Installation of the Upper High-Pressure Duct

TASK 36-11-49-400-003-A
Installation of the Upper High-Pressure Duct

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	ACCESS PLATFORM 1M (3 FT)-ADJUSTABLE
No specific	AR	FOIL - ALUMINUM
No specific	AR	HAMMER - FIBER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 60 and 45 lbf.in (0.68 and 0.51 m.daN )
No specific	Torque wrench: range to between 60 and 54 lbf.in (0.68 and 0.61 m.daN )
No specific	Torque wrench: range to between 90 and 75 lbf.in (1.02 and 0.85 m.daN )
No specific	Torque wrench: range to between 110 and 90 lbf.in (1.24 and 1.02 m.daN )
No specific	Torque wrench: range to between 110 and 100 lbf.in (1.24 and 1.13 m.daN )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CP2101)	graphite grease
(Material No.CP3010)	dry cleaner
(Material No.CP8001)	lockwire 0.032 in. (0.8 mm) dia.
(Material No.CP8004)	lockwire 0.6 mm (0.0236 in.) dia
(Material No.08CKB9)	Cleaner-Hydraulic Spillage Absorbent powder -

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [1000EM1] (ENGINE-1)
437AL, 438AR, 451AL, 452AR
FOR [1000EM2] (ENGINE-2)
447AL, 448AR, 461AL, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
45	SEALS	AIPC 36-11-49-01-050
40	SEAL	AIPC 36-11-49-01-140

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 24-41-00-862-002-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 31-60-00-860-001-A	EIS Start Procedure
TASK 31-60-00-860-002-A	EIS Stop Procedure
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 70-51-00-230-001-A	Fluorescent-Penetrant Inspection-Portable Water-Washable
TASK 71-00-00-710-003-A	Engine Automatic Start
TASK 71-00-00-710-004-A	Engine Manual Start
TASK 71-00-00-710-028-A	Engine Shutdown
TASK 71-13-00-010-040-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-040-A	Closing of the Fan Cowl Doors
TASK 78-30-00-081-041-A	Make the Thrust Reverser Serviceable after Maintenance
TASK 78-30-00-481-041-A	Make the Thrust Reverser Unserviceable for Maintenance
TASK 78-36-00-010-040-A	Opening of the Thrust Reverser Doors
TASK 78-36-00-410-040-A	Closing of the Thrust Reverser Doors
Upper High Pressure Duct
Duct Coupling Installation

3. Job Set-up
Subtask 36-11-49-860-070-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) or (Ref. AMM TASK 24-41-00-861-002).
(2) Make sure that engine 1(2) is shutdown for a minimum of 5 minutes before you do this procedure.
(3) In the cockpit, on AIR COND panel 30VU:

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

(4) In the cockpit, on ENG panel 115VU:

Make sure that the WARNING NOTICE(S) is in position to tell persons not to start engine 1(2).

(5) On the HP ground connector:

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

(6) In the cockpit, 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 the WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).

(7) Make sure that the ACCESS PLATFORM 1M (3 FT)-ADJUSTABLE is in position below the engine.

Subtask 36-11-49-865-125-A ** ON A/C NOT FOR ALL

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	AIR BLEED/ENG 1/CTL	3HA1	D12
49VU	AIR BLEED/ENG 1/MONG	2HA1	D11
122VU	AIR BLEED/ENG 2/CTL	3HA2	Z23
122VU	AIR BLEED/ENG 2/MONG	2HA2	Z22

Subtask 36-11-49-010-120-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-040):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(2) Make sure that the thrust reverser doors are open (Ref. AMM TASK 78-36-00-010-040):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR

Subtask 36-11-49-040-093-A ** ON A/C NOT FOR ALL

D. Make sure that the thrust reverser is unserviceable (Ref. AMM TASK 78-30-00-481-041).

4. Procedure
Subtask 36-11-49-420-083-A ** ON A/C NOT FOR ALL

A. Installation of the Upper High Pressure (HP) Duct
(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) Remove the blanking plugs from the upper HP duct (30), the engine ports, and the HP tee duct.
(4) Remove the protective covers from the hose and the boss (left side only).
(5) Apply a layer of graphite grease (Material No.CP2101) to the bolts (50) and (55).
(6) Put the upper HP duct (30) on the engine. Put new AIPC 36-11-49-01-050 SEALS (45) on the engine ports and loosely install the bolts (50) and (55).
(7) Tighten the bolts (50) and (55) sufficiently to hold the upper HP duct (30) in position. Do not TORQUE the bolts at this time.
(8) Attach the upper HP duct (30) to the HP tee duct with a AIPC 36-11-49-01-140 SEAL (40) and the coupling (35). Do not TORQUE the nuts on the coupling at this time.
(9) Make sure that the upper HP duct (30) is in the correct position.
(10) TORQUE the bolts (50) and (55) to between 60 and 45 lbf.in (0.68 and 0.51 m.daN )

WARNING: USE PROTECTIVE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

(11) Safety the bolts with CP8001lockwire 0.032 in. (0.8 mm) dia..
(12) TORQUE the nut on the coupling as follows:

CAUTION: TWO TYPES OF COUPLINGS ARE USED ON THE BLEED AIR DUCTS. IT IS POSSIBLE TO INSTALL ONE OF THESE TYPES INCORRECTLY. WHEN YOU INSTALL THIS TYPE OF COUPLING, MAKE SURE THE SLIDE PART OF THE COUPLING (WITH THE SADDLE WASHER) ENGAGES THE RECESSES OF THE OTHER HALF OF THE COUPLING. IF THE COUPLING IS INSTALLED INCORRECTLY, IT CAN DISENGAGE AND CAUSE LARGE AIR LEAKS AND POSSIBLE DAMAGE.

CAUTION: MAKE SURE THE SMOOTH CIRCULAR SURFACE OF THE COUPLING IS RADIALLY OUTBOARD FROM THE ENGINE. DO NOT LET THE COUPLING TOUCH ENGINE COMPONENTS OR STRUCTURE. DAMAGE TO THE COMPONENTS OR STRUCTURE COULD OCCUR.

(a) TORQUE the coupling nut to the value shown on the coupling.
(b) Lightly hit the perimeter of the coupling with a HAMMER - FIBER, then TORQUE the coupling nut again.
(c) Do the TORQUE procedure two times, then TORQUE the coupling nut again.
(13) Install the support links, as follows:

NOTE: When you install the links, make sure that the countersunk side of the washer is against the bolt head.

(a) Install the support link (60) on the bracket at flange Sta. 233 (R). Attach it with the bolt (5), washer (10) and nut (15).
(b) Install the support link (25) on the bracket at flange Sta. 239 (S). Attach it with the bolt (5), washer (10) and nut (15).
(c) Attach the support link (25) to the duct (30). Attach it with the bolt (5), washer (10) and nut (15).
(d) Attach the support link (60) to the duct (30). Attach it with the bolt (5), washer (10) and nut (15).
(e) If required, adjust the support links (60) and (25) so they do not put a load on the upper HP duct (30):
1 Adjust the support link (60) to approximately 2.62 IN. (66.55 MM) between hole centers.
2 Adjust the support link (25) to approximately 3.3 IN. (83.82 MM) between hole centers.
(f) Make sure the bolts (5) move freely in the support links.
(14) TORQUE the adjustment nuts on the support links to between 60 and 54 lbf.in (0.68 and 0.61 m.daN )

(15) Safety the nuts with CP8001lockwire 0.032 in. (0.8 mm) dia..
(16) TORQUE the nuts (15) to between 90 and 75 lbf.in (1.02 and 0.85 m.daN )

.
(17) Install the union (20) into the boss on the upper HP duct (30) (left side only). TORQUE the union (20) to between 110 and 90 lbf.in (1.24 and 1.02 m.daN )

CAUTION: MAKE SURE THAT THE HOSE IS IN THE CORRECT DIRECTION WHEN YOU INSTALL IT. IF YOU DO NOT ATTACH THE HOSE CORRECTLY, IT CAN RUB AND BE DAMAGED.

(18) Connect the hose to the union (20) (left side only). TORQUE the coupling nut on the hose to between 110 and 100 lbf.in (1.24 and 1.13 m.daN )

Subtask 36-11-49-480-051-A ** ON A/C NOT FOR ALL

B. Preparation for the Leak Test
(1) Find the location of a pneumatic joint air-leak with one of the two procedures that follow:
(a) Apply a Cleaner-Hydraulic Spillage Absorbent powder - (Material No.08CKB9) or dry cleaner (Material No.CP3010) (Ref. AMM TASK 70-51-00-230-001) around the pneumatic joints, only on the connections of the removed pneumatic components.

NOTE: Airbus recommends that you do not apply the dry developer on all the pneumatic components.

(b) Install an FOIL - ALUMINUM around the pneumatic joint locations:
1 Wind the foil wrap around the joint one time.
2 Twist the seam of the foil wrap to make it tight.
3 Make the foil wrap as tight as possible on the tube but do not cause damage to the wrap.

4 Attach the foil wrap with a CP8004lockwire 0.6 mm (0.0236 in.) dia on the two sides of the pneumatic joint.

Subtask 36-11-49-410-119-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the left thrust reverser door (Ref. AMM TASK 78-36-00-410-040):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR

Subtask 36-11-49-440-081-A ** ON A/C NOT FOR ALL

D. Make the thrust reverser serviceable (Ref. AMM TASK 78-30-00-081-041).

Subtask 36-11-49-865-134-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
49VU	AIR BLEED/ENG 1/CTL	3HA1	D12
49VU	AIR BLEED/ENG 1/MONG	2HA1	D11
122VU	AIR BLEED/ENG 2/CTL	3HA2	Z23
122VU	AIR BLEED/ENG 2/MONG	2HA2	Z22

Subtask 36-11-49-860-076-A ** ON A/C NOT FOR ALL

F. Do the EIS start procedure (upper ECAM DU and lower ECAM DU only)
(Ref. AMM TASK 31-60-00-860-001).

Subtask 36-11-49-720-066-A ** ON A/C NOT FOR ALL

G. Do this Test
(1) on the ECAM control panel 11VU, push the BLEED key (on the lower ECAM DU, the BLEED page comes into view).
(2) On the lower ECAM DU, on the BLEED page:

Make sure that the related HP bleed valve is shown closed.

(3) Start the related engine with the automatic or manual start procedure (Ref. AMM TASK 71-00-00-710-003) or (Ref. AMM TASK 71-00-00-710-004) and keep it at idle.
(4) On the AIR COND panel 30VU:

Push the ENG 1(2) BLEED pushbutton switch (OFF legend goes off).

(5) After 5 minutes, on the lower ECAM DU, on the BLEED page:

Make sure that the related HP bleed valve is shown open.

(6) Stop the engine (Ref. AMM TASK 71-00-00-710-028).

Subtask 36-11-49-040-105-A ** ON A/C NOT FOR ALL

H. Make sure that the thrust reverser is unserviceable (Ref. AMM TASK 78-30-00-481-041).

Subtask 36-11-49-010-140-A ** ON A/C NOT FOR ALL

I. Open the left thrust reverser doors (Ref. AMM TASK 78-36-00-010-040).
(1) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(2) FOR [1000EM2] (ENGINE-2)
461AL 462AR

Subtask 36-11-49-080-051-A ** ON A/C NOT FOR ALL

J. Make sure that there are no leaks at the junction between the HP bleed valve and the duct on the related engine.

NOTE: There is a leak when the foil installed on the duct breaks or when it is too hot.
There is a leak when the leak air removes the dry developer from the junction.

(1) Remove the materials used to do the leak test.

5. Close-up
Subtask 36-11-49-860-082-A ** ON A/C NOT FOR ALL

A. Do the EIS stop procedure
(Ref. AMM TASK 31-60-00-860-002).

Subtask 36-11-49-865-126-A ** ON A/C NOT FOR ALL

B. 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
49VU	AIR BLEED/ENG 1/CTL	3HA1	D12
49VU	AIR BLEED/ENG 1/MONG	2HA1	D11
122VU	AIR BLEED/ENG 2/CTL	3HA2	Z23
122VU	AIR BLEED/ENG 2/MONG	2HA2	Z22

Subtask 36-11-49-410-101-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser doors (Ref. AMM TASK 78-36-00-410-040):
(a) FOR [1000EM1] (ENGINE-1)
451AL 452AR
(b) FOR [1000EM2] (ENGINE-2)
461AL 462AR

Subtask 36-11-49-440-072-A ** ON A/C NOT FOR ALL

D. Make the thrust reverser serviceable (Ref. AMM TASK 78-30-00-081-041).

Subtask 36-11-49-410-102-A ** ON A/C NOT FOR ALL

E. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-040):
(a) FOR [1000EM1] (ENGINE-1)
437AL 438AR
(b) FOR [1000EM2] (ENGINE-2)
447AL 448AR
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

Subtask 36-11-49-862-077-A ** ON A/C NOT FOR ALL

F. 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 12:38:49 UTC