TASK 72-44-00-440-001-A02 HP Turbine (HPT) Stage 1 Nozzle Assembly - Assemble The Nozzle, Assembly-001

DMC:V2500-A1-72-44-0000-00B-710A-B|Issue No:005.00|Issue Date:2020-08-01

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

Common Information

TASK 72-44-00-440-001-A02 HP Turbine (HPT) Stage 1 Nozzle Assembly - Assemble The Nozzle, Assembly-001

General

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

Special torque data and 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.

To identify, lubricate and install seal rings, refer to SPM TASK 70-44-01-400-501.

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.

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 1F10052 Two cables sling0AM53IAE 1F100521
IAE 1P16075 Fixture0AM53IAE 1P160751
IAE 1P16076 Support0AM53IAE 1P160761
IAE 1P16077 Fixture0AM53IAE 1P160771
IAE 1P16078 Alignment pin0AM53IAE 1P160784
IAE 1P16109 cover0AM53IAE 1P161091
IAE 1P16226 Alignment fixture0AM53IAE 1P162261

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-573 WAX BLEND, PARAFFIN24269CoMat 01-573
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-00-220-057-A02 Reference Fits and Clearances of the Stage 1 HPT Support Assembly and the Stage 1 HPT Vane Assembly at Location 2004

    1. Refer to Figure.

    2. Reference clearance/interference at Location 2004. If required, use the data written as a note in TASK 72-44-30-200-001-B00 (INSPECTION-001) and TASK 72-44-20-200-001-B01 (INSPECTION-001).

      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 2004

      Inner Combustion Chamber Assembly ENGINE-COMBUSTION CHAMBER INNER LINER (72-44-30, 01-401), Axial Distance (Between Mount Flanges)

      Stage 1 HPT Vane Assembly ENGINE-STAGE 1 HPT VANE CLUSTER ASSEMBLY (72-44-20, 01-240), Axial Distance (Front Flange Front Face To Rear Flange Rear Face)

      Chamber Distance

      0.844

      Clear

      0.845

      Clear

      0.835

      0.002

      0.830

      0.003

      Vane Distance

      0.852

      0.017

      0.852

      0.022

      0.842

      Intf

      0.842

      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 2004

      Inner Combustion Chamber Assembly ENGINE-COMBUSTION CHAMBER INNER LINER (72-44-30, 01-401), Axial Distance (Between Mount Flanges)

      Stage 1 HPT Vane Assembly ENGINE-STAGE 1 HPT VANE CLUSTER ASSEMBLY (72-44-20, 01-240), Axial Distance (Front Flange Front Face To Rear Flange Rear Face)

      Chamber Distance

      21.438

      Clear

      21.463

      Clear

      21.209

      0.050

      21.082

      0.076

      Vane Distance

      21.640

      0.430

      21.640

      0.559

      21.390

      Intf

      21.390

      Intf

    2. SUBTASK 72-44-00-220-060 Reference Fits and Clearances of the Inner Combustion Chamber Assembly and the Stage 1 HPT Cooling Air Duct at Location 2000

    1. Refer to Figure.

    2. Reference clearance/interference at location 2000. If required, use the data written as a note in TASK 72-44-30-200-001-B00 (INSPECTION-001) and TASK 72-44-50-200-001-C00 (INSPECTION-001).

      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 2000

      Inner Combustion Chamber Assembly ENGINE-COMBUSTION CHAMBER INNER LINER (72-44-30, 01-401), Rear Location Bore

      Stage 1 HPT Cooling Air Duct ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-010), Rear Location Diameter

      Chamber Assembly Bore

      19.398

      Intf

      19.400

      Clear

      19.392

      0.000

      19.392

      0.002

      Air Duct Diameter

      19.402

      0.010

      19.402

      0.010

      19.398

      Intf

      19.398

      Intf

      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 2000

      Inner Combustion Chamber Assembly ENGINE-COMBUSTION CHAMBER INNER LINER (72-44-30, 01-401), Rear Location Bore

      Stage 1 HPT Cooling Air Duct ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-010), Rear Location Diameter

      Chamber Assembly Bore

      492.709

      Intf

      492.760

      Clear

      492.557

      0.000

      492.557

      0.051

      Air Duct Diameter

      492.810

      0.250

      492.811

      0.254

      492.710

      Intf

      492.710

      Intf

    3. SUBTASK 72-44-00-220-061 Reference Fits and Clearances of the Stage 1 Turbine Nozzle Assembly at Location 2006, Refer to

    1. Refer to Figure.

    2. Reference interference at location 2006. If required, use the data written as a note in TASK 72-44-50-200-001-C00 (INSPECTION-001) and TASK 72-44-50-200-002 (INSPECTION-002).

      NOTE

      Must maintain tight fit. Reject HPT cooling duct if loose.
      Table 5. Fits and Clearances (all dimensions are in inches)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 2006 (Reference Only)

      HPT Cooling Duct Deflector ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-080), Location Diameter

      Stage 1 HPT Cooling Duct Assembly ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-010), Location Diameter

      Deflector Location Diameter

      17.360

      17.340

      Intf

      0.000

      Intf

      0.000

      Duct Location Diameter

      17.370

      17.360

      0.030

      Intf

      0.050

      Intf

      Table 6. Fits and Clearances (all dimensions are in millimeters)

      NEW PART

      DIMENSIONS

      WORN PART

      DIMENSIONS

      REJECT IF

      PART IDENT

      Size

      Clearance

      (Non-select)

      MORE THAN

      LOCATION 2006 (Reference Only)

      HPT Cooling Duct Deflector ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-080), Location Diameter

      Stage 1 HPT Cooling Duct Assembly ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-010), Location Diameter

      Deflector Location Diameter

      440.94

      440.44

      Intf

      0.00

      Intf

      0.00

      Duct Location Diameter

      441.20

      440.94

      0.76

      Intf

      1.27

      Intf

    4. SUBTASK 72-44-00-440-070 Install the Stage 1 HPT Support Assembly on the Fixture

    1. Refer to Figure.

    2. Put the IAE 1P16075 Fixture 1 off dowel pin up, on the bench.

    3. Put the Stage 1 HPT Support Assembly, small end down, in the fixture.

    4. Put the small hole in the Stage 1 HPT Support Assembly over the dowel pin in the fixture.

    5. SUBTASK 72-44-00-440-060-A02 Install the Stage 1 HPT Vane Seals in the Slots of the Stage 1 Vane Assemblies

      SBE 72-0151 and SBE 72-0598: New stage 1 HPT vane seals.

    1. Refer to Figure.

      2. Install the stage 1 HPT vane seal in the slots that are located on the left side of the Stage 1 HPT Vane Assemblies ENGINE-STAGE 1 HPT VANE CLUSTER ASSEMBLY (72-44-20, 01-240).

        1. Install the stage 1 HPT vane seals (01-480) in the outer vane platform slots.

        1. Use CoMat 01-573 WAX BLEND, PARAFFIN to hold the seals in position. Remove any wax that is not needed.

        2. Install the stage 1 HPT vane seals (01-512) and (01-514) in the inner vane platform slots.

        1. Use CoMat 01-573 WAX BLEND, PARAFFIN to hold the seals in position. Remove any wax that is not needed.

      3. Make sure all the seals are installed.

    6. SUBTASK 72-44-00-440-061 Install the Stage 1 HPT Vane Assemblies in the Stage 1 HPT Support Assembly

    1. Refer to Figure.

      2. Install a Stage 1 HPT Vane Assembly from the vane set.

      1. Install this vane assembly in the Stage 1 HPT Support Assembly with the leading edge up.

      2. Align the bolt slots in the outer platform of the vane assembly with the boltholes in the support assembly.

      3. Get the second vane assembly from the vane set.

      1. Install this vane in the support assembly in a counterclockwise direction to the first installed vane assembly.

      2. Carefully align the seals in the inner and outer vane platforms with the seal slots in the first installed vane.

      3. Push the two vane assemblies together.

      4. Do this procedure again until all the vanes are installed.

      5. Make sure all the seals are installed between the vane assemblies.

    7. SUBTASK 72-44-00-440-062 Install the Stage 1 HPT Seal Assembly

    1. Refer to Figure.

    2. Install the bolt 1 off ENGINE-STAGE 1 HPT VANE CLUSTER ASSEMBLY (72-44-20, 01-520), screw head type at the location approximately 180 degrees from the offset hole in the Stage 1 HPT Support Assembly, Figure.

      NOTE

      This bolt is under two flanges where Stage 1 HPT Seal Assembly and the classified spacer connect when the seal assembly is installed.

    3. Torque the bolt to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    4. Install the stage 1 HPT spacers 39 off ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-019) in the recesses around the boltholes (with the tangs positioned to the outside diameter).

    5. Install the Stage 1 HPT Seal Assembly 1 off ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-010).

    6. Install the spring tension washers 39 off ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-100).

    7. Install the sleeve bushings 39 off ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-120).

    8. Install the bolts ENGINE-STAGE 1 HPT OUTER SEAL ASSEMBLY (72-44-40, 01-140) which hold the Stage 1 HPT Seal Assembly in position.

    9. Tighten the bolts with your hand.

      NOTE

      The bolts will be torqued when the classified spacer is installed. Refer to TASK 72-00-44-420-001-001 (INSTALLATION-001), TASK 72-00-44-420-001-002 (INSTALLATION-002), or TASK 72-40-00-430-005 (ASSEMBLY-005).

    10. Attach the support assembly to the fixture with the capscrews, washers and nuts.

    8. SUBTASK 72-44-00-440-063 Install the Inner Combustion Chamber Liner Assembly

    1. Refer to Figure and Figure.

      2. Install the Inner Combustion Chamber Liner Assembly ENGINE-COMBUSTION CHAMBER INNER LINER (72-44-30, 01-420) in the IAE 1P16076 Support 1 off, Figure.

      1. Center the Inner Combustion Chamber Liner Assembly in the fixture.

      2. Put the front flange of the Inner Combustion Chamber Liner Assembly on the rubber pad.

    3. Install the IAE 1P16078 Alignment pin 4 off at equal spaces around the flange and in the captured nuts on the Inner Combustion Chamber Liner Assembly.

    4. Put the Stage 1 HPT Cooling Duct Assembly ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-010) with the small hole in the inner flange on the dowel pin on the fixture ring, Figure.

    5. Turn the combustion chamber as necessary to locate the IAE 1P16078 Alignment pins through the holes in the Stage 1 HPT Cooling Duct Assembly flange.

    6. Remove the Stage 1 HPT Cooling Duct Assembly but do not move the combustion chamber.

      NOTE

      This puts the combustion chamber in the correct position.

    7. Attach the IAE 1F10052 Two cables sling 1 off to the spools on the IAE 1P16075 Fixture.

    8. Attach a hoist to the sling.

    9. Lift and turn the fixture to position the leading edges of the Stage 1 HPT Vane Assemblies so they point down.

      10. Lower the Stage 1 HPT Support Assembly and the Stage 1 HPT Vane Assemblies on to the Inner Combustion Chamber Liner Assembly.

      1. Put the alignment pins in the holes in the ID flanges of the vane assemblies.

      2. Put the dowel pin on the IAE 1P16075 Fixture 1 off so it goes in the offset hole in the IAE 1P16076 Support 1 off.

        NOTE

        The four IAE 1P16078 Alignment pin alignment pins should locate in the vane inner flange slots.

      3. Engage the vane assembly with the Inner Combustion Chamber Liner Assembly flange.

    11. Remove the IAE 1P16075 Fixture from the Stage 1 HPT Vane Assemblies.

    9. SUBTASK 72-44-00-440-064 Install the HPT Cooling Duct Deflector, the Stage 1 HPT Cooling Duct Assembly and the Stage 1 HPT Duct Segments

    1. Refer to Figure, Figure and Figure.

    2. Install the HPT cooling duct deflector ENGINE-STAGE 1 HPT COOLING DUCT ASSEMBLY (72-44-50, 01-080) on the Stage 1 HPT Cooling Duct Assembly, Figure.

      3. Lower the Stage 1 HPT Cooling Duct Assembly and put the small hole in the inner flange on the dowel pin in the ring.

        NOTE

        The four IAE 1P16078 Alignment pin should locate in the cooling duct assembly outer flange.

      1. Engage the aligning pins.

      2. Install the Stage 1 Cooling Duct Assembly on the inner combustion chamber inner diameter.

    4. Install the 20 Stage 1 HPT Duct Segments ENGINE-STAGE 1 HPT SEGMENT (72-44-60, 01-010), Figure.

    5. Install the stops ENGINE-STAGE 1 HPT SEGMENT (72-44-60, 01-020) and the bolts ENGINE-STAGE 1 HPT SEGMENT (72-44-60, 01-040), except at the alignment pin locations.

    6. Remove the alignment pins.

    7. Install the remaining stops and the bolts.

    8. Loosen the nut and the swing bolt on IAE 1P16226 Alignment fixture 1 off. Install the fixture to round out the duct assembly and secure with the swing bolt and nut.

    9. Torque the bolts to 85 lbfin to 95 lbfin (9.604 Nm to 10.734 Nm).

    10. Loosen the nut and the swing bolt and remove the alignment fixture.

    11. Install the IAE 1P16077 Fixture 1 off on the assembly.

    12. Remove the Stage 1 Turbine Nozzle Assembly from the support and put it on a pallet.

    13. Remove the fixture from the assembly.

    14. Install the IAE 1P16109 cover 1 off over the Stage 1 HPT Support Assembly, Figure.

    10. Figure: Stage 1 Turbine Nozzle Assembly - Fits and Clearances

    Stage 1 Turbine Nozzle Assembly - Fits and Clearances

    Figure: Install the Stage 1 HPT Vane Assemblies and the Stage 1 HPT Support Assembly in the IAE 1P16075 Fixture

    Install the Stage 1 HPT Vane Assemblies and the Stage 1 HPT Support Assembly in the IAE 1P16075 Fixture

    Figure: Install the Stage 1 HPT Seal Assembly and Stage 1 HPT Spacers

    Install the Stage 1 HPT Seal Assembly and Stage 1 HPT Spacers

    Figure: Install the Stage 1 HPT Support Assembly and the Stage 1 HPT Vane Assemblies

    Install the Stage 1 HPT Support Assembly and the Stage 1 HPT Vane Assemblies

    Figure: Install the HPT Cooling Duct Assembly and the Cooling Duct Deflector

    Install the HPT Cooling Duct Assembly and the Cooling Duct Deflector

    Figure: Install the Stage 1 HPT Duct Segments

    Install the Stage 1 HPT Duct Segments

    Figure: Install the IAE 1P16109 Cover

    Install the IAE 1P16109 Cover

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added SBE 72-0598 information. (18VC516)

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:24269
Enterprise Name:SCHAEFER MACHINE CO., INC.
BU Name:SCHAEFER MACHINE CO., INC.
Street:200 COMMERCIAL DRIVE
City:DEEP RIVER
State:CT
Zip Code:06417
Country:USA
Phone Number:1-860-526-4000
Fax Number:1-860-526-4654
Internet:www.schaeferco.com
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Manufacturer Code:24269
Supply Number:CoMat 01-573
Type:sp01
Supply Short Name:CoMat 01-573 WAX BLEND, PARAFFIN
Supply Name:CoMat 01-573 WAX BLEND, PARAFFIN
Specification Groups:
Doc NumberType
PMC 9462 (PW REF)CW-5
PMC 9462 (PW REF)WB17 ADHESIVE WAX
Suppliers:
ManufacturerRemarks
24269
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 1F10052
Tool Name:IAE 1F10052 Two cables sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16075
Tool Name:IAE 1P16075 Fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16076
Tool Name:IAE 1P16076 Support
Manufacturer Code:0AM53
Tool Number:IAE 1P16077
Tool Name:IAE 1P16077 Fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16078
Tool Name:IAE 1P16078 Alignment pin
Manufacturer Code:0AM53
Tool Number:IAE 1P16109
Tool Name:IAE 1P16109 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16226
Tool Name:IAE 1P16226 Alignment fixture