DASSAULT AVIATION

FAN JET FALCON

MAINTENANCE MANUAL

TURBOJET ENGINE - REMOVAL/INSTALLATION

1- Reasons for the job

If the turbojet engine is removed for one of the following reasons : failure, hot area inspection, expiration of scheduled operating time, no
adjustment of the parts attaching the engine to the pylon is required at installation of the engine. Contrarily, in case of replacement of the jib
fitting and of the rear attachment rod assembly or if the main attachment louver link-rod adjustment is accidentally altered, the position of
the engine in relation to the pylon will have to be checked with a special tool attached to the front attachment fitting.

In all cases, the adjustment of the throttle control at the fuel control unit will have to be checked at engine installation (pointer moving
before a graduated quadrant).

NOTE: Following the removal and installation of the turbojet engine, the aircraft balance may be affected.
If the indication "SPOOL RTR" (see engine identification plate) is present only on the engine removed or installed, a weighing of
the aircraft must be performed to check its balance.

2- Equipment and materials

Engine hoisting gear T.MY20. 71.102

Engine storage and fitting out trolley
Engine alignment fixture T. MY20. 71. 303
Glue S1125
Hot air gun (Local procurement)
Grease AIR 420SA (MIL-G-3545 B).
Mastinox 6856H for all non cadmium-plated pins and steel bush as shown in figure 403.

3- Engine removal

A. Preliminary steps
Remove the following parts:
Lower outboard cowling (511), lower inboard cowling (512), upper cowling (500) and rear cowling (See chapter 54).
Pylon access doors (280 - 281 - 282 - 283).
Plug on turbofan air intake casing (upper part).

B. Installation of engine hoisting gear

(1) Install the hoisting gear as follows:

(a) Attach the be(~m to a hoisting equipment by sliding the hook of the latter through the beam slider loop.

(b) Unscrew the knurled nut of the rear hoisting fitting and screw the hoisting fitting onto the turbofan air intake casing (upper
part).

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FAN JET FALCON
MAINTENANCE MANUAL

INSTALLATION OF HOISTING GEAR INSTALLATION OF ALIGNMENT FIXTURE

$

2
N”
Self-aligning bearing to be reamed 20 mmdia. 0
to dia. 11. 11 mm and adjusted to .Qoft steel 0 d
suit engine pin without play. round bar ’ ’

t l-=-d t
1.5mmdia. .
\ \ taper pin. 2

10 mm dia.
HB nut
J
I
1 -

Machine- - 0.006
-11.11 mm dia.
- 0.017

ENGINE REMOVAL AN3 INSTALLATION

i PO jj+Ny’on thread

Turbojet engine/Removal - Installation - Adjustment 71-00-2

15 July 1965 Figure 40 1 Page 403

“DASSAULT A VIA T/ON Proprietary Data”

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 AVIONS MARCEL DASSAULT
FAN JET FALCON
MAINTENANCE MANUAL

(c) Carefully check that the quick-release pin of the rear rod (on hoisting beam side) is fully inserted
(the ball locking devices shah protrude from the forks).
(d) Bring the beam over the engine, being careful to prevent the beam from knocking against the engine.
(e) Lower the beam so that the front cable and the rear rod can be pinned to the engine by means of the
quick-release pins (check their ball locking devices).
(f) Move the slider to evenlydistriiute the engine weight.
(g) Slightly tighten the assembly to take up any slack in the front cable

C. Disconnection of functional connections

(1) Disconnect the pylon de-icing line

(2) Disconnect the fuel supply line

(3) Disconnect the throttle control

NOTE : To disconnect the throttle control, proceed as follows :

Loosen the two nuts on the sleeve bolts.
Slide the sleeve over the torque shaft until engaging the spring.
This spring is intended to retain the sleeve.
Disconnect the pin and the torque shaft at dimple level.

(4) Disconnect the electrical connectors on nacelle pylon side :

(a) Left-hand engine
- Grounding lug 100 A N
- Starter-generator output connector 301 A 1 G
- Grounding lugs 99 A N
- Engine indicator connector 302 A 1 G
- Starter-generator excitation connector 304 A 1 G
- TS temperature indicator connector 18 El G
(b) Right-hand engine
- Grounding lug 100 A N
- Starter-generator output connector 301 A 2 D
- Grounding lugs 99 A N.

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 REAR ATTACHMENT

Rear ring
JIB FITTING AITACHMENT \ -___.- d-

Bonding strip / Flange on rod

(90 mm long)

Accesdoor n \\
7-r- +RONT AITACHMENT

ding strip
mm long)

Bonding strip
( I50 mm long)

Bonding strip
t (100 mm long)

\ Shock-absorbers
 AVIONS MARCEL DASSAULT
FAN JET FALCON
MAINTENANCE MANUAL

Engine indicator connector 302A2 D.

Starter-generator excitation connector 304A2 D.
T5 temperature indicator connector 18 EZ D.
Disconnect the bellows coupling the fire extinguishing line and the line with two n o d e s
attached to the engine.
Disconnect the air conditioning line.
Disconnect the aircraft de-icing line.
Disconnect the hydraulic pump regulation line.
Disconnect the hydraulic pump suction line.
Disconnect the hydraulic pump discharge line.
Disconnect the EPR line,
Disconnect the fuel heater line.

D - Disconnect the bonding strips.

( 1) Front suspension : on engine side.
(2) Main upper attachment : on jib-fitting side.
NOTE : The main lower attachment and the rear attachment bonding strips will
7

automatically be disconnected a t removal of the attachment bolts.

E - Disconnection of mechanical connections.

Remove the three screws, washers and nuts attaching the hydraulic line firewall on pylon
side.
Remove the pin attaching the shock-absorber to the front engine ring. Kecover the nut,
the washer, the bushing and the spacer.
Remove the pin attaching the rod to the rear engine ring. The washer remains
attached t o the rod through the bonding strip.
Remove the lower pin connecting the eccentric hub t o the lower clevis of the jib fitting.
(The washer remains attached t o the engine through the bonding strip).
Remove the pin connecting the rear cowling attachment fitting, the tie-rod and the
jib-fitting sleeve. Recover the washer and the nut.
Unsafety and unscrew the nut attaching the tie-rod to the jib-fitting. Recover the
washer and the nut.

-
F Removal of engine :

I Slowly lower the engine and free the eccentric hub from the lower clevis of the jib fitting ;
keep lowering the engine t o free the tie-rod threaded portion while guiding the rear rod t o
prevent any interference.
CAUTION : NEVER LEAVE THE ENGINE HANGING FROM THE HOISTING GEAR
UNATTENDED FOR EXTENDED PERIODS O F TIME.

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 AVIONS MARCEL DASSAULT
FAN JET FALCON
MAINTENANCE MANUAL

G - Installation of engine on storage and fitting out trolley.

pin the engine onto the trolley, taking every precaution and safety measure.

H - Final steps.
The following parts which belong to the aircr+ must be recovered on the removed engine and installed
on the replacement engine :
- the tie-rod and its pin (washer and spacer) used for attachment to the engine.The pin which connects
the tie-rod and the rear cowling attachment fitting.
NOTE : Replacement parts for ball-jointed tie-rods which were symmetrical and consequently specifically
associated with each engine jib-fitting are now identical in order to prevent confusions between parts
during maintenance operations (Mod. 1352).
- The main attachment lower link-rod and its pin for attachment to the engine.
- The pins connecting :
the shock-absmbers to the front engine ring
the rear attachment rod to the rear engine ring
the main attachment lower link-rod to the jib-fitting.
(1) Unfasten the hoisting gear and install the turbofan air intake casing cap (at the upper part).
(2) Plug the lines on pylon side and engine side.
(3) Protect the bleed valves with adhesive fabric.
(4) Install the engine air inlet and outlet caps.
(5) Reinstall the pylon access doors.

4 - Engine installation
A - Preliminary steps
(1) Remove the pylon access doors (280 - 281 - 282 - 283).

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 AVIONS MARCEL DASSAULT
FAN JET FALCON
MAINTENANCE MANUAL

(2) Closely inspect the pylon as follows before installation of engine :

- check the pylon for cleanliness and cracks. Check the pressure seal for condition and security of
attachment.
- check the jib-fitting for correct external condition and attachment to the aircraft.
- check condition of the front and rear engine attachment fittings (support bearings).
- check the fire extinguisher line for correct condition and attachment.
- check the self-sealing valves (hydraulic power supply unit suction, discharge and regulation connections)
for correct condition and attachment.
- check electrical connectors for correct condition and attachment.
- check condition of the throttle control torque shaft.
- check the lines and WIGGINS couplings in following systems :
air conditioning system
de-icing system.
- check the following system couplings for correct condition and attachment :
fuel supply system
EPR system
fuel heater system.
- through the lower surface door of pylon No. 282, remove the rear engine attachment link-rod. To this
end :
- remove the AEROQUIP attaching clamp between rod barrel.flange and PRECISAVIA sealing sleeve
on firewall ;
- remove the attaching pin between rod clevis and pylon fitting ; remove the bonding braid from the
structure ; remove all traces of mastinox from the pin, the fitting and the rod clevis.
- if required, clean the rod and lubricate its ball joints on clevises(after removing the ball joints and
observing their matching) ;
- check the PRECISAVIA sleeve for condition ; if it is cracked or strongly corroded, replace it (13 POP
rivets, 3,17 mm).
NOTE : Black exhaust gas traces appearing on the pylon box walls and the rod portion on pylon side,
upstream of the flange, are likely to denote sleeve tears or improper tightness of the flanges at the
clamp.
- coat the pin connecting the rear engine link rod to the pylon fitting with mastinox.
- fit the rear engine attachment link-rod back to the pylon fitting, after positioning its flange in the
PRECISAVIA sleeve. Install the AEROQUIP clamp and safety it. Attach the bonding braid to the
structure.
NOTE : The clevis pin tightening torque is given in figure 403.

(3) Remove the turbofan intake casing cap (at the upper part).
(4) Remove the plugs (on pylon side and engine side).

I
l B. Installation of hoisting gear :

( 1) Install the hoisting gear as previously described in para. 3-B.

C. Installation of engine :

(1) Free the engine from its storage and fitting-out trolley.
I (2) Bring the engine hanging from the hoisting gear against the fuselage at the pylon (Hoisting equipment :
crane or hoist).
(3) Slowly hoist the engine and insert the tie-rod threaded portion into the upper sleeve integral with the
jib-fitting.
NOTE : The ground zones of the tie-rod should be first coated with mastinox.

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 AVIONS MARCEL DASSAULT
FAN JET FALCON
MAINTENANCE MANUAL

(4) Guide the engine as required to insert :

the eccentric hub into the lower jib-fitting clevis,
the rear attachment rod into the rear ring clevis.

D. Connection of mechanical connections

(1) Main attachment +l

Install the washer and the nut attaching the tie-rod to the jib-fitting (torque value : 10 _ o 5 m. daN). Fit the
safety pin.
Fit the pin (coated with grease and head facing forward) joining the rear cowling attachment fitting, the
jib-fitting sleeve and the tie-rod. Fit the washer, the nut and a safety pin.
Insert the eccentric hub fitting pin (coated with mastinox and head facing forward) in the jib-fitting clevis
Fit the washer and bonding strip assembly and the castellated nut.
Fully tighten and fit a safety pin.
(2) Rear attachment
Fit the pin (coated with mastinox and head facing forward) attaching the rod to the rear engine cowling.
Fit the washer connected to the rod through the bonding strips and secure with the casteilated nut.
Fully tighten and fit a safety pin.
(3) Front suspension
The two front shock-absorbers are attached to the front engine ring by means of :
a pin (coated with mastinox) which is to be fitted with its head facing forward
a spacer between the two inner flanges of the shock-absorbers
a bushing fitted between the rear shock-absorber and the inside portion of the front ring clevis
a washer and a castellated nut.
Fully tighten and safety the nut with a pin.
(4) Attach the hydraulic line firewall to the pylon (with three screws, washers and nuts).

NOTE : Lightly lubricate the pins before installation and grease the ball-joints on the shock-absorber rods
(AIR 4205 A).

E. Remove the hoisting gear.

I
F. Connect the bonding strips.
( 1) Front suspension : on engine side.
(2) Main attachment : on jib-fitting side.

G. Connection of functional connections

(1) Connect the pylon de-icing line.
(2) Connect the fuel supply line.

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FAN JET FALCON
MAINTENANCE MANUAL
(3) Connect the throttle control as follows:

(a) In the flight compartment, place the throttle control lever in the full power position.
(b) Couple the pin to the torque shaft at dimple level.
(c) Slide the sleeve towards the fuel con h I unit drive pin.
(d) Fully tighten the two sleeve bolt nuts.

(4) Connect the electrical connectors on pylon side:

(a) Connect positive power feeder cable (1) to lug terminal strip (301i1IG) left engine / (301i12D) right engine as follows
(see figure 404):
Insert new heat-shrinkable sleeve (4) (0IPROPMO-1-18-5 or RAYCHEM 202AI63-25-0 or 202A163-3 or
HELLERMAN 103-1 G) over positive power feeder cable (1).
Install screw (2).
Torque screw (2) 2.2 m.daN (16,2 ft.lbf).
Heat-shrink sleeve (4) with a hot air gun.
Apply glue (Sl125) to both ends of heat-shrinkable sleeve (4).
(b) Left-hand engine
Grounding lug 100 i1 N.

Grounding lugs 99 i1 N.
Engine indicator connector 302 i11G.
Starter-generator excitation connector 304 i1 1G.
T5 temperature indicator connector 18 EI G.
(c) Right-hand engine
Grounding lug 100 i1 N.

Grounding lugs 99 i1 N.
Engine indicator connector 302 i12D.
Starter-generator excitation connector 304 i1 2D.
T5 temperature indicator connector 18 E2 D.

(5) Connect the bellows coupling the fire extinguishing line with the line with two nozzles attached to the engine.

(6) Connect the air conditioning line.

(7) Connect the aircraft de-icing line.

(8) Connect the hydraulic pump regulation line.

(9) Connect the hydraulic pump suction line.

(10) Connect the hydraulic pump discharge line.

(11) Connect the EPR line.

(12) Connect the fuel heater line.

H. Throttle control adjustments

Refer to chapter 76-10-0, page 501

1. Alignment of engine with pylon

NOTE 1: This operation is to be accomplished only in case of:

- Replacement of the jib fitting.
- Replacement or misadjustment of the rear attachment rod.

NOTE 2: - The value of the incidence should be 0° ± 20'

- The value of the divergence between each engine should be 2° ± 20'.

(1) Preliminary steps (before engine installation)

(a) Remove the two front shock-absorbers.

(b) Install the alignment fixture.
(c) Install the rear rod with the lockwasher tabs not bent down and the checknuts loosened.
Adjust to theoretical length (218.5 mm).

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FAN JET FALCON
MAINTENANCE MANUAL

(d) Loosen the two main attachment louver link-rod screws.

(2) Adjustment

NOTE: To adjust the engine incidence, rotate the louver link-rod hub (hexagonal drive inside the jib fitting clevis). The
divergence between the engine axis and the aircraft axis is adjusted by means of the rear rod (rod length adjustment).
Alternately adjust the length of the rod and move the louver link-rod along its axis so that the attaching pin of the
shock-absorbers can be freely inserted through the front ring clevis and the alignment fixture.

(3) Final steps

(a) Fully tighten the louver link-rod screws.

(b) Fully tighten the rear rod checknuts and bend the lockwasher tabs down.
(c) Remove the alignment fixture.
(d) Attach the front shock-absorbers to the engine and the pylon. Connect the bonding strips

J. Final steps

(1) Install and safety the turbofan air intake casing cap (at the upper part)

(2) Install the engine cowlings (see chapter 54) and the pylon access doors

(3) Aircraft balance check (if necessary)

(a) Perform an aircraft weighing and balance determination in accordance with the performance manual, section 2- Loading, if
- the turbojet engine to be installed is identified "SPOOL RTR" (indicated on its identification plate) and if the turbojet
engine removed does not have this indication,
or if
- the turbojet engine removed is identified "SPOOL R T R (indicated on its identification plate) and if the turbojet
engine to be installed does not have this indication.
(b) If the balance is out of limits:
- install the ballast weight in accordance with the Service Bulletin F20-773,
or
- remove the ballast weight installed with the Service Bulletin F20-773.
(4) Perform an engine check-out run-up.

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FAN JET FALCON
MAINTENANCE MANUAL

GLUE

ENGINE PYLON

Positive Power Feeder Cable

Figure 404

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