Installation of the Pylon Bleed Duct Assembly

TASK 36-11-49-400-830-A
Installation of the Pylon Bleed Duct Assembly

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
ZONE: 450
ZONE: 460

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 4M (13 FT)-ADJUSTABLE
No specific	AR	FOIL - ALUMINUM
No specific	AR	PLUG - BLANKING
No specific	AR	WARNING NOTICE(S)
No specific	AR	WATER - SOAPY SOLUTION
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 155 and 145 lbf.in (1.75 and 1.64 m.daN )
98D27803000000	1	LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION
98L12003001000	1	HARNESS,SAFETY

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.14QEB1)	Wire-Locking Dia: 0.6 mm CRES Nickel Alloy -

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
450	ENG 1 THRUST REVERSER & EXHAUST SECTION
460	ENG 2 THRUST REVERSER & EXHAUST SECTION
191DB
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
411AL, 413AT, 413BT, 413CT, 437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
421AL, 423AT, 423BT, 423CT, 447AL, 448AR, 461AL, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
26	SEAL	AIPC 36-11-86-50-150
49	GLASS-FIBER YARN BRAID	AIPC 36-11-86-50-210
21	SEAL	AIPC 36-11-86-52-100

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 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 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 71-00-51-000-803-A	Removal of the Power Plant with 2D Bootstrap
TASK 71-00-51-400-803-A	Installation of the Power Plant with 2D Bootstrap
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-803-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-807-A	Deactivation of the Thrust Reverser System for Nacelle Maintenance (ICU)
TASK 78-30-00-440-807-A	Reactivation of the Thrust Reverser System after Nacelle Maintenance (ICU)
TASK 78-36-00-010-806-A	Opening of the Thrust Reverser Cowl Doors
TASK 78-36-00-410-806-A	Closing of the Thrust Reverser Cowl Doors
TASK 80-12-49-400-802-A	Installation of the Starter Air Duct (from the Pylon to the Starter Air Valve (SAV))
Pylon Bleed Ducts

3. Job Set-up
Subtask 36-11-49-860-127-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) In the cockpit, on AIR COND panel 30VU:
(a) Make sure that the ENG 1(2) BLEED pushbutton-switch is released (OFF legend on).
(b) Make sure that the APU BLEED pushbutton-switch is released (ON legend off).
(c) Make sure that the WARNING NOTICE(S) is in position to tell persons not to operate the pneumatic system.
(3) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector-switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control-switch is in the OFF position for a minimum of five minutes before you do this procedure.
(c) Make sure that the WARNING NOTICE(S) are in position to tell persons not to operate:

The ENG/MODE selector-switch and
The ENG/MASTER 1(2) control-switch.

(4) In the cockpit, on the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton-switch is off.
(b) Make sure that the WARNING NOTICE(S) is in position to tell persons not to energize FADEC 1(2).
(5) On access door 191DB, 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.
(6) In the cockpit, on FLAPS panel 114VU:
(a) 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).
(b) 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.
(7) Put on and attach a 98L12003001000 HARNESS,SAFETY before you start work in the work area (Ref. AMM TASK 12-00-00-481-002).
(8) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position.

Subtask 36-11-49-865-205-A

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENGINE 1)
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENGINE 2)
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-49-010-241-A

C. Get Access
(1) Make sure that the access panels that give access to the ducts that you will install are removed (Ref. AMM TASK 54-52-11-000-807):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
411AL 413AT 413BT 413CT
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
421AL 423AT 423BT 423CT

Subtask 36-11-49-010-242-A

D. Removal of the Components
(1) If you must install the lower bleed elbow and/or a new T-duct, make sure that the engine is removed (Ref. AMM TASK 71-00-51-000-803).

Subtask 36-11-49-410-208-A

E. Get Access
(1) Make sure that the thrust reverser cowl-doors are closed (Ref. AMM TASK 78-36-00-410-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL, 462AR

Subtask 36-11-49-440-124-A

F. Reactivation of the Thrust Reverser System
(1) Make sure that you did the reactivation of the thrust reverser system (Ref. AMM TASK 78-30-00-440-807).

Subtask 36-11-49-410-209-A

G. Get Access
(1) Make sure that the fan cowl doors are closed (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

4. Procedure
Subtask 36-11-49-420-142-A

A. Preparation for the Installation of the Starter Duct and the Forward Starter 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) Clean the component interfaces and the adjacent area.
(4) Do an inspection of the component interfaces and the adjacent area.
(5) Make sure that the work area is clean and clear of tools and other items.
(6) Prepare the starter duct (5) for installation as follows:
(a) Remove the PLUG - BLANKING from the starter duct (5).
(b) Carefully install the starter duct (5) in the pylon. Do not put in position the starter duct (5) at this time.
(7) Prepare the forward starter duct (11) for installation as follows:
(a) Install the forward starter duct (11) in the pylon.
(b) Install the bolts (18) and washers (19) on the forward starter duct (11) and the structure of the pylon. Do not tighten the bolts at this step.

Subtask 36-11-49-010-270-A

B. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

Subtask 36-11-49-040-172-A

C. Deactivation of the Thrust Reverser 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) Do the deactivation of the thrust reverser system for nacelle maintenance (Ref. AMM TASK 78-30-00-040-807).

Subtask 36-11-49-010-271-A

D. Get Access
(1) Open the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-010-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL, 462AR

Subtask 36-11-49-420-150-A

E. Installation of the Forward Starter Duct in the Lower Zone
(1) Install the bolt (13), washer (12) and nut (10) on the rod (9) and the forward starter duct (11). Do not tighten the bolts at this step.
(2) Install the bolt (15), washer (16) and nut (17) on the rod (14) and the forward starter duct (11).
(3) Tighten the bolts (13) and (15).
(4) If the engine is not removed, install a new seal (24), the coupling (23) and the engine starter air-duct (22) (Ref. AMM TASK 80-12-49-400-802).

Subtask 36-11-49-410-190-A

F. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL, 462AR

Subtask 36-11-49-410-210-A

G. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

Subtask 36-11-49-420-151-A

H. Installation of the Forward Starter Duct in the Upper Zone and Installation of the Starter Duct
(1) Tighten the four bolts (18).
(2) Install the starter duct (5):
(a) Install a new AIPC 36-11-86-52-100 SEAL (21) between the starter duct (5) and the forward starter duct (11).
(b) Carefully put in position the starter duct (5) in the pylon.
(c) Install the two bolts (3) and bushings (4) on the starter duct (5) and rod (2). Do not tighten the bolts (3) at this time.
(d) Install the bolt (7) and bushing (8) on the starter duct (5) and the rod (6). Do not tighten the bolt (7) at this time.
(e) Install the coupling (20) that attaches the forward starter duct (11) to the starter duct (5). Do not tighten the nut of the coupling (20) at this time.
(f) Tighten the bolts (3) and (7).
(g) TORQUE the nut of the coupling (20) to between 155 and 145 lbf.in (1.75 and 1.64 m.daN )

.
(h) Identify the tightened union nut of the coupling (20) with a red line (Ref. AMM TASK 20-23-22-910-001).
(3) If the bellows (54) is not removed, install a new seal (53) and the coupling (52) (Ref. AMM TASK 36-11-53-400-803).

Subtask 36-11-49-010-272-A

I. Get Access
(1) Do Steps 4.B. thru 4.D..

Subtask 36-11-49-420-152-A

J. Installation of the Lower Bleed Elbow
(1) Install the lower bleed elbow (27):
(a) Install the bolt (32), nut (36) and bushings (33) and (35) on the lower bleed elbow (27) and the bracket (34). Tighten the nut (36).
(b) Install the bolt (44), nut (42) and bushing (43) on the lower bleed elbow (27) and the rod (41). Tighten the nut (42).
1 Do not change the rigging of the adjustable rod (41).
(c) Install the bolt (29), bushing (30) and nut (31) on the lower bleed elbow (27) and the rod (28). Tighten the nut (31).
1 If necessary, adjust the adjustable rod (28).
(d) Install the bolt (40), bushing (39) and nut (38) on the lower bleed elbow (27) and the rod (37). Tighten the nut (38).
1 If necessary, adjust the adjustable rod (37).

Subtask 36-11-49-420-153-A

K. Installation of the Bleed Duct and the T-Duct
(1) Install a new AIPC 36-11-86-50-150 SEAL (26) on the lower bleed elbow (27).
(2) If you change or replace the T-duct, loosen the bolts (46) of the collar (45). Thus you can adjust the position of the bleed duct (1) to agree with the new T-duct (57).
(3) Do Steps 4.F. and 4.G.
(4) Install the bleed duct (1):
(a) Install the bleed duct (1) in the pylon.
1 Make sure that you can easily engage the flange of the bleed duct (1) in the flange of the lower bleed elbow (27).
2 Do not try to push the flange of the bleed duct (1) with your hands to make it go into the flange of the elbow duct (27).
(b) Put the half plates (50) and (51) in position.
(c) Cut 234 mm (9.21 in.) of new AIPC 36-11-86-50-210 GLASS-FIBER YARN BRAID (49).
(d) Put the glass-fiber yarn braid (49) in position in the half plate (50).

NOTE: Do not align the end of the glass-fiber yarn braid (49) with the end of the half plate (50).

(e) Put the two bolts (48) and washers (47) in position on the half plate (50) and tighten them with your hand.
(f) Put the glass-fiber yarn braid (49) in position in the half plate (51).
(g) Put the two bolts (48) and washers (47) in position on the half plate (51) and tighten them with your hand.
(h) Carefully put the remaining glass-fiber yarn braid (49) in position in the half plate (50).
(5) Install, on the overpressure valve (64), the bleed duct (1) and starter duct (5), the T-duct (57), bellows (54), shims (65), couplings (52), (55), (63) and (67), new seals (53), (56), (62) and (66), bolts (59) and (61), washer (58) and bushing (60) (Ref. AMM TASK 36-11-53-400-803).
(6) Tighten the four bolts (48).
(7) Do Steps 4.B. thru 4.D.
(8) Install the coupling (25) that attaches the bleed duct (1) to the lower bleed elbow (27). Do not tighten at this time.
(9) Make sure that the coupling (25) is installed in the same position as recorded during the removal procedure.
(10) TORQUE the nut of the coupling (25) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(11) If you change or replace the T-duct, tighten the bolts (46) of the collar(45).
(12) Install the engine if it is removed (Ref. AMM TASK 71-00-51-400-803).

Subtask 36-11-49-480-090-A

L. Prepare for the Leak Test
(1) There are two procedures to do a leak check at the connections of the bleed air ducts (duct joint, flexible connections).
(a) Soap solution procedure:

Leaks are permitted if the WATER - SOAPY SOLUTION stays on the joint line with a continuous series of bubbles.
Leaks are not permitted if the air pressure (from the air source) blows the soap solution off the joint line and prevents a continuous series of bubbles.

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.

(b) Aluminum foil procedure:

NOTE: We recommend that you do this procedure when you do a leak check with hot air.

1 Wind the FOIL - ALUMINUM on the joint one time.
2 Twist tight the seam of the foil wrap.
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 at the two sides of the pneumatic joint with 14QEB1Wire-Locking Dia: 0.6 mm CRES Nickel Alloy -.

Subtask 36-11-49-865-206-A

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C ALL
FOR FIN: 4020KM1 (POWER PLANTDEMOUNTABLE, ENGINE 1)
49VU	AIR BLEED/ENG 1/CTL	2HA1	D11
122VU	AIR BLEED/ENG 1/MONG	3HA1	Z23
FOR FIN: 4020KM2 (POWER PLANTDEMOUNTABLE, ENGINE 2)
49VU	AIR BLEED/ENG 2/MONG	3HA2	D12
122VU	AIR BLEED/ENG 2/CTL	2HA2	Z22

Subtask 36-11-49-790-061-A

N. Leak Test
(1) Remove the WARNING NOTICE(S) from the HP ground connector.
(2) 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).
(a) Make sure that there are no leaks at all the connections of the ducts (1), (5), (11), (57), elbow (27) and bellows (54).

NOTE: There is a leak when the foil installed on the connection breaks or becomes too hot.

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

5. Close-up
Subtask 36-11-49-410-215-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL, 462AR

Subtask 36-11-49-440-125-A

B. Do the reactivation of the thrust reverser system after nacelle maintenance (Ref. AMM TASK 78-30-00-440-807).

Subtask 36-11-49-410-191-A

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR
(2) Install the access panels (Ref. AMM TASK 54-52-11-400-807):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
411AL 413AT 413BT 413CT
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
421AL 423AT 423BT 423CT
(3) On FLAPS panel 114VU:

Remove the 98D27803000000 LOCKING TOOL-FLAP SLAT LEVER,INT. POSITION from the flap/slat control lever.

(4) Remove the access platform(s).
(5) Remove the WARNING NOTICE(S).

Subtask 36-11-49-862-114-A

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 01:11:47 UTC