DMC:V2500-A1-72-00-5000-01B-720A-B|Issue No:004|Issue Date:2020-05-01

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-A1 and Pre SBE 72-0063

Common Information

TASK 72-00-50-420-001-A00 LPT Module - Install The LPT Module (Horizontal) - Method 1, Installation-002 - Pre SBE 72-0063

General

This TASK gives the procedure to install the LP Turbine Module in horizontal position. Other related TASKS are:

Install the LP Turbine Module without TEC by TASK 72-00-50-420-002 (INSTALLATION-003).

Install the LP Turbine Module (vertical) - Method 2 by TASK 72-00-50-420-004-A00 (INSTALLATION-005).

Turn the LP Turbine Module from horizontal to vertical (front end down) by TASK 72-00-50-560-001 (REMOVAL-003).

Fig/item numbers in parentheses in this 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 by the symbol * after the torque value.

Special assembly tolerances are included in this 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 the air drying enamel. Refer to the SPM TASK 70-63-02-400-501.

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.

Transportation covers/blanks must be removed immediately before the installation of the components.

For lockwire data and procedures refer to the SPM TASK 70-42-05-400-501.

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

Name	Manufacturer	Part Number / Identification	Quantity
Dial Gage	LOCAL	Dial Gage
Vernier depth gage	LOCAL	Vernier depth gage
IAE 1F10016 Mechanical wrench	0AM53	IAE 1F10016	1
IAE 1F10026 Hydraulic hand pump	0AM53	IAE 1F10026	1
IAE 1F10052 Two cables sling	0AM53	IAE 1F10052	1
IAE 1F10058 Handling fixture	0AM53	IAE 1F10058	1
IAE 1F10063 Expanding retainer	0AM53	IAE 1F10063	1
IAE 1F10080 Horizontal stand	0AM53	IAE 1F10080	1
IAE 1F10084 Support fixture	0AM53	IAE 1F10084	1
IAE 2F10418 Length gage	0AM53	IAE 2F10418	1
IAE 2F10415 Loading fixture	0AM53	IAE 2F10415	1
IAE 2F10368 Plate, Vacuum check	0AM53	IAE 2F10368	1
IAE 6F10027 Heater control unit	0AM53	IAE 6F10027	1
IAE 6F10029 Air flow test cart	0AM53	IAE 6F10029	1
IAE 6F10030 Vacuum test cart	0AM53	IAE 6F10030	1
IAE 1J12220 Hydraulic pusher/puller	0AM53	IAE 1J12220	1
IAE 1J12221 Impact hammer	0AM53	IAE 1J12221	1
IAE 1J12243 Sizing sleeve	0AM53	IAE 1J12243	1
IAE 1J12259 Seal slider	0AM53	IAE 1J12259	1
IAE 1J12260 Spanner wrench	0AM53	IAE 1J12260	1
IAE 1J12279 Grinding fixture	0AM53	IAE 1J12279	1
IAE 1J12280 Guide bar	0AM53	IAE 1J12280	1
IAE 1J12281 0AM53 heater	0AM53	IAE 1J12281	1
IAE 1J12282 Expanding pliers	0AM53	IAE 1J12282	1
IAE 1J12522 Seal slider	0AM53	IAE 1J12522	1
IAE 1M14127 Support plate	0AM53	IAE 1M14127	2
IAE 1P16354 Vacuum Test Adapter	0AM53	IAE 1P16354	1
IAE 1P17523 Blank-off Plate	0AM53	IAE 1P17523	1
IAE 1R18908 Guide plug	0AM53	IAE 1R18908	1
IAE 2R18871 Inspection bridge	0AM53	IAE 2R18871	1

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 02-119 LOCKWIRE	LOCAL	CoMat 02-119
CoMat 07-038 AIR DRYING ENAMEL	k3504	CoMat 07-038
CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE	03530	CoMat 10-045
CoMat 10-045A LEAK CHECK FLUID, BUBBLES-TYPE	LOCAL	CoMat 10-045A
CoMat 10-077 APPROVED ENGINE OILS	LOCAL	CoMat 10-077

Spares

Name	Manufacturer	Part Number / Identification	Quantity	Remark
Sealing ring			1
Packing			1

Safety Requirements

NONE

Procedure

1. Make very sure that the replacement LP Turbine Module is fully interchangeable with the module that it replaces and with the module to which it is to be installed. Refer to the SPM for module identification and interchangeability.
1. Examine the HP System Module at interface D-45. Refer to TASK 72-00-45-220-001 (INSPECTION-001).
2. Examine the front face of the LP Turbine Module at interface D-50/10. Refer to TASK 72-00-50-220-001 (INSPECTION-001).
3. Examine the LP Compressor/Intermediate Case Module at interface F-32. Refer to TASK 72-00-32-220-004 (INSPECTION-004).
4. Examine the LP Turbine Module at interface F-50. Refer to TASK 72-00-50-220-005 (INSPECTION-005).
1. Examine the LP Turbine Module externally and examine the non-modular parts.

SUBTASK 72-00-50-220-055 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5624

Refer to Figure.

Calculate the fit at location 5624.

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 5624
LP Turbine Case (72-50-21, 01-010), Bore HP Turbine Stage 2 Support Case ENGINE-STAGE 2 HPT SUPPORT ASSEMBLY (72-45-27, 01-010), Diameter
LP Turbine Case Bore	28.527	Intf	28.527	Intf
	28.533	0.002	28.533	0.002
HP System Case Diameter	28.535	0.014	28.529	0.014
	28.541		28.541

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 5624
LP Turbine Case (72-50-21, 01-010), Bore HP Turbine Stage 2 Support Case ENGINE-STAGE 2 HPT SUPPORT ASSEMBLY (72-45-27, 01-010), Diameter
LP Turbine Case Bore	724.586	Intf	724.586	Intf
	724.738	0.050	724.738	0.050
HP Turbine Case Diameter	724.789	0.356	724.637	0.356
	724.941		724.941

SUBTASK 72-00-50-220-103 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5623 (Pre SBE 72-0028)

Refer to Figure.

Calculate the clearance at Location 5623.

Table 3. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	(Select)	REJECT IF MORE THAN
LOCATION 5623
Inner Duct Segment ENGINE-LP TURBINE INNER STATIC SEALS (72-50-24, 01-010), Honeycomb Surface Stage 2 HPT Blade Retaining Plate ENGINE-STAGE 2 HPT BLADE RETAINING PLATE (72-45-33, 01-010), Knife Edge Outside Diameter
Inner Duct Segment Honeycomb Surface	19.896	0.118	19.896	0.118
	19.925	Clear	19.925	Clear
Knife Edge Outside Diameter	19.807	Clear	19.797	Clear
	19.812	0.084	19.812	0.084

Table 4. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	(Select)	REJECT IF MORE THAN
LOCATION 5623
Inner Duct Segment ENGINE-LP TURBINE INNER STATIC SEALS (72-50-24, 01-010), Honeycomb Surface Stage 2 HPT Blade Retaining Plate ENGINE-STAGE 2 HPT BLADE RETAINING PLATE (72-45-33, 01-010), Knife Edge Outside Diameter
Inner Duct Segment Honeycomb Surface	505.36	3.00	505.36	3.00
	506.10	Clear	506.10	Clear
Knife Edge Outside Diameter	503.10	Clear	502.84	Clear
	503.22	2.13	503.22	2.13

SUBTASK 72-00-50-220-251 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5623 (SBE 72-0028)

Refer to Figure.

Calculate the clearance at Location 5623.

Table 5. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	(Select)	REJECT IF MORE THAN
LOCATION 5623
Inner Duct Segment ENGINE-LP TURBINE INNER STATIC SEALS (72-50-24, 01-010), Honeycomb Surface Stage 2 HPT Blade Retaining Plate ENGINE-STAGE 2 HPT BLADE RETAINING PLATE (72-45-33, 01-010), Knife Edge Outside Diameter
Inner Duct Segment Honeycomb Surface	19.896	0.121	19.896	0.121
	19.925	Clear	19.925	Clear
Knife Edge Outside Diameter	19.804	Clear	19.797	Clear
	19.812	0.084	19.812	0.084

Table 6. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	(Select)	REJECT IF MORE THAN
LOCATION 5623
Inner Duct Segment ENGINE-LP TURBINE INNER STATIC SEALS (72-50-24, 01-010), Honeycomb Surface
Stage 2 HPT Blade Retaining Plate ENGINE-STAGE 2 HPT BLADE RETAINING PLATE (72-45-33, 01-010), Knife Edge Outside Diameter
Inner Duct Segment Honeycomb Surface	505.36	3.07	505.36	3.07
	506.10	Clear	506.10	Clear
Knife Edge Outside Diameter	503.02	Clear	502.84	Clear
	503.22	2.13	503.22	2.13

SUBTASK 72-00-50-220-104 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5620

Refer to Figure.

Calculate the fit at location 5620.

Table 7. 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 5620
LP Stub Shaft (72-32-51, 01-350), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Stub Shaft Bore	3.5433	Intf
	3.5447	0.0006
LP Turbine Shaft Diameter	3.5453	0.0029
	3.5462

Table 8. 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 5620
LP Stub Shaft (72-32-51, 01-350), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Stub Shaft Bore	90.000	Intf
	90.035	0.016
LP Turbine Shaft Diameter	90.051	0.073
	90.073

SUBTASK 72-00-50-220-105 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5621.

Refer to Figure.

Calculate the fit at location 5621.

Table 9. 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 5621
LP Stub Shaft (72-32-51, 01-350), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Stub Shaft Bore	3.9370	Intf
	3.9379	0.0006
LP Turbine Shaft Diameter	3.9385	0.0023
	3.9393

Table 10. 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 5621
LP Stub Shaft (72-32-51, 01-350), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Stub Shaft Bore	100.000	Intf
	100.022	0.015
LP Turbine Shaft Diameter	100.037	0.059
	100.059

SUBTASK 72-00-50-220-106 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5622.

Refer to Figure.

Calculate the clearance at location 5622.

Table 11. 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 5622
Differential Seal (72-32-26, 01-110), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Seal Bore	3.9410
	3.9449	0.0017
LP Turbine Shaft Diameter	3.9385	0.0064
	3.9393

Table 12. 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 5622
Differential Seal (72-32-26, 01-110), Bore To LP Turbine Shaft ENGINE-LP TURBINE SHAFT (72-50-41, 01-200), Diameter
Seal Bore	100.100
	100.200	0.041
LP Turbine Shaft Diameter	100.037	0.163
	100.059

1. Refer to Figure.
2. Install the IAE 1F10052 Two cables sling 1 off to the IAE 1F10058 Handling fixture 1 off.
3. Install the IAE 1F10084 Support fixture 1 off to the IAE 1F10063 Expanding retainer 1 off.
4. Install the expanding retainer to the inner diameter of the LP Turbine Shaft. Attach the support fixture to the rear inner flange of the TEC.
5. Turn the handwheel counter clockwise until the support is installed safely in the rear end of the LP Turbine Shaft.
6. Turn the knob counter clockwise to push the clamps against the inner diameter of the LP Turbine Shaft.
7. Lift the handling fixture and install it to the expanding retainer. Align the guide pin of the handling fixture with the hole in the rear flange of the TEC.
8. Attach the handling fixture to the rear flange of the TEC with the 13 screws. Tighten the screws.
9. CAUTION
  MAKE SURE THAT THE NUTS ARE TIGHTENED. IF THE FIXTURES ARE NOT CORRECTLY SECURED THE LP TURBINE CASE AND ROTOR PARTS CAN BE DAMAGED DURING HANDLING OF THE LP TURBINE MODULE.
  Safety the expanding retainer to the handling fixture with the two nuts. Tighten the nuts.
1. Refer to Figure.
2. Connect the front shaft and the rear shaft of the IAE 2F10418 Length gage 1 off.
3. Compress the guiding slides of the front shaft and put the length gage from the rear in to the engine. Observe the top position of the front and the rear shaft.
4. Move the length gage in to the engine until the locating face of the front shaft touches the adjusting ring location on the LP Turbine Stub Shaft.
1. Refer to Figure.
2. Install the beam (part of the IAE 2F10418 Length gage) to the rear flange of the HP Turbine Case. Safety the beam to the HP Turbine Case with the eight bolts and nuts. The end of the rear shaft must be on the beam.
3. Safety the shaft in radial position to the beam with the safety pin.
1. Install the handle to the front end of the IAE 2F10418 Length gage 1 off.
2. Safety the handle to the length gage with the nut. Torque the nut to 521 lbfin (58.9 Nm).
1. Refer to Figure.
2. 1. Engage the guide plug to the inner flange of the LP Stub Shaft.
  2. Align the four holes in the guide plug with the four holes in the inner flange of the LP Stub Shaft.
  3. Safety the guide plug to the LP Stub Shaft with the four pins (parts of the IAE 1R18908 Guide plug ).
  4. Safety the four pins to the guide plug with the four screws (parts of the IAE 1R18908 Guide plug).
  5. Install the force gage to the guide plug.
  6. Safety with the socket head cap screw and nut (parts of the IAE 2F10415 Loading fixture).
  7. Install the bolt to the force gage.
  8. Safety with the socket head cap screw and nut (parts of the IAE 2F10415 Loading fixture).
3. Install the flange (part of the IAE 2F10415 Loading fixture 1 off) to the front flange of the Fan Case. The bolt must come out through the center hole of the flange. Attach the flange to the Fan Case with eight screws, eight nuts and 16 washers.
4. Install the support (part of the IAE 2F10415 Loading fixture 1 off) to the bolt and the flange.
5. Install the thrust bearing (part of the IAE 2F10415 Loading fixture 1 off) on to the support. Safety all together with the ring and four screws.
6. Install the speed ball handle (part of the IAE 2F10415 Loading fixture 1 off). Safety it to the support with two screws.
1. Refer to Figure.
2. NOTE
  Load must be applied in rearward direction.
  Turn the speed ball handle of the IAE 2F10415 Loading fixture 1 off until the force gage shows the load of 900 lbf (4.0kN).
1. Refer to Figure.
2. Hold the dial gage against the measuring base plane of the beam.
3. Calibrate the zero position on the beam datum plane.
1. Refer to Figure.
2. Point the dial gage to the rear end of the IAE 2F10418 Length gage 1 off.
3. Read the dial gage and write down the dimension as dimension C.
4. Remove the dial gage.
1. Write the dimension C in the table 1, Figure.
2. Calculate the dimension T as shown in the table 1, Figure.
3. Record all the necessary dimensions in a component dimension record sheet. See the example in Figure.
1. NOTE
  Figure.hows all available adjusting rings and related thickness ranges.
  Calculated dimension T and Figure are necessary for the selection of required adjusting ring.
2. If the calculated dimension of T is out of the limits given in Figure. the applicable adjusting ring must be machined to calculated dimension T. Refer to Figure. Use the grinding machine and IAE 1J12279 Grinding fixture grinding fixture 1 off.
1. Refer to Figure.
2. Disassemble the speed ball handle, the ring, the thrust bearing and the support (parts of the IAE 2F10415 Loading fixture).
3. Remove the flange from the front flange of the Fan Case.
4. Remove the bolt, the force gage and the IAE 1R18908 Guide plug 1 off from the curvic coupling of the LP Stub Shaft.
1. Refer to Figure.
2. Remove the IAE 2F10418 Length gage 1 off from the engine.
3. Disassemble the front shaft and the rear shaft of the length gage.
1. Remove the old adjusting ring from the LP Turbine Shaft and install the new adjusting ring. Use the IAE 1J12282 Expanding pliers 1 off.
2. Make sure that the new adjusting ring is correctly fitted on the adjusting ring location.
1. 1. Install the local heater to the front flange of the LP Turbine Stub Shaft.
  2. Align the four holes in the guide of the local heater with the four slots in the flange of the LP Stub Shaft.
  3. Safety the guide of the heater to the LP Stub Shaft with the four pins.
  4. Safety the four pins to the guide with the four screws.
2. Install the guide ring A1 (part of IAE 1J12280 Guide bar) on to the lock nut at the rear flange of the Stage 2 Turbine Disk. Refer to Figure.
3. 1. Connect the two guide bars (parts of the IAE 1J12280 Guide bar).
  2. Install the connected guide bars with the conical end through the guide ring A1.
  3. Make sure that the conical end of the guide bars is correctly engaged in to the local heater.
1. Refer to Figure.
2. Attach the IAE 1F10052 Two cables sling 1 off to the front spool of the IAE 1F10058 Handling fixture 1 off which is installed at the LP Turbine Module.
3. Loosen the nut of the eye bolt (part of the IAE 1F10080 Horizontal stand 1 off).
4. Loosen the ring nut A. Turn the ring nut A to the end position.
5. Loosen the ring nut B from the rear end of the support.
6. Disengage the eye bolt. Turn the block in open position.
7. Loosen and remove the 28 head cap screws which attach the LP Turbine Module to the rear support of the horizontal stand.
8. Move the LP Turbine Module carefully to get it free from the horizontal stand. Lift the LP Turbine Module from the horizontal stand.
9. Loosen the ring nut C and remove the shaft (part of the horizontal stand) from the LP Turbine Shaft.
10. Install the shaft to the front support of the horizontal stand. Close the block and safety with the eye bolt and the nut.
11. Lift the LP Turbine Module to the same level as the guide bar installed in the engine before. Connect the LP Turbine Shaft front end to the guide bar.
1. Refer to Figure.
2. Remove the guide ring A1 and install the guide ring A3 (part of the IAE 1J12280 Guide bar 1 off) to the lock nut at the rear flange of the Stage 2 Turbine Disk.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure and Figure.
2. Move the LP Turbine Module forward until the LP Turbine Shaft is installed 1.6 ft (0.5 m) in to the engine.
3. Remove the guide ring A3 and install the guide ring A2 (part of the IAE 1J12280 Guide bar 1 off) to the lock nut at the rear flange of the Stage 2 Turbine Disk. Refer to Figure.
4. Continue to move the LP Turbine Module forward in to the engine. Move it forward until the front flange of the LP Turbine Case is approximately 20 in. (500 mm) behind the rear flange of the HP Turbine Case.
5. Push the IAE 1J12281 0AM53 heater 1 off backwards, until it is against the stop position. Increase the temperature of the spline area of the LP Stub Shaft to the temperature of 275 deg F to 329 deg F (135 deg C to 165 deg C). Use the IAE 6F10027 Heater control unit 1 off.
6. During this time remove the IAE 1M14127 Support plate 2 off from the LP Turbine Case front flange and the LP Turbine Shaft. Refer to Figure.
7. Remove the guide ring A2 from the lock nut at the rear flange of the Stage 2 Turbine Disk.
8. 1. Make sure that the locating pin at the HP Turbine Case rear flange aligns with the locating pin hole at the LP Turbine Case front flange.
9. Remove the guide bar.
10. 1. Remove the four screws and the four pins from the guide part of the IAE 1J12281 0AM53 heater.
  2. Disengage the guide of the heater from the four slots in the flange of the LP Stub Shaft.
  3. Remove the heater.
11. Remove the guide bar from the LP Turbine Shaft front end.
12. 1. Install the inner subassembly of the hydraulic pusher/puller (which has the spanner, the plunger and the nut) in to the inner threaded hole of the LP Turbine Shaft.
    Turn the inner subassembly clockwise fully.
    Hold the LP Turbine Shaft rear end and turn the inner subassembly counter clockwise by one turn to loosen it.
    NOTE
    The procedure in Step makes the release of the inner subassembly from the LP Turbine Shaft in Step easy.
  2. Attach the outer subassembly of the hydraulic pusher/puller (which has the guide, the cylinder and hydraulic cylinder) to the front flange of the LP Stub Shaft. The four flanges of the guide must be in line with the scallops of the LP Stub Shaft.
    NOTE
    Make sure that the hydraulic connection of the hydraulic cylinder is at the opposite side of the cylinder.
  3. Turn the guide until the holes in its stoppers are in line with the slots in the front flange of the LP Stub Shaft. Put the four pins in the holes in the flanges of the guide. Safety the pins to the guide with the four screws.
  4. Install the nut D and the set screw and tighten the set screw to hold the plunger.
  5. Install the stud bolt through the hydraulic cylinder in to the nut C. Hold the stud bolt with a wrench and tighten the nut A.
  6. Loosen the set screw.
13. Install the IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic connection of the hydraulic pusher/puller.
14. Install 6 work bolts and nuts through the LP Turbine front flange boltholes in opposite positioned pairs.
  NOTE
  The bolt heads and nuts must be identified by a red paint mark.
15. Pull the LP Turbine Module in correct position. Tighten the work nut pairs at the HP/LP Turbine Flanges in opposite sequence. Apply equal force all around the flange to pull them together. At the same time operate the hydraulic pump stepwise to connect the LP Turbine Shaft with the LP Stub Shaft.
  NOTE
  Tighten the work nuts, and operate the hydraulic pump at the same time to prevent overloading of the handling fixture.
16. If the HP/LP Turbine Flanges are together, loosen the two nuts which secure the IAE 1F10063 Expanding retainer 1 off to the IAE 1F10058 Handling fixture 1 off.
17. CAUTION
  DO NOT SUPPLY THE HYDRAULIC PUSHER/PULLER WITH MORE THAN 5000 PSI (345 BAR) PRESSURE, TOO MUCH HYDRAULIC PRESSURE CAN CAUSE DAMAGE TO THE HYDRAULIC PUSHER/PULLER.
  Operate the hydraulic pump to make sure that the LP Turbine Shaft and the LP Stub Shaft are correctly engaged.
18. Disconnect the hydraulic pump from the hydraulic pusher/puller.
19. 1. Tighten the set screw.
  2. Loosen the nut A which secures the stud bolt to the hydraulic cylinder. Remove the stud bolt.
  3. Remove the set screw and the nut D.
  4. Loosen and remove the four screws which safety the pins to the guide of the IAE 1J12220 Hydraulic pusher/puller 1 off.
  5. Remove the four pins which safety the guide to the flange of the LP Stub Shaft.
  6. Remove the outer subassembly from the front flange of the LP Stub Shaft.
  7. Remove the inner subassembly from the inner thread of the LP Turbine Shaft.
20. 1. Install the front lock nut (01-140) to the LP Turbine Shaft.
    NOTE
    If the LP Compressor Disk and Fan Blades are installed, do Step and continue then with Step.
    NOTE
    If the LP Compressor Disk and Fan Blades are not installed, do Step alternatively to Step.
  2. Install the support B (part of the IAE 1J12260 Spanner wrench 1 off) to the retaining ring of the LP Compressor Disk. Attach the support B with the four bolts. Refer to Figure.
  3. Install the support A (part of the spanner wrench) to the curvic coupling of the LP Stub Shaft. Attach the support A with the four bolts. Refer to Figure.
  4. Install the drive bar and the drive coupling of the spanner wrench through the support. Engage the outside spanner teeth of the wrench on to the front lock nut of the LP Turbine Shaft.
  5. Install the rod and the nut of the spanner wrench to the inner thread of the LP Turbine Shaft.
  6. CAUTION
    MAKE SURE THAT THE IMMOBILIZER IS FULLY ENGAGED WITH THE LOCK NUT TEETH BEFORE YOU TORQUE THE FRONT LOCK NUT.
    Carefully install the immobilizer in to the drive bar until a yellow line goes out of view.
  7. NOTE
    The immobilizer is correctly installed against the lock nut if the yellow line can not be seen.
  8. Install the center thumb nut on to the rod to safety the immobilizer.
  9. Assemble the IAE 1F10016 Mechanical wrench 1 off to the spanner wrench.
  10. Install the spring, the anchor plate and the clamp disk on to the immobilizer and safety with the two thumb nuts.
21. 1. Install the front lock nut finger tight.
  2. Apply initial tightening torque of 3150 lbfft to 3250 lbfft (4271 Nm to 4407 Nm).
  3. Loosen the front lock nut.
  4. Install the front lock nut finger tight.
  5. Apply initial tightening torque of 950 lbfft to 1050 lbfft (1288 Nm to 1424 Nm).
  6. Put an angle of turn of 26 degrees to the front lock nut.
  7. CAUTION
    DO NOT TURN THE FRONT LOCK NUT MORE THAN 3250 LBFFT (4407 NM). DAMAGE TO THE PARTS OR TOOLS CAN OCCUR.
    Apply additional turn on the front lock nut to align the slots of the nut with the slots of the LP Turbine Shaft. The maximum angle turn is two degrees.
22. 1. Release the two thumb nuts and remove the clamp disk, the anchor plate and the spring.
  2. Remove the mechanical wrench from the spanner wrench.
  3. Release the center thumb nut from the rod and remove the immobilizer from the center of the drive bar.
  4. Release the nut from the inner thread of the LP Turbine Shaft and remove the rod.
  5. Remove the drive bar and the Drive Coupling Assembly.
  6. Remove the support A or the support B.
23. Safety the front lock nut of the LP Turbine Shaft with the locking cap and the Internal Retaining Ring ENGINE-LP TURBINE SHAFT (72-50-41, 01-100). Refer to Figure.
24. Remove the red marked work bolts and nuts from the HP/LP Turbine Flange.
25. 1. CAUTION
    HOLD THE BOLTS IN THEIR POSITION IF YOU INSTALL THE NUTS ON TO THE BOLTS. DO NOT TURN THE BOLTS OR MAKE TO-AND-FRO MOVEMENTS. THE LP TURBINE CASE/HP TURBINE CASE FLANGE AND/OR THE BOLTS CAN BE DAMAGED.
    Torque the 84 nuts installed on the bolts which have their heads located on the HP Turbine Flange from 180.0 lbfin to 220.0 lbfin (20.0 Nm to 25.0 Nm).
  2. Torque the 16 bolts which have their heads located on the LP Turbine Flange from 180.0 lbfin to 220.0 lbfin (20.0 Nm to 25.0 Nm). Safety the bolts with CoMat 02-119 LOCKWIRE.
1. Refer to Figure.
2. Turn the knob clockwise to disengage the clamps of the IAE 1F10063 Expanding retainer 1 off.
3. Release the nut and turn it rearwards to the end position.
4. Loosen and remove the 13 screws which attach the IAE 1F10058 Handling fixture 1 off to the rear flange of the TEC.
5. Remove the handling fixture from the expanding retainer.
6. Turn the handwheel of the IAE 1F10084 Support fixture 1 off clockwise to disengage the support from the LP Turbine Shaft.
7. Release the support fixture from the inner rear flange of the TEC. Remove the support fixture and the expanding retainer from the LP Turbine Module.
1. Refer to Figure.
2. Install the IAE 2F10415 Loading fixture 1 off on to the front flange of the Fan Case. Refer to Step.
3. Install the IAE 2R18871 Inspection bridge 1 off to the rear flange of the Turbine Exhaust Case.
4. Saftey the inspection bridge with four nuts and bolts.
5. Push the LP Turbine Rearwards from the front of the engine.
1. Load the LP Turbine Module with 900 lbf (4.0 kN).
  NOTE
  Load must be applied in rearward direction.
2. Use a suitable vernier depth gage to measure the dimension P (actual). Refer to Figure.
  DIM. P to be within 13.7988 in to 13.8421 in. (350.49 mm to 351.59 mm).
3. Release the load from the LP Turbine Module.
1. Refer to Figure.
2. Remove the IAE 2F10415 Loading fixture 1 off from the front flange of the Fan Case refer to Step.
3. Remove the IAE 2R18871 Inspection bridge from the rear flange of the Turbine Exhaust Case.
1. Refer to Figure, Figure, Figure, Figure and Figure.
2. NOTE
  Use of IAE 1J12259 Seal slider without IAE 1J12243 Sizing sleeve is not permitted.
3. 1. Put the blind cap with the rear end down ENGINE-LP TURBINE SHAFT (72-50-41, 01-150) on to a work bench.
  2. Install the IAE 1J12259 Seal slider 1 off on the blind cap.
  3. Lubricate the new ENGINE-LP TURBINE SHAFT (72-50-41, 01-160) sealing ring with CoMat 10-077 APPROVED ENGINE OILS.
  4. Lubricate the outer diameter faces of the seal slider and the blind cap with CoMat 10-077 APPROVED ENGINE OILS.
  5. Put the sealing ring on the seal slider. The open side of the sealing ring must be in down direction.
  6. CAUTION
    MOVE THE SEALING RING SMOOTHLY AND EQUALLY OVER THE ALL CIRCUMFERENCE, IF NOT SO, THE SEALING RING IS EXTENDED LOCALLY. LOCAL EXTENSION CAN CAUSE DAMAGE TO THE SEALING RING.
    Push the sealing ring down with four or more fingers until it is installed in to the groove of the blind cap.
  7. Remove the seal slider from the blind cap.
4. 1. Put the IAE 1J12243 Sizing sleeve 1 off with the front end down on to the work bench.
  2. Lubricate the inner diameter face of the sizing sleeve and the outer diameter of the sealing ring with CoMat 10-077 APPROVED ENGINE OILS.
  3. Put the blind cap in to the sizing sleeve. Diaphragm of the blind cap must be in down direction. Refer to Figure position A.
  4. Slowly push down the blind cap until it touches the work bench. Refer to Figure position A.
  5. Keep the blind cap in the sizing sleeve for ten or more minutes.
  6. Remove the sizing sleeve from the blind cap.
5. 1. Make sure that there is no damage on the surface.
  2. CAUTION
    DO NOT CORRECT TWISTED CONDITION OF THE SEALING RING. DISCARD THE TWISTED SEALING RING.
    Make sure that the sealing ring is not twisted. Refer to Figure.
6. Install the blind cap to the LP Turbine Shaft. Use the IAE 1J12221 Impact hammer 1 off.
7. Install the Internal Retaining Ring ENGINE-LP TURBINE SHAFT (72-50-41, 01-100). Refer to Figure.
1. Refer to Figure, Figure, Figure and Figure.
2. 1. Put the blind cap with the front end down on to the work bench.
  2. Install the IAE 1J12522 Seal slider 1 off on the blind cap.
  3. Lubricate the sealing ring with CoMat 10-077 APPROVED ENGINE OILS .
  4. Lubricate the outer diameter faces of the seal slider and the blind cap with CoMat 10-077 APPROVED ENGINE OILS.
  5. Put the sealing ring on the seal slider. The open side of the sealing ring must be in up direction.
  6. CAUTION
    MOVE THE SEALING RING SMOOTHLY AND EQUALLY OVER ALL THE CIRCUMFERENCE. IF NOT SO, THE SEALING RING IS EXTENDED LOCALLY, LOCAL EXTENSION CAN CAUSE DAMAGE TO THE SEALING RING.
    Put the sealing ring down with four or more fingers until it is installed into the groove of the blind cap.
  7. Remove the seal slider from the blind cap.
3. 1. Make sure that there is no damage on the surface.
  2. CAUTION
    DO NOT CORRECT TWISTED CONDITION OF THE SEALING RING. DISCARD THE TWISTED SEALING RING.
    Make sure that the sealing ring is not twisted. Refer to Figure.
4. Install the blind cap on to the LP Turbine Shaft. Use the IAE 1J12221 Impact hammer 1 off.
5. CAUTION
  DO NOT USE THE INTERNAL RETAINING RING P/N RR295 WITH THE BLIND CAP P/N 5A1703.
  Install the Internal Retaining Ring ENGINE-LP TURBINE SHAFT (72-50-41, 01-100). Refer to Figure.
1. Refer to Figure.
2. Lubricate packing ENGINE-NO.5 BEARING COMPARTMENT COVER (72-58-01, 01-160) with CoMat 10-077 APPROVED ENGINE OILS. Install the packing on the groove of the compartment cover ENGINE-NO.5 BEARING COMPARTMENT COVER (72-58-01, 01-120).
3. Install the compartment cover ENGINE-NO.5 BEARING COMPARTMENT COVER (72-58-01, 01-120) to the Turbine Exhaust Case.
4. 1. WARNING
    IF YOU DO NOT SECURE THE COMPARTMENT COVER DURING THE LEAK TEST THERE IS A RISK OF PERSONAL INJURY FROM THE RELEASED COVER.
    Install 12 work bolts to the compartment cover. Tighten the bolts.
  2. Install the IAE 1P17523 Blank-off Plate 1 off to the No. 5 Bearing Outer Oil Feed Tube. Refer to Fig. 72-00-50-990-490.
  3. Install the IAE 1P16354 Vacuum Test Adapter 1 off to the No. 5 Bearing Oil Scavenge Tube Outlet with three bolts (part of the adapter). Tighten the bolts. Refer to Figure.
  4. Attach the hose on the IAE 6F10029 Air flow test cart 1 off to the adapter.
  5. Control the air pressure to the adapter to 10 PSI (68.95 kPa).
  6. Apply CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE or CoMat 10-045 LEAK CHECK FLUID, BUBBLES-TYPE around the cover and oil tube interfaces to check for leaks. Replace the seal of any leaking interface with a new seal.
  7. Do the leak test again.
  8. Remove the 12 work bolts.
5. Install the rear thermal blanket ENGINE-NO.5 BEARING COMPARTMENT COVER (72-58-01, 01-100) on to the compartment cover. Align the boltholes.
6. Attach the 12 bolts. Torque the bolts to 101.784 lbfin (11.5 Nm).
1. 1. Make sure that the adapter has no damage.
  2. Lubricate the bolts, nuts and washers with CoMat 10-077 APPROVED ENGINE OILS.
  3. Attach the adapter to No. 5 Bearing Outer Oil Scavenge Tube and safety with 4 bolts. Torque the bolts to 85 lbfinto 105 lbfin (9.604 Nm to 11.863 Nm).
2. 1. Make sure that the plate has no damage.
  2. Lubricate the bolts, nuts and washers with CoMat 10-077 APPROVED ENGINE OILS.
  3. Attach the plate to No.5 Bearing Outer Oil Feed and safety with 3 bolts. Torque the bolts to 85 lbfin to 105 lbfin (9.60 Nm to 11.86 Nm).
1. Refer to Figure.
2. Connect the hose of IAE 6F10030 Vacuum test cart 1 off of the nipple to the IAE 1P16354 Vacuum Test Adapter 1 off. Refer to Figure.
3. NOTE
  Refer to manufacturer manual for the operation of the vacuum test cart.
  Attach the cart vacuum gage hose to the plug of the IAE 1P16354 Vacuum Test Adapter.
4. Set the air pressure at the test port to -20inHg (-508 mmHg gage). Based on the ambiente pressure, refer to the table below for the vacuum pressure in psia.
  Ambient Pressure of the Day (psia)
  Vacuum Pressure (psia)
  14.7
  4.9
  14.5
  4.7
  14.3
  4.5
  14.1
  4.3
  13.9
  4.1
  13.7
  3.9
  13.5
  3.7
  13.3
  3.5
  13.1
  3.3
  Vacuum pressure (psia) = Ambient pressure of the day (psia) - 9.8 psia
5. Read the airflow indicated by the rotor meters on the vacuum test cart.
6. Record the indicated airflow.
7. If the indication is more than 10 PPH (4.54 kg per hour) reject the module.
8. Stop the vacuum pump.
1. Disconnect the hoses of the vacuum test cart from the adapter. Refer to Figure.
2. Remove the plate and the adapter. Refer to Figure and Figure.
1. Install the module dressings. Refer to TASK 72-00-50-420-005 (INSTALLATION-007).
1. Install the Inlet Cone. Refer to TASK 72-38-11-420-001 (INSTALLATION).

Fits and Clearances at Interface D-45 and D-50/10

Fits and Clearances at Interface F-32 and F-50

Attachment of the Handling Fixture and the Expanding Retainer

Installation of the Heater and the Guide Bar

Installation of the Guide Rings

Sheet 1

Sheet 2

Sheet 3

Sheet 4

Sheet 5

Sheet 1

Sheet 2

Sheet 3

Sheet 4

Connect the LP Shaft Front End with the LP Stub Shaft

Sheet 1

Sheet 2

Safety the Front Lock Nut of the LP Turbine Shaft

Removal of the Support Plate

Sheet 1

Sheet 2

Sheet 3

Sheet 4

Installation of the Compartment Cover and the Rear Thermal Blanket

Install the Blind Cap

Sheet 1

Sheet 2

Installation of the Adapter to No. 5 Bearing Outer Oil Scavenge Tube

Sheet 1

Connect the Fitting of the Vacuum Test Cart to the Adapter

Install/Remove the Loading Fixture

Sheet 1

Sheet 2

Sheet 3

SBE 72-0037 and Pre SBE 72-0227: Installation of the Sealing Ring in to the Sizing Sleeve

SBE 72-0037: Installed Condition of the Sealing Ring

Example of Incorrect Installation of the Sealing Ring onto the Blind Cap

Installation of Blind Cap and Retaining Ring

Install the Plate to the No. 5 Bearing Outer Feed Tube

Requirements After Job Completion

Follow-On Conditions

NONE

Manufacturer Code:	03530
Enterprise Name:	AMERICAN GAS AND CHEMICAL CO LTD
BU Name:	AMERICAN GAS AND CHEMICAL CO LTD
Street:	220 PEGASUS AVE
City:	NORTHVALE
State:	NJ
Zip Code:	07647
Country:	USA
Phone Number:	1-201-767-7300, 1-800-526-1008
Fax Number:	1-201-767-1741
Internet:	www.amgas.com

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

Ambient Pressure of the Day (psia)	Vacuum Pressure (psia)
14.7	4.9
14.5	4.7
14.3	4.5
14.1	4.3
13.9	4.1
13.7	3.9
13.5	3.7
13.3	3.5
13.1	3.3

Manufacturer Code:	LOCAL
Tool Number:	Dial Gage
Tool Name:	Dial Gage

TASK 72-00-50-420-001-A00 LPT Module - Install The LPT Module (Horizontal) - Method 1, Installation-002 - Pre SBE 72-0063

Export Control

Copyright

Applicability

Common Information

TASK 72-00-50-420-001-A00 LPT Module - Install The LPT Module (Horizontal) - Method 1, Installation-002 - Pre SBE 72-0063

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-00-50-420-051 Identify the LP Turbine Module

SUBTASK 72-00-50-210-051 Examine the Module Interfaces

SUBTASK 72-00-50-210-052 Examine the LP Turbine Module Externally and Examine the Non-Modular Parts

SUBTASK 72-00-50-220-055 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5624

SUBTASK 72-00-50-220-103 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5623 (Pre SBE 72-0028)

SUBTASK 72-00-50-220-251 Measure that the Fits and Clearances between the LP Turbine Module and the HP System Module are in the Limits given at Location 5623 (SBE 72-0028)

SUBTASK 72-00-50-220-104 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5620

SUBTASK 72-00-50-220-105 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5621.

SUBTASK 72-00-50-220-106 Measure that the Fits and Clearances between the LP Turbine Module and the LP Compressor are in the Limits given at Location 5622.

SUBTASK 72-00-50-420-052 Attach the LP Handling Fixture to the LP Turbine Module

CAUTION

SUBTASK 72-00-50-420-055 Install the Length Gage in to the Engine

SUBTASK 72-00-50-420-056 Install the Beam of the Length Gage to the Rear Flange of the HP Turbine Case

SUBTASK 72-00-50-420-058 Install the Handle to the Length Gage

SUBTASK 72-00-50-420-196 Install the Loading Fixture to the Front Flange of the Fan Case

SUBTASK 72-00-50-420-135 Load the No. 1 Bearing

NOTE

SUBTASK 72-00-50-420-060 Calibrate the Zero Position on the Dial Gage

SUBTASK 72-00-50-420-061 Measure the Dimension C

SUBTASK 72-00-50-420-062 Calculate the Adjusting Ring Thickness

SUBTASK 72-00-50-420-136 Adjust the Thickness of the Adjusting Ring

NOTE

SUBTASK 72-00-50-420-067 Remove the Loading Fixture from the Engine

SUBTASK 72-00-50-420-068 Remove the Length Gage from the Engine

SUBTASK 72-00-50-420-069 Install the Adjusting Ring to the LP Turbine Shaft

SUBTASK 72-00-50-420-070 Prepare the Engine for the Installation of the LP Turbine Module

SUBTASK 72-00-50-420-071 Remove the LP Turbine Module from the Horizontal Stand

SUBTASK 72-00-50-420-137 Remove the Guide Ring A1

SUBTASK 72-00-50-420-072 Install the LP Turbine Module

NOTE

NOTE

NOTE

NOTE

CAUTION

NOTE

NOTE

CAUTION

NOTE

CAUTION

CAUTION

SUBTASK 72-00-50-420-131 Remove the Handling Fixture from the LP Turbine Module

SUBTASK 72-00-50-420-132 Install the Loading Fixture and Inspection Bridge to the LP Turbine Module

SUBTASK 72-00-50-420-073 Measure the Dimension P After the Installation of the LP Turbine Module

NOTE

SUBTASK 72-00-50-420-133 Remove the Loading Fixture and the Inspection Bridge from the LP Turbine Module

SUBTASK 72-00-50-420-074-B00 Install the Blind Cap to the LP Turbine Shaft (SBE 72-0037 and Pre SBE 72-0227)

NOTE

CAUTION

CAUTION

CAUTION

SUBTASK 72-00-50-420-074-D00 Install the Blind Cap to the LP Turbine Shaft (SBE 72-0227)

CAUTION

CAUTION

CAUTION

SUBTASK 72-00-50-420-075 Install the Compartment Cover

WARNING

SUBTASK 72-00-50-420-197 Install the Adapter and the Plate to the Turbine Exhaust Case

SUBTASK 72-00-50-420-198 Do an Evacuation Check for the No. 5 Bearing Compartment

NOTE

SUBTASK 72-00-50-420-199 Remove the Vacuum Test Cart, the Adapter and the Plate

SUBTASK 72-00-50-420-076 Install the Module Dressings

SUBTASK 72-00-50-420-077 Install the Inlet Cone

Figure: Fits and Clearances at Interface D-45 and D-50/10

Fits and Clearances at Interface D-45 and D-50/10