Preliminary Requirements

Procedure

1. SUBTASK 72-41-00-440-257 Install the HP Front Split Cases

   1. Refer to Figure and Figure.

   2. NOTE

      The retaining clamp plate assembly will need to be released and moved clear of the jacking screws if the axial settings need to be adjusted.

      Loosen the locknut on the heel pin (detail 15). Release the hand knob (detail 22) and move the retaining clamp plate assembly clear of the three jacking screws (detail 12).

   3. If necessary loosen the locknut on the tie-rod adapter (installed through the center of the HP module) by approximately 0.40 in. (10.0 mm) to let axial movement of the static and rotating parts.

   4. Position the six dial test indicators or equivalent instrumentation measuring devices as follows.

      1. NOTE

         This instrumentation will monitor the relative movement of the HP static components and the stand.

         Put three dial test indicators, equally spaced, on the surface of the stand top plate (detail 3) so each dial indicator button contacts each of the three support plates (detail 4).

      2. NOTE

         This instrumentation will monitor the true relative movement of the HP rotating components and the static components. This is the critical dimension to be monitored.

         Put three dial test indicators, spaced equally, on the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture tooling structure so each dial indicator button contacts the rear surface of the stage 2 retaining plate slot on the stage 2 turbine hub ENGINE-STAGE 2 TURBINE HUB (72-45-31,01-011).

   5. Confirm the true axial displacement of the HP module cases and stage 2 HP turbine and the IAE 1R19463 Stand - Surgical strike Surgical Strike Stand 1 off.

      1. Refer to the record of the readings taken at the six positions with the front half casings removed, refer to TASK 72-41-00-040-001-D00.

      2. Take the readings on the three dial test indicators in contact with each of the three support plates (detail 4). These readings should be the same as the final readings taken during TASK 72-41-00-040-001-D00.

      3. NOTE

         This is to make sure that the relative reverse movement during installation is the same as that recorded during the removal of the cases.

         Take the readings on the three dial test indicators in contact with the rear surface of the stage 2 retaining plate slot on the stage 2 turbine hub ENGINE-STAGE 2 TURBINE HUB (72-45-31,01-011). These readings should be the same as the final readings taken during TASK 72-41-00-040-001-D00. These readings must not be more than 0.020 in. (0.50 mm) of the readings taken at the three support plates.

   6. Install the HP compressor front split half casings as given in Step at the same time as the procedure in this SUBTASK.

      1. 

         CAUTION

         THESE READINGS ARE THE MAXIMUM PERMITTED TOTAL MOVEMENT TO RETURN TO THE DATUM POSITION. YOU MUST NOT EXCEED THESE READINGS OR DAMAGE TO ENGINE COMPONENTS WILL OCCUR.

         Make sure the dial test indicator readings agree with the final readings taken in TASK 72-41-00-040-001-D00.

      2. 

         CAUTION

         DO NOT USE TOO MUCH FORCE THAN IS NECESSARY DURING THE REMOVAL AND INSTALLATION OF THE HP COMPRESSOR FRONT HALF CASES. TOO MUCH FORCE CAN DAMAGE THE HP COMPRESSOR ROTOR BLADES.

         Support the split casings on detail 10 half rings. Move the cases carefully into position on detail 10 and then install and fully locate the split casings around the HP compressor assembly. Make sure that the casings do not touch and damage the HP compressor rotor blades.

      3. 

         CAUTION

         THERE MUST NOT BE A DIFFERENCE OF MORE THAN 0.020 IN. (0.50 MM) BETWEEN THE READINGS OF EACH OF THE DIAL TEST INDICATORS. IF THE DIFFERENCE IS MORE THAN THIS LIMIT THEN DAMAGE MAY OCCUR TO HP MODULE COMPONENTS.

         

         CAUTION

         YOU MUST MAKE A RECORD OF THE DIAL TEST INDICATOR READINGS AFTER EACH INCREMENTAL MOVEMENT MADE.

         Refer to the readings taken in TASK 72-41-00-040-001-D00. During installation use the readings in a series of incremental steps to reverse and match those taken during the Disassembly procedure.

      4. Adjust the three jacking screws (detail 12) to make adjustments to the axial movement of the static components relative to the rotating components. Turn the jacking screws in an anti-clockwise direction to move the HP compressor rear cases forward (the rear cases move in a direction towards the base of the build stand). Make each adjustment so each of the dial test indicator readings are no more than 0.020 in. (0.50 mm) for each increment adjustment.

      5. Make sure that readings do not differ by more than 0.020 in. (0.50 mm) between dial test indicators. This is to make sure that the axial movement is adjusted evenly and equally and is the same as that recorded during Disassembly.

      6. The readings at stage 2 HP turbine position is the critical dimension to be monitored and represents the true axial movement between the static and rotating assemblies. The final reading must agree with that taken during Disassembly to make sure that the original axial displacement is correctly restored.

      7. Remove the instrumentation.

      8. Move the retaining clamp plate assembly into position to make contact with the three jacking screws (detail 12). Adjust and tighten the locknut on the heel pin (detail 15) but do not fully torque the lock nut. Tighten the hand knob (detail 22) to hold the assembly firmly.

      9. Tighten the locknut on the tie-rod adapter (installed through the center of the HP module) to prevent the axial movement of the static and rotating parts.

2. SUBTASK 72-41-00-440-258 Install the HP Compressor Front Cases

   1. Refer to Figure and Figure.

   2. Do this assembly procedure in conjunction with Step.

   3. Install the stage 4, 5 and 6 sealing strips.

      1. Install the two sealing strips HP COMPRESSOR SPLIT CASE (72-41-31,01-678) at the stage 4 rotor path ring HP COMPRESSOR SPLIT CASE (72-41-31,01-690). Install the sealing strips at the opposite split line flanges.

      2. Install the two sealing strips HP COMPRESSOR SPLIT CASE (72-41-31,01-679) at the stage 5 rotor path ring HP COMPRESSOR SPLIT CASE (72-41-31,01-695). Install the sealing strips at the opposite split line flanges.

      3. Install the two sealing strips HP COMPRESSOR SPLIT CASE (72-41-31,01-680) at the stage 6 rotor path ring HP COMPRESSOR SPLIT CASE (72-41-31,01-705). Install the sealing strips at the opposite split line flanges.

   4. Install the upper and lower half HP compressor front case HP COMPRESSOR SPLIT CASE (72-41-31,01-400).

      1. Carefully put the upper and lower half HP compressor front cases on to the build stand.

      2. Align the dowel pin holes in the HP compressor front cases rear flange with the correct holes in the compressor rear outer case.

      3. The pin holes at TDC and BDC are off set.

      4. Align the split line flanges. Make sure the stage 4, 5 and 6 sealing strips are correctly engaged in the opposite rotor path ring segment.

   5. Make sure that the procedure to confirm the axial movement of the static and rotating parts as given in Step is completed before the front case split line bolts are installed.

   6. 
      CAUTION
      THE BOLTS ARE A CLOSE TOLERANCE FIT. THEY MUST NOT BE TURNED WHEN BEING INSTALLED. IF YOU DO NOT DO THIS, IT WILL DAMAGE THE HP COMPRESSOR FRONT CASE SPLIT LINE FLANGE.

      Install the HP compressor front case split line flange bolts, spacers and nuts.

      1. NOTE

         Do not install bolts, nuts and spacers at the bolt positions 11 and 31.

         Install the 30 bolts HPC Assembly (72-41-00,01-108) the 30 spacers HPC Assembly (72-41-00,01-104) and the 30 nuts HPC Assembly (72-41-00,01-102) at the split line flanges.

      2. At the bolt positions 11 and 31 install the upper and lower support brackets HPC Assembly (72-41-00,04-600) and HPC Assembly (72-41-00,04-650).

         1. Install the two bolts HPC Assembly (72-41-00,01-112) through the upper and lower support brackets and the split line flange.

         2. Install the two nuts HPC Assembly (72-41-00,01-101) on to the bolts.

      3. NOTE

         Do not install bolts, nuts and spacers at the bolt positions 27, 23, 29 and 31.

         Torque the nuts in sequence to 180 to 220 lbfin (20.00 to 25.00 Nm).

      4. At the bolt positions 27, 23, 29 and 31 install the upper and lower support brackets HPC Assembly (72-41-00,04-600), HPC Assembly (72-41-00,04-650), HPC Assembly (72-41-00,04-620) and HPC Assembly (72-41-00,04-670).

         1. Install the four bolts HPC Assembly (72-41-00,01-112) through the upper and lower support brackets and the split line flange.

         2. Install the four nuts HPC Assembly (72-41-00,01-101) on to the bolts.

      5. Torque the nuts in sequence to 180 to 220 lbfin (20.00 to 25.00 Nm).

3. SUBTASK 72-41-00-440-259 Install the HP Compressor Front Case Rear Flange Attach Parts

   1. Refer to Figure and Figure.

   2. Install the 10 pins HPC Assembly (72-41-00,01-322) and the 10 lock plates HPC Assembly (72-41-00,01-320) together with 10 bolts HPC Assembly (72-41-00,01-308) and the 10 nuts HPC Assembly (72-41-00,01-302). Lightly tighten the nuts at the positions B.

   3. Install the bracket HPC Assembly (72-41-00,03-780).

      1. Put the bracket into position on the HP compressor front case rear flange at the bolt positions 3 and 4.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   4. Install the bracket HPC Assembly (72-41-00,03-240).

      1. Put the bracket into position on the compressor rear outer case front flange at the bolt positions 5 and 6.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   5. Install the bracket HPC Assembly (72-41-00,03-260).

      1. Put the bracket into position on the compressor rear outer case front flange at the bolt positions 7 and 8.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   6. Install the bracket HPC Assembly (72-41-00,03-320).

      1. Put the bracket into position on the HP compressor front case rear flange at the bolt positions 16 and 17.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   7. Install the bracket HPC Assembly (72-41-00,03-380).

      1. Install the actuator rear bracket HPC Assembly (72-41-00,03-380) into position on the HP compressor front case rear flange at the bolt positions 21 and 22.

      2. Install the bolt HPC Assembly (72-41-00,01-314) and the nut HPC Assembly (72-41-00,01-302) at the position 22 to attach the bracket HPC Assembly (72-41-00,03-380) and the bracket HPC Assembly (72-41-00,03-350) to the flange.

      3. Install the bolt HPC Assembly (72-41-00,01-308) and the nut HPC Assembly (72-41-00,01-302) at the position 23.

      4. Lightly tighten the nuts.

   8. Install the bracket HPC Assembly (72-41-00,03-360).

      1. Put the bracket into position on the compressor rear outer case front flange at the bolt positions 25 and 26.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   9. Install the bracket HPC Assembly (72-41-00,03-510).

      1. Put the bracket into position on the compressor rear outer case front flange at the bolt position 30 and 31.

      2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

      3. Lightly tighten the two nuts.

   10. Install the bracket HPC Assembly (72-41-00,03-530).

       1. Put the bracket into position on the HP compressor front case rear flange at the bolt positions 35 and 36.

       2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

       3. Lightly tighten the two nuts.

   11. Install the bracket HPC Assembly (72-41-00,03-550).

       1. Put the bracket into position on the HP compressor front case rear flange at the bolt positions 38 and 39.

       2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

       3. Lightly tighten the two nuts.

   12. Install the bracket HPC Assembly (72-41-00,03-720).

       1. Put the bracket into position on the compressor rear outer case front flange at the bolt holes 43 and 44.

       2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

       3. Lightly tighten the two nuts.

   13. Install the bracket HPC Assembly (72-41-00,03-760).

       1. Put the bracket into position on the compressor rear outer case front flange at the bolt holes 45 and 46. Bracket HPC Assembly (72-41-00,03-760).

       2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the brackets to the flange.

       3. Lightly tighten the two nuts.

   14. Install the bracket HPC Assembly (72-41-00,03-770).

       1. Put the bracket into position on the compressor rear outer case front flange at the bolt holes 52 and 53.

       2. Install the two bolts HPC Assembly (72-41-00,01-314) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

       3. Lightly tighten the two nuts.

   15. Install the bracket HPC Assembly (72-41-00,03-790).

       1. Put the bracket into position on the compressor rear outer case front flange at the bolt holes 54 and 1.

       2. Install the two bolts HPC Assembly (72-41-00,01-308) and the two nuts HPC Assembly (72-41-00,01-302) to attach the bracket to the flange.

       3. Lightly tighten the two nuts.

   16. Install the remaining bolts HPC Assembly (72-41-00,01-308) and the nuts HPC Assembly (72-41-00,01-302) at the remaining bolt holes.

   17. Torque the 54 nuts to 180 to 220 lbfin (20.00 to 25.00 Nm).

4. SUBTASK 72-41-00-440-260 Install the Variable Inlet Guide Vane Bridging Pieces

   1. Refer to Figure and Figure.

   2. Install the variable inlet guide vane bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,02-200) and HPC Variable Stator Vane Actuation System (72-41-34,02-201)).

      1. Remove the four bolts HPC Variable Stator Vane Actuation System (72-41-34,02-102) and the four actuating levers HPC Variable Stator Vane Actuation System (72-41-34,02-100) from the inlet guide vanes at the positions 1, 2, 39 and 40.

      2. Put the left hand bridging pieces into position on the upper and lower actuating rings.

      3. Install the four bolts HPC Variable Stator Vane Actuation System (72-41-34,02-202) and four self locking nuts HPC Variable Stator Vane Actuation System (72-41-34,02-204) which attach the left hand VIGV bridging pieces to the upper and lower actuating rings. Torque the bolts to 85 to 105 lbfin (10.00 to 12.00 Nm).

      4. Install the remaining bridging pieces as given in steps B.(2) to (3) on to the actuating rings adjacent to the inlet guide vanes at the positions 19 to 22.

   3. Install the actuating levers on to the inlet guide vanes and bridging pieces. These were removed in step B.

      1. Install the actuating levers on to the inlet guide vanes at the positions 1, 2, 19 to 22, 39 and 40. Install the pins of the actuating levers into the correct location in the bridging pieces.

      2. Install the bolts on to the inlet guide vane spindles. These were removed in step B.

      3. Set the inlet guide vane actuating levers parallel with the HP compressor assembly centre line. This is the null position.

      4. Torque the 40 bolts on the inlet guide vane spindles to 85 to 105 lbfin (10.00 to 12.00 Nm).

5. SUBTASK 72-41-00-440-261 Install the Stage 3 Actuating Ring Bridging Pieces

   1. Refer to Figure, Figure and Figure.

   2. Install the two bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)).

      1. Put the right hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) into position on the upper and lower actuating rings adjacent to the stator vanes at the positions 1, 2, 31 and 32. Engage the bridging pieces on the pins of the stator vanes actuating levers. Make sure the actuating levers pins are correctly engaged in the bridging pieces.

      2. Install the four bolts HPC Variable Stator Vane Actuation System (72-41-34,03-202) and four self locking nuts HPC Variable Stator Vane Actuation System (72-41-34,03-204). These attach the bridging pieces to the actuating rings.

      3. Torque the bolts to 85 to 105 lbfin (10.00 to 12.00 Nm).

      4. Remove the two rigging pins adjacent to the HP compressor front case left hand split line flange.

      5. Install the left hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) on to the actuating rings adjacent to the stage 3 stator vanes at the positions 15 to 18 as given in steps B.(2) to (3).

      6. Torque the four bolts to 85 to 105 lbfin (10.00 to 12.00 Nm).

      7. Torque the bolts which attach the actuating levers to the stage 3 stator vanes at the positions 1, 2, 15 to 18, 31 and 32.

         1. Set the stage 3 actuating levers parallel with the HP compressor assembly centre line. This is the null position.

         2. Torque the eight nuts to 85 to 105 lbfin (10.00 to 12.00 Nm).

6. SUBTASK 72-41-00-440-262 Install the Stage 4 Actuating Ring Bridging Pieces

   1. Refer to Figure, Figure and Figure.

   2. Install the two bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,04-200) and HPC Variable Stator Vane Actuation System (72-41-34,04-201)).

      1. Put the right hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) into position on the upper and lower actuating rings adjacent to the stator vanes at the positions 1, 2, 49 and 50. Engage the bridging pieces on the pins of the stator vanes actuating levers. Make sure the actuating lever pins are correctly engaged in the bridging pieces.

      2. Install the four bolts HPC Variable Stator Vane Actuation System (72-41-34,04-202) and four self locking nuts HPC Variable Stator Vane Actuation System (72-41-34,04-203), which attach the right hand stage 4 bridging pieces and centraliser support assemblies to the stage 4 upper and lower actuating rings.

      3. Torque the bolts to 85 to 105 lbfin (10.00 to 12.00 Nm).

      4. Install the left hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) on to the actuating rings adjacent to the stage 4 stator vanes at the positions 24 to 27 as given in steps B.(2) to (3).

   3. Torque the bolts which attach the actuating levers to the stage 4 stator vanes at the positions 1, 2, 24 thru 27, 49 and 50.

      1. Set the stage 4 actuating levers parallel with the HP compressor assembly centre line. This is the null position.

      2. Torque the eight nuts to 85 to 105 lbfin (10.00 to 12.00 Nm).

7. SUBTASK 72-41-00-440-263 Install the Stage 5 Actuating Ring Bridging Pieces

   1. Refer to Figure and Figure.

   2. Install the two bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,05-200) and HPC Variable Stator Vane Actuation System (72-41-34,05-201)).

      1. Put the right hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) into position on the upper and lower actuating rings adjacent to the stator vanes at the positions 1 to 3 and 62 to 64. Engage the bridging pieces on the pins of the stator vanes actuating levers. Make sure the actuating lever pins are correctly engaged in the bridging pieces.

      2. Install the four bolts HPC Variable Stator Vane Actuation System (72-41-34,05-202) and the four self locking nuts HPC Variable Stator Vane Actuation System (72-41-34,05-203), which attach the right hand stage 5 bridging pieces and centraliser support assemblies to the stage 5 upper and lower actuating ring.

      3. Torque the bolts to 85 to 105 lbfin (10.00 to 12.00 Nm).

      4. Install the left hand bridging pieces (HPC Variable Stator Vane Actuation System (72-41-34,03-200) and HPC Variable Stator Vane Actuation System (72-41-34,03-201)) on to the actuating rings adjacent to the stage 5 stator vanes at the positions 30 thru 35 as given in steps B.(2) to (3).

   3. Torque the bolts which attach the actuating levers to the stage 5 stator vanes at the positions 1 to 3, 30 to 35 and 62 to 64.

      1. Set the stage 5 actuating levers parallel with the HP compressor assembly centre line. This is the null position.

      2. Torque the 12 nuts to 85 to 105 lbfin (10.00 to 12.00 Nm).

8. SUBTASK 72-41-00-440-264 Connect the Stage 3 VSV Control Rod

   1. Refer to Figure.

   2. Install the stage 3 control rod assembly (72-41-34,01-250).

      1. Locate the left hand bearing (72-41-34,01-240) in the drive bracket on the lower stage 3 actuating ring HPC Variable Stator Vane Actuation System (72-41-34,03-540).

      2. Install the bolt (72-41-34,01-232) to attach the stage 3 control rod to the stage 3 unison ring.

      3. Torque the nut to 180 to 220 lbfin (20 to 25 Nm).

9. SUBTASK 72-41-00-560-026 Install the HP Compressor Support Rods

   1. Refer to Figure and Figure.

   2. Make sure that the variable stator vanes (VSV) are in the low speed position.

   3. Install IAE 1R18247 Rigging pin rigging pin 1 off through the bracket and into the HP compressor cases to lock the VSV's.

   4. Remove the six bolts HP COMPRESSOR SPLIT CASE (72-41-31,01-122), the two brackets (HP COMPRESSOR SPLIT CASE (72-41-31,01-115) and HP COMPRESSOR SPLIT CASE (72-41-31,01-118)) and the three blanks HP COMPRESSOR SPLIT CASE (72-41-31,01-120) from the HP compressor front cases.

   5. Install IAE 1R18234 Support rod support rod 3 off into the holes in the split cases.

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

      2. Install the support rods through the holes in the HP compressor split case. Make sure the tool blades are rearwards.

      3. Safety the support rods to the HP compressor split cases with the six tool bolts.

      4. Turn the adjustment handles until the tool blades touch the HP compressor stage 3 disk then hand tighten the handles.

10. SUBTASK 72-41-00-560-027 Install the Trunnion Assemblies on to the HP System Module

    1. Refer to Figure and Figure.

    2. NOTE

       Keep the 10 nuts removed in step B. so that they can be used to install the trunnion assemblies.

       Remove the 10 nuts and the 10 bolts from the HP compressor front and rear cases split line at the No. 8, 10, 16, 17, 19, 35, 37, 38, 44 and 46 positions. The No. 1 hole position is to the right of TDC.

    3. Install IAE 1R18325 Trunnion assembly 2 off.

       1. Locate the right hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 9 and 18 positions.

       2. Attach the trunnion assembly to the module with the five tool bolts and five of the nuts removed in step B. Tighten the nuts to safety the trunnion assembly.

       3. Locate the left hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 36 and 45 positions.

       4. Attach the trunnion assembly to the module with the five tool bolts and the other five nuts removed in step B. Tighten the nuts to safety the trunnion assembly.

11. SUBTASK 72-41-00-440-265 Remove the HP Compressor Assembly from the Build Stand IAE 1R19463

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

    2. Attach a hoist to the lift eye on IAE 1F10052 Two cables sling 1 off.

    3. Attach the lift sling to the remove/install fixture trunnions.

       1. Use the hoist to position the lift sling over the HP system module.

       2. Adjust the height of the lift sling to permit the hook and bolt plate to be attached to the remove/install fixture trunnions.

       3. Attach the hook and bolt plate to the remove/install fixture trunnions.

    4. Disassemble and remove the three hand knobs, pins, plain washers and studs (details 22, 27, 16 and 14). Loosen the locknut on the heel pin (detail 15). Remove three retaining clamp plates (detail 5).

    5. 

       CAUTION

       YOU MUST KEEP THE WEIGHT OF THE MODULE ON THE HOIST WHEN THE SLIDE IN-RIGGERS ARE LOOSENED AND MOVED FROM THEIR SECURING POSITIONS. THE HP CASES COULD MOVE RELATIVE TO THE HP ROTOR AND CAUSE DAMAGE TO ENGINE COMPONENTS.

       Take up the weight of the module on the hoist and slightly loosen the 12 nuts (detail 24) which secure the three in-riggers, remove the three jacking screws (detail 12) from through the three support plates (detail 4). Slide the in-riggers (detail 6, 7 and 8) outwards from their positions.

    6. Remove the six bolts (detail 17) at positions 1, 8, 9, 17, 18 and 25 which secure the three support plates (detail 4) to the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture and module rear flange. Remove the three support plates.

    7. Install the six bolts, nuts and washers at positions 1, 8,9, 17, 18 and 25. Tighten the bolts.

    8. Make sure that the remove/install fixture lifting eyes are stowed securely so as not to interfere with the surgical strike tooling when the module is lifted from the stand.

    9. Slowly and carefully lift the module so the dummy stub shaft is clear of the location pot. Remove the HP system module from the build stand.

12. SUBTASK 72-41-00-440-266 Install the Variable Inlet Guide Vane Front Shroud

    1. Refer to Figure.

    2. Remove the two halves of the split ring assembly IAE 1R19633 Split ring assembly. Make sure the 40 one piece bushes are attached to the stator vanes.

    3. Install the Variable inlet guide vane front shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33,01-200).

       1. Apply a thin layer of CoMat 04-007 SILICONE GREASE to the 40 bushes HPC Variable Stator Vane Shrouds And Related Part (72-41-33,01-190) outer surface.

       2. NOTE

          The inlet guide vane rear upper half shroud has four location dowels.

          Align the variable inlet guide vane front and rear half shrouds.

       3. Install the 20 bolts HPC Variable Stator Vane Shrouds And Related Part (72-41-33,01-138), the 20 nuts HPC Variable Stator Vane Shrouds And Related Part (72-41-33,01-130) and the 40 dee-headed washers HPC Variable Stator Vane Shrouds And Related Part (72-41-33,01-134). These attach the two halves of the inlet guide vane front shroud.

       4. Torque the 20 nuts to 36 to 45 lbfin (4.00 to 5.00 Nm).

13. SUBTASK 72-41-00-560-028 Turn the HP System Module and Install on to the Support Posts and Cradle Pedestal

    1. Refer to Figure and Figure.

    2. Attach a hoist to the lift eye on a second IAE 1F10052 Two cables sling 1 off.

    3. Attach the lift sling to the HP compressor trunnion assemblies.

       1. Use the hoist to position the lift sling adjacent to the HP system module.

       2. Adjust the height of the lift sling so that the hook and bolt plate can be attached to the HP compressor trunnion assemblies.

       3. Attach the hook and bolt plate to the trunnions, safety the hook and bolt plate with the safety clip.

    4. Use the forward lift sling to move the HP system module in to the horizontal position.

    5. 
       CAUTION
       YOU MUST MAKE SURE THAT THE HEIGHT OF THE MODULE IS SUFFICIENT FOR THE CRADLE PEDESTAL TO BE INSTALLED. IF THE HEIGHT IS NOT SUFFICIENT THE MODULE CAN BE DAMAGED.

       Install the HP system module on to the support posts and cradle pedestal.

       1. Make sure that the trunnion support brackets, part of IAE 1F10028 Support Pedestal 2 off are at their lowest position.

       2. Put the support posts adjacent to the trunnion assemblies with the trunnion supports below the trunnions.

       3. Move the trunnion support brackets up the support posts until they touch the trunnions.

       4. Look at the holes in the trunnion support brackets and the support posts to see if they are aligned.

       5. If necessary adjust the height of the HP system module to make the holes align.

       6. Install the retaining pins through the holes.

       7. Put IAE 1P16002 Cradle pedestal 1 off under the HP system module with the support bracket slightly forward of the diffuser case rear flange. Make sure that the large face of the support bracket is forward.

       8. Turn the adjustment handle on the cradle pedestal to move the support bracket upwards. When the cradle pedestal has taken the weight of the module stop the procedure.

       9. Remove the retaining pins from the lift sling hook and bolt plates.

       10. Adjust the height of the lift slings so that the hook and bolt plates can be removed.

       11. Remove the hook and bolt plates from the trunnions.

       12. Put the lift slings on an applicable work surface.

       13. Remove the hoists from the lift slings.

14. SUBTASK 72-41-00-560-029 Remove the Remove/Install Fixture and the Tie-Rod Adapter from the Rear of the HP System Module

    1. Refer to Figure.

    2. NOTE

       If continuing with TASK 72-00-40-420-002-B00, Install the HP system module (horizontal) then the remove/install fixture need not be removed.

       Attach a hoist to the lift eye on the remove/install fixture and adjust the hoist to hold the remove/install fixture.

    3. Remove the 25 nuts and the 25 bolts which safety the remove/install fixture to the HP Turbine case. Remove the two split rings.

    4. Release the locknut on the end of the tie-rod shaft. Do not remove the locknut.

    5. Remove the two screws that safety the tie-rod adapter on to the remove/install fixture.

    6. Move the shaft in to the engine to disengage the puck from the HP compressor shaft front shoulder.

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

    8. Remove the remove/install fixture from the module and put it on an applicable work surface. Remove the hoist.

15. SUBTASK 72-41-00-220-210 Examine the HPC Rear Shaft for Surface Damage

    1. Refer to Figure.

    2. Examine the rear shaft inner bore at locations 11 for surface damage. Refer to TASK 72-41-13, Inspection/Check-00.

       1. Surface damage not more than 0.0030 in. (0.076 mm) in depth

          1. Accept

       2. Other than (1)

          1. Reject

16. SUBTASK 72-41-00-560-030 Remove the Dummy Stub Shaft from the HP System Module

    1. Refer to Figure.

    2. NOTE

       The 20 curvic coupling tool bolts remain with the dummy stub shaft.

       Release the 20 curvic coupling tool bolts.

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

    4. Install the curvic protector on to the dummy stub shaft.

       1. Align the location pins on the dummy stub shaft with the applicable location holes in the curvic protector.

       2. Secure the curvic protector with four of the dummy stub shaft curvic coupling bolts and the curvic protector nuts.

       3. Put the dummy stub shaft on to an applicable work surface.

    5. Install the curvic protector on to the stage 3 disk curvic coupling.

17. SUBTASK 72-41-00-440-267 Install the Modules

    1. Install the HP stack.

       1. Install the HP system module (horizontal). Refer to TASK 72-00-40-420-002-B00.

       2. Install the components, the external harnesses and the tubes to the HP system module. Refer to TASK 72-00-40-420-005-B00, TASK 72-00-40-420-006-B00, TASK 72-00-40-420-007-B00, TASK 72-00-40-420-004 and associated TASKS.

       3. Turn the LP turbine module from vertical to horizontal. Refer to TASK 72-00-50-560-002.

       4. Install the LP turbine module. Refer to TASK 72-00-50-420-001.

       5. Install the components, the external harnesses and the tubes to the LP turbine module. Refer to TASK 72-00-50-420-005-B00.

18. SUBTASK 72-41-00-720-006 Do a Check of the No. 4 Front and Rear Bearing Compartment for Leaks

    1. Refer to Figure.

    2. Do a check on the No. 4 bearing chamber, if not disassembled.

    3. Install the IAE 1P16089 Leak check cap 1 off in the coupling nut of the pressure tube.

    4. Install the IAE 1P16088 Leak check adapter 1 off in the scavenge tube.

    5. Connect the IAE 6F10030 Vacuum test cart 1 off to the adapter.

    6. Adjust the vacuum on the cart to 20 in. HG and evacuate the bearing compartment. Based on the ambient pressure, refer to the table below for the vacuum pressure in psia.

       Ambient Pressure of the Day (psia)	Vacuum Pressure (psia)
       14.7	4.9
       14.5	4.7
       14.3	4.5
       14.1	4.3
       13.9	4.1
       13.7	3.9
       13.5	3.7
       13.3	3.5
       13.1	3.3

       Vacuum pressure (psia) = Ambient pressure of the day (psia) - 9.8 psia

    7. Check the air flow on the No. 4 front and rear bearing compartment. The air flow must be no more than 17 pph (7.71 Kgph). Make a record of the reading. The reading must agree with the vacuum check in TASK 72-41-00-040-001-D00.

    8. Decrease the vacuum to 0 in. Hg and disconnect the cart from the fixture.

    9. Remove the leak check cap from the pressure tube.

    10. Remove the leak check adapter from the scavenge tube.

Figure: Set the True Axial Displacement of the HP Module Cases and Stage 2 HP Turbine

Set the True Axial Displacement of the HP Module Cases and Stage 2 HP Turbine



Figure: Install the HP Compressor Front Case Split Line Flange Bolts

Sheet 1



Legend

Install the HP Compressor Front Case Split Line Flange Bolts

Sheet 1

Close

Figure: Install the HP Compressor Front Case Split Line Flange Bolts

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Legend

Install the HP Compressor Front Case Split Line Flange Bolts

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Close

Figure: Install the Brackets, the Pins, the Bolts and the Nuts at the HP Compressor Front Case to the Compressor Rear Outer Case Flange

Sheet 1



Legend

Install the Brackets, the Pins, the Bolts and the Nuts at the HP Compressor Front Case to the Compressor Rear Outer Case Flange

Sheet 1

Close

Figure: Install the Brackets, the Pins, the Bolts and the Nuts at the HP Compressor Front Case to the Compressor Rear Outer Case Flange

Sheet 2



Legend

Install the Brackets, the Pins, the Bolts and the Nuts at the HP Compressor Front Case to the Compressor Rear Outer Case Flange

Sheet 2

Close

Figure: Install the Inlet Guide Vane Bridging Pieces

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Legend

Install the Inlet Guide Vane Bridging Pieces

Sheet 1

Close

Figure: Install the Inlet Guide Vane Bridging Pieces

Sheet 2



Legend

Install the Inlet Guide Vane Bridging Pieces

Sheet 2

Close

Figure: Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 1



Legend

Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 1

Close

Figure: Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 2



Legend

Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 2

Close

Figure: Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 3



Legend

Install the Stage 3 Actuating Ring Bridging Pieces

Sheet 3

Close

Figure: Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 1



Legend

Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 1

Close

Figure: Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 2



Legend

Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 2

Close

Figure: Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 3



Legend

Install the Stage 4 Actuating Ring Bridging Pieces

Sheet 3

Close

Figure: Install the Stage 5 Actuating Ring Bridging Pieces

Sheet 1



Legend

Install the Stage 5 Actuating Ring Bridging Pieces

Sheet 1

Close

Figure: Install the Stage 5 Actuating Ring Bridging Pieces

Sheet 2



Legend

Install the Stage 5 Actuating Ring Bridging Pieces

Sheet 2

Close

Figure: VSV Crankshaft and Unison Rings - Connect Stage 3 Control Rod

VSV Crankshaft and Unison Rings - Connect Stage 3 Control Rod



Figure: Install the HP Compressor Support Rods

Sheet 1



Legend

Install the HP Compressor Support Rods

Sheet 1

Close

Figure: Install the HP Compressor Support Rods

Sheet 2



Legend

Install the HP Compressor Support Rods

Sheet 2

Close

Figure: Install the HP Compressor Trunnions

Install the HP Compressor Trunnions



Figure: Remove the HP Compressor Assembly from the Build Stand IAE 1R19463

Sheet 1



Legend

Remove the HP Compressor Assembly from the Build Stand IAE 1R19463 Stand - Surgical strike

Sheet 1

Close

Figure: Remove the HP Compressor Assembly from the Build Stand IAE 1R19463

Sheet 2



Legend

Remove the HP Compressor Assembly from the Build Stand IAE 1R19463 Stand - Surgical strike

Sheet 2

Close

Figure: Remove the HP Compressor Assembly from the Build Stand IAE 1R19463

Sheet 3



Legend

Remove the HP Compressor Assembly from the Build Stand IAE 1R19463 Stand - Surgical strike

Sheet 3

Close

Figure: Install the Variable Inlet Guide Vane Front Shroud

Install the Variable Inlet Guide Vane Front Shroud



Figure: Install the Forward Lift Sling to the HP Compressor Trunnions

Install the Forward Lift Sling to the HP Compressor Trunnions



Figure: Install the Lift Slings on to the Trunnions

Install the Lift Slings on to the Trunnions



Figure: Remove the Dummy Stub Shaft from the Stage 3 Disk Curvic Coupling

Remove the Dummy Stub Shaft from the Stage 3 Disk Curvic Coupling



Figure: Remove the Remove/Install Fixture and Tie-rod Adapter from the HP System Module

Remove the Remove/Install Fixture and Tie-rod Adapter from the HP System Module



Figure: Check the No. 4 Front and Rear Bearing Compartment for Leaks

Check the No. 4 Front and Rear Bearing Compartment for Leaks



Figure: HPC Rear Shaft Inspection Location

HPC Rear Shaft Inspection Location