CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

POWER PLANT - REMOVAL/INSTALLATION

TASK 49−10−00−000−801
1. Removal of the Auxiliary Power Unit (APU) Power Plant

A. Service Bulletin List

SERVICE BULLETIN NO. SERVICE BULLETIN TITLE

604−49−006 Introduction of the 36−150 (CL) Auxillary Power Unit (APU)

B. Reference Information

REFERENCE DESIGNATION

TASK 36−11−07−000−801 Removal of the Auxiliary Power Unit (APU)−Supply

Check−Valve

TASK 49−10−00−910−801 Auxiliary Power Unit (APU) Safety Precautions

TASK 49−11−04−000−801 Removal of the Auxiliary Power Unit (APU)

Enclosure Access Panel (311BZ)

TASK 49−11−04−400−801 Installation of the Auxiliary Power Unit (APU)

Enclosure Access Panel (311BZ)

TASK 49−12−01−000−801 Removal of the Auxiliary Power Unit (APU) Support

Skid Assembly

TASK 49−51−01−000−801 Removal of the Auxiliary Power Unit (APU) Load

Control Valve

TASK 52−41−00−010−801 Open the Aft Equipment−Compartment Door

(311BB)

SPM−MM 20−50−00−000−801 Removal of Lockwire

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

C. Tools and Equipment

REFERENCE DESIGNATION

GSE 24−00−24 Circuit Breaker Tag − Red

GSE 49−00−01 Kit − APU Removal/Installation

Commercially Available Stand, Mobile

NOTE: Refer to the Illustrated Tool and Equipment Manual to make sure that you use
the correct equipment configuration.

On A/C 5301 to 5630 Pre SB 604−49−006

D. Job Set−Up

(1) Open and tag the circuit breakers that follow:

LOCATION CB NUMBER CB NAME ZONE

CBP−1 L1 APU ECU 221

CBP−1 L2 APU FAULT ANN 221

CBP−1 L3 APU START CONT 221

CBP−1 R5 APU FIRE EXT 221

CBP−1 S3 FUEL SOV APU 221

CBP−2 P4 APU FUEL PUMP 222

(2) Open the aft equipment compartment access−door (311BB)

(TASK 52−41−00−010−801).

(3) Obey all the auxiliary power unit (APU) safety precautions
(TASK 49−10−00−910−801).

(4) Remove the APU enclosure access panel (311BZ) (TASK 49−11−04−000−801).

(5) Remove the lockwire from the electrical connectors (2), (4) and (6)
(SPM−MM 20−50−00−000−801).

(6) Disconnect the electrical connector (2) from the receptacle (3) for the generator
control unit. Install protective covers.

(7) Disconnect the electrical connector (4) from the receptacle (5) of the low
oil−pressure switch for the APU generator adapter. Install the protective covers.

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(8) Disconnect the electrical connector (6) from the receptacle (7) of the hot
oil−temperature switch for the APU generator adapter. Install the protective covers.

(9) Disconnect the electrical connector (8) J2KD from the receptacle (9) on the APU
enclosure. Install protective covers.

(10) Loosen the screws (10) and open the clamps (11) that attach the electrical
harness (12) to the APU enclosure.

(11) Temporarily attach the electrical harness (12) to the APU (1).

(12) Remove the parts from the integrated drive generator (13) as follows:

(a) Remove the bolts (14), the washers (69), and the clamp (15) that attach the
terminal block cover (16) to the terminal block (17).

(b) Remove the nuts (18), the washers (19) and the electrical cables (20) from the
terminal lugs (T1, T2, T3, and G) on the terminal block (17).

NOTE: Tag and identify each electrical cable (20) before you remove it.

(c) Loosely install the nuts (18), the washers (19), the terminal block cover (16),
the bolts (14), and the washers (69) on the terminal block (17).

(13) Remove the parts from the starter motor (21) as follow:

(a) Remove the nut (22) and the washer (23) that attaches the electrical cable (24)
to the positive terminal on the starter motor (21).

(b) Remove the nut (87) and the washer (88) that attach the electrical cable (25)
to the negative terminal on the starter motor (21).

NOTE: Tag and identify each of the electrical cables (24) and (25) before the
removal.

(c) Remove the starter cables (24) and (25) from the terminals on the starter
motor (21).

(d) Loosely install the nuts (22) and (87) and the washers (23) and (88) on the
terminals on the starter motor (21).

(14) Remove the exhaust nozzle (26) as follows:

(a) Loosen the coupling (27) that attaches the exhaust nozzle (26) to the exhaust
outlet flange (28).

(b) Remove the exhaust nozzle (26) from the APU (1) and move it into the
exhaust duct (29).

(c) Temporarily attach the coupling (27) to the exhaust nozzle flange (28).

(d) Install protective covers on the exhaust nozzle flange (28).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(15) Remove the APU outlet bleed duct (32) and the APU supply check valve from the
load control valve (31) (TASK 36−11−07−000−801).

(16) Disconnect the APU inlet duct assembly (33) as follows:

(a) Remove the retaining clips (34) that attach the APU inlet bellows
assembly (35) to the flange on the APU inlet duct (36).

(b) Lift the APU inlet bellows assembly (35) and attach it to the hanger bellows
clips (37).

(c) Install a protective cover on the APU inlet duct (36).

CAUTION: USE TWO WRENCHES WHEN YOU REMOVE/TORQUE THE

HOSES/TUBES. USE ONE WRENCH TO HOLD THE FITTING, AND
THE OTHER WRENCH TO LOOSEN/TORQUE THE COUPLING NUT.
IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(17) Disconnect the hoses (38), (39), (41), (43), (44), (46) and (47) as follows:

(a) Disconnect the drain hose (38) at the APU inlet duct (36). Install protective
covers.

(b) Disconnect the drain hose (39) at the tee−fitting (40) for the combustor drains.
Install protective covers.

(c) Disconnect the fuel inlet hose (41) at the generator adapter (42). Install
protective covers.

(d) Disconnect the fuel return hose (43) at the generator adapter (42). Install
protective covers.

(e) Disconnect the fuel supply hose (44) from the fuel control unit (45). Install
protective covers.

(f) Disconnect the drain hose (46) from the fuel control unit (45). Install protective
covers.

(g) Disconnect the vent hose (47) from the vent tube (48) on the generator
adapter (42). Install the protective covers.

(18) Do a visual inspection of the aircraft frame holes where the beam (74) is to be
attached. Make sure the aluminum holes of the frames at FS654.50 and FS700.00
are not damaged.

NOTE: These holes are each protected by a steel doubler.

EFFECTIVITY: ALL

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WARNING: USE ONLY APPROVED LIFTING POINTS WHEN YOU MOVE, LIFT, OR
LOWER THE APU. YOU CAN CAUSE INJURIES TO PERSONS AND
DAMAGE TO THE EQUIPMENT.

MAKE SURE THAT THE APU SLING AND THE APU HOIST IS
ASSEMBLED CORRECTLY. YOU CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.

(19) Install the APU hoist (73), the APU sling (75) and the beam (74) as follows:

(a) Install the beam (74) to the aircraft attaching points at FS654 and FS700.

(b) Install the APU sling cable (82) to the APU upper gearcase adapter (86).

(c) Install the APU sling cable (77) to the APU lifting cable (78) with the bolt (79)
the washer (80) and the nut (81).

(d) Install the APU hoist cable to the APU sling (75) with the shackle (76).

(e) Install the APU hoist (73) to the beam (74).

On A/C 5631 and subs and 5301 to 5630 Post SB 604−49−006

E. Job Set−Up

(1) Open and tag the circuit breakers that follow:

LOCATION CB NUMBER CB NAME ZONE

CBP−1 L1 APU ECU 221

CBP−1 L2 APU FAULT ANN 221

CBP−1 L3 APU START CONT 221

CBP−1 R5 APU FIRE EXT 221

CBP−1 S3 FUEL SOV APU 221

CBP−2 P4 APU FUEL PUMP 222

CBP−5 A2 APU ECU PRIM 311

CBP−5 A3 APU ECU SEC 311

(2) Obey all the auxiliary power unit (APU) safety precautions
(TASK 49−10−00−910−801).

(3) Open the aft equipment compartment access−door (311BB)

(TASK 52−41−00−010−801).

EFFECTIVITY: ALL

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(4) Remove the APU enclosure access panel (311BZ) (TASK 49−11−04−000−801).

(5) Remove the lockwire from the electrical connectors (2), (4) and (6)
(SPM−MM 20−50−00−000−801).

(6) Disconnect the electrical connector (2) from the receptacle (3) for the generator
control unit. Install protective covers.

(7) Disconnect the electrical connector (4) from the receptacle (5) of the low
oil−pressure switch for the APU generator adapter. Install the protective covers.

(8) Disconnect the electrical connector (6) from the receptacle (7) of the hot
oil−temperature switch for the APU generator adapter. Install the protective covers.

(9) Disconnect the electrical connector (8) J2KD from the receptacle (9) on the APU
enclosure. Install protective covers.

(10) Loosen the screws (10) and open the clamps (11) that attach the electrical
harness (12) to the APU enclosure.

(11) Temporarily attach the electrical harness (12) to the APU (1).

(12) Remove the parts from the integrated drive generator (13) as follows:

(a) Remove the screws (14), the washers (15), and the clamp (16) that attach the
terminal block cover (17) to the terminal block (18).

(b) Remove the nuts (19), the washers (20) and the electrical cables (21) from the
terminal lugs (T1, T2, T3, and G) on the terminal block (18).

NOTE: Tag and identify each electrical cable (21) before you remove it.

(c) Loosely install the nuts (19), the washers (20), the terminal block cover (17),
the screws (14), and the washers (15) on the terminal block (18).

(13) Remove the parts from the starter motor (22) as follow:

(a) Remove the nut (23) and the washer (24) that attaches the electrical cable (25)
to the positive terminal on the starter motor (22).

(b) Remove the nut (87) and the washer (88) that attaches the electrical cable (26)
to the negative terminal on the starter motor (22).

NOTE: Tag and identify each of the electrical cables (25) and (26) before
removal.

(c) Remove the starter cables (25) and (26) from the terminals on the starter
motor (22).

(d) Loosely install the nuts (23) and (87) and the washers (24) and (88) on the
terminals on the starter motor (22).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(14) Remove the exhaust nozzle (27) as follows:

(a) Loosen the coupling (28) that attaches the exhaust nozzle (27) to the exhaust
outlet flange (29).

(b) Remove the exhaust nozzle (27) from the APU (1) and move it into the
exhaust duct (30).

(c) Temporarily attach the coupling (28) to the exhaust nozzle flange (29).

(d) Install protective covers on the exhaust nozzle flange (29).

(15) Remove the APU outlet bleed duct (32) and the APU supply check valve from the
load control valve (31) (TASK 36−11−07−000−801).

(16) Disconnect the APU inlet duct assembly (33) as follows:

(a) Remove the retaining clips (34) that attach the APU inlet bellows
assembly (35) to the flange on the APU inlet duct (36).

(b) Lift the APU inlet bellows assembly (35) and attach it to the hanger bellows
clips (37).

(c) Install a protective cover on the APU inlet duct (36).

CAUTION: USE TWO WRENCHES WHEN YOU REMOVE/TORQUE THE

HOSES/TUBES. USE ONE WRENCH TO HOLD THE FITTING, AND
THE OTHER WRENCH TO LOOSEN/TORQUE THE COUPLING NUT.
IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(17) Disconnect the hoses (38), (39), (41), (42) and (45) as follows:

(a) Disconnect the drain hose (38) at the APU inlet duct (36). Install protective
covers.

(b) Disconnect the fuel inlet hose (39) at the generator adapter (40). Install
protective covers.

(c) Disconnect the fuel return hose (41) at the generator adapter (40). Install
protective covers.

(d) Disconnect the fuel supply hose (42) from the fuel control unit (44). Install
protective covers.

(e) Disconnect the drain hose (45) from the fuel control unit (44). Install protective
covers.

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

CAUTION: USE TWO WRENCHES WHEN YOU REMOVE/TORQUE THE

HOSES/TUBES. USE ONE WRENCH TO HOLD THE FITTING, AND
THE OTHER WRENCH TO LOOSEN/TORQUE THE COUPLING NUT.
IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(18) Disconnect the fuel solenoid tube (53) from the fuel control unit (44). Install
protective covers.

(19) Do a visual inspection of the aircraft frame holes where the beam (74) is to be
attached. Make sure the aluminum holes of the frames at FS654.50 and FS700.00
are not damaged.

NOTE: These holes are each protected by a steel doubler.

WARNING: USE ONLY APPROVED LIFTING POINTS WHEN YOU MOVE, LIFT, OR
LOWER THE APU. YOU CAN CAUSE INJURIES TO PERSONS AND
DAMAGE TO THE EQUIPMENT.

MAKE SURE THAT THE APU SLING AND THE APU HOIST IS
ASSEMBLED CORRECTLY. YOU CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.

(20) Install the beam (74) to the aircraft attaching points at FS654.50 and FS700.00 with
the two lock pins supplied.

(21) Install the APU sling cable (82) to the APU upper gearcase adapter (77).

(22) Install the APU sling cable (77) to the APU lifting cable (78) with the bolt (79) the
washer (80) and the nut (81).

(23) Install the APU hoist cable to the APU sling (75) with the shackle (76).

(24) Install the APU hoist (73) to the beam (74).

On A/C 5301 to 5630 Pre SB 604−49−006

F. Procedure

Refer to Figure 401 and Figure 403.

WARNING: MAKE SURE THAT THERE ARE NO PERSONS NEAR THE APU
DURING THE REMOVAL/INSTALLATION. YOU CAN CAUSE INJURIES
TO PERSONS AND DAMAGE TO THE EQUIPMENT.

(1) Put the mobile stand below the aft equipment compartment door.

(2) Remove the bolts (83) and the washers (84) that attach the APU support skid
assembly (85) to the APU enclosure floor.

EFFECTIVITY: ALL

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CAUTION: MAKE SURE THAT THE APU AND ITS COMPONENTS (ESPECIALLY
THE LOAD CONTROL VALVE) DO NOT TOUCH THE SIDES OF THE
APU ENCLOSURE. YOU CAN CAUSE DAMAGE TO THE APU, ITS
COMPONENTS AND THE APU ENCLOSURE.

(3) Carefully operate the hoist to lift the weight of the APU (1) from the APU enclosure.
As the weight of the APU is removed, move the APU out of the APU enclosure.

(4) When the weight of the APU (1) is fully on the APU hoist (73), turn the APU
90 degrees.

(5) Carefully lower the APU (1) through the aft equipment compartment door until it is
clear of the aircraft.

(6) Continue to lower the APU (1) until the APU support skid assembly (85) is on the
mobile stand.

(7) Attach the APU support skid assembly (85) to the mobile stand.

(8) If necessary, remove the APU support skid assembly (85) from the APU (1)
(TASK 49−12−01−000−801).

(9) If necessary, install the APU enclosure access panel (311BZ)

(TASK 49−11−04−400−801).

(10) Remove the APU hoist (73), from the beam (74).

(11) Remove the APU hoist cable from the APU sling (75).

(12) Remove the bolt (79), the washer (80) and the nut (81) that attache the APU sling
cable (77) to the APU lifting cable (78).

(13) Remove the APU sling cable (82) from the APU upper gearcase adapter (86).

(14) Remove the beam (74) from the aircraft attaching points at FS654.00 and
FS700.00.

(15) Do a visual inspection of the aircraft frame holes where the beam (74) was
attached. Make sure the aluminum holes of the frames at FS654.50 and FS700.00
are not damaged.

NOTE: These holes are each protected by a steel doubler.

(16) If the APU (1) will be replaced, remove the parts that follow:

(a) Remove the APU load control valve (31) (TASK 49−51−01−000−801).

(b) Remove the union (49) and the packing (50) from the fuel inlet port (51) on the
generator adapter (42). Install protective covers.

(c) Remove the union (52) and the packing (53) from the fuel return port (54) on
the generator adapter (42). Install protective covers.

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(d) Remove the union (55) and the packing (56) from the inlet port (57) on the fuel
control unit (45). Install protective covers.

(e) Remove the union (58) and the packing (59) from the drain port (60) on the
fuel control unit (45). Install protective covers.

(f) Discard the packings (50), (53), (56) and (59).

(g) Remove the drain tubes (61) and (62) from the combustor/plenum drain
valve/orifice fittings (63) and (64). Install protective covers.

(h) Remove the coupling (27) from the exhaust nozzle flange (28).

On A/C 5631 and subs and 5301 to 5630 Post SB 604−49−006

G. Procedure

Refer to Figure 402 and Figure 403.

WARNING: MAKE SURE THAT THERE ARE NO PERSONS NEAR THE APU
DURING THE REMOVAL/INSTALLATION. YOU CAN CAUSE INJURIES
TO PERSONS AND DAMAGE TO THE EQUIPMENT.

(1) Put the mobile stand below the aft equipment compartment door.

(2) Remove the bolts (83) and the washers (84) that attach the APU support skid
assembly (85) to the APU enclosure floor.

CAUTION: MAKE SURE THAT THE APU AND ITS COMPONENTS (ESPECIALLY
THE LOAD CONTROL VALVE) DO NOT TOUCH THE SIDES OF THE
APU ENCLOSURE. YOU CAN CAUSE DAMAGE TO THE APU, ITS
COMPONENTS AND THE APU ENCLOSURE.

(3) Carefully operate the hoist to lift the weight of the APU (1) from the APU enclosure.
As the weight of the APU is removed, move the APU out of the APU enclosure.

(4) When the weight of the APU (1) is fully on the APU hoist (73), turn the APU
90 degrees.

(5) Carefully lower the APU (1) through the aft equipment compartment door until it is
clear of the aircraft.

(6) Continue to lower the APU (1) until the APU support skid assembly (85) is on the
mobile stand.

(7) Attach the APU support skid assembly (85) to the mobile stand.

(8) If necessary, remove the APU support skid assembly (85) from the APU (1)
(TASK 49−12−01−000−801).

(9) If necessary, install the APU enclosure access panel (311BZ)

(TASK 49−11−04−400−801).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(10) Remove the APU hoist (73) from the beam (74).

(11) Remove the APU hoist cable from the APU sling (75).

(12) Remove the bolt (79), the washer (80) and the nut (81) that attache the APU sling
cable (77) to the APU lifting cable (78).

(13) Remove the APU sling cable (82) from the APU upper gearcase adapter (86).

(14) Remove the beam (74) from the aircraft attaching points at FS654.50 and
FS700.00.

(15) Do a visual inspection of the aircraft frame holes where the beam (74) was
attached. Make sure the aluminum holes of the frames at FS654.50 and FS700.00
are not damaged.

NOTE: These holes are each protected by a steel doubler.

(16) If the APU (1) will be replaced, remove the parts that follow:

(a) Remove the APU load control valve (31) (TASK 49−51−01−000−801).

(b) Remove the union (56) and the packing (57) from the fuel inlet port (58) on the
generator adapter (40). Install protective covers.

(c) Remove the union (59) and the packing (60) from the fuel return port (61) on
the generator adapter (40). Install protective covers.

(d) Remove the union (46) and the packing (47) from the inlet port (48) on the fuel
control unit (44). Install protective covers.

(e) Remove the union (49) and the packing (50) from the drain port (51) on the
fuel control unit (44). Install protective covers.

(f) Remove the union (54) and the packing (55) from the drain port (52) on the
fuel control unit (44). Install protective covers.

(g) Discard the packings (47), (50), (55), (57) and (60).

(h) Remove the coupling (28) from the exhaust nozzle flange (29).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

33
35 37 34 32
31
FS650.00 43

41 28
3
2 5 27
4

26

29
1

36

22
13
23 87
88
24

25
LMM4910004_001

21

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 PRE SB 604−49−006)
Figure 401 (Sheet 1 of 3)

EFFECTIVITY: ALL

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17

16
17

13

20
19
10
18
15
9 8

69

12 7
11 44 6
46
14
16

64
63
62

40
39 61
LMM4910004_002

38

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 PRE SB 604−49−006)
Figure 401 (Sheet 2 of 3)

EFFECTIVITY: ALL

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43
41

42

36 13

63

48

61 64
39

47

40 46
62

44

43

52
71
53 45
54 42

60

57 59
41
56 58
49
55
LMM4910004_003

50 46
51
44 72

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 PRE SB 604−49−006)
Figure 401 (Sheet 3 of 3)

EFFECTIVITY: ALL

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33
35 37 34 32
31
41
39
29
3
2 5
4 28

27

30

38
LMM4910004_004

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 POST SB 604−49−006 and
5631 and SUBS)
Figure 402 (Sheet 1 of 4)
EFFECTIVITY: ALL

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10
16
9 8

11 12 7
43 42 6

21

20
19

15
18
LMM4910004_005

17

14

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 POST SB 604−49−006 and
5631 and SUBS)
Figure 402 (Sheet 2 of 4)
EFFECTIVITY: ALL

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13

36

23

24
87
25
88

26
LMM4910004_006

22

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 POST SB 604−49−006 and
5631 and SUBS)
Figure 402 (Sheet 3 of 4)
EFFECTIVITY: ALL

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41

59 62

60
61

40

39

56

57 63
58

52
54 55
44

51

53
48
50
47
49
LMM4910004_007

46

45
42

Auxiliary Power Unit (APU) − Removal/Installation− (A/C 5301 to 5630 POST SB 604−49−006 and
5631 and SUBS)
Figure 402 (Sheet 4 of 4)
EFFECTIVITY: ALL

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74

73

75

76

77
86
78
82

79
83
LMM4910004_011

80
81
84

85

Auxiliary Power Unit (APU) Sling and Hoist − Removal/Installation

Figure 403

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

TASK 49−10−00−400−801
2. Installation of the Auxiliary Power Unit (APU) Power Plant

A. Service Bulletin List

SERVICE BULLETIN NO. SERVICE BULLETIN TITLE

604−49−006 Introduction of the 36−150 (CL) Auxillary Power Unit (APU)

604−49−003 Improve Leak Resistance and Drainage

B. Reference Information

REFERENCE DESIGNATION

TASK 12−13−49−612−801 Replenishing of the Auxiliary Power Unit (APU) Oil

Supply

TASK 12−13−49−612−802 Replenishing of the Auxiliary Power Unit (APU)

Generator/Adaptor Oil Supply

TASK 36−11−07−400−801 Installation of the Auxiliary Power Unit (APU) Supply

Check−Valve

TASK 49−10−00−710−801 Operational Test of the Auxiliary Power Unit (APU)

TASK 49−10−00−710−802 Operational Test of the Auxiliary Power Unit (APU)

(Loaded)

TASK 49−10−00−790−801 Auxiliary Power Unit (APU) Fuel and Oil Leak Check

TASK 49−10−00−790−802 Auxiliary Power Unit (APU) Bleed Air Leak Check

TASK 49−11−04−000−801 Removal of the Auxiliary Power Unit (APU)

Enclosure Access Panel (311BZ)

TASK 49−11−04−400−801 Installation of the Auxiliary Power Unit (APU)

Enclosure Access Panel (311BZ)

TASK 49−12−01−400−801 Installation of the Auxiliary Power Unit (APU)

Support Skid Assembly

TASK 49−51−01−400−801 Installation of the Auxiliary Power Unit (APU) Load

Control Valve

TASK 49−81−01−400−801 Installation of the Auxiliary Power Unit (APU)

Exhaust Nozzle

TASK 52−41−00−410−801 Close the Aft Equipment−Compartment Door

(311BB)

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

REFERENCE DESIGNATION

SPM−MM 20−21−00−910−801 Torquing of Threaded Fasteners

SPM−MM 20−22−00−910−801 Torquing of Plumbing Line Fittings

SPM−MM 20−30−00−910−805 Marman Couplings and V−Band Couplings

SPM−MM 20−50−00−400−801 Installation of Lockwire

SPM−MM 51−23−00−390−809 Wet Installation of Fasteners

CMM 24−22−01 Generator Assembly (UTC Aerospace Systems)

CMM 49−20−00 Engine − Maintenance Manual (Part of CMM

49−21−59) (AlliedSignal / Honeywell International)

CMM 49−21−59 Pneumatic and Shaft Power Gas Turbine Engine

(Alliedsignal Engines)

CMM 49−24−73 Gas Turbine Engine Assembly (Honeywell

International)

CMM 49−24−75 Gas Turbine Engine (Honeywell International)

C. Tools and Equipment

REFERENCE DESIGNATION

GSE 49−00−01 Kit − APU Removal/Installation

Commercially Available Stand, Mobile

Commercially Available Wrench, Torque 18 to 20 lbf in (2.04 to 2.25 Nm)

Commercially Available Wrench, Torque 25 to 30 lbf in (2.83 to 3.38 Nm)

Commercially Available Wrench, Torque 35 to 40 lbf in (3.95 to 4.51 Nm)

Commercially Available Wrench, Torque 40 lbf in (4.52 Nm)

Commercially Available Wrench, Torque 48 to 53 lbf in (5.43 to 5.98 Nm)

Commercially Available Wrench, Torque 70 lbf in (7.91 Nm)

Commercially Available Wrench, Torque 70 to 120 lbf in (7.91 to 13.55 Nm)

Commercially Available Wrench, Torque 75 to 80 lbf in (8.48 to 9.03 Nm)

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

REFERENCE DESIGNATION

Commercially Available Wrench, Torque 80 lbf in (9.04 Nm)

Commercially Available Wrench, Torque 100 to 250 lbf in (11.30 to

28.24 Nm)

Commercially Available Wrench, Torque 120 lbf in (13.56 Nm)

Commercially Available Wrench, Torque 133 to 147 lbf in (15.03 to

16.60 Nm)

Commercially Available Wrench, Torque 135 to 150 lbf in (15.26 to

16.94 Nm)

Commercially Available Wrench, Torque 17.50 to 35.00 lbf ft (23.73 to

47.45 Nm)

Commercially Available Wrench, Torque 21.42 to 23.66 lbf ft (29.04 to

32.07 Nm)

Commercially Available Wrench, Torque 39.59 to 43.75 lbf ft (53.67 to

59.31 Nm)

NOTE: Refer to the Illustrated Tool and Equipment Manual to make sure that you use
the correct equipment configuration.

D. Consumable Materials

REFERENCE DESIGNATION MANUFACTURERS’ REFERENCE

AND/OR SPECIFICATION

04−024 Petrolatum VV−P−236

05−004 Lockwire, CRES 0.020 in (0.51 mm) MS20995C20

06−070 Sealant, Firewall Dapco 18−4F

Cytec Engineered Materials

06−070B Sealing Compound Aircraft Firewall, Dapco 2200 Type 4

Silicone Cytec Engineered Materials

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

E. Parts

On A/C 5301 to 5630 Pre SB 604−49−006

REFERENCE NAME OF PART QUANTITY IPC SEQUENCE NO.

1 Unit, Auxiliary Power 1 49−00−01−01−001

49−00−01−01−002

14 Screw 2 24−22−01−01−045

15 Clamp 1 49−13−01−01−030

18 Nut 4 24−22−01−01−055

19 Washer 4 24−22−01−01−060

22 Nut 1 CMM 49−41−04

23 Washer 1 CMM 49−41−04

26 Nozzle, Exhaust 1 49−81−01−01−005

27 Coupling 1 49−81−01−01−010

31 Valve, Auxiliary Power Unit (APU) 1 49−51−01−01−035

Load Control

32 Duct 1 36−11−00−01−346

34 Clip, Retaining 2 49−14−04−01−010

49−14−04−01−015

49 Union 1 49−31−22−01−130

50 Packing 1 49−31−22−01−135

52 Union 1 49−31−22−01−130

53 Packing 1 49−31−22−01−135

55 Union 1 49−31−22−01−120

56 Packing 1 49−31−22−01−125

58 Union 1 49−15−01−01−265

59 Packing 1 49−15−01−01−270

69 Washer 1 24−22−01−01−050

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

83 Bolt 4 49−12−01−01−135

84 Washer 4 49−12−01−01−140

87 Nut 1 CMM 49−41−04

88 Washer 1 CMM 49−41−04

F. Parts

On A/C 5631 and subs and 5301 to 5630 Post SB 604−49−006

REFERENCE NAME OF PART QUANTITY IPC SEQUENCE NO.

1 Unit, Auxiliary Power 1 49−00−01−01A−001

14 Screw 2 24−22−01−01−045

15 Washer 1 24−22−01−01−050

16 Clamp 1 49−13−01−01A−040

19 Nut 4 24−22−01−01−055

20 Washer 4 24−22−01−01−060

23 Nut 1 CMM 49−41−14

24 Washer 1 CMM 49−41−14

27 Nozzle, Exhaust 1 49−81−01−01B−005

28 Coupling 1 49−81−01−01B−010

31 Valve, Auxiliary Power Unit (APU) 1 49−51−01−01B−020

Load Control

32 Duct 1 36−11−00−01A−355

34 Clip, Retaining 2 49−14−04−01A−010

46 Union 1 49−31−22−01A−115

47 Packing 1 49−31−22−01A−120

49 Union 1 49−15−01−01B−210

50 Packing 1 49−15−01−01B−215

54 Union 1 CMM 49−24−73

EFFECTIVITY: ALL

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55 Packing 1 CMM 49−24−73

56 Union 1 49−31−22−01A−125

57 Packing 1 49−31−22−01A−130

59 Union 1 49−31−22−01A−125

60 Packing 1 49−31−22−01A−130

74 Bolt 4 49−12−01−01A−130

75 Washer 4 49−12−01−01A−135

87 Nut 1 CMM 49−41−14

88 Washer 1 CMM 49−41−14

On A/C 5301 to 5630 Pre SB 604−49−006

G. Job Set−Up

CAUTION: READ THE TORQUE VALUES CAREFULLY. SOME ARE POUND-FORCE

INCHES (LBF IN) AND SOME ARE POUND-FORCE FEET (LBF FT). IF YOU
TORQUE INCORRECTLY, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(1) Make sure the aircraft is in the same configuration as in the removal task.

NOTE: Make sure the mating surfaces are clean with no corrosion, paint, grease
or preservation fluids.

(2) If necessary, remove the APU enclosure access panel (311BZ)

(TASK 49−11−04−000−801).

(3) Do the detailed inspection of the APU enclosure and its components as follows:

(a) Make sure that the exhaust nozzle (26) is in the exhaust duct (29).

(b) Make sure that the APU inlet bellows assembly (35) are attached to the hanger
bellows clips (37).

(c) Make sure that there are no unwanted objects in the APU enclosure.

(d) Make sure that the electrical harnesses and the electrical cables are attached
to the sides of the APU enclosure.

(e) Make sure that the drain, the vent and the fuel hoses/tubes will not prevent the
installation of the APU (1).

EFFECTIVITY: ALL

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(f) Examine the condition of the gasket (71).

NOTE: Make sure the gasket (71) is installed on the APU enclosure and not
on the flapper door (72).

(4) If the APU (1) was replaced, install the parts that follow:

(a) Lubricate the packings (50), (53), (56) and (59) with petrolatum.

(b) Remove the protective cover. Install the packing (50) and the union (49) on the
fuel inlet port (51) on the generator adapter (42).

(c) Remove the protective cover. Install the packing (53) and the union (52) on the
fuel return port (54) on the generator adapter (42).

(d) Remove the protective cover. Install the packing (56) and the union (55) on the
inlet port (57) on the fuel control unit (45).

(e) Remove the protective cover. Install the packing (59) and the union (58) on the
drain port (60) on the fuel control unit (45).

(f) Remove the protective covers. Install the drain tubes (61) and (62) on the
combustor/plenum drain valve/orifice fittings (63) and (64).

(g) Install the APU load control valve (31) (TASK 49−51−01−400−801).

NOTE: Do not torque the coupling on the APU load control valve (31) at this
time.

(h) Loosely install the coupling (27) on the exhaust nozzle flange (28)
(SPM−MM 20−30−00−910−805).

(5) If the APU (1) was replaced, torque the parts that follow
(SPM−MM 20−22−00−910−801):

(a) Torque the unions (49) and (52) from 39.59 to 43.75 lbf ft (53.67 to 59.31 Nm).

(b) Torque the union (55) from 21.42 to 23.66 lbf ft (29.04 to 32.07 Nm).

(c) Torque the union (58) from 133 to 147 lbf in (15.03 to 16.60 Nm).

(d) Torque the drain tubes (61) and (62) from 135 to 150 lbf in (15.26 to
16.94 Nm).

EFFECTIVITY: ALL

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WARNING: USE ONLY APPROVED LIFTING POINTS WHEN YOU MOVE, LIFT, OR
LOWER THE APU. YOU CAN CAUSE INJURIES TO PERSONS AND
DAMAGE TO THE EQUIPMENT.

MAKE SURE THAT THE APU SLING AND THE APU HOIST IS
ASSEMBLED CORRECTLY. YOU CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.

(6) Install the APU hoist (73), the APU sling (75) and the beam (74) as follows:

(a) Do a visual inspection of the aircraft frame holes where the beam (74) is to be
attached. Make sure the aluminum holes of the frames at FS654.50 and
FS700.00 are not damaged.

NOTE: These holes are each protected by a steel doubler.

(b) Install the beam (74) to the aircraft attaching points at FS654.50 and
FS700.00.

(c) Install the APU sling cable (82) to the APU upper gearcase adapter (86).

(d) Install the APU sling cable (77) to the APU lifting cable (78) with the bolt (79)
the washer (80) and the nut (81).

(e) Attach the APU sling (75) to the shackle (76) on the APU hoist (73).

(f) Attach the APU hoist (73) to the beam (74).

On A/C 5631 and subs and 5301 to 5630 Post SB 604−49−006

H. Job Set−Up

CAUTION: READ THE TORQUE VALUES CAREFULLY. SOME ARE POUND-FORCE

INCHES (LBF IN) AND SOME ARE POUND-FORCE FEET (LBF FT). IF YOU
TORQUE INCORRECTLY, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(1) Make sure the aircraft is in the same configuration as in the removal task.

NOTE: Make sure the mating surfaces are clean with no corrosion, paint, grease
or preservation fluids.

(2) If necessary, remove the APU enclosure access panel (311BZ)

(TASK 49−11−04−000−801).

(3) Do the detailed inspection of the APU enclosure and its components as follows:

(a) Make sure that the exhaust nozzle (27) is in the exhaust duct (30).

(b) Make sure that the APU inlet bellows assembly (35) are attached to the hanger
bellows clips (37).

EFFECTIVITY: ALL

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(c) Make sure that there are no unwanted objects in the APU enclosure.

(d) Make sure that the electrical harnesses and the electrical cables are attached
to the sides of the APU enclosure.

(e) Make sure that the drain, the vent and the fuel hoses/tubes will not prevent the
installation of the APU (1).

(f) Examine the condition of the gasket (62).

NOTE: Make sure the gasket (62) is installed on the APU enclosure and not
on the flapper door (63).

(4) If the APU (1) was replaced, install the parts that follow:

(a) Lubricate the packings (47), (50), (55), (57) and (60) with petrolatum.

(b) Remove the protective cover. Install the packing (47) and the union (46) on the
fuel inlet port (48) on the generator adapter (44).

(c) Remove the protective cover. Install the packing (50) and the union (49) on the
fuel return port (51) on the generator adapter (44).

(d) Remove the protective cover. Install the packing (55) and the union (54) on the
inlet port (52) on the fuel control unit (44).

(e) Remove the protective cover. Install the packing (57) and the union (56) on the
drain port (58) on the fuel control unit (40).

(f) Remove the protective cover. Install the packing (60) and the union (59) on the
drain port (61) on the fuel control unit (40).

(g) Install the APU load control valve (31) (TASK 49−51−01−400−801).

NOTE: Do not torque the coupling on the APU load control valve (31) at this
time.

(h) Loosely install the coupling (28) on the exhaust nozzle flange (27)
(SPM−MM 20−30−00−910−805).

(5) If the APU (1) was replaced, torque the parts that follow
(SPM−MM 20−22−00−910−801):

(a) Torque the unions (56) and (59) from 39.59 to 43.75 lbf ft (53.67 to 59.31 Nm).

(b) Torque the union (46) from 21.42 to 23.66 lbf ft (29.04 to 32.07 Nm).

(c) Torque the union (49) from 133 to 147 lbf in (15.03 to 16.60 Nm).

(d) Torque the union (54) to 70 lbf in (7.91 Nm) (CMM 49−24−75).

EFFECTIVITY: ALL

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WARNING: USE ONLY APPROVED LIFTING POINTS WHEN YOU MOVE, LIFT, OR
LOWER THE APU. YOU CAN CAUSE INJURIES TO PERSONS AND
DAMAGE TO THE EQUIPMENT.

MAKE SURE THAT THE APU SLING AND THE APU HOIST IS
ASSEMBLED CORRECTLY. YOU CAN CAUSE INJURIES TO
PERSONS AND DAMAGE TO THE EQUIPMENT.

(6) Install the APU hoist (73), the APU sling (75) and the beam (74) as follows:

(a) Do a visual inspection of the aircraft frame holes where the beam (74) is to be
attached. Make sure the aluminum holes of the frames at FS654.50 and
FS700.00 are not damaged.

NOTE: These holes are each protected by a steel doubler.

(b) Install the beam (74) to the aircraft attaching points at FS654.50 and FS700.00
with the two lock pins supplied.

(c) Install the APU sling cable (82) to the APU upper gearcase adapter (77).

(d) Install the APU sling cable (77) to the APU lifting cable (78) with the bolt (79)
the washer (80) and the nut (81).

(e) Attach the APU sling (75) to the shackle (76) on the APU hoist (73).

(f) Attach the APU hoist (73) to the beam (75).

On A/C 5301 to 5630 Pre SB 604−49−006

I. Procedure

Refer to Figure 401 and Figure 403.

WARNING: MAKE SURE THAT THERE ARE NO PERSONS NEAR THE APU
DURING THE REMOVAL/INSTALLATION. YOU CAN CAUSE INJURIES
TO PERSONS AND DAMAGE TO THE EQUIPMENT.

(1) Put the mobile stand below the aft equipment compartment door (311BB).

(2) Remove the fasteners that attach the APU support skid assembly (85) to the mobile
stand.

(3) Carefully operate the APU hoist (73) to lift the APU (1) off of the mobile stand.

(4) If removed, install the APU support skid assembly (85) on the APU (1)
(TASK 49−12−01−400−801).

(5) Carefully operate the APU hoist (73) to lift the APU (1) through the aft equipment
compartment door (311BB).

(6) Turn the APU (1) 90 degrees.

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

CAUTION: MAKE SURE THAT THE APU AND ITS COMPONENTS (ESPECIALLY
THE LOAD CONTROL VALVE) DO NOT TOUCH THE SIDES OF THE
APU ENCLOSURE. YOU CAN CAUSE DAMAGE TO THE APU, ITS
COMPONENTS AND THE APU ENCLOSURE.

(7) Carefully operate the APU hoist (73) to lower the APU (1) into the APU enclosure.
As the APU is lowered, push the APU into the APU enclosure.

(8) Align the holes in the APU support skid assembly (85) with the holes in the floor of
the APU enclosure.

On A/C 5301 to 5399 Pre SB 604−49−003

(9) Attach the APU support skid (85) to the APU enclosure floor with the bolts (83) and
the washers (84).

On A/C 5400 and subs and 5301 to 5399 Post SB 604−49−003

(10) Wet install the bolts (83) and the washers (84) that attach the APU support skid
assembly (85) to the APU enclosure floor (SPM−MM 51−23−00−390−809).

(11) Torque the bolts (83) from 25 to 30 lbf in (2.83 to 3.38 Nm) and add running torque
(SPM−MM 20−21−00−910−801).

(12) Remove the APU hoist (73), the APU sling (75) and the beam (74) as follows:

(a) Remove the APU hoist (73) from the beam (74).

(b) Remove the APU sling (75) from the shackle (76) on the APU hoist (73).

(c) Remove the bolt (79), the washer (80) and the nut (81) that attache the APU
sling cable (77) to the APU lifting cable (78).

(d) Remove the APU sling cable (82) from the APU upper gearcase adapter (86).

(e) Remove the beam (74) from the aircraft attaching points at FS654.50 and
FS700.00.

(f) Do a visual inspection of the aircraft frame holes where the beam (74) was
attached. Make sure the aluminum holes of the frames at FS654.50 and
FS700.00 are not damaged.

NOTE: These holes are each protected by a steel doubler.

(13) Connect the drain, the vent and the fuel hoses/tubes as follows:

(a) Remove the protective covers from the hoses/tubes (38), (39), (41), (43), (44),
(46), (47) and (48).

(b) Connect the vent hose (47) to the vent tube (48) on the generator adapter (42).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(c) Connect the fuel return hose (43) to the union (52) on the generator
adapter (42).

NOTE: Make sure that the fuel return hose (43) does not touch the ignition
unit, its electrical harness or the ignition lead.

(d) Connect the fuel inlet hose (41) to the union (49) on the generator
adapter (42).

NOTE: Make sure that the fuel inlet hose (41) does not touch the ignition
unit, its electrical harness or the ignition lead.

(e) Connect the fuel supply hose (44) to the union (55) on the fuel control
unit (45).

(f) Connect the drain hose (46) to the union (58) the fuel control unit (45).

(g) Connect the drain hose (38) to the APU inlet duct (36).

(h) Connect the drain hose (39) to the tee−fitting (40) for the combustor drains.

CAUTION: USE TWO WRENCHES WHEN YOU REMOVE/TORQUE THE

HOSES/TUBES. USE ONE WRENCH TO HOLD THE FITTING, AND
THE OTHER WRENCH TO LOOSEN/TORQUE THE COUPLING NUT.
IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(14) Torque the fittings that follow (SPM−MM 20−22−00−910−801):

(a) Torque the vent hose (47) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(b) Torque the fuel return hose (43) from 17.50 to 35.00 lbf ft (23.73 to 47.45 Nm).

(c) Torque the fuel inlet hose (41) from 17.50 to 35.00 lbf ft (23.73 to 47.45 Nm).

(d) Torque the fuel supply hose (44) from 100 to 250 lbf in (11.30 to 28.24 Nm).

(e) Torque the drain hose (46) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(f) Torque the drain hose (38) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(g) Torque the drain hose (39) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(15) Install the APU outlet bleed duct (32) and the APU check valve
(TASK 36−11−07−400−801)

Connect the load control valve (31) as follows:

NOTE: At this moment, check the distance between the APU load control valve
and the APU enclosure then torque the APU LCV V−band coupling
(SPM−MM 20−30−00−910−805).

EFFECTIVITY: ALL

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(16) Install the exhaust nozzle (26) (TASK 49−81−01−400−801).

(17) Connect the APU inlet duct assembly (33) as follows:

(a) Remove the protective cover from the APU inlet duct (36).

(b) Remove the APU inlet bellows assembly (35) from the hanger bellows
clips (37).

(c) Attach the APU inlet bellows assembly (35) to the flange on the APU inlet
duct (36) with the retaining clips (34).

(18) Install the parts on the starter motor (21) as follow:

(a) Remove the nuts (22) and (87) and the washers (23) and (88) from the
terminals on the starter motor (21).

(b) Attach the starter cable (24) to the positive terminal on the starter motor (21)
with the washer (23) and the nut (22).

(c) Attach the starter cable (25) to the negative terminal on the starter motor (21)
with the washer (88) and the nut (87).

(d) Torque the nut (22) on the positive terminal from 35 to 40 lbf in
(3.95 to 4.51 Nm) (CMM 49−21−59) and (SPM−MM 20−21−00−910−801).

(e) Torque the nut (87) on the negative terminal from 75 to 80 lbf in
(8.48 to 9.03 Nm) (CMM 49−21−59) and (SPM−MM 20−21−00−910−801).

(19) Install the parts on the integrated drive generator (13) as follow:

(a) Remove the screws (14), the washers (69), the terminal block cover (16), the
nuts (18) and the washers (19) from the terminal block (17).

(b) Install the electrical cables (20) on the terminal lugs (T1, T2, T3 and G) on the
terminal block (17).

(c) Attach the electrical cables (20) to the terminal lugs (T1, T2, T3 and G) on the
terminal block (17) with the washers (19) and the nuts (18).

(d) Torque the nuts (18) from 48 to 53 lbf in (5.43 to 5.98 Nm)
(SPM−MM 20−21−00−910−801).

(e) Attach the clamp (15) and the terminal block cover (16) to the terminal
block (17) with the screws (14) and washers (69).

(f) Torque the screws (14) from 18 to 20 lbf in (2.04 to 2.25 Nm)
(CMM 24−22−01) and (SPM−MM 20−21−00−910−801).

EFFECTIVITY: ALL

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 CL−604 AIRCRAFT MAINTENANCE MANUAL − PART II

(20) Connect the electrical connectors that follow:

(a) Attach the electrical harness (12) to the APU enclosure with the screws (10)
and the clamps (11).

(b) Remove the protective covers from the electrical connectors and their
receptacles.

(c) Connect the electrical connector (2) to the receptacle (3).

(d) Connect the electrical connector (4) to the receptacle (5).

(e) Connect the electrical connector (6) to the receptacle (7).

(f) Connect the electrical connector (8) J2KD to the receptacle (9).

(21) Safety the electrical connectors (2), (4) and (6) with lockwire
(SPM−MM 20−50−00−400−801).

(22) Remove the tags and close the circuit breakers that follow:

LOCATION CB NUMBER CB NAME ZONE

CBP−1 L1 APU ECU 221

CBP−1 L2 APU FAULT ANN 221

CBP−1 L3 APU START CONT 221

CBP−1 R5 APU FIRE EXT 221

CBP−1 S3 FUEL SOV APU 221

CBP−2 P4 APU FUEL PUMP 222

(23) Do the servicing of the APU as follows:

(a) If a new APU is installed or the APU has been preserved, do the Prepare the
APU for Service procedure (CMM 49−20−00).

(b) Do the replenishing of the APU oil tank (TASK 12−13−49−612−801).

(c) Do the replenishing of the APU generator/adaptor

(TASK 12−13−49−612−802).

(24) Install the APU enclosure access panel (311BZ) (TASK 49−11−04−400−801)

(25) If you installed a new APU, do the tests that follow:

(a) Do the operational test of the APU (loaded) (TASK 49−10−00−710−802).

EFFECTIVITY: ALL

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(b) Do the APU fuel and oil leak check (TASK 49−10−00−790−801).

(c) Do the APU bleed air leak check (TASK 49−10−00−790−802).

(26) If you installed the same APU, do the tests that follow:

(a) Do the operational test of the APU (TASK 49−10−00−710−801).

(b) Do the APU fuel and oil leak check (TASK 49−10−00−790−801).

(c) Do the APU bleed air leak check (TASK 49−10−00−790−802).

On A/C 5631 and subs and 5301 to 5630 Post SB 604−49−006

J. Procedure

Refer to Figure 402 and Figure 403.

WARNING: MAKE SURE THAT THERE ARE NO PERSONS NEAR THE APU
DURING THE REMOVAL/INSTALLATION. YOU CAN CAUSE INJURIES
TO PERSONS AND DAMAGE TO THE EQUIPMENT.

(1) Put the mobile stand below the aft equipment compartment door (311BB).

(2) Remove the fasteners that attach the APU support skid assembly (85) to the mobile
stand.

(3) Carefully operate the APU hoist (73) to lift the APU (1) off of the mobile stand.

(4) If removed, install the APU support skid assembly (85) on the APU (1)
(TASK 49−12−01−400−801).

(5) Carefully operate the APU hoist (73) to lift the APU (1) through the aft equipment
compartment door (311BB).

(6) Turn the APU (1) 90 degrees.

CAUTION: MAKE SURE THAT THE APU AND ITS COMPONENTS (ESPECIALLY
THE LOAD CONTROL VALVE) DO NOT TOUCH THE SIDES OF THE
APU ENCLOSURE. YOU CAN CAUSE DAMAGE TO THE APU, ITS
COMPONENTS AND THE APU ENCLOSURE.

(7) Carefully operate the APU hoist (73) to lower the APU (1) into the APU enclosure.
As the APU is lowered, push the APU into the APU enclosure.

(8) Align the holes in the APU support skid assembly (85) with the holes in the floor of
the APU enclosure.

(9) Wet install the bolts (83) with firewall silicon sealant and the washers (84) that
attach the APU support skid assembly (85) to the APU enclosure floor
(SPM−MM 51−23−00−390−809).

EFFECTIVITY: ALL

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(10) Torque the bolts (83) from 25 to 30 lbf in (2.83 to 3.38 Nm) and add running torque
(SPM−MM 20−21−00−910−801).

(11) Remove the APU hoist (73), the APU sling (75) and the beam (65) as follows:

(a) Remove the APU hoist (73) from the beam (74).

(b) Remove the APU sling (76) from the shackle (77) on the APU hoist (73).

(c) Remove the bolt (79), the washer (80) and the nut (81) that attache the APU
sling cable (77) to the APU lifting cable (78).

(d) Remove the APU sling cable (82) from the APU upper gearcase adapter (86).

(e) Remove the beam (74) from the aircraft attaching points at FS654.50 and
FS700.00.

(f) Do a visual inspection of the aircraft frame holes where the beam (74) was
attached. Make sure the aluminum holes of the frames at FS654.50 and
FS700.00 are not damaged.

NOTE: These holes are each protected by a steel doubler.

(12) Connect the drain, the vent and the fuel hoses/tubes as follows:

(a) Remove the protective covers from the hoses/tubes (38), (39), (41), (42),
and (43).

(b) Connect the fuel return hose (41) to the union (60) on the generator
adapter (40).

NOTE: Make sure that the fuel return hose (43) does not touch the ignition
unit, its electrical harness or the ignition lead.

(c) Connect the fuel inlet hose (39) to the union (56) on the generator
adapter (40).

NOTE: Make sure that the fuel inlet hose (39) does not touch the ignition
unit, its electrical harness or the ignition lead.

(d) Connect the fuel supply hose (42) to the union (46) on the fuel control
unit (44).

(e) Connect the drain hose (45) to the union (49) the fuel control unit (44).

(f) Connect the fuel solenoid tube (53) to the union (54) the fuel control unit (44).

(g) Connect the drain hose (38) to the APU inlet duct (36).

EFFECTIVITY: ALL

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CAUTION: USE TWO WRENCHES WHEN YOU REMOVE/TORQUE THE

HOSES/TUBES. USE ONE WRENCH TO HOLD THE FITTING, AND
THE OTHER WRENCH TO LOOSEN/TORQUE THE COUPLING NUT.
IF YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
COMPONENTS.

(13) Torque the fittings that follow (SPM−MM 20−22−00−910−801):

(a) Torque the fuel return hose (41) from 17.50 to 35.00 lbf ft (23.73 to 47.45 Nm).

(b) Torque the fuel inlet hose (39) from 17.50 to 35.00 lbf ft (23.73 to 47.45 Nm).

(c) Torque the fuel supply hose (42) from 100 to 250 lbf in (11.30 to 28.24 Nm).

(d) Torque the drain hose (45) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(e) Torque the fuel solenoid tube (53) to 120 lbf in (13.56 Nm) (CMM 49−24−75).

(f) Torque the drain hose (38) from 70 to 120 lbf in (7.91 to 13.55 Nm).

(14) Connect the load control valve (31) as follows:

(a) At this moment, check the distance between the APU load control valve (31)
and the APU enclosure and torque the V−band coupling
(SPM−MM 20−30−00−910−805).

(b) Install the APU outlet bleed duct (32) and the APU check valve
(TASK 36−11−07−400−801)

(15) Install the exhaust nozzle (27) (TASK 49−81−01−400−801).

(16) Connect the APU inlet duct assembly (33) as follows:

(a) Remove the protective cover from the APU inlet duct (36).

(b) Remove the APU inlet bellows assembly (35) from the hanger bellows
clips (37).

(c) Attach the APU inlet bellows assembly (35) to the flange on the APU inlet
duct (36) with the retaining clips (34).

(17) Install the parts on the starter motor (22) as follow:

(a) Remove the nuts (23) and (87) and the washers (24) and (88) from the
terminals on the starter motor (22).

(b) Attach the starter cable (25) to the positive terminal on the starter motor (22)
with the washer (24) and the nut (23).

(c) Attach the starter cable (26) to the negative terminal on the starter motor (22)
with the washer (88) and the nut (87).

EFFECTIVITY: ALL

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(d) Torque the nut (23) on the positive terminal to 40 lbf in (4.52 Nm)
(CMM 49−24−75) and (SPM−MM 20−21−00−910−801).

(e) Torque the nut (87) on the negative terminal to 80 lbf in (9.04 Nm)
(CMM 49−24−75) and (SPM−MM 20−21−00−910−801).

(18) Install the parts on the integrated drive generator (13) as follow:

(a) Remove the screws (14), the washers (15), the terminal block cover (17), the
nuts (19) and the washers (20) from the terminal block (18).

(b) Install the electrical cables (21) on the terminal lugs (T1, T2, T3 and G) on the
terminal block (18).

(c) Attach the electrical cables (21) to the terminal lugs (T1, T2, T3 and G) on the
terminal block (18) with the washers (20) and the nuts (19).

(d) Torque the nuts (19) from 48 to 53 lbf in (5.43 to 5.98 Nm)
(SPM−MM 20−21−00−910−801).

(e) Attach the clamp (16) and the terminal block cover (17) to the terminal
block (18) with the screws (14) and washers (15).

(f) Torque the screws (14) from 18 to 20 lbf in (2.04 to 2.25 Nm)
(CMM 24−22−01) and (SPM−MM 20−21−00−910−801).

(19) Connect the electrical connectors that follow:

(a) Attach the electrical harness (12) to the APU enclosure with the screws (10)
and the clamps (11).

(b) Remove the protective covers from the electrical connectors and their
receptacles.

(c) Connect the electrical connector (2) to the receptacle (3).

(d) Connect the electrical connector (4) to the receptacle (5).

(e) Connect the electrical connector (6) to the receptacle (7).

(f) Connect the electrical connector (8) J2KD to the receptacle (9).

(20) Safety the electrical connectors (2), (4) and (6) with lockwire
(SPM−MM 20−50−00−400−801).

EFFECTIVITY: ALL

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(21) Remove the tags and close the circuit breakers that follow:

LOCATION CB NUMBER CB NAME ZONE

CBP−1 L1 APU ECU 221

CBP−1 L2 APU FAULT ANN 221

CBP−1 L3 APU START CONT 221

CBP−1 R5 APU FIRE EXT 221

CBP−1 S3 FUEL SOV APU 221

CBP−2 P4 APU FUEL PUMP 222

CBP−5 A2 APU ECU PRIM 311

CBP−5 A3 APU ECU SEC 311

(22) Do the servicing of the APU as follows:

(a) If a new APU is installed or the APU has been preserved, do the Prepare the
APU for Service procedure (CMM 49−24−75).

(b) Do the replenishing of the APU oil tank (TASK 12−13−49−612−801).

(c) Do the replenishing of the APU generator/adaptor

(TASK 12−13−49−612−802).

(23) Install the APU enclosure access panel (311BZ) (TASK 49−11−04−400−801)

(24) If you installed a new APU, do the tests that follow:

(a) Do the operational test of the APU (loaded) (TASK 49−10−00−710−802).

(b) Do the APU fuel and oil leak check (TASK 49−10−00−790−801).

(c) Do the APU bleed air leak check (TASK 49−10−00−790−802).

(25) If you installed the same APU, do the tests that follow:

(a) Do the operational test of the APU (TASK 49−10−00−710−801).

(b) Do the APU fuel and oil leak check (TASK 49−10−00−790−801).

(c) Do the APU bleed air leak check (TASK 49−10−00−790−802).

EFFECTIVITY: ALL

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K. Close Out

(1) Remove all tools, equipment, and unwanted materials from the work area.

(2) Close the aft equipment compartment access−door (311BB)

(TASK 52−41−00−410−801).

EFFECTIVITY: ALL

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