TASK 72-00-42-420-002-002 Combustion System - Install The Outer Combustion Chamber Assembly (Vertical) - Method 2, Installation-002

DMC:V2500-A0-72-00-4200-02A-720B-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 72-00-42-420-002-002 Combustion System - Install The Outer Combustion Chamber Assembly (Vertical) - Method 2, Installation-002

General

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 SPM TASK 70-41-00-400-501 and SPM TASK 70-41-02-400-501.

For lockwire data and procedures refer to SPM TASK 70-42-05-400-501.

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 SPM 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 1P16092 Igniter immersion gage0AM53IAE 1P160921
IAE 1P16102 Lift sling0AM53IAE 1P161021
IAE 1P16231 Alignment pin0AM53IAE 1P162312

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-141 LOCKWIRELOCALCoMat 02-141
CoMat 10-003 COLLOIDAL GRAPHITE DRY FILM LUBRICANTLOCALCoMat 10-003
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-42-420-064 Attach the Lift Sling

    1. Install the sling cables, equally apart, in the holes in the outer combustion chamber nearest the large end.

    2. SUBTASK 72-00-42-420-065 Install the Outer Combustion Chamber

    1. Refer to Figure.

    2. Install the two IAE 1P16231 Alignment pins, equally spaced, to the bosses on the outer diameter of the diffuser case and retract the inner portion of the pins.

    3. Lift the outer combustion chamber and install in to the engine. Align the swirlers with the fuel nozzles.

    4. Push the inner portion of the alignment pins to align the combustion chamber mount lugs with the diffuser case at two places.

    5. Install three doweled end bolts to attach the outer combustion chamber to the diffuser case and torque the bolts to 550 to 650 lbf.in (62.1 to 73.4 Nm). Safety with CoMat 02-141 LOCKWIRE.

    6. Remove one alignment pin at a time and install the remaining doweled end bolts. Torque the bolts to 550 to 650 lbf.in (62.142 to 73.440 Nm). Safety with CoMat 02-141 LOCKWIRE.

    7. Remove the sling from the combustion chamber.

    3. SUBTASK 72-00-42-420-066 Install the Igniter Plugs

    1. Refer to Figure.

      2. CAUTION

        DO NOT BEND THE ELECTRICAL CABLE CONDUITS TOO MUCH WHEN YOU CONNECT THE ELECTRICAL CONNECTOR. THE CONDUIT CAN BE DAMAGED AND CAN CAUSE ELECTRICAL CIRCUIT DEFECTS.

        CAUTION

        APPLY ANTI-SEIZE COMPOUND MODERATELY TO THE PLUG THREADS. IF TOO MUCH COMPOUND IS APPLIED IT COULD GO THROUGH IN TO THE ENGINE.

        NOTE

        If you replace only the igniter plug, you do not have to check the igniter plug immersion depth.

        Check the igniter plug immersion depth.

      1. Measure distance E from the top of the insert to point L on the outer combustion chamber nearest the fuel nozzle. Use the IAE 1P16092 Igniter immersion gage 1 off.

      2. Measure distance D from the surface of the igniter plug that touches the threaded insert to the inner end of the igniter plug.

      3. Subtract distance E from Distance D. The difference between distance E and distance D is the igniter immersion depth F which must be 0.040 to 0.080 in. (1.02 to 2.03 mm).

        4. If depth F is not 0.040 to 0.080 in. (1.02 to 2.03 mm), do the steps that follow:

        1. Remove the lockwire which safeties the igniter threaded insert.

        2. Remove the insert and the spacer(s). A maximum of two spacers can be used at each igniter location. The total thickness of the two spacers must not be more than 0.300 in. (7.62 mm).

        3. After you remove the insert, inspect the threads in the diffuser case and on the insert for damage and metal pick-up. Carefully remove loose or sheard metal on the threads.

        4. If the diffuser case threads have damage, repair the threads with a 1.0625-16UNJ-3B tap. If any threads are missing, rounded, sheared, grooved or pitted, remove the engine from service.

        5. If the threads on the insert have damage, replace the insert.

        6. Choose one or two spacers that are not more than the 0.300 in. (7.62 mm) limit to get the necessary igniter plug immersion.

        7. Apply CoMat 10-003 COLLOIDAL GRAPHITE DRY FILM LUBRICANT to the insert. Remove all excess compound.

        8. Install the spacer(s) and the insert.

        9. Torque the insert to 600 to 700 lbf.in (67.791 to 79.089 Nm).

        10. Safety the insert with CoMat 02-141 LOCKWIRE.

      3. Install the igniter plugs.

      1. Make sure that the thread of the igniter plugs are clean.

      3. NOTE

        When installing the igniter plugs make sure that the plugs go through the outer liner of the combustion chamber.

        Install the igniter plugs. Hold the inserts with a wrench while you tighten the igniter plugs so the insert will not turn.

      4. Torque the igniter plugs to 300 to 360 lbf.in (33.895 to 40.675 Nm).

    4. SUBTASK 72-00-42-420-067 Connect the High Tension Leads

    1. Connect the high tension leads to the igniter plugs.

    2. Torque the high tension leads to 275 lbf.in (31.071 Nm).

    5. SUBTASK 72-00-42-420-068 Install the Cooling Shrouds

    1. Install the cooling shrouds to the connection between the igniter plugs and the high tension leads.

    2. Install the clamps to the cooling shrouds.

    3. Torque the clamp screws to 40 to 45 lbf.in (4.519 to 5.084 Nm).

    6. SUBTASK 72-00-42-420-069 Install the Stage 1 Turbine Nozzle Assembly

    1. Install the stage 1 turbine nozzle assembly. Refer to TASK 72-00-44-420-001-001 (INSTALLATION-001) or TASK 72-00-44-420-001-002 (INSTALLATION-002).

      .

    7. Figure: Install the Outer Combustion Chamber

    Install the Outer Combustion Chamber

    Figure: Install the igniter plugs

    Install the igniter plugs

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:LOCAL
Supply Number:CoMat 02-141
Type:sp01
Supply Short Name:CoMat 02-141 LOCKWIRE
Supply Name:CoMat 02-141 LOCKWIRE
Specification Groups:
Doc NumberType
AS3214-02 (0.8 mm)AMS 5689
Suppliers:
ManufacturerRemarks
LOCAL
81343
IE508
58401
Manufacturer Code:70079
Supply Number:CoMat 10-003
Type:sp01
Supply Short Name:CoMat 10-003 COLLOIDAL GRAPHITE DRY FILM LUBRICANT
Supply Name:CoMat 10-003 COLLOIDAL GRAPHITE DRY FILM LUBRICANT
Specification Groups:
Doc NumberType
OMAT: 497 (RR REF)DAG 580
JCR-206 (JAEC REF)DAG 580
Suppliers:
ManufacturerRemarks
70079
H3221
K6835
LOCAL
50833
U5F65
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 1P16092
Tool Name:IAE 1P16092 Igniter immersion gage
Manufacturer Code:0AM53
Tool Number:IAE 1P16102
Tool Name:IAE 1P16102 Lift sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16231
Tool Name:IAE 1P16231 Alignment pin