B737 NG APU REMOVAL / INSTALLATION
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1 Form No: ENG/5806 A/C Reg: Issue: 02 Check: Date: JULY 2018 Date: Compiled From: 737 NG AMM CHAPTER Station: S/No Off: A/C Type Boeing 737 NG S/No On: EQUIPMENT AND MATERIALS: APU CRADLE, FISHPOLE HOISTS X 2, THREAD PROTECTORS X 3, SUPPORT BEAM ASSEMBLY AS LISTED IN AMM This form contains two tasks; The first (A) removes the APU and the second (B) installs the APU. PART A: REMOVAL IAW AMM Make sure the APU master switch on the P5 forward overhead panel is OFF and attach a DO-NOT-OPERATE tag. 2 Open the APU Fire SW Power and APU Cont circuit breakers on the P6-2 and P6-4 panels and install safety tags. 3 Open and secure APU cowl door. 4 Disconnect the four electrical connectors from the APU firewall receptacles on the 1088 bulkhead. 5 Disconnect, drain fuel from and remove the fuel supply tube. 6 Remove coupling clamps holding bleed air duct to the bleed air valve. Remove the bleed air duct and carefully remove the two seals from the duct. FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 1 of 6
2 7 8 Remove the terminal block cover from the starter generator and disconnect the four terminal lugs. Reinstall the terminal block cover on the starter generator. Disconnect the bonding jumper from the APU. 9 Remove the drain tube for the exhaust muffler. 10 Inspect the two APU lift fittings to make sure no signs of cracking or elongation. Caution, damaged fittings can fail to support the APU Install the centre beam assembly to the two APU lift fittings. Take care not to contact the fire detector assembly with the centre beam assembly as damage can occur. Check fishpole hoists are serviceable with no signs of damage. Make sure the hoists are equally wound around the drums as a cable that is not equally wound can cause the APU to suddenly fall. Attach the two fishpole hoists to the forward and aft arm assemblies. 14 Install the forward and aft arm assemblies on the centre beam assembly Install the two fishpole hoists to the forward and aft hoist brackets on the APU and wind the two cables a sufficient amount to take the weight off the APU mounts. Disconnect the APU from the left forward mount. 17 Disconnect the APU from the left aft, right aft and forward right mounts and install the thread protectors on the three cone bolts. FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 2 of 6
3 18 Tilt the APU so forward end is lower than the aft end at an approximate angle of degrees and lower with the fishpole hoists. 19 Install the forward and two aft attach assemblies, lower APU onto cradle assembly and remove fishpole hoists Carry out inspection of the seven insulation panels in accordance with AMM Note: This is a scheduled maintenance task ref AMP task Carry out air inlet seal inspection in accordance with AMM Note: This is a scheduled maintenance task ref AMP task Visually examine the front area and inner surfaces of the exhaust duct muffler that you can get access from the APU compartment for cracks and damage. Visually examine the APU muffler drain tube fitting to make sure there is no blockage of unwanted materials. 24 Carry out exhaust duct muffler seal inspection in accordance with AMM Visually examine the inner surfaces of the APU air inlet plenum that you can get access to from the APU compartment for cracks and damage. 26 Carry out educator inlet duct inspection in accordance with AMM Visually examine the bleed air duct for signs of oil and other contamination. FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 3 of 6
4 PART B: INSTALLATION MM TASK Visually inspect the APU mounts for signs of wear, cracks or damage. If any damage found, inspect IAW Visually inspect the forward and aft hoist brackets on the APU for wear cracks and damage. 3 Measure the height of the air inlet seal with the APU removed, the height from the bottom to the top of the air inlet seal must be (34.9mm) (41.3mm). 4 Position the APU below the APU compartment and attach the two fishpole hoists to the forward and aft hoist brackets on the APU. 5 Remove any protective covers on the APU openings. 6 Make sure the fishpole hoist cables are tight and detach the APU from the stand. 7 Make sure the thread protectors are installed on the cone bolts Tilt the APU 11 degrees forward whilst lifting until the left aft, right aft and right forward brackets are below the three cone bolts. Make sure the mounts are engaged at the same time and lift the APU until the three cone bolts are engaged and the air inlet seal is fully engaged with the compressor inlet. Measure the height of the compressed area of the air inlet seal with the APU installed. The height between the top of the air inlet seal (between the inlet adapter assembly and the APU) must be less than (28.6mm). Remove the cone protectors and connect the APU to the left aft, right aft and right forward mounts. Carry out torque test and tighten as required in AMM subtask FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 4 of 6
5 11 Connect the APU to the left forward mount adjusting the mount if necessary. 12 Remove the fishpole hoists from the forward and aft hoist brackets on the APU. 13 Remove the forward and aft arm assemblies from the centre beam assembly. 14 Remove the centre beam assembly from the two APU lift fittings. 15 Connect the exhaust duct muffler to the APU and torque the V-band clamp to the values given in AMM subtask Install the drain tube for the exhaust duct muffler Connect the bonding jumper to the APU. Use a bonding meter to make sure the bonding resistance between the APU and the airplane is 0.5 miliohms or less. Remove the terminal block cover from the starter generator and connect the four terminal lugs. Reinstall the terminal block cover on the starter generator. Install the bleed air duct to the APU and torque the two coupling clamps per the values in AMM subtask Connect the fuel supply line. Torque the nuts and fittings to the values in AMM subtask Connect the four electrical connectors to the APU firewall receptacles on the 1088 bulkhead. FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 5 of 6
6 Visually inspect the seven insulation panels that you can get access to from the APU compartment. If any holes, tears, separation or damage on the insulation panels is found inspect per AMM Remove the safety tags from and clos the following circuit breakers. The APU Fire SW Power on P6-2 panel and the APU Cont on the P6-4. Remove the Do Not Operate tag from the APU master switch on the P5 forward overhead panel. Check oil level per AMM Start the APU per AMM task and examine for signs of fuel leakage 26 Carry out the APU BITE procedure and look at the IDENT/CONFIG page for APU hours. Reset the APU hours if necessary. 27 Carry out APU operational test per AMM Close APU doors and return the airplane to its usual condition. This task was carried out and completed in accordance with the requirements of the MOE Part 2 procedure C.A.A. Approval Ref: UK PRINT NAME: DATE: SIGNATURE: STAMP: The Stamp/Signature denotes work has been carried out in accordance with the above Certification. FORM No: ENG/5806 Issue 02 (Jul 2018) - Page 6 of 6
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