Installation of the Left Modulated Turbine Cooling Valve [CFML]

A. Installation of the Left Modulated Turbine Cooling Valve:
   (1) Remove all the COVER - PROTECTION and CAP - PROTECTION from the openings, tubes, hoses and connectors.
   (2) Install the left modulated turbine cooling valve (89) as follows:
See the sheet 12 of the figure.
     (a) Apply Super 77 Spray Adhesive (Material No.CP2614) into the grooves for the modulated turbine cooling valve piston rings.
     (b) Install and compress the two new EIPC 75-23-10-01-080 PISTON RINGS (84) into the left modulated turbine cooling valve (89) ring groove. Make sure that the piston ring end gaps are 180 degrees apart.
     (c) Install a new EIPC 75-23-10-01-070 INTERNAL PRESSURE C-SEAL (85) on the combustion case (1).
     (d) If necessary, remove the red shipping bolt to permit installation of the modulated turbine cooling valve on the engine.
     (e) Apply engine oil (Material No.CP2442) on the threads of the bolt (86), bolt (87) and four bolts (88).
     (f) Locally manufacture an modulated turbine cooling valve ferrule alignment tool LOCALLY MANUFACTURED - PIN to align the ferrule of the modulated turbine cooling manifold with the modulated turbine cooling valve mounting holes of the combustion case.
     (g) Insert the alignment tool into one of the modulated turbine cooling mounting holes to align the modulated turbine cooling manifold with the modulated turbine cooling mounting holes. Remove the alignment tool.
     (h) Put the left modulated turbine cooling valve (89) in position on the bracket (82) and bracket (83) and put it into the open port on the combustion case (1).
     (i) Loosely install the four bolts (88) that attach the left modulated turbine cooling valve (89) to the bracket (82) and the bracket (83).
     (j) Put the left modulated turbine cooling valve (89) in the closed position.
See the sheet 13 of the figure.
     (k) Loosely install the bolts (86) and (87) that attach the left modulated turbine cooling valve (89) to the combustion case (1).
     (l) TORQUE the bolts (86) and (87) to between 189 and 161 lbf.in (2.14 and 1.82 m.daN ) .
     (m) If removed before, install the red shipping bolt to permit the rigging procedure to be done correctly.
     (n) Remove the flexible Active Clearance Control (ACC) wye duct (98) as follows:
See the sheet 14 of the figure.
       1 Remove the hose clamp (99) that attaches the ACC wye duct (98) to the High Pressure Turbine Active Clearance Control (HPTACC) valve (100).
       2 Remove the hose clamp (95) that attaches the ACC wye duct (98) to the Low Pressure Turbine Active Clearance Control (LPTACC) valve (94).
       3 Remove the hose clamp (96) that attaches the ACC wye duct (98) to the ACC inlet duct (97).
       4 Remove the ACC wye duct (98) from the engine.
     (o) Connect the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART to the modulated turbine cooling actuator (93) as follows:
See the sheet 12 of the figure.
       1 Remove the four bolts (103) that attach the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) to the split control unit (104).
       2 Remove and discard the gasket (105) on the split control unit (104).
       3 Disconnect the B-nuts on the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) from the modulated turbine cooling actuator fuel hydraulic manifold (102).
       4 Put the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART in position near the engine.
       5 Connect the two hoses from the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART to the two fittings on the modulated turbine cooling actuator fuel hydraulic manifold (102):

• It can be necessary to put manual pressure on the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) to get access to the two fittings.
  

       6 Connect the two hoses on the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART to the two fittings on the modulated turbine cooling actuator fuel hydraulic manifold (102).
       7 TORQUE the B-nuts on the two hoses to between 205 and 175 lbf.in (2.32 and 1.98 m.daN ) .
     (p) Align the left modulated turbine cooling valve (89) with the left modulated turbine cooling actuator (93) as follows:
See the sheet 12 of the figure.
       1 Move the clevis (90) out of the path of the left modulated turbine cooling actuator (93) rod end. This is necessary to permit the modulated turbine cooling actuator (93) to move and not touch the clevis (90).
       2 Slowly operate the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART to apply pressure to the modulated turbine cooling valve actuator. Monitor the pressure to make sure that it does not go above 45 psi (3.10 bar). Continue until the left modulated turbine cooling actuator (93) is in the fully extended position.
       3 Align the holes:
         a Align the clevis (90) bolt hole and the left modulated turbine cooling actuator (93) rod end bolt hole.
     (q) If necessary, adjust the left modulated turbine cooling valve (89) rod end as follows:
       1 Remove the safety wire and loosen the left modulated turbine cooling valve (89) rod end jam nut.
       2 Turn the rod end 180 degrees at a time to align the safety wire holes.
       3 TORQUE the left modulated turbine cooling valve (89) rod end jam nut to between 95 and 85 lbf.in (1.07 and 0.96 m.daN ) .
       4 Installation of the safety wire:

CAUTION: MAKE SURE THAT THE SAFETY WIRE ENDS ARE AT THE MODULATED TURBINE COOLING-VALVE ROD-END JAM-NUT. KEEP THE ENDS OF THE SAFETY WIRE AWAY FROM THE PATH OF THE MODULATED TURBINE COOLING-VALVE PISTON. THE SHARP ENDS OF THE SAFETY WIRE CAN CAUSE DAMAGE TO THE PISTON.

         a Install safety wire to lock the rod end jam nut with CP8007safetywire 0.020 in. (0.50mm) dia or CP8008safetywire 0.020 in. (0.50mm) dia.
     (r) Install the bolt (91) and nut (92) that attach the left modulated turbine cooling valve (89) and clevis (90) to the left modulated turbine cooling actuator (93) rod end.
     (s) If necessary, align the clevis (90) as follows:
       1 Loosen the four bolts (88) that attach the left modulated turbine cooling valve (89) to bracket (82) and the bracket (83).
       2 Align the clevis in line with the left modulated turbine cooling valve (89) rod end and the left modulated turbine cooling actuator (93) rod end.
       3 TORQUE the four bolts (88) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .
     (t) TORQUE the bolt (91) and nut (92) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .

NOTE: Make sure that the pressure is 45 psi (3.10 bar) to the left modulated turbine cooling actuator (93) rod end.

     (u) If not removed before, remove and discard the red shipping bolt.
     (v) Do a cycle test of the left modulated turbine cooling actuator (93) as follows:
       1 Operate the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART to move the left modulated turbine cooling actuator (93) to the fully retracted and fully extended positions.
       2 Do this step again two or three times.
       3 Make sure that the linkage moves smoothly. Make sure that there are no parts in the path of the actuator as it moves.
     (w) Disconnect the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART from the engine as follows:
See the sheet 15 of the figure.
       1 Remove the pressure from the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART and make sure that the pressure decreases to zero.
       2 Disconnect the two fittings on the hoses from the modulated turbine cooling actuator fuel-hydraulic-manifold (102).
       3 Install CAP - SEALING on the open ends of the hoses to prevent leakage.
       4 Wind the two hoses and put them in the storage position on the 9465M11 HAND OPERATED VSV ACTUATOR HYD. CART.
     (x) Connect the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) to the split control unit (104) and the modulated turbine cooling actuator fuel-hydraulic-manifold (102) as follows:
See the sheet 15 of the figure.
       1 Install a new EIPC 73-00-00-20-230 GASKET (105) between the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) and the split control unit (104).
       2 Apply engine oil (Material No.CP2442) on the threads of the four bolts (103).
       3 Install the four bolts (103) that attach the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) to the split control unit (104).
       4 TORQUE the four bolts (103) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
       5 Align the two B-nuts on the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) with the mating fittings on the modulated turbine cooling actuator fuel-hydraulic-manifold (102).
       6 Manually connect the two B-nuts on the modulated turbine cooling-ACC fuel-hydraulic-manifold (101) with the mating fittings.
       7 TORQUE the two B-nuts to between 205 and 175 lbf.in (2.32 and 1.98 m.daN ) .
     (y) Install the flexible ACC wye duct (98) as follows:
See the sheet 14 of the figure.
       1 Put the ACC wye duct (98) in position between the LPTACC valve (94), the HPTACC valve (100) and the ACC inlet duct (97).
       2 Install and manually tighten the hose clamp (96) that attaches the ACC wye duct (98) to the ACC inlet duct (97).
       3 Install and manually tighten the hose clamp (95) that attaches the ACC wye duct (98) to the LPTACC valve (94).
       4 Install and manually tighten the hose clamp (99) that attaches the ACC wye duct (98) to the HPTACC valve (100).
       5 TORQUE the hose clamp (99), hose clamp (96) and hose clamp (95) to between 38 and 32 lbf.in (0.43 and 0.36 m.daN ) .
   (3) Install the High Pressure Turbine (HPT) cooling 7th stage air manifold (69) as follows:
See the sheets 10 and 11 of the figure.
     (a) Apply engine oil (Material No.CP2442) on the threads of the four bolts (76), the two bolts (73) and the four bolts (70).
     (b) Install a new EIPC 75-11-00-01-170 SEAL (71) on the HPT cooling 7th stage air manifold (69).
     (c) Install a new EIPC 75-11-00-01-180 SEAL (77) on the HPT cooling 7th stage air manifold (69).
     (d) Put the HPT cooling 7th stage air manifold (69) in position on the engine.
     (e) Install and hand-tighten the four bolts (76) that attach the HPT cooling 7th stage air manifold (69) to the HPT case (78).
     (f) Install and hand-tighten the four bolts (70) that attach the HPT cooling 7th stage air manifold (69) to the aft compressor stator case extension (72).
     (g) Loosely install the two bolts (73) that attach the retaining strap (74) and the HPT cooling 7th stage air manifold (69) to the support bracket (75).
     (h) TORQUE the four bolts (76) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (i) TORQUE the four bolts (70) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (j) TORQUE the two bolts (73) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
   (4) Install the 4th stage air manifold (32) as follows:
See the sheets 5, 6 and 7 of the figure.
     (a) Apply engine oil (Material No.CP2442) on the threads of the four bolts (31), the two bolts (39), the two bolts (45), the four bolts (46), the four bolts (49), the two bolts (57), the four bolts (67), four bolts (38), two bolts (30), two bolts (28), two nuts (63), two nuts (51) and two nuts (42).
     (b) Put the 4th stage air manifold (32) in position on the engine.
     (c) Put a new EIPC 75-11-00-01-370 SEAL (33) in position on the 4th stage air manifold (32).
     (d) Put a new EIPC 75-11-00-01-380 GASKET (47) in position on the 4th stage air manifold (32).
     (e) Put a new EIPC 75-11-00-01-390 METAL SEAL RING (48) in position on the 4th stage air manifold (32).
     (f) Put a new EIPC 75-11-00-01-380 GASKET (68) in position on the 4th stage air manifold (32).
     (g) Put the bracket valve (61) in position on the turbine center frame (40).
     (h) Install and hand tighten the two nuts (63) with the two washers (62) that attach the bracket valve (61) to the turbine center frame (40).
     (i) TORQUE the two nuts (63) to between 124.0 and 106.0 lbf.in (1.40 and 1.20 m.daN ) .
     (j) Put the support bracket (65) in position above the four bolt flange of the 4th stage air manifold (32). Install and hand tighten the four bolts (67) that attach the 4th stage air manifold (32) to the turbine center frame (40).
     (k) Install and hand tighten the four bolts (49) that attach the 4th stage air manifold (32) to the turbine center frame (40).
     (l) Install and hand tighten the four bolts (46) that attach the 4th stage air manifold (32) to the turbine center frame (40).
     (m) Install and hand tighten the four bolts (31) that attach the 4th stage air manifold (32) to the forward compressor stator case (34).
     (n) Connect and hand tighten the B-nut on the 4th stage air manifold (32) to the scavenge cover (58).
     (o) Put the support bracket (52) in position on the turbine center frame (40).
     (p) Install and hand tighten the two nuts (51) with the two washers (50) that attach the support bracket (52) to the turbine center frame (40).
     (q) TORQUE the two nuts (51) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (r) Put the support bracket (43) in position on the turbine center frame (40).
     (s) Install and hand tighten the two nuts (42) with the two washers (41) that attach the support bracket (43) to the turbine center frame (40).
     (t) TORQUE the two nuts (42) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (u) Put the support bracket (37) in position on the support bracket (36).
     (v) Install and hand tighten the four bolts (38) that attach the support bracket (37) to the support bracket (36).
     (w) TORQUE the four bolts (38) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (x) Install and hand tighten the two bolts (57) that attach the retaining strap (56) and the 4th stage air manifold (32) to the support bracket (52).
     (y) Install and hand tighten the two bolts (45) that attach the retaining strap (44) and the 4th stage air manifold (32) to the support bracket (43).
     (z) Install and hand tighten the two bolts (39) that attach the retaining strap (35) and the 4th stage air manifold (32) to the support bracket (37).
     (aa) TORQUE the four bolts (67), four bolts (49), four bolts (46) and four bolts (31) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (ab) Attach the bolts (67), (49) and (46) with CP8006safety cable 0.032 in. (0.8 mm) or safetywire (Material No.CP8002) .
     (ac) TORQUE the 4th stage air manifold (32) at the scavenge cover (58) to between 308.0 and 262.0 lbf.in (3.48 and 2.96 m.daN ) .
     (ad) TORQUE the two bolts (57), two bolts (45) and two bolts (39) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (ae) Put the bracket (25) in position on the bracket (29).
     (af) Install and hand tighten the two bolts (30) that attach the bracket (25) to the bracket (29).
     (ag) TORQUE the two bolts (30) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (ah) Install and hand tighten the bolt (28) that attaches the loop clamp (27) and the tube (23) to the bracket (25).
     (ai) Install and hand tighten the bolt (28) that attaches the loop clamp (26) and the tube (24) to the bracket (25).
     (aj) TORQUE the bolts (28) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .
     (ak) Put the tube (108) in position on the engine. See the sheet 16 of the figure.
     (al) Connect and hand tighten the B-nut (106) to the tube (23).
     (am) Connect and hand tighten the B-nut (114).
     (an) Put the tube (109) in position on the engine. See the sheet 16 of the figure.
     (ao) Connect and hand tighten the B-nut (107) to the tube (24).
     (ap) Connect and hand tighten the B-nut (113).
     (aq) Apply engine oil (Material No.CP2442) to the threads of the three bolts (110).
     (ar) Install the two bolts (110) that attach the two loop clamps (111) and the tube (109) to the bracket (37) and bracket (36).
     (as) Install the bolt (110) that attaches the loop clamp (112) and the tube (108) to the bracket (37).
     (at) TORQUE the three bolts (110) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .
     (au) TORQUE the B-nuts (107) and (113) to between 540 and 460 lbf.in (6.10 and 5.20 m.daN ) .
     (av) TRIPLE-TORQUE the B-nuts (106) and (114) to between 308 and 262 lbf.in (3.48 and 2.96 m.daN ) .
   (5) Install the drain tube (16) as follows:
See the sheet 3 of the figure.
     (a) Put the drain tube (16) in position on the drain tube (18), drain tube (14) and the modulated turbine cooling ACC fuel hydraulic manifold (15).
     (b) Connect and hand-tighten the B-nut on the drain tube (16) to the drain tube (14).
     (c) Connect and hand-tighten the B-nut on the drain tube (16) to the modulated turbine cooling ACC fuel hydraulic manifold (15).
     (d) Connect and hand-tighten the B-nut on the drain tube (18) to the drain tube (16).
     (e) Apply engine oil (Material No.CP2442) to the threads of the bolt (20) and bolt (19).
     (f) Install and hand-tighten the bolt (20) that attaches the loop clamp (21) and the drain tube (14) to the support bracket (22).
     (g) Install the bolt (19) that attaches the loop clamp (17) and the drain tube (16) to the support bracket (13).
     (h) TORQUE the drain tube (16) B-nut at the drain tube (14) to between 308 and 262 lbf.in (3.48 and 2.96 m.daN ) .
     (i) TORQUE the drain tube (16) B-nut at the modulated turbine cooling ACC fuel hydraulic manifold (15) to between 308 and 262 lbf.in (3.48 and 2.96 m.daN ) .
     (j) TORQUE the drain tube (18) B-nut at the drain tube (16) to between 308 and 262 lbf.in (3.48 and 2.96 m.daN ) .
     (k) TORQUE the bolt (19) and bolt (20) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .
   (6) Install the Environmental Control System (ECS) HP leg (3) as follows:
See the sheet 2 of the figure.
     (a) Put a new AIPC 36-11-49-05-100 SEAL (45) in position on the end of the ECS HP leg (3).
     (b) Put the new AIPC 36-11-49-05-110 SEAL (12) in position on the end of the ECS HP leg (3).
     (c) Put the ECS HP leg (3) in position on the ECS wye duct (10) and the open port on the combustion case (1).
     (d) Install the four bolts (2) that attach the ECS HP leg (3) to the combustion case (1) hand-tight.
     (e) Loosely install the coupling (11) that attaches the ECS wye duct (10) to the ECS HP leg (3).
     (f) Install and hand-tighten the two bolts (8) that attach the ECS HP leg (3) to the bracket (9).
     (g) Install and hand-tighten the bolt (7) and nut (6) that attach the turnbuckle (5) to the ECS HP leg (3).
     (h) TORQUE the four bolts (2) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (i) TORQUE the coupling (11) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (j) TORQUE the nut (6) to between 432 and 368 lbf.in (4.88 and 4.16 m.daN ) .
     (k) TORQUE the two bolts (8) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
   (7) Connect the core compartment cooling air duct (81) as follows:
See the sheets 10 and 11 of the figure.
     (a) Connect the hose clamp (80) that attaches the rubber core compartment cooling air duct (81) to the left side core compartment cooling manifold (79).
     (b) TORQUE the hose clamp (80) to between 38 and 32 lbf.in (0.43 and 0.36 m.daN ) .
   (8) Install the eductor valve brackets as follows:
See the sheets 7 and 17 of the figure.
     (a) Install the two bolts (66) and one bolt (64) hand tight that attach the valve bracket (65) to the valve bracket (61).
     (b) Install the three bolts (60) hand tight that attach the bracket (59) to the valve bracket (65).
     (c) Install the bolt (53) that attach the loop clamp (54) and tube (55) to the bracket (59).
     (d) TORQUE the bolt (53) to between 70 and 60 lbf.in (0.79 and 0.68 m.daN ) .
     (e) TORQUE the two bolts (66), one bolt (64) and the three bolts (60) to between 124 and 106 lbf.in (1.40 and 1.20 m.daN ) .
     (f) Apply engine oil (Material No.CP2442) on the threads of the four bolts (117).
     (g) Put the oil manifold (118) in position and connect the B-nut (115) that attaches the oil manifold (118) to the turbine center frame (40) case.
     (h) Install and hand tighten the four bolts (117) that attach the loop clamps (116) and the oil manifold (118) to the brackets.
     (i) TORQUE the four bolts (117) to between 38 and 32 lbf.in (0.43 and 0.36 m.daN ) .
     (j) TORQUE the oil manifold B-nut (115) to between 540 and 460 lbf.in (6.10 and 5.20 m.daN ) .
   (9) Install the eductor valve (Ref. AMM TASK 79-21-45-400-802).