Installation of the Starter [PW11]

TASK 80-11-01-400-801-A
Installation of the Starter

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

ZONE: 400
FIN: 100KM ** ON A/C NOT FOR ALL

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	COVER - PROTECTION
No specific	1	MALLET - SOFT FACE
No specific	1	PLIERS - JAWED, SOFT
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 27 and 23 lbf.in (0.31 and 0.26 m.daN )
No specific	Torque wrench: range to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )
No specific	Torque wrench: range to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )
PWA106340	1	JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER
PWA211284	1	ADAPTER, INSTALLATION
PWA80611	1	JACK-HYDRAULIC

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P03-001)	lubricant, aircraft turbine engine
(Material No.P05-005)	lint-free cotton cloth
(Material No.P05-395)	beeswax
(Material No.P06-054)	Antigalling Compound

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
4	PACKING	EIPC 80-11-01-01-040
2	PACKING	EIPC 80-11-01-01-050
19	SEAL	EIPC 80-11-01-01-070
5	PACKING	EIPC 80-11-01-01-080
6	PACKING	EIPC 80-11-01-01-090
16	SEAL	EIPC 80-11-03-01-090

E. Referenced Information

REFERENCE	DESIGNATION
TASK 71-00-00-720-811-A	Test No. 3A - Idle Power Test
TASK 71-00-00-860-832-A	Procedure to Prevent Engine Motoring and to Stop the Electrical Supply to the EEC
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 73-25-34-400-802-A	Installation of the Engine Interface Unit (EIU)
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
TASK 80-11-00-600-801-A	Fill the Starter with Oil
Installation of the Starter
Removal of the PWA 211284 Adapter

3. Job Set-up
Subtask 80-11-01-941-051-A ** ON A/C NOT FOR ALL

A. Safety Precautions

WARNING: IF IT IS NECESSARY TO ENERGIZE THE AIRCRAFT FOR A MAINTENANCE WORK WHILE YOU DO THIS MAINTENANCE PROCEDURE, MAKE SURE THAT ONLY EXTERNAL POWER IS USED. THE USE OF APU OR ENGINE POWER CAN CAUSE PRESSURIZED AIR LEAKAGE IN THE PNEUMATIC SYSTEM, AND INJURY CAN OCCUR.

(1) Make sure that you did the procedure to prevent engine motoring and to stop the electrical supply to the Electronic Engine Control (EEC)
(Ref. AMM TASK 71-00-00-860-832).
(2) On OVERHEAD CTL & IND panel 25VU:

Make sure that the ON legend of the APU MASTER SW pushbutton switch is off.
Make sure that the WARNING NOTICE(S) is in position to tell persons not to start the APU.

(3) On AIR COND panel 30VU:
(a) Make sure that the ENG 1(2) BLEED pushbutton switch is released (the OFF legend is on).
(b) Make sure that the APU BLEED pushbutton switch is released (the ON legend is off).
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the pneumatic system.
(d) Make sure that the X-BLEED selector switch is in the SHUT position.
(4) On the HP ground connector:
(a) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the pneumatic system.

Subtask 80-11-01-010-052-A ** ON A/C NOT FOR ALL

B. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR.

Subtask 80-11-01-040-051-A ** ON A/C NOT FOR ALL

C. Deactivation of the Thrust Reverser for Ground Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-805).

Subtask 80-11-01-010-053-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Make sure that the right thrust-reverser cowl-door is open (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
462AR.

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 80-11-01-420-050-A ** ON A/C NOT FOR ALL

A. Installation of the Starter
(1) Removal of the protection covers:

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(2) Fill the starter with oil (Ref. AMM TASK 80-11-00-600-801).
(3) Install the PWA211284 ADAPTER, INSTALLATION to the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER as follows:

NOTE: It is permitted to use the PWA80611 JACK-HYDRAULIC as an alternative if the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER is not available.

(a) Install the detail support base to the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER with the two detail cap screws and the detail cap screw.
(b) Attach the PWA211284 ADAPTER, INSTALLATION to the support base with the four detail cap screws.
(4) Prepare the starter (1) and the starter pad on the main gearbox as follows:
(a) Attach the starter (1) to the PWA211284 ADAPTER, INSTALLATION with the detail strap.

NOTE: If the transfer tube was not removed with the starter, only apply oil to the new packing.

(b) Apply the P03-001lubricant, aircraft turbine engine on the new EIPC 80-11-01-01-050 PACKING (2) and install it in the groove of the transfer tube (3).
(c) If necessary, apply the P03-001lubricant, aircraft turbine engine on the new EIPC 80-11-01-01-040 PACKING (4) and install it in the groove of the transfer tube (3).
(d) Install the larger end of the transfer tube (3) in the hole of the main gearbox.
(e) Install the ring (8) in the hole of the main gearbox.
(f) Apply the P03-001lubricant, aircraft turbine engine on the new EIPC 80-11-01-01-090 PACKING (6).
(g) Install the packing (6) in the packing groove on the starter output shaft.
(h) Apply the P03-001lubricant, aircraft turbine engine on the new EIPC 80-11-01-01-080 PACKING (5).
(i) Install the packing (5) in the packing groove on the starter (1).
(5) Install the starter (1) as follows:
(a) Raise the PWA211284 ADAPTER, INSTALLATION to the correct installation position with the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER.

NOTE: The hydraulic lift is used to position the starter to the correct installation angle.

(b) Move the starter (1) to the gearbox while you align the starter drive gear with the gearbox drive and install the starter (1).
(c) Apply a lint-free cotton cloth (Material No.P05-005) to the threads of the coupling (7).
(d) Put the coupling (7) on the starter pad.
(e) Apply the P03-001lubricant, aircraft turbine engine on the splines of the starter output shaft.
(f) Align the tube hole of the starter (1) with the transfer tube (3) and the output shaft splines with the splines in the starter pad and engage the starter (1) completely.
(g) Move the coupling (7) to engage the starter (1) and the starter pad.
(h) TORQUE the coupling (7) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(i) Lightly tap the coupling (7) retainer ring around its perimeter with the MALLET - SOFT FACE.
(j) TORQUE the coupling (7) again to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(k) Remove the adapter detail strap from the starter (1).
(l) Lower the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER.
(m) Remove the four detail cap screws and the PWA211284 ADAPTER, INSTALLATION.
(n) Remove the two detail cap screws and the detail cap screw.
(o) Remove the support base from the PWA106340 JACK, HYDRAULIC - VFG, EDP, FUEL PUMP, STARTER.
(6) Install the intake duct (17) as follows:
(a) If necessary, loosen the starter coupling (7) to align the intake duct (17).
(b) Attach the new EIPC 80-11-01-01-070 SEAL (19) to the starter end and the lower end of the intake duct (17) with a small amount of the beeswax (Material No.P05-395) .
(c) Attach the new EIPC 80-11-03-01-090 SEAL (16) to the starter valve end and the upper end of the intake duct (17) with a small amount of the beeswax (Material No.P05-395) .
(d) Apply the P03-001lubricant, aircraft turbine engine to the threads of the two couplings (15) and (18).
(e) Put the coupling (18) on the starter (1).
(f) Put the coupling (15) on the Starter Air Valve (SAV).
(g) Put the intake duct (17) in position between the starter (1) and the SAV.
(h) Align the notches between the intake duct (17) and the SAV.
(i) Move the coupling (18) to engage the intake duct (17) and the starter (1).
(j) Move the coupling (15) to engage the intake duct (17) and the SAV.
(k) Attach the nut (21) and the bolt (20) to connect the support rod to the intake duct (17).
(l) If necessary, TORQUE the coupling (7) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(m) TORQUE the nut (21) to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )

.
(n) TORQUE the coupling (15) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(o) Lightly tap the coupling (15) around its perimeter with the MALLET - SOFT FACE.
(p) TORQUE the coupling (15) again to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(q) TORQUE the coupling (18) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(r) Lightly tap the coupling (18) around its perimeter with the MALLET - SOFT FACE.
(s) TORQUE the coupling (18) again to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(t) Apply the Antigalling Compound (Material No.P06-054) on the threads of the bolts (31).

NOTE: For the new or refurbished bolts or nuts with baked-on lubricant, do not do the wet application.

(u) Install the bolts (31) and the clamps (32) that attach the Flow Divider Valve (FDV) cooling duct to the intake duct (17).
(v) TORQUE the bolts (31) to between 27 and 23 lbf.in (0.31 and 0.26 m.daN )

.
(7) Connect the connector (P30) of the wiring harness (WC08) to the receptacle (J30) of the starter (1) as follows:

CAUTION: MAKE SURE THAT THE ELECTRICAL CONNECTOR AND RECEPTACLE ARE CLEAN WHEN YOU CONNECT THEM. DIRTY CONNECTORS CAN CAUSE DAMAGE TO EQUIPMENT.

(a) Examine, align and engage the connector.
(b) Lightly push the connector while you tighten the coupling ring.
(c) Use the PLIERS - JAWED, SOFT to tighten the connector against the receptacle.
(d) While you tighten the connector, push it from side to side.
(e) Make sure that you can feel the ratchet feature.
(f) Tighten the connector until the PLIERS - JAWED, SOFT slip on the connector ring.
(8) Attach the harness (WC08) to the spring clip on the intake duct (17).
(9) Attach the igniter cables to the spring clips on the intake duct (17).
(10) Examine the assembly for foreign objects, damage and correct assembly.
(11) Installation of the protection covers:

CAUTION: INSTALL PROTECTION COVERS ON ALL THE OPENINGS IMMEDIATELY TO PREVENT DAMAGE TO THE ENGINE.

(a) Make sure that you install the COVER - PROTECTION as necessary to prevent damage to the engine.

5. Close-up
Subtask 80-11-01-860-050-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the right thrust-reverser cowl-door (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
462AR.

Subtask 80-11-01-440-050-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after ground maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 80-11-01-410-050-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR.
(2) Remove the WARNING NOTICE(S).
(3) Make sure that all the circuit breakers shown in the paragraph Procedure of the engine interface unit installation are closed. If they are not, close them in the recommended sequence
(Ref. AMM TASK 73-25-34-400-802).

Subtask 80-11-01-720-050-A ** ON A/C NOT FOR ALL

D. Test
(1) Do the test No. 3 - Idle power test (Ref. AMM TASK 71-00-00-720-811).

[Rev.10 from 2021] 2026.04.01 13:03:26 UTC