TASK 72-41-10-440-002-B00 HPC Rotor Assembly - Assemble The Rotor Assembly, Assembly-002

DMC:V2500-A0-72-41-1000-02C-710A-B|Issue No:009.00|Issue Date:2020-02-01

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-B00 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-B00 (ASSEMBLY-003).

Grind the tips of the HP Compressor Blades by TASK 72-41-10-440-004-B00 (ASSEMBLY-004).

Final balance the HP Compressor Rotor Assembly by TASK 72-41-10-440-005-B00 (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:

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 SmartStack 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

NameManufacturerPart Number / IdentificationQuantityRemark
Air circulated ovenLOCALAir circulated oven
ComputerLOCALComputer
Heat resistant glovesLOCALHeat resistant gloves
Rotary air tableLOCALRotary air table
Soft Faced MalletLOCALSoft Faced Mallet
Nylon Drift (maximum length = 6 inches, maximum diameter = 0.75 inch)LOCALNylon Drift
IAE 1P18865 Immobilizer tool0AM53IAE 1P18865
IAE 1R18020 Build stand0AM53IAE 1R180201
IAE 1R18021 Support ring0AM53IAE 1R180211
IAE 1R18022 Support ring0AM53IAE 1R180221
IAE 1R18059 Trolley0AM53IAE 1R180591
IAE 1R18061 Rail0AM53IAE 1R180612
IAE 1R18062 Master curic base0AM53IAE 1R180621
IAE 1R18063 Location piece0AM53IAE 1R180631
IAE 1R18064 Bolt0AM53IAE 1R1806420
IAE 1R18065 Lifter0AM53IAE 1R180651
IAE 1R18075 Support pedestal0AM53IAE 1R180751
IAE 1R18078 Clamp assembly0AM53IAE 1R180786
IAE 1R18085 Adjusting unit0AM53IAE 1R180854
IAE 1R18086 Clamp assembly0AM53IAE 1R180864
IAE 1R18087 Block0AM53IAE 1R180874
IAE 1R18088 Pillar0AM53IAE 1R180881
IAE 1R18089 Lifting adapter0AM53IAE 1R180891
IAE 1R18090 Safety support stand0AM53IAE 1R180901
IAE 1R18091 Support stand0AM53IAE 1R18091
IAE 1R18094 Washer0AM53IAE 1R180948
IAE 1R18095 Universal slinging adapter0AM53IAE 1R180952
IAE 1R18096 Pallet0AM53IAE 1R180961
IAE 1R18441 Lifting adapter0AM53IAE 1R18441
IAE 1R18443 Puller0AM53IAE 1R184431
IAE 1R18673 Dummy stub shaft0AM53IAE 1R186731
IAE 1R18683 Caliper adapter0AM53IAE 1R186831
IAE 1R18691 Lifting fixture0AM53IAE 1R186911
IAE 1R18692 Indexing ring0AM53IAE 1R18692
IAE 1R18708 Protection cover0AM53IAE 1R187081
IAE 1R18776 Spacer0AM53IAE 1R1877614

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-001 SOLVENT, DELETEDX111XCoMat 01-001
CoMat 01-002 SOLVENT, DELETED.X111XCoMat 01-002
CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYONIE304CoMat 02-121
CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYONK6835CoMat 02-122
CoMat 02-130 POLAR GRAPH PAPERLOCALCoMat 02-130
CoMat 03-026 LIQUID NITROGENLOCALCoMat 03-026
CoMat 07-038 AIR DRYING ENAMELk3504CoMat 07-038
CoMat 07-090 YELLOW MARKING PAINT,WATER BASEDLOCALCoMat 07-090
CoMat 07-091 POTASSIUM SILICATE SOLUTIONLOCALCoMat 07-091
CoMat 10-070 ANTI-SEIZE COMPOUNDLOCALCoMat 10-070
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077
CoMat 10-142 ANTI-SEIZE PASTE71984CoMat 10-142

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
BOLT0AM53BLT536834

(SBE 72-0632)

PLATE0AM536A379517

(SBE 72-0632)

WASHER0AM536A415920

(SBE 72-0632)

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-10-220-077 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1006

    2. Refer to Figure.

    3. 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 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 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 ENGINE-HP COMPRESSOR DISCS (STAGES 9-12) (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 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 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 ENGINE-HP COMPRESSOR DISCS (STAGES 9-12) (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

    1. SUBTASK 72-41-10-440-119 Calculate the Data Used to Find the Best Position of the Stages 3 to 8 HP Compressor Disks (72-41-11, 01-200), the Vortex Reducer Ring (72-41-12, 01-575) and the Stages 9 to 12 HP Compressor Disks (72-41-12, 01-600), in Relation to Each Other

    2. Refer to Figure.

    3. Measure the length of the stages 9 to 12 compressor disks. Write down this value.

      1. Calculate the radius of the stages 3 to 8 compressor disks rear location diameter.

      2. Measure the rear location diameter, (diameter E), of the stages 3 to 8 compressor disks.

      3. Divide the value from Step by two. This will give the radius. Write down this value.

      1. Calculate the total swash effect, (TSE).

        1. Use the subsequent formula to calculate the TSE.

        2. where;

        3. 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.

      2. Write down the value and angle of TSE.

        NOTE

        The angle of TSE is the angle of the swash of the stages 3 to 8 compressor disks plus 180 degrees.
      1. Calculate the combined swash and run-out effect of the stages 3 to 8 compressor disks.

      2. Set the computer to the applicable program.

      3. 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.

      4. 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.

      5. The computer will calculate the value and angle of combined swash and run-out effect.

      6. Write down the value and angle of combined swash and run-out effect.

      7. 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. SUBTASK 72-41-10-440-120 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)

      CAUTION

      BE CAREFUL WHEN YOU MOVE AND ASSEMBLE THE VORTEX REDUCER TO PREVENT DAMAGE TO THE VORTEX REDUCER. DAMAGE TO THE VORTEX REDUCER CAN CAUSE A VORTEX REDUCER FRACTURE IN SERVICE.
    2. Refer to Figure, Figure, Figure and Figure.

    3. Operate the turnover stand to turn the stages 9 to 12 compressor disks until the lifter is at the bottom.

      NOTE

      The stages 9 to 12 compressor disks are installed in the turnover stand.
      If the HP compressor stage 3-8 drum is exchanged at this shop visit with a Pre SBE 72-0376 standard HP compressor stage 3-8 drum with a life of less than 3000 cycles since new, then the operated vortex reducer must be replaced with a new vortex reducer.
    4. Examine the front mating face of the Stage 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.

    5. SBE 72-0632: 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 Stage 9 Compressor Disk Front Flange. Turn the special head bolts so that they are correctly engaged.

    6. 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.

      1. Install the Vortex Reducer Ring on to the Stage 9 Compressor Disk.

      2. Find the position of correct run-out of the Stage 12 Compressor Disk rear location diameter (diameter N). Refer to TASK 72-41-10-440-001.

      3. 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.

      4. 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.

      5. Install the Vortex Reducer Ring (with the front flange at the top) over the 34 special headed bolts, on to the Stage 9 Compressor Disk. Make sure that the two positions found in Step and Step are opposite each other.

      6. Install IAE 1R18094 Washer 8 off on to eight equally spaced special headed bolts.

      7. SBE 72-0632: 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).

      8. Let the temperature of the assembly come to room temperature.

      9. Remove the eight nuts and washers.

      1. Make sure that the 34 special headed bolts HPC Stage 9 - 12 Drum Disk And Vortex Reducer Ring (72-41-12, 01-608) are engaged correctly.

      2. Make sure that the 34 special headed 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.

      3. If one or more of the special headed bolts can turn more than five degrees, then do Step.

      1. Correct the incorrectly engaged special headed bolt(s). Refer to Figure.

        1. Install IAE 1R18443 Puller 1 off on to the Vortex Reducer Ring.

        2. Loosen the eight clamp nuts sufficient to let the four clamps be moved to the center of the removal puller.

        3. Lift the clamp nuts and move the clamps to the center of the removal puller.

        4. Make sure that the six extraction bolts are fully retracted.

        5. 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.

        6. Use the handles to lift the removal puller and install it on to the Stage 9 Compressor Disk. Engage the special headed bolts through the holes in the removal puller.

        7. Make sure that all of the pressure ring touches the Stage 9 Compressor Disk.

        8. 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 Stage 9 Compressor Disk.

      4. Use the handles to lift the removal puller and Vortex Reducer Ring Assembly off the Stage 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. SUBTASK 72-41-10-440-121 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)

    2. NOTE

      The stages 3 to 8 compressor disks are installed in the support tool.
    3. 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.

    4. 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 °F (150 °C).

      1. Prepare the stages 9 to 12 compressor disks to be installed on to the stages 3 to 8 compressor disks. Refer to Figure.

      2. Operate the turnover stand to turn the stages 9 to 12 compressor disks until the lifting fixture is at the top.

      3. Attach a hoist to the lift eye of the lifting fixture that is attached to the stages 9 to 12 compressor disk.

      4. Adjust the height of the hoist to hold the weight of the stages 9 to 12 compressor disks.

      5. Remove six of the 12 nuts that safety one half of the adapter plate to the turnover stand adapter.

      6. Remove one half of the adapter plate.

        1. Disengage the stages 9 to 12 compressor disks from the other half of the adapter plate.

        2. Disengage the stages 9 to 12 compressor disks from the adapter plate.

        3. 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.

      1. Prepare the build stand for use. Refer to Figure.

      2. Remove the eight screws from the top of IAE 1R18020 Build stand 1 off.

      3. Put IAE 1R18022 Support ring 1 off on to the top of the build stand with the spigot diameter at the bottom.

      4. Adjust the support ring until the eight holes in the support ring are aligned with the eight holes in the build stand.

      5. 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.
    5. 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 Stage 12 Compressor Disk after assembly. Write down the calculated values of swash and run-out.

      1. WARNING

        YOU MUST PUT ON THE CORRECT PROTECTIVE GLOVES BEFORE YOU TOUCH THE STAGES 3 TO 8 COMPRESSOR DISKS OR THE SUPPORT TOOL.

        Prepare the stages 3 to 8 compressor disks for assembly.

      2. Remove the stages 3 to 8 compressor disks and the support tool assembly from the air circulating oven.

        1. Install IAE 1R18065 Lifter 1 off on to the Stage 8 Compressor Disk. Refer to Figure.

        2. Loosen the two right hand nuts sufficient to let the right hand clamp be moved to the center of the lifter.

        3. Loosen the two left hand nuts sufficient to let the left hand clamp be moved to the center of the lifter.

        4. Lift the right and left hand nuts and move the clamps to the center of the lifter.

        5. Put the lifter on to the Face C of the Stage 8 Compressor Disk, with the lift eye to the top.

        6. Move the clamps to the outer edge of the lifter.

        7. Tighten the right and left hand nuts.

        8. Attach a hoist to the lift eye.

      3. Carefully lift the stages 3 to 8 compressor disks out of the support tool.

      4. Put the stages 3 to 8 compressor disks above the build stand.

        1. 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. Refer to Figure.

        2. Carefully lower the stages 3 to 8 compressor disks on to the build stand.

        3. 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.

        1. Remove the lifter from the Stage 8 Compressor Disk.

        2. Loosen the two right and the two left hand nuts sufficient to let the two clamps be moved to the center of the lifter.

        3. Move the two clamps to the center of the lifter.

        4. Lift the lifter off the stages 3 to 8 compressor disks.

        5. Remove the lifter from the hoist.

      1. Do a check of the interference Location 1005. Refer to Figure.

      2. 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 0.0044 in. (0.113 mm) interference.

        1. If you can not get the interference fit given in Step.

          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.

          2. and/or.

        2. Examine the Stage 3 To 8 Compressor Disk Assembly location diameter. Refer to TASK 72-41-11-200-001-B00, 72-41-11-220-086, para. A.

      1. Install the stages 9 to 12 compressor disks on to the stages 3 to 8 compressor disks. Refer to Figure.

      2. Put the stages 9 to 12 compressor disks above the stages 3 to 8 compressor disks.

      3. 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.

      4. 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.

        1. Attach IAE 1R18078 Clamp assembly 6 off on to the stages 8 to 9 joint.

        2. Make sure the nuts of each clamp assembly are loose.

        3. Install the clamp assemblies in to the stage 8 and 9 blade grooves at six equally spaced positions.

        4. Tighten the clamp assembly nuts in sequence.

      5. Let the assembly become cool.

        1. Remove the lifter from the Stage 12 Compressor Disk Rear Flange. Refer to Figure.

        2. 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.

        3. Lift the two right hand and the two left hand nuts and move the clamps to the center of the lifter.

        4. Lift the lifter off the Stage 12 Compressor Disk Rear Flange.

        5. Remove the lifter from the hoist.

    1. SUBTASK 72-41-10-440-352 Assemble the HP Compressor Rotor Disks

      1. For disk assembly using Tool Part number IAE1R19895.

      1. For disk assembly using Tool Part number IAE1P16616.

    1. SUBTASK 72-41-10-220-099 Examine the HP Compressor Stages 3 to 8 Disk for Surface Damage

    2. Refer to Figure.

      1. Examine the HP compressor stages 3 to 8 disk interstage cavity between at stage 7 and Stage 8 Disks for damage. Refer to TASK 72-41-11-200-000 (Inspection/Check-000).

        1. General nicks, dents, scratches and scores not more than 0.002 in. (0.05 mm).

        2. Accept.

        1. Other than Step.

        2. Reject.

      1. Visually examine the nuts to confirm seating.

        1. Properly seated.

        2. Accept.

        1. Other than Step.

        2. Reject.

      1. Examine the HP Compressor stages 3 to 8 disks at stage 7 and 8 diaphragm bore and surface for damage. Refer to TASK 72-41-11-200-000 (Inspection/Check-000).

        1. Nicked, dented, scratched or scored.

        2. Reject.

    1. SUBTASK 72-41-10-440-128 Assemble the Tools used to Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks Assembly

    2. Refer to Figure.

    3. 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. SUBTASK 72-41-10-440-129 Correct the Run-out of the Assembled Tools

    2. 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. SUBTASK 72-41-10-440-130 Install the Stages 3 to 12 HP Compressor Disks Assembly on to the Master Curvic Base

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

      1. Install IAE 1R18691 Lifting fixture 1 off on to the Stage 12 Compressor Disk Rear Flange. Refer to Figure.

      2. Loosen the two right hand nuts sufficient to let the right hand clamp be moved to the center of the lifting fixture.

      3. Loosen the two left hand nuts sufficient to let the left hand clamp be moved to the center of the lifting fixture.

      4. Lift the right and left hand nuts and move the clamps to the center of the lifting fixture.

      5. Put the lifting fixture on to the Stage 12 Compressor Disk Rear Flange, with the lift eye to the top.

      6. Move the clamps to the outer edge of the lifting fixture.

      7. Tighten the right and left hand nuts.

      8. 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 Stage 3 To 12 Compressor Disks Assembly off the build stand.

      1. Examine the curvic teeth of the Stage 3 Disk and the master curvic base curvic couplings.

      2. 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.

      3. Put the Stage 3 To 12 Compressor Disks Assembly above the safety support stand.

      4. CAUTION

        YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE SAFETY SUPPORT STAND.

        Slowly lower the Stage 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.

      5. Continue to lower the Stage 3 To 12 Compressor Disks Assembly until the Stage 3 Disk touches the stand adapter.

      6. 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.

    4. Install IAE 1R18063 Location piece 1 off on the master curvic base. Refer to Figure.

    5. Lift the Stage 3 To 12 Compressor Disks Assembly off the safety support stand and put it above the master curvic base.

    6. CAUTION

      YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE MASTER CURVIC BASE.

      Slowly lower the Stage 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. Refer to Figure.

    7. Continue to lower the Stage 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.

    8. Install the IAE 1R18064 Bolt 20 off through the master curvic base, in to the Stage 3 Disk Curvic Coupling. Lightly tighten the bolts.

      1. Torque all of the bolts. Do these three steps in the sequence shown. Refer to Figure.

        NOTE

        The torque sequence is identified on the outer diameter of the master curvic base front flange.
      2. Torque all of the bolts to 18 lbfin (2.034 Nm).

      3. Torque all of the bolts to 35 lbfin (3.955 Nm).

      4. Torque all of the bolts to 70 * lbfin (7.900 Nm).

      1. Remove the lifting fixture from the Stage 12 Compressor Disk Rear Flange. Refer to Figure.

      2. 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.

      3. Lift the two right and the two left hand nuts and move the clamps to the center of the lifting fixture.

      4. Lift the lifting fixture off the Stage 12 Compressor Disk Rear Flange.

      5. Remove the lifting fixture from the hoist.

    1. SUBTASK 72-41-10-220-079 Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks Assembly

    2. Refer to Figure and Figure.

    3. Find the eight numbered positions on the rear of the Stage 12 Compressor Disk. The positions are identified on the face P. Refer to TASK 72-41-10-440-001.

      1. Use IAE 1R18088 Pillar 1 off and measuring equipment to measure the swash of face M and the run-out of face N.

      2. Measure the swash at the eight positions found in Step.

      3. 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.

      4. Measure the run-out at the eight positions found in Step.

      5. 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.

      1. Turn the Stage 3 To 12 Compressor Disks Assembly 180 degrees in relation to the master curvic base.

      2. Attach IAE 1R18691 Lifting fixture 1 off on to the Stage 12 Compressor Disk Rear Flange. Refer to Step.

      3. Remove the 20 bolts from the master curvic base and the Stage 3 Disk Curvic Coupling.

      4. Lift the Stage 3 To 12 Compressor Disks Assembly off the master curvic base.

      5. Turn the rotary air table and assembled tools through 180 degrees. Make sure the Stage 3 To 12 Compressor Disks Assembly does not move.

      6. Install the Stage 3 To 12 Compressor Disks Assembly on to the master curvic base. Refer to Step.

    4. 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.

      1. Calculate the correct swash and run-out values.

      2. 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.

      3. 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.

      4. Make a line between the point S3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.

      5. 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.
      6. 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 Stage 3 To 12 Compressor Disks Assembly.

      7. 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.
      8. 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 Stage 3 To 12 Compressor Disks Assembly.

      9. Write down the amount and angle of correct run-out.

      1. Make an analysis of the Stage 3 To 12 Compressor Disks Assembly, swash and run-out values.

      2. Compare the swash and run-out values (refer to Step and Step) to those calculated in Step.

      3. 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.

        1. 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.

        2. 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.

        3. 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-B00 again.

    1. SUBTASK 72-41-10-440-131 Disassemble, Examine and Assemble the Stages 3 to 12 HP Compressor Disks Assembly

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

    3. Remove the Stage 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.
      1. Install the stages 3 to 12 compressor Disks in to IAE 1R18020 Build stand 1 off. Refer to Figure.

      2. Put the Stage 3 To 12 Compressor Disks Assembly above the build stand.

        1. CAUTION

          YOU MUST NOT LET THE STAGES 3 TO 12 COMPRESSOR DISKS ASSEMBLY HIT THE BUILD STAND.

          Install the Stage 3 To 12 Compressor Disks Assembly on to the build stand.

        2. Carefully lower the Stage 3 To 12 Compressor Disks Assembly on to the build stand.

        3. Continue to lower the Stage 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 Stage 12 Compressor Disk Rear Flange. Refer to Step.

      1. Make sure that the swash and run-out of the master curvic base is correct. Refer to TASK 72-41-10-440-001.

        If the swash and run-out of the master curvic base was correct, then continue to Step.

        If the swash and run-out of the master curvic base was incorrect, then do the subsequent procedure.

      2. Install the Stage 3 To 12 Compressor Disks Assembly on to the master curvic base. Refer to Step.

      3. Measure the swash and run-out of the Stage 3 To 12 Compressor Disks Assembly. Refer to Step.

        1. Make an analysis of the Stage 3 To 12 Compressor Disks Assembly, swash and run-out values.

        2. Compare the swash and run-out values (refer to Step) to those calculated in 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.

        4. If the difference between the two sets of swash and run-out values is less than 0.0003 in. (0.008mm), 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.
    4. 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.

    5. 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.
    6. 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.

    7. If the swash and run-out of the Stage 3 To 12 Compressor Disks Assembly is more than the limits given in Step, then the assembly must be rejected.

    1. SUBTASK 72-41-10-440-132 Install the Stages 3 to 12 HP Compressor Disks Assembly in to the Build Stand

    2. Refer to Figure and Figure.

    3. Remove the Stage 3 To 12 Compressor Disks Assembly from the master curvic base. Refer to Step and Figure.

    4. Install the Stage 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. SUBTASK 72-41-10-220-081 Examine the Double Retaining Washer

    2. Refer to Figure.

    3. 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 14 off.

    4. Write down the value of the dimension.

    5. Do Step and Step. again on the other 19 washers.

    1. SUBTASK 72-41-10-220-082 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1062 (Pre SB 72-0687)

    2. Refer to Figure.

    3. 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 4. 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

      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

      0.1575

      0.1614

      0.002

      Inner Location Width

      0.1535

      0.012

      0.1555

      Table 5. 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

      4.000

      4.100

      0.05

      Inner Location Width

      3.900

      0.30

      3.950

    1. SUBTASK 72-41-10-440-133 Calculate the Data Used to Find the Best Positon of the HP Compressor Shaft (01-850) in Relation to the Stages 3 to 12 HP Compressor Disks Assembly

    2. Refer to Figure.

    3. Measure the length of compressor shaft. Write down this value as 'L'.

      1. Calculate the radius of the compressor shaft front location bore.

      2. Measure the diameter of the front location bore (diameter Q).

      3. Divide the value from Step by two. This will give the radius. Write down this value.

      1. Calculate the total swash effect, (TSE).

        1. Use the subsequent formula to calculate the TSE.

          TSE = S x L

          r

        2. Where;

          S

          -

          The swash of the Stage 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 Stage 3 To 12 Compressor Disks Assembly plus 180 degrees.
      2. Write down the value and angle of TSE.

      1. Calculate the combined swash and run-out effect of the Stage 3 To 12 Compressor Disks Assembly.

      2. Set the computer to the applicable program.

      3. 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.

      4. 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.

      5. The computer will calculate the value and angle of combined swash and run-out effect.

      6. Write down the value and angle of combined swash and run-out effect. These values are necessary when you do Step.

    1. SUBTASK 72-41-10-440-134 Prepare the Stages 3 to 12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (72-41-13, 01-520) (Pre SB 72-0687)

    2. Refer to Figure.

    3. 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.

      NOTE

      The Stage 3 To 12 Compressor Disks Assembly is installed in the build stand.
      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 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 ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-850), Front Location Bore

      Compressor Disk Diameter

      9.8065

      Intf

      9.8060

      9.8083

      0.0015

      9.8080

      Compressor Shaft Bore

      9.8031

      0.0051

      9.8020

      9.8050

      Intf

      9.8050

      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 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 ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-850), Front Location Bore

      Compressor Disk Diameter

      249.084

      Intf

      249.072

      Intf

      249.130

      0.038

      249.123

      0.026

      Compressor Shaft Bore

      249.000

      0.130

      248.971

      0.145

      249.046

      Intf

      249.046

      Intf

      1. CAUTION

        A NEW DOUBLE RETAINING WASHER MUST BE USED IF THE TABS ARE MADE STRAIGHT DURING ASSEMBLY.

        Install 28 square head bolts HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-858) and double retaining washer 14 off HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-856) through the rear of the Stage 12 Compressor Disk Rear Flange.

      2. Install one double retaining washer on to the rear of the Stage 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.

      3. Install two of the square headed bolts through the rear of the Stage 12 Compressor Disk Rear Flange and the double retaining washer.

      4. Hold the square headed bolts in position with IAE 1R18776 Spacer spacer (14 per operation) and 2 slave nuts (28 slave nuts per operation).

      5. Do Step thru Step again until all of the square headed bolts, double retaining washers and spacer plates are installed.

      6. 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).

      7. 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.

      8. Remove the slave nuts and spacer plates.

    1. SUBTASK 72-41-10-440-253 Prepare the Stages 3 to 12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (72-41-13, 01-520) (Post SB 72-0687)

    2. Refer to Figure, Figure, and Figure.

    3. 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.

      NOTE

      The Stages 3 to 12 Compressor Disks Assembly is installed in the build stand.
      Table 10. Fits and Clearances (all dimensions are in inches)

      NEW PART

      WORN PART

      DIMENSIONS

      DIMENSIONS

      PART IDENT

      Size

      Clearance

      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 ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-850), Front Location Bore

      Compressor Disk Diameter

      9.8065

      Intf

      9.8060

      9.8083

      0.0015

      9.8080

      Compressor Shaft Bore

      9.8031

      0.0051

      9.8020

      9.8050

      Intf

      9.8050

      Table 11. Fits and Clearances (all dimensions are in millimeters)

      NEW PART

      WORN PART

      DIMENSIONS

      DIMENSIONS

      PART IDENT

      Size

      Clearance

      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 ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-850), Front Location Bore

      Compressor Disk Diameter

      249.084

      Intf

      249.072

      Intf

      249.130

      0.038

      249.123

      0.026

      Compressor Shaft Bore

      249.000

      0.130

      248.971

      0.145

      249.046

      Intf

      249.046

      Intf

      1. Install the washers and bolts onto the Stages 9-12 Drum Rear Flange.

      2. CAUTION

        MAKE SURE THAT THE MATING SURFACES ARE FREE OF ANY DAMAGE, BURRS AND DEBRIS BEFORE INSTALLATION OF THE IAE 1R18692 Indexing ring.

        Install the IAE 1R18692 Indexing ring or IAE 1R18776 Spacer on the rear flange of the stages 9-12 drum.

      3. Install the two bolts HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-858, pn AS58020) into one washer HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-856A, pn 6C6658).

      4. From fore face of the rear flange on the stages 9-12 drum to the aft face, place the bolts through the flange and the IAE 1R18692 Indexing ring or the IAE 1R18776 Spacer.

      5. Attach two work nuts onto the two bolts until hand tight.

      6. Repeat Step thru Step above for the remaining thirteen Rear Flange Washers.

      1. Install the retention blocks between the rear face and 12th stage disc bore.

      2. Install the ten Retention Blocks between the bolt head and the stages 9-12 drum bore. Top side of Retention Blocks will press against the bolt head and the bottom side of the Retention Blocks will press against the stages 9-12 Drum Bore.

        NOTE

        There are nine full-size and one half-size retention blocks in IAE 1P18865 Immobilizer tool. The half-size block is black in color and is to be the last block installed.
      3. Inspect the blocks, washers and bolts to make sure that all bolt washers and blocks are properly installed.

      4. Remove nuts installed in Step.

      5. Remove the Index ring or spacer installed in Step.

    1. SUBTASK 72-41-10-440-135 Install the HP Compressor Shaft (01-850) on to the Stages 3 to 12 HP Compressor Disks Assembly

    2. Refer to Figure, Figure and Figure.

      1. Install IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft. Refer to Figure.

      2. Engage the lifter on to the end of the compressor shaft.

      3. Turn the lifter clockwise to move the lifter on to the compressor shaft.

      4. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the compressor shaft.

      5. 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 counter clockwise until the lockscrew will go in to the first available slot.

      6. Turn the sleeve until a hoist can be attached to the lift eye.

      7. 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.

    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 °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 Stage 3 To 12 Compressor Disks Assembly (refer to Step). Use these values to calculate the position of the compressor shaft in relation to the Stage 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 Stage 3 To 12 Compressor Disks Assembly.

      1. Install the compressor shaft on to the Stage 3 To 12 Compressor Disks Assembly.

      2. CAUTION

        YOU MUST MAKE SURE THE SLAVE NUTS AND SPACERS, INSTALLED IN Step, ARE REMOVED BEFORE INSTALLING THE COMPRESSOR SHAFT.

        Make sure the position of the compressor shaft in relation to the Stage 3 To 12 Compressor Disks Assembly is that calculated in Step.

      3. Lower the compressor shaft on to the stages 3 to 12 compressor disks. Make sure the 28 square headed bolts engage in the holes in the compressor shaft front flange. Refer to Figure.

      4. Install eight slave nuts, on to the square headed bolts at position numbers 1, 13, 3, 27, 2, 14, 4 and 28. Refer to Figure. Torque the eight nuts to 290 lbfin to 370 lbfin (33 Nm to 42 Nm), in sequence.

      5. Let the assembly become cool.

    11. Remove the lifter from the end of the compressor shaft. Move the sleeve on the lifter to make the lifter safe.

    1. SUBTASK 72-41-10-440-141 Install the HP Compressor Rotating Air Seal (01-800)

    2. Refer to Figure and Figure.

    3. Remove the eight slave nuts, installed in Step, Step which attach the HPC shaft (01-850) to the stage 3 to 12 compressor disks.

    4. 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.

      1. Install the compressor rotating air seal on to the compressor shaft. Refer to Figure.

      2. Put the rotating air seal over the compressor shaft with the location diameter at the bottom.

      3. Lower the rotating air seal onto the compressor shaft until the 28 square headed bolts go into the 28 boltholes in the rotating air seal.

      4. Install eight slave nuts on the square headed bolts, at position numbers 1, 13, 3, 27, 2, 14, 4 and 28. Refer to Figure.

      5. Torque the eight nuts to 290 lbfin to 370 lbfin (33 Nm to 42 Nm) in sequence.

      6. Let the temperature of the assembly come to room temperature. Remove the eight slave nuts.

      7. Install the 28 nuts HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-852) on the square headed bolts.

      8. Torque the 28 nuts to 290 lbfin to 370 lbfin (33 Nm to 42 Nm) in the sequence given in Figure.

    1. 72-41-10-440-254 Remove Retention Blocks (post SB 72-0687)

    2. Refer to Figure.

    3. Locate and remove the retention blocks using the IAE 1P18865 Immobilizer tool.

      NOTE

      There are nine full-sized and one half-sized retention blocks in IAE 1P18865 Immobilizer tool. The half-size retention block is black in color and is to be the first block removed.
    4. Visually inspect between rear face and 12th stage disc bore using mirror or scope to confirm that all retention blocks have been removed.

    1. SUBTASK 72-41-10-440-136 Assemble the Tools Used to Measure the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly

    2. Refer to Figure.

    3. 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. SUBTASK 72-41-10-440-137 Correct the Run-out of the Assembled Tools

    2. 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. SUBTASK 72-41-10-440-138 Install the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly on to the Master Curvic Base

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

      1. Install IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft. Refer to Figure.

      2. Engage the lifter on to the end of the compressor shaft.

      3. Turn the lifter clockwise to move the lifter on to the compressor shaft.

      4. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the compressor shaft.

      5. 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 counterclockwise until the lockscrew will go in to the first available slot.

      6. Turn the sleeve until a hoist can be attached to the lift eye.

      7. 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.

      1. Examine the curvic teeth of the stage 3 disk and the master curvic base curvic couplings.

      2. 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.

      3. Put the stages 3 to 12 compressor disks and Compressor Shaft Assembly above the safety support stand.

      4. 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.

      5. Continue to lower the stages 3 to 12 compressor disks and Compressor Shaft Assembly until the stage 3 disk touches the stand adapter.

      6. 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.

    4. Install IAE 1R18063 Location piece 1 off on to the master curvic base.

    5. Lift the stages 3 to 12 compressor disks and Compressor Shaft Assembly and put it above the master curvic base.

    6. 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.

    7. 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.

    8. Install the IAE 1R18064 Bolt 20 off through the master curvic base in to the Stage 3 Disk Curvic Coupling. Lightly tighten the bolts.

      1. Torque all of the bolts. Do these three steps in the sequence shown. Refer to Figure.

        NOTE

        The torque sequence is identified on the outer diameter of the master curvic base front flange.
      2. Torque all of the bolts to 18 lbfin (2.034 Nm).

      3. Torque all of the bolts to 35 lbfin (3.955 Nm).

      4. Torque all of the bolts to 70 * lbfin (7.900 Nm).

      1. Remove the lifter from the end of the compressor shaft.

      2. Remove the lifter from the end of the compressor shaft.

      3. Move the sleeve on the lifter to make the lifter safe.

    1. SUBTASK 72-41-10-220-083 Measure the Swash and Run-out of the Stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly

    2. Refer to Figure and Figure.

    3. Find the eight numbered positions on the compressor shaft front seal face (face V). Refer to TASK 72-41-10-440-001.

      1. Use IAE 1R18088 Pillar 1 off and measuring equipment to measure the swash of face T and the run-out of diameter U. Refer to Figure and Figure.

      2. Measure the swash at the eight positions found in Step.

      3. 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.

      4. Measure the run-out at the eight positions found in Step.

      5. 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.

      1. Turn the stages 3 to 12 compressor disks and Compressor Shaft Assembly 180 degrees in relation to the master curvic base.

      2. Attach IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft. Refer to Step.

      3. Remove the 20 bolts from the master curvic base and the Stage 3 Disk Curvic Coupling.

      4. Lift the stage 3 to 12 compressor disks and Compressor Shaft Assembly off the master curvic base.

      5. 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.

      6. Install the stages 3 to 12 compressor disks and Compressor Shaft Assembly on to the master curvic base. Refer to Step.

    4. 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.

      1. Calculate the correct swash and run-out values.

      2. 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.

      3. 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.

      4. Make a line between the point S3 and the center of the CoMat 02-130 POLAR GRAPH PAPER.

      5. 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.
      6. 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.

      7. 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.
      8. 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.

      9. Write down the amount and angle of the correct run-out.

    5. If the swash is more than 0.002 in. (0.051 mm) and/or the run-out is more than 0.014 in. (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.

      1. Identify the Stage 3 Disk with the position of the maximum positive run-out of the rear bearing diameter (diameter U) on the compresser shaft.

      2. 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.

      3. 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.

    1. SUBTASK 72-41-10-220-084 Reference Fits and Clearances of the HP Compressor Rotor Assembly at Location 1008

    2. Refer to Figure.

    3. 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

      9.7598

      Intf

      9.7598

      Intf

      9.7627

      0.0004

      9.7627

      0.0003

      Seal Diameter

      9.7631

      0.0051

      9.7630

      0.0051

      9.7650

      Intf

      9.7650

      Intf

      NOTE

      Seal diameter on used parts below the minimum value of 9.7630 may be acceptable as long as the minimum interference fit (Intf) of 0.0003 with the related compressor shaft bore can be maintained.
      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

      247.900

      Intf

      247.900

      Intf

      247.973

      0.011

      247.973

      0.006

      Seal Diameter

      247.984

      0.130

      247.979

      0.130

      248.030

      Intf

      248.030

      Intf

      NOTE

      Seal diameter on used parts below the minimum value of 247.979 may be acceptable as long as the minimum interference fit (Intf) of 0.006 with the related compressor shaft bore can be maintained.
    1. SUBTASK 72-41-10-440-139 Install the Dummy Stub Shaft on to the HP compressor Disks and Shaft Assembly

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

    3. 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.
      1. Install IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft. Refer to Figure.

      2. Engage the lifter on to the end of the compressor shaft.

      3. Turn the lifter clockwise to move the lifter on to the compressor shaft.

      4. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and the lifter is tight on the shaft.

      5. 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 counterclockwise until the lockscrew will go in to the first availiable slot.

      6. Turn the sleeve until a hoist can be attached to the lift eye.

      7. Attach a hoist to the lift eye.

      1. Remove the compressor disks and shaft assembly from the master curvic base.

      2. Remove the 20 bolts from the master curvic base and the Stage 3 Disk Curvic Coupling.

      3. Lift the compressor disks and shaft assembly off the master curvic base.

      1. Examine the curvic teeth of the stage 3 disk and the dummy stub shaft curvic couplings.

      2. 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.

      3. Put the compressor disks and shaft assembly above the safety support stand.

      4. 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.

      5. Continue to lower the compressor disks and shaft assembly until the stage 3 disk touches the stand adapter.

      6. 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.

        1. Examine the curvic teeth of the dummy stub shaft.

        2. Remove the three nuts from the three bolts that safety the curvic protector to the dummy stub shaft and remove the curvic protector.

        3. 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.

    4. Lift the compressor disks and shaft assembly and put it above the dummy stub shaft.

      1. CAUTION

        YOU MUST NOT LET THE COMPRESSOR DISKS AND SHAFT ASSEMBLY HIT THE DUMMY STUB SHAFT OR THE SUPPORT PEDESTAL.

        Install the dummy stub shaft. Refer to Figure.

      2. 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.

      3. Slowly lower the compressor disks and shaft assembly on to the dummy stub shaft.

      4. 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.

        1. Torque all of the bolts. Do these three steps in the sequence shown. Refer to Figure.

        2. Torque all of the bolts to 18 lbfin (2.034 Nm).

        3. Torque all of the bolts to 35 lbfin (3.955 Nm).

        4. Torque all of the bolts to 70 * lbfin (7.900 Nm).

    1. SUBTASK 72-41-10-440-140 Install the HP Compressor Disks and Shaft Assembly in to the Build Stand

    2. Refer to Figure and Figure.

    3. Lift the compressor disks and shaft assembly off the support pedestal and put it above IAE 1R18020 Build stand 1 off. Refer to Figure.

    4. 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.

    5. Remove the eight screws from the top of the build stand.

    6. 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.

      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.
    7. Install the other half of the support ring. Refer to Step.

    8. Remove the lifter from the end of the compressor shaft. Refer to Figure.

    9. Move the sleeve on the lifter to make the lifter safe.

    1. SUBTASK 72-41-10-440-142 Install the stages 3 to 12 HP Compressor Disks and HP Compressor Shaft Assembly in to the Trolley

    2. Refer to Figure, Figure and Figure.

      1. Install IAE 1R18708 Protection cover 1 off on to the compressor rotating air seal. Refer to Figure.

      2. Put the cover over the compressor shaft. Move the cover down the shaft.

      3. Engage the cover over the compressor rotating air seal. Make sure the cover is correctly installed on the seal.

      4. Attach the O-ring on to the O-ring location to safety the cover.

      1. Install IAE 1R18089 Lifting adapter 1 off on to the end of the compressor shaft.

      2. Engage the lifting adapter on to the compressor shaft. Tighten the lifting adapter.

      1. Attach one of IAE 1R18095 Universal slinging adapter 2 off, on to the lifting adapter. Refer to Figure.

      2. 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.

      3. 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.

      4. Tighten the lock nut on to the lifting adapter. Attach a hoist to the lift eye.

    3. 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.

      1. Install the other universal slinging adapter on to the dummy stub shaft.

      2. 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.

      3. Attach the universal slinging adapter on to the dummy stub shaft. Refer to Step thru Step.

    4. Lift the compressor disks and shaft assembly off the safety support stand.

      1. Install the compressor disks and shaft assembly in to IAE 1R18059 Trolley 1 off. Refer to Figure.

      2. 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.

      3. Lower the compressor disks and shaft assembly until the trunnions are engaged in to the trunnion supports.

      4. 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.

    5. Remove the hoist.

      1. Install IAE 1R18061 Rail 2 off on to the trolley.

      2. Remove the eight bolts from the trolley rail locations.

      3. Install the rails on to the trolley and safety with the eight bolts.

    1. SUBTASK 72-41-10-440-143 Install the Jacking Screw and Locknut Assemblies in to the Stages 6 thru 12 HP Compressor Disks

    2. Refer to Figure.

    3. 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 jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-165).

    4. Use a brush to apply CoMat 10-070 ANTI-SEIZE COMPOUND to the threads of the stage 6 jacking screw and locknut assemblies.

    5. Assemble the jacking screw and locknut assemblies. Make sure the bottom end of the screws are below the surface of nuts.

    6. Install the jacking screw and locknut assemblies through the stage 6 blade loading slots and move them to their correct position.

    7. Torque the screws to 4 lbfin to 5 lbfin (0.45 Nm to 0.56 Nm) above the applicable locking torque.

      1. Make sure that the screws are correctly installed.

      2. The screws must not be more than 0.0137 in. (0.347 mm) above the top of the nut and not more than 0.0787 in. (1.999 mm) below the top of the nut. Get the dimension at the position of the nut that points to the front of the engine.

      1. Install the two nut and screw lock assemblies HPC Rotor Blades (72-41-15, 02-265) in the stage 7 disk.

      2. Do Step thru Step again on the stage 7 nut and screw lock assemblies.

      1. Install the two jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-365) in the Stage 8 Disk.

      2. Do Step thru Step again on the stage 8 nut and screw lock assemblies.

      1. Install the two jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-465) in the Stage 9 Disk.

      2. Do Step thru Step again on the stage 9 nut and screw lock assemblies.

      1. Install the two jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-565) in the Stage 10 Disk.

      2. Do Step thru Step again on the stage 10 jacking screw and locknut assemblies.

      1. Install the two jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-665) in the Stage 11 Disk.

      2. Do Step thru Step again on the stage 11 jacking screw and locknut assemblies.

      1. Install the two jacking screw and locknut assemblies HPC Rotor Blades (72-41-15, 02-765) in the Stage 12 Disk.

      2. Do Step thru Step again on the stage 12 jacking screw and locknut assemblies.

  1. Figure: Stages 3 to 8 HP Compressor Disks, the Vortex Reducer Ring, the Stages 9 to 12 HP Compressor Disks and the HP Compressor Shaft (Pre SB 72-0687)

    Stages 3 to 8 HP Compressor Disks, the Vortex Reducer Ring, the Stages 9 to 12 HP Compressor Disks and the HP Compressor Shaft (Pre SB 72-0687)

    Figure: Stages 3 to 8 HP compressor disks and Vortex Reducer Ring data

    Stages 3 to 8 HP compressor disks and Vortex Reducer Ring data

    Figure: Install the Vortex Reducer Ring on to the stages 9 to 12 HP compressor disks

    Install the Vortex Reducer Ring on to the stages 9 to 12 HP compressor disks

    Figure: Install the Vortex Reducer Ring on to the stages 9 to 12 HP compressor disks

    Install the Vortex Reducer Ring on to the stages 9 to 12 HP compressor disks

    Figure: Remove the Vortex Reducer Ring from the stages 9 to 12 HP compressor disks

    Remove the Vortex Reducer Ring from the stages 9 to 12 HP compressor disks

    Figure: Remove the stages 3 to 8 HP compressor disks from the support tool

    Remove the stages 3 to 8 HP compressor disks from the support tool

    Figure: Install the stages 3 to 8 HP compressor disks in to the build stand

    Install the stages 3 to 8 HP compressor disks in to the build stand

    Figure: Install the lifter on to the stages 3 to 8 HP compressor disks

    Install the lifter on to the stages 3 to 8 HP compressor disks

    Figure: Install the stages 9 to 12 HP compressor disks and Vortex Reducer Ring Assembly 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

    Figure: Remove the lifter from the stage 12 HP compressor disk rear flange

    Remove the lifter from the stage 12 HP compressor disk rear flange

    Figure: Swash and run-out data

    Swash and run-out data

    Figure: Assemble the tools used to measure the swash and run-out of the stages 3 to 12 HP compressor disks assembly

    Assemble the tools used to measure the swash and run-out of the stages 3 to 12 HP compressor disks assembly

    Figure: Remove the stages 3 to 12 HP compressor disks assembly from the build stand

    Remove the stages 3 to 12 HP compressor disks assembly from the build stand

    Figure: Install the stage 3 to 12 compressor disks in the safety support stand

    Install the stage 3 to 12 compressor disks in the safety support stand

    Figure: Measure the stages 3 to 12 HP compressor disks assembly

    Measure the stages 3 to 12 HP compressor disks assembly

    Figure: Stage 3 Disk Curvic Coupling bolts torque sequence

    Stage 3 Disk Curvic Coupling bolts torque sequence

    Figure: Calculate the correct swash and run-out values

    Calculate the correct swash and run-out values

    Figure: Examine the double retaining washer

    Examine the double retaining washer

    Figure: Stages 3 to 12 HP compressor disks assembly and HP compressor shaft data

    Stages 3 to 12 HP compressor disks assembly and HP compressor shaft data

    Figure: Prepare the Stages 3 to 12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (Pre SB 72-0687)

    Prepare the Stages 3 to 12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (Pre SB 72-0687)

    Figure: Install the lifter on to the HP compressor shaft

    Install the lifter on to the HP compressor shaft

    Figure: Put the HP compressor shaft in to the oven

    Put the HP compressor shaft in to the oven

    Figure: Install the HP compressor shaft on to the stages 3 to 12 HP compressor disks assembly

    Install the HP compressor shaft on to the stages 3 to 12 HP compressor disks assembly

    Figure: Sequence to tighten the Stage 12 Disk to HP compressor shaft joint nuts

    Sequence to tighten the Stage 12 Disk to HP compressor shaft joint nuts

    Figure: Measure the swash and the run-out of the stages 3 to 12 HP compressor disks and the HP Compressor Shaft Assembly

    Measure the swash and the run-out of the stages 3 to 12 HP compressor disks and the HP Compressor Shaft Assembly

    Figure: Install the HP compressor rotating air seal

    Install the HP compressor rotating air seal

    Figure: Install the dummy stub shaft

    Install the dummy stub shaft

    Figure: Install the stages 3 to 12 HP compressor disks and HP Compressor Shaft Assembly in to the build stand

    Install the stages 3 to 12 HP compressor disks and HP Compressor Shaft Assembly in to the build stand

    Figure: Install the protection cover on to the HP compressor rotating air seal

    Install the protection cover on to the HP compressor rotating air seal

    Figure: Install the lifting adapter and the universal slinging adapter on to the HP compressor shaft

    Install the lifting adapter and the universal slinging adapter on to the HP compressor shaft

    Figure: Install the stages 3 to 12 HP compressor disks and HP Compressor Shaft Assembly in to the trolley

    Install the stages 3 to 12 HP compressor disks and HP Compressor Shaft Assembly in to the trolley

    Figure: Install the jacking screw and locknut assemblies in to the stages 6 thru 12 HP compressor disks

    Install the jacking screw and locknut assemblies in to the stages 6 thru 12 HP compressor disks

    Figure: HP Compressor Stage 3 to 8 Disks Inspection Location for Damage

    HP Compressor Stage 3 to 8 Disks Inspection Location for Damage

    Figure: Stages 3 to 8 HP Compressor Disks, the Vortex Reducer Ring, the Stages 9 to 12 HP Compressor Disks and the HP Compressor Shaft (Post SB 72-0687)

    Stages 3 to 8 HP Compressor Disks, the Vortex Reducer Ring, the Stages 9 to 12 HP Compressor Disks and the HP Compressor Shaft (Post SB 72-0687)

    Figure: Prepare the Stages 3-12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (Post SB 72-0687)

    Prepare the Stages 3-12 HP Compressor Disks Assembly for the Installation of the HP Compressor Shaft (Post SB 72-0687)

    Figure: (Post SB 72-0687) Configuration Immobilizer Tool (IAE 1P18865)

    (Post SB 72-0687) Configuration Immobilizer Tool (IAE 1P18865)

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added note. (19VG316)

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:X111X
Enterprise Name:N/A – DELETED CONSUMABLE MATERIAL
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Link not Found
Part Number:6A3795
Part Name:PLATE
Manufacturer Code:0AM53
Part Number:6A4159
Part Name:WASHER
Manufacturer Code:0AM53
Part Number:BLT5368
Part Name:BOLT
Manufacturer Code:0AM53
Manufacturer Code:X111X
Supply Number:CoMat 01-001
Type:sp01
Supply Short Name:CoMat 01-001 SOLVENT, DELETED
Supply Name:CoMat 01-001 SOLVENT, DELETED
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐001 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 01‐001 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: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:IE304
Supply Number:CoMat 02-121
Type:sp01
Supply Short Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Supply Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Specification Groups:
Doc NumberType
OMAT: 261BEROL VERITHIN (HARD TYPE)
Suppliers:
ManufacturerRemarks
IE304
K5720
K6835
LOCAL
Manufacturer Code:K6835
Supply Number:CoMat 02-122
Type:sp01
Supply Short Name:CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON
Supply Name:CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
K6835
IE133
Manufacturer Code:LOCAL
Supply Number:CoMat 02-130
Type:sp01
Supply Short Name:CoMat 02-130 POLAR GRAPH PAPER
Supply Name:CoMat 02-130 POLAR GRAPH PAPER
Specification Groups:
Doc NumberType
POLAR GRAPH PAPER
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-026
Type:sp01
Supply Short Name:CoMat 03-026 LIQUID NITROGEN
Supply Name:CoMat 03-026 LIQUID NITROGEN
Specification Groups:
Doc NumberType
OMAT:220BB-N-411 T2GBC1
JCR-135BB-N-411 T2GBC1
Suppliers:
ManufacturerRemarks
LOCAL
U2046
U2096
Manufacturer Code:00BB6
Supply Number:CoMat 07-038
Type:sp01
Supply Short Name:CoMat 07-038 AIR DRYING ENAMEL
Supply Name:CoMat 07-038 AIR DRYING ENAMEL
Specification Groups:
Doc NumberType
OMAT:7/22B (RR REF)IP9138 R1
JCR-029 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
K3504
Manufacturer Code:LOCAL
Supply Number:CoMat 07-090
Type:sp01
Supply Short Name:CoMat 07-090 YELLOW MARKING PAINT, WATERBASED
Supply Name:CoMat 07-090 YELLOW MARKING PAINT,WATER BASED
Specification Groups:
Doc NumberType
OMAT: 7/84PL 168A
Suppliers:
ManufacturerRemarks
LOCAL
85570
k3504
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 07-091
Type:sp01
Supply Short Name:CoMat 07-091 POTASSIUM SILICATE SOLUTION
Supply Name:CoMat 07-091 POTASSIUM SILICATE SOLUTION
Specification Groups:
Doc NumberType
OMAT:7/124AKASIL 33 WT RATIO 2-2.1
Suppliers:
ManufacturerRemarks
LOCAL
85570
k3504
Manufacturer Code:X222X
Supply Number:CoMat 10-070
Type:sp01
Supply Short Name:CoMat 10-070 ANTI-SEIZE COMPOUND
Supply Name:CoMat 10-070 ANTI-SEIZE COMPOUND
Specification Groups:
Doc NumberType
DELETED. USE COMAT 10-070A
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Manufacturer Code:3CU95
Supply Number:CoMat 10-142
Type:sp01
Supply Short Name:CoMat 10-142 ANTI-SEIZE PASTE
Supply Name:CoMat 10-142 ANTI-SEIZE PASTE
Specification Groups:
Doc NumberType
MOLYKOTE P-37
Suppliers:
ManufacturerRemarks
3CU95
818U1
Manufacturer Code:LOCAL
Tool Number:Air circulated oven
Tool Name:Air circulated oven
Manufacturer Code:LOCAL
Tool Number:Computer
Tool Name:Computer
Manufacturer Code:LOCAL
Tool Number:Heat resistant gloves
Tool Name:Heat resistant gloves
Manufacturer Code:0AM53
Tool Number:IAE 1P18865
Tool Name:IAE 1P18865 Immobilizer tool
Manufacturer Code:0AM53
Tool Number:IAE 1R18020
Tool Name:IAE 1R18020 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18021
Tool Name:IAE 1R18021 Support ring
Manufacturer Code:0AM53
Tool Number:IAE 1R18022
Tool Name:IAE 1R18022 Support ring
Manufacturer Code:0AM53
Tool Number:IAE 1R18059
Tool Name:IAE 1R18059 Trolley
Manufacturer Code:0AM53
Tool Number:IAE 1R18061
Tool Name:IAE 1R18061 Rail
Manufacturer Code:0AM53
Tool Number:IAE 1R18062
Tool Name:IAE 1R18062 Master curic base
Manufacturer Code:0AM53
Tool Number:IAE 1R18063
Tool Name:IAE 1R18063 Location piece
Manufacturer Code:0AM53
Tool Number:IAE 1R18064
Tool Name:IAE 1R18064 Bolt
Manufacturer Code:0AM53
Tool Number:IAE 1R18065
Tool Name:IAE 1R18065 Lifter
Manufacturer Code:0AM53
Tool Number:IAE 1R18075
Tool Name:IAE 1R18075 Support pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1R18078
Tool Name:IAE 1R18078 Clamp assembly
Manufacturer Code:0AM53
Tool Number:IAE 1R18085
Tool Name:IAE 1R18085 Adjusting unit
Manufacturer Code:0AM53
Tool Number:IAE 1R18086
Tool Name:IAE 1R18086 Clamp assembly
Manufacturer Code:0AM53
Tool Number:IAE 1R18087
Tool Name:IAE 1R18087 Block
Manufacturer Code:0AM53
Tool Number:IAE 1R18088
Tool Name:IAE 1R18088 Pillar
Manufacturer Code:0AM53
Tool Number:IAE 1R18089
Tool Name:IAE 1R18089 Lifting adapter
Manufacturer Code:0AM53
Tool Number:IAE 1R18090
Tool Name:IAE 1R18090 Safety support stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18091
Tool Name:IAE 1R18091 Support stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18094
Tool Name:IAE 1R18094 Washer
Manufacturer Code:0AM53
Tool Number:IAE 1R18095
Tool Name:IAE 1R18095 Universal slinging adapter
Manufacturer Code:0AM53
Tool Number:IAE 1R18096
Tool Name:IAE 1R18096 Pallet
Manufacturer Code:0AM53
Tool Number:IAE 1R18441
Tool Name:IAE 1R18441 Lifting adapter
Manufacturer Code:0AM53
Tool Number:IAE 1R18443
Tool Name:IAE 1R18443 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1R18673
Tool Name:IAE 1R18673 Dummy stub shaft
Manufacturer Code:0AM53
Tool Number:IAE 1R18683
Tool Name:IAE 1R18683 Caliper adapter
Manufacturer Code:0AM53
Tool Number:IAE 1R18691
Tool Name:IAE 1R18691 Lifting fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18692
Tool Name:IAE 1R18692 Indexing ring
Manufacturer Code:0AM53
Tool Number:IAE 1R18708
Tool Name:IAE 1R18708 Protection cover
Manufacturer Code:0AM53
Tool Number:IAE 1R18776
Tool Name:IAE 1R18776 Spacer
Link not Found
Manufacturer Code:LOCAL
Tool Number:Rotary air table
Tool Name:Rotary air table
Manufacturer Code:LOCAL
Tool Number:Soft Faced Mallet
Tool Name:Soft Faced Mallet