TASK 72-00-42-420-001 Combustion System - Install The Diffuser Case Assembly, Installation-001

DMC:V2500-A0-72-00-4200-01A-720A-B|Issue No:001.00|Issue Date:2014-05-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-00-42-420-001 Combustion System - Install The Diffuser Case Assembly, Installation-001

General

The word 'reject' after an interface inspection statement requires that further detailed inspection or repair as applicable, of the affected area be accomplished using data in the applicable ATA section of the part in question. Contact IAE for FAA approved data if the referenced TASK is not in the manual.

Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

For standard torque data and procedures, refer to TASK 70-41-00-400-501 and TASK 70-41-02-400-501.

Special torque data and assembly tolerances are included in this procedure.

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS, unless other lubricants are referred to in the procedure.

To identify, lubricate and install seal rings, refer to TASK 70-44-01-400-501.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Transportation covers/blanks must be removed immediately before the installation of the components.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1P16104 Cover0AM53IAE 1P161041
IAE 1P16108 cover0AM53IAE 1P161081
IAE 1P16122 Installation fixture0AM53IAE 1P161221
IAE 1R18247 Rigging pin0AM53IAE 1R182471
IAE 1R18234 Support rod0AM53IAE 1R182343
IAE 1P16107 cover0AM53IAE 1P161071
IAE 1P16004 Handling bracket0AM53IAE 1P160042
IAE 1P16005 Build stand0AM53IAE 1P160051

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-42-220-051 Make sure that the Fits and Clearances of the Combustion System are in the Limits given at Location 2242

    1. Refer to Figure.

    2. Calculate the interference at location 2242. Use the data made as a note in TASK 72-41-23-200-001-A00 (INSPECTION-001, CONFIG-001) and TASK 72-42-11-200-001-A00 (INSPECTION-001, CONFIG-001).

      Table 1. Fits and Clearances (all dimensions are in inches)

      NEW PART

      WORN PART

      DIMENSIONS

      DIMENSIONS

      PART IDENT

      Size

      Clearance

      (Non-select)

      REJECT IF MORE THAN

      LOCATION 2242

      HP compressor case HPC Rear Outer Case And Related Parts (72-41-23, 02-400), bore and diffuser case assembly Diffuser Case (72-42-11, 01-010), location diameter

      Case bore

      25.2017

      Intf

      25.2017

      Intf

      25.1969

      0.0023

      25.1969

      0.0023

      Diffuser case assembly location diameter

      25.2090

      0.012

      25.209

      0.012

      25.2040

      25.199

      Table 2. Fits and Clearances (all dimensions are in millimeters)

      NEW PART

      WORN PART

      DIMENSIONS

      DIMENSIONS

      PART IDENT

      Size

      Clearance

      (Non-select)

      REJECT IF MORE THAN

      LOCATION 2242

      HP compressor case HPC Rear Outer Case And Related Parts (72-41-23, 02-400), bore and diffuser case assembly Diffuser Case (72-42-11, 01-010), location diameter

      Case bore

      640.125

      Intf

      640.125

      Intf

      640.000

      0.057

      640.000

      0.057

      Diffuser case assembly location diameter

      640.308

      0.308

      640.31

      0.308

      640.182

      640.05

    2. SUBTASK 72-00-42-420-063-A00 V2500-A1: Install the Static Seal Assembly and the Heatshield (Pre SBE 72-0143)

    1. NOTE

      This SUBTASK is only to be completed if the diffuser case has not been overhauled.

      Refer to Figure.

    2. Remove the IAE 1P16108 cover from the ID of the No. 4 bearing cooling duct.

      3. Install the static seal assembly.

      1. Align the offset holes in the static seal assembly and the diffuser case, and align the six vent tubes with the tube connectors on the seal assembly.

      2. Install six of the bolts ENGINE-STATIC SEAL (72-42-50, 01-102) at equal distances around the static seal assembly.

      3. Turn each bolt one turn in sequence to pull the static seal down equally.

      4. Do Step again until the static seal assembly is fully installed.

      5. Remove the six bolts.

    4. Install 20 of the 30 bolts ENGINE-STATIC SEAL (72-42-50, 01-102) through the seal assembly and OGV case, in to the diffuser case. Install the 20 bolts by hand and start with the offset hole. Do not install every third bolt after the offset hole. Torque the bolts to 85 to 105 lbf.in (10.0 to 12.0 Nm).

      5. Install the heatshield ENGINE-STATIC SEAL (72-42-50, 01-096).

      1. Align the 10 holes in the heatshield with the 10 empty hole positions.

      2. Install the other 10 bolts through the heatshield, the seal assembly and the OGV case, in to the diffuser case. Torque the bolts to 85 to 105 lbf.in (10.0 to 12.0 Nm).

    6. Install the IAE 1P16108 cover 1 off to the ID of the No. 4 bearing cooling duct.

    3. SUBTASK 72-00-42-420-063-B00 V2500-A1: Install the Static Seal Assembly (SBE 72-0143)

    1. NOTE

      This SUBTASK is only to be completed if the diffuser case has not been overhauled.

      Refer to Figure.

    2. Remove the IAE 1P16108 cover from the ID of the No. 4 bearing cooling duct.

      3. Install the static seal assembly.

      1. Align the offset holes in the static seal assembly and the diffuser case, and align the six vent tubes with the tube connectors on the seal assembly.

      2. Install six of the bolts ENGINE-STATIC SEAL (72-42-50, 01-102) at equal distances around the static seal assembly.

      3. Turn each bolt one turn in sequence to pull the static seal down equally.

      4. Do Step again until the static seal assembly is fully installed.

      5. Remove the six bolts.

    4. Install the 30 bolts ENGINE-STATIC SEAL (72-42-50, 01-102) through the seal assembly and OGV case, in to the diffuser case. Install the bolts by hand and start with the offset hole. Torque the bolts to 85 to 105 lbf.in (10.0 to 12.0 Nm).

    5. Install the IAE 1P16108 cover 1 off to the ID of the No. 4 bearing cooling duct.

    4. SUBTASK 72-00-42-420-063-C00 V2500-A5: Install the Static Seal Assembly

    1. NOTE

      This SUBTASK is only to be completed if the diffuser case has not been overhauled.

      Refer to Figure.

    2. Remove the IAE 1P16108 cover from the ID of the No. 4 bearing cooling duct.

      3. Install the static seal assembly.

      1. Align the offset holes in the static seal assembly and the diffuser case, and align the two vent tubes with the tube connectors on the seal assembly.

      2. Install six of the bolts ENGINE-STATIC SEAL (72-42-50, 01-102) at equal distances around the static seal assembly.

      3. Turn each bolt one turn in sequence to pull the static seal down equally.

      4. Do Step again until the static seal assembly is fully installed.

      5. Remove the six bolts.

    4. Install the 30 bolts ENGINE-STATIC SEAL (72-42-50, 01-102) through the seal assembly and OGV case, into the diffuser case. Install the bolts by hand and start with the offset hole. Torque the bolts to 85 to 105 lbf.in (10.0 to 12.0 Nm).

    5. Install the IAE 1P16108 cover 1 off to the ID of the No. 4 bearing cooling duct.

    5. SUBTASK 72-00-42-420-056 Remove the Covers from the Combustion System

    1. Remove the IAE 1P16108 cover 1 off from the No. 4 bearing cooling duct.

    2. CAUTION

      MAKE SURE YOU USE TWO PERSONS TO TURN THE COMBUSTION SYSTEM IN THE BUILD STAND.

      Turn the combustion system so the rear flange is up.

    3. Remove the IAE 1P16107 cover 1 off from the No. 4 bearing support.

    6. SUBTASK 72-00-42-420-057 Install the Fixture on to the Rear Flange of the Combustion System

    1. Refer to Figure.

    2. Make sure the IAE 1P16104 Cover 1 off is installed.

    3. Attach a hoist to the eyebolt of the IAE 1P16122 Installation fixture 1 off. Raise the fixture over the combustion system.

    4. Lower the fixture and align the hole in the fixture flange with the dowel pin in the inner flange of the diffuser case assembly.

    5. Attach the fixture to the flange with the 15 work bolts.

    7. SUBTASK 72-00-42-420-058 Remove the Combustion System from the Build Stand

    1. Refer to Figure.

    2. Remove the 10 screws that attach the IAE 1P16004 Handling bracket 2 off to the front flange of the diffuser case assembly.

    3. Lift the combustion system away from the IAE 1P16005 Build stand 1 off.

    8. SUBTASK 72-00-42-420-070 Install the HP Compressor Support Rods

    1. Refer to Figure.

    2. Make sure the variable stator vanes (VSV) are in the low speed position.

    3. Install IAE 1R18247 Rigging pin 1 off through the bracket and into the HP compressor case to lock the VSVs.

    4. Remove the six bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122), the two brackets HP COMPRESSOR SPLIT CASE (72-41-31, 01-115) and HP COMPRESSOR SPLIT CASE (01-118) and three blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) from the HP compressor front cases.

      5. Install the IAE 1R18234 Support rod 3 off.

      1. Turn the adjustment handle to retract the blade of the tool.

      2. Carefully install the support rods through the holes in the HP compressor lower split case. Make sure the blades are rearwards.

      3. Safety the support rods to the HP compressor lower split case with the six tool bolts.

      4. Turn the adjustment handle until the blades touch the HP compressor stage 3 disk and lightly tighten.

    9. SUBTASK 72-00-42-420-059 Install the Combustion System on to the HP Compressor

    1. Refer to Figure and Figure.

    2. Lift the combustion system above the HP compressor rear hub.

    3. Lower the combustion system until the IAE 1P16122 Installation fixture 1 off engages the HP compressor rear hub.

    4. Align the dowel pin in the front flange of the diffuser case assembly with the hole in the rear flange of the HP compressor case.

    5. Lower the combustion system until the front flange of the diffuser case touches the rear flange of the HP compressor case and the weight of the combustion system is not on the hoist.

    6. Remove the work bolts from the IAE 1P16122 Installation fixture 1 off and lift the fixture away from the combustion system.

    7. Install the 114 bolts (the heads to the rear), the nuts and the related brackets. Torque the nuts to 180 to 220 lbf.in (20.34 to 24.86 Nm).

    8. Install the two bolts which hold the fuel distribution valve to the bracket on flange J. Torque these bolts to 180 to 200 lbf.in (20.337 to 22.597 Nm).

    10. SUBTASK 72-00-42-420-060 Install Cover on to the Rear Flange of the Diffuser Case Assembly

    1. Install IAE 1P16104 Cover 1 off on the rear flange of the diffuser case assembly.

      .

    11. Figure: Remove the combustion system from the IAE 1P16005 build stand

    Remove the combustion system from the IAE 1P16005 build stand

    Figure: Install the combustion system on to the HP compressor

    Install the combustion system on to the HP compressor

    Figure: V25000-A1: Combustion system installation - Fits and Clearances

    V25000-A1: Combustion system installation - Fits and Clearances

    Figure: V2500-A5: Combustion system installation - Fits and Clearances

    V2500-A5: Combustion system installation - Fits and Clearances

    Figure: Install the heatshield and the static seal

    Install the heatshield and the static seal

    Figure: V2500-A5: Install the static seal

    V2500-A5: Install the static seal

    Figure: Install the support rods into the HP compressor front cases

    Install the support rods into the HP compressor front cases

    Figure: Install the support rods into the HP compressor front cases

    Install the support rods into the HP compressor front cases

    Figure: Pre SBE 73-0131 Install the bolts, the nuts and the brackets to diffuser case front flange

    Sheet 1

    Legend
    Pre SBE 73-0131 Install the bolts, the nuts and the brackets to diffuser case front flange

    Sheet 1

    Close

    Figure: SBE 73-0131 Install the bolts, the nuts and the brackets to diffuser case front flange

    Sheet 2

    Legend
    SBE 73-0131 Install the bolts, the nuts and the brackets to diffuser case front flange

    Sheet 2

    Close

Requirements After Job Completion

Follow-On Conditions

NONE
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Manufacturer Code:0AM53
Tool Number:IAE 1P16004
Tool Name:IAE 1P16004 Handling bracket
Manufacturer Code:0AM53
Tool Number:IAE 1P16005
Tool Name:IAE 1P16005 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1P16104
Tool Name:IAE 1P16104 Cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16107
Tool Name:IAE 1P16107 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16108
Tool Name:IAE 1P16108 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16122
Tool Name:IAE 1P16122 Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18234
Tool Name:IAE 1R18234 Support rod
Manufacturer Code:0AM53
Tool Number:IAE 1R18247
Tool Name:IAE 1R18247 Rigging pin