* * * FOR ALL PIP 2
TASK 72-30-00-440-805
1 . General.
A.This procedure gives instructions to assemble the high pressure compressor (HPC) module assembly (33-012 , 72-00-02) (SIN 00108) thru the installation of the compressor stator assembly (05-201) (SIN 07000). Refer to TASK 72-30-00-440-804 (72-30-00, ASSEMBLY 002, CONFIGURATION 02) to continue the assembly of the HPC module assembly after completing this procedure.
B.This procedure starts with the HPC rotor assembly (15-012) (SIN 05000) installed on the 11C3338   dolly or the 11C3352   shipping container. Refer to Figure 1001 or Figure 1002.
C.Install all the bolts with the boltheads up and/or forward, unless specified differently.
D.Apply lubricants to the threads and friction surfaces only.
E.All directions are aft looking forward (ALF), unless specified differently.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools.
 
Tool No.
Description
 
9C2376G01
Beam, Lifting (lift beam)
 
11C3010G02
Fixture, Build-Up Core Module (build-up fixture)
NOTE:
Tool 11C3010 is an alternative to 11C4279.
 
11C3074G01
Tool Kit, Dummy Bolt - Compressor Discharge Seal/SP, Stage 6-10 (tool kit)
 
11C3106G02
Fixture, Lift/Turn - HP Compressor Rotor, Aft End (aft end lift and turn fixture)
 
11C3190G02
Bar, Lifting Extension Case - HP Compressor (extension case lift bar)
 
11C3254G01
Seating, Tool - Seal, Rotating, No. 3 Bearing (seating tool)
 
11C3293G02
Dummy, Stator - High Pressure Stator Assembly (dummy stator)
 
11C3294P05
Pin, Guide-HP Compressor Forward Stator Case (guide pin)
 
11C3294P06
Pin, Guide-HP Compressor Forward Stator Case (guide pin)
 
11C3297G01
Fixture, Lift - Aft Stator (lift fixture)
 
11C3338G03
Dolly, Shipping - HP Compressor Rotor - Horizontal (dolly)
 
11C3352G03
Container, Shipping - HPC Rotor - Horizontal (shipping container)
 
11C3356P01
Blanket, Protective - HPC Rotor (blanket)
 
11C3363G01
Pin Set, Alignment - Stage 5-10 Rings - HPC Stator (alignment pin)
 
11C3372G01
Pin, Guide - Extension Case - Installation HP Compressor Rotor (guide pin set)
 
11C4279G03
Fixture, Buildup - Core Module (buildup fixture)
 
11C4279G04
Fixture, Buildup - Core Module (buildup fixture)
 
11C4548G01
Fixture, Support / Lock - HPCR (support fixture)
 
11C4589G01
Fixture, Removal - Aft Extension Case (removal fixture)
 
11C4688G01
Fixture, Guide - HPC Aft Stator Wear Guides (alignment guides)
 
11C4689P01
Fixture, Installation - HPC Aft Stator Wear Guide (installation fixture)
 
11C4882G01
Fixture, Lift/Turn - HP Compressor Rotor Assembly/Forward Shaft, Forward End (lift and turn fixture)
 
9429M14G02
Fixture, Lift Arm - Standard 6000 lb (2721 Kg) (lift arm)
 
9429M19G01
Fixture, Lift - Vertical, 1500 lb (680 Kg) (lift fixture)
 
9429M19G02
Fixture, Lift - Vertical, 150 lb (68 Kg) (lift fixture)
NOTE:
Tool 9429M19G02 is not an alternative to tool 9429M19G01. Tool 9429M19G01 is used to lift the extension case and tool 9429M19G02 is used to lift the stator rings.
 
9429M56G01
Stand, Build - Core Module (build stand) (part of tool 11C3010)
 
9429M77G04
Fixture, Lift and Turn - General Purpose (lift fixture)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
C-Clamps
Local Purchase
 
Heat Gun
Local Purchase
 
Mallet, Rubber
Local Purchase
 
Nylon Bar, Tapered
Local Purchase
 
Pliers, Duckbill
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C02-058
Compound, Thread Lubricating (lubricant)
 
C02-071
Anti-Seize and Lubricating Compound (lubricant)
 
C02-097
Lubricant, Anti-Seize Compound (lubricant)
 
C04-002
Solvent, General (Stoddard solvent)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C04-228
Solvent, General (94-96% assay Ethanol) (denatured alcohol)
 
C05-003
Marking Pen (pen)
 
C10-109
Utility Wax (wax)
 
C10-154
Beeswax
 
C10-182
Cloth, Cleaning for Aircraft Structural (cleaning cloth)
C.Referenced Procedures.
 
ATA No.
Description
 
72-30-00
Special Procedure 002
 
72-30-00
Assembly 002
 
72-31-00
Assembly 001
D.Expendable Parts.
 
CSN
Description
 
05-010
Self-Locking Nut
 
05-011
Self-Locking Nut
 
10-070
Machine Bolt (bolt)
 
10-170
Breakaway Nut
 
15-220
Stage 5 Vane Sector Forward Guide
 
15-210
Stage 5 Vane Sector Aft Guide
 
15-170
Stage 6 Vane Sector Forward Guide
 
15-160
Stage 6 Vane Sector Aft Guide
 
15-120
Stage 7 Vane Sector Forward Guide
 
15-110
Stage 7 Vane Sector Aft Guide
 
15-070
Stage 8 Vane Sector Forward Guide
 
15-060
Stage 8 Vane Sector Aft Guide
 
15-030
Stage 9 Vane Sector Forward Guide
 
15-020
Stage 9 Vane Sector Aft Guide
3 . Procedure.
Subtask 72-30-00-440-567
A.Install the rotating seal (seal) (02-820 , 72-31-00) (SIN 03005) on the forward shaft (shaft) (02-780 , 72-31-00) (SIN 050B5) as follows:
Subtask 72-30-00-160-005
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.
(1)Use a C10-182  cleaning cloth wet with C04-035  isopropyl alcohol, C04-002  Stoddard solvent, or a 50-50 blend of C04-035  isopropyl alcohol and C04-228  denatured alcohol to clean the mating surfaces of the seal and shaft.
Subtask 72-30-00-220-021
(2)Measure dimension V and dimension T. Refer to Figure 1003, Figure 1004, Figure 1005, and do as follows:
(a)Measure dimension V at four locations on the forward flange of the seal.
(b)Calculate the average dimension.
(c)Record the result as dimension V on the record sheet.
(d)Measure dimension T at four locations on the shaft. Do the measurement from the forward face of the shaft to the seal seating surface.
(e)Calculate the average dimension.
(f)Record the result as dimension T on the record sheet.
(g)Subtract average dimension V from average dimension T and record the result as dimension VCAL.
* * * FOR ALL PIP 2
Figure 1001   HPC Rotor Assembly Installed on the Dolly, 11C3338
* * * FOR ALL PIP 2
Figure 1002   HPC Rotor Assembly Installed on the Shipping Container, 11C3352
* * * FOR ALL PIP 2
Figure 1003   Dimensional Inspection of the Seal
* * * FOR ALL PIP 2
Figure 1004   Dimensional Inspection of the Shaft
* * * FOR ALL PIP 2
Figure 1005   Dimensional Inspection Record Sheet
Subtask 72-30-00-220-022
(3)Measure the diameter of across the knife-edge seals of the seal (02-820 , 72-31-00) (SIN 03005) at four equally spaced locations. Record the result as dimension DMN/DMX.
Subtask 72-30-00-440-568
(4)Install the seal on the shaft as follows:
(a)Find the anti-rotation lug on the ID of the seal (02-820 , 72-31-00) (SIN 03005). Refer to Figure 1006.
(b)Use a C05-003  pen to put a mark on the location of the anti-rotation lug on the forward face of the seal.
(c)Find the slot for the anti-rotation lug, located on the shaft (02-780 , 72-31-00) (SIN 050B5). Refer to Figure 1007.
(d)Use a C05-003  pen to put a mark on the location of the slot on the shaft diameter just forward of the seal seating face.
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(e)Use a heat gun and increase the temperature of the seal to 300°F (148.9°C).
(f)Align the tab of the seal with the slot on the shaft and put the seal on the shaft. Refer to Figure 1008.
(g)Install the 11C3254   seating tool on the forward end of the shaft and tighten it against the seal. Refer to Figure 1009.
(h)Let the temperature of the seal decrease to room temperature and remove the 11C3254   seating tool.
* * * FOR ALL PIP 2
Figure 1006   Anti-Rotation Lug
* * * FOR ALL PIP 2
Figure 1007   Slot Location
* * * FOR ALL PIP 2
Figure 1008   Installation of the Seal on the Shaft
* * * FOR ALL PIP 2
Figure 1009   Use of Seating Tool, 11C3254
Subtask 72-30-00-220-023
(5)Measure dimension VMES. Refer to Figure 1010 and do as follows:
(a)Measure from the forward face of the shaft to the forward face of the seal at four equally spaced locations.
(b)Calculate the average dimension.
(c)Record this dimension as dimension VMES on the record sheet. Refer to Figure 1005.
(6)Compare dimension VMES to dimension VCAL on the record sheet as follows:
(a)Dimension VMES is serviceable if dimension VMES = VCAL to 0.001 inch (0.03 mm) or less and do as follows:
1If dimension VMES is SERVICEABLE, continue with the HPC rotor assembly.
2If dimension VMES is NOT SERVICEABLE, stop here. Contact your GEAE representative.
* * * FOR ALL PIP 2
Figure 1010   Dimension VMES
Subtask 72-30-00-440-569
B.Alternative Procedure Available. Install the HPC rotor assembly (15-012) (SIN 05000) on the 11C4279   buildup fixture. Refer to Figure 1011 and do as follows:
(1)Prepare the 11C4279   buildup fixture as follows:
CAUTION:
MAKE SURE THAT THE FLOOR LOCKS STAY LOCKED AT ALL TIMES BUT NOT WHEN THE BUILDUP FIXTURE IS MOVED. THE BUILDUP FIXTURE CASTERS DO NOT GIVE SUFFICIENT STABILITY FOR SAFE WORKING CONDITIONS.
(a)Make sure that the floor locks (item 32) touch the floor and stay locked to prevent movement of the 11C4279   buildup fixture.
(b)Pull the locking pin (item 6) out at two locations and rotate clockwise (CW) or counterclockwise (CCW) to make sure it is in the unlocked position.
NOTE:
This will let the locking ring shaft (item 9) and the locking ring (item 27) to rotate.
(c)Turn the knob (item 23) to loosen it.
(d)Turn the thumb screw (item 33) CCW.
(e)Move the pusher plate (item 21) and the head gage (item 25) out.
(f)Remove the capscrews (item 48) at 20 locations from the storage holes on the case support base (item 7 and 56).
(2)Install the 11C4882   lift and turn fixture on the shaft (02-780 , 72-31-00) (SIN 050B5). Refer to Figure 1012 and do as follows:
(a)Put the 11C4882   lift and turn fixture on the threads of the shaft. Hand-tighten the fixture only.
(b)Attach a hoist to the 9429M14   lift arm and attach it to the 11C4882   lift and turn fixture with a ball-lock pin (item 5) of the 9429M14   lift arm.
(3)Install the 11C3106   aft end lift and turn fixture on the CDP seal (CDP rotating seal) (02-460 , 72-31-00) (SIN 050NC). Refer to Figure 1013 and do as follows:
NOTE:
The 11C3074 tool kit was installed on the HPC rotor assembly. Refer to TASK 72-31-00-440-802 (72-31-00, ASSEMBLY 001, CONFIGURATION 02).
(a)Put the 11C3106   aft end lift and turn fixture above eight nuts (item 4) of the 11C3074   tool kit and on the CDP rotating seal.
(b)Attach the 11C3106   aft end lift and turn fixture to the CDP rotating seal with eight flange nuts (item 5) of the 11C3074   tool kit. Tighten the flange nuts in a criss-cross pattern.
(c)Install one more 9429M14   lift arm on the 11C3106   aft end lift and turn fixture and attach it with a ball-lock pin (item 5) of the 9429M14   lift arm.
(d)Attach one more hoist to the 9429M14   lift arm.
Subtask 72-30-00-440-570
(4)Install the HPC rotor assembly (15-012) (SIN 05000) on the 11C4279   buildup fixture as follows:
(a)Alternative Procedure Available. Remove the upper front clamp ring (item 29) and the upper rear clamping ring (item 42) of the 11C3338   dolly that attach the HPC rotor assembly to the 11C3338   dolly. Refer to Figure 1001.
Subtask 72-30-00-440-571
(a).A.Alternative Procedure. Remove the upper front clamp ring (item 27) and the upper rear clamping ring (item 38) of the 11C3352   shipping container that attach the HPC rotor assembly to the 11C3352   shipping container. Refer to Figure 1002.
Subtask 72-30-00-440-572
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(b)Operate the two hoists and lift the HPC rotor assembly up and away from the 11C3338   dolly or the 11C3352   shipping container .
(c)Turn the HPC rotor assembly as follows:
CAUTION:
MAKE SURE THAT THE TOOLS ARE HINGED IN THE CORRECT DIRECTION BEFORE THE HARDWARE IS TURNED. IF THIS IS NOT DONE, DAMAGE TO THE TOOLS OR THE HARDWARE CAN OCCUR.
1Operate the two hoists to lift the aft end while lowering the forward end of the HPC rotor assembly.
2Continue this procedure until the HPC rotor assembly is in the vertical position, forward end down.
3Remove the 11C4882   lift and turn fixture from the shaft (02-780 , 72-31-00) (SIN 050B5).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(d)Move the HPC rotor assembly above the 11C4279   buildup fixture. Refer to Figure 1011.
(e)Make sure the teeth on the shaft (02-780 , 72-31-00) (SIN 050B5) engage in the locking ring shaft (item 9) of the 11C4279   buildup fixture. If necessary, rotate the locking ring (item 27) and the locking ring shaft (item 9) to let the teeth engage.
(f)Continue to lower the HPC rotor assembly onto the case support base (item 7 and 56).
(g)Move the locking pin (item 6) forward to engage the locking ring (item 27). If necessary, rotate the HPC rotor to let the locking pin (item 6) engage in the locking ring (item 27).
(h)Move the pusher plate (item 21) inward to put the head gage (item 25) against the shaft.
(i)Turn the thumb screw (item 33) CW until it touches the pusher plate (item 21).
(j)Tighten the knob (item 23) to secure the pusher plate (item 21).
Subtask 72-30-00-440-573
B.A.Alternative Procedure. Install the HPC rotor assembly (15-012) (SIN 05000) on the 9429M56   build stand as follows:
NOTE:
The 11C3010   build-up fixture is installed on the 9429M56   build stand.
Subtask 72-30-00-440-574
(1)Install the 11C4882   lift and turn fixture on the shaft (02-780 , 72-31-00) (SIN 050B5). Refer to Figure 1012 and do as follows:
(a)Put the 11C4882   lift and turn fixture on the threads of the shaft. Hand-tighten the fixture only.
(b)Attach a hoist to the 9429M14   lift arm and attach it to the 11C4882   lift and turn fixture with a ball-lock pin (item 5) of the 9429M14   lift arm.
* * * FOR ALL PIP 2
Figure 1011   (Sheet 1 ) Installation of the HPC Rotor Assembly on the Buildup Fixture, 11C4279
* * * FOR ALL PIP 2
Figure 1011   (Sheet 2 ) Installation of the HPC Rotor Assembly on the Buildup Fixture, 11C4279
* * * FOR ALL PIP 2
Figure 1012   Use of Lift and Turn Fixture, 11C4882
Subtask 72-30-00-440-575
(2)Install the 11C3106   aft end lift and turn fixture on the CDP rotating seal (02-460 , 72-31-00) (SIN 050NC). Refer to Figure 1013 and do as follows:
NOTE:
The 11C3074   tool kit was installed on the HPC rotor assembly. Refer to TASK 72-31-00-440-802 (72-31-00, ASSEMBLY 001, CONFIGURATION 02).
(a)Put the 11C3106   aft end lift and turn fixture above eight nuts (item 4) of the 11C3074   tool kit and on the CDP rotating seal.
(b)Attach the 11C3106   aft end lift and turn fixture to the CDP rotating seal with eight flange nuts (item 5) of the 11C3074   tool kit. Tighten the flange nuts in a criss-cross pattern.
(c)Install one more 9429M14   lift arm on the 11C3106   aft end lift and turn fixture and attach it with a ball-lock pin (item 5) of the 9429M14   lift arm.
(d)Attach one more hoist to the 9429M14   lift arm.
* * * FOR ALL PIP 2
Figure 1013   Aft End Lift and Turn Fixture, 11C3106
Subtask 72-30-00-440-576
(3)Install the HPC rotor assembly (15-012) (SIN 05000) on the 9429M56   build stand as follows:
(a)Alternative Procedure Available. Remove the upper front clamp ring (item 29) and the upper rear clamping ring (item 34) of the 11C3338   dolly that attach the HPC rotor assembly to the 11C3338   dolly. Refer to Figure 1001.
Subtask 72-30-00-440-577
(a).A.Alternative Procedure. Remove the upper clamp ring (item 27) and the upper rear clamping ring (item 38) of the 11C3352   shipping container that attach the HPC rotor assembly to the 11C3352   shipping container. Refer to Figure 1002.
Subtask 72-30-00-440-578
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(b)Operate the two hoists and lift the HPC rotor assembly up and away from the 11C3338   dolly or 11C3352   shipping container.
(c)Turn the HPC rotor assembly as follows:
CAUTION:
MAKE SURE THAT THE TOOLS ARE HINGED IN THE CORRECT DIRECTION BEFORE THE HARDWARE IS TURNED. IF THIS IS NOT DONE, DAMAGE TO THE TOOLS OR HARDWARE CAN OCCUR.
1Operate the two hoists to lift the aft end while lowering the forward end of the HPC rotor assembly.
2Continue this procedure until the HPC rotor assembly is in the vertical position, forward end down.
3Remove the 11C4882   lift and turn fixture from the shaft (02-780 , 72-31-00) (SIN 050B5).
Subtask 72-30-00-440-579
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(d)Move the HPC rotor assembly above the 9429M56   build stand.
Subtask 72-30-00-440-580
(e)Align the ID of the shaft (02-780 , 72-31-00) (SIN 050B5) with the pilot (item 22) of the 11C3010   build-up fixture and slowly lower the HPC rotor assembly on the 9429M56   build stand. Refer to Figure 1014.
(f)Remove the 11C3106   aft end lift and turn fixture from the CDP rotating seal.
NOTE:
The nuts (item 4) of the 11C3074   tool kit installed on the CDP rotating seal stay in position until the end of the assembly procedure.
* * * FOR ALL PIP 2
Figure 1014   Installation of the HPC Rotor Assembly on the Build-up Fixture, 11C3010
Subtask 72-30-00-440-581
C.Alternative Procedure Available. Install the two halves of the 11C3293   dummy stator on the 11C4279   buildup fixture. Refer to Figure 1015 and do as follows:
(1)Remove the threaded knobs (item 16) that attach the fitting fork (item 5) to the left arm (item 6) and right arm (item 7).
(2)Remove the fitting fork (item 5).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(3)Use a strap belt to lift the 11C3293   dummy stator.
(4)Install one half (the table with the pivot (item 12)) of the 11C3293   dummy stator on the case support base (item 7 and item 56) of 11C4279   buildup fixture. Refer to Figure 1011.
(5)Install the second half (the table without the pivot (item 12)) of the 11C3293   dummy stator on the case support base (item 7 and 56) of 11C4279   buildup fixture.
(6)Attach the 11C3293   dummy stator halves together with two capscrews (item 24), washers (items 26), and nuts (item 25) on each side. Refer to Figure 1015.
(7)Attach the fitting fork (item 5) to the left arm (item 6) and right arm (item 7) with the threaded knobs (item 16).
Subtask 72-30-00-440-582
C.A.Alternative Procedure. Install the two halves of the 11C3293   dummy stator on the 11C3010   build-up fixture. Refer to Figure 1015 and do as follows:
(1)Remove the threaded knobs (item 16) that attach the fitting fork (item 5) to the left arm (item 6) and right arm (item 7).
(2)Remove the fitting fork (item 5).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(3)Use a strap belt to lift the 11C3293   dummy stator.
(4)Install one half (the table with the pivot (item 12)) of the 11C3293   dummy stator on the table ring (item 21) of the 11C3010   build-up fixture. Make sure that the 12:00 o'clock position of the table is aligned with the TOP VERT mark on the table ring (item 21).
(5)Install the second half (the table without the pivot (item 12)) of the 11C3293   dummy stator on the table ring (item 21) of the 11C3010   build-up fixture.
(6)Attach the 11C3293   dummy stator halves together with two capscrews (item 24), washers (items 26), and nuts (item 25) on each side.
(7)Attach the fitting fork (item 5) to the left arm (item 6) and right arm (item 7) with the threaded knobs (item 16).
* * * FOR ALL PIP 2
Figure 1015   Installation of the Two Halves of the Dummy Stator, 11C3293
Subtask 72-30-00-440-583
D.Install the stage 5 HPC vanes (stage 5 vane sectors) (15-231) (SIN 084A0) and (15-241) (SIN 084AA) as follows:
(1)Put the stage 5 aft case (10-180) (SIN 080AJ) on a clean work surface, forward side down.
(2)Install 24 slab head bolts (10-150) (SIN 080F2) in the twenty-four 0.282 inch (7.16 mm) holes. Attach the slab head bolts to the stage 5 aft case with 24 breakaway nuts (10-170) (SIN 08040). Refer to Figure 1016.
(3)Make sure that the flat side of the slab head bolt (10-150) (SIN 080F2) is on the outer edge of the stage 5 aft case or a longer flat side of the slab head bolt (10-150) (SIN 080F2) is on the outer edge of the stage 5 aft case.
Subtask 72-30-00-440-584
(4)Tighten the breakaway nuts (10-170) (SIN 08040) until the wrenching hex collars break off.
NOTE:
The wrenching hex collar will break off at 40-60 lb in. (4.5-6.8 N.m).
(5)Make sure that the heads of the slabbed head bolts are correctly installed on the stage 5 aft case.
CAUTION:
MAKE SURE NOT TO DEFORM TO THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
(6)Install ten stage 5 vane sector forward guides (stage 5 forward guides) (15-220) (SIN 080T1) in the aft groove of the stage 5 aft case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(a)Make sure that the mating flanges are clean of all unwanted material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove unwanted material.
(b)Install one guide in each of the sectors between the vane sector alignment pins located in the aft groove of the stage 5 aft case. Refer to Figure 1017.
(c)Make sure that the stage 5 forward guides do not overlap.
(d)Make sure that there is no damage to the forward guides.
(e)Use the 11C4689   installation fixture to install the stage 5 forward guides in the groove of the stage 5 aft case.
(7)Deleted.
(8)Find the top vertical centerline (TVCL) of the stage 5 aft case. Refer to Figure 1018.
NOTE:
The TVCL of the stage 5 aft case is located at a 0.250 inch (6.35 mm) elongated hole.
(9)Align the TVCL of the stage 5 aft case with the TOP VERT mark on the case support base (item 7 and 56) of the 11C4279   buildup fixture or table ring (item 21) of the 11C3010   build-up fixture and put the stage 5 aft case on the 11C3293   dummy stator.
NOTE:
Table ring (item 21) of the 11C3010   build-up fixture has rotational capability to help the alignment.
* * * FOR ALL PIP 2
Figure 1016   Installation of the Slab Head Bolts and Breakaway Nuts
* * * FOR ALL PIP 2
Figure 1017   (Sheet 1 ) Installation of the Stage 5 Forward Guides
* * * FOR ALL PIP 2
Figure 1017   (Sheet 2 ) Installation of the Stage 5 Forward Guides
* * * FOR ALL PIP 2
Figure 1018   Installation of the Stage 5 Aft Case on the Dummy Stator, 11C3293
Subtask 72-30-00-440-585
(10)Install the stage 5 vane sectors (15-231) (SIN 084A0) and (15-241) (SIN 084AA) on the stage 5 aft case (10-180) (SIN 080AJ) as follows:
NOTE:
The stage 5 vane sector (15-241) (SIN 084AA) is the vane sector with the borescope port.
Subtask 72-30-00-440-586
(a)Align the notch on the outer platform of the stage 5 vane sector (15-241) (SIN 084AA) with the larger diameter pin on the stage 5 aft case at approximately the 9:00 o'clock position and install it on the case. Refer to Figure 1020.
NOTE:
One locating pin on the stage 5 aft case has a larger diameter. The stage 5 vane sector (15-241) (SIN 084AA) with the borescope port is installed at this location.
(b)Align the notch on the outer platform of the stage 5 vane sector (15-231) (SIN 084A0) with the smaller diameter locating pins in the aft groove on the stage 5 aft case. Engage the notch of the stage 5 vane sectors with the smaller diameter pin and install the nine vane sectors one at a time. Refer to Figure 1019.
(c)Make sure that the HPC rotor assembly (15-012) (SIN 05000) turns freely after the stage 5 vane sectors are installed. Listen for a clicking noise caused by contact of misplaced guides with HPC blades.
CAUTION:
IF A VANE SECTOR GUIDE IS INCORRECTLY INSTALLED, IT CAN CAUSE COMPRESSOR DAMAGE.
(d)Use duckbill pliers to install ten stage 5 spline seals (spline seal) (15-250) (SIN 080N0) between the stage 5 vane sectors. Refer to Figure 1021.
* * * FOR ALL PIP 2
Figure 1019   Installation of the Stage 5 Vane Sectors on the Stage 5 Aft Case
* * * FOR ALL PIP 2
Figure 1020   Installation of the Stage 5 Vane Sector (Borescope)
* * * FOR ALL PIP 2
Figure 1021   Installation of the Spline Seals
Subtask 72-30-00-440-587
(11)Install the stage 5-6 aft case (5-6 stacked ring) (10-200) (SIN 080AM) on the stage 5 aft case (10-180) (SIN 080AJ) and above the outer platforms of the vane sectors as follows:
(a)Put the 5-6 stacked ring forward side down on a clean work surface. Refer to Figure 1022 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the flange of the 5-6 stacked ring.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the flange of the 5-6 stacked ring.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
4Lift the 5-6 stacked ring and put it on a clean work surface, forward side down.
5Remove the 9429M19G02   lift fixture from the 5-6 stacked ring.
(b)Install the ten stage 5 vane sector aft guides (stage 5 aft guides) (15-210) (SIN 080T2) on the aft outer tangs of the stage 5 vane sectors (15-231) (SIN 084A0) and (15-241) (SIN 084AA). Refer to Figure 1023 and do as follows:
NOTE:
Deleted.
NOTE:
Use of C10-154  beeswax or C10-109  wax is permitted to help secure the guides to the vane sectors.
1If necessary, use a rubber mallet to install the stage 5 aft guides on the aft tang of the stage 5 vane sectors.
2Make sure that the ten stage 5 aft guides are centered on the stage 5 vane sector gaps.
3Make sure that the stage 5 aft guides do not overlap.
4Make sure there is no damage to the stage 5 aft guides.
CAUTION:
MAKE SURE NOT TO DEFORM THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
(c)Install the ten stage 6 vane sector forward guides (stage 6 forward guides) (15-170) (SIN 080T3) in the aft groove of the 5-6 stacked ring. Refer to Figure 1023 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Make sure that the mating flanges are clean of all unwanted material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove unwanted material.
2Install one guide in each of the sectors between the vane sector alignment pins located in the aft groove of the stage 5-6 stacked ring.
3Make sure that the stage 6 forward guides do not overlap.
4Make sure there is no damage to the stage 6 forward guides.
5Use the 11C4689   installation fixture to install the stage 6 forward guides in the aft groove of the 5-6 stacked ring.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(d)Make sure that the mating flanges are clean of all foreign material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove foreign material.
CAUTION:
MAKE SURE THAT THE 5-6 STACKED RING IS CORRECTLY INSTALLED ON THE STAGE 5 AFT CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(e)Install the 5-6 stacked ring on the stage 5 aft case. Refer to Figure 1024 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to install the three block hooks (item 3).
2Put the three block hooks (item 3) on the flange of the 5-6 stacked ring.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft flange of the 5-6 stacked ring.
4Move the 5-6 stacked ring above the stage 5 aft case.
5Make sure that the tops of the cases that will be installed are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL CAUSE GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
7If adjustment of the flanges is required to align the 11C3363   alignment pin again after any contact, fully remove top stage 5-6 aft case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
8Align the 11C3363   alignment pin on the forward flange of the 5-6 stacked ring with the 0.250 inch (6.35 mm) elongated hole at the TVCL of the stage 5 aft case. Lower the 5-6 stacked ring onto the stage 5 aft case and on the outer platforms of the stage 5 vane sectors.
9Remove the 9429M19G02   lift fixture.
CAUTION:
MAKE SURE THAT THE 5-6 STACKED RING IS CORRECTLY INSTALLED ON THE STAGE 5 AFT CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(f)Install the self-locking nut (10-140) and spacers (10-160) that attach the stage 5-6 stacked ring to the stage 5 aft case. Refer to Figure 1026 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight self-locking nuts (10-140) (SIN 080K5).
2Install the eight self-locking nuts (10-140) (SIN 080K5) on the slab head bolts (10-150) (SIN 080F2) with spacers (10-160) (080TC) equally spaced on the stage 5 aft case.
3Torque the self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
Subtask 72-30-00-220-024
CAUTION:
MAKE SURE THAT THE AFT GUIDES ARE NOT DAMAGED. AFT GUIDES THAT ARE NOT CORRECTLY INSTALLED CAN CAUSE ENGINE DAMAGE.
4Do a visual inspection of the stage 5 aft guides (15-210) (SIN 080T2) for damage. Make sure the stage 5 aft guides are not crushed, extruded, or have come loose.
Subtask 72-30-00-440-588
5Turn compressor rotor CCW to make sure that there are no misplaced guides. Misplaced guides will make a clicking noise when contacting with the HPC blades.
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT SEATED CORRECTLY CAN CAUSE ENGINE DAMAGE.
6Use a borescope to make sure that each wear guide is seated correctly.
7Loosen the eight self-locking nuts (10-140) (SIN 080K5) and spacers (10-160) (SIN 080TC) on the flange of the 5-6 stacked ring (10-200) (SIN 080AM) to remove the clamp on the flange joint. Do not remove the self-locking nuts from the flange.
Subtask 72-30-00-440-589
(g)Install the eight heat shields (10-130) (SIN 080D1) on the 5-6 stacked ring. Refer to Figure 1025, Figure 1026, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight machine bolts (bolt) (10-090) (SIN 080FS).
2Put the eight heat shields on the flange of the 5-6 stacked ring and attach them with the eight bolts (10-090) (SIN 080FS).
Subtask 72-30-00-440-590
(h)Attach the 5-6 stacked ring (10-200) (SIN 080AM) to the stage 5 aft case (10-180) (SIN 080AJ). Refer to Figure 1026 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 16 self-locking nuts (10-140) (SIN 080K5).
2Torque the eight first installed self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
3Torque the eight first installed self-locking nuts again to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
4Install the remaining 16 self-locking nuts with spacers (10-160) (SIN 080TC) on the slab head bolts (10-150) (SIN 080F2).
5Torque all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
6Torque the eight bolts (10-090) (SIN 080FS) that attach the heat shields again to 32-38 lb in. (3.6-4.3 N.m) in a circle pattern.
7Do a final torque to all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1022   Installation of the Lift Fixture, 9429M19G02, on the 5-6 Stacked Ring
* * * FOR ALL PIP 2
Figure 1023   Installation of the Stage 5 Aft Guides on the Stage 5 Vane Sectors and Stage 6 Forward Guides in the 5-6 Stacked Ring
* * * FOR ALL PIP 2
Figure 1024   Installation of the 5-6 Stacked Ring on the Stage 5 Aft Case
* * * FOR ALL PIP 2
Figure 1025   Installation of the Heat Shields on the 5-6 Stacked Ring
* * * FOR ALL PIP 2
Figure 1026   Installation of Self-Locking Nuts on 5-6 Stacked Ring
Subtask 72-30-00-440-591
E.Install the stage 6 HPC vanes (stage 6 vane sectors) (15-181) (SIN 084A1) and (15-191) (SIN 084AB) as follows:
NOTE:
The stage 6 vane sector (15-191) (SIN 084AB) is the vane sector with the borescope port.
(1)Align the notch on the outer platform of the stage 6 vane sector (15-191) (SIN 084AB) with the larger diameter pin on the 5-6 stacked ring at approximately the 10:00 o'clock position and install it on the ring. Refer to Figure 1028.
NOTE:
One locating pin on the 5-6 stacked ring has a larger diameter. The stage 6 vane sector (15-191) (SIN 084AB) with the borescope port is installed at this location.
(2)Align the notch on the outer platforms of the stage 6 vane sector (15-181) (SIN 084A1) with the smaller diameter locating pins in the aft groove on the 5-6 stacked ring (10-200) (SIN 080AM).
(3)Engage the notch of the stage 6 vane sectors with the smaller diameter pin and install the nine stage 6 vane sectors one at a time. Refer to Figure 1027.
(4)Make sure that the HPC rotor assembly (15-012) (SIN 05000) turns freely after the stage 6 vane sectors are installed. Listen for a clicking noise caused by contact of misplaced guides with HPC blades.
CAUTION:
IF A VANE SECTOR GUIDE IS INCORRECTLY INSTALLED, IT CAN CAUSE COMPRESSOR DAMAGE.
(5)Use duckbill pliers to install ten stage 6 spline seals (spline seals) (15-200) (SIN 080N1) between the stage 6 vane sectors. Refer to Figure 1029.
* * * FOR ALL PIP 2
Figure 1027   Installation of Stage 6 Vane Sectors on the 5-6 Stacked Ring
* * * FOR ALL PIP 2
Figure 1028   Installation of Stage 6 Vane Sector (Borescope)
* * * FOR ALL PIP 2
Figure 1029   Installation of the Spline Seals
Subtask 72-30-00-440-592
(6)Install the stage 6-7 aft case (6-7 aft inner case) (10-220) (SIN 080AR) on the 5-6 stacked ring and above the outer platforms of the stage 6 vane segments as follows:
(a)Put the 6-7 aft inner case on a clean work surface. Refer to Figure 1030 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 6-7 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 6-7 aft inner case.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
4Lift the 6-7 aft inner case and put it on a clean work surface, forward side down.
5Remove the 9429M19G02   lift fixture from the 6-7 aft inner case.
(b)Install the ten stage 6 vane sector aft guides (stage 6 aft guides) (15-160) (SIN 080T4) on the aft outer tangs of the stage 6 vane sectors (15-181) (SIN 084A1) and (15-191) (SIN 084AB). Refer to Figure 1031.
1Apply C10-109  wax to the stage 6 aft guides.
2If necessary, use a rubber mallet to install the stage 6 aft guides on the aft outer tangs of the stage 6 vane sectors.
3Make sure that the ten stage 6 aft guides are centered on the stage 6 vane sector gaps.
4Make sure that the stage 6 aft guides do not overlap.
5Make sure there is no damage to the astage 6 aft guides.
CAUTION:
MAKE SURE NOT TO DEFORM THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
(c)Install the 11 stage 7 vane sector forward guides (stage 7 forward guides) (15-120) (SIN 080T5) in the aft groove of the 6-7 aft inner case. Refer to Figure 1031 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Make sure that the mating flanges are clean of all unwanted material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove unwanted material.
2Install one guide in each of the sectors between the vane sector alignment pins located in the aft groove of the stage 6-7 aft case.
3Make sure that the stage 7 aft guides do not overlap.
4Make sure there is no damage to the stage 7 aft guides.
5Use the 11C4689   installation fixture to install the stage 7 forward guides in the aft groove of the 6-7 aft inner case.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(d)Make sure the mating flanges are clean of all foreign material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove foreign material.
Subtask 72-30-00-440-658
CAUTION:
MAKE SURE THAT THE 6-7 AFT INNER CASE IS CORRECTLY INSTALLED ON THE STAGE 5-6 STACKED RING. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(e)Alternative Procedure Available. Install the 6-7 aft inner case on the stage 5-6 stacked ring and stage 6 vane sector outer platforms. Refer to Figure 1032 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 6-7 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 6-7 aft inner case.
4Move the 6-7 aft inner case above the 5-6 stacked ring.
5Make sure that the tops of the cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL CAUSE GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
7If adjustment of the flanges is necessary to align the pin again after any contact, fully remove the top stage 5-5 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
8Align the 0.250 inch (6.35 mm) elongated hole on the forward flange at the TVCL with the pin on the aft flange of the 5-6 stacked ring. Lower the 6-7 aft inner case on the stage 5-6 stacked ring and above the outer platforms of the stage 6 vane sectors.
9Remove the 9429M19G02   lift fixture.
Subtask 72-30-00-440-659
CAUTION:
MAKE SURE THAT THE 6-7 AFT INNER CASE IS CORRECTLY INSTALLED ON THE STAGE 5-6 STACKED RING. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(e).A.Alternative Procedure. Install the 6-7 aft inner case on the stage 5-6 stacked ring and stage 6 vane sector outer platforms. Refer to Figure 1032 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to permit the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 6-7 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 6-7 aft inner case.
4Move the 6-7 aft inner case above the 5-6 stacked ring.
5Make sure that the tops of the cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
7Align 6-7 aft inner case and stage 5-6 stacked ring with 11C4688   alignment guides as follows:
aAlign the top vertical markings of the stage 6-7 case and the alignment stage 5-7 guide.
bInsert the three pins of the alignment stage 5-7 guide through three holes of the stage 6-7 case forward flange.
cUse the pins of the alignment stage 5-7 guide to align the cases before the flanges come in contact.
dMake sure that the tops of the cases being assembled are aligned as flanges touch.
eRemove the alignment stage 5-7 guide.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL PERMIT GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
8If the adjustment of the flanges is necessary to align the pin again after any contact, fully remove the top stage 5-6 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
9Align the 0.250 inch (6.35 mm) elongated hole on the forward flange at the top vertical centerline with the pin on the aft flange of the 5-6 stacked ring. Lower the 6-7 aft inner case on the stage 5-6 stacked ring and above the outer platforms of the stage 6 vane sectors.
10Remove the lift fixture.
Subtask 72-30-00-440-660
CAUTION:
MAKE SURE THAT THE 6-7 AFT INNER CASE IS CORRECTLY INSTALLED ON THE STAGE 5-6 STACKED RING. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(f)Install the 6-7 aft case on the 5-6 stacked ring (10-200) (SIN 080AM) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight self-locking nuts (10-140) (SIN 080K5) and eight bolts (10-190) (SIN 080F5).
2Install the eight self-locking nuts and eight bolts equally spaced on the stage 6 flange (every 5th hole - bolt head forward).
3Torque the self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
Subtask 72-30-00-220-025
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT CORRECTLY INSTALLED CAN CAUSE ENGINE DAMAGE.
4Do a visual inspection of the stage 7 forward guides (15-120) (SIN 080T5) for damage. Make sure the stage 7 forward guides are not crushed, extruded, or have come loose.
Subtask 72-30-00-440-593
5Turn compressor rotor CCW to make sure that there are no misplaced guides. Misplaced guides will make a clicking noise when contacting with the HPC blades.
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT SEATED CORRECTLY CAN CAUSE ENGINE DAMAGE.
6Use a borescope to make sure that each wear guide is seated correctly.
7Remove the eight self-locking nuts (10-140) (SIN 080K5) and bolts (10-190) (SIN 080F5) from the 5-6 stacked ring (10-200) (SIN 080AM).
Subtask 72-30-00-440-594
(g)Install the eight heat shields (10-210) (SIN 080D2) on the forward flange of the 6-7 aft inner case. Refer to Figure 1033 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 30 bolts (10-190) (SIN 080F5) and 30 self-locking nuts (10-140) (SIN 080K5).
2Attach the eight heat shields to the forward flange of the 6-7 aft inner case with the ten bolts (10-190) (SIN 080F5), boltheads forward, and ten self-locking nuts (10-140) (SIN 080K5) used to install the 6-7 aft inner case.
Subtask 72-30-00-440-595
(h)Attach the 6-7 aft inner case (10-220) (SIN 080AR) to the 5-6 stacked ring (10-200) (SIN 080AM). Refer to Figure 1032, Figure 1033, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 40 self-locking nuts (10-140) (SIN 080K5) and 40 bolts (10-190) (SIN 080F5).
2Install eight of the self-locking nuts and eight bolts equally spaced on the stage 6 flange (every 5th hole - bolthead forward).
3Torque the eight self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
4Torque the eight self-locking nuts again to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
5Install the remaining 32 self-locking nuts (10-140) (SIN 080K5) and 32 bolts (10-190) (SIN 080F5) into the remaining open locations of the stage 6-7 flange (bolthead forward).
6Torque all 40 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
7Do a final torque to all 40 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1030   Installation of the Lift Fixture, 9429M19G02, on the 6-7 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1031   Installation of the Stage 6 Aft Guides on the Stage 6 Vane Sectors and Stage 7 Forward Guides in the 6-7 Inner case (Aft Inner Case)
* * * FOR ALL PIP 2
Figure 1032   Installation of the 6-7 Aft Inner Case on the 5-6 Stacked Ring
* * * FOR ALL PIP 2
Figure 1033   Installation of the Heat Shields and Attaching Hardware
Subtask 72-30-00-440-596
F.Install the stage 7 HPC vanes (stage 7 vane sectors) (15-131) (SIN 084A2) and (15-141) (SIN 084AC) as follows:
NOTE:
The stage 7 vane sector (15-141) (SIN 084AC) is the vane sector with the borescope port.
(1)Align the notch on the outer platform of the stage 7 vane sector (15-141) (SIN 084AC) with the larger diameter pin on the 6-7 aft inner case at approximately the 10:00 o'clock position and install it on the 6-7 aft inner case. Refer to Figure 1035.
NOTE:
One locating pin on the 6-7 aft inner case has a larger diameter. The stage 7 vane sector (15-141) (SIN 084AC) with the borescope port is installed at this location.
(2)Align the notch on the outer platform of the stage 7 vane sector (15-131) (SIN 084A2) with the smaller diameter locating pins in the aft groove on the 6-7 aft inner case (10-220) (SIN 080AR). Engage the notch of the stage 7 vane sectors with the smaller diameter pin and install the ten vane sectors one at a time. Refer to Figure 1034.
(3)Make sure HPC rotor assembly (15-012) (SIN 05000) turns freely after the stage 7 vane sectors are installed. Listen for clicking noise caused by contact of misplaced guides with HPC blades.
CAUTION:
IF A VANE SECTOR GUIDE IS INCORRECTLY INSTALLED, IT CAN CAUSE COMPRESSOR DAMAGE.
(4)Use duckbill pliers to install 11 stage 7 spline seals (spline seals) (15-150) (SIN 080N2) between the stage 7 vane sectors. Refer to Figure 1036.
* * * FOR ALL PIP 2
Figure 1034   Installation of the Stage 7 Vane Sectors on the 6-7 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1035   Installation of the Stage 7 Vane Sector (Borescope)
* * * FOR ALL PIP 2
Figure 1036   Installation of the Spline Seals
Subtask 72-30-00-440-597
(5)Install the stage 7-8 aft case (7-8 stacked ring) (10-231) (SIN 080AS) on the 6-7 aft inner case (10-220) (SIN 080AR) and above the outer platforms of the stage 7 vane segments as follows:
(a)Put the 7-8 stacked ring on a clean work surface. Refer to Figure 1037 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 7-8 stacked ring.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 7-8 stacked ring.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
4Lift the 7-8 stacked ring and put it on a clean work surface, forward side down.
5Remove the 9429M19G02   lift fixture from the 7-8 stacked ring.
(b)Install the 11 stage 7 vane sector aft guides (stage 7 aft guides) (15-110) (SIN 080T6) on the aft outer tangs of the stage 7 vane sectors (15-131) (SIN 084A2) and (15-141) (SIN 084AC). Refer to Figure 1038 and do as follows:
NOTE:
Deleted.
NOTE:
Use of C10-154  beeswax or C10-109  wax is permitted to help secure the stage 7 aft guides to the vane sectors.
1If necessary, use a rubber mallet, tapered nylon bar, and a mallet to install the stage 7 aft guides on the aft outer tangs of the stages 7-8 vane sectors.
2Make sure that the stage 7 aft guides do not overlap.
3Make sure there is no damage to the stage 7 aft guides.
4Make sure to start the installation of the stage 7 aft guides on either side of the borescope hole of the stage 7 vane sectors (15-131) (SIN 084A2) and (15-141) (SIN 084AC).
(c)Install 21 slab head bolts (10-150) (SIN 080F2) in the twenty-four 0.272 inch (6.91 mm) holes on the aft flange of the 7-8 stacked ring. Refer to Figure 1039 and do as follows:
CAUTION:
DO NOT INSTALL THREE SLAB HEAD BOLTS AT TVCL OR EITHER SIDE OF TVCL. DAMAGE TO THE 7-8 STACKED RING CAN OCCUR.
1Mark the bolthole and either side of the TVCL on the 7-8 stacked ring to align the TVCL with the stage 8-9 aft case (8-9 aft inner case) (10-260) (SIN 080CS).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
2Apply C02-058  lubricant to the threads and face surfaces of the 21 slab head bolts (10-150) (SIN 080F2) and 21 breakaway nuts (10-170) (SIN 08040).
3Attach the slab head bolts (10-150) (SIN 080F2), boltheads forward, to the 7-8 stacked ring with 21 breakaway nuts (10-170) (SIN 08040).
Subtask 72-30-00-440-598
4Tighten the breakaway nuts (10-170) (SIN 08040) until the wrenching hex collars break off.
NOTE:
The wrenching hex collar will break off at 40-60 lb in. (4.5-6.8 N.m).
5Make sure that the heads of the slab head bolts are correctly installed on the 7-8 stacked ring.
Subtask 72-30-00-440-599
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY-DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(d)Make sure the mating flanges are clean of all foreign material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove foreign material.
(e)Install nine stage 8 vane sector forward guides (stage 8 forward guides) (15-070) (SIN 080T7) in the aft groove of the 7-8 stacked ring. Refer to Figure 1038.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
CAUTION:
MAKE SURE NOT TO DEFORM THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
1Make sure that the mating flanges are clean of all unwanted material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove unwanted material.
2Install one guide in each of the sectors between the vane sector alignment pins located in the aft groove of the stage 7-8 stacked ring.
3Make sure that the stage 8 forward guides do not overlap.
4Use the 11C4689   installation fixture to install the stage 8 forward guides in the aft groove of the 7-8 stacked ring.
Subtask 72-30-00-440-661
CAUTION:
MAKE SURE THAT THE 7-8 STACKED RING IS CORRECTLY INSTALLED ON THE 6-7 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(f)Alternative Procedure Available. Install the 7-8 stacked ring on the 6-7 aft inner case and stage 7 vane sector outer platforms. Refer to Figure 1040 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 7-8 stacked ring.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 7-8 stacked ring.
4Move the 7-8 stacked ring above the 6-7 aft inner case.
5Make sure that the tops of cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL CAUSE GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
7If adjustment of the flanges is necessary to align the pin again after any contact, fully remove the top stage 5-5 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
8Align the 0.250 inch (6.35 mm) elongated hole on the forward flange of the 7-8 stacked ring with the pin on the aft inner flange of the 6-7 aft inner case. Lower the 7-8 stacked ring on the stage 6-7 aft inner case and above the outer platforms of the stage 7 vane sectors.
9Remove the 9429M19G02   lift fixture.
Subtask 72-30-00-440-662
CAUTION:
MAKE SURE THAT THE 7-8 STACKED RING IS CORRECTLY INSTALLED ON THE 6-7 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(f).A.Alternative Procedure. Install the 7-8 stacked ring on the 6-7 aft inner case and stage 7 vane sector outer platforms. Refer to Figure 1040 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to permit the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 7-8 stacked ring.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 7-8 stacked ring.
4Move the 7-8 stacked ring above the 6-7 aft inner case.
5Make sure that the tops of the cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
7Align 6-7 aft inner case and stage 7-8 stacked ring with 11C4688   alignment guides as follows:
aAlign the top vertical markings of the stage 7-8 case and the alignment stage 6-8 guide.
bInsert the three pins of the alignment stage 6-8 guide through three holes of the stage 6-7 case forward flange.
cUse the pins of the alignment stage 6-8 guide to align the cases before the flanges come in contact.
dMake sure that the tops of the cases being assembled are aligned as flanges touch.
eRemove the alignment stage 6-8 guide.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL PERMIT GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
8If adjustment of the flanges is necessary to align the pin again after any contact, fully remove the top stage 5-6 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
9Align the 0.250 inch (6.35 mm) elongated hole on the forward flange at the top vertical centerline with the pin on the aft flange of the 7-8 stacked ring. Lower the 6-7 aft inner case on the stage 7-8 stacked ring and above the outer platforms of the stage 6 vane sectors.
10Remove the lift fixture.
Subtask 72-30-00-440-663
CAUTION:
MAKE SURE THAT THE 7-8 STACKED RING IS CORRECTLY INSTALLED ON THE 6-7 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(g)Install four heat shields (10-240) (SIN 080D3) on the forward flange of the 7-8 stacked ring. Make sure the curved surface of the heat shields face forward. Refer to Figure 1041.
(h)Install the 7-8 stacked ring (10-231) (SIN 080AS) on the 6-7 aft inner case (10-220) (SIN 080AR) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight self-locking nuts (10-140) (SIN 080K5) and eight bolts (10-190) (SIN 080F5).
2Install the eight self-locking nuts and eight bolts equally spaced on the stage 7 flange (every 3rd hole - bolthead aft).
3Torque the self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
Subtask 72-30-00-220-026
CAUTION:
MAKE SURE THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT INSTALLED CORRECTLY CAN CAUSE ENGINE DAMAGE.
4Do a visual inspection of the stage 8 forward guides (15-070) (SIN 080T7) for damage. Make sure the stage 8 forward guides are not crushed, extruded, or have come loose.
Subtask 72-30-00-440-600
5Turn compressor rotor CCW to make sure that there are no misplaced guides. Misplaced guides will make a clicking noise when contacting with the HPC blades.
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT SEATED CORRECTLY CAN CAUSE ENGINE DAMAGE.
6Use a borescope to make sure that each wear guide is seated correctly.
7Loosen the eight self-locking nuts (10-140) (SIN 080K5) and bolts (10-190) (SIN 080F5) on the flange of the 7-8 stacked ring (10-231) (SIN 080AS) to remove the clamp on the flange joint. Do not remove the self-locking nuts from the flange.
Subtask 72-30-00-440-601
(i)Attach the 7-8 stacked ring (10-231) (SIN 080AS) to the 6-7 aft inner case (10-220) (SIN 080AR). Refer to Figure 1040, Figure 1041, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of the remaining 16 self-locking nuts (10-140) (SIN 080K5) and 16 bolts (10-190) (SIN 080F5).
2Install the remaining 16 self-locking nuts (10-140) (SIN 080K5) and 16 bolts (10-190) (SIN 080F5) into the remaining open locations of the stage 6-7 flange (boltheads aft).
3Torque all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
4Do a final torque to all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1037   Installation of the Lift Fixture, 9429M19G02, on the 7-8 Stacked Ring
* * * FOR ALL PIP 2
Figure 1038   Installation of the Stage 7 Aft Guides on the Stage 7 Vane Sectors and Stage 8 Forward Guides in the 7-8 Stacked Ring
* * * FOR ALL PIP 2
Figure 1039   Installation of the Slab Head Bolts and Breakaway Nuts
* * * FOR ALL PIP 2
Figure 1040   Installation of the 7-8 Stacked Ring on the 6-7 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1041   Installation of the HPC Stage 7 Heat Shields
Subtask 72-30-00-440-602
G.Install the stage 8 HPC vane (stage 8 vane sectors) (15-081) (SIN 084A3) and (15-091) (SIN 084AD) as follows:
NOTE:
The stage 8 vane sector (15-091) (SIN 084AD) is the vane sector with the borescope port.
(1)Install the nine stage 8 spline seals (spline seals) (15-100) (SIN 080NP) in the recess on the outer platforms of the stage 8 vane sectors. Refer to Figure 1042.
NOTE:
Use of C10-154  beeswax or C10-109  wax is permitted to hold the spline seals in their recesses and make their installation easier.
(2)Align the notch on outer platform of the stage 8 vane sector (15-091) (SIN 084AD) with the larger diameter pin on the 7-8 stacked ring at approximately the 11:00 o'clock position and install it on the 7-8 aft inner case. Refer to Figure 1043.
NOTE:
The last two stage 8 vane sectors are installed together to let the installation of the spline seals.
(3)Align the notch on the outer platforms of the stage 8 vane sector (15-081) (SIN 084A3) with the smaller diameter locating pins in the aft groove on the 7-8 stacked ring (10-231) (SIN 080AS). Engage the notch of the stage 8 vane sectors with the smaller diameter pin and install the eight vane sectors one at a time. Refer to Figure 1042.
NOTE:
One locating pin on the 7-8 stacked ring has a larger diameter. The stage 8 vane sector (15-091) (SIN 084AD) with the borescope port is installed at this location.
(4)Make sure the compressor rotor turns freely after stage 8 vane sectors are installed. Listen for a clicking noise caused by contact of misplaced guides with HPC blades.
CAUTION:
IF A VANE SECTOR GUIDE IS INCORRECTLY INSTALLED, IT CAN CAUSE COMPRESSOR DAMAGE.
(5)Use duckbill pliers to install nine spline seals (15-100) (SIN 080NP) in the slots at the ends of the stage 8 vane sectors (15-081) (SIN 084A3) and (15-091) (SIN 084AD). Refer to Figure 1043 and Figure 1044.
* * * FOR ALL PIP 2
Figure 1042   Installation of the Stage 8 Vane Sectors on the 7-8 Stacked Ring
* * * FOR ALL PIP 2
Figure 1043   Installation of the Stage 8 Vane Sector (Borescope)
Subtask 72-30-00-440-603
(6)Install the 8-9 aft inner case (10-260) (SIN 080CS) on the 7-8 stacked ring (10-231) (SIN 080AS) and above the outer platforms of the stage 8 vane segments as follows:
(a)Put the 8-9 aft inner case on a clean work surface. Refer to Figure 1044 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft flange of the 8-9 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft flange of the 8-9 aft inner case.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
4Lift the 8-9 aft inner case and put it on a clean work surface, forward side down.
5Remove the 9429M19G02   lift fixture from the 8-9 aft inner case.
CAUTION:
MAKE SURE NOT TO DEFORM THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
(b)Install the nine stage 8 vane sector aft guides (stage 8 aft guides) (15-060) (SIN 080T8) on the aft outer tangs of the stage 8 vane sectors (15-081) (SIN 084A3) and (15-091) (SIN 084AD). Refer to Figure 1045.
NOTE:
Deleted.
NOTE:
Use of C10-154  beeswax or C10-109  wax is permitted to help secure the guides to the vane sectors.
1If necessary, use a rubber mallet to install the stage 8 aft guides on the aft outer tangs of the stage 8 vane sectors.
2Make sure that the nine stage 8 aft guides are centered on the vane sector gaps.
3Make sure that the stage 8 aft guides do not overlap.
4Make sure there is no damage to the stage 8 aft guides.
(c)Install three slab head bolts (10-150) (SIN 080F2) in the TVCL holes of the 8-9 aft inner case and aft flange of the 7-8 stacked ring as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and face surfaces of the three slab head bolts (10-150) (SIN 080F2) and three breakaway nuts (10-170) (SIN 08040).
2Attach the three slab head bolts (10-150) (SIN 080F2) to the TVCL holes of the 8-9 aft inner case with three breakaway nuts (10-170) (SIN 08040).
Subtask 72-30-00-440-604
3Tighten the breakaway nuts (10-170) (SIN 08040) until the wrenching hex collars break off.
NOTE:
The wrenching hex collar will break off at 40-60 lb in. (4.5-6.8 N.m).
4Make sure that the heads of the slab head bolts and the breakaway nuts are correctly installed on the 8-9 aft inner case.
Subtask 72-30-00-440-605
(d)Install nine stage 9 vane sector forward guides (stage 9 forward guides) (15-030) (SIN 080T9) in the aft groove of the 8-9 aft inner case. Refer to Figure 1044.
(e)Install one stage 9 forward guide in each of the sectors between the vane sector alignment pins located in the aft groove of the 8-9 aft inner case.
NOTE:
Deleted.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
CAUTION:
MAKE SURE NOT TO DEFORM THE GUIDES DURING INSTALLATION. THIS CAN CAUSE INCORRECT INSTALLATION OF THE VANE SECTORS INTO THE CASE GROOVE.
1Make sure that the mating flanges are clean of all unwanted material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove unwanted material.
2Install one guide in each of the sectors between the vane sector alignment pins located in the aft groove of the stage 8-9 aft case.
3Make sure that the stage 9 forward guides do not overlap.
4Make sure there is no damage to the stage 9 forward guides.
5Use the 11C4689   installation fixture to install the stage 9 forward guides in the aft groove of stage 8-9 aft inner case, between the pins.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(f)Make sure the mating flanges are clean of all foreign material. If necessary, clean mating flanges with C04-035  isopropyl alcohol to remove foreign material.
CAUTION:
MAKE SURE THAT THE 8-9 AFT INNER CASE IS CORRECTLY INSTALLED ON THE 7-8 STACKED RING. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(g)Install the 8-9 aft inner case on the 7-8 stacked ring and stage 8 vane sector outer platforms. Refer to Figure 1046 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft outer flange of the 8-9 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft outer flange of the 8-9 aft inner case.
4Move the 8-9 aft inner case above the 7-8 stacked ring.
5Make sure that the tops of cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL CAUSE GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
7If adjustment of the flanges is necessary to align the pin again after any contact, fully remove the top stage 5-5 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
8Find the mark on the circumferential bolt flange of the 8-9 aft inner case and align it with the 0.250 inch (6.35 mm) elongated hole on the aft flange of the 7-8 stacked ring. Lower the 8-9 aft inner case on the 7-8 stacked ring and above the outer platforms of the stage 8 vane sectors.
9Remove the 9429M19G02   lift fixture.
CAUTION:
MAKE SURE THAT THE 8-9 AFT INNER CASE IS CORRECTLY INSTALLED ON THE 7-8 STACKED RING. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(h)Install the stage 8-9 aft inner case on the 7-8 stacked ring (10-231) (SIN 080AS) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight self-locking nuts (10-140) (SIN 080K5).
2Install the eight self-locking nuts with spacers (10-160) (SIN 080TC) equally spaced on the slab head bolts (10-150) (SIN 080F2).
3Torque the self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
Subtask 72-30-00-220-027
CAUTION:
MAKE SURE THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT INSTALLED CORRECTLY CAN CAUSE ENGINE DAMAGE.
4Do a visual inspection of the stage 8 forward guides (15-070) (SIN 080T7) for damage. Make sure the stage 8 forward guides are not crushed, extruded, or have come loose.
Subtask 72-30-00-440-606
5Turn compressor rotor CCW to make sure that there are no misplaced guides. Misplaced guides will make a clicking noise when contacting with the HPC blades.
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT SEATED CORRECTLY CAN CAUSE ENGINE DAMAGE.
6Use a borescope to make sure that each wear guide is seated correctly.
7Loosen the eight self-locking nuts (10-140) (SIN 080K5) and spacers (10-160) (SIN 080TC) on the flange of the 8-9 aft inner case (10-260) (SIN 080CS) to remove the clamp on the flange joint. Do not remove the self-locking nuts from the flange.
Subtask 72-30-00-440-607
(i)Install eight heat shields (10-111) (SIN 080D5), (10-121) (SIN 080D6), and (10-101) (SIN 080D7) on the flange of the 8-9 aft inner case and 7-8 stacked rings. Refer to Figure 1047, Figure 1048, and do as follows:
1Find the mark on the circumferential bolt flange of the 8-9 aft inner case.
2Use the mark as a guide and put the first heat shield (10-111) (SIN 080D5) at this location.
3Continue in a CW direction (ALF) and put the heat shield (10-121) (SIN 080D6), (10-101) (SIN 080D7), (10-111) (SIN 080D5), (10-121) (SIN 080D6), (10-111) (SIN 080D5), heat shield (10-101) (SIN 080D7), and then (10-111) (SIN 080D5) on the flange. Make sure the heat shields are tight in the slot at the aft end of the 7-8 stacked ring (10-231) (SIN 080AS).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
4Apply C02-058  lubricant to the threads and friction surfaces of eight bolts (10-090) (SIN 080FS).
5Attach the heat shields (10-111) (SIN 080D5), (10-121) (SIN 080D6), and (10-101) (SIN 080D7) to the flange of the 8-9 aft inner case with eight bolts (10-090) (SIN 080FS).
6Torque the eight bolts (10-090) (SIN 080FS) to 32-38 lb in. (3.6-4.3 N.m) in a criss-cross pattern.
(j)Attach the 8-9 aft inner case (10-260) (SIN 080CS) to the 7-8 stacked ring (10-231) (SIN 080AS). Refer to Figure 1047, Figure 1048, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of the remaining 16 self-locking nuts (10-140) (SIN 080K5).
2Torque the first installed eight self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
3Torque the first eight self-locking nuts again to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
4Install the remaining 16 self-locking nuts (10-140) (SIN 080K5) with spacers (10-160) (SIN 080TC) on the slab head bolts (10-150) (SIN 080F2).
5Torque all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
6Do a final torque to all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
7Do a final torque to the eight bolts (10-090) (SIN 080FS) that attach the heat shields to 32-38 lb in. (3.6-4.3 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1044   Installation of the Lift Fixture, 9429M19G02, on the 8-9 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1045   Installation of the Stage 8 Aft Guides on the Stage 8 Vane Sectors and Stage 9 Forward Guides in the 7-8 Stacked Ring
* * * FOR ALL PIP 2
Figure 1046   Installation of the 8-9 Aft Inner Case on the 7-8 Stacked Ring
* * * FOR ALL PIP 2
Figure 1047   Installation of the Stage 8 HPC Heat Shields
* * * FOR ALL PIP 2
Figure 1048   Installation of the Bolts and Self-Locking Nuts
Subtask 72-30-00-440-608
CAUTION:
MAKE SURE THAT THE HONEYCOMB SEALS ARE PRE-GROOVED BEFORE INSTALLATION, IF AN USED SERVICEABLE HPC STAGE 6-10 SPOOL IS INSTALLED IN THE HPC, AND REPLACEMENT OF ONE OR MORE STAGE 9 HPC VANES IS REQUIRED WITH NEW STAGE 9 HPC VANES. REFER TO TASK 72-30-00-800-802 (72-30-00, SPECIAL PROCEDURE 002). DAMAGE TO THE ENGINE CAN OCCUR.
H.Install the nine stage 9 HPC vane (stage 9 vane assemblies) (15-041) (SIN 084A4). Refer to Figure 1049 and do as follows:
(1)Install the stage 9 vane assemblies on the 8-9 aft inner case (10-260) (SIN 080CS) as follows:
(a)Install the stage 9 spline seals (spline seal) (15-050) (SIN 080NY) in the recess on the outer platforms of the stage 9 vane assemblies.
NOTE:
C10-154  beeswax can be used to hold the spline seals (15-050) (SIN 080NY) in their recesses and make their installation easier.
(b)Align the notch in the outer platform of the stage 9 vane assemblies with the pin in the aft groove of the 8-9 aft inner case and install the stage 9 vane assemblies on the 8-9 aft inner case one at a time.
NOTE:
The last two stage 9 vane assemblies are installed together to let the installation of the spline seals.
(c)Make sure that the HPC rotor assembly (15-012) (SIN 05000) turns freely.
(d)Make sure that the nine spline seals are correctly installed between all stage 9 vane assemblies.
(2)Make sure that the compressor rotor turns freely after the vane sectors are installed. Listen for a clicking noise caused by contact of misplaced guides with HPC blades.
* * * FOR ALL PIP 2
Figure 1049   Installation of the Stage 9 Vane Assemblies on the 8-9 Aft Inner Case
Subtask 72-30-00-440-609
(3)Install the stage 9-10 case (9-10 aft inner case) (10-270) (SIN 080CT) on the 8-9 aft inner case (10-260) (SIN 080CS) and above the outer platforms of the stage 9 vane assemblies (SIN 15-041) (SIN 084A4) as follows:
(a)Put the 9-10 aft inner case on a clean work surface. Refer to Figure 1050 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft flange of the 9-10 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft flange of the 9-10 aft inner case.
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
4Lift the 9-10 aft inner case and put it on a clean work surface, forward side down.
5Remove the 9429M19G02   lift fixture from the 9-10 aft inner case.
(b)Install nine stage 9 vane sector aft guides (stage 9 aft guides) (15-020) (SIN 080T0). Refer to Figure 1051 and do as follows:
NOTE:
Deleted.
NOTE:
Use of C10-154  beeswax or C10-109  wax is permitted to help secure the guides to the vane sectors.
1Install the nine stage 9 aft guides on the aft outer tangs of the stage 9 vane sectors.
2If necessary, use a rubber mallet to install the stage 9 aft guides on the outer tangs of the stage 9 vane sectors.
3Make sure that the nine stage 9 aft guides are centered on the vane sector gaps.
4Make sure that the stage 9 aft guides do not overlap.
5Make sure there is no damage to the stage 9 aft guides.
(c)Install the two self-locking nut assemblies (gang channels) (10-310) (SIN 080K1) and one (10-300) (SIN 080K4). Refer to Figure 1052 and do as follows:
1Put the gang channels on the forward face of the aft flange of the 9-10 aft inner case.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
2Apply C02-058  lubricant to the threads and friction surfaces of nine machine screws (screw) (10-290) (SIN 080FR).
3Attach the three gang channels (10-310) (SIN 080K1) and gang channel (10-300) (SIN 080K4) with nine screws (10-290) (SIN 080FR).
4Torque the screws to 60-70 lb in. (6.8-7.9 N.m).
Subtask 72-30-00-440-664
CAUTION:
MAKE SURE THAT THE 9-10 AFT INNER CASE IS CORRECTLY INSTALLED ON THE 8-9 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(d)Alternative Procedure Available. Install the 9-10 aft inner case on the 8-9 aft inner case and stage 9 vane assemblies outer platforms. Refer to Figure 1053 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to let the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft flange of the 9-10 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft flange of the 9-10 aft inner case.
4Move the 9-10 aft inner case above the 8-9 aft inner case.
5Make sure that the tops of cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL CAUSE GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
7If flanges require adjustment to align the pin again after any contact, fully remove top the stage 5-5 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
8Align the pin on the forward flange of the 9-10 aft inner case with the 0.250 inch (6.35 mm) elongated hole on the aft flange of the 8-9 aft inner case. Lower the 9-10 aft inner case on the 8-9 aft inner case and above the outer platforms of the stage 9 vane assemblies.
9Remove the 9429M19G02   lift fixture.
Subtask 72-30-00-440-665
CAUTION:
MAKE SURE THAT THE 9-10 AFT INNER CASE IS CORRECTLY INSTALLED ON THE 8-9 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(d).A.Alternative Procedure. Install the 9-10 aft inner case on the 8-9 aft inner case and stage 9 vane assemblies outer platforms. Refer to Figure 1053 and do as follows:
1Turn the pins (item 6) of the 9429M19G02   lift fixture CCW to permit the installation of the three block hooks (item 3).
2Put the three block hooks (item 3) on the aft flange of the 9-10 aft inner case.
3Tighten the pins (item 6) CW to attach the block hooks (item 3) to the aft flange of the 9-10 aft inner case.
4Move the 9-10 aft inner case above the 8-9 aft inner case.
5Make sure that the tops of the cases that will be assembled are aligned as flanges touch.
6If necessary, use the 11C3363   alignment pin.
7Align 8-9 aft inner case and stage 9-10 aft inner case with 11C4688   alignment guides as follows:
aAlign the top vertical markings of the stage 9-10 aft inner case and the alignment stage 8-10 guide.
bInsert the three pins of the alignment stage 8-10 guide through three holes of the stage 9-10 aft inner case forward flange.
cUse the pins of the alignment stage 8-10 guide to align the cases before the flanges come in contact.
dMake sure that the tops of the cases being assembled are aligned as flanges touch.
eRemove the alignment stage 8-10 guide.
CAUTION:
GUIDES COULD COME LOOSE DURING INITIAL CONTACT. THIS WILL PERMIT GUIDE MISS-ASSEMBLY AND POTENTIAL FOR THE GUIDE TO PROTRUDE INTO THE FLOWPATH AND CONTACT THE HPC BLADE.
8 If flanges require adjustment to align the pin again after any contact, fully remove top the stage 5-6 case to make sure that all wear guides are still correctly positioned on the aft tangs of the stage 5 stator vane segments.
9Align the pin on the forward flange of the 9-10 aft inner case with the 0.250 inch (6.35 mm) elongated hole on the aft flange of the 8-9 aft inner case. Lower the 9-10 aft inner case on the 8-9 aft inner case and above the outer platforms of the stage 9 vane assemblies.
10Remove the lift fixture.
Subtask 72-30-00-440-666
CAUTION:
MAKE SURE THAT THE 9-10 AFT INNER CASE IS CORRECTLY INSTALLED ON THE 8-9 AFT INNER CASE. DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
(e)Install the stage 9-10 aft inner case on the 8-9 aft inner case (10-260) (SIN 080CS) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of eight machine bolts (bolts) (10-250) (SIN 080F6) and eight self-locking nuts (10-140) (SIN 080K5).
2Install the eight bolts (10-250) (SIN 080F6), boltheads forward, with eight spacers (10-160) (SIN 080TC) and eight self-locking nuts (10-140) (SIN 080K5) equally spaced in the 9-10 aft inner case and the 8-9 aft inner case mating flanges.
3Tighten the eight self-locking nuts (10-140) (SIN 080K5) to install the 9-10 aft inner case. Do not torque at this time.
Subtask 72-30-00-220-028
CAUTION:
MAKE SURE THE AFT GUIDES ARE NOT DAMAGED. AFT GUIDES THAT ARE NOT CORRECTLY INSTALLED CAN CAUSE ENGINE DAMAGE.
4Do a visual inspection of the stage 9 aft guides (15-020) (SIN 080T0) and stage 9 forward guides (15-030) (SIN 080T9) for damage. Make sure the stage 9 aft and forward guides are not crushed, extruded, or have come loose.
5Turn compressor rotor CCW to make sure that there are no misplaced guides. Misplaced guides will make a clicking noise when contacting with the HPC blades.
CAUTION:
MAKE SURE THAT THE FORWARD GUIDES ARE NOT DAMAGED. FORWARD GUIDES THAT ARE NOT SEATED CORRECTLY CAN CAUSE ENGINE DAMAGE.
6Use a borescope to make sure that each wear guide is seated correctly.
7Remove the eight self-locking nuts (10-140) (SIN 080K5), bolts (10-250) (SIN 080F6), and spacers (10-160) (SIN 080TC) from the 9-10 aft inner case (10-270) (SIN 080CT).
Subtask 72-30-00-440-610
(f)Install the eight heat shields (10-280) (SIN 080D4) above the 9-10 aft inner case and the 8-9 aft inner case mating flanges. Make sure that the boltholes are aligned. Refer to Figure 1054.
(g)Attach the 9-10 aft inner case (10-270) (SIN 080CT) to the 8-9 aft inner case (10-260) (SIN 080CS). Refer to Figure 1053, Figure 1054, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 24 self-locking nuts (10-140) (SIN 080K5) and 24 bolts (10-250) (SIN 080F6).
2Install the eight self-locking nuts, eight bolts, and eight spacers again under the boltheads equally spaced on the stage 9 flange (every 3rd hole - bolthead forward).
3Torque the eight self-locking nuts to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
4Torque the eight self-locking nuts again to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
5Install the remaining 16 self-locking nuts (10-140) (SIN 080K5), 16 bolts (10-250) (SIN 080F6), and 16 spacers (10-160) (SIN 080TC) under the boltheads into the remaining open locations of the stage 9-10 flange (boltheads forward).
6Torque all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
7Do a final torque to all 24 self-locking nuts to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1050   Installation of the Lift Fixture, 9429M19G02, on the 9-10 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1051   Installation of the Stage 9 Aft Guides on the 9-10 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1052   Installation of the Gang Channels on the 9-10 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1053   Installation of the 9-10 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1054   Installation of the Heat Shields, Bolts, and Self-Locking Nuts
Subtask 72-30-00-440-611
I.Install the extension case (10-080) (SIN 080AL) on the 6-7 aft inner case (10-220) (SIN 080AR), 9-10 aft inner case (10-270) (SIN 080CT), and HPC rotor assembly (15-012) (SIN 05000) as follows:
(1)Prepare the extension case for installation as follows:
(a)Install three equally spaced guide pins (item 2) of the 11C3372   guide pin set on the aft flange of the 9-10 aft inner case. Refer to Figure 1055.
(b)Find the stage 5 borescope port on the extension case.
NOTE:
The stage 5 borescope port is at approximately the 9:00 o'clock position.
(c)Find the TVCL of the stage 10 HPC seal (10-061) (SIN 080CU). Refer to Figure 1056.
NOTE:
The TVCL is at the two offset boltholes.
(d)Align the TVCL of the stage 10 HPC seal with the 12:00 o'clock position of the extension case at the inner aft bolt flange.
(e)Make sure that the pin on the stage 10 HPC seal is aligned with the larger oval hole of the aft extension case and into pin hole of the stage 10 HPC seal, between the slotted hole and a regular bolthole on the extension case. Refer to Figure 1056.
* * * FOR ALL PIP 2
Figure 1055   Installation of the Guide Pin Set, 11C3372, in the Aft Flange of the 9-10 Aft Inner Case
* * * FOR ALL PIP 2
Figure 1056   Installation of the Stage 10 HPC Seal
Subtask 72-30-00-440-613
(2)Alternative Procedure Available. Install the 11C4548   support fixture and the 11C4589   removal fixture on the extension case (10-080) (SIN 080AL). Refer to Figure 1057 and do as follows:
NOTE:
The 11C4548   support fixture and the 11C4589   removal fixture must be installed together before they are engaged on the extension case flange.
(a)Remove the nut from the leveling fleet (item 8) of the 11C4548   support fixture.
(b)Release the ball lock pin (item 7) of the 11C4548   support fixture and the ball lock pin (item 6) of the 11C4589   removal fixture from the beam subassemblies.
(c)Move out the pivot arms (item 4) of the 11C4548   support fixture and the pivot arms (item 2) of the 11C4589   removal fixture and install the ball lock pin (item 7) of the 11C4548   support fixture and ball lock pin (item 6) of the 11C4589   removal fixture again to keep the open position.
(d)Manually put the beam subassembly on the extension case.
(e)Remove the ball lock pin (item 7) of the 11C4548   support fixture and the ball lock pin (item 6) of the 11C4589   removal fixture from the beam subassembly and move in the pivot arms (item 4) of the 11C4548   support fixture and the pivot arms (item 2) of the 11C4589   removal fixture to get the close position.
(f)Make sure the pads (item 5) of the 11C4548   support fixture and pads (item 4) of the 11C4589   removal fixture are under the extension case aft flange forward side. Adjust the leveling feet (item 8) of the 11C4548   support fixture as necessary to let the installation of the pivot arms.
(g)Align the holes of the pivot arms (item 4) of the 11C4548   support fixture and the holes of the pivot arms (item 2) of the 11C4589   removal fixture with the holes of the extension case aft flange.
(h)Attach the pivot arms (item 4) of the 11C4548   support fixture and the pivot arms (item 2) of the 11C4589   removal fixture to the extension case aft flange with the spacers (item 6) and shoulder screws (item 13) of the 11C4548   support fixture and the spacers (item 5) and shoulder screws (item 12) of the 11C4589   removal fixture.
(i)Put the ball lock pin (item 7) of the 11C4548   support fixture and the ball lock pin (item 6) of the 11C4589   removal fixture into its first position to make sure that there is hole alignment with the extension case aft flange.
* * * FOR ALL PIP 2
Figure 1057   Installation of the Support Fixture, 11C4548, and Removal Fixture, 11C4589, on the Extension Case
Subtask 72-30-00-440-614
CAUTION:
MAKE SURE TO USE THE 9429M19G01 LIFT FIXTURE WITH LIFT CAPACITY OF 1500 LB (680 KG) TO LIFT THE EXTENSION CASE OR DAMAGE TO THE HPC ROTOR ASSEMBLY CAN OCCUR.
(2).A.Alternative Procedure. Install the 9429M19G01   lift fixture on the extension case (10-080) (SIN 080AL). Refer to Figure 1058 and do as follows:
(a)Turn the pins (item 4) of the 9429M19G01   lift fixture CCW to let the installation of the three block hooks (item 2).
(b)Put the three block hooks (item 2) on the aft flange of extension case.
(c)Tighten the pins (item 4) CW to attach the block hooks (item 2) to the aft flange of the extension case.
* * * FOR ALL PIP 2
Figure 1058   Installation of the Lift Fixture, 9429M19G01, on the Extension Case
Subtask 72-30-00-440-615
(3)Alternative Procedure Available. Install the extension case (10-080) (SIN 080AL) on the 6-7 aft inner case (10-220) (SIN 080AR), 9-10 aft inner case (10-270) (SIN 080CT), and HPC module assembly (33-012 , 72-00-02) (SIN 00108). Refer to Figure 1059 and do as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
CAUTION:
BE CAREFUL WHEN INSTALLING THE EXTENSION CASE ABOVE THE HPC ROTOR ASSEMBLY. MAKE SURE THAT THE EXTENSION CASE IS CORRECTLY ALIGNED OR DAMAGE TO THE HPC ROTOR ASSEMBLY CAN OCCUR.
(a)Lift and move the extension case with the 11C4548   support fixture and the 11C4589   removal fixture above the 6-7 aft inner case, 9-10 aft inner case, and the HPC module assembly.
(b)Put the extension case in the center above the HPC rotor assembly and align the TVCL of the 9-10 aft inner case with the offset boltholes at the 12:00 o'clock position of the extension case. Refer to Figure 1056.
(c)Make sure that the borescope ports of the extension case are aligned with the borescope ports on the 5-6 stacked ring (10-200) (SIN 080AM), 6-7 aft inner case, and 8-9 aft inner case (10-260) (SIN 080CS).
CAUTION:
BE CAREFUL WHEN INSTALLING THE EXTENSION CASE ABOVE THE HPC ROTOR ASSEMBLY. MAKE SURE THAT THE EXTENSION CASE IS CORRECTLY ALIGNED OR DAMAGE TO THE HPC ROTOR ASSEMBLY CAN OCCUR.
(d)Install the extension case on the outer bolt flanges of the 9-10 aft inner case. Refer to Figure 1059, Figure 1060, Figure 1063, and do as follows:
1Make sure that the guide pins (item 2) in the aft outer flange of the 9-10 aft inner case are aligned with the boltholes of the aft inner flange of the extension case and lower the extension case. Refer to Figure 1055.
2Continue to lower the extension case above the HPC module assembly and on the outer flanges of the 6-7 aft inner case and the 9-10 aft inner case.
3Make sure that the stage 10 HPC seal (10-061) (SIN 080CU) did not move and that all boltholes are aligned.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
4Apply C02-058  lubricant to the threads and friction surfaces of 77 machine bolts (bolts) (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN 080GC). Refer to Figure 1061.
5Attach the extension case to the 9-10 aft inner case as follows:
aInstall one shoulder bolt (10-055) (SIN 080GC) with bolthead aft, in the bolthole No. 40 counting CCW ALF from the bolthole No. 1 at the 12:00 o'clock position. Hand tighten the shoulder bolt. Refer to Figure 1061.
bInstall 74 bolts (10-051) (SIN 080FB), with boltheads aft. Hand tighten the bolts.
6Remove the three guide pins (item 3) of the 11C3372   guide pin set from the extension case.
7Install three bolts (10-051) (SIN 080FB), boltheads aft, where the guide pins (item 3) were removed. Hand tighten the bolts but do not seat them on the flange.
8Tighten the leveling feet (item 8) of the 11C4548   support fixture as necessary only to lock the extension case with the HPC module assembly. Do not over tighten the leveling feet nut (item 8).
9Torque eight equally spaced bolts (10-051) (SIN 080FB) to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
10Loosen the same eigth bolts (10-051) (SIN 080FB) until the bolts are not seat on the flange.
11Torque the same eight equally spaced bolts again (10-051) (SIN 080FB) to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
12Tighten the other 69 bolts and one shoulder bolt until they are snug on the flange.
(e)Attach the extension case to the inner bolt flange of the 6-7 aft inner case. Refer to Figure 1063 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 78 bolts (10-070) (SIN 080FJ).
2Install 78 bolts (10-070) (SIN 080FJ), boltheads forward, to the 6-7 aft inner case and extension case. Do not torque the bolts (10-070) (SIN 080FJ) at this time. Refer to Figure 1063.
3Torque eight equally spaced bolts (10-070) (SIN 080FJ) to 138-162 lb in. (15.6-18.3 N.m) in a criss-cross pattern.
4Loosen the same eight bolts (10-070) (SIN 080FJ) until the bolts are not seat on the flange.
5Tighten the 78 bolts until they are snug on the flange.
6Torque the eight original equally spaced bolts (10-070) (SIN 080FJ) again to 138-162 lb in. (15.6-18.3 N.m) in a criss-cross pattern.
7Torque the eight original equally spaced bolts (10-070) (SIN 080FJ) again to 184-216 lb in. (21.0-24.4 N.m) in a criss-cross pattern.
8Torque the remaining 70 bolts (10-070) (SIN 080FJ) to 184-216 lb in. (21.0-24.4 N.m) in a criss-cross pattern.
9Torque all 78 bolts again to 184-216 lb in. (21.0-24.4 N.m) in a circle pattern.
(f)Finish installation of the extension case on the outer bolt flanges of the 9-10 aft inner case as follows:
1Torque all 77 bolts (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN SIN 080GC) in the stage 9-10 aft inner case and extension case aft flange to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
2Torque all 77 bolts (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN 080GC) in the stage 9-10 aft inner case and extension case aft flange again to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
* * * FOR ALL PIP 2
Figure 1059   Installation of the Extension Case with the Support Fixture, 11C4548 and Removal Fixture, 11C4589
Subtask 72-30-00-440-616
(3).A.Alternative Procedure. Install the extension case (10-080) (SIN 080AL) on the 6-7 aft inner case (10-220) (SIN 080AR), 9-10 aft inner case (10-270) (SIN 080CT), and HPC rotor assembly (33-012 , 72-00-02) (SIN 00108). Refer to Figure 1060 and do as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
CAUTION:
BE CAREFUL WHEN INSTALLING THE EXTENSION CASE ABOVE THE HPC ROTOR ASSEMBLY. MAKE SURE THAT THE EXTENSION CASE IS CORRECTLY ALIGNED OR DAMAGE TO THE HPC ROTOR ASSEMBLY CAN OCCUR.
(a)Lift and move the extension case with the 9429M19G01   lift fixture above the 6-7 aft inner case, 9-10 aft inner case, and the HPC rotor assembly.
(b)Put the extension case in the center above the HPC rotor assembly and align the TVCL of the 9-10 aft inner case with the offset boltholes located at the 12:00 o'clock position of the extension case.
(c)Make sure that the borescope ports of the extension case are aligned with the borescope ports on the 5-6 stacked ring (10-200) (SIN 080AM), the 6-7 aft inner case, and the 8-9 aft inner case (10-260) (SIN 080CS).
(d)Install the extension case on the outer bolt flanges of the 9-10 aft inner case. Refer to Figure 1061 and do as follows:
1Make sure that the guide pins (item 2) in the aft outer flange of the 9-10 aft inner case are aligned with the boltholes of the aft inner flange of the extension case and lower the extension case. Refer to Figure 1055.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
2Make sure the mating flanges are clean of all foreign material. If necessary, clean the mating flanges with C04-035  isopropyl alcohol to remove foreign material.
3Continue to lower the extension case above the HPC rotor assembly and on the outer flanges of the 6-7 aft inner case and the 9-10 aft inner case.
4Make sure that the stage 10 HPC seal did not move and that all boltholes are aligned.
5Remove the 9429M19G01   lift fixture.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
6Apply C02-058  lubricant to the threads and friction surfaces of 77 bolts (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN 080GC).
7Attach the extension case to the 9-10 aft inner case. Refer to Figure 1063 and as follows:
aInstall one shoulder bolt (10-055) (SIN 080GC) with bolthead aft in the bolthole No. 40 counting CCW ALF from bolthole No. 1 at the 12:00 o'clock position. Hand tighten the bolt. Refer to Figure 1061.
bInstall 74 bolts (10-051) (SIN 080FB) with boltheads aft. Hand tighten the bolts.
8Remove the three guide pins (item 2) of the 11C3372   guide pin set from the 9-10 aft inner case.
9Install three bolts (10-051) (SIN 080FB), boltheads aft, where the guide pins (item 2) were removed. Hand tighten the bolts, but do not seat the boltheads on the flange.
10Torque eight equally spaced bolts (10-051) (SIN 080FB) to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
11Loosen the same eight bolts (10-051) (SIN 080FB) until the bolts are not seat on the flange.
12Torque the same eight equally spaced bolts (10-051) (SIN 080FB) again to 94-109 lb in. (10.6-12.3 N.m) in a criss-cross pattern.
13Tighten the other 69 bolts and one shoulder bolt until they are snug on the flange.
(e)Attach the extension case to the inner bolt flange of the 6-7 aft inner case. Refer to Figure 1063 and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply C02-058  lubricant to the threads and friction surfaces of 78 bolts (10-070) (SIN 080FJ).
2Install 78 bolts (10-070) (SIN 080FJ) into the mid-flange of the extension case and the stage 6-7 aft inner case. Refer to Figure 1065.
3Torque eight equally spaced bolts (10-070) (SIN 080FJ) to 138-162 lb in. (15.6-18.3 N.m) in a criss-cross pattern.
4Loosen the same eight bolts (10-070) (SIN 080FJ) until the bolts are not seat on the flange.
5Tighten the 78 bolts until they are snug on the flange.
6Torque the eight first equally spaced bolts (10-070) (SIN 080FJ) to 138-162 lb in. (15.6-18.3 N.m) in a criss-cross pattern.
7Torque the remaining 70 bolts (10-070) (SIN 080FJ) to 184-216 lb in. (21.0-24.4 N.m) in a criss-cross pattern.
8Torque all 78 bolts again to 184-216 lb in. (21.0-24.4 N.m) in a circle pattern.
(f)Complete the installation of the extension case on the outer bolt flanges of the 9-10 aft inner case as follows:
1Torque all 77 bolts (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN 080GC) in the stage 9-10 aft inner case and extension case aft flange to 124-146 lb in. (14.0-16.5 N.m) in a criss-cross pattern.
2Torque all 77 bolts (10-051) (SIN 080FB) and one shoulder bolt (10-055) (SIN 080GC) in the stage 9-10 aft inner case and extension case aft flange again to 124-146 lb in. (14.0-16.5 N.m) in a circle pattern.
(g)Attach the 11C3190   extension case lift bar to the CDP rotating seal (02-460 , 72-31-00) (SIN 050NC). Refer to Figure 1062 and do as follows:
1Remove the 11C3074   tool kit except four dummy bolts (item 2), washers (item 6), and nuts (item 4) of the same 11C3074   tool kit and leave them equally spaced.
2Turn the capstan (item 4) CCW to lower the hub (item 16) of the 11C3190   extension case lift bar on the CDP rotating seal.
3Make sure that the boltholes in the hub (item 16) of the 11C3190   extension case lift bar are aligned with the boltholes of the extension case and that the hub (item 16) is fully installed.
4Attach the hub (item 16) to the extension case with 16 cap screws (item 11), boltheads forward, washers (item 14), and nuts (item 12) of the 11C3190   extension case lift bar.
5Lower the capstan (item 5) of the 11C3190   extension case lift bar until the hub (item 16) makes contact with CDP rotating seal. Align boltholes with the four dummy bolts (item 2) of the 11C3074   tool kit.
6Install four flange nuts (item 5) equally spaced on the dummy bolts (item 2) of the 11C3074   tool kit.
7Torque the four dummy nuts (item 5) to 276-324 lb in. (31.2-36.6 N.m) in a criss-cross pattern.
* * * FOR ALL PIP 2
Figure 1060   Installation of the Extension Case
* * * FOR ALL PIP 2
Figure 1061   Installation of the Bolts in the Extension Case Aft Flange
* * * FOR ALL PIP 2
Figure 1062   Attachment of the Extension Case Lift Bar, 11C3190, to the CDP Rotating Seal
* * * FOR ALL PIP 2
Figure 1063   Installation of Bolts in the Extension Case Mid Flange
Subtask 72-30-00-440-617
J.Install the compressor stator assembly (compressor assembly) as follows:
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(1)Alternative Procedure Available. Remove the lifting hoist from the 11C4589   removal fixture.
Subtask 72-30-00-440-618
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(1).A.Alternative Procedure. Remove the 9C2376   lift beam from the 11C3190   extension case lift bar. Refer to Figure 1062.
Subtask 72-30-00-440-619
(2)Remove the two halves of the 11C3293   dummy stator from the case support base (item 7 and 56) of the 11C4279   buildup fixture or the table ring (item 21) of the 11C3010   build-up fixture. Refer to Figure 1015.
Subtask 72-30-00-160-006
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THESE PRODUCTS.
(3)Use a C10-182  cleaning cloth wet with C04-035  isopropyl alcohol, C04-002  Stoddard solvent, or a 50-50 blend of C04-035  isopropyl alcohol and C04-228  denatured alcohol to clean the forward flange of the extension case, aft flange, and horizontal flanges of the compressor assembly.
Subtask 72-30-00-440-620
(4)Install the compressor stator assembly as follows:
(a)Install the 11C3297   lift fixture on the upper case half of the compressor assembly. Refer to Figure 1064 and do as follows:
1Put the plate (item 2) on the aft flange of the upper case half.
2Align the boltholes of the plate (item 2) with the boltholes in the aft flange and attach the plate to the upper case half with six capscrews (item 4) and nuts (item 5).
WARNING:
ALWAYS USE APPROVED EQUIPMENT AND PROCEDURES TO LIFT PARTS. STAY OUT FROM BELOW LOADS. IF THE PARTS ACCIDENTALLY MOVE OR FALL, THEY CAN CAUSE AN INJURY OR KILL YOU.
(b)Attach a hoist to the hoist ring (item 3).
(c)Align the 12:00 o'clock position of the upper case half with the 12:00 o'clock position of the extension case and put the upper case half on the case support base (item 7 and 56) of the 11C4279   buildup fixture or the table ring (item 21) of the 11C3010   build-up fixture. Refer to Figure 1065.
(d)Remove the plate (item 2) of the 11C3297   lift fixture from the upper case half.
(e)Move the upper case half into the correct position.
NOTE:
The 9:00 o'clock horizontal flange of the upper case half is aligned with the stage 5 borescope port on the extension case.
(f)Install the 11C3297   lift fixture on the lower case half of the compressor assembly. Refer to Figure 1066 and do as follows:
1Put the plate (item 2) on the aft flange of the lower case half.
2Align the boltholes of the plate (item 2) with the boltholes in the aft flange and attach the plate (item 2) to the lower case half with six capscrews (item 4) and nuts (item 5).
(g)Attach a hoist to the hoist ring (item 3).
(h)Align the 6:00 o'clock position of the lower case half with the 6:00 o'clock position of the extension case and put the lower case half on the case support base (item 7 and 56) of the 11C4279   buildup fixture or the table ring (item 21) of the 11C3010   build-up fixture. Refer to Figure 1067.
(i)Remove the plate (item 2) of the 11C3297   lift fixture from the lower case half.
(j)Move the lower case half into the correct position.
NOTE:
The 9:00 o'clock horizontal flange of the lower case half aligns with the borescope port F on the extension case.
(k)Make sure that the boltholes on the aft flange of the compressor assembly align with the boltholes on the forward flange of the extension case. If necessary, use the two guide pin handles (item 4) of the 11C3372   guide pin set to align the boltholes. Refer to Figure 1068.
NOTE:
It may be necessary to lift the extension case to let the installation of the compressor assembly.
* * * FOR ALL PIP 2
Figure 1064   Installation of the Lift Fixture, 11C3297, on the Upper Half of the Compressor Assembly
* * * FOR ALL PIP 2
Figure 1065   Installation of the Upper Half of the Compressor Assembly
* * * FOR ALL PIP 2
Figure 1066   Installation of the Lift Fixture, 11C3297, on the Lower Half of the Compressor Assembly
* * * FOR ALL PIP 2
Figure 1067   Installation of the Lower Half of the Compressor Assembly
* * * FOR ALL PIP 2
Figure 1068   Alignment of Boltholes of the Extension Case and the Compressor Assembly
Subtask 72-30-00-440-621
(5)Attach the compressor assembly to the extension case (10-080) (SIN 080AL). Refer to Figure 1069 and do as follows:
NOTE:
All bolts that attach the compressor assembly to the extension case are installed with the boltheads in the aft position.
Subtask 72-30-00-440-622
(a)Use the C05-003  pen to put a mark on the bolthole numbers on the extension case forward flange. Mark the boltholes in a CW direction.
1Start with bolthole No. 1 at the TVCL, and mark every ten boltholes.
NOTE:
Bolthole No. 1 is at the 12:00 o'clock position and bolthole No. 31 is the last bolthole CW at the 3:00 o'clock position on the upper half of the compressor assembly.
* * * FOR ALL PIP 2
Figure 1069   Installation of Bolts, Spacers, Brackets, and Self-Locking Nuts on the Compressor Assembly to the Extension Case Flanges
Subtask 72-30-00-440-623
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(b)Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of two self-locking nuts (05-011) (SIN 080K2) and the bolt (05-120) (SIN 080FE).
(c)Install a bolt (05-120) (SIN 080FE) with a bolt spacer (spacer) (05-031) (SIN 080TA) below the bolt and self-locking nut (05-011) (SIN 080K2) at bolthole No. 63.
1Tighten the self-locking nut (05-011) (SIN 080K2) until it is fully installed on the forward face of the compressor assembly aft flange.
(d)Install a bolt (05-020) (SIN 080FC) with a spacer (05-031) (SIN 080TA) below the bolt and a self-locking nut (05-011) (SIN 080K2) at the bolthole No. 2.
1Tighten the self-locking nut (05-011) (SIN 080K2) until it is fully installed on the forward face of the compressor assembly aft flange.
Subtask 72-30-00-090-003
(e)Alternative Procedure Available. Remove the 11C4548   support fixture and the 11C4589   removal fixture from the extension case (10-080) (SIN 080AL) as follows:
1Loosen the leveling feet (item 8) of the 11C4548   support fixture to release the extension case and HPC module assembly.
2Loosen and remove the spacers (item 6) and shoulder screws (item 13) of the 11C4548   support fixture and the spacers (item 5) and shoulder screws (item 12) of the 11C4589   removal fixture from the extension case.
3Remove the ball lock pins (item 7) of the 11C4548   support fixture and ball lock pins (item 6) of the 11C4589   removal fixture and move out the pivot arms (item 4) of the 11C4548   support fixture and pivot arms (item 2) of the 11C4589   removal fixture.
4Remove the 11C4548   support fixture and the 11C4589   removal fixture from the extension case.
Subtask 72-30-00-090-004
(e).A.Alternative Procedure. Remove the 11C3190   extension case lift bar from the extension case (10-080) (SIN 080AL) as follows:
1Loosen and remove the 11C3074   tool kit from the hub (item 16) and CDP rotating seal.
2Loosen the capstans (item 4 and 5) to let the extension case rest on the compressor stator cases.
3Tighten the capstans (item 4 and 5).
4Make sure that there is not gap between the extension case and the compressor stator cases.
5Loosen and removed the 16 nuts (item 12), washers (item 14), and cap screws (item 11) from the extension case.
6Remove the 11C3190   extension case lift bar.
7Put a protective cover to the aft end of 11C3190   extension case lift bar.
Subtask 72-30-00-440-624
(6)Alternative Procedure Available. Attach the halves of the compressor stator assembly together. Refer to Figure 1071, Figure 1072, and do as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(a)Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of two hex shear bolts (bolts) (05-190) (SIN 073G5) and two self-locking nuts (05-180) (SIN 073L3).
NOTE:
The boltholes are numbered 1 thru 17. Bolthole No. 1 is the most forward and bolthole No. 17 is the most aft.
(b)Install the bolts (05-190) (SIN 073G5) and self-locking nuts (05-180) (SIN 073L3) in bolthole No. 17 on the 3:00 and 9:00 o'clock horizontal flanges.
1Tighten the two self-locking nuts (05-180) (SIN 073L3) at boltholes No. 17 until they are fully installed on the face of the flanges.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(c)Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of ten hex shear bolts (bolts) (05-170) (SIN 073G3) and ten self-locking nuts (05-160) (SIN 073L2).
(d)Install five bolts (05-170) (SIN 073G3) and self-locking nuts (05-160) (SIN 073L2) with the boltheads facing the 12:00 o'clock position in boltholes No. 1, 4, 7, 12, and 15 on the 9:00 o'clock horizontal flange. Refer to Figure 1071.
Subtask 72-30-00-440-625
(e)Install five bolts (05-170) (SIN 073G3) and five self-locking nuts (05-160) (SIN 073L2) on the 3:00 o'clock horizontal flange as follows:
1Install four bolts (05-170) (SIN 073G3) and four self-locking nuts (05-160) (SIN 073L2) with the boltheads facing the 12:00 o'clock position in boltholes No. 1, 4, 7, and 12.
2Install one bolt (05-170) (SIN 073G3) and one self-locking nut (05-160) (SIN 073L2) with the bolthead facing the 6:00 o'clock position in bolthole No. 15.
Subtask 72-30-00-440-626
(f)Tighten the ten self-locking nuts (05-160) (SIN 073L2) until they are fully installed on the face of the flange. Tighten one self-locking nut from the 3:00 o'clock horizontal flange and then one self-locking nut from the 9:00 o'clock horizontal flange in the order that follows: bolthole No. 7, 12, 4, 15, and 1.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(g)Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of 22 bolts (05-170) (SIN 073G3) and 22 self-locking nuts (05-160) (SIN 073L2).
(h)Install the 22 bolts (05-170) (SIN 073G3) and self-locking nuts (05-160) (SIN 073L2), boltheads facing the 12:00 o'clock position, in the remaining boltholes from No. 16 thru 1 on the 3:00 o'clock and 9:00 o'clock horizontal flanges.
(i)Tighten the 22 self-locking nuts (05-160) (SIN 073L2) until they are fully installed on the face of the flange. Tighten one self-locking nut from the 3:00 o'clock horizontal flange and then one self-locking nut from the 9:00 o'clock horizontal flange from boltholes No. 16 thru 1.
Subtask 72-30-00-440-672
(6).C.Alternative Procedure. Attach the halves of the compressor stator assembly together as follows. Refer to Figure 1071 and Figure 1072.
CAUTION:
USE CUT PROTECTION SLEEVES AND PROTECTING GLOVES WITH THE 11C3294   GUIDE PINS.
(a)Align horizontal split flanges at boltholes No. 17, No. 12, No. 7 and No. 1 with 11C3294   guide pins alternating flanges from aft to forward. Refer to Figure 1070.
NOTE:
The boltholes are numbered 1 to 17, bolthole No. 1 is the most forward and bolthole No. 17 is the most aft.
(b)Install bolts (05-170) (SIN 073G3) and self-locking nuts (05-160) (SIN 073L2) in the 3 o’clock position flange boltholes No. 2 thru No. 6, No. 8 thru No. 11, No. 13, No. 14, and No. 16 with the boltheads facing the 12:00 o'clock position. Refer to Figure 1072.
(c)Install bolt (05-170) (SIN 073G3) and self-locking nut (05-160) (SIN 073L2) in the 3 o’clock position flange bolthole No. 15 with the boltheads facing the 06:00 o'clock position. Refer to Figure 1072.
(d)Install bolts (05-170) (SIN 073G3) and self-locking nuts (05-160) (SIN 073L2) in the 9 o’clock position flange boltholes No. 2 thru No. 6, No. 8 thru No. 11, and No. 13 thru No. 16 with the boltheads facing the 12:00 o'clock position. Refer to Figure 1072.
(e)Tighten the self-locking nuts (05-160) (SIN 073L2) until they are fully installed on the face of the flange starting at aft-side alternating flanges to the forward-side.
(f)Torque the self-locking nuts (05-160) (SIN 073L2) to 552 to 648 lb in. (62.4 to 73.2 Nm) starting at the aft-side alternating flanges to the forward-side.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER'S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(g)Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of six hex shear bolts (bolts) (05-170) (SIN 073G3), six self-locking nuts (05-160) (SIN 073L2), two hex shear bolts (bolts) (05-190) (SIN 073G5) and two self-locking nuts (05-180) (SIN 073L3).
(h)Remove the 11C3294   guide pins and install bolts (05-170) (SIN 073G3) and self-locking nuts (05-160) (SIN 073L2) in boltholes No. 1, No. 7, and No. 12 with the boltheads facing the 12:00 o'clock position. Install bolts (05-190) (SIN 073G5) and self-locking nuts (05-180) (SIN 073L3) in bolthole No. 17 with the boltheads facing the 12:00 o'clock position.
(i)Tighten self-locking nuts (05-160) (SIN 073L2) in boltholes No. 1, No. 7, and No. 12 until they are fully installed on the face of the flange. Tighten self-locking nut (05-180) (SIN 073L3) in bolthole No. 17 until they are fully installed on the face of the flange.
(j)Torque the self-locking nuts (05-160) (SIN 073L2) in boltholes No. 1, No. 7, and No. 12 on both flanges to 552 to 648 lb in. (62.4 to 73.2 Nm).
(k)Torque the self-locking nuts (05-180) (SIN 073L3) in bolthole No. 17 on both flanges to 828 to 972 lb in. (93.6 to 109.8 Nm).
(l)Torque again the two self-locking nuts (05-180) (SIN 073L3) at bolthole No. 17 on the two flanges to 828 to 972 lb in. (93.6 to 109.8 Nm).
(m)Torque again the 32 self-locking nuts (05-160) (SIN 073L2) in decreasing bolthole numbers from bolthole No. 16 to No. 1. Torque one bolthole on the 3:00 o'clock position flange and then one on the 9:00 o'clock position flange. Torque the bolts to 552 to 648 lb in. (62.4 to 73.2 Nm).
* * * FOR ALL PIP 2
Figure 1070   11C3294 Guide Pins Installation
Subtask 72-30-00-440-673
(7)Torque the self-locking nuts on the 3:00 o'clock and 9:00 o'clock horizontal flanges as follows:
(a)Torque the two self-locking nuts (05-180) (SIN 073L3) at bolthole No. 17 on the two flanges to 828-972 lb in. (93.6-109.8 N.m).
(b)Torque the 32 self-locking nuts (05-160) (SIN 073L2) in decreasing bolthole numbers from bolthole No. 16 to 1. Torque one self-locking nut on the 3:00 o'clock flange and then one on the 9:00 o'clock flange to 552-648 lb in. (62.4-73.2 N.m).
(c)Torque again the two self-locking nuts (05-180) (SIN 073L3) at bolthole No. 17 on the two flanges to 828-972 lb in. (93.6-109.8 N.m).
(d)Torque again the 32 self-locking nuts (05-160) (SIN 073L2) in decreasing bolthole numbers from bolthole No. 16 to No. 1. Torque one self-locking nut on the 3:00 o'clock flange and then one on the 9:00 o'clock flange to 552-648 lb in. (62.4-73.2 N.m).
* * * FOR ALL PIP 2
Figure 1071   Installation of the Bolts and Self-Locking Nuts on the 9:00 O'clock Horizontal Flange
* * * FOR ALL PIP 2
Figure 1072   (Sheet 1 ) Installation of Bolts and Self-Locking Nuts on the 3:00 O'clock Horizontal Flange - Different Orientation of Bolt at Bolthole No. 15
* * * FOR ALL PIP 2
Figure 1072   (Sheet 2 ) Installation of Bolts and Self-Locking Nuts on the 3:00 O'clock Horizontal Flange - Different Orientation of Bolt at Bolthole No. 15
Subtask 72-30-00-440-627
(e)Install the bolts (05-020) (SIN 080FC) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of 20 bolts (05-020) (SIN 080FC).
2Install the 20 bolts (05-020) (SIN 080FC) with spacers (05-090) (SIN 080TB) below the boltheads, at boltholes No. 36 thru 44, No. 73 thru 82, and No. 101. Hand tighten the bolts.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
3Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of 53 bolts (05-020) (SIN 080FC) and 53 self-locking nuts (05-011) (SIN 080K2).
4Install the 56 bolts (05-020) (SIN 080FC) with spacers (05-031) (SIN 080TA), below the boltheads, and 56 self-locking nuts (05-011) (SIN 080K2) at boltholes No. 2 thru 4, No. 10, No. 11, No. 15 thru 20, No. 24 thru 26, No. 32 thru 35, No. 45 thru 56, No. 59 thru 62, No. 64 thru 72, No. 100, No. 107 thru 113, and No. 118 thru 122. Hand tighten the self-locking nuts.
Subtask 72-30-00-440-628
(f)Attach the support bracket (bracket) (05-060) (SIN 6101J) on the forward flange of the extension case (10-080) (SIN 080AL) as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of five bolts (05-020) (SIN 080FC) and five self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket with the five bolts (05-020) (SIN 080FC), boltheads aft, and five self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at boltholes No. 5 thru 9.
(g)Attach the support bracket (bracket) (05-040) (SIN 34512) on the forward flange of the extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of three bolts (05-020) (SIN 080FC) and three self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket, nutplates aft, with the three bolts (05-020) (SIN 080FC), boltheads aft, and three self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at boltholes No. 12 thru 14.
Subtask 72-30-00-440-629
(h)Attach the bracket (05-100) (SIN 29914) on the forward flange of extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of two bolts (05-020) (SIN 080FC) and two self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket with the two bolts (05-020) (SIN 080FC), boltheads aft, and two self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at boltholes No. 57 and 58. Hand tighten the self-locking nuts.
Subtask 72-30-00-440-630
(i)Attach the bracket (01-121 , 73-11-20) (SIN 42411) on the forward flange of extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of six bolts (05-020) (SIN 080FC) and six self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket, nutplates aft, with the six bolts (05-020) (SIN 080FC), boltheads aft, and self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at boltholes No. 94 thru 99. Hand tighten the self-locking nuts.
Subtask 72-30-00-440-631
(j)Attach the bracket (05-140) (SIN 62118) on the forward flange of extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of five bolts (05-020) (SIN 080FC) and four self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket, nutplates aft, with a bolt (05-020) (SIN 080FC), bolthead aft, on the aft face of the extension case forward flange at bolthole No. 102. Hand tighten the bolt.
3Install the remaining four bolts (05-020) (SIN 080FC), boltheads aft, and self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at boltholes No. 103 thru 106. Hand tighten the self-locking nuts.
(k)Attach the bracket (05-135) (SIN 34514) on the forward flange of extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of four bolts (05-020) (SIN 080FC) and four self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket with the four bolts (05-020) (SIN 080FC), boltheads aft, and self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at bolthole No. 114 thru 117. Hand tighten the self-locking nuts.
(l)Attach the bracket (05-070) (SIN 34510) on the forward flange of extension case as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
1Apply a thin layer of C02-097  lubricant to the threads and the pressure faces of six bolts (05-020) (SIN 080FC) and six self-locking nuts (05-011) (SIN 080K2).
2Attach the bracket with four bolts (05-020) (SIN 080FC), boltheads aft, and four self-locking nuts (05-011) (SIN 080K2) on the aft face of the extension case forward flange at bolthole No. 123 thru 1. Hand tighten the self-locking nuts.
Subtask 72-30-00-440-632
CAUTION:
MAKE SURE THAT ALL THE SELF-LOCKING NUTS (05-160) (SIN 073L2) AND (05-180) (SIN 073L3) ON THE SPLIT COMPRESSOR FLANGES ARE TORQUED BEFORE SEATING THE EXTENSION CASE (10-080) (SIN 080AL). DAMAGE TO THE HARDWARE CAN OCCUR.
(8)Torque the self-locking nuts (05-011) (SIN 080K2) on the compressor assembly to the extension case flanges. Refer to Figure 1069 and do as follows:
(a)Torque the bolts (05-020) (SIN 080FC) at locations that do not have self-locking nuts (05-011) (SIN 080K2).
(b)Torque the self-locking nut (05-011) (SIN 080K2) at the bolthole No. 63 to 276-324 lb in. (31.2-36.6 N.m).
(c)Torque again the self-locking nut (05-011) (SIN 080K2) at the bolthole No. 63 to 368-432 lb in. (41.6-48.8 N.m).
(d)Torque 16 self-locking nuts (05-011) (SIN 080K2) equally spaced to seat the extension case to 276-324 lb in. (31.2-36.6 N.m) in a criss-cross pattern.
(e)Torque the 125 self-locking nuts (05-011) (SIN 080K2) or bolts (05-020) (SIN 080FC) to 368-432 lb in. (41.6-48.8 N.m) in a criss-cross pattern.
(f)Torque the 125 self-locking nuts (05-011) (SIN 080K2) or bolts (05-020) (SIN 080FC) to 368-432 lb in. (41.6-48.8 N.m) in a circular pattern.
(g)Deleted.
(h)Deleted.
(i)Torque the two self-locking nuts (02-355) (SIN 07500-32) to attach the thrust link (02-235) (SIN 07500-6) to 331-389 lb in. (37.4-44.0 N.m).
(j)Torque the two self-locking nuts (02-160) (SIN 07501-32) to attach the thrust link (02-040) (SIN 07501-6) to 331-389 lb in. (37.4-44.0 N.m).
Subtask 72-30-00-220-030
K.Do a visual inspection of the borescope plugs and ports. Refer to TASK 72-00-00-800-804 (72-00-00, SPECIAL PROCEDURE 004) (paragraph 5.A. and 5.B.).
Subtask 72-30-00-440-633
L.Install the borescope plugs in the ports F, G, H, and I. Refer to Figure 1074, Figure 1075, and do as follows:
(1)Install the stage 6 borescope plug (10-010) (SIN 080AD) in the borescope port F as follows:
(a)Make sure that the borescope port F in the extension case (10-080) (SIN 080AL) is aligned with the borescope port F in the 5-6 stacked ring (10-200) (SIN 080AM).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(b)Apply C02-071  lubricant to the inner and outer threads of the stage 6 borescope plug.
(c)Install the inner part of the stage 6 borescope plug through the borescope port F in the extension case and into the borescope port F of the 5-6 stacked ring.
(d)Torque the inner part of the stage 6 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(e)Loosen the inner part of the stage 6 borescope plug and torque to 23-27 lb in. (2.6-3.1 N.m).
(f)Torque again the inner part of the stage 6 borescope plug to 23-27 lb in. (2.6-3.1 N.m).
(g)Compress the spring and tighten the outer part of the stage 6 borescope plug in the borescope port F in the extension case.
(h)Torque the outer part of the stage 6 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(i)Torque again the outer part of the stage 6 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(j)After the plug has been torqued, perform a visual inspection of the plug and make sure that the locking feature is fully engaged with the lug on the borescope boss. Also make sure that the head of the borescope plug is fully seated against the borescope boss. If one of the two conditions are not met, the ratcheting feature of the plug can be seized or locked. Apply a penetrating oil directly in between the locking ring and the head of the plug. Re-apply torque to the plug until the plug begins to rotate freely. Tighten the plug from 81 to 95 lb in. (9.2 to 10.7 Nm). Do the visual inspection again before proceeding. If the conditions above cannot be met, replace the plug. Refer to Figure 1073.
(2)Install the stage 7 borescope plug (10-020) (SIN 080AU) in the borescope port G as follows:
(a)Make sure that the borescope port G in the extension case is aligned with the borescope port G in the 6-7 aft inner case (10-220) (SIN 080AR).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(b)Apply C02-071  lubricant to the inner and outer threads of the stage 7 borescope plug.
(c)Install the inner part of the stage 7 borescope plug through the borescope port G in the extension case and into the borescope port G of the 6-7 aft inner case.
(d)Torque the inner part of the stage 7 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(e)Loosen the inner part of the stage 7 borescope plug and torque to 23-27 lb in. (2.6-3.1 N.m).
(f)Torque again the inner part of the stage 7 borescope plug to 23-27 lb in. (2.6-3.1 N.m).
(g)Compress the spring and tighten the outer part of the stage 7 borescope plug in the borescope port G in the extension case.
(h)Torque the outer part of the stage 7 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(i)Torque again the outer part of the stage 7 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(j)After the plug has been torqued, perform a visual inspection of the plug and make sure that the locking feature is fully engaged with the lug on the borescope boss. Also make sure that the head of the borescope plug is fully seated against the borescope boss. If one of the two conditions are not met, the ratcheting feature of the plug can be seized or locked. Apply a penetrating oil directly in between the locking ring and the head of the plug. Re-apply torque to the plug until the plug begins to rotate freely. Tighten the plug from 81 to 95 lb in. (9.2 to 10.7 Nm). Do the visual inspection again before proceeding. If the conditions above cannot be met, replace the plug. Refer to Figure 1073.
(3)Install the stage 8 borescope plug (10-030) (SIN 080AW) in the borescope port H as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(a)Apply C02-071  lubricant to the threads of the stage 8 borescope plug.
(b)Install the stage 8 borescope plug through the borescope port H in the extension case.
(c)Torque the outer part of the stage 8 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(d)Torque again the outer part of the stage 8 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(e)After the plug has been torqued, perform a visual inspection of the plug and make sure that the locking feature is fully engaged with the lug on the borescope boss. Also make sure that the head of the borescope plug is fully seated against the borescope boss. If one of the two conditions are not met, the ratcheting feature of the plug can be seized or locked. Apply a penetrating oil directly in between the locking ring and the head of the plug. Re-apply torque to the plug until the plug begins to rotate freely. Tighten the plug from 81 to 95 lb in. (9.2 to 10.7 Nm). Do the visual inspection again before proceeding. If the conditions above cannot be met, replace the plug. Refer to Figure 1073.
(4)Install the stage 9 borescope plug (10-040) (SIN 080BA) in the borescope port I in the extension case as follows:
(a)Make sure that the borescope port I in the extension case is aligned with the borescope port I in the 8-9 aft inner case (10-260) (SIN 080CS).
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(b)Apply C02-071  lubricant to the inner and outer threads of the stage 9 borescope plug.
(c)Install the inner part of the stage 9 borescope plug through the borescope port I in the extension case and into the borescope port I of the 8-9 aft inner case.
Subtask 72-30-00-440-645
* * * PRE SB   72-0436
(d)Torque the inner part of the stage 9 borescope plug to 81 to 95 lb in. (9.2 to 10.7 Nm).
(e)Loosen the inner part of the stage 9 borescope plug and torque to 23 to 27 lb in. (2.6 to 3.1 Nm).
(f)Torque again the inner part of the stage 9 borescope plug to 23 to 27 lb in. (2.6 to 3.1 Nm).
* * * END PRE SB   72-0436
Subtask 72-30-00-440-646
(g)Compress the spring and tighten the outer part of the stage 9 borescope plug in the borescope port I in the extension case.
(h)Torque the outer part of the stage 9 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(i)Torque again the outer part of the stage 9 borescope plug to 81-95 lb in. (9.2-10.7 N.m).
(j)After the plug has been torqued, perform a visual inspection of the plug and make sure that the locking feature is fully engaged with the lug on the borescope boss. Also make sure that the head of the borescope plug is fully seated against the borescope boss. If one of the two conditions are not met, the ratcheting feature of the plug can be seized or locked. Apply a penetrating oil directly in between the locking ring and the head of the plug. Re-apply torque to the plug until the plug begins to rotate freely. Tighten the plug from 81 to 95 lb in. (9.2 to 10.7 Nm). Do the visual inspection again before proceeding. If the conditions above cannot be met, replace the plug. Refer to Figure 1073.
* * * FOR ALL PIP 2
Figure 1073   Correct/Incorrect Installation of BSI Plugs
Subtask 72-30-00-440-634
M.Continue to assemble the HPC module assembly. Refer to TASK 72-30-00-440-804 (72-30-00, ASSEMBLY 002, CONFIGURATION 02).
* * * FOR ALL PIP 2
* * * PRE SB   72-0436( Borescope Plug with Inner Thread )
Figure 1074   (Sheet 1 ) Installation of the Borescope Plugs in Ports F, G, H, and I
* * * FOR ALL PIP 2
* * * SB   72-0436( Borescope Plug without Inner Thread )
Figure 1074   (Sheet 2 ) Installation of the Borescope Plugs in Ports F, G, H, and I
* * * FOR ALL PIP 2
Figure 1074   (Sheet 3 ) Installation of the Borescope Plugs in Ports F, G, H, and I
* * * FOR ALL PIP 2
Figure 1075   Installation of the Borescope Plugs in Ports F, G, and I