DMC:V2500-A0-72-41-1000-02B-710A-B|Issue No:005|Issue Date:2019-08-01

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 72-41-10-440-002-A00 HPC Rotor Assembly - Assemble The Rotor Assembly, Assembly-002

General

This TASK gives the procedure to assemble the HP Compressor Rotor Assembly. Refer to the TASKS that follow for other related procedures.

Measure the HP Compressor Rotor Assembly Parts by TASK 72-41-10-440-001 (ASSEMBLY-001).

Do a balance check of the HP Compressor Rotor Assembly and install the blades by TASK 72-41-10-440-003-A00 (ASSEMBLY-003).

Grind the tips of the HP Compressor Blades by TASK 72-41-10-440-004-A00 (ASSEMBLY-004).

Final balance the HP Compressor Rotor Assembly by TASK 72-41-10-440-005-A00 (ASSEMBLY-005).

Assemble the HP Compressor Rotor Disks using IAE1R19895 by TASK 72-41-10-440-008-A00 (ASSEMBLY-008).

Assemble the HP Compressor Rotor Disks using IAE1P16616 by TASK 72-41-10-440-008-B00 (ASSEMBLY-008).

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.

Overhaul processes referred to in this procedure by the TASK/SUBTASK number are in SPM.

For standard torque data and procedures, refer to SPM TASK 70-41-00-400-501, SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-410-501.

Special torque data is identified with the symbol * after the torque value.

Special assembly tolerances are included in this procedure.

Lubricate all threads and mating faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS unless other lubricants are referred to in the procedure.

All the mating faces and curvic teeth must be cleaned with CoMat 01-001 SOLVENT, DELETED or CoMat 01-002 SOLVENT, DELETED. before assembly. Refer to SPM TASK 70-11-01-300-503. They must also be dry assembled unless told differently in the procedure.

After assembly apply CoMat 07-038 AIR DRYING ENAMEL to damaged surface protection, joint flanges and attach parts. Use the correct color of the air drying enamel. Refer to SPM TASK 70-63-02-380-501.

Do a check of the interference dimensions of the Stage 3 To 8 Disk Assembly to the Stage 9 To 12 Disk assembly. Also do a check of the Stage 9 To 12 Disk assembly to the HPC Rear Shaft. This must be done to make sure you get the correct interference fits.

All the temporary marks made in this procedure must be removed before the engine is started.

The data found in this procedure, when used during assembly, will permit the rotor assembly to be assembled with all of the parts concentric to specified limits.

The following SUBTASKS can also be achieved in conjunction with the Axiam V2500 High Pressure Compressor, Rotor Component Measurement and Smart Stack Assembly Process. Document No V2500-HPC-01, Revision G (last revised in August 2010). Use of other versions need to be validated by IAE.

Details of this procedure are available from.

Axiam Incorporated

58 Blackburn Center

Gloucester

Massachusetts

01930

USA

It is important to prevent unwanted swash and run-out during this procedure. Thus, all of the rotor parts, tools and equipment used in this procedure must be kept very clean.

Run-out

Run-out is the total movement of the measuring equipment display, in relation to a location diameter, when a part is turned. Run-out includes eccentricity and ovality, (or out of roundness).

All of the dimensions given in this procedure in relation to run-out, refer only to eccentricity. If there is ovality, it will be necessary to correct it. To correct the ovality, get the difference between two opposite values only. The difference between these values must not be more than the total specified dimension permitted.

If there is irregular ovality, it can be necessary to make a graph of the run-out values on CoMat 02-130 POLAR GRAPH PAPER. The quantity of ovality can then be calculated.

Swash

Swash is the total movement of the measuring equipment display, in relation to a mating face, when a part is turned.

Run-out and Swash data

The subsequent data must be used when you measure run-out and swash, to permit the values to be put in to a computer.

All of the measured values are to be known as positive if;

The location diameter moves radially out, and/or the mating face moves rearwards in relation to a datum face.

This is correct if the measuring equipment display reads positive or negative values.

A minimum of nine values for run-out and swash must be read at eight equally spaced positions, for all components. The first and last values must be the same. If the first and last values are not the same, read all of the nine values again and again until the first and last values are the same.

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

Name	Manufacturer	Part Number / Identification	Quantity
Air circulated oven	LOCAL
Computer	LOCAL
Protective Gloves	LOCAL
Rotary air table	LOCAL
Soft Faced Mallet	LOCAL
Nylon Drift (maximum length = 6 inches, maximum diameter = 0.75 inch)	LOCAL
IAE 1R18020 Build stand	0AM53	IAE 1R18020	1
IAE 1R18021 Support ring	0AM53	IAE 1R18021	1
IAE 1R18022 Support ring	0AM53	IAE 1R18022	1
IAE 1R18026 Lifting fixture	0AM53	IAE 1R18026	1
IAE 1R18027 Indexing ring	0AM53	IAE 1R18027	1
IAE 1R18059 Trolley	0AM53	IAE 1R18059	1
IAE 1R18061 Rail	0AM53	IAE 1R18061	2
IAE 1R18062 Master curic base	0AM53	IAE 1R18062	1
IAE 1R18063 Location piece	0AM53	IAE 1R18063	1
IAE 1R18064 Bolt	0AM53	IAE 1R18064	20
IAE 1R18065 Lifter	0AM53	IAE 1R18065	1
IAE 1R18075 Support pedestal	0AM53	IAE 1R18075	1
IAE 1R18078 Clamp assembly	0AM53	IAE 1R18078	6
IAE 1R18085 Adjusting unit	0AM53	IAE 1R18085	4
IAE 1R18086 Clamp assembly	0AM53	IAE 1R18086	4
IAE 1R18087 Block	0AM53	IAE 1R18087	4
IAE 1R18088 Pillar	0AM53	IAE 1R18088	1
IAE 1R18089 Lifting adapter	0AM53	IAE 1R18089	1
IAE 1R18090 Safety support stand	0AM53	IAE 1R18090	1
IAE 1R18091 Support stand	0AM53	IAE 1R18091
IAE 1R18094 Washer	0AM53	IAE 1R18094	8
IAE 1R18095 Universal slinging adapter	0AM53	IAE 1R18095	2
IAE 1R18096 Pallet	0AM53	IAE 1R18096	1
IAE 1R18223 Spacer	0AM53	IAE 1R18223	20
IAE 1R18441 Lifting adapter	0AM53	IAE 1R18441
IAE 1R18443 Puller	0AM53	IAE 1R18443	1
IAE 1R18629 Protective cover	0AM53	IAE 1R18629	1
IAE 1R18673 Dummy stub shaft	0AM53	IAE 1R18673	1

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 01-001 SOLVENT, DELETED	X111X	CoMat 01-001
CoMat 01-002 SOLVENT, DELETED.	X111X	CoMat 01-002
CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON	IE304	CoMat 02-121
CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON	K6835	CoMat 02-122
CoMat 02-130 POLAR GRAPH PAPER	LOCAL	CoMat 02-130
CoMat 03-026 LIQUID NITROGEN	LOCAL	CoMat 03-026
CoMat 07-038 AIR DRYING ENAMEL	k3504	CoMat 07-038
CoMat 07-090 YELLOW MARKING PAINT,WATER BASED	LOCAL	CoMat 07-090
CoMat 07-091 POTASSIUM SILICATE SOLUTION	LOCAL	CoMat 07-091
CoMat 10-070 ANTI-SEIZE COMPOUND	LOCAL	CoMat 10-070
CoMat 10-077 APPROVED ENGINE OILS	X333X	CoMat 10-077
CoMat 10-142 ANTI-SEIZE PASTE	71984	CoMat 10-142

Spares

Name	Quantity	Remark
Bolt	34	(SBE 72-0632)
Anti-fret plate	17	(SBE 72-0632)
Double retaining washer	20	(SBE 72-0632)

Safety Requirements

NONE

Procedure

SUBTASK 72-41-10-220-084 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1005

Refer to Figure.

Reference dimensions at Location 1005. If required use the data written as a note in the applicable TASK. Refer to TASK 72-41-11-200-000 and TASK 72-41-12-200-000.

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 1005
Stages 3 To 8 HP Compressor Disks HPC Stage 3 - 8 Drum Disk And Wire Seals (72-41-11, 01-200), Rear Location Bore The Stages 9 to 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Front Location Diameter
Compressor Disk Bore	16.1417
	16.1442	0.0002
Compressor Disk Diameter	16.1438	0.0044
	16.1462	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 1005
Stages 3 To 8 HP Compressor Disks HPC Stage 3 - 8 Drum Disk And Wire Seals (72-41-11, 01-200), Rear Location Bore The Stages 9 to 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Front Location Diameter
Compressor Disk Bore	410.000
	410.063	0.005
Compressor Disk Diameter	410.053	0.113
	410.113	Intf

SUBTASK 72-41-10-220-056 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1006

Refer to Figure.

Reference dimensions at Location 1006. If required use the data written as a note in the applicable TASK. Refer to TASK 72-41-12-200-000.

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 1006
Vortex Reducer Ring HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-575), Rear Location Diameter The Stages 9 To 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Front Location Bore.
Reducer Ring Diameter	12.522	Intf
	12.526	0.010
Compressor Disk Bore	12.510	0.016
	12.512

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 1006
Vortex Reducer Ring HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-575), Rear Location Diameter The Stages 9 to 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Front Location Bore
Reducer Ring Diameter	318.062	Intf
	318.160	0.258
Compressor Disk Bore	317.754	0.406
	317.804

SUBTASK 72-41-10-220-085 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1007

Refer to Figure.

Reference dimensions at location 1007. If required use the data written as a note in the applicable TASK. Refer to TASK 72-41-12-200-000 and TASK 72-41-13-200-000.

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 1007
Stages 9 To 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Rear Location Diameter The HP Compressor Shaft HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-850), Front Location Bore
Compressor Disk Diameter	13.5080	Intf	13.5080
	13.5090	0.0020	13.5090
Compressor Shaft Bore	13.5040	0.0050	13.5030
	13.5060	Intf	13.5060

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 1007
Stages 9 To 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Rear Location Diameter The HP Compressor Shaft HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-850) Front Location Bore
Compressor Disk Diameter	343.104	Intf	343.104
	343.129	0.052	343.129
Compressor Shaft Bore	343.002	0.127	342.976
	343.052	Intf	343.052

SUBTASK 72-41-10-440-056 Calculate the Data Used to Find the Best Position of the Stages 3 to 8 HP Compressor Disks (01-200), the Vortex Reducer Ring (01-575) and the Stages 9 to 12 HP Compressor Disks (01-600), in Relation to Each Other

Refer to Figure.
Measure the length of the Stages 9 To 12 Compressor Disks. Write down this value.
1. Measure the rear location diameter, (diameter E), of the Stages 3 To 8 Compressor Disks.
2. Divide the value from Step by two. This will give the radius. Write down this value.

Calculate the total swash effect, (TSE).

Use the subsequent formula to calculate the TSE.

where;

TSE = S x L divided by r.

S	-	The swash of the stages 3 to 8 compressor rear mating face (face D). Refer to TASK 72-41-10-440-001.
L	-	The length of the Stages 9 To 12 Compressor Disk (refer to Step), plus the maximum thickness of the vortex reducer ring front flange (dimension AC). Refer to TASK 72-41-10-440-001.
r	-	The radius of the Stages 3 To 8 Compressor Disks rear location diameter. Refer to Step.

NOTE

The angle of TSE is the angle of the swash of the Stages 3 To 8 Compressor Disks plus 180 degrees.

Write down the value and angle of TSE.

1. Set the computer to the applicable program.
2. Put the run-out of the Stages 3 To 8 Compressor Disks rear location diameter in to the computer. Refer to TASK 72-41-10-440-001. Put the value of the run-out in to the computer as Vector L1. Put the angle of the run-out in to the computer as Angle A1.
3. Put the TSE value and angle in to the computer. Refer to Step. Put the value of the TSE in to the computer as Vector L2. Put the angle of the TSE in to the computer as Angle A2.
4. The computer will calculate the value and angle of combined swash and run-out effect.
5. Write down the value and angle of combined swash and run-out effect.
6. Make a mark on face F of the Stages 3 To 8 Compressor Disks at the position of the combined swash and run-out effect. Use CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON or CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON to make the mark. Refer to SPM TASK 70-09-01-400-501.

1. Refer to Figure, Figure, Figure and Figure.
  NOTE
  The Stages 9 To 12 Compressor Disks are installed in the turnover stand.
2. Operate the turnover stand to turn the Stages 9 To 12 Compressor Disks until the lifter is at the bottom.
3. Examine the front mating face of the Stages 9 Compressor Disk for contamination and/or high metal. If there is contamination the mating face must be cleaned. If there is high metal, use a stone to make the surface smooth.
4. Install the 17 new anti-fret plates HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-610) and the 34 new special head bolts HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-608) through the rear of the Stages 9 Compressor Disk front flange. Turn the special head bolts so that they are correctly engaged.
5. Examine the front and rear mating faces of the vortex reducer ring front flange for contamination and/or high metal. If there is contamination the mating faces must be cleaned. If there is high metal, use a stone to make the surface smooth.
6. 1. Find the position of correct run-out of the Stages 12 Compressor Disk rear location diameter (diameter N). Refer to TASK 72-41-10-440-001.
  2. Find the position of the maximum thickness of the vortex reducer ring front flange. This position is temporarily identified with a 'T' on the outer diameter.
  3. WARNING
    YOU MUST PUT ON THE CORRECT GLOVES BEFORE YOU USE LIQUID NITROGEN.
    Lower the vortex reducer ring rear location diameter in to CoMat 03-026 LIQUID NITROGEN until the strong bubbles have stopped.
  4. Install the vortex reducer ring (with the front flange at the top) over the 34 special headed bolts, on to the Stages 9 Compressor Disk. Make sure that the two positions found in Step and Step are opposite each other.
  5. Install IAE 1R18094 Washer 8 off on to eight equally spaced special head bolts.
  6. Install eight new splined nuts HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-602) onto the special head bolts and washers. Torque the bolts in sequence to 110* lbfin (12.43* Nm).
  7. Allow the temperature of the assembly to come to room temperature.
  8. Remove the eight nuts and washers.
7. 1. Make sure that the 34 special head bolts HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-608) can not be turned more than five degrees in the two directions.
  2. If one or more of the special headed bolts can turn more than five degrees, then do Step.
8. 1. Install IAE 1R18443 Puller 1 off onto the vortex reducer ring.
    Loosen the eight clamp nuts sufficient to let the four clamps be moved to the center of the removal puller.
    Lift the clamp nuts and move the clamps to the center of the removal puller.
    Make sure that the six extraction bolts are fully retracted.
    Examine the mating face of the removal puller for contamination and/or high metal. If there is contamination then the mating face must be cleaned. If there is high metal, use a stone to make the surface smooth.
    Use the handles to lift the removal puller and install it on to the Stages 9 Compressor Disk. Engage the special headed bolts through the holes in the removal puller.
    Make sure that all of the pressure ring touches the Stages 9 Compressor Disk.
    Lift the clamp nuts and move the clamps to the outer edge of the removal puller. Make sure the clamps are engaged correctly on the vortex reducer ring. Tighten the eight clamp nuts.
  2. CAUTION
    YOU MUST MAKE SURE THERE IS A CLEARANCE BETWEEN THE SPECIAL HEADED BOLTS AND THE HOLES IN THE REMOVAL PULLER.
    CAUTION
    THE EXTRACTION BOLTS MUST BE TIGHTENED IN SEQUENCE AND NOT MORE THAN ONE TURN AT A TIME.
    Tighten the six extraction bolts, one complete turn only, in the sequence shown.
  3. Do Step again and again until the vortex reducer ring is disengaged from the Stages 9 Compressor Disk.
  4. Use the handles to lift the removal puller and vortex reducer ring assembly off the Stages 9 Compressor Disk. Put the assembly on to a suitable work surface. Remove the removal puller from the vortex reducer ring.
  5. Make sure that the special headed bolts that were incorrectly engaged are in the correct position.
  6. Install the vortex reducer ring. Refer to Step and Step.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.
  NOTE
  The Stages 3 To 8 Compressor Disks are installed in the support tool.
2. Examine the rear mating face of the Stages 3 To 8 Compressor Disks for contamination and/or high metal. If there is contamination, the mating face must be cleaned. If there is high metal, use a stone to make the surface smooth.
3. Put the Stages 3 To 8 Compressor Disks and support tool assembly in to an air circulating oven. The oven must be at a temperature of NOT MORE THAN 302 deg F (150 deg C).
4. 1. Operate the turnover stand to turn the Stages 9 To 12 Compressor Disks until the lifter is at the top.
  2. Attach a hoist to the lift eye of the lifter that is attached to the Stages 9 To 12 Compressor Disk.
  3. Adjust the height of the hoist to hold the weight of the Stages 9 To 12 Compressor Disks.
  4. Remove six of the 12 nuts that safety one half of the adapter plate to the turnover stand adapter.
  5. Remove one half of the adapter plate.
  6. Disengage the Stages 9 To 12 Compressor Disks from the other half of the adapter plate.
    Disengage the Stages 9 To 12 Compressor Disks from the adapter plate.
    Adjust the position of the hoist to hold the Stages 9 To 12 Compressor Disks in the disengaged position.
  7. Lift the Stages 9 To 12 Compressor Disks out of the turnover stand.
5. 1. Remove the eight screws from the top of IAE 1R18020 Build stand 1 off.
  2. Put IAE 1R18022 Support ring 1 off on to the top of the build stand with the spigot diameter at the bottom.
  3. Adjust the support ring until the eight holes in the support ring are aligned with the eight holes in the build stand.
  4. Safety the support ring to the build stand with the eight screws.
    NOTE
    The maximum thickness of the vortex reducer ring front flange can be used to help get the minimum swash and run-out. Refer to TASK 72-41-10-440-001.
6. Refer to the run-out of the Stages 9 To 12 Compressor Disks (Refer to TASK 72-41-10-440-001), and the combined swash and run-out effect of the Stages 3 To 8 Compressor Disks (refer to Step). Use these values to calculate the position of the Stages 9 To 12 Compressor Disks in relation to the Stages 3 To 8 Compressor Disks. Calculate the position that will give the minimum swash and run-out of the rear of the Stages 12 Compressor Disk after assembly. Write down the calculated values of swash and run-out.
7. 1. Remove the Stages 3 To 8 Compressor Disks and the support tool assembly from the air circulating oven.
  2. Install IAE 1R18065 Lifter 1 off on to the Stages 8 Compressor Disk. Refer to Figure.
    Loosen the two right hand nuts sufficient to let the right hand clamp be moved to the center of the lifter.
    Loosen the two left hand nuts sufficient to let the left hand clamp be moved to the center of the lifter.
    Lift the right and left hand nuts and move the clamps to the center of the lifter.
    Put the lifter on to the Face C of the Stages 8 Compressor Disk, with the lift eye to the top.
    Move the clamps to the outer edge of the lifter.
    Tighten the right and left hand nuts.
    Attach a hoist to the lift eye.
  3. Carefully lift the Stages 3 To 8 Compressor Disks out of the support tool. Refer to Figure.
  4. Put the Stages 3 To 8 Compressor Disks above the build stand.
  5. CAUTION
    YOU MUST NOT LET THE STAGES 3 TO 8 COMPRESSOR DISKS HIT THE BUILD STAND.
    Install the Stages 3 To 8 Compressor Disks on to the build stand.
    Carefully lower the Stages 3 To 8 Compressor Disks on to the build stand.
    Continue to lower the Stages 3 To 8 Compressor Disks until; the stage 5 disk is engaged in the spigot diameter and the stage 6 disk touches the support ring.
  6. Remove the lifter from the Stages 8 Compressor Disk.
    Loosen the two right and the two left hand nuts sufficient to let the two clamps be moved to the center of the lifter.
    Move the two clamps to the center of the lifter.
    Lift the lifter off the Stages 3 To 8 Compressor Disks.
    Remove the lifter from the hoist.
8. 1. The assembly of the Stage 3 To 8 Disk to the Stage 9 To 12 Disk at location 1005 must have a fit of between 0.0002 in. (0.005 mm) clearance and 0.0043 in. (0.108 mm) interference.
  2. If you can not get the interference fit given in para. (1).
    Examine the stage 9 to 12 compressor disk assembly location diameter. Refer to TASK 72-41-12-200-001, 72-41-12-220-051.
    and/or.
    Examine the stage 3 to 8 compressor disk assembly location diameter. Refer to TASK 72-41-11-200-001-A00, 72-41-11-220-063, para. A.
9. 1. Put the Stages 9 To 12 Compressor Disks above the Stages 3 To 8 Compressor Disks.
  2. Make sure the position of the Stages 9 To 12 Compressor Disks, in relation to the Stages 3 To 8 Compressor Disks, is that calculated in Step.
  3. Lower the Stages 9 To 12 Compressor Disks on to the Stages 3 To 8 Compressor Disks. Make sure the 34 special headed bolts engage in the holes in the Stages 3 To 8 Compressor Disks rear flange.
  4. Attach IAE 1R18078 Clamp assembly 6 off on to the stages 8 to 9 joint.
    Make sure the nuts of each clamp assembly are loose.
    Install the clamp assemblies in to the stage 8 and 9 blade grooves at six equally spaced positions.
    Tighten the clamp assembly nuts in sequence.
  5. Let the assembly become cool.
  6. Remove the lifter from the Stages 12 Compressor Disk rear flange. Refer to Figure.
    Loosen the two right hand and the two left hand nuts sufficient to let the two clamps be moved to the center of the lifter.
    Lift the two right hand and the two left hand nuts and move the clamps to the center of the lifter.
    Lift the lifter off the Stages 12 Compressor Disk rear flange.
    Remove the lifter from the hoist.
1. 1. Refer to TASK 72-41-10-440-008-A00.
2. 1. Refer to TASK 72-41-10-440-008-B00.
1. Refer to Figure.
2. 1. General nicks, dents, scratches and scores not more than 0.002 in. (0.05 mm).
    Accept.
  2. Other than Step.
    Reject.
3. 1. Properly seated.
    Accept.
  2. Other than Step.
    Reject.
4. 1. Nicked, dented, scratched or scored.
    Reject.
1. Refer to Figure
2. Install IAE 1R18062 Master curic base 1 off, IAE 1R18086 Clamp assembly 4 off, IAE 1R18087 Block 4 off and IAE 1R18085 Adjusting unit 4 off on to the Rotary air table. Refer to TASK 72-41-10-440-001.
1. Use IAE 1R18088 Pillar 1 off and measuring equipment to correct the run-out of the assembled tooling. Refer to TASK 72-41-10-440-001.
1. Refer to Figure, Figure, Figure, Figure and Figure
2. 1. Loosen the two right hand nuts sufficient to let the right hand clamp be moved to the center of the lifting fixture.
  2. Loosen the two left hand nuts sufficient to let the left hand clamp be moved to the center of the lifting fixture.
  3. Lift the right and left hand nuts and move the clamps to the center of the lifting fixture.
  4. Put the lifting fixture on to the Stages 12 Compressor Disk rear flange, with the lift eye to the top.
  5. Move the clamps to the outer edge of the lifting fixture.
  6. Tighten the right and left hand nuts.
  7. Attach a hoist to the lift eye.
3. CAUTION
  YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE BUILD STAND.
  Lift the stages 3 to 12 compressor disks assembly off the build stand. Refer to Figure.
4. 1. Install IAE 1R18091 Support stand 1 off on to the top of IAE 1R18090 Safety support stand 1 off. Make sure that the stand adapter is correctly engaged in the safety support stand. Refer to Figure.
  2. Put the stages 3 to 12 compressor disks assembly above the safety support stand.
  3. CAUTION
    YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE SAFETY SUPPORT STAND.
    Slowly lower the stages 3 to 12 compressor disks assembly on to the safety support stand. Make sure the stage 3 disk curvic coupling goes through the hole in the stand adapter.
  4. Continue to lower the stages 3 to 12 compressor disks assembly until the stage 3 disk touches the stand adapter.
  5. Examine the curvic teeth of the master curvic base and the stage 3 disk curvic coupling for contamination and/or high metal. If there is contamination then the curvic teeth must be cleaned. If there is high metal, use a stone to make the surface smooth. Refer to Figure.
5. Lift the stages 3 to 12 compressor disks assembly off the safety support stand and put it above the master curvic base.
6. Install IAE 1R18063 Location piece 1 off on the master curvic base.
7. CAUTION
  YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE MASTER CURVIC BASE.
  Slowly lower the stages 3 to 12 compressor disks assembly until the location piece is engaged in the bore of the stage 3 compressor disk. Make sure that the four location dowels in the master curve base are aligned with the four holes in the stage 3 disk curvic coupling.
8. Continue to lower the stages 3 to 12 compressor disks assembly until the four location dowels are engaged in the stage 3 disk curvic coupling. Lower the stage 3 compressor disk on to the master curvic base.
9. Install the IAE 1R18064 Bolt 20 off through the master curvic base, in to the stage 3 disk curvic coupling. Lightly tighten the bolts.
  NOTE
  The torque sequence is identified on the outer diameter of the master curvic base front flange.
10. 1. Torque all of the bolts to 18 lbfin (2.034 Nm).
  2. Torque all of the bolts to 35 lbfin (3.955 Nm).
  3. Torque all of the bolts to 70* lbfin (7.900* Nm).
11. 1. Loosen the two right and the two left hand nuts sufficient to let the two clamps be moved to the center of the lifting fixture.
  2. Lift the two right and the two left hand nuts and move the clamps to the center of the lifting fixture.
  3. Lift the lifting fixture off the Stages 12 Compressor Disk rear flange.
  4. Remove the lifting fixture from the hoist.
1. Refer to Figure and Figure.
2. Find the eight numbered positions on the rear of the Stages 12 Compressor Disk. The positions are identified on the face P. Refer to TASK 72-41-10-440-001.
3. 1. Measure the swash at the eight positions found in Step.
  2. Set the computer to the applicable program and put the swash values in to the computer. The computer will calculate the FIR and the angle of the swash. Make a mark on CoMat 02-130 POLAR GRAPH PAPER to show the FIR and angle and identify it as S1.
  3. Measure the run-out at the eight positions found in Step.
  4. Put the run-out values in to the computer. The computer will calculate the FIR and the angle of the run-out. Make a mark on the CoMat 02-130 POLAR GRAPH PAPER to show the FIR and the angle and identify it as R1.
4. 1. Attach IAE 1R18026 Lifting fixture 1 off on to the Stages 12 Compressor Disk rear flange. Refer to Step.
  2. Remove the 20 bolts from the master curvic base and the stage 3 disk curvic coupling.
  3. Lift the stages 3 to 12 compressor disks assembly off the master curvic base.
  4. Turn the Rotary air table and assembled tools through 180 degrees. Make sure the stages 3 to 12 compressor disks assembly does not move.
  5. Install the stages 3 to 12 compressor disks assembly on to the master curvic base. Refer to Step.
5. Measure the swash and run-out, refer to Step. Identify the swash as S2 and the run-out as R2 on the CoMat 02-130 POLAR GRAPH PAPER.
6. 1. Make a line between the points S1 and S2. Make a mark at the middle position between the points S1 and S2. Identify this point as S3.
  2. Make a line between the points R1 and R2. Make a mark at the middle position between the points R1 and R2. Identify this point as R3.
  3. Make a line between the point S3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.
  4. Make a line between the point R3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.
    NOTE
    The distance between the points S1 or S2 and the point S3, (distance G), shows the swash error in the tools.
  5. The distance between the center of the CoMat 02-130 POLAR GRAPH PAPER and the point S3, (distance H), shows the correct swash of the stages 3 to 12 compressor disks assembly.
  6. Write down the amount and angle of the correct swash.
    NOTE
    The distance between the points R1 or R2 and the point R3, (distance J), shows the run-out error in the tools.
  7. The distance between the center of the CoMat 02-130 POLAR GRAPH PAPER and the point R3, (distance K), shows the correct run-out of the stages 3 to 12 compressor disks assembly.
  8. Write down the amount and angle of correct run-out.
7. 1. Compare the swash and run-out values (refer to Step and Step) to those calculated in Step.
  2. If the difference between the two sets of swash and run-out values is less than 0.0003 in. (0.008 mm), then continue to Step.
  3. If the difference between the two sets of swash and run-out values is more than 0.0003 in. (0.008 mm), then continue to Step.
    If the final runout and swash after assembly of the HPC Rear Shaft are less than the limits given in Step, continue assembly of the rotor.
    If the final runout and swash after assembly of the HPC Rear Shaft are more than the limits given in Step, do the TASK 72-41-10-440-002-A00 again.
1. Refer to Figure, Figure, Fig. 72-41-10-990-085-003, Figure, Figure and Figure
2. Remove the stages 3 to 12 compressor disks assembly from the master curvic base. Refer to Step and Figure.
  NOTE
  The build stand has had IAE 1R18022 Support ring 1 off installed in Step.
3. 1. Put the stages 3 to 12 compressor disks assembly above the build stand.
  2. CAUTION
    YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE BUILD STAND.
    Install the stages 3 to 12 compressor disks assembly on to the build stand.
    Carefully lower the stages 3 to 12 compressor disks assembly on to the build stand.
    Continue to lower the stages 3 to 12 compressor disks assembly until; the stage 5 disk is engaged in the spigot diameter and the stage 6 disk touches the support ring.
  3. Remove the lifting fixture from the Stages 12 Compressor Disk rear flange. Refer to Step.
4. 1. Install the stages 3 to 12 compressor disks assembly on to the master curvic base. Refer to Step.
  2. Measure the swash and run-out of the stages 3 to 12 compressor disks assembly. Refer to Step.
  3. Make an analysis of the stages 3 to 12 compressor disks assembly, swash and run-out values.
    Compare the swash and run-out values (refer to Step) to those calculated in Step.
    If the difference between the two sets of swash and run-out values is more than 0.0003 in. (0.008 mm), then continue to Step.
    If the difference between the two sets of swash and run-out values is less than 0.0003 in. (0.008 mm), then continue to Step.
    NOTE
    After you have done the procedure identified in Step, the compressor parts will be in the subsequent positions.
    The Stages 3 To 8 Compressor Disks will be in the build stand. Refer to Figure.
    The Stages 9 To 12 Compressor Disks will be in the turnover stand. Refer to Figure.
    The vortex reducer ring will be on a suitable work surface.
5. Remove the Stages 9 To 12 Compressor Disks and vortex reducer ring assembly from the Stages 3 To 8 Compressor Disks. Remove the vortex reducer ring from the Stages 9 To 12 Compressor Disks. The procedure to do this is given in TASK 72-41-10-040-001.
6. Remove the temporary marks from all of the compressor parts.
  NOTE
  It is very important that:
  All of the mating faces are examined for contamination and/or high metal. If there is contamination and/or high metal, it must be removed. The procedure to do this is given in the related SUBTASK.
  During assembly, all of the joints are fully engaged and the related torque sequences must be followed.
  You must make sure that all of the values measured and the subsequent calculations are correct.
7. Measure and assemble the Stages 3 To 8 Compressor Disks HPC Stage 3 - 8 Drum Disk And Wire Seals (72-41-11, 01-200), the vortex reducer ring HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-575) and the Stages 9 To 12 Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600). Refer to TASK 72-41-10-440-001 and Step.
8. If the swash and run-out of the stages 3 to 12 compressor disks assembly is more than the limits given in Step, then the assembly must be rejected.
1. Refer to Figure and Figure
2. Remove the stages 3 to 12 compressor disks assembly from the master curvic base. Refer to Step and Figure.
3. Install the stages 3 to 12 compressor disks assembly in to IAE 1R18020 Build stand 1 off that has got IAE 1R18022 Support ring 1 off attached. Refer to Step and Figure.
1. Refer to Figure
2. Measure the width of the location slot (dimension A) of one of the HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-856) double retaining washer 20 off.
3. Write down the value of the dimension.
4. Do Step and Step again on the other 19 washers.

SUBTASK 72-41-10-220-060 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1062

Refer to Figure

Reference dimensions at location 1062. If required use the data written as a note in Step and the applicable TASK. Refer to TASK 72-41-12-200-000.

Table 8. 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 1062
Double Retaining Washer HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-856), Location Slot
To The Stages 9 to 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Rear Flange Inner Location
Location Slot Width	0.138
	0.146	0.002
Inner Location Width	0.134	0.012
	0.136

Table 9. 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 1062
Double Retaining Washer HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-856), Location Slot
The Stages 9 to 12 HP Compressor Disks HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-600), Rear Flange Inner Location
Location Slot Width	3.50
	3.70	0.05
Inner Location Width	3.40	0.30
	3.45

SUBTASK 72-41-10-440-144 Calculate the Data Used to Find the Best Position of the HP Compressor Shaft (01-850) in Relation to the Stages 3 to 12 HP Compressor Disks Assembly

Refer to Figure.
Measure the length of compressor shaft. Write down this value as 'L'.
1. Measure the diameter of the front location bore (diameter Q).
2. Divide the value from Step by two. This will give the radius. Write down this value.

Calculate the total swash effect, (TSE).

Use the subsequent formula to calculate the TSE.

TSE = S x L

Where;

S	-	The swash of the stages 3 to 12 compressor disks assembly rear mating face (face M). Refer to Step.
L	-	The length of the compressor shaft (refer to Step).
r	-	The radius of the compressor shaft front location bore (refer to Step).

NOTE

The angle of the TSE is the angle of the swash of stages 3 to 12 compressor disks assembly plus 180 degrees.

Write down the value and angle of TSE.

1. Set the computer to the applicable program.
2. Put the run-out of the Stages 9 To 12 Compressor Disks assembly rear location diameter (diameter N) in to the computer. Refer to Step. Put the value of the run-out in to the computer as vector L1. Put the angle of the run-out in to the computer as angle A1.
3. Put the TSE value and angle in to the computer. Refer to Step Put the value of the TSE in to the computer as vector L2. Put the angle of the TSE in to the computer as angle A2.
4. The computer will calculate the value and angle of combined swash and run-out effect.
5. Write down the value and angle of combined swash and run-out effect. These values are necessary when you do Step.

1. Refer to Figure and Figure
  NOTE
  The stages 3 to 12 compressor disks assembly is installed in the build stand.
2. 1. The assembly of the stage 9 to 12 compressor disk to the HP Compressor rear shaft at location 1007 must have an interference fit of between 0.002 in. (0.051 mm) and 0.0050 in. (0.127 mm).
  2. If you can not get the interference fit given in para. (1).
    Examine the stage 9 to 12 compressor disk assembly location diameter. Refer to TASK 72-41-12-200-002-A00, 72-41-12-220-069.
    and/or.
    Examine the HP Compressor rear shaft location diameter at location 3. Refer to TASK 72-41-13-200-001-A00, 72-41-13-220-078.
3. 1. Install one double retaining washer on to the rear of the Stages 12 Compressor Disk rear flange. Make sure the washer is correctly engaged on the disk and the holes are aligned with two holes in the disk.
  2. Install two of the square headed bolts through the rear of the Stages 12 Compressor Disk rear flange and the double retaining washer.
  3. Hold the square headed bolts in position with IAE 1R18223 Spacer and 2 slave nuts.
  4. Do Step thru Step again until all of the square headed bolts, double retaining washers and spacer plates are installed.
  5. Tighten the slave nuts sufficiently to stop the movement of each bolt, retaining washer and spacer plate. Torque the slave nuts to 265 lbfin to 310 lbfin (30 Nm to 35 Nm).
  6. CAUTION
    YOU MUST NOT USE AN ALUMINUM DRIFT TO BEND THE RETAINING WASHER LOCKING TABS. USE OF AN ALUMINUM DRIFT CAN CAUSE DAMAGE TO THE HARDWARE AND TOOLS.
    CAUTION
    USE OF EXCESSIVE FORCE MAY DAMAGE THE HARDWARE OR TOOLS.
    Using a Nylon Drift (maximum length = 6 inches, maximum diameter = 0.75 inch) and Soft Faced Mallet, lightly tap the retaining washer tabs until they bend around the heads of the bolts.
  7. Remove the slave nuts and spacer plates.
1. Refer to Figure, Figure, Figure and Figure
2. 1. Engage the lifter on to the end of the compressor shaft.
  2. Turn the lifter clockwise to move the lifter on to the compressor shaft.
  3. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the compressor shaft.
  4. Tighten the lockscrew in to the lifter. Make sure the lockscrew goes in to a slot on the end of the compressor shaft. If the lockscrew does not go in to a slot then turn the lifter anti-clockwise until the lockscrew will go in to the first available slot.
  5. Turn the sleeve until a hoist can be attached to the lift eye.
  6. Attach a hoist to the lift eye.
3. Lift the rear shaft and put it above IAE 1R18096 Pallet 1 off.
4. Carefully lower the compressor shaft on to the tray on the pallet. Refer to Figure.
5. Remove the lifter from the end of the compressor shaft. Move the sleeve on the lifter to make the lifter safe.
6. Put the compressor shaft in to an air circulating oven, that is at a temperature of NOT MORE THAN 302 deg F (150 C), for 20 minutes.
7. Refer to the run-out of the compressor shaft (refer to TASK 72-41-10-440-001) and the combined swash and run-out effect of the stages 3 to 12 compressor disks assembly (refer to Step. Use these values to calculate the position of the compressor shaft in relation to the stages 3 to 12 compressor disks assembly. Calculate the position that will give the minimum swash and run-out of the compressor shaft. Write down the calculated values of swash and run-out.
8. WARNING
  YOU MUST PUT ON THE CORRECT PROTECTIVE GLOVES BEFORE YOU TOUCH THE COMPRESSOR SHAFT OR TRAY.
  Move the tray out of the oven on to the pallet.
9. Install the lifter on to the end of the compressor shaft. Refer to Step thru Step.
10. Lift the compressor shaft off the pallet and put it above the stages 3 to 12 compressor disks assembly.
11. 1. CAUTION
    YOU MUST MAKE SURE THE SLAVE NUTS AND SPACERS INSTALLED IN TASK 72-41-00-440-002-A00, 72-41-00-440-070 ARE REMOVED BEFORE INSTALLING THE COMPRESSOR SHAFT.
    Make sure the position of the compressor shaft in relation to the stages 3 to 12 compressor disks assembly is that calculated in Step.
  2. Lower the compressor shaft on to the stages 3 to 12 compressor disks. Make sure the 40 square headed bolts engage in the holes in the compressor shaft front flange. Refer to Figure.
  3. Install eight slave nuts, on to the square head bolts at position numbers 1, 25, 3, 27, 2, 26, 4 and 28. Refer to Figure. Torque the eight nuts to 180 lbfin to 220 lbfin (20 Nm to 25 Nm), in sequence.
  4. Let the assembly become cool and remove the eight slave nuts.
  5. Install the 40 nuts HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-852) on to the square headed bolts.
  6. Torque all the nuts to 180 lbfin to 220 lbfin (20 Nm to 25 Nm), in the sequence given in Figure.
12. Remove the lifter from the end of the compressor shaft. Move the sleeve on the lifter to make the lifter safe.
1. Refer to Figure
2. Install IAE 1R18062 Master curic base 1 off, IAE 1R18086 Clamp assembly 4 off, IAE 1R18087 Block 4 off and IAE 1R18085 Adjusting unit 4 off on to the Rotary air table. Refer to TASK 72-41-10-440-001.
1. Use IAE 1R18088 Pillar 1 off and measuring equipment to correct the run-out of the assembled tools. Refer to TASK 72-41-10-440-001.
1. Refer to Figure, Figure, Figure and Figure
2. 1. Engage the lifter on to the end of the compressor shaft.
  2. Turn the lifter clockwise to move the lifter on to the compressor shaft.
  3. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the compressor shaft.
  4. Tighten the lockscrew in to the lifter. Make sure the lockscrew goes in to a slot on the end of the compressor shaft. If the lockscrew does not go in to a slot, then turn the lifter anti-clockwise until the lockscrew will go in to the first available slot.
  5. Turn the sleeve until a hoist can be attached to the lift eye.
  6. Attach a hoist to the lift eye.
3. CAUTION
  YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS AND COMPRESSOR SHAFT ASSEMBLY HIT THE BUILD STAND.
  Lift the stages 3 to 12 compressor disks and compressor shaft assembly off the build stand.
4. 1. Install IAE 1R18091 Support stand 1 off on to the top of IAE 1R18090 Safety support stand 1 off. Make sure that the stand adapter is correctly engaged in the safety support stand. Refer to Figure.
  2. Put the stages 3 to 12 compressor disks and compressor shaft assembly above the safety support stand.
  3. CAUTION
    YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS AND COMPRESSOR SHAFT ASSEMBLY HIT THE SAFETY SUPPORT STAND.
    Slowly lower the stages 3 to 12 compressor disks and compressor shaft assembly on to the safety support stand. Make sure the stage 3 disk curvic coupling goes through the hole in the stand adapter.
  4. Continue to lower the stages 3 to 12 compressor disks and compressor shaft assembly until the stage 3 disk touches the stand adapter.
  5. Examine the curvic teeth of the master curvic base and the stage 3 disk curvic coupling for contamination and/or high metal. If there is contamination then the curvic teeth must be cleaned. If there is high metal, use a stone to make the surface smooth. Refer to Figure.
5. Lift the stages 3 to 12 compressor disks and compressor shaft assembly and put it above the master curvic base.
6. Install IAE 1R18063 Location piece 1 off on to the master curvic base.
7. CAUTION
  YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS AND COMPRESSOR SHAFT ASSEMBLY HIT THE MASTER CURVIC BASE.
  Slowly lower the stages 3 to 12 compressor disks and compressor shaft assembly until the location piece is engaged in the bore of the stage 3 compressor disk. Make sure that the four location dowels in the master curvic base are aligned with the four holes in the stage 3 disk curvic coupling.
8. Continue to lower the stages 3 to 12 compressor disks and compressor shaft assembly until the four location dowels are engaged in the stage 3 disk curvic coupling. Lower the stage 3 compressor disk on to the master curvic base.
9. Install the IAE 1R18064 Bolt 20 off through the master curvic base in to the stage 3 disk curvic coupling. Lightly tighten the bolts.
  NOTE
  The torque sequence is identified on the outer diameter of the master curvic base front flange.
10. 1. Torque all of the bolts to 18 lbfin (2.034 Nm).
  2. Torque all of the bolts to 35 lbfin (3.955 Nm).
  3. Torque all of the bolts to 70* lbfin (7.900* Nm).
11. 1. Remove the lifter from the end of the compressor shaft.
  2. Move the sleeve on the lifter to make the lifter safe.
1. Refer to Figure and Figure
2. Find the eight numbered positions on the compressor shaft front seal face (face V). Refer to TASK 72-41-10-440-001.
3. 1. Measure the swash at the eight positions found in Step.
  2. Set the computer to the applicable program and put the swash values in to the computer. The computer will calculate the FIR and the angle of the swash. Make a mark on CoMat 02-130 POLAR GRAPH PAPER to show the FIR and angle and identify it as S1.
  3. Measure the run-out at the eight positions found in Step.
  4. Put the run-out values in to the computer. The computer will calculate the FIR and the angle of the run-out. Make a mark on the CoMat 02-130 POLAR GRAPH PAPER to show the FIR and angle and identify it as R1.
4. 1. Attach IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft. Refer to Step.
  2. Remove the 20 bolts from the master curvic base and the stage 3 disk curvic coupling.
  3. Lift the stage 3 to 12 compressor disks and compressor shaft assembly off the master curvic base.
  4. Turn the Rotary air table and assembled tools through 180 degrees. Make sure the stages 3 to 12 compressor disks and compressor shaft assembly do not move.
  5. Install the stages 3 to 12 compressor disks and compressor shaft assembly on to the master curvic base. Refer to Step.
5. Measure the swash and run-out, refer to Step.Identify the swash as S2 and the run-out as R2 on the CoMat 02-130 POLAR GRAPH PAPER.
6. 1. Make a line between the points S1 and S2. Make a mark at the middle position between the points S1 and S2. Identify this point as S3.
  2. Make a line between the points R1 and R2. Make a mark at the middle position between the points R1 and R2. Identify this point as R3.
  3. Make a line between the point S3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.
  4. Make a line between the point R3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.
    NOTE
    The distance between the points S1 or S2 and the point S3, (distance G), shows the swash error in the tools.
  5. The distance between the center of the CoMat 02-130 POLAR GRAPH PAPER and the point S3, (distance H), shows the correct swash of the stages 3 to 12 compressor disks and compressor shaft assembly.
  6. Write down the amount and angle of the correct swash.
    NOTE
    The distance between the points R1 or R2 and the point R3, (distance J), shows the run-out error in the tools.
  7. The distance between the center of the CoMat 02-130 POLAR GRAPH PAPER and the point R3, (distance K), shows the correct run-out of the stages 3 to 12 compressor disks and compressor shaft assembly.
  8. Write down the amount and angle of the correct run-out.
7. If the swash is more than 0.002in. (0.051 mm) and/or the run-out is more than 0.014in. (0.356 mm) then reject the assembly. If the swash and run-out is less than these values then continue to assemble the compressor rotor assembly.
8. 1. Use a brush to apply CoMat 07-091 POTASSIUM SILICATE SOLUTION in line with the maximum run-out. Apply the solution on face W. Refer to Figure.
  2. Use a brush to apply CoMat 07-090 YELLOW MARKING PAINT,WATER BASED on to the potassium silicate solution in line with the maximum run-out.

SUBTASK 72-41-10-220-062 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1008

Refer to Figure.

Reference dimensions at location 1008. If required use the data written as a note in the applicable TASK. Refer to TASK 72-41-13-200-000 and TASK 72-41-14-200-000.

Table 12. 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 1008
HP Compressor Shaft HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-850), Rear Location Bore
HP Compressor Rotating Air Seals ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-800), Front Location Diameter Shaft Bore
Compressor Shaft Bore	10.1340	Intf	10.1330
	10.1360	0.0018	10.1360
Seal Diameter	10.1380	0.0060	10.1380
	10.1400	Intf	10.14000

Table 13. 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 1008
HP Compressor Shaft HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-850), Rear Location Bore
HP Compressor Rotating Air Seals ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-800), Front Location Diameter Shaft Bore
Compressor Shaft Bore	257.404	Intf	257.378
	257.454	0.046	257.454
Seal Diameter	257.500	0.146	257.500
	257.550	Intf	257.550

1. Refer to Figure, Figure, Figure and Figure
2. Put IAE 1R18673 Dummy stub shaft 1 off in to IAE 1R18075 Support pedestal 1 off with the curvic teeth at the top. Refer to Figure.
  NOTE
  The compressor disks and shaft assembly is installed in the master curvic base. Refer to Step.
3. 1. Engage the lifter on to the end of the compressor shaft.
  2. Turn the lifter clockwise to move the lifter on to the compressor shaft.
  3. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the shaft.
  4. Tighten the lockscrew in to the lifter. Make sure the lockscrew goes in to a slot in the end of the compressor shaft. If the lockscrew does not go in to a slot, then turn the lifter counter clockwise until the lockscrew will go in to the first availiable slot.
  5. Turn the sleeve until a hoist can be attached to the lift eye.
  6. Attach a hoist to the lift eye.
4. 1. Remove the 20 bolts from the master curvic base and the stage 3 disk curvic coupling.
  2. Lift the compressor disks and shaft assembly off the master curvic base.
5. 1. Install IAE 1R18091 Support stand 1 off on to the top of IAE 1R18090 Safety support stand 1 off. Make sure that the stand adapter is correctly engaged in the safety support stand. Refer to Figure.
  2. Put the compressor disks and shaft assembly above the safety support stand.
  3. CAUTION
    YOU MUST NOT LET THE COMPRESSOR DISKS AND SHAFT ASSEMBLY HIT THE SAFETY SUPPORT STAND.
    Slowly lower the compressor disks and shaft assembly on to the safety support stand. Make sure the stage 3 disk curvic coupling goes through the hole in the stand adapter.
  4. Continue to lower the compressor disks and shaft assembly until the stage 3 disk touches the stand adapter.
  5. Examine the curvic teeth of the stage 3 disk curvic coupling for contamination and/or high metal. If there is contamination then the curvic teeth must be cleaned. If there is high metal, use a stone to make the surface smooth.
  6. Examine the curvic teeth of the dummy stub shaft. Refer to Figure.
    Remove the three nuts from the three bolts that safety the curvic protector to the dummy stub shaft and remove the curvic protector.
    Examine the curvic teeth of the dummy stub shaft for contamination and/or high metal. If there is contamination then the curvic teeth must be cleaned. If there is high metal, use a stone to make the surface smooth.
6. Lift the compressor disks and shaft assembly and put it above the dummy stub shaft.
7. 1. Make sure that the four location dowels in the dummy stub shaft are aligned with the four holes in the stage 3 disk curvic coupling.
  2. Slowly lower the compressor disks and shaft assembly on to the dummy stub shaft.
  3. Engage the 20 bolts in the dummy stub shaft in to the threads in the stage 3 disk curvic coupling and lightly tighten the bolts.
  4. Torque all of the bolts. Do these three steps in the sequence shown. Refer to Figure.
    Torque all of the bolts to 18 lbfin (2.034 Nm).
    Torque all of the bolts to 35 lbfin (3.955 Nm).
    Torque all of the bolts to 70* lbfin (7.900* Nm).
1. Refer to Figure and Figure
2. Lift the compressor disks and shaft assembly off the support pedestal and put it above IAE 1R18020 Build stand 1 off. Refer to Figure.
3. Slowly lower the compressor disks and shaft assembly in to the build stand. Make sure the dummy stub shaft engages in the location in the bottom of the build stand.
4. Remove the eight screws from the top of the build stand.
  NOTE
  The edge of the support ring that touches the compressor disks and shaft assembly is at an angle. Thus, one face of the support ring is shorter than the other face. The short face must go to the top.
5. Put one half of IAE 1R18021 Support ring 1 off on to the top of the build stand and align the four holes in the support ring with four holes in the build stand. Install four of the screws through the support ring in to the build stand. Tighten the screws.
6. Install the other half of the support ring. Refer to Step.
7. Remove the lifter from the end of the compressor shaft. Refer to Figure.
8. Move the sleeve on the lifter to make the lifter safe.
1. Refer to Figure and Figure
2. WARNING
  YOU MUST PUT ON THE CORRECT GLOVES BEFORE YOU USE LIQUID NITROGEN.
  Put the compressor rotating air seal fully in to CoMat 03-026 LIQUID NITROGEN until the violent action of the bubbles decreases.
3. 1. Put the compressor rotating air seal over the compressor shaft with the location diameter at the bottom. Engage the compressor rotating air seal on to the compressor shaft. Make sure that the 36 holes in the compressor rotating air seal are aligned with the correct holes in the compressor shaft.
  2. Install eight of the 18 bolts ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-808) through the compressor rotating air seal in to the compressor shaft. Install the bolts at the position numbers 1 thru 8. Refer to Figure.
  3. Torque the bolts, in sequence, to 85 lbfin to 105 lbfin (10 Nm to 12 Nm).
  4. Allow the temperature of the assembly to come to room temperature.
4. Install the other 10 bolts ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-808) through the compressor rotating air seal in to the compressor shaft. Install the bolts at the position numbers 9 thru 18. Lightly tighten the bolts.
5. Install the 18 bolts ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-785) through the compressor rotating air seal in to the compressor shaft. Install the bolts at the position numbers 19 thru 36. Lightly tighten the bolts.
6. 1. Release the bolts tightened in Step.
  2. Torque the 18 bolts ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-808) to 85 lbfin to 105 lbfin (10 Nm to 12 Nm) in the sequence given on Figure position numbers 1 thru 18.
  3. Torque the 18 bolts ENGINE-HP COMPRESSOR ROTATING AIR SEALS (72-41-14, 01-785) to 36 lbfin to 45 lbfin (4 Nm to 5 Nm) in the sequence given on Figure position numbers 19 thru 36.
1. Refer to Figure, Figure and Figure.
2. 1. Put the cover over the compressor shaft. Move the cover down the shaft.
  2. Engage the cover over the compressor rotating air seal. Make sure the cover is correctly installed on the seal.
  3. Attach the 'O'-ring on to the 'O'-ring location to safety the cover.
3. 1. Engage the lifting adapter on to the compressor shaft. Tighten the lifting adapter.
4. 1. Lift pin E and put the adapter end of the tool in to the lifting adapter. Turn the tool to engage the locations. Lower the pin E.
  2. Install the lifting end of the tool in to the adapter end. Install the trunnion pin through both parts of the tool and tighten it.
  3. Tighten the lock nut on to the lifting adapter. Attach a hoist to the lift eye.
5. CAUTION
  YOU MUST NOT LET THE COMPRESSOR DISKS AND SHAFT ASSEMBLY HIT THE BUILD STAND.
  Remove the compressor disk and shaft assembly from the build stand.
6. 1. Install IAE 1R18091 Support stand 1 off on to IAE 1R18090 Safety support stand 1 off and install the compressor disks and shaft assembly on to the safety support stand. Refer to Step.
  2. Attach the universal slinging adapter on to the dummy stub shaft. Refer to Step thru Step.
7. Lift the compressor disks and shaft assembly off the safety support stand.
8. 1. Move the compressor disks and shaft assembly and put it above the trolley. Make sure trunnions on the universal slinging adapter (front) are above the trunnion supports.
  2. Lower the compressor disks and shaft assembly until the trunnions are engaged in to the trunnion supports.
  3. Adjust the position and height of the hoist so that the compressor disks and shaft assembly turns to the horizontal position. Make sure that the trunnions on the universal slinging adapter (rear) engage in to the trunnion supports.
9. Remove the hoist.
10. 1. Remove the eight bolts from the trolley rail locations.
  2. Install the rails on to the trolley and safety with the eight bolts.
1. Refer to Figure.
  NOTE
  Each nut and screw lock assembly is a set and must not be divided.
2. WARNING
  WHEN YOU USE CoMat 01-001 SOLVENT, DELETED OR CoMat 01-002 SOLVENT, DELETED. 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 CoMat 01-001 SOLVENT, DELETED or CoMat 01-002 SOLVENT, DELETED. and a cloth to clean the threads of the two Stage 6 nut and screw lock assemblies HPC Rotor Blades (72-41-15, 02-165).
3. Use a brush to apply CoMat 10-070 ANTI-SEIZE COMPOUND to the threads of the Stage 6 nut and screw and lock assemblies.
4. Install the screws in to the nuts. Make sure the bottom end of the jacking screws are below the surface of nuts.
5. Install the nut and screw lock assemblies through the Stage 6 blade loading slots and move them to their correct position.
6. Torque the jacking screws to 4 lbfin to 5 lbfin (0.45 Nm to 0.56 Nm) above the applicable locking torque.
7. 1. The screws must not be more than 0.0137 in. (0.347 mm) above the top of the nuts and not more than 0.0787 in. (1.999 mm) below the top of the nuts. Get the dimension at the position of the nut that points to the front of the engine.
8. 1. Do Step thru Step again on the stage 7 nut and screw lock assemblies.
9. 1. Do Step thru Step again on the stage 8 nut and screw lock assemblies.
10. 1. Do Step thru Step again on the Stage 9 nut and screw lock assemblies.
11. 1. Do Step thru Step again on the Stage 10 nut and screw lock assemblies.
12. 1. Do Step thru Step again on the Stage 11 nut and screw lock assemblies.
13. 1. Do Step thru Step again on the Stage 12 nut and screw lock assemblies.

Stages 3 to 8 HP Compressor Disks, the Vortex Reducer Ring, the Stages 9 to 12 HP Compressor Disks and the HP Compressor Shaft

Stages 3 to 8 HP Compressor Disks and Vortex Reducer Ring Data

Sheet 1

Sheet 2

Remove the Vortex Reducer Ring from the Stages 9 to 12 HP Compressor Disks

Remove the Stages 3 to 8 HP Compressor Disks from the Support Tool

Install the Stages 3 to 8 HP Compressor Disks in to the Build Stand

Install the Lifter on to the Stages 3 to 8 HP Compressor Disks

Install the Stages 9 to 12 HP Compressor Disks and Vortex Reducer Ring Assembly on to the Stages 3 to 8 HP Compressor Disks

Remove the Lifting Fixture from the Stage 12 HP Compressor Disk Rear Flange

Swash and run-out Data

Assemble the Tools used to Measure the Swash and run-out of the Stages 3 to 12 HP Compressor Disks assembly

Remove the Stages 3 to 12 HP Compressor Disks Assembly from the Build Stand

Install the Stage 3 to 12 Compressor Disks in the Safety Support Stand

Measure the Stages 3 to 12 HP Compressor Disks Assembly

Stage 3 Disk Curvic Coupling Bolts Torque Sequence

Calculate the Correct Swash and run-out Values

Examine the Double Retaining Washer

Stages 3 to 12 HP Compressor Disks Assembly and HP Compressor Shaft Data

Prepare the Stages 3 to 12 HP Compressor Disks Assembly

Install the Lifter on to the HP Compressor Shaft

Put the HP Compressor Shaft in to the Oven

Install the HP Compressor Shaft on to the Stages 3 to 12 HP Compressor Disks Assembly

Sequence to Tighten the Stage 12 disk to HP Compressor Shaft Joint Nuts

Measure the Swash and the run-out of the Stages 3 to 12 HP Compressor Disks and the HP Compressor Shaft Assembly

Install the HP Compressor Rotating Air Seal

Install the Dummy Stub Shaft

Install the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly in to the Build Stand

HP Compressor Rotating Air Seal Bolts Torque Sequence

Install the Protective Cover on to the HP Compressor Rotating Air Seal

Install the Lifting Adapter and the Universal Slinging Adapter on to the HP Compressor Shaft

Install the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly in to the Trolley

Install the Nut and Screw Lock Assemblies in to the Stages 6 thru 12 HP Compressor Disks

HP Compressor Stage 3 to 8 Disks Inspection Location for Damage

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:	71984
Enterprise Name:	DOW SILICONES CORP
BU Name:	DOW SILICONES CORP
Street:	2200 W SALZBURG RD
City:	MIDLAND
State:	MI
Zip Code:	48611
Country:	UNITED STATES OF AMERICA
Phone Number:	1-800-248-2481, 1-989-496-7881, 1-989-496-6000
Fax Number:	1-989-496-6731, 1-989-496-5956
Internet:	www.dowcorning.com

Manufacturer Code:	IE304
Enterprise Name:	DELETED
BU Name:	DELETED,SEE CAGE CODE 0V6W9

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:	0AM53
Tool Number:	IAE 1R18020
Tool Name:	IAE 1R18020 Build stand

TASK 72-41-10-440-002-A00 HPC Rotor Assembly - Assemble The Rotor Assembly, Assembly-002

Export Control

Copyright

Applicability

Common Information

TASK 72-41-10-440-002-A00 HPC Rotor Assembly - Assemble The Rotor Assembly, Assembly-002

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-41-10-220-084 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1005

SUBTASK 72-41-10-220-056 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1006

SUBTASK 72-41-10-220-085 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1007

SUBTASK 72-41-10-440-056 Calculate the Data Used to Find the Best Position of the Stages 3 to 8 HP Compressor Disks (01-200), the Vortex Reducer Ring (01-575) and the Stages 9 to 12 HP Compressor Disks (01-600), in Relation to Each Other

NOTE

SUBTASK 72-41-10-440-057 Install the Vortex Reducer Ring (72-41-12, 01-575) onto the Stages 9 to 12 HP Compressor Disks (72-41-12, 01-600) (SBE 72-0632)

NOTE

WARNING

CAUTION

CAUTION

SUBTASK 72-41-10-440-058 Install the Stages 9 to 12 HP Compressor Disks and Vortex Reducer Ring Assembly on to the Stages 3 to 8 HP Compressor Disks (01-200)

NOTE

NOTE

WARNING

CAUTION

SUBTASK 72-41-10-440-351 Assemble the HP Compressor Rotor Disks

SUBTASK 72-41-10-220-097 Examine the HP Compressor Stage 3 to 8 Disk for Surface Damage

SUBTASK 72-41-10-440-065 Assemble the Tools used to Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks Assembly

SUBTASK 72-41-10-440-066 Correct the Run-out of the Assembled Tools

SUBTASK 72-41-10-440-067 Install the Stages 3 to 12 HP Compressor Disks Assembly on to the Master Curvic Base

CAUTION

CAUTION

CAUTION

NOTE

SUBTASK 72-41-10-220-057 Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks Assembly

NOTE

NOTE

SUBTASK 72-41-10-440-068 Disassemble, Examine and Assemble the Stages 3 to 12 HP Compressor Disks Assembly

NOTE

CAUTION

NOTE

NOTE

SUBTASK 72-41-10-440-069 Install the Stages 3 to 12 HP Compressor Disks Assembly in to the Build Stand

SUBTASK 72-41-10-220-059 Examine the Double Retaining Washer

SUBTASK 72-41-10-220-060 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1062

SUBTASK 72-41-10-440-144 Calculate the Data Used to Find the Best Position of the HP Compressor Shaft (01-850) in Relation to the Stages 3 to 12 HP Compressor Disks Assembly

NOTE

SUBTASK 72-41-10-440-070 Prepare the Stages 3 to 12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (01-850),and.

NOTE

CAUTION

CAUTION

CAUTION

SUBTASK 72-41-10-440-071 Install the HP Compressor Shaft (01-850) on to the Stages 3 to 12 HP Compressor Disks Assembly

WARNING

CAUTION

SUBTASK 72-41-10-440-072 Assemble the Tools Used to Measure the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly

SUBTASK 72-41-10-440-073 Correct the Run-out of the Assembled Tools

SUBTASK 72-41-10-440-074 Install the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly on to the Master Curvic Base

CAUTION

CAUTION

CAUTION

NOTE

SUBTASK 72-41-10-220-061 Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly

NOTE

NOTE

SUBTASK 72-41-10-220-062 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1008

SUBTASK 72-41-10-440-075 Install the Dummy Stub Shaft on to the HP Compressor Disks and Shaft Assembly

NOTE

CAUTION

CAUTION

SUBTASK 72-41-10-440-076 Install the HP Compressor Disks and Shaft Assembly in to the Build Stand

NOTE

SUBTASK 72-41-10-440-077 Install the HP Compressor Rotating Air Seal (01-800)

WARNING