DMC:V2500-A5-72-00-5000-01C-520A-B|Issue No:005|Issue Date:2021-02-01

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-A5

Common Information

TASK 72-00-50-020-001-B00 LPT Module - Remove The LPT Module Components, External Harnesses, And Tubes, Removal-001

General

Fig/item numbers in parentheses in the procedure agree with those used in the EIPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the EIPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

Apply the approved CoMat 10-058 PENETRATING OIL before the removal of threaded parts. Let the parts soak before removal.

Discard all the rubber seal rings, split cotter pins, keywashers and gaskets removed in the procedure.

Remove and discard the lockwire before the tube or connector is disconnected.

Refer to the V2500 Illustrated Tool and Equipment Manual Pub.ref. ITE-V2500-1IA, for the illustrations of the special tools given in this procedure.

All the electrical harnesses and cables removed in this procedure must have their maintenance completed, as given in the Component Maintenance Manual, Pub.ref. CMM-EHC-V2500-1IA.

All the tubes, hoses and ducts removed in this procedure must have their maintenance completed, as given in the Component Maintenance Manual, Pub.ref. CMM-THD-V2500-1IA.

During the removal procedure make sure that the harnesses are held temporarily along their different lengths. This is to prevent too much strain on the harnesses, cables and electrical connectors.

During the removal procedure put the special plastic caps on the electrical connectors. This is to give protection from unwanted fluids or materials.

During the removal procedure put the transportation covers/blanks on all openings. This is to give protection from unwanted fluids or materials.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

Name	Manufacturer	Part Number / Identification	Quantity
IAE 1M14084 Support fixture	0AM53	IAE 1M14084	2
IAE 1M14077 Protective plug	0AM53	IAE 1M14077	1
IAE 1M14083 Protective plug	0AM53	IAE 1M14083	2
IAE 1N20015 Aft engine mount sling	0AM53	IAE 1N20015	1

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification	Quantity	Remark
CoMat 10-058 PENETRATING OIL	X222X	CoMat 10-058

Spares

NONE

Safety Requirements

NONE

Procedure

1. Refer to Figure, Figure, Figure and Figure.
2. Disconnect the electrical connectors 4001WD1-A and 4001WD2-A.
3. Remove the nuts, the bolts, the washers and the spacers from the clip positions 5928 and 5929.
4. Remove the nut, the bolt, the washer and the clip from the clip position 5500.
5. Pre SBE 75-0049: Remove the nut, the bolt, the spacer, the washer and the clip from the clip position 5723.
6. SBE 75-0049: Remove the nut, the bolt, the two spacers and the two clips at the clip position 5723.
7. NOTE
  The core zone fire detector removed in this procedure must have its maintenance completed as given in the Systron Donner Component Maintenance Manual (26-12-17).
  Remove the core zone fire detector.
1. Refer to Figure and Figure.
2. Disconnect the electrical connectors 4001WD1-A and 4001WD2-A.
3. Pre SBE 71-0295: Remove the bolts, the washers and the nuts from the clip positions 6120 and 6126.
4. SBE 71-0295: Remove the bolts, the washers and the nuts from the clip positions 6078 and 6126.
5. Remove the nut, the bolt, the washer and the clip from the clip position 5500.
6. Remove the nut, the bolt, the washer and the clip from the clip position 6115.
7. NOTE
  The core zone fire detector removed in this procedure must have its maintenance completed as given in the Systron Donner Component Maintenance Manual (26-12-17).
  Remove the core zone fire detector.
1. Refer to Figure, Figure, Figure and Figure.
2. WARNING
  DURING DISASSEMBLY DO NOT BREATHE DUST OF THE LOOSENED BOLTS. PREVENT SKIN AND EYE CONTACT WITH RELEASED DUST. THE DUST CONTAINS NICKEL PARTICLES WHICH CAN POSE A HEALTH HAZARD. BEFORE DISASSEMBLY LUBRICATE ACCESSIBLE BOLTS AND BOLT HEADS, NUTS AND EXPOSED THREADS WITH AN APPROVED, SUITABLE PENETRANT OIL. WEAR A FACE MASK AND GOGGLES. DO NOT REMOVE DUST DEPOSITS WITH COMPRESSED AIR. REMOVE ANY SURFACE DUST PARTICLES WITH A DISPOSABLE DAMP RAG OR SIMILAR. AFTER END OF THIS PROCEDURE CLEAN YOUR HANDS AND EXPOSED SKIN WHERE POSSIBLE.
  Disengage the periseal housing LPT ACC Air Ducts And Tubes (75-24-49, 01-540) from the three spring clips and retract it from the T-piece above the ACC rear duct.
3. SBE 75-0051: Loosen the two bolts LPT ACC Air Ducts And Tubes (75-24-49, 01-490) of the T-piece of the connector tube.
4. Remove the bolts and the two periseal clamps LPT ACC Air Ducts And Tubes (75-24-49, 01-480).
5. Disengage the periseal housing and retract it from the T-piece above the ACC rear duct.
6. Remove the ACC rear duct.
7. Remove the nuts and bolts from the two retainig clamps LPT ACC Air Ducts And Tubes (75-24-49, 01-670) and LPT ACC Air Ducts And Tubes (75-24-49, 01-570) which safety the periseal connectors LPT ACC Air Ducts And Tubes (75-24-49, 01-730) and LPT ACC Air Ducts And Tubes (75-24-49, 01-630) to the connector tube.
8. Retract the periseal connectors above the ends of the tube connector.
9. Remove the bolts LPT ACC Air Ducts And Tubes (75-24-49, 01-030) and the washers LPT ACC Air Ducts And Tubes (75-24-49, 01-050) that attach the connector tube to the supports.
10. Loosen the bolt from the T-piece angle bracket that attaches the connector tube to the support.
11. Remove the connector tube from the LP Turbine case.
12. Removet the two periseal connectors, the two retaining clamps and the two clamps LPT ACC Air Ducts And Tubes(75-24-49,01-130) and LPT ACC Air Ducts And Tubes (75-24-49, 01-090) from the connector tube.
13. Remove the bolt, the washer and the spacer LPT ACC Air Ducts And Tubes (75-24-49, 01-070) from the T-piece angle bracket.
14. Remove the LP Turbine ACC connector tube from the engine.
15. Remove the periseal housing from the ACC rear duct.
16. Install the IAE 1M14077 Protective plug protective plug 1 off, on to the LP turbine ACC connector tube.
17. Install the IAE 1M14083 Protective plug protective plug 2 off, on to the LP turbine ACC connector tube.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure
2. 1. Remove the two nuts and the two washers from the alumel studs.
  2. Remove the two nuts and the two washers from the chromel studs.
  3. Remove the four harness leads from the four terminals.
  4. Put the four nuts and the four washers back on to the applicable studs.
  5. Do Step thru Step for the EGT probes at the other locations.
3. 1. Remove the four screws and the cover, from the junction box.
  2. Remove the two nuts from the alumel studs.
  3. Remove the two nuts from the chromel studs.
  4. Remove the four core EGT harness leads from the four terminals.
  5. Pre SBE 77-0009 : Put the four nuts back on to the applicable studs.
  6. CAUTION
    ONCE A NEW STYLE NUT IS INSTALLED ON TO THE MATING STUD YOU MUST NOT INSTALL AN OLD NUT ON THAT STUD.
    SBE 77-0009 : Put the four self locking nuts back on to the applicable studs.
  7. Remove the two bolts and the two nuts that attach the earth points 5340 and 5705 to the junction box.
  8. Replace the cover and the four screws.
4. 1. Remove the two bolts and the two nuts that secure the junction box to the bracket LP Turbine (LPT) And Turbine Exhaust Case (TEC) Unit (72-50-00, 01-640).
  2. Remove the clips, the bolts, the washers, the spacers, the clip nuts and the nuts from the clip positions 6000 thru 6019.
  3. NOTE
    The EGT harness/junction box removed in this procedure must have its maintenance completed as given in the Harco Component Maintenance Manual (77-21-43).
    Remove the EGT harness/junction box from the engine.
5. Remove the bolts, the washers, the nuts, the spacers and the clips from the clip positions 6055, 6054, 6053, 6052, 6051 and 5549.
6. Remove the bolt, the washer, the clip nut, the spacer, the clips and the mounting brackets from the datum clip position 5523.
7. NOTE
  Make sure that this position is identified, for subsequent reference.
  Remove the bolt, the washer, the nut and the clip from the datum clip position 5734.
8. Move the core EGT harness away from the LP turbine module and temporarily attach it to the HP system module.
1. Refer to Figure and Figure.
2. Remove the bolts, the washers, the nuts, the clip nuts and the clips from the clip positions 6050, 5204, 5205 and 5206.
3. 1. Remove the two bolts and the two nuts from the flange connection.
  2. Remove the metallic oil seal and temporarily attach it to the outer oil feed tube.
4. Disconnect the tube 1 from the tube 17.
5. Remove the tube 1.
6. Remove the two bolts that secure the bracket OIL-PRESSURE OIL TUBES-ENGINE (79-21-49, 16-070) on the the LP turbine active clearance control at the seven o'clock position. Remove the bracket from the engine.
1. Refer to Figure and Figure.
2. Remove the bolts, the washers, the clip nuts and the clips at the clip positions 5226 and 5227.
3. Remove the bolts, the washers, the clip nuts, the clips and the bracket at the clip position 5228.
4. 1. Remove the four bolts and the two threaded plates from the flange connection.
  2. Remove the metallic oil seal, and temporarily attach it to the outer oil scavenge tube flange.
5. Disconnect the tube 2 from the tube 20.
6. Remove the tube 2 from the engine.
1. Refer to Figure.
2. Remove the bolt, the washer, the clip nut and the clips at the clip position 5201.
3. Remove the bolt, the washer, the nut and the clip at the clip position 6062.
4. Disconnect the tube 4, from the tube 18 and the LP turbine case connector.
5. Remove the tube 4 from the engine.
1. Refer to Figure and Figure.
2. 1. Disconnect the tube 3, from the pipe adapter and the tube 19.
  2. Carefully remove the tube 3 from the engine.
3. 1. Disconnect the tube 81 from the pipe adapter.
  2. Remove the two bolts at the flange connection on the LP turbine case.
  3. Carefully remove the tube 81 from the engine.
  4. Remove the piston rings. Temporarily attach the piston rings to the tube 81.
4. 1. Disconnect the tube 70 from the pipe adapter.
  2. Remove the two bolts at the flange connection on the LP turbine case.
  3. Remove the tube 70 from the engine.
  4. Remove the piston rings. Temporarily attach the piston rings to the tube 70.
5. 1. Remove the two bolts and the bracket from the pipe adapter.
  2. Remove the pipe adapter from the engine.
  3. Remove the piston rings. Temporarily attach the piston rings to the pipe adapter.
1. Refer to Figure, Figure and Figure.
2. Remove the bolts, the washer, the clips and the clip nuts from clip positions 5207 and 5208.
3. 1. Remove the three bolts, the washer and the two brackets from the flange connection on tube 11.
  2. Remove the three bolts from the flange connection on tube 12.
4. Remove the bolts, the spacers and the nuts that attach the number 4 bearing compartment air cooler to the brackets on the diffuser case rear flange and the HP turbine rear flange.
5. Remove the number 4 bearing compartment air cooler from the engine.
6. NOTE
  The number 4 bearing compartment air cooler removed in this procedure must have its maintenance completed as given in the Marston Palmer Component Maintenance Manual (75-22-41).
  Remove and discard the two corrujoint washers.
1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.
2. 1. Remove the bolt, the washer, the clip nut and the clip from the clip position 5554.
  2. Remove the two bolts, the four washers, the two nuts and the two clips which attach the tube 5 and tube 25 to the bracket at the clip position 5793. Remove the bracket.
  3. Remove the bolts, the clip nuts and the clamps from the tube.
  4. Remove the four bolts from the HP compressor case connector flange.
  5. Remove the four bolts from the HP turbine case connector flange.
  6. Remove the tube from the engine.
  7. Remove the two metal 'C' seals and temporarily attach them to the tube.
3. 1. Remove the bolts, the clip nuts and the clamps from the tube.
  2. Remove the four bolts from the HP compressor case connector flange.
  3. Do Step thru Step again for tube 6.
4. 1. Do Step thru Step again for tube 7.
  2. Remove the two bolts, the four washers, the two nuts and the two clips which attach the tube 7 and tube 26 to the bracket at the clip position 5792. Remove the bracket.
5. 1. Remove the bolts, the clip nuts and the clamps from the tube.
  2. Remove the four bolts from the HP compressor case connector flange.
  3. Remove the four bolts and the bracket from the HP turbine case connector flange.
  4. Do Step thru Step for tube 8.
1. Refer to Figure, Figure, Figure and Figure.
2. WARNING
  DURING DISASSEMBLY DO NOT BREATHE DUST OF THE LOOSENED BOLTS. PREVENT SKIN AND EYE CONTACT WITH RELEASED DUST. THE DUST CONTAINS NICKEL PARTICLES WHICH CAN POSE A HEALTH HAZARD. BEFORE DISASSEMBLY LUBRICATE ACCESSIBLE BOLTS AND BOLT HEADS, NUTS AND EXPOSED THREADS WITH AN APPROVED, SUITABLE PENETRANT OIL. WEAR A FACE MASK AND GOGGLES. DO NOT REMOVE DUST DEPOSITS WITH COMPRESSED AIR. REMOVE ANY SURFACE DUST PARTICLES WITH A DISPOSABLE DAMP RAG OR SIMILAR. AFTER END OF THIS PROCEDURE CLEAN YOUR HANDS AND EXPOSED SKIN WHERE POSSIBLE.
  Loosen all the bolts on the support assemblies C and G.
3. Remove the bolts, the washers, the spacers and the nuts that attach the lower ACC duct to the front flange and the rear bosses.
4. Carefully remove the lower ACC manifold.
5. PRE SBE 75-0095: Remove the bolts, the washers, the spacers LPT ACC Air Ducts And Tubes (75-24-49, 04-440) and the nuts that attach the support assembly C. Discard the spacers.
6. SBE 75-0095: Remove the bolts, the washers, the spacers and the nuts that attach the support assembly C.
7. Remove the support assembly C.
8. Put the support assembly C temporarily on to the lower ACC duct, and lightly tighten all the support assembly nuts.
9. 1. Loosen the knurled nut and move the swing bolt in to the horizontal position.
  2. Carefully put the lower ACC duct in to the support fixture.
  3. Install the two tool bolts and lightly tighten.
  4. Move the swing bolt in to the vertical position and hand tighten the knurled nut.
10. Move the support assembly G on to the upper ACC manifold and lightly tighten the support assembly nuts.
11. Remove all the bolts, the washers, the spacers LPT ACC Air Ducts And Tubes (75-24-49, 04-040) and the nuts that attach the upper ACC duct to the front flange and the rear bosses.
12. Remove the upper ACC manifold.
13. PRE SBE 75-0095: Remove the bolts, the washers, the spacer LPT ACC Air Ducts And Tubes (75-24-49, 04-040) and the nuts that attach the support assembly G. Discard the spacers.
14. SBE 75-0095: Remove the bolts, the washers, the spacers and the nuts that attach the support assembly G.
15. Remove the support assembly G.
16. Put the support assembly G temporarily on to the lower ACC duct, and lightly tighten all the support assembly nuts.
17. 1. Loosen the knurled nut and move the swing bolt in to the horizontal position.
  2. Carefully put the upper ACC manifold in to the support fixture.
  3. Install the two tool bolts and lightly tighten.
  4. Move the swing bolt in to the vertical position and hand tighten the knurled nut.
1. Refer to Figure, Figure and Figure.
2. 1. Remove the nuts and the bolts that attach the left hand turbine cooling manifold to the brackets on the flange FN.
  2. Remove the nuts and the bolts that attach the left hand turbine cooling manifold to the brackets on the flange FM.
  3. Remove the four bolts from the lower turbine cooling manifold and the left hand turbine cooling manifold.
  4. Remove the left hand turbine cooling manifold from the engine.
  5. Loosely install the bolts and the nuts removed in Step on to the left hand turbine cooling manifold.
3. 1. Remove the nuts and the bolts that attach the right hand turbine cooling manifold to the brackets on the flange FN.
  2. Remove the nuts and the bolts that attach the right hand turbine cooling manifold to the brackets on the flange FM.
  3. Remove the four bolts from the lower turbine cooling manifold and the right hand turbine cooling manifold.
  4. Remove the right hand turbine cooling manifold from the engine.
  5. Loosely install the bolts and nuts removed in Step on to the right hand turbine cooling manifold.
4. 1. Remove the clips and the bolts that attach the lower turbine cooling manifold to the bracket on flange FN.
  2. Remove the two bolts and the two nuts that attach the lower turbine cooling manifold to the bracket on flange FM.
  3. Remove the lower turbine cooling manifold.
  4. Loosely install the bolts and nuts removed in Step on to the flange FM.
1. Refer to Figure.
2. Remove the two bolts that attach one of the EGT probes to the turbine exhaust case.
3. Carefully remove the EGT probe.
4. NOTE
  The EGT probes removed in this procedure must have their maintenance completed as given in the Weston Component Maintenance Manual (77-21-15).
  The piston rings must be examined before installation. Refer to TASK 72-00-50-200-000.
  Remove the two piston ring from the EGT probe.
5. Do steps Step thru Step again, for the other three EGT probes.
1. Refer to Figure and Figure.
2. WARNING
  BE CAREFUL WHEN YOU REMOVE THE AFT MOUNT BECAUSE IT WEIGHS 64 LBS (29 KG).
  Attach IAE 1N20015 Aft engine mount sling 1 off to a hoist.
3. Put the aft engine mount sling in to position above the engine.
4. Attach the aft engine mount sling to the aft engine mount with the two tool bolts. Use two diagonally opposite holes on the aft engine mount. Tighten the bolts to safety the aft engine mount sling.
5. Remove the four bolts, the four nuts and the eight washers at each of the three positions A.
6. Remove the two retainers at each of the three positions A.
7. Remove the inner pin and the outer pin at each of the three positions A.
8. NOTE
  The aft mount assembly must have its maintenance completed as given in 71-22-11 of this manual.
  Remove the aft mount from the engine.
9. Put the aft engine mount on to a suitable work surface.
10. Remove the aft engine mount sling from the aft engine mount and the hoist.
11. Put the aft engine mount sling on to a suitable work surface.

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Remove the No. 4 Bearing Oil Weep Tube

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Install the LP Turbine Active Clearance Control Manifold in to the Support Fixture

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Remove the EGT Probes

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Requirements After Job Completion

Follow-On Conditions

NONE

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:	X222X
Enterprise Name:	N/A – REFER TO APPLICABLE COMAT SUFFIX

Manufacturer Code:	0AM53
Tool Number:	IAE 1M14077
Tool Name:	IAE 1M14077 Protective plug

TASK 72-00-50-020-001-B00 LPT Module - Remove The LPT Module Components, External Harnesses, And Tubes, Removal-001

Export Control

Copyright

Applicability

Common Information

TASK 72-00-50-020-001-B00 LPT Module - Remove The LPT Module Components, External Harnesses, And Tubes, Removal-001

General

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-00-50-020-123-A00 Remove the Core Zone Fire Detector (Pre SBE 79-0088)

NOTE

SUBTASK 72-00-50-020-123-B00 Remove the Core Zone Fire Detector (SBE 79-0088, Pre SBN 71-0295 and SBN 71-0295)

NOTE

SUBTASK 72-00-50-020-124 Remove the LP Turbine Active Clearance Control (ACC) Connector Tube (Pre SBE 75-0051 and SBE 75-0051)

WARNING

SUBTASK 72-00-50-020-125Remove the Core Exhaust Gas Thermocouple (EGT) Harness, and the Exhaust Gas Thermocouple Harness/Junction Box (Pre SBE 77-0009 and SBE 77-0009)

CAUTION

NOTE

NOTE

SUBTASK 72-00-50-020-126 Remove the Tube 1, Number 5 Bearing Oil Feed Tube

SUBTASK 72-00-50-020-127 Remove the Tube 2, Number 5 Bearing Oil Scavenge Tube

SUBTASK 72-00-50-020-128 Remove the Tube 4, Number 4 Bearing Oil Weep Tube

SUBTASK 72-00-50-020-129 Remove the Tubes 3, 70 and 81, P4.9 Pressure Rake Tubes

SUBTASK 72-00-50-020-130 Remove the Number 4 Bearing Compartment Air Cooler

NOTE

SUBTASK 72-00-50-020-131 Remove the Tubes 5, 6, 7 and 8 the Turbine Cooling Air Supply Tubes

SUBTASK 72-00-50-020-132 Remove the LP Turbine Active Clearance Control (ACC) Manifold (SBE 75-0095PRE and SBE 75-0095)

WARNING

SUBTASK 72-00-50-020-133 Remove the HP Turbine Active Clearance Control Manifolds

SUBTASK 72-00-50-020-134 Remove the Exhaust Gas Thermocouple (EGT) Probes from the LP Turbine Module

NOTE

SUBTASK 72-00-50-020-135 Remove the Aft Mount

WARNING

NOTE

Figure: Pre SBE 79-0088: Remove the Core Zone Fire Detector

Sheet 1

Figure: SBE 71-0295: Remove the Core Zone Fire Detector

Sheet 2

Figure: Pre SBE 71-0295 and SBE 71-0295: Remove the Core Zone Fire Detector

Sheet 3

Figure: SBE 71-0295: Remove the Core Zone Fire Detector

Sheet 4

Figure: SBE 79-0088 and Pre SBE 71-0295: Remove the Core Zone Fire Detector

Sheet 5

Figure: SBE 71-0295: Remove the Core Zone Fire Detector

Sheet 6

Figure: Remove the LP Turbine Active Clearance Control Connector Tube

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Figure: Remove the LP Turbine Active Clearance Control Connector Tube

Sheet 2

Figure: Remove the LP Turbine Active Clearance Control Connector Tube

Sheet 3

Figure: Remove the LP Turbine Active Clearance Control Connector Tube

Sheet 4

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

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Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 2

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 3

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 4

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 5

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 6

Figure: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 7

Figure: Pre SBE 77-0009: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 8

Figure: SBE 77-0009: Remove the EGT Harness/Junction Box and the Core EGT Harness

Sheet 9

Figure: Remove the No.5 Bearing Oil Feed Tube

Sheet 1