Preliminary Requirements

Procedure

1. SUBTASK 72-41-10-040-120 Prepare the Tip Check Fixture for Installation of the HP Compressor Rotor Assembly

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

   2. Install IAE 1R18454 Location block 1 off on to the rear pedestal of IAE 1R18451 Tip check fixture 1 off and safety.

   3. Install IAE 1R18455 Location block 1 off on to the front pedestal of the tip check fixture and safety.

   4. Install the IAE 1R18453 Bearing housing (front) 1 off and safety with the two keep plates.

   5. Install the IAE 1R18452 Bearing housing (rear) 1 off and safety with the two keep plates.

   6. Turn the quarter turn screw, in the front bracket, 90 degrees and move the front bracket down on to the stop plate.

   7. Do step F. again for the rear bracket.

2. SUBTASK 72-41-10-040-121 Install the HP Compressor Rotor Assembly in to the Tip Check Fixture

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

      NOTE

      The HP compressor rotor assembly is on the build stand (IAE 1R18204 Location ring) with the dummy stub shaft installed.

   2. Install the IAE 1R18708 Protection cover 1 off on to the compressor rotating air seal.

      1. Put the cover over the compressor shaft and move the cover down the shaft.

      2. Engage the cover over the rotating air seal. Make sure the cover is correctly installed.

      3. Attach the O-ring on to the O-ring location to safety the cover.

   3. Install the IAE 1R18089 Lifting adapter 1 off on to the end of the compressor shaft and tighten.

   4. Attach IAE 1R18095 Universal slinging adapter 1 off on to the lifting adapter.

      1. Lift pin E and put the adapter end of the tool in to the lifting adapter. Turn the tool to engage it and lower the pin E.

      2. Install the lifting end of the tool in to the adapter end. Install the trunnion pin through both parts of the tool and tighten it.

      3. Tighten the locknut on to the lifting adapter attach a hoist to the lift eye.

   5. 

      CAUTION

      DO NOT LET THE COMPRESSOR ROTOR ASSEMBLY HIT THE BUILD STAND. IF THE COMPRESSOR ROTOR ASSEMBLY HITS THE BUILD STAND YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

      Remove the compressor rotor assembly from the build stand.

   6. Install IAE 1R18095 Universal slinging adapter 1 off on to the dummy stub shaft.

      1. Install the IAE 1R18091 Support stand 1 off on to IAE 1R18090 Safety support stand 1 off.

      2. Install the compressor rotor assembly on to the safety support stand.

      3. Attach the universal slinging adapter on to the dummy stub shaft. Refer to step D.(1) thru D.(3).

   7. Lift the compressor rotor assembly off the safety support stand.

   8. 

      CAUTION

      DO NOT LET THE COMPRESSOR ROTOR ASSEMBLY HIT THE TIP CHECK FIXTURE. IF THE COMPRESSOR ROTOR ASSEMBLY HITS THE TIP CHECK FIXTURE YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

      Install the compressor rotor assembly in to the IAE 1R18451 Tip check fixture 1 off. Make sure the dummy stub shaft is correctly located in the front bearing housing.

   9. Remove the universal slinging adapter and the lifting adapter from the compressor shaft and the universal slinging adapter from the dummy stub shaft.

   10. Install the IAE 1R18466 Thruster plate 1 off in to the compressor shaft.

   11. Adjust the handwheels on the front and rear brackets to make sure the thruster brackets are fully retracted.

   12. Lift the front and rear brackets up in to position and safety with the quarter turn screws.

3. SUBTASK 72-41-10-040-122 Set the Axial Position of the HP Compressor Rotor Assembly

   1. Refer to Figure and Figure.

   2. Install the IAE 1R18459 Axial setting gage 1 off on to the front pedestal.

   3. With IAE 1R18467 Setting block 1 off adjust the IAE 1R18460 Transducer carrier 1 off to the applicable zero setting on the digital read out equipment.

   4. Install the transducer in to the axial setting gage and hand tighten the knurled nut.

   5. With the front and rear handwheels, adjust the position of the compressor rotor assembly in the fixture until the dummy stub shaft front face causes the transducer plunger to operate. Continue to adjust the position of the rotor until the transducer gives the initial zero reading.

   6. Remove the transducer carrier and the axial setting gage.

   7. Install the IAE 1R18714 Checking beam 1 off on the front and rear location blocks.

      1. Locate the two dowels and safety the beam in position with the two bolts and washers.

   8. Install the IAE 1R18458 Brake strap 1 off on to the front pedestal and adjust.

4. SUBTASK 72-41-10-040-123 Do a Check on the Compressor Rotor for Concentricity and Swash

   1. Refer to Figure and Figure.

   2. With standard workshop equipment measure the swash at face A; the swash must not be more than 0.0051 in. (0.130 mm). Measure the concentricity at diameter B; the concentricity must not be more than 0.0031 in. (0.080 mm).

5. SUBTASK 72-41-10-040-124 Set the Transducer Carriers to the Zero Position

   1. Refer to Figure.

   2. Set the zero position of the 3 to 4 seal transducer carrier. Use IAE 1R18463 Transducer carrier 1 off.

      1. Connect the transducer carrier to the digital read out equipment.

      2. Loosen the two setscrews that safety the transducer in to the rear transducer block.

      3. Install the transducer carrier on to IAE 1R18794 Setting gage 1 off.

         1. Align the transducer with the correct setting block and at the same time locate the two location plates of the transducer carrier in to the location slot in the setting gage.

         2. Make sure that the transducer carrier rear anvil touches the front stop on the setting gage.

      4. Adjust the position of the transducer in the rear transducer block until the roller touches the setting block and the transducer is approximately in the middle of its range of movement.

      5. Tighten the two setscrews to safety the transducer in position in the rear transducer block.

      6. Set the display of the resolver angle position unit to read zero and make sure that a positive (+) reading is given when the plunger moves in to the transducer.

      7. Remove the transducer carrier from the setting gage.

6. SUBTASK 72-41-10-040-125 Measure and Calculate the Stage 3 to 4 Seal Fin Diameters at Location 1001

   1. Refer to Figure and Figure.

   2. Measure the stage 3 to 4 seal fin diameters at location 1001.

      1. Install IAE 1R18463 Transducer carrier 1 off in the correct position on the IAE 1R18714 Checking beam.

         1. Carefully locate the transducer roller on the first seal fin and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

         2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

      2. Turn the HP compressor rotor smoothly in a clockwise direction.

      3. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

      4. Carefully move the front transducer block until the transducer roller is located on the second seal fin.

      5. Do steps B.(2) and B.(3) again.

      6. Carefully move the front transducer block until the transducer roller is located on the third seal fin.

      7. Do steps B.(2) and B.(3) again.

      8. Carefully move the front transducer block until the transducer roller is located on the fourth seal fin.

      9. Do steps B.(2) and B.(3) again.

      10. Remove the transducer carrier from the seal check beam.

   3. Calculate the stage 3 to 4 seal fin diameters at location 1001.

      1. Calculate the diameter of each of the four seal fins as follows:

         Seal fin diameter = 2 (A+B)

         where, A = Tool setting radius = 5.1646 in. (131.180 mm)

         B = Transducer reading

         Example 1, where B = -0.046 in. (-1.17 mm)

         Seal fin diameter = 2 (5.1646 + -0.046)

         = 10.237 in. (260.02 mm)

         Example 2, where B = 0.046 in. (1.17 mm)

         Seal fin diameter = 2 (5.1646 + 0.046)

         = 10.421 in. (264.69 mm)

      2. Write down the calculated minimum and maximum diameters for each of the four seal fins. This data is to be used in the INSPECTION/CHECK of the 3 to 8 compressor disks. Refer to TASK 72-41-11-200-000 (INSPECTION/CHECK-000).

7. SUBTASK 72-41-10-040-126 Measure and Calculate the Stage 4 to 5 Seal Fin Diameters at Locations 1002 and 1003

   1. Refer to Figure and Figure.

   2. Set the zero position of IAE 1R18462 Transducer carrier 1 off.

      1. Do the procedure given in SUBTASK 72-41-10-040-094.

   3. Measure the stage 4 to 5 seal fin diameter at location 1002.

      1. Install the transducer carrier in the correct position on the seal check beam.

         1. Carefully locate the transducer roller on to the seal fin at location 1002 and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

         2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

      2. Turn the HP compressor rotor smoothly in a clockwise direction.

      3. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

   4. Calculate the stage 4 to 5 seal fin diameter at location 1002.

      1. Calculate the diameter of the seal fin as follows:

         Seal fin diameter = 2 (A + B)

         where A = Tool setting radius = 5.9362 in. (150.780 mm)

         B = Transducer reading

         Refer to SUBTASK 72-41-10-040-095 for calculation examples.

      2. Write down the calculated minimum and maximum diameter for the seal fin. This data is to be used in the INSPECTION/CHECK of the 3 to 8 compressor disks. Refer to TASK 72-41-11-200-000 (INSPECTION/CHECK-000).

   5. Measure the stage 4 to 5 seal fin diameters at location 1003.

      1. Remove IAE 1R18462 Transducer carrier from the seal check beam.

      2. Install the transducer carrier in the correct position on the seal check beam.

         1. Carefully locate the transducer roller on to the first seal fin at location 1003 and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

         2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

      3. Turn the HP compressor rotor smoothly in a clockwise direction.

      4. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

      5. Carefully move the front transducer block until the transducer roller is located on the second seal fin.

      6. Do steps E.(3) and E.(4) again.

      7. Remove the transducer carrier from the seal check beam.

   6. Calculate the stage 4 to 5 seal fin diameters at location 1003.

      1. Calculate the diameter of each of the seal fins as follows:

         Seal fin diameter = 2 (A + B)

         where A = Tool setting radius = 6.1252 in. (155.580 mm)

         B = Transducer reading

         Refer to SUBTASK 72-41-10-040-095 for calculation examples.

      2. Write down the calculated minimum and maximum diameters for each of the two seal fins. This data is to be used in the INSPECTION/CHECK of the 3 to 8 compressor disks. Refer to TASK 72-41-11-200-000 (INSPECTION/CHECK-000).

8. SUBTASK 72-41-10-040-127 Measure and Calculate the Stage 5 to 6 Seal Fin Diameters at Location 1004

   1. Refer to Figure and Figure.

   2. Set the zero position of IAE 1R18461 Transducer carrier 1 off.

      1. Do the procedure given in SUBTASK 72-41-10-040-094.

   3. Measure the stage 5 to 6 seal fin diameters at location 1004.

      1. Install the transducer carrier in the correct position on the seal check beam.

         1. Carefully locate the transducer roller on to the first seal fin and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

         2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

      2. Turn the HP compressor rotor smoothly in a clockwise direction.

      3. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

      4. Carefully move the front transducer block until the transducer roller is located on the second seal fin.

      5. Do steps C.(2) and C.(3) again.

      6. Carefully move the front transducer block until the transducer roller is located on the third seal fin.

      7. Do steps C.(2) and C.(3) again.

      8. Remove the transducer carrier from the seal check beam.

   4. Calculate the stage 5 to 6 seal fin diameters at location 1004.

      1. Calculate the diameter of each of the seal fins as follows:

         Seal fin diameter = 2 (A + B)

         where A = Tool setting radius = 6.9382 in. (176.230 mm)

         B = Transducer reading

         Refer to SUBTASK 72-41-10-040-095 for calculation examples.

      2. Write down the calculated minimum and maximum diameters for each of the four seal fins. This data is to be used in the INSPECTION/CHECK of the 3 to 8 compressor disks. Refer to TASK 72-41-11-200-000 (INSPECTION/CHECK-000).

9. SUBTASK 72-41-10-040-128 Measure and Calculate the Stator Vane Path Diameters

   1. Refer to Figure and Figure.

   2. Set the zero position of IAE 1R18464 Transducer carrier 1 off.

      1. Do the procedure given in SUBTASK 72-41-10-040-094.

   3. Measure the stage 6 to 7 stator vane path diameter at location 1056.

      1. Install the transducer carrier in the correct position on the seal check beam.

         1. Carefully locate the transducer roller on to the vane path and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

         2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

      2. Turn the HP compressor rotor smoothly in a clockwise direction.

      3. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

      4. Remove the transducer carrier from the seal check beam.

   4. Measure the stage 7 to 8 stator vane path diameter at location 1057.

      1. Do steps B.(1) and C.(1) thru C.(4) to measure the stage 7 to 8 stator vane path diameter.

   5. Measure the stage 8 to 9 stator vane path diameter at location 1058.

      1. Do steps B.(1) and C.(1) thru C.(4) to measure the stage 8 to 9 stator vanes path diameter.

   6. Measure the stage 9 to 10 stator vane path diameter at location 1059.

      1. Do steps B.(1) and C.(1) thru C.(4) to measure the stage 9 to 10 stator vane path diameter.

   7. Measure the stage 10 to 11 stator vane path diameter at location 1060.

      1. Do steps B.(1) and C.(1) thru C.(4) to measure the stage 10 to 11 stator vane path diameter.

   8. Measure the stage 11 to 12 stator vane path diameter at location 1061.

      1. Do steps B.(1) and C.(1) thru C.(4) to measure the stage 11 to 12 stator vane path diameter.

   9. Calculate the stator vane path diameters.

      1. Calculate the diameter of each of the stator vane paths as follows:

         Stator vane path diameter = 2 (A + B)

         where A = Tool setting radius

         B = Transducer reading

         1. The tool setting radius values (A) used in the calculations for the different stator vane path diameters are as follows:

            A = 8.6047 in. (218.560 mm) for the stage 6 to 7 vane path (location 1056).

            A = 8.9387 in. (227.044 mm) for the stage 7 to 8 vane path (location 1057).

            A = 9.1530 in. (232.485 mm) for the stage 8 to 9 vane path (location 1058).

            A = 9.2891 in. (235.944 mm) for the stage 9 to 10 vane path (location 1059).

            A = 9.3117 in. (236.516 mm) for the stage 10 to 11 vane path (location 1060).

            A = 9.3147 in. (236.594 mm) for the stage 11 to 12 vane path (location 1061).

            Refer to SUBTASK 72-41-10-040-095 for calculation examples.

      2. Write down the calculated minimum and maximum diameters for each of the stator vane paths. The 6 to 7 and 7 to 8 stator vane path diameters are to be used in the INSPECTION/CHECK of the 3 to 8 compressor disk; refer to TASK 72-41-11-200-000 (INSPECTION/CHECK-000). The 8 to 9, 9 to 10, 10 to 11 and 11 to 12 stator vane path diameters are to be used in the INSPECTION/CHECK of the 9 to 12 compressor disk assembly; refer to TASK 72-41-12-200-000 (INSPECTION/CHECK-000).

10. SUBTASK 72-41-10-040-129 Measure and Calculate the HP Compressor Rear Rotating Seal Fin Diameters

    1. Refer to Figure and Figure.

    2. Set the zero position of IAE 1R18795 Transducer carrier 1 off.

       1. Do the procedure given in SUBTASK 72-41-10-040-094.

    3. Measure the rear rotating seal fin diameter at locations 1401A, 1401B, 1401C and 1401D.

       1. Install the transducer carrier in the correct position on the seal check beam.

          1. Carefully locate the transducer roller on the first seal fin at location 1401A and at the same time locate the transducer carriers two location plates in to the slot in the seal check beam.

          2. Move the transducer carrier in the location slot until the rear anvil touches the threaded stop on the seal check beam.

       2. Turn the HP compressor rotor smoothly in a clockwise direction.

       3. Write down the minimum and maximum values given on the transducer display. Also record the values as a negative or positive reading.

       4. Carefully move the front transducer block until the transducer roller is located on the seal fin at location 1401B.

       5. Do steps C.(2) and C.(3) again.

       6. Carefully move the front transducer block until the transducer roller is located on the seal fin at location 1401C.

       7. Do steps C.(2) and C.(3) again.

       8. Carefully move the front transducer block until the transducer roller is located on the seal fin at location 1401D.

       9. Do steps C.(2) and C.(3) again.

       10. Remove the transducer carrier from the seal check beam.

    4. Calculate the rear rotating seal fin diameters at locations 1401A, 1401B, 1401C and 1401D.

       1. Calculate the diameter of each of the seal fins as follows:

          Seal fin diameter = 2 (A + B)

          where A = Tool setting radius

          B = Transducer reading

          1. The tool setting radius values (A) used in the calculations for the different rear rotating air seal fin diameter locations are as follows:

             A = 3.4528 in. (87.700 mm) for location 1401A.

             A = 3.5591 in. (90.400 mm) for location 1401B.

             A = 3.6654 in. (93.100 mm) for location 1401C.

             A = 3.7717 in. (95.800 mm) for location 1401D.

             Refer to SUBTASK 72-41-10-040-095 for calculation examples.

       2. Write down the calculated minimum and maximum diameters for each of the seal fins. This data is to be used in the INSPECTION/CHECK of the rear rotating air seal. Refer to TASK 72-41-14-200-000 (INSPECTION/CHECK-000).

11. SUBTASK 72-41-10-040-130 Remove the HP Compressor Rotor Assembly from the Tip Check Fixture

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

    2. Remove the seal check beam from the tip check fixture.

    3. Remove the brake strap from the front pedestal.

    4. Remove the front and rear location blocks from the front and rear pedestals.

    5. Turn the quarter turn screw in the front and rear brackets, 90 degrees and move the brackets down on to the stop plates.

    6. Remove the thruster plate adapter from the compressor shaft.

    7. Install the IAE 1R18089 Lifting adapter 1 off and the IAE 1R18095 Universal slinging adapter 2 off. Refer to SUBTASK 72-41-10-040-091.

    8. Attach a hoist to the compressor rotor and lift the rotor clear of the tip check fixture.

12. SUBTASK 72-41-10-040-131 Install the HP Compressor Rotor Assembly in the Trolley

    
    CAUTION
    DO NOT LET THE COMPRESSOR ROTOR ASSEMBLY HIT THE TROLLEY. IF THE COMPRESSOR ROTOR ASSEMBLY HITS THE TROLLEY YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

    1. Refer to Figure.

    2. Install the compressor rotor assembly in to the IAE 1R18059 Trolley 1 off.

       1. Move the compressor rotor and put it above the trolley. Make sure the trunnions on the universal slinging adapter (front) are above the trunnion supports.

       2. Lower the rotor until the trunnions engage in the trunnion supports.

    3. Remove the hoist.

    4. Install the IAE 1R18061 Rail 2 off on to the trolley.

       1. Remove the eight bolts from the trolley rail locations.

       2. Install the rails on to the trolley and safety with the eight bolts.

13. SUBTASK 72-41-10-040-102 Remove the HP Compressor Rotor Assembly from the Trolley and Install it in to the Grinding Machine

    1. Refer to Figure and Figure.

    2. Install IAE 1R18081 Beam sling 1 off to the HP compressor rotor assembly.

       1. Make sure that the bracket is at the identified position for the center of gravity of the beam sling only.

       2. Attach a hoist to the ring.

       3. Lift the beam sling and put it above the rotor assembly.

       4. Adjust the height of the beam sling until the shackles and screw pins can be attached to the universal sling adapter. Remove the screw pins.

       5. Install the screw pins through the shackles and universal sling adapters; tighten the screw pins.

       6. Set the beam sling to the identified position for the center of gravity of the beam sling and rotor assembly.

    3. Carefully lift the HP compressor rotor assembly out of the trolley and install it on to an applicable stand which will permit the grinding machine tools to be installed.

    4. Remove the beam sling from the HP compressor rotor assembly.

       1. Set the beam sling to the identified position for the center of gravity of the beam sling only.

       2. Remove the screw pins from the shackles and disengage the shackles from the universal sling adapters.

       3. Install the screw pins in to the shackles and then lift the beam sling away from the rotor assembly. Put the beam sling on to an applicable surface and remove the hoist.

    5. Remove the necessary tools from the HP compressor rotor assembly to permit the grinding machine adapters to be installed.

       NOTE

       The applicable grinding machine adapters are identified by machine type.

    6. Install the applicable grinding machine adapters on to the HP compressor rotor assembly to prepare it for installation in to the grinding machine.

       NOTE

       The applicable tools are identified by machine type.

    7. Install the applicable tools which are necessary to lift the HP compressor rotor assembly.

    8. Carefully lift the HP compressor rotor assembly and install it in to the grinding machine.

    9. Safety the headstock and tailstock adapters in position.

    10. Remove the tools which were used to lift the HP compressor rotor assembly.

14. SUBTASK 72-41-10-040-103 Measure the Swash and Run-out of the HP Compressor Rotor Assembly

    1. Measure the swash and run-out of the HP compressor rotor assembly on the applicable tool surfaces.

    2. Make sure the swash and run-out are not more than 0.0012 in. (0.030 mm).

15. SUBTASK 72-41-10-040-104 Measure the Length of the HP Compressor Blades

    1. Refer to Figure and Figure.

    2. If the HPC rotor is not scheduled to be disassembled and refurbished refer to Special Procedure TASK 72-00-00-200-801 (Special Procedure-001).

       NOTE

       The grinding machine must use a measuring device to measure the blade lengths.

    3. Measure the blade lengths and write the results.

    4. Use CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON or CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON to identify the blades that are too short.

16. SUBTASK 72-41-10-040-105 Remove the HP Compressor Rotor Assembly from the Grinding Machine and Install it in to the Trolley

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

       NOTE

       The necessary tools are identified by machine type.

    2. Install the tools which are necessary to lift the HP compressor rotor assembly out of the grinding machine.

    3. Attach a hoist to the tools.

    4. Remove the bolts which secure the HP compressor rotor assembly to the headstock and tailstock of the grinding machine.

    5. Lift the HP compressor rotor assembly out of the grinding machine and put it on to an applicable stand.

    6. Remove the hoist and tools which were installed on to the HP compressor rotor assembly for installation in to the grinding machine.

    7. Put IAE 1R18708 Protection cover 1 off on to the end of the HP compressor shaft.

    8. Install IAE 1R18089 Lifting adapter 1 off to the end of the HP compressor shaft. Tighten the lifting adapter.

    9. Attach one of IAE 1R18095 Universal slinging adapter 1 off on to the lifting adapter.

       1. Lift pin E and put the adapter end of the tool in to the adapter. Turn the tool to engage the locations. Lower pin E.

       2. Install the lifting end of the tool in to the adapter end. Install the trunnion pin through both parts of the tool and tighten it.

       3. Tighten the locknut on to the lifting adapter.

    10. Make sure IAE 1R18673 Dummy stub shaft 1 off is installed on the HP compressor rotor assembly. Do the steps which follow if the dummy stub shaft was removed for the installation of the grinding machine tools.

        1. Examine the curvic teeth of the dummy stub shaft and the stage 3 disk for contamination and/or high metal. If there is contamination then the curvic teeth must be cleaned. If there is high metal, use a stone to make the surface smooth.

        2. Align the four location dowels in the dummy stub shaft with the holes in the stage 3 disk curvic coupling.

        3. Install the dummy stub shaft on to the curvic coupling and engage the 20 bolts in the dummy stub shaft in to the holes in the stage 3 disk. Lightly tighten the bolts.

        4. Torque all of the bolts. Do these three steps in the sequence shown.

           1. Torque all of the bolts to 18 lbfin (2.034 Nm).

           2. Torque all of the bolts to 35 lbfin (3.955 Nm).

           3. Torque all of the bolts to 70 * lbfin (7.900 Nm).

    11. Install the second universal sling adapter on to the dummy stub shaft.

        1. Do steps I.(1) thru I.(3) again.

    12. Install IAE 1R18081 Beam sling 1 off to the HP compressor rotor assembly. Refer to Step.

    13. Install the HP compressor rotor assembly in to IAE 1R18059 Trolley 1 off.

        1. Lift the compressor rotor assembly and put it above the trolley. Make sure that the trunnions on the universal sling adapters are above the trunnion supports.

        2. Carefully lower the compressor rotor assembly in to the trolley. Make sure that the trunnions on the universal sling adapters engage in the trunnion supports of the trolley.

    14. Make sure IAE 1R18708 Protection cover is installed on to the compressor rotating air seals.

        1. Engage the protection cover over the compressor rotating air seals. Make sure the protection cover is correctly installed on the seals.

        2. Attach the O ring on to the O ring location to safety the protection cover.

    15. Remove the beam sling from the compressor rotor assembly. Refer to Step.

    16. Install IAE 1R18061 Rail 2 off on to the trolley.

        1. Remove the eight bolts from the trolley rail locations.

        2. Install the rails on to the trolley and safety with the eight bolts.

17. SUBTASK 72-41-10-040-106 Remove the Blades from the HP Compressor Rotor Assembly

    NOTE

    Keep the blades that were identified with a mark (in Step) apart from the other blades during removal.

    NOTE

    Each nut and screw lock assembly must be kept as a set.

    1. Refer to Figure for damper wire locations.

    2. Remove the stage 12 blades.

       1. With IAE 1R18590 Socket end 1 off release the two nut and screw lock assemblies.

       2. With IAE 1R18097 Drift 1 off move the blades around the disk until a blade can be removed through the loading slot.

       3. Do Step again, to remove each blade and the two nut and screw lock assemblies, until all the blades have been removed.

    3. Remove the blades from the stages 11, 10 and 9 disks.

       1. Do steps Step thru Step for each stage of blades.

          NOTE

          To drill out seized blade locknuts use the following tools: IAE 1R18911 Drill 1 off, IAE 18914 Setting gage 1 off (stage 6), IAE 18913 Setting gage 1 off (stage 7) and IAE 1R18912 Setting gage 1 off (stage 8).

    4. Remove the blades from the stage 6, 7 and 8 disks.

       1. Do steps A.(1) thru A.(3) to remove the blades from the disks.

       2. For Post SB 72-0642, remove the damper wires (72-41-11, 01-386, 01-388, 01-390, 01-392, 01-394 and 01-396) from the Stage 6, 7 and 8 disks.

    5. Remove the blades from the stage 3 disk.

       1. With an applicable tool remove the lockplates from the rear of the stage 3 disk and discard.

       2. With IAE 1R18079 Drift 1 off move the retaining plates around the disk to close up the spaces between them. This will give sufficient space to remove one blade, forwards, from the disk.

       3. Continue to move the retaining plates around in a counterclockwise direction (when viewed from the rear) until the next blade can be removed.

       4. Continue this procedure until sufficient blades have been removed to let you remove one of the retaining plates.

       5. Move the retaining plates, in turn, around the disk until they have all been removed.

       6. Remove the remaining blades in a counterclockwise direction from the stage 3 disk.

    6. Remove the blades from the stage 4 disk.

       1. With an applicable tool remove the lockplates from the front of the stage 4 disk and discard.

       2. With IAE 1R18080 Drift 1 off move the retaining plates around the disk to close up the space between them. This will give sufficient space to remove one blade, forwards, from the disk.

       3. Continue to move the retaining plates around the disk until sufficient blades have been removed to let you remove one of the retaining plates.

       4. Move the retaining plates, in turn, around the disk until they have all been removed.

       5. Remove the remaining blades from the stage 4 disk.

       6. Remove and discard the sealing strips HPC Rotor Blades (72-41-15,01-520) from all the stage 4 blades.

    7. Remove the blades from the stage 5 disk.

       1. Do steps D.(1) thru D.(5) to remove the retaining plates and the blades from the stage 5 disk.

       2. Remove and discard the sealing strips HPC Rotor Blades (72-41-15,01-820) from all the stage 5 blades.

18. SUBTASK 72-41-10-040-107 Install the HP Compressor Disks and Shaft Assembly in to the Build Stand

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

    2. Install the IAE 1R18091 Support stand 1 off on to the IAE 1R18090 Safety support stand 1 off.

    3. Lift the compressor disks and shaft assembly from the trolley and install it on to the safety support stand.

    4. Remove the universal slinging adapter from the dummy stub shaft.

    5. Lift the compressor disks and shaft assembly off the safety support stand and put it above the IAE 1R18020 Build stand 1 off.

    6. 

       CAUTION

       DO NOT LET THE COMPRESSOR DISKS AND SHAFT ASSEMBLY HIT THE BUILD STAND. IF THE COMPRESSOR DISKS AND SHAFT ASSEMBLY HITS THE BUILD STAND YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

       Slowly lower the compressor disks and shaft assembly in to the build stand. Make sure the dummy stub shaft engages in the location in the bottom of the build stand.

    7. Remove the eight screws from the top of the build stand.

       NOTE

       The edge of the support ring that touches the compressor disks and shaft assembly is at an angle. Thus, one face of the support ring is shorter than the other face. The short face must go to the top.

    8. Put one half of IAE 1R18021 Support ring 1 off on to the top of the build stand; align the four holes in the support ring with the four holes in the build stand. Install four of the screws through the support ring in to the build stand. Tighten the screws.

    9. Install the other half of the support ring. Refer to step G. and H.

    10. Remove the lifting adapter and universal slinging adapter from the end of the compressor shaft.

19. SUBTASK 72-41-10-040-108 Remove the Rotating Air Seal

    1. Refer to Figure.

    2. Remove the protection cover from the rotating air seal.

    3. Remove the nuts that attach the rotating air seal to the compressor shaft.

    4. Install the IAE 1R19006 Extractor 1 off.

       1. Install the thrust plate in to the end of the compressor shaft.

       2. Assemble the extractor and locate the two puller halves on the rotating air seal. Slide the retaining ring down on to the puller halves.

       3. Install the ENERPAC 102 hydraulic jack 1 off in to the extractor and with IAE 1F10026 Hydraulic hand pump 1 off slowly remove the rotating air seal. Put the rotating air seal on to an applicable surface.

       4. Remove the thrust plate from the compressor shaft.

20. SUBTASK 72-41-10-040-109 Remove the HP Compressor Shaft

    1. Refer to Figure and Figure.

    2. Install the IAE 1R18441 Lifting adapter 1 off on to the end of the compressor shaft.

    3. Assemble the IAE 1R19008 Puller 1 off with the two split rings located on the front face of the shaft forward flange. Make sure the tufnol pads are correctly located on the rear face of the stage 12 disk.

    4. With a hoist support the compressor shaft.

    5. 

       CAUTION

       THE SET SCREWS MUST BE TIGHTENED IN SEQUENCE AND NOT MORE THAN ONE TURN AT A TIME. IF YOU DO NOT TIGHTEN THE SET SCREWS IN SEQUENCE OR IF YOU TURN MORE THAN ONE AT A TIME, YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

       Turn each of the six set screws in small increments until the shaft is released from the stage 12 disk. Lift the shaft clear of the stage 12 disk and put it on an applicable surface.

    6. Release the double retaining washers and remove the square head bolts. Discard the double retaining washers.

21. SUBTASK 72-41-10-040-110-001 Remove the Splined Nuts and Anti-score Washers (Geared Indexing Spanner Method)

    1. Refer to Figure, Figure and Figure.

    2. Install IAE 1R18029 Blanking tool 1 off in to the bore of the stages 3 to 12 compressor disks assembly.

       1. Move the handles together to compress the spring and retract the flanges.

       2. Put the blanking tool in to the bore of the stages 3 to 12 compressor disks assembly. Make sure the flanges are aligned with the space between the stage 7 and 6 compressor disks.

       3. Release the handles and put the blanking tool on to the stage 6 compressor disk.

    3. Install IAE 1R18400 Protection sleeve 1 off in to the bore of the stages 3 to 12 compressor disks assembly.

       1. Carefully lower the protection sleeve in to the bore of the stages 3 to 12 compressor disk assembly. Let the rear flange of the protection sleeve touch the rear face of the stage 12 compressor disk.

    4. 
       CAUTION
       MAKE SURE THAT THE MATING SURFACES ARE FREE OF ANY DAMAGE, BURRS AND DEBRIS BEFORE INSTALLATION OF THE IAE 1R18692 Indexing ring.

       Install the IAE 1R18692 Indexing ring 1 off on to the stage 12 compressor disk rear flange.

       1. Find the location dowel hole on the stage 12 compressor disk rear flange.

       2. Put the indexing ring (with the numbers to the top) on to the stage 12 compressor disk rear flange. Engage the dowel in the indexing ring in to the location dowel hole. Make sure the stage 12 compressor disk rear flange outer diameter is fully engaged in the indexing ring.

    5. Prepare the IAE 1R18024 Geared indexing spanner 1 off for installation.

       1. Remove the location pin from the bush in the carrier.

       2. Pull the knob (on the end of the installation arm) to move the installation arm out of the carrier.

       3. Install the retaining pin through the hole in the carrier and the installation arm.

       4. Move the carrier until it touches the carrier stop.

    6. Install the geared indexing spanner on to the indexing ring.

       1. Lift the geared indexing spanner and put it on to the indexing ring. Make sure the geared head goes in to the protection sleeve.

    7. Remove the anti-score washers and splined nuts from the special head bolt.

       1. Remove the retaining pin from the carrier and installation arm.

       2. Move the installation arm in to the bore of the stages 3 to 12 compressor disks assembly.

       3. Move the carrier away from the carrier stop until the bush is aligned with the holes in the indexing ring.

       4. Adjust the position of the geared indexing spanner until the bush is aligned with the No. 1 hole in the indexing ring.

       5. Install the location pin through the bush and the No. 1 hole.

       6. Install a Snap-on TMX60 extension in to the geared head extension. Push the extension to move the geared head towards the special head bolts.

       7. Install a Snap-on TM70B wrench on to the extension.

       8. Push the knob (on the end of the installation arm) to compress the spring. At the same time, push the wrench to make the geared head align with the special head bolts. Remove pressure from the knob.

       9. Operate the wrench to remove the splined nut from the special head bolt.

    8. Release the geared head from the splined nut.

       1. Push the knob (on the end of the installation arm) to compress the spring. At the same time, pull the wrench to move the geared head clear of the special head bolt.

       2. Remove the wrench from the extension.

       3. Pull the extension to make the geared head extension fully retract.

       4. Remove the extension from the geared head extension.

       5. Remove the location pin from the bush in the carrier.

       6. Move the carrier until it touches the carrier stop.

       7. Pull the knob (on the end of the installation arm) to move the installation arm out of the carrier.

       8. Install the retaining pin through the hole in the carrier and the installation arm. Remove the splined nut and anti-score washer from the geared head extension.

    9. Remove the other 33 anti-score washers and splined nuts from the special head bolts.

       1. Do steps F. thru H. again and again until all of the spline nuts and anti-score washers have been removed.

       2. Remove all the tooling.

       3. Discard all the splined nuts, anti-score washers, special head bolts and anti-fret plates. Do not use this hardware again.

22. SUBTASK 72-41-10-040-110-002 Remove the Splined Nuts and Anti-score Washers (Torque Spanner Method)

    1. Refer to Figure and Figure.

    2. Install IAE 1R18029 Blanking tool 1 off in to the bore of the stages 3 to 12 compressor disks assembly.

       1. Move the handles together to compress the spring and retract the flanges.

       2. Put the blanking tool in to the bore of the stages 3 to 12 compressor disks assembly. Make sure the flanges are aligned with the space between the stage 7 and 6 compressor disks.

       3. Release the handles and put the blanking tool on to the stage 6 compressor disk.

    3. Install IAE 1R18400 Protection sleeve 1 off in to the bore of the stages 3 to 12 compressor disks assembly.

       1. Carefully lower the protection sleeve in to the bore of the stages 3 to 12 compressor disk assembly. Let the rear flange of the protection sleeve touch the rear face of the stage 12 compressor disk.

    4. 
       CAUTION
       MAKE SURE THAT THE MATING SURFACES ARE FREE OF ANY DAMAGE, BURRS AND DEBRIS BEFORE INSTALLATION OF THE IAE 1R18692 Indexing ring.

       Install the IAE 1R18692 Indexing ring 1 off on to the stage 12 compressor disk rear flange.

       1. Find the location dowel hole on the stage 12 compressor disk rear flange.

       2. Put the indexing ring (with the numbers to the top) on to the stage 12 compressor disk rear flange. Engage the dowel in the indexing ring in to the location dowel hole. Make sure the stage 12 compressor disk rear flange outer diameter is fully engaged in the indexing ring.

    5. Prepare the IAE 1R18201 Torque spanner 1 off for installation.

       1. Make sure the nut (part of the IAE 1R18201 Torque spanner) is loose.

       2. Install a Snap-on TES10 socket on to the arm.

       3. Install the arm, socket end first, through the bore of the stages 3 to 12 compressor disk. Put the arm through the space between the stage 8 and 9 compressor disk.

    6. Install the torque spanner on to the indexing ring.

       NOTE

       Make sure the spring is installed on the location pin.

       NOTE

       The hole position numbers are identified on the indexing ring and on Figure.

       1. Put the rod through the bore of the stages 3 to 12 compressor disks. Engage the location pin in to the indexing ring at the No. 1 position.

    7. Remove the anti-score washers and splined nuts from the special head bolt.

       1. Engage the end of the rod on to the end of the arm.

       2. Install the screw, through the rod, in to the arm. Hand tighten the screw.

          NOTE

          Make sure the locator touches the top plate before the nut is tightened.

       3. Tighten the nut to engage the socket on to the first splined nut.

       4. Attach a torque wrench to the torque wrench location.

       5. Operate the torque wrench to remove the splined nut from the special head bolt.

    8. Move the torque spanner to the No. 2 hole position.

       1. Loosen the nut on the rod.

          NOTE

          Step H.(2) will release the socket from the splined nut.

       2. Push the top plate until the stop touches the indexing ring.

       3. Pull the top plate until the location pin is clear of the bush in the indexing ring. Make sure the rod does not move.

       4. Move the torque spanner to the No. 2 position.

          NOTE

          Make sure the locator touches the top plate before the nut is tightened.

       5. Tighten the nut to engage the socket on to the second splined nut.

    9. Do step G.(4) and G.(5) again.

    10. Remove the other 32 splined nuts and anti-score washers.

        1. Do steps F. thru I. again and again until all of the spline nuts and anti-score washers have been removed.

        2. Remove all the tooling.

        3. Discard all the splined nuts, anti-score washers, special head bolts and anti-fret plates. Do not use this hardware again.

23. SUBTASK 72-41-10-040-111 Remove the Stage 9 to 12 Disks and Vortex Reducer Ring from the Stage 3 to 8 Disks

    1. Refer to Figure, Figure and Figure.

    2. Install the IAE 1R18691 Lifting fixture 1 off on to the stage 12 disk.

    3. Install the IAE 1R18067 Extractor 1 off on to the compressor disks assembly.

       1. Assemble the lower split ring and install it on the stage 8 disk.

       2. Assemble the top split ring assembly and install it on the stage 9 disk. Make sure the six set screws touch the lower split ring assembly.

    4. With a hoist support the stage 9 to 12 disks.

    5. 

       CAUTION

       THE SET SCREWS MUST BE TIGHTENED IN SEQUENCE AND NOT MORE THAN ONE TURN AT A TIME. IF YOU DO NOT TIGHTEN THE SET SCREWS IN SEQUENCE OR IF YOU TURN MORE THAN ONE AT A TIME, YOU CAN DAMAGE THE EQUIPMENT/MATERIALS.

       Turn each of the set screws in small increments until the stage 9 to 12 disks is released from the stage 3 to 8 disks.

    6. Lift the stage 9 to 12 disks clear of the stage 3 to 8 disks.

    7. Install the IAE 1R18025 Turnover stand adapter 1 off on to the IAE 1R18322 Turnover stand 1 off.

    8. Install the stage 9 to 12 disks in the turnover stand.

24. SUBTASK 72-41-10-040-112 Remove the Vortex Reducer Ring from the Stage 9 to 12 Disks

    1. Refer to Figure.

    2. Operate the turnover stand to turn the stage 9 to 12 disks until the lifter is at the bottom.

    3. Install the IAE 1R18443 Puller 1 off on to the vortex reducer ring.

       1. Loosen the eight clamp nuts sufficient to let the four clamps be moved to the center of the removal puller.

       2. Lift the clamp nuts and move the clamps to the center of the removal puller.

       3. Make sure that the six extraction bolts are fully retracted.

       4. 

          CAUTION

          YOU MUST MAKE SURE THERE IS A CLEARANCE BETWEEN THE SPECIAL HEADED BOLTS AND THE HOLES IN THE REMOVAL PULLER. IF THERE IS NO CLEARANCE BETWEEN THE SPECIAL HEADED BOLTS AND THE HOLES IN THE REMOVAL PULLER YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

          Use the handles to lift the removal puller and install it on to the stage 9 disk. Engage the special headed bolts through the holes in the extractor.

       5. Make sure that all of the pressure ring touches the stage 9 disk.

       6. Lift the clamp nuts and move the clamps to the outer edge of the removal puller. Make sure the clamps are engaged correctly on the vortex reducer ring. Tighten the eight clamp nuts.

       7. 

          CAUTION

          THE EXTRACTION BOLTS MUST BE TIGHTENED IN SEQUENCE AND NOT MORE THAN ONE TURN AT A TIME. IF YOU DO NOT TIGHTEN THE EXTRACTION BOLTS IN SEQUENCE OR IF YOU TURN MORE THAN ONE AT A TIME, YOU CAN CAUSE DAMAGE TO THE EQUIPMENT/MATERIALS.

          Tighten the six extraction bolts in small increments until the vortex reducer ring is released from the stage 9 disk.

       8. Use the handles to lift the removal puller and vortex reducer ring assembly off the stage 9 disk. Put the assembly on an applicable surface and remove the removal puller.

25. SUBTASK 72-41-10-040-113 Remove the Stage 3 to 8 Disks from the Build Stand

    1. Refer to Figure, Figure and Figure.

    2. Install the IAE 1R18065 Lifter 1 off on to the stage 8 disk.

    3. Remove the bolts that attach the dummy stub shaft to the stage 3 to 8 disks.

    4. Attach a hoist and lift the stage 3 to 8 disks clear of the build stand and the dummy stub shaft and install it in the IAE 1R18092 Support tool 1 off.

    5. Remove the IAE 1R18673 Dummy stub shaft and install the curvic protector.

Figure: Install the Protection Cover on the Rotating Air Seal

Install the Protection Cover on the Rotating Air Seal



Figure: Install the Beam Sling on to the HP Compressor Rotor Assembly

Sheet 1



Legend

Install the Beam Sling on to the HP Compressor Rotor Assembly

Sheet 1

Close

Figure: Remove/Install the Universal Sling Adapters

Sheet 2



Legend

Remove/Install the Universal Sling Adapters

Sheet 2

Close

Figure: Install the HP Compressor Rotor Assembly on to the Safety Support Stand

Install the HP Compressor Rotor Assembly on to the Safety Support Stand



Figure: Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 1



Legend

Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 1

Close

Figure: Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 2



Legend

Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 2

Close

Figure: Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 3



Legend

Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 3

Close

Figure: Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 4



Legend

Install the HP Compressor Rotor in to the Tip Check Fixture

Sheet 4

Close

Figure: Set the Transducer Carriers to Zero

Set the Transducer Carriers to Zero



Figure: Measure the Seal and Stator Path Diameters

Sheet 1



Legend

Measure the Seal and Stator Path Diameters

Sheet 1

Close

Figure: Measure the Seal and Stator Path Diameters

Sheet 2



Legend

Measure the Seal and Stator Path Diameters

Sheet 2

Close

Figure: Install the HP Compressor Rotor Assembly in to the Trolley

Install the HP Compressor Rotor Assembly in to the Trolley



Figure: HP Compressor Rotor Tip Radius

Sheet 1



Legend

HP Compressor Rotor Tip Radius

Sheet 1

Close

Figure: HP Compressor Rotor Tip Radius

Sheet 2



Legend

HP Compressor Rotor Tip Radius

Sheet 2

Close

Figure: Stage 3 Disk Curvic Coupling Bolts Torque Sequence

Stage 3 Disk Curvic Coupling Bolts Torque Sequence



Figure: Install the HP Compressor Rotor Assembly in to the Build Stand

Install the HP Compressor Rotor Assembly in to the Build Stand



Figure: Remove the Rotating Air Seal

Remove the Rotating Air Seal



Figure: Install the Lifter on the Compressor Shaft

Install the Lifter on the Compressor Shaft



Figure: Remove the HP Compressor Shaft

Remove the HP Compressor Shaft



Figure: Remove the Splined Nuts and the Anti-Score Washers

Sheet 1



Legend

Remove the Splined Nuts and the Anti-Score Washers

Sheet 1

Close

Figure: Remove the Splined Nuts and the Anti-Score Washers

Sheet 2



Legend

Remove the Splined Nuts and the Anti-Score Washers

Sheet 2

Close

Figure: Remove the Splined Nuts and the Anti-Score Washers

Sheet 3



Legend

Remove the Splined Nuts and the Anti-Score Washers

Sheet 3

Close

Figure: Remove the Splined Nuts and the Anti-Score Washers

Sheet 4



Legend

Remove the Splined Nuts and the Anti-Score Washers

Sheet 4

Close

Figure: Remove the Splined Nuts and the Anti-Score Washers

Sheet 5



Legend

Remove the Splined Nuts and the Anti-Score Washers

Sheet 5

Close

Figure: Install the Lifter on the Stage 12 Disk

Install the Lifter on the Stage 12 Disk



Figure: Remove the Stage 9 to 12 Disks from the Stage 3 to 8 Disks

Remove the Stage 9 to 12 Disks from the Stage 3 to 8 Disks



Figure: Install the Stage 9 to 12 Disks in the Turnover Stand

Install the Stage 9 to 12 Disks in the Turnover Stand



Figure: Remove the Vortex Reducer Ring from the Stage 9 to 12 Disks

Remove the Vortex Reducer Ring from the Stage 9 to 12 Disks



Figure: Install the Lifter on to the Stage 8 Disk

Install the Lifter on to the Stage 8 Disk



Figure: Remove the Dummy Stub Shaft

Remove the Dummy Stub Shaft



Figure: Install the Stage 3 to 8 Disks in the Support Tool

Install the Stage 3 to 8 Disks in the Support Tool



Figure: Remove the Blades from the HP Compressor Rotor Assembly

Remove the Blades from the HP Compressor Rotor Assembly