TASK 72-32-00-430-003-C00 LPC/Intermediate Case Module - Install The No. 3 Bearing, Internal Gearbox And Support Assembly (Post Surgical Strike Procedure For FBC Area), Assembly-003

DMC:V2500-A5-72-32-0000-03A-710A-B|Issue No:002.00|Issue Date:2017-08-01

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-A5

Common Information

TASK 72-32-00-430-003-C00 LPC/Intermediate Case Module - Install The No. 3 Bearing, Internal Gearbox And Support Assembly (Post Surgical Strike Procedure For FBC Area), Assembly-003

General

This TASK gives the procedure to assemble the No. 3 bearing, internal gearbox and support assembly (internal gearbox assembly) and install the assembly on to the LP compressor/Intermediate case module on which the HP system module and the external gearbox module are installed.

Where TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003) is used for removal of the internal gearbox assembly, it is recommended to use this TASK for assembly and installation of the assembly.

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 item number.

For standard torque data and procedures, refer to the SPM TASK 70-41-00-400-501 and SPM TASK 70-41-02-400-501.

Special torque data is identified with the symbol * after the torque value.

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILSs, unless other lubricants are referred to in the procedure.

To identify, lubricate and install seal rings, refer to the SPM TASK 70-64-02-640-501.

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
Vernier depth gageLOCALVernier depth gage
Electric heat gunLOCALElectric heat gun

(Alternative to IAE 1J12505 Local heater 1 off)

IAE 1J12005 Leak test fixture0AM53IAE 1J120051
IAE 1J12024 Special wrench0AM53IAE 1J120241
IAE 1J12102 Blanking Rod0AM53IAE 1J121021
IAE 1J12105 Cantileer sling0AM53IAE 1J121051
IAE 1J12108 Sling adapter0AM53IAE 1J121081
IAE 1J12117 TBD0AM53IAE 1J121171
IAE 1J12118 Storage stand0AM53IAE 1J12118
IAE 1J12119 Extension adapter0AM53IAE 1J121191
IAE 1J12120 TBD0AM53IAE 1J121201
IAE 1J12182 Retaining protector0AM53IAE 1J12182
IAE 1J12326 Vertical sling0AM53IAE 1J123261
IAE 1J12470 Leak check fixture0AM53IAE 1J124701
IAE 1J12502 No.3 bearing guide0AM53IAE 1J125021
IAE 1J12504 Ring holder0AM53IAE 1J125041
IAE 1J12505 0AM53 heater0AM53IAE 1J125051

(Alternative to an electric heat gun)

IAE 1J12507 Guide pin0AM53IAE 1J125071
IAE 1J12508 Measuring stretch0AM53IAE 1J125081
IAE 1J12527 Setting master0AM53IAE 1J125271
IAE 1J12529 Measuring stretch0AM53IAE 1J125291
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P16046
IAE 1P16285 Tie-rod adapter0AM53IAE 1P16285
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P16543
IAE 1R18234 Support rod0AM53IAE 1R18234
IAE 6F10027 Heater control unit0AM53IAE 6F100271
IAE 6F10030 Vacuum test cart0AM53IAE 6F100301

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Sealing ring1
Sealing ring2
Packing1

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-00-430-370 Find the Condition of the No.3 Bearing, Internal Gearbox and Support Assembly (Internal Gearbox Assembly)

    1. Refer to Figure.

    2. If the internal gearbox assembly is not disassembled and returned to the initial module, selection of the HPC adjusting washer Gearbox Driving Bevel Gearshaft And Related Parts (72-32-26, 01-501 to Gearbox Driving Bevel Gearshaft And Related Parts 01-512) is not necessary. Go to Step.

    3. If the internal gearbox assembly is disassembled and the specified parts, which have effect on the HP compressor rotor location, are not replaced, selection of the new HPC adjusting washer Gearbox Driving Bevel Gearshaft And Related Parts (72-32-26, 01-501 to Gearbox Driving Bevel Gearshaft And Related Parts 01-512) is not necessary. Go to Step.

    4. If the internal gearbox assembly is disassembled and the specified parts are replaced, selection of the HPC adjusting washer Gearbox Driving Bevel Gearshaft And Related Parts (72-32-26, 01-501 to Gearbox Driving Bevel Gearshaft And Related Parts 01-512) is necessary. Go to Step.

      5. If the internal gearbox assembly is replaced, disassembly of the internal gearbox assembly and selection of the new HPC adjusting washer Gearbox Driving Bevel Gearshaft And Related Parts (72-32-26, 01-501 to Gearbox Driving Bevel Gearshaft And Related Parts 01-512) is necessary.

      1. Disassemble the internal gearbox assembly (72-32-10). Refer to TASK 72-32-10-040-001 (DISASSEMBLY).

      2. Disassemble the No. 3 bearing, rotor center and support assembly (72-32-20). Refer to TASK 72-32-20-040-001 (DISASSEMBLY).

      3. Go to Step.

    2. SUBTASK 72-32-00-430-371 Find the HPC Adjusting Washer (01-501 to-001-512)

    1. Refer to Figure, Figure, Figure, Figure and Figure.

      2. Prepare the No. 3 bearing seal seat No. 3 Bearing Rear Seal Assembly (72-32-25, 02-400) and the No. 3 bearing No. 3 Bearing (72-32-24, 01-100) for measurement of the axial dimensions.

      1. Put the guide (part of IAE 1J12529 Measuring stretch 1 off) on IAE 1J12504 Ring holder 1 off.

        2. Install the No. 3 bearing seal seat and the No. 3 bearing on IAE 1J12502 No.3 bearing guide No. 3 bearing guide 1 off.

        1. NOTE

          The inner race of the No. 3 bearing front half has the marking FRONT on the front face.

          Put the No. 3 bearing front inner race No. 3 Bearing (72-32-24, 01-100) on the guide. The No. 3 bearing is a matched part. The inner race front and rear halves, the cage and the outer race must all have the same serial number.

        2. Attach the No. 3 bearing guide to the guide.

        3. Install the ball and cage assembly of the No. 3 bearing into the No. 3 bearing outer race groove.

        4. NOTE

          Hold the ball and cage assembly together by hand when you move the No. 3 bearing, because the ball and cage assembly can release from the outer race.

          Lower slowly the No. 3 bearing along the No. 3 bearing guide and install on the front inner race.

        5. Remove the No. 3 bearing guide from the guide.

        6. Install the rear inner race No. 3 Bearing (72-32-24, 01-100) of the No. 3 bearing on the guide.

        7. Install the No. 3 bearing seal seat No. 3 Bearing Rear Seal Assembly (72-32-25, 02-400) on the guide.

        8. Attach the No. 3 bearing seal seat with the ring nut (part of IAE 1J12529 Measuring stretch). Tighten the ring nut.

      3. Turn IAE 1J12529 Measuring stretch, the No. 3 bearing and the No. 3 bearing seal seat and put them with the rear end down on the ring holder.

        4. Install the flange (part of IAE 1J12529 Measuring stretch ) on the No. 3 bearing outer race front face.

        1. Turn the swing C washer to open the center hole of the flange.

        2. Align the hole in the flange with the lift bolt (part of IAE 1J12529 Measuring stretch). Install the flange on the No. 3 bearing outer race front face.

        3. Loosen the lock nut and lift the plain washer (part of IAE 1J12529 Measuring stretch) along the lift bolt to make enough clearance for the swing C washer.

        4. Turn the swing C washer and insert it under the plain washer.

        5. Tighten the lock nut to attach the flange to the bearing face. Torque the lock nut to minimum 26.0 lbfin.

      5. Turn IAE 1J12529 Measuring stretch, the No. 3 bearing and the No. 3 bearing seal seat and put them with the front end down on the ring holder.

      3. Measure the dimensions A, C, D and G at four positions equally apart. Make sure that the difference between the maximum and the minimum of each dimension does not exceed 0.0012 in. (0.03 mm).

      1. Measure the dimension A and C (in millimeter) with the depth gage.

      2. Calculate the dimension B by the following formula.

        B = A - C.

      3. Measure the dimension D (in millimeter) from the No. 3 bearing outer race mating face to the No. 3 bearing seal support flange.

      4. Measure the dimension G (in millimeter) the No. 3 bearing seal support flange thickness.

    4. Find the mounting distance S (in millimeters) of the HPC front shaft and seal assembly. Refer to TASK 72-32-20-440-001-B00 (ASSEMBLY, CONFIG-002).

    5. Contact IAE to get the data of the dimension F (in millimeter). Dimension F from the fan frame rear flange to the fan frame mating face.

    6. Calculate the maximum and minimum limit of the adjusting washer thickness (in millimeter).

    7. Find the HPC adjusting washer whose thickness is in the limits E. Refer to TASK 72-32-20-440-001-B00 (ASSEMBLY, CONFIG-002).

    8. Remove the stretch (part of IAE 1J12508 Measuring stretch) and the measuring stretch (IAE 1J12529 Measuring stretch) and the ring holder from the No. 3 bearing and seal seat assembly.

    3. SUBTASK 72-32-00-430-372 Assemble the Internal Gearbox Assembly

    1. Assemble the No. 3 bearing, rotor center and support assembly. Refer to TASK 72-32-20-440-001-B00 (ASSEMBLY, CONFIG-002).

    2. Assemble the internal gearbox assembly. Refer to TASK 72-32-10-440-001-B00 (ASSEMBLY, CONFIG-002).

    4. SUBTASK 72-32-00-430-373 Prepare the Tools for Installation of the Internal Gearbox Assembly

    2. Install the three pins (part of IAE 1J12120 TBD 1 off) into the bushes of HP compressor front shaft.

      3. Assemble IAE 1J12105 Cantileer sling 1 off and IAE 1J12108 Sling adapter 1 off (sling assembly).

      1. Install sling adapter to cantilever sling with the pin (part of the cantilever sling).

      4. Adjust the center of gravity of the sling assembly.

      1. Turn the adjustment handle (part of the cantilever sling) to align the witness hole in the side plate (part of the cantilever sling) with S3-mark on the beam (part of the cantilever sling).

      2. Lock the adjustment handle in position.

    5. Lift the sling assembly.

    6. Adjust the two hoists to turn the sling assembly to horizontal position.

    7. Install IAE 1J12119 Extension adapter 1 off to the sling assembly with the bolts, washers and nuts.

      8. Adjust the center of gravity of the sling and the extension adapter assembly.

      1. Turn the adjustment handle (part of the cantilever sling) to align the witness hole in the side plate (part of the cantilever sling) with S8-mark on the beam (part of the cantilever sling).

      9. Install IAE 1J12326 Vertical sling 1 off to the internal gearbox assembly.

      1. Loosen the three nuts on the clamps (part of the vertical sling). Set the clamps not in locked position.

      2. Put the vertical sling on to the internal gearbox assembly.

      3. Set the clamps in locked position. Tighten the nuts on the clamps.

    10. Adjust the two hoists to turn the sling and the extension adapter assembly to vertical position.

    11. Install the extension adapter to the vertical sling with the bolts, washers and nuts.

    12. Remove the 20 bolts which attach the internal gearbox assembly to the work stand.

      13. Adjust the center of gravity of the sling assembly, the extension adapter, the vertical sling, the internal gearbox assembly.

      1. Turn the adjustment handle (part of the cantilever sling) to align the witness hole in the side plate (part of the cantilever sling) with S7-mark on the beam (part of the cantilever sling).

      2. Lock the adjustment handle in position.

    14. Lift the internal gearbox assembly until it is clear of the work stand.

    15. Adjust the two hoists to turn the tools and the internal gearbox assembly to horizontal position.

    16. Remove the hoist from the link (part of the sling adapter).

    17. Move the internal gearbox assembly to the position near to the fan frame assembly.

    5. SUBTASK 72-32-00-430-374 Install the Internal Gearbox Assembly in to the Fan Frame Assembly

      2. NOTE

        You can use an electric heat gun as alternative to the IAE J12505 heater 1 off. Refer to SPM TASK 70-46-04-400-501.

        Increase the temperature of the mounting flange on the fan frame assembly.

      1. Install IAE 1J12505 0AM53 heater to the mounting flange.

      2. Connect the cable of the local heater to IAE 6F10027 Heater control unit 1 off.

      3. Increase the temperature of the mounting flange to 194 deg F (90 deg C).

      4. WARNING

        USE APPROVED GLOVES WHEN YOU TOUCH THE LOCAL HEATER.

        Disconnect the cable of the local heater from the heater control and remove the local heater from the mounting flange.

    3. Install the seal ring LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-495) into the internal gearbox assembly.

    4. Lubricate the new "NO.3 BEARING,ROTOR CENTRE & SUPPORT ASSY (72-32-20, 01-100) packing 1 off with CoMat 10-077 APPROVED ENGINE OILS. Install the packing into the groove in the internal gearbox assembly.

    5. Install three aligning pins (part of IAE 1J12507 Guide pin 1 off) into three of the 14 holes for bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-480) of fan frame.

      6. Install the internal gearbox assembly into the fan frame assembly.

      1. Turn the HP compressor front shaft and align one of the four locating bolts with the correlation mark on the No.3 bearing support outer face which was written in TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003).

        2. Align the HP compressor front shaft with the HP compressor stage 3-8 disks.

        1. Align the four dowel pins of the HP compressor front shaft with the dowel holes in the HP compressor stage 3-8 disks.

        2. Make sure that the three guide pins (part of IAE 1J12120 TBD) in the HP compressor front shaft are aligned with the shank nut holes in the HP compressor stage 3-8 disks.

      3. Align the locating hole in the internal gearbox assembly with the locating pin on the fan frame assembly.

      4. Slowly move the internal gearbox assembly until it is installed on the mount flange of the fan frame assembly and the curvic teeth of the HP compressor Stage 3-8 disk assembly.

      5. Remove three guide pins from the bushes of the HP compressor front shaft.

      6. Remove the bolts, washers and nuts which attach the extension adapter to the vertical sling. Remove the extension adapter from the vertical sling.

        7. Remove the vertical sling from the internal gearbox assembly.

        1. Loosen the three nuts on the clamps. Set the clamps not in locked position.

        2. Remove the vertical sling.

        8. Adjust the center of the gravity of the sling assembly and extension adapter.

        1. Turn the adjustment handle (part of cantilever sling) to align the witness hole in the side plate (part of cantilever sling) with the S8-mark on the cantilever sling beam (part of cantilever sling).

        2. Lock the adjustment handle in position.

      9. Remove the bolts, washers and nuts which attach the extension adapter to the sling assembly. Remove the extension adapter from the sling assembly.

        10. Adjust the center of the gravity of the sling assembly.

        1. Turn the adjustment handle (part of cantilever sling) to align the witness hole in the side plate (part of cantilever sling) with the S3-mark on the cantilever sling beam (part of cantilever sling).

        2. Lock the adjustment handle in position.

      11. Remove the cantilever sling from the hoist and stow.

      12. Install an applicable cover sheet over the openings XX and YY of the No.6 strut to prevent foreign objects accidentally entering the strut.

        13. Attach the internal gearbox assembly to the fan frame assembly.

        1. Remove the three aligning pins (part of IAE 1J12507 Guide pin 1 off) from three of the 14 holes for bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-480) of fan frame.

        2. NOTE

          1. Use IAE 1J12024 Special wrench special wrench 1 off to tighten the three bolts at the holes Z.

          2. The two bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-350) that attach the oil filter housing are installed into the holes X in SUBTASK 72-32-00-430-375.

          Put the 14 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-480) into the holes of the mounting flange of the internal gearbox assembly, but not into holes X and Y. Tighten the bolts lightly.

        3. Install the NF C and NF D brackets LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-466 and LP Compressor (LPC) - Intermediate Structure Module 02-468) on to the mounting flange of the internal gearbox assembly with the four bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-472) at holes Y. Tighten the bolts lightly.

        4. NOTE

          Use the special wrench (IAE 1J12024 Special wrench) to torque the three bolts at holes Z.

          Torque the 18 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-480 and LP Compressor (LPC) - Intermediate Structure Module 02-472) to 180 to 220 lbfin (22.00 to 25.00 Nm) for the bolt torque sequence.

      14. Remove the tie-rod adapter (IAE 1P16285 Tie-rod adapter) from the install/removal fixture (IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture).

        NOTE

        The tie-rod adapter (IAE 1P16285 Tie-rod adapter) and the install/removal fixture (IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture) were installed in TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003).

      15. Torque the No.3 bearing rotor center and the HP compressor stage 3 disk curvic coupling bolts. Refer to TASK 72-00-40-420-002-B00 (INSTALLATION-002, CONFIG-002).

      16. Remove the cover sheet from the openings XX and YY of the No.6 strut.

    6. SUBTASK 72-32-00-220-154 Check the HP Turbine Running Distance to Make Sure of the Correct Calculation of the HPC Adjusting Washer

      NOTE

      If the internal gearbox assembly and the specified parts, which have effect on the HP compressor rotor location, are not replaced nor repaired, it is not necessary to do this SUBTASK. Refer to Step.

    1. NOTE

      The support rods (IAE 1R18234 Support rod) were installed in TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003).

      Remove the two (IAE 1R18234 Support rod) from the HP compressor. Refer to TASK 72-00-40-420-002-B00 (INSTALLATION-002, CONFIG-002).

    3. Install the LP compressor master bleed actuator LPC Bleed Master Actuator(75-31-42,01-100). Refer to TASK 72-00-40-420-006-B00 (INSTALLATION-006, CONFIG-002).

    4. Check the HP turbine assembly running distance. Refer to TASK 72-00-45-420-001-B01 (INSTALLATION-001, CONFIG-002).

    5. Make sure that the distance is within the limits.

    6. If the distance is not within the limits, the thickness of the HPC adjusting washer, must be changed.

    7. SUBTASK 72-32-00-430-375 Connect the NF Electrical Harness and Install the No. 2 and No. 3 Bearing Oil Feed Tube

    1. Install the No. 2 and the No. 3 bearing oil feed tubes. Refer to TASK 72-32-00-430-004 (ASSEMBLY-004).

    2. Connect the eight harness terminals to the mounting pins on the fan speed probes and the trim balance probe. Refer to TASK 72-32-00-430-004 (ASSEMBLY-004).

    8. SUBTASK 72-32-00-430-376 Install the LPC Stub Shaft and No. 1 Bearing Support Assembly to the Fan Frame Assembly (Pre SBE 72-0391 and SBE 72-0391)

    1. SBE 72-0391: New separate type No. 1 bearing support assembly

    3. NOTE

      The retaining protector (IAE 1J12182 Retaining protector) was installed in TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003).

      Remove the retaining protector (IAE 1J12182 Retaining protector) from the LPC stub shaft.

    4. Attach a hoist to the link (part of the sling adapter).

    5. Adjust the two hoists to turn the sling assembly to the vertical position.

      6. Install the LPC stub shaft and No. 1 bearing support assembly to the fan frame assembly.

      1. Attach the sling adapter to the front flange of the LPC stub shaft and No. 1 bearing support assembly with the six bolts and washers (part of the sling adapter). Tighten the bolts.

      2. NOTE

        The storage stand (IAE 1J12118 Storage stand) was installed in TASK 72-32-00-030-013-C00 (DISASSEMBLY-013, CONFIG-003).

        Remove the eight screws and washers (part of IAE 1J12118 Storage stand storage stand) which attach the LPC stub shaft and No.1 bearing support assembly to the storage stand.

      3. Slowly lift the LPC stub shaft and No. 1 bearing support assembly until it is clear of the storage stand.

      4. Adjust the two hoists to turn the sling assembly and the LPC stub shaft and No. 1 bearing support assembly to horizontal position. Remove the hoist from the link (part of the sling adapter).

        5. Adjust the center of the gravity of the sling assembly and LPC stub shaft and No. 1 bearing support assembly.

        1. Turn the adjustment handle (part of cantilever sling) to align the witness hole in the side plate (part of cantilever sling) with the S5-mark on the cantilever sling beam (part of cantilever sling).

      6. Lubricate the new LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-188) sealing ring 1 off with engine oil. Install the ring into the groove in the No.1 bearing support.

      7. Lubricate the new LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-190) sealing rings 2 off with engine oil. Install them on the oil feed tube in the No. 1 bearing support assembly.

      8. Increase the temperature of the mounting flange of the fan frame assembly to 212 deg F (100 deg C) maximum with a hot air gun.

      9. Install the three aligning pins (part of IAE 1J12507 Guide pin aligning pin set 1 off) into three of the 42 threaded holes in the mounting flange. The three aligning pins must be installed at approximately 120 degrees apart from each other.

        10. Install the LP shaft and the No. 1 bearing support assembly to the fan frame assembly.

        1. CAUTION

          THE OIL FEED TUBE AND HOLE C IN THE SUB OIL DISTRIBUTOR MUST BE ALIGNED. OIL CAN NOT BE SUPPLIED TO THE NO. 1 BEARING IF THEY ARE NOT ALIGNED.

          Move the LP shaft and the No. 1 bearing support assembly adjacent to the mounting flange.

        2. Align the 42 bolt holes in the No. 1 bearing support rear flange with the three aligning pins and the 39 threaded holes in the mounting flange.

        3. Install the oil feed tube to the bracket with the bolt ENGINE-NO.1 BEARING SUPPORT ASSEMBLY (72-32-40, 01-230), clip ENGINE-NO.1 BEARING SUPPORT ASSEMBLY (72-32-40, 01-180) and clip ENGINE-NO.1 BEARING SUPPORT ASSEMBLY (72-32-40, 01-200).

        4. Make sure that the oil feed tube of the No. 1 bearing support assembly and the hole C in the sub oil distributor on the fan frame are aligned.

        5. Move the LP shaft and the No. 1 bearing support assembly on to the fan frame assembly.

          6. Make sure that the oil feed tube is installed in hole C.

          1. Try to rotate slightly clockwise and counterclockwise the No. 1 bearing support assembly and make sure that you can not rotate the assembly.

      11. Remove the three aligning pins from the threaded holes in the mounting flange.

      12. NOTE

        You must identify the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187) and the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182) by their length. The bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187) is longer than the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182).

        Pre SBE 72-0391: Attach the No. 1 bearing support assembly with the 18 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187) and 24 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182). Torque the bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182 and LP Compressor (LPC) - Intermediate Structure Module 02-187) to 180 to 220 lbfin (20.00 to 25.00 Nm).

      13. NOTE

        You must identify the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187) and the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182) by their length. The bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187) is longer than the bolt LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182).

        SBE 72-0391: Attach the No. 1 bearing support assembly with the 18 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-187), 24 bolts LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-182) and 42 washers LP Compressor (LPC) - Intermediate Structure Module (72-32-00, 02-181). Torque the bolts to 180 to 220 lbfin (20.00 to 25.00 Nm).

      14. Remove the IAE 1J12105 Cantileer sling and the IAE 1J12108 Sling adapter from the front flange of the LPC stub shaft.

    7. Do an air flow check for the oil feed tubes of the front bearing compartment. Refer to TASK 72-32-00-430-005 (ASSEMBLY-005).

    9. SUBTASK 72-32-00-430-377 Engage the Hydraulic Seal Assembly with the LPC Stub Shaft

    1. Engage the hydraulic seal assembly with the LPC stub shaft. Refer to TASK 72-32-00-430-006 (ASSEMBLY-006).

    2. Make sure that the hydraulic seal assembly and the hydraulic ring are in the correct locations. Refer to TASK 72-32-00-430-006 (ASSEMBLY-006).

    10. SUBTASK 72-32-00-430-378 Install the No. 1 Bearing Compartment Scavenge Oil Tube

    1. Install the No. 1 bearing compartment scavenge oil tube. Refer to TASK 72-32-00-430-007-C00 (ASSEMBLY-007, CONFIG-003).

    11. SUBTASK 72-32-00-430-379 Replace the Center Bearing Adjusting Washer as Necessary

    1. Refer to Figure.

      2. Make sure that the following parts are not replaced.

      1. Gearshaft bearing housing Gearbox Driven Gearshaft And Housing Assembly (72-32-16, 01-150).

      2. No. 2 bearing support No. 2 Bearing Support And Related Parts (72-32-17, 01-850).

      3. No. 3 bearing seal support ENGINE-NO.3 BEARING SEAL SUPPORT (72-32-22, 01-040).

    3. If the parts shown in step B. are not replaced, use the initial adjusting washer. Go to Step.

      4. If one or more parts are replaced, do a check for location of the center bearing. Replace the adjusting washer as necessary.

      1. Remove the external gearbox module. Refer to TASK 72-00-60-020-003-001 (REMOVAL-003).

      2. Use IAE 1J12527 Setting master 1 off to make sure that the center bearing is in the correct location. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

      3. NOTE

        If the center bearing is in the correct location, use the initial adjusting washer.

        If the center bearing is not in the correct location, replace the existing adjusting washer with the found adjusting washer. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

    5. Install the external gearbox module. Refer to TASK 72-00-60-420-001-001 (INSTALLATION-001).

    12. SUBTASK 72-32-00-790-055 Prepare for Evacuation Check

    1. Refer to Figure and Figure.

      2. Install IAE 1J12102 Blanking Rod 1 off in the PTO oil seal tube.

      1. Remove the three nut Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-070) and washers Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-075) which attach the plug Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-060) to the radial gear support. Refer to TASK 72-60-40-040-001 (DISASSEMBLY).

      2. Remove the plug. Refer to TASK 72-60-40-040-001 (DISASSEMBLY).

      3. Lubricate the two o-rings (part of the blanking rod) with CoMat 10-077 APPROVED ENGINE OILS.

      4. Install the o-rings into the groove in the blanking rod.

      5. Install the blanking rod into PTO oil seal tube through the angle gearbox with the removed three nuts Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-070).

      3. Install the plug D (part of IAE 1J12470 Leak check fixture 1 off) on the No. 1, 2 and 3 bearing scavenge tube flange in No. 6 strut.

      1. Remove the No. 1, 2 and 3 bearing compartment scavenge tube assembly (Tubes 107 and 108). Refer to TASK 72-00-60-020-002-B00 (REMOVAL-002, CONFIG-002).

      2. Install the plug D on the scavenge tube. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

    4. Remove the oil tube cover and install the plug A (part of the leak check fixture 1 off) on to the oil feed adapter in the No. 4 strut. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

      1. Turn the coupling nut (part of the leak test fixture) counterclockwise and remove it from the cylinder (part of IAE 1J12005 Leak test fixture).

      2. Insert IAE 1J12005 Leak test fixture in the LPC stub shaft from the front side.

      3. Attach the guide (part of the leak test fixture) to the front flange on the LPC stub shaft through the cylinder.

      4. Insert the guide pin (part of the leak test fixture) into the hole of the guide.

      5. Adjust the angle of the guide to put the guide pin and the dowel pin (part of the leak test fixture) between the area A of the LP stub shaft front flange.

      6. Tighten the coupling nut to the guide.

    13. SUBTASK 72-32-00-790-056 Do a Evacuation Check for Leaks

    1. Refer to Figure.

    2. Disconnect the tube 169 from the hot vent tube. Refer to TASK 72-00-32-020-003 (REMOVAL-003).

    3. Install the joint (part of IAE 1J12470 Leak check fixture 1 off) on to the hot vent tube. Attach the adapter (part of IAE 6F10030 Vacuum test cart 1 off) to on joint on hot vent tube. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

    4. Connect IAE 6F10030 Vacuum test cart 1 off to the electrical power. Refer to TASK 72-32-00-430-011-B00 (ASSEMBLY-011, CONFIG-002).

    5. Connect IAE 1J12005 Leak test fixture to shop air supply source.

    6. Inflate the ballon (part of IAE 1J12005 Leak test fixture) to the pressure between 7.0 (48.0 kPa) and 7.5 psig (52.0 kPa).

    7. Operate IAE 6F10030 Vacuum test cart. Set the air pressure at the test port (part of vacuum test cart) at -20 in.Hg gage (-508 mmHg).

    8. Read the value of airflow indicated by flowmeter.

    9. Make sure that the indication is not more than 13 PPH (5.89 Kg per hour).

    10. Stop operation of vacuum pump.

    14. SUBTASK 72-32-00-790-057 Remove the Special Tools for Evacuation Check

    1. Refer to Figure and Figure.

    4. Remove the blanking tools and back to the engine configuration prior to the evacuation check.

    15. SUBTASK 72-32-00-430-380 Install the Quill Shaft in the Fan Frame Strut Through the Gearbox Module

    1. Refer to Figure.

      2. NOTE

        The shaft has spline teeth at two ends of the shaft. The end, which has 24 spline teeth, must be installed in to the oil seal tube. The end, which has 28 spline teeth and four scallops, must be out of the oil seal tube.

        Install the quill shaft ENGINE-PTO SHAFT (72-32-95, 01-100) into the oil seal tube through the gearbox module.

      1. Lubricate the outer faces and spline teeth on the shaft with CoMat 10-077 APPROVED ENGINE OILS.

      2. Install the collet (part of IAE 1J12117 TBD 1 off) and the rod (part of the quill shaft puller/pusher) into the end, which has 28 spline teeth and four scallops, of the shaft.

      3. Turn clockwise the knob (part of the quill shaft puller/pusher) to expand the end of the collet in the depression of the shaft.

      4. NOTE

        The shaft moves lightly before it touches the sealing ring Gearbox Driven Gearshaft And Housing Assembly (72-32-16, 01-100). When the shaft touches the ring , the movement of the shaft becomes hard.

        Insert the shaft, collet and rod through the angle gear box slowly to prevent the damage to the bearing ENGINE-PTO DRIVE SHAFT BEARING AND SUPPORT (72-32-05, 01-250) in the center bearing housing ENGINE-PTO DRIVE SHAFT BEARING AND SUPPORT (72-32-05, 01-300).

      5. Engage the spline of the shaft with the spline of the bevel shaft gear Gearbox Driven Gearshaft And Housing Assembly (72-32-16, 01-750).

      6. Turn counterclockwise the hand knob to return the end of the collet to the original shape before expansion.

      7. Remove the rod and collet through the angle gear box from the quill shaft.

      3. Install the plug Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-060), the oil duct Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-130) and the coupling shaft Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-210).

      1. Install the coupling shaft and the oil duct in to the internal of the radial gearshaft. Refer to TASK 72-60-40-440-001 (ASSEMBLY-001).

      2. Install the nut Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-120) which attach the oil duct to the radial gearshaft. Refer to TASK 72-60-40-440-001 (ASSEMBLY).

      3. Install the lock washer Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-110) and the segment Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-100) to lock the nut. Refer to TASK 72-60-40-440-001 (ASSEMBLY).

      4. Install the oil nozzle Angle Gearbox Assembly (72-60-40, 01-400) and the plug Angle Gearbox Driving Gearshaft Assembly (72-60-42, 01-060) to the angle gearbox. Refer to TASK 72-60-40-440-001 (ASSEMBLY).

    16. SUBTASK 72-32-00-430-381 Install the LP Turbine Module

    1. Install the LP turbine module to the engine. Refer to TASK 72-00-50-420-001-C00 (INSTALLATION-001, CONFIG-003).

    2. Install the LP turbine module components, external harnesses and tubes to the engine. Refer to TASK 72-00-50-420-005-B00 (INSTALLATION-005, CONFIG-002).

    17. SUBTASK 72-32-00-430-382 Install the LPC Booster Stage Assembly (Booster Assembly)

    1. Install the LPC booster stage assembly. Refer to TASK 72-32-00-430-010-D00 (ASSEMBLY-010, CONFIG-004).

    18. Figure: Sectional View of the No. 3 Bearing, Internal Gearbox and Support Assembly

    Sectional View of the No. 3 Bearing, Internal Gearbox and Support Assembly

    Figure: Set up the Measuring Stretch and the No. 3 Bearing Seal Seat and the No. 3 Bearing for Finding the HPC Adjusting Washer

    Sheet 1

    Legend
    Set up the Measuring Stretch and the No. 3 Bearing Seal Seat and the No. 3 Bearing for Finding the HPC Adjusting Washer

    Sheet 1

    Close

    Figure: Install the No. 3 Bearing Seal Seat and the No. 3 Bearing on the No. 3 Bearing Guide

    Sheet 2

    Legend
    Install the No. 3 Bearing Seal Seat and the No. 3 Bearing on the No. 3 Bearing Guide

    Sheet 2

    Close

    Figure: Install the Flange on the No. 3 Bearing Outer Race Front Face

    Sheet 3

    Legend
    Install the Flange on the No. 3 Bearing Outer Race Front Face

    Sheet 3

    Close

    Figure: Measure the Dimensions at the Positions Equally Apart

    Sheet 4

    Legend
    Measure the Dimensions at the Positions Equally Apart

    Sheet 4

    Close

    Figure: Find the HPC Adjusting Washer

    Find the HPC Adjusting Washer

    Figure: Install the Guide Pin into the Bushes of HPC Front Shaft

    Install the Guide Pin into the Bushes of HPC Front Shaft

    Figure: Assemble Cantilever Sling and Sling Adapter

    Assemble Cantilever Sling and Sling Adapter

    Figure: Adjust the Two Hoists to Turn the Sling Assembly to Horizontal Position

    Adjust the Two Hoists to Turn the Sling Assembly to Horizontal Position

    Figure: Install the Extension Adapter to the Sling Assembly

    Install the Extension Adapter to the Sling Assembly

    Figure: Install the Vertical Sling to the No.3 Bearing, Internal Gearbox and Support Assembly

    Install the Vertical Sling to the No.3 Bearing, Internal Gearbox and Support Assembly

    Figure: Adjust the Two Hoists to Turn the Sling Assembly and the Extension Adapter to Vertical Position

    Adjust the Two Hoists to Turn the Sling Assembly and the Extension Adapter to Vertical Position

    Figure: Install the Extension Adapter to the Vertical Sling

    Install the Extension Adapter to the Vertical Sling

    Figure: Adjust the Two Hoists to Turn the Tools and the No.3 Bearing, Internal Gearbox and Support Assembly to Horizontal Position

    Adjust the Two Hoists to Turn the Tools and the No.3 Bearing, Internal Gearbox and Support Assembly to Horizontal Position

    Figure: Install the Local Heater to Mount Flange on the Fan Frame Assembly

    Install the Local Heater to Mount Flange on the Fan Frame Assembly

    Figure: Install the No.3 Bearing, Internal Gearbox and Support Assembly into the Fan Frame Assembly

    Install the No.3 Bearing, Internal Gearbox and Support Assembly into the Fan Frame Assembly

    Figure: Remove the Extension Adapter from the Vertical Sling

    Remove the Extension Adapter from the Vertical Sling

    Figure: Remove the Vertical Sling from the No.3 Bearing, Internal Gearbox and Support Assembly

    Remove the Vertical Sling from the No.3 Bearing, Internal Gearbox and Support Assembly

    Figure: Install an Applicable Cover Sheet over the Openings XX and YY of the No.6 Strut

    Install an Applicable Cover Sheet over the Openings XX and YY of the No.6 Strut

    Figure: Attach the Support Assembly to the Fan Frame Assembly

    Attach the Support Assembly to the Fan Frame Assembly

    Figure: Remove the Retaining Protector from the LPC Stub Shaft

    Remove the Retaining Protector from the LPC Stub Shaft

    Figure: Attach the Sling Adapter to the Front Flange of the LPC Stub Shaft and No.1 Bearing Support Assembly

    Sheet 1

    Legend
    Attach the Sling Adapter to the Front Flange of the LPC Stub Shaft and No.1 Bearing Support Assembly

    Sheet 1

    Close

    Figure: Attach the Sling Adapter to the Front Flange of the LPC Stub Shaft and No.1 Bearing Support Assembly

    Sheet 2

    Legend
    Attach the Sling Adapter to the Front Flange of the LPC Stub Shaft and No.1 Bearing Support Assembly

    Sheet 2

    Close

    Figure: Adjust the Two Hoists to Turn the Sling Assembly and the LPC Stub Shaft and No.1 Bearing Support Assembly to Horizontal Position

    Adjust the Two Hoists to Turn the Sling Assembly and the LPC Stub Shaft and No.1 Bearing Support Assembly to Horizontal Position

    Figure: Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 1

    Legend
    Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 1

    Close

    Figure: Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 2

    Legend
    Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 2

    Close

    Figure: Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 3

    Legend
    Install the LP Shaft and the No.1 Bearing Support Assembly to the Fan Frame Assembly

    Sheet 3

    Close

    Figure: Install the Oil Feed Tube on to the No.1 Bearing Support

    Install the Oil Feed Tube on to the No.1 Bearing Support

    Figure: Parts which have Effect on Location of the Center Bearing

    Parts which have Effect on Location of the Center Bearing

    Figure: Install the Blanking Rod in the PTO Oil Seal Tube

    Install the Blanking Rod in the PTO Oil Seal Tube

    Figure: Leak Test Fixture

    Leak Test Fixture

    Figure: Install the Quill Shaft into the Fan Frame Strut

    Install the Quill Shaft into the Fan Frame Strut

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add IAE 1P16543 as an option to IAE 1P16046. (14VC396)

Link not Found
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
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:LOCAL
Tool Number:Electric heat gun
Tool Name:Electric heat gun
Manufacturer Code:0AM53
Tool Number:IAE 1J12005
Tool Name:IAE 1J12005 Leak test fixture
Manufacturer Code:0AM53
Tool Number:IAE 1J12024
Tool Name:IAE 1J12024 Special wrench
Manufacturer Code:0AM53
Tool Number:IAE 1J12102
Tool Name:IAE 1J12102 Blanking Rod
Manufacturer Code:0AM53
Tool Number:IAE 1J12105
Tool Name:IAE 1J12105 Cantileer sling
Manufacturer Code:0AM53
Tool Number:IAE 1J12108
Tool Name:IAE 1J12108 Sling adapter
Manufacturer Code:0AM53
Tool Number:IAE 1J12117
Tool Name:IAE 1J12117 TBD
Manufacturer Code:0AM53
Tool Number:IAE 1J12118
Tool Name:IAE 1J12118 Storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1J12119
Tool Name:IAE 1J12119 Extension adapter
Manufacturer Code:0AM53
Tool Number:IAE 1J12120
Tool Name:IAE 1J12120 TBD
Manufacturer Code:0AM53
Tool Number:IAE 1J12182
Tool Name:IAE 1J12182 Retaining protector
Manufacturer Code:0AM53
Tool Number:IAE 1J12326
Tool Name:IAE 1J12326 Vertical sling
Manufacturer Code:0AM53
Tool Number:IAE 1J12470
Tool Name:IAE 1J12470 Leak check fixture
Manufacturer Code:0AM53
Tool Number:IAE 1J12502
Tool Name:IAE 1J12502 No.3 bearing guide
Manufacturer Code:0AM53
Tool Number:IAE 1J12504
Tool Name:IAE 1J12504 Ring holder
Manufacturer Code:0AM53
Tool Number:IAE 1J12505
Tool Name:IAE 1J12505 0AM53 heater
Manufacturer Code:0AM53
Tool Number:IAE 1J12507
Tool Name:IAE 1J12507 Guide pin
Manufacturer Code:0AM53
Tool Number:IAE 1J12508
Tool Name:IAE 1J12508 Measuring stretch
Manufacturer Code:0AM53
Tool Number:IAE 1J12527
Tool Name:IAE 1J12527 Setting master
Manufacturer Code:0AM53
Tool Number:IAE 1J12529
Tool Name:IAE 1J12529 Measuring stretch
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16285
Tool Name:IAE 1P16285 Tie-rod adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18234
Tool Name:IAE 1R18234 Support rod
Manufacturer Code:0AM53
Tool Number:IAE 6F10027
Tool Name:IAE 6F10027 Heater control unit
Manufacturer Code:0AM53
Tool Number:IAE 6F10030
Tool Name:IAE 6F10030 Vacuum test cart
Manufacturer Code:LOCAL
Tool Number:Vernier depth gage
Tool Name:Vernier depth gage