AIRBUS M35 APU SINGLE AISLE TECHNICAL TRAINING MANUAL MAINTENANCE COURSE M35 LINE MECHANICS (V2500A5.ME)

 SINGLE AISLE   TECHNICAL TRAINING MANUAL   MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)   APU  This document must be used for training purposes only Under no circumstances should this document be used as a reference It will not be updated All rights reserved No part of this manual may be reproduced in any form, by photostat, microfilm, retrieval system, or any other means, without the prior written permission of AIRBUS S.A.S SINGLE AISLE TECHNICAL TRAINING MANUAL APU HONEYWELL 131-9(A) APU Level (2)  2 APU Installation Presentation (2)  16 APU Basic Description (3)  18 APU Fuel Feed System D/O (3)  20 APU Ignition & Starting D/O (3)  22 APU Fuel System D/O (3)  24 APU Oil System D/O (3)  28 APU Air System D/O (3)  32 APU System Management D/O (3)  36 APU Basic Description (3)  150 # APU Fuel Feed System D/O (3)  156 APU Ignition & Starting D/O (3)  158 APU Fuel System D/O (3)  160 APU Oil System D/O (3)  164 APU Air System D/O (3)  166 APU System Management D/O (3)  168 APU Film Presentation (2)  176 MAINTENANCE PRACTICE # COMPT Access Doors Opening & Closing (2)  198 MAINTENANCE PRACTICE COMPT Access Doors Opening & Closing (2)  44 HONEYWELL GTCP 36-300 U3U06191 - U0O35M0 # APU Level (2)  50 # APU Installation Presentation (2)  64 APU Basic Description (3)  66 # APU Fuel Feed System D/O (3)  68 APU Ignition & Starting D/O (3)  70 APU Fuel System D/O (3)  72 APU Oil System D/O (3)  74 APU Air System D/O (3)  78 APU System Management D/O (3)  84 APU Film Presentation (2)  110 MAINTENANCE PRACTICE # COMPT Access Doors Opening & Closing (2)  128 APIC # APU Level (2)  134 # APU Installation Presentation (2)  148 MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU TABLE OF CONTENTS May 11, 2006 Page SINGLE AISLE TECHNICAL TRAINING MANUAL APU LEVEL (2) SYSTEM OVERVIEW U3U06191 - U0O35M0 - UM49BA000000001 The Auxiliary Power Unit (APU) is a constant speed gas turbine engine It is located in the unpressurized tail cone The APU is a self-contained unit, which enables the aircraft to be independent of external pneumatic and electrical power sources The constant-speed gas turbine engine drives the accessory gearbox and a load compressor The APU provides: - electrical power for the aircraft systems, - bleed air for engine starting (MES), air conditioning (ECS) and wing anti ice testing on ground (not GTCP 36-300), - bleed air for air conditioning and pressurization in flight until the specified manufacturer limit The APU is designed to operate throughout the entire flight envelope Electrical power is available whenever the APU operates, but bleed air is shut off above the specified manufacturer limit The APU has an air intake flap The intake flap is open when the APU master switch is selected ON and closes when the master switch is selected OFF When open, it provides air to the APU inlet for combustion and pneumatic supply MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page U3U06191 - U0O35M0 - UM49BA000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL SYSTEM OVERVIEW MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page SINGLE AISLE TECHNICAL TRAINING MANUAL APU LEVEL (2) SERVICING Close and lock the oil filler cap APU OIL SERVICING U3U06191 - U0O35M0 - UM49BA000000001 APU oil servicing is accomplished on an "as-needed" basis or after scheduled oil quantity checks The oil indicating system shows if the oil quantity is sufficient or if an oil servicing is necessary The oil level information is displayed on the EIS and the Multipurpose Control & Display Units (MCDUs) in the cockpit on: - the APU page on the lower ECAM display unit (LOW OIL LEVEL advisory), - the APU SERVICE DATA page on the MCDU, indicating APU OIL Level O.K or LOW NOTE: Note: The advisory appears on the ECAM APU page when the oil level has reached the ADD mark on the APU oil tank Airbus recommends servicing the APU oil at the next daily maintenance when the LOW OIL LEVEL message comes on With no oil leakage, sufficient oil is available to allow a further 10 hours of APU operation Prior to servicing, shut down the APU and open the APU cowl doors Make sure to use the operator approved oil for servicing (operators may select from the approved list) The oil may be serviced by the gravity (most common) or pressure fill procedure (optional) Gravity procedure: - Open the lock and slowly loosen the oil filler cap to release remaining pressure from the oil reservoir, - Check sight glass for level, - Slowly add oil until the level is at the FULL mark on the sight glass Pressure fill procedure: - Check sight glass for level, - Connect pressure and overfill lines to APU gearbox, - Slowly pump oil into the gearbox until the level is at the FULL mark on the sight glass MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page U3U06191 - U0O35M0 - UM49BA000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL SERVICING - APU OIL SERVICING MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page SINGLE AISLE TECHNICAL TRAINING MANUAL APU LEVEL (2) SERVICING (continued) APU COWL DOOR OPENING & CLOSING U3U06191 - U0O35M0 - UM49BA000000001 The APU cowl doors are secured with three quick-release fasteners and four shoot bolts The quick-release fasteners secure the doors together and the shoot bolts secure the doors to the aircraft structure Procedure to open the doors: - Release the quick-release fasteners, - Hold the LH door and release the latches of the shoot bolts, - Open the door and secure it with the telescopic strut, - Hold the RH door and release the latches of the shoot bolts, - Open the door and use the control handle to secure the door over center The doors are closed opposite from the opening sequence The RH door is closed and secured first MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page SINGLE AISLE TECHNICAL TRAINING MANUAL APU FILM PRESENTATION (2) INDICATING AND RECORDING SYSTEM U3U06191 - U0O35M0 - UM49P3000000002 The APU rotational speed is measured by two speed sensors They are installed in the ducting gear case at the and o'clock positions The Exhaust Gas Temperature (EGT) is measured by two thermocouple rakes installed in the exhaust case at the and o'clock positions The speed and temperature data is monitored by the Electronic Control Box and displayed on the ECAM display The engine identification module is mounted on a bracket on the left side of the air inlet plenum near the o'clock position The resistor-type module transmits the APU serial number to the Electronic Control Box MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 190 U3U06191 - U0O35M0 - UM49P3000000002 SINGLE AISLE TECHNICAL TRAINING MANUAL INDICATING AND RECORDING SYSTEM MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 191 SINGLE AISLE TECHNICAL TRAINING MANUAL APU FILM PRESENTATION (2) CONTROL AND MONITORING U3U06191 - U0O35M0 - UM49P3000000002 The APU is controlled and monitored by a Full Authority Digital Engine Control type Electronic Control Box The Electronic Control Box is located on the right side of the aft cargo compartment It records the APU serial number, the operating hours, the cycles and other condition monitoring parameters It serves as a maintenance interface with the aircraft Central Maintenance System (CMS) for fault reporting and troubleshooting operations MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 192 U3U06191 - U0O35M0 - UM49P3000000002 SINGLE AISLE TECHNICAL TRAINING MANUAL CONTROL AND MONITORING MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 193 SINGLE AISLE TECHNICAL TRAINING MANUAL APU FILM PRESENTATION (2) SUMMARY U3U06191 - U0O35M0 - UM49P3000000002 The APU serves as an integral part of the aircraft systems It enhances the operations of the aircraft by providing an independent source of pneumatic and electrical power, which can be used in flight for emergencies or for extended-range operations, and on the ground to permit the aircraft to operate independently of ground facilities and services Some of the components that were identified are Line Replaceable Units (LRUs) Please consult the appropriate maintenance manual for additional information MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 194 U3U06191 - U0O35M0 - UM49P3000000002 SINGLE AISLE TECHNICAL TRAINING MANUAL SUMMARY MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 195 SINGLE AISLE TECHNICAL TRAINING MANUAL APU FILM PRESENTATION (2) APU MODIFICATION INTRODUCTION One of the three major assemblies, the load compressor, has been modified: the in-power was replaced by a centrifugal compressor The power section has also been modified: instead of driving only the load compressor to a single shaft turbine, the power section drives the load compressor and the AGB via a single shaft GEARBOX COMPONENTS Before the modification of the APU, the generator oil scavenge filter was monitored by a visual clog indicator and a differential pressure switch, and the engine oil supply filter was monitored by a visual clog Now, both filters are monitored by visual clog indicators and differential pressure switches In the old procedure, if the pressure increased to a specific value, the ECB transmitted a maintenance message to the A/C centralized maintenance system; now, if pressure increases to a specific value, the ECB conducts an automatic shutdown before transmitting a maintenance message to the A/C centralized maintenance system U3U06191 - U0O35M0 - UM49P3000000002 OIL SYSTEM The LOP was relocated from the right side of the air inlet plenum, near the o'clock position, to the lower RH side of the AGB, near the o'clock position FUEL SYSTEM The fuel system of the APU during shutdown has changed In the old system, when the APU was shut down, the residual fuel purged through the APU exhaust came from the fuel manifold; now, the residual fuel purged through the APU exhaust comes from the pilot fuel injectors and the manifold Another modification occurs in the drain system, which drained fluids from the air bypass plenum and the actuator and MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU pump sealed drain areas to the drain mast located at the o'clock position on the right side of the APU; now, the drain system drains fluids from the air bypass plenum and the actuator and pump sealed drain areas to the drain system interface plate located at the o'clock position on the right side of the APU AIR SYSTEM Before the modification of the APU, the air inlet plenum supplied air to the power section compressor, the load compressor and the gearbox fan; now, the air inlet plenum supplies air to the power section compressor, the load compressor and the cooling fan The airflow to the power section was used for combustion, oil system pressurization and to operate the APU compartment cooling valve; now the airflow to the power section is used for combustion only The data of the load compressor inlet pressure/temperature sensor was used for fuel metering control only; now the data is also used for load compressor control The butterfly-type valve is now installed on the compressor outlet scroll at the o'clock position instead of the o'clock position The temperature data is no longer used for airflow control The temperature is no longer monitored by the load compressor discharge temperature sensor installed on the compressor outlet scroll Air from the plenum is ducted to the gearbox mounted cooling fan instead of the gearbox fan The fan supplies air to the APU compartment and the oil cooler, and no longer to the APU compartment cooling valve IGNITION SYSTEM The ignition exciter is now mounted on the left side of the air inlet plenum at the o'clock position instead of the o'clock position APU FILM PRESENTATION (2) May 10, 2006 Page 196 U3U06191 - U0O35M0 - UM49P3000000002 SINGLE AISLE TECHNICAL TRAINING MANUAL APU MODIFICATION - INTRODUCTION IGNITION SYSTEM MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU FILM PRESENTATION (2) May 10, 2006 Page 197 SINGLE AISLE TECHNICAL TRAINING MANUAL # COMPT ACCESS DOORS OPENING & CLOSING (2) WARNING U3U06191 - U0O35M0 - UM49Y1000000001 WARNING: DO NOT TOUCH THE AUXILIARY POWER UNIT (APU) UNTIL IT IS SUFFICIENTLY COOL TO PREVENT BURNS WHEN YOU DO THE MAINTENANCE TASK MAKE SURE THAT THE THREE QUICK RELEASE FASTENERS ON THE APU LEFT ACCESS DOOR ARE CORRECTLY STOWED THIS PREVENTS DAMAGE TO THE SEAL ON THE APU LEFT ACCESS DOOR MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 198 U3U06191 - U0O35M0 - UM49Y1000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL WARNING MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 199 SINGLE AISLE TECHNICAL TRAINING MANUAL # COMPT ACCESS DOORS OPENING & CLOSING (2) U3U06191 - U0O35M0 - UM49Y1000000001 APU ACCESS DOOR OPENING PROCEDURE In the cockpit, open the APU C/Bs Position a work stand suitable to reach the A/C under the APU compartment The APU doors are secured by a total of seven latches, five latches secure the left door and two latches secure the right door The LH door must be opened first to gain access to the latches for the RH door Start by releasing the rear latch Next, the three latches connecting the doors together are undone As each latch is undone, secure the latch hook on the latch lever Continue to release the remaining latches When all latches have been released, pull the door open and secure with the door support strut The strut is stowed at the FWD end of the left door Release the strut pip-pin from the door, extend the telescopic strut and secure to the A/C using the pip-pin Push the door open until the strut locks are in the fully extended position This completes the opening of the LH door With the LH door open, the two latches securing the RH door are now visible The FWD latch is released Followed by the rear latch and the door is ready to be opened Use the assist handle mounted on the air inlet duct and swings with the door fully open The door hold-open mechanism incorporates a counterbalance spring that takes most of the door weight The door will lock automatically in the door-open position No locking pins are necessary to secure the RH door in the open position A red colored pip-pin is provided to lock the door hold-open spring mechanism should it become necessary to remove the door from the A/C In this event the red pip-pin should be removed from its stowage and inserted in the adjacent hole with a red surround To prevent injury, a placard advises against removal of the red colored bolt when the access door is removed This completes the APU door opening procedure CAUTION: In the event of door removal, you must secure the right access door hold-open device by inserting the locking pin in the locking hole The pin is stowed next to this locking hole MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 200 U3U06191 - U0O35M0 - UM49Y1000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL APU ACCESS DOOR OPENING PROCEDURE MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 201 SINGLE AISLE TECHNICAL TRAINING MANUAL # COMPT ACCESS DOORS OPENING & CLOSING (2) U3U06191 - U0O35M0 - UM49Y1000000001 APU ACCESS DOOR CLOSING PROCEDURE To close the RH door, apply a lifting force to the door with one hand, and at the same time, tap the orange colored release handle marked "PUSH" in a downward, outward direction to release the over center geometric lock on the door hold-open mechanism Lift the door to the closed position, using the assist handle on the air inlet duct Secure the FWD and rear latches on the RH door The left door support strut must be stowed before closing the left door To release the lock on the LH door support strut, pull down on the knurled collar While holding the collar down, partially close the door Hold the door with the LH, and with the RH release the door support strut pip-pin from the A/C Stow the support strut on the door Close the left door Secure the FWD latch Ensure that the latch release lever is flush with the latch Secure the rear latch Secure the three latches holding the left and right doors together To secure these latches: - release the latch hook by pressing the latch release lever, - engage the latch hook in the locking bracket, - close the latch lever, - ensure that the latch release lever is flush with the latch Repeat the closing procedure for the remaining latches Carry out a final visual inspection to ensure that all latches are secure This completes the APU access door closing procedure Finally, reset the APU C/Bs in the cockpit MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 202 U3U06191 - U0O35M0 - UM49Y1000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL APU ACCESS DOOR CLOSING PROCEDURE MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU # COMPT ACCESS DOORS OPENING & CLOSING (2) May 11, 2006 Page 203 AIRBUS S.A.S 31707 BLAGNAC cedex, FRANCE STM REFERENCE U3U06191 MAY 2006 PRINTED IN FRANCE AIRBUS S.A.S 2006 ALL RIGHTS RESERVED AN EADS JOINT COMPANY WITH BAE SYSTEMS ... UM49BA000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL MAINTENANCE TIPS MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page 13 SINGLE AISLE TECHNICAL TRAINING MANUAL. .. UM49BA000000001 SINGLE AISLE TECHNICAL TRAINING MANUAL SERVICING - APU OIL SERVICING MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU LEVEL (2) May 10, 2006 Page SINGLE AISLE TECHNICAL TRAINING. .. SINGLE AISLE TECHNICAL TRAINING MANUAL APU ON-SPEED MAINTENANCE COURSE - M35 LINE MECHANICS (V2500-A5/ME)  49 - APU APU SYSTEM MANAGEMENT D/O (3) May 10, 2006 Page 39 SINGLE AISLE TECHNICAL TRAINING