 | GEnx-1B SERVICE BULLETIN - 73-0060 R02 | Revised: 04/28/2021 |
| SB 73-0060 R02 ENGINE FUEL AND CONTROL - General (73-00-00) - Introduction of Redesigned W30 Harness, W31 Harness, and Support Brackets | Issued: 09/29/2017 | |
| GEnx-1B SERVICE BULLETIN - 73-0060 R02 | Revised: 04/28/2021 |
| SB 73-0060 R02 ENGINE FUEL AND CONTROL - General (73-00-00) - Introduction of Redesigned W30 Harness, W31 Harness, and Support Brackets | Issued: 09/29/2017 | |
| GE Designated: -CONFIDENTIAL- | |
| The information contained in this document is GE proprietary information and is disclosed in confidence. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation, manufacture, development, or derivation of any repairs, modifications, spare parts, designs, or configuration changes or to obtain FAA or any other government or regulatory approval to do so. If consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or part. | |
| This technical data is considered subject to the Export Administration Regulations (EAR) pursuant to 15 CFR Parts 730-774. Transfer of this data by any means to a Non-U.S. Person, whether in the United States or abroad, without the proper U.S. Government authorization (e.g., License, exemption, NLR, etc.), is strictly prohibited. | |
| Copyright (2021) General Electric Company, U.S.A. |
| TRANSMITTAL INFORMATION |
| REVISION 2 TO SERVICE BULLETIN 73-0060 |
| Revision 2 is issued to update paragraphs 1., PLANNING INFORMATION, 2., MATERIAL INFORMATION, and 3., ACCOMPLISHMENT INSTRUCTIONS. |
| Revision 1 was issued July 10, 2019. The original was issued September 29, 2017. Revision bars in the left margin identify changes. |
| 1. | PLANNING INFORMATION |
| A. | Effectivity |
| * * * FOR GEnx-1B64, -1B64/P1, -1B64/P2, -1B67, -1B67/P1, -1B67/P2, -1B70, -1B70/75/P1, -1B70/75/P2, -1B70/P1, -1B70/P2, -1B70C/P1, -1B70C/P2, -1B74/75/P1, -1B74/75/P2, -1B76/P2, -1B76A/P2 |
| This Service Bulletin is applicable to all GEnx-1B engines. |
| This Service Bulletin has been introduced in production to these GEnx-1B engines: |
| • |
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| These serial numbers are the best available data. |
| The W30 harness VIN 504643-13 (P/N 2613M71P01), W31 harness VIN 504644-10 (P/N 2613M72P01), and their support system are affected by this Service Bulletin. |
| B. | Description |
| This Service Bulletin introduces a new W30 harness VIN 504643-14 (P/N 2737M42P01) and W31 harness VIN 504644-11 (P/N 2737M43P01). It also provides the instructions to replace the affected parts and improves their mounting hardware and routing. |
| Revision 2 of this Service Bulletin reduces quantity of the machine bolts (bolts) P/N J1494P07A (SIN 98021) from 17 to 12 and the remaining five bolts are added to P/N J1494P07A (SIN 98028) with a torque of 60 to 70 lb in. (6.7 to 7.9 Nm). |
| C. | Compliance |
| Category 4 |
| GE recommends that you do this Service Bulletin when the W30 and/or W31 harness are exposed. |
| Impact E |
| This recommendation is to improve the cost of ownership, reduce maintenance requirements or is a product improvement. |
| NOTE: |
|
| This Service Bulletin is offered to improve the reliability or performance of your GE product, or to help prevent the occurrence of the event or condition described in this Service Bulletin. If the operator elects not to participate in the bulletin, that decision will be taken into consideration by GE in evaluating future product performance issues that may arise in the operators fleet. |
| D. | Concurrent Requirements |
| Boeings Service Bulletin B787-81205-SB290034-00 implementation is recommended before or at the same time as this Service Bulletin is incorporated to reduce the vibration received by branch P311 of the W31 harness and prevent damage to this branch. |
| E. | Reason |
| (1) | Objective: |
| To introduce new parts, improve reliability, improve the routing of the harnesses, and address the current known failure modes. |
| (2) | Condition: |
| The current W30 and W31 harnesses design has shown signs of distress on the fire detectors harness pigtails, the P311 branch in the W31 harness experiences vibration-induced damage and chafing damage has been recorded in the polyether ether ketone (PEEK) braiding during regular operation. |
| Incorrect torque value found applied to the bolts (SIN 98021) (five locations) that attach the W30 harness integral clamps to the new fire detector support brackets [SIN 9801G, SIN 9801J (QTY-2), SIN 9801L, and SIN 9801K]. |
| (3) | Cause: |
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| (4) | Improvement: |
| The introduction of a design with diminished high cycle fatigue-driven displacement, increased high cycle fatigue resistance due to reduced pigtail length, and increased stiffness (enabled by the addition of a stronger material and two layers of metallic overbraid in the pigtails) to eliminate the fire detector harness pigtail failures. |
| The introduction of an improved design for vibration and wear resistance to eliminate the W31 P311 branch failures. This design includes an additional support point for the P311 branch, improved cable construction for vibration, and improved connector and contacts. |
| The introduction of an optimized harness routing with improved clearances and slack, support, and clamping methods, among other harness definition improvements to minimize chaffing probability. |
| The reduction of torque value in order to avoid any twisting or deformation on the W30 harness tabs. This new torque value for the new bolts (SIN 98028) (five locations) is consistent with GE Aviation design practices for clamps and tabs joints. |
| (5) | Substantiation: |
| Substantiation is by analysis and comparative analysis. |
| F. | Approval |
| The data contained in this Service Bulletin has been reviewed by the FAA or authorized entity representing the FAA and the repair(s) and modification(s) herein comply with the applicable Aviation Regulations and are APPROVED for installation in the model(s) listed in this Service Bulletin. |
| G. | Manpower |
| After you get access to the W30 and W31 harnesses area, you will need approximately 8 man-hours with four technicians working for each engine. |
| H. | Weight and Balance |
| The complete compliance with this Service Bulletin increases weight by 2.56 lb (1.16 kg). |
| I. | References (Use the latest version of these documents) |
| GEnx-1B, Boeing 787 Aircraft Maintenance Manual (AMM) |
| GEK 112851, GEnx-1B Engine Manual (EM) |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| GEnx-1B S/B 73-0040, ENGINE FUEL AND CONTROL - General (73-00-00) - Introduction of New W30 Harness, W31 Harness, and Support Brackets |
| GEnx-1B S/B 73-0063, ENGINE FUEL AND CONTROL - General (73-00-00) - GEnx-1B Electrical Harnesses Bonding Rework |
| GEnx-1B, Boeings Service Bulletin B787-81205-SB290034-00 |
| NOTE: |
|
| J. | Publications Affected |
| GEK 112851, GEnx-1B Engine Manual (EM) |
| GEK 112864, GEnx-1B Engine Illustrated Parts Catalog (EIPC) |
| K. | Interchangeability |
| Qualified interchangeability. |
| The W30 harness P/N 2737M42P01, W31 harness P/N 2737M43P01, harness support tubes, and their attaching hardware must be introduced as a set. |
| The W30 harness P/N 2777M96P01 is two-way interchangeable with the W30 harness P/N 2613M71P01. The W31 harness P/N 2777M97P01 is two-way interchangeable with the W31 harness P/N 2613M72P01. The harness support tubes and their attaching hardware must be introduced as a set. |
| The brackets P/N ER6443G01 and P/N ER6447G01 should be introduced together only if GEnx-1B S/B 73-0040 has not been complied with. |
| L. | Software Accomplishment Summary |
| Not applicable. |
| 2. | MATERIAL INFORMATION |
| A. | Material - Price and Availability |
| (1) | Parts necessary to do this Service Bulletin: |
|
| The following parts are not included in the spare kits P/N K520144 and P/N RPK01XG01, and must be ordered separately: |
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| NP = Not Provisioned |
| NOTE: |
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| *Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following: |
|
| **Part not supplied by GE Engine Services Distribution L.L.C. Procure through local purchase. |
| ***For pre-GEnx-1B S/B 79-0007 two gaskets are required. For post-GEnx-1B S/B 79-0007 one gasket is required. |
| ****Parts required only if GEnx-1B S/B 73-0040 has not been complied with. |
| *****To procure parts, contact GE Engine Services Distribution L.L.C. |
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| (2) | Other Spare Parts: |
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| The following parts are included in the spare kit P/N K520144. It is not necessary to order these parts separately: |
|
| The following parts are included in the spare kit P/N RPK01XG01. It is not necessary to order these parts separately: |
|
| NP = Not Provisioned |
| NOTE: |
|
| *Part not supplied by GE Engine Services Distribution L.L.C. To procure parts, contact the following: |
|
| This part number already complies with GEnx-1B S/B 73-0063. |
| (3) | Consumables: |
|
| B. | Industry Support Information |
| GE-Unison is pleased to provide industry support for compliance, outlined as follows: |
| (1) | Material Support: |
| (a) | GE-Unison is pleased to extend a special discounted pricing for the kit P/N K520144. The kit consists of one W30 harness and one W31 harness. |
| Please contact Unison or Unison's authorized distributor for quote and details on discounted pricing and delivery. This pricing program will expire 24 months after the original release date of this Service Bulletin. |
|
| (b) | GE Aviation is pleased to extend a discounted pricing for the kit P/N RPK01XG01. This pricing shown below is available for 24 months after the original release date of this Service Bulletin and is applicable to on-wing incorporation and incorporation at shop visit. |
| 1 | For engine serial numbers (ESNs) 956-458 and below, that have complied with GEnx-1B S/B 73-0040 in the field or at a shop visit by incorporating Kit P/N GENX1BHARNESS1 purchased from GE-Unison, GE Aviation is extending an up-front 100 percent discount (free of charge) for kit P/N RPK01XG01. |
| 2 | For ESNs 956-458 and below, that have not incorporated GEnx-1B S/B 73-0040 in the field or at shop visit, GE Aviation is extending a discounted price of $5,977.30 for kit P/N RPK01XG01. |
| 3 | For ESNs 956-459 and up, GE Aviation is extending a discounted price of $5,977.30 for kit P/N RPK01XG01. |
| (c) | GE Aviation will provide aircraft on ground (AOG) support for the prior configuration of the W30 harness P/N 50464-13 and W31 harness P/N 504644-10. This AOG support will be available for 24 months after the original release date of this Service Bulletin. In case of an unscheduled removal without adequate time to incorporate this Service Bulletin, GE-Unison will provide the required part(s) free of change (FOC). Customers must notify GE-Unison about the unscheduled removal and place a no change Purchase Order (PO) to Unison directly through your regional sales director: |
| http://www.unisonindustries.com/contact/sales.html. |
| Removed parts must be returned to Unison on a PO for evaluation. |
| (2) | Labor Support: |
| (a) | GE Aviation will provide a back-end spare parts credit for direct labor hours to complete this Service Bulletin for engines on wing. |
| 1 | For each engine that complies with this Service Bulletin on wing (outside of quick-turn or shop visit), GE Aviation will provide up to 24 man-hours of labor per engine for the incorporation of this Service Bulletin. |
| (3) | All GE warranty claims must have complete information including: |
| (a) | Engine serial number (ESN). |
| (b) | Provide evidence of compliance with GEnx-1B S/B 73-0040. |
| (c) | Date of compliance with GEnx-1B S/B 73-0040. |
| (d) | Reference to GEnx-1B S/B 73-0040. |
| This support is available until September 30, 2019. All claims must be submitted within 12 months of work completion and by September 30, 2020. All claims must be submitted at: |
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| The support offered in this Service Bulletin is contingent on the customer having an active general terms agreement (GTA) for the applicable GE engine model. This offer may not be assigned or otherwise transferred to any other party without the written consent of GE Aviation, which consent shall be in the sole and complete discretion of GE Aviation. The offer is extended to the customer based on unique facts and circumstances, which the customer hereby acknowledges to be non-precedent setting between the customer and GE Aviation. The commitment is subject to the terms and conditions of the current GTA between the customer and GE Aviation for the applicable GE engine model. |
| By accepting the support listed in this section as offered by GE Aviation, the customer agrees that the Service Bulletin offering satisfies the customers commercial needs. The remaining terms and conditions of the customers GTA are applicable and remain in effect. |
| Please contact your Customer Support Manger (CSM) for any questions regarding this support. |
| C. | Configuration Chart |
|
| *Replacement is required only if GEnx-1B S/B 73-0040 has not been complied with. |
| **P/N AS3237-06 (QTY-48) is permitted as an alternate configuration to P/N AS3237-06 (QTY-49). |
| Operation Codes AD=Add DE=Delete QTC=Quantity Change RE=Replace RM=Remains |
| Change Codes 2=Two-way interchangeable. 5=Qualified interchangeability. Refer to paragraph 1.K., Interchangeability. |
| Support Codes C=Old parts will be supplied until September 2019 . E=Old parts will be supplied and can be used at other engine locations. |
| D. | Parts Disposition |
| Use serviceable old parts at other engine locations. |
| E. | Tooling - Price and Availability |
|
| 3. | ACCOMPLISHMENT INSTRUCTIONS |
| A. | General |
| (1) | If the engine is on wing, prepare the aircraft for the W30 harness (1, Figure 1) and W31 harness (2) replacement. Refer to the GEnx-1B Boeing 787 AMM, DMC-B787-A-26-11-03-00A-520A-A, step 1.B. |
| B. | Removal |
| (1) | Remove the W30 harness (1) and W31 harness (2) as follows: |
| (a) | For the on-wing procedure, refer to the GEnx-1B Boeing 787 AMM, DMC-B787-A-26-11-03-00A-520A-A. |
| (b) | For the in-shop procedure, refer to the GEnx-1B EM, 72-00-02, DISASSEMBLY 001, Subtask 72-00-02-030-354. |
| (2) | Remove the six sensing elements (5, Figure 2, Sheet 3) from the LPT ACC air manifolds (2, 3, and 4, Sheet 1) as follows: |
| (a) | For the on-wing procedure, refer to the GEnx-1B Boeing 787 AMM, DMC-B787- A-26-11-01-01B-520A-A, steps C.(1) through C.(6). When the sensing elements are removed, continue to step 3.B.(3). |
| (b) | For the in-shop procedure, refer to the GEnx-1B EM, 72-00-02, DISASSEMBLY 002, CONFIG 01 or CONFIG 02. When the sensing elements are removed, continue to step 3.B.(3). |
| (3) | Remove the end lug brackets (8, 9, 12, 13 and 14, Figure 2, Sheets 3, 4, and 5) and support bracket (11) as follows: |
| (a) | Remove the bolts (6 and 7, Sheet 3, VIEW B) that attach the bracket (8) to the LPT ACC air manifold (2) at the 1:45 oclock position, aft looking forward (ALF). |
| (b) | Remove the bolts (10, VIEW C) that attach the bracket (11) to the LPT ACC air manifold (2) at the 2:10 oclock position, ALF and do as follows: |
| 1 | Discard the bracket (11). |
| (c) | Remove the bolts (6 and 7, VIEW D) that attach one bracket (9) to the LPT ACC air manifold (2) at the 4:15 oclock position, ALF. |
| (d) | Remove the bolts (6 and 7, Sheet 4, VIEW E) that attach the bracket (12) to the LPT ACC air manifold (3) at the 4:45 oclock position, ALF. |
| (e) | Remove the bolts (6 and 7, VIEW F) that attach the remaining bracket (9) to the LPT ACC air manifold (3) at the 7:15 oclock position, ALF. |
| (f) | Remove the bolts (6 and 7, Sheet 5, VIEW G) that attach the bracket (13) to the LPT ACC air manifold (4) at the 7:45 oclock position, ALF. |
| (g) | Remove the bolts (6 and 7, VIEW H) that attach the bracket (14) to the LPT ACC air manifold (4) at the 10:15 oclock position, ALF. |
| (h) | Remove the bracket (3, Figure 3, Sheet 2) as follows: |
| 1 | Remove two bolts (1) and two self-locking nuts (nuts) (2) that attach the bracket (3) to the oil tube (4). |
| 2 | Remove the bracket (3). |
| 3 | Keep the bolts (1) and nuts (2) for installation. |
| (i) | Remove the control cables bridge bracket (bracket) (8, Sheet 2, VIEW B) as follows: |
| 1 | Remove the nuts (6) that attach the bracket (8) to the bridge upper bifurcation (7). |
| 2 | Remove the bracket (8). |
| 3 | Keep the nuts (6) for installation. |
| (j) | Remove the harness support bracket (10, Sheet 3, VIEW C) as follows: |
| 1 | Remove the bolts (9) that attach the retaining strap (11) to the harness support bracket (10). |
| 2 | Remove the bolts (12) that attach the harness support bracket (10) to the support bracket (13). |
| 3 | Remove the harness support bracket (10). |
| (k) | Remove the bracket (19, Sheet 3, VIEW D) as follows: |
| 1 | Remove the bolts (16 and 17) that attach the hydraulic pressure block clamps (18) and bracket (19) to the cowl support (14). |
| 2 | Remove the bracket (19). |
| (l) | Remove the bracket (20, Sheet 4) as follows: |
| 1 | Remove the bolts (21) that attach the bracket (20) to the cowl support (14). |
| 2 | Remove the bracket (20). |
| 3 | Keep the bolts (21) for installation. |
| (m) | Remove the support bracket (25, Sheet 5) as follows: |
| 1 | Remove the bolts (22, 27, and 28) and clamps (26 and 29) that attach the support bracket (25) to the brackets (23 and 24). |
| 2 | Remove the support bracket (25). |
| 3 | Keep the bolts (22, 27, and 28), clamps (26 and 29), and brackets (23 and 24) for installation. |
| (n) | Remove the bracket (31, Sheet 6, VIEW F) as follows: |
| 1 | Remove the bolts (30) that attach the bracket (31) to the cowl support (14). |
| 2 | Remove the bracket (31). |
| 3 | Keep the bolts (30) for installation. |
| (o) | Remove the bracket (32, VIEW G) as follows: |
| 1 | Remove the bolts (30) that attach the bracket (32) to the cowl support (14). |
| 2 | Remove the bracket (32). |
| 3 | Keep the bolts (30) for installation. |
| (p) | Remove the brackets (3, Figure 4, Sheet 2, VIEW A) as follows: |
| 1 | Remove the bolts (1, 2, and 8) that attach the bracket (3) to the hydraulic pump housing (6), bracket (5), and clamp (7). |
| 2 | Remove the bracket (3). |
| 3 | Keep the bolts (1, 2, and 8) and clamp (7) for installation. |
| (q) | Remove the bracket (5) as follows: |
| 1 | Remove the bolts (4 and 15) and clamp (14) that attach the bracket (5) to the hydraulic pump housing (6). |
| 2 | Remove the bracket (5). |
| 3 | Keep the bolts (4 and 15) and clamp (14) for installation. |
| (r) | Remove the bracket (13, VIEW B) as follows: |
| 1 | Remove the bolts (10 and 11) and clamp (9) that attach the bracket (13) to the inlet fuel tube (12). |
| 2 | Remove the bracket (13). |
| 3 | Keep the bolts (10 and 11) and clamp (9) for installation. |
| (4) | Remove the oil vent manifold (3, Figure 5, Sheet 2) and the oil tube (25, Sheet 4) as follows: |
| (a) | Remove two bolts (1, VIEW A) and one retaining strap (2) that attach the oil vent manifold (3) to the support bracket (4). |
| (b) | Remove two bolts (1, VIEW B) and one retaining strap (2) that attach the oil vent manifold (3) to the support brackets (13). |
| (c) | Remove three bolts (6) and support bracket (5) that attach the oil vent manifold (3) to the turbine center frame (TCF) vent tube (7). |
| (d) | Remove and discard the outer seal (8). |
| (e) | Remove two bolts (1) and one retaining strap (2) that attach the oil vent manifold (3) to the 7th stage air support bracket P/N 2380M14G01 (SIN 46115). |
| (f) | Remove four nuts (9, VIEW B) and four bolts (10) that attach the oil vent tube (11) to the oil vent manifold (3). |
| (g) | Remove and discard the seal flange gasket (12). |
| (h) | Remove the insulation blankets (14, 15, 16, 17, 18, 19, 20, 21, 22, and 23, Sheet 3) as follows: |
| 1 | Remove the tiedown straps (straps) (24, Sheet 3) that attach the insulation blankets (14, 15, 16, 17, 18, 19, 20, 21, 22, and 23) to the oil vent manifold (3). |
| 2 | Remove the insulation blankets (14, 15, 16, 17, 18, 19, 20, 21, 22, and 23). |
| 3 | Keep the insulation blankets (14, 15, 16, 17, 18, 19, 20, 21, 22, and 23) for installation. |
| (i) | Remove the four bolts (29, Sheet 4, VIEW C), four nuts (9), and the bracket (26) that attach the oil vent manifold (3) to the oil tube (25). |
| (j) | Remove and discard one seal flange gasket (gasket) (30). |
| (k) | Remove four bolts (27, VIEW D) that attach the oil tube (25) to the fan hub frame (FHF) assembly (28) at the 12:00 o'clock position. |
| (l) | Remove two bolts (1, Sheet 5) that attach the oil tube (25) to the oil tube bracket (31) and do as follows: |
| 1 | Keep the bolts (1) for installation. |
| (m) | Remove two bolts (27) that attach the oil tube (25) to the oil tube bracket (32, Sheet 5) and do as follows: |
| 1 | Keep the bolts (27) for installation. |
| (n) | Remove the bolts (35) and P-clamp (33) that attach the oil tube (25) to the tube oil bracket (34) and do as follows: |
| 1 | Keep the bolts (35) and P-clamp (33) for installation. |
| (o) | Remove the oil tube (25). |
| (p) | Remove and discard the remaining gasket (30). |
| (q) | Loose the V-retainer coupling (36, Sheet 6) of the engine anti-ice tube in the upper bifurcation to make sufficient space to maneuver the oil tube (25, Sheet 4). |
| (5) | Remove the drain tube (1, Figure 6, Sheets 1, 2, and 3) as follows: |
| (a) | Remove the two bolts (4, Sheet 2) and two bolts (6) that attach the four clamps (5) to the brackets (7, 8, 9, and 11, Sheet 3). |
| (b) | Loosen and disconnect the B-nuts that attach the drain tube (1) to the drain hose tube (3) and to the upper drain manifold (10, Sheet 3). |
| (c) | Remove and discard the drain tube (1). |
| (d) | Remove the brackets (7, 8, and 9, Sheets 2 and 3). |
| (6) | Remove the drain manifold (tube) (2, Sheet 4) as follows: |
| (a) | Remove the bolts (12 and 16) that attach the clamps (13) to the bracket (15) and to the drain support brackets (11 and 18). |
| (b) | Loosen and disconnect the B-nuts that attach the tube (2) to the drain tubes (14 and 17) and to the upper drain manifold (10, Sheet 4). |
| (c) | Loosen and disconnect the B-nuts that attach the tube (2) to the bearing support. |
| (d) | Remove the tube (2). |
| (7) | For engines that have not complied with GEnx-1B S/B 73-0040, refer to Figure 7 and do as follows: |
| (a) | Remove the drain support bracket (3, Sheet 3) as follows: |
| 1 | Remove the bolts (6) and the cushioned loop clamps (7) that attach the drain manifold tube to the drain bracket (5). |
| 2 | Remove the bolts (4, Sheet 2, VIEW A) of pre-GEnx-1B S/B 73-0040, configuration 1 or 2, that attach the drain support bracket (3) to the LPT ACC air manifold (1). |
| 3 | Remove and keep the drain bracket (5, Sheet 3, VIEW C) for installation. |
| 4 | Remove the drain support bracket (3). |
| (b) | Remove the drain support bracket (8, Sheet 4) as follows: |
| 1 | Remove the bolts (4) that attach the harness support bracket (8) to the LPT ACC air manifold (2). |
| 2 | Remove the harness support bracket (8). |
| C. | Installation |
| (1) | For engines that did not comply with GEnx-1B S/B 73-0040, do as follows: |
| NOTE: |
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| (a) | Install the drain support bracket (3, Figure 7, Sheet 3, VIEW C) and the drain bracket (5) at the LPT ACC air manifold (1), at the 5:30 o'clock position, ALF, as follows: |
| 1 | Put the upper tab of the drain bracket (5) between the LPT ACC air manifold (1) and the drain support bracket (3). |
| 2 | Put the lower tab of the drain bracket (5) in position, above the middle tab of the drain support bracket (3). |
| 3 | Install the drain support bracket (3) with four bolts (4). |
| 4 | Attach the drain manifold tube to the drain bracket (5) with the cushioned clamps (7) and bolts (6). |
| 5 | Torque the bolts (4) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 6 | Toque the bolts (6) to 60 to 70 lb in. (6.7 to 7.9 Nm). |
| (b) | Install the drain support bracket (8, Sheet 4, VIEW B) located at the 2:30 o'clock position, forward looking aft (FLA), of the LPT ACC air manifold (2) with three bolts (4) as follows: |
| 1 | Torque the bolts (4) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (2) | Install the new brackets and clamps for the new W30 and W31 harnesses. Refer to Figure 8 and do as follows: |
| (a) | Install the new brackets for the left hand (L/H) fire detectors as follows: |
| 1 | Install the support bracket (6, Sheet 2) to the top of the harness support bracket (8) with a bolt (7) and two bolts (5). |
| 2 | Torque bolt (7) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 3 | Torque the bolts (5) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| 4 | Install the end lug bracket (9) to the L/H side, ALF, of the LPT ACC air manifold (1) with two bolts (5). |
| 5 | Torque the bolts (5) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (b) | Install the clamps (10, Sheet 3) for the L/H fire detectors as follows: |
| 1 | Install seven clamps (10) with bolts (5) (two for each clamp). |
| 2 | Torque the bolts (5) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (c) | Install the new brackets for the lower fire detectors as follows: |
| 1 | Install the end lug bracket (11, Sheet 4) to the L/H side, ALF, of the LPT ACC air manifold (2) with two bolts (5), a bolt (12), and one nut (13). |
| 2 | Install the support bracket (14) to the R/H side, ALF, of the LPT ACC air manifold (2) with two bolts (5). |
| 3 | Torque the bolts (5) and the nut (13) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (d) | Install the clamps (10, Sheet 5) for the lower fire detectors as follows: |
| 1 | Install seven clamps (10) with bolts (5) (two for each clamp). |
| 2 | Torque the bolts (5) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (e) | Install the support brackets for the lower and upper right fire detectors as follows: |
| 1 | Install the end lug bracket (11, Sheet 6) to the lower R/H side, ALF, of the LPT ACC air manifold (3) with two bolts (5) and a bolt (12). |
| 2 | Install the end lug bracket (bracket) (15) to the upper R/H side, ALF, of the LPT ACC air manifold (3) with two bolts (5). |
| 3 | Torque the bolts (5 and 12) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (f) | Install the clamps (10, Sheet 7) for the right fire detectors as follows: |
| 1 | Install six clamps (10) on top to the R/H side, FLA, of the LPT ACC air manifold (3) with two bolts (5) (two for each clamp). |
| 2 | Torque the bolts (5) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| (3) | Install the sensing elements (4, Figure 9, Sheet 2) on the LPT ACC air manifold (1) as follows: |
| NOTE: |
|
| (a) | Assemble the left sensing elements (4) as follows: |
| NOTE: |
|
| 1 | Put two adjacent sensing elements (4) on a clean work surface. Set the sensing elements (4) opposite to each other so the pair of sensing elements (4) has a No. 8 lug and a No. 10 lug at each end. |
| 2 | Install seven grommets (5) on each of the sensing elements (4). |
| CAUTION: |
|
| (b) | Align the No. 8 and No. 10 lugs at a 30 degree angle from the support bracket (bracket) (7, Sheet 3, VIEW D) at the top of the core fire detector No. 2. |
| (c) | Put the No. 8 lug end of the sensing element (4) through the forward-side opening at the end of the bracket (7). |
| (d) | Attach the No. 8 lug to the bracket (7) with the nut connector (nut) (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (e) | Safety the nut (6) with C10-071 safety wire. |
| (f) | Put the No. 10 lug end of the other sensing element (4) through the aft-side opening in the bracket (7). |
| (g) | Attach the No. 10 lug to the bracket (7) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (h) | Safety the nut (6) with C10-071 safety wire. |
| (i) | Connect the pairs of grommets (5) on the sensing elements (4) with clamps (9). |
| CAUTION: |
|
| (j) | Align the No. 8 and No. 10 lugs at a 0 degree angle from the support bracket (bracket) (8, VIEW E) at the bottom of core fire detector No. 2. |
| (k) | Put the No. 10 lug end of the sensing element (4) through the forward-side opening in the bracket (8). |
| (l) | Attach the No. 10 lug to the bracket (8) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (m) | Safety the nut (6) with C10-071 safety wire. |
| (n) | Put the No. 8 lug end of the other sensing element (4) through the aft-side opening in the bracket (8). |
| (o) | Attach the No. 8 lug to the bracket (8) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (p) | Safety the nut (6) with C10-071 safety wire. |
| (4) | Install the sensing elements (4, Sheet 4) on the LPT ACC air manifold (2) as follows: |
| NOTE: |
|
| (a) | Assemble the lower sensing elements (4) as follows: |
| NOTE: |
|
| 1 | Put two adjacent sensing elements (4) on a clean work surface. Set the sensing elements (4) opposite to each other so the pair of sensing elements (4) has a No. 8 lug and a No. 10 lug at each end. |
| 2 | Install seven grommets (5) on each of the sensing elements (4). |
| CAUTION: |
|
| (b) | Align the No. 8 and No. 10 lugs at a 30 degree angle from the support bracket (bracket) (11, Sheet 5, VIEW G) at the L/H, FLA, of the core fire detector No. 3. |
| (c) | Put the No. 10 lug end of the sensing element (4) through the forward-side opening in the bracket (11). |
| (d) | Attach the No. 10 lug to the bracket (1) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (e) | Safety the nut (6) with C10-071 safety wire. |
| (f) | Put the No. 8 lug end of the other sensing element (4) through the aft-side opening in the bracket (11). |
| (g) | Attach the No. 8 lug to the bracket (11) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (h) | Safety the nut (6) with C10-071 safety wire. |
| (i) | Connect the pairs of grommets (5) on the sensing elements (4) with clamps (9). |
| CAUTION: |
|
| (j) | Align the No. 8 and No. 10 lugs at a 0 degree angle from the support bracket (bracket) (10, VIEW F) at the R/H, FLA, of core fire detector No. 3. |
| (k) | Put the No. 8 lug end of the sensing element (4) through the forward-side opening in the bracket (10). |
| (l) | Attach the No. 8 lug to the bracket (10) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (m) | Safety the nut connector with C10-071 safety wire. |
| (n) | Put the No. 10 lug end of the other sensing element (4) through the aft-side opening in the bracket (10). |
| (o) | Attach the No. 10 lug to the bracket (10) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (p) | Safety the nut connector with C10-071 safety wire. |
| (5) | Install the sensing elements (4, Figure 9, Sheet 6) on the LPT ACC air manifold (3) as follows: |
| NOTE: |
|
| (a) | Assemble the right sensing elements (4) as follows: |
| NOTE: |
|
| 1 | Put two adjacent sensing elements (4) on a clean work surface. Set the sensing elements (4) opposite to each other so the pair of sensing elements (4) has a No. 8 lug and a No. 10 lug at each end. |
| 2 | Install six grommets (5) on each of the sensing elements (4). |
| CAUTION: |
|
| (b) | Align the No. 8 and No. 10 lugs at a 30 degree angle from the support bracket (bracket) (12, Sheet 7, VIEW H) at the top of the core fire detector No. 1. |
| (c) | Put the No. 10 lug end of the sensing element (4) through the forward-side opening in the bracket (12). |
| (d) | Attach the No. 10 lug to the bracket (12) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (e) | Safety the nut (6) with C10-071 safety wire. |
| (f) | Put the No. 8 lug end of the other sensing element (4) through the aft-side opening in the bracket (12). |
| (g) | Attach the No. 8 lug to the bracket (12) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (h) | Safety the nut (6) with C10-071 safety wire. |
| (i) | Connect the pairs of grommets (5, Figure 9, Sheet 6, VIEW J) on the sensing elements (4) with clamps (9). |
| CAUTION: |
|
| (j) | Align the No. 8 and No. 10 lugs at a 0 degree angle from the bracket (10, VIEW J) at the bottom of core fire detector No. 1. |
| (k) | Put the No. 10 lug end of the sensing element (4) through the aft-side opening in the bracket (10). |
| (l) | Attach the No. 10 lug to the bracket (10) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (m) | Safety the nut (6) with C10-071 safety wire. |
| (n) | Put the No. 8 lug end of the other sensing element (4) through the forward-side opening in the bracket (10). |
| (o) | Attach the No. 8 lug to the bracket (10) with the nut (6). Torque the nut (6) to 92 to 108 lb in. (10.4 to 12.2 Nm). |
| (p) | Safety the nut (6) with C10-071 safety wire. |
| (6) | Install the drain tube (1, Figure 10) as follows: |
| (a) | Connect the B-nuts of the drain tube (1, Sheet 2, VIEW B) to the upper drain manifold (2). |
| WARNING: |
|
| (b) | Lubricate the threads and friction surfaces of the bolt (6, VIEW C) with C02-023 engine oil. |
| (c) | Attach the drain tube to the bracket (8) with a cushioned loop clamp (clamp) (5) and a bolt (6). |
| (d) | Attach the drain tube to the drain support bracket (bracket) (4) with a clamp (5) and a bolt (3). |
| (e) | Torque the B-nut at the upper drain manifold (2, View B) to 460 to 540 lb in. (51.9 to 61.0 Nm). |
| (f) | Torque the bolts (3 and 6, VIEW C) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| (g) | Connect the B-nut of the drain tube (1) to the strut drain hose tube (9). |
| (h) | Torque the B-nut on the drain tube (1) to 78 to 92 lb ft (105.7 to 124.7 Nm). |
| (7) | Install the oil vent manifold (1, Figure 11, Sheet 1) and the oil tube (2) as follows: |
| (a) | Install the oil tube (2, Sheet 2) and do as follows: |
| WARNING: |
|
| 1 | Apply C02-019 engine oil or C02-023 engine oil to the new gasket (4, VIEW B). |
| 2 | Install the gasket (4) on the assembly fan hub frame (fan hub frame) (5) at the 12:00 o'clock position. |
| 3 | Install the oil tube (2) on the fan hub frame (5). Attach the oil vent tube (2) with bolts (3). |
| 4 | Attach the oil tube (2, VIEW C) to the oil tube bracket (6) with two bolts (3). |
| 5 | Attach the oil tube (2, VIEW D) to the oil tube bracket (9) with two bolts (7). |
| 6 | Attach the oil tube (2, VIEW E) to the oil tube bracket (8) with the P-clamp (11) and bolts (10). |
| 7 | Torque the bolts (10) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| 8 | Torque the bolts (3, VIEW B) and bolts (7, VIEW D) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 9 | Torque the V-retainer coupling (36, Figure 5, Sheet 6) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (b) | Install the insulation blankets (blankets) (12, 13, 15, 16, 17, 18, 19, 20, 21, and 22, Sheet 3) as follows: |
| 1 | Install the blankets (12 and 13) on the oil vent manifold (1). Attach the blankets (12 and 13) with straps (14). Align the ends of the straps. |
| 2 | Install the blankets (19 and 20) on the oil vent manifold (1). Attach the blankets (19 and 20) with straps (14). Align the ends of the straps. |
| 3 | Install the blankets (16 and 17) on the oil vent manifold (1). Attach the blankets (16 and 17) with straps (14). Align the ends of the straps. |
| 4 | Install the blankets (18 and 15) on the oil vent manifold (1). Attach the blankets (18 and 15) with straps (14). Align the ends of the straps. |
| 5 | Install the blankets (21 and 22) on the oil vent manifold (1). Attach the blankets (21 and 22) with straps (14). Align the ends of the straps. |
| (c) | Install the oil vent manifold (1, Sheet 4) as follows: |
| WARNING: |
|
| 1 | Apply C02-019 engine oil or C02-023 engine oil to the gasket (4, VIEW F). |
| 2 | Install the gasket (4) on the forward end of the oil vent manifold (1). |
| 3 | Install the oil vent manifold (1) on the oil tube (2). |
| 4 | Put the bracket (23) at the upper boltholes on the forward side of the flange. |
| 5 | Attach the oil vent manifold (1) and oil tube (2) with bolts (24) and nuts (25). Install the nuts on the forward side of the flange. |
| WARNING: |
|
| 6 | Apply C02-019 engine oil or C02-023 engine oil to the outer seal (26, VIEW G). |
| 7 | Put the outer seal (26) on the oil vent manifold (1). |
| 8 | Put the oil vent manifold (1) and outer seal (26) on the TCF vent tube (27). |
| CAUTION: |
|
| 9 | Make sure that the protrusion on the flange of the oil vent manifold (1) is fully inserted in the TCF vent tube (27). |
| 10 | Attach the oil vent manifold (1) to the tube (27) with the bolts (28) and support bracket (29). |
| WARNING: |
|
| 11 | Apply C02-019 engine oil or C02-023 engine oil to the seal flange gasket (30, Sheet 5, VIEW H). |
| 12 | Put the seal flange gasket (30) between the oil vent tube (31) and the oil vent manifold (1). Attach the tubes with four bolts (32) and four nuts (33). Install the boltheads at the 12:00 o'clock position. |
| 13 | Attach the oil vent manifold (1) to the support bracket (36) with the retaining strap (34) and bolts (7). |
| 14 | Attach the oil vent manifold (1, VIEW J) to the support bracket (35) with the retaining strap (34) and bolts (7). |
| 15 | Torque the bolts (28, Sheet 4, VIEW G) that attach the oil vent manifold (1) to the support bracket (29) and tube (27) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 16 | Torque the nuts (33, Sheet 5, VIEW H) that attach the oil vent tube (31) to the oil vent manifold (1) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 17 | Torque the nuts (25, Sheet 4, VIEW F) that attach the oil vent manifold (1) to the oil tube (2) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 18 | Torque the bolts (7, Sheet 5, VIEW H) on the retaining straps (34) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 19 | Torque the bolts (7, Sheet 5, VIEW J) on the retaining straps (34) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (d) | Install the drain manifold (1, Figure 12) as follows: |
| 1 | Connect the two B-nuts of the drain manifold (1, Sheet 2, VIEW A) to the upper drain manifold (2). |
| 2 | Connect the upper B-nut of the drain manifold (1, VIEW C) to the nipple of the hydraulic pump bearing support (3). |
| 3 | Attach the drain manifold (1, VIEW B) to the bracket (4) with two clamps (5) and bolts (6). |
| 4 | Connect the B-nut of the drain tube (9, VIEW D) to the drain manifold (1). |
| 5 | Attach the drain manifold (1, VIEW A) to the bracket (7) with a clamp (5) and bolt (6). |
| 6 | Connect the B-nut of the VBV right drain tube (8, VIEW C) to the remaining upper end of the drain manifold (1). |
| 7 | Torque the three B-nuts of the drain manifold (1), the B-nut of the VBV right drain tube (8), and the B-nut of the drain tube (9) to 262 to 308 lb in. (29.6 to 34.7 Nm). |
| 8 | Torque the bolts (6, VIEW B) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| (8) | Install the electrical support bracket (1, Figure 13) as follows: |
| (a) | Install the electrical support bracket (1) in the upper bifurcation bridge (2) with two nuts (3). |
| (b) | Torque the nuts (3) to 69 to 81 lb in. (7.7 to 9.1 Nm). |
| (9) | Install the electrical support bracket (1, Figure 14) as follows: |
| (a) | Install the electrical support bracket (1) on the L/H side, FLA, of the LPT ACC air manifold (2) with a bolt (4). |
| (b) | Torque the bolt (4) to 60 to 70 lb in. (6.7 to 7.9 Nm). |
| (10) | Continue with the installation of the new bracket configuration as follows: |
| (a) | Install the harness support bracket (bracket) (1, Figure 15, Sheet 2, VIEW A) as follows: |
| 1 | Attach the bracket (1) to the support bracket (2) with two bolts (3). |
| 2 | Torque the bolts (3) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 3 | Attach the forward drain assembly hose tube (hose tube) (4) to the lower part of the bracket (1) with a clamp (5) and bolt (6). |
| 4 | Torque the bolt (6) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 5 | Attach the booster anti-ice air downstream duct tube (duct tube) (7) to the bracket (1) with a retaining strap (8) and two bolts (9). |
| 6 | Torque the bolts (9) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (b) | Install the support bracket (10, VIEW B) as follows: |
| WARNING: |
|
| 1 | Apply C03-001 primer to the surface of the support bracket (10) that will touch the support cowl. |
| 2 | Align the support bracket (10) with the nut plate boltholes of the support cowl. |
| 3 | Attach the hydraulic pressure hose tube (13) and support bracket (10) to the support cowl with two hydraulic pressure block clamps (block clamps) (14), and two bolts (12) at the block clamps aft boltholes, and two bolts (11) at the block clamps forward boltholes. |
| 4 | Torque the bolts (11 and 12) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (c) | Install the support bracket (15, Sheet 3, VIEW C) as follows: |
| 1 | Attach the support bracket (15) to the support brackets (16 and 17) with three bolts (18). |
| 2 | Torque the bolts (18) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 3 | Attach the LPT fuel hose VBV manifold (manifold) (19) to the support bracket (15) with two clamps (20) and two bolts (21). |
| 4 | Torque the bolts (21) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 5 | Attach the PS3 air tube (22) to the bottom part of the support bracket (15) with a clamp (23) and bolt (24). Make sure that the loop of the clamp (23) points downwards when you install it. |
| 6 | Torque the bolt (24) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 7 | Attach the drain tube (25, VIEW H) to the support bracket (15) with a clamp (26) and bolt (27). |
| 8 | Attach the strut drain hose tube (hose tube) (28) to the support bracket (15) with a clamp (26) and bolt (27). |
| 9 | Torque the bolts (27) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 10 | Attach the hydraulic supply tube (29) and hydraulic case drain hose tube (hydraulic hose tube) (30) to the support bracket (15) with a P-clamp (31) and two bolts (32). |
| 11 | Torque the bolts (32) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (d) | Install the support bracket (33, Sheet 4, VIEW D) on the cowl support at the 3:00 o'clock position, ALF, as follows: |
| WARNING: |
|
| 1 | Lubricate the threads of the bolts (34) with C02-023 engine oil. |
| 2 | Attach the support bracket (33) to the cowl support with two bolts (34). |
| 3 | Torque the bolts (34) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (e) | Install the support bracket (35, VIEW E) on the cowl support at the 3:45 o'clock position, ALF, as follows: |
| WARNING: |
|
| 1 | Lubricate the threads of the bolts (36) with C02-023 engine oil. |
| 2 | Attach the support bracket (35) to the cowl support with two bolts (36). |
| 3 | Torque the bolts (36) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (f) | Install the control cable support bracket (37, Sheet 5, VIEW F) on the cowl support at the 1:00 o'clock position, ALF, as follows: |
| 1 | Attach the control cable support bracket (37) to the cowl support with two bolts (38). |
| 2 | Torque the bolts (38) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (g) | Install the support bracket (39, VIEW G) and the drain support bracket (40) as follows: |
| WARNING: |
|
| 1 | Apply C02-058 lubricant to the threads and friction surfaces of the bolts (41, 42, and 43). |
| 2 | Attach the support bracket (39) to the hydraulic pump housing with a bolt (43). Do not torque the bolt (43) at this time. |
| 3 | Attach the drain support bracket (40) and support bracket (39) to the hydraulic pump housing with bolts (41 and 42). |
| 4 | Attach the drain tube (25) to the support bracket (39) with a clamp (26) and bolt (44). |
| 5 | Attach the drain manifold (45) to the drain support bracket (40) with a clamp (46) and bolt (47). |
| 6 | Torque the bolts (44 and 47) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 7 | Torque the bolts (41, 42, and 43) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (h) | Install the harness support bracket (support bracket) (1, Figure 16, Sheet 2) as follows: |
| 1 | Align the flowmeter inlet fuel tube (3), support bracket (1), and gasket (2) with the respective boltholes of the fuel flow meter. |
| 2 | Loose the B-nuts of the drain tube (7). |
| 3 | Attach the flowmeter inlet fuel tube (3), support bracket (1), and gasket (2) to the fuel flow meter with two bolts (4). |
| 4 | Torque the bolts (4) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 5 | Attach the drain tube (7) to the bracket (1) with a cushioned loop clamp (8) and bolt (9). |
| 6 | Torque the bolt (9) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 7 | Torque the B-nuts of the drain tube (7) to 262 to 308 lb in. (29.6 to 34.7 Nm). |
| (i) | Install the harness support bracket (bracket) (5) as follows: |
| 1 | Align the boltholes of the bracket (5) with the accessory gearbox casing boltholes. |
| 2 | Attach the bracket (5) to the accessory gearbox casing with two bolts (6). |
| 3 | Torque the bolts (6) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (j) | Install the W31 electrical harness support bracket (bracket) (1, Figure 17) and the harness W31 support brackets (brackets) (2 and 3) as follows: |
| 1 | Attach the bracket (1, VIEW B) to the left-side cable shield and the lower bifurcation fill and overfill manifold (lower bifurcation manifold) (6) with a bolt (4). |
| 2 | Attach the bracket (2) to the lower bifurcation manifold (6) with a bolt (5). |
| 3 | Torque the bolt (4) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| 4 | Attach the bracket (3, VIEW C) to the lower bifurcation manifold (6) with a bolt (5). |
| 5 | Torque the bolts (5) to 106 to 124 lb in. (11.9 to 14.0 Nm). |
| (11) | Install the W30 and W31 harnesses with the new support system configuration as follows: |
| (a) | Install the W30 harness (5, Figure 18, Sheet 3) as follows: |
| 1 | Put the W30 harness (5) in position along the LPT ACC air manifold (1, VIEW B). |
| 2 | Attach the W30 harness (5, VIEW A) to the bracket (7) with one bolt (6). Tighten the bolt (6) with your hand. |
| 3 | Attach the W30 harness (5, VIEW B) to the LPT ACC air manifold (1) with two bolts (6). Tighten the bolts (6) with your hand. |
| 4 | Attach the W30 harness (5, Sheet 4) to the LPT ACC air manifold (2) and bracket (8) with a bolt (9). Tighten the bolt (9) with your hand. |
| 5 | Attach the W30 harness (5) to the LPT ACC air manifold (2) with six bolts (6). Tighten the bolts (6) with your hand. |
| 6 | Attach the W30 harness (5) to the LPT ACC air manifold (2) and bracket (11) with a bolt (9). Tighten the bolt (9) with your hand. |
| 7 | Attach the W30 harness (5) branches to the brackets (8 and 11) with clamps (12 and 13) and with two bolts (10) respectively. Tighten the bolts (10) with your hand. |
| 8 | Attach the W30 harness (5, Sheet 5) to the LPT ACC air manifold (3) and drain support bracket (bracket) (14) with a bolt (9). Tighten the bolt (9) with your hand. |
| 9 | Attach the W30 harness (5) to the LPT ACC air manifold (3) with four bolts (6). Tighten the bolts (6) with your hand. |
| 10 | Attach the W30 harness (5) to the LPT ACC air manifold (3) and bracket (15) with two bolts (6). Tighten the bolts (6) with your hand. |
| 11 | Attach the W30 harness (5) to the LPT ACC air manifold (3) and bracket (11) with a bolt (9). Tighten the bolt (9) with your hand. |
| 12 | Attach the W30 harness (5) branches to the brackets (11 and 14) with two clamps (13) and two bolts (10). Tighten the bolts (10) with your hand. |
| 13 | Attach the W30 harness (5, Sheet 6) to the LPT ACC air manifold (4) and bracket (16) with a bolt (9). Tighten the bolt (9) with your hand. |
| 14 | Attach the W30 harness (5) to the LPT ACC air manifold (4), bracket (17), and support bracket (18) with six bolts (6). Tighten the bolts (6) with your hand. |
| 15 | Attach the W30 harness (5) branches to the brackets (16 and 19) with two clamps (13) and two bolts (10). Tighten the bolts (10) with your hand. |
| 16 | Attach the W30 harness (5, Sheet 7) to the oil vent manifold (20) with two clamps (21 and 22) and bolts (23 and 24) respectively. Torque the bolts (23 and 24) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 17 | Put the W30 harness (5) in the spring clips of the bracket (25) and to the remaining spring clips of the oil tube (26). |
| 18 | Attach the W30 harness (5) to the oil tube (26) with a clamp (21) and a bolt (23). Torque the bolt (23) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 19 | Put the W30 harness (5, Sheet 8, VIEW G) in the spring clips of the brackets (27 and 28). |
| 20 | Put the W30 harness (5) in the spring clip of the bracket (29) and attach it with a clamp (21) and bolt (23). Torque the bolt (23) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 21 | Connect the P303 harness connector (VIEW H) to the engine anti ice (EAI) controller (34). |
| CAUTION: |
|
| 22 | Tighten the P303 harness connector with Teflon-jawed pliers. |
| 23 | Put the W30 harness (5, VIEW J) in the spring clip of the bracket (30). |
| 24 | Put the W30 harness (5) in the spring clips of the brackets (31 and 32) and the drain tube (33). |
| 25 | Attach the W30 harness (5, Sheet 9, VIEW K) to the bracket (36) with a clamp (13) and a bolt (24). Torque the bolt (24) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 26 | Attach the W30 harness (5) to the bracket (35) with a clamp (12) and a bolt (23) and to the spring clip. Torque the bolt (23) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 27 | Connect the P301 harness connector to the fuel metering unit (FMU). |
| 28 | Tighten the P301 harness connector with Teflon-jawed pliers. |
| 29 | Put the W30 harness (5, Sheet 10, VIEW L) on the sping clips of the bracket (38). |
| 30 | Put the W30 harness (5) on the sping clips of the bracket (39). |
| 31 | Put the W30 harness (5) on the sping clips of the bracket (42). |
| 32 | Attach the W30 harness (5, VIEW M) to the bracket (43) with one clamp (41) and one bolt (39). Torque the bolt (39) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| (b) | Install the W30 harness (1, Figure 19) into the sensor elements (5) as follows: |
| CAUTION: |
|
| 1 | Connect the harness blue terminal lug G8 as follows: |
| a | Attach the terminal lug G8 to the bracket (4) on the lower bifurcation manifold (manifold) (6) with a bolt (2). |
| b | Torque the bolt (2) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 2 | Connect the harness yellow terminal lugs T7 and T8 (Figure 19, Sheet 1) as follows: |
| a | Attach the terminal lugs T7 and T8 to the sensor element (5) on the manifold (6) with two No. 8 screws (7), washers (8), and nuts (9). |
| NOTE: |
|
| b | Torque the nuts (9) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| 3 | Connect the W30 harness (1, Sheet 1) to the sensing element (10) on the LPT ACC manifolds as follows: |
| a | Connect the harness blue terminal lugs G1 and G9 on the LPT ACC manifold at the 1:45 o'clock position as follows: |
| (1) | Attach the terminal lugs G1 and G9 to the bracket (12) with a bolt (11) and nut (3). |
| NOTE: |
|
| (2) | Torque the nuts (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| b | Connect the harness black terminal lug GND on the LPT ACC manifold at the 1:45 o'clock position as follows: |
| (1) | Attach the terminal lug GND to the bracket (12) with a bolt (11) and nut (3). |
| (2) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| c | Connect the harness yellow terminal lug T1 (Figure 19, Sheet 1) on the LPT ACC manifold at the 1:45 o'clock position as follows: |
| (1) | Attach the terminal T1 to the sensing element (10) with one No. 8 screw (7), washer (8), and nut (9). |
| NOTE: |
|
| (2) | Torque the nut (9) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| d | Connect the harness blue terminal lug G2 (Figure 19, Sheet 2), on the LPT ACC manifold at the 4:15 o'clock position as follows: |
| (1) | Attach the terminal lug G2 to the bracket (13) with a bolt (11) and nut (3). Tighten the nut (3) with your hand. |
| NOTE: |
|
| e | Connect the harness yellow terminal lug T2 (Figure 19, Sheet 2) on the LPT ACC manifold at the 4:15 o'clock position as follows: |
| (1) | Attach the terminal lug T2 to the sensing element (10) with a No. 10 screw (14), No. 10 washer (washer) (15), and No. 10 nut (nut) (16). |
| NOTE: |
|
| (2) | Torque the nut (16) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| f | Connect the harness blue terminal lug G3 (Figure 19, Sheet 2) on the LPT ACC manifold at the 4:45 o'clock position as follows: |
| (1) | Attach the terminal lug G3 to the bracket (17) with a bolt (11) and nut (3). Tighten the nut (3) with your hand. |
| NOTE: |
|
| g | Connect the harness yellow terminal lug T3 (Figure 19, Sheet 2) on the LPT ACC manifold at the 4:45 o'clock position as follows: |
| (1) | Attach the terminal lug T3 to the sensing element (10) with a No. 8 screw (7), washer (8), and nut (9). |
| NOTE: |
|
| (2) | Torque the nut (9) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| h | Connect the harness blue terminal lug G4 (Figure 19, Sheet 3) on the LPT ACC manifold at the 7:15 o'clock position as follows: |
| (1) | Attach the terminal lug G4 to the bracket (13) with a bolt (11) and nut (3). Tighten the nut (3) with your hand. |
| NOTE: |
|
| i | Connect the harness yellow terminal lug T4 (Figure 19, Sheet 3) on the LPT ACC manifold at the 7:15 o'clock position as follows: |
| (1) | Attach the terminal lug T4 to the sensing element (10) with a No. 10 screw (14), washer (15), and nut (16). |
| NOTE: |
|
| (2) | Torque the nut (16) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| j | Connect the harness blue terminal lug G5 (Figure 19, Sheet 3) on the LPT ACC manifold at the 7:45 o'clock position as follows: |
| (1) | Attach the terminal lug G5 to the bracket (18) with a bolt (11) and nut (3). Tighten the nut (3) with your hand. |
| NOTE: |
|
| k | Connect the harness yellow terminal lug T5 (Figure 19, Sheet 3) on the LPT ACC manifold at the 7:45 o'clock position as follows: |
| (1) | Attach the terminal lug T5 to the sensing element (10) with a No. 8 screw (7), washer (8), and nut (9). |
| NOTE: |
|
| (2) | Torque the nut (9) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| l | Connect the harness blue terminal lug G6 (Figure 19, Sheet 3) on the LPT ACC manifold at the 10:15 o'clock position as follows: |
| (1) | Attach the terminal lug G6 to the bracket (19) with a bolt (11) and the nut (3). |
| NOTE: |
|
| (2) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| m | Connect the harness yellow terminal lug T6 (Figure 19, Sheet 3) on the LPT ACC manifold at the 10:15 o'clock position as follows: |
| (1) | Attach the terminal lug T6 to the sensing element (10) with a No. 10 screw (14), washer (15), and nut (16). |
| NOTE: |
|
| (2) | Torque the nut (16) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 4 | Torque the bolts (6, Figure
18, Sheet 3) from steps 3.C.(11)(a)2 , 3.C.(11)(a)3 , 3.C(11)(a)5 , 3.C.(11)(a)9 , 3.C.(11)(a)10 , and 3.C.(11)(a)14 to 60 to 70 lb in. (6.7 to 7.9 Nm). |
| 5 | Torque the bolts (9) from steps 3.C.(11)(a)4 , 3.C.(11)(a)6 , 3.C.(11)(a)8 , 3.C.(11)(a)11 , and 3.C.(11)(a)13 to 60 to 70 lb in. (6.7 to 7.9 Nm). |
| 6 | Torque the bolts (10) from steps 3.C.(11)(a)7 , 3.C.(11)(a)12 , and 3.C.(11)(a)15 to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| (c) | Install the W31 harness (5, Figure 20, Sheet 2) as follows: |
| 1 | Put the W31 harness (5) in position along the LPT ACC air manifold (1, Sheet 3). |
| 2 | Attach the W31 harness (5) to the bracket (6) with one bolt (7). Tighten the bolt (7) with your hand. |
| 3 | Attach the W31 harness (5) to the LPT ACC air manifold (1) with three bolts (7). Tighten the bolts (7) with your hand. |
| 4 | Attach the W31 harness (5, Sheet 4) to the LPT ACC air manifold (4), bracket (8), and support bracket (9) with eight bolts (7). Tighten the bolts (7) with your hand. |
| 5 | Attach the W31 harness (5) branches to the bracket (10) and to the bracket (11) with two clamps (12 and 13) and two bolts (14) respectively. Tighten the bolts (14) with your hand. |
| 6 | Attach the W31 harness (5, Sheet 5) to the LPT ACC air manifold (3), bracket (15), bracket (16), and bracket (17) with eight bolts (7). Tighten the bolts (7) with your hand. |
| 7 | Attach the W31 harness (5) branches to the end lug brackets (15 and 17) with two clamps (13) and two bolts (14). Tighten the bolts (14) with your hand. |
| 8 | Attach the W31 harness (5, Sheet 6) to the LPT ACC air manifold (2) and brackets (15 and 18) with eight bolts (7). Tighten the bolts (7) with your hand. |
| 9 | Attach the W31 harness (5) to the bracket (18) with a clamp (13) and a bolt (14). Tighten the bolt (14) with your hand. |
| 10 | Attach the W31 harness (5) branch to the bracket (15) with a clamp (13) and a bolt (14). Tighten the bolt (14) with your hand. |
| 11 | Attach the W31 harness (5, Sheet 7) to the oil brackets on the oil vent manifold (19) with two clamps (20 and 21) and two bolts (22 and 23) respectively. Torque the bolts to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 12 | Put the W31 harness (5) in the spring clips attached to the bracket (24) and the brackets attached to the oil tube (25). |
| 13 | Attach the W31 harness (5) to the oil tube (25) with a clamp (12) and a bolt (22). Torque the bolt (22) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 14 | Put the W31 harness (5, Sheet 8, VIEW F) in the spring clips attached to the bracket (28) and attach it with a clamp (12) and a bolt (22). Torque the bolt (22) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 15 | Put the W31 harness (5) in the spring clips attached to the brackets (26, 27, 29, 30, and 31). |
| 16 | Put the W31 harness (5) in the spring clips attach to the tube (32, Figure 20, Sheet 8, VIEW G) and attach it with a clamp (12) and a bolt (22). Torque the bolt (22) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| CAUTION: |
|
| 17 | Connect the P311 harness connector to the hydraulic pump (SIN C00A6). |
| CAUTION: |
|
| 18 | Tighten the P311 harness connector with Teflon-jaw pliers. |
| 19 | Attach the W31 harness (5) to the bracket (33) with a clamp (20) and a bolt (22). Torque the bolt (22) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 20 | Put the W31 harness (5, Sheet 9, View H) in the spring clips of the drain tube (39) and attach it with a clamp (12) and a bolt (22). Torque the bolt (22) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 21 | Put the W31 harness (5, Sheet 9, VIEW J) in the spring clips attached to the brackets (34 and 35). |
| 22 | Put the W31 harness (5) in the spring clips attached to the bracket (38). |
| 23 | Put the W31 harness (5, VIEW K) in the spring clips attached to the bracket (40). |
| 24 | Attach the W31 harness (5) to the brackets (41) with one clamp (37) and bolt (36). Torque the bolt to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 25 | Attach a bolt (7, Sheet 4, VIEW M) to the bracket (9). |
| 26 | Torque the bolt (7) to 60 to 70 lb in. (6.7 to 7.9 Nm). |
| NOTE: |
|
| (d) | Install the W31 harness (1, Figure 21, Sheet 1) into the sensing elements as follows: |
| 1 | Connect the harness green terminal lug G8 as follows: |
| a | Attach the harness green terminal lug G8 to a bolt (2). |
| b | Attach the bolt (2) to the bracket (4). |
| c | Torque the bolt (2) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 2 | Connect the harness white terminal lugs T7 and T8 as follows: |
| a | Attach the terminal lugs T7 and T8 to the No. 10 sensor element (sensor element) (5) on the lower bifurcation manifold with No. 10 screws (screws) (6), washers (7), and nuts (8). |
| b | Make sure that the terminal lugs T7 and T8 are below the screwhead (6) and the washer (7) is below the nut (8). |
| c | Torque the nuts (8) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 3 | Connect the W31 harness (1, Figure 21, Sheet 1) to the sensing elements (9) on the LPT ACC air manifolds as follows: |
| a | Connect the harness green terminal lugs G1 and G9 as follows: |
| (1) | Attach the terminal lug G9 to a bolt (10). |
| (2) | Attach the bolt (10) to the bracket (11) at the 10:15 o'clock position. |
| (3) | Attach the terminal lug G1 with a bolt (10) and a nut (3). |
| (4) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| b | Connect the harness black terminal lug GND as follows: |
| (1) | Attach the terminal GND to a bolt (10) at the 10:15 o'clock position. |
| (2) | Attach the bolt (10) to the bracket (11) with a nut (3). |
| (3) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| c | Connect the harness white terminal lug T1 as follows: |
| (1) | Attach the terminal lug T1 to the sensing element (9) at the 10:15 o'clock position with one screw (12), washer (13), and nut (14). |
| (2) | Make sure that the terminal lug T1 is below the screwhead (12) and the washer (13) is below the nut (14). |
| (3) | Torque the nut (14) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| d | Connect the harness green terminal lug G2 (Figure 21, Sheet 2) as follows: |
| (1) | Loosen the nut (3) on the bracket (15) at the 7:45 o'clock position. |
| (2) | Attach the terminal lug G2 with a bolt (10) and a nut (3) to the bracket (15) at the 7:45 o'clock position. |
| (3) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| e | Connect the harness white terminal lug T2 as follows: |
| (1) | Attach the terminal lug T2 to the sensing element (9) at the 7:45 o'clock position with one screw (6), washer (7), and nut (8). |
| (2) | Make sure that the terminal lug T2 is below the screwhead (6) and the washer (7) is below the nut (8). |
| (3) | Torque the nut (8) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| f | Connect the harness green terminal lug G3 as follows: |
| (1) | Loosen the nut (3) located on the bracket (16) at the 7:15 o'clock position. |
| (2) | Attach the terminal lug G3 with a bolt (10) and a nut (3). |
| (3) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| g | Connect the harness white terminal lug T3 as follows: |
| (1) | Attach the terminal lug T3 to the sensing element (9) at the 7:15 o'clock position with one screw (12), washer (13), and nut (14). |
| (2) | Make sure that the terminal lug T3 is below the screwhead (12) and the washer (13) is below the nut (14). |
| (3) | Torque the nut (14) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| h | Connect the harness green terminal lug G4 (Figure 21, Sheet 3) as follows: |
| (1) | Loosen the nut (3) located on the bracket (17) at the 4:45 o'clock position. |
| (2) | Attach the terminal lug G4 with a bolt (10) and a nut (3). |
| (3) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| i | Connect the harness white terminal lug T4 as follows: |
| (1) | Attach the terminal lug T4 to the sensing element (9) at the 4:45 o'clock position with one screw (6), washer (7), and nut (8). |
| (2) | Make sure that the terminal lug T4 is below the screwhead (6) and the washer (7) is below the nut (8). |
| (3) | Torque the nut (8) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| j | Connect the harness green terminal lug G5 as follows: |
| (1) | Loosen the nut (3) located on the bracket (16) at the 4:15 o'clock position. |
| (2) | Attach the terminal lug G5 with a bolt (10) and a nut (3). |
| (3) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| k | Connect the harness white terminal lug T5 as follows: |
| (1) | Attach the terminal lug T5 to the sensing element (9) at the 4:15 o'clock position with one screw (12), washer (13), and nut (14). |
| (2) | Make sure that the terminal lug T5 is below the screwhead (12) and the washer (13) is below the nut (14). |
| (3) | Torque the nut (14) to 23 to 27 lb in. (2.5 to 3.0 Nm). |
| l | Connect the harness green terminal lug G6 as follows: |
| (1) | Attach the terminal lug G6 with a bolt (10) and a nut (3). |
| (2) | Torque the nut (3) to 51 to 59 lb in. (5.7 to 6.6 Nm). |
| m | Connect the harness white terminal lug T6 as follows: |
| (1) | Attach the terminal lug T6 to the sensing element (9) at the 1:45 o'clock position with one screw (6), washer (7), and nut (8). |
| (2) | Make sure that the terminal lug T6 is below the screwhead (6) and the washer (7) is below the nut (8). |
| (3) | Torque the nut (8) to 32 to 38 lb in. (3.6 to 4.2 Nm). |
| 4 | Torque the bolts (7, Figure
20, Sheet 3) from steps 3.C.(11)(c)2 , 3.C.(11)(c)3 , 3.C.(11)(c)4 , 3.C.(11)(c)6 , and 3.C.(11)(c)8 to 60 to 70 lb in. (6.8 to 7.9 Nm). |
| 5 | Torque the bolts (14) from steps 3.C.(11)(c)5 , 3.C.(11)(c)7 , 3.C.(11)(c)9 , and 3.C.(11)(c)10 to 32 to 38 lb in. (3.6 to 4.3 Nm). |
| D. | Close-up and Test Procedures |
| (1) | Do the Test No. 4 - Part-Power Leak Test. Refer to the GEnx-1B Boeing 787 AMM, 71-00-00, STANDARD PRACTICES, TASK DMC-B787-A-G71-00-00-13A-364A-A. |
| (2) | Put the airplane back to its usual condition. Refer to the GEnx-1B Boeing 787 AMM, 26-11-03, INSTALLATION, TASK DMC-B787-A-26-11-03-00A-720A-A. |
