Revision 32 - FedEx...124vu apu/fire det/fire warn 3wg b69 124vu apu/fire det/loop/a 1wg b70 124vu apu/fire det/loop/b 2wg b71 124vu apu/ind/oil qty 1kk b72 124vu apu/ind/n 1kn b73

FED ALLPOWER PLANT - REMOVAL/INSTALLATION

WARNING : ALLOW APU TO COOL SUFFICIENTLY TO PREVENT PERSONALINJURY. MAKE CERTAIN THAT FIRE FIGHTING EQUIPMENT ISAVAILABLE.

WARNING : APU WEIGHS APPROX. 260 kg (573 lb.).

WARNING : MAKE CERTAIN THAT THE CABLE IS NOT KINKED OR TWISTED.KEEP THE CABLE CLEAR OF ANY SHARP OBJECTS THAT CAN DAMAGEIT.

WARNING : WHEN LOWERING THE APU, MAKE SURE THAT THE TRANSPORTATIONTROLLEY IS IN THE CORRECT POSITION. LOWER DIRECTLY INTOPOSITION ON TO THE TROLLEY. DO NOT TRY TO FORCE THE APUON TO THE TROLLEY.

WARNING : MAKE SURE THAT THE APU IS DIRECTLY BELOW THE INSTALLATIONPOINT BEFORE LIFTING THE APU INTO POSITION.

WARNING : USE EXTREME CARE WHEN WORKING WITH CLEANING AGENTS.MAKE CERTAIN THAT WORKING AREA IS WELL VENTILATED. AVOIDINHALATION OF FUMES, MIST OR DUST. PROTECT EYES AND SKIN.APPLY MATERIALS IN ACCORDANCE WITH MANUFACTURER'SINSTRUCTIONS. FIRE PROTECTION REGULATIONS MUST BEOBSERVED.

CAUTION : IF APU AC GENERATOR IS NOT INSTALLED, APU WILL NOT BE INBALANCE WHEN REMOVED FROM MOUNTS. TO AVOID UNBALANCE,SUPPORT APU AS NECESSARY.

CAUTION : MAKE CERTAIN THAT SUPPLY CONNECTION POSITIVE 8 KA(+) ISCONNECTED TO STARTER MOTOR TERMINAL PRIOR TO RESISTORASSEMBLY.

CAUTION : WASHERS MUST BE INSTALLED BETWEEN THE TERMINAL NUTS ANDPHASE LEADS. DO NOT INSTALL ANY WASHERS UNDER PHASELEADS. LOCALIZED RESISTANCE HEATING AND BURNING OF THETERMINAL BLOCK WILL RESULT.

CAUTION : MAKE CERTAIN THAT BLEED AIR COVER P/N A4907016100600 ISINSTALLED.

CAUTION : MAKE CERTAIN THAT CLEANING AGENT IS COMPLETELY REMOVEDBEFORE INSTALLATION OF BLEED AIR DUCT ELBOW.

A310-200 AMM - POWER PLANT - REMOVAL/INSTALLATIONRevision 32.0

P.Blk EFFECTIVITY: FED ALL 49-10-00-04Printed - Date: 12/11/12 Time:Copyright © 12 FedEx Express Corporation, Memphis TN, 38194, All rights reserved.

Page 1 of 38JUN 02/2010

1. Equipment and Materials

A. Equipment and Materials

ITEM DESIGNATION

A. Access Platform, 6 m (20 ft.)

B. Container, 2 l (0.50 US gal.) Capacity

C. Blanking Caps and Plugs

D. Protective Covers

E. Tie-straps

F. Circuit Breaker Safety Clips and Tags

G. Torque Wrench, 0-100 lbf.in. (0-1 m.daN)

H. Torque Wrench, 100-200 lbf.in. (1-2 m.daN)

J. Torque Wrench, 200-450 lbf.in. (2-5 m.daN)

K. Torque Wrench, 450-1000 lbf.in. (5-11 m.daN)

L. 98A28007570000 Adapter - Vent and Drain Valve, APU

M. A1-91-139 or

A2-43-1091 or

FedEx P/N A3t-49-001

ZT-49-001

91/541

Hoist - Minilift

Hoist - Minilift

Hoist - Fishpole

APU Engine Assembly Hoist Mount

Didsbury

ALKAN P/N M025B01 or


Mechanical Hoisting System




ALKAN P/N M027H004






Page 2 of 38JUN 02/2010

ITEM DESIGNATION

N. 98A49107504001 Protector - Thread, APU Mounting Bolts

P. 98A49207605000 Trolley - Assembly and Transport, APU

Q. A4907015200051 Flight without APU Kit (Ref. IPC)

R. A4907016100600 Bleed Air Cover (Ref. IPC)

S. Corrosion-Resistant Steel Lockwire, 0.8 mm (0.032in.) dia.

T. O-Rings

U. Material No. 04-012 Common Greases (Ref. 20-31-00 ) )

V. Material No. 05-027 Special Materials (Ref. 20-31-00 ) )

W. Material No. 06-001A Lubricants (Ref. 20-31-00 ) )

X. Material No. 11-003 Cleaning Agents (Ref. 20-31-00 ) )

Y. Material No. 11-012 Cleaning Agents (Ref. 20-31-00 ) )

Referenced Procedures

- (Ref. 20-28-11, P. Block001 )

Electrical Bonding

- (Ref. 21-51-00, P. Block301 )

Air Cooling System

- (Ref. 21-51-16, P. Block301 )

Water-Separator

- (Ref. 24-23-11, P. Block401 )

APU AC Generator (8XS)

- (Ref. 49-00-00, P. Block501 )

Airborne Auxiliary Power

- (Ref. 49-00-00, P. Block701 )

Airborne Auxiliary Power

- (Ref. 49-10-00, P. Block 801 ) Power Plant



Page 3 of 38JUN 02/2010

ITEM DESIGNATION

- (Ref. 49-12-00, P. Block601 )

APU Mounts

- (Ref. 49-12-14, P. Block401 )

APU Mount Brackets

- (Ref. 49-16-14, P. Block401 )

Inlet Duct

- (Ref. 49-17-11, P. Block401 )

Drain Tank

- (Ref. 49-17-15, P. Block201 )

Hose-Turbine Plenum and Exhaust Drain

- (Ref. 49-32-11, P. Block401 )

Fuel Control Unit

- (Ref. 49-52-14, P. Block401 )

Oil Cooler Outlet Duct

- (Ref. 49-81-15, P. Block401 )

Exhaust Muffler and Sealing Ring

- (Ref. 49-90-00, P. Block301 )

Oil

- (Ref. 51-75-10, P. Block801 )

Repair of Paint Coatings

- (Ref. 52-41-21, P. Block401 )

APU Access Doors

- (Ref. 55-00-00, P. Block301 )

Stabilizers - Standard Warnings and Procedures

B. Procedure

(1) Job Set-Up

(a)FED 401-405,407-409,424-426,428,443,445-450,453-454

Open, safety and tag the following circuitbreakers:

FED ALL



Page 4 of 38JUN 02/2010

PANEL SERVICE IDENT. LOCATION

124VU APU/FIRE DET/FIRE WARN 3WG B69

124VU APU/FIRE DET/LOOP/A 1WG B70

124VU APU/FIRE DET/LOOP/B 2WG B71

124VU APU/IND/OIL QTY 1KK B72

124VU APU/IND/N 1KN B73

124VU APU/IND/EGT 1KP B74

124VU APU/LP VALVE/CTL 4WF C69

124VU APU/ISOL VALVE/CTL 3WF C70

124VU APU/FIRE EXTING/AUTO EXTING GND TEST 30WF C71

124VU APU/FIRE EXTING/SQUIB/A 1WF C72

124VU APU/FIRE EXTING/SQUIB/TEST 7WF C73

124VU APU/FIRE EXTING/SQUIB/B 2WF C74

124VU APU/FUEL/BLOW OFF/CTL 10QC D69

124VU APU/FUEL/BLOW OFF/PUMP 11QC D70

124VU APU/FUEL/PUMP SUPPLY 1QC D71

124VU APU/FUEL/LP VALVE 2QF D72

124VU APU/FUEL/ISOL VALVE 1QF D73

124VU APU/START 50KA E70

124VU APU/AIR INTAKE FLAP 1KB E71

124VU APU/WARN 2KD E72

124VU APU/ECB SUPPLY/MAIN 1KD E73

124VU APU/ECB SUPPLY/BACK UP 58KD E74



Page 5 of 38JUN 02/2010


124VU ELEC PWR/APU GEN GCU/SUPPLY 6XS E79

124VU ELEC PWR/APU GEN GCU/WARN 5XS E80

124VU AIR BLEED/ X COMP TEMP/VALVES APU BLEED X FEED/CTL & AMP;WARN

4HV K59

128VU

HYD/L/G/ PROX DET/RELAYS/SYS 2 GEAR DOWN/POSIND/OVHD PNL 83GB N72


124VU APU/FIRE DET/FIRE WARN 3WG B69

124VU APU/FIRE DET/LOOP/A 1WG B70

124VU APU/FIRE DET/LOOP/B 2WG B71

124VU APU/IND/OIL QTY 1KK B72

124VU APU/IND/N 1KN B73

124VU APU/IND/EGT 1KP B74

124VU APU/LP VALVE/CTL 4WF C69

124VU APU/ISOL VALVE/CTL 3WF C70

124VU APU/FIRE EXTING/AUTO EXTING GND TEST 30WF C71

124VU APU/FIRE EXTING/SQUIB/A 1WF C72

124VU APU/FIRE EXTING/SQUIB/TEST 7WF C73

124VU APU/FIRE EXTING/SQUIB/B 2WF C74

124VU APU/FUEL/BLOW OFF/CTL 10QC D69

124VU APU/FUEL/BLOW OFF/PUMP 11QC D70

124VU APU/FUEL/PUMP SUPPLY 1QC D71

124VU APU/FUEL/LP VALVE 2QF D72



Page 6 of 38JUN 02/2010


124VU APU/FUEL/ISOL VALVE 1QF D73

124VU APU/START 50KA E70


124VU APU/WARN 2KD E72

124VU APU/ECB SUPPLY/MAIN 1KD E73

124VU APU/ECB SUPPLY/BACK UP 58KD E74

124VU APU/ECB BACK UP/CTL 71KD E75

124VU ELEC PWR/APU GEN GCU/SUPPLY 6XS E79

124VU ELEC PWR/APU GEN GCU/WARN 5XS E80

125VU AIR BLEED/ X COMP TEMP/VALVES APU BLEED X FEED/CTL & AMP;WARN

4HV K59

128VU HYD/L/G/ PROX DET/RELAYS/SYS 2 GEAR DOWN/POSIND/OVHD PNL 83GB N72

(b) Make horizontal stabilizer safe (Ref.55-00-00, P. Block 301 ) .

(c) Position access platform and open access doors315AL and 316AR.

NOTE : Removal of access doors 315AL and316AR (Ref. 52-41-21, P. Block 401 )avoids obstruction of working area onaccess platform.

(2) Removal

NOTE : Install blanking caps and plugs or protectivecovers to disconnected ducts, lines andelectrical connectors.

(a) Remove inlet duct (Ref. 49-16-14, P. Block401 ) .

(b) Release exhaust coupling (11) to disconnectexhaust muffler sealingring coupling (Ref. Fig. 404 ) .



Page 7 of 38JUN 02/2010

1) Push guide ring rearwards into the sealingring coupling until a finger-wide gap ismade between turbine heat shield flange andguide ring flange.

2) Remove coupling (11).

(c) Remove bleed air duct elbow.(Ref. Fig. 401 )

1) Remove nut (8), washer (9) and screw (10) todisconnect bonding strap (11).

2) Support bleed air duct elbow (3) and removeclamp (2).

3) Remove nuts (6), washers (5) and bolts (4),disconnect tie-rods (7) and remove bleed airduct elbow (3).

4) Install bleed air cover P/NA4907016100600(part of APU substitution kit).

- Position bleed air cover (12) and connecttie-rods (7).

- Install bolts (4), washers (5) and nuts(6).

(d) Disconnect electrical connections.(Ref. Fig. 402, 403 )

1) Cut and remove lockwire and disconnectelectrical plugs P2 and P3 (1) from sockets6032VC and 6033VC. Remove clamps, supportingharness to structure. To prevent damage,secure harness ends carefully to APU.

2) Cut and remove lockwire and disconnectgenerator control connector (2) 8XS-A.

3) Cut and remove lockwire, and remove bolts(8), washers (7) and cover (6).

4) Remove nuts (5), washers (4) and disconnectgenerator connections (3) 8XS T1 thru T3 andN.

** FOR STARTER MOTOR 519858 -3,-4,-5,-6 and subsequent (Ref. Fig. 403)

5) Remove and retain nuts (1, 2), washers (3,4) and disconnect starter motor electricalconnections negative 8KA(-) (7), resistorassembly (5) and positive 8KA(+) (6).1 Secure resistor assembly (5) to startermotor.



Page 8 of 38JUN 02/2010

6) To prevent damage, attach generator andstarter harness ends to FR95.

(e) Disconnect fuel feed line(Ref. Fig. 404 ) .

1) Position container, 2 l (0.50 US gal.)capacity, below fuel feed line vent anddrain valve port (2).

2) Carry out draining of fuel feed line usingvent and drain valve adapter (Ref.49-32-11, P. Block 401 ) .

3) Cut and remove lockwire.

4) Release nut (3) and then disconnect fuelfeed line (1) by removing fitting (4).1 Discard O-ring (5).

5) To prevent damage, stow fuel feed line inappropriate bracket onFR95.

6) Remove container.

(f) Disconnect drain lines(Ref. Fig. 404 ) .

1) Position 2 l (0.50 US gal.) capacitycontainer below drain tank.

2) Cut and remove lockwire, remove drain plug(6) and allow liquid to drain.

3) Discard drain plug O-ring.

4) Install new O-ring onto drain plug (6).

5) Install drain plug (6).

6) Safety drain plug (6) with lockwire.

7) Disconnect drain hoses from collector drainline (10) and fuel flow divider drain line(7).

8) Disconnect and remove heat shield drain line(8) and turbine plenum drain line (9) as anassembly.

(g) Remove oil cooler outlet duct (Ref. 49-52-14, P.Block 401 ) .

(h) Remove APU mounts bonding straps.(Ref. Fig. 405 ) .



Page 9 of 38JUN 02/2010

1) Remove nuts (14), bolts (12), washers (13)and bonding straps (10) from bondingbrackets (11) on tie-rods.

2) To prevent damage, fix bonding straps (10)to APU mount brackets.(Ref. Fig. 404 )(Ref. Fig. 405 )

(j) Install Hoist


CAUTION : CAREFULLY CHECK THE FISHPOLE HOISTBEFORE EACH USE. FULLY EXTEND THE CABLEOUT AND CAREFULLY INSPECT TGHE CABLR FORANY SIGN OF DAMAGE, WEAR, BROKEN WIRES,CORROSION OR REDUCTION IN DIAMETER. DONOT USE IF ANY DAMAGE IS OBSERVED.

1) Use hoist P/N A1-91-139 or A2-43-1091 (Ref.Fig. 406 ) or FedEx P/N A3t-49-001.(Ref. Fig. 406 )

- Connect suspension (3) of hoist (1) to APUcompartment hoist bracket (2) byinstalling pip pin (4).

- Adjust and connect bracket (6) of hoist (1)to sidewall attaching point (5) byinstalling pip pin (7).

- Position APU Engine Assembly HoistUnit onto forward (13) and aft (14)APU hoist brackets and install pip pins(12).

- Connect shackle adaptor (8) to spreader bar(11) with shackle pin

- (9).

- Secure shackle adaptor (9) with retainingpin (10).

(k) Remove load from APU shock mounts.

WARNING : WHEN LOWERING THE APU, MAKE SURE THATTHE TRANSPORTATION TROLLEY IS IN THECORRECT POSITION. LOWER DIRECTLY INTOPOSITION ON TO THE TROLLEY. DO NOT TRYTO FORCE THE APU ON TO THE TROLLEY.



Page 10 of 38JUN 02/2010

(l) Position assembly and transport trolley beneathAPU.

(m) Remove shock mount nuts (4, 5)(Ref. Fig. 405 ) and install thread protectors toAPU shock mount cone bolts.

CAUTION : IF APU AC GENERATOR IS NOT INSTALLED,APU WILL NOT BE IN BALANCE WHEN REMOVEDFROM MOUNTS. TO AVOID UNBALANCE, SUPPORTAPU AS NECESSARY.

(n) Lower APU carefully.

NOTE : Cable run must not interfere with pulleyguide.

(p) Remove mount brackets (Ref. 49-12-14, P. Block401 ) .

(q) Position APU on trolley.

1) Install trolley adapter brackets and mountAPU on trolley (3 places).

(r) Disconnect hoist from APU.

NOTE : If no serviceable APU is available andaircraft is scheduled for flight withoutan APU installed, install APUsubstitution kit (Ref. AMM 49-10-00, P.Block 801) .

(Ref. Fig. 406 )

(3) Preparation for Installation.

NOTE : Remove items of APU substitution kit, ifinstalled (Ref. AMM 49-10-00, P. Block 801) .Items of substitution kit are colored red.

NOTE : If required bleed Air Cover P/N A4907016100600remains installed until load compressorcleaning run after APU replacement is carriedout (refer to Para. E.).



Page 11 of 38JUN 02/2010

(a) Inspect APU compartment.

1) Inspect APU shock mounts, tie-rods andstructural brackets (Ref. 49-12-00, P.Block 601 ) .

2) Inspect bleed air duct elbow connectionflanges and attachments.

3) Inspect oil cooler outlet duct attachbrackets (Ref. 49-52-14, P. Block 401 ) .

4) Inspect drain tank and lines (Ref.49-17-11, P. Block 401 ) .

5) Inspect turbine plenum and exhaust drainhoses, Part No. BA3280 (Ref. 49-17-15, P.Block 201 ) .

6) Clean APU compartment if necessary (Ref.49-00-00, P. Block 701 ) .

7) Inspect exhaust duct felt metal and sealingring coupling (Ref. 49-81-15, P. Block401 ) .

(b) When replacement APU is not fully equipped, thefollowing items must be transferred from theremoved APU:

1) APU mount brackets (Ref. 49-12-14, P.Block 401 ) .

2) APU AC generator and gasket (Ref.24-23-11, P. Block 401 ) .

3) Bellows of oil cooler outlet duct (Ref.49-52-14, P. Block 401 ) .

4) Drain lines with appropriate brackets andclamps.

NOTE : Make certain that all transferreditems are serviceable.

(3) Install APU Engine Assembly Hoist Mount(Ref. Fig. 406 ) .

(4) Installation

NOTE : Remove blanking caps and plugs and protectivecovers from all ducts, lines and electricalconnectors before connection.




Page 12 of 38JUN 02/2010

WARNING : MAKE SURE THAT THE CABLE IS NOT KINKED ORTWISTED.KEEP THE CABLE CLEAR OF ANY SHARP OBJECTS THATCAN DAMAGE IT.

WARNING : MAKE SURE THAT THE APU IS DIRECTLY BELOW THEINSTALLATION POINT BEFORE LIFTING THE APU INTOPOSITION.

NOTE : For use of hoist refer to para. 2. B. (9).

(a) Position APU beneath APU compartment and connecthoist cable to spreader bar.

(b) Lift APU out of trolley, remove trolley adapterbrackets and install APU mount brackets (Ref.49-12-14, P. Block 401 ) .

1) Hoist APU into APU compartment.

- Carefully insert LH and RH mount cones intobrackets and AFT mount cone into shockmount.

(c) Remove thread protectors and install shock mountnuts (4, 5).(Ref. Fig. 405 ) .

CAUTION : TORQUE VALUES FOR FORWARD AND AFT SHOCKMOUNT NUTS AREDIFFERENT.

1) TORQUE LH and RH mount nuts (4) to between260 lbf.in. and 330 lbf.in.(2.9 m.daN and 3.7 m.daN.).

2) TORQUE AFT mount nut (5) to between 630lbf.in. and 830 lbf.in.(7.1 m.daN and 9.4 m.daN).

(d) Remove hoist(Ref. Fig. 406 ) .

1) Remove APU Engine Assembly Hoist Mount .

(e) Install bonding straps(Ref. Fig. 405 ) .

1) Make certain, that bonding brackets (11) ontie-rods, bonding straps (10), bolts (12),washers (13) and nuts (14) are clean.

2) Install bonding straps (10) with bolts (12),washers (13) and nuts (14) to bondingbrackets (11) on tie-rods. For electrical



Page 13 of 38JUN 02/2010

bonding refer to (Ref. 20-28-11, P. Block001 ) .

(f) Connect drain lines(Ref. Fig. 404 ) .

1) Install heat shield drain line (8) andturbine plenum drain line (9) as anassembly.

2) Connect drain hoses to collector drain line(10) and fuel flow divider drain line (7).

(g) Install oil cooler outlet duct (Ref. 49-52-14,P. Block 401 ) .

(h) Clean threads of fitting (4), coupling nut (3) andfuel feed line with cleaning agent (Mat. No.11-012).

(j) Check fitting, coupling nut and fuel feed linethreads for damage.

(k) Lubricate new O-ring (5) with vaseline (Mat. No.04 012).

(l) Install new O-ring (5) to fitting (4).

(m) Install fuel feed line.

1) Lubricate fuel feed line connection (1),fitting (4) and coupling nut (3) threadswith lubricant (Mat. No. 06-001A).

2) Install fitting (4)(Ref. Fig. 404 ) .

3) TORQUE fitting (4) to 5.5 m.daN (40.56lbf.ft) and safety with lockwire.3 Position fuel feed line (1) and attachwith coupling nut (3).

4) TORQUE coupling nut (3) to 5.5 m.daN (40.56lbf.ft) and safety with lockwire.

(n) Connect electrical connections(Ref. Fig. 402, 403 ) .

CAUTION : MAKE CERTAIN THAT SUPPLY CONNECTIONPOSITIVE 8KA(+) IS CONNECTED TO STARTERMOTOR TERMINAL PRIOR TO RESISTORASSEMBLY.

CAUTION : WASHERS MUST BE INSTALLED BETWEEN THETERMINAL NUTS AND PHASE LEADS. DO NOTINSTALL ANY WASHERS UNDER PHASE LEADS.



Page 14 of 38JUN 02/2010

LOCALIZED RESISTANCE HEATING AND BURNINGOF THE TERMINAL BLOCK WILL RESULT.

1) Connect starter motor connections.** FOR STARTER MOTOR 519858 -3,-4,-5,-6 and subsequent (Ref. Fig. 403)

- Position electrical supply connectionpositive 8KA(+) (6), resistor assembly(5), washer (3) and install nut (1).

- TORQUE nut (1) of positive terminal tobetween 0.85 m.daN (75 lbf.in.) and 0.90m.daN (80 lbf.in.).

- Position electrical connection negative 8KA(-) (7) , washer (4) and install nut (2).

NOTE : Make certain that negativeterminal post is tight in startermotor before connecting terminal.

- TORQUE nut (2) of negative terminal tobetween 0.56 m.daN and 0.62 m.daN (50lbf.in.) and (55 lbf.in.).

2) Connect generator connections (3) 8XS T1thru T3 and N. Install washers (4) and nuts(5).

- TORQUE nuts (5) to between 1.6 and 1.9m.daN (144 and 168 lbf.in.).

3) Install cover (6), washers (7) and bolts(8).

- Safety bolts (8) with lockwire.

4) Connect generator control connector 8XS-A(2). Safety with lockwire.

5) Connect electrical plugs (1), P2 to socket6032VC and P3 to socket 6033VC. Safety withlockwire.

- Install harness support clamps tostructure.

(p) Exhaust muffler connection(Ref. Fig. 404 ) .



Page 15 of 38JUN 02/2010

1) Position coupling (11) onto guide ringflange.

2) Pull guide ring towards turbine heat shieldflange.

- Install coupling (11) with coupling locksin 3 and 9 o'clock position.

3ORQUE clamp (11) to between 0.73 and 0.85m.daN (64.6 and_

75.2 lbf.in).

(q) Install inlet duct (Ref. 49-16-14, P. Block401 ) .

(r) Check oil level in gearbox sump. Replenish, ifnecessary (Ref. 49-90-00, P. Block 301 ) .

CAUTION : FUEL FEED LINE MUST BE PURGED BEFOREFIRST START IS ATTEMPTED.FAILURE TO PURGE MAY RESULT IN HOTSTART.

(s) Purge fuel feed line(Ref. Fig. 404 ) .

1) Position container 2 l (0.50 US gal.)capacity, below fuel feed line vent anddrain valve port (2).

2) Carry out purging of fuel feed line usingvent and drain valve adapter (Ref.49-32-11, P. Block 401 ) .

3) Remove container.

(5) Not applicable

(6) Installation of bleed air duct elbow.

(a) Install bleed air duct elbow(Ref. Fig. 401 ) .



Page 16 of 38JUN 02/2010

1) Position and support bleed air duct elbow(3).

2) Connect tie-rods (7) and install bolts (4),washers (5) and nuts (6).

3) Align bleed air duct elbow (3) with bleedload valve (1).

4) Install clamp (2).

NOTE : Make certain that bleed air ductelbow (3) is installed withouttension.

5) Connect bonding strap (11) with screw (10),washer (9) and nut (8).For electrical bonding refer to (Ref.20-28-11, P. Block 001 ) .

(b) Activate APU bleed load valve(Ref. Fig. 401 ) .

1) Remove blanking caps and bleed air cover(12).

2) Install electrical connector P20 (16) andsafety with lockwire.

3)FED 401-405,407-409,424-426,428,443,445-450,453-454

Remove safety clips and tags and closecircuit breakers 50KA, 1KD, 2KD and 58KD.

FED 410-414,416-423,427,429-436,442,451-452,455-499

3) Remove safety clips and tags and closecircuit breakers 50KA, 1KD, 2KD, 58KD and71KD.

FED ALL

(c) Clean APU compartment, if necessary (Ref.49-00-00, P. Block 701 ) .

(7) Test

(a) Erase ECB memory (Ref. 49-00-00, P. Block501 ) .

(b) Perform operational test (Ref. 49-00-00, P.Block 501 ) .

NOTE : Both air conditioning packs must beoperated during the first run with bleedair duct elbow installed after



Page 17 of 38JUN 02/2010

installation of an APU for a minimum of10 minutes. If an odor is detected inflight or passenger compartment, carryout cleaning procedure of both waterseparators (Ref. 21-51-16, P. Block301 ) and the air conditioning duct(Ref. 21-51-00, P. Block 301 ) .

(c) Check connection of bleed air duct elbow, duringAPU run.

NOTE : Slight, diffused air leakage at bleedair duct connection is permitted, but ajet-like escape is not permissible.



Page 18 of 38JUN 02/2010

(9) Record APU compartment, if necessary (Ref 49-00-00, P.Block 701).

(a) On the ACARS IDU select Main Menu.

(b) Select ACMS (LSK 2L). Verify that the ACMS MAINMENU appears.

(c) Select DMU MENU (LSK 2L). Verify that the ACMS DMUMENU appears.

(d) Press the ALPHA key. Enter SFIM (will display as****) then press RETURN

(e) Select PROGRAMMING (LSK 3L). Verify that the ACMSENGINE DATA INIT page appears.

(f) Select ENGINE DATA INIT (LSK 1 L). Verify that theACMS ENGINE DATA INIT appears.

(g) Press the NUM key. Enter the APU serial number,(numbers only, preceding or trailing letters areomitted), then press RETURN.

(h) Enter the data by pressing LSK 5L. Note that thehours and cycles will clear to zero.

(j) Press the NUM key. Enter the current APU hours andcycles (example: 15/18 for 15 hours/18 cycles)then press RETURN.

(k) Enter the data by pressing LSK 5R

(l) Verify APU serial number, hours, and cyclesdisplay correctly on the IDU.

(m) Press RETURN three (3) times to return to the ACMSMAIN MENU.

(10) Test

(a) Erase ECB memory (Ref. 49-00-00, P. Block 501).

(b) Perform operational test (Ref. 49-00-00, P. Block501).

NOTE : Both air conditioning packs must beoperated during the first run with bleedair duct elbow installed afterinstallation of an APU for a minimum of10 minutes. If an odor is detected inflight or main deck cargo compartment,carry out cleaning procedure of bothwater separators (Ref. 21-51-16, P.Block 301) and the air conditioning duct(Ref. 21-51-00, P. Block 301).



Page 19 of 38JUN 02/2010

(c) Check connection of bleed air duct elbow, duringAPU run.

NOTE : Slight, diffused air leakage at bleedair duct connection is permitted, butjet-like escape is not permissible.

(8) Close-Up

(a) Install access doors 315AL and 316AR (Ref.52-41-21, P. Block 401 ) if removed.

(b) Check alignment of oil cooler outlet duct and dooroutlet duct (Ref. 49-52-14, P. Block 401 ) .

(c) If necessary, apply lubricant (Mat. No. 05-027)thinly to the following areas (Ref. 51-75-10, P.Block 801 ) :

- fire detection loop attachments

- APU suspension structural brackets and shockmounts

- bleed air duct tie-rod attachments

- air inlet duct tie-rod attachments

- bolt of exhaust coupling clamp

- access door hinges.

(d) Make certain that working areas are clean andclear of tools and miscellaneous items ofequipment.

(e) Close access doors 315AL and 316AR. Remove accessplatform.

(f) Return horizontal stabilizer to operatingcondition (Ref. 55-00-00, P. Block 301 ) .POWER PLANT - FLIGHT WITHOUT APU - APPROVEDREPAIRS

WARNING : THE APU SUBSTITUTION KIT MUST BEINSTALLED WHENEVER AIRCRAFT FLIGHT ISPLANNED WITHOUT AN APU INSTALLED.INSTALLATION OF THE APU SUBSTITUTION KITIS A TEMPORARY MEASURE ONLY, PENDINGSUBSEQUENT INSTALLATION OF A NEW ORSERVICEABLE APU.

CAUTION : ISOLATION VALVES MUST NOT BE SUBJECTEDTO INTERMITTENT OPERATION FOR MORE THAN30 SECONDS. ALLOW MOTORS TO COOL AFTERSEVERAL OPERATIONS.



Page 20 of 38JUN 02/2010

CAUTION : MAKE CERTAIN THAT RETAINED AIRCRAFTCOMPONENTS ARE SERVICEABLE PRIOR TOINSTALLATION.

A. Reason for the Job(1) Installation and Removal of Flight without APUKitB. Equipment and Materials

ITEM DESIGNATION

(1) A4907015200051 Flight without APU Kit:

NOTE : For components of flight without APU refer to IPC chapter49-11-04.

(2) 98A49107504001 Protector - Thread, APU Mounting Bolts

(3) Blanking Caps and Plugs

(4) Corrosion-Resistant Steel Lockwire, 0.04 in. (1 mm)dia.

(5) Corrosion-Resistant Steel Lockwire, 0.032 in. (0.8mm.) dia.

Referenced Procedures

- (Ref. 49-10-00, P. Block401 )

Power Plant

- (Ref. 49-12-00, P. Block601 )

APU Mounts

- (Ref. 49-16-12, P.Block 201 )

Air Intake Flap Actuator (50KB)

- (Ref. 49-17-11, P. Block401 )

Drain Tank

- (Ref. 52-41-21, P. Block401 )

APU Access Doors



Page 21 of 38JUN 02/2010

C. Procedure

(1) Installation of Flight without APU Kit

(a) Job Set-Up

FED 401-405,407-409,424-426,428,443,445-450,453-454

CAUTION : ISOLATION VALVES MUST NOT BE SUBJECTEDTO INTERMITTENT OPERATION FOR MORE THAN30 SECONDS. ALLOW MOTORS TO COOL AFTERSEVERAL OPERATIONS.

1) Make certain that the APU Master SWcontrolling APU pump and APU isolation(shutoff) valve is in OFF position.

2) Make certain that the following circuitbreakers are opened, safetied and tagged.


124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

125VU

APU/FIRE DET/FIRE WARN

APU/FIRE DET/LOOP A

APU/FIRE DET/LOOP B

APU/IND/OIL QTY

APU/IND/N

APU/IND/EGT

APU/LP VALVE/CTL

APU/ISOL VALVE/CTL

APU/FIRE EXTING/AUTO EXTINGGND TEST

APU/FIRE EXTING/SQUIB/A

APU/FIRE EXTING/SQUIB/TEST

APU/FIRE EXTING/SQUIB/B

APU/FUEL/BLOW OFF/CTL

APU/FUEL/BLOW OFF/PUMP

APU/FUEL/PUMP SUPPLY

APU/FUEL/LP VALVE

APU/FUEL/ISOL VALVE

APU/START

APU/ECB SUPPLY/MAIN

APU/ECB SUPPLY/BACK UP

ELEC PWR/APU GEN GCU/SUPPLY

ELEC PWR/APU GEN/GCU/WARN

AIR BLEED X COMP TEMP/VALVES

3WG

1WG

2WG

1KK

1KN

1KP

4WF

3WF

30WF

1WF

7WF

2WF

10QC

11QC

1QC

2QF

1QF

50KA

1KD

58KD

6XS

5XS

4HV

B69

B70

B71

B72

B73

B74

C69

C70

C71

C72

C73

C74

D69

D70

D71

D72

D73

E70

E73

E74

E79

E80

K59



Page 22 of 38JUN 02/2010


128VU APU BLEED X FEED/CTL & amp;WARN

HYD/L/G PROX DET/RELAYS/SYS2 GEAR

DOWN/POS IND/OVHD PNL

83GB N72

FED 410-414,416-423,427,429-436,442,451-452,455-499

CAUTION : ISOLATION VALVES MUST NOT BE SUBJECTED TO INTERMITTENTOPERATION

FOR MORE THAN 30 SECONDS. ALLOW MOTORS TO COOL AFTER SEVERALOPERATIONS.

1

2

Make certain that the APU Master SW controlling APU pump and APU

isolation (shutoff) valve is in OFF position.

Make certain that the following circuit breakers are opened,

safetied and tagged.

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

124VU

128VU


APU/FIRE DET/LOOP A

APU/FIRE DET/LOOP B

APU/IND/OIL QTY

APU/IND/N

APU/IND/EGT

APU/LP VALVE/CTL

APU/ISOL VALVE/CTL

APU/FIRE EXTING/AUTO EXTINGGND TEST




APU/FUEL/BLOW OFF/CTL

APU/FUEL/BLOW OFF/PUMP

APU/FUEL/PUMP SUPPLY

APU/FUEL/LP VALVE

APU/FUEL/ISOL VALVE

APU/START

APU/ECB SUPPLY/MAIN

APU/ECB SUPPLY/BACK UP

APU/ECB/BACK UP CTL

ELEC PWR/APU GEN GCU/SUPPLY

ELEC PWR/APU GEN/GCU/WARN

3WG

1WG

2WG

1KK

1KN

1KP

4WF

3WF

30WF

1WF

7WF

2WF

10QC

11QC

1QC

2QF

1QF

50KA

1KD

58KD

71KD

6XS

5XS

83GB

B69

B70

B71

B72

B73

B74

C69

C70

C71

C72

C73

C74

D69

D70

D71

D72

D73

E70

E73

E74

E75

E79

E80

N72



Page 23 of 38JUN 02/2010


APU BLEED X FEED/CTL & amp;WARN

HYD/L/G PROX DET/RELAYS/SYS2 GEAR

DOWN/POS IND/OVHD PNL

FED ALL

3) Close air intake flap electrically ormanually (Ref. 49-16-12, P. Block 201 ) .

- Make certain that the following circuitbreaker is open, safetied and tagged:



FED 416-430,442-443,445-450,453-499POST SB 49-2003 for A/C 416-430,442-443,445-450,453-499

4) Open, safety and tag the following circuitbreaker:



Close air intake flap manually (Ref.49-16-12, P. Block 201 ) , if electricalactuation system of air intake flap failed.

NOTE : With APU MASTER SW in OFFposition, air intake flap isnormally closed.

FED ALL

(b) Installation of APU substitution Kit

NOTE : Components of Flight without APU Kit arecolored red.components removed by this procedure,must be retained for subsequentinstallation of APU.



Page 24 of 38JUN 02/2010

1) Suspension and Electrical Connections(Ref. Fig. 407 )

- Remove nut (6), bolt (7) and air intake LHtie-rod (8).

- Position and support cross member (9).Remove thread protectors and installwashers (10) and nuts (11).

NOTE : Nuts (11) are not components offlight without APU Kit.Use APU attachment nuts (Ref.49-10-00, P. Block 401 ) .

- Connect starter cables 8KA(+) (13) and 8KA(-) (14), and secure with nuts (12).

- Connect generator cables 8XS T1-T4 (17) andsecure with nuts (18).

- Remove blanking cap and connect generatorcontrol 8XSA (16).

- Install blanking caps (15) on connectorsockets 6032VC and 6033VC.

- Position rear suspension (2) and installbolt (3), washer (4) and nut (5). Removethread protector and install nut (1).

NOTE : Nut (1) is not a component offlight without APU Kit.Use APU attachment nut (Ref.49-10-00, P. Block 401 ) .

2) Fuel and Drain Lines(Ref. Fig. 408 )

- Install blanking cap (4) on fuel feed line.Position fuel feed line on bracket at FR95as shown and secure with lockwire,

0.04 in. (1 mm dia.).

- Remove nut (10), screw (9) and releaseclamp (8). Disconnect and remove drainhoses (2). Install blanking caps (3).

- Install blanking cap (1) on drain linefitting.

3) RH Tie-Rods of Air Inlet Duct

- Remove nuts (7), bolts (6) and tie-rods(5).



Page 25 of 38JUN 02/2010

4) Exhaust Muffler(Ref. Fig. 409 )

- Release clamp (11) and remove exhaustcoupling and bellows (12).

- Position clamp halves (10) on exhaustmuffler at 12 and 6 o'clock positions andinstall bolts (16).

- Open access fairing 317. Position exhaustcover (9) and close access fairings.

5) Bleed Air Duct

- Remove protective cover and position bleedair cover (7). Connect tie-rods (17) andinstall bolts (8), washers (6) and nuts(5).

- Connect bonding strap (1) with screw (2),washer (3) and nut (4).

NOTE : Bolts (8), washers (6, 3) and nuts(5, 4) are not components offlight without APU Kit. Use bleedair duct components.

6) Install access doors 315AL and 316AR (Ref.AMM 52-41-11, P. Block 401) .

7) Oil Cooler Outlet

- Position oil cooler cover (15) and installwashers (14) and bolts (13).



Page 26 of 38JUN 02/2010

(c) Close-Up

1) Make certain that working area is clean, andclear of tools and miscellaneous items ofequipment.

2) Close access doors 315AL and 316AR andremove access platform.

3) Remove safety clips and tags and closecircuit breakers 30WF, 1WF, 7WF, 2WF, 3WG,1WG and 2WG.

4) Make an entry in the aircraft technicallogbook.

(2) Removal of Flight without APU Kit

(a) Job Set-Up

1) Open, safety and tag the following circuitbreakers:


124VU

124VU

124VU

124VU

124VU

124VU

124VU


APU/FIRE DET/LOOP A

APU/FIRE DET/LOOP B

APU/FIRE EXTING/AUTO EXTING GND TEST




3WG

1WG

2WG

30WF

1WF

7WF

2WF

B69

B70

B71

C71

C72

C73

C74

2) Make certain that all other circuit breakerslisted in Para. 3.A.(1)(a) are opened,safetied and tagged.

3) Position access platform and open accessdoors 315AL and 316AR.

(b) Removal

CAUTION : MAKE CERTAIN THAT RETAINED AIRCRAFTCOMPONENTS ARE

SERVICEABLE PRIOR TO INSTALLATION.

1) Exhaust Muffler.(Ref. Fig. )

- Open access fairing 317 and remove exhaustcover (9). Close access

- fairing.



Page 27 of 38JUN 02/2010

- Remove bolts (16) and clamps halves (10).

- Position bellows and exhaust coupling (12)and secure with clamp (11). Safety clampwith lockwire, (0.032 in.) (0.8 mm) dia.

NOTE : Drainage overflow lip of exhaustcoupling must be located

at 6 o'clock position.

2) Electrical Connections and APU MountSuspensions.(Ref. Fig. 407 )

- Remove nut (1) and fit thread protector.Remove nut (5), washer (4) and bolt (3)and rear suspension (2).

- Remove nuts (12) and disconnect startercables 8KA(-) (14) and 8KA(+) (13).Reinstall nuts.

- Disconnect generator control cable 8XSA(16) and fit blanking cap.

- Remove nuts (18) and disconnect generatorcables 8XS T1-T4 (17).

- Reinstall nuts.

- To prevent damage during APU installation,temporarily secure generator and starterharnesses at FR95.

- Support cross member (9) and remove nuts(11) and washers (10). Fit threadprotectors and remove cross member.

- Position air inlet duct LH tie-rod (8) andisntall bolt (7) and nut (6).

- Inspect APU shock mounts, tie-rods andstructural brackets (Ref. 49-12-00, P.Block 601 ) .

3) Fuel Feed and Drain Lines.(Ref. Fig. 408 )

- Cut and remove securing lockwire frombracket and fuel feed line.

- Inspect drain tank and drain lines (Ref.49-17-11, P. Block 401 ) .

- Remove blanking caps (3) and install drainhoses (2).



Page 28 of 38JUN 02/2010

- Position clamp (8) and install screw (9)and nut (10).

4) RH Tie-Rods of Air Inlet Duct

- Position tie-rods (5) and install bolts (6)and nuts (7).

5) Bleed Air Duct(Ref. Fig. 409 )

- Remove nut (4), washer (3), screw (2) anddisconnect bonding strap (1).

- Support bleed air cover (7), remove nuts(5), washer (6) and bolts (8). Disconnecttie-rods (17) and remove bleed air cover.

- Inspect bleed air duct connection flangesand attachment.

- Fit protective cover.

6) Oil Cooler Outlet(Ref. Fig. 409 )

- Remove bolts (13), washers (14) and oilcooler cover (15).

7) Remove the following blanking caps duringAPU installation procedure.

- From electrical connector sockets 6032VCand 6033VC (15)

(Ref. Fig. 407 )

- From fuel feed line (4) (Ref. Fig. 408 )

- From drain line fitting (1) (Ref. Fig.408 )



Page 29 of 38JUN 02/2010

(c) Test

1) Carry out Functional Test of air intakeflap (Ref. 49-16-12, P. Block 201 ) .

(d) Close-Up

1) Make certain that Flight without APU Kit iscomplete.

2) Install APU (Ref. 49-10-00, P. Block401 ) .

3) Clear entry in the aircraft technicallogbook.



Page 30 of 38JUN 02/2010

FED ALL

Figure 401Figure 401 (Sheet 1)



Page 31 of 38JUN 02/2010

FED ALL




Page 32 of 38JUN 02/2010

FED ALL




Page 33 of 38JUN 02/2010

FED ALL




Page 34 of 38JUN 02/2010

FED ALL




Page 35 of 38JUN 02/2010

FED ALL




Page 36 of 38JUN 02/2010

FED ALL




Page 37 of 38JUN 02/2010

FED ALL


(Ref. Fig. 409 )



Page 38 of 38JUN 02/2010

Documents

Revision 32 - FedEx...124vu apu/fire det/fire warn 3wg b69 124vu apu/fire det/loop/a 1wg b70 124vu apu/fire det/loop/b 2wg b71 124vu apu/ind/oil qty 1kk b72 124vu apu/ind/n 1kn b73