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 72-00-40-420-003-A00 HP System Module - Install The HP System Module (Vertical), Installation-005
General
Transporation covers/blanks must be removed immediately before installation.
This TASK gives the procedure to install the HP system module in the vertical position. Other related TASKS are:
TASK 72-00-40-560-006 Turn the LP compressor/intermediate case module and the 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 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 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.
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 1P16046 Removal/Installation fixture | 0AM53 | IAE 1P16046 | 1 | |
| IAE 1P16057 Tie-rod adapter | 0AM53 | IAE 1P16057 | 1 | |
| IAE 1P16543 Removal/Installation fixture | 0AM53 | IAE 1P16543 | 1 | |
| IAE 1R18075 Support pedestal | 0AM53 | IAE 1R18075 | 1 | |
| IAE 1R18090 Safety support stand | 0AM53 | IAE 1R18090 | 1 | |
| IAE 1R18091 Support stand | 0AM53 | IAE 1R18091 | 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 | ||
| IAE 1R18254 Rigging pin | 0AM53 | IAE 1R18254 | 1 | |
| IAE 1R18673 Dummy stub shaft | 0AM53 | IAE 1R18673 | 1 |
Consumables, Materials and Expendables
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| CoMat 01-002 SOLVENT, DELETED. | LOCAL | 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 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 72-00-40-220-076 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 72-00-40-220-077 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 72-00-40-220-078 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 case to lock the VSVs.
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 72-00-40-420-115 Install the HP Compressor Support Rods
Refer to Figure.
Attach a hoist to the IAE 1F10052 Two cables sling 1 off and attach the lift sling to the remove/install fixture trunnions.
Attach IAE 1P16057 Tie-rod adapter 1 off on to the center ring (Part of IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off).
SUBTASK 72-00-40-420-116 Install the Remove/Install Fixture and the Tie-Rod Adapter to the HP System Module Rear Flange
Refer to Figure.
SUBTASK 72-00-40-420-117 Remove the HP System Module from the Build Stand
Refer to Figure.
Lower the HP system module on to IAE 1R18075 Support pedestal 1 off. Do not release the hold on the HP system module.
SUBTASK 72-00-40-420-118 Remove the Dummy Stub Shaft from the HP System Module
Lower the HP system module on to the IAE 1R18090 Safety support stand 1 off.

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 10-077 APPROVED ENGINE OILS 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 72-00-40-420-119 Prepare the Curvic Couplings for Assembly
Install IAE 1R18236 Alignment tool 1 off on to the HP system module front flange.
SUBTASK 72-00-40-420-120 Prepare the HP System Module and LP Compressor/Intermediate Case for Assembly
Refer to Figure.
SUBTASK 72-00-40-420-121 Lower the 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) and the 37 nuts ENGINE-ATTACH PARTS & FITTINGS-HP SYSTEM MODULE (72-00-40, 01-030).
Install the remaining bolts and nuts.
SUBTASK 72-00-40-420-122-A00 Install the Parts that Attach the LP Compressor/Intermediate Case Module to the 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 lbfin (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 72-00-40-420-122-B00 Install the Parts that Attach the LP Compressor/Intermediate Case Module to the 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.
Use the sequence shown on Figure.nd on the index unit to do the subsequent three steps.
Do Step again until all of the bolts have been torqued.
Make sure that the 20 bolts are at the necessary torque of 155 * lbfin (17.51 Nm).
SUBTASK 72-00-40-420-123 Torque the No. 3 Bearing Rotor Center and the HP Compressor Stage 3 Disk Curvic Coupling Bolts,.nd
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, 01-115) 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, 01-118) 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 lbfin to 105 lbfin (10 Nm to 12 Nm).
Remove the support rods.
SUBTASK 72-00-40-420-124 Remove the Hoist, the Remove/Install Fixture, the Tie-Rod Adapter and the HP Compressor Support Rods and
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
Sheet 1

Figure: Install the support rods in to the HP compressor front cases
Sheet 2

Figure: Install the remove/install fixture and the tie-rod adapter on to the HP system module
Sheet 1

Figure: Install the remove/install fixture and the tie-rod adapter on to the HP system module
Sheet 2

Figure: Remove the HP system module from the build stand
Remove the 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 HP system module on the safety support stand
Install the HP system module on the safety support stand

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

Figure: Set the alignment tool on the HP system module
Sheet 2

Figure: LP compressor/intermediate case module to HP system module flange hole positions
LP compressor/intermediate case module to HP system module 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
Sheet 1

Figure: Torque the stage 3 HP compressor curvic bolts
Sheet 2

