Bypass Direction Control Valve Stuck

TASK 73-11-00-810-849-A
Bypass Direction Control Valve Stuck

1. Possible Causes

INTEGRATED FUEL PUMP AND CONTROL [4360KS]
W04 HARNESS [4088KS]
WC08 HARNESS-CORE [4094KS]
W03 HARNESS [4087KS]
[4000KS]

2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	MULTIMETER - STANDARD
No specific	1	PLIERS - JAWED, SOFT

B. Referenced Information

REFERENCE	DESIGNATION
TSM TASK 71-00-00-810-834-A	General Troubleshooting Guidelines for Additional Troubleshooting Information
TSM TASK 71-00-00-810-835-A	Component and Harness Intermittent Troubleshooting Procedure for Guidance Troubleshooting Intermittent Faults
AMM 70-70-00-910-803	SPOP 6 - Cleaning of the Contact Points and Wiring Harnesses
AMM 73-11-01-000-801	Removal of the Integrated Fuel Pump and Control (IFPC)
AMM 73-11-01-400-801	Installation of the Integrated Fuel Pump and Control (IFPC)
AMM 73-21-00-710-807	Test No.6 - EEC Operation Test (Idle Test)
AMM 73-21-01-000-801	Removal of the Electronic Engine Control (EEC)
AMM 73-21-01-400-801	Installation of the Electronic Engine Control (EEC)
AMM 73-21-63-000-802	Removal of the Electronic Engine Control (EEC) Wiring Harness (W03)
AMM 73-21-63-400-802	Installation of the Electronic Engine Control (EEC) Wiring Harness (W03)
AMM 73-21-64-000-802	Removal of the Electronic Engine Control (EEC) Wiring Harness (W04)
AMM 73-21-64-400-802	Installation of the Electronic Engine Control (EEC) Wiring Harness (W04)
AMM 73-21-68-000-802	Removal of the EEC Wiring Harness (WC08)
AMM 73-21-68-400-802	Installation of the EEC Wiring Harness (WC08)
AMM 78-36-00-010-802	Opening of the Thrust Reverser Cowl-Doors
AMM 78-36-00-410-802	Closing of the Thrust Reverser Cowl-Doors
EEC Wiring Harnesses
W04/WC08 Wiring Harness Interconnect
Integrated Fuel Pump and Control Wiring Harnesses
Integrated Fuel Pump and Control Channel A Wiring Schematic
Integrated Fuel Pump and Control Channel B Wiring Schematic

3. Fault Confirmation
Subtask 73-11-00-710-109-A ** ON A/C NOT FOR ALL

A. Do an engine run to idle to confirm this fault AMM 73-21-00-710-807.

NOTE: The Electronic Engine Control (EEC) has detected that the bypass Directional Control Valve (DCV) for the Integrated Fuel Pump and Control (IFPC) is not able to move to its commanded position within an acceptable period of time in channel A and channel B. The bypass DCV is integral to the integrated fuel pump and control. The integrated fuel pump and control is attached to the fuel manifold located on the top of the main gearbox at the 4 o'clock position.

Refer to the general troubleshooting guidelines for additional troubleshooting information (Ref. TSM TASK 71-00-00-810-834).
Refer to the component and harness intermittent troubleshooting procedure for guidance troubleshooting intermittent faults (Ref. TSM TASK 71-00-00-810-835).

(1) If the maintenance message does not come back, examine the harnesses and electrical connectors as described in the component and harness intermittent fault isolation procedure (Ref. TSM TASK 71-00-00-810-835).
(a) If no problems are found, return the engine to service. Monitor the engine for reoccurring maintenance message.
(2) If the maintenance message comes back (hard fault), go to the Para. Fault Isolation.

4. Fault Isolation

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 WARNING, INJURY CAN OCCUR.

WARNING: REFER TO THE MSDS FOR ALL MATERIAL USED AND THE MANUFACTURER'S SAFETY INSTRUCTIONS FOR ALL EQUIPMENT USED. IF YOU DO NOT OBEY THIS WARNING, INJURY CAN OCCUR.

CAUTION: MAKE SURE YOU REMOVE ELECTRICAL POWER FROM THE EEC BEFORE YOU REMOVE THE ELECTRICAL CONNECTORS. IF YOU DO NOT OBEY THIS INSTRUCTION, DAMAGE TO THE EEC CAN OCCUR.

Subtask 73-11-00-810-109-A ** ON A/C NOT FOR ALL

A. If there is confirmation of the fault:
(1) Open the thrust reverser cowl-doors AMM 78-36-00-010-802.
(2) Replace INTEGRATED FUEL PUMP AND CONTROL [4360KS] AMM 73-11-01-000-801 and AMM 73-11-01-400-801.
(a) Do the test given in Para. 3.
(3) If the fault continues:
(a) Examine the W04 (4088KS), WC08 (4094KS) and W03 (4087KS) harnesses, connectors P13 (4000KS-P13) and P14 (4000KS-P14) - EEC (4000KS), interconnect J109 (4112VC)/P109 (4112VC-A) and connectors P15 (4360KS-P15) and P16 (4360KS-P16) - IFPC (4360KS), for problems which are possible between the EEC (4000KS) and the IFPC (4360KS).
1 Inspect for harness damage.
2 Inspect for loose or damaged connectors.

NOTE: Loosen connectors must be disconnected and examined for further wear or damage.

3 If a problem is found with the harnesses or connectors:
a Replace W04 HARNESS [4088KS] AMM 73-21-64-000-802 and AMM 73-21-64-400-802, or
b Replace WC08 HARNESS-CORE [4094KS] AMM 73-21-68-000-802 and AMM 73-21-68-400-802, or
c Replace W03 HARNESS [4087KS] AMM 73-21-63-000-802 and AMM 73-21-63-400-802.
d Do the test given in Para. 3.
(4) If no problems are found with the harnesses or the fault continues, use a PLIERS - JAWED, SOFT to disconnect the electrical connectors P13 (4000KS-P13) and P14 (4000KS-P14) from the EEC (4000KS), interconnect J109 (4112VC)/P109 (4112VC-A) and connectors P15 (4360KS-P15) and P16 (4360KS-P16) from the IFPC (4360KS).
(a) Examine the pins and sockets (contacts) for alignment and damage. Look for contacts pushed into the connector face. Replace parts as necessary.
(b) Clean the contacts with contact cleaner and clean cloth per SPOP 6 AMM 70-70-00-910-803. Blow dry with air (at less than 30 psi) across connector face.
(c) Reconnect the electrical connectors P13 (4000KS-P13) and P14 (4000KS-P14) to the EEC (4000KS), interconnect J109 (4112VC)/P109 (4112VC-A) and connectors P15 (4360KS-P15) and P16 (4360KS-P16) to the IFPC (4360KS).
(d) Do the test given in Para. 3.
(5) If the fault continues:
(a) Disconnect the electrical connectors P13 (4000KS-P13) and P14 (4000KS-P14) from the EEC (4000KS), interconnect J109 (4112VC)/P109 (4112VC-A) and connectors P15 (4360KS-P15) and P16 (4360KS-P16) from the IFPC (4360KS). Use a MULTIMETER - STANDARD to test the IFPC (4360KS) bypass DCV solenoid circuits in the harnesses. Refer to Table 1 and Table 2. Look for:
1 Wire-to-wire shorts
2 Shorts to ground
3 Continuity (less than 5 ohms resistance).

NOTE: A short to ground is found when the resistance is less than 100 000 (100K) ohms.

Table 1: IFPC Bypass DCV Solenoid Channel A Connector Contacts

W04 (4088KS) Harness P13 (4000KS-P13) EEC (4000KS) Connector Contacts	W04 (4088KS) Harness J109 (4112VC) Connector Contacts	WC08 (4094KS) Harness P109 (4112VC-A) Connector Contacts	WC08 (4094KS) Harness P15 (4360KS-P15) IFPC (4360KS) Connector Contacts
GG	24	24	3
v	25	25	12

Table 2: IFPC Bypass DCV Solenoid Channel B Connector Contacts

W03 (4087KS) Harness P14 (4000KS-P14) EEC (4000KS) Connector Contacts	W03 (4087KS) Harness P16 (4360KS-P16) IFPC (4360KS) Connector Contacts
GG	6
v	12

(6) If a problem is found with the harnesses or connectors:
(a) Replace W04 HARNESS [4088KS] AMM 73-21-64-000-802 and AMM 73-21-64-400-802, or
(b) Replace WC08 HARNESS-CORE [4094KS] AMM 73-21-68-000-802 and AMM 73-21-68-400-802, or
(c) Replace W03 HARNESS [4087KS] AMM 73-21-63-000-802 and AMM 73-21-63-400-802.
(d) Do the test given in Para. 3.
(7) If no problems are found with the harnesses or the fault continues:
(a) Replace [4000KS] AMM 73-21-01-000-801 and AMM 73-21-01-400-801.
(b) Do the test given in Para. 3.

5. Close-up
Subtask 73-11-00-860-097-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.
(a) Close the thrust reverser cowl-doors AMM 78-36-00-410-802.

[Rev.8 from Aug 2018] 2026.04.04 04:36:36 UTC