Installation of the Isolation Control Unit (ICU) [CFML]

TASK 78-31-51-400-804-A
Installation of the Isolation Control Unit (ICU)

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

ZONE: 400

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	MAT - PROTECTIVE
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 0.79 and 0.69 m.daN (69.91 and 61.06 lbf.in )
No specific	Torque wrench: range to between 1.06 and 0.82 m.daN (93.81 and 72.57 lbf.in )
No specific	Torque wrench: range to between 3.16 and 2.43 m.daN (23.30 and 17.92 lbf.ft )
No specific	Torque wrench: range to between 6.21 and 5.31 m.daN (45.80 and 39.16 lbf.ft )
No specific	Torque wrench: range to between 8.3 and 7.5 m.daN (61.21 and 55.31 lbf.ft )

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CPNCL00035)	Phosphate ester hydraulic fluid
(Material No.CPNCL00062)	Synthetic base lubricating oil - turbine engine
(Material No.CPNCL02069)	Textile - lint free cotton
(Material No.CPNCL02662)	Isopropyl alcohol
(Material No.06BJA4)	Silicone Sealant-High Temp. Brushable 200°C
(Material No.06BJB4)	Silicone Sealant-High Temp. - 200°C

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
5	PACKING	AIPC 78-31-80-01-035

E. Referenced Information

REFERENCE	DESIGNATION
TASK 54-52-11-400-807-A	Installation of the Access Skin Panels
TASK 70-70-00-910-804-A	Electrical Standard Practices
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 73-29-00-740-804-A	Thrust Reverser Cycling Test (Menu Mode)
TASK 78-30-00-040-809-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-809-A	Reactivation of the Thrust Reverser System after Ground Maintenance
SPM 702400910814
ICU
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
TASK 29-10-00-863-001-A	Pressurize the Green Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-864-001-A	Depressurize the Green Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
TASK 29-10-00-863-002-A	Pressurize the Yellow Hydraulic System with a Hydraulic Ground Power-Cart
TASK 29-10-00-864-002-A	Depressurize the Yellow Hydraulic System
TASK 29-14-00-614-001-A	Depressurization of the Hydraulic Reservoirs
TASK 29-14-00-614-002-A	Pressurization of the Hydraulic Reservoirs through the Ground Connector
TASK 29-14-00-614-002-A-01	Pressurization of the Hydraulic Reservoirs with the Auxiliary Power Unit (APU)

3. Job Set-up
Subtask 78-31-51-941-077-A

A. Safety Precautions
(1) 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 was in the OFF position not less than 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
The ENG/MASTER 1(2) control switch.

(2) 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).

Subtask 78-31-51-010-097-A

B. Get Access
(1) Make sure that the fan cowl doors are open (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
(2) Make sure that the ACCESS PLATFORM 2M (6 FT) - ADJUSTABLE is in position below the fan cowl door.
(3) Make sure that the MAT - PROTECTIVE is under the ICU (3) to prevent damage to the engine.

Subtask 78-31-51-864-061-A

C. Depressurization of the Aircraft Hydraulic Systems
(1) Make sure that the WARNING NOTICE(S) is in position to tell persons not to pressurize the applicable system.
(a) On the HYD/FUEL panel 40VU of the overhead panel
(b) On the ground service panel of the applicable hydraulic system.
(2) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
(a) Make sure that the Green hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-001).
(b) Make sure that the reservoir of the Green hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).
(3) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
(a) Make sure that the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-10-00-864-002).
(b) Make sure that the reservoir of the Yellow hydraulic system is depressurized (Ref. AMM TASK 29-14-00-614-001).

Subtask 78-31-51-040-079-A

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 78-30-00-040-809).

4. Procedure

WARNING: DO NOT GET HYDRAULIC FLUID ON YOUR SKIN, IN YOUR EYES OR IN YOUR MOUTH. HYDRAULIC FLUID IS POISONOUS AND CAN GO THROUGH YOUR SKIN AND INTO YOUR BODY. FLUSH HYDRAULIC FLUID FROM YOUR EYES, MOUTH OR SKIN WITH WATER. GET MEDICAL AID IF YOU GET HYDRAULIC FLUID IN YOUR EYES OR MOUTH.

WARNING: OBEY THE HYDRAULIC SAFETY PROCEDURES.

WARNING: DO NOT TOUCH THE HYDRAULIC SYSTEM COMPONENTS FOR A SHORT TIME AFTER THE ENGINE IS SHUTDOWN. THE ENGINE COMPONENTS STAY HOT FOR SOME TIME AND CAN CAUSE INJURY.

CAUTION: DO NOT LET HYDRAULIC FLUID FALL ON THE ENGINE. UNWANTED HYDRAULIC FLUID MUST BE REMOVED IMMEDIATELY WITH A CLEAN LINT FREE CLOTH. THE FLUID CAN CAUSE DAMAGE TO THE SURFACE PROTECTION AND TO SOME PARTS.

Subtask 78-31-51-420-069-A

A. Installation of the ICU

NOTE: Each time TRIPLE TORQUE is required, perform as per SPM 702400910814.

(1) Position the packing (5) on the ICU (3).
(2) Lubricate the new AIPC 78-31-80-01-035 PACKING (5) with Phosphate ester hydraulic fluid (Material No.CPNCL00035) .
(3) Remove the COVER - PROTECTION and CAP - PROTECTION on all the openings, tubes, hoses and connectors.
(4) Lubricate the threads of the bolts that follow with Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) :

Four bolts (6)
Four bolts (12).

(5) Install the plate (11) to the ICU (3) as follows:
(a) Align the plate (11) with the mating surface of the ICU (3) and attach it with the four bolts (6).
(b) TORQUE the four bolts (6) to between 1.06 and 0.82 m.daN (93.81 and 72.57 lbf.in )

.
(6) Install a new packing (5).
(7) Install the ICU (3) and plate (11) as follows:
(a) Put the ICU (3) in a position under the pylon.
1 Align the slotted holes in the plate (11) with the mating holes in the pylon.
(b) Hold the ICU (3) and install the two bolts (12) and washers (13) to attach the left side of plate (11) with the mating holes in the pylon. Keep the bolts (12) loose.
(c) Lubricate the threads of coupling nuts and ferrules on the hydraulic tube (4) with Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(d) Put the hydraulic tube (4) in position.
(e) Tighten the hydraulic tube (4).
(f) TRIPLE TORQUE the coupling nut that connects the hydraulic tube (4) to the ICU (3) to between 8.3 and 7.5 m.daN (61.21 and 55.31 lbf.ft )

.
(g) Install the two bolts (12) and washers (13) to attach the right side of plate (11) to the pylon. Keep the bolts (12) loose.
(h) Adjust the position of the plate (11).
(i) TORQUE the four bolts (12) to between 0.79 and 0.69 m.daN (69.91 and 61.06 lbf.in )

.
(j) Clean cavity area using two-cloth cleaning method with clean Textile - lint free cotton (Material No.CPNCL02069) and Isopropyl alcohol (Material No.CPNCL02662) .
(k) Fill cavity with Silicone Sealant-High Temp. - 200°C (Material No.06BJB4) or Silicone Sealant-High Temp. Brushable 200°C (Material No.06BJA4) .
(8) Connect the electrical connectors (7) and (8) to the ICU (3) (Ref. AMM TASK 70-70-00-910-804).
(9) Connect the return tube (9) to the ICU (3) as follows:
(a) Lubricate the threads of coupling nut and ferrule on the return tube (9) with Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(b) Connect the return tube (9) to the fitting on the ICU (3) hand-tight.
(c) TRIPLE TORQUE the coupling nut that connects the return tube (9) to the ICU (3) to between 3.16 and 2.43 m.daN (23.30 and 17.92 lbf.ft )

.
(10) Connect the supply tube (10) to the ICU (3) as follows:
(a) Lubricate the threads of coupling nuts and ferrules on the supply tube (10) with Synthetic base lubricating oil - turbine engine (Material No.CPNCL00062) .
(b) Connect the supply tube (10) to the fitting on the ICU (3) hand-tight.
(c) TRIPLE TORQUE the coupling nut that connects the supply tube (10) to the ICU (3) to between 6.21 and 5.31 m.daN (45.80 and 39.16 lbf.ft )

.
(11) Remove the MAT - PROTECTIVE from under the ICU (3).
(12) 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
(13) Install the forward pylon fairing (2) with screws (1) on the engine nacelle (Ref. AMM TASK 54-52-11-400-807). Keep the access platform from the fairing installation procedure in position at the pylon.

Subtask 78-31-51-440-069-A

B. Do the reactivation of the thrust reverser after maintenance (Ref. AMM TASK 78-30-00-440-809).

Subtask 78-31-51-863-057-A

C. Pressurization of the Aircraft Hydraulic Systems
(1) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
(a) Pressurize the reservoir of the Green hydraulic system (Ref. AMM TASK 29-14-00-614-002).
(b) Pressurize the Green hydraulic system (Ref. AMM TASK 29-10-00-863-001).
(2) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
(a) Pressurize the reservoir of the Yellow hydraulic system (Ref. AMM TASK 29-14-00-614-002).
(b) Pressurize the Yellow hydraulic system (Ref. AMM TASK 29-10-00-863-002).
(3) Bleed the thrust reverser hydraulic system.
(a) Do the thrust reverser cycling test (Ref. AMM TASK 73-29-00-740-804).

Subtask 78-31-51-010-099-A

D. 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 78-31-51-210-066-A

E. Return to Service Testing
(1) Do a visual check of the ICU (3) and hose connections for evidence of hydraulic leakage.

5. Close-up
Subtask 78-31-51-410-084-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) 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
(3) Remove the access platform(s).
(4) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 03:35:31 UTC