DMC:V2500-A5-72-45-1000-00A-710A-B|Issue No:009|Issue Date:2020-08-01

Export Control

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

Copyright

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

Applicability

V2500-A5

Common Information

TASK 72-45-10-440-001-C00 HPT Stage 1 Rotor Assembly - Assemble The HPT Stage 1 Rotor Assembly, Assembly-001

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

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

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

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

The number for each radial location must be identified in a clockwise direction. Use CoMat 06-153 FELT TIP MARKER, RAPID DRYING, CoMat 06-153X FELT TIP MARKER, RAPID DRYING, FINE POINT, BLACK, TRACE ELEMENT CERTIFIED or CoMat 06-158 MARKER, EXTRA FINE POINT(BLACK). These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

For temporary marking procedures, refer to SPM TASK 70-09-01-400-501.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

Name	Manufacturer	Part Number / Identification	Quantity
Vertical balance machine	LOCAL	Vertical balance machine
IAE 1F10052 Two cables sling	0AM53	IAE 1F10052	1
IAE 1P16006 Fixture	0AM53	IAE 1P16006	1
IAE 1P16008 Fixture	0AM53	IAE 1P16008	1
IAE 1P16014 Fixture	0AM53	IAE 1P16014	1
IAE 1P16015 Adapter	0AM53	IAE 1P16015	1
IAE 1P16029 Drift	0AM53	IAE 1P16029	1
IAE 1P16032 Calibration weight	0AM53	IAE 1P16032	1
IAE 1P16061 Support ring	0AM53	IAE 1P16061	1
IAE 1P16140 Support base	0AM53	IAE 1P16140	1
IAE 1P16220 Heater	0AM53	IAE 1P16220	1
IAE 1P16442 Calibration weight	0AM53	IAE 1P16442	1
IAE 1P16495 Installation Fixture	0AM53	IAE 1P16495	1
IAE 1P17024 Lift fixture	0AM53	IAE 1P17024	1
IAE 1P17030 Blade retainer	0AM53	IAE 1P17030	1
IAE 1P17750 Fixture	0AM53	IAE 1P17750	1
IAE 1P17763 Metering plug drift	0AM53	IAE 1P17763	1
IAE 6F10027 Heater control unit	0AM53	IAE 6F10027	1

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 01-573 WAX BLEND, PARAFFIN	24269	CoMat 01-573
CoMat 06-153 FELT TIP MARKER, RAPID DRYING	LOCAL	CoMat 06-153
CoMat 06-153X FELT TIP MARKER, RAPID DRYING, FINE POINT, BLACK, TRACE ELEMENT CERTIFIED	86874	CoMat 06-153X
CoMat 06-158 MARKER, EXTRA FINE POINT(BLACK)	0AM53	CoMat 06-158

Spares

Name	Manufacturer	Part Number / Identification	Quantity	Remark
Seal	77445	Seal	1
Seal	77445	Seal	1

Safety Requirements

NONE

Procedure

SUBTASK 72-45-10-220-064-002 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1516 (SBE 72-0240)

SBE 72-0240: New Stage 2 HPT Airseal and new Stage 1 HPT hub metering plugs.
Refer to Figure.

Reference the interference at Location 1516. If required, use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001) and TASK 72-45-13-200-001-C00 (INSPECTION-001), TASK 72-45-13-200-001-D00 (INSPECTION-001), TASK 72-45-13-200-001-E00 (INSPECTION-001) and TASK 72-45-13-200-001-F00 (INSPECTION-001).

Table 1. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	REJECT IF MORE THAN
PART IDENT	Size	Clearance	(Non-select)
LOCATION 1516
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Seal Bore
Stage 1 HPT Air Seal HPT Stage 1 Rotating Inner Air Seal And Damper (72-45-13,01-020) Rear
Outside Location Diameter
Hub Seal Bore	8.624	Intf	See TASK 72-45-11-200-001-D00 (INSPECTION-001) for acceptable select fit limits.	Intf
	8.618	0.017		0.017
Air Seal Diameter	8.635	0.009		0.008
	8.633	Intf		Intf

Table 2. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	REJECT IF MORE THAN
PART IDENT	Size	Clearance	(Non-select)
LOCATION 1516
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Seal Bore
Stage 1 HPT Air Seal HPT Stage 1 Rotating Inner Air Seal And Damper (72-45-13,01-020) rear
Outside Location Diameter
Hub Seal Bore	219.050	Intf	See TASK 72-45-11-200-001-D00 (INSPECTION-001) for acceptable select fit limits.	Intf
	218.897	0.432		0.432
Air Seal Diameter	219.329	0.229		0.203
	219.279	Intf		Intf

SUBTASK 72-45-10-220-064-003 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Hub Metering Plugs at Location 1517 (SBE 72-0451 and Pre SBE 72-0511)

CAUTION

IF ONE HUB HOLE AT LOCATION 1517 DOES NOT MEET THE DIMENSIONAL REQUIREMENTS, THEN YOU MUST NOT INSTALL A METERING PLUG AT THAT LOCATION. WRITE THIS IN THE ENGINE BUILD RECORDS.

CAUTION

IF TWO OR MORE HOLES AT LOCATION 1517 DO NOT MEET THE DIMENSIONAL REQUIREMENTS, THEN CONTACT IAE. DO NOT ASSEMBLE THE ROTOR.

NOTE

The fit 1517 limit is applicable only for Stage 1 HPT hub metering plug, PN 2A3847 installed in Stage 1 Turbine Hub PNs 2A2801 and 2A5001.

SBE 72-0451: New Stage 1 HPT hub metering plugs
Pre SBE 72-0511: New Stage 1 rotor assembly with metering plugs removed
Refer to Figure.

Reference interference at Location 1517. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001).

Table 3. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Select)	MORE THAN
LOCATION 1517
Stage 1 HPT Hub HPT Stage 1 Hub (72-45-11,01-011), Hole Diameter
Stage 1 HPT Metering PlugHPT Stage 1 Hub (72-45-11,01-040), Outside Diameter Contact Surface
Hub Hole Diameter	0.379 0.383	Intf 0.004	0.379 0.387	Intf 0.004
Metering Plug Diameter	0.387 0.391	0.012 Intf	0.387 0.391	0.012 Intf

Table 4. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Select)	MORE THAN
LOCATION 1517
Stage 1 HPT HubHPT Stage 1 Hub (72-45-11,01-011), Hole Diameter
Stage 1 HPT Metering PlugENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Outside Diameter Contact Surface
Hub Hole Diameter	9.627 9.728	Intf 0.102	9.627 9.830	Intf 0.102
Metering Plug Diameter	9.830 9.931	0.305 Intf	9.830 9.931	0.305 Intf

SUBTASK 72-45-10-220-065 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1502

Refer to Figure.

Reference clearance/interference at Location 1502. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001) and TASK 72-45-12-200-001-D00 (INSPECTION-001).

Table 5. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
LOCATION 1502
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Inside Lug Location Diameter
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Inside Lug Location Diameter
Hub Diameter	14.1667 14.162	Clear 0.002		Clear 0.003
Air Seal Diameter	14.168 14.164	0.006 Intf		0.006 Intf

Table 6. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
LOCATION 1502
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Inside
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Inside Lug Location Diameter
Hub Location	359.834 359.715	Clear 0.051		Clear 0.076
Air Seal Diameter	359.867 359.766	0.152 Intf		0.152 Intf

SUBTASK 72-45-10-220-066 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1504

Refer to Figure.

Reference clearance at Location 1504. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001) and TASK 72-45-12-200-001-D00 (INSPECTION-001).

Table 7. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
LOCATION 1504
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Outside Lug Location Diameter
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Outside Lug Location Diameter
Air Seal Diameter	17.752 17.756	Clear 0.007		Clear 0.0065
Hub Diameter	17.763 17.767	0.015 Clear		0.0165 Clear

Table 8. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
LOCATION 1504
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Outside Lug Location Diameter
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Outside Lug Location Diameter
Air Seal Diameter	450.901 451.002	Clear 0.178		Clear 0.165
Hub Diameter	451.181 451.281	0.381 Clear		0.419 Clear

SUBTASK 72-45-10-220-067 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1550

Refer to Figure.

Reference the interference at Location 1550. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001) and TASK 72-45-12-200-001-D00 (INSPECTION-001).

Table 9. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PARTS REJECT IF
PART IDENT	Size	Clearance	MORE THAN
	Use new part dimensions only if both the seal and hub are new; otherwise use worn part dimensions
LOCATION 1550
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Lug Axial Location
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Lug Axial Location
Hub Lug Axial Location	0.500 0.496	Intf 0.0275	Intf 0.0275
Air Seal Lug Axial Location	0.5435 0.5275	0.0475 Intf	0.0475 Intf

Table 10. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PARTS REJECT IF
PART IDENT	Size	Clearance	MORE THAN
	Use new part dimensions only if both the seal and hub are new; otherwise use worn part dimensions
LOCATION 1550
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Lug Axial Location
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-012), Lug Axial Location
Hub Lug Axial Location	12.700 12.599	Intf 0.6985	Intf 0.6985
Air Seal Lug Axial Location	13.800 13.400	1.2065 Intf	1.2065 Intf

SUBTASK 72-45-10-220-068 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1551

Refer to Figure.

Calculate the interference at Location 1551. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001) and TASK 72-45-12-200-001-D00 (INSPECTION-001).

Table 11. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
LOCATION 1551
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Lug Axial Location
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12,01-040), Lug Axial Location
Hub Lug Axial Location	0.500 0.496	Intf 0.018		Intf 0.016
Air Seal Lug Axial Location	0.528 0.518	0.032 Intf		0.032 Intf

Table 12. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Non-select)	MORE THAN
Location 1551
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11, 01-011) Lug Axial Location
Stage 1 HPT Air Seal ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12, 01-040), Lug Axial Location
Hub Lug Axial Location	12.700 12.599	Intf 0.460		Intf 0.406
Air Seal Lug Axial Location	13.410 13.160	0.810 Intf		0.810 Intf

SUBTASK 72-45-10-220-069 Reference Fits and Clearances of the Stage 1 HPT Air Seal, Stage 1 HPT Blade and Stage 1 Turbine Hub at Location 1552

Refer to Figure and Figure.

Reference clearance/interference at Location 1552. If required use the data written as a note in TASK 72-45-11-200-001-D00 (INSPECTION-001), TASK 72-45-14-200-001-C00 (INSPECTION-001) and TASK 72-45-15-200-001 (INSPECTION-001).

Table 13. Fits and Clearances (all dimensions are in inches)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Select)	MORE THAN
LOCATION 1552
Stage 1 HPT Air Seal (Rear) ENGINE-STAGE 1 AIR SEAL (REAR) (72-45-15,01-020), Dimension A
Stage 1 HPT Blade HPT Stage 1 Blade And Related Parts (72-45-14, 01-010), Dimension B
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Dimension C
Seal Dimension A	0.276		0.276
	0.274		0.272
Blade Dimension B	0.890		0.890
	0.882	Intf	0.882	Intf
Hub Dimension C	1.162	0.004	1.162	0.006
	1.160	0.004	1.160*	0.004
		Clear		Clear

NOTE

*Acceptable if the hub dimension is less than 1.160 in. and up to 1.159 in., and the final assembly fit 1552 is in limits and the dimensions in TASK 72-45-12-200-001-D00 Location 3 are from 0.0115 in. to 0.0155 in.

Table 14. Fits and Clearances (all dimensions are in millimeters)
	NEW PART DIMENSIONS		WORN PART DIMENSIONS	WORN PARTS REJECT IF
PART IDENT	Size	Clearance	(Select)	MORE THAN
LOCATION 1552
Stage 1 HPT Air Seal (Rear) ENGINE-STAGE 1 AIR SEAL (REAR) (72-45-15,01-020), Dimension A
Stage 1 HPT Blade HPT Stage 1 Blade And Related Parts (72-45-14,01-010), Dimension B
Stage 1 Turbine Hub HPT Stage 1 Hub (72-45-11,01-011), Dimension C
Seal Dimension A	7.010		7.010
	6.960		6.909
Blade Dimension B	22.606		22.606
	22.403	Intf	22.403	Intf
Hub Dimension C	29.514	0.102	29.514	0.152
	29.464	0.102	29.464*	0.102
		Clear		Clear

NOTE

*Acceptable if the hub dimensions is less than 29.464 mm and up to 29.438 mm and the final assembly fit 1552 is in limits and the dimensions in TASK 72-45-12-200-001-D00 Location 3 are from 0.2921 mm to 0.3937 mm.

1. Refer to Figure and Figure.
2. Measure and make a record of the Stage 1 HPT air seal (rear) (72-45-15, 01-020) Dimension A.
3. Measure and make a record of the Stage 1 HPT blade HPT Stage 1 Blade And Related Parts (72-45-14, 01-010) Dimension B.
4. Measure and make a record of the Stage 1 turbine hub HPT Stage 1 Hub (72-45-11,01-011) Dimension C.
5. 1. Add Dimensions A and B.
  2. Subtract Dimension C from the total of Dimensions A and B.
  3. Make a record of the results. This is the fit you must have at Location 1552 when you install the Stage 2 HPT air seal in TASK 72-45-00-430-001-C00 (ASSEMBLY-003).
1. 1. Install the new Stage 1 metering plugs. Refer to Repair, VRS3814 TASK 72-45-11-300-022 (Repair-022) for the required metering plug installation procedures.
  2. Inspect the installed metering plugs.
    Make sure the metering plug tangs touch the outer side of the hub hole.
1. Refer to Figure and Figure.
2. 1. Remove the shaft from the block, Figure.
  2. Remove the bar from the block.
  3. Loosen the four nuts securing the clamps to the block.
  4. Move the clamps out of the block until they can be turned.
  5. Turn the clamps until the side of the clamp foot is in line with the adjacent block diameter (approximately 90 degrees).
  6. Hold the block assembly against the turbine hub front face and turn the dowel pin until the clamp threaded end is pointing away from the hub centreline.
  7. The dowel pin should align with the arrows on the block face.
  8. Tighten the clamp nuts until the block flange face touches the rotor end face.
  9. Attach the bar to the shaft with the quick release pin.
  10. Attach a hoist to the bar.
    NOTE
    Dimension AA is used at the assembly of the HPT rotor and stator assembly.
  11. Find and write Dimension AA on the paperwork.
  12. Lift the turbine hub with the hoist.
  13. Attach the bar to the block with the quick release pin, Figure.
1. Refer to Figure.
2. Attach a second hoist to the fixture and turn the turbine hub so it is small end up.
3. Lower the turbine hub in to the IAE 1P16220 Heater 1 off.
4. Adjust the thermocouple so that it touches the turbine hub.
5. Connect the IAE 6F10027 Heater control unit 1 off to the heater.
6. Remove the IAE 1P16014 Fixture 1 off from the turbine hub.
1. Refer to Figure.
2. 1. Put the ring slotted end up, on a bench with a hoist and IAE 1F10052 Two cables sling 1 off.
  2. Install the stage 1 HPT airseal, knife edge down, on the ring.
  3. Put the stage 1 HPT airseal so the four tabs do not line up with the slots in the ring.
  4. CAUTION
    DAMAGE TO PART MAY OCCUR IF CLAMPS ARE FORCED OR IMPROPERLY INSTALLED.
    Carefully install the 36 clamps and align the taper on the clamp with the taper on the ring.
  5. Install the capscrews and the washers to hold the stage 1 HPT airseal in place.
  6. Turn the assembly with a hoist and a sling and put it down on the end face of the clamps.
  7. Install the plate assembly so that the block touches stage 1 HPT airseal.
  8. Align the bolt holes in the plate with the bolt holes in the ring.
  9. Attach the plate to the ring with the capscrews and the washers.
  10. Tighten the capscrews until there is no gap between the plate and the ring.
  11. Lift and turn the fixture, with the hoist and the sling, so the clamps are facing up.
1. Refer to Figure and Figure.
2. 1. Do a check for the clearance between the two ends of the seal.
  2. If necessary, cut one end of the seal to keep the clearance of 0.030 in. (0.8 mm) minimum to 0.225 in. (5.7 mm) maximum between the two ends.
3. Install the damper ENGINE-STAGE 1 HPT AIR SEAL (OUTER) (72-45-12, 01-020) in to the groove in the inner diameter of the stage 1 HPT airseal, Figure.
  NOTE
  The rotor parts may be heated to 300 deg F (149 deg C) to permit assembly. Minimum difference in temperature between the parts must be 200 deg F (97 deg C).
4. Heat the turbine hub with the heater.
5. Cool the stage 1 HPT airseal with dry ice.
6. Lift the fixture with a hoist and a sling and put the stage 1 HPT airseal on to the front face of the turbine hub.
7. 1. Use the balance marks to put the parts in position, Figure.
  2. Put the stage 1 HPT airseal so the balance mark is in the correct position for the vector stack.
8. Align the slots in the plate with the slots in the turbine hub.
9. Move the fixture to the lock position and lock the stage 1 HPT airseal.
10. Remove the fixture from the turbine hub.
11. 1. Install the two stage 1 HPT blades HPT Stage 1 Blade And Related Parts (72-45-14, 01-010), with one of the blades in each of the blade slots adjacent to the antirotation tabs.
  2. Check each of the locations.
  3. The antirotation tabs shall not interfere with the blade attachments.
  4. Remove the stage 1 HPT blades from the hub.
12. Adjust the position of the parts if necessary.
1. Refer to Figure.
2. Install a stage 1 HPT damper HPT Stage 1 Rotating Inner Air Seal And Damper (72-45-13, 01-010) in the stage 1 HPT airseal.
3. Install the IAE 1P16029 Drift 1 off on the stage 1 HPT airseal.
4. Lower the drift and the stage 1 HPT airseal on to the turbine front hub.
5. Put the stage 1 HPT airseal so that the balance mark is in the correct position to complete the vector stack with the turbine front hub and the other stage 1 HPT airseal Figure.
6. Fully engage the stage 1 HPT airseal on the turbine front hub with the drift.
1. Refer to Figure.
2. Install the IAE 1P16014 Fixture 1 off to the turbine front hub. Refer to Step.
3. Attach a hoist to the fixture and lift the assembly.
4. Attach a second hoist to the fixture and turn the assembly so that the small end is down.
5. Lower the assembly in to the IAE 1P16140 Support base 1 off.
6. Remove the fixture from the turbine hub.
1. Refer to Figure.
2. Loosen the two handles and retract ring so the jaws can be moved inward for clearance.
3. 1. Lift the center ring from the three jaws with the two handles. Put the handles in the spring clips located in the top weldment plate of the eye.
  2. Attach a hoist to the lifting eye.
  3. Lift the eye and install into the bore of the turbine hub until the lower weldment plate touches the rear face of the hub.
  4. Release the two handles from the spring clips and lower the center ring to push the jaws against the inner bore of the hub.
4. Move the jaws outward so the ring can be moved to the lowest position.
5. Make sure the jaws are in contact with the inside diameter shoulder of the turbine hub.
6. Tighten the handles to make the eye touch the rear face of the turbine hub.
1. Refer to Figure.
2. Attach a hoist to the lifting eye.
3. Lift the assembly with the hoist and lower it on to the IAE 1P16061 Support ring 1 off.
4. Remove the hoist but do not remove the lifting eye.
1. Refer to Figure.
2. Install and attach the IAE IAE 1P16015 Adapter 1 off to the lever arm on the moment weighing equipment.
3. Zero the moment weighing equipment.
  NOTE
  The blade must touch the dowel pin and the root must be seated on the pin.
4. Install the blade root on the dowel pin in the locator assembly. Lift the clamp and move the blade root to the side of the blade adapter.
5. Release the pressure on the clamp and adjust the slide support so the blade will locate square on the face of the locator.
6. Moment weigh the blade.
7. Remove the blade from the blade adapter.
8. Mark the moment weight on the concave side of the blade airfoil. Use CoMat 06-153 FELT TIP MARKER, RAPID DRYING, CoMat 06-153X FELT TIP MARKER, RAPID DRYING, FINE POINT, BLACK, TRACE ELEMENT CERTIFIED or CoMat 06-158 MARKER, EXTRA FINE POINT(BLACK). Refer to SPM TASK 70-09-01-400-501.
9. Do the moment weight procedure again for each of the blades in the assembly.
1. Refer to Figure and Figure.
  NOTE
  A blade set contains two blades of equal weight or as near as possible to the same weight.
2. Put the moment weighed stage 1 HPT blades HPT Stage 1 Blade And Related Parts (72-45-14, 01-010) in to 32 blade sets on a bench, Figure.
3. 1. Put one blade of a set at the top of row one. Put the other blade at the top of row two.
  2. Put the next blade set under the first blade in rows one and two. Continue this until you have 32 blades in each row.
4. 1. Put the damper with the internal cavities up and the slot to the right.
  2. Hold the seal by the right angle bend (the side with the right angle channel).
  3. Put the seal down through the slot with the right angle bend to the right.
    NOTE
    The left channel of the seal will move to the ridge of the damper. This will attach the seal to the damper.
  4. Move the right angle bend of the seal until the left angle bend is installed on the ridge of the damper.
  5. Do the procedure again for all the dampers and seals that remain.
    NOTE
    The blades must be installed in a clockwise direction with the leading edge (thicker edge) pointed down.
5. 1. Put the blade root into the fir tree of the hub only until the hub will support the blade. Do not seat the blade in the hub.
6. 1. CAUTION
    FAILURE TO REPLACE AN ADEQUATE NUMBER OF BLADE TIPS MAY REDUCE ENGINE PERFORMANCE AND/OR REDUCE BLADE AND OUTER AIRSEAL REPAIRABILITY. IT IS RECOMMENDED TO MINIMIZE THE NUMBER OF CAT C BLADES INSTALLED.
    NOTE
    Up to 21 of the blades installed may be Cat C blades, which possess a limited cutting ability. Cat C blades have been fully repaired, except that the tip has not been fully restored. At component repair, these blades are ink marked on the airfoil Cat C.
    Install the assembled seal and damper in the right side of the blade pocket.
    The seal must point down and be parallel with the blade platform.
    Wax the seal and damper in position with CoMat 01-573 WAX BLEND, PARAFFIN. Remove the wax that is not necessary.
  2. CAUTION
    MAKE SURE THE SEAL AND DAMPER ARE IN THE CORRECT POSITION AFTER THE BLADE IS INSTALLED. DAMAGE TO THE PARTS CAN OCCUR IF THEY ARE NOT INSTALLED CORRECTLY.
    Carefully install the No. 2 blade adjacent to the first installed blade in a clockwise direction in the turbine hub.
    Carefully align the blade platform pocket on the first installed blade with the installed seal and damper on the No. 2 blade.
7. Do the procedure again until all the blades are installed.
8. Carefully install the last assembled seal and damper on the right side of the blade platform pocket of the first installed blade.
9. Attach a hoist to the lifting eye.
10. Raise the assembly until the turbine hub clears the support.
11. Lightly hit the blades with a rawhide mallet until they are at the bottom of the hub blade slots.
1. Refer to Figure and Figure.
  NOTE
  A blade set contains two blades of equal weight or as near as possible to the same weight.
2. Put the moment weighed stage 1 HPT blades HPT Stage 1 Blade And Related Parts (72-45-14, 01-010) in to 32 blade sets on a bench, Figure.
3. 1. Put one blade of a set at the top of row one. Put the other blade at the top of row two.
  2. Put the next blade set under the first blade in rows one and two. Continue this until you have 32 blades in each row.
    NOTE
    The blades must be installed in a clockwise direction with the leading edge (thicker edge) pointed down.
4. 1. Put the blade root into the fir tree of the hub only until the hub will support the blade. Do not seat the blade in the hub.
5. 1. CAUTION
    FAILURE TO REPLACE AN ADEQUATE NUMBER OF BLADE TIPS MAY REDUCE ENGINE PERFORMANCE AND/OR REDUCE BLADE AND OUTER AIRSEAL REPAIRABILITY. IT IS RECOMMENDED TO MINIMIZE THE NUMBER OF CAT C BLADES INSTALLED.
    NOTE
    Up to 21 of the blades installed may be Cat C blades, which possess a limited cutting ability. Cat C blades have been fully repaired, except that the tip has not been fully restored. At component repair, these blades are ink marked on the airfoil Cat C.
    Install the damper in the right side of the blade pocket.
    The damper must be parallel with the blade platform and installed as shown in Figure.
    Wax the seal and damper in position with CoMat 01-573 WAX BLEND, PARAFFIN. Remove the wax that is not necessary.
  2. CAUTION
    MAKE SURE THE SEAL AND DAMPER ARE IN THE CORRECT POSITION AFTER THE BLADE IS INSTALLED. DAMAGE TO THE PARTS CAN OCCUR IF THEY ARE NOT INSTALLED CORRECTLY.
    Carefully install the No. 2 blade adjacent to the first installed blade in a clockwise direction in the turbine hub.
    Carefully align the blade platform pocket on the first installed blade with the installed damper on the No. 2 blade.
6. Do the procedure again until all the blades are installed.
7. Carefully install the last damper on the right side of the blade platform pocket of the first installed blade.
8. Attach a hoist to the lifting eye.
9. Raise the assembly until the turbine hub clears the support.
10. Lightly hit the blades with a rawhide mallet until they are at the bottom of the hub blade slots.
1. Refer to Figure, Figure and Figure.
2. 1. Put one end of seal in the center of any blade bottom radius. Use CoMat 01-573 WAX BLEND, PARAFFIN, to hold the seal in position. Remove any wax that is not needed.
  2. Do a check for the clearance between the two ends of the seal. See Figure.
  3. If necessary, cut one end of the seal to keep the clearance of 0.030 in. (0.76 mm) minimum to 0.225 in. (5.71 mm) maximum between the two ends.
1. Refer to Figure, Figure and Figure.
2. 1. Make sure the outer end of the air seals touch the stage 1 and 2 turbine seal.
1. Refer to Figure.
2. Remove the nut at the top of the IAE 1P16006 Fixture 1 off with the spanner wrench.
3. Install the lift adapter in place of the nut.
4. Lift the fixture from the storage box with a hoist and a nylon belt.
5. Lower the fixture on to a vertical balance machine with the hoist.
6. Clamp the fixture to the balance machine with the four capscrews.
7. Remove the lift adapter from the balance fixture.
8. Release the hydraulic chucks actuation pressure and remove the cover assembly.
9. Remove the large nut with the spanner wrench.
10. Remove the spacer and the large diameter master.
1. Refer to Figure.
2. Attach a hoist to the lifting eye.
3. Lift the stage 1 turbine rotor assembly with the hoist and position it over the balance fixture.
4. Lower the stage 1 turbine rotor assembly large end up on to the fixture. Engage the rotor inside spline with the fixture spline.
5. Remove the hoist and the lifting eye from the rotor assembly.
6. 1. Install the spacer and the large nut.
  2. Hand tighten the nut.
  3. Install the small master over the top hydraulic chuck.
  4. Turn the center actuation screw to expand the two hydraulic chucks and centralize the rotor assembly on the arbor.
  5. Tighten the large nut using the spanner wrench.
  6. Release the hydraulic pressure and remove the smaller master from the top of the arbor.
  7. Install the cover and engage the slot in the inside diameter on top of the capscrew in the top of the arbor.
  8. Install the small nut and hand tighten it.
  9. Extend the hydraulic chucks and tighten the smaller nut with the spanner wrench.
7. 1. Install the IAE 1P16442 Calibration weight 1 off at the OD radius between the second knife edge and the third knife edge flange.
  2. Attach the weight with tape.
    NOTE
    The weight is designed to produce a moment of 4 oz in (2880 gm mm).
  3. Calibrate the balance machine.
  4. Remove the calibration weight and put it in the container.
1. Refer to Figure, Figure and Figure.
2. Turn the assembly at 900 rpm.
3. Correct unbalance to within 3 oz in (2160 gm mm) by moving stage 1 HPT blades (Figure) and/or stage 1 turbine air seals ENGINE-STAGE 1 AIR SEAL (REAR) (72-45-15, 01-020), Figure and Figure.
4. Correct unbalance to within 0.5 oz in (360 gm mm) by adding up to six counterweights, Figure and Figure.
5. Make a mark for amount and location of unbalance with CoMat 06-153 FELT TIP MARKER, RAPID DRYING, CoMat 06-153X FELT TIP MARKER, RAPID DRYING, FINE POINT, BLACK, TRACE ELEMENT CERTIFIED or CoMat 06-158 MARKER, EXTRA FINE POINT(BLACK). Refer to SPM TASK 70-09-00-400-501 and Figure.
1. Refer to Figure and Figure.
2. Remove the nut with the spanner wrench, Figure.
3. Release the hydraulic chucks actuation pressure and remove the cover assembly.
4. Remove the large nut with the spanner wrench.
5. Remove the spacer.
6. 1. Lift the center ring from the three jaws with the two handles. Put the handles in the spring clips located in the top weldment plate of the eye.
  2. Attach a hoist to the IAE 1P17024 Lift fixture 1 off.
  3. Lift the eye and install into the bore of the turbine hub until the lower weldment plate touches the rear face of the hub.
  4. Release the two handles from the spring clips and lower the center ring to push the jaws against the inner bore of the hub.
7. Attach a hoist to the eye.
8. Remove the stage 1 turbine rotor assembly from the balance fixture.
1. Refer to Figure.
2. Lower the stage 1 turbine rotor assembly into the IAE 1P16140 Support base 1 off.
3. Remove the hoist and the lifting eye.
1. Refer to Figure.
2. 1. Wax the seals in position with CoMat 01-573 WAX BLEND, PARAFFIN. Remove the wax that is not necessary.
1. Refer to Figure.
2. 1. Before you install the retainer, turn and position the four clamps to the center of the retainer.
  2. Install the retainer on the turbine hub and the stage 1 HPT air seals.
  3. Turn and position the four clamps to engage the step in the hub.
  4. Tighten the clamp nuts.

Pre SBE 72-0180: Stage 1 Turbine Rotor Assembly - Fits and Clearances

SBE 72-0180, Pre SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Stage 1 Turbine Rotor Assembly - Fits and Clearances

Install the IAE 1P16014 Fixture

Install the Bar to the Block

Install the Stage 1 HPT Airseal (Outer)

Check the Seal Gap

Location of the Balance Marks

Install the Stage 1 HPT Airseal (Inner)

Install the IAE 1P17024 Lifting Eye

Install the Stage 1 Turbine Rotor Assembly in the IAE 1P16061 Support Ring

Stage 1 IAE 1P16015 Mount Weight Blade Adapter

Sheet 1

SBE 72-0242 Install the Stage 1 HPT Dampers, Seals and Counterweights

Check the Seal Clearance

Install the Stage 1 Turbine Rotor Assembly in the IAE 1P16006 Fixture

Mark the Stage 1 Turbine Rotor Assembly

Install the Stage 1 Turbine Rotor Assembly in the IAE 1P16140 Support Base

Install the IAE 1P17030 Blade Retainer on the Stage 1 Turbine Rotor Assembly

Requirements After Job Completion

Follow-On Conditions

NONE

Manufacturer Code:	0AM53
Enterprise Name:	IAE INTERNATIONAL AERO ENGINES AG
BU Name:	NULL
Building:	SUITE 400
Street:	628 HEBRON AVENUE
City:	GLASTONBURY
State:	CT
Zip Code:	06033
Country:	USA

Manufacturer Code:	24269
Enterprise Name:	SCHAEFER MACHINE CO., INC.
BU Name:	SCHAEFER MACHINE CO., INC.
Street:	200 COMMERCIAL DRIVE
City:	DEEP RIVER
State:	CT
Zip Code:	06417
Country:	USA
Phone Number:	1-860-526-4000
Fax Number:	1-860-526-4654
Internet:	www.schaeferco.com

Manufacturer Code:	77445
Enterprise Name:	PRATT AND WHITNEY
BU Name:	PRATT & WHITNEY
Street:	400 MAIN STREET
City:	EAST HARTFORD
Country:	USA
Phone Number:	8605657700

Manufacturer Code:	86874
Enterprise Name:	SANFORD CORPORATION
BU Name:	SANFORD CORPORATION
Street:	2711 WASHINGTON BLVD
City:	BELLWOOD
State:	IL
Zip Code:	60104
Country:	USA
Phone Number:	1-708-547-6650, 1-800-323-0749
Fax Number:	1-708-547-6719, 1-800-457-9208
Internet:	www.sanfordcorp.com

Manufacturer Code:	LOCAL
Enterprise Name:	LOCALLY SUPPLIED

Manufacturer Code:	0AM53
Tool Number:	IAE 1F10052
Tool Name:	IAE 1F10052 Two cables sling

TASK 72-45-10-440-001-C00 HPT Stage 1 Rotor Assembly - Assemble The HPT Stage 1 Rotor Assembly, Assembly-001

Export Control

Copyright

Applicability

Common Information

TASK 72-45-10-440-001-C00 HPT Stage 1 Rotor Assembly - Assemble The HPT Stage 1 Rotor Assembly, Assembly-001

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-45-10-220-064-002 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1516 (SBE 72-0240)

SUBTASK 72-45-10-220-064-003 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Hub Metering Plugs at Location 1517 (SBE 72-0451 and Pre SBE 72-0511)

CAUTION

CAUTION

NOTE

SUBTASK 72-45-10-220-065 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1502

SUBTASK 72-45-10-220-066 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1504

SUBTASK 72-45-10-220-067 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1550

SUBTASK 72-45-10-220-068 Reference Fits and Clearances of the Stage 1 Turbine Hub and Stage 1 HPT Air Seal at Location 1551

SUBTASK 72-45-10-220-069 Reference Fits and Clearances of the Stage 1 HPT Air Seal, Stage 1 HPT Blade and Stage 1 Turbine Hub at Location 1552

NOTE

NOTE

SUBTASK 72-45-10-440-090 Measure and Calculate the Stage 1 HPT Air Seal (rear), Stage 1 HPT Blade and Stage 1 Turbine Hub Dimensions at Location 1552

SUBTASK 72-45-10-440-091 Install the Stage 1 HPT Hub Metering Plugs (72-45-11, 01-040) (Pre SBE 72-0511)

CAUTION

NOTE

SUBTASK 72-45-10-440-092 Install the Fixture to the Turbine Hub (72-45-10, 01-010)

NOTE

SUBTASK 72-45-10-440-093 Install the Turbine Hub on to the Heater

SUBTASK 72-45-10-440-094 Install the Stage 1 HPT Airseal (Outer) (72-45-12, 01-040) in the Fixture

CAUTION

SUBTASK 72-45-10-440-095 Install the Stage 1 HPT Airseal (Outer) on to the Turbine Hub

NOTE

SUBTASK 72-45-10-440-096 Install the Stage 1 HPT Airseal (Inner) (72-45-13, 01-020)

SUBTASK 72-45-10-440-097 Install the Turbine Hub in to the Support Base

SUBTASK 72-45-10-440-098 Install the Lifting Eye on the Turbine Front Hub

SUBTASK 72-45-10-440-099 Install the Turbine Hub in to the Support Ring

SUBTASK 72-45-10-440-700 Moment Weigh the Stage 1 HPT Blades (72-45-14, 01-010)

CAUTION

NOTE

NOTE

SUBTASK 72-45-10-440-101 Put the Stage 1 HPT Blades in to the Blade Slots in the Turbine Front Hub (Pre SBE 72-0242)

NOTE

NOTE

NOTE

CAUTION

NOTE

CAUTION

SUBTASK 72-45-10-440-111 Put the Stage 1 HPT Blades in to the Blade Slots in the Turbine Front Hub (SBE 72-0242)

NOTE

NOTE

CAUTION

NOTE

CAUTION

SUBTASK 72-45-10-440-112 Install the Stage 1 and 2 Turbine Seal (72-45-14, 01-060)

SUBTASK 72-45-10-440-103 Install the Stage 1 HPT Air Seals (72-45-15,01-020)

SUBTASK 72-45-10-440-104 Install the Balance Fixture on a Vertical Balance Machine

SUBTASK 72-45-10-440-105 Install the Stage 1 Turbine Rotor Assembly in to the Fixture

NOTE

SUBTASK 72-45-10-440-106 Balance the Stage 1 Turbine Rotor Assembly

SUBTASK 72-45-10-440-107 Prepare and Remove the Stage 1 Turbine Rotor Assembly from the Balance Fixture

SUBTASK 72-45-10-440-108 Put the Stage 1 Turbine Rotor Assembly in to the Support Base

SUBTASK 72-45-10-440-109 Install the Stage 1 Turbine Seals (72-45-15, 01-040)

SUBTASK 72-45-10-440-110 Install the Blade Retainer on the Stage 1 Turbine Rotor Assembly

Figure: Pre SBE 72-0180: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Pre SBE 72-0180: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Figure: SBE 72-0180, Pre SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

SBE 72-0180, Pre SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Figure: SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

SBE 72-0240: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Figure: Stage 1 Turbine Rotor Assembly - Fits and Clearances

Stage 1 Turbine Rotor Assembly - Fits and Clearances

Figure: Install the IAE 1P16014 Fixture

Install the IAE 1P16014 Fixture