Installation of the Bleed-Air Precooler Exchanger

TASK 36-11-42-400-804-A
Installation of the Bleed-Air Precooler Exchanger

WARNING: BE CAREFUL WHEN YOU REMOVE OR INSTALL THIS EQUIPMENT. THIS EQUIPMENT IS HEAVY (MORE THAN 12 KG (26.5 lb)) AND CAN CAUSE INJURY AND/OR DAMAGE.

WARNING: MAKE SURE THAT THE PNEUMATIC SYSTEM IS DEPRESSURIZED BEFORE YOU START WORK. PRESSURIZED AIR CAN CAUSE INJURY TO PERSONNEL.

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

WARNING: YOU MUST NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE AN INJURY.

WARNING: PUT THE SAFETY DEVICES AND THE WARNING NOTICES IN POSITION BEFORE YOU START A TASK ON OR NEAR:

THE FLIGHT CONTROLS
THE FLIGHT CONTROL SURFACES
THE LANDING GEAR AND THE RELATED DOORS
COMPONENTS THAT MOVE.

MOVEMENT OF COMPONENTS CAN KILL OR CAUSE INJURY TO PERSONS AND/OR CAN CAUSE DAMAGE TO THE EQUIPMENT.

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

CAUTION: BE VERY CAREFUL WHEN YOU DO WORK ON OR NEAR THE AIR-CONDITIONING DUCTS. THE DUCTS ARE MADE OF THIN MATERIAL AND YOU CAN EASILY BREAK THEM.

ZONE: 410
ZONE: 420
FIN: 7150HM1
FIN: 7150HM2

1. Reason for the Job
The weight of this equipment is approximately 41 kg (88 lb). Two persons are necessary to do this task.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE
No specific	1	CLOTH - PROTECTIVE
No specific	1	CRANE 100KG (220 LB)
No specific	AR	PLUG - BLANKING
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.78 and 0.56 m.daN (69.03 and 49.56 lbf.in )
No specific	Torque wrench: range to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )
No specific	Torque wrench: range to between 1.7 and 1.5 m.daN (12.54 and 11.06 lbf.ft )
No specific	Torque wrench: range to between 2.69 and 2.24 m.daN (19.84 and 16.52 lbf.ft )
98D27803000000	2	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98L12003001000	AR	HARNESS,SAFETY
98L36103000000	1	RI PRECOOLER

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.06LDG2)	Non Hardening Jointing Putty-High Temp. Area - Structure

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
410	ENG 1 PYLON BOX AND FORWARD FAIRING
420	ENG 2 PYLON BOX AND FORWARD FAIRING
191DB
FOR [7150HM1] (EXCHANGER-BLEED AIR PRECOOL)
413CT, 413DT, 413ET
FOR [7150HM2] (EXCHANGER-BLEED AIR PRECOOL)
423CT, 423DT, 423ET

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
6	SEAL	AIPC 36-11-86-50-300
11	SEAL	AIPC 36-11-86-50-370
14	SEAL	AIPC 36-11-86-50-370
13	SEAL	AIPC 36-11-86-50-380
10	SEAL	AIPC 36-11-86-50-390
32	SEAL	AIPC 36-11-86-51-410
35	SEAL	AIPC 36-11-86-51-410

E. Referenced Information

REFERENCE	DESIGNATION
TASK 12-00-00-481-002-A	Installation of the Wingrip
TASK 20-23-22-910-001-A	Marking of the Unions after Application of Standard or Specific Tightening Torque
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
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 24-41-00-862-002-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 27-00-00-480-002-A	Installation of the Flap/Slat Control-Lever Locking Tool (98D27803000000)
TASK 36-11-53-400-803-A	Installation of the Overpressure Valve
TASK 36-12-00-860-805-A	Pressurization of the Bleed System with the APU
TASK 36-12-00-860-806-A	Pressurization of the Bleed System through the HP Ground Connector
TASK 36-22-00-790-803-A	Leak Check on all the Bleed Air Ducts and the Pack Components
TASK 49-00-00-860-009-A	APU Shutdown by External Power (131-9(A))
TASK 49-00-00-860-009-A-01	APU Shutdown by Batteries (131-9(A))
TASK 54-52-11-000-807-A	Removal of the Access Skin Panels
TASK 54-52-11-400-807-A	Installation of the Access Skin Panels
TASK 54-52-22-300-801-B	Replacement of the Upper Seals of the Bleed-Air Precooler Exchanger
Bleed-Air Precooler Exchanger
Precooler Exchanger Tool
Assembled Rib and Half-Guillotine
Upper Seal of the Bleed-Air Precooler Exchanger

3. Job Set-up
Subtask 36-11-42-860-056-A

A. Aircraft Maintenance Configuration
(1) Make sure that the aircraft electrical circuits are energized (Ref. AMM TASK 24-41-00-861-002) or (Ref. AMM TASK 24-41-00-861-002).
(2) Make sure that an ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in the position.
(3) Make sure that these access panels are removed (Ref. AMM TASK 54-52-11-000-807):
(a) FOR [7150HM1] (EXCHANGER-BLEED AIR PRECOOL)
413CT, 413DT, 413ET
(b) FOR [7150HM2] (EXCHANGER-BLEED AIR PRECOOL)
423CT, 423DT, 423ET

Subtask 36-11-42-865-061-A

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-42-941-056-A

C. Safety Precautions
(1) On AIR COND panel 30VU:

Make sure that the APU BLEED pushbutton switch is released (ON legend off).
Make sure that the ENG 1(2) BLEED pushbutton switch is released (OFF legend on).
Make sure that a WARNING NOTICE(S) is in position to tell persons not to operate the pneumatic system.

(2) On ENG panel 115VU:

Make sure that the ENG/MODE selector switch is in the NORM position.
Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
Make sure that a WARNING NOTICE(S) is in position to tell persons not to operate the ENG/MODE selector switch and the ENG/MASTER 1(2) control switch.

(3) On access door 191DB, on the HP ground connectors:

Make sure that a WARNING NOTICE(S) is in position to tell persons not to pressurize the pneumatic system.

(4) On the ENG section of maintenance panel 50VU:

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

(5) Put on and attach a 98L12003001000 HARNESS,SAFETY before you start work in the work area (Ref. AMM TASK 12-00-00-481-002).
(6) On FLAPS panel 114VU:

Make sure that the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION is in position on the flap/slat control lever (Ref. AMM TASK 27-00-00-480-002).
Make sure that the WARNING NOTICE(S) is in position on the flap/slat control lever to tell persons not to operate the flap/slat controls.

4. Procedure
Subtask 36-11-42-420-057-A

A. Preparation of the Bleed-Air Precooler Exchanger
(1) If you use the APU to energize the electrical circuits, stop the APU:

For GTCP 36-300 APU (Ref. AMM D/O 49-00-00-86)
For APS 3200 APU (Ref. AMM D/O 49-00-00-86)
For 131-9(A) APU (Ref. AMM TASK 49-00-00-860-009).

(2) In the cockpit, on the SD bleed page:
(a) Make sure that the pressure and the temperature of the bleed-air duct system are in ambient conditions.

WARNING: MAKE SURE THAT THE PNEUMATIC SYSTEM IS DEPRESSURIZED BEFORE YOU START WORK. PRESSURIZED AIR CAN CAUSE INJURY TO PERSONNEL.

WARNING: DO NOT TOUCH THE UNIT UNTIL IT IS SUFFICIENTLY COOL TO PREVENT BURNS WHEN YOU DO THE MAINTENANCE TASK(S).

(3) Do a visual inspection of the seals (10), (11), (13) and (14):

If the seals are damaged, discard them and replace them with a new AIPC 36-11-86-50-390 SEAL (10), and/or a new AIPC 36-11-86-50-370 SEAL (11), a new AIPC 36-11-86-50-380 SEAL (13) and/or a new AIPC 36-11-86-50-370 SEAL (14).

(4) Do a visual inspection of the seal (35) of the assembled rib and half-guillotine (38) and the seal (32) of the fairing support (29):

If the seal(s) is(are) damaged, discard it(them) and replace it(them) with a new AIPC 36-11-86-51-410 SEAL (32) and/or a new AIPC 36-11-86-51-410 SEAL (35).

(5) Remove the PLUG - BLANKING from the disconnected line end(s).
(6) Remove the PLUG - BLANKING from the precooler exchanger (8).
(7) Make sure that the parts retained from the removed component are clean and in the correct condition.

Subtask 36-11-42-420-058-A

B. Installation of the 98L36103000000 RI PRECOOLER Tool

Precooler Exchanger Tool

(1) Make sure that the tool is clean and in the correct condition.
(2) Attach the 98L36103000000 RI PRECOOLER tool to the CRANE 100KG (220 LB).
(3) Put the CRANE 100KG (220 LB) with the 98L36103000000 RI PRECOOLER tool in position above the precooler exchanger (8).
(4) Attach the 98L36103000000 RI PRECOOLER tool to the hoisting points of the precooler exchanger (8).
(5) Obey the tool manufacturer's instructions and install the four links (25) on the precooler exchanger (8).

Subtask 36-11-42-420-059-A

C. Installation of the Bleed-Air Precooler Exchanger

CAUTION: WHEN YOU INSTALL THE FASTENERS OF THE PRECOOLER, DO NOT APPLY TOO MUCH FORCE. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO THE BRACKETS.

(1) Make sure that the work area is clean and clear of tools and other items.
(2) Clean the mating surface of the precooler exchanger aft-right fixation (Ref. AMM TASK 20-28-00-912-802).
(3) Apply a thin layer of Non Hardening Jointing Putty-High Temp. Area - Structure (Material No.06LDG2) on the mating surface.
(4) Carefully lift the 98L36103000000 RI PRECOOLER tool with the CRANE 100KG (220 LB) until it holds the weight of the precooler exchanger (8).

NOTE: The precooler exchanger weighs 41.2 kg.

(5) Put the precooler exchanger (8) in position on the supports (9).
(a) Use the metal tubes (27) and (28) to install the precooler exchanger (8) in the correct position.

NOTE: The metal tubes (27) go into the guide rail (26).

(6) Remove the 98L36103000000 RI PRECOOLER tool from the precooler exchanger (8).
(7) Attach the precooler exchanger (8) to the supports (9).

CAUTION: MAKE SURE THAT YOU INSTALL THE BOLTS IN THE CORRECT SEQUENCE. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO THE SUPPORTS AND THE PRECOOLER EXCHANGER.

(a) Make sure that the positions of the screws (17), (18), (21) and (23) agree with the positions you recorded at the removal.
(b) Install the washer (16) and screw (17) on the precooler exchanger (8). Do not torque the screw (17) at this time.
(c) Install the washer (19) and screw (18) on the precooler exchanger (8). Do not torque the screw (18) at this time.
(d) Install the washer (22) and screw (21) on the precooler exchanger (8). Do not torque the screw (21) at this time.
(e) Install the washer (24) and screw (23) on the precooler exchanger (8). Do not torque the screw (23) at this time.
(8) Do an electrical bonding of the precooler exchanger aft-right fixation (Ref. AMM TASK 20-28-00-912-802).
(9) TORQUE the screws (17),(18),(21) and (23) to between 2.69 and 2.24 m.daN (19.84 and 16.52 lbf.ft )

.
(10) Identify the four tightened screws (17),(18),(21) and (23) with a red line (Ref. AMM TASK 20-23-22-910-001).
(11) Install the Overpressure Valve (OPV) (15) (Ref. AMM TASK 36-11-53-400-803).
(12) Install the bellows (4).
(a) Install a new AIPC 36-11-86-50-300 SEAL (6) on the bellows (4).
(b) Put the bellows (4) in position on the precooler exchanger (8) and the wing bleed duct (1).
(c) Install the clamps (2) and (5) on the bellows (4).
(d) Make sure that the positions of the clamps (2) and (5) agree with the positions you recorded at the removal.
(e) TORQUE the nut on the clamp (5) to between 1.41 and 1.30 m.daN (124.78 and 115.04 lbf.in )

.
(f) TORQUE the nut on the clamp (2) to between 0.78 and 0.56 m.daN (69.03 and 49.56 lbf.in )

.
(13) Identify the tightened union nuts of the clamps (2) and (5) with a red line (Ref. AMM TASK 20-23-22-910-001).
(14) Connect the pipes (7) and (20) to the precooler exchanger (8).
(15) TORQUE the nuts of the pipes (7) and (20) to between 1.7 and 1.5 m.daN (12.54 and 11.06 lbf.ft )

.
(16) Identify the tightened union nuts of the pipes (7) and (20) with a red line (Ref. AMM TASK 20-23-22-910-001).

Subtask 36-11-42-410-053-A

D. Installation of the Components

Assembled Rib and Half-Guillotine

Upper Seal of the Bleed-Air Precooler Exchanger

(1) Install the assembled rib and half-guillotine (38) as follows:
(a) Put the assembled rib and half-guillotine (38) in their correct position.
1 Make the assembled rib and half-guillotine (38) move vertically down to install it on the fairing support (29).
(b) Put a CLOTH - PROTECTIVE on the upper spar over the precooler aft duct-flange.

NOTE: This is to make sure that the nuts do not go into the precooler if they fall.

(c) Put the washers (37), the screws (36) and the nuts (40) in their position and tighten them.
(d) Put the washers (30), the screws (31) and the nuts (41) in their position and tighten them.
(e) Put the screws (34) and the nuts (42) in their position and tighten them.
(f) Put the screws (33) and the nuts (39) in their position and tighten them.
(2) Install the upper seals (44), (45), (46) and (47) of the bleed-air precooler exchanger as follows:
(a) Do a visual inspection of the upper seals of the bleed-air precooler exchanger.
(b) Make sure that there are no:

Burned color
Cracks during the visual inspection
Cracks when you push/pull them
Silicone parts removed from the seals.

(c) If you find these types of damage, replace all the upper seals (44), (45), (46) and (47) (Ref. AMM TASK 54-52-22-300-801).

Subtask 36-11-42-865-062-A

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-42-710-051-A

F. Test
(1) Pressurize the bleed system through the HP ground connector (Ref. AMM TASK 36-12-00-860-806) or with the APU (Ref. AMM TASK 36-12-00-860-805).
(2) On AIR COND panel 30VU, set the X-BLEED selector to OPEN.
(3) Do the leak check (Ref. AMM TASK 36-22-00-790-803).
(a) If you pressurize the bleed system through the HP ground connector, the supplied pressure of 30 psi (2.07 bar) must be stable.
(b) Make sure that there are no leaks at the junctions downstream and upstream of the precooler exchanger (8) and between the wing duct and the bellows (4).
(c) Install the thermal protection (3) on the bellows (4).

5. Close-up
Subtask 36-11-42-860-057-A

A. Close Access
(1) Put the aircraft back to its initial configuration.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) Install these access panels (Ref. AMM TASK 54-52-11-400-807):
(a) FOR [7150HM1] (EXCHANGER-BLEED AIR PRECOOL)
413CT, 413DT, 413ET
(b) FOR [7150HM2] (EXCHANGER-BLEED AIR PRECOOL)
423CT, 423DT, 423ET
(4) Remove all the fixtures, tools, test and support equipment used during this procedure.
(5) Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/slat control lever on panel 114VU.
(6) Remove the access platform(s).
(7) Remove the WARNING NOTICE(S).
(8) De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002) or (Ref. AMM TASK 24-41-00-862-002).

[Rev.10 from 2021] 2026.04.01 01:09:21 UTC