TASK 72-00-44-420-001-001 Stage 1 Turbine Nozzle Assembly - Install The Stage 1 Turbine Nozzle Assembly (Horizontal) - Method 1, Installation-001

DMC:V2500-A0-72-00-4400-00A-720A-B|Issue No:002.00|Issue Date:2017-05-01

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 72-00-44-420-001-001 Stage 1 Turbine Nozzle Assembly - Install The Stage 1 Turbine Nozzle Assembly (Horizontal) - Method 1, Installation-001

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 70-44-01-400-501.

Special torque data and assembly tolerances are included in the 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 1P16077 Fixture0AM53IAE 1P160771
IAE 1P16087 Air flow adapter0AM53IAE 1P160871
IAE 1P16109 cover0AM53IAE 1P161091
IAE 1P16111 cover0AM53IAE 1P161111
IAE 1P16122 Installation fixture0AM53IAE 1P161221
IAE 6P16353 Air flow cart0AM53IAE 6P163531
IAE 1P16112 cover0AM53IAE 1P161121

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-141 LOCKWIRELOCALCoMat 02-141
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077
CoMat 10-041 PETROLATUM, WHITELOCALCoMat 10-041

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-44-220-051 Reference Fits and Clearances of the Diffuser Case Assembly and the Stage 1 HPT Support Assembly at Location 2252.

    1. Refer to Figure.

    2. Reference interference at location 2252. If required, use the data written as a note in TASK 72-42-11-200-001-A00 (INSPECTION-001), TASK 72-42-11-200-001-B00 (INSPECTION-001), TASK 72-44-10-200-001-A00 (INSPECTION-001), TASK 72-44-10-200-001-B00 (INSPECTION-001) and TASK 72-44-10-200-001-C00 (INSPECTION-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 2252

      Diffuser Case Assembly Diffuser Case (72-42-11, 01-010), Bore

      Stage 1 HPT Support Assembly HPT Stage 1 Support Assembly And Support Seal (72-44-10, 01-010), Front Outside Location Diameter

      Diffuser Case Bore

      28.233

      28.227

      Intf

      0.002

      28.233

      28.222

      Intf

      0.002

      Support Diameter

      28.241

      28.235

      0.014

      Intf

      28.241

      28.230

      0.014

      Intf

      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 2252

      Diffuser Case Assembly Diffuser Case (72-42-11, 1-010), Bore

      Stage 1 HPT Support Assembly HPT Stage 1 Support Assembly And Support Seal (72-44-10, 01-010), Front Outside Location Diameter

      Diffuser Case Bore

      717.118

      716.966

      Intf

      0.050

      717.12

      716.84

      Intf

      0.050

      Support Diameter

      717.321

      717.169

      0.360

      Intf

      717.321

      717.040

      0.360

      Intf

    2. SUBTASK 72-00-44-220-052 Reference Fits and Clearances of the No. 4 Bearing Support and the Stage 1 HPT Cooling Duct Assembly at Location 2263.

    1. Refer to Figure.

    2. Reference interference at location 2263. If required, use the data written as a note in TASK 72-42-31-200-001 (INSPECTION-001) and TASK 72-44-50-200-001-A00 (INSPECTION-001).

      Table 3. 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 2263

      No. 4 Bearing Support ENGINE-NO.4 BEARING SUPPORT ASSEMBLY (72-42-31, 01-010), Bore

      Stage 1 HPT Cooling Duct Assembly HPT Stage 1 Cooling (TOBI) Duct And Duct Deflector (72-44-50, 01-010), Front Outside Location Diameter

      Support Bore

      13.033

      13.027

      Intf

      0.000

      Duct Diameter

      13.039

      13.033

      0.012

      Intf

      Table 4. 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 2263

      No. 4 Bearing Support ENGINE-NO.4 BEARING SUPPORT ASSEMBLY (72-42-31, 01-010), Bore

      Stage 1 HPT Cooling Duct Assembly HPT Stage 1 Cooling (TOBI) Duct And Duct Deflector (72-44-50, 01-010), Front Outside Location Diameter

      Support Bore

      331.038

      330.886

      Intf

      0.000

      Duct Diameter

      331.191

      331.038

      0.300

      Intf

    3. SUBTASK 72-00-44-220-053 Reference Fits and Clearances of the Outer Combustion Chamber Assembly and the Inner Combustion Chamber Assembly at Location 2265.

    1. Refer to Figure.

    2. Reference clearance/interference at location 2265. If required, use the data written as a note in TASK 72-42-61-200-001-A00 (INSPECTION-001) and TASK 72-44-30-200-001-A00 (INSPECTION-001).

      Table 5. 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 2265

      Combustion Chamber Assembly Outer Combustion Chamber Assembly (72-42-61, 01-020), Hood Bore

      Inner Combustion Chamber Assembly Inner Combustion Chamber Assembly (72-44-30, 01-020), Location Diameter

      Hood Bore

      16.628

      16.640

      Intf

      0.003

      16.624

      16.640

      Intf

      0.007

      Chamber Diameter

      16.619

      16.631

      0.021

      Clear

      16.616

      16.631

      0.024

      Clear

      Table 6. 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 2265

      Combustion Chamber Assembly Outer Combustion Chamber Assembly (72-42-61, 01-020), Hood Bore

      Inner Combustion Chamber Assembly Inner Combustion Chamber Assembly (72-44-30, 01-020), Location Diameter

      Hood Bore

      422.351

      422.656

      Intf

      0.076

      422.250

      422.656

      Intf

      0.178

      Chamber Diameter

      422.123

      422.427

      0.533

      Clear

      422.046

      422.427

      0.610

      Clear

    4. SUBTASK 72-00-44-420-051 Install the No. 4 Bearing and Rear Compartment Parts

    1. Refer to TASK 72-00-43-420-001 (INSTALLATION-001).

    5. SUBTASK 72-00-44-420-052 Install the Fixture on to the Stage 1 HPT Support Assembly

    1. Refer to Figure and Figure.

    2. Remove the cover from the Stage 1 HPT Support Assembly. Refer to Figure.

    3. Attach a standard three cable sling to the three eyebolts on the IAE 1P16077 Fixture 1 off. Refer to Figure.

    4. Connect the sling to a hoist.

    5. Loosen the bolts in the ring segments and move the ring segments to the outer position.

    6. Lift the fixture above the Stage 1 HPT Support Assembly with the hoist and the sling.

      7. Attach the fixture to the Stage 1 HPT Support Assembly HPT Stage 1 Support Assembly And Support Seal (72-44-10, 01-010).

      1. Put the top plate at the 12 o'clock position, 180 degrees from the dowel pin hole in the outer flange of the support assembly.

      2. Install the dowel pins on the fixture through two holes in the Stage 1 HPT Support Assembly.

      3. Move the ring segments to the center and below the flange of the Cooling Duct Assembly HPT Stage 1 Cooling (TOBI) Duct And Duct Deflector (72-44-50, 01-010).

      4. Look through the slots in the fixture to see if the ring segments are in the correct position.

      5. Tighten the three nuts at each location until the ring segments are tight.

    8. Lift the assembly from the pallet.

    9. Attach a hoist to the eye on the top plate.

    10. Lift and turn the assembly to the horizontal position with the two hoists.

    11. Remove the hoist that is attached to the three cable sling and remove the sling.

    6. SUBTASK 72-00-44-420-053 Find the Correct Dimension for the Combustion Chamber Clamp Spacers and Install the Spacers

    1. Refer to Figure, Figure and Figure.

    2. Position the Stage 1 Turbine Nozzle Assembly and get access to the Stage 1 HPT Seal ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-010).

      3. NOTE

        Correct spacer selection is important to make sure you get maximum post assembly engine performance and durability. Incorrect spacer selection will effect performance (EGT margin) and high pressure turbine durability.

        Find the correct dimension for the Combustion Chamber Clamp Spacer ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-061) thru ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-078), Figure.

      1. Examine the forward surface of clamp assembly flanges for Diameter L (marked as L followed by diameter). Write diameter on paperwork and continue with Step. If Diameter L mark can not be found or can not be used do Step thru Step to find Diameter L.

      2. Install a 0.250-28 tool bolt and a non-locking tool nut on the Stage 1 HPT Seal Assembly ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-010) without the spacer.

      3. Tighten the nut sufficiently to bring the seal assembly flanges together.

      4. Measure Diameter L (the inside diameter of the seal assembly) with PI tape.

      5. Measure Diameter M (the outside diameter of the Outer Combustion Chamber) with PI tape.

      6. Remove the tool bolt and the nut.

      7. NOTE

        Dimension G can not be more than 0.304 in. (7.722 mm).

        Calculate Dimension G as follows:

        G = PI (3.1416) x (Diameter M - Diameter L) + 0.009 in. (0.229 mm).

      8. Get the correct class or classes of spacer(s) that is nearest to Dimension G, Figure.

    4. Install the spacer(s) between the Stage 1 HPT Seal Assembly Flanges, Figure.

    5. Install the bolt ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-040) through the holes in the flanges of the Stage 1 HPT Seal Assembly and in the spacer(s).

    6. Install the nut ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-080) on the bolt.

    7. Torque the nut to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    8. Torque the bolts which attach the seal assembly to the vane cluster assemblies to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    7. SUBTASK 72-00-44-420-054 Install the Stage 1 Turbine Nozzle Assembly on the Combustion System.

    1. Refer to Figure, Figure and Figure.

    2. Lubricate the slip joints of the Inner Combustion Chamber and the Outer Combustion Chamber with CoMat 10-041 PETROLATUM, WHITE or CoMat 10-077 APPROVED ENGINE OILS, Figure.

    3. Raise the assembly behind the engine, Figure.

      4. Move the assembly forward and on to the combustion system.

      1. Engage the dowel pin in the Cooling Duct Assembly with the dowel pin hole in the Diffuser Case Assembly.

        2. Work by hand and start to engage the assemblies.

        1. CAUTION

          DO NOT INSTALL BOLTS ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-020) OR PULL STAGE 1 HPT SUPPORT ASSEMBLY AND DIFFUSER CASE ASSEMBLY TOGETHER UNLESS CLEARANCES ARE EQUAL AND PARTS ARE ALIGNED, OR DAMAGE TO THE COMBUSTION CHAMBERS MAY RESULT.

          Keep an equal clearance all around between the Stage 1 HPT Support Assembly and the Diffuser Case Assembly.

    5. Install 2 bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-020) to the Cooling Duct at each of the three cut outs in the fixture to hold the assembly in place when the fixture is removed.

    6. Loosen the ring segments bolts on the fixture.

    7. Move the three ring segments out and remove the fixture from the support assembly.

    8. Install the IAE 1P16111 cover 1 off over the Cooling Duct Assembly, Figure.

    9. Install the IAE 1P16112 cover 1 off over the trailing edges of the Turbine Vane Assemblies.

    10. Install all the bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-020) that attach the Cooling Duct Assembly to the Diffuser Case Assembly at the inner flange, Figure.

    11. Tighten the bolts hand tight.

      12. Measure Dimension B, the clearance between the Stage 1 HPT Support Assembly and the Diffuser Case Assembly, Figure.

      1. When the clearance is 0.400 in. (10.160 mm) the slip joints align and engage, but not fully.

      2. When the clearance is 0.200 in. (5.080 mm) the tight fits at the Diffuser Case Assembly and the Cooling Duct Assembly begin to engage.

      13. Do a visual check of Dimension A, Figure. the clearance at the front of the Inner Combustion Chamber Liner Assembly.

      1. Remove the cover from the vane assemblies.

      2. Use a light with a diameter limit.

      3. Look through the vane assemblies.

      4. The slip joints align when the clearance is equal all around the assembly.

      5. Install the cover to the vane assemblies.

      14. When the parts align pull the assemblies together.

      1. Install the work bolts through the holes in the Stage 1 HPT Support Assembly and the Diffuser Case Assembly.

      2. Install the nuts on the bolts.

      3. Tighten the bolts at the Cooling Duct Assembly and the nuts at the Diffuser Case outer flange in diametrically opposed pairs.

      4. Apply an equal force all around the flanges and pull the parts together.

    15. Torque the bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM (72-40-00, 02-020) to 225 lbfin to 300 lbfin (25.442 Nm to 33.985 Nm). Refer to Figure for torque sequence.

    8. SUBTASK 72-00-44-720-051 Do a Check of the No. 4 Bearing Compartment Cooled Air System

    1. Refer to Figure.

    2. Install the three hoses of the IAE 1P16087 Air flow adapter 1 off to the three No. 4 Bearing Cooling Air Supply Tube Nuts on the Diffuser Case.

    3. Connect the IAE 6P16353 Air flow cart 1 off to the air flow adapter.

      4. Flow air at 10 psig (68.9 kPa) to the system. The air flow through the system must be as follows:

      1. 160 lb to 200 lb (72.57 kg to 90.72 kg) for each hour for all V2500-A1 engines and V2500-A5 engines that do not have SB V2500-ENG-72-0239.

      2. 185 lb to 230 lb (83.91 kg to 104.33 kg) for V2500-A5 engines with SB V2500-ENG-72-0239.

    5. Decrease the pressure to 0 psig (0 kPa) and disconnect the airflow adapter from the air flow cart.

    6. Remove the air flow adapter hoses from the three air supply tube nuts on the Diffuser Case.

    7. If the test is in limits, continue the engine build.

    8. If the test is not in limits remove the nozzle assembly, refer to TASK 72-00-44-020-001-001 (REMOVAL-001) or TASK 72-40-00-030-002 (DISASSEMBLY-002) and remove the No. 4 Bearing compartment parts, refer to TASK 72-40-00-030-004 (DISASSEMBLY-004).

    9. SUBTASK 72-00-44-420-055 Safety the Bolts, Remove the Workbolts and Nuts and Remove and Install the Covers

    1. Safety the Cooling Duct Assembly bolts with CoMat 02-141 LOCKWIRE.

    2. Remove the nuts, the work bolts and the covers.

    3. Install the IAE 1P16109 cover 1 off on the Stage 1 HPT Support Assembly.

    10. Figure: The IAE 1P16109 Cover Installation

    The IAE 1P16109 Cover Installation

    Figure: Installation of the Stage 1 Turbine Nozzle Assembly on the IAE 1P16077 Fixture

    Installation of the Stage 1 Turbine Nozzle Assembly on the IAE 1P16077 Fixture

    Figure: Measure the Spacer Clearance

    Measure the Spacer Clearance

    Figure: Combustion Chamber Clamp Spacer Installation

    Combustion Chamber Clamp Spacer Installation

    Figure: Install the Stage 1 Turbine Nozzle Assembly

    Install the Stage 1 Turbine Nozzle Assembly

    Figure: The IAE 1P16111 and IAE 1P16112 Covers Installation

    The IAE 1P16111 and IAE 1P16112 Covers Installation

    Figure: Assembly Clearances and Torque Sequence

    Assembly Clearances and Torque Sequence

    Figure: Stage 1 Turbine Nozzle Assembly - Fits and Clearances

    Stage 1 Turbine Nozzle Assembly - Fits and Clearances

    Figure: Combustion Chamber Clamp Spacer Classes

    Combustion Chamber Clamp Spacer Classes

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Updated procedure, fits and clearances tables to standard format. (Editorial)

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:LOCAL
Supply Number:CoMat 10-041
Type:sp01
Supply Short Name:CoMat 10-041 PETROLATUM, WHITE
Supply Name:CoMat 10-041 PETROLATUM, WHITE
Specification Groups:
Doc NumberType
VASELINE PETROLEUM JELLY
Suppliers:
ManufacturerRemarks
LOCAL
H5C97
KCKB8
V561V
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 1P16077
Tool Name:IAE 1P16077 Fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16087
Tool Name:IAE 1P16087 Air flow adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16109
Tool Name:IAE 1P16109 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16111
Tool Name:IAE 1P16111 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16112
Tool Name:IAE 1P16112 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16122
Tool Name:IAE 1P16122 Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 6P16353
Tool Name:IAE 6P16353 Air flow cart