Installation of the Air Intake Flap (APS 3200)

TASK 49-16-43-400-002-A
Installation of the Air Intake Flap (APS 3200)

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

ZONE: 313
ZONE: 314

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	1	FLASHLIGHT
No specific	AR	SAFETY CLIP - CIRCUIT BREAKER
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.8 and 0.7 m.daN (70.80 and 61.95 lbf.in )
98L12003001000	AR	HARNESS,SAFETY

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.03HBD9)	Synthetic Ester base Grease-General Purpose Low Temp -
(Material No.06AAB1)	Polysulfide Sealant-General Purpose Fillet -
(Material No.06LCG9)	Non Hardening Jointing Putty-Medium Temp. Area - -
(Material No.06LDG2)	Non Hardening Jointing Putty-High Temp. Area - Structure
(Material No.12AGC2)	Corrosion Preventive Compound-- Soft Film System

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
313	TAIL CONE APU AIR INTAKE AREA
314	TAIL CONE APU AIR INTAKE AREA
314AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
3	COTTER PIN	AIPC 49-16-04-03-070
15	SEAL PROFILE	AIPC 49-16-43-01-020
3	COTTER PIN	AIPC 49-16-84-40-350
15	SEAL PROFILE	AIPC 49-16-84-48-020

E. Referenced Information

REFERENCE	DESIGNATION
TASK 20-28-00-912-802-A	Electrical Bonding - General Maintenance Procedure
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 24-41-00-861-002-A-02	Energize the Aircraft Electrical Circuits from Engine 1(2)
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 24-41-00-862-002-A-02	De-energize the Aircraft Electrical Circuits Supplied from the Engine 1(2)
TASK 29-00-00-864-001-A	Put the Related Hydraulic System in the Depressurized Configuration before Maintenance Action
TASK 49-16-00-710-004-A	Operational Test of the Air Intake Flap and Diverter (APS 3200)
TASK 49-16-43-000-005-A	Removal of the Catwalk Panel (APS3200)
TASK 49-16-43-400-005-A	Installation of the Catwalk Panel (APS3200)
TASK 52-41-23-010-801-A	Opening of Access Door 314AR
TASK 52-41-23-410-801-A	Closing of Access Door 314AR
Air Intake Flap
Air Intake Measurements

3. Job Set-up
Subtask 49-16-43-860-050-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).
(2) On the overhead panel 25VU, make sure that the APU MASTER SW pushbutton switch is released (ON legend is off).
(3) On the APU section of overhead panel 25VU, make sure that the WARNING NOTICE(S) is 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 49-16-43-865-054-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
121VU	APU/APU/CTL	2KD	L42
121VU	APU/ECB/SPLY	1KD	L41

Subtask 49-16-43-010-060-A ** ON A/C NOT FOR ALL

C. 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) Make sure that the 98L12003001000 HARNESS,SAFETY is put and attached before you start work in the work area.
(2) Make sure that the ACCESS PLATFORM 4M (13 FT)-ADJUSTABLE is in position below access door 314AR.
(3) Make sure that access door 314AR is open and safetied in the open position.
(Ref. AMM TASK 52-41-23-010-801).
(4) If necessary, use a FLASHLIGHT.
(5) Make sure that the catwalk panel is removed (Ref. AMM TASK 49-16-43-000-005).

4. Procedure
Subtask 49-16-43-210-053-A ** ON A/C NOT FOR ALL

A. Preparation for Installation
(1) Do an inspection of the air intake flap (8) for damage, dents and cracks and do an inspection of the seal lip (9) for damage. Replace the air intake flap (8) if necessary.
(2) Do an inspection of the seal profile (15) for damage. Replace the seal profile (15) if necessary.

Subtask 49-16-43-560-050-A ** ON A/C NOT FOR ALL

B. Preparation of a Replacement Component
(1) Remove the seal profile (15).
(a) Remove the screws (18), the washers (17), the bracket (16).
(b) Remove the seal profile (15) from the air intake flap (8).
(2) Installation of the new seal profile (15).
(a) Put the new AIPC 49-16-43-01-020 SEAL PROFILE (15) or AIPC 49-16-84-48-020 SEAL PROFILE (15) and the bracket (16) in position.
(b) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) or Non Hardening Jointing Putty-High Temp. Area - Structure (Material No.06LDG2) to the screws (18) and the washers (17).
(c) Install the screws (18) and the washers (17). Do not fully tighten the screws at this time.
(d) Put the seal profile (15) in the center of the air intake flap (8). The ends of the seal profile (15) must not extend over the air intake flap (8).
(e) Adjust the seal profile (15) as shown in detail B. The dimension X is 6.0 mm (0.2362 in.).
(f) Tighten the screws (18).
(g) Seal the screws (18) with the Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) .
(h) Apply Corrosion Preventive Compound-- Soft Film System (Material No.12AGC2) around the heads of screws.

Subtask 49-16-43-420-055-B ** ON A/C NOT FOR ALL

C. Installation of the Air Intake Flap
(1) Apply Non Hardening Jointing Putty-Medium Temp. Area - - (Material No.06LCG9) or Non Hardening Jointing Putty-High Temp. Area - Structure (Material No.06LDG2) to all attaching parts.
(2) Put the air intake flap (8) in position and hold it.
(3) Install the screws (7) to the hinge assembly (10). Tighten only the outer screws (7).
(4) Make sure that the:

clearance C (between the trailing edge of the air intake flap (8) and the air intake nose) is between 0.5 mm (0.0197 in.) and 1.5 mm (0.0591 in.).
left and right clearance A (between the air intake flap (8) and the air inlet duct (2)) is between 1.5 mm (0.0591 in.) and 2.5 mm (0.0984 in.) in the open an closed position.

If necessary, adjust the clearance C and A as follows:
(a) Loosen the screws (7) which attach the hinge assembly (10) to the air intake flap (8).
(b) Adjust the clearance C and A.
(c) Make sure that the change of profile from the diverter (in the open position) to the air intake flap (8) (in the open position) stays a smooth contour.
(d) Tighten only the outer screws (7).
(5) Connect the actuator (1) to the air intake flap (8) in the closed position. Get access through the APU air intake in the fire wall at FR80.
(6) Apply Synthetic Ester base Grease-General Purpose Low Temp - (Material No.03HBD9) to the bolt (6).
(7) Install the bolt (6), the washer (5) and the castle nut (4).
(8) TORQUE the castle nut (4) to between 0.8 and 0.7 m.daN (70.80 and 61.95 lbf.in )

and safety it with a new AIPC 49-16-04-03-070 COTTER PIN (3) or AIPC 49-16-84-40-350 COTTER PIN (3).
(9) Open the air intake flap (8) electrically.
(a) Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):
121VU...APU/APU/CTL...(2KD)...L42
121VU...APU/ECB/SPLY..(1KD)...L41
(b) Push the APU MASTER SW pushbutton switch on the panel 25VU to the ON position.
(c) Wait until the air intake flap (8) is fully open.
(d) Open, safety and tag this(these) circuit breaker(s):
121VU...APU/APU/CTL...(2KD)...L42
121VU...APU/ECB/SPLY..(1KD)...L41
(10) Make sure that the maximum permitted clearance B between the air inlet flap (8) and the inner top wall of the air inlet duct (2) is 1.0 mm (0.0394 in.).
(11) Adjust the air inlet flap (8) by increasing or decreasing the length of the actuator (1).
(12) Close the air intake flap (8) electrically.
(a) Remove the safety clip(s) and the tag(s) and close this(these) circuit breaker(s):
121VU...APU/APU/CTL...(2KD)...L42
121VU...APU/ECB/SPLY..(1KD)...L41
(b) Release the APU MASTER SW pushbutton switch on the panel 25VU to the OFF position.
(c) Wait until the air intake flap (8) is fully closed.
(d) Open, safety and tag this(these) circuit breaker(s):
121VU...APU/APU/CTL...(2KD)...L42
121VU...APU/ECB/SPLY..(1KD)...L41
(13) Adjust the seal profile (15) to the air intake nose with the flap in the closed position. The seal profile (15) must touch the air intake nose with maximum 0.5 mm (0.0197 in.) compression F.

Subtask 49-16-43-865-060-A ** ON A/C NOT FOR ALL

D. 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 49-16-43-710-051-A ** ON A/C NOT FOR ALL

E. Operational Test
(1) Do the operational test of the air intake flap (Ref. AMM TASK 49-16-00-710-004).

5. Close-up
Subtask 49-16-43-910-050-A ** ON A/C NOT FOR ALL

A. Application of the Surface Protection
(1) Apply Polysulfide Sealant-General Purpose Fillet - (Material No.06AAB1) to all the nuts, washers and heads of screws.
(2) Apply Corrosion Preventive Compound-- Soft Film System (Material No.12AGC2) around all heads of screws.
(3) Seal the bonding connections (Ref. AMM TASK 20-28-00-912-802).

Subtask 49-16-43-410-051-A ** ON A/C NOT FOR ALL

B. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Install the catwalk panel (Ref. AMM TASK 49-16-43-400-005).
(3) Close access door 314AR (Ref. AMM TASK 52-41-23-410-801).
(4) Remove the access platform(s).
(5) Remove the safety harness.

Subtask 49-16-43-860-067-A ** ON A/C NOT FOR ALL

C. Aircraft Maintenance Configuration
(1) Put the related hydraulic system in the pressurized configuration (Ref. AMM TASK 29-00-00-864-001).
(2) De-energize the aircraft electrical circuits
(Ref. AMM TASK 24-41-00-862-002)
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 12:42:30 UTC