Preliminary Requirements

Procedure

1. SUBTASK 72-41-13-440-051 Install the HP Compressor Rear Shaft in to the Immobilizer Stand

   1. Refer to Figure.

   2. Install IAE 1R18643 Lifting bung 1 off to the front of the HP compressor rear shaft ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-850).

      1. Loosen the two hand knobs sufficient to let the clamps be turned.

      2. Turn the two clamps counterclockwise to the center of the lifter.

      3. Carefully put the lifting bung in to the front of the rear shaft, with the lift eye to the top.

      4. Hold the lifting bung in position and turn the two clamps in a clockwise direction until they touch the stop dowel.

      5. Tighten the two hand knobs to safety the lifting bung in position.

      6. Attach a suitable hoist to the lift eye.

   3. Install the HP compressor rear shaft in to IAE 1R18640 Immobilizer stand 1 off.

      1. Lift the rear shaft and put it above the immobilizer stand.

      2. Carefully lower the rear shaft until the splines of the rear shaft are near to the splines in the immobilizer stand.

      3. Align the splines and continue to lower the rear shaft carefully until it is correctly installed.

   4. Remove the lifting bung from the HP compressor rear shaft.

      1. Remove the hoist from the lifting bung.

      2. Hold the lifting bung in position and loosen the two hand knobs sufficient to let the clamps be turned.

      3. Turn the two clamps counterclockwise to the center of the lifter.

      4. Carefully remove the lifting bung from the bore of the rear shaft.

2. SUBTASK 72-41-13-440-052 Install the Heatshield, Washer and Ring Nut in to the HP Compressor Rear Shaft

   1. Refer to Figure and Figure.

   2. Install IAE 1R18646 Fitting tool 1 off in to the heatshield ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-875). Refer to Figure.

      1. Loosen the two hand knobs sufficient to let the clamps be moved.

      2. Move the two clamps to the center of the tool.

      3. Install the fitting tool on to the front of the heatshield.

      4. Hold the tool in position and move the two clamps out until they go in to the groove in the front bore of the heatshield.

      5. Tighten the two hand knobs to safety the tool in position.

   3. Install the heatshield in to the HP compressor rear shaft.

      1. 

         WARNING

         YOU MUST PUT ON PROTECTIVE GLOVES BEFORE HANDLING COMPONENTS THAT HAVE BEEN FROZEN.

         Put the heatshield fully in to CoMat 03-026 LIQUID NITROGEN until the violent action of the bubbles decreases.

      2. Install the heatshield in to the front bore of the rear shaft.

   4. Release and move the two clamps of the fitting tool to the center, then remove the tool from the heatshield.

   5. Install the washer ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-873) and the ring nut ENGINE-HP COMPRESSOR SHAFT (72-41-13, 01-872) to the front bore of the HP compressor rear shaft and tighten the ring nut hand tight.

   6. Allow the temperature of the heatshield to normalize to room temperature.

   7. Remove all signs of moisture from the heatshield and apply CoMat 10-010 DEWATERING FLUID (COLD) to the heatshield.

   8. Install the tools necessary to torque tighten the ring nut. Refer to Figure.

      1. Release and remove the four nuts and washers, part of IAE 1R18640 Immobilizer stand immobilizer stand.

      2. Install IAE 1R18641 Locking plate 1 off on to the top of the immobilizer stand.

      3. Safety the locking plate in position with the four washers and nuts removed in step G.(1).

      4. Install IAE 1F10019 Mechanical wrench 1 off on to the locking plate. Make sure the two dowels of the mechanical wrench are installed in the two holes in the locking plate.

      5. Align the splines of IAE 1R18642 Spanner 1 off with the splines in the mechanical wrench and install the spanner in to the torque multiplier. Make sure that the teeth of the spanner engage in the slots in the nut.

   9. Operate the mechanical wrench and torque the ring nut to 7200 lbfin (813.50 Nm).

   10. Remove the tools used to torque tighten the ring nut.

       1. Remove the mechanical wrench.

       2. Remove the spanner from the ring nut.

       3. Remove the locking plate from the immobilizer stand.

   11. Use IAE 1R18644 Punch 1 off to crimp the washer in two positions opposite each other to lock the ring nut in position.

3. SUBTASK 72-41-13-440-053 Install the HP Compressor Rear Shaft Assembly in to the Turnover Stand

   1. Refer to Figure and Figure.

   2. Prepare the turnover stand. Refer to Figure.

      1. Install IAE 1R18650 Turnover stand adapter 1 off to IAE 1R18322 Turnover stand 1 off.

      2. Safety the adapter in position with the six screws.

      3. Release and remove the two bolts, washers and the clamp from the turnover stand adapter.

      4. Turn the turnover stand adapter so that the rear shaft assembly can be installed in the vertical position.

   3. Install IAE 1R18643 Lifting bung 1 off to the front of the HP compressor rear shaft assembly. Refer to Figure.

      1. Do the procedure given in Step.

   4. Carefully lift the HP compressor rear shaft assembly from the immobilizer stand and position it above the turnover stand.

   5. Lower the HP compressor rear shaft assembly until the location diameter is aligned with the clamp position of the turnover stand adapter.

   6. Safety the HP compressor rear shaft assembly to the turnover stand adapter with the clamp, bolts and washers removed in step A.(3).

   7. Remove the lifting bung from the HP compressor rear shaft assembly.

      1. Do the procedure given in Step.

4. SUBTASK 72-41-13-440-054 Prepare the HP Compressor Rear Shaft Assembly for Balancing

   1. Refer to Figure and Figure.

   2. Install IAE 1R18649 Slae balancing shaft 1 off to the front of the HP compressor rear shaft assembly.

      1. Examine the mating faces of the slave balancing shaft and rear shaft assembly for contamination and/or high metal. If there is contamination then the faces must be cleaned. If there is high metal, use a stone to make the surface smooth.

      2. Install the slave balancing shaft on to the front of the compressor rear shaft. Make sure that the slave balancing shaft location dowel is correctly engaged.

      3. Safety the slave balancing shaft in position with 20 nuts and bolts and 40 washers. Install the bolts from the compressor rear shaft side.

      4. Torque all of the nuts in sequence to 160 lbfin (18 Nm).

   3. Turn IAE 1R18650 Turnover stand adapter turnover stand adapter so that the rear shaft is horizontal.

   4. Install IAE 1R18089 Lifting adapter 1 off on to the rear end of the rear shaft. Tighten the lifting adapter.

   5. Install IAE 1R18095 Universal slinging adapter 2 off. Refer to Figure.

      1. Install one universal sling adapter on to the lifting adapter.

         1. Lift pin E and put the adapter end of the tool in to the lifting adapter. Turn the tool to engage the locations. Lower the pin E.

         2. Install the lifting end of the tool in to the adapter end. Install the trunnion pin through both parts of the tool and tighten it.

         3. Tighten the locknut on to the lifting adapter.

      2. Install one universal sling adapter on to the slave balancing shaft.

         1. The procedure to install the universal sling adapter on to the slave balancing shaft is the same as the procedure given in steps D.(1)(a) thru D.(1)(c).

5. SUBTASK 72-41-13-440-055 Prepare the Balancing Machine for Use

   1. Refer to Figure

   2. NOTE

      The bolts that attach the end drive to the balancing machine must all have the same weight.

      Attach Schenck 022748 end drive to the dynamic balancing machine.

   3. Install the balancing machine rollers on to the pedestals.

   4. Set the distance between the No. 1 and No. 2 pedestals. This distance must be sufficient so that the slave balancing shaft touches the No. 1 pedestal and the compressor shaft location diameter touches the No. 2 pedestal.

6. SUBTASK 72-41-13-440-056 Install the HP Compressor Rear Shaft Assembly in to the Balancing Machine

   1. Refer to Figure, Figure and Figure

   2. Install IAE 1R18647 Beam sling 1 off on to the HP compressor rear shaft assembly.

      1. Make sure that the bracket is at the identified position for the center of gravity of the beam sling only.

      2. Attach a hoist to the beam sling.

      3. Lift the beam sling and position it above the rear shaft assembly.

      4. Adjust the height of the beam sling and attach it to the universal sling adapters.

      5. Set the beam sling to the identified position for the center of gravity of the beam sling and the rear shaft assembly.

   3. Lift the HP compressor rear shaft assembly out of the turnover stand and install in on to the dynamic balancing machine.

      1. Release and remove the two bolts and washers, part of the turnover stand adapter, then remove the clamp.

      2. NOTE

         Make sure that the slave balancing shaft points to the balancing machine drive head.

         Lift the rear shaft assembly out of the turnover stand and put it above the balancing machine pedestals.

      3. Carefully lower the rear shaft assembly on to the balancing machine. Make sure that the slave balancing shaft touches the No. 1 pedestal and the rear shaft location diameter touches the No. 2 pedestal.

   4. Remove the beam sling from the HP compressor rear shaft assembly.

      1. Set the beam sling to the identified position for the center of gravity of the beam sling only.

      2. Disconnect the beam sling from the universal sling adapters.

      3. Lift the beam sling away from the rear shaft assembly. Put the beam sling on to an applicable surface and remove the hoist.

   5. Remove the universal sling adapters. Refer to Figure.

      1. Remove the universal sling adapter from the slave balancing shaft.

         1. Release the locknut.

         2. Remove the trunnion pin; remove the lifting end of the tool.

         3. Turn the adapter end to disengage the locations then remove the adapter end.

      2. Remove the universal sling adapter from the end of the rear shaft assembly.

         1. Do steps D. (1)(a) thru D.(1)(c) again to remove the universal sling adapter.

   6. Remove the lifting adapter from the end of the HP compressor rear shaft assembly.

   7. NOTE

      The bolts that attach the end drive to the slave balancing machine must all have the same weight.

      Attach the end drive on to the slave balancing shaft with the six bolts. Make sure that the datum mark on the slave balancing shaft is aligned with the 0 degrees position on the balancing machine protractor.

7. SUBTASK 72-41-13-440-057 Do a Check Balance of the HP Compressor Rear Shaft Assembly

   NOTE

   You must let the balancing machine run for a short time so that it can become stable, before balance values are read.

   1. Refer to Figure, Figure and Figure

   2. Plane separate and calibrate the balancing machine through planes AA and AB. Measure and record the quantity and angular positions of the unbalance in both planes. Refer to Figure.

   3. NOTE

      The 180 degree turn of the slave balancing shaft is necessary so that the tool unbalance can be calculated and removed.

      Install IAE 1R18649 Slae balancing shaft on to the HP compressor rear shaft assembly, 180 degrees from the original position.

      1. Use CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON or CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON to make a mark that identifies the position of the slave balancing shaft in relation to the balancing machine drive head.

      2. Make a second mark that identifies the position of the slave balancing shaft in relation to the rear shaft assembly.

      3. Remove the rear shaft assembly from the balancing machine and install it in to the turnover stand. Refer to Step. Remove the slave balancing shaft, but do not remove the universal sling adapters or the lifting adapter.

      4. Install the slave balancing shaft on to the rear shaft assembly, with the temporary mark of the slave balancing shaft 180 degrees opposite the temporary mark on the rear shaft assembly. Make sure that the slave balancing shaft location dowel is correctly engaged.

      5. Safety the slave balancing shaft in position with the 20 nuts and bolts and 40 washers. Install the bolts from the HP compressor rear shaft side.

      6. Torque all of the nuts in sequence to 160 lbfin (18 Nm).

      7. Turn IAE 1R18650 Turnover stand adapter so that the rear shaft assembly is horizontal.

   4. Install the HP compressor rear shaft assembly in to the balancing machine.

      1. Do the procedure given in Step. Make sure that the temporary mark on the slave balancing shaft is aligned with the temporary mark on the balancing machine drive head.

   5. Plane separate and calibrate the balancing machine through planes AA and AB. Measure and record the quantity and angular positions of the unbalance in both planes.

   6. Calculate the correct unbalance of the HP compressor rear shaft assembly in planes AA and AB. Write a record of the quantity and angular position of the unbalance in both planes.

   7. The initial unbalance values must not exceed 22.8 ozin. (16450 gmm) in plane AA and 1.39 ozin. (1000 gmm) in plane AB. If the inital unbalance values exceed the given values, the HP compressor rear shaft assembly must be rejected.

   8. Use CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON or CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON to make a mark on surface X to identify the initial unbalance (heavy position) in plane AA. Make a temporary mark on surface Z to identify the initial unbalance (heavy position) in plane AB. Refer to Figure.

8. SUBTASK 72-41-13-440-058 Correct the Unbalance of the HP Compressor Rear Shaft Assembly in Plane AA

   1. Refer to Figure

   2. Find the temporary mark on surface X of the HP compressor rear shaft that identifies the initial unbalance (heavy position) in plane AA. The position of unbalance was identified in Step.

   3. Use hand tools to remove the necessary quantity of metal from surface Y of the HP compressor rear shaft. Make sure that the surface finish is the same as the adjacent material.

      1. If it is necessary to remove metal to correct a small quantity of unbalance, the metal must be removed from a minimum arc of 20 degrees.

9. SUBTASK 72-41-13-440-059 Correct the Unbalance of the HP Compressor Rear Shaft Assembly in Plane AB

   1. Refer to Figure, Figure, Figure and Figure

   2. Find the mark on surface Z of the HP compressor rear shaft that identifies the initial unbalance (heavy position) in plane AB. The position of unbalance was identified in Step.

   3. NOTE

      To find the quantity of metal to be removed for unbalance values of less than 0.42 ozin. (300 gmm) do step C.

      Find the position and quantity of metal to be removed from the HP compressor rear shaft tangs to correct the initial unbalance. Refer to Figure.

      1. Measure the angle (angle AS) counterclockwise between the identified position of maximum unbalance and the centerline of a tang (tang AT). The tang AT must give an angle (angle AS) between 18 and 54 degrees.

      2. NOTE

         It is better to under estimate the position of the intersection point.

         Use the initial unbalance graph, Figure the initial unbalance and angle AS to find the quantity of metal to be removed (dimension AU) from tang AT. Record the quantity of metal to be removed.

         Dimension AU is found if you make an estimate of where the point of intersection of the initial unbalance line and angle AS line is, along a horizontal line drawn through this intersection point and between the curves either side of it. The horizontal distance between the curves represents 1.00 mm, therefore if the intersection point is estimated at a third of the way along the line, approximately 0.3 mm would be added to the dimension associated with the curve to the left.

         Example.

         Initial unbalance = 400 gmm.

         Angle AS = 24 degrees.

         From the initial unbalance graph the quantity of metal to be removed (Dimension AU) from tang AT is 6.50 mm. The position of the intersection point is estimated at half way along a horizontal line drawn between the 6.00 and 7.00 mm curves. Therefore 0.5 mm is added to the 6.00 mm to give a dimension AU of 6.50 mm.

      3. NOTE

         Angle AS + Angle AV = 72 degrees.

         Measure the angle (angle AV) between the identified position of maximum unbalance and the centerline of the tang (tang AW) clockwise.

      4. Use the initial unbalance graph, Figure the initial unbalance and angle AV to find the quantity of metal to be removed (dimension AX) from tang AW. Record the quantity of metal to be removed. The procedure to find dimension AX is the same as the procedure to find dimension AU given in Step B.(2).

         Example.

         Initial unbalance = 400 gmm.

         Angle AV = 48 degrees.

         From the initial unbalance graph the quantity of metal to be removed (dimension AX) from tang AW is 3.50 mm.

   4. Find the quantity of metal to be removed from the HP compressor rear shaft tangs to correct unbalance values of less than 0.42 ozin. (300 gmm).

      1. NOTE

         If necessary small amounts of unbalance can be corrected by metal removal from tangs AT and AW. Refer to step B.

         Use the small quantity of unbalance graph, Figure and the quantity of unbalance to find the quantity of metal to be removed (dimension AZ) from tang AY. Record the quantity of metal to be removed.

         Example.

         Unbalance = 240 gmm.

         From the small quantity unbalance graph the quantity of metal to be removed (dimension AZ) from tang AY is 10.00 mm.

   5. Use hand tools to remove the correct quantity of metal from the necessary tangs. Metal can be removed from the tangs up to the minimum dimensions given in Figure. Metal must only be removed from the non-datum face of tang AY.

10. SUBTASK 72-41-13-440-060 Do a Check Balance of the HP Compressor Rear Shaft Assembly

    1. Refer to Figure

    2. Do Step again.

    3. Make sure the HP compressor rear shaft assembly unbalance is not more than 0.208 ozin (150 gmm) in plane AA or plane AB. If the unbalance is more than the given limit do the steps which follow until the unbalance in both planes is less than the given limit.

       1. Do Step to correct unbalance in plane AA.

       2. Do Step to correct unbalance in plane AB.

       3. Do Step to check the balance of the HP compressor rear shaft assembly.

11. SUBTASK 72-41-13-440-061 Install the HP Compressor Rear Shaft Assembly in to the Turnover Stand

    1. Refer to Figure, Figure and Figure

    2. Release and remove the six bolts that attach the end drive to the slave balancing shaft.

    3. Install IAE 1R18089 Lifting adapter 1 off on to the end of the HP compressor rear shaft. Tighten the lifting adapter.

    4. Install IAE 1R18095 Universal slinging adapter 1 off. Refer to Figure.

       1. Install one universal sling adapter on to the lifting adapter.

          1. Lift pin E and put the adapter end of the tool in to the adapter. Turn the tool to engage the locations. Lower pin E.

          2. Install the lifting end of the tool in to the adapter end. Install the trunnion pin through both parts of the tool and tighten it.

          3. Tighten the locknut on to the lifting adapter.

       2. Install the other universal sling adapter on to IAE 1R18649 Slae balancing shaft slave balancing shaft.

          1. The procedure to install the universal sling adapter on to the slave balancing shaft is the same as the procedure given in steps C.(1)(a) thru C.(1)(c).

    5. Install IAE 1R18647 Beam sling 1 off on to the HP compressor rear shaft assembly. Refer to Figure.

       1. Make sure that the bracket is at the identified position for the center of gravity of the beam sling only.

       2. Attach a hoist to the beam sling.

       3. Lift the beam sling and position it above the rear shaft assembly.

       4. Adjust the height of the beam sling and attach it to the universal sling adapters.

       5. Set the beam sling to the identified position for the center of gravity of the beam sling and the rear shaft assembly.

    6. Install the HP compressor rear shaft assembly in to the turnover stand. Refer to Figure.

       1. Make sure IAE 1R18650 Turnover stand adapter 1 off is installed in IAE 1R18322 Turnover stand 1 off.

       2. Release and remove the two bolts, washers and the clamp from the turnover stand adapter.

       3. Turn the turnover stand adapter so that the rear shaft can be installed in the horizontal position.

       4. Carefully lift the rear shaft assembly from the balancing machine and position it above the turnover stand.

       5. Lower the rear shaft assembly in to the turnover stand adapter. Make sure the rear shaft assembly is correctly located.

       6. Safety the rear shaft assembly in position with the clamp, bolts and washers removed in step E.(2).

    7. Remove the beam sling from the HP compressor rear shaft assembly.

       1. Set the beam sling to the identified position for the center of gravity of the beam sling only.

       2. Disconnect the beam sling from the universal sling adapters.

       3. Lift the beam sling away from the rear shaft assembly. Put the beam sling on to an applicable surface and remove the hoist.

    8. Remove the universal sling adapters.

       1. Remove the universal sling adapter from the slave balancing shaft.

          1. Release the locknut.

          2. Remove the trunnion pin; remove the lifting end of the tool.

          3. Turn the adapter end to disengage the locations then remove the adapter end.

       2. Remove the universal sling adapter from the end of the rear shaft assembly.

          1. Do steps G.(1)(a) thru G.(1)(c) again to remove the universal sling adapter.

    9. Remove the lifting adapter from the end of the HP compressor rear shaft assembly.

    10. Remove the slave balancing shaft from the HP compressor rear shaft assembly.

        1. Turn IAE 1R18650 Turnover stand adapter so that the rear shaft assembly is vertical and the slave balancing shaft is at the top.

        2. Release and remove the 20 nuts and bolts that safety the slave balancing shaft to the rear shaft assembly.

        3. Remove the slave balancing shaft from the rear shaft assembly and put it on an applicable surface.

Figure: Install the HP compressor rear shaft in to the immobilizer stand

Install the HP compressor rear shaft in to the immobilizer stand



Figure: Install the heatshield in to the HP compressor rear shaft

Install the heatshield in to the HP compressor rear shaft



Figure: Install the tools necessary to torque tighten the ring nut

Install the tools necessary to torque tighten the ring nut



Figure: Install the HP compressor rear shaft assembly in to the turnover stand

Install the HP compressor rear shaft assembly in to the turnover stand



Figure: Install the tools necessary to lift the HP compressor rear shaft assembly

Install the tools necessary to lift the HP compressor rear shaft assembly



Figure: Remove/install the universal sling adapters

Remove/install the universal sling adapters



Figure: Install the HP compressor rear shaft assembly in to the balancing machine

Install the HP compressor rear shaft assembly in to the balancing machine



Figure: Example to show positions and quantity of metal to be removed

Example to show positions and quantity of metal to be removed



Figure: Initial unbalance graph

Initial unbalance graph



Figure: Small quantity of unbalance graph

Small quantity of unbalance graph