TASK 72-45-00-030-001-B00 HP Turbine (HPT) Rotor And Stator Assembly - Disassemble The HPT Rotor And Stator Assembly, Disassembly-001

DMC:V2500-A0-72-45-0000-00B-530A-B|Issue No:006.00|Issue Date:2021-02-01

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

V2500-A5

Common Information

TASK 72-45-00-030-001-B00 HP Turbine (HPT) Rotor And Stator Assembly - Disassemble The HPT Rotor And Stator Assembly, Disassembly-001

General

Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

Remove and discard the lockwire before parts are disconnected or removed.

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

Refer to TASK 72-45-00-990-501 (DESCRIPTION AND OPERATION) for a sectional view of the HP turbine rotor and stator assembly.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10052 Two cables sling0AM53IAE 1F100521
IAE 1P16028 Build stand0AM53IAE 1P160281
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P160461
IAE 1P16047 Hydraulic adapter0AM53IAE 1P160471
IAE 1P16051 Clamp0AM53IAE 1P160511
IAE 1P16055 Locator plug0AM53IAE 1P160551
IAE 1P16063 Fixture0AM53IAE 1P160631
IAE 1P16140 Support base0AM53IAE 1P161401
IAE 1P16173 Lift sling0AM53IAE 1P161731
IAE 1P16219 remove puller0AM53IAE 1P162191
IAE 1P16272 Adapter0AM53IAE 1P16272
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P165431
IAE 1P17021 Separate pusher0AM53IAE 1P170211
IAE 1P17022 Removal/installation jaws assembly0AM53IAE 1P170221
IAE 1P17024 Lift fixture0AM53IAE 1P170241
IAE 1P17026 Lift fixture0AM53IAE 1P17026
IAE 1P17758 Protective cover0AM53IAE 1P177581

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-149 DRY ICELOCALCoMat 02-149

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-45-00-030-062 Install the Tooling to Position the HP Turbine Rotor and Stator Assembly

    1. Refer to Figure.

    2. Remove the IAE 1P17758 Protective cover 1 off from the rear of the HP Turbine Rotor And Stator Assembly.

      1. Attach a standard two-cable sling to the two hoist rings on the fixture and attach the sling to a hoist.

      2. Loosen the eight hand knobs and move the center ring of the fixture to the rear until the flanged end is in line with the front surface of the hub of the fixture.

      3. Tighten two of the hand knobs (one in each row) to hold the center ring in this position.

      4. Lift the fixture and install on to the HP Turbine Assembly and align the offset hole in the fixture with the dowel pin in the HP Turbine Case Flange. Remove the sling and hoist.

      5. Attach the fixture with the two-piece ring on the HP Turbine Rear Flange front surface and the large offset hole over the flare of the dowel pin.

      6. Hold in position with the 25 bolts and nuts.

      7. Hold the center ring of the fixture and loosen the hand knobs.

      8. Move the center ring of the fixture down until it touches the rear surface of the second stage turbine hub.

      9. Remove the sling and the hoist.

      1. Install the four jaws (bolt flange up) in the inner diameter of the Stage 2 Hub.

      2. Move the jaws radially out until the lip on the jaws engage the inner diameter groove of the hub and the socket head capscrews engage the flange of the fixture center ring.

      3. Install the jaw assembly sleeve in to the jaws to move the jaws out. Align the slots in the sleeve with the large socket head capscrews. Install the sleeve until the flange contacts the jaws.

      4. Attach the jaws to the sleeve with the eight capscrews. Tighten the capscrews.

      5. Tighten the large socket head cap screws.

        6. Check to see if HPT is in the proper running position.

        1. NOTE

          Make sure when you take the measurements that the vernier does not go into the slots that are located on the hub flange.

          Measure the distance from the two machined areas of the fixture to the rear flange of the stage 2 hub. Use a depth vernier.

        2. To get dimension D, add the two measurements together and do an average of the total measurement.

        3. Subtract dimension D from the dimension marked on the machined surface of the fixture.

        4. This dimension must be 1.194 in. to 1.214 in. (30.33 mm to 30.84 mm). This is the HP Turbine Assembly running distance.

        5. If necessary, adjust the center pedestal of the build stand to get this running distance dimension.

        6. Tighten the hand knobs on the hub of the fixture to hold the pedestal of the build stand in position.

    2. SUBTASK 72-45-00-030-063 Remove the Ladder Lock

    1. Refer to Figure, Figure and Figure

    2. Attach the scalloped plate of the IAE 1P16047 Hydraulic adapter 1 off to the center ring on the fixture with the 12 tool bolts. Tighten the bolts.

    3. Install the smaller plate to the center of the scalloped plate, Figure.

    4. Attach the IAE 1F10052 Two cables sling 1 off with a hoist to the trunnion spools on the fixture and lift the assembly from the build stand, Figure.

    5. Turn the assembly to the front end up position and lower into the IAE 1P16028 Build stand 1 off.

    6. Remove the sling and the hoist.

      7. Install the IAE 1P16051 Clamp 1 off and the hydraulic cylinder, Figure.

      1. Remove the locator from the center adapter on the build stand and install the hydraulic cylinder detail of the IAE 1P16272 Adapter (with the threaded end down) to the center adapter on the stand.

      2. Install the detail clamp on to the stage 1 HP Turbine Hub. Position in to the internal fit.

      3. Install the jam nut on to one end of the rod and install the rod through the detail clamp, the scalloped adapter and the hydraulic cylinder. Hold in place with the washer and the nut. Hand tighten the nut.

      4. Attach the IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic adapter.

      5. Apply a hydraulic load to the adapter to move the two hubs together. Do not release the hydraulic load.

      6. Move the ladder lock up and out of the locked position.

      7. Release the hydraulic pressure.

      8. Remove the hand pump from the hydraulic adapter.

      9. Remove the nut and the washer from the lower end of the shaft and remove the shaft.

      10. Remove the clamp from the end of the stage 1 HP turbine hub.

      11. Remove the ladder lock from the center of the hub.

      12. Remove the hydraulic cylinder from the center adapter on the stand.

    3. SUBTASK 72-45-00-030-064 Turn the HP Turbine Rotor and Stator Assembly

    1. Refer to Figure and Figure

      2. Install the IAE 1P16055 Locator plug 1 off, Figure.

      1. Install the plug and rod assembly down through the rotor and through the IAE 1P16047 Hydraulic adapter at the base of the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture with the plug positioned in to the stage 1 turbine hub.

      2. Hold the plug and rod assembly in position with the washer and the nut. Tighten the nut.

    3. Attach IAE 1F10052 Two cables sling 1 off with a hoist to the trunnion spools on the fixture, Figure.

    4. Lift the HP Turbine Rotor and Stator Assembly from the build stand. Turn the assembly to position the front end down.

    5. Install the build stand locator on to the center adapter on the build stand.

    6. Lower the assembly in to the build stand with the locator plug positioned in to the locator on the build stand.

    7. Adjust the center locator on the build stand to support the rotor.

    8. Remove the sling and the hoist.

    4. SUBTASK 72-45-00-030-065 Remove the Tooling from the HP Turbine Rotor and Stator Assembly

    1. Refer to Figure.

    2. Remove the nut and the washer which hold the locator plug in position. Use a wrench on the inner diameter of the shaft and remove the locator plug shaft.

      3. Remove the IAE 1P17022 Removal/installation jaws assembly 1 off from the fixture.

      1. CAUTION

        THE HP TURBINE ROTOR MUST BE SUPPORTED BY THE CENTER LOCATOR ON THE BUILD STAND TO PREVENT DAMAGE TO THE PARTS.

        Remove the hexagon head bolts which hold the inner sleeve to the jaws.

      2. Remove the inner sleeve from the jaws.

      3. Release the socket head capscrews which hold the jaws to the stage 2 rotor and remove the jaws from the rotor.

      4. Remove the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture from the turbine rotor and stator assembly.

      1. Release and remove the 25 bolts and nuts which hold the two piece ring and the fixture to the HP Turbine Case Rear Flange. Remove the two piece ring.

      2. Attach a standard two-cable sling to a hoist and to the two lift rings on the fixture.

      3. Carefully lift the fixture from the HP Turbine Rotor and Stator Assembly.

    5. SUBTASK 72-45-00-030-066 Install the Retaining Fixture to the Stage 2 Turbine Rotor Assembly

    1. Refer to Figure.

      2. Prepare the IAE 1P16063 Fixture 1 off.

      1. Put the retaining fixture on a work bench with the larger outer diameter up.

      2. Remove all the hook assemblies from the fixture.

      3. Loosen the wing nut on the six clamp assemblies.

      4. Turn the clamp lugs to a horizontal position and tighten the wing nuts.

      5. Position the ring assembly on the inner side of the airseal on the stage 2 HPT retaining plate.

        6. Install one hook assembly through the ring assembly and push the pin in and turn and position the hook on the leading edge of the blade.

        1. Install and position three hook assemblies 90 degrees apart by the procedure given above.

      7. Loosen the wing nut on the six clamp assemblies.

      8. Turn and position the clamp lugs to below the airseal on the retaining plate and tighten the wing nuts.

      9. Install the hook assemblies that remain by the procedure given in Step.

    6. SUBTASK 72-45-00-030-067 Remove the Stage 2 Turbine Rotor Assembly from the Stage 1 Turbine Rotor Assembly

    1. Refer to Figure, Figure and Figure.

      1. Install the expander assembly detail of the pusher in to the HP Turbine Rotor.

      2. Align the jaws with the ladder lock groove in the Stage 1 Turbine Rotor Hub.

      3. Turn the hexagon nut to extend the jaws out in to the groove until the nut can not move freely.

      4. Install the two jaws in to the inner diameter of the stage 2 turbine rotor hub 180 degrees apart. Push the jaws out to touch the hub and attach with the swivel screw clamps.

      5. Install the ring assembly with the hydraulic cylinder through the jaws on the stage 2 rotor over the expander assembly.

      6. Attach the ring assembly to the jaws with the hexagon head bolts. Tighten the bolts.

      7. Attach the IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic cylinder.

      8. Apply a hydraulic load to move apart the stage 2 rotor from the Stage 1 Rotor.

      9. Release the hydraulic pressure and remove the hand pump from the hydraulic cylinder.

      10. Release and remove the hexagon head bolts which hold the ring assembly to the jaws on the Stage 2 Rotor. Remove the ring assembly from the rotor.

      11. Release the swivel screw clamps and remove the two jaws from the Stage 2 Rotor.

      12. Turn the hexagon nut on the expander assembly to release the jaws from the Stage 1 Rotor and remove the expander assembly from the rotor.

      3. Install the IAE 1P17026 Lift fixture 1 off, Figure.

      1. Turn the three hooks on the lift fixture in.

      2. Install the lift fixture to the inner diameter of the Stage 2 Turbine Rotor Assembly.

      3. Turn the jaws out to engage the jaws with the groove in the Stage 2 Turbine Rotor. Tighten the hand knobs to hold the jaws in place.

      4. Attach a hoist to the lift fixture and remove the Stage 2 Turbine Rotor from the assembly.

      5. Lower the Stage 2 Turbine Rotor to the IAE 1P16140 Support base 1 off and remove the hoist, Figure.

      6. Remove the seal from the groove on the rear of the stage 2 HPT airseal. Discard the seal.

    7. SUBTASK 72-45-00-030-073 Remove Spacer

    1. Remove No. 4 bearing spacer HP Turbine (HPT) Rotor And Stator Assembly (72-45-00, 01-061) thru HP Turbine (HPT) Rotor And Stator Assembly (72-45-00, 01-070) from the stage 1 turbine rotor assembly.

    8. SUBTASK 72-45-00-030-068 Remove the Lift Fixture

    1. Refer to Figure.

    2. Release the hand knobs and turn the jaws in on the lift fixture.

    3. Remove the lift fixture.

    9. SUBTASK 72-45-00-030-069 Remove the Retaining Fixture

    1. Refer to Figure.

    2. Push the hook assembly pins in and turn all the hooks 90 degrees from the leading-edge of the blades.

    3. Loosen the wing nut on the six clamp assemblies.

    4. Turn and position the clamp lugs to disengage from the airseals and tighten the wing nuts.

    5. Remove the retaining fixture from the Stage 2 Rotor Assembly and put in storage.

    10. SUBTASK 72-45-00-220-242 Inspect HPT Stage 2 Rotor

    1. Examine the Stage 2 Rotor Assembly for soot and oil. If soot and oil found, do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

    11. SUBTASK 72-45-00-030-070 Remove the HP Turbine Case and Vane Assembly

    1. Refer to Figure.

    2. Attach the IAE 1P16173 Lift sling 1 off to a hoist and to the rear flange of the HP Turbine Case.

    3. Attach the sling to the case at three equally spaced bolt holes with the washers and the nuts. Tighten the nuts.

    4. Lift the HP Turbine Case and vane assembly slowly, from the Stage 1 Turbine Rotor Assembly and the stand.

    5. Put the case and vane assembly on the workbench and remove the sling and the hoist.

    6. Install the IAE 1P17758 Protective cover 1 off on the rear flange of the case and vane assembly.

    12. SUBTASK 72-45-00-220-243 Measure Bore Drop of the Stage 2 HP Turbine Airseal Installed on HPT Stage 1 Rotor Assembly

    1. Refer to Figure.

    2. Use SPOP 209 (TASK 70-11-03-300-503) wipes to remove dirt and residue from rear flange and bore surface of the Stage 2 HP Turbine Airseal.

      3. Measure the bore drop of the Stage 2 HP Turbine Airseal per limits in TASK 72-45-00-200-000.

      1. If bore axial position out of limit, do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

      2. If bore axial position is within the limits, make a record in the relevant part and engine documents.

    13. SUBTASK 72-45-00-030-071-A00 Remove the Stage 2 HP Turbine Airseal (Pre SBE 72-0158)

    1. Refer to Figure, Figure and Figure.

    2. Install the lift assembly of the IAE 1P16055 Locator plug 1 off to the center of the stage 1 HP Turbine Hub and attach to the detail plug, Figure.

    3. Attach a hoist to the lift assembly.

    4. Lift the Stage 1 Rotor Assembly and airseal from the build stand and install in to the IAE 1P16140 Support base 1 off. Remove the hoist, Figure.

    5. Remove the lift assembly from the plug and remove these tools from the rotor assembly.

      6. Install the IAE 1P16219 remove puller 1 off, Figure.

      1. Remove the four pins from the four clamps and move the clamps to the inner position.

      2. Install the puller into the bore of the Stage 1 Turbine Rotor Assembly.

      3. Move the four clamps to the outer position, under the airseal flange. Install the four pins.

      4. Attach the IAE 1F10026 Hydraulic hand pump 1 off to the puller.

    7. Apply a hydraulic load with the hand pump to release the stage 2 HPT airseal.

      8. Remove the puller from the seal.

      1. Release the pressure from the hand pump and disconnect the hand pump from the hydraulic cylinder.

      2. Remove the four pins from the four clamps and push the clamps in. Install the pins in the clamps.

      3. Remove the puller from the seal assembly.

    9. Remove the stage 2 HP turbine airseal from the Stage 1 Turbine Rotor Assembly.

    10. Remove and discard the two seals from the rear of the Stage 1 Turbine Rotor Assembly.

    14. SUBTASK 72-45-00-030-071-B00 Remove the Stage 2 HP Turbine Airseal (SBE 72-0158)

      SBE 72-0158: 72-0158': Remove the stage 1 and 2 turbine wire seal

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

    2. Install the lift assembly detail of the IAE 1P16055 Locator plug 1 off to the center of the stage 1 HP Turbine Hub and attach it to the detail plug.

    3. Attach a hoist to the lift assembly.

    4. Lift the Stage 1 Rotor Assembly and airseal from the build stand and install it into the IAE 1P16140 Support base 1 off. Remove the hoist.

    5. Remove the lift assembly from the plug and remove the tools from the rotor assembly.

    6. Cool the Stage 2 HPT Airseal with CoMat 02-149 DRY ICE around the front flange.

      7. Remove the Stage 2 HP Turbine Airseal from the Stage 1 Turbine Rotor Assembly.

      1. If the Stage 2 Airseal cannot be removed with the CoMat 02-149 DRY ICE, use IAE 1P16219 remove puller tool.

      8. Install the IAE 1P16219 remove puller 1 off.

      1. Remove the four pins from the four clamps and move the clamps to the inner position.

      2. Install the puller into the bore of the Stage 1 Turbine Rotor Assembly.

      3. Move the four clamps to the outer position, under the airseal flange. Install the four pins.

      4. Attach the IAE 1F10026 Hydraulic hand pump 1 off to the puller.

    9. Apply a hydraulic load with the hand pump to release the stage 2 HPT airseal.

      10. Remove the puller from the seal.

      1. Release the pressure from the hand pump and disconnect the hand pump from the hydraulic cylinder.

      2. Remove the four pins from the four clamps and push the clamps in. Install the pins in the clamps.

      3. Remove the puller from the seal assembly.

    11. Remove the stage 2 HP turbine airseal from the Stage 1 Turbine Rotor Assembly.

    12. Remove and discard the seal from the rear of the Stage 1 Turbine Rotor Assembly.

    15. SUBTASK 72-45-00-220-244 Inspect the Stage 2 HP Turbine Airseal, Regardless of Whether the Seal is to be Returned to Service or Not

    1. Examine the Stage 2 HP Turbine Airseal for soot and oil. If soot and oil found, do inspection of HPT for possible oil ignition event. Refer to TASK 72-45-00-200-801. Report all findings to IAE Technical Services.

    2. Examine the Stage 2 HP Turbine Airseal Part Numbers 2A1160, 2A3108, 2A3179, 2A3425, 2A3596 for cracks. Refer to TASK 72-45-00-200-000.

    16. Figure: Install tooling for the HP Turbine Rotor and Stator Assembly

    Install tooling for the HP Turbine Rotor and Stator Assembly

    Figure: Turn HP Turbine Rotor and Stator Assembly

    Turn HP Turbine Rotor and Stator Assembly

    Figure: HP Turbine Rotor and Stator Assembly Clamp Installation

    HP Turbine Rotor and Stator Assembly Clamp Installation

    Figure: Locator Plug Installation

    Locator Plug Installation

    Figure: HP Turbine Rotor and Stator Locator Plug Installation

    HP Turbine Rotor and Stator Locator Plug Installation

    Figure: IAE 1P16063 Retaining Fixture Installation

    IAE 1P16063 Retaining Fixture Installation

    Figure: IAE 1P17021 Separate Pusher

    IAE 1P17021 Separate Pusher

    Figure: Remove Stage 2 Turbine Rotor Assembly

    Remove Stage 2 Turbine Rotor Assembly

    Figure: Install the Stage 2 Turbine Rotor Assembly To The Support

    Install the Stage 2 Turbine Rotor Assembly To The Support

    Figure: Remove the HP Turbine Case and Vane Assembly

    Remove the HP Turbine Case and Vane Assembly

    Figure: Remove the Stage 1 Rotor Assembly and Airseal From The Build Stand

    Remove the Stage 1 Rotor Assembly and Airseal From The Build Stand

    Figure: Stage 1 HP Turbine Rotor Assembly and Airseal

    Stage 1 HP Turbine Rotor Assembly and Airseal

    Figure: Pre SBE 72-0158: Remove the Stage 2 HPT Airseal

    Pre SBE 72-0158: Remove the Stage 2 HPT Airseal

    Figure: SBE 72-0158: Remove the Stage 2 HPT Airseal

    SBE 72-0158: Remove the Stage 2 HPT Airseal

    Figure: Measure the Stage 2 HP Turbine Airseal

    Measure the Stage 2 HP Turbine Airseal

    Figure: Cool The Stage 2 HP Turbine Airseal

    Cool The Stage 2 HP Turbine Airseal

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added consumable, procedural steps and figure. (20VC276)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-149
Type:sp01
Supply Short Name:CoMat 02-149 DRY ICE
Supply Name:CoMat 02-149 DRY ICE
Specification Groups:
Doc NumberType
DRY ICE
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10052
Tool Name:IAE 1F10052 Two cables sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16028
Tool Name:IAE 1P16028 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16047
Tool Name:IAE 1P16047 Hydraulic adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16051
Tool Name:IAE 1P16051 Clamp
Manufacturer Code:0AM53
Tool Number:IAE 1P16055
Tool Name:IAE 1P16055 Locator plug
Manufacturer Code:0AM53
Tool Number:IAE 1P16063
Tool Name:IAE 1P16063 Fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16140
Tool Name:IAE 1P16140 Support base
Manufacturer Code:0AM53
Tool Number:IAE 1P16173
Tool Name:IAE 1P16173 Lift sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16219
Tool Name:IAE 1P16219 remove puller
Manufacturer Code:0AM53
Tool Number:IAE 1P16272
Tool Name:IAE 1P16272 Adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P17021
Tool Name:IAE 1P17021 Separate pusher
Manufacturer Code:0AM53
Tool Number:IAE 1P17022
Tool Name:IAE 1P17022 Removal/installation jaws assembly
Manufacturer Code:0AM53
Tool Number:IAE 1P17024
Tool Name:IAE 1P17024 Lift fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P17026
Tool Name:IAE 1P17026 Lift fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P17758
Tool Name:IAE 1P17758 Protective cover