Removal of the Power Plant (APU) (APS 3200)

TASK 49-11-11-000-003-A
Removal of the Power Plant (APU) (APS 3200)

WARNING: MAKE SURE THAT YOU HAVE THE CORRECT FIRE FIGHTING EQUIPMENT AVAILABLE.

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

WARNING: MAKE SURE THAT THE SAFETY DEVICES AND THE WARNING NOTICES ARE IN POSITION BEFORE YOU START A TASK ON OR NEAR:

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

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

ZONE: 310
FIN: 4005KM ** 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 4M (13 FT)-ADJUSTABLE
No specific	AR	CAP - BLANKING
No specific	AR	CONTAINER 1 L (1/4 USGAL)
No specific	AR	COVER - BLANKING
No specific	AR	PLUG - BLANKING
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	TAPE - SELF-AMALGAMATING
No specific	AR	TIE WRAP
No specific	AR	WARNING NOTICE(S)
98A28007570000	1	ADAPTER - VENT AND DRAIN VALVE, APU
98A49107504001	1	PROTECTOR-THREADS,APU MOUNTING BOLTS
98D49207527000	1	SUPPORT FRAME FOR APU WITH TROLLEY
OR	OR
98D49209001000	1	APU SUPPORT FRAME
OR	OR
98D49209002000	1	APU INST TROLLEY
OR	OR
98D49209002001	1	APU INST TROLLEY
98L12003001000	AR	HARNESS,SAFETY
A1-91-265	1	HOIST-MINILIFT

B. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
310	FUSLG TAIL SECTION AFT OF AFT PRESS BHD
315AL, 316AR

C. Referenced Information

REFERENCE	DESIGNATION
TASK 24-23-51-000-001-A	Removal of the APU Generator
TASK 24-23-51-000-001-A-01	Removal of the APU Generator with the Minilift Hoist
TASK 24-42-00-861-001-A	Energize the Ground Service Network from the External Power
TASK 28-22-14-000-001-A	Removal of the APU Fuel LP-Switch
TASK 29-00-00-864-001-A	Put the Related Hydraulic System in the Depressurized Configuration before Maintenance Action
TASK 31-36-00-740-015-A	Printout of the Engine/APU Hours and Cycles Stored in the Flight Data Interface and Management Unit (FDIMU)
TASK 49-00-00-080-001-A	Removal of the APU Hoist Tool
TASK 49-00-00-480-001-A	Installation of the APU Hoist Tool
TASK 49-12-00-220-003-A	Dimensional Check of the APU Vibration Isolators (APS 3200)
TASK 49-12-54-000-002-A	Removal of the APU Mount Brackets (APS 3200)
TASK 49-52-41-000-002-A	Removal of the Oil Cooler Outlet Duct (APS 3200)
TASK 52-41-00-010-001-A	Open the APU Doors for Access
TASK 52-41-21-000-001-A	Removal of APU Access Door 315AL
TASK 52-41-22-000-001-A	Removal of the APU Access Door and the related Door Mechanism
Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler
Electrical Connections and Attachment Points of the Harness
Electrical Connections to the Starter Motor and Generator
APU Mounts and Tie Rods
APU Hoisting Points

3. Job Set-up
Subtask 49-11-11-860-057-A ** ON A/C NOT FOR ALL

A. Aircraft Maintenance Configuration
(1) Energize the ground service network
(Ref. AMM TASK 24-42-00-861-001).
(2) On overhead panel 25VU, make sure that the APU MASTER SW pushbutton switch is released (the ON legend is off).
(3) On the APU section of overhead panel 25VU, put the WARNING NOTICE(S) in position to tell persons not to start the APU.
(4) Make sure that the hydraulic systems are depressurized
(Ref. AMM TASK 29-00-00-864-001).

Subtask 49-11-11-740-052-A ** ON A/C NOT FOR ALL

B. Printout of the APU Hours and Cycles
(1) Use the Multipurpose Control & Display Unit (MCDU) and print the APU hours and cycles (Ref. AMM TASK 31-36-00-740-006).
(2) Record the APU hours and cycles in the APU log.

Subtask 49-11-11-865-060-A ** ON A/C NOT FOR ALL

C. Open, safety and tag this(these) circuit breaker(s):

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
49VU	APU/FUEL/BLOW OFF/PUMP	2QC	B14
121VU	APU/FUEL/BLOW OFF/CTL	1QC	K39
121VU	APU/FIRE AND OVHT/DET/LOOP A	1WG	L43
121VU	APU/APU/CTL	2KD	L42
121VU	APU/ECB/SPLY	1KD	L41
121VU	APU/AUTO/EXTIG/GND/TEST	30WF	L40
121VU	APU/FIRE/EXTIG/SQUIB/B	2WF	L39
121VU	APU/FIRE/EXTIG/SQUIB/A	1WF	L38
121VU	APU/FIRE/LP VALVE/NORM	4WF	M42
121VU	APU/FIRE/LP VALVE/STBY	3WF	M41
121VU	APU/FUEL/LP VALVE/CTL	1QF	M40
121VU	APU/FUEL/LP VALVE/SPLY	2QF	M39
121VU	APU/FUEL/PUMP/CTL	3QC	M38

Subtask 49-11-11-010-055-A ** ON A/C NOT FOR ALL

D. Get Access

WARNING: BEFORE YOU START WORK, YOU MUST PUT ON A SAFETY HARNESS AND ATTACH IT TO THE ACCESS PLATFORM. WITHOUT A SAFETY HARNESS, YOU CAN FALL. THIS CAN KILL YOU OR CAUSE YOU INJURY.

(1) Put on and attach the HARNESS, SAFETY before you start work in the work area.
(2) Put the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE in position below APU access doors 315AL and 316AR.
(3) Open APU access doors 315AL and 316AR (Ref. AMM TASK 52-41-00-010-001).
(4) Set the light switch 11LJ to the ON position.
(5) Remove APU access doors 315AL and 316AR (Ref. AMM TASK 52-41-21-000-001) (Ref. AMM TASK 52-41-22-000-001).

NOTE: The removal of the APU is also possible if you do not remove the access doors but their removal will:

Make the access to the APU compartment easier
Make the installation and the operation of the hoist tool easier
Decrease the risk of injury to the personnel
Decrease the risk of damage to the doors with the maintenance platform.

4. Procedure
Subtask 49-11-11-020-053-C ** ON A/C NOT FOR ALL

A. Disconnection of the APU

Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler ** ON A/C NOT FOR ALL

(1) Do the dimensional check of the APU vibration isolators (Ref. AMM TASK 49-12-00-220-003).
(2) Disconnection of the APU Bleed-Air Duct Elbow
(a) Loosen the clamp (2).

NOTE: Let the clamp (2) stay loosely on the the bleed-air duct of the APU (1).

(b) Put blanking caps on the openings of the bleed-air duct elbow (3) and the bleed -air duct of the APU (1).
(3) Remove the oil-cooler outlet duct and put PLUG - BLANKING on the oil cooler outlet and oil cooler duct (Ref. AMM TASK 49-52-41-000-002).
(4) Disconnect the APU Fuel Line with Vent and Drain Valve from the APU

Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler ** ON A/C NOT FOR ALL

WARNING: OBEY THE FUEL SAFETY PROCEDURES.

CAUTION: PUT PLASTIC CAPS OR PLUGS ON ALL FUEL AND/OR LUBRICATION SYSTEM COMPONENTS AND LINES. IF YOU USE TAPE, CLOTH, OR METAL CAPS ON THEM, YOU CAN DAMAGE THE APU.

CAUTION: YOU MUST USE TWO WRENCHES AND HOLD THE COMPONENT WHEN YOU REMOVE/INSTALL THE PIPE COUPLINGS AND/OR UNIONS. THIS PREVENTS DAMAGE TO THE COMPONENT.

(a) Put the CONTAINER 1 L (1/4 USGAL) in position below the fuel control unit and the vent and drain valve (21).
(b) Remove the blanking cap (22) from the LP fuel inlet vent and drain valve (21).
(c) Install the 98A28007570000 ADAPTER - VENT AND DRAIN VALVE, APU to the vent and drain valve (21).
(d) Drain the unwanted fuel into the container.
(e) Remove the 98A28007570000 ADAPTER - VENT AND DRAIN VALVE, APU from the vent and drain valve.
(f) Install the blanking cap (22).
(g) Remove and discard the lockwire and disconnect the vent and drain valve (21) from the Union Assy (20).
(h) Put the PLUG-BLANKING in each disconnected line end.
(i) Put the main fuel inlet-pipe in the stowage bracket attached to the firewall of the APU compartment. This will prevent damage during the APU removal.
(j) Remove the container below the vent and drain valve (21).
(5) Disconnection of the Electrical Harness

Electrical Connections and Attachment Points of the Harness ** ON A/C NOT FOR ALL

(a) Disconnect the electrical connections (50) P1 , (51) P2 and (55) P3 from the APU compartment front fire-wall.
(b) Put blanking plugs on all electrical connectors.
(c) Remove the bolts (54) and the washers (95) from the clamps (53) at the APU compartment front fire-wall.

NOTE: Hold the spacers (52) in position when the bolts (54) are removed.

(d) Move the clamps (53) away from the brackets and temporarily install the washers (95), the bolts (54) and the spacers (52).
(e) Remove the bolt (56) and the washer (57) from the bracket (59) at the RH side of the APU compartment.
(f) Move the clamp (58) away from the bracket (59) and temporarily install the bolt (56) and the washer (57) to bracket (59).
(g) Remove the bolt (61) and the nut (62) from the brackets (60) and (63) at FWD RH tie-rod.
(h) Move the clamp (63) away from clamp (60) and temporarily install the bolt (61) and nut (62) to the clamp (60).
(i) Attach the electrical connectors (50) P1, (51) P2 and (55) P3 with TIE WRAP to the APU. This prevents damage to the harness when the APU is removed.
(6) Disconnection of the Electrical Cables from the Starter Motor

Electrical Connections to the Starter Motor and Generator ** ON A/C NOT FOR ALL

(a) Carefully pull back the rubber sleeves (89) and (91) to get access to the starter motor terminals.

CAUTION: MAKE MATCH MARKS ON ALL THE ELECTRICAL WIRES BEFORE YOU DISCONNECT THEM. INCORRECT CONNECTION OF WIRES WILL CAUSE DAMAGE TO EQUIPMENT.

(b) Remove the nuts (72) and (76), the lock-washer (88) and (90) together with the washers (73) and (75) from the starter motor terminals.
(c) Disconnect the starter motor cables (74) and (77) from the starter motor terminals.
(d) Temporarily attach the nuts (72) and (76), the washers (73) and (75) and the lock-washers (88) and (90) to the studs of the starter motor.
(e) Put CAP - BLANKING on the disconnected ring terminals of the starter motor cables (74) and (77).
(f) Temporarily attach the starter motor cables (74) and (77) to the FWD LH tie rod with TIE WRAP. This prevents damage to the starter cables when the APU is removed.

NOTE: Because the electrical harness is removed together with the APU, it is not necessary to disconnect the electrical connector (79) P32 from the starter motor.

(7) Disconnection of the Generator Cables

Electrical Connections to the Starter Motor and Generator ** ON A/C NOT FOR ALL

(a) Remove the bolts (70) , the washers (84) and remove the phase lead cover (71).
(b) For generator type 5913667 or type BA03604, remove the nuts (83), the washers (85) and the phase leads (82) from the generator (80).
(c) For generator type BA16501, remove the nuts (83) and the phase leads (82) from the generator (80).
(d) Make sure that the phase leads (82) are identified correctly. Identify the phase leads (82) if necessary.
(e) Do not remove the washers (86) from the lower part of the terminal studs (the part that does not have threads).
(f) Put CAP - BLANKING on the ring terminals of the disconnected phase leads (82).
(g) Temporarily install the nuts (83) to the terminal studs.
(h) Temporarily attach the phase leads (82) to the FWD RH tie rod with TIE WRAP. This prevents damage to the phase leads when APU is removed.
(i) Temporarily install the phase lead cover (71) with the washers (84) and the bolts (70).

NOTE: Because the electrical harness is removed together with the APU, it is not necessary to disconnect the electrical connector (81) P4 from the generator.

(8) Disconnection of the Exhaust-Muffler Drain Pipe

Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler ** ON A/C NOT FOR ALL

(a) Disconnect the exhaust-muffler drain pipe (35) at the T-fitting of the APU drain system.
(b) Put the PLUG-BLANKING in each disconnected line end.

NOTE: Watch that there is sufficient clearance between the APU and exhaust-muffler drain pipe when the APU is removed.

(9) Disconnection of the Exhaust Muffler

Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler ** ON A/C NOT FOR ALL

(a) Remove and discard the lockwire between the studs on the insulation blanket (34) and (33) and the studs on the nozzle assy (31).
(b) Remove and discard the lockwire between the two halves of the insulation blanket (33) and (34).
(c) Remove the two halves of the insulation blanket (33) and (34).
(d) Disconnect the exhaust coupling clamp (30) and push the exhaust muffler rearwards.

NOTE: Make sure that the clearance between the APU exhaust and hot nozzle assy flange is sufficient to prevent damage when the APU is removed.
Make sure that the exhaust muffler stays in position when the APU is removed.

(e) Put COVER - BLANKING on the hot nozzle assy flange (32).
(10) Disconnection of the Bonding Straps

APU Mounts and Tie Rods ** ON A/C NOT FOR ALL

(a) Remove the nuts (45) and the washers (44) from the stud (49) and remove the bonding straps (43) at the LH and RH FWD mount brackets (46).
(b) Temporarily install again the nuts (45) and the washers (44) to the studs (49) on the LH and RH FWD mount brackets (46).
(c) To prevent damage when the APU is removed attach the bonding straps (43) with TAPE - SELF-AMALGAMATING to the APU tie-rods.

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

B. Installation of the the APU A1-91-265 HOIST-MINILIFT.
(1) Install the A1-91-265 HOIST-MINILIFT (Ref. AMM TASK 49-00-00-480-001).
(2) Remove the weight of the APU from the APU mount brackets

CAUTION: DO NOT TURN THE HOIST HANDLE MORE THAN 90 DEGREES, AFTER YOU REMOVE THE SLACK FROM THE HOIST CABLE. IF YOU TURN THE HOIST HANDLE MORE THAN 90 DEGREES, YOU CAN CAUSE DAMAGE TO THE APU AND THE APU MOUNTS.

(a) Operate the A1-91-265 HOIST-MINILIFT until the weight of the APU is removed from the mounts.

NOTE: Before you install the hoist handle, turn the upper drum shaft of the A1-91-265 HOIST-MINILIFT with your hand until you have removed the slack from the hoist cable. Then install the hoist handle on the upper drum shaft and turn the handle 90 degrees in clockwise direction. Thus you make sure that the weight of the APU is removed from the APU mounts.

NOTE: Do a check and make sure that the A1-91-265 HOIST-MINILIFT is assembled and installed correctly and holds the load.

(3) Put the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY in position below the APU.

Subtask 49-11-11-020-054-C ** ON A/C NOT FOR ALL

C. Remove the APU from the APU Compartment
(1) Removal of the mount nuts

WARNING: OBEY THE HOISTING SAFETY PROCEDURES. MAKE SURE THAT THE HOIST IS ASSEMBLED AND ATTACHED CORRECTLY BEFORE YOU PUT A LOAD ON IT. OBEY THE MANUFACTURER'S INSTRUCTIONS WHEN YOU USE THE HOIST. IF THE HOIST IS IN AN INCORRECT CONDITION THE LOAD CAN MOVE ACCIDENTALLY AND KILL PERSONS OR CAUSE INJURY.

WARNING: DO NOT FULLY REMOVE THE APU MOUNT NUTS. LEAVE THE NUTS ON THE ENDS OF THE MOUNT STUDS UNTIL THE HOIST SUPPORTS THE FULL WEIGHT OF THE POWER PLANT. THUS THE POWER PLANT CANNOT FALL IF THE HOIST CABLE BREAKS.

(a) Loose the APU mount nuts (40), (47) and (48).
(b) Lift the APU with the A1-91-265 HOIST-MINILIFT and make sure it can support the weight.
(c) Remove the APU mount nuts (40), (47) and (48).
(d) Install the 98A49107504001 PROTECTOR-THREADS,APU MOUNTING BOLTS to the threads (41) of the rear APU mount and the vibration isolators.
(2) Removal of the APU from the APU mount vibration-isolators

CAUTION: MAKE SURE THAT THE THREE ATTACHMENT NUTS ARE REMOVED AND THAT THE APU CAN MOVE DOWN FREELY. IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE TIE RODS WHEN YOU LOWER THE APU.

CAUTION: MAKE SURE THAT ALL PLUMBING IS FREE FROM OBSTRUCTION.

(a) Remove the APU from the APU mount vibration-isolators and lower it carefully from the APU compartment.
(3) Attachment of the APU to the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY:

APU Hoisting Points ** ON A/C NOT FOR ALL

CAUTION: MAKE SURE THAT ALL PLUMBING IS FREE FROM OBSTRUCTION.

(a) Attach the APU hoisting points (1), (2) and (3) to the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.
1 Make sure that the pip-pins are fully engaged in the brackets of the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY and in the APU hoisting points (1) and (2).
2 Make sure that the screw at the rear of the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY is fully engaged in the attachment plate and in the APU hoisting point (3).
(b) Disconnect the A1-91-265 HOIST-MINILIFT from the APU (Ref. AMM TASK 49-00-00-080-001).
(c) Put COVER - BLANKING on the APU exhaust flange.
(4) Removal of parts.
(a) Remove the Generator (80) (Ref. AMM TASK 24-23-51-000-001).
(b) Remove the FWD and AFT APU mount brackets (46) and (42) (Ref. AMM TASK 49-12-54-000-002).
(c) Remove the APU LP Switch 5030QM (Ref. AMM TASK 28-22-14-000-001).
(d) Keep the parts for the subsequent installation procedure.
(5) If you will not install a new APU, you must install the components of the kit for the FLIGHT WITHOUT APU.

[Rev.10 from 2021] 2026.04.01 04:53:44 UTC