TASK 72-41-30-440-002-B02 HPC Front Case And Vane Assembly - Measure And Machine The Stage 6 Stator Vanes And Stage 3 Through 6 Rotor Path Rings (Mechanical Clamping Tool Method), Assembly-002

DMC:V2500-A5-72-41-3000-01A-710C-B|Issue No:003.00|Issue Date:2020-02-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

V2500-A5

Common Information

TASK 72-41-30-440-002-B02 HPC Front Case And Vane Assembly - Measure And Machine The Stage 6 Stator Vanes And Stage 3 Through 6 Rotor Path Rings (Mechanical Clamping Tool Method), Assembly-002

General

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 standard torque data and procedures, refer to SPM TASK 70-41-00-400-501, SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-400-501.

Special torque data and assembly tolerances are included in the procedure.

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

To identify, lubricate and install seal rings, refer to the SPM TASK 70-44-01-400-501.

After assembly apply CoMat 07-038 AIR DRYING ENAMEL to any damaged surface protection, joint flanges and parts used to attach. Use the correct color of the air drying enamel. Refer to SPM TASK 70-63-02-380-501.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

This TASK gives the procedure to measure and then machine the stage 6 stator vanes and the stage 3, 4, 5 and 6 rotor path rings. The subsequent TASKS give the procedure to assemble HP compressor front cases.

TASK 72-41-30-440-001-C00 (ASSEMBLY-001, CONFIG-003) Install the HP Compressor Stage 3, 4 and 5 Rotor Path Rings and Stage 6 Rotor Ring Segments

Install the VIGV by TASK 72-41-30-440-003-B00 (ASSEMBLY-003, CONFIG-002).

Install the Stage 3 VSV by TASK 72-41-30-440-004-B00 (ASSEMBLY-004, CONFIG-002).

Install the Stage 4 VSV by TASK 72-41-30-440-005-B00 (ASSEMBLY-005, CONFIG-002).

Install the Stage 5 VSV by TASK 72-41-30-440-006-B00 (ASSEMBLY-006, CONFIG-002).

Install the Stage 6 Stator Vanes by TASK 72-41-30-440-007-B00 (ASSEMBLY-007, CONFIG-002).

Install the VIGV and the Stages 3 to 5 Bridge Pieces by TASK 72-41-30-440-008-B00 (ASSEMBLY-008, CONFIG-002).

Measure the HP Compressor Front Cases by TASK 72-41-30-440-009-B00 (ASSEMBLY-009, CONFIG-002).

Disassemble the HP Compressor Front CasesTASK 72-41-30-440-010-B00 (ASSEMBLY-010, CONFIG-002).

TASK 72-41-30-440-011-B00 (ASSEMBLY-011, CONFIG-002) Check and Set VSV System with Optimised Build and Setting Clearances - SBE 72-0400.

Machine Requirements

The information that follows is a guideline. If any additional information is necessary contact IAE.

For the rotor path ring machining, a machine is necessary that can meet the conditions that follow:

Permits a 34.00 in. (863.6 mm) diameter by 18.00 in. (457.2 mm) depth workpiece to be installed.

The workpiece must be turned in a counterclockwise direction, when viewed from the tailstock.

Permits a K grade carbide I.T.T. turning too with a 0.031 in. (0.80 mm) radius tip to be installed.

The conditions that follow must be used when you machine the rotor path linings:

A component surface speed of 70 m/min. This is equivalent to speed of 42 r.p.m.

The maximum depth of cut to be used is 0.006 in. (0.15 mm).

The feed rate is to be determined by general feel for the workpiece.

For the stator vane tip grinding, a machine is necessary that can meet the conditions that follow:

Permits a 34.00 in. (863.6 mm) diameter by 18.00 in. (457.2 mm) depth workpiece to be installed.

The workpiece must be turned in a clockwise direction, when viewed from the tailstock.

Permits a grinding set-up to be attached to the machine. It will be necessary for the grinding wheel to be turned.

The grinding wheel must be turned in a counterclockwise direction, when viewed from the tailstock.

Permits a swarf extraction unit to be installed.

The conditions that follow must be used when you are grinding the stator vane tips:

A component surface speed of 34 m/min. This is equivalent to a speed of 23 r.p.m.

A grinding wheel surface speed of 1675 m/min. This is equivalent to a speed of approximately 4090 r.p.m. at the recommended grinding wheel diameter.

A grinding wheel diameter of between 4.6 in. (118 mm) and 5.5 in. (140 mm).

Grind the repair area to the requirements of Figure to Figure. Refer to the SPM for consumables and definition where it is appropriate.

It is recommended that you use a plunge grinding method with an infeed rate of 0,0075 mm per revolution.

Use a 'spark-out' time of 10 revolutions or 25 seconds.

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
Grinding MachineLOCALGrinding Machine
Mechanical BrushLOCALMechanical Brush
LatheLOCALLathe
Vibration peening equipmentLOCALVibration peening equipment
K Grade I.T.T. Turning ToolLOCALK Grade I.T.T. Turning Tool
Protective GlovesLOCALProtective Gloves
IAE 1R18205 Lifting tool0AM53IAE 1R182051
IAE 1R18207 Support stand0AM53IAE 1R182071
IAE 1R18212 Support ring0AM53IAE 1R182121
IAE 1R18321 Turnover stand0AM53IAE 1R183211
IAE 1R18410 Transport/park stand0AM53IAE 1R184101
IAE 1R18411 Machine fixture0AM53IAE 1R184111
IAE 1R18413 Turnover stand adaptor0AM53IAE 1R184131
IAE 1R18414 Boring bar0AM53IAE 1R184141
IAE 1R18417 Lifting Turnover trunnions0AM53IAE 1R184172
IAE 1R18418 Multiflex holder0AM53IAE 1R184181
IAE 1R18419 Probe holder0AM53IAE 1R184191
IAE 1R18430 Turning holder0AM53IAE 1R184301
IAE 1R18431 Lifting beam0AM53IAE 1R184311
IAE 1R19284 Lifting fixture0AM53IAE 1R192842
IAE 1R19834 Centralising tool0AM53IAE 1R198341
IAE 1R19835 Clamping tool0AM53IAE 1R198351
IAE 3R18232 Lifting beam0AM53IAE 3R182321
VacuumLOCALVacuum1

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 07-038 AIR DRYING ENAMELk3504CoMat 07-038
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-30-440-215 Install the Stage 6 Stator Vanes

      CAUTION

      THE STAGE 6 STATOR VANES HAVE BEEN IDENTIFIED WITH THEIR POSITION NUMBERS. MAKE SURE THE VANES ARE INSTALLED IN THEIR CORRECT POSITIONS. IF THE VANES ARE NOT INSTALLED IN THEIR CORRECT POSITION YOU CAN CAUSE DAMAGE TO THE STATOR VANES.

    1. Refer to Figure, Figure and Figure.

      2. Install 20 stage 6 stator vanes (HPC Stator Vanes (72-41-22,01-400) and HPC Stator Vanes (72-41-22,01-448) or HPC Stator Vanes (72-41-22,01-450)) in to the right hand side of the upper half HP compressor front case.

      1. Engage the first stator vane in to the stage 6 front and rear liners. Push the vane in a counterclockwise direction until it touches the stop vane installed at the top center position.

      2. Engage the remaining 19 stage 6 stator vanes in to the stage 6 front and rear liners. Push each vane in a counterclockwise direction until their platforms touch.

      3. Install 20 stage 6 stator vanes (HPC Stator Vanes (72-41-22,01-400) and HPC Stator Vanes (72-41-22,01-448) or HPC Stator Vanes (72-41-22,01-450)) and one stage 6 stop vane HPC Stator Vanes (72-41-22,01-350) in to the left hand side of the upper half HP compressor front case.

      1. Engage the first stator vane in to the stage 6 front and rear liners. Push the vane in a clockwise direction until it touches the stop vane installed at the top center position.

      2. Engage the remaining 19 stage 6 stator vanes in to the stage 6 front and rear liners. Push each vane in a clockwise direction until their platforms touch.

      3. Engage the stage 6 stop vane in to the stage 6 front and rear liners. Push the stop vane in a clockwise direction until the stop touches the rotor ring segment.

      4. Install 20 stage 6 stator vanes (HPC Stator Vanes (72-41-22,01-400) and HPC Stator Vanes (72-41-22,01-448) or HPC Stator Vanes (72-41-22,01-450)) in to the left hand side of the lower half HP compressor front case.

      1. Engage the first stator vane in to the stage 6 front and rear liners. Push the vane in a counterclockwise direction until it touches the stop vanes installed at the bottom center position.

      2. Engage the remaining 19 stage 6 stator vanes in to the stage 6 front and rear liners. Push each vane in a counterclockwise direction until their platforms touch.

      5. Install 20 stage 6 stator vanes (HPC Stator Vanes (72-41-22,01-400) and HPC Stator Vanes (72-41-22,01-448) or HPC Stator Vanes (72-41-22,01-450)) and one stage 6 stop vane HPC Stator Vanes (72-41-22,01-350) in to the right hand side of the lower half HP compressor front case.

      1. Engage the first stator vane in to the stage 6 front and rear liners. Push the vane in a clockwise direction until it touches the stop vane installed at the bottom center position.

      2. Engage the remaining 19 stage 6 stator vanes in to the stage 6 front and rear liners. Push each vane in a clockwise direction until their platforms touch.

      3. Engage the stage 6 stop vane in to the stage 6 front and rear liners. Push the stop vane in a clockwise direction until the stop touches the rotor ring segment.

    2. SUBTASK 72-41-30-440-216 Install the HP Compressor Front Case Split Line Flange Bolts

    1. Refer to Figure and Figure.

      2. Install IAE 1R19284 Lifting fixture 2 off, on to the rear flanges of the upper and lower half front cases.

      1. Use a suitable hoist and lift a lifting fixture in to position on each HP compressor half front case rear flange.

      2. Engage the two location pins on the lifting fixture in the bolt holes in the split line flanges.

      3. Adjust the six pins and engage them in six bolt holes in the rear flange of each HP compressor half front case.

    3. Use a suitable hoist and lift the two HP compressor half front cases on to the inspection table. Carefully lower the HP compressor half front cases on to the inspection table.

    4. Remove the two lifting fixtures from the HP compressor half front cases.

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

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

    7. Install the two stage 6 sealing strips HP COMPRESSOR SPLIT CASE (72-41-31,01-680) in to the slots in the stage 6 rotor ring segments at the split line flanges.

    8. Align the HP compressor front case split line flanges. As the split line flanges are aligned, engage the sealing strips in their opposite rotor path ring segments.

    9. CAUTION

      YOU MUST NOT LET THE BOLTS TURN WHEN YOU INSTALL THEM AND WHEN YOU TORQUE THE NUTS. THE BOLTS ARE A CLOSE TOLERANCE FIT.

      Install the four bolts HPC Assembly (72-41-00,01-112) and four nuts HPC Assembly (72-41-00,01-101) at positions 23, 27, 29 and 31. Install the 28 bolts HPC Assembly (72-41-00,01-108), 28 spacers HPC Assembly (72-41-00,01-104) and 28 nuts HPC Assembly (72-41-00,01-102) at the remaining split line flange positions.

    10. Torque the nuts to 180 lbfin to 220 lbfin (20.00 Nm to 25.00 Nm). Refer to Figure for the sequence to torque the nuts.

    11. CAUTION

      MAKE SURE THAT THE STAGE 6 STATOR VANES CAN MOVE IN THEIR LOCATIONS.

      Do a check to make sure all the stage 6 stator vanes can be moved in their locations. Any vane that can not be moved must be renewed.

    3. SUBTASK 72-41-30-220-453 Measure the Stage 6 Stator Vanes Inter-Platform Clearances

    1. Refer to Figure.

      2. Measure and record the inter-platform clearances at the stage 6 stop vanes. Measure all four clearances at the same time.

      1. Push the stage 6 stator vanes in a clockwise direction until their platforms touch and they touch a stop vane.

      2. Measure and record the clearance between the last stator vane and the adjacent stop vane platforms. The clearance must be 0.030 in. (0.77 mm) to 0.046 in. (1.17 mm).

      3. NOTE

        If the inter-platform clearances are not correct do Step.

        Do Step and Step at the remaining three stage 6 stop vanes.

    4. SUBTASK 72-41-30-440-217 Install the Stage 6 Undersize Vanes

      NOTE

      To get the specified inter-platform clearance at the four stage 6 stop vanes HPC Stator Vanes (72-41-22,01-350), use the undersize stator vanes HPC Stator Vanes (72-41-22,01-450) or stage 6 stator vanes HPC Stator Vanes (72-41-22,01-448) as necessary.
      This SUBTASK must only be done if the inter-platform clearances measured in SUBTASK 72-41-30-220-453 are not correct.

    1. Remove the HP compressor front case split line flange nuts, spacers and bolts as given in Step.

    2. CAUTION

      YOU MUST OBEY THESE INSTRUCTIONS WHEN YOU INSTALL THE UNDERSIZE VANES:
      A MAXIMUM OF FIVE UNDERSIZE VANES CAN BE USED BETWEEN ANY TWO ADJACENT STOP VANES.
      THE UNDERSIZE VANES MUST BE INSTALLED AT EQUAL DISTANCES BETWEEN THE STOP VANES.
      THE UNDERSIZE VANES MUST NOT BE INSTALLED ADJACENT TO STOP VANES OR OTHER UNDERSIZE VANES.

      Remove and install the stage 6 stator vanes HPC Stator Vanes (72-41-22,01-448) or stage 6 undersize vanes HPC Stator Vanes (72-41-22,01-450) as necessary. One undersize vane will give an increase in the inter-platform clearance of 0.0157 in. (0.400 mm).

    3. Install the HP compressor front case split line flange bolts as given in Step.

    4. Measure the stage 6 stator vanes inter-platform clearances as given in Step.

    5. SUBTASK 72-41-30-440-232 Install the Clamping Tool for HP Compressor Front Case Stage 6

      CAUTION

      MAKE SURE THE TOOL FACES AND COMPONENT FACES THAT TOUCH ARE CLEAN AND NOT DAMAGED. DIRTY OR DAMAGED SURFACES CAN CAUSE INCORRECT INDICATIONS AND CAN DAMAGE COMPONENTS.

      CAUTION

      YOU MUST REPLACE DAMAGED CLAMPING ELEMENTS. DAMAGED CLAMPING ELEMENTS CAN CAUSE DAMAGE TO THE STATOR VANES DURING THE GRINDING PROCEDURE.

      NOTE

      Rotor paths must be machined before fitting the mechanical clamping tool.

    1. Refer to Figure and Figure.

      2. Do the checks that follow the clamping elements (part of the IAE 1R19835 Clamping tool) before use.

      1. Make sure that the rubber protection faces of the clamping elements are clean and free of damage. Damaged rubber protection faces can cause the metal parts of the clamping element to touch the stator vanes. If the metal parts of the clamping element touch the stator vane, they can cause damage.

      2. Make sure that the clamping elements are not bent out of shape.

      3. Make sure that the screws that adjust the clamping elements have been screwed out to the mechanical stops. Do not turn the screws past the mechanical stops.

      4. Replace any damaged clamping elements.

      3. Install the clamping elements at stage 6.

      1. Identify the clamping element with its stage number and the top position. The number one span element must be installed after the number two and three clamping elements.

      2. CAUTION

        MAKE SURE THAT THE EYE BOLTS ARE REMOVED FROM THE TOP PLATE AFTER INSTALLATION.

        CAUTION

        TAKE CARE NOT TO MARK THE VANES WHEN YOU INSERT THE BOLTS. ALWAYS USE AN ALLEN KEY TO PREVENT DAMAGE TO THE THREADS OF THE BOLTS.

        Place the top plate No. 1 equally on the vanes and install. Hold a corresponding bottom plate below the vanes aligned by number and tighten the four bolts.

      3. Set the power driver to a torque value of 9 lbfin (1 Nm) and tighten the four bolts sequentially.

      4. When all the four bottom plates are fitted, insert remaining bolts and tighten with to a torque value of 9 lbfin (1 Nm).

    6. SUBTASK 72-41-30-440-233 Install the Centralising Tool for HP Compressor Front Case Stage 6

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

    2. Install the centralising pillar (part of the IAE 1R19834 Centralising tool) on the draw bar.

    3. Install the spider (part of the IAE 1R19834 Centralising tool) on the setting bush for stage 6 with the four arms inward.

    4. Move the spider arms outwards.

    5. WARNING

      DO NOT INFLATE THE CENTRALISING RING TYRE TO 3.5 BAR (51 PSI). IF YOU PUT TOO MUCH PRESSURE IN THE TYRE, THE TYRE CAN EXPLODE. AN EXPLOSION CAN CAUSE INJURY TO PERSONNEL AND/OR DAMAGE EQUIPMENT.

      Connect the airline and pressure gauge to the tyre of centralising ring and inflate to a maximum pressure of 3.5 bar (51 psi).

    6. Disconnect the airline.

    7. Put the four spider arm inwards and carefully remove the spiders.

    8. Remove the centralising pillar.

    9. Set the power driver to torque value of 18 lbfin (2 Nm).

    10. Tighten the bolts (part of the IAE 1R19834 Centralising tool) on the stage 6 clamps with the power driver.

    11. Deflate the stage 6 centralising ring tyre to collapse and carefully remove the centralising ring tyre.

    12. Keep the centralising ring tyre in the storage carefully.

    13. Remove the power driver.

    14. Examine the clamp plates are fitted correctly.

    7. SUBTASK 72-41-30-440-220 Assemble the Tools to Turn the HP Compressor Front Cases

    1. Refer to Figure.

      2. Install IAE 1R18413 Turnover stand adaptor 1 off in IAE 1R18321 Turnover stand turnover stand 1 off.

      1. Put the turnover adapter in to position in the turnover stand.

      2. Install three bolts with washers, through each flange of the turnover adapter, to attach the turnover adapter to the turnover stand.

      3. Tighten the six bolts.

      3. Install IAE 1R18411 Machine fixture 1 off in to the turnover adapter.

      1. Put the machine fixture in to position in the turnover adapter. Align the locating pin in the turnover adapter with the location hole in the machine fixture.

      2. Install the four bolts with washers through the bottom of the turnover adapter in to the machine fixture.

      3. Tighten the four bolts.

    8. SUBTASK 72-41-30-440-221 Install the HP Compressor Front Case in the Machine Fixture

    1. Refer to Figure, Figure and Figure.

      2. Install IAE 1R18205 Lifting tool 1 off, on the HP Compressor front case rear flange.

      1. Release the six adjusting screws then remove the six bolts, washers and the two clamps from the lifting fixture.

      2. Use a suitable hoist and lift the lifting fixture on to the HP compressor front case rear flange.

      3. Install the two clamps at their correct positions on the lifting fixture and the HP Compressor front case rear flange.

      4. Install the six bolts and washers to attach the two clamps to the lifting tool. Do not tighten the six bolts.

      5. Adjust the six adjusting screws until the two clamps touch the front face of the rear flange of the HP Compressor front case.

      6. Tighten the six bolts installed in Step.

    3. Use a suitable hoist attached to the lifting eye on the lifting fixture and lift the HP Compressor front case from the stand.

      4. Install the HP compressor front case in IAE 1R18411 Machine fixture 1 off.

      1. Align the four dowels in the machine fixture with the four dowel holes in the front flange of the HP Compressor front case.

      2. Align the 10 studs on the machine fixture with 10 holes in the front flange of the HP Compressor front case.

      3. Carefully lower the HP Compressor front case on to the machine fixture.

      4. Install 10 washers and nuts onto the 10 studs.

      5. Torque the 10 nuts to 100 lbfin (11.5 Nm).

      5. Remove the lifting fixture from the HP Compressor front case rear flange.

      1. Release the six adjusting screws.

      2. Remove the six bolts and washers which attach the two clamps to the lifting fixture.

      3. Remove the two clamps.

      4. Use a suitable hoist and remove the lifting fixture from the HP Compressor front case rear flange.

      5. Attach the two clamps to the lifting fixture with the six bolts and washers.

    6. Use the turnover mechanism of the turnover stand to turn the HP Compressor front case in to the horizontal position.

    7. Install IAE 3R18232 Lifting beam 1 off on to the HP Compressor front case and machine fixture.

    8. Use a suitable hoist and lift the HP Compressor front case and machine fixture from the turnover stand. Lower the assembly in to IAE 1R18410 Transport/park stand 1 off.

    9. Remove the hoist and send the assembly to the machine shop.

    9. SUBTASK 72-41-30-324-054 Machine the Stage 6 Stator Vanes

    1. Refer to Figure.

    2. Lift the assembled HP Compressor front case and machine fixture from the transport/park stand.

    3. Install the assembly in the grinding machine. Remove the lifting adapter.

    4. Set the assembly in the center of the grinding machine.

      NOTE

      The material that is removed must not touch the stator vane aerofoils.

    5. Use the conditions given in 3. Machine Requirements, to machine the stage 6 stator vanes to the dimensions given in Figure. Write a record of the dimensions which the stator vanes are machined to.

    6. Use a mechanical brush to remove the burrs from the stator vane tips.

    7. Measure the stator vane tip profile.

    8. Install IAE 3R18232 Lifting beam 1 off, on to the HP Compressor front case and the machine fixture.

    9. Use a suitable hoist and remove the HP Compressor front case and the machine fixture from the grinding machine.

    10. SUBTASK 72-41-30-325-053 Machine the Stage 3, 4, 5 and 6 Rotor Path Linings

    1. Refer to Figure and Figure.

    2. Install the assembly in the lathe. Remove the lifting adapter.

    3. Set the assembly in the center of the lathe.

      4. Set up the tools to machine the stage 3, 4, 5 and 6 rotor path linings.

      1. Attach the IAE 1R18414 Boring bar 1 off to the machine tool post. Safety with the three set screws.

      2. Install the IAE 1R18418 Multiflex holder 1 off in the locating slot on the measure support. Safety with the three grub screws.

      3. Attach the IAE 1R18430 Turning holder 1 off at the measurement holder interface. Safety with the allen screw.

      4. To measure the rotor path linings, remove the turning holder and attach the IAE 1R18419 Probe holder 1 off to the measurement holder interface. Safety with the allen screw.

    5. Use the conditions given in 3. Machine Requirements, to machine the stage 4, 5 and 6 rotor path linings to the dimensions given in Figure.

    6. When the rotor path linings have been machined remove the unwanted abradable lining. Remove the unwanted abradable lining as shown in detail A on Figure at the front and rear of each rotor path linings. Remove only the minimum quantity of abradable lining to show the metal at the front and rear of the lining.

    7. Remove all the unwanted material after the assembly has been machined.

    8. Install IAE 3R18232 Lifting beam 1 off on to the HP Compressor front case and machine fixture.

    9. Remove the HP Compressor front case and machine fixture from the lathe.

    10. Install the HP Compressor front case and machine fixture in IAE 1R18410 Transport/park stand 1 off.

    11. Send the assembly to the assembly shop.

    11. SUBTASK 72-41-30-440-223 Install the HP Compressor Front Cases on the Stand

    1. Install IAE 3R18232 Lifting beam 1 off on to the HP Compressor front case and machine fixture. Refer to Step.

    2. Use a suitable hoist and install the assembly in to IAE 1R18413 Turnover stand adaptor 1 off. The turnover adapter is installed in the turnover stand. Refer to Step. Remove the lifting adapter.

    3. Use the turnover mechanism of the turnover stand to turn the HP Compressor front case to the vertical position.

    4. Install IAE 1R18205 Lifting tool 1 off as given in Step.

    5. Remove the 10 nuts and washers which attach the HP Compressor front case to the machine fixture.

    6. Use a suitable hoist and lift the HP Compressor front case from the machine fixture.

    7. Carefully lower the HP Compressor front case on to IAE 1R18207 Support stand 1 off.

    8. Remove the lifting fixture as given in Step.

    12. SUBTASK 72-41-30-110-053 Clean and Disassemble the HP Compressor Front Cases and the Stage 6 Stator Vanes

    1. Use a Vacuum to remove any loose swarf or dust which may have accumulated during the grinding process.

    2. Clean the HP Compressor front cases and Stage 6 stator vanes by TASK 70-11-03-300-503

    3. CAUTION

      YOU MUST NOT LET THE BOLTS TURN WHEN YOU REMOVE THEM. THE BOLTS ARE A CLOSE TOLERANCE FIT.

      Remove the 32 nuts, the 32 spacers and the 32 bolts from the HP Compressor front case split line flanges.

    4. Carefully move the upper and lower HP Compressor front cases apart. Make sure the sealing strips at the split line flanges are kept in their locations.

      NOTE

      The stop vanes at the top center position and the bottom center position are kept in position by the stage 6 rotor path ring segments. Do not remove these two stop vanes.

    5. Remove the stage 6 stop vanes and the stage 6 stator vanes from the HP Compressor front cases. Make sure that the stop vanes and stator vanes have been identified with their position numbers. Use vibration peening equipment to identify any vanes not already identified.

    13. Figure: Install the Stage 6 Stator Vanes

    Sheet 1

    Legend
    Install the Stage 6 Stator Vanes

    Sheet 1

    Close

    Figure: Install the Stage 6 Stator Vanes

    Sheet 2

    Legend
    Install the Stage 6 Stator Vanes

    Sheet 2

    Close

    Figure: Install the Stage 6 Stator Vanes

    Sheet 3

    Legend
    Install the Stage 6 Stator Vanes

    Sheet 3

    Close

    Figure: Install the Lifting Fixture

    Install the Lifting Fixture

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

    Install the HP Compressor Front Case Split Line Flange Bolts

    Figure: Measure the Inter-Platform Clearances

    Measure the Inter-Platform Clearances

    Figure: Install the Clamping Tool

    Sheet 1

    Legend
    Install the Clamping Tool

    Sheet 1

    Close

    Figure: Install the Clamping Tool

    Sheet 2

    Legend
    Install the Clamping Tool

    Sheet 2

    Close

    Figure: Install the Centralising Tool

    Sheet 1

    Legend
    Install the Centralising Tool

    Sheet 1

    Close

    Figure: Install the Centralising Tool

    Sheet 2

    Legend
    Install the Centralising Tool

    Sheet 2

    Close

    Figure: Install the Centralising Tool

    Sheet 3

    Legend
    Install the Centralising Tool

    Sheet 3

    Close

    Figure: Install the Centralising Tool

    Sheet 4

    Legend
    Install the Centralising Tool

    Sheet 4

    Close

    Figure: Assemble the Tools to Turn the HP Compressor Front Case

    Assemble the Tools to Turn the HP Compressor Front Case

    Figure: Install the Lifting Fixture

    Install the Lifting Fixture

    Figure: Install the HP Compressor Front Case in the Machine Fixture

    Sheet 1

    Legend
    Install the HP Compressor Front Case in the Machine Fixture

    Sheet 1

    Close

    Figure: Install the HP Compressor Front Case in the Machine Fixture

    Sheet 2

    Legend
    Install the HP Compressor Front Case in the Machine Fixture

    Sheet 2

    Close

    Figure: Machine the Stage 6 Stator Vanes

    Machine the Stage 6 Stator Vanes

    Figure: Dimensions to Machine the Stage 3, 4, 5 and 6 Rotor Path Linings

    Sheet 1

    Legend
    Dimensions to Machine the Stage 3, 4, 5 and 6 Rotor Path Linings

    Sheet 1

    Close

    Figure: Dimensions to Machine the Stage 3, 4, 5 and 6 Rotor Path Linings

    Sheet 2

    Legend
    Dimensions to Machine the Stage 3, 4, 5 and 6 Rotor Path Linings

    Sheet 2

    Close

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised step. (19VG309)

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
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Link not Found
Manufacturer Code:00BB6
Supply Number:CoMat 07-038
Type:sp01
Supply Short Name:CoMat 07-038 AIR DRYING ENAMEL
Supply Name:CoMat 07-038 AIR DRYING ENAMEL
Specification Groups:
Doc NumberType
OMAT:7/22B (RR REF)IP9138 R1
JCR-029 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
K3504
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:Grinding Machine
Tool Name:Grinding Machine
Manufacturer Code:0AM53
Tool Number:IAE 1R18205
Tool Name:IAE 1R18205 Lifting tool
Manufacturer Code:0AM53
Tool Number:IAE 1R18207
Tool Name:IAE 1R18207 Support stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18212
Tool Name:IAE 1R18212 Support ring
Manufacturer Code:0AM53
Tool Number:IAE 1R18321
Tool Name:IAE 1R18321 Turnover stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18410
Tool Name:IAE 1R18410 Transport/park stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18411
Tool Name:IAE 1R18411 Machine fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18413
Tool Name:IAE 1R18413 Turnover stand adaptor
Manufacturer Code:0AM53
Tool Number:IAE 1R18414
Tool Name:IAE 1R18414 Boring bar
Manufacturer Code:0AM53
Tool Number:IAE 1R18417
Tool Name:IAE 1R18417 Lifting Turnover trunnions
Manufacturer Code:0AM53
Tool Number:IAE 1R18418
Tool Name:IAE 1R18418 Multiflex holder
Manufacturer Code:0AM53
Tool Number:IAE 1R18419
Tool Name:IAE 1R18419 Probe holder
Manufacturer Code:0AM53
Tool Number:IAE 1R18430
Tool Name:IAE 1R18430 Turning holder
Manufacturer Code:0AM53
Tool Number:IAE 1R18431
Tool Name:IAE 1R18431 Lifting beam
Manufacturer Code:0AM53
Tool Number:IAE 1R19284
Tool Name:IAE 1R19284 Lifting fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R19834
Tool Name:IAE 1R19834 Centralising tool
Manufacturer Code:0AM53
Tool Number:IAE 1R19835
Tool Name:IAE 1R19835 Clamping tool
Manufacturer Code:0AM53
Tool Number:IAE 3R18232
Tool Name:IAE 3R18232 Lifting beam
Manufacturer Code:LOCAL
Tool Number:K Grade I.T.T. Turning Tool
Tool Name:K Grade I.T.T. Turning Tool
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Mechanical Brush
Tool Name:Mechanical Brush
Manufacturer Code:LOCAL
Tool Number:Protective Gloves
Tool Name:Protective Gloves
Manufacturer Code:LOCAL
Tool Number:Vacuum
Tool Name:Vacuum
Manufacturer Code:LOCAL
Tool Number:Vibration peening equipment
Tool Name:Vibration peening equipment