TASK 72-41-00-040-002-B00 HPC Assembly - Remove The HPC Front Cases For Access To Stage 3 Through 6 (HPC Surgical Strike Procedure), Special Procedure-002

DMC:V2500-A0-72-41-0001-02B-530A-B|Issue No:003.00|Issue Date:2019-11-01

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 72-41-00-040-002-B00 HPC Assembly - Remove The HPC Front Cases For Access To Stage 3 Through 6 (HPC Surgical Strike Procedure), Special Procedure-002

General

This TASK gives the procedure to remove the HP compressor front cases to gain access to stages 3 to 6 rotor blades (HPC Surgical strike). This procedure uses a method that does not require separation of the HP compressor module from the combustor and HP turbine modules.

If the front half casings cannot be removed using the procedure in Step then strip the module using the procedures in TASK 72-41-00-040-001-B00 and inform IAE Technical Services.

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.

Apply the approved CoMat 10-058 PENETRATING OIL before the removal of threaded parts and parts with an interference fit. Let the parts soak before removal.

Discard all rubber seal rings, cotter pins and keywashers removed in this procedure.

Remove and discard the CoMat 02-126 LOCKWIRE before any part is disconnected or removed.

As each item is removed it must be identified with its position on the mini-module.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

NOTE

  1. Refer to TASK 72-41-00-040-000 (DISASSEMBLY-000) for the related Surgical Strike TASKS and engine series.

  2. Refer to TASK 72-41-00-440-000 (ASSEMBLY-000) for the related Surgical Strike TASKS and engine series.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Dial indicatorLOCALDial indicator6
Dial Test Indicator Stands, Blocks And Associated Equipment0AM53Dial Test Indicator Stands, Blocks And Associated Equipment
Feeler gageLOCALFeeler gage
IAE 1F10028 Support Pedestal0AM53IAE 1F10028
IAE 1F10052 Two cables sling0AM53IAE 1F100522
IAE 1P16002 Cradle pedestal0AM53IAE 1P160021
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P160461
IAE 1P16088 Leak check adapter0AM53IAE 1P160881
IAE 1P16089 Leak check cap0AM53IAE 1P160891
IAE 1P16285 Tie-rod adapter0AM53IAE 1P162851
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P165431
IAE 1R18234 Support rod0AM53IAE 1R182343
IAE 1R18250 Split ring assembly0AM53IAE 1R182501
IAE 1R18325 Trunnion assembly0AM53IAE 1R183252
IAE 1R18673 Dummy stub shaft0AM53IAE 1R186731
IAE 1R19463 Stand - Surgical strike0AM53IAE 1R194631
IAE 1R19633 Split ring assembly0AM53IAE 1R196331
IAE 6F10030 Vacuum test cart0AM53IAE 6F100301
IAE 1F10052 Two cables sling0AM53IAE 1F10052
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P16046
IAE 1P16088 Leak check adapter0AM53IAE 1P16088
IAE 1P16089 Leak check cap0AM53IAE 1P16089
IAE 1P16285 Tie-rod adapter0AM53IAE 1P16285
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P16543
IAE 1R18250 Split ring assembly0AM53IAE 1R18250
IAE 1R18673 Dummy stub shaft0AM53IAE 1R18673
IAE 1R19463 Stand - Surgical strike0AM53IAE 1R19463
IAE 6F10030 Vacuum test cart0AM53IAE 6F10030

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-002 SOLVENT, DELETED.LOCALCoMat 01-002
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005
CoMat 10-058 PENETRATING OILX222XCoMat 10-058
CoMat 02-126 LOCKWIREK6835CoMat 02-126

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-00-720-001 Do a Check of the No. 4 Front and Rear Bearing Compartment for Leaks

    1. Refer to Figure.

    2. Do a check on the No. 4 bearing chamber, if not disassembled.

    3. Install the IAE 1P16089 Leak check cap 1 off in the coupling nut of the pressure tube.

    4. Install the IAE 1P16088 Leak check adapter 1 off in the scavenge tube.

    5. Connect the IAE 6F10030 Vacuum test cart 1 off to the adapter.

    6. Adjust the vacuum on the cart to 20 in. HG and evacuate the bearing compartment. Based on the ambient pressure, refer to the table below for the vacuum pressure in psia.

      Ambient Pressure of the Day (psia)

      Vacuum Pressure (psia)

      14.7

      4.9

      14.5

      4.7

      14.3

      4.5

      14.1

      4.3

      13.9

      4.1

      13.7

      3.9

      13.5

      3.7

      13.3

      3.5

      13.1

      3.3

      Vacuum pressure (psia) = Ambient pressure of the day (psia) - 9.8 psia

    7. Check the air flow on the No. 4 front and rear bearing compartment. The air flow must be no more than 17 pph (7.71 Kgph). Make a record of the reading. Keep the reading as it will be needed during the Vacuum check in TASK 72-41-00-440-002-D00.

    8. Decrease the vacuum to 0in. Hg and disconnect the cart from the fixture.

    9. Remove the leak check cap from the pressure tube.

    10. Remove the leak check adapter from the scavenge tube.

    2. SUBTASK 72-41-00-020-001 Remove Modules for Access

      1. Remove the HP stack and stow vertically in the build stand as follows :

      1. Remove the components, the external harnesses and the tubes from the LP turbine module. Refer to TASK 72-00-50-020-001.

      2. Remove the LP turbine module. Refer to TASK 72-00-50-020-002.

      3. Turn the LP turbine module from horizontal to vertical. Refer to TASK 72-00-50-560-001.

      4. Remove the components, the external harnesses and the tubes from the HP system module sufficient to remove the HP compressor front cases. Refer to TASK 72-00-40-020-001-B00, TASK 72-00-40-020-002-B00, TASK 72-00-40-020-003-B00, TASK 72-00-40-020-004 and associated TASKS.

      5. Remove the HP system module (horizontal). Refer to TASK 72-00-40-020-006-B00.

    3. SUBTASK 72-41-00-560-001 Install the IAE 1P16046 or IAE 1P16543 Remove/Install Fixture and Tie-Rod Adapter on to the HP System Module Rear Flange

    1. Refer to Figure.

      1. Put the puck and shaft through the center ring until the tie-rod adapter touches the rear face of the center ring.

      2. Align the two holes on the tie-rod adapter with two opposite holes in the center ring. Install the two tool screws. Tighten the screws.

      3. Attach the remove/install fixture and tie-rod adapter to the HP system module.

      1. Move the locknut until it is adjacent to the wrench location.

      2. Push the tie-rod adapter in to the engine until the puck engages on the HP compressor front shoulder. At the same time push the center ring over the HP compressor shaft until it touches the stage 2 HP turbine disk.

        NOTE

        If necessary use a wrench on the wrench location so that the shaft does not turn.

      3. Turn the locknut until the puck is against the HP compressor front shoulder. Tighten the locknut.

      4. Attach a hoist to the remove/install fixture lift eye.

      5. Lift the remove/install fixture and move it adjacent to the rear of the HP system module. Make sure the hand knobs are rearwards.

      6. Move the remove/install fixture along the center ring until it touches the HP turbine case rear flange.

      7. Put the upper split ring on to the front of the HP turbine case rear flange. Install 12 of the tool bolts and 12 of the tool nuts.

      8. Put the lower split ring on to the front of the HP turbine case rear flange. Install 13 of the tool bolts and 13 of the tool nuts.

      9. Tighten the 25 tool nuts.

      10. Remove the hoist from the lift eye.

    4. SUBTASK 72-41-00-560-002 Install the Dummy Stub Shaft on to the Stage 3 Disk Curvic Coupling

    1. Refer to Figure.

    2. Remove the curvic protector from the stage 3 disk curvic coupling, if applicable.

      3. Remove the curvic protector from IAE 1R18673 Dummy stub shaft 1 off.

        NOTE

        The bolts remain with the dummy stub shaft.

      1. Release the bolts and the nuts from the curvic protector.

      2. Remove the curvic protector.

      4. Clean the curvic teeth of the dummy stub shaft and the stage 3 disk.

      1. WARNING

        WHEN YOU USE COMAT 01-002 INHIBITED AND STABILIZED TRICHLOROETHANE YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.

        Use a soft brush and apply CoMat 01-002 SOLVENT, DELETED. to the curvic teeth.

      2. Dry the curvic teeth with a clean dry air blast.

      5. Install the dummy stub shaft on to the stage 3 disk curvic coupling.

      1. Align the four location pins on the dummy stub shaft with the applicable location holes on the curvic coupling.

      2. Safety the dummy stub shaft with the 20 curvic coupling tool bolts.

    5. SUBTASK 72-41-00-560-003 Prepare for the Lift and Turn of the HP System Module

    1. Refer to Figure.

    2. Attach a hoist to the lift eye on each IAE 1F10052 Two cables sling 2 off.

    3. Make sure the lift brackets are in the inner position on the sling beam.

    4. Lift one of the lift slings and put it above the remove/install fixture.

    5. Adjust the height of the lift sling to permit the hook and bolt plates to be installed on to the remove/install fixture trunnions.

    6. Install the hook and bolt plates on to the remove/install fixture trunnions. Safety the hook and bolt plate with the safety clip.

    7. Lift the other lift sling and put above the front of the HP system module.

    8. Adjust the height of the lift sling to permit the hook and bolt plates to be installed on to the HP compressor trunnion assembly.

    9. Install the hook and bolt plates on to the trunnions. Safety the hook and bolt plate with the safety clip.

    6. SUBTASK 72-41-00-560-004 Lift and Turn the HP System Module and Prepare the Module for Installation into IAE 1R19463 Stand (Surgical Strike Stand) (Pre SBE 72-0410 and SBE 72-0410)

    1. SBE 72-0410: HP compressor variable inner shrouds - Introduction of revised one piece bushes

    2. Refer to Figure, Figure, Figure and Figure.

    3. Adjust the two lift slings to hold the weight of the HP system module.

      4. Remove the support posts and cradle pedestal.

      1. Remove the retaining pins from the forward support posts and lower the support brackets to their lowest position.

      2. Turn the adjustment handle on the rear cradle pedestal to lower the support bracket to its lowest position.

      3. Move the support posts and cradle pedestal away from the engine.

        NOTE

        The HP system module must not hit the ground.

    5. Use the rear lift sling to move the HP system module in to the vertical position.

    6. Remove the hook and bolt plate from the forward HP system module trunnions.

    7. Put the forward lift sling on to an applicable work surface.

    8. Remove the hoist from the forward lift sling.

    9. Remove the Variable Inlet Guide Vane Front Shroud, Figure.

    10. Remove the 20 nuts, the 40 dee-headed washers and the 20 bolts that attach the variable inlet guide vane front shroud to the variable inlet guide vanes.

      NOTE

      Keep the variable inlet guide vane front shroud with the HP compressor front cases.

    11. Remove the variable inlet guide vane front shroud.

      12. Pre SBE 72-0410: Install IAE 1R18250 Split ring assembly 1 off. Refer to Figure.

      1. Install one half of the split ring assembly on the front of the variable inlet guide vanes. Make sure that the split line is aligned with the split line in the variable inlet guide vane rear shroud.

      2. Install the three tool bolts and the three tool nuts.

      3. Tighten the nuts to safety the split ring assembly.

      4. Do steps C.(1) thru C.(3) again for the other half of the split ring assembly.

    7. SUBTASK 72-41-00-040-170 Install the Module into the Surgical Strike Build Stand IAE 1R19463

    1. Refer to Figure, Figure and Figure.

      2. Install the HP compressor assembly on IAE 1R19463 Stand - Surgical strike 1 off.

      1. Remove the 6 bolts, nuts and washers at positions 1,8,9,17,18 and 25 from the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture and the HP turbine case.

        NOTE

        The two capscrews (detail 25) are used for storage purposes only.

      2. Remove the two capscrews (detail 25).

      3. Install the three support plates (detail 4) to the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture and module rear flange with the 6 bolts (detail 17). Tighten the 6 bolts (detail 17).

      4. Make sure that the remove/install fixture lifting eyes (part of IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture), refer to Figure are stowed securely so as not to interfere with the surgical strike tooling when the HP module is lowered into the stand.

        5. CAUTION

          YOU MUST KEEP THE WEIGHT OF THE MODULE ON THE HOIST UNTIL THE SLIDE IN-RIGGERS ARE POSITIONED AND SECURED. THIS IS TO PREVENT DAMAGE TO MODULE COMPONENTS.

          Lower and position the module into the stand and make sure the front half casing split line is in the correct orientation, 90 degrees to the TDC marked on the in-rigger (detail 6), refer to Figure.

        1. Keep the weight on the hoist and locate and fully engage the dummy stub shaft in the location pot. Use a feeler gauge at four positions spaced equally and make sure no gap exists between the front face of the dummy stub shaft and location pot of the build stand.

        2. Take the weight off the hoist and make sure that the full weight of the module is supported by the stand. Keep the module in the vertical position with the hoist.

        3. Loosen the 12 nuts (detail 24) slightly and slide the in-riggers (detail 6,7 and 8) into position then install the three jacking screws (detail 12) through the three support plates (detail 4). Tighten the 12 nuts (detail 24) to secure the three in-riggers (detail 6, 7 and 8).

          NOTE

          The retaining plate assembly is made secure after the module axial movement (in relation to the stand) is set in Step.

        4. Assemble and install the three retaining clamp plates (detail 5), the heel pin (detail 15), the three studs (detail 14), the three plain washers, pins and hand knobs (details 16, 27 and 22). Move the three retaining clamp plates outwards so the three jacking screws (detail 12) can be adjusted.

        5. Adjust the three jacking screws (detail 12) to set the axial position of the module vertically. Make sure that the clearance is equal at each of the three positions between the in-riggers and the support plates.

    3. Remove the lifting sling.

    8. SUBTASK 72-41-00-560-005 Remove the Lift Equipment from the HP System Module

    1. Refer to Figure, Figure and Figure.

      2. Remove the support rods.

      1. Turn the adjustment handle to retract the blade.

      2. Release the six support rod tool bolts.

      3. Remove the support rod.

        4. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31,01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31,01-118) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31,01-122) in to the HP compressor at location C.

        1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on to the bracket where it touches the blank.

        2. Install the blank, the bracket and the bolts.

        3. Torque the bolts to 85 to 105 lbfin (10 to 12 Nm).

        5. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31,01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31,01-115) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31,01-122) in the HP compressor at location A.

        1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on the bracket where it touches the blank.

        2. Install the blank, the bracket and the bolts.

        3. Torque the bolts to 85 to 105 lbfin (10 to 12 Nm).

      6. Install the other blank HP COMPRESSOR SPLIT CASE (72-41-31,01-120) and the other bolts HP COMPRESSOR SPLIT CASE (72-41-31,01-122) in to the HP compressor at location B. Torque the bolts to 85 to 105 lbfin (10 to 12 Nm).

      7. Remove the rigging pin from the bracket in the stage 3 unison ring.

      3. Remove the HP compressor trunnion assemblies.

        NOTE

        Keep the five nuts removed in step C.(1).

      1. Remove the five tool bolts and the five nuts HPC Assembly (72-41-00, 01-302) that safety the right hand trunnion on to the module.

      2. Remove the right hand trunnion assembly from the module.

      3. Install the five bolts HPC Assembly (72-41-00,01-308) and the five nuts removed in step C.(1) and torque to 180 to 220 lbfin (20 to 25 Nm).

        NOTE

        Keep the five nuts removed in step C.(4).

      4. Remove the five tool bolts and the five nuts that safety the left hand trunnion on to the module.

      5. Remove the left hand trunnion assembly from the module.

      6. Install the five bolts HPC Assembly (72-41-00,01-308) and the five nuts removed in step C.(4) and torque to 180 to 220 lbfin (20 to 25 Nm).

    9. SUBTASK 72-41-00-040-171 Disconnect the Stage 3 VSV Control Rod

    1. Refer to Figure.

    2. Remove the nut HPC Variable Stator Vane Actuation System (72-41-34,01-232) and bolt HPC Variable Stator Vane Actuation System (72-41-34,01-236) and disconnect the stage 3 control rod from the stage 3 unison ring.

    10. SUBTASK 72-41-00-040-172 Remove the Inlet Guide Vane Actuating Ring Left Hand and Right Hand Connectors (Pre SBE 72-0385 or SBE 72-0416 and SBE 72-0385 or SBE 72-0416)

    1. Refer to Figure and Figure.

    2. SBE 72-0385 or SBE 72-0416: Introduction of revised actuation ring connectors and unison ring assemblies.

      3. Remove the inlet guide vane actuating ring left hand and right hand connectors.

      1. Correlate the left hand and right hand connectors/parts during this disassembly procedure and keep the parts as sets.

      2. Remove the four nuts which attach the actuating levers to the inlet guide vanes at the positions 1, 2, 39 and 40.

      3. Remove the four actuating levers from the four inlet guide vanes.

      4. Pre SBE 72-0385 or SBE 72-0416: Remove the four bolts and the four hollow dowels which attach the right hand connector to the upper and lower actuating rings.

      5. SBE 72-0385 or SBE 72-0416: Remove the four bolts which attach the right hand connector to the upper and lower actuating rings.

      6. Remove the right hand connector.

      7. Temporarily install the four nuts and the four actuating levers, removed in step A.(1) and (2) on the inlet guide vanes at the positions 1, 2, 39 and 40.

      8. Remove the left hand connector as given in steps A.(1) to (6). The left hand connector is adjacent to inlet guide vanes at the positions 19 to 22.

      4. Remove the connector housings from the connectors.

      1. Remove the four bolts which attach the two connector housings to the right hand connector.

      2. Remove the two connector housings and the adjusting washers from the right hand connector.

      3. Remove the two connector housings from the left hand connector as given in steps B.(1) and (2).

    11. SUBTASK 72-41-00-040-173 Remove the Stage 3 Actuating Ring Connectors (Pre SBE 72-0385 or SBE 72-0416 and SBE 72-0385 or SBE 72-0416)

    1. Refer to Figure.

    2. SBE 72-0385 or SBE 72-0416: Introduction of revised actuation ring connectors and unison ring assemblies.

      3. Remove the stage 3 actuating ring left hand and right hand connector.

      1. Correlate the left hand and right hand connectors/parts during this disassembly procedure and keep the parts as sets.

      2. Pre SBE 72-0385 or SBE 72-0416: Remove the five bolts and the five hollow dowels which attach the right hand connector to the upper and lower actuating rings.

      3. SBE 72-0385 or SBE 72-0416: Remove the five bolts and washers which attach the right hand connector to the upper and lower actuating rings.

      4. Remove the right hand connector.

      5. Pre SBE 72-0385 or SBE 72-0416: Remove the four bolts and the four hollow dowels which attach the left hand connector to the upper and lower actuating rings.

      6. SBE 72-0385 or SBE 72-0416: Remove the four bolts and washers which attach the left hand connector to the upper and lower actuating rings.

      7. Remove the left hand connector.

      4. Remove the connector housings from the connector.

      1. Remove the four bolts which attach the two connector housings to the right hand connector.

      2. Remove the two connector housings and the adjusting washers from the right hand connector.

      3. Remove the two connector housings from the left hand connector as given in steps B.(1) and (2).

    12. SUBTASK 72-41-00-040-174 Remove the Stage 4 Actuating Ring Connector (Pre SBE 72-0348, Pre SBE 72-0385 or SBE 72-0416, SBE 72-0348 and SBE 72-0385 or SBE 72-0416)

    1. Refer to Figure.

    2. SBE 72-0348: Introduction of revised actuation ring connectors.

      SBE 72-0385 or SBE 72-0416: Introduction of revised actuation ring connectors and unison ring assemblies.

      3. Remove the stage 4 actuating ring left hand and right hand connector.

      1. Correlate the left hand and right hand connectors/parts during this disassembly procedure and keep the parts as sets.

      2. Pre SBE 72-0348: Remove the four bolts and the four hollow dowels which attach the right hand connector to the upper and lower actuating rings.

      3. Pre SBE 72-0385 or SBE 72-0416: Remove the four bolts and the four washers which attach the right hand connector to the upper and lower actuating rings.

      4. SBE 72-0348: Remove the four bolts and four washers which attach the right hand connector to the upper and lower actuating rings.

      5. SBE 72-0385 or SBE 72-0416: Remove the four bolts and two washers which attach the right hand connector to the upper and lower actuating rings.

      6. Remove the right hand connector.

      7. Remove the left hand connector as given in steps A.(1) and (5).

      4. Remove the connector housings from the connector.

      1. Remove the four bolts and four washers which attach the two connector housings to the right hand connector.

      2. Remove the two connector housings and the adjusting washers from the right hand connector.

      3. Remove the two connector housings from the left hand connector as given in steps B.(1) and (2).

    13. SUBTASK 72-41-00-040-175 Remove the Stage 5 Actuating Ring Connectors (Pre SBE 72-0348, Pre SBE 72-0385 or SBE 72-0416, SBE 72-0348 and SBE 72-0385 or SBE 72-0416)

    1. Refer to Figure.

    2. SBE 72-0348: Introduction of revised actuation ring connectors.

      SBE 72-0385or SBE 72-0416: Introduction of revised actuation ring connectors and unison ring assemblies.

      3. Remove the stage 5 actuating ring left hand and right hand connectors.

      1. Correlate the left hand and right hand connectors/parts during this disassembly procedure and keep the parts as sets.

      2. Pre SBE 72-0348: Remove the four bolts and the four hollow dowels which attach the right hand connector to the upper and lower actuating rings.

      3. Pre SBE 72-0385 or SBE 72-0416: Remove the four bolts and the four washers which attach the right hand connector to the upper and lower actuating rings.

      4. SBE 72-0348: Remove the four bolts and four washers which attach the right hand connector to the upper and lower actuating rings.

      5. SBE 72-0385 or SBE 72-0416: Remove the four bolts and two washers which attach the right hand connector to the upper and lower actuating rings.

      6. Remove the right hand connector.

      7. Remove the left hand connector as given in steps A.(1) and (5).

      4. Remove the connector housings from the connector.

      1. Remove the four bolts and four washers which attach the two connector housings to the right hand connector.

      2. Remove the two connector housings and the adjusting washers from the right hand connector.

      3. Remove the two connector housings from the left hand connector as given in steps B.(1) and (2).

    14. SUBTASK 72-41-00-040-176-A00 Remove the HP Compressor Front Case Split Line and Rear Flange Nuts, Bolts and Brackets (Pre SBE 74-0001)

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

    2. Remove the 54 nuts and bolts and the brackets from the HP compressor front case to compressor rear outer case flange.

    3. CAUTION

      THE SPLIT LINE BOLTS ARE A CLOSE TOLERANCE FIT AND MUST NOT BE TURNED DURING THEIR REMOVAL.

      Remove the two nuts and the two bolts which attach the upper and lower support brackets at the HP compressor front case right hand split line.

    4. Remove the remaining 30 nuts, bolts and spacers from the HP compressor front case split line flanges.

    15. SUBTASK 72-41-00-040-176-B00 Remove the HP Compressor Front Case Split Line and Rear Flange Nuts, Bolts and Brackets (SBE 74-0001)

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

    2. SBE 74-0001: Ignition - Introduce new ignition exciter mounting brackets

    3. Remove the 54 nuts and bolts and the brackets from the HP compressor front case to compressor rear outer case flange.

    4. CAUTION

      THE SPLIT LINE BOLTS ARE A CLOSE TOLERANCE FIT AND MUST NOT BE TURNED DURING THEIR REMOVAL.

      Remove the four nuts and the four bolts which attach the upper and lower support brackets at the HP compressor front case right hand split line. Remove the upper and lower support brackets.

    5. Remove the remaining 28 nuts, bolts and spacers from the HP compressor front case split line flanges.

    16. SUBTASK 72-41-00-040-177 Remove the HP Front Split Cases

    1. Refer to Figure.

      2. Set the true axial displacement of the HP module cases and stage 2 HP turbine and the IAE 1R19463 Stand - Surgical strike.

        Position the six dial test indicators or equivalent instrumentation measuring devices as follows.

      1. Put three dial test indicators, one on each in-rigger (details 6, 7 and 8), use the clamped area only of the in-rigger, refer to Figure.

        NOTE

        This instrumentation will monitor the relative movement of the HP static components and the stand.

      2. Put each dial indicator button in contact with each of the three support plates (detail 4), refer to Figure. Pre-load and zero the instrumentation.

        NOTE

        This instrumentation will monitor the true relative movement of the HP rotating components and the static components. This is the critical dimension to be monitored and recorded.

      3. Put three dial test indicators, spaced equally, on the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture tooling structure so each dial indicator button contacts the rear surface of the stage 2 retaining plate slot on the stage 2 turbine hub ENGINE-STAGE 2 TURBINE HUB (72-45-31,01-011). Pre-load and zero the instrumentation.

    3. Loosen the locknut on the tie-rod adapter (installed through the center of the HP module) refer to Figure by approximately 0.40 in. (10 mm) to allow axial movement of the static and rotating parts.

      4. Release the HP compressor front split half casings.

        1. CAUTION

          YOU MUST MAKE A RECORD OF THE DIAL TEST INDICATOR READINGS AFTER EACH INCREMENTAL MOVEMENT MADE.

          CAUTION

          THE RELATIVE AXIAL MOVEMENT MUST NOT BE MORE THAN 0.160 IN. (4 MM) IN TOTAL AS MEASURED ON THE DIAL TEST INDICATORS MOUNTED ON THE IAE 1P16046 Removal/Installation fixture OR IAE 1P16543 Removal/Installation fixture AND THE REAR FACE OF THE STAGE 2 HP TURBINE DISK. IF THE MOVEMENT IS MORE THAN THIS MAXIMUM LIMIT THEN DAMAGE WILL OCCUR TO CRITICAL COMPONENTS IN THE HP MODULE.

          CAUTION

          THERE MUST NOT BE A DIFFERENCE OF MORE THAN 0.020 IN. (0.5 MM) BETWEEN THE READINGS OF EACH OF THE DIAL TEST INDICATORS. IF THE DIFFERENCE IS MORE THAN THIS LIMIT THEN DAMAGE MAY OCCUR TO HP MODULE COMPONENTS.

          CAUTION

          DURING THE REMOVAL AND INSTALLATION OF THE HP COMPRESSOR FRONT HALF CASES TAKE CARE NOT TO DAMAGE THE HP COMPRESSOR ROTOR BLADES. DO NOT USE EXCESSIVE OR MORE FORCE THAN IS NECESSARY.

          Release the front half split casings. If the front split casings will not release from the module then make an adjustment to the axial position of the static components relative to the rotating components. The total axial movement must not be more than 0.160 in. (4 mm). Refer to steps C. (1) (a) and (b).

          Support the half casings on detail 10 half rings when the casings are released and clear of the module. Use detail 10 half rings and carefully move the casings away from the module.

        1. Adjust the three jacking screws (detail 12) in a clockwise direction to move the HP rear case rearwards (the rear case moves in a direction towards the top of the build stand). Make each adjustment in incremental steps of not more than 0.020 in. (0.5 mm) each time until the split casings can be released. There must not be a difference of 0.020 in. (0.5 mm) between the readings of each of the dial test indicators. After each adjustment is made check and make a record of the reading at each of the three support plates (detail 4). Make a record of the true axial movement seen on the three dial test indicators on the stage 2 HP turbine position.

        2. Make a record of the readings with the front half casings removed. It is important to keep all the readings at the six positions, especially those taken at the stage 2 HP turbine position.

          NOTE

          Removal of the instrumentation is optional.

      2. Remove the instrumentation.

        NOTE

        The retaining clamp plate assembly will need to be released and moved clear of the jacking screws before the axial settings can be adjusted.

      3. Move the retaining clamp plate assembly into position to make contact with the the three jacking screws (detail 12). Adjust and tighten the locknut on the heel pin (detail 15) but do not fully torque the lock nut. Tighten the hand knob (detail 22) to hold the assembly firmly.

    5. The module is now prepared for the necessary work in relation to the surgical strike procedure, refer to TASK 72-41-00-440-001-D00.

    17. Figure: Check the No. 4 front and rear bearing compartment for leaks

    Check the No. 4 front and rear bearing compartment for leaks

    Figure: Install the remove/install fixture and tie-rod adapter on to the HP system module

    Install the remove/install fixture and tie-rod adapter on to the HP system module

    Figure: Install the dummy stub shaft on to the stage 3 disk curvic coupling

    Install the dummy stub shaft on to the stage 3 disk curvic coupling

    Figure: Install the lift slings on to the trunnions

    Install the lift slings on to the trunnions

    Figure: Remove the forward lift sling from the HP compressor trunnions

    Remove the forward lift sling from the HP compressor trunnions

    Figure: Remove the variable inlet guide vane front shroud

    Remove the variable inlet guide vane front shroud

    Figure: Install the VIGV split ring IAE1R18250

    Install the VIGV split ring IAE1R18250

    Figure: Install the HP compressor assembly in the build stand IAE 1R19463

    Sheet 1

    Legend
    Install the HP compressor assembly in the build stand IAE 1R19463 Stand - Surgical strike

    Sheet 1

    Close

    Figure: Install the HP compressor assembly in the build stand IAE 1R19463

    Sheet 2

    Legend
    Install the HP compressor assembly in the build stand IAE 1R19463 Stand - Surgical strike

    Sheet 2

    Close

    Figure: Install the HP compressor assembly in the build stand IAE 1R19463

    Sheet 3

    Legend
    Install the HP compressor assembly in the build stand IAE 1R19463 Stand - Surgical strike

    Sheet 3

    Close

    Figure: Remove the HP compressor support rods

    Sheet 1

    Legend
    Remove the HP compressor support rods

    Sheet 1

    Close

    Figure: Remove the HP compressor support rods

    Sheet 2

    Legend
    Remove the HP compressor support rods

    Sheet 2

    Close

    Figure: Remove the HP compressor trunnions

    Remove the HP compressor trunnions

    Figure: VSV Crankshaft and unison rings - Disconnect stage 3 control rod

    VSV Crankshaft and unison rings - Disconnect stage 3 control rod

    Figure: Remove the VIGV actuating ring connectors

    Sheet 1

    Legend
    Remove the VIGV actuating ring connectors

    Sheet 1

    Close

    Figure: Remove the VIGV actuating ring connectors

    Sheet 2

    Legend
    Remove the VIGV actuating ring connectors

    Sheet 2

    Close

    Figure: Remove the stage 3 actuating ring connectors

    Remove the stage 3 actuating ring connectors

    Figure: Remove the stage 4 actuating ring connectors

    Remove the stage 4 actuating ring connectors

    Figure: Remove the stage 5 actuating ring connectors

    Remove the stage 5 actuating ring connectors

    Figure: Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 1

    Legend
    Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 1

    Close

    Figure: Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 2

    Legend
    Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 2

    Close

    Figure: Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 3

    Legend
    Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 3

    Close

    Figure: Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 4

    Legend
    Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 4

    Close

    Figure: Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 5

    Legend
    Remove the HP compressor front case split line and rear flange nuts, bolts and brackets

    Sheet 5

    Close

    Figure: Set the True Axial Displacement of the HP Module Cases and Stage 2 HP Turbine

    Set the True Axial Displacement of the HP Module Cases and Stage 2 HP Turbine

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Correct tool pn and provide link (CAS-20822-G2C1H9)

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:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:X111X
Supply Number:CoMat 01-002
Type:sp01
Supply Short Name:CoMat 01-002 SOLVENT, DELETED.
Supply Name:CoMat 01-002 SOLVENT, DELETED.
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐002 is specified to clean mechanical components, use one or more of the solvents that SPM TASK 70‐11‐26‐300‐503 specifies as applicable.DELETED. Where CoMat 01‐002 is specified to clean electrical contacts or wiring harnesses, use one or more of the solvents that SPM TASK 70‐11‐57‐110‐501 specifies to clean electrical contacts or
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:K6835
Supply Number:CoMat 02-126
Type:sp01
Supply Short Name:CoMat 02-126 LOCKWIRE
Supply Name:CoMat 02-126 LOCKWIRE
Specification Groups:
Doc NumberType
DTD 189A, 0.028 TO 0.032 IN DIA
Suppliers:
ManufacturerRemarks
K6835
KB362
LOCAL
U06C8
Manufacturer Code:LOCAL
Supply Number:CoMat 04-005
Type:sp01
Supply Short Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Supply Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Specification Groups:
Doc NumberType
OMAT: 4/47 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
JCR-026 (JAEC REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
DTD 900/4586 (RR REF, MOD UK REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:X222X
Supply Number:CoMat 10-058
Type:sp01
Supply Short Name:CoMat 10-058 PENETRATING OIL
Supply Name:CoMat 10-058 PENETRATING OIL
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:0AM53
Tool Number:Dial Test Indicator Stands, Blocks And Associated Equipment
Tool Name:Dial Test Indicator Stands, Blocks And Associated Equipment
Manufacturer Code:LOCAL
Tool Number:Dial indicator
Tool Name:Dial indicator
Manufacturer Code:LOCAL
Tool Number:Feeler gage
Tool Name:Feeler gage
Manufacturer Code:0AM53
Tool Number:IAE 1F10028
Tool Name:IAE 1F10028 Support Pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1F10052
Tool Name:IAE 1F10052 Two cables sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16002
Tool Name:IAE 1P16002 Cradle pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16088
Tool Name:IAE 1P16088 Leak check adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16089
Tool Name:IAE 1P16089 Leak check cap
Manufacturer Code:0AM53
Tool Number:IAE 1P16285
Tool Name:IAE 1P16285 Tie-rod adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18234
Tool Name:IAE 1R18234 Support rod
Manufacturer Code:0AM53
Tool Number:IAE 1R18250
Tool Name:IAE 1R18250 Split ring assembly
Manufacturer Code:0AM53
Tool Number:IAE 1R18325
Tool Name:IAE 1R18325 Trunnion assembly
Manufacturer Code:0AM53
Tool Number:IAE 1R18673
Tool Name:IAE 1R18673 Dummy stub shaft
Manufacturer Code:0AM53
Tool Number:IAE 1R19463
Tool Name:IAE 1R19463 Stand - Surgical strike
Manufacturer Code:0AM53
Tool Number:IAE 1R19633
Tool Name:IAE 1R19633 Split ring assembly
Manufacturer Code:0AM53
Tool Number:IAE 6F10030
Tool Name:IAE 6F10030 Vacuum test cart