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-A5
Common Information
TASK 72-00-40-420-007-B00 HP System Module - Install The Components, Electrical Harnesses, Tubes, And Brackets To The HPT, Installation-010
General
This TASK gives the procedure to install the components, electrical harnesses, tubes and brackets to the HP turbine module. Refer to the TASKs which follow for other related procedures.
TASK 72-00-40-420-004-B00 Install the initial components, the air off-take ducts and tubes to the HP system module.
TASK 72-00-40-420-005-B00 Install the components, the ducts, the electrical harnesses and the tubes to the HP compressor case vertical splitline.
TASK 72-00-40-420-006-B00 Install and connect the components, the electrical harnesses and the tubes to the front of the HP compressor case.
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 the 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 70-41-01-400-501 and SPM TASK 70-41-02-400-501.
Special torque data is identified with the symbol * after the torque value. Assembly tolerances are included in this procedure.
If the cotter pin holes do not align within the torque range a different nut must be used. Do not loosen the nut or tighten the nut more than the maximum torque to align the holes.
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.
After assembly apply CoMat 07-038 AIR DRYING ENAMEL to damaged surface protection, joint flanges and attach parts. Use the correct color of air drying enamel. Refer to SPM TASK 70-38-21-380-501.
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 installation of the components.
Do not remove the special plastic caps from the electrical connections until immediately before installation. This will give protection from unwanted fluids and materials. For the data on the connection of the electrical connectors refer to the SPM TASK 70-43-00-400-501.
For lockwire data and procedures refer to SPM TASK 70-42-05-400-501.
For safety cable data and procedures refer to the SPM TASK 70-42-08-400-501. | ||
Safety the threaded fasteners in this TASK with CoMat 02-274 SAFETY CABLE KIT or CoMat 02-275 SAFETY CABLE KIT for the ATA Chapter/Section/Subjects which follow: |
Refer to the V2500 Illustrated Tool and Equipment Manual (ITE-V2500-1IA) for the illustrations of the special tools used in this procedure.
NOTE
Preliminary Requirements
Pre-Conditions
NONESupport Equipment
NONEConsumables, Materials and Expendables
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| CoMat 02-126 LOCKWIRE | K6835 | CoMat 02-126 | ||
| CoMat 02-148 ADHESIVE TAPE (ELECTRICAL) | LOCAL | CoMat 02-148 | ||
| CoMat 02-274 SAFETY CABLE KIT | LOCAL | CoMat 02-274 | ||
| CoMat 02-275 SAFETY CABLE KIT | X111X | CoMat 02-275 | ||
| CoMat 07-038 AIR DRYING ENAMEL | 00BB6 | CoMat 07-038 | ||
| CoMat 10-077 APPROVED ENGINE OILS | X333X | CoMat 10-077 |
Spares
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| PIN | 96906 | MS24665-151 | 1 | 75-24-47, 01-510 |
| PIN | 96906 | MS24665-151 | 1 | 75-24-47, 01-560 |
| PIN | 96906 | MS24665-151 | 1 | 75-24-51, 01-410 |
| PIN | 96906 | MS24665-151 | 1 | 75-24-51, 01-495 |
| RING, RETAINING | 96906 | MS16625-4037 | 1 | 79-21-49, 15-488 |
Safety Requirements
NONEProcedure
Refer to Figure.
Install the clips, the clipnuts, the washers and the bolts at the clip positions 5234, 5233 and 5232.
Refer to Figure.
Install the tube 15 AIR-BEARING COMPARTMENT COOLING & SEALING TUBES (75-22-49, 09-500).
Install the tube 13 Bearing Compartment Cooling And Sealing Air Tubes (75-22-49, 08-500).
Install the clips, the clipnuts, the washers and the bolts at the clip positions 5231, 5230 and 5229.
Refer to Figure.
Install the tube 12 Bearing Compartment Cooling And Sealing Air Tubes (75-22-49, 08-100).
SBE 75-0049: Install the two clips, the bolt, the spacer and the nut at the clip position 5224.
SBE 75-0049: Torque the nut at the clip position 5224 to 36 to 44 lbfin (4 to 5 Nm).
Refer to Fig. 72-00-40-990-004.
Install the tube 11 AIR-BEARING COMPARTMENT COOLING & SEALING TUBES (75-22-49, 10-100).
SUBTASK 72-00-40-420-157 Install the Cold Buffer Air Tubes
Refer to Figure.
Install the restrictor Engine Pressure Oil Tubes (79-21-49, 15-491).
Install the new Engine Pressure Oil Tubes (79-21-49, 15-488) retaining ring 1 off.
Connect the tube 17 to the tube 23.
Install the tube 17 Engine Pressure Oil Tubes (79-21-49, 15-500).
Connect the tube 18 No. 4 Bearing Compartment Weep Oil Tubes (71-73-49, 01-100) to the No.4 bearing outer tube No. 4 Bearing Compartment Tubes (72-42-20, 03-040).
Install the tube 19 Fuel System Air Tubes (73-22-49, 01-500).
SUBTASK 72-00-40-420-158 Install the Number 5 Oil Feed Tube (17), the Oil Weep Tube (18) and the P4.9 ECC Tube (19)
Refer to Figure.
During the installation procedure make sure the harnesses are held temporarily along their different lengths. Always install the datum clip positions when you install each electrical connector. This will give correct installation of the different harnesses, prevent too much strain on the electrical connectors and give the necessary drip loops (the drip loop makes sure moisture or fluids do not go in to the electrical connector).
Because of the differences between the harness diameters, the specified clip could be too large or too small. You can use a clip from a range of six clips that have the same part numbers. If the harness diameter is between two of the clips in the range, use the larger clip. When you do this use CoMat 02-148 ADHESIVE TAPE (ELECTRICAL) to increase the harness diameter.
For the data on the electrical connectors refer to SPM TASK 70-43-00-400-501 and SPM TASK 70-43-01-400-501.
SUBTASK 72-00-40-420-159 Electrical Harness Installation Procedure
Pre SBE 79-0088: Attach the electrical receptacle 4007VC to the bracket HPC Assembly (72-41-00, 03-350) with the four screws Exhaust Gas Temperature (EGT) Harness (71-52-45, 01-022) and the four assembled washer nuts Exhaust Gas Temperature (EGT) Harness (71-52-45, 01-020). Torque the four assembled washer nuts to between 6 and 8 lbfin (0.68 and 0.90 Nm).
SBE 79-0088: Attach the electrical receptacle 4007VC to the bracket Engine Air Off-Take Air Ducts (75-00-49, 01-680) with the four screws Exhaust Gas Temperature (EGT) Harness (71-52-45, 01-022) and the four assembled washer nuts Exhaust Gas Temperature (EGT) Harness (71-52-45, 01-020). Torque the four assembled washer nuts to between 6 and 8 lbfin (0.68 and 0.90 Nm).
Pre SBE 72-0189: Install the clip, the clipnut, the washer and the bolt at the datum clip position 5553.
SBE 72-0189 and SBE 79-0088: Install the clip, the clipnut, the spacer and the bolt at the datum clip position 5553.
SBE 72-0189 and SBE 79-0088: Install the clip, the clipnut, the washer and the bolt at the clip position 6085.
SBE 72-0189 and SBE 79-0088: Install the clip, the washer, the nut, the spacer and the bolt at the clip position 6086.
Pre SBE 75-0049: Install the clips, the washers, the bolts and the nuts at the clip positions 5551, 5529 and 5781.
SBE 75-0049: Install the bolt, the spacer, the clips and the nut at the clip position 5529.
NOTE
This procedure will be continued in TASK 72-00-50-420-005.Temporarily attach the remaining part of the harness to the engine.
SUBTASK 72-00-40-420-160 Install the Core EGT Harness (Pre SBE 75-0049, Pre SBE 72-0189, Pre SBE 79-0088, SBE 75-0049, SBE 72-0189 and SBE 79-0088)
HPT Vane has plugs installed, proceed to Step if installed.
Remove the four nuts, washers, screws (plugs) and bushings from the plug storage plate of the ACC valve. Refer to Figure.
Install the bushings (4 off), screws (plugs) (4 off), washers (4 off) and nuts (4 off) in the four holes located on the HPT vane in the ACC valve.
Torque the four nuts to 10.0 lbf.in to 11.5 lbf.in (1.13 Nm to 1.30 Nm).
Continue with Step.
HPT Vane plugs are not installed.
Verification Active Clearance Control Valve Active Clearance Control (ACC) Valve (75-24-51, 01-100) has plugs installed in HPT Vane. Refer to Figure.
Attach the ACC front duct Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-100) to the ACC valve Active Clearance Control (ACC) Valve (75-24-51, 01-100) with the 12 bolts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-140) and the 12 nuts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-135). Torque the 12 nuts to 85 lbfin to 105 lbfin (10 Nm to 12 Nm).
Attach the two clamps Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-125) and Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-120) and the heatshield Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-190) to the ACC valve with the two bolts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-115) and the two nuts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-110).
Install the four bolts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-210) and the four nuts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-200).
Attach the rear duct Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-300) to the ACC valve with the four bolts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-315) and the four nuts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-310).
Attach the ACC valve bracket Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-500) to the rear duct with the two bolts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-325) and the two nuts Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-320).
Attach the link Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-550) to the ACC valve bracket with the two bushes Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-590), the bolt Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-570) and the nut Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-565). Torque the nut to 85 to 105 lbfin (10 to 12 Nm) and align the hole in the bolt with a slot in the castellated nut. Install the new Active Clearance Control (ACC) Supply Air Ducts(75-24-47, 01-510 and 01-560) cotter pins 1 off.
Attach the Stator Rod Active Clearance Control (ACC) Valve (75-24-51, 01-485) to the mount bracket with the Bolt Active Clearance Control (ACC) Valve (75-24-51, 01-155), two bushes Active Clearance Control (ACC) Valve (75-24-51, 01-210), and nut Active Clearance Control (ACC) Valve (75-24-51, 01-140). Torque the nut to 36 to 44 lbfin (4 to 5 Nm). Align the slot of the nut with the pin hole of the bolt and safety the nut with the new Active Clearance Control (ACC) Valve (75-24-51, 01-136) cotter pin 1 off.
Connect the acutator rod to the valve rod with the bolt Active Clearance Control (ACC) Valve (75-24-51, 01-120) and the nut Active Clearance Control (ACC) Valve (75-24-51, 01-115).
Torque the nut to 22 to 30 lbfin (3 to 3.5 Nm) and align the slot of the nut with the pin hole of the bolt and safety the nut with the new Active Clearance Control (ACC) Valve (75-24-51, 01-110) cotter pin 1 off.
Connect the actuator rod to the HPT/LPT ACC air valve.
Attach the link to the bracket HPC Module - Attaching Parts (72-40-00, 05-500) with the two bushings Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-540), the bolt Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-520) and the nut Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-515). Torque the nut to 85 to 105 lbfin (10 to 12 Nm) and align the hole in the bolt with a slot in the castellated nut. Install and safety the new Active Clearance Control (ACC) Supply Air Ducts (75-24-47, 01-510) cotter pin 1 off.
Assemble the ACC housing Active Clearance Control (ACC) Valve (75-24-51, 01-275), ACC seal retainer Active Clearance Control (ACC) Valve (75-24-51, 01-370), ACC seal Active Clearance Control (ACC) Valve (75-24-51, 01-350), and the joint heat shield Active Clearance Control (ACC) Valve (75-24-51, 01-360) with the four bolts Active Clearance Control (ACC) Valve (75-24-51, 01-375). Torque the bolts to 36 to 44 lbfin (4 to 5 Nm).
Attach the ACC HPT valve link AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-100) to the ACC housing Active Clearance Control (ACC) Valve (75-24-51, 01-275) with the two bushings AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-160), the bolt AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-150), and the nut AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-145). Torque the nut to 36 to 44 lbfin (4 to 5 Nm) and safety with the new AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-140) cotter pin 1 off.
Attach the ACC HPT valve link AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-250) to the ACC housing Active Clearance Control (ACC) Valve (75-24-51, 01-275) with the two bushings AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-380), the bolt AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-300) and the nut AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-295). Torque the nut to 36 to 44 lbfin (4 to 5 Nm) and safety with the new AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-290) cotter pin 1 off.
Attach the ACC HPT valve bracket HPC Module - Attaching Parts (72-40-00, 05-570) to the ACC HPT valve link AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-250) with the two bushings AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-310), the bolt AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-270), and the nut AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-265). Torque the nut to 36 to 44 lbfin (4 to 5 Nm) and safety with the new AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-260) cotter pin 1 off.
Lightly lubricate the five bolts with CoMat 10-077 APPROVED ENGINE OILS approved engine oil.
Install the five bolts Active Clearance Control (ACC) Valve (75-24-51, 01-290) and torque them to 85 to 105 lbfin (10 to 12 Nm).
Install the ACC housing assembly to the HPT/LPT ACC air valve.
Install the ACC HPT valve link AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-100) to the ACC HPT valve bracket HPC Module - Attaching Parts (72-40-00, 05-550) installed to Flange FM with the two bushings AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-130), the bolt AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-120) and the nut AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-115). Torque the nut to 36 to 44 lbfin (4 to 5 Nm) and safety with the new AIR-ACTIVE CLEARANCE CONTROL VALVE (75-24-51, 02-110) cotter pin 1 off.
Connect the actuator rod to the ACC actuator with the two bushings Active Clearance Control (ACC) Valve (75-24-51, 01-470), the bolt Active Clearance Control (ACC) Valve (75-24-51, 01-420) and the nut Active Clearance Control (ACC) Valve (75-24-51, 01-415). Torque the nut to 22 to 30 lbfin (3 to 3.5 Nm) and align the hole in the bolt with a slot in the castellated nut. Install and safety the new Active Clearance Control (ACC) Valve (75-24-51, 01-410) cotter pin 1 off.
Connect the stator rod to the ACC actuator with the bushing Active Clearance Control (ACC) Valve (75-24-51, 01-555), the bolt Active Clearance Control (ACC) Valve (75-24-51, 01-505) and the nut Active Clearance Control (ACC) Valve (75-24-51, 01-500). Torque the nut to 36 to 44 lbfin (4 to 5 Nm) and align the hole in the bolt with a slot in the castellated nut. Install and safety the new Active Clearance Control (ACC) Valve (75-24-51, 01-495) cotter pin 1 off.
Connect the ACC valve to the ACC actuator.
SUBTASK 72-00-40-420-161 Install the Active Clearance Control (ACC) Valve, the Front Duct and the Rear Duct
To check the clearance, push the harness with a light pressure of the thumb then release. The harness must spring back and give the minimum clearance. The harness must not move through the adjacent clips (refer to Step).
Measure the clearance between all the different harnesses and the engine parts.
SUBTASK 72-00-40-220-116 Measure the Harness Clearances and Examine the Harness Routing
Refer to Figure.
Make sure that all the applicable backshells and cable clamps are safetied with CoMat 02-126 LOCKWIRE. Refer to SPM TASK 70-42-05-400-501.
SUBTASK 72-00-40-210-060 Visually Inspect the Electrical Backshells and Cable Clamps
Figure: Install the Cold Buffer Air Tubes
Sheet 1

Figure: Install the Cold Buffer Air Tubes
Sheet 2

Figure: Install the Cold Buffer Air Tubes
Sheet 3

Figure: Install the Cold Buffer Air Tubes
Sheet 4

Figure: Install the Cold Buffer Air Tubes
Sheet 5

Figure: Install the Tubes 17, 18 and 19
Install the Tubes 17, 18 and 19

Figure: Electrical Harnesses Installation
Electrical Harnesses Installation

Figure: Pre SBE 72-0189: Install the Core EGT Harness
Sheet 1

Figure: SBE 72-0189 and SBE 79-0088: Install the Core EGT Harness
Sheet 2

Figure: SBE 72-0189 and Pre SBE 79-0088: Install the Core EGT Harness
Sheet 3

Figure: SBE 79-0088: Install the Core EGT Harness
Sheet 4

Figure: Pre SBE 79-0088: Install the Core EGT Harness
Sheet 5

Figure: SBE 79-0088: Install the Core EGT Harness
Sheet 6

Figure: Install the Core EGT Harness
Sheet 7

Figure: Install the Core EGT Harness
Sheet 8

Figure: Install the ACC Valve, the Front Duct and Rear Duct
Sheet 1

Figure: Install the ACC Valve, the Front Duct and the Rear Duct
Sheet 2

Figure: Visually Inspect the Backshells and Cable Clamps
Visually Inspect the Backshells and Cable Clamps

Figure: Active Clearance Control (ACC) Valve Plug Position
Active Clearance Control (ACC) Valve Plug Position

