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-A1
Common Information
TASK 72-00-40-420-001-A00 HP System Module - Install The Partial HP System Module (Vertical), Installation-001
General
This TASK gives the procedure to install the partial HP system module in the vertical position. Other related TASKS are:
TASK 72-00-40-560-002 Turn the LP compressor/intermediate case module and the partial HP system module from the vertical to the horizontal.
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 is identified with the symbol * after the torque value.
Assembly tolerances are included in the procedure.
Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS, unless other lubricants are referred to in the procedure.
After assembly apply CoMat 07-038 AIR DRYING ENAMEL to any damaged surface protection, joint flanges and attach parts. Use the correct color of air drying enamel. Refer to the SPM TASK 70-38-21-380-501.
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.
Transporation covers/blanks must be removed immediately before installation.
NOTE
NOTE
Preliminary Requirements
Pre-Conditions
NONESupport Equipment
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| IAE 1F10052 Two cables sling | 0AM53 | IAE 1F10052 | 1 | |
| IAE 1P16043 Lift and turn fixture | 0AM53 | IAE 1P16043 | 1 | |
| IAE 1P16056 Hand wrench | 0AM53 | IAE 1P16056 | 1 | |
| IAE 1R18673 Dummy stub shaft | 0AM53 | IAE 1R18673 | 1 | |
| IAE 1R18075 Support pedestal | 0AM53 | IAE 1R18075 | 1 | |
| IAE 1R18090 Safety support stand | 0AM53 | IAE 1R18090 | 1 | |
| IAE 1R18228 Torque spanner | 0AM53 | IAE 1R18228 | 1 | |
| IAE 1R18229 Index unit | 0AM53 | IAE 1R18229 | 1 | |
| IAE 1R18230 Wrench | 0AM53 | IAE 1R18230 | 1 | |
| IAE 1R18234 Support rod | 0AM53 | IAE 1R18234 | 3 | |
| IAE 1R18236 Alignment tool | 0AM53 | IAE 1R18236 | 1 | |
| IAE 1R18247 Rigging pin | 0AM53 | IAE 1R18247 | 1 |
Consumables, Materials and Expendables
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| CoMat 01-002 SOLVENT, DELETED. | 0AM53 | CoMat 01-002 | ||
| CoMat 07-038 AIR DRYING ENAMEL | K3504 | CoMat 07-038 | ||
| CoMat 10-070 ANTI-SEIZE COMPOUND | LOCAL | CoMat 10-070 | ||
| CoMat 10-077 APPROVED ENGINE OILS | LOCAL | CoMat 10-077 | ||
| CoMat 10-039 ENGINE OIL | LOCAL | CoMat 10-039 | ||
| CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE | LOCAL | CoMat 04-005 |
Spares
NONESafety Requirements
NONEProcedure
Refer to Figure.
Reference dimensions at location 5600. If required use the data written as a note in TASK 72-41-31-200-000 and TASK 72-32-03-200-000.
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 5600
HP Compressor front cases front location hole bore to LP compressor/Intermediate case module rear face location dowels diameter
Location hole bore
0.4755
0.4770
0.0019
Location dowel diameter
0.4730
0.0039
0.4736
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 5600
HP Compressor front cases front location hole bore to LP compressor/Intermediate case module rear face location dowels diameter
Location hole bore
12.080
12.116
0.050
Location dowel diameter
12.015
0.101
12.030
SUBTASK 72-00-40-220-068 Reference Fits and Clearances of the HP System Module to the LP Compressor/Intermediate Case Module Interface at Location 5600
Refer to Figure.
Reference dimensions at location 5601. If required use the data written as a note in TASK 72-41-31-200-000 and TASK 72-00-40-200-000.
Table 3. Fits and Clearances (all dimensions are in inches) NEW PART
WORN PART
DIMENSIONS
DIMENSIONS
PART IDENT
Size
Clearance
(Non-select)
REJECT IF MORE THAN
LOCATION 5601
HP Compressor front cases dowel pin hole bore to dowel pin diameter
Dowel pin hole bore
0.2389
0.2401
0.0018
Dowel pin diameter
0.2366
0.0034
0.2371
Table 4. Fits and Clearances (all dimensions are in millimeters) NEW PART
WORN PART
DIMENSIONS
DIMENSIONS
PART IDENT
Size
Clearance
(Non-select)
REJECT IF MORE THAN
LOCATION 5601
HP Compressor front cases dowel pin hole bore to dowel pin diameter
Dowel pin hole bore
6.070
6.100
0.046
Dowel pin diameter
6.012
0.088
6.024
SUBTASK 72-00-40-220-069 Reference Fits and Clearances of the HP System Module to the LP Compressor/Intermediate Case Module Interface at Location 5601
Refer to Figure.
Reference dimensions at location 5602. If required use the data written as a note in TASK 72-00-40-200-000 and TASK 72-32-03-200-000.
Table 5. Fits and Clearances (all dimensions are in inches) NEW PART
WORN PART
DIMENSIONS
DIMENSIONS
PART IDENT
Size
Clearance
(Non-select)
REJECT IF MORE THAN
LOCATION 5602
LP Compressor/Intermediate case module rear face dowel pin hole bore to dowel pin diameter
Dowel pin hole bore
0.2389
0.2401
0.0018
Dowel pin diameter
0.2366
0.0034
0.2371
Table 6. Fits and Clearances (all dimensions are in millimeters) NEW PART
WORN PART
DIMENSIONS
DIMENSIONS
PART IDENT
Size
Clearance
(Non-select)
REJECT IF MORE THAN
LOCATION 5602
LP Compressor/Intermediate case module rear face dowel pin hole bore to dowel pin diameter
Dowel pin hole bore
6.070
6.100
0.046
Dowel pin diameter
6.012
0.088
6.024
SUBTASK 72-00-40-220-070 Reference Fits and Clearances of the HP System Module to the LP Compressor/Intermediate Case Module Interface at Location 5602
Refer to Figure.
Install IAE 1R18247 Rigging pin 1 off through the bracket and in to the HP compressor cases to lock the VSV's.
Remove the six bolts ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-122), the two brackets ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-115 and ENGINE-HP COMPRESSOR SPLIT CASES 01-118) and the three blanks ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-120) from the HP compressor front cases.
Install the IAE 1R18234 Support rod 3 off.
SUBTASK 72-00-40-420-051 Install the HP Compressor Support Rods
Refer to Figure.
Engage the fixture nut on to the thread on the end of the HP compressor shaft and tighten the nut. Use IAE 1P16056 Hand wrench 1 off.
Put the sleeve (part of IAE 1P16043 Lift and turn fixture 1 off) on to the HP compressor shaft.
Attach the hoist to the lift eye on IAE 1F10052 Two cables sling 1 off.
Install the fixture assembly onto the diffuser case rear flange.
SUBTASK 72-00-40-420-052 Attach the Lift and Turn Fixture on to the Rear of the Partial HP System Module
Refer to Figure.
SUBTASK 72-00-40-420-053 Remove the Partial HP System Module from the Build Stand
Refer to Figure.
Lower the partial HP system module on to IAE 1R18075 Support pedestal 1 off. Do not release the hold on the partial HP system module.
SUBTASK 72-00-40-420-054 Remove the Dummy Stub Shaft from the Partial HP System Module
Lower the partial HP system module on to the IAE 1R18090 Safety support stand 1 off. The HP system module front flange must touch the safety support stand pads. Do not release the hold on the lift sling.

WARNING
WHEN YOU USE COMAT 01-002 INHIBITED AND STABILIZED TRICHLOROETHANE YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.Use a soft brush and apply CoMat 01-002 SOLVENT, DELETED. to the curvic teeth.
Clean the curvic teeth on the HP compressor stage 3 disk and the No. 3 bearing rotor center curvic couplings.
Apply CoMat 10-039 ENGINE OIL to the threads and abutment faces of the curvic bolts.
Install the curvic bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-010) in to the No. 3 bearing rotor center curvic coupling. Use IAE 1R18230 Wrench 1 off.
SUBTASK 72-00-40-420-055 Prepare the Curvic Couplings for Assembly
Install IAE 1R18236 Alignment tool 1 off on to the HP compressor front flange.
SUBTASK 72-00-40-420-056 Prepare the Partial HP System Module and LP Compressor/Intermediate Case Module for Assembly
Refer to Figure.
SUBTASK 72-00-40-420-057 Lower the Partial HP System Module on to the LP Compressor/Intermediate Case Module
Refer to Figure.
NOTE
There is a countersunk hole in the head of the bolts.Install the four bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-050), the four lock plates ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-080), the four pins ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-082) and the four nuts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-030), at the position Y.
Install the 37 bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-050), the 37 nuts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-030).
SUBTASK 72-00-40-420-058-A00 Install the Parts that Attach the LP Compressor/Intermediate Case Module to the Partial HP System Module (Pre SBE 72-0290)
Refer to Figure.
NOTE
There is no countersunk hole in the head of the bolts.Lubricate the 41 bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-050) with CoMat 10-070 ANTI-SEIZE COMPOUND. SPM TASK 70-41-02-410-501.
Install four of the bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40,01-050) with the four lock plates ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-080), the four pins ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-082) and four of the nuts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-030), at the four positions identified Y. Figure.
Torque the 37 nuts and bolts to 315 lbf.in (36 Nm) evenly and in the sequence shown. Figure.
Install the remaining 37 bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-050) and the 37 nuts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-030).
SUBTASK 72-00-40-420-058-B00 Install the Parts that Attach the LP Compressor/Intermediate Case Module to the Partial HP System Module (SBE 72-0290)
Use IAE 1R18230 Wrench 1 off to engage the 20 bolts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-010) and tighten them lightly.

CAUTION
WHEN YOU TORQUE THE BOLTS IT IS IMPORTANT THAT THE TORQUE VALUE IS ON THE INCREASE. A NEW BOLT MUST BE INSTALLED IF THE TORQUE VALUE IS CONSTANT OR DECREASES.THE BOLTS MUST NOT BE POWER WRENCHED.Install the IAE 1R18229 Index unit 1 off on to the front face of the LP stubshaft and rotor center. Make sure that the hole No.3 is at the top. Safety the index unit on to the LP stub shaft and rotor center with the location pin.
Install IAE 1R18228 Torque spanner 1 off on to the index unit and the curvic bolt. Make sure that the spanner is in the hole No.1.
SUBTASK 72-00-40-420-059 Torque the No. 3 Bearing Rotor Center and the HP Compressor Stage 3 Disk Curvic Coupling Bolts
Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on to the bracket where it touches the blank.
Install one of the blanks ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-120), the bracket ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-118) and two of the bolts ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-122) in to the HP compressor at location C.
Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on the bracket where it touches the blank.
Install one of the blanks ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-120), the bracket ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-115) and two of the bolts ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-122) in the HP compressor at location A.
Install the other blank ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-120) and the other bolts ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-122) in to the HP compressor at location B. Torque the bolts to 85 to 105 lbf.in (10 to 12 Nm).
Remove the rigging pin installed in Step.
Remove the support rods.
Remove the fixture nut. Use IAE 1P16056 Hand wrench 1 off.
Remove the lift and turn fixture from the rear of the partial HP system module.
SUBTASK 72-00-40-420-060 Remove the Hoist, the Lift and Turn Fixture and the HP Compressor Support Rods
Figure: Locations for the fits and clearances
Locations for the fits and clearances

Figure: Install the support rods in to the HP compressor front cases
Install the support rods in to the HP compressor front cases

Figure: Install the support rods in to the HP compressor front cases
Install the support rods in to the HP compressor front cases

Figure: Install the lift and turn fixture on to the HP partial system module
Install the lift and turn fixture on to the HP partial system module

Figure: Install the lift and turn fixture on to the HP partial system module
Install the lift and turn fixture on to the HP partial system module

Figure: Remove the partial HP system module from the build stand
Remove the partial HP system module from the build stand

Figure: Remove the dummy stub shaft from the stage 3 disk curvic coupling
Remove the dummy stub shaft from the stage 3 disk curvic coupling

Figure: Install the partial HP system module on the safety support stand
Install the partial HP system module on the safety support stand

Figure: Set the alignment tool on the partial HP system module
Set the alignment tool on the partial HP system module

Figure: Align the No.3 bearing rotor center curvic coupling
Align the No.3 bearing rotor center curvic coupling

Figure: LP compressor/intermediate case module to HP system module joint flange hole positions
LP compressor/intermediate case module to HP system module joint flange hole positions

Figure: Lightly tighten the stage 3 HP compressor curvic bolts
Lightly tighten the stage 3 HP compressor curvic bolts

Figure: Torque the stage 3 HP compressor curvic bolts
Torque the stage 3 HP compressor curvic bolts

Figure: Torque the stage 3 HP compressor curvic bolts
Torque the stage 3 HP compressor curvic bolts

