Overhauls

 

Update 4/17/2025 - Liberty Turbines, with the help of some extremely talented colleagues, has disassembled a crashed TJ-100 engine, performed all inspections necessary and placed it back into service as a test engine. This engine is perfect as a 'worst-case' endeavor. It was crashed at high speed into a shallow lake. Unfortunately, the pilot was killed. The aircraft was completely destroyed and the engine was ripped from its mounts. While still spinning, the engine plowed into the lake bottom and ingested lots of mud and debris. The engine was recovered from the lake and placed (still full of mud) in a hangar in Florida for almost four years.

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In January, 2025, we received the engine, compliments of its owner, with the intent of disassembling it, determining how bad it was damaged and to see if any parts could be salvaged. A thorough inspection revealed no significant damage to the internal engine components. This engine is built tough! Despite engine's age (10 years) and a series of events that would have destroyed most mechanical devices, after we cleaned and inspected all engine components, dressed out some very minor damage to the tips of the compressor blades, knocked out a significant dent on its outer case, replaced the fuel pump bearings, oil separator bearings and all o-rings, the engine ran perfectly on our test stand.

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We are now confident that we have the skills to overhaul these engines. We have designs for new turbine blisks and compressors to replace the original parts with upgraded parts. After a lengthy search we have found domestic vendors to manufacture them. These will be manufactured using the latest processes and materials to ensure long life and fatigue resistance. We will conduct modal analysis to reduce resonance problems. Once we have thoroughly tested these, we will begin offering overhauls in the USA.

 

TJDU Panel Display - The TJDU provides a display of all important engine functions. They are reliable and fit in a standard 2.25" instrument hole. Information is color-coded with bar graphs, indicators and digital display of EGT and RPM. Bus voltage is also displayed. Panel has dimmer. Easily accessible SD card logs engine data in CSV (Excel) format. Additional screens show total times and last flight times. The TJDU firmware may be configured for single or dual engine operation. The TJDU display has been in operation for many years. The TJDU is currently manufactured in Europe, but units are kept in stock in the USA.

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EGT probe - New EGT probe replaces the original PBS unit at a fraction of the cost. Connectorized EGT probe allows easy replacement. EGT probe comes with connector pins installed. Modification of the EGT wires is required. Kit comes with connector pins & and loaner pin crimp tool. Once pins are installed, original EGT probe may still be used. This unit is being tested now. This EGT probe is manufactured in the USA.

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Engine Control unit (ECU) - The heart and brain of the engine, the ECU controls the function of all active engine components to ensure smooth, safe engine operation. The Liberty Turbines ECU will feature upgraded safety and reliability features, including dual EGT monitoring, customer-adjustable settings, and on-screen error, caution and warning notices, which allow the pilot to make important operation choices in the even of off-nominal conditions. It will also feature easily accessible on-board data logging. We are discussing the design with several companies capable of producing new ECUs. We are in the process of writing the design and control documents for their production. We expect the first new ECUs by late summer 2025.

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Compressor wheels - We have designed a new compressor wheel to replace the original wheel. The manufacturer is currently programming the CNC machine that will produce these compressor wheels. We expect new wheels for testing by mid-summer 2025.

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Turbine blisk - We have designed a new turbine blisk to replace the one affected by the 2024 Service Bulletin. We believe we have solved the turbine blade resonance issue of the PBS unit. These parts will be manufactured using the latest processes, materials and technology to ensure fatigue resistance and long service life. We expect to be testing the first batch of these components by late summer 2025.

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Overhauls and inspections - Our certified engine specialists will overhaul your TJ-100 engine. The turbine blisk will be replaced and rotating components balanced. All internal components will be inspected and repaired or replaced. All seals will be replaced with upgraded materials. Once overhauled by Liberty Turbines, the engine will be placed on a new, reasonable  inspection/maintenance/overhaul schedule with age-related maintenance removed.