TASK 72-32-00-430-010-A00 LPC/Intermediate Case Module - Install The LPC Booster Stage Assembly, Assembly-010

DMC:V2500-A1-72-32-0000-10A-710A-B|Issue No:003.00|Issue Date:2017-03-23

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 72-32-00-430-010-A00 LPC/Intermediate Case Module - Install The LPC Booster Stage Assembly, Assembly-010

General

This TASK gives the procedure to install the LP Compressor Booster Assembly. For other parts of the LP Compressor/Intermediate Case Module, refer to TASK 72-32-00-430-000 (ASSEMBLY-000).

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 70-41-00-400-501 and SPM TASK 70-41-02-410-501.

To identify, lubricate and install seal rings, refer to the SPM TASK 70-64-02-640-501.

Special torque data and 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.

The abbreviation Intf shows an interference or tight fit. This causes REJECT IF MORE THAN to become REJECT IF LESS THAN. The abbreviation Clear shows a clearance fit.

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.

The No. 1 Strut, which is the top position Strut of the Fan Frame Assembly, is identified by the five pressure tubes on the No. 1 Strut leading edge.

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

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1J12457 Measuring stretch0AM53IAE 1J124571
IAE 1J12507 Guide pin0AM53IAE 1J125071
IAE 1J13109 0AM53 heater0AM53IAE 1J131091
IAE 1J13103 Vertical sling0AM53IAE 1J131031
IAE 6F10027 Heater control unit0AM53IAE 6F100271

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-124 ISOPROPYL ALCOHOLLOCALCoMat 01-124
CoMat 04-004 JOINTING COMPOUND, LIGHT GRADELOCALCoMat 04-004
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-00-430-187-A00 Prepare the Fan Frame Assembly (Pre SBE 72-0094)

    1. Refer to Figure.

    2. Make sure that the FEGV's are removed.

    3. CAUTION

      THE BOLTS (01-377) MUST BE REMOVED BEFORE YOU INSTALL THE LP COMPRESSOR BOOSTER STAGE ASSEMBLY. THE BOLTS CAN TOUCH THE ASSEMBLY AND CAUSE DAMAGE TO IT.

      Remove the FEGV's if they are installed. Refer to TASK 72-32-00-030-004 (Disassembly-004).

    4. Turn the Fan Frame Assembly vertical with the front end up. Refer toTASK 72-32-00-430-009-A00 (ASSEMBLY-009).

    2. SUBTASK 72-32-00-430-187-B00 Prepare the Fan Frame Assembly (SBE 72-0094)

      SBE 72-0094: Shorter FEGV platform bolts.

    1. Refer to Figure.

    2. Make sure that the Fan Frame Assembly is installed vertically with the front end up, on the turnover stand. Refer to TASK 72-32-00-430-009-A00 (ASSEMBLY-009).

    3. SUBTASK 72-32-00-430-131-A00 Measure the Interface Dimensions for the Installation of the LP Compressor Booster Stage Assembly (Pre SBE 72-0391)

    1. Refer to Figure.

      2. Install IAE 1J12457 Measuring stretch 1 off onto the stub shaft.

      1. Clean the mating faces of the stub shaft and the measuring stretch with a clean lint free cloth made moist with CoMat 01-124 ISOPROPYL ALCOHOL.

      2. Engage the curvic teeth of the measuring stretch with the curvic teeth of the stub shaft.

      3. Safety the measuring stretch with the four set screws (part of the measuring stretch). Tighten the set screws.

      3. Calibrate the dial gage (part of the measuring stretch).

      1. Install the dial gage onto the base pin on the measuring stretch.

      2. Calibrate the zero position of the dial gage.

      4. Measure the dimension XF with the dial gage at 12 o'clock positions.

      1. Put the clocking pin onto the front end of the case of the Stage 2.5 Vanes through the measuring stretch hole.

      2. Put the dial gage on the clocking pin.

      3. Read the dial gage and write down the dimension as dimension XF.

      4. Remove the dial gage from the measuring stretch.

      5. Remove the clocking pin from the Stage 2.5 Vanes.

    5. Use the following formula to calculate the dimension AE.

      AE = L - XF - H.

    6. Make sure that the dimension AE is between 11.590 in. and 11.623 in. (294.38 mm and 295.23 mm).

    7. Do Step through Step at 3, 6 and 9 o'clock positions.

    8. Remove the four set screws which attach the measuring stretch to the stub shaft. Remove the measuring stretch.

    4. SUBTASK 72-32-00-430-131-B00 Measure the Interface Dimensions for the Installation of the LP Compressor Booster Stage Assembly (SBE 72-0391)

      SBE 72-0391: New separate type No. 1 Bearing Support Assembly.

    1. Refer to Figure.

      2. Install IAE 1J12457 Measuring stretch 1 off onto the stub shaft.

      1. Clean the mating faces of the stub shaft and the measuring stretch with a clean lint free cloth made moist with CoMat 01-124 ISOPROPYL ALCOHOL.

      2. Engage the curvic teeth of the measuring stretch with the curvic teeth of the stub shaft.

      3. Safety the measuring stretch with the four set screws (part of the measuring stretch). Tighten the set screws.

      3. Calibrate the dial gage (part of the measuring stretch).

      1. Install the dial gage onto the base pin on the measuring stretch.

      2. Calibrate the zero position of the dial gage.

      4. Measure the dimension XF with the dial gage at 12 o'clock positions.

      1. Put the clocking pin onto the front end of the case of the Stage 2.5 Vanes through the measuring stretch hole.

      2. Put the dial gage on the clocking pin.

      3. Read the dial gage and write down the dimension as dimension XF.

      4. Remove the dial gage from the measuring stretch.

      5. Remove the clocking pin from the Stage 2.5 Vanes.

    5. Use the following formula to calculate the dimension AE.

      AE = L - XF - H.

    6. Make sure that the dimension AE is between 11.572 in. and 11.604 in. (293.91 mm and 294.76 mm).

    7. Do Step through Step at 3.6 and 9 o'clock positions.

    8. Remove the four set screws which attach the measuring stretch to the stub shaft. Remove the measuring stretch.

    5. SUBTASK 72-32-00-220-087 Reference Fits and Clearances of the LP Compressor Booster Stage Disk and the Rotor Center Shaft at Location 0108

    1. Refer to Figure.

    2. Reference dimensions at location 0108. If required use the data written as a NOTE in TASK 72-32-81-200-000 (INSPECTION-000) and TASK 72-32-51-200-000 (INSPECTION-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 0108

      LP Compressor Booster Stage Disk Assembly "ENGINE-LP COMPRESSOR STAGE 1.5,2 AND 2.5 DISC (72-32-81, 01-200), Front Location Bore

      Rotor Center Shaft ENGINE-LP STUB SHAFT AND ROTOR CENTRE (72-32-51, 01-100), Front Location Diameter

      Disk Bore

      11.8051

      Intf

      11.8032

      0.0012

      Shaft Diameter

      11.8074

      0.0042

      11.8063

      Intf

      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 0108

      LP Compressor Booster Stage Disk Assembly "ENGINE-LP COMPRESSOR STAGE 1.5,2 AND 2.5 DISC (72-32-81, 01-200), Front Location Bore

      Rotor Center Shaft ENGINE-LP STUB SHAFT AND ROTOR CENTRE (72-32-51, 01-100), Front Location Diameter

      Disk Bore

      299.852

      Intf

      299.800

      0.026

      Shaft Diameter

      299.910

      0.110

      299.878

      Intf

    6. SUBTASK 72-32-00-430-132 Apply Jointing Compound to the Mating Faces on the LP Compressor Stage 2.5 Vanes (Stage 2.5 Vanes)

    1. Refer to Figure.

    2. Use a clean cloth made moist with CoMat 01-124 ISOPROPYL ALCOHOL to clean the mating faces.

    3. Apply CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the mating faces with a soft brush.

      NOTE

      Do not get the jointing compound to the threaded holes of the clinch nuts on the Stage 2.5 Vanes.
      Install the LP Compressor Booster Stage Assembly to the Stage 2.5 Vanes before the jointing compound becomes dry.

    7. SUBTASK 72-32-00-430-133 Prepare the LP Compressor Booster Stage Assembly (LPC Assembly) for Installation of It to the Rotor Center Shaft and the Stage 2.5 Vanes

    1. Refer to Figure and Figure.

      2. Install IAE 1J13103 Vertical sling 1 off onto the disk front flange of the LPC Assembly, Figure.

        NOTE

        The LPC Assembly is installed on the storage stand in TASK 72-32-80-440-001-A00 (ASSEMBLY-001) and TASK 72-32-80-440-001-B00 (ASSEMBLY-001).

      1. Install the three eye bolts (part of the vertical sling) into three of the six threaded holes in the disk flange. The three threaded holes must be equally apart.

      2. Attach the three hooks (part of the vertical sling) to the eye bolts.

    3. Attach a hoist to the vertical sling.

      4. Move the LPC Assembly from the storage stand to IAE 1J13109 0AM53 heater 1 off, Figure.

      1. Slowly lift the LPC Assembly until it is clear of the storage stand.

      2. Move the LPC Assembly above the local heater and slowly lower the LPC Assembly onto the local heater.

      3. Remove the vertical sling.

    5. Connect the cables of the local heater to IAE 6F10027 Heater control unit 1 off.

    8. SUBTASK 72-32-00-430-134 Install the LP Compressor Booster Stage Assembly (LPC Assembly) to the Rotor Center Shaft and the LP Compressor Stage 2.5 Vanes (Stage 2.5 Vane)

    2. Increase the temperature of the disk front flange of the LPC Assembly to 248 deg F (120 deg C) with the local heater, Figure.

    3. Install the three aligning pins (part of IAE 1J12507 Guide pin 1 off) into three of the 24 nuts of the Rotor Center Shaft. The three aligning pins must be installed at 120 degrees apart from each other.

      4. WARNING

        TOUCH THE LPC ASSEMBLY AND THE VERTICAL SLING WITH THE APPROVED GLOVES.

        Install the LPC Assembly onto the Rotor Center Shaft before the LPC Assembly becomes cold.

      1. Install the vertical sling onto the disk front flange of the LPC Assembly.

      2. Attach a hoist to the vertical sling.

      3. Lift the LPC Assembly until it is clear of the local heater and move the LPC Assembly above the Rotor Center Shaft.

      4. Align the -*- mark on the disk of the LPC Assembly with the correlation U-slot in the stub shaft.

      5. Slowly lower the LPC Assembly onto the Rotor Center Shaft through the aligning pins.

    5. Remove the three aligning pins from the nuts of the Rotor Center Shaft.

    6. Attach the LPC Assembly with the 24 bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-605). Tighten the bolts lightly.

    7. Remove the hoist from the vertical sling.

    8. Remove the three eye bolts of the vertical sling, Figure.

      9. Remove the four holding supports from the LPC Assembly, Figure.

        NOTE

        The holding supports are installed to the LPC Assembly in TASK 72-32-80-440-001-A00 (ASSEMBLY-001) and TASK 72-32-80-440-001-B00 (ASSEMBLY-001).

      1. Remove the screw, the two plate washers and the nuts which attach each support to the LP Compressor front case of the LPC Assembly.

      2. Remove the two wing nuts and adapters which attach each support to the moment weight mounting flange of the disk.

      10. Attach the LP Compressor rear case to the Stage 2.5 Vanes.

      1. Align the TOP mark of the LP Compressor front case with the TOP mark of the Stage 2.5 Vanes, Figure.

      2. Attach the rear case to the Stage 2.5 Vanes with the 26 bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-615) and washers ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-618), Figure, Figure and Figure.

        NOTE

        Do not install the bolts V2500-A5-72-32-93-01A-941A-D (72-32-93, 01-720) and the brackets A, B, C, D, E, F, G and H in this TASK. The bolts and the brackets are installed inTASK 72-32-00-430-012-A00 (ASSEMBLY-012).

      3. Tighten the bolts lightly.

    11. When the LPC Assembly becomes cool, loosen the 24 bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-605) fully.

    12. Torque the 24 bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-605) to between 180 lbfin and 220 lbfin (20.00 Nm and 25.00 Nm).

      NOTE

      Hold the LP Compressor Disk Assembly to prevent the rotation of it while you apply the torque to each bolt.

    13. Torque the 26 bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-615) to between 36 lbfin and 45 lbfin (4.00 Nm to 5.00 Nm), Figure and Figure.

    9. Figure: Make Sure that the FEGVs are Removed

    Make Sure that the FEGVs are Removed

    Figure: Measure the Interface Dimensions for the Installation of the LP Compressor Booster Stage Assembly

    Measure the Interface Dimensions for the Installation of the LP Compressor Booster Stage Assembly

    Figure: Reference Fits and Clearances of the LP Compressor Booster Stage Disk and the Rotor Center Shaft at Location 0108

    Reference Fits and Clearances of the LP Compressor Booster Stage Disk and the Rotor Center Shaft at Location 0108

    Figure: Apply Jointing Compound to the Mating Faces on the LP Compressor Stage 2.5 Vanes

    Apply Jointing Compound to the Mating Faces on the LP Compressor Stage 2.5 Vanes

    Figure: Install the Vertical Sling onto the LP Compressor Booster Stage Assembly

    Install the Vertical Sling onto the LP Compressor Booster Stage Assembly

    Figure: Install the LP Compressor Booster Stage Assembly onto the Local Heater

    Install the LP Compressor Booster Stage Assembly onto the Local Heater

    Figure: Install the LP Compressor Booster Stage Assembly onto the Rotor Center Shaft and the LP Compressor Stage 2.5 Vanes

    Sheet 1

    Legend
    Install the LP Compressor Booster Stage Assembly onto the Rotor Center Shaft and the LP Compressor Stage 2.5 Vanes

    Sheet 1

    Close

    Figure: Install the LP Compressor Booster Stage Assembly onto the Rotor Center Shaft and the LP Compressor Stage 2.5 Vanes

    Sheet 2

    Legend
    Install the LP Compressor Booster Stage Assembly onto the Rotor Center Shaft and the LP Compressor Stage 2.5 Vanes

    Sheet 2

    Close

    Figure: Remove the Holding Supports from the LP Compressor Booster Stage Assembly

    Remove the Holding Supports from the LP Compressor Booster Stage Assembly

    Figure: Position of the Bolts (72-32-00,01-615) and Torque Sequence

    Sheet 1

    Legend
    Position of the bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-615) and torque sequence

    Sheet 1

    Close

    Figure: Position of the Bolts (72-32-00,01-615) and Torque Sequence

    Sheet 2

    Legend
    Position of the bolts ENGINE-LP COMP/INTERMEDIATE CASE MODULE (72-32-00, 01-615) and torque sequence

    Sheet 2

    Close

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Updated procedure, fits and clearances tables to standard format. (Editorial)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 01-124
Type:sp01
Supply Short Name:CoMat 01-124 ISOPROPYL ALCOHOL
Supply Name:CoMat 01-124 ISOPROPYL ALCOHOL
Specification Groups:
Doc NumberType
OMAT:1/40GPR TECHNICAL GRADE
PMC 9094GPR TECHNICAL GRADE
JCR-011GPR TECHNICAL GRADE
Suppliers:
ManufacturerRemarks
LOCAL
U1185
24853
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 04-004
Type:sp01
Supply Short Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Supply Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Specification Groups:
Doc NumberType
OMAT: 4/46 (REF RR)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
JCR-025 (JAEC REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Manufacturer Code:0AM53
Tool Number:IAE 1J12457
Tool Name:IAE 1J12457 Measuring stretch
Manufacturer Code:0AM53
Tool Number:IAE 1J12507
Tool Name:IAE 1J12507 Guide pin
Manufacturer Code:0AM53
Tool Number:IAE 1J13103
Tool Name:IAE 1J13103 Vertical sling
Manufacturer Code:0AM53
Tool Number:IAE 1J13109
Tool Name:IAE 1J13109 0AM53 heater
Manufacturer Code:0AM53
Tool Number:IAE 6F10027
Tool Name:IAE 6F10027 Heater control unit