Installation of the Overpressure Valve

TASK 36-11-53-400-802-A
Installation of the Overpressure Valve

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.

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

ZONE: 454
ZONE: 464
FIN: 7115HM1 ** ON A/C NOT FOR ALL
FIN: 7115HM2 ** 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	1	ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE
No specific	1	ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE
No specific	AR	HAMMER - FIBER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 125 and 115 lbf.in (1.41 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
3	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 36-11-00-740-802-A	BITE Test of the Engine Bleed Air System (EBAS) (System Test)
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 36-11-49-400-824-A	Installation of the Environmental Control System (ECS) Interface Duct
TASK 36-12-00-860-802-A	Pressurization of the Bleed System with the APU
TASK 36-12-00-860-803-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 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
Overpressure Valve

3. Job Set-up
Subtask 36-11-53-860-052-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 the engine 1(2) is shut down for a minimum of 5 minutes before you do this procedure.
(3) 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(are) 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(are) in position tell persons not to the start the engine 1(2).

(5) On the HP ground connector:

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

(6) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR 1(2) pushbutton switch is off.
(b) Make sure that the WARNING NOTICE(S) is(are) in position to tell persons not to energize FADEC 1(2).
(7) Make sure that an ACCESS PLATFORM 3M (10 FT)- ADJUSTABLE is in position below the engine 1(2).

Subtask 36-11-53-865-059-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 36-11-53-010-066-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 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
(3) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position below the fan cowl doors.

Subtask 36-11-53-040-058-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 36-11-53-420-055-A ** ON A/C NOT FOR ALL

A. Installation of the Overpressure Valve
(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 (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).

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.

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.

(3) If necessary, loosen the ECS ducts to allow the clearance during the installation of the overpressure valve (1) (Ref. AMM TASK 36-11-49-000-822).
(4) Remove the protection covers from the overpressure valve (1), the interface duct assembly and the starter duct assembly.
(5) Make sure that the parts retained from the removed component are clean and in the correct condition.
(6) Put the AIPC 36-11-86-30-110 SEAL (3) and the overpressure valve (1) in position on the starter duct assembly and attach the V-band coupling (2). Do not torque the V-band coupling (2) at this time.

NOTE: Make sure that the flow direction arrow on the valve is pointed in the correct direction.

(7) Put the AIPC 36-11-86-30-110 SEAL (3) and overpressure valve (1) in position on the interface duct assembly and attach the V-band coupling (2). Do not torque the V-band coupling (2) at this time.

NOTE: Make sure that the alignment tab engages.

(8) Put the V-band couplings (2) in the approximate orientation as shown.
(9) Install the three link assemblies on the interface duct assembly. Do not tighten the hardware at this time (Ref. AMM TASK 36-11-49-400-824).
(10) Adjust the link assemblies to remove the preload on the interface duct assembly.
(11) Torque the V-band couplings (2):
(a) TORQUE the V-band couplings (2) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

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

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

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

.
(h) Make sure that two full threads are shown on the V-band couplings (2).
(12) Tighten the hardware that attaches the three link assemblies to the interface duct assembly (Ref. AMM TASK 36-11-49-400-824).
(13) Adjust and tighten the ECS ducts as necessary to remove the preload on the ECS system (Ref. AMM TASK 36-11-49-400-822).

Subtask 36-11-53-865-060-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 36-11-53-720-073-A ** ON A/C NOT FOR ALL

C. Test
(1) Do the BITE test of BMC 1(2) (Ref. AMM TASK 36-11-00-740-802).
(2) Do the leak test:
(a) Pressurize the bleed system with one of the air sources that follow:
1 The APU (Ref. AMM TASK 36-12-00-860-802) or
2 The HP ground connector (Ref. AMM TASK 36-12-00-860-803).
(3) Make sure that there are no leaks at the joints between the overpressure valve, the sensor lines and the ducts 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 air removes the dry developer from the joint.

(4) Remove the materials that are used to do the leak test.

5. Close-up
Subtask 36-11-53-410-060-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 36-11-53-440-055-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 36-11-53-410-061-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 36-11-53-862-055-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 01:13:19 UTC