Installation of the Lower Starter Air Duct [PW11]

TASK 80-11-49-400-802-A
Installation of the Lower Starter Air Duct

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

ZONE: 400

1. Reason for the Job
Use this procedure to install the lower starter air duct.
For more information about the engine starting system, refer to (80-11-00-00U).
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	MALLET - SOFT FACE
No specific	AR	WARNING NOTICE(S)
No specific	Torque wrench: range to between 24 and 22 lbf.in (0.27 and 0.25 m.daN )
No specific	Torque wrench: range to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )
No specific	Torque wrench: range to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )
PWA202076	1	STARTER DUCT VALVE LINKAGE TEMPLATE

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P03-001)	lubricant, aircraft turbine engine (synthetic base)
(Material No.P05-292)	ferrule, safety cable
(Material No.P05-395)	beeswax
(Material No.P05-396)	paraffin wax blend
(Material No.P06-038)	compound, antigallant

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
447AL, 448AR, 461AL, 462AR

D. Expendable Parts

FIG.ITEM	DESIGNATION	IPC-CSN
1	SEALS	EIPC 80-11-03-01-090

E. Referenced Information

REFERENCE	DESIGNATION
TASK 70-24-00-910-813-A	Assembly - PWA 316 - Safety Cable Installation
TASK 71-00-00-720-809-A	Test No. 2 - Engine Motor Leak Test (Dry Method)
TASK 71-00-00-860-832-A	Procedure to Prevent Engine Motoring and to Stop the Electrical Supply to the EEC
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 73-25-34-400-802-A	Installation of the Engine Interface Unit (EIU)
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
Remove The Starter Air Duct
Starter Air Duct - Rod Assembly Measurement

3. Job Set-up
Subtask 80-11-49-941-054-A ** ON A/C NOT FOR ALL

A. Safety Precautions

WARNING: IF IT IS NECESSARY TO ENERGIZE THE AIRCRAFT FOR A MAINTENANCE WORK WHILE YOU DO THIS MAINTENANCE PROCEDURE, MAKE SURE THAT ONLY EXTERNAL POWER IS USED. THE USE OF APU OR ENGINE POWER CAN CAUSE PRESSURIZED AIR LEAKAGE IN THE PNEUMATIC SYSTEM, AND INJURY CAN OCCUR.

(1) Make sure that you did the procedure to prevent engine motoring and to stop the electrical supply to the Electronic Engine Control (EEC)
(Ref. AMM TASK 71-00-00-860-832)
(2) On OVERHEAD CTL & IND panel 25VU:

Make sure that the ON legend of the APU MASTER SW pushbutton switch is off.
Make sure that the WARNING NOTICE(S) is in position to tell persons not to start the APU.

(3) On the HP ground connector:

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

Subtask 80-11-49-010-055-A ** ON A/C NOT FOR ALL

B. 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

Subtask 80-11-49-040-051-A ** ON A/C NOT FOR ALL

C. 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).

Subtask 80-11-49-010-056-A ** ON A/C NOT FOR ALL

D. Get Access
(1) Make sure that right the thrust reverser cowl-doors is open (Ref. AMM TASK 78-36-00-010-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL, 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL, 462AR

4. Procedure

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

Subtask 80-11-49-420-051-A ** ON A/C NOT FOR ALL

A. Installation of the Starter Air Duct (AP51)
(1) Removal of the protection covers

CAUTION: REMOVE THE PROTECTION COVERS FROM THE OPENINGS AS NECESSARY TO PREVENT ENGINE DAMAGE.

(a) Make sure that you remove all the necessary COVER - PROTECTION to prevent damage to the engine.
(2) Install the starter air duct (AP51) (3) on the starter and Starter Air Valve (SAV) as follows:
(3) Measure the rod assembly (6) as follows:
(a) Method 1:
1 Install both ends of the rod assembly (6) on the PWA202076 STARTER DUCT VALVE LINKAGE TEMPLATE. See sheet 1 of the figure:

Starter Air Duct - Rod Assembly Measurement ** ON A/C NOT FOR ALL

2 If the rod assembly (6) installs on the template freely, the rod assembly (6) length is correct. Continue to step 4.A.(4).
3 If the rod assembly (6) does not install on the template freely, adjust the rod assembly (6) as follows:

WARNING: USE 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.

a Remove the ferrule, safety cable from one end of the rod assembly (6). See sheet 2 of the figure:

Starter Air Duct - Rod Assembly Measurement ** ON A/C NOT FOR ALL

b Loosen one of the nuts (17) or (19) and turn the rod end (16) or (20) until the rod assembly (6) installs on the template.
c TORQUE the nut (17) or (19) to between 24 and 22 lbf.in (0.27 and 0.25 m.daN )

d Install the new P05-292ferrule, safety cable on the nut (17) or (19) and the rod (18) (Ref. AMM TASK 70-24-00-910-813).
(b) Method 2:
1 Install two gage pins with 0.3121 in. (7.9273 mm) and 0.3125 in. (7.9375 mm) diameter into both ends of the rod assembly (6). See sheet 2 of the figure:

Starter Air Duct - Rod Assembly Measurement ** ON A/C NOT FOR ALL

2 Measure the distance from the center of each rod end and record the measurement as Dimension A.
3 Dimension A must be to between 4.585 in. (116.459 mm) and 4.615 in. (117.221 mm).
4 If the rod assembly (6) measurement is not within the limits, adjust the rod assembly (6) until the measurement is within the limits. Refer to step 4.A.(3)(a)3_a_ thru step 4.A.(3)(a)3_d_.
(4) Apply the P06-038compound, antigallant to the threads of the two bolts (5). See the figure:

Remove The Starter Air Duct ** ON A/C NOT FOR ALL

(a) For new or refurbished bolts or nuts with baked-on lubricant, do not do the wet application.
(5) Apply the beeswax (Material No.P05-395) or the paraffin wax blend (Material No.P05-396) to the two new EIPC 80-11-03-01-090 SEALS (1).
(6) Apply the P03-001lubricant, aircraft turbine engine (synthetic base) to the two couplings (2).
(7) Install the two seals (1) on the starter and SAV.
(8) Install one end of the rod assembly (6) on the starter air duct (AP51) (3) with the bolt (5) and the nut (4).
(9) TORQUE the nut (4) to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )

.
(10) Install the starter air duct (AP51) (3) and the rod assembly (6) on the clevis with the bolt (5) and the nut (4).
(11) Align and install the starter air duct (AP51) (3) on the starter and SAV.
(12) Install the two couplings (2).
(13) TORQUE the two couplings (2) to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(14) Use a MALLET - SOFT FACE and lightly tap the couplings (2).
(15) TORQUE the two couplings (2) again to between 125 and 115 lbf.in (1.41 and 1.30 m.daN )

.
(16) TORQUE the nut (4) to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )

.
(17) Do a check for pre-load on the starter air duct (AP51) (3) as follows:
(a) Hold the rod assembly (6) by the hand and manually turn it clockwise and counterclockwise.
1 If the rod assembly (6) freely turns without too much hand torque, nothing needs to be done.
2 If too much hand torque is necessary to turn the rod assembly (6), adjust the rod assembly (6). Refer to step 4.A.(17)(b).
(b) Adjust the rod assembly (6) length as follows:
1 Remove the two nuts (4) and the two bolts (5).

2 Remove the ferrule, safety cable from both ends of the rod assembly (6). See the figure:

Starter Air Duct - Rod Assembly Measurement ** ON A/C NOT FOR ALL

3 Loosen the two nuts (17) and (19) and while you hold the rod ends (16) and (20), turn the rod (18) to adjust the rod assembly (6) as necessary.
a After adjustment, the threads of the rod ends (16) and (20), must be in view through the inspection holes in the rod (18) and the two bolts (5) can easily be installed.
4 TORQUE the two nuts (17) and (19) to between 24 and 22 lbf.in (0.27 and 0.25 m.daN )

5 Install the new P05-292ferrule, safety cable on the two nuts (17) and (19) and the rod (18) (Ref. AMM TASK 70-24-00-910-813).
6 Install the rod assembly (6) on the starter air duct (AP51) (3) and clevis with the two bolts (5) and the two nuts (4).
7 TORQUE the two nuts (4) to between 195 and 175 lbf.in (2.20 and 1.98 m.daN )

.
(c) Do a check to make sure that the rod assembly (6) easily turns clockwise and counterclockwise while you hold the rod assembly (6) by hand as described in step 4.A.(17)(a).
1 If it does not, adjust the rod assembly (6). Refer to step 4.A.(17)(b).
(18) Connect the two ignition cables and WC08 harness to the duct spring clips.
(19) Examine the assembly for foreign objects, damage and correct assembly.

5. Close-up
Subtask 80-11-49-410-050-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 thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-802):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENG 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENG 2)
461AL 462AR

Subtask 80-11-49-440-050-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 80-11-49-410-051-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 WARNING NOTICE(S).
(3) Make sure that all the circuit breakers shown in the paragraph Procedure of the engine interface unit installation are closed. If they are not, close them in the recommended sequence
(Ref. AMM TASK 73-25-34-400-802)

Subtask 80-11-49-720-051-A ** ON A/C NOT FOR ALL

D. Test
(1) Do the test N°2- Engine Motor Leak Test (Dry Method) (Ref. AMM TASK 71-00-00-720-809).

[Rev.10 from 2021] 2026.04.01 12:57:08 UTC