TASK 72-50-10-430-006 LPT Case And Rotor Assembly - Assemble The LPT Stage 5 Rotor Assembly To The LPT, Assembly-006

DMC:V2500-A0-72-50-1000-06A-710A-B|Issue No:003.00|Issue Date:2014-11-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-50-10-430-006 LPT Case And Rotor Assembly - Assemble The LPT Stage 5 Rotor Assembly To The LPT, Assembly-006

General

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

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

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

Special torque data and assembly tolerances are included in the procedure.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Use new rotor bolts and new nuts

NOTE

To identify the consumable materials, refer to the PCI.

NOTE

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

NOTE

During assembly, it is not necessary to measure, calculate and record the fits and clearances if:
a) Both parts are new, or
b) Used parts (inspected and/or repaired) are within limits.
Above is valid for any combinations of a) and b), except for "Selected Fit" parts.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Straight edgeLOCALStraight edge
Depth gageLOCALDepth gage
IAE 6F10027 Heater control unit0AM53IAE 6F100271
IAE 1M14030 Assembly trolley0AM53IAE 1M140301
IAE 1M14049 Position retainer0AM53IAE 1M140491
IAE 1M14054 Torque wrench adapter0AM53IAE 1M140541
IAE 1M14055 Special wrench0AM53IAE 1M140551
IAE 1M14059 Lifting fixture0AM53IAE 1M140591
IAE 1M14062 Heating fixture0AM53IAE 1M140621
IAE 1M14074 Heating fixture carrier0AM53IAE 1M140741
IAE 1M14081 Clamping ring0AM53IAE 1M140811
IAE 1M14131 Guide pin0AM53IAE 1M141311
IAE 1M14134 Installation bolt/nut0AM53IAE 1M141346
IAE 1M14156 Lifting fixture0AM53IAE 1M141561
IAE 1M14010 Assembly/Disassembly fixture0AM53IAE 1M14010

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-129A ANTI-SEIZE PASTE71984CoMat 10-129A
CoMat 10-129 ANTI-SEIZE PASTE34568CoMat 10-129

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Bolt36
Nut36

Safety Requirements

WARNING

DO NOT GET ANTI-SEIZE PASTE ON YOUR SKIN WHEN YOU LUBRICATE THREADS AND ABUTMENT FACES OF NUTS AND BOLTS. WEAR PROTECTIVE GLOVES.

Procedure

    1. SUBTASK 72-50-10-220-096-A00 V2500-A1: Make sure that the Fits and Clearances of the Stage 4 Turbine Blade Disk and the Stage 5 Turbine Disk are in the Limits given at Location 3353 (Pre SBE 72-0138)

    1. Refer to: Figure

    2. Calculate the clearance at location 3353.

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

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3353

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      18.9252

      18.9213

      Intf

      0.0276

      Intf

      0.0295

      Stage 5 disk diameter

      18.9016

      18.8976

      0.0197

      0.0138

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

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3353

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      480.7

      480.6

      Intf

      0.7

      Intf

      0.75

      Stage 5 disk diameter

      480.1

      480.0

      0.5

      0.35

    2. SUBTASK 72-50-10-220-096-B00 V2500-A1: Make sure that the Fits and Clearances of the Stage 4 Turbine Disk and the Stage 5 Turbine Disk are in the Limits given at Location 3653 (SBE 72-0138)

    1. Refer to: Figure

    2. SBE 72-0138: Rotor and stator assembly introduce new LP turbine blades and vanes

    3. Calculate the clearance at location 3653.

      Table 3. Fits and Clearances (all dimensions are in inches)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3653

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      18.9252

      18.9213

      Intf

      0.0276

      Intf

      0.0295

      Stage 5 disk diameter

      18.9016

      18.8976

      0.0197

      0.0138

      Table 4. Fits and Clearances (all dimensions are in millimeters)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3653

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      480.7

      480.6

      Intf

      0.7

      Intf

      0.75

      Stage 5 disk diameter

      480.1

      480.0

      0.5

      0.35

    3. SUBTASK 72-50-10-220-096-C00 V2500-A5: Make sure that the Fits and Clearances of the Stage 4 Turbine Disk and the Stage 5 Turbine Disk are in the Limits given at Location 3753

    1. Refer to: Figure

    2. Calculate the clearance at location 3753.

      Table 5. Fits and Clearances (all dimensions are in inches)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3753

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      18.9252

      18.9213

      Intf

      0.0276

      Intf

      0.0295

      Stage 5 disk diameter

      18.9016

      18.8976

      0.0197

      0.0138

      Table 6. Fits and Clearances (all dimensions are in millimeters)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 3753

      Stage 3 to 4 turbine disk to the

      abutment diameter of the

      stage 5 turbine disk

      Stage 4 disk diameter

      480.7

      480.6

      Intf

      0.7

      Intf

      0.75

      Stage 5 disk diameter

      480.1

      480.0

      0.5

      0.35

    4. SUBTASK 72-50-10-430-117 Install the Clamping Ring to the Stage 5 Disk

    1. Refer to: Figure

    2. Install the two halves of the IAE 1M14081 Clamping ring 1 off to the stage 5 disk.

    3. Connect the two halves with the single acting ball lock pin.

    4. Attach the clamping ring with the hand knob. Tighten the hand knob.

    5. SUBTASK 72-50-10-430-118 Put the Stage 5 Disk on to the Assembly Trolley

    1. Refer to Figure.

    2. Use hoist equipment to install the IAE 1M14156 Lifting fixture 1 off to the clamping ring.

    3. Lift the stage 5 disk.

    4. CAUTION

      HOLD THE BOLTS IN THEIR POSITION IF YOU LOOSEN AND REMOVE THE NUTS FROM THE BOLTS. DO NOT TURN THE BOLTS OR MAKE TO AND FRO MOVEMENTS. THE DISK/INNER AIR SEAL FLANGES AND THE BOLTS CAN BE DAMAGED BY SCORES.

      Loosen and remove the six work nuts and work bolts.

    5. Put the stage 5 disk, front side down, on to the IAE 1M14030 Assembly trolley 1 off.

    6. Make sure that the stage 5 disk hole aligns with the hole in the assembly trolley.

    7. Remove the hoist equipment and the lifting fixture.

    8. Loosen the hand knob and disconnect the single acting ball lock pin. Remove the two halves of the clamping ring from the stage 5 disk.

    6. SUBTASK 72-50-10-430-119 Attach the Lifting Fixture on to the Stage 5 Disk

    1. Refer to: Figure

    2. Use hoist equipment to install the IAE 1M14059 Lifting fixture 1 off. Make sure that the clamps of the lifting fixture are locked in the inner position. Install the teflon bolts in the holes which are marked with the stage number of the disk to be installed.

    3. Hoist the lifting fixture above the assembly trolley.

    4. Lower the lifting fixture carefully on to the stage 5 disk.

    5. Loosen the hand knobs. Move the clamps on the fixture to the outer direction in the identified position for the stage 5. Attach the clamps with the hand knobs. Tighten the hand knobs.

    7. SUBTASK 72-50-10-430-120 Install the Heating Fixture on to the Heating Fixture Carrier

    1. Refer to: Figure

    2. Put the IAE 1M14062 Heating fixture 1 off on to the IAE 1M14074 Heating fixture carrier 1 off. The two locating pins must engage to the bushings of the heating fixture carrier.

    3. Attach the heating fixture with the two hand knobs. Tighten the hand knobs.

    8. SUBTASK 72-50-10-430-121 Install the Heating Fixture Carrier with the Heating Fixture on to the LP Turbine Case

    1. Refer to: Figure

    2. Put the heating fixture carrier with the heating fixture on to the LP turbine case rear flange. Make sure that the four insulation plates, parts of the heating fixture carrier, touch the LP turbine case rear flange.

    9. SUBTASK 72-50-10-430-122 Install the Stage 5 Disk to the Heating Fixture

    1. Refer to: Figure

    2. NOTE

      Make sure that the temperature feeler of the heating fixture touches the stage 5 air seal.

      Lift the stage 5 disk with the lifting fixture above the heating fixture. Lower the stage 5 disk carefully until the flange is correctly positioned on the heating fixture.

    10. SUBTASK 72-50-10-430-123 Install the Guide Pin to the Stage 4 Disk

    1. Refer to: Figure

    2. NOTE

      The high point position of the stage 4 rotor is marked on the disk hub by a circled dash symbol. Refer to TASK 72-50-30-440-002 (ASSEMBLY-002).

      Engage the guide cable, part of the IAE 1M14131 Guide pin 1 off, through a hole 175 to 185 degrees apart of the marked high point position of the stage 4 rear flange.

    3. Compress the IAE 1M14049 Position retainer 1 off and put it under the guide pin.

    11. SUBTASK 72-50-10-430-124 Increase the Temperature of the Stage 5 Disk Front Flange

    1. Refer to: Figure

    2. Increase the temperature of the stage 5 disk front flange with the heating fixture. Use the IAE 6F10027 Heater control unit 1 off.

    3. NOTE

      The temperature of the stage 5 parts must not have more than 464.0 deg F (240.0 deg C).

      Increase the temperature of the flange to get a minimum temperature differential of 338.0 deg F (170.0 deg C) between the stage 4 disk rear flange and the stage 5 disk front flange.

    12. SUBTASK 72-50-10-430-125 Remove the Heating Fixture from the LP Turbine Case

    1. Refer to: Figure

    2. Switch off the heater control if the stage 5 disk has the assembly temperature.

    3. Lift the stage 5 disk from the heating fixture.

    4. Remove the heating fixture carrier with the heating fixture from the LP turbine case.

    5. Remove the heating fixture from the heating fixture carrier.

    13. SUBTASK 72-50-10-430-126 Install the Stage 5 Disk on to the Stage 4 Disk Rear Flange

    1. Refer to: Figure

    2. Examine the stage 4 disk rear flange and the stage 5 disk front flange.

    3. CAUTION

      MAKE SURE THAT THE THREE PROTECTOR RING SEGMENTS ARE NOT INSTALLED.

      NOTE

      The high point position of the stage 5 rotor is marked on the disk hub by a circled dash symbol. Refer to TASK 72-50-30-440-003 (ASSEMBLY-003).

      Engage the guide cable through a hole near the marked high point position of the stage 5 disk.

    4. Install the stage 5 disk carefully on to the stage 4 disk.

    5. Check for correct touch of the two flanges (shrink fit).

    14. SUBTASK 72-50-10-430-127 Remove the Lifting Fixture from the Stage 5 Disk

    1. Refer to: Figure

    2. Loosen the hand knobs of the lifting fixture. Move the clamps in to inner position. Remove the lifting fixture from the stage 5 disk.

    15. SUBTASK 72-50-10-430-128 Remove the Guide Pin

    1. Refer to: Figure

    2. Remove the position retainer under the guide pin.

    3. Remove the guide pin from the stage 4 disk.

    16. SUBTASK 72-50-10-430-129 Attach the Disk Flanges

    1. Refer to Figure.

    2. CAUTION

      HOLD THE INSTALLATION BOLTS IN THEIR POSITION WHEN YOU INSTALL THE INSTALLATION NUTS ON TO THE INSTALLATION BOLTS. DO NOT TURN THE INSTALLATION BOLTS OR MAKE TO AND FRO MOVEMENTS. THE DISK/INNER AIR SEAL FLANGES CAN BE DAMAGED BY SCORES.

    3. Install 60 degrees apart 6 installation bolts with the head up and 6 installation nuts, parts of the IAE 1M14134 Installation bolt/nut 6 off, to the disk flanges.

    4. Tighten the installation nuts. Use the IAE 1M14055 Special wrench 1 off.

    5. Torque the installation nuts from 119.0 to 133.0 lbfin. (13.5 to 15 Nm). Use the IAE 1M14054 Torque wrench adapter 1 off.

    17. SUBTASK 72-50-10-430-130 Attach the Stage 4 Disk and the Stage 5 Disk with the Bolts and the Nuts

    1. Refer to Figure, Figure and Figure.

      2. Wait until the temperature of the disk flanges decreases to room temperature.

      1. WARNING

        DO NOT GET ANTI-SEIZE PASTE ON YOUR SKIN WHEN YOU LUBRICATE THREADS AND ABUTMENT FACES OF NUTS AND BOLTS. WEAR PROTECTIVE GLOVES.

        CAUTION

        USE NEW ROTOR BOLTS AND NEW NUTS.

      3. Lubricate all bolts and nuts with CoMat 10-129A ANTI-SEIZE PASTE as follows.

      1. Apply the anti-seize paste on to the thread of all bolts. Use a paint brush to apply the anti-seize paste on to the bolts.

      2. Apply the anti-seize paste on to the mating surface of all nuts. Use a paint brush to apply the anti-seize paste on to the nuts.

    4. CAUTION

      HOLD THE BOLTS IN THEIR POSITION WHEN YOU INSTALL/REMOVE THE NUTS ON TO/FROM THE BOLTS. DO NOT TURN THE BOLTS OR MAKE TO AND FRO MOVEMENTS. THE DISK/INNER AIR SEAL FLANGES AND/OR THE BOLTS CAN BE DAMAGED BY SCORES.
      MAKE SURE THAT THE LOCKING TORQUE OF THE NUTS IS BETWEEN 3.5 AND 30.0 LBFIN (0.4 AND 3.4 NM). TURN THE NUTS DOWN ON TO THE BOLTS UNTIL FINGER TIGHT. CONTINUE TO TURN THE NUTS WITH A WRENCH. MAKE SURE THAT THE NUTS GIVE SUFFICIENT RESISTANCE. IT SHOWS THAT THE SELF LOCKING PROPERTY IS STILL AVAILABLE.
      IT IS PERMITTED TO USE POWER TOOLS TO TURN THE NUTS ON TO THE REMAINING BOLT THREADS. MAKE SURE THAT THE POWER TOOL IS SET TO A TORQUE VALUE WHICH IS NOT MORE THAN 50 PERCENT OF THE FINAL TORQUE VALUE. THE SPEED MUST BE SLOW TO PREVENT INCREASE OF HEAT, WHICH CAN CAUSE THREAD PICK-UP AND SEIZURE.

      Install 30 new bolts with the head up and the new nuts to the disk flanges. Tighten the nuts on to the bolts with the IAE 1M14055 Special wrench 1 off.

    5. Loosen the 6 installation nuts.

    6. Remove the installation nuts and installation bolts. Use the IAE 1M14055 Special wrench to remove the installation nuts.

    7. Install the remaining six new bolts with the head up and the six new nuts. Tighten the nuts on to the bolts with the IAE 1M14055 Special wrench.

      8. CAUTION

        MAKE SURE THAT ALL INSTALLATION BOLTS AND INSTALLATION NUTS ARE REPLACED.

        NOTE

        The tightening torque value includes the self locking torque value.

        Torque the nuts with the IAE 1M14054 Torque wrench adapter 1 off in two steps. For the torque sequence, refer to Figure.

      1. Torque the nuts at the first step from 62.0 to 71.0 lbfin. (7.0 to 8.0 Nm).

      2. Torque the nuts at the second step from 119.0 to 133.0 lbfin. (13.5 to 15.0 Nm).

      3. Check all nuts again in clockwise direction for final torque. Use the IAE 1M14054 Torque wrench adapter 1 off.

    18. SUBTASK 72-50-10-430-291 Move the Lifting Ring

    1. Move the lifting ring of the IAE 1M14010 Assembly/Disassembly fixture from the zero-position into the lifting-position with the lever.

    19. Figure: Lift and Turn the Stage 5 Disk with the Clamping Ring

    Lift and Turn the Stage 5 Disk with the Clamping Ring

    Figure: Increase the Temperature of the Stage 5 Disk with the Heating Fixture

    Increase the Temperature of the Stage 5 Disk with the Heating Fixture

    Figure: Install the Stage 5 Disk

    Install the Stage 5 Disk

    Figure: Torque Sequence of the Nuts which Attach the Stage 4 Disk and the Stage 5 Disk

    Torque Sequence of the Nuts which Attach the Stage 4 Disk and the Stage 5 Disk

    Figure: Pre SBE 72-0138 V2500-A1: Fits and Clearances of the Stage 5 Rotor

    Sheet 1

    Legend
    Pre SBE 72-0138 V2500-A1: Fits and Clearances of the Stage 5 Rotor

    Sheet 1

    Close

    Figure: SBE 72-0138 V2500-A1: Fits and Clearances of the Stage 5 Rotor

    Sheet 2

    Legend
    SBE 72-0138 V2500-A1: Fits and Clearances of the Stage 5 Rotor

    Sheet 2

    Close

    Figure: V2500-A5: Fits and Clearances of the Stage 5 Rotor

    V2500-A5: Fits and Clearances of the Stage 5 Rotor

    Figure: Tighten the Nuts with the Special Wrench

    Tighten the Nuts with the Special Wrench

    Figure: Lubrication of the Bolt Thread and the Nut Mating Surface

    Lubrication of the Bolt Thread and the Nut Mating Surface

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added note for fits and clearances in the procedure. (13VM530)

Link not Found
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:34568
Enterprise Name:TIODIZE CO., INC.
BU Name:TIODIZE CO., INC.
Street:5858 ENGINEER DRIVE
City:HUNTINGTON BEACH
State:CA
Zip Code:92649
Country:USA
Phone Number:1-714-898-4377
Fax Number:1-714-891-7467
Internet:www.tiodize.com
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:34568
Supply Number:CoMat 10-129
Type:sp01
Supply Short Name:CoMat 10-129 ANTI-SEIZE PASTE
Supply Name:CoMat 10-129 ANTI-SEIZE PASTE
Specification Groups:
Doc NumberType
TIODIZE T8E PASTE
Suppliers:
ManufacturerRemarks
34568
Manufacturer Code:3CU95
Supply Number:CoMat 10-129A
Type:sp01
Supply Short Name:CoMat 10-129A ANTI-SEIZE PASTE
Supply Name:CoMat 10-129A ANTI-SEIZE PASTE
Specification Groups:
Doc NumberType
MOLYKOTE P-37
Suppliers:
ManufacturerRemarks
3CU95
818U1
Manufacturer Code:LOCAL
Tool Number:Depth gage
Tool Name:Depth gage
Manufacturer Code:0AM53
Tool Number:IAE 1M14010
Tool Name:IAE 1M14010 Assembly/Disassembly fixture
Manufacturer Code:0AM53
Tool Number:IAE 1M14030
Tool Name:IAE 1M14030 Assembly trolley
Manufacturer Code:0AM53
Tool Number:IAE 1M14049
Tool Name:IAE 1M14049 Position retainer
Manufacturer Code:0AM53
Tool Number:IAE 1M14054
Tool Name:IAE 1M14054 Torque wrench adapter
Manufacturer Code:0AM53
Tool Number:IAE 1M14055
Tool Name:IAE 1M14055 Special wrench
Manufacturer Code:0AM53
Tool Number:IAE 1M14059
Tool Name:IAE 1M14059 Lifting fixture
Manufacturer Code:0AM53
Tool Number:IAE 1M14062
Tool Name:IAE 1M14062 Heating fixture
Manufacturer Code:0AM53
Tool Number:IAE 1M14074
Tool Name:IAE 1M14074 Heating fixture carrier
Manufacturer Code:0AM53
Tool Number:IAE 1M14081
Tool Name:IAE 1M14081 Clamping ring
Manufacturer Code:0AM53
Tool Number:IAE 1M14131
Tool Name:IAE 1M14131 Guide pin
Manufacturer Code:0AM53
Tool Number:IAE 1M14134
Tool Name:IAE 1M14134 Installation bolt/nut
Manufacturer Code:0AM53
Tool Number:IAE 1M14156
Tool Name:IAE 1M14156 Lifting fixture
Manufacturer Code:0AM53
Tool Number:IAE 6F10027
Tool Name:IAE 6F10027 Heater control unit
Manufacturer Code:LOCAL
Tool Number:Straight edge
Tool Name:Straight edge