Installation of the Environmental Control System (ECS) Interface Duct

TASK 36-11-49-400-824-A
Installation of the Environmental Control System (ECS) Interface Duct

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 AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: ALWAYS USE APPLICABLE GLOVES TO TOUCH HOT PARTS. HOT PARTS CAN CAUSE INJURY TO PERSONS.

WARNING: WEAR APPLICABLE PERSONAL PROTECTIVE EQUIPMENT (PPE) WHEN YOU DO THIS TASK. BEFORE YOU USE PPE, READ, UNDERSTAND AND OBEY ALL INSTRUCTIONS FOR ITS USE. THESE INSTRUCTIONS INCLUDE INSTRUCTIONS FROM THE MANUFACTURER, YOUR EMPLOYER AND GOVERNMENT REGULATIONS. YOU CAN GET INJURED IF YOU DO NOT USE PPE. GET INSTRUCTIONS FROM YOUR EMPLOYER ON WHICH PPE IS NECESSARY.

ZONE: 454
ZONE: 464

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	1	HAMMER - FIBER
No specific	AR	WARNING NOTICE(S)
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 125 and 115 lbf.in (1.41 and 1.30 m.daN )
No specific	Torque wrench: range to between 130 and 115 lbf.in (1.47 and 1.30 m.daN )

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
454	HOT SECTION
464	HOT SECTION
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 462AR

C. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
9	SEAL	AIPC 36-11-86-30-110

D. 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 36-11-49-000-822-A	Removal of the Environmental Control System (ECS) Ducts
TASK 36-11-49-400-822-A	Installation of the Environmental Control System (ECS) Ducts
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 71-00-00-790-802-A	Test No. 1 - Pneumatic Leak Test
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 71-13-00-010-802-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-802-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-805-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-805-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-802-A	Opening of the Thrust Reverser Cowl-Doors
TASK 78-36-00-410-802-A	Closing of the Thrust Reverser Cowl-Doors
Environmental Control System (ECS) Interface Duct

3. Job Set-up
Subtask 36-11-49-860-123-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) In the cockpit, on AIR COND panel 30VU:
(a) Make sure that the ENG 1(2) BLEED pushbutton switch is released (the OFF legend is on).
(b) Make sure that the APU BLEED pushbutton switch is released (the ON legend is off).
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the pneumatic system.
(3) Make sure that you did the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833).
(4) On the HP ground connector:
(a) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the pneumatic system.

Subtask 36-11-49-865-193-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 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 36-11-49-010-229-A ** ON A/C NOT FOR ALL

C. Get Access
(1) Make sure that the fan cowl doors are open (Ref. AMM TASK 71-13-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position below the fan cowl doors.
(3) Make sure that the right thrust-reverser cowl-door is open (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
462AR

Subtask 36-11-49-040-156-A ** ON A/C NOT FOR ALL

D. Deactivation of the Thrust Reverser System for Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Make sure that you did the deactivation of the thrust reverser system for maintenance (Ref. AMM TASK 78-30-00-040-805).

4. Procedure
Subtask 36-11-49-420-138-A ** ON A/C NOT FOR ALL

A. Installation of the ECS Interface 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).

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

(2) Make sure that you wait for a minimum of 5 minutes until there is no pressure in the bleed-air duct system.

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

(3) In the cockpit, on the SD bleed page:
(a) Make sure that the temperature of the bleed-air duct system are in the ambient conditions.
(4) Remove all the necessary COVER - PROTECTION from the ECS interface duct (1), the Over Pressure Valve (OPV) and the pylon precooler-duct engine.

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

CAUTION: MAKE SURE THAT:

THERE IS NO TENSION ON THE LINK ASSEMBLIES FOR THE ECS DUCTS
THE MATING SURFACES BETWEEN THE DUCTS CORRECTLY ALIGN.

TENSION AND INCORRECT ALIGNMENT CAN CAUSE AIR LEAKAGE, WHICH CAN CAUSE DAMAGE TO THE EQUIPMENT.

(5) Install the link assemblies as follows:
(a) Adjust the link assembly (6) to a nominal length of 2.62 in. (66.55 mm):
1 Make sure that the threads of the link assembly (6) rod cover the inspection hole.
(b) Install the link assembly (6) of the upper ECS interface-bracket with the bolt (5), washers (2), bushing (4) and nut (3):
1 Do not torque the nut (3) at this time.
(c) Adjust the link assembly (7) to a nominal length of 3.50 in. (88.90 mm):
1 Make sure that the thread of the link assembly (7) rod cover the inspection hole.
(d) Install the link assembly (7) of the lower ECS interface-bracket with the bolt (5), washers (2), bushing (4) and nut (3):
1 Do not torque the nut (3) at this time.
(e) For CONFIGURATION 1, install the link assembly as follows:
1 If necessary, assemble the turnbuckle (12) and the rod ends (11) with the jamb nuts (10):
a Do not tighten the jamb nuts (10) at this time.
2 Install the rod ends (11) of the link assembly to the aft ECS interface-bracket with the bolt (5), washers (2), bushing (4) and nut (3):
a Do not torque the nut (3) at this time.
(f) For CONFIGURATION 2, install the link assembly as follows:
1 Install the link assembly (13) to the aft ECS interface-bracket with the bolt (5), washers (2), bushing (4) and nut (3):
a Do not torque the nut (3) at this time.
(6) Install the ECS interface duct (1) as follows:
(a) Attach the ECS interface duct (1) to the pylon precooler duct with the V-band coupling (8) and the AIPC 36-11-86-30-110 SEAL (9).
(b) Put the V-band coupling (8) in the approximate position:
1 Do not torque the V-band coupling (8) at this time.
(c) Attach the ECS interface duct (1) to the OPV with the V-band coupling (8) and the AIPC 36-11-86-30-110 SEAL (9):
1 Do not torque the V-band coupling (8) at this time.
2 Make sure that the alignment tab engages.
(d) Attach the ECS interface duct (1) to the link assemblies (6) and (7) with the bolts (5), washers (2), bushings (4) and nuts (3):
1 Do not torque the nuts (3) at this time.
(e) For CONFIGURATION 1, install the link assembly as follows:
1 Attach the ECS interface duct (1) to the rod end (11) of the link assembly with the bolt (5), washers (2), bushing (4) and nut (3):
a Do not torque the nut (3) at this time.
(f) For CONFIGURATION 2, install the link assembly as follows:
1 Attach the ECS interface duct (1) to the link assembly (13) with the bolt (5), washers (2), bushing (4) and nut (3):
a Do not torque the nut (3) at this time.

CAUTION: MAKE SURE THAT:

THERE IS NO TENSION ON THE LINK ASSEMBLIES FOR THE ECS DUCTS
THE MATING SURFACES BETWEEN THE DUCTS CORRECTLY ALIGN.

TENSION AND INCORRECT ALIGNMENT CAN CAUSE AIR LEAKAGE, WHICH CAN CAUSE DAMAGE TO THE EQUIPMENT.

(g) Adjust the ECS interface duct (1) and the link assemblies until there is no preload. If necessary, loosen and adjust other ECS ducts and valves to remove preload (Ref. AMM TASK 36-11-49-000-822) and (Ref. AMM TASK 36-11-49-400-822).
(h) Tighten the V-band coupling (8) on the OPV as follows:
1 TORQUE the V-band couplings (8) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
2 Tap around the outer surface of the V-band couplings (8) with the HAMMER - FIBER.
3 TORQUE the V-band couplings (8) again to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
4 Tap around the outer surface of the V-band couplings (8) again with the HAMMER - FIBER.
5 TORQUE the V-band couplings (8) a third time to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
6 Tap around the outer surface of the V-band couplings (8) again with the HAMMER - FIBER.
7 TORQUE the V-band couplings (8) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
8 Make sure two full threads are shown on the V-band couplings (8).
(7) TORQUE the nuts (3) to between 90 and 75 lbf.in (1.02 and 0.85 m.daN )

.
(8) TORQUE the lock nuts on the link assemblies (6) and (7) to between 130 and 115 lbf.in (1.47 and 1.30 m.daN )

:
(a) Make sure the threads of the link assembly rods cover the inspection hole.
(9) For CONFIGURATION 1, install the link assembly as follows:
(a) TORQUE the jamb nuts (10) to between 130 and 115 lbf.in (1.47 and 1.30 m.daN )

:
1 Make sure the threads of the link assembly rods cover the inspection hole.
(10) For CONFIGURATION 2, install the link assembly as follows:
(a) TORQUE the lock nuts on the link assembly (13) to between 130 and 115 lbf.in (1.47 and 1.30 m.daN )

:
1 Make sure the threads of the link assembly rods cover the inspection hole.
(11) Remove all the necessary COVER - PROTECTION to prevent damage to the engine.

Subtask 36-11-49-865-194-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 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 36-11-49-720-098-A ** ON A/C NOT FOR ALL

C. Do the Test No. 1 - Pneumatic Leak Test (Ref. AMM TASK 71-00-00-790-802).

5. Close-up
Subtask 36-11-49-410-183-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the right thrust-reverser cowl-door (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
462AR

Subtask 36-11-49-440-113-A ** ON A/C NOT FOR ALL

B. Do the reactivation of the thrust reverser system after maintenance (Ref. AMM TASK 78-30-00-440-805).

Subtask 36-11-49-410-184-A ** ON A/C NOT FOR ALL

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL 448AR
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

Subtask 36-11-49-862-110-A ** ON A/C NOT FOR ALL

D. 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 04:53:50 UTC