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B727 AMM - HEAT EXCHANGERS - REMOVAL/

INSTALLATION
Revision

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HEAT EXCHANGERS - REMOVAL/INSTALLATION
1. General
A. Four heat exchangers are used in the air conditioning packs;
one primary and one secondary heat exchanger in each pack. The
following instructions are for either of the heat exchangers
with any difference noted in the applicable step.
2. Equipment and Materials
A. Offset box end wrench (fabricate per Ref. Fig. 401 )
3. Remove Heat Exchanger (Fig. 402)
A. Remove applicable exhaust door.
(1) Remove screws attaching applicable center fairing panel
to exhaust door frame and screws attaching fairing panel
to airplane structure and remove center fairing panel.
(2) Remove modulating door actuator access panel.
(3) Remove bolt holding actuator drive rod to crank arm and
free drive rod from crank arm.
(4) Support exhaust door and remove bolts securing flexible
duct to bottom of heat exchanger. Remove exhaust door.
B. Disconnect ducts from heat exchanger.
(1) Secondary (Fwd) Heat Exchanger
(a) Renove V-band couplings from forward and aft end of
forward hot air bypass duct.
(b) Remove duct support rod from forward hot air bypass
duct and remove duct.
(c) Remove V-band coupling from aft end of center hot
air bypass duct.
(d) Remove duct support clamp from center hot air
bypass duct and remove duct.

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Printed - Date: 12/10/15 Time:
Copyright © 15 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 10/1996
B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

(e) Remove V-band couplings securing ducts to heat


exchanger ( two at forward plenum, one at aft
plenum).
(f) Remove V-band coupling connecting heat exchanger to
check valve.
(2) Primary (Aft) Heat Exchanger
(a) Remove V-band couplings at each end of aft hot air
bypass duct and remove duct.
(b) Remove V-band coupling from forward end of center
hot air bypass duct.
(c) Remove support clamp from center hot air bypass
duct and remove duct.
(d) Remove V-band couplings securing ducts to heat
exchanger.
(e) Remove V-band coupling connecting heat exchanger to
check Valve.
C. Remove heat exchanger.
(1) Secondary Heat Exchanger
(a) While supporting heat exchanger, remove bolts
attaching heat exchanger to ram air duct then remove
heat exchanger.
NOTE : Use special offset box end wrench to
facilitate removal of heat exchanger inboard
flange mounting bolts.

(2) Primary Heat Exchanger


(a) Remove bolts which attach cooling fan duct to
outboard side of ram air duct.
(b) Remove wire support clip from flexible duct clamp.
(c) Remove both flexible duct clamps.
(d) For right heat exchanger removal, disconnect flow
multiplier bearing cooling line from cooling fan
duct.

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B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

(e) Lower cooling fan duct for access inside ram air
duct.
NOTE : The cooling fan cone prevents removal of
cooling fan duct.

(f) Remove mounting bolts (7) for cooling air guide


vane assemblies and remove guide vanes.
(g) While supporting heat exchanger, remove bolts
attaching heat exchanger to ram air duct then remove
heat exchanger.
NOTE : Use special offset box end wrench to
facilitate removal of heat exchanger inboard
flange mounting bolts.

4. Install Heat Exchanger (Fig. 402)


A. Check heat exchanger-to-ram air duct seal for breaks, tears or
missing pieces and repair as required (Ref Heat Exchanger Seal
- Approved Repair).
B. With seal in place position heat exchanger to ram air duct and
install mounting bolts.
C. Install fan air components (primary heat exchanger installation
only)
(1) Position cooling air guide vanes inside ram air duct and
secure with mounting bolts (7).

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B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

Offset Box End Wrench


Figure 401 (Sheet 1)
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(2) Position cooling fan duct to ram air duct and install
mounting bolts.
(3) Locate flexible duct between cooling fan and cooling fan
duct and install flexible duct clamps in a position so
cooling fan electrical wire support clip can be attached
to clamp trunnion bolt. Install wire support clip.
(4) For right heat exchanger, connect flow multiplier bearing
cooling line to cooling fan duct.
D. Install V-band clamp connecting check valve to heat exchanger.

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B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

NOTE : If both heat exchangers are being installed, install


check valve with direction arrow pointing forward.

E. Secure all ducts to heat exchanger removed in par. 3.B. with V-


band couplings except the hot air ducts.
F. Locate hot air ducts removed in par. 3.B. in place, and loosely
install support clamps and forward support rod.
G. Rotate hot air ducts as required for alignment and install V-
band couplings but do not tighten.
H. Tighten support clamps, then V-band couplings.
I. Position ram air exhaust door beneath heat exchanger and secure
flexible duct to heat exchanger with mounting bolts.
J. Connect actuator drive rod to exhaust door crank arm.
K. Position fairing panel beneath exhaust door and install one
screw at each corner of exhaust door.
L. Install screws attaching fairing panel to airplane structure.
M. Install remaining exhaust door screws.
N. Provide electrical power.
O. Check that applicable PACK COOLING DOOR circuit breaker on
panel P6 is closed.
P. Check that all air conditioning and pneumatic systems circuit
breakers are closed.
Q. Pressurize pneumatic system using auxiliary power unit (APU)
(Ref Chapter 49 ).
NOTE : When pressurizing with APU at least one of the isolation
valve switches must be moved to OPEN. The pneumatic
system may also be pressurized with ground pneumatic
cart or engine bleed, but if either is used, isolation
valves and/or engine bleed valves must be positioned
properly for operating air conditioning (Ref Chapter
36 ).

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Copyright © 15 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 10/1996
B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

Heat Exchanger Installation


Figure 402 (Sheet 1) (Sheet 1)

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B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

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Copyright © 15 FedEx Express Corporation, Memphis TN, 38194, All rights reserved. JAN 10/1996
B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

Heat Exchanger Installation


Figure 402 (Sheet 2) (Sheet 2)
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B727 AMM - HEAT EXCHANGERS - REMOVAL/
INSTALLATION
Revision

R. Open entry door or control cabin window.


S. Move applicable A/C PACK switch to OPEN.
T. Hold applicable COOLING DOORS switch to closed until movement
can no longer be detected on the cooling doors position
indicator.
U. Check that exhaust louver dimension is per detail B, per Ref.
Fig. 402 .
NOTE : Dimension shown is average gap for the louvers of any
exhaust door assembly with pack cooling fans operating.

V. Hold COOLING DOORS switch to open until movement can no longer


be detected on position indicator.
W. Hold applicable cabin temperature selector toward MANUAL WARM
until mix valve position indicator pointer moves to 75% HOT
then return selector to OFF.
CAUTION : DO NOT LEAVE MIX VALVE AT HOT ANY LONGER THAN
NECESSARY TO CHECK FOR LEAKAGE. DUCT OVERHEAT TRIP
MAY RESULT IF CHECK IS MADE DURING HOT WEATHER.

X. Check for leakage at all couplings disturbed during removal/


installation. Diffused leakage is allowed, jet blasts are not.
WARNING : DO NOT ATTEMPT TO REPAIR JET BLAST LEAKAGE WITH
PACKS ON OR PERSONNEL MAY BE INJURED.

Y. Move temperature selector to an automatic position.


Z. Move A/C PACK switch to CLOSE.
AA. Move isolation valve switch(es) to CLOSE.
AB. Remove pneumatic pressure if no longer required.
AC. Remove electrical power if no longer required.
AD. Install modulation door actuator access panel.

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