Installation of the Green Engine Pump

TASK 29-11-51-400-041-A
Installation of the Green Engine Pump

WARNING: OBEY THE HYDRAULIC SAFETY PROCEDURES.

WARNING: DO NOT TOUCH THE HYDRAULIC SYSTEM COMPONENTS FOR A SHORT TIME AFTER THE ENGINE IS SHUTDOWN. THE ENGINE COMPONENTS STAY HOT FOR SOME TIME AND CAN CAUSE INJURY.

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

CAUTION: DO NOT LET HYDRAULIC FLUID FALL ON THE ENGINE. UNWANTED HYDRAULIC FLUID MUST BE REMOVED IMMEDIATELY WITH A CLEAN LINT FREE CLOTH. THE FLUID CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

ZONE: 435
ZONE: 436
ZONE: 445
ZONE: 446
FIN: 1030GK ** 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	CONTAINER 5 L (1.32 USGAL)
No specific	1	PLIERS - CONNECTOR, JAW, SOFT
No specific	AR	WARNING NOTICE(S)
No specific	2	WRENCH - TORQUE
No specific	1	WRENCH GLENAIR TG70 - STRAP
No specific	Torque wrench: range to between 245 and 215 lbf.in (2.77 and 2.43 m.daN )
No specific	Torque wrench: range to between 320 and 260 lbf.in (3.62 and 2.94 m.daN )
No specific	Torque wrench: range to between 290 and 270 lbf.in (3.28 and 3.05 m.daN )
No specific	Torque wrench: range to between 900 and 800 lbf.in (10.17 and 9.04 m.daN )
No specific	Torque wrench: range to between 940 and 860 lbf.in (10.62 and 9.72 m.daN )
No specific	Torque wrench: range to between 1000 and 900 lbf.in (11.30 and 10.17 m.daN )
No specific	Torque wrench: range to between 1450 and 1350 lbf.in (16.39 and 15.26 m.daN )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.02ABA1)	Phosphate Ester Hydraulic Fluid-General Power - -
(Material No.03ABA1)	Synthetic base Lubricating Oil-Turbine Engine - -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
435	FAN AND ACCESSORY GEARBOX
436	FAN AND ACCESSORY GEARBOX
445	FAN AND ACCESSORY GEARBOX
446	FAN AND ACCESSORY GEARBOX
195BB, 197CB, 437AL

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
70	ADAPTER	AIPC 29-11-38-01-010
50	NUT	AIPC 29-11-51-02-010
45	GASKET	AIPC 29-11-51-02-020
30	PACKING	AIPC 29-11-51-02-040
55	PACKING	AIPC 29-11-51-02-060
63	BACK-UP RING	AIPC 29-11-51-02-080
60	PACKING	AIPC 29-11-51-02-090
40	PACKING	AIPC 29-11-51-20-040

E. Referenced Information

REFERENCE	DESIGNATION
TASK 24-41-00-861-002-A	Energize the Aircraft Electrical Circuits from the External Power
TASK 24-41-00-861-002-A-01	Energize the Aircraft Electrical Circuits from the APU
TASK 24-41-00-861-002-A-02	Energize the Aircraft Electrical Circuits from Engine 1(2)
TASK 24-41-00-862-002-A	De-energize the Aircraft Electrical Circuits Supplied from the External Power
TASK 24-41-00-862-002-A-01	De-energize the Aircraft Electrical Circuits Supplied from the APU
TASK 24-41-00-862-002-A-02	De-energize the Aircraft Electrical Circuits Supplied from the Engine 1(2)
TASK 29-10-00-720-001-A	Functional Check of Hydraulic Fire Shut-Off Valves
TASK 29-10-00-864-001-A	Depressurize the Green Hydraulic System
TASK 29-11-51-860-040-A	Hydraulic Maintenance Procedure after an Engine Installation (with Engine Pump Installed) or after an Engine Pump Installation
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 71-13-00-010-040-B	Opening of the Fan Cowl Doors
TASK 71-13-00-410-040-B	Closing of the Fan Cowl Doors
Green Engine Pump (Vickers)
Green Engine Pump (Abex)

3. Job Set-up
Subtask 29-11-51-860-055-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Make sure that the aircraft electrical circuits are energized (Ref. AMM TASK 24-41-00-861-002).
(2) Make sure that the Green hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-001).
(3) Make sure that the Green hydraulic reservoir is depressurized (Ref. AMM TASK 29-14-00-614-001).
(4) Make sure that the WARNING NOTICE(S) is (are) in position to tell persons not to pressurize the Green hydraulic system:

on the ground service panel 197CB.

(5) Make sure that the WARNING NOTICE(S) is (are) in position on the access door 195BB to tell persons not to pressurize the Green hydraulic reservoir.
(6) Make sure that the left fan cowl door 437AL is open (Ref. AMM TASK 71-13-00-010-040).
(7) On the ECAM control panel:

Make sure that the HYD key is pushed.

(8) On the overhead panel 20VU:

Make sure that the ENG1/FIRE pushbutton is released.

(9) On the SD:

Make sure that the fire shut-off valve (1046GK) is closed.

Subtask 29-11-51-941-054-A ** ON A/C NOT FOR ALL

B. Safety Precautions
(1) On the center pedestal, on the ENG panel 115VU:

make sure that the WARNING NOTICE(S) is (are) in position to tell persons not to start the engine.

(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) Make sure that the WARNING NOTICE(S) is (are) in position to tell persons not to pressurize the Green hydraulic system:

in the cockpit, on the HYD section of the panel 40VU.

(4) On the maintenance panel 50VU:

make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off
make sure that the WARNING NOTICE(S) is (are) in position to tell persons not to energize the FADEC 1(2).

(5) Make sure that a CONTAINER 5 L (1.32 USGAL) is below the Green engine pump to collect the remaining fluid.

Subtask 29-11-51-865-057-A ** ON A/C NOT FOR ALL

C. Make sure that this(these) circuit breaker(s) is(are) open, safetied and tagged:

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/G HYD/PUMP ENG1/CTL	1701GK	R35
121VU	HYDRAULIC/G HYD/PUMP ENG1/MONG	1702GK	R34

4. Procedure
Subtask 29-11-51-640-051-A ** ON A/C NOT FOR ALL

A. Preparation before Installation

CAUTION: DO NOT APPLY LUBRICANT ON POLYAMIDE-TYPE INTERNAL COUPLING- SHAFTS WHEN YOU INSTALL THE SHAFT ON THE PUMP. IF YOU APPLY LUBRICANT, DAMAGE CAN OCCUR.

(1) Apply Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) to the new AIPC 29-11-51-20-040 PACKING (40).

CAUTION: MAKE SURE THAT THE PACKING IS IN THE CORRECT LOCATION ON THE SPLINE SHAFT. IF THE PACKING IS NOT IN THE SQUARE SECTION GROOVE, THERE IS A RISK OF OIL LEAKAGE.

(2) Install the packing (40) in the square section groove on the input splined shaft of the pump (35).
(3) Remove the blanking covers from the threads that attach the unions (15) and (25), the union reducer (65) and from the ports of the pump (35).
(4) Apply Phosphate Ester Hydraulic Fluid-General Power - - (Material No.02ABA1) to the new AIPC 29-11-51-02-080 BACK-UP RING (63) and the new AIPC 29-11-51-02-040 PACKING (30), AIPC 29-11-51-02-060 PACKING (55) and AIPC 29-11-51-02-090 PACKING (60).

Subtask 29-11-51-640-051-B ** ON A/C NOT FOR ALL

A. Preparation before Installation
(1) Apply Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) on the new AIPC 29-11-51-20-040 PACKING (40).

CAUTION: MAKE SURE THAT THE PACKING IS IN THE CORRECT LOCATION ON THE SPLINE SHAFT. IF THE PACKING IS NOT IN THE SQUARE SECTION GROOVE, THERE IS A RISK OF OIL LEAKAGE.

CAUTION: WHEN YOU HANDLE THE COUPLING SHAFT PACKING, MAKE SURE THAT YOU DO NOT PUT IT IN CONTACT WITH THE ALKYL PHOSPHATE ESTER BASE FLUIDS USED IN THE PUMP. IF THE PACKING COMES IN CONTACT WITH THE ALKYL PHOSPHATE ESTER BASE FLUIDS, THIS WILL DECREASE ITS SERVICE LIFE TIME.

Subtask 29-11-51-420-056-A ** ON A/C NOT FOR ALL

B. Installation of the Unions

CAUTION: BE CAREFUL WHEN YOU INSTALL/CONNECT PARTS ON THE PUMP TO MAKE SURE THAT THE HYDRAULIC FLUID DOES NOT FLOW OUT. THE PUMP IS FULL OF HYDRAULIC FLUID.

(1) Put the back-up ring (63) and the packing (60) on the union/reducer (65).
(2) Install the union/reducer (65) in the pressure port of the pump (35).
(3) TORQUE the union/reducer (65) to between 1450 and 1350 lbf.in (16.39 and 15.26 m.daN )

.
(4) Install the packing (30) on the union (25).
(5) Install the union (25) in the case drain port of the pump (35).
(6) TORQUE the union/reducer (25) to between 290 and 270 lbf.in (3.28 and 3.05 m.daN )

.
(7) Install the packing (55) on the union (15).
(8) Install the union (15) in the pump (35) suction port.
(9) TORQUE the union (15) to between 940 and 860 lbf.in (10.62 and 9.72 m.daN )

.
(10) Install the new AIPC 29-11-51-02-020 GASKET (45) on the gearbox mount pad.
(11) Install the new mount AIPC 29-11-51-02-010 NUT (50) loosely on the four studs on the pump mount pad.

Subtask 29-11-51-420-055-A ** ON A/C NOT FOR ALL

C. Installation of the Green-Engine Pump Vickers
(1) Put the pump (35) in position on the gearbox mount pad through the large holes in the pump flange.
(2) Turn the pump (35) counterclockwise until it touches the studs.
(3) Install the new nuts (50) on the studs of the mount pad and turn the nuts (50) until resistance is felt.
(4) Do a running torque check of the nuts (50) with a WRENCH - TORQUE:
(a) Set the WRENCH - TORQUE to 9.5 lbf.in (0.11 m.daN) and turn each nut (50) in the tightening direction. The nut(s) (50) must not turn before the set torque value.
(b) If the nut(s) (50) turns (turn) before you get 9.5 lbf.in (0.11 m.daN) torque, replace the nut(s) (50) and do step (4) again for each replacement nut (50).
(c) If the running torque check is correct, do not remove the nut(s) (50) from the stud(s) and do the next step (5).
(5) TORQUE the nuts (50) to between 320 and 260 lbf.in (3.62 and 2.94 m.daN )

.
(6) Remove the blanking covers from the hose couplings.
(7) Connection of the case drain hose:

CAUTION: BE CAREFUL WHEN YOU INSTALL/CONNECT PARTS ON THE PUMP TO MAKE SURE THAT THE HYDRAULIC FLUID DOES NOT FLOW OUT. THE PUMP IS FULL OF HYDRAULIC FLUID.

(a) Connect the case drain hose (20) to the union (25).
(8) TORQUE the case drain-hose coupling-nut to between 245 and 215 lbf.in (2.77 and 2.43 m.daN )

.
(a) Use a second WRENCH - TORQUE to hold the union (25) when you torque the case drain-hose coupling-nut.
(9) Make sure that the seal of the adapter (70) is in correct position and condition.
(a) If the seal of the adapter (70) is damaged, replace the AIPC 29-11-38-01-010 ADAPTER (70).
(10) Connect the suction hose adapter (70) to the union (15) in the pump (35) suction port.
(11) Connect the suction hose (10) to the adapter (70).
(12) TORQUE the coupling nut of the suction hose (10) to the adapter (70) to between 900 and 800 lbf.in (10.17 and 9.04 m.daN )

.
(13) TORQUE the coupling nut of the adapter (70) to the union (15) to between 900 and 800 lbf.in (10.17 and 9.04 m.daN )

.
(a) Use the second WRENCH - TORQUE to hold the union (15) when you torque the hose adapter (70) coupling-nut.
(14) Connect the pressure hose (5) to the reducer (65).
(15) TORQUE the hose (5) coupling nut to between 1000 and 900 lbf.in (11.30 and 10.17 m.daN )

.
(a) Use the second WRENCH - TORQUE to hold the union/reducer (65) when you torque the hose coupling nut.
(16) Remove the protective cover from the electrical connector (1030GKA).
(17) Connect the electrical connector (1030GKA) to the pump (35).
(a) Make sure that all the electrical connections are clean and in the correct condition.
(b) Align the master-key (largest key) on the connector with the master-key in the receptacle.
(c) Use light hand pressure and push the connector in the receptacle. Turn the coupling nut clockwise to engage the connector threads.
(d) Tighten the connection.

CAUTION: YOU MUST NOT STOP AT THE COLORED COUPLING INDICATOR LINE ON THE RECEPTACLE WHEN YOU TIGHTEN THE CONNECTOR. IF YOU STOP AT THE COLORED LINE THE CONNECTION WILL NOT BE TIGHT. THIS CAN CAUSE MECHANICAL AND/OR ELECTRICAL FAILURE.

1 With the threads correctly engaged, continue to turn the coupling nut clockwise with your hand until the connection is tight. Make sure that you can not see the colored coupling indicator-line on the receptacle when the connection is fully tight.

Green Engine Pump (Vickers) ** ON A/C NOT FOR ALL

NOTE: If you move the connector from side to side when you turn the coupling nut it will make it easier to tighten.

(e) Use PLIERS - CONNECTOR, JAW, SOFT or WRENCH GLENAIR TG70 - STRAP.

CAUTION: YOU MUST NOT USE PLIERS WITH METAL JAWS TO TIGHTEN OR LOOSEN THE CONNECTOR. THE METAL JAWS WILL CAUSE DAMAGE TO THE CONNECTOR.

1 Turn the connector ring from one eighth to a quarter of a turn with PLIERS - CONNECTOR, JAW, SOFT or WRENCH GLENAIR TG70 - STRAP make sure that the connector is tight. Stop before the pliers or strap wrench moves but does no catch on the connector ring.

Subtask 29-11-51-420-067-A ** ON A/C NOT FOR ALL

D. Installation of the Green-Engine Pump Abex
(1) Put the pump (35) in position on the gearbox mount pad with the nuts (50) through the large holes in the pump flange.
(2) Turn the pump (35) counterclockwise until it touches the studs.
(3) Do a running torque check of the nuts with a WRENCH - TORQUE.

CAUTION: DISCARD THE NUT(S) IF YOU CAN TURN THEM BY HAND WITH NO RESISTANCE.

(a) Install new nuts (50) on the studs of the mount pad and turn the nuts until resistance is felt.
(b) Set the WRENCH - TORQUE to 9.5 lbf.in (0.11 m.daN) and turn each nut in the tightening direction. The nut(s) must not turn before the set torque value.
(c) If the nut(s) turn before you get 9.5 lbf.in (0.11 m.daN) torque, replace the nut(s) and do step (3) again for each replacement nut.
(d) If the running torque check is correct, do not remove the nut(s) from the stud(s) and do the next step (4).
(4) TORQUE the nuts (50) to between 320 and 260 lbf.in (3.62 and 2.94 m.daN )

.
(5) Remove the blanking covers from the hose couplings.
(6) Connection of the case drain hose:

CAUTION: BE CAREFUL WHEN YOU INSTALL/CONNECT PARTS ON THE PUMP TO MAKE SURE THAT THE HYDRAULIC FLUID DOES NOT FLOW OUT. THE PUMP IS FULL OF HYDRAULIC FLUID.

(a) Connect the case drain hose (20) to the union (25).
(7) TORQUE the coupling nut to between 245 and 215 lbf.in (2.77 and 2.43 m.daN )

.
(a) Use a second WRENCH - TORQUE to hold the union (25) when you torque the hose coupling nut.
(8) Make sure that the seal of the adapter (70) is in correct position and condition.
(a) If the seal of the adapter (70) is damaged, replace the AIPC 29-11-38-01-010 ADAPTER (70).
(9) Connect the suction hose adapter (70) to the union (15) in the pump (35) suction port.
(10) Connect the suction hose (10) to the adapter (70).
(11) TORQUE the coupling nut of the suction hose (10) to the adapter (70) to between 900 and 800 lbf.in (10.17 and 9.04 m.daN )

.
(12) TORQUE the coupling nut of the adapter (70) to the union (15) to between 900 and 800 lbf.in (10.17 and 9.04 m.daN )

.
(a) Use the second WRENCH - TORQUE to hold the union (15) when you torque the hose adapter (70) coupling-nut.
(13) Connect the pressure hose (5) to the union/reducer (65).
(14) TORQUE the hose (5) coupling nut to between 1000 and 900 lbf.in (11.30 and 10.17 m.daN )

.
(a) Use the second WRENCH - TORQUE to hold the union/reducer (65) when you torque the hose coupling nut.
(15) Remove the protective cover from the electrical connector (1030GKA).
(16) Connect the electrical connector (1030GKA) to the pump (35).
(a) Make sure that all the electrical connections are clean and in the correct condition.
(b) Align the master-key (largest key) on the connector with the master-key in the receptacle.
(c) Use light hand pressure and push the connector in the receptacle. Turn the coupling nut clockwise to engage the connector threads.
(d) Tighten the connection.

1 With the threads correctly engaged, continue to turn the coupling nut clockwise with your hand until the connection is tight. Make sure that you cannot see the colored coupling indicator line on the receptacle when the connection is fully tight.

Green Engine Pump (Abex) ** ON A/C NOT FOR ALL

NOTE: If you move the connector from side to side when you turn the coupling nut it will make it easier to tighten.

(e) Use PLIERS - CONNECTOR, JAW, SOFT or WRENCH GLENAIR TG70 - STRAP.

CAUTION: YOU MUST NOT USE PLIERS WITH METAL JAWS TO TIGHTEN OR LOOSEN THE CONNECTOR. THE METAL JAWS WILL CAUSE DAMAGE TO THE CONNECTOR.

1 Turn the connector ring from one eighth to a quarter of a turn with PLIERS - CONNECTOR, JAW, SOFT or WRENCH GLENAIR TG70 - STRAP to make sure that the connector is tight. Stop before the pliers or strap wrench moves but does no catch on the connector ring.

Subtask 29-11-51-865-058-A ** ON A/C NOT FOR ALL

E. Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
121VU	HYDRAULIC/G HYD/PUMP ENG1/CTL	1701GK	R35
121VU	HYDRAULIC/G HYD/PUMP ENG1/MONG	1702GK	R34

Subtask 29-11-51-860-062-A ** ON A/C NOT FOR ALL

F. Do the hydraulic maintenance procedure after an engine pump installation (Ref. AMM TASK 29-11-51-860-040).

5. Close-up
Subtask 29-11-51-860-073-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) On the ECAM control panel, push the HYD key:

On the SD, the HYD page comes into view.

(2) On the overhead panel 20VU:

Push the ENG1/FIRE pushbutton switch.

(3) On the SD:

Make sure that the fire shut-off valve (1046GK) is opened.

(4) Do a functional test of the engine pump fire-valve (Ref. AMM TASK 29-10-00-720-001).

Subtask 29-11-51-942-052-A ** ON A/C NOT FOR ALL

B. Remove the safety precautions
(1) Remove the WARNING NOTICE(S).
(2) Remove the container.
(3) Make sure that the work area is clean and clear of tools and other items.

Subtask 29-11-51-410-052-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the left fan cowl door 437AL (Ref. AMM TASK 71-13-00-410-040).

Subtask 29-11-51-862-051-A ** ON A/C NOT FOR ALL

D. De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002).

[Rev.10 from 2021] 2026.04.01 00:18:11 UTC