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

TASK 49-11-11-400-003-A
Installation of the Power Plant (APU) (APS 3200)

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

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	BRUSH - BRISTLED, FIBER, MEDIUM
No specific	AR	CONTAINER 1 L (1/4 USGAL)
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	TIE WRAP
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 115 and 105 lbf.in (1.30 and 1.19 m.daN )
No specific	Torque wrench: range to between 180 and 170 lbf.in (2.03 and 1.92 m.daN )
No specific	Torque wrench: range to between 0.34 and 0.31 m.daN (30.09 and 27.43 lbf.in )
No specific	Torque wrench: range to between 0.5 and 0.4 m.daN (44.25 and 35.40 lbf.in )
No specific	Torque wrench: range to between 0.47 and 0.43 m.daN (41.59 and 38.05 lbf.in )
No specific	Torque wrench: range to between 0.93 and 0.81 m.daN (82.30 and 71.68 lbf.in )
No specific	Torque wrench: range to between 2.5 and 2.3 m.daN (18.44 and 16.96 lbf.ft )
No specific	Torque wrench: range to between 2.8 and 2.5 m.daN (20.65 and 18.44 lbf.ft )
No specific	Torque wrench: range to between 3.1 and 2.5 m.daN (22.86 and 18.44 lbf.ft )
No specific	Torque wrench: range to between 5.31 and 4.85 m.daN (39.16 and 35.77 lbf.ft )
No specific	Torque wrench: range to between 8.5 and 7.7 m.daN (62.68 and 56.78 lbf.ft )
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	1	HARNESS,SAFETY
A1-91-265	1	HOIST-MINILIFT

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03ABA1)	Synthetic base Lubricating Oil-Turbine Engine - -
(Material No.03ABB1)	Synthetic base Lubricating Oil-Turbine Engine Low Temp. -
(Material No.03QBA1)	Dry lubricant-General Assembly - -
(Material No.04SAB2)	Varnish Polyurethane-- Marking Structure
(Material No.08ABC1)	Aqueous Cleaner-Aircraft Exterior Pressure Spraying -
(Material No.12ABC1)	Corrosion Preventive Compound_Water Displacing Soft Film -
(Material No.14QFB1)	Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -

C. Work Zones and Access Panels

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

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
4	NUTS	AIPC 24-23-04-01-020
4	NUTS	AIPC 24-23-84-01-020

E. Referenced Information

REFERENCE	DESIGNATION
TASK 20-21-11-911-001-A	Tightening Torques for Standard Threaded Fasteners
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
TASK 21-00-00-100-001-A	Cleaning of Special Components in the Environmental Control System (ECS)
TASK 21-00-00-615-802-A	Level A Decontamination of the Environmental Control System (ECS)
TASK 21-00-00-615-803-A	Level B Decontamination of the Environmental Control System (ECS)
TASK 21-00-00-615-804-A	Level C Decontamination of the Environmental Control System (ECS)
TASK 24-23-51-400-001-A	Installation of the APU Generator
TASK 24-23-51-400-001-A-01	Installation 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 24-42-00-862-001-A	De-energize the Ground Service Network Supplied from the External Power
TASK 28-22-00-710-001-A	Operational Test of the APU Fuel-Pump System on Ground to Purge the Fuel Line
TASK 28-22-14-400-001-A	Installation 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 31-36-00-740-013-A	Update of the APU Hours and Cycles in the FDIMU after APU, ECB or FDIMU Replacement
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 49-00-00-710-005-A	Self-Test of the ECB
TASK 49-00-00-710-008-A	Operational Test of the APU
TASK 49-00-00-790-002-A	Leak Test of the APU
TASK 49-00-00-790-005-A	Air Leak Test with closed APU Doors
TASK 49-00-00-860-011-A	Update of APU Data (hours/cycles)
TASK 49-11-00-000-003-A	Removal of the APU Substitution Kit (APS 3200)
TASK 49-12-00-210-004-A	Detailed Inspection of APU Suspension Rods, Vibration Isolator Structure including Brackets and visible part of Structure Attachment Fittings (APS 3200)
TASK 49-12-54-400-002-A	Installation of the APU Mount Brackets (APS 3200)
TASK 49-16-00-210-002-A	Detailed Inspection of APU Air Intake, Diffuser Elbow, Seals and Felt Metal (APS 3200)
TASK 49-16-00-210-805-A	General Visual Inspection of the APU Air Inlet Plenum and APU Air Intake (APS 3200)
TASK 49-17-00-200-001-A	Inspect the APU Drain System (APS 3200)
TASK 49-51-42-000-003-A	Air By-Pass Duct - Removal (APS 3200)
TASK 49-51-42-400-003-A	Air By-Pass Duct - Installation (APS 3200)
TASK 49-52-41-000-002-A	Removal of the Oil Cooler Outlet Duct (APS 3200)
TASK 49-52-41-400-002-A	Installation of the Oil Cooler Outlet Duct (APS 3200)
TASK 49-81-00-200-004-A	Visual Check of the Sealing Ring Coupling, V-Clamp and Portion of Exhaust Duct Inside of the APU Compartment (APS 3200)
TASK 49-81-00-200-005-A	Visual Check of the Sealing-Ring Coupling Bellows (APS 3200)
TASK 49-81-41-000-002-A	Removal of the Exhaust Muffler (APS 3200)
TASK 49-81-41-400-002-A	Installation of the Exhaust Muffler (APS 3200)
TASK 49-90-00-600-004-A	Check Oil Level and Replenish (APS 3200)
TASK 49-91-42-200-003-A	Inspection of the Magnetic Drain Plug (APS 3200)
TASK 52-41-00-010-001-A	Open the APU Doors for Access
TASK 52-41-00-410-001-A	Close the APU Doors after Access
TASK 52-41-21-000-001-A	Removal of APU Access Door 315AL
TASK 52-41-21-400-001-A	Installation of APU Access Door 315AL
TASK 52-41-22-000-001-A	Removal of the APU Access Door and the related Door Mechanism
TASK 52-41-22-400-001-A	Installation of the APU Access Door and the related Door Mechanism
APU Mounts and Tie Rods
APU Generator Cover
APU Hoisting Points
Disconnection Points of the Bleed-Air Duct, Fuel Line and Exhaust Muffler
Electrical Connections to the Starter Motor and Generator
Electrical Connections and Attachment Points of the Harness

3. Job Set-up
Subtask 49-11-11-865-066-A ** ON A/C NOT FOR ALL

A. 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	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 49-11-11-860-056-A ** ON A/C NOT FOR ALL

B. Aircraft Maintenance Configuration
(1) Make sure that the ground service network is energized
(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, make sure that the WARNING NOTICE(S) is (are) 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).
(5) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position below APU access doors 315AL and 316AR.

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.

(6) Make sure that you put on and attach the 98L12003001000 HARNESS,SAFETY before you start work in the work area.
(7) Make sure that APU access doors 315AL and 316AR are open (Ref. AMM TASK 52-41-00-010-001) or removed (Ref. AMM TASK 52-41-21-000-001) and (Ref. AMM TASK 52-41-22-000-001).

NOTE: The installation 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.

(8) Make sure that the light switch 11LJ is in the ON position.
(9) Make sure that:

The oil-cooler outlet duct is removed (Ref. AMM TASK 49-52-41-000-002).
The exhaust muffler is disconnected and moved in the rear position.
The APU fuel line is correctly drained.

(10) If the components of the kit for the flight without the APU are installed, remove them (Ref. AMM TASK 49-11-00-000-003).

4. Procedure
Subtask 49-11-11-560-052-B ** ON A/C NOT FOR ALL

A. Preparation of a Replacement Component

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

(1) Make sure that the APU is installed on the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.
(2) Do a check of the APU generator installation:
(a) If you install an APU that you removed from the same aircraft or from a different aircraft, make sure that the generator is installed correctly on the APU (Ref. AMM TASK 24-23-51-400-001).
(b) If you install a new APU:

APU Generator Cover ** ON A/C NOT FOR ALL

1 Remove the nuts (3) from the generator cover (2) and discard them.

NOTE: The nuts (3) are only for the transportation and the storage of the APU.

2 Remove the generator cover (2).
3 Install the new AIPC 24-23-04-01-020 NUTS (4) or the new AIPC 24-23-84-01-020 NUTS (4) on the studs (1).
4 Install the APU generator (5) (Ref. AMM TASK 24-23-51-400-001).
(3) Make sure that the forward and aft APU mount-brackets (46) and (42) are installed correctly (Ref. AMM TASK 49-12-54-400-002).
(4) Make sure that the APU fuel LP-switch is installed correctly (Ref. AMM TASK 28-22-14-400-001).
(5) Make sure that the parts retained from the removed component are clean and in the correct condition.
(6) Make sure that the 98A49107504001 PROTECTOR-THREADS,APU MOUNTING BOLTS are installed on the threads of the aft APU mount-bracket (42).
(7) Fill the APU oil reservoir (Ref. AMM TASK 49-90-00-600-004).

Subtask 49-11-11-210-065-B ** ON A/C NOT FOR ALL

B. Prepare for the installation:
(1) Make sure that the APU compartment is in the correct condition. If necessary, clean the APU compartment with the Aqueous Cleaner-Aircraft Exterior Pressure Spraying - (Material No.08ABC1) and a BRUSH - BRISTLED, FIBER, MEDIUM.
(2) Make sure that the nuts (40), (47) and (48) are in the correct condition.
(a) Obey Paragraph 3.B. of this procedure (Ref. AMM TASK 20-21-11-911-001) for the installation of the used bolts and nuts.
(3) Make sure that the 98A49107504001 PROTECTOR-THREADS,APU MOUNTING BOLTS are installed on the threads (41) of the forward APU-mount vibration-isolators.
(4) Examine the connection flanges and the attachment points of the bleed air duct.
If necessary, replace the bleed air duct (Ref. AMM TASK 49-51-42-000-003) and (Ref. AMM TASK 49-51-42-400-003).
(5) Examine the exhaust V-clamp and the hot-nozzle assembly (Ref. AMM TASK 49-81-00-200-004).
(6) Examine the bellows and the sealing ring (Ref. AMM TASK 49-81-00-200-005).
(7) Examine the exhaust duct felt-metal.
If necessary, replace the exhaust duct felt-metal (Ref. AMM TASK 49-81-41-000-002) and (Ref. AMM TASK 49-81-41-400-002).
(8) Examine the drain tank and the APU drain tubes (Ref. AMM TASK 49-17-00-200-001).
(9) Examine the drain tubes and the hoses between the spring adapters and the drain mast.
(a) Replace the hoses that are not correctly sealed.
(b) Replace the drain tubes that are bent or twisted.
(c) Replace the drain tubes that show signs of damage or leaks.
(10) Examine the support assembly of the oil-cooler outlet duct to make sure that it is correctly attached.
If necessary, remove the oil-cooler outlet duct (Ref. AMM TASK 49-52-41-000-002) and install a new oil-cooler outlet-duct (Ref. AMM TASK 49-52-41-400-002).
(11) Make sure that the threads of the vent and drain valve (21) are clean and in the correct condition.
(12) Make sure that these items are clean and in the correct condition:

The electrical cables of the APU starter motor
The ring terminals of the starter motor cables.

(13) Make sure that these items are clean and in the correct condition:

The phase leads of the APU generator
The ring terminals of the APU generator phase-leads.

(14) Put the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY (with the APU temporarily installed on it) in the correct position below the APU compartment.
(15) Make sure that the A1-91-265 HOIST-MINILIFT is installed correctly (Ref. AMM TASK 49-00-00-480-001).
(16) Remove the blanking covers from the APU exhaust and the hot-nozzle assembly flange.
(17) Temporary position of the hot-nozzle assembly:

CAUTION: DURING THE INSTALLATION OF THE APU, MAKE SURE THAT THERE IS SUFFICIENT CLEARANCE BETWEEN THE HOT-NOZZLE ASSEMBLY AND THE EXHAUST FLANGE. IF THERE IS NOT SUFFICIENT CLEARANCE, YOU CAN CAUSE DAMAGE TO THE APU.

(a) Make sure that the temporary position of the hot-nozzle assembly flange is the same as the one during the APU removal.

Subtask 49-11-11-420-056-B ** ON A/C NOT FOR ALL

C. Installation of the APU

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

(1) Removal of the APU from the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.

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.

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

(a) Connect the A1-91-265 HOIST-MINILIFT to the APU (Ref. AMM TASK 49-00-00-480-001).
(b) Operate the A1-91-265 HOIST-MINILIFT carefully until the APU weight is removed from the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY, then disconnect the APU hoisting points (1), (2) and (3) from the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.
1 Turn the upper drum shaft of the A1-91-265 HOIST-MINILIFT until you have removed the slack from the hoist cable, then disconnect the APU from the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.
2 Make sure that you do not lift the 98D49207527000 SUPPORT FRAME FOR APU WITH TROLLEY98D49209001000 APU SUPPORT FRAME98D49209002000 APU INST TROLLEY98D49209002001 APU INST TROLLEY.
3 Do a check and make sure that the A1-91-265 HOIST-MINILIFT is assembled and installed correctly.
(2) Installation of the APU on the APU mount vibration-isolators.

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

WARNING: DO NOT TURN THE HOIST HANDLE MORE THAN 90 DEGREES WHEN THE APU MOUNT BRACKETS ARE TIGHTLY ENGAGED ON THE VIBRATION ISOLATORS. IF YOU TURN THE HOIST HANDLE MORE THAN 90 DEGREES, YOU CAN CAUSE DAMAGE TO THE APU AND THE APU MOUNTS. THEN THE APU CAN FALL AND KILL PERSONS OR CAUSE THEM INJURY.

CAUTION: BE CAREFUL WHEN YOU ENGAGE THE TWO FORWARD MOUNT BRACKETS ON THE VIBRATION ISOLATORS. THE MACHINED FACES ON THE CONE BOLTS OF THE VIBRATION ISOLATORS MUST BE ALIGNED WITH THE SLOTS ON THE MOUNT BRACKETS. IF NOT YOU WILL CAUSE DAMAGE TO THE MATING FACES.

CAUTION: DO NOT RELEASE THE LOAD FROM THE HOIST UNTIL THE MOUNT NUTS ARE TORQUED. IF THE MOUNT NUTS HOLD THE LOAD BEFORE THEY ARE TORQUED, YOU CANNOT APPLY THE CORRECT TORQUE VALUE.

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

(a) Operate the A1-91-265 HOIST-MINILIFT and carefully lift the APU into the correct position in the APU compartment.
(b) Carefully engage the APU mount brackets (42) and (46) on the APU vibration isolators.
(c) Remove the 98A49107504001 PROTECTOR-THREADS,APU MOUNTING BOLTS from the threads (41) of the rear APU mount bracket and the vibration isolators.
(d) Installation of the nuts (40), (47) and (48).
1 Install and turn the nuts (40), (47) and (48) a few turns on the threads (41) of the vibration isolators and aft mount bracket.
2 Use a torque wrench to turn the nuts and measure the breakaway torques of the nuts (40), (47) and (48).

NOTE: If the breakaway torque of the LH (47) or RH FWD nut (48) is less than 0.10 m.daN (8.85 lbf.in) replace the nut.
If the breakaway torque of the AFT nut (40) is less than 0.20 m.daN (17.70 lbf.in) replace the nut.

3 Turn the nuts (40), (47) and (48) until they are in contact with the APU mount brackets or vibration isolator.
4 TORQUE the LH (47) and the RH (48) nuts to between 3.1 and 2.5 m.daN (22.86 and 18.44 lbf.ft )

.
5 TORQUE the aft nut (40) to between 8.5 and 7.7 m.daN (62.68 and 56.78 lbf.ft )

.
6 Make marks on the nuts with Varnish Polyurethane-- Marking Structure (Material No.04SAB2) to identify the torqued position.
(e) Do a visual check of the FWD LH vibration isolator, FWD RH vibration isolator and AFT vibration isolator (Ref. AMM TASK 49-12-00-210-004).

Subtask 49-11-11-080-053-A ** ON A/C NOT FOR ALL

D. Removal of the A1-91-265 HOIST-MINILIFT

CAUTION: MAKE SURE THAT THE THREE ATTACHMENT NUTS ARE INSTALLED AND CORRECTLY TORQUED BEFORE YOU DISCONNECT THE HOIST. IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE TIE RODS.

(1) Remove the A1-91-265 HOIST-MINILIFT from the APU compartment (Ref. AMM TASK 49-00-00-080-001).

Subtask 49-11-11-420-058-B ** ON A/C NOT FOR ALL

E. Connection of the APU
(1) Connection of the Bonding Straps

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

(a) Remove and discard the tape which temporarily attached the bonding straps (43) to the mount brackets (46).
(b) Remove the temporarily installed nuts (45), washers (44) and bolts (49) from the FWD LH and FWD RH tie rods.
(c) Connect the bonding straps (43) with the bolts (49), the nuts (45) and washers (44) to the FWD LH and FWD RH tie rods (Ref. AMM TASK 20-28-00-912-802).
(2) Connection of the Exhaust Muffler

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

(a) Make sure that the APU exhaust and the exhaust muffler are free and clear of unwanted materials.
(b) Push the exhaust muffler forward until the hot-nozzle assy (32) flange touches the APU exhaust flange.
(c) Make sure that the drain outlet on the hot-nozzle assy (31) is at the 6 o'clock position.
(d) Adjust the flange of the hot-nozzle assy radially to the APU exhaust flange.

NOTE: Before the clamp is installed, the offset around should not be more than 0 +4 mm or -4 mm (0.0000 +0.1575 in. or -0.1575 in.).

(e) Install the exhaust coupling clamp (30) with the lockbolts in the 3 and 9 o'clock position.

NOTE: Make sure that the exhaust coupling clamp (30) is engaged equally.

(f) TORQUE the lockbolts:
1 of the exhaust coupling clamp (30) (P/N D49885041200) equally to between 0.93 and 0.81 m.daN (82.30 and 71.68 lbf.in )

.
2 of the exhaust coupling clamp (30) (AEROQUIP P/N 6299342) equally to between 0.34 and 0.31 m.daN (30.09 and 27.43 lbf.in )

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.

(g) Install the two halves of the insulation blanket (33) and (34) in position at the exhaust coupling clamp (30), connect the two halves with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
(h) Connect the two halves of the insulation blanket (33) and (34) with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy - to the studs on the hot-nozzle assy (31).
(3) Connection 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) Remove the blanking plugs from the disconnected line ends.
(b) Connect the exhaust-muffler drain pipe (35) at the T-fitting to the APU drain system.
(c) TORQUE the nut of the drain pipe (35) to between 2.8 and 2.5 m.daN (20.65 and 18.44 lbf.ft )

.
(4) Connection of the Generator Cables

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

(a) Remove and discard the tie-wraps which temporarily hold the phase leads (82) to the FWD RH tie rod.
(b) Remove the plastic blanking caps from the ring terminals of the phase leads.
(c) Remove the bolts (70), the washers (84) and the phase lead cover (71) from the terminal block of the generator.
(d) Remove the temporarily installed nuts (83) from the terminal studs.
(e) Connection of the phase leads (82).

CAUTION: MAKE SURE THAT THE WASHER IS INSTALLED BETWEEN THE PHASE LEADS AND THE TERMINAL BLOCK. IF NOT, THE TERMINAL BLOCK WILL BURN LOCALLY BECAUSE OF RESISTANCE HEATING.

1 Make sure that the washers (86) are on the lower part of the terminal studs (the part that does not have threads).
2 For generator type 5913667 or type BA03604, attach the phase leads (82) with the washers (85) and the nuts (83) to the correct terminal studs on the generator (80).
Connect:

The phase lead with red label 8XS-T1 to terminal stud T1
The phase lead with yellow label 8XS-T2 to terminal stud T2
The phase lead with blue label 8XS-T3 to terminal stud T3
The phase lead with white label 8XS-N to terminal stud N.

3 For generator type BA16501, attach the phase leads (82) with the nuts (83) to the correct terminal studs on the generator (80).
Connect:

The phase lead with red label 8XS-T1 to terminal stud T1
The phase lead with yellow label 8XS-T2 to terminal stud T2
The phase lead with blue label 8XS-T3 to terminal stud T3
The phase lead with white label 8XS-N to terminal stud N.

4 Make sure that the terminals of the generator (80) and the ring terminals of the phase leads (82) are clean and not damaged.
5 TORQUE the nuts (83) to between 2.5 and 2.3 m.daN (18.44 and 16.96 lbf.ft )

.
(f) Lubrication of the bolts (70).

WARNING: USE THE CORRECT PERSONAL PROTECTION. OIL CAN HAVE ADDITIVE CALLED TRICRESYL PHOSPHATE IN IT. THIS CHEMICAL IS AN ASPHYXIANT, IT IS POISONOUS AND CAN BE ABSORBED THROUGH THE SKIN. USE CARE WHEN ENGINE OIL IS DRAINED. HOT OIL CAN POSSIBLY CAUSE BAD BURNS.

1 Lubricate the bolts (70) with Synthetic base Lubricating Oil-Turbine Engine - - (Material No.03ABA1) or Synthetic base Lubricating Oil-Turbine Engine Low Temp. - (Material No.03ABB1) .
(g) Install the cover plate (71), the washers (84) and the bolts (70).
(h) TORQUE the bolts (70) to between 0.47 and 0.43 m.daN (41.59 and 38.05 lbf.in )

.
(5) Connection of the Starter Motor

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

(a) Remove and discard the tie-wraps which temporarily attached the starter motor cables (74) and (77) to the FWD LH tie rod.
(b) Remove the blanking caps from the ring terminals of the starter cables (74) and (77).
(c) Remove the nuts (72) and (76), the lock-washer (88) and (90) and the top washers (73) and (75) which are temporarily installed on the terminal studs.
(d) Install the positive starter motor cable (77), the washer (75), the lock-washer (90) and the nut (76) on top of the washer (75) that is installed on the bottom of the positive terminal stud.

NOTE: The positive starter cable is identified through the label reading 8KAPOS.

(e) Install the negative starter motor cable (74), the washer (73), the lock-washer (88) and the nut (72) on top of the washer (73) that is installed on the bottom of the negative terminal stud.

NOTE: The negative starter cable is identified through the label reading 8KANEG.

(f) TORQUE the nut (76) of the positive starter cable to between 180 and 170 lbf.in (2.03 and 1.92 m.daN )

.
(g) TORQUE the nut (72) of the negative starter cable to between 115 and 105 lbf.in (1.30 and 1.19 m.daN )

.
(h) Push the rubber sleeves (89) and (91) around the starter motor terminals.
(6) Connection of the Electrical Harness

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

(a) Remove and discard the tie-wraps which temporarily attach the electrical connectors (50) P1, (51) P2 and (55) P3 to the APU.
(b) Remove the blanking caps from the connectors.
(c) Make sure the connectors are clean and in a correct condition.
(d) Remove the temporarily installed bolt (61) and nut (62) from the clamp (60) on the FWD RH tie rod.
(e) Put the clamp (63) in position on the clamp (60), install and tighten the bolt (61) and the nut (62).
(f) Remove the temporarily installed bolt (56) and the washer (57) from the bracket (59) at the RH side of the APU compartment.
(g) Make sure that the nut clip on the bracket (59) is in the correct position.
(h) Put the clamp (58) into position, install the washer (57) and the bolt (56), tighten the bolt (56).
(i) Install the connector (50) P1 to the correct connector on the forward firewall.
(j) Remove the temporarily installed bolts (54), washers (95) and spacers (52) from the brackets on the APU compartment front firewall.
(k) Make sure that the nut clips on the brackets (on the front firewall) are in the correct position.
(l) Put the two clamps (53) in position, install the spacers (52), the washers (95) and bolts (54), tighten the bolts (54).
(m) Install the connectors (51) P2 and (55) P3 to the correct connectors on the forward firewall.

NOTE: On APU Harness P/N 4500062 K:
If necessary, to make the length of harness cables P1 and P3 shorter, make a loop and add them to the attachment clamp on the AC-generator.
Attach the harness cable P2 with a TIE WRAP to the loop, to give more stiffness.

(7) Connection of the APU Fuel Line to the APU Fuel Control Unit

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

WARNING: OBEY THE FUEL SAFETY PROCEDURES.

(a) Put the CONTAINER 1 L (1/4 USGAL) in position below the fuel and control unit.
(b) Remove the main fuel inlet-pipe from the stowage bracket attached to the front firewall of the APU compartment.
(c) Remove the plastic blanking plugs from the disconnected line ends.
(d) Connection of the main fuel inlet pipe

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.

1 Apply Dry lubricant-General Assembly - - (Material No.03QBA1) to the connector internal threads and connect the main fuel inlet pipe (20) to the vent and drain valve (21).
2 TORQUE the nut of the main fuel inlet pipe (20) to between 5.31 and 4.85 m.daN (39.16 and 35.77 lbf.ft )

3 Safety the nut with 14QFB1Wire-Locking Dia: 0.8 mm CRES Nickel Alloy -.
4 Make marks on the nut of the main fuel inlet pipe (20) with Varnish Polyurethane-- Marking Structure (Material No.04SAB2) to identify the torqued position.
(8) Installation of the the oil cooler outlet-duct
(a) Remove the blanking covers from the oil cooler outlet and oil cooler duct.
(b) Install the oil cooler outlet-duct (Ref. AMM TASK 49-52-41-400-002).
(9) Connection of the Bleed-Air Duct Elbow

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

(a) Remove the blanking covers from the openings of the bleed-air duct elbow (3), and the bleed air duct of the APU (1).
(b) Clean the component interfaces and the adjacent area.
(c) Do an inspection of the component interfaces and the adjacent area.
(d) Make sure that mounting flanges of the bleed-air duct elbow (3) is positioned, without forces in the X, Y and Z direction, 0 +2 mm or -2 mm (0.0000 +0.0787 in. or -0.0787 in.) to the APU interface.

NOTE: If necessary adjust the position with the rods.

(e) Put the clamp (2) over the mounting flanges of the bleed-air duct elbow (3) and APU bleed-air duct (1).
(f) TORQUE the clamp (2) to between 0.5 and 0.4 m.daN (44.25 and 35.40 lbf.in )

Subtask 49-11-11-865-067-A ** ON A/C NOT FOR ALL

F. 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	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 49-11-11-740-053-B ** ON A/C NOT FOR ALL

G. BITE Test and Update of the Electronic Control Box (ECB)
(1) Do the self-test of the ECB (Ref. AMM TASK 49-00-00-710-005).
(2) Update the APU hours and cycles in the ECB.

NOTE: This workstep is only necessary if the TSO of installed APU is > 0 and operator wants to monitor TSO.

(a) Make sure that the APU offsets are set to zero (Ref. AMM TASK 31-36-00-740-004).
(b) Update the APU hours and cycles with:

The Data Management Unit (DMU) (Ref. AMM D/O 31-36-00-74), or
The Flight Data Interface and Management Unit (FDIMU) (Ref. AMM TASK 31-36-00-740-013), or
The ECB (Ref. AMM TASK 49-00-00-860-011).

(3) Bleeding of the APU fuel line
(a) Bleed the APU fuel line (Ref. AMM TASK 28-22-00-710-001).

Subtask 49-11-11-410-066-A ** ON A/C NOT FOR ALL

H. Installation and locking of the APU access doors
(1) If removed install the APU access doors 315AL 316AR (Ref. AMM TASK 52-41-21-400-001) and (Ref. AMM TASK 52-41-22-400-001).

Subtask 49-11-11-210-073-A ** ON A/C NOT FOR ALL

I. Do a visual inspection of the APU Air Intake System (Ref. AMM TASK 49-16-00-210-002) and (Ref. AMM TASK 49-16-00-210-805).

Subtask 49-11-11-710-055-A ** ON A/C NOT FOR ALL

J. Operational Test

CAUTION: DO NOT START THE APU WITH ACCESS DOORS 315AL AND 316AR OPEN/REMOVED. THE APU FIRE EXTINGUISHER SYSTEM IS NOT SUFFICIENT TO EXTINGUISH A FIRE IF THE ACCESS DOORS 315AL AND 316AR ARE OPEN/REMOVED.

CAUTION: OBEY THE SAFETY PRECAUTIONS.

CAUTION: MAKE SURE THAT THE FUEL-FEED SYSTEM DOES NOT HAVE ANY LEAKS. LEAKS IN THE FUEL-FEED SYSTEM CAN CAUSE A FIRE.

CAUTION: MAKE SURE THAT THE APU OIL RESERVOIR IS FILLED BEFORE YOU START THE APU. IF YOU OPERATE THE APU WITHOUT OIL, DAMAGE WILL OCCUR.

(1) Do the Operational test of the APU (Ref. AMM TASK 49-00-00-710-008) and the Air Leak test with APU doors closed (Ref. AMM TASK 49-00-00-790-005).
(2) Do the ground air-preconditioning with the APU for a minimum of 10 minutes during the first run of an APU after its installation. If you smell fumes in the cockpit and/or passenger compartment, remove the contamination from the air conditioning system (Ref. AMM TASK 21-00-00-615-802) or (Ref. AMM TASK 21-00-00-615-803) or (Ref. AMM TASK 21-00-00-615-804) and (Ref. AMM TASK 21-00-00-100-001).

Subtask 49-11-11-865-069-A ** ON A/C NOT FOR ALL

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

PANEL	DESIGNATION	FIN	LOCATION
** ON A/C NOT FOR ALL
121VU	APU/APU/CTL	2KD	L42
121VU	APU/ECB/SPLY	1KD	L41

Subtask 49-11-11-210-063-A ** ON A/C NOT FOR ALL

L. Inspection of the APU after shutdown

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

(1) Open the access doors 315AL, 316AR (Ref. AMM TASK 52-41-00-010-001).
(2) Carefully examine the APU, the vent and drain valve connections and the drain lines for fuel and/or oil leakage (Ref. AMM TASK 49-00-00-790-002).

NOTE: Leaks are not permitted.

(3) Do a check of the magnetic drain plug for unwanted metal (Ref. AMM TASK 49-91-42-200-003).
(4) Do a check of the APU oil level on the oil sight glass. If necessary add oil until the oil level reaches the full mark. (Ref. AMM TASK 49-90-00-600-004).

5. Close-up
Subtask 49-11-11-410-061-A ** ON A/C NOT FOR ALL

A. Close Access
(1) Apply a thin layer of the Corrosion Preventive Compound_Water Displacing Soft Film - (Material No.12ABC1) on the surfaces and the components that follow:
(a) The brackets and the tie-rod ends on the top firewall of the APU compartment
(b) The APU mount brackets and the vibration isolators
(c) The tie-rods and the brackets of the APU bleed-air duct
(d) The bolts of the V-clamps that attach the bleed air duct to the APU
(e) The brackets of the fire sensing elements
(f) The door hinges of the left and right APU access doors.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) Set the light switch 11LJ to the OFF position.
(4) Close APU access doors 315AL and 316AR (Ref. AMM TASK 52-41-00-410-001).
(5) Remove the access platform(s).
(6) Remove the 98L12003001000 HARNESS,SAFETY.

Subtask 49-11-11-865-077-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
121VU	APU/APU/CTL	2KD	L42
121VU	APU/ECB/SPLY	1KD	L41

Subtask 49-11-11-860-058-A ** ON A/C NOT FOR ALL

C. Put the aircraft back to its initial configuration.
(1) De-energize the ground service network
(Ref. AMM TASK 24-42-00-862-001).
(2) Remove the WARNING NOTICE(S).
(3) Remove the ground support and maintenance equipment, the special and standard tools and all other items.

[Rev.10 from 2021] 2026.04.01 04:26:55 UTC