TASK 72-32-00-430-010-D00 LPC/Intermediate Case Module - Install The LPC Booster Stage Assembly onto The LPC/Intermediate Case Module, Assembly-010

DMC:V2500-A0-72-32-0000-10C-710A-B|Issue No:001.00|Issue Date:2013-11-01

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 72-32-00-430-010-D00 LPC/Intermediate Case Module - Install The LPC Booster Stage Assembly onto The LPC/Intermediate Case Module, Assembly-010

General

This TASK gives the procedure to install the LP compressor booster stage assembly onto the LP compressor/intermediate case module on which the HP system module and the external gearbox module are installed.

Where TASK 72-32-00-030-006-D00 (DISASSEMBLY-006, CONFIG-004) is used for removal of the LP compressor booster stage assembly, it is recommended to use this TASK for installation of the LP compressor booster stage assembly onto the LP compressor/intermediate case module.

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

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.

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 1J12026 Turning handle0AM53IAE 1J120261
IAE 1J12105 Cantileer sling0AM53IAE 1J121051
IAE 1J12106 Aligning pin set0AM53IAE 1J121061
IAE 1J12108 Sling adapter0AM53IAE 1J121081
IAE 1J12505 0AM53 heater0AM53IAE 1J125051
IAE 6F10027 Heater control unit0AM53IAE 6F100271
IAE 1J12182 Retaining protector0AM53IAE 1J121821
IAE 1J12541 Holding support0AM53IAE 1J125411

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-124 ISOPROPYL ALCOHOLLOCALCoMat 01-124
CoMat 04-004 JOINTING COMPOUND, LIGHT GRADELOCALCoMat 04-004
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-00-430-361 Make sure that the Engine is in a Horizontal Position

    1. Make sure that the engine is in a horizontal position. If not, turn the engine from the vertical to the horizontal position. Refer to TASK 72-00-40-560-002 (INSTALLATION-002) or TASK 72-00-50-560-004 (INSTALLATION-013).

    2. SUBTASK 72-32-00-430-362 Adjust the Angular Position of the LPC Stub Shaft

    1. Refer to Figure, Figure, Figure, Figure and Figure.

    2. Put a workmat in position in the fan case.

    3. NOTE

      The retaining protector is installed in TASK 72-32-00-030-006-D00 (DISASSEMBLY-006, CONFIG-004).

      Remove the retaining protector (IAE 1J12182 Retaining protector) from the LPC stub shaft.

    4. Install the three aligning pins (part of the IAE 1J12106 Aligning pin set 1 off) into three of 24 nuts of the rotor center shaft through the holes B.

    5. Turn each aligning pin until the R mark line on the pin reaches the bottom of the curvic teeth.

      6. Adjust the angular position of the stub shaft.

      1. Install IAE 1J12026 Turning handle 1 off onto the stub shaft with the two wing bolts and washers (part of the turning handle).

      2. Turn the turning handle until the correlation mark * on the stub shaft becomes at 12 o'clock position.

      3. Remove the turning handle.

    3. SUBTASK 72-32-00-430-363 Prepare the Cantilever Sling and the Sling Adapter (Sling Assembly)

    1. Refer to Figure.

    2. Attach the first hoist to link (part of IAE 1J12108 Sling adapter 1 off) and lift up.

    3. Move the sling adapter onto the work bench and remove the first hoist from the sling adapter.

    4. Attach the second hoist to the shackle (part of IAE 1J12105 Cantileer sling 1 off).

    5. Lift and attach the cantilever sling to the sling adapter and safety them with the pin.

    6. Attach the first hoist to the lifting ring (part of the cantilever sling).

    7. Engage the pin to the outer holes of bracket (part of the cantilever sling).

    8. Make the rope/chains of the first hoist tighter.

    9. Move the second hoist from the shackle (part of the cantilever sling) to the link (part of sling adapter).

    10. Make the rope/chains of the second hoist tighter.

    4. SUBTASK 72-32-00-430-364 Install the LP Compressor Booster Stage Assembly (LPC Assembly) to the Engine

      1. NOTE

        Install the LPC assembly to LPC stage 2.5 stator assembly (Stage 2.5 Stator) before the front flange of the LPC assembly becomes cool and the jointing compound becomes dry.

        Increase the temperature of the LPC assembly, Figure.

      1. Install the IAE 1J12505 0AM53 heater 1 off to the LPC assembly.

      2. Connect the cables of the local heater to the IAE 6F10027 Heater control unit 1 off.

      3. Increase the temperature of the front flange of the LPC assembly to 248 deg F (120 deg C) with the local heater.

      4. Remove the local heater.

      2. Apply jointing compound to the mating faces of the stage 2.5 stator, Figure.

      1. Use a clean cloth made moist with CoMat 01-124 ISOPROPYL ALCOHOL to clean the mating faces.

      2. Apply CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the mating faces with a soft brush.

      3. WARNING

        DO NOT TOUCH THE LPC ASSEMBLY WITHOUT PROTECTIVE GLOVES.

        WARNING

        HOT PARTS CAN CAUSE REDDENING AND BLISTERING OF THE SKIN IF THE HANDS ARE NOT PROTECTED.

        WARNING

        IMMERSE THE CONTACTED AREA IN COLD WATER FOR 10 MINUTES IF THE SKIN IS BURNED. IMMEDIATELY GET MEDICAL ATTENTION IF PAIN OR BLISTERING PERSISTS.

        Install the sling assembly to the LPC assembly.

      1. Adjust the position of the LPC stage 1.5-2.5 disk to align the top position of the sling adapter with the correlation mark * on the LPC stage 1.5-2.5 disk, Figure.

      2. Lower the sling assembly and install the sling adapter to the front end of LPC assembly with the six bolts and washers (part of the sling adapter) at the holes C, Figure and Figure. Tighten the bolts.

        3. Remove the LPC assembly from the storage stand.

        1. Slowly lift the two hoists equally at the same time until the LPC assembly is clear of the storage stand, Figure.

      4. Adjust the center of the gravity of the sling assembly and the LPC assembly, Figure and Figure.

      1. Disengage the pin from the outer holes and engage to inner holes of bracket of the cantilever sling.

      2. Turn the adjustment handle to align the witness hole in the side plate with the S4-mark on the cantilever sling beam.

      3. Lock the adjustment handle in position.

      4. Adjust the two hoists to turn the LPC assembly to the horizontal position.

      5. Remove the second hoist from the link of the sling adapter.

      5. Install the LPC assembly to the engine.

        1. Attach the LPC assembly to the rotor center shaft, Figure.

        1. Align the correlation mark * on the disk of the LPC assembly with the correlation mark in the stub shaft, Figure and Figure.

        2. Slowly move the LPC assembly to the rotor center shaft along the aligning pins, Figure.

        3. Attach the LPC assembly to the rotor center shaft with the four of 24 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-605) at the holes E, Figure and Figure. Tighten the bolts lightly.

          4. Remove the sling assembly from the LPC assembly.

          1. Turn the adjustment handle to align the witness hole in the side plate with S3-mark on the beam (part of the cantilever sling), Figure.

          2. Remove the six bolts and washers (part of the sling adapter) which attach the sling adapter to the LPC assembly, Figure.

          3. Move the sling assembly forward until they are clear of the engine.

        5. Install the remaining 20 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-605) which attach the LPC assembly to the rotor center shaft, Figure. Tighten the bolts lightly.

        2. Attach the LPC assembly to the stage 2.5 stator, Figure, Figure and Figure.

        1. NOTE

          The holding supports are installed to the LPC assembly in TASK 72-32-00-030-006-D00 (DISASEMBLY-006, CONFIG-004) or TASK 72-32-80-440-001-B00 (ASSEMBLY, CONFIG-002).

          Remove the holding supports set (IAE 1J12541 Holding support) from the LPC assembly.

        2. Align the locating hole in the LPC asembly rear end with the locating pin on the stage 2.5 stator.

        3. Attach the LPC assembly to the stage 2.5 stator with the 62 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-615) and the 62 washers LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-618).

      3. When the LPC assembly becomes cool, loosen the 24 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-605). Then, torque the 24 bolts to 180 to 220 lbfin (20.00 to 25.00 Nm), Figure.

      4. Torque the 62 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 01-615) to 36 to 45 lbfin (4.00 to 5.00 Nm).

      5. Make sure that no gap between the LPC assembly and the rotor center shaft is found, Figure.

    5. SUBTASK 72-32-00-430-365 Install the Retaining Protector onto the Curvic Teeth of the Stub Shaft

    1. Refer to Figure and Figure.

    2. Remove the three aligning pins from the stub shaft.

    3. Align the three guide pin holes in IAE 1J12182 Retaining protector with the three guide pins of the stub shaft.

    4. Attach the retaining protector to the front face of the stub shaft flange with the three bolts (part of the retaining protector). Tighten the bolts.

    6. SUBTASK 72-32-00-430-366 Install the LPC Inlet Guide Vane Assembly to the LP Compressor Front Case

    1. Install the LPC inlet guide vane assembly. Refer to TASK 72-32-00-430-013-B00 (ASSEMBLY-013, CONFIG-002).

    7. SUBTASK 72-32-00-430-367 Install the Rear Fairing, the FEGV's, the Front Liner Panels and the Splitter Fairing on the Engine

    1. Refer to Figure.

    2. Install the rear fairing, the 20 FEGV's, the 10 front liner panels and the splitter fairing. Refer to TASK 72-32-00-430-014-B00 (ASSEMBLY-014, CONFIG-002).

    8. SUBTASK 72-32-00-430-368 Install the LP Compressor (Fan) Module

    1. Install the LP compressor (fan) module. Refer to TASK 72-00-31-420-001 (INSTALLATION).

    9. SUBTASK 72-32-00-430-369 Install the Inlet Cone and Inlet Cone Fairing

    1. Install the inlet cone fairing and inlet cone. Refer to TASK 72-38-11-420-001 (INSTALLATION).

    10. Figure: Sectional view of the LP compressor/intermediate case module

    Sectional view of the LP compressor/intermediate case module

    Figure: Remove the retaining protector from the LPC stub shaft

    Remove the retaining protector from the LPC stub shaft

    Figure: Install the aligning pins to the LPC stub shaft

    Sheet 1

    Legend
    Install the aligning pins to the LPC stub shaft

    Sheet 1

    Close

    Figure: Install the aligning pins to the LPC stub shaft

    Sheet 2

    Legend
    Install the aligning pins to the LPC stub shaft

    Sheet 2

    Close

    Figure: Install the LP compressor booster stage assembly onto the rotor center shaft and the LPC stage 2.5 stator assembly

    Install the LP compressor booster stage assembly onto the rotor center shaft and the LPC stage 2.5 stator assembly

    Figure: Install the turning handle onto the stub shaft

    Install the turning handle onto the stub shaft

    Figure: Assemble the cantilever sling and the sling adapter

    Assemble the cantilever sling and the sling adapter

    Figure: Increase the temperature of the LP compressor booster stage assembly

    Increase the temperature of the LP compressor booster stage assembly

    Figure: Apply jointing compound to the mating faces on the LPC stage 2.5 stator assembly

    Apply jointing compound to the mating faces on the LPC stage 2.5 stator assembly

    Figure: Install the sling assembly to the LP compressor booster stage assembly

    Sheet 1

    Legend
    Install the sling assembly to the LP compressor booster stage assembly

    Sheet 1

    Close

    Figure: Install the sling assembly to the LP compressor booster stage assembly

    Sheet 2

    Legend
    Install the sling assembly to the LP compressor booster stage assembly

    Sheet 2

    Close

    Figure: Turn the LP compressor booster stage assembly to horizontal position

    Turn the LP compressor booster stage assembly to horizontal position

    Figure: Install the sling assembly to the LP compressor booster stage assembly

    Install the sling assembly to the LP compressor booster stage assembly

    Figure: Remove the holding supports from the LP compressor booster stage assembly

    Remove the holding supports from the LP compressor booster stage assembly

    Figure: Gap between the LP compressor booster stage assembly and the rotor center shaft

    Gap between the LP compressor booster stage assembly and the rotor center shaft

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 01-124
Type:sp01
Supply Short Name:CoMat 01-124 ISOPROPYL ALCOHOL
Supply Name:CoMat 01-124 ISOPROPYL ALCOHOL
Specification Groups:
Doc NumberType
OMAT:1/40GPR TECHNICAL GRADE
PMC 9094GPR TECHNICAL GRADE
JCR-011GPR TECHNICAL GRADE
Suppliers:
ManufacturerRemarks
LOCAL
U1185
24853
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 04-004
Type:sp01
Supply Short Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Supply Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Specification Groups:
Doc NumberType
OMAT: 4/46 (REF RR)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
JCR-025 (JAEC REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
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 1J12026
Tool Name:IAE 1J12026 Turning handle
Manufacturer Code:0AM53
Tool Number:IAE 1J12105
Tool Name:IAE 1J12105 Cantileer sling
Manufacturer Code:0AM53
Tool Number:IAE 1J12106
Tool Name:IAE 1J12106 Aligning pin set
Manufacturer Code:0AM53
Tool Number:IAE 1J12108
Tool Name:IAE 1J12108 Sling adapter
Manufacturer Code:0AM53
Tool Number:IAE 1J12182
Tool Name:IAE 1J12182 Retaining protector
Manufacturer Code:0AM53
Tool Number:IAE 1J12505
Tool Name:IAE 1J12505 0AM53 heater
Manufacturer Code:0AM53
Tool Number:IAE 1J12541
Tool Name:IAE 1J12541 Holding support
Manufacturer Code:0AM53
Tool Number:IAE 6F10027
Tool Name:IAE 6F10027 Heater control unit