Preliminary Requirements

Procedure

1. SUBTASK 72-00-40-020-155 Install the Remove/Install Fixture and the Tie-Rod Adapter to the HP System Module Rear Flange

   1. Refer to Figure.

   2. Attach IAE 1P16285 Tie-rod adapter 1 off onto the center ring (part of IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off).

      1. Put the puck and shaft through the center ring until the tie-rod adapter touches the rear face of the center ring.

      2. Align the two holes on the tie-rod adapter with two opposite holes in the center ring. Install the two tool screws. Tighten the screws.

      3. Move the locknut until it is adjacent to the wrench location.

      4. Push the tie-rod adapter into the engine until the puck engages on the HP compressor front shoulder. At the same time push the center ring over the HP compressor shaft until it touches the stage 2 HP turbine disk.

      5. NOTE

         If necessary use a wrench on the wrench location so that the shaft does not turn.

         Turn the locknut until the puck is against the HP compressor front shoulder. Tighten the locknut.

      6. Attach a hoist to the IAE 1F10052 Two cables sling 1 off and attach the lift sling to the remove/install fixture lift eye.

      7. Lift the remove/install fixture and move it adjacent to the rear of the HP system module. Make sure the hand knobs are rearwards.

      8. Move the remove/install fixture over the center ring until it touches the HP turbine case rear flange.

      9. Put the upper split ring onto the front of the HP turbine case rear flange. Install 12 of the tool bolts and 12 of the tool nuts.

      10. Put the lower split ring onto the front of the HP turbine case rear flange. Install 13 of the tool bolts and 13 of the tool nuts.

      11. Tighten the 25 tool nuts.

      12. Remove the hoist from the lift eye.

2. SUBTASK 72-00-40-020-156 Install the HP Compressor Support Rods

   1. Refer to Figure.

   2. Make sure the variable stator vanes are in the low speed position.

   3. Install IAE 1R18247 Rigging pin 1 off through the bracket and into the HP compressor cases to lock the variable stator vanes.

   4. Remove the six bolts and three blanks from the HP compressor front cases.

   5. Install IAE 1R18234 Support rod 3 off.

      1. Turn the adjustment handle to retract the blade of the tool.

      2. Carefully install the support rods through the holes in the HP compressor lower split case. Make sure the blades are rearwards.

      3. Safety the support rods to the HP compressor lower split case with four of the six tool bolts.

      4. Turn the adjustment handle until the blades touch the HP compressor stage 3 disk and lightly tighten.

3. SUBTASK 72-00-40-020-157 Remove the Bolts from the HP Compressor Stage 3 Disk Curvic Coupling

   1. Refer to Figure.

   2. Use IAE 1R18230 Wrench 1 off to release and remove the curvic bolts from the No.3 bearing rotor center.

4. SUBTASK 72-00-40-020-216 Remove the Parts that Attach the LP Compressor/Intermediate Case Module and the HP System Module Joint Flanges (SBE 72-0290)

   1. Refer to Figure.

   2. NOTE

      There is no countersunk hole in the head of the bolts.

      Remove the 37 nuts, the 37 bolts from the joint flange. Do not remove the nuts and the bolts from the positions Y.

   3. Remove the four nuts, the four bolts from the joint flange at the positions Y.

   4. Use an applicable parallel punch to remove the four pins and the four lock plates from the joint flange at the positions Y.

5. SUBTASK 72-00-40-020-158 Remove the Parts that Attach the LP Compressor/Intermediate Case Module and the HP System Module Joint Flanges (Pre SBE 72-0290)

   1. Refer to Figure.

   2. NOTE

      There is a countersunk hole in the head of the bolts.

      Remove the 37 nuts and the 37 bolts from the joint flange. Do not remove the nuts and the bolts from the positions Y.

   3. Remove the four nuts and the four bolts from the joint flange at the positions Y.

   4. Use an applicable parallel punch to remove the four pins and the four lock plates from the joint flange at the positions Y.

6. SUBTASK 72-00-40-020-159 Remove the HP System Module from the LP Compressor/Intermediate Case Module

   1. Refer to Figure.

   2. Use the hoist and carefully lift the HP system module.

7. SUBTASK 72-00-40-020-160 Prepare the HP System Module for Interface Inspection

   1. Refer to Figure.

   2. Lower the HP system module onto IAE 1R18090 Safety support stand 1 off. The HP compressor front flange should touch the safety support stand pads. Do not release the lift sling hold.

8. SUBTASK 72-00-40-220-106 Visually Examine the Interfaces

   1. Visually examine the HP system module and the LP compressor/intermediate case module at interfaces C-32 and C-41. Refer to TASK 72-00-00-200-002.

9. SUBTASK 72-00-40-020-161 Install the Dummy Stub Shaft onto the HP System Module

   1. Refer to Figure.

   2. Install the IAE 1R18673 Dummy stub shaft 1 off into the IAE 1R18673 Dummy stub shaft 1 off. Make sure the curvic protector is at the rear.

   3. Remove the curvic protector from the dummy stub shaft.

      1. NOTE

         The bolts remain with the dummy stub shaft.

         Release the bolts and the nuts from the curvic protector.

      2. Remove the curvic protector.

   4. Clean the curvic teeth on the dummy stub shaft and the HP compressor stage 3 disk.

      1. 

         WARNING

         WHEN YOU USE COMAT 01-002 INHIBITED AND STABILIZED TRICHLOROETHANE YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.

         Use a soft brush and apply CoMat 01-002 SOLVENT, DELETED. to the curvic teeth.

      2. Dry the curvic teeth with a clean dry air blast.

   5. Install the dummy stub shaft onto the HP system module.

      1. Align the four tool location pins on the dummy stub shaft with the applicable location hole on the curvic coupling.

      2. Lift the HP system module from the safety support stand and position over the build pedestal.

      3. Carefully lower the HP system module onto the dummy stub shaft and hold in position.

      4. Safety the dummy stub shaft with the 20 curvic coupling tool bolts.

10. SUBTASK 72-00-40-020-162 Install the HP System Module onto the Build Stand

    1. Refer to Figure.

    2. Install IAE 1R18222 Support rod 2 off onto the IAE 1R18214 Build stand 1 off.

       1. Align the support ring end faces so that they are adjacent to the two location pins on the build stand.

       2. Secure the support rings with the six build stand/support ring bolts.

    3. Lift the HP module system off the pedestal build stand and carefully lower onto the build stand. Make sure the support ring splitline is aligned with the HP compressor front cases splitline. Also align the support ring location pins with the applicable hole in the HP compressor front flange.

    4. Secure the HP compressor front flange to the support ring. Use the six HP compressor/support ring bolts.

    5. Release the hold on the lift sling.

11. SUBTASK 72-00-40-020-163 Remove the Hoist, the Remove/Install Fixture, the Tie-Rod Adapter and the HP Compressor Support Rods

    1. Refer to Figure and Figure

    2. Remove the support rods.

       1. Turn the adjustment handles to retract the blade.

       2. Release the six support rod tool bolts.

       3. Remove the support rods.

       4. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-118) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) into the HP compressor at location C.

          1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE onto the bracket where it touches the blank.

          2. Install the blank, the bracket and the bolts.

          3. Torque the bolts to 85 lbfin to 105 lbf.in (10 Nm to 12 Nm).

       5. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-115) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) in the HP compressor at location A.

          1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on the bracket where it touches the blank.

          2. Install the blank, the bracket and the bolts.

          3. Torque the bolts to 85 lbfin to 105 lbf.in (10 Nm to 12 Nm).

       6. Install the other blank HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) and the other bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) into the HP compressor at location B. Torque the bolts to 85 lbfin to 105 lbf.in (10 Nm to 12 Nm).

       7. Remove the rigging pin installed in Step.

    3. Remove the remove/install fixture and the tie-rod adapter from the rear of the HP system module.

       1. Adjust the height of the hoist to hold the weight of the remove/install fixture to the HP turbine case. Remove the two split rings.

       2. Release the locknut on the end of the tie-rod shaft.

       3. Remove the two screws that safety the tie-rod adapter onto the remove/install fixture.

       4. Move the shaft into the engine to disengage the puck from the HP compressor shaft front shoulder.

       5. Remove the tie-rod adapter from the module.

       6. Remove the remove/install fixture from the module and put it onto a suitable work surface. Remove the hoist and the lift sling.

Figure: Install the remove/install fixture and the tie-rod adapter onto the HP system module

Install the remove/install fixture and the tie-rod adapter onto the HP system module



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

Install the remove/install fixture and the tie-rod adapter to the HP system module



Figure: Install the support rods into the HP compressor

Install the support rods into the HP compressor



Figure: Install the support rods into the HP compressor

Install the support rods into the HP compressor



Figure: Remove the stage 3 HP compressor curvic bolts

Remove the stage 3 HP compressor curvic bolts



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

LP compressor/intermediate case module to HP system module joint flange hole positions



Figure: Install the HP system module onto the safety support stand

Install the HP system module onto the safety support stand



Figure: Install the dummy stub shaft onto the stage 3 disk curvic coupling

Install the dummy stub shaft onto the stage 3 disk curvic coupling



Figure: Install the HP compressor/diffuser case assembly onto the build stand

Install the HP compressor/diffuser case assembly onto the build stand