co
N
~
USE
1Il"
.. n ..
~
'1
11 2 3 4 I
OVERSPEEO
INOICATOR
DETAIL B
'2
TEMPERATURE W-19A-1379
DETAIL A SENSOR TB?
Figure 5-9. JFS ContraI Uox AsscmbIy \Hring Diagram

"
- -
--
,,r---------------- -----,I AC-De PEIlMANENT IMO""" r.ENEIATOR
••
~oHJ
AHA
I IHI
I JfS CONTIOI. IOX ASSEMllV I
I I "LUI 2
I I H--fF
t- K2 5A .... t-
•
A
,H-~" FI A
•
WHT -IED
WHT -ILIC
r--t ICHC 3~~
f\Ql1 < i. __ .J" 1
(
J
I~,
,~n c ~
~O . s,.
F
I
D
.~.
'
I
3.
CI113 i-
~.
D
E
•
'IlU
lo'"=-
WHT
WHT ....
~~
U =l: fit: rh
IrL...2:.J~
-.--,1, I
K~~"
•
VEL ~
l t-'t " F
ILIC
WHT
P6 P7
r;.;.,'.....,r-------,
;§:<D
I WHT .ILU
I K~ ~.
CI I I' CR2 J GRN
~ I : l
GRN WHT· GIN
I I
I I ~ ôolOllMAL C3l J2 n nu
SENSlTIVE
SWlTCH
IL _____ .., :I (I)
iW1iIff)
INDICATOR (2) II ILIC
F <D ASSEMBlV
i
M N Til-lI
: I
Til-lo' TII:'2
IIEÔI I
P4
•
~EST POINT" ~ISPEm AND ~ ~81-2 ~
.t-I-......,
WHT
UNDER FREQUENCV MANUAL PRIME NC

1 SENSING CIRCUlT 1 OVERSI'EED GIIN SOLENOID VAL VE
I IINDICATOR Al-I _ . . J
{T:~:;
1 C
~
0 K2
ENElGlUD ABOVE
310HZ DE-ENERGlZED
c0IC'RCUIT
Kl OVERTEMP
CIRCUlT
ENElGIZED WHEN VOI.TAGE
AT TIl-I IS AIOVE 7 VOLTS De
TIl-51
:
IA
---
GIN 'AL) WHT
r5
1It---....
NORMALLV OPl!N
GaN
III
A11----' SOLENOID VALVE
.[JI=?
_ f I:
. o--:J, ªr~
IELOW37OHZ DE-ENERGlZED WHEN OVEISI'EED
CONDInON OI OVERTEMP C
CONe"OH ""'"' "'" CA'ACne.
~6 vom<'TO no-lO
WHEN ENGINE CUTour SWlTCH VIL DISCHAaGf
: no-lO' OH'
9 ~
~ I Til-I SENSOR ASSEMllV C CHlOMU ~

:z,.:
OQ H
RI THEIIMOCOUP Ll ~
.... I, • : ALUMEL
I O"" o
L ____________________ :::..J n
J3 ILK
IED ~~LY
SENSITIVE ~
W-"A-1378
....
o
'f
....
~ Figure 5-10. E1ectrica1 System ~
l.n
N
NAVAIR 03-105AB-52
CAUTION
To prevent damage to fuel manifold assembIys use wrench to

hold inIet fitting of fuel manif01d assembIy when connecting
hose assembIy (6B) to fitting.
(7) Connect hose assembIy (6A) to fuel manifold assembIy (6B). f

(8) Position gas generator assemb1y with in1et up, and instaII packing
with retainers (7)s manifold assemb1y (6B), packing with retainers (5) and bolts
(4). Tighten bo1ts to torque of 35 to 45 inch-pounds.
(9) Connect hose assemb1y (6A) to tee (21).
(10) Insta1l shroud (3) into shroud (49) and secure with c1amp (2). In-
sta1l screen assemb1y (1) to shroud (3).
5-83. Assembly of Gas Generator and Accessory Drive Assemb1y. Instructions for
assembly of the gas generator assemb1y are the same as in paragraph 4-276, except
the following instructions shou1d be comp1eted immediate1y after step age InstaI1
bushing (20A, figure 5-3) on filter (19).
5-84. Assembly of Power Turbine Assemb1y. Instructions for the assembly of the
power turbine assembly is the same as in paragraphs 4-727 through 4-732, except as
fo110ws:
a. Steps p and q of paragraph 4-728 are not applicable. Complete the fol-
lowing instructions in p1ace of steps p and q.
(1) Insta11 1ever (93, figure 5-2) rnto support (94) and secure with
pin (92). Install switch assemb1y (91), plates (89 and 90)s screws (88) and nuts
(87). Tighten nuts to a torque va1ue of four to six inch-pounds. Insert wires of
switch assembly (91) through holes in support (94).
CAUTION
Ensure wire of switch assembIy (91) are correctly routed.

Damage to insulation of wires may resulte
(2) Insert wires of switch assembly (91) through hole in gear carrier
(136). Insta1I assembled bearing support (88 through 94) into carrier (136). In-
stall screws (86) and tighten to a torque value of 12 to 15 inch-pounds.
(3) Install bearing (84) into hub (85) and secure with ring (83). In-
stall Iockring (82) on hub (85). Compress Iockring tight against hub (85)s and
press assembled hub (82 through 85) onto support (94) using Bearing Press Part No.
287157-1-1. InstaI1 ring (81).
5-42 Change 1
NAVAIR 03-l05AB-52
NOTE
The starter housing/drive shaft/turbine parts group, con-
sisting of items 58 through 78 and 81 through 136, was
assembled in accordance with previous steps of instruction.
b. Step f of paragraph 4-728 is not applicable. Complete the following in-

structions in the place of step f.
(1) Coat threads of screws (52, 56) with compound (Fel-Pro C5-A, Fe1-
Pro Inc, Div of Felt Products Mfg Co, 7450 N McCormick B1vd, Skokie, IL 60076, or
equivalent).
CAUTION
Do not lift starter housing/drive shaft/turbine parts
group, items 58 through 78 and 81 through 136, by housing
(74).
NOTE
Use temporary match marks applied during disassembly when
aligning housings (74 and 80).
(2) Install assembled parts (58 through 78) and (81 through 136) into
housing (80). Install washers (53), and screws (52). Install bracket assembly .
(56, 57), washers (55), and screws (54). Tighten screl~ to a torque value of 115
to 120 inch-pounds and 1 ocklrlre •
c. Steps a through q of paragraph 4-730 are not applicable. Complete the

following instructions in the place of steps a through q.
(1) Install gasket (38) over fitting (39), and thread fitting (39) into
starter housing (94).
(2) Assemble gasket (24) over thermocouple (23); wrap thermocouple

probe with micro-quartz, six pound-foot density (Johns-Manville Sales Corp at
Greenwood Plaza, Denver, CO 80217) and position assembled thermocouple (23 and 24)
on housing assembly (80).
(3) Position tube assembly (37) so that hole in bracket aligns with
upper thermocouple hole, and thread tube assembly (37) onto fitting (39). Install
one washer (22) and one bolt (21) to secure tube assembly (37), thermocouple (23)
and gasket (24) to housing (80).
(4) Install packing (35) on dipstick assembly (36), and install assem-
bled dipstick assembly (35 and 36) into tube ass~b1y (37).
(5) Instal1 tube (34) and connector (27) as fol10ws. (See figure 5-11.)
(a) Install packing (1) on tube (2).
Change 1 5-43
•
NAVAIR 03-105AB-52
7 6
\ I
8
Bt - - - BLACK
Dt - - - RED
E
A
5 F t---ORANGE
C
I
I
I WIRING SCHEMAT/C
I
!
SB-2S39
1. PACKING (REF 33, FIG 5-2) 6. SLEEVING (REF 28, FIG 5-2)
2. TUBE (REF 34, FIG 5-2) 7. PACKING (REF 29, FIG 5-2)
3. WASHER (REF 32, FIG 5-2) 8. CONNECTOR (REF 27, FIG 5-2)
4. SCREW (REF 31, FIG 5-2) 9. WASHER (REF 26, FIG 5-2)
5. ENGINE STARTER HOUSING (REF 74, 10. SCREW (REF 25, FIG 5-2)
FIG 5-2)
Figure 5-11. Instal1ation of Tube and Connector
5-44 Change 1
NAVAIR 03-l05AB-52
(b) Route wiring from switch assembly (91, figure 5-2) through
tube (2, figure 5-11). Install tube (2) on housing (5) and secure using washer (3)
and screw (4). Tighten screw (4) to torque of 50 to 70 inch-pounds.
(c) Position clamp (30, figure 5-2) on tube (34) so that hole in
clamp aligns with lower hole in base of thermocouple (23). Secure clamp (30),
thermocouple (23), and gasket (24) to housing (80) with remaining bolt (21).
(d) Cut three pieces, one-half inch in length, from sleeving (6,
figure 5-11). Install one-half inch lengths of sleeving on wires of switch assem-
bly.
(e) Install packing (7) into flange of tube (2).

NOTE
50ldering shall be in accordance with Specification llIL-

5-454, Requirement 5, using solder 5b5 in accordance with
Specification QQ-S-57l.
(f) Solder switch wires to connector (8) as shown in wiring sche-

matic in figure 4A and as follmvs:
1 S01der BLACK lvire to Contact B.
2 50lder RED lvire to Contact D.

3 Solder ORANGE wire to Contact F.
(g) Position sleeving (6) over soldered connections.
(h) Secure connector (8) to tube (2) using washers (9) and screws
(10). Lockwire screws (10) using }IS20995C20 lock:wire.
(6) Install gaskets (17, figure 5-2) and fluid passage bolt (16) to oil
drain adapter (20) and install on housing (74). Torque fluid passage bolt (16) to
50 to 80 inch-pounds torque and loclavire.
(7) Install packing (18) on magnetic p1ug (19). Install magnetic p1ug
(19) in oil drain adapter (20).
(8) Assemb1e gasket (7) on p1ug (8), and insta11 assemb1ed p1ug (7, 8)
into oi1 fil1er housing (10, 11). Insta11 1ubrication plate (9) in accordance with
instructions as follows:
(a) Clean surface to which application is to be made with tolu~ne,

TT-T-548, or methy1-ethyl-ketone.
(b) Immerse p1ate in water for approximate1y one minute. Remove

excess moisture by blotting with cloths or paper towels.
Change 1 5-45
NAVAIR 03-105AB-52
(c) Carefu11y remove ce110phane backing to avoid contact with

adhesive.
(d) App1y p1ate immediate1y, adhesive side down, and press firmly
with fingers or ro11er.
(e) A110w p1ate to dry, and spray acrylic 1acquer (Kry10n No. 1301,
Borden Inc, Dept CP, Co1umbus, OH 43215, or equiva1ent) over painted surface and
a110w to air-dry for at 1east 15 minutes.
(f) App1y Nycote 7-11 (Nycote Laboratories, 15002 Delano, Van Nuys,
CA 91401) over surface and extend 1/8 inch beyond peripheral edge of p1ate 1abe1 on
decai to seal edge.
(g) Cure coating at room temperature for 72 hours or for one hour
at room temperature fol10wed by air-dry period of 12 hours at 120°F, 8 hours at
150°F, four hours at 180°F, two hours at 220°F or one-ha1f hour at 300°F.
(9) Connect f1exib1e hose (15) to oil fi11er housing (10, 11) and oi1
drain adapter (20). Insta11 c1amp (14) and se cure with washer (13) and bo1t (12).
(10) Insta11 quick re1ease pin (6) into ho1es of oi1 fil1er housing
(10, 11).
5-85. Assembly of Major Assemblies into JFS Assembly. Instructions for assemb1y
of major assemb1ies into JFS assemb1y are the same as in paragraph 4-732, except as
follows:
a. Step d is not app1icab1e. Complete instructions that fol10w in the

p1ace of step d.
(1) Connect harness assemb1y (10, figure 5-1) to control box assembly
and power turbine connectors.
(2) Install clamp (8) and secure with bolt (9). Tighten bolt (9) to
torque of 25 inch-pounds.
b. Install lubrication instruction p1ate (11) following step e. Use in-
structions that fo1low.
5-46 Change 1
NAVAIR 03-l05AB-52
NOTE
Lubrication instruction plate (11) shall be installed in
, a moderate temperature. Temperature below 60°F results

in poor adhesion; very warm temperatures result in
stretching of the filme
Newly painted control box assemblies shall be allowed to

air-cure at least 24 hours before applying the lubrication
instruction plate.
(1) Remove oil, grease, and dirt from application surface with solvent,
Stoddard (Federal Specification P-D-680, Type lI). Wipe application surface with
toluene (Federal Specification TT-T-548) or methyl-ethyl-ketone and dry with clean,
dry cloth.
(2) Wipe face of lubrication instruction plate and edge of low friction
plastic squeegee with soft c10th.
NOTE
Lubrication instruction plate (11) consists of two matched
labels. Install each label separately using the instruc-
tions that follow.
(3) Place lubrication instruction plate face down on clean surface, and
peel backing away from labels, one at a time.
(4) Slide labe1 into position with notch(es) in labe1 aligned with cover
screw heads. Touch 1abe1 only 1ight1y during positioning to prevent activation.
(5) Tack label lightly in place with fingers at two points on outer
edge.
(6) Secure label firm1y on application surface using low friction

plastic squeegee edge. Start at center, and use overlapping strokes to work out-
ward to edges. Initial squeegee pressures must be very firm to avoid formation of
air pockets. When:nearing upper edge, 1ift comers back beyond points at which
1abe1 was pre-tacked to prevent wrink1es at tack points as activation proceeds.
(7) Seal label by tracing comp1etely around plate edge with squeegee
using very firm pressure.
(8) Repeat steps (3) through (7) for remaining labe1.
Change 1 5-47
NAVAIR 03-105AB-52
5-86. Testing. Instruetions for testing are the same as in paragraphs 4-738
through 4-766, exeept as fo11ows:
a. The fo11ow1ng instruetions should be aeeomp1ished in eonjunetion with

instruetions in paragraph 4-740.
(1) Remove p1ug (98, figure 4-95).
(2) Insta11 thermoeoup1e (43) in port in p1aee of p1ug (98).
b. Instruetions in step a of paragraph 4-741 are not applieable. Complete

instruetions that fo1low in plaee of step a.
NOTE
Starter sha11 be in normal horizontal position when

servieing lubrieation system.
(1) Initia1 servieing of power turbine 1ubrieation system shall be per-

formed as follows. Remove dipstiek assembly (36, figure 5-2). Refer to plate (11,
figure 5-1) for instruetions. Remove p1ug (8, figure 5-2), and serviee power
turbine assemb1y with 375 +25 cu em of 1ubrieation oi1 (MIL-L-23699) through oil
fi11er housing (11). Reinsta11 p1ug (8) and dipstiek assembly (36).
(2) Cheek and reserviee power turbine lubrieation system in accordance

with instruetions on lubrieating instruction plates (11, figure 5-1) and (9, figure
5-2).
e. Step a of paragraph 4-748 is not applieable. Complete the following

-
instruetions in place of step a. Observe that power turbine assembly sensitive
switeh assemb1y is adjusted to aetivate at 3200 to 3500 rpm.
5-48 Change 1
NAVAIR 03-105AB-52
JET FUEL GAS TURBINE ENGINE STARTER PART NO. 384092-1-4
THE INSTRUCTIONS CONTAINED IN THE PRECEDING SECTIONS OF TRIS ~~AL

APPLY EXCEPT FOR THE DIFFERENCES LISTED IN THIS DATA SHEET.
NOTE
The difference between Starter Part No. 384092-1-1 and
Part No. 384092-1-4 is compliance with Accessory Change
No. 469.
5-87. INTRODUCTION.
No differences.
5-88. CHARACTERISTICS.
Starter Part No. 384092-1-4 is physica11y and functiona11y similar to Starter Part
No. 384092-1-1. Differences are as fo11ows. A different hydraulic motor is used.
The new motor incorporates a different cap (1, figure 4-14), packing (5) and sea1s
(7). Bushing (4) and washer (6) are not app1icab1e.
5-89. AEROSPACE GROUND EQUIPMENT MAINTENANCE.
Not app1icab1e.
5-90. DEPOT MAINTENANCE.
The differences in the depot maintenance instructions are provided in the fo11owing
paragraphs.
5-91. DISASSEMBLY. Disassemb1y instructions are the same except that references
to bushing (4, figur.e 4-14) and washer (6) should be omitted when using paragraph
4-41. .'
5-92. ASSEMBLY. Assemb1y instructions are the sarne except for step i of paragraph
4-674. Complete the instructions that fo11ow in p1ace of the inatructions in step
i.
a. Insta11 pack1ng (5, figure 4-14) into cap (1).
CAUTION
Press on metal outside diameter of seals.
b. Press sea1s (7) into cap (1).
c. Assemb1e packings (2 and 3) onto capo
Change 1 5-49/(5-50 b1ank)

I
I
I
I
I
I
I
I
I
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I
I
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I
NAVAIR 03-l05AB-52
ALPHABETlCAL INDEX
Paragraph
Figure, Table
Subject Number
A
Abort Control, Starter •••••••••••••••••••••••••••••••••••••••••••• 2-37

AC-DC Permanent Magnet Generator
Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-699
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-7
Dlsassembly •••••••••••••••••••••••••••••••••••••••••••••••••• 4-28
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-283
Repair ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-565
Accessory Drive Assembly
Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-702
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-5
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-7
Disassembly •••••••••••••••••••••••••••••••••••••••••••••••••• F4-7, 4-25
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• T4-2, 4-240
Location and Identification •••••••••••••••••••••••••••••••••• F2-3
Repair ••••••••••••••••••••••••••••••••••••••••••••••••••••••• T4-2, 4-522
Table of Limits •••••••••••••••••••••••••••••••••••••••••••••• T4-8
Accumulator Assembly
Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-684
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-20
Disassemhly •••••••••••••••••••••••••••••••••••••••••••••••••• F4-l0, 4-32
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• T4-2, 4-309
Repair ••••••••••••••••••••••••••••••••••••••••••••••••••••••• T4-2, 4-588
Alignment and Adjustment
Fuel Control •••••••••••••••••••••••••••••• ~ •••••••••••••••••• 4-736
Fuel Manifold •••••••••••••••••••••••••••••••••••••••••••••••• t-737
Sensitive Switch Assembly (Power Turbine Assembly) ••••••••••• 4-734
Sensitive Switch Assembly (Accessory Drive Assembly) ••••••••• 4-735
Assembly
AC-DC Permanent Magnet Generator ••••••••••••••••••••••••••••• 4-699
Accessory Drive Assembly ••••••••••••••••••••••••••••••••••••• 4-702
Accumulator Assembly ••••••••••••••••••••••••••••••••••••••••• 4-684
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-78, 5-92
JFS Control Box Assembly ••••••••••••••••••••••••••••••••••••• 4-686
Fuel Control Assembly •••••••••••••••••••••••••••••••••••••••• 4-676
Gas Generator Assembly ••••••••••••••••••••••••••••••••••••••• 4-715
Gas Generator and Accessory Drive Assembly ••••••••••••••••••• 4-725
General Instructions ••••••••••••••••••••••••••••••••••••••••• 4-661
Governar Assemhly •••••••••••••••••••••••••••••••••••••••••••• 4-679
Hydraulic Motor •••••••••••••••••••••••••••••••••••••••••••••• 4-673
Power Turbine Assembly ••••••••••••••••••••••••••••••••••••••• 4-727
Starter, Jet Fuel Gas Turbine Engine ••••••••••••••••••••••••• 4-731
Switch Assembly (Power Turbine Assembly) ••••••••••••••••••••• 4-682
Change 1 Index 1
NAVAIR 03-105AB-52
Paragraph
Figure, Tab1e
Subject Number
Bracket Assembly, Lifting 0.00 •• 0 • • • • • • • • • • • • • • • 0 ••••• 0 ••••••••• 0 •• F2-3

Bearings .•.•....•..•.•.•...••...•••••••...•••....•...•.••••.. O • O • O 4-105
c
Clamp
Orientation • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • o • • • o • • • • • • • ~ • • F4-93
Clean1ng ~ 4-42
0 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 00000 • • • • • • • • • • •••
Soap Cleaning Solution •••• 4-47

0.0 • • • 0 • • • • • • • 000 • • • • • • • • • • • • 0.0 • • •
Rust Stripper Solut1on ••••••••••••• o~ • • • • • • • • • • • • • • • • • • • • • • • • 4-48

Chromic-Nitric Pickle ........................................ 4-49
Heavy-Duty Alkaline Cleaner Solution • • • • • 000 • • • 0 4-51
• • • • • • • • • 000;)
Hydrofluoric Acid Pickle ••• 0:.0 •••••••••••••••••••••••••••••• 4-53

Chromic Acid Pickle •••••• 0 ••• 0 ••••••••• 0.0 ••• 0 ••••••••••••••• 4-55
Aluminum Touch-up So!ution e' ••
•• 0.0 ••••• 4-58
0.0 • • • • • • • • • • • 0 •• 0 •••
Magnesium Touch-up Solut:ton 4-59

• • 0 • • • • • • • 0 • • • • • • • • • • 0 • • • ;) • • • • • • 0 .
Petroleum Solvent Degreasing •• 4-61

0 • • • • • • • • • • • 0 • • • • • • • 00 • • • • 0 • • • •
Vapor Degreasing ••••••••• O •••••••• O ••••••• O •••• ~.O 4-62

• • • • O.D • • • •
Glass Bead Peening ••••••••••••••••••••.•••••••••••••• 4-63

0 •••••••
Glass Bead Peening of Lip Seal Surfaces •••••••••••••••••••••• 4-64

Abrasive Blasting 0 ••••••••••••••••••••••••••••••••• 0 ••••••••• 4-66
Stripping of Paint from Components ••• 0 ••••••••••• 0 ••• 0 4-67
••••• 0.
Electrical Components •••••••••••••••••• 0 •••• 0 •••• 0 ••• 0 4-70

•••••••
Plumbing Components • • • • • • • • • • • • • • • • 00 • • • • • • • • • • 0 •••••••••••••4-72

Aluminum Parts Not Corroded •••••• 0 ••••• 0 4-74
•• 00.0 • • • • • • • • • • • • 0 ••
Aluminum Parts Corroderl •••••••• •.•••.•••.•• o ç o ••••••

•••••••••• 4-76
Magnesium Parts Not Corrorled ••••••••••••••••••••••••••••••••• 4-78
Magnesium arts Corroded ••••••••••••••••••••••• 4-80
00 • • • • • • • • • • • •
Removal of Corrosion froM MagnesiuM COMponents Hav:.i.ng

Loosely Bonded or Completely Deteriorated Paint •••••.•• 4-83 0 •••
Cleaning of Plain and Stainless Steel Parts •••••••••••••••••• 4-85

Preservation of Steel Parts After Cleanins ••••••••••••••••••• 4-87
Cb.romate Conversion Coating .••...............................•......•••..••....... 4·92A
Control Box Assembly, JFS
Assembly ............................................. o •••
I 4-686
••••
Descr1ption •••••••••••••••••••••• 000 • • • • • 0 ••••••••••••••••••• 2-12

Difference Data •••••••• 5-8
0 • • • • • • • • 00 • • • • • • • • • • • • • • • • • • • • • • • • • • •
Disassembly •••••••••••••••• 0 ••••••••• 0 ••••••••••••••• 0 ••••••• F4-9, 4-30

Inspection ••••••••••••••••••••••••• 0 ••••••••••••••••••••••• 0 • 4-292
Location and Identification •••••••••••••••••••••••••••• F2-J
0 •••••
Re pa1r •••••••••••••••••• o • • o • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • 4-5"11

Testing ••••••••••••• 4-688
0.0 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • ••••••••
Troubleshooting •••••• 0 •••••••••••••• 0 ••••••••• 0 •••••••••••••• T4-12

Wiring Diagram ••••••••••••••••••••••••••••••••••••••• 0 F4-85
•• 0 •• 0.
Index2 Change2
NAVAIR 03-105AB-52
Paragraph
Figure, Table
Subject Number
Difference Data
Accessory Drive Assemb1y ••••••••••••••••••••••••••••••••••••• 5-7
Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••.•• 5-78
Characteristics •••••••••••••••••••••••••••••••••••••••••••••• 5-2, 5-92
Disassembly •••••••••••••••••••••••••••••••••••••••••••••••••• 5-13, 5-91
Fue1 Contro1 Assemb1y •••••••••••••••••••••••••••••••••••••••• 5-9
Cas Cenerator and Accessory Drive Assemb1y ••••••••••••••••••• F5-3, 5-5
Cas Cenerator Assemb1y ••••••••••••••••••••••••••••••••••••••• F5-4, 5-6
Hydraulic Motor •••••••••••••••••••••••••••••••••••••••••••••• 5-10
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• 5-23
Jet Fue1 Cas Turbine Engine Starter Part No. 384092-1-4 •••••• 5-87
Jet Fue1 Cas Turbine Engine Starter Part No. 384092-1-7 •••••• F5-1, 5-1
JFS Contro1 Box Assemb1y ••••••••••••••••••••••••••••••••••••• 15-5, 5-8
Power Turbine Assemb1y •••• ~ •••••••••••••••••••••••••••••••••• F5-2, 5-4
Repair and Rep1acement ••••••••••••••••••••••••••••••••••••••• 5-50
Testing •••••••••••••••••••••••••••••••••••••••••••••••••••••• 5-86
Drain, Fuel ••••••••••••••••••••••••••••••••••••••••••••••••••••••• F2-3
Drain, Oil •••••••••••••••••••••••••••••••••••••••••••••••••••••••• F2-3
Disassemb1y
Accessory Drive Assemb1y ••••••••••••••••••••••••••••••••••••• F4-7, 4-25
Accumulator Assemb1y ••••••••••••••••••••••••••••••••••••••••• F4-10, 4-32
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-13, 5-91
JFS Contro1 Box Assemb1y ••••••••••••••••••••••••••••••••••••• F4-9, 4-30
Fue1 Contro1 Assemb1y •••••••••••••••••••••••••••••••••••••••• F4-13, 4-38
Cas Cenerator Assemb1y ••••••••••••••••••••••••••••••••••••••• F4-5, 4-23
Cas Cenerator and Accessory Drive Assemb1y ••••••••••••••••••• F4-4, 4-21
Governor Assemb1y •••••••••••••••••••••••••••••••••••••••••••• F4-12 , 4-36
Hydraulic Motor •••••••••••••••••••••••••••••••••••••••••••••• 14-14, 4-40
Power Turbine Assemb1y ••••••••••••••••••••••••••••••••••••••• F4-3, 4-19
Start Cyc1e Protection Sensor •••••••••••••••••••••••••••••••• 4-31A
Starter into Major Assemb1ies •••••••••••••••••••••••••••••••• F4-2, 4-16
Switch Assemb1y (power Turbine Assemb1y) ••••••••••••••••••••• 14-11, 4-34
E
E1ectrica1 Contro1 System, Jet Fue1 Cas

Turbine Engine Starter
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-8
Wiring Diagram ••••••••••••••••••••••••••••••••••••••••••••••• F2-2, F5-1O
Change 1 Index 3
NAVAIR 03-105AB-52
Paragraph
Figure, Tab1e
Subject Nwnber
Filter, Fuel Inlet

Description
Fluid, Hydrau11c
·................................................. 2-15
Fue1
Specification, Table of J.eading Particulars .................. T2-1
Specification, Table of Leading Part;_cll!ars

Fuel Control Assembly
.................. T2-1
Assembly ·...................................................
Description ·.................................................. 4-676
2-16
Difference Data
Disassemb1y
·............................................ .
··.................................................
................................................ .
5-9
F4-13, 4-38
Inspection
Locat1on and Identification ................................... 4-324
F2-J
Repair ·......................................................
Fuel Manifold Assembly
4-604
Description
Fue1 Nozzles
·................................................. 2-22
Description
Fuel System
·................................................. 2-23
Depreserve and Prime ......................................... 4-742

Description ·................................................
Leading Particulars, Table of ................................
. 2-14
T2-1
Schematic .................................................... F2-4
Gas Generator Assemb1y

Assemb1y ·...................................................
Description ·................................................ .
.
4-725
2-3
Difference Data ·............................................. 5-6
Disassemb1y
Inspection ··.................................................
..................................................
Location and Identification ..................................
F4-5, 4-23
4-197
F2-3
Repair ·.....................................................
Table of LiJll.Us·.............................................. 4-479
T II-6
Governor Assemb1y
Assembly ·...................................................
·.................................................
. 4-679
Disassembly
Inspection
Repair
·...................................................
·.....................................................
F4-12, 4-36
4-319
4-5Y8
Index 4 Change I
NAVAIR 03-105AB-52
Paragraph
Figure, Tab1e
Subject Number
, Hydraulic Motor
H
. .
Assembly •••••••••••••••••••••••••••••••••••••••••••••••••••••
Descrlptlon ••••••••••••••••••••••••••••••••••••••••••••••••••
4-673
2-25
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-10
Dis8ssembly •••••••••••••••••••••••••••••••••••••••••••••••••• F4-14, 4-40
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-354
Location and Identification •••••••••••••••••••••••••••••••••• F':-3
Repair ••••••••••••••••••••••••••••••••••••••••••••••••.•••••• 4-634
Troubleshooting ••••• •.•••••••••••••••••••••••••••••••••••••••• T4-9
Hydraulic System
Purge Air From ••••••••••••••••••••••••••••••••••••••••••••••• 4-742
Ignition System
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-13
Inspection T4-2
Accessory Drive Assemb1y ••••••••••••••••••••••••••••••••••••• 4-240
Accumulator Assembly ••••••••••••••••••••••••••••••••••••••••• 4-309
Bearings ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-105
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-23
JFS Control Box Assembly ••••••••••••••••••••••••••••••••••••• 4-292
F1uorescent Penetrant •••••••••••••••••••••••••••••••••••••••• 4-110
Fue1 Contro1 Assembly •••••••••••••••••••••••••••••••••••••••• 4-324
Gas Generator Assemb1y ••••••••••••••••••••••••••••••••••••••• 4-197
Gas Generator and Accessory Drive Assemb1y ••••••••••••••••••• 4-176
Gears •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-106
Governor Assembly •••••••••••••••••••••••••••••••••••••••••••• 4-319
Magnetic Particle •••••••••••••••••••••••••••••••••••••••••••• 4-108
Power Turbine.Âssemb1y ••••••••••••••••••••••••••••••••••••••• 4-122
Start Cycle Protection Sensor •••••••••••••••••••••••••••••••• 4-102
Switch Assemb1y (power Turbine Assemb1y) ••••••••••••••••••••• 4-315
L
Lubrication System •••••••••••••••••••••••••••••••••••••••••••••••• F2-5

Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-26
Instruction P1ates ••••••••••••••••••••••••••••••••••••••••••• F2-3, F5-1,
F5-2
Leading Particu1ars •••••••••••••••••••••••••••••••••••••••••• T2-1
Change 1 Index 5
-------------~_'T.----- .- - - ... - ._------
NAVAIR 03-105AB-52
Paragraph
Figure, Table
Subject Number
o
oil Fil! and Dipstick f
Location and Identification
Overspeed Protection
.................................. F2-3, F5-2
Operation ....................................................
Overtemperature Protection
2-35
Operation .................................................... 2-31
Preparation for Storage or Shipment

Preservation
...............................
...................................................... 4-773
4-769
Power Turbine Assemb1y
Assemb1y ·...................................................
Description ·................................................ .. 4-727
2-4
Difference Data
DisassembIy · ·..............................................
................................................ 5-4
F4-3, 4-19
Inspection ................................................... 4-122
Location and Identification
Repair
..................................
....................................................... F2-3
4-404
TabIe of Limits ·............................................ . T4-5
Repair
AC-DC Permanent Magnet Generator ............................. 4-565
Accessory Drive Assembly
Accumulator Assembly
.....................................
......................................... 4-522
4-588
Difference Data ·............................................
Fuel Control AssembIy ......................................... 5-50
4-604
Gas Generator Assembly .......................................
Gas Generator and Accessory Drive Assemb1y ................... 4-479
4-458
Governor AssembIy ............................................
JFS Control Box Assembly ..................................... 4-598
4-571
Power Turbine Assemb1y ....................................... 4-404
Switch AssembIy (power Turbine Assemb1y) ..................... 4-594
s
Starter, Jet Fuel Gas Turbine Engine
AssembIy
...............................
·................................................... Fl-l
4-731
Check, Functional
Check, Performance
............................................
........................................... 4-750
4-751
Check, Post Shutdown ......................................... 4-752
Checkout ·...................................................
Description
.
·................................................ .
4-1
2-2
Index 6 Change I
NAVAIR 03-105AB-52
Paragraph
Figure, Table
Subject Number
S (Cont)
Difference Data •••••••••••••••••••••••••••••••••••••••••••••• 5-3

Disassembly into Major Assemblies •••••••••••••••••••••••••••• F4-2, 4-16
Leading Particulars •••••••••••••••••••••••••••••••••••••••••• T2-l
Operating Parameters ••••••••••••••••••••••••••••••••••••••••• T4-l4
.
Operat10n •••••••••••••••••••••••••••••••••••••••••••••••••••• 2-28
Preparation for Storage or Shipment •••••••••••••••••••••••••• 4- 7 70
Preservation ••••••••••••••••••••••••••••••••••••••••••••••••• 4- ·,69
Purpose •••••••••••••••••••••••••••••••••••••••••••••••••••••• 1-6
Removal from Shipping Container •••••••••••••••••••••••• ~ ••••• 4-10
Servicing •••••••••••••••••••••••••••••••••••••••••••••••••••• 4-741
Systems Schematic Diagram •••••••••••••••••••••••••••••••••••• F2-4
Tes ting •••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-738
Troubleshooting •••••••••••••••••••••••••••••••••••••••••••••• T4-l
Start Cycle Protection Sensor
Calibration •••••••••••••••••••••••••••••••••••••••••••••••••• 4-587C
Dis8ssembly •••••••••••••••••••••••••••••••••••••••••••••••••• 4-31A
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-295A
Repai r ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-587A
Troubleshooting •••••••••••••••••••••••••••••••••••••••••••••• T4-3A
Switch Assembly (Power Turbine Assembly)
Alignment and Adjustment ••••••••••••••••••••••••••••••••••••• 4-734
Assembly ••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-682
Description •.••.....••••••••••••••.••.••••••.••••••.••••••••• 2-10
Disasaembly •••••••••••••••••••••••••••••••••••••••••••••••••• F4-11 , 4-34
Inspection ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-315
Repair ••••••••••••••••••••••••••••••••••••••••••••••••••••••• 4-594
Switch Assembly (Accessory Drive Assembly)
Alignment and Adjustment ••••••••••••••••••••••••••••••••••••• 4-735
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-9
T
Testing
Starter, Jet Fuel Gas Turbine Engine ••••••••••••••••••••••••• 4-738
Start Cycle Protection Sensor Test Setup ••••••••••••••••••••• F4-65A
Test Setup, Fuel Control Assembly •••••••••••••••••••••••••••• F4-84
Test Setup, Starter, Jet Fuel, Gas Turbine Engine •••••••••••• F4-95
Troubleshooting
Fuel Control Assembly •••••••••••••••••••••••••••••••••••••••• T4-9
Hydraulic Motor •••••••••••••••••••••••••••••••••••••••••••••• T4-8
Jet Fuel Starter ••••••••••••••••••••••••••••••••••••••••••••• T4-21
JFS Control Box Assembly ••••••••••••••••••••••••••••••••••••• T4-11
Start Cycle Protection Sensor •••••••••••••••••••••••••••••••• T4-3A
Change 1 Index 7
NAVAl R 03-105AB-52
Paragraph,
Figure, Table
Subject Number
v
Valve, Acceleration Limiter
Adjust Crack Pressure ........................................
Check Crack Pressure •••••••••••••••••••••••••••••••••••••••••
4-736
4-743
Va1ve, Fuel Solenoid Drain
Description •••••••••••••••••••••••••••••••••••••••••••••••••. 2-19
Va1ve, Manual Prime Fue1
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-18
Va1ve, Restricted Flow Check
Description •••••••••••••••••••••••••••••••••••••••••••••••••• 2-21
Va1ve, Reverse Flow Check
Description •••••.•••••••.•••••••..••••.•••••••..••.••••...... 2-17
w
Wiring Diagram
AC-DC Permanent Magnet Generator ••••••••••••••••••••••••••••• F4-88
Electrical Contro1 System •••••••••••••••••••••••••••••••••••• F2-2, F5-10
JFS Control Box Assembly ••••••••••••••••••••••••••••••••••••• F4-85, F5-9
Wiring Harness Assemb1y, JFS Branched (Main) •••••••••••••••••••••• F4-69 , 4-697
Index 8 Change 1
;~~
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'I'SG- 23
\ ..... --::--~~ Supp. 3
12-1-73
FOREvlARiJ
This manual, when used in conjunction with Training Study
Guide (?SG-83) is intended to provide ~raining information
on the Jet Fuel Starter, Model JFS 100-34.
TSG-83 describes typical Jet Fuel Star~er operation and
general construction features. This s~pplement provides the
reader with a more detaiied operational description as applies
to the JFS model 100-34. Additionally -c.ile units' fuel, lebe
and electrical systems are discussed in detail in this ma~ual.
The reader i8 reminded that the inforDation contained herein
does not supercede nor supplement that contained in any
official publication relating to the equi~~ent.
Ali vaIues of pressure, temperature, speed, power, etc., are
choscn for their illustrative value only, and not necessarily
representative of actual values. For actual values, the
applicable maintenance manual must be consulted. Addi tionally ,
any information with respect to the JFS - aircraft interface
must be considered as reference only o.Del is used simply to
c1arify the integrated operation of the JFS.
1.
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1 C""S GUiíRATOO ANO ACCF5,o.lY ';,CTlON MOOUl! 11 STARTIR MA/«JAl CONTRO!. V)I.VE
2 S1ARTl:R ElO!AU 51 12 STARll:R SYSlIM Ifl'DIlAUlIC t!.'J1LlF1J:IIP
3 PC-'NE1I TURBiNl MOOUlf 13 lM/«JAl DISCtlARGE VALVE
4 STARTER Ml SYS1lM ACCUMUlAfOR 14 RlV!:RS( flOW RíllfF V.Jül
5 H.fCTRiCAl COtITROI. 80)( 15 HANI)J>\IIt1P Rf!llúYABU HANDlE
ó P!:RMMENT IAAGNIJ CEMRATOR 16 IGNITION START SIYI1CH
7 PRt5SUR( msu 11 ntROI1U lEVER
8 5TMml! SYSlHõ f!YORAUlIC "CCW~lATOR 13 SElF-CCIITAIt«:D EllGI/ol STAA1U1 STMT/OfF Sl'IITCH
9 AIR PR(S SURf GAG[ 19 Sf~lnlJ! LIGlfT
10 AIR Y,l.lVE 2D STARTIR HANDlE
STl\.Rr SYSTEM COMPONEN1'::'; LOCAT ION

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Supp. 3
12-1-73
SEc~'rIO~~ -
,JFS 100- 34 D::::SC!:ü2'.::'ION & U~JEn.l\TIC::J
1- 1 General
The Jet Fuel Starter, model JFS 100-34 is designed for
attachment to, a:1d starting O::::, t!".e model J 52-P408 P & W
propulsion engine used on the Douglns A4M aircraft. It
operates on jet fuel as a self contained unit with hydrauli
start initiation. Figures 1-1, 1-2 and 1-3 ~epict the gen-
8ral a.pr)ea~ance of tllG JFS a.p.d S110~d i -:.5 l~clati ve loca~ion
in the installation. Figure 1-4 ShC\'J:3 the cTFS hydraulic
start accumulator and its installatioD.
'---- 1-2. ne-cY'i..,tio"'"

-J' ...l-I;""
;:, -- ......
.......
A. ~,lajor II,Ssemblies
The Jet Fuel Starter (Figures 1-5 through 1-8) is a
small, compac':', lightweight free--::'urbine type, gas
turbine engine. It is comprised of three separable
asserrJ:)lies: the gas generacor 23sembIy, the power
turbine asse;nbl"j, and thc acccssory drive assembly.
'1'11(, je'::. [11e1 starter is <3.ttacl'C'd to the aircraft engine
acces:.;ory gearbox by a quick c:.is connect coupling.
7.11e Cj3.S generator asseIT_b1y is ;: siníjle-spool gas turbinc
engir..e consisting ot a réldial-flow compressor, an annulé
combus tor, 2_n axia1 fI.:)'", tlJrbi,ne, t'tlO turbine s tcd::or
asserr"ü)lics, a fucl wa.niÍolc;, with five fue'l nozzles I é~lld

'--
a~ ignition co~l and içnitor plugo
-I 1
~.- _1
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TSG- 83
Supp. 3
12-1-73
·27
EXHAUST FlANGE
ClAMP
EXHAUST DUCT
LOWER SECTlON
-~XHAUST DUCT
UPPER SECTION
\ '-DH ACH ClAMP

'~
A!RCRAFT OUTER SK~N ' - i:XHAUST EXíT
JET FUH S"fARTER iNSTA L!.. A TlON Figure 1-1
1 "
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TSG- 83
Supp. 3
12-1-73
',---
ClAMP
EXHAUST HANGE
ClAMP
~
INDEXING PiN
..
I ~EXHAUST D~AIN
Ll.. OWER EXHAUST Duer SECTlON
'--- JET fUEl STARTER POWE~ TURBINE INSTAllATlON

Figure 1-2
1-3
POWER TURBINE
-BRACKET
>Tj
ro-
lO
C -5UPPORT IMOUNTS
i-' I-i
(!)
I
A
I-'
I
(..J
INDEXIN G PIN
FIII A ND DRA IN UNE - 7"'ICAL

-F.!.í:C.... OR
éONNECT
INSTALLA TlON
( (
HYD~AUl.lC rOl-;r
BRACKET ASSUABl Y-
CUSHIOI'J-~
f-'
I
líl
NITROGrN UNE-
AIR Vl\lVE
PRESSURE VESSEl- I~'
Cf) ~3
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J 'U GJ
~.J'ti J
J • 00
-..1 W
wW
JET FUa STARTt:R HYDRAULlC ACCUMUlA lOR INSTALlATlON
t-
'TI
[m]
tn
........
o
o
I
t..J
~
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o
o
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m t-rj
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(
ASSEMBLY UNIT
ACCUMULATOR
QUle K - RElEASE
ASSEMBLY
PIN
"rl
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I
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f-'.
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ç:;
ti
ri)
/
POWER TURBINE
OIL FILL AND
I--' OIL DIPSTICK
I
m
COMPRESSOR INLET
SCREEN ASSEMBLY
MANUAL PRIME
FUEL DRAI i'J SOLEi'JOID VALVE
JFS100-34 COMPONENTS LOCATIOt~J FRONT VIEW I-' Cf)

Nç:;Cf)
1-3
I 'O Gl
I-' 'O I
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POWER TURBINE ASSEMBL Y GAS GfNERATOR ANO ACCESSORY ORIVE AS:.,\\8LY
'--""._!ii_m.
_ .."____..~,,.c>_"'~ ;:~_-!I!!~....,II!i-lI!!U=;IiiI----Iil:=-::!IIIII"Á~--'';!':_~~
II
FUEL CONTROl
ASSEMBlY
OUTPUT SHAF T
ASSEM8lY
\
hj
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f-' ,.o
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-I
ASSEMBlY
EXHAUST FLANGE \
ACCE5S0RY ORIVE OIL DRAIN
ANO ""AGNETlC INSPECTlON
PLUG
I-'Ult-3
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JFS1JO-34 COMPO~j~NTS lOCATION tEF'T SIDE I 'd Ç)
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GAS GENERATOR AND ACCESSORY

DRIVE AS5EMBLY POWER fURBI NE ASSEMBL Y
~...;- ....,,-
FORWARQ LlFTlNG
ACCUMULATOR IGNITER SUPPORT IDENTIFICATlON BRACKEf
t--
ASSEMBLY PLUG PADS PLATE ASSEM8L Y
Q
,....
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PERMAl'lfNi ELECTRI~AL 5TART SOLENIOD VALVE IMMERSION

MAGNET CONTROL COUNTER (DRAIN) THERt/OCOUPLE
CENERArOR BOX
JFS100-34 COMPONENTS lOCATION RIGHT SIDE ,...o

NÇ;cn
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L_::'::....--:-_,--......-J
Ao DIVIS,O .... Of- T!--l[ GARrn:7T CORPOHATION
Supp. 3
12-1-73
The power t'Jrbine asserrbly consists of an axial-flow
(free) power turbine, a blO-S tep reduct~_an gear assembly,
a pawl-and-ratchet clutch asserrbly, an output sha::"t, primary
cutout switch and governar, a quick attach-detach mounting
flange, and a housing assembly with an integral oil sump.
The accessary drive assembly consists of an accessory drive
housing, fuel pump, fuel control, lubrication pump, 50
percent initiation cutout switch and governar, oil sump,
hydrau1ic start motor and a clutch asserrbly and a permanent
~agnet generator.
B. §ystems
The electrical system consists of a wiring harness, fuel
shutoff solenoid, fuel drain solenoid valve, start counter,
primary cutout swi tch, 50 percent cutout swi tch r igni tion coil,
ignitor plug, and an eIectrical control box. Customer fur-
nished items include a start-stop switch, a cockpit mounted
indicator Iight, a manually operated ~ydrauIic control vaIve
and a hydraulic accumulator system.
The fuel system consists of 10w and high pressure fuel fi'}:',ters,
fuel pump, acceleration control, constant pressure dífferential
valve, fuel governor, a f~el manifold with five air-assist
fuel nozzles, a fuel injection accumulator, and a combustor
drain valve. The two fuel solenoids included with the e:ec-
trical sys tem can traI the fuel f10w.
1-10
~._--:::----1
.~~!
ii·-:'J.,~~n7Ti t\', Fi.: iE Z;. Ri~::H F,.~I'"\.?"-~ ;_' F r~ ::TiJRl ;'~~J C!J M P t" '. :".( C; ~';:' ~\R ~,Z:: ~4A TSG- 83
[':.:::::~~ /1: A D'V'!'.'8N cr THe (!AJ:HU:TI C:;J,;{':->Ci..:',~,":""!JN
Supp. 3
12-1-73
The hili::j_cation syste;n, consist.:.s of two sub-systeD.s. An
oil sump with splash lubrication is provided for the power
turbinc: asserrIbly, whereas t:1P gas generato,: assernbly and
accessory cri ve assembly are 1 ubrica ted by é1 sys tem con-
sisting of an oil sump, low and high pressure filter~, oil
pump, oil pressure relief valve, and pressure jets.
1- 3. Operation (Figure 1-9)
To describe JFS operation, t~e assumption ~s made that aJe-
quate fuel supply is available, the hydraulic accumulator i.
charged and an engine start is to be accomplished.
The aircraft engine starting cycle is initiated by closing

'-~
a start switch and opening a tydraulic control valve. The
START/OFF swi tch is placed in tll(:~ "ST1\RT" posi tion. 'l'he
hydraulic control vaI ve is oper,ed by pulling c.:pward on a
"'1''' handle labeled "STARTER". Both the start switch and
hand1e are 10cated on the 1eft pedestal in the cockpit.
Pos i ti oning the START/OFF s'l1i tch in the "START" posi tion
providos olcctrical circuitry to permit JFS opcration.
Oponincr tho manual hydraulic valve rcleases high pres's''urc~
hydraulic fluid frorn the accumulator to the JFS hydraulic
start motor. This hydraul~c motor rapidly rotates the JFS
accessory section and gas senerato:r- cOflprcsso:r-/turbine assomb~'
The JFS starting se~uence is co~pletcly auto~atic after man-
'--- ual1y opening the hydraulic control v2.1ve.
l-ll
GAS GENERA TOR ASSEMBl 'y POWER TURBINE ASSEIv\lll Y
~
,....~-=-..........,..,~'~·,""""-;H_"""'" i'l
(Jl
FUEL NOZlLES COMBUSTOR ENG:\GE AND (~
OISENGAGE ;p.
~J
MECHANISM n
=t
OUTPUT
SHAFT
ASSEMBLY
RETAINER (J
·"1
>
;JJ
1--'-
I
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REDUCTION
GEAR
SYSTEM
/
PEPMANENT
EXHAUST OUTLET
MAGNET " " HYDR-<\ULlC MOTOR !--'CJ1r3
GEl'lER.MOR N C fn
I
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DRIVE ASSEMBL Y -...J W
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JFS100-34 SC:'iEMAT~C
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L--_ __ _
Supp. 3
12-1-73
Wit~ rotation of the accessory secticn the PMG (permanent
magnet generator) begins to produce an AC voltage. The AC
is converted to DC by a transformer/rectifier in the PMG
assembly. Initial acce1eration of the gas generator starts
lubricant, fuel and air flow through the JFS and its systems.
The airflow through the power turbine causes a slow rotation
of the power turbine, thereby removing alI backlash of the
geartrain resulting in a soft engagement at the englne acces-
sory gearbox.
As PMG speed increases, the DC voltage output increases. At
a pre-determined voltage leveI (approximately 7 volts De) the
fuel shutoff solenoid valve and the fueI drain solenoid valve
'--
are powered.* The fuel shutoff valve opens and the fuel drain
valve closes. This will permit fuel flow into the gas generatcr
combustor. Also at this time the JFS ign=-tion system is pro-
viding spark into the combustor. Gas generator light off
occurs. The gas generator accelerates at a rapid rate, with
the assist of the hydraulic start motor, to above self sus-
taining speed.
With acceleration of the gas generator, airflow through the
JFS increases. The heated gases produced in the gas generator
pass through the power turbine stator and across the blades
of the axial flow, free turbine 'wheel of the power turbine
assemblv. At approximately 50% gas generator speed, the air-
"--
*One second delay if electronic box temperature is above 60 o P.
1-13
--=-<
~
~~~~ I AlrtESEAR::::;H lMl',N'".H""jl,CT;J!;!!NG CQ[\'>::IANY 0;:- ,"\~!ZONA TSG- 83
\,,--~ I A O!V!~UJN 0"- TH~ OARRt::~ CiJR~,:::Ij;:ATlaN
I
Supp. 3
12-1-73
f10w throug~l the power turbine is of hic)l enough energy
leveI to begin rotation of the power turbine wheel. Through
the reduction gearing of the power turbine, sufficient torque
will be present to begin rotation of the prcpulsion engine.
Acceleration of the gas generator continues with the rate of
acceleration being automatically controlled by the JFS fuel
control system. At 50% gas generator speed, a speed sen-
sitive switch is actuated. Actuation of the 50% switch powers
a relay in the PMG, swi tching the PIv':G to a 10'wer vol tage outpu':..
Addi tionally r at 50% gas generator speed, the JFS, start counter
is powered to record the GFS start.
Both the gas generator and power turbine accelerate upward in
speed with the gas generator accelerating at a very rapid rate.
As the PMG output frequency increases to approximately 370 Hz,
a relay contained in the e1ectrica1 control box 1s actuated.
Actuation of this relay turns off the JFS ignition unit and
turns on a 1ight in the cockpit labeled "S'IARTER". Additionally
actuation of this re1ay provides both AC and DC power to the
aircraft electrical systems. (AC power required for propulsion
engine ignit~on system).
As the gas generator approaches its 100% design speed, the
JFS fue1 control system automatically adjusts its fue1 schedule
to limit gas generator speed to 100%. ~otal elapsed time from
JFS start initiatiop to 100% gas generator speed is in the order

\
of 5 seconds. At this point in the propulsion engi~e start
1-14
l~.~\
I~~,~,,:
J\n~;;::~It\rt:;:\..'~ ~A~-:~~~:A~T:;...~'Rr~~:3 CO~V;R/;~~~f OF i\.R~Zr;t~i;
TSG- 83
I' , ... OIV::::;:ON O~ Tr.{S:: GA;U;tJ:7T COriP:::J;tO;A"'rI::"'l.l
iL _ ...t>.::::::::J Supp. 3
12-1-73
cycle, the operator should close the hydraulic start va1ve
by pushing the "Til handle to the rull down position.
vii t.1I the gas generator speed stabi1ized at 100%, the power
turbine continues to accelerate the propulsion engine. At
approximate1y 5 percent RPM of the propulsion engine, the
operator would move the throttle lever to actuate the air-
craft engine ignition switch. (Note: power to the pro-
pulsion engine ignition system is provided by the JFS PMG).
At approximately 15% engine speed the operator moves the
throttle lever to the "IDLE" position to introduce :Euel
into the propulsion engine. The propulsion engine should
now 1igh t off. Aided by the JFS power turbine, the pro-
pulsion engine is accelerated to above seI f sustaining speed.

'-----,
At a propulsion engine speed of 43 to 47 percent, a speed
sensitive switch in L~e JFS power turbine output is actuated.
Actuat~on of this switch terminates JFS gas generator oper-
ation by removing De power from the JFS fuel shutoff solenoid
valve. Actuation of the switch also turns off the "STARTER"
light in the cockpi t. At this time t~e operator should return
the START/OFF switch to the "OFF" position. E1apsed time

I
from JFS start initiation to gas generator shutdown (e::1gine
idle, 43 to 47%) is approximately 30 seconds.
Wi th fõ" utdown of the gas generator, t~e power turbine begins to
decelerate. This decrease in power turbi:-:.e speed coupled wi th
the increase in propulsion engine speed release pressure from t!

"'--'
1-15
r-
:~,! A!RtES~A~CK ;t/'·\f'...IUF/\~T~,J~if~G ':CilMPi:c.NY CF i~·... (~~ZC~"~,,~\
':'SG-83
í~!i
A iJ!V~~;ON 0'- 7H~ :;AR~~7T CQ~POR;\T1CH~
Supp. 3
:L2-1-73
pawls of the power turbine overrc,nrür.g c=.utch. Centrifugal
force acting on the pawls causes them to pivot 2.way from thcir
mating hub jaw gear. This results in the JFS and propulsion
engine being mechanically disconnected for the balance of
t11e propulsion engine run period. The overrunning clutch
automatically resets during rolldown of G~e propulsion engine.
1-4. Supplernenta1 Information Pertaining to ~FS Operation.
The hydraulic accumulator (aircraft equipment) is norrnally
recharged by the p~op~lsion engine hyeraulic system during
engine operation.
The JFS may be used for motoring the propulsion engine without
1ight off. This would result in depletion of t~e hydraulic
accumulator pressure without the normal accumulator recharge.
Provisions are included in the i:1stalla cion to hand pump J
the accumulator.
Engine starts rnay be aborted at any time by opening the start
switch.
The JFS has an overtemperature protection system which will
automatically terminate JFS operation in the evcnt of excessive
e~~aust gas temperature. Overspeed protection is also provided.
1-5. Leadi:1g Particulars
Table 1 lists the leading particulars and design features of the
JET FUEL STARTER model JFS 100-34.
1-16
~
!
J
"li'"
__
i
;
AiRE.::a::,~RCM MA'-t:"Fl\r.:;nJR!i"<'!3 CVM,';:At"'~Y DF ARIZC":A
r. '01,,/:E:dCN ar T~I: OA':U~1[rr COQpCnA'7'ION
TSG- 83
I -, i Supp. 3
12-1-73
"--...-
Tl\3LE 1
AiResearch Model No. ':FS 120-34
AiResearch Part No. 384092-:L-l
A
~
. +- •
J_lca,_lon
Aircraft A~M
Engine J52-P-408A
Basic envelope 9-in. diam by 20-in. length
Overhaul li fe 700 start cyc1es, 1200 hr engine

overrunning, and 5 hr of motorin'i
time
Modular Assembly
Gas generatcr module Replaceable at field level
Power turbine module Replac(3able at field leveI

'----- Accessory drive module Replaceab 1e at field leve:;"
Duty Cxcle (starts) 3 consecutive start cycles of no~

more than 60 sec duration each a~
2 min interva1s; no more than 6
engine start cycles within a l-hr
period
Motori:!1g C~ The starter shall be capable of

motoring the engine for a period 0
2 min followed by a normal start
cycle within 5 mini no more than 3
of these motoring-start cycles ao-C">
required w~thin
, a 1 hr period
The starter shall be cap'~le of

motoring the engine for a period o
5 min; no more than 1 s uch motor:L.:-
cycle ~s required within a 1 hr
period
',,---,
1-17
~(~"...,.
I =::::---1:J1 j}JRE:SEA~C--i t"~l.,~a·;J:;:-I~\CTL~R~t";G COtfr:A.f'>.,~Y C7 ;,~;::~iZO~~/\
'~'!'h"'1,.,~~J
:I ,..... c!'" TH~ ~j/,~R,:":'"r CORPCHiiAT~!JN ~SG- 83
,,_. Ir .t.. O'VI:.':l!,'Jo...!
~~
SL'pp. 3
l2-l-73
r:::'AELE 1 (Con-::'d)
Performance
Horsepower outgUt 75 hp
(sea leveI +59 'F)
Start time (to engine idIe) 27.8 sec

(sea leveI +59 0 F)
Weight (wet) 97 Ib
Environment
TemDerature
"
Engine start and -30 o F to +130 o p at sea level
motoring cyçIe -15 0 F to +9SoF at 8000 feet
Overrunning operation -65°F to +200o:~
Non-operation condition -650F to +160 o F
Altitude
Operation The starter shall meet the pe~

formance requirewEn~ herein from
sea levei to 8000 feet, and shall
satisfactorily withstand overrunning
from sea levei to 50,000 feet
Gas Generator Module
Compressor type Single-stage ccnt~ifugal
Turb i ne type Axial
Combus tor type Annular
Number of fuel nozzles 5
Lubrication Pressure-lubricated by a gerotor

pump in the accessory module
Containment Provisions
Compressor Hub containmen-:: to maximum operatinc

speedi wheel integrity to maximum
possible overspeed
}_ -18
r~l
t/ 'V' ")1
!(GlIo;~1
P\tR~S~.,~riC~ Mt'l;.;\~t;'FACT;_~R~~~ c;o~~~r:,'~1-"'l o~ /f:,R";~:=~';\
j"~./; A O:Vt!SlQ"l cr ~HE OA~ii:!:rTT CQ:"tPQ:.? .... TI.':)N ':'SG-85
---"----'
Sc,pp. 3
3.2-1-73
TA!3:S~ 1 (Cont.~d)
Turbine Hub containment to maximum o?era~<.

speed~ wheel integrity to maximu~
possib:e overspeed
Start indicator Start counter ineicating total

nUITlber ofstarts
Igni tion sys tem High-voltage capacitor-discharge

coil, air-gap plug, and lead assc~
blYi stored coil energy 2.0 joulcs
Power Turbine Module
Turbine type Axial
Oil System
Type Splash system
Lubricant MIL-L-7808, MIL-L-23699
Capaci ty 460 cu cm
,--. Containment Provisions
Turbine Hub containment to maximum opera~j

speed; b::"ade containment if whee~.
free~0..ns
Output shaft Replaceable, shear vaI ue 640 1})- 5: '.

(max)
Reduction gearing Compo~nd planetary 18.3:1 ratio
Moun ting f1ange Mounting f1ange and drive sp1ine

per AND20002 1ype XII-F
Direction of rqtation Counterçlockwise (viewing output

shaft)
Cutout swi tC}1 Nor~ally closed, open at 3200 +

rpm output shaft speed
Overtemperature swi tC~1 Starter shutdown if overtemperat~~

occurs
Engage-disengage clutch ?awl-2,nd-ratchet type
'"",--,
1-19
F~.) AIREBEA.RCH MA;\!\..lFACTl.i1".!NG ~~:-:lMFANY Q,]'" ARIZONA TSS- 85
~I A O'V"""''' '=, THE """"~TT CO""O",""!"IO"
Supp. 3
12-l-73
TABLE 1 (Con t: I d)
Accessory Module
Fue]_ Sys tem
Pump Positive-disp1acement gear type
Fuel MIL-T-5624, Grades JP-4 and JP-5

MIL-J-5161 Referee
InIet pressure o- 35 psig
Filters Reuseable, sintered metal type

Rep1aceable, cartridge type
Residual fuel Drained a'.ltomatiea11y at shutdown

'
Lub rlca\..lO!1
J....c:
vysL.em
J...
Type Pressure feed system ut~lizing a

positive-displacement integral
gear-type p1.Ãrnp
Lubricant MIL-L-7808, MIL-L-23699
Capacity 320 cu cm
Filter Reuseable metal screen type (2)
Starter !nitiation System
Initiation source Hyàraulic accumulator (150 cu-in.

min air volume)
Initiation motor Fixed-displaeement piston-type

hydrau1ic motor (0.14 in. 3/rev)
Electrica1 Power Generation
Generating device Permanent magnet generato~'
Starter subsystems Power supplied by perrnanent magnet

generatür
lü rcraft sys teills 400 Hz, 115 volts, single-phase AC

power at 825 VA for 45 seconc:s aftel-
s~arter output speed reaches 300 rpr
and. 100 VA thereafter
1 a:np of 28 vde power continuously
Fuse protection Replaceable 5 amp fuses incorpor2tec~

or. JFS
1- 2 (I
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Supp. 3
12-1-73
SECTICN I I
'ELECTRICAL SYSTEM
2-1. GENERAL DESCRIPTION
The Jet Fuel Starter, JFSlJO- 34, employs a completely sel:E-
sufficient electrical sysb:'!m. No ext€rnal electrical power
is required to permit operation of the JFS. In addition to
providing electrical ~ower for its own requirements, the
JFS provides a limited amount or bot~ AC and DC power for
the ai rcraft. (Engine ignition system, annunciator lights,
relays, etc.)
2-2. OPERATION
"-...-
To describe operation of the electrical 8ysten, reference is
made to Figure 2-1. Basic operational description of aircraft
eIectrical system com?onents is included, but only to the
extent necessary to describe JFS operation. The assumption
is made that an aircraft engine start cycle is to be accom-
plished. By refere~ce to Figure 2-1, the reader may follow
the sequence of events that occur. AlI of the component,s of
the JFS electrical system are covered in subsequent paragraphs
of this section of the manual.
With initiation of the JFS start as eesc~ibed in Section l,
the PMG begins to produce an AC volt.age output. The AC is
transformed to bc and passes through the JFS start switch to
(1) the igni tion uni t, through t.1-}e normal]_y closed contacts of
'----
2-1
r-:;:::==--->
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_ _ _- - - J
Supp. 3
12-1-73
K2
_ r olay
c' 12'
\ _/ ~n'
J..;_..:L..-_ , o~
)_ o'pc~ro~~c
........}.. _ '1-. ..... ", .. ,.,L r~r~u;~
_ ...... "- ___ \.. hc~r~
.V -'':''1. ,....A (~)
\...,) ~hc
~l .....;.
normally open contacts of Kl relay through the cutout switch
and (4) to the closed contacts of the nQmber 1 50% switch.
As DC voltage rises with increasing PMG speed, the ignition
unit will begin to produce s?ark inside the JFS gas generator
combustor. The ignition system will operate at a r'21atively
low input voltage; perhaps as law as 4 VDC.
The electronic c8ntrol circ~it senses DC voltage at T31-1. As
DC voltage at TBl-l rises to 7 volts, KI relay coil is energize~
closing Kl relay contacts. This permits DC to pass to (1)
manual prime solenoid valve, (fuel sh~toff valve) causing it to
open (2) fuel drain solenoid valve,causing it to close and (3)
the visual overspeed indicator circuit to reset it.
with the gas generator rotating and producing air flaw, the
ignition unit producing spark in the gas generator combusto~
and the fuel contrai system providing fuel into the gas generator,
all ingredients are present to pe::::-mit com.bust ion. The ga5, ,
generator lights off. Note: introduction of fuel is delayed
one second by delaying actuation of Kl re:ay if electrical
control box temperature is above 60 o P.
2-2
(
r-- -,
I I
I I
I I
I ElECTRONIC CONTROL BOX
I
I I
~ ___ K1
-I:~-
SA
-----~-----_l A ,., "'.-_. . . _L_--'___
Wf1T - RED
IVHT - Bl K. _ _ _ _ _- - l
c c
A1------+--.- ...----------~. ________•________
E i ~2 ------+---+-- c
VIO~
--'-------------t-..,
WHT
~
-------+._-....... ------T~----~~---------+------~----------------.-~O BLU
~START::U-N-T-ER--~~~: WIiT
I
(28 WHT
VDq
YH
---GS H---+---+-+---I--~·- 11
t----:---..;-.-+---il------~---+-~ f
KI
..
M
WHT
GRN
ON GRN '111fT - G!!N
JI
S~NSITIVE
START I J2 P2 8lU
S''IlKH
ASS!M81 Y
SWITCH I (\iIHITE) I _ _ _ _ _8lK (50 i'fRCENT)
I
L_ _ __ _ I (I) OVH\~HO (2) I
-: ' [-C"{R'Ê5
--J
I\.)
'J-J
3
I
I I
w ~iBl-J I.BI-K TBI~í-~I--12---' I
P4
I ' '_,-----' '- --..lI ~ VlHT

~
I
, TEST POINT OVERSPEEO AND
, UNDER fREQUENCV'
I
T31-13 I I.'.ANIj,'L PalME
, SENSING CIRCUIT I OVERSPEED cnN _ ICUNOID VAL'.'€
A
I 1 , INOICATOR
C
I Q ~RC~~ERTEMP {T~:-l: _ _ _. ~ WHT(CH) ----~_.--
-11J~j--J
I V
ENERGIZED ABOVE
. '. V ORCUIT
'ENHGIZED WilEN VOLTAGE TS1-S A --
UN (AL)
I 370HZ DE-ENERCIZED Ar TSl-! IS MOVE 7 VOLTS DC __. _ _ _ _ _ ~. A. . SCUNOID VAI. VI'

(D!\AIN)
6ELOW 370HZ
I DE-ENE~CIZED IVHEN OVERSPEED C
CONDITlON OR OVERTEf,IP
I CONDITION OCCURS AND P8
~E.l~I":J c==t-Dh<J-;fI'
Wl1EN ENGINE CUTOUT SIVITCH
I
IGtUTION
I _S_U_W_L_IE_S_V_O_LT_A_G_E_T_O_T_B_I-_I_S___T__
BI-jl; - - - - - - - , ..,
WHT
A"- --~
UNlT
I P9 ----- f
.....--'I-IT81-1 ELECT~ONIC CIRCUIT 80ARD
I WHT C CHWMEL
I ,-----~D ~ ____~~____________•____~GRN i
A ~A.:;;LU~M;;;E:.:l,--.-
TH~RMOCOUPLE
I ----------------~-----------~. OitN o SENSITIVE

L ____________ _ _ ~P3 L-,._ _ _ Rf.D ~ SWITCH I-'
Cf) ;.,]
~ --=--.J
ASSEMBLY N~(j)
A·,·4M-+-JFS KONE SECOND TIME DELAY ON - - - - (CUTOUT) I rO C;)
PULL IN IF BOX TEMP ABOVE 60° f-' 'O
I
.... J
JF5100-34 SYSTEM SCH~f.~A,TIC

LU Lo)
r7~'
!ç;;:~lfVT)1 A1R:::S7::AR:::H Mft.""L~f'.A:;;TU~ING CaMPANY De- ,~~:ZCNA 'I'SG-83
i'~1
I~-
A C:V:!;~ON ar T~E GA~f'J'~TT CG~PC~Ar'O'"
S0_?P. 3
12-1-73
with light off of the gas generator, it accelerates rapidly.
As gas generator speed reaches a.pproxit"'l1a'::ely 50%, the speed
sensitive 50% switch is actuated. Closure of the number 1
50% switch completes electrical circuitry to pO\Ver 'cl1e JFS
start counter,causing ~t to advance one count and recor~ the
start. Closure of the m.ln'ber 2 50% s'witch p:Laces a ground on
the coil of K3 relay causing it to actuate its contacts open.
Opening the contacts of K3 reduces the De output voltage of
the PMG by splitting or by-passing part of the P~~G windings.
This preven'cs DC voltage from reaching excessive. leveI when
the PMG is at full speed.
Acceleration of the gas generator results in increasec fre~
quency of the AC voltage produced by the PMG. The electronic
control senses AC voltage and frequency at TBI-10and TBl-ll.
As AC frequency increases to 370 Hz (approxL~ately 95% gas
generator speeà), K2 relay coil ~3 energized. Opening the
normally closed contacts of K2 opens the DC circuit to the JFS
ignition unit, thus terminating JFS igni~ion. Closing th~
normally open contacts of K2 proviàes AC and DC pO\Ver to the
aircraft. (AC through pins K and A of Jl, 2nd DC through pins
G and J of Jl) .
2-4
,i/~", ,
l A7RE8:~/\R=~ ~;A,NU~t,CT.l.~R~N~ !:O'V;F"'t\"<"'r CF A~:~Z~:-':I~ TSG-83
!,~g;:;""
:\~~
~~, DIVI::;::JN C'- THE OAPr.U:TT cc~pnR,:.TI'JN
Supp. 3
12-1-73
The ga.s ge:,erator speed st2.1:Jilizes c.': 100%. ':::'he PM.G ot.::t'.put
supplies regulated AC voltage to the aircraft ig~ition system
and DC voltage to various annunciators, relays etc., of the
aircraft. r:::he J?S pOVler turbine cor:,tinues to accelerate the
aircraft engine to light ori sDeed and above. As the engine
is accelerated to a predetermined speed (43 to 47% RPM), the
speed sensitive cutout switch (located in the JFS power turbin:~
output) is actua.~ed. Actuation of the cutout switch renoves
DC pawer from the ~uel shutoff valve, fuel drain valve and
start counter. The fuel shutoff valve closes to terminate
fuel fIm'! to the gas generator cOITcbustor resulting in slIutdown
......... _
...... of the gas generator. The ruel drain valve opens to drain the
fuel nozzle manifold line. Additionally, with actuation of th~
cutout switch, DC pawer is placed on TBI-15 of the electronic
contraI c:~_rcuit board. This de-energizes Rl re~ 3..y coil allowi:-..
the relay contacts to open ensur ing termi.nat ion of DC power to
the fuel solenoids.
with shutdown of the gas generator, both the gas generator and
the power turbine decelerate. As the PMG outi;mt frequency dro~-;~c
below 370 Hz, K2 relay is de-energized. This removes both AC
and De irom the aircraft electrical system. with decay of
speed of the power turbine, the overrunning clutch disconnects

'''-.-
2-5
r;----~I A~R!::9EA:;':Cl-; MA;"JUFAC!TUR!!'."::il ;:OMPANY CF /.,R:Z:JNA TE'3-83
'~I
I~ ..... ~: Ao O!VIS:ON CF "T:--tC O,A.q:ll[T'T ,:;C',~paRATION
Supp. 3
L..::.=--.l
12-1-73
as previously described. The po-wer turbine comes to res-t
with the cutout switch resetting to the position shcwn in
Figure 2-1. The 50% switches reset to t~e position shown
during ro11dawn of t~e gas generator.
During alI modes of operation of ~he JFS, a thermocouple
mounted in the JFS pawer turbine exhaust plenlli~ monitors the
JFS EGT (Exhaust Gas Ternperature). In the event the EGT
shou1d rise to a vaIue of 1900-1950 o F, the JFS gas generator
would be automatical1y shut dawn by de-energ~zing K1 relay.
In the event of malfunction of the JFS fuel co~trol system

.~
that would alIa"" excess speed cf the gas generator, overspeed
protection is provided in the electronic control. AC voltage
and frequency are sensed at TBI-IO and TB1-ll of the electronic
control circuit board. Should the frequency of the AC reach
a predetermined value, (420 to 439 Hz) RI reIay would be
de-energized and gas generator shutdown would occur. Addi-
tionally, the overspeed indication circuit (TBI-12 and TBI-13)
would be energized to actuate the vis~a1 overspeed indicator/
which would display red.
2-6
,-~
I'~/~"'~I'.' "( .... ~~-~-·',..,IJ

"\i.;""1~';;,;"/~~ ,.~ ~'" "-,, --;- •• .",,,.-
... ~ -, ,..,..,,<\'4 ...... :....J:~i',_' .... f7.1:.','fi"';:>
~""'IlP'" '-"( ,"".,.
i""~'~, ,\""".-"," i
"_)~ §'.1<"'","_'-!'~vr\
I
" '.
;.p...\Sl~JIF1'"7\ L>:....i'.'t<M TSG-83
! j~ A ;::H .... ,51:J~ O~ l"i-1::: GAF"R'E~i C':l~PORA.T,aN
l.~~ Supp. 3
12-1-73
2-3. ELEC'='~ICAI. SYS':C'EM COMPONE.t-..""I' DESC:::C::PT TON
A. Permanent f.':agnet Generator (PIv1Q)
The PMG is mounted cn and àriven by the JFS aeeessory
module. See Figure 2-2.
Figure 2-3 depiets an exploded view of the PMG asseIT~ly.
Internally the PMG eontains a rotor, a stator, an EMI
filter and a transformer reetifier module.
The rotor eonsists of a disk fabrieated of non-ferrous
material. Inbedded in the disk is a permanent magnet.
The rotor shaft is supported by two 1::earings and is gear
driven. The stator asse~bly is ~a~risated of segments

"-~
of lrnv permeability, fer~ous material wound with coils
of wire. When the PMG is assemb~ed, the stato~ is
pos it ioned and held in elose proxirnity to the rotor. A
magnetic field is present between the rotor and stator.
As the rotor containing the magnet is turned, this rnag-
netic field is disturbed. (Corr.morüy referred to as euttin~
the magnetie flux lines). This induees a voltage into the
windings of the stator. This AC vo1tage will rise with
inereasing speed of the Pr1G as will the frequency of the AC"
The AC vo]. tage is fed into the trans for=ner reetifier modul;~.
',,--,
2-7
i~..."...~1
!~ ~ ~~
!,'!1'~~;! A~RE5Ji::ARCH UV:.l\.NU7A::::TUR&I'.lG C::JMP/"NY CF AmZC['U\.
;\ L'>. )i A 'YVI~!ON ar n ..u: r.; .... :R"'!TT caÇlPO~p.":'"ION
,~I
TSG-83
S\1pp. 3
12-1-73
I
\~I/l I
I I
jl
GAS GENERATOR ASSY.
Figure 2-2
2-8
( (
t-:<j
~. '1j
LO ~
--t0 ~ G'J
fi
I (O ~
1..0 (j)
N (j)
I
Lv .t-<
_/
r .~=r
!t0~: A:~~ES'E~:;t::~ M!~~,"\j")F/\CT~,j~~',~G CCMPp~~y ~JF" f~R~::C;~iti. ':'8G-83

F~~!q, li A ~lV;':'iON Dr lHi: CA~RLTT COrirO~I<\71':J~
,~/!
L--::_~~ Supp. 3
12-1-73
The transformer rectif 3r module converts the AC to DC
for use on the DC powered components of the JFS and
various De p~~ered components of the aircraft. Also
included in the module is a voltage regulatcr which lL'1\its
AC voltage to nominal 110 volts. The K3 relay is included
in the module assembly. The reader shoulC rec~ll that
K3 relay i3 actuated at 50% gãoS generator speed. Above
50% gas generator speed, part of the r~G stator windings
are by-passed. This results in reduced AC vol~age into
the transformer rectifier and reduced DC voltage out of
the t:ransformer rectifier. lf one were to monitor DC
voltage àuring JFS operation, the fol10'v\ling would occur.
With JFS start initiation, De voltase would rise from o

to approxL'1\ately 35-38 volts when the gas senerator speed
reached 50%. At 50% gas generator speed and with actuation
of K3 relay, the DC voltage would drop sharply to approx-

i
imately 18 volts and then rise to approximately 22 volts
at 100% gas generator speed.
An EMI (Electro Magnetic Interference) filter is provided
in the Pi1G assembly to filter any random electrical signals
that could influence sensitive e1.'ê'!ctrical/electronic ecuip-

... -
ment of the aircraft.
2-10
~---~~
li .~! ,~~~'F.S~P~~:;:-~ ':~.<\N~J~:'"AC~~J~~"~3 C~~tT::A-'"1·( i: F' .A~~~:rC~~i\ 'l'SG-83
:l'~~~":t",')
i'",,e,, SU~)p.3
i " :JIV~~ION 0'- THIi: G,\~RIt":"T CO~O::Of:lf;;:A"'f;O."<!
~-_.~-=--===---~~
12-1-73
B. El'8ctr:_ca,l Con~~o"' Box
~he electrical control box is mounted on the side of the
gas generator. See Figure 2-4.
An exploded view of the electrical contrai box is shown
in Figure 2-5. Internal:y it ccntains (1) the electronie
circuit board, (2) arrbient temperat'-J.re sensor, (3) visual
overspeed indicator, (4) start counter, (5) and relays In
and K2. Two 5 amp cartridge type fuses are provided to
protect the JFS and aircraft l\.C and De components.
The basie operation of the electrical control box is
, covered in paragraph 2-2 of this section of the manual.

'--,
It is not the intent of this manual to provide detailed
operat::_o:1al information as pert2.ir.s to printed circuits
employing solid state electronic devices. Additionally
some of the components of the electrical control box
assembly are hermetically sealed devices which are sL~ply
remove and replace components. By utilizing appropriate
test equipment, experienced personnel may accomp:)..ish
functional test of the assem~ly.
'-- 2-11
í~~! AH~E:8r::A.RCH M,1\t\!UFAGTUR!o.,'G :::QM?A~Y OF" Afel;::JNA
il~rr'i
["'--~.--/! I!', DIVIBHJN ar TH~ GAIQ~ETT CORPCr:'AT!QN
TSG- 8 3 •
Supp. 3
12-1-73
~ N
~ ~
F;]EL L 'JECTTON• ACCUMULATOR ""
(1.)
\'''J II
~~/
~.
'\\ ~~ln 'V<'I,k:@~
't\'h_ J~LfJ }J ~
'",
t ~~~".~,Q
~~~~~-.;::;:;
,..
,
"'_
,
I
/ ""
~ '~
/'
L(,l /-;<:-2-,~
/ ~i)~ ""
,~ ~-",t:€, '~~~; ~
" f .. ,,
,
"l"""~-
2~
Figure v cECTI~
GAS GENERATOR ~~D ACCESSOR~ u
2-12
jL--~1
I~4:\Q:iQ.i!Ti.\i A.:RESE$S;!CH MAN:.JFACTUR:NG COMPANY Cr ARiZOi~A
or THE G .... ~HH:TT CCRPCRATI:'!N
'...... """" /:1
J' A. OIVl13IQN
"--====~ TSG 83
Supp. 3
TEHPERATURE 12-1-73
~~SENSOR @
I
I
I
Kl RELAY
ELECTRONIC
o
"
::
"
I~
,','
,\
1\ ,I~ 'A....,
. ',1.:)
" C'®~
M
FUSES irJk ~
l "-
".
I
"----' r'\
~
LI
I ..,·i,
I,
*
OVERSPEED ,.,
INDICATOR
(~rc~=T ER
<!>
U
()i2 ,
7:' "
. ~'.
Q
~
9 ..
<>
~
~
ELECTRICAL CO~~ROL 30X
Figure 2-5
2-13
r-::::=~, TSG-S3
'/~~,:,I A&RE5EA?::!""": f0:f~~~~Urt'\C7Ui;.li~""G C~Mr.-?ANY Q.,;" ;:\:::2!Z:T.J~:J.\
;,~~v,úLT7"'11
Sl.:;;:,p. 3
\ --
i"c...._/i ... <:ifVI:lI'J"-.l 0::- THC GARwltTT CORPQ\l;:ATlON
1.2-l-73
("I
\.... 5:)% SPZED SWITCH
The 50% speed switch or switches, since there are actually
two switches, are mounted inside a housing attached to the
accessory assernbly. See Pi-9ure 2-6 e
During acceleration of the ~FS, the 50% switches are
mechanical1y actuated at approximately 50% gas generator
speed. Referring to Figure 2-1, it may be recalled that
actuation of 50% switch #1 completes electrical circuitry
to the start counter. Closure of #2 50% switch completes
the e1ectrical circ..::it for K3 relay coil, which vJhen
actuated reduces PMG output voltage. Both switches are
actuated by the 50% speed switch governor.
The 50% speed switch governor is mounted on and driven by

I ,.
one of the shafts of the 'accessorj drive assembly. The
governor consists of a body containing a pair of fly-
weights, a moveable plunger, a spring an2 calibration
shims. The end of the plunger contacts the 50% electrical
switch actuator lever. See Figures 2-6, 2-7 and 3-2.
The spring in the governar exerts a force on the plunger
in the direction of the electrical switches. Springs, in
the electrical switches exert a force in the direction of
the plunger. At approximately 50% gas generator speed,
centrifugaI force actj_ng on the f:'yweights will overcome
the spring force on the plunger and move the plunger away
from t~e switch lever. The springs in the e1ectrica1
2-14
-.--=---<
:~~.
(~: .>I,'RE3EAP;:CH (\.:t,~·~JF"ACTURING COMPANY OI'" A;;!!ZONA
'I "--.... ~ /1 A o;VIs.aN or TMI[ GARJ:õlt:TT ':OQPCR ... T;ON
L -----====-----..J
TSG 83
Supp. 3
12-1-73
~ ~ I
~, I
Ó:
d~
'<-CY Q;i.
"---
... h LEVER
SWrI' f"a .
LEVER
. HINGE
f1 ' . ~ swrlHES
N~~0r
PIN
Y
50 % SPEED Figure 2-6
swr::.'CH
'---
2-15
[ --=----o
~!
i~rumn), A;RE8EP,~~H Y~NU,"ACrJR!N13 C~:::'U"~!='ANY Cf" ARiZONA TSG-83
I~ i A O'VISIC~ or THl!: OA~RP.J:TT CO~PORA'710N S'.:,pp. 3
2.2-l.-73
s·witches ,,;i.11 aC':':uate the switcnes to compJ_ete the
electrical circuits previously described~
The reader should be advised that in this type governor,
the rate of movement of the plunger is not proportional
to the rate cf flyweight centrifugaI force increase. In
other words, the plunger does not move until the flyweights
move, and once they move they pivot tr.eir full traveI.
This results in the pIunger moving with a snap action.
As shown in Figure 3-4 a metal sleeve or cylinder is fitted
over the body of the governor. This prevents overtravel
cf the flyweights as they pivot outward. The governor
trip point is calibrated to the required speed range by
shirnrning its spring.
The 50% switch housing is shimmed at its base so as to
establish a preload on the switches, thereby holding them
open. As the gas generator accelerates to 50% speed, and
the switch governor moves its plunger away irom the switch
lever, the switches actuate their contacts c:osed.
D. CUTOUT SWITCH M-.!l) GOVERNOR
The cutout switch and its governor are located in the pawer
turbine output. See Figures 2-8,2-9,3-6. The cutout . '-

SWlL.Cn
"
is rnechanically actuated by a switch governar similar in
construction to the 50% switch governar. The cutout switch
governor is shawn in Figure 2-10. 1his governor actuates
the cutout switches at 43-47% RPM engine speed to auto-
2-l6
r---
I~I'
I, AiFU:!E:1;:ARCH MA;>"UV'"ACTURfNGl COMPA:-';Y O:=- ARfZONA
l\~'
,~I
A OIV:SIí:JN O~ 1~E GArlRETT CORPCl'lATtON
!
TSG 83
Supp. 3
12-1-73
SWITCH LEVER
(MOUNTED IN
SWITCH HOUSING)
COMMON TfItMlNAl
'--/
N~LY O:FfN TERMiNAL
NOIIMAI.lY CLOSED TERMINAL ~

50% SWITCH
GOVERNOR ASSY.
THREADED TO
SHAFT
Figure 2-7
'---'
2-17
;;;--~1
A:t~E3EI\~~H MANl~F~.CTUf.'!l""~ CO~':!IANY iC);;:' ARtZ:=:NA
!~iR~1 or
I'--~i
A O'Vl~10"" TK[ l"ARJil'I~TT CORPO~AT~C""
~SG-83
SUFP. 3
12-1-73
Figure 2-8
2-18
'---~
I ,/'F~~
,~~:'
A!R'E~d::;:.c'~"::::K M/\~{.UF'ACTUR1NG ::::CMPANY CF AQi;::;::NA
r~i A ""IV~E;C1N Oi'" TH:l: OAR~!ETT CQRPOJ:fATION TSG- 83
Supp. 3
12-::'-72
"-
,,-.
Figure 2-9
"--
2-19
I ---
:,~
;i~,i fl,lR:rSZ:;"r.;C"': ~(fo.N:J?A:::TL!~!N'3 C:rJMFANY Df" ARlZuNA.
!~í I
, .. OlVI810M ~f" TH~ tbA:~~~T CD~lJ'ORATIC,N
TSG 83
SUCD.
... ,. 3
:':.2-1-73
PLUNGE
CALIBRATION SHT.M
SPRING
CUTOur SW I'TCH GOVERNOR
Figure 2-10
2-20
I~I ':.'8'3-83
l~.m~cn-r\j AIR;;:SEARCH :tY:t,"Ui'"A::TUl8:n>"lG CO~PANY;:-~ AR::e:C1N.A
!~/; A. DfV~::3!~.JN or T~[ GA!CiR:::TT CCRPORATIDN
S'Jpp. 3
12-1-73
matically terminates gas se'"'cerajco?:' ope:'Cab.on.
E. IGNITION SYSTEM
The ignition system is comprised of the ignition unit,
an ignition lead and an air gap ignitor plugo AlI are
mounted on the gas generator housing.
The ignition unit, or exciter as it is sometimes referred
to, is a high energy capacitor discharge system feeding
a surface air-gap ignitor plug with a spark of short
duration. This system has a limited duty cycle but since
the ignition is ceased as the gas generator passes approx-
imately 95% speed,the cycle each JFS start is of short
durat~on.
\------
Caution: Due to the high intensity spark of t~is unit,
it should be handled with some degree of resFect.
The energy leveI of eac~ discharge spark can
be lethal.
The ignition unit is a hermetically sealed unit and is
mounted on the gas generator housing. (See Figure 1-1)
The unit has an input power (28 VDC) connectioD and an
output connection to mate with the ignitor plugo
Tne ignitor p1ug is flange mounted to the gas generator
housing with the spark air-gap extending into the com-
bustion area for ignition of the fuel-air mixture. A
crush type gasket sea1s tne ignit:or to the gas generator

'--
housing preventing 10ss of compressed air.
2-21
í~l TSS-83
i~ii An';J:::S=.k\~s~",,; Wt\NL'-:-A~t:'~1N~ CC~~Pfi'>iI,~~~l{ Cf" AR~;~Oi\~i~
i'~!
A O,Vr9!ON or T)-')l: ~A..~RETT CC,RPOClA,TION
Supp. 3
12-1-73
This system is c~ecked ve..::',:l s .~:r-,ply by providing an externaI
source of 24 vdc to the device and witnessing the accom-
panying s?ark. This system should alwa.ys be checked only

as a system will alI components connected. railure to
have either ignitor plug or lead i~ place may cause
failure of the components due to insulation brea~< down.
F. FUEL SHUI'OFF AND DAAIN VAJ..JVES
Both of these valves are simple solenoid operated gate

valves. They are similar in construction; their difference
being the fuel shutoff va2.ve 1.s normally closed a.nd the
fuel drai'1 valve is nonnally open. k~dditiOnal1y, the fuel

shu·toff valve has a manual override feature. During CPS
start, both valves are pO\'Jered sümltaneously with actuat:"on
of Kl relay. See Figure 2-1.
Figure 2-11 de.'?:_cts a solenoid valve .,r- the type used as
a fuel shutoff valve (referred to as Manual Prime Solenoid

Valve in Figure 2-1). It consists of a solenoid coil,
rnovable plunger and valve body. i~e lower end of the
plunger has a nole in which are set two spring loaded

carbon discs. The discs are spring-loaded outward -fp
contact the lapped faces of two seats. With the solenoid
de-energized as S'lovln, the plur.ger is positioned by it.s
spring to interpose the discs in line with t~e holes in
the seats. !ncoming fuel pressure, entering through
either port, forces its way into the area between the
2-22
rEB
i
I~-")
~i
"IV '
A;~i::SE!..\J?CH M.~NI_'f"ACTUi';;;~~~ CCMP.<\?'>'Y DF" A7,!~ZCNA
h OIVI;lION C,. THl aAR1U::TT COR?C.;.!tA7JC~
TSG 83
Supp. 3
"'---- 1.2-1-73
PLUNG3R
LAPPEI) SEAT IAPPED SEAT
BODY
• "I; o
~
~
. ':::"'' ' 1
CARBON ~ISK (SEE BELOW)
'------ M.A.J..~UAL OV:SRRn)E
/
SEAT
CAR30N DISK
JIf.lAl~UAL
Figure 2-11
'-
2-23
>~ ~ t\!~C:3~:,,~.r.1:::-J ;,,<.,}'~tw1f-Â:;T:J~~N3 r;::J~·~~J·\~V C·F ;\K~ZCNI~ TS,G-83
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~
12-1-73
carbo::: aiscs and forces the downstre,:L.'11 di.sc tig~tly
against the seat. \Vhen tlie solenoid i3 energized,
the p1_tmger is magne. ..::ally attracte::: upward by the
core, sliding;. the c.~.scs over the seat faces until they
clear the holes in the seats. The fuel then passes
relatively unopposed through the valve body. The prime
button is provided to allow opening the solenoid valve
'Ift"ithout proviàing electrical pO\oJer. By pressing the
button, the solenoid valve is opened. The pur?cse of
this feature is to provide means of purging the fuel
system of air. This would be necessary after a JFS
replacernent on the aircraft or following any maintenance
action of the aircraft which coulà intrcduce air into
the JFS fuel system.
The fuel drain valve serves to drain t~e fuel nozzle
manifold of residual fuel after gas generator shutdown.
Its construction is the same as the fuel shutoff valve
except that the plunger is spring lo~ded tQhold the
valve open. On most solenoid valves of this type both
seats and carbon discs are lapped~ the valve is thus
symmetrical with respect to flow directio::1. In t'le event

of a leak in the valve, it can be tur~ed around so that
the inle-t and outlet ports are reversed. However, some
valves of this general type have only one disc and seat
lapped, and thus they will leak if insta:led backward.
2-24
r-:::--~
:/7-----~1
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A[RiE:31':,~i':~H ;v.i~N',:rA::"n..F:rN!3 CQ1-!PA;"Y!:I1"" AR'Z::r-.:A, I'SG-83
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A OI\l'9'CN Tl-'E: OARP.<t:"" CO;:::PQKlAT!O .....
S'-'-pp. 3
l2-1-73
G• mp,<,D'V1OCO-T?
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'-- ... L.i.....ot OVPR':'PV,D-r;:"r
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The thermocouple is used for sens.i.ng J?S exhaus~ gas
temperature. :t is mounted in the DOv,1er turbine ex.'1aust
plenum. See Figure 2-12. The thermocouple consists of
a junction of two dissimilar metal wires contained in a
me~a: encasernent provided with an electrical connector.
The dissirnilar metals are chrornel and alumel. When heat
is applied to the j'::nction ç~ these dissirnilar metaIs, él.
voltage proportional to temperatu~e is generated. This
voltage is fed to the electronic contraI circuit and
compared to a reference voltage. In the event the JFS
wO'Jld experience excess exhaust gas te-'.?erature, the
thermocouple "otJould generate highe:::- tha.n normal voltage

'-
to the electronic controlo The electronic control would
recognize this higher than normal milivolt signal from
the t:lermocouple by comparison with the reference voltage.
The electronic control would take immediate action by
de-energizing KI relay which would result in termination
of gas generator operation thereby preventi~g heat damage
to the gas generator turbine section.
This overtemperature protection system is very responsive
and has proven very reliable in t~is apolication as well
as similar applications~ Additio~ally the system lS
fail safe,; that is, t:le JFS -vJill :'1ot s'.:art if the thermo-
couple is open, shorted or disconnected.

"---
2-25
.~.
!L_~:.i Amir.::SEAR::H MANIJFt~.CTUR!N~ COMPANY CF AR~ZW'NA
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2-26
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12-1-73
"--
I-I. EI,ZCT'~:CJA.J..J rI.L'\~tNESS
The electrica1 harness is se1f-exp1anatory. It simply
serves to interconnect the various electrical components
of the JFS. Figure 2-13 :_s provided as an aid in wire
and connector identification.
'--
'-
2-27
IGNITION UNIT l"UEL
SHUT OFF SOLENOID
1'4
lENGTH
11.00 INCHES
FUEL DRAIN SOLENOID
PS
LENCTH
9.75 INCHES
i'\'WHT- . .v.81381-7-20-9
11 ~YEL M81381-7-20-4-
J GRN-- M81J81-7-20-5
!( WHT---'- MBl381-7-20-9 - - - - - - - - - - - '
LENGTH
l GRN- -- MSJ3aI-7-20-S------ 24.75 INCHES
t-'---=-~-------t'- :
~l W H T - - - - - · , MBI38I-7-2Q.-9
A - W H T - R E D - - - - - - - - - - - · ·- MBI381-7-2o-n ----~------
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CON'l'ROr.. BOX LENGTH

24.25 INCHES
LENGTH f-' (f) )-.'J

7.63 INCHES t--J c:: Cf)
I "(j G')
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Lv
W W
F A B C D E
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50 % SPEED SW
JFS100-34 GAS G~:~~ERATOR ElECTRICAL HARNESS

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I"-~'
L-.:::.=------.J Supp. 3
12"-1-73
SEC'I'10N 111
LUBRICATION SYSTEM
3-1. General Description
The lubrication system is integral wi thin thc JFS and provides
continuous lubrication during ope::::ation. It is made up of two
separate systems operating independent!y of each other; the
accessory drive assewbly Gil system and the power turbine
assembly oil system.
The accessory drive assembly oil system cO::1sists of a low pres-
sure oil filter, gerotor type oil pum?, pressure relief valve,
"-- high pressure oil filter, pressure jets and a sump which is an
integral part of the accessorj drive assemoly housing.
The power turbine asserrbly oil system consists of a sump which
is an integral part of the power turbine assembly housing.
3- 2. Operation
A. Accessory Drive Lube System
The accessory drive assembly oil system pressure lubricates
the gas generator rotating group support bearings'ànd bevei
gear set, and by means of the spJ_ash. method, lubricates thc
remaining accessory drive assembly cemponents. At the
initial rotation of the gas generator, the oil in the sump
flows through t~e low pressure oil filter, the gerotor
'--- type oil pump, pressure regu.Iating re:ief valve, high
3-1
r'-----~
I~i t\mES:<:AR::H ;v.AI'oH':;:-I\CTUr;;;:~Nr.:;CCMPANY OF ARIZONA

'~ir.lIlIn\
1!~:/: A OIVlSl':tN Cf'" 'THFr GA~f.lt:õT CORPOR ..... T1CN
TSG- 83
Supp. 3
12-1-73
pressure oil filter, and is then directed onto the gas gen-
erator assembly bearings and bevel gear set. Gravi ty returns
the oi1 to the sump located in the bottom of the accessory
drive housing.
Figure 3-1 depicts the accessory housing (which serves as the
oil sump) , the inlet Gil filter and the relief valve.
The Gil pressure pump is mounted inside the accessory
asseTbly and is driven by the same shaft which drives the
50% speed switch governor. See Figure 3-2.
The pump is a positive displacement gear type pump having
two rotational elements. These elements consist of a gear
and a rotor encased in a housing provided with an inlet
port and an out1et porto This type p~mp is some times
referred to as a gerotor type pump. Figure 3-3 depicts a
typical gerotor type pump with the gear and rotor shown in
various positions through one complete revo1ution of the
pump. The reader shou1d note that the rotor has one 1ess
tooth D~an D~e gear. This forms a pocket between the teeth.
As this pocket passes the pump 's inlet port, oi 1 is dr,awn
in. As the pocket of oi1 rotates to the outlet port, the
oil is expelled.
The pumps flow capacity is approximately one quart per
minute when operating at its full speed of approximate1y
6000 RPM. However, due to the small size of the oi1 jets
3-2
Í,~
;~""Svc;\1! A1Rfi::;H:AC;:::;H l"'ANU~t',CT'..'~:NI3 CCMPANY ai'" A~~ZONI\
'''..âb..
l_=-----j .
---'=---->
A O:V,O:ON or TH1'L QAi'llIõlr;T'T '::ORPCRAT!:JN TSG- 83
Supp. 3
12-1-73
"---
OIL PRLSSUR"S
ACCESSORY
~~
',,------
~//
HYDRAULIC t~
FUEL CONTROL UNIT .
.,---, Figure 3-1
3- 3
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Supp. 3
12-1-73
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50% SWITCH ASSY.
Figure 3-2
ACCESSORY DRIVE SECTION
3-4
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TSG- 83
SUP? 3
]2-':'-73
in the sys te;n I o~,-I flow o:' tr..is magni <=.uc.e \'ioul.d res uI t in
prohibitive oil pressure. Therefore, apressure regulating
relief valve' is incorporated to limi t the pumps discharge
pressure and thereby maintain the desi~ed oi I flow through
the oil jets. The valve is shown in Figure 3-1. Figure
3-4 schematicalJ.,y illustrat~s the pump and relief valve.
The valve is a simple, spring-loaded closed, ball type
valve. At low pump speeds, the pump discharge pressure
is lm'1 and the valve remains closed resulting in alI of
th.e pumps flow passing through the oi 1 jets. As the
pump speed increases, i ts discharge pressure, inc::::-eases.
The relief valve ball is held on its seat ~y a spring.
wnen the Gil pressure acting on the bal~._ reaches a pre-
determined pressure value, the spring force holcing the ball
on its seat is overcome and the ball begins to move off its
seat. This results in purnp ãischarge pressure being by-
passed back to the pump inlet. Spring pressure on the ball
will rnodulate the valve to maintain a relatively constant
pressure to the oil jets during full speed operation.
Normal operating oil pressure is 30-35 PSIG when measured
at the oil pressure gauge port located on the accessory
housing. No adjustment of the ~essu~e regulating relief
valve is required.
3-6
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~.""AR~ !!
f1:\lR::S::I~R=~ f~Ar~I_~F'l\CTURING COM~ANY
ti.. ~IV;~lO~ Cf" "":'"H:t ClA~R'i:rr CC'RF'CRATlON
CF JJ~R\7:.0;'~:A
! .4", '
I J TSG- 83
Supp. 3
:_2-1-73
"-
OIL INLET
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RELIEF
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OIL OUTLET,
THROUGH FILTER
TO OIL JETS
Figure 3- 4
',,--
3-7
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!\--~~~~ II A mV'~Ir:;N ::J,- Tkf.: QARA":-;T C~RPC:-;:ATIOt~
i~l S·,,:pp. 3
12-1-73
The pressurized oil i5 routed through cast ~nternal
passages of the accessory housing to a port at its
mounting surface. An oil transfer tube connects this
port to a mating port in the tower shaft cover of the gas
generato:!:'. The oil transfer tube also includes the high
pressure oil filter (screen). See Figure 3-2 and 3-5.
From the tower shaft cover, the oil 1s directed through
cast internaI passages of the gas generator rotating group
carrier housing. Two orifices are drilled into the passage
to se:!:'ve as Gil jets. One orifice direc~s a spray of oil
to the corrpressor bearing and one directs a spray of oil
to the bevel gears and bearingo whi ch dri ve the accessory.
Near the aft end of the support housing a removable oil
jet directs an oil spray to the turbine bea~ing.
After lubricating the aforementioned gears and bearings,
gravity returns the oil to the sump for recirculation
through the system.
The various gears and bearings contained in the accessory
asserrbly are lubricated by the splash method.
From the foregoing discussions, it should be obvious to the
reader G~at inspection of the high pressure filter (screen)
would require removal of the accessory assembly from the
gas generator. The inlet filter (screcn) may be removed
for inspection, cleaning etc., by threading it out of the
accessory housing. Refer to Figure 3-1.
3- 8
1
1
1
1
1
1
1
1
1
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I~I AlRESEit.r:iCH MA~:UFÃCTURING COMPANY OF A1'<'ZONA
1\ ... J A OlVI9 t ON ar TH[ OARR[TT CORPO~"TION TSG- 83
I~;
• 1
Supp. 3
12-1-73
..
I
J
""----
TOWER SHAFT-
COVER
OIL TRANS?ER
TUBE & SCREEN
ASSEMBLY--
GAS GBNEPATOR~.
TURB!NE WHEEL
'''--"',
Figure 3-5
3-9
;~~I
A1N':~~EtJ<!I':;~ ~'~fo\~~t:':!/\~T~~~NG ~D.;vlPÀ~Y Cf' /\~~ZC:'JI\
!/(;;A~~! TSG- 83
'~~i
It. O:VllLGN or TXt': GAf{!=f ;:TT CCOAPOP<!A.Taoro1
L:::::::;:;_i S'-'pp. ..)
12-1-73
T:l.e accesso-,-y dri ve oi 1 sys te:n capaci ty is ::;,20 cc. The
oil level is checked visually by a dipstick on the accessory
sectio:1.
B. Powe'::" Turbine V.:be Sys tem
The bottom of D1e power turbine assernbly provides the oil
sump used for splash lubricatir.g t~e bearings and ~otating
components in that asserub':"y. At the ini tial rotation of
t.~e power turbine, the rotating componen ts dip aY1d splash
oil over the bearings, gears and components.
During operation of t.1J.e propulsion engir.2 the rotating por-
tion of the power turbine overrUt"1ning clutch is s:?lash
Iubricated.
The power turbine lube system capacity is 460 cc. A combir.-
ation fill-drain hose is used on the power turbine. One end
of the flexible hose is attached to the bottom of the power
turbine oil sump. The other end of the hose is attached to
the a.ccessory section by a q'-~_ck detachable pin arrangerr.ent.
This end of the hose is provided with a plug and dipstick.
To check power turbine oil leveI, the plug and dipstick are
removed. To drain the power t'.lrbine o:Ll sump, the quick
detachable pin is removed and the hose is lowered. Addi-
t~onally, a. magnetic drain plug is prcvided in an adapter
fitting at tne bottom of tne power turbine. See Figure 3-6.
3-10
f-=6B1
i
!....
I
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!
AIRCSEA;;;:::j-J MANUFACTURING
A Dlv:~rON Cf" TH! GAFUH:TT COI'lPORATICN
COMP/~NY DF AR~ZCN;:"
TSG- 83
Supp. 3
12-1-73
DIPSTICK
DETACH PIN ~
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p( ,
'/1Z't. :;.--:;
'••.... ::::~.:;;. I::·:·::;~,I::.:'! CUTOUT SWITCl!
~,.,. .. 'lÃo
/{~ f,
I:... :", "';"
'@ r
GOVERNOR
I~:t _:;; .
:::','1'.:-'.":..,, '~
"-::;<\i;~~ttB~~ ,
/~,
/ ~/.~.
'
~ ,
'o..
./'~,~~ /"~ ~ '1: e;/~,
V
\? l~ t!,
OUTPUT SHAFT
/' , Q
",'!?>&..'','iR fi.!
"'/ ~;p
~~~ {d17 .~v~
. "-0' c?'~ â
N'!AG.~E }" 'fIC TN PLUG
\ DR.zL_"
Figure 3-6
"--'
3-11
'~'
I""r7
I~:
i\.;r.::---)Ii AiREGt::Jl.\RC:~ M~\7\·!..n'~/\~7~~::'''H3 caMPA~'Y
A D!VltHC;..l DI'" T~Z: CAP;ôi~TT CQR~ORATiON
Cf" p';~;:~Z~~/\
TSG- 83
i~1 Supp. 3
l2-1-73
Figure 3-7 depicts boL'! the accessory dri ve a:1d pO'l'ler
turbine lt:be systems schemat:_cally. I\o te: the accessory
dri ve lube system is vented through t>e qas generator
compressor/turbine shaft and the power turbine lube sump
is vented through the output shaft.
3-12
( ( (
GA5 GENERATOR ASSEM8L Y POWER TUR81NE ASSEM8l Y

'~ t"~~--'~~~~"-~~~-~----"
Oll JET5 Oll JETS
SEAL
{
w
I
~-'
~
f-".
Lq
ç:;
ti
(D
PU MP
DISCHARGE
\
OIL STRAINER
w AS5EMBLY,
w
I
-J
PRESSURE
RElIEF
LEGEND
ECTION ROTATED 90 0 a!I!i1l!!1 PRESSURI ZED o IL
~""----------y~-- ______ I
elm .. OIL RETURN
DRIVE ASSEMBL Y I-' Ul :-3

(\J C (j)
I 'O G'l
I-' '1j I
I • co
JFS100-34 LUBRICATION SYSTEM SCI iEMATIC 6 -J
WW
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9
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A.:~:rE::,:p,~:;,r; ~Ah:",~rt".CTU~IN~ Cafv!P/~\~'(
A. IDIVI'm'CN a,. 7~E GlARf'!l:rr CORPCRATI:=N
C7 J\:::~Z:Cf\~A
TSG- 83
SUP?·3
12-1-73
",~
SECTICN IV
FUEL CONTROL SYSTEM
4-1 ~ . GENERAL
The fuel control system is ful1y automatic in operation and
does not require the manipulation of manual controIs for its
operation. After initiation of the JFS start, the fue1 contro~
system provides t..'le correct fuel flov schedule for smooth acced-
era tion of t~l.e gas genera tor to J_O O% speed, and contro 1s the fl:':' j
flow as necessary to keep the engj.ne speed reIativeIy constLlnl
once fuI1 speed has been attained.
The system is comprised of a nlliToer of components that function
',,--, together and in proper sequence to provide correct fuel flow
schedule for the full range of engine operatio~. Included i.n
the fuel system components are: (1) low pressure fuel filter,
(2) fuel control unit, (3) a fuel manifold with five fue1
atomizers (nozzles), (4) two f1.1e1 solenoid valves, (5) a fue1
injection accumulator, and (6) a combustor drain valve.
4-2. OPERATION
Before the function of the fuel system can be discussed in det2il
lS necess ,1 r
• f-'
a basic understanding of the fueI system requlremen<.-s
The first requirerr.ent of the fueI system is to provide a fue1
flow schedule which will accelerate the engine in such a rnanner
that the maximum turbine temperature .~_s not exceeded, and yct
'",--,
accomplish it in the shortest possib3.e tir:l8. The amount of fl1C~
which can safely be injected into the co:.-rDustion charnber varicri
4-1
'~I
'~....
~, 1
:~.: ,~
AlfiES'EARCd 0~At-."~'::-/\ç-rL'i'1I:'-''3 ~CP,,;FA"lY C i'" 1:''''.iZDNA mr~ "'1
"~;:; J - b J
: .<)o. J~ A OIV:SION af" T~ r Gf.\PRil[1""'!" CCFlPQ~.f!"TIQ ...
, -'''/1
~~ S:"l?p. 3
12-~-73
direct~.y vii th compressor air flcw. At lO'1l s?2eds, very li ttle
air flows throug~ the tu:cbine so 1:.."1e fuel flow must be limi ted
to a 10\'1 value to pro':.ect the 'curbine f:rom excessi ve temperature.
As speed increases t.'1e compressor PUT.r,pS more a2.r through the
turbine and more fuel may be added. Thus, fuel flow must be
varied directly wi th compressor air flo'\v or a function of com-
pressor al.r f1ow, to obtain a fuel schedule which will provide
t.~e turbine ",'i th enough power for good acceleration wi thout
excessive temperature, in such a way that the power developed
slightly exceeds t.hat required a": any particula:::- speed.
In controlling the fuel flow c.'J.ring acc21eration of the uni t the
foI10wing assumptions ar'2 necessary: (1) measuring the fuel
pressure provides a measuremen":: cf the :cuel flcw through the
a torni zers and (2) engine RP.M (f'J.e 1 pump RPH) ar:c. compressor ãis-
charge pressure are :.ndicati ve of turbine a':"r fIm" . rf these
assumptions are correct, it follows that if the fuel pump R?M
and compressor discharge pressure are used to control the f~.lel
pressure, the fuel fIow will be proportional to turbine air fIow
and proper mixture for 1igh t-off and acceleration wi 1.3.. be achiev'2~~..
The next requirement of the fuel system is speed control~. The
gas turbine derives i ts pOvler from fuel, which must be regulated
to control the power develcped and thereby co~trol the speed.
rf the power developed exceeds the power required (load), the
difference will cause an increase in speed. Conversely, if the
power required (load) exceeds the pOVIe:::- cevelopeà, t:-le turbine
4-2
I~~ AtR=:S~/~R:::'t-( ~j\r>J~~::;-A':TUR~7'~3 COM?lt.f'~Y Cf- AR~Z:;t\;A
II .~""",,,",I'
\. ...c>. /1 " QrV'::i!:;)N Of TH~ GARR'tTT caRPO~AT~ON
':.':'sc- 8 3
:~l
SUP;J. 3
]_2-1-73
wi :.1 s 1m, covm. Therefore, to operate at a re:atively constant
speed, the fuel flo'w must be varied in p:-::-o:?ortion to the load.
Figure 4-1 illustrates the components of thc fuel control systcrn
in b1ock. formo By refcrring to this i~lustrntion thc render
may follow the flow of fuel through th(~ sys tem and gain a gene l~" 1
.,
knowleege of system operation. Each of the system components
will be discussed in subsequent paragraphs.
The assumptions are made that fuel supply i5 availa..'Jle and thJt
a JFS start is going to be accomplished.
Wi t..1. start ini tiation, hydraulic pressure is r~leased to the
JFS hydraulic start motor. Additional~y hydraulic pressure is
'---..-' provided to the fuel injection accumulator causing its piston
to stroke. As the piston strokes, a small amount of fuel
contained in the fuel injection accumulator is displaced. The
fuel flows through and around the orificed check va1ve but can
not flow through the other check valve (wrong direct~on) or
the fuel shutoff valve (not yet powered) . The result is: a
small quantity of fuel between the fuel injection accumulator,
the check valve and the fuel sr.utoff valvc becomes pressurizec1.
As the speed of the gas generator incrcases, the fuel shutoff
valve and fuel drain valve are powered. The fuel drain vaIve
,
cleses, the fuel shutoff valve c?ens and the small quantity\of
pressurized fuel fIows into the fuel manifolc1 and atomizers.
'~ As the fuel pressure at the atomizers rises, atomization and
4-3
HYDRAULIC
" p "~SS ':IRE IN
FUEL
INLET
OVERBOARD
INLET DR1\IN
FUEL
FILTER
FUEL FUEL
ACCUMULATOR
FUEL
ATOf.'lIZERS
DRAIN
(NOZ ZLES)
VALVE
(N. O. )
FUr'T" CONTROL UNIT o

Q~00
CONSISTS OF:
FUEL
SHUTOFFM~1IflI
~COMBUSTOR
:. PUMP
VALVE
ACCELERATION LIMITER
GOVERNOR
DIFFEFENTIAL PFESSURE VALVE
Cid.::Cf( VAL VE
(N. C. )
~O~O .
fI I GH P RE S S URE FI LT_E.~,RiiiIIiIl'!'~IiIIIm63:!ilIRI!.
O
COHBus'rOR
DRAIN
E~. COMPRESSOR PHESSURE VALVE
OVERBOARD
DRAIN
}-, (j)'J
N ç:: U)
FIGURE 4-1 I 'U GJ'
I-' 'O I
I • O)
---J W
CJ W
FUEL CONTROL SYSTEN nLOCK DIAGRi\H

~'
!~~~\\
,. ~'I
AlRESíE,t,~;:::H Mfr.N!...iFACTr~R'NG CO~P,i'.NY Of" A~L;::tH;A TSG- 83
I, ~.
, r.., I A OIVIS'ON cr THIE: CIAt.lqRlI:TT CORPOR .•,T~C""
I, I
Supp. 3
12-1-73
vaporizõ.tion of t!l.e ruel ent.ering the ccrrJ.)ustcr occurs. ~vi th
igniticn present, the gas ' erator lights of~.
As gas generator acceleration continues, the fuel control unit
pump speed increases causing an increase =-n fuel pressure. 'lhe
acceleration limiter of the fuel co~trol unit limits the rato
of fuel pressure rise by sensing compressor pressure riso and
allowing excess fuel pressure to be by-passed back into toe
pumps' inlet. This prevents overtemperature of the turbine
during acceleration.
As the gas generator speed approaches approximately 95%, thc
governor portion of the fuel control unit be~ins to take over
control of the fuel scheduling. This is accomplished by by-

'--
passing fuel back to the pumps' inIet. i\t full speed of the
gas generator, the governor is responsible ~or providing the
correct fuel pressure and resultant fuel flow to the ato:nizec;
to maintain 100% speed.
After the JFS power turbine nas acce1erated the aircraft engine
to its predetermined idle speed, the gas generator is shut down
by action of the cutout switch. Opening the cutout swi tch
results in e~ectrical power being removed from the fue! solenoid
valves. The fuel shut off valve closes, terminating fuel flow
to the combustor. The fuel drai!1 valve opens and drains the
fue 1 mani fold.
"-, During the JFS start and with decay cf hydraulic pressure, tho
fuel injection accumulator is slowly refilled to provide initiaJ
4-5
!/T~ A~RE.sEARC)-;~ MA.~;U~A:::T:"J;;::~ít3 C2M?AN'Y::-::- ;\~:ZC'N/\
f ::~V.t>R:·~11 r~S'G- 83
í~/:
A alv'SI':',,! Cf" 'TH[ GAPJ:,H: .... r ::Q:r:f~C,~ATIQ'-1
Supp. 3
12-1-71
fuel for the next start. Note: flov; i3 restric'::ed back. i:1to
the accumulator by the orificed check. valve.
The combustor drain vaIve serves to dra.in the co~ustor of any
residual fuel caused by a false start or blow out.
4- 3. FUEL SYSTEM COMPONENT DESCRIPTION
A. InIet puel Filter
The inIet fuel filter is a repIaceable element contained 1n
a housing which is mounted at the forward end of the gas
generator. The housing is provided with an inlet port and
an outlet porto Fuel from the aircra=t fuel supply system
is pIumbed to the inlet porto After the fuel passes through
the filter eIement i t passes through the outlet port which is
pIumbed to the fuel control uni t inlet porto
B. Fuel Control Unit
The fuel control unit is mounted on and driven by the
accessory module. See Figures 3-1 and 4-3. This assembly
consists of fuel pump, high pressure filter, acceleration
limiter, governor and a differential pressure vaIve.
Fuel Pump
The fuel pu~p is a two gear positive dispIacement typc. It
consists 0= a driven gear and idler gear which are sandwichcd
between bt'.shings. The bushings are spring-loaded against
the gears to maintain minimum cIearance and thus, reducc
internal leak.age within the fuel pump assembIy, and to main-
tain the pump's efficiency during normal wear. Fiaure 4-4
depicts this type pump.

4-6
~
!~q":l!Irfl A1RESEA::!CH MASU""ACT','H:!1\:G CCM::>ANY Sf" ARi7:0Nt, TSG 83
I~~!
L_-' ___-.J
A :;)lvr9:::a,'<I 0'- TH~ GARAl(íT CORPa~I\"'laN
Supp. 3
:2-1-73
"
'-
GOV:Sr<.I\OR
ADJUSn;ENT
L>P \'AL VE AI\;USTIlENT
DRAIN
PUNP DISCHARGE '-PL'MP I?\LET

PRESSURE PORT
Figure 4-3
'-~
4-7
r- --==_--=--:- -----,
1;/ ~ - ,!
A'R~S~A;:C~4 ?v~,C'.~~;....\F . .:\C:;...:R~NG C::t--1PANY CF A~~ZQN/\
!;-::;-,..."U.l~~TW):.
:,,- ~/; A D~'v'S!G"'-oI o r:- l ' \ l t CiAPR(T, CORoORAT!ClN ':'SG 83
~- --.:_':::-:::::::::::::: __ .-....J
S'c.:pp. 3
12-1-73
CRIVEN G:'::AR
~r:J
._- .;:.- OUTLET
~~
- +"
. " ~..
DRIVE GEAR
Figure 4-4
The fuel pump initially causes the fuel to flow. The drive
gear is turned by the accessory module. As the pump is turned,
the spaces between adjacent teeth pick up a given volume of
fuel and transfer it to the outlet porto For a given speed,
the purr.p will move a constant fueI volume through the fuel
system. This is depicted in Figure 4-5. From the pump, fuel
is forced through the high pressGre filter.
t
:3:
O
H
rx..
~ 00
~1Y.
H
"-1 ~~
;::,
rx..
V
*
PUMP SPEED
Figure 4-5
Note: The values given for RPM, flow,pressure, etc., in the
folLowing discussion is for illustrative value only
4-8
1
1
I-~
,~.,i.
i~~.j"nT A!RE5lEi)"R::::H M/~~JUf"A::""UR:NG COMPANY DF ARIZ- ':/\
TSG- 8 3
l~~\ A OIY~51:J~ O~ THI":. OA.RRIETT CO!QpaqA~IO:o..l
---~ Supp. 3
12-1-73
",--,
and are not necessarily representative of actual

values in the JFS.
Figure 4-6 shm..·s a pump connected to a fuel nozzle. The

pump is capable of pushing its entire 100% speed output of
400 pounds of fuel per hour through the fuel nozzlei how-
ever, only 120 lbs/hr. is required to run the engine at fu11

speed.
FUEL NOZZLE
FUEL PUMP
--
o C
--- 't-' 4CfO lbs/hr .>:----~~
n
M'MtMMW .il. li....- Õü-O

-2
O O
7
COHBUSTOR ~~
I
Figure 4-6
To prevent the entire 400 lbs/hr. from flowing through the
fuel noz z le, an a.l terna.te path rrus J,: be provided. This is
shown in Figure 4-7.
'-....-
4-9
ie-~l
i .~:
AIRE5L4R::H MAN:":::-"\C:TU~:N;? CO!4?A'\'Y CF A;:<';ZiJl',P, TSG- 83
! __::~_/;j A OIViS'O"'" DI'" THJ;: GAr:1P[TT CO;:t?OPA":'ION
L-.-'=,----, S :.:'.?P • __
=_2-1-73 "
[I --l: CONTROL VALVE
280
I ALTERNATE PATH
----
FUEL
Figure 4-7
When the speed control valve is closed, alI or- the pump's
output will be forced through the f~el nozzle. However, as
t~e valve is opened, some of the pumpts output will be
diverted into the alternate path, and will be returned to the
pump inlet. This fuel by-passes the fuel nozzle path and
results in less flow to the combustion charnber. By proper
adjustment of the speed control valve, the fual flow may be
varied so that the power developed is just equal to that re-
auired at the desired speed. The speed control valve is
controlled by a flyweight governor. The operation of the
governor will be discussed later.
The fuel nozzle represents a high resistance to the passage
of fuel in+-o the combustor. Therefore, if a large volume of
4-10
r2.ffi'l? i A!R:E:SF.:ARS;-; MA;-':UF'AC'UP.ING ::::Otv:~ANY OF ARI;:ONA ~SG-S3
.
1' '~~ ,
1 11. OrV!3'':IN ':),- T~( GAf:F::TT ca~pOP!ATION
l \
Sup~. 3
12-1-73
fue: is to be forced t~rough it, a high p~essure must be
provided by the pump. A low pressure in the fual line re-
sults in a lo·,.; :low through t~-;.e nozzlej hiSh pressure, high
flow. Thus, another method of controlling combustor fuel
flow is to regulate ~~e pressure in the pump discharge line.
Figure 4-8 shows a system utilizing a vari~)le relief valve
for controlling nozzle fuel flow.
The relief valve setting is controlled by varying compressor
pressure acting above the dia.phragm. This type of system is
used to automatically accelerate the engine to governed speed.
BOL~ of the controls regulate fuel flow to the .e~gine by by-
passing pump volume in excess of that requir-ed. The diffe:r-ence

,,-.
in the controls being that one is speed sensitive and the other
is pressure sensitive.
Acceleratibn Limi~er
The amount of fuel which can safely be injected into the
combustor varies directly wi th the compressor a~_r flow. At
low rpm, very little air flows through ~~e turbine so the fuel
flow must be limited to a low value to protect the turbine
from excessive tempera.ture. As the compressor accelerat'e~,
i t pmnps more ai:::- through the turbine, and more fuel can be
added. In fact, more f~el must be added as t~e unit acceler-
ates in order to proviàe enough power to continue ~~e acceler-
ation.
"'---'
4-11
~
r~.
n'!
~il
--===_J
AIRESEARCH fViANU;O-ACTURING C:;V,PANY CF ARI;:ONA
A D1VISION Or THI[ GAq-U;TT cCq?O~ATtON
TSG- 83
SUP?
~2-1-73
3
ADJUSTMENT SPRING
~ COMPRESSOR PRESSURE
TO PUMP INLET -,..-.(~_ _ _ _. .

u « : VA.RIABLE PRESSURE
HELIEF VALVE
FUEI. INLET
~~r _"::J~.:
BY-PASS FtJEL
- : :::-jlL -2 O
_~"iJ -.
O
O
fOUUO
:>\l "iH
l!i"l'e= mar"""':Wi'íit"lJPJ"'="'ní_~ -
~
PUfvP
FUEL NOZZLE
Figure 4-8
4-12
A:;;:n:SEARCH MANIJ."ACTU~!"IG C!JMPANY CF An!ZONA
A OlV1910N O" iHE GAR~I:TT CORPQ~A.'T!ON
TSG- 8 3
SU?p. 3
12-1-73
"-
'l'he fuel pump's fIO\,.; excee·' the turbine's requirements at
alI times during the acceleraticn and full speed running of
the unit. Therefore, it is necessary to continuously by-pass
some of the pumpls output, and return it to. the pump in1et.
The governor controls the by-pass only at speeds above 95%;
the acceleration limiter is used to control t~e by-pass during
acceleration of the unit up to 95%.
In controlling the fuel flow during the acceleration of the
unit we shall have to rely upon two basic assumptions:
(1) measuring the fuel pressure provides us with a measure-
ment of the fuel flow through the nozzle, and (2) compressor
pressure is a reliable indication of turbine air flow. rf

-- these assumptions are correct, then it follows t~at if the
compressor pressure is used to control t~e fuel pressure, then
the fuel flow will be proport~oned to the turbine air fIow.
The acceleration limiter consists of a control air diaphragm,
adjustable crack pressure spring, ball vaIve, and a sealing
diaphragm. For operation of the acceleration limiter refer
to Figure 4-8. Fuel pump discharge pressure is applied to
the fuel nozzle and also to one side of the ball valve,
tending to open .~
~ '-. Compressor discharge pressure (Pcd) aci:s
on top of the control air diaphragm, tending to keep the ball
on 'J...
1. L.S seat.. The small diaphragm above the ball valve acts
as a flexible seal to prevent 10s5 of by-passed fuel through

'-'
4-13
,~:
f. __~z: '\
i~i
I
Af~E5Zf-~RCH M!~~:Ur-P.=T~'~;~"-lG CQMP,,\NY <':~7 AR~ZONf4.
~SG- 83
A O'VtSICN Cf THE '3AiRQETT CC~~OllAT1CN
!~---- S~"'pp.
3
12-1-73
the overboard vento The =uel ?~essure is thus linited to
~~at value which can 11ft the ball against the force of the
compressor pressure. The effective area of the diaphragm is
10 times the effective area of the ball valve; thus, a

compressor pressure of 2 psig w111 hold the acceleration lirn-
iter on its seat urtil the fuel pressure tries to exceed 20
psig. As the unit accelerates, compressor pressure rises,

increasing the pressure setting of the acceleration limiter.
Fuel pressure increases with the speed of t..he l.mit, always

staying 10 times as great as compressor pressure. The pneu-
matic line which connects the limite= to compres~or discharge
ia referred to as the "CONTROL AIR LINE".
A graph showing fuel nozzle pressure, at eifferent turbine

speeds, i5 5ho\~'n in Figure 4-9. The dctted line snows the
maximum amount of fual pressure that the fuel pump can deliver
to the fuel nozzle. The 501id line shm.,s the act.ual nozzle
pressure as limited by the acce1eration limiter, as the tur-
bine speed increases. The values used :Ln the gra?h are for
illustration only and are not necessarily representative of
true values for the JFS.
At a speed of lO%,the curve shows that t~e fuel pressure
would t~ limited to approximately 10 PSIG. This pressure is

toa low to produce a good spray pattern from t~e fuel r.czzle.
In order to assure that there is sufficient fuel pre5sure at
4-14
( (
/
400
I /
/
/
;p
;U
UNSCHEDUI.ED PUMP // H
til
350 OUTPUT PRESSURE ;- ~!
~,
;;J
tl
X
\ ///i// • :'!::
~ J,'>
300 < ';'
!Ã K~
Õ (;
/ Z 'I
-"
o ...
/ .., í:1
/ ; ·oi
r
I--l 250 / il
~ 56
Ul / ~ ,.-~
p~ / " 7-
/ J fil
" r1
~ / ~ n
I'"
lQ
~ 200 / J<
»
~ / '(j
~ C
1-\
Cf)
/ ~ »
I
(l) cn ~
Q .,
/
~
l-'
Vl
~ / IJ
P.! ~il
1
\Q 150 / »
~.:] / ;;O
rLl / N
D / []
t.T.<
;
100 -/
/
;/
/
/ ACCELERA1'ION L::'HITER
50 // CONTROLLED FUEL FLOW
/
/
/ f--' c.n f-]
o Nç:(J)
I 'U .7l
f.---'"U I
o 10 20 30 40 50 60 70 80 90 100 I
."
• OJ
vJ
LV Lv
% RPM
~~j
1
1/ ",Q"7T,
i~~
, i AiR::~:li::,c"R;:;H MAN'J'AC"TUR1"-'G
A O'Vi!;\ION OF"
CvMPA~Y
n . u: (U.r~![TT CC~PO~A,tCN
OF A~IZONA TSG- 83
'----== I Supp. 3
:2-l-73
light-off speed, a spring i5 incorporated in the acceleration

limiter. See Figure 4-8. The spring has sufficient force
to prevent the valves "crackir!g" off it.5 5eat until the fue]_
pressure has reached a value of about 70 PSIG. For this
reason, the spring is referred to c.s the CRll.CK PRESSURE spring.
The crack pressure spring adds its force to that of the corn-
pressor pressure at alI speeds as shown graphically in

Figure 4-10. Now at 10 % RP~l, the fuel pressure would be
approximately 80 PSIG.
The setting of the crack pressure spring is criticaI, ane

should be checked on routine inspections as called for in
t:'1e ma.intenance manual. It is obviot7.3 that the crack pres-
sure should be high enough to provi de ~roper 5pray from the

nozzle at light-off, but its value must not produce a pres-
sure at ligh t-off speed which rnay dro-wn the igni tor, or
cause hot , booming or flaming starts.
From the foregoing the reader will realize that no control

air need be applied to the control air diaphragm to obtain
sufficient fuel for light-off: control air is necessary,' '~ow-
ever, to permit the unit to accelerate after light-off. Also,
any leakage of air from the control air lines wiIl reduce the
fuel pressure at alI speeds, thereby caus~ng slow acceleration
....ç:
of the unit. J.J.. the leakage is severe, the acceIeration lim-
iter may ne:: aIlow sufficient fue: pressure to bring the unit
4-16
( ( (
~
400
/
/ "
350
UNSCHEDULED PUHP
OUTPUT PRESSUHE /
" "
\////
300 ,
-
t!>
H 250
,,""
~
1-'-
U)
~
/ """
lQ
~
,f:>,
I
~
11
,1> P
200 / "
,"
f-' Ul
....J ti)
~ /
~
o
I
}-I
~
H
150 ,
/
r<l
;-..)
r....
100
ACCELERATION LHUTER
50 CONTROLLED FUEL FLO~l
WITH ADDITION OF
CRACK PRESSURE SPRING , .... Cf) f3
N Ç. Ul
I ':J CJ
I-J ~c I
o I • co
--.l 0-1
(->.J W
o 10 20 30 40 50 60 70 80 90 100
% RPM
7~1 '::'SG- 8 3
l~§"A.'~!·~In""J\ f
A~RE~.;!:A~CH V.t\Ntír-ACTUR~)\-{G CO~'f?ANY C !F" I\R~ZGNA
í \.
I~;
/>,. Ji Ao OI' ::;:CN..)v THí! (;,;AA'Rt:TT CO~P'iJR:Jt"n~N
Supp. 3
12-1-73
to fu:i..l speec..
Speed Governing
Speed control of the unit is acconplished by the corbined

action of the governor and the differential pressure valve.
The governor regulates fu."ü fIm.., to 'che co::nbustion charnber

so that the power developed by the turbine equals the re-
quirement at the desired speed. The essential parts of the
speed governor are shown schematically in Figure 4-11. The
governor shaft. mounts t·wo L-shaped flyweights which are
pivoted at the corner of the "L". The governor shaft is
turned by the aecessory gears through the fuelpump shaft.

As the fly~eights are rotated, centrifugaI force acts to
move them radially outward. Movement of the flyweights is
opposed by a speeder spring. The tangs of the fI 1 Neights
position a fuel valve to control the flow of fue1 to the
fue1 nozzle. At speeds b310w 95%, speeder spring force

acting against ~~e flyweights hold the va1ve in the open
position. The governor is 50 designed that the flyweight
force equals spring force at, and above 95% speed. Thus,
the va:ve begins to elose at 95% speed and closes further'in
proportion to speed above 95%.
"
With speeds belo"", 95%, the governor valve is open and there
is little or no pressure drop across the governor. As the
speed incréases above 95% and the governor valve moves to-
4-18
( ( (
CRACK PRESSURE
ADJUST~
AOJUSTMENT SPRING ~~kCOMPRESSOR

G
___,--e__--
:_
~'-1
~.•~
PRESSURE
-_
VARI~nLE PRESSURE
......
RELIEF VALVE
- - - SPEED ADJUSTMENT
LYWEIGH'r
PUMP
COVERNOR
~ VALVE
TO DIFFEREN'l'IAL I-'('J)~
PRESSURE VALVE NCU1
I 'U GJ
~'d I
I • co
--.J W
ww
f /:;:;,.~1
I( " ,
i;,~~"~ q.
i~2f;lC·.-rl' -:t~\~Ci-3 ~\IU)\; "~~.J;rA:;Tr.';RiN3 ~~~~ANY CF J~:';l~4:.lNA TSG- 33
I\ "''''' /i A. ':lfVI5PJN !Jf" THl: GI\RR(:l'T Ca'1tPQR'ATlQN
Supp. 3
~--,:
~_2-1-7 3
fllard closed, a c.ifferential pressure across Jc.:'1e governar
occurs. The hig{}.er the speed, t."e greater the c.ifferential

pressure. (Pump discharge pressure vs fuel nozzle pressure).
The governor differential pressure is sensed by ~le differ-

ential pressure valve. This valve is shown schematically i~
Figure 4-12. It is a simp:'..e spring loa,ded slide valve and

is shown in the closed position. During acceleration of the
gas generator up to 95% s?eed, the valve remains closed.
K~ove 95% speed, ~~e çovernor valve differential pressure
increases as described in the previous ;??ragraphs. As the
pump disc~arge pressure (acting on the lef~ end of the hp
valve) reaches a value of approximately 40 PSIG hisr..er than
nozzle pressure (acting on right end of /lP valve), tne AP
valve will stroke to t.~e right anc open a by-pass porto
Tais will result in excess pump pressure being by-passed
back to the pump inlet. At 100% speed, the ~P valve position
is controlled by the governor to maintain the exact fuel
pressure at the fuel nozzle to operate at 100%.
Figure 4-13 graphically depicts:~he action of t.'1e governo r

and ~p valve.
Figure 4-14 i5 an exploded view of the fuel contraI unit

showing the ft,el control compcnents discussed.
/
I
4-20
( (
(
ADJUSTMENT PRESSURE
c-~""
TO PUMP INLET - - ~u - VhRIAnL8 PRESSURE
~lf""~-
RE LI
.-.ill----:: EF VJ\ LVE
FUEL INLE1' 1f""~lJl'Sl!I~~i;~~",~--- SPEED, ADJUSTr1ENT
~.-
~
~ "'LYHEIGHT
8:::::::::e
...,.
"'j
I..Q
s:
.J:>. li
(1)
PUMP
J
!'-) ,p,.
I" ....
I
I-'
N
FUEL NOZZr,E 1-" Cf) >-::

rvClfl
I 'O C)
~-..i, I-" 'O I
I • co
....... J {~
AP ADJUSTMENT WW
"'TO PUMP ~""-TiB'!I!IIIlIIIBII'!!JBmJ~~~~ DIFFERENTlri.u

PRESSURE \,-_:'>,L'ílE
M...:~~~~e~E~~~~~2~
400 /
/
""
GOVERL'lOR BEGINS
'roSCHEDULE F'ÜEL ~
lrn
UNSCHEDULED PUMP
/
,,/
"
\/////
350 ~0TPUT PRESSURE /
300
REQUI RED TO RUN
- "" FUEL FI,OW @

t!J
250 "
;' 100% SPEED
hj
H
ti)
"
t-'"
tO
s:.::
t1
p..
/
/ "
~ IV f;1.... 200
/
J
N
N
~
I
::::>
ti)
ti)
""
}-I
w ~
p..
""
~
150
""
Çil
::::>
fZ.t /
/ "
100
""
""
50
"
f-J Cf) :.;]
N ~:~. Cf)
! 'd GJ
~-'"d I
o I • co
~ w
C0 Lv
o 10 20 30 50 60 70 80 90 100
% RPM
'e?'
l' ~
.,
I. ~"'fIIT'·1
-,
i
A'~'S.A,·._,
~'. ~"í ~'AW." 'v,
"""'0'0"", ~"''''ETT_'0,'0""
-AC~U"',,~
" .
o
''''r:l Cí:l~."PA'_,
_
. ~'Y
_'o"
,
.... ,~
CF" AR.i---"'1A
===u_ .. =
__
TSG- 83
3_
Supp. __
12-1-73
I ~.
~"
1
, El.....
·'G·'" 1JIRESSURS/F~~
~ ....... . u ,
T"'I'k"R
I (l)~6t~ >.~~
I 1/::, ~~ I "" ACCEL
I /I§')~/ ~ ~~~
<' "''/'' f"-..~ '\
~, ~? ',-
/ "'.,' G":.
@~ .' SPRING~A,' "'''> Pru:SS-rU~~Z)?~Yff~

C·
-,.~. 1 _RACK
''', /'
SP RIC< G
"-,.~
""'~,~ '(!f:J'( .....-0 I
I
~)
I ,,;> " ./' •
~J) ~~~o ~~
ACCE"h .... ,,,
I 'a-"'--...
",-I /
' .I
( '-/
v..... '
(' ("
LIMITER, "-..
~
pcd
INLET
~ '. "> -:; (~/õJ. ~, ~fI) ~-", cÇ~. o. O~1.~~.,

1D1l~ J
" '-.! (O a '(j}.
I "" t* , •
Ii \-~I
I
I a c\;" oU' fJ.,,).
w~r ;f~rI/fi'-:.
f%j},;, ',~
, '" ",
- l 1--:0--- ''(l '.
~
'OL AI?:.
('~~, < CONTR
-~~'~, ~'.-,J
PUMP INLET DIAPHRAGM
~
;OO o /~~""f
/ ,. ~ ~
OOVERNOR SHAFT pj:.)
-'o I
-L
GOV
FLYWEIGHT
, ,~.í~
"'''ER......
.. ""11~ "
~~'
~ . '", /
/ /' ;
.~ SP ..Ew I ú ,', , '"
O I ~.A.
' SPRING " " L" -I'}f I . ...
' "
GOV
...
"v. _
r""
AP VAL\"E O " , ADJ \ {
~\
~C "~'~~
'-, J..-. "4Q ""
I. - .
IJ.P ADJ
Figure 4-14
4-23
r--~
I~I A;;:;;ESEAR~H MANUF~":::T1..ln!N3 CCMPANY DF /'.<;!i;;:ONA TSG- 83

!~I Ao OlVI310N Or THE OARR{TT COo;;lPCRATICN
Supp. 3
12-1-73
c. Fuel Shutoff and Puel Drain Valves
These two valves are covered in detail in Secti_on II of the

manual. The reader may refer to that section for review
of b~eir operation.
D. Fuel Atomizers and Fuel Manifold
The fuel atomizers, or nozzles as they are sometirnes called,

are necessary to break up the fuel flowing into the combustor
into ve~ small droplets (atornize the fuel), so that it will

vaporize more readily. Only in vapor forro can ~~e fue1 be
combined with air and burned.
A fuel atomizer asserr~ly is shown in Figure 4-15 and the

manifold assembly is shown in Figure 4-16.
The five fuel atomizers are threaded into the forward end of
the gas generator using a sealing type washer. The tip of
the nozzle. passes through a grornrnet in the co~bustor with
only tne very end of the nozzle extending into the cornbustion
area. Five special bolts (hollow) with their mating sealing
washers pass through the manifold and thread into the end
of the atomizer. '..
The rnechanic should be cautioned that extreme care should

be exercised in installation of the fuel atomizers. He must
insure that the nozzle tip passes through the growmet in the
cornbustor rather than bottorning out against it. Improper
4-24
( ( (
l~e1
___J
»l>
;0
1';1
00
M
li>
li
n
X
~ J:
~ »
< -,;::
~C
z "1
n 1;"")
-. >" - -'.
~ '" ~ d
1 --I
~-, '" t:
[J
;u
,'~
~
"n"
-I
-
_...
'7
Q
n
hj ~ iJ
1-'" ~ :1:
LQ " 1]
C ~
a
»
-
.~ li z ~
I <D
N fJ
,~ '''I
V1
I t>
I-' ,';3
V1 N
\l
;r.
?
~ -l fJ) 1-3
1\) \:; (f)
I '0 Cl
I'-"u
I • CO
...,J t,)
C0 L0
'O,
I-tj
1-'-
LO
.r:. C
I ti
1'-) (1)
(j'\
~
I
1-'
(J\
l-' Cf.) I J
N C Cf)
I 'TI Cl
f,J',)
I • (j)
-..J v)
l.v (.,.,)
i
r~'
!~!
AIR:;:E:::A~C"'l MAN:.JFACTUR~NG CO~PA~Y CF" A~'ZONA TSG 83
A. OIVISIC:-.I o,. T .... I[ GARAE:TT CORPORA"!"I":JN
Supp. 3
12·-1-73
installation o~ the atomizer will result in disruption of the
fue1 spray pattern and extreme temperature stratification
within the cornbustor.
Figure 4-17 àepicts the complete fue1 system schematica11y.
Figures 4-18 and 4-19 illustrate a cross-sectional view and
an exploded view of the fuel injection accumulator.
--
',--,
4-27
j
j
HYDRAULIC PRESSUiU
INLEl
ORIFI<:ED
ENGINE CHEC,~
FUH VALVIE
PUMP
~~~~~ FUEL
No " SUPPLY
DRAIN
ACCHERA TlON CRACK PRESSU~E

lL'/dTER .--"\:~?--.. ADJUSTMENT FUEL
COMPR!!SSOR ~ ~~ DRAIN
DISCHARG~ IV' _ _ _ _--.I
INtEl
VENT
DRAIN
VA!.VE
l'Yj
1-'.
lQ MANUAL
C
*'I"
N
I-~
(\)
FUH
VAlVE
CO
~ ~~
I
1"..... INlET FUEL FILHR
-...J FUEL PUMP
FIl.HR r:ut:l.
NOIZU
--C~---__,- 7 V D C Jf S
}..... rf) ~'1
Nem
I '0 (,)
LEGEND t--'t'Q
I • CO
~ LOW PRESSURE -...J lA>
~""m HIGH PRESSURE WW
JET f UH STARTER fUEL SYSTEM

" I
( ( (
HYDRAULIC
BLEEDER PLUG FUEL PISTON
t'Ij
1-"
t.O HYDRAUJ,IC
~
~ li PRESSURE FUEL
I (1)
FROM
1\.) it-t--JFLm-l
..o ~ STARTP.R
I
1-'
CO
~
"~ DRAIN &
VENT
JFS100-34 FUEL ;NJECTION ACClJMULATOR

t.
I-' rj) ~-3
I\.lÇ;Ul
I 'd GJ
f-' 'd I
I • co
'.1 GJ
CJ C,)
r~1 AIRESEAo;;r;:;H MANUFACTl':;;:;NG COMPA,,'':' 0;:- AR:Z:.lNA
TSG- 83
I~MO<~~!
f _ _/ ;
1\ O,YI:!IDN 0'- TH( GA~RC::TT COqPOl?ATlCN
SUp? 3
J_2-1-73
I~
HOUSING (FUEL CYLINDER)
~
RETU&~ SPRING
BLEED HOLE~.. ,::- ULIC FLiJID--j

HiDRA PLUG
BLEED
1\
Ir~
( ,,-'~)
!'~~ FI?ING
CAP ~. '~
HYDRAULIC CYLINDER ~ ~~..(j ,;"
'~~~
"',
z
D
RA.~N
..,.. ~ / z
4~NG
PTT'T'T
A
JFS100-34 FUtL INJECTIO~~ ACCUMULATOI

Figure 4-19
4-30
r~-~l
1 ~ !
;"'-"'''''lJ,,"_ i A~~t::5~/:.~CH W:r~\~}UFACTUPING CCMPJ~~;1' Ct" AF!~ZOf";A TSG 83
I~/I
~ ___ --.l
A ;::'IY!S'O,,", Cf" r ..... E Q,I"RR:t:TT CCp.par.:A~·!aN
Supp. 3
12-1-73
SECTION V
HYDRAULIC START SYS'l'SM
OVERRUNNING CLUTCH
5-1. GENERAL
This secticn of the manual provides supplemental information
pertaining to the Aircraft/JFS hydraulic start system.
Additianally, the JFS overrunning clutch is examined in
more detai 1.
5- 2 • OPERAT ION
OVERRUNNING CL~?CH
'--
Fig~re 5-1 i11ustates the major components of the overrunniny
clutch. This type clutch is commonly referred to as a pawl
and ratchet clutch. As shown in t:,e illustratioD, the pawl
sprinss hold the pawls against the ja-,.; gear when t'he clutch
is at resto When the JFS power turbine rotates the jaw gear
the torque produced by the power turbine is transmitted
through the pawls into the hub. This results in rotation of
the jet engine. With acceleration of the jet engine to JFS
cutout speed, this torque is presente At JFS cutout speed,
the torque input is removed as a result of JFS shutdown.
The hub continues to rotate with the jet engine, which
continues to accelerate up'lrJa.rà in speed. Centrifuga.l force
acting on the pawls overCOIT,es the pawl sp:~ing force anel

'--
5-1
I"!j
1-'-
lO
~
I'i
(D
U1
I U1
N I
1-'
HUB (OUTPUT SHAFT ATTACHED)
ROrATES WITH JET ENGiNE
BY PO~lER TURBINE
OUT
PA V'/l 5PRING
f-' m 8
t0 ç; (/)
I 'O GJ
t-.... ·O
I • CO
--.J Lv
JFS100-34 ClUTC;~ OPi:RATIOf'J WW
r-=--,
.~,
i~~.,
·";,;,~~~ii A~~,a::S:E:!\;:;:CH ~<:\N'....'FACT'JRiNG ÇQ~1P,t:... ~Y DF" A:'iCiZer"A TSG 83
I
l
..,.,.
,
A D!\I!3'ON 0::- Tkl!: GAr.Uu::rr CORP::PA,IDN
Supp. 3
12-1-73
the pavlls pivot outward, away from the ja\\l gear. The JFS
and the jet engine are now mechanical1y disconnected for the
balance of the jet engine run period. With shutdown of thc
jet engine, centrifugai force acting on the pawls decreases
and the springs move the pawls back against the jaw gear
which at this time is not rotating. Due to the shape of the
pawls and the shape of the teeth o:': the jaw gear, the clutch
simply -~tchets until the engine stops rotating.
The clutch used on the JFS hydraulic start motor is of
similiar designo The jaw gear is pinned to the output
shaft of the hydraulic start motor and the hub and pawl
assembly are part of the accessory assembly. See Figure
3-2, SECTION 111.
HYDRAULIC START SYSTEM
The complete JFS/Aircraft hydraulic start system is shown
schematically in Figure 5-2. The step by step sequence of
events that occur during JFS start initiation have been
previously discussed. However, several of the components
should be examined in more detail to provide the reader a
basic understanding of system operation.
HYDRAULIC ACCUMULATOR Figure 5-3
The hydraulic accuIDulator is basically a cylinder containing

'-e
5-3
TO JET FUra
STARTER SYSTEM
HAND
PUMP
RElIEF
VAlVE
STARTER
CHECK CONTROl
VALVE
(,J1
1
,j:::.
hj
1-'.
lO
s::::
ti
ro
F~OM
..
UTlllTY
H YDRAUllC SYSTEM
..:,'
MANUAL
DISCHARGE
VALVE
SHUT OH
MANOAl
VAL VE CHECK
VAlVE
~ UTllITY
PRESSUltE ACCUMUlATOR
N
GAOE PRESSURE
CHECK GAGE
VAlVE
PRE-CHARGE
PRE5SUIH
GAGE
()UICK
DIS(ONNECT
UTILlTY r-' rn ~1
FllTER NCcn
-al!l1iDmillilm_ _ _ H Y D RA U LI C balllilil""I!lI\1I':---lBtREBliiRI_ _C::Jmmril I 'O Q
... SYSTEM ,.. ~-' '0
RESERVOIR CHECK I • OJ
lEGEND t.
.," VAlVE -...j w
~ RETURN PRESSuíü
ww
E':2';'ô·,,·;·J S Y STEM P RESS U RE
~ NITROGEN
JET FUEl STARTER HYDRAUlIC SYSTEM
I~i A~RESEA~CH ~\IlANl.:t/~C-'-URi't~G ~OM?A.~,~Y DF' A.F~~ZO~;A
I~~:
i~!I
L_
h t..'IV!:;::ON OI' TYC QA;U:a:n CCRPORATI'::'I TSG 83
Supp. 3
12-1-73
a piston. Referring to Figure 5-2, it may be ~oted one end
of the cylinder is pressurized \vith dry nitrogen; a compress-
able fluido The other end of the cylinder is pressurized
with hydraulic oil; an uncompressable fluido Opening of the
manual starter contraI valve allows flow of the pressurized
~ydraulic oil through the hydraulic motor causing it to
rotate the JFS. As the hydraulic oil pressure begins to
decay, the pre-charge pressure, now higher than hydraulic
pressure, forces the accumulator piston to move and displace
the hydraulic oil in the accurnulator cylinder. This results
in a relatively high pressure oil f]_01tJ through -:::he hydraulic
motor enabling it to produce the required torque to start

'-.-
t:1e JFS.
From the foregoing discussion, it should be obvious that
adequate pre-charge pressure is essential to ensure proper
starts of the JFS. Toa little precharge will cause hot
starts of the JFS due -:::0 poor assist from the hydraulic
start motor.
'.
During normal operation of the Aircraft, the hydraulic
side of the accumulator (and related plumbing) is recharged
by the Aircraft utility hydraulic system. HO'v"Jever, the
manual starter control valve m'..J.st ~e closed to permit
recharge. A hand pump is also provided to'recharge the system.

"---
5-5
HYDRAULlC POíH
lJ1 BRACKET ASSEM3l Y

I
w
CUSHION
VI
I NITROGEN PORT
(j)
-ACCUMUlATOR BARIHl
NilROGEN lINI.: ~
PR~SSURE VESSEl f-' Cf) 1 ,3

Necn
I 'u C'l
1-' 'O
I • OJ
.....1 lu
WW
JH FUH STARTER HYDRAUUC ACCUMUlATOR

~:--1
i~~1
~~~AJrT,~1 AfREE~AfG;Cr~'1 \{A,~"'·L·'FACTU;;X~f\.~G CC;\O~J:;.Ó,.ht'-" C"F .a,;;;:~?:Cj·J.:!!,
i~~;I 1\ :'~'V!"!1:::N D'F T:~l:: GARl=!'f:Ti CORPOPATiO'" TSG 83
L
SUDD. 3
12:'i-73
'~
HYDRL"\UI,IC STA.:'O:'C J'v1a~
The hydraulic start motor i3 basically an axial, multiple
piston pUlllp. As a pump I by exert ing atorque on the shaft
the pistons are forced to move in the~r cylinders; displacing
and pre3s~rizing hydraulic oil. As a motor, the process is
re"versed. Pressurized oil is introduced to the cylinders
causing the pistons to move. As the pistons move in their
cylinders, they force tLe shaft to rCltat,(; 21jd produc(~ an
output torque.
Figure 5-4 is a cross-secticnal cutaway view of the
hydraulic start motor. It is a nine cylinder unit having

'-~ · - t
a d l.sp~acemen
1 f=
0~ .• ~ ~
1 4 :> i n.••
~, ')/".a,c ','-;
__ ·_vO_,-h.. ~on. The rotating cylinder
block is splined to the output sl:a::t. '1'he stationary vaI ve
plate containing the inlet and outlet ports is spring loaded
against the face of the cylinder block.
\,'
'--
y ... 7
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1I
':\'
'.," l
~
-:-~.... :. ":, . < •• ;.1.;
',' ..
,
lEBl
'''>-'!.
A~R!CSEARCH MA~·...lF"ÃCTLH~ING COIMPANY CF" ARI;-ONA ,.:,

OA~AI!:TT
" D1V I 2'!ON O"F"" 1'H[
..
COFlPDRATICN
. ,TS;G 83'
~ .,,,~·~.I:~~ "
~
'S,'?_ ,3
1.2,,,,1-73'
'",
VALVE PLl\TE
'~ ~.~
HYDRAULIC START MOTOR
Figure 5-4
5-8

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THIS PUBLlCATION IS NO

TECHNICAL MAN ~ALL----------_

JET FUEL GAS TURBINE ENGINE STARTER

plSTRIBUTION SWEMENT C. Dlstrlbutlon authorlzed to U.S. Govemment agencies and

PUBlIStEO BY DlRECTION CF Tf-E COMMANDER. NAVAl AIA SYSTEMS COMMAN>

BBB3LPSBB2?2B 1 JUNE 1975

Dates Df issue for original and changed pages are:

Page 11 Change Page # Change

-Zelo ia thiI column indicates an oriainal pap.

UST OF EFFECTlVE PAGES (Cont)

Page , Change Page , Change

LIST OF ILLUSTRATIONS ••••••••••••-••••••••••••••••••••••••••••••••••••••••••• i

I INTRODUCTION •••••••••••••••••••••••••••••••••••••••••••••••••••••••• 1-1

II CHARACTERISTICS ••••••••••••••••••••••••••••••••••••••••••••••••••••• 2-1

2-1. Description ••••••••••••••••••••••••••••••••• ~ ••••••• :••••••• 2-1

III AEROSPACE GROUND EQUIPMENT MAINTENANCE (Not app1icable) ••••••••••••• 3-1

IV DEPOT MAINTENANCE ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-1

4-1. Checkout ••••••••••••••••••••••••••••••••••••••••••••••••••• 4-1

V DIFFERENCE DATA SHEETS ..••.......................•.........••.• ~ .... 5-1

Number Title Page

1-1. Jet Fuel Gas Turbine Engine Starter ••••••••••••••••••••••••••••••••• 1-2

LIST OF ILLUSTRATIONS (CONT)

Number Tit1e Page

4-1. Disassemb1y of P1umbing and E1ectrica1 Lines and Leads

LIST OF ILLUSTRATIONS (CONT)

Number Title Page

4-30. Inspection of Gear Carrier Assembly ••••••••••••••••••••••••••••••••• 4-114

LIST OF ILLUSTRATIONS (CONT)

Number Title Page

4-77 • Repair of First Stage Stator Assemb1y ••••••••••••••••••••••••••••••• 4-196

LIST OF ILLUSTRATIONS (CONT)

Number Title Page

5-8. Inspeetion of Gear Carrier Assembly ••••••••••••••••••••••••••••••••• 5-33

Number Tit1e Page

2-1. Table of Leading Particulars •••••••••••••••••••••••••••••••••••••••• 2-11

LIST OF TECHNICAL PUBUCATION DEFICIENCY REPORTS (TPDR) INCORPORATED

1-3. This manual is arranged in sections. Sections I through IV contain depot

1-5. PURPOSE OF EQUIPMENT.

Figure 1-1. Jet Fuel Gas Turbine Engine Starter

Refer to NAVAIR 03-l05-AB-5l, Intermediate Maintenance

TEST POINT OVERSPEED ANO I

GAS GENERATOR ANO ACCESSORY

ElECTRICAl NORMAllY OPEN IMMERSION

Figure 2-3. Component Location and Identification (Sheet 1 of 2)

and dc outputs by providing feedback, in relation to ac and dc output leveIs, to the

FUEL MANIFOLO ASSEMBLY

CAPACITOR OISCHARGE HIGH

FLfL NOZZLE ASSEMBLY '~~a~I~;~~~~V07GN"ION UNIT

QUlCK-RELEASE P I N ' ACCUMULATOR ASSEMBLY

"\. ELECTRICAL RECEPTACLE

POWER TURBINE ASSEMBLY GAS GENERATOR ANO ACCESSORY ORIVE ASSEMBLY

Figure 2-3. Component Location and Identification (Sheet 2 of 2)

._____ACCElERATlON liMITE RVALVE

A A A AA METERED FUEL FROM FUEL CONTROL

Figure 2-4. Combined Starter Systems (Fuel, Electrical,

2~28. STARTER OPERATION.

OIL JETS OIL JETS

Figure 2-5. Lubrication System

generator assembly, and the accumulator assembly forces a premeasured quantity of

2-31. OVERTEHPERATURE PROTECTION.

R-091904ZJOUT DE ESQAVI VG CONSIDERANDO AS CARACTERISTICAS DE OPERAÇÃO DO

ALFA - ADOÇÃO ÚNICA DO "START CYCLES" COMO FATOR PARA CONTAGEM DA

BRAVO - A MANUTENÇÃO "ON CONDITION" DA UNIDADE "CONTROL BOX" PTVG