TASK 72-40-00-430-002 HP System Module - Install The Diffuser Case Assembly, Assembly-002

DMC:V2500-A0-72-40-0000-02A-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 72-40-00-430-002 HP System Module - Install The Diffuser Case Assembly, Assembly-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 the SPM TASK 70-41-00-400-501 and SPM 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 the 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 1P16104 Cover0AM53IAE 1P161041
IAE 1P16108 cover0AM53IAE 1P161081
IAE 1P16122 Installation fixture0AM53IAE 1P161221
IAE 1P16107 cover0AM53IAE 1P16107
IAE 1P16004 Handling bracket0AM53IAE 1P16004
IAE 1P16005 Build stand0AM53IAE 1P16005

Consumables, Materials and Expendables

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

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-40-00-220-058 Make sure that the Fits and Clearances of the Combustion System are in the Limits given at Location 2242, (V2500-A1 Series) and (V2500-A5 Series)

    1. Refer to Figure and Figure.

    2. Calculate the interference at location 2242. Use the data made as a note in TASK 72-41-23-200-000 (INSPECTION-000) and TASK 72-42-11-200-000 (INSPECTION-000).

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

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 2242

      HP compressor case

      HPC Rear Outer Case And Related Parts (72-41-23, 02-400), bore

      Diffuser case assembly

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

      Location diameter

      Case bore

      25.2017

      25.1969

      Intf

      0.0023

      25.2017

      25.1969

      Intf

      0.0023

      Diffuser case assembly

      location diameter

      25.2090

      25.2040

      0.012

      Intf

      25.2090

      25.1990

      0.012

      Intf

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

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 2242

      HP compressor case

      HPC Rear Outer Case And Related Parts (72-41-23, 02-400), bore

      Diffuser case assembly

      (72-42-11, 01-010

      location diameter

      Case bore

      640,125

      640,000

      Intf

      0,057

      640,125

      640,000

      Intf

      0,057

      Diffuser case assembly

      location diameter

      640,308

      640,182

      0,308

      Intf

      640,310

      640,050

      0,308

      Intf

    2. SUBTASK 72-40-00-430-088-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 off set 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 lbfin (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 lbfin (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 72-40-00-430-088-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 off set 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 V2500-A5-72-41-50-01A-941A-D (72-41-50, 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 HPT Stage 1 Rotor Assembly (72-45-10, 01-102) through the seal assembly and OGV case, into the diffuser case. Install the bolts by hand. Torque the bolts to 85 to 105 lbfin (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 72-40-00-430-088-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 off set 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, in to the diffuser case. Install the bolts by hand. Torque the bolts to 85 to 105 lbfin (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 72-40-00-430-081 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 72-40-00-430-082 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 72-40-00-430-083 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 72-40-00-430-084-A00 V2500-A1 Series Engines : Install the Combustion System on to the HP Compressor

    1. Refer to 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. NOTE

      Refer to TASK 72-00-42-420-001 (INSTALLATION-001) for Pre SBE 73-0131 and SBE 73-0131 bracket installation.

      Install the 114 bolts (the heads to the rear), the nuts and the related brackets to the HP diffuser case front flange. Torque the nuts to 180 to 220 lbfin (20.34 to 24.86 Nm). Refer to Figure, Figure, Figure and Figure.

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

    9. SUBTASK 72-40-00-430-084-B00 V2500-A5 Series Engines : Install the Combustion System on to the HP Compressor,. (SBE 72-0191)

    1. Refer to 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. NOTE

        Refer to TASK 72-00-42-420-001 (INSTALLATION-001) for Pre SBE 73-0131 and SBE 73-0131 bracket installation.

        Install the brackets to the HP diffuser case front flange, refer to Figure, Figure, Figure and Figure.

      1. Install the bracket HPC Module - Attaching Parts (72-40-00, 01-770) to the front side of the flange at the holes 105 and 106 and bracket HPC Module - Attaching Parts (72-40-00, 01-760) to the rear side of the flange at the holes 104 and 105 with the two bolts and two nuts HPC Module - Attaching Parts (72-40-00, 01-052 and HPC Module - Attaching Parts 01-030).

      2. Pre SBE 72-0191 : Install the bracket HPC Module - Attaching Parts (72-40-00, 01-880) to the front side of the flange at the holes 101, 102 and 103 with the three bolts and three nuts HPC Module - Attaching Parts (72-40-00, 01-054 and HPC Module - Attaching Parts01-030).

      3. SBE 72-0191 : Install the bracket HPC Module - Attaching Parts (72-40-00, 01-880) to the rear side of the flange at the holes 100, 101 and 102 with the three bolts and three nuts HPC Module - Attaching Parts (72-40-00, 01-050 and HPC Module - Attaching Parts 01-030).

      4. Install the remaining flange brackets with the 109 bolts and nuts HPC Module - Attaching Parts (72-40-00, 01-050 and HPC Module - Attaching Parts 01-030).

      5. Torque the nuts to 180 to 220 lbfin (20.34 to 24.86 Nm).

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

    10. SUBTASK 72-40-00-430-085 Install the 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: V2500-A1: Combustion system installation Fits and Clearances

    Sheet 1

    Legend
    V2500-A1: Combustion system installation Fits and Clearances

    Sheet 1

    Close

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

    Sheet 2

    Legend
    V2500-A5: Combustion system installation Fits and Clearances

    Sheet 2

    Close

    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: V2500-A1: Install the heatshield and the static seal

    Sheet 1

    Legend
    V2500-A1: Install the heatshield and the static seal

    Sheet 1

    Close

    Figure: V2500-A5: Install the static seal

    Sheet 2

    Legend
    V2500-A5: Install the static seal

    Sheet 2

    Close

    Figure: V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 1

    Legend
    V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 1

    Close

    Figure: V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 2

    Legend
    V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 2

    Close

    Figure: V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 3

    Legend
    V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 3

    Close

    Figure: V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 4

    Legend
    V2500-A1: Install the brackets to the HP diffuser case front flange

    Sheet 4

    Close

    Figure: V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 1

    Legend
    V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 1

    Close

    Figure: V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 2

    Legend
    V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 2

    Close

    Figure: V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 3

    Legend
    V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 3

    Close

    Figure: V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 4

    Legend
    V2500-A5: Install the brackets to the HP diffuser case front flange

    Sheet 4

    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