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TASK 72-32-00-440-802
1 . General.
A.This procedure gives instructions to assemble the high pressure compressor (HPC) forward stator assembly (fwd stator assembly) (05-201 , 72-30-00) (SIN 07000). Refer to Figure 1001.
B.Left and right sides of the forward stator assembly (15-011) (SIN 073A0) and case halves are always from aft looking forward (ALF).
C.Make sure that you build the forward stator assembly in an area that has two hoists available.
D.The upper forward stator assembly case half has four borescope ports and the lower forward stator assembly case half has built-in brackets.
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
 
11C3297G01
Fixture, Lift - Forward Compressor Stator Assembly (lift fixture)
 
11C3301G01
Stand, Adapter - Assembly/Disassembly HP Compressor Half - Case Forward (adapter stand)
 
11C3302G02
Pusher, Bushings - IGV/VSV Actuation Rings Stages 1-4 (bushing pusher)
 
11C3305G01
Tool Set, Countertorque - Stator Vanes, Stages 1-4 and IGV (countertorque tool)
NOTE:
Tool 11C3305G01 is an alternative to 11C4657G02.
 
11C4657G02
Set Holder, Variable Stator Vanes (installation tool)
 
11C4803G01
Fixture, Install - HPC Deflector (install fixture)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Wrench, Hex-Head
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C02-008
Petroleum Jelly (petrolatum)
 
C02-058
Compound, Thread Lubricating (lubricant)
 
C02-071
Anti-Seize and Lubricating Compound (anti-seize)
 
C04-035
Solvent, General (isopropyl alcohol)
C.Referenced Procedures.
 
ATA No.
Description
 
72-00-00
Special Procedure 004
 
72-32-09
Inspection 001
 
72-32-10
Inspection 001
D.Expendable Parts.
 
CSN
Description
 
(10-020)
Bolts
 
(10-010)
Washers
 
(10-030)
Nuts
 
(01-070)
Stage 1 Outer Bushings (bushings)
 
(01-020)
Lever Pin Bushings
 
(02-470)
Lever Pin Bushings
3 . Procedure.
Subtask 72-32-00-440-055
A.Install each forward case assembly (15-011) (SIN 073A0) half on a clean work table or on the 11C3301   adapter stand as follows:
NOTE:
Assembly of the case halves can be completed on a clean work table or on the recommended 11C3301   adapter stand. One 11C3301   adapter stand is needed for each case half.
NOTE:
The case halves point forward-side down on the table or the adapter stand.
(1)Attach the 11C3297   lift fixture on the case half assembly. Refer to Figure 1002 and do as follows:
(a)Put the plate (item 2) on the aft flange of the case half.
(b)Align 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).
(c)Attach an overhead hoist to the hoist ring (item 3) of the 11C3297   lift fixture.
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
(2)Lift the case half assembly and put the forward side down on the adapter (item 2) of the 11C3301   adapter stand. Make sure that the first and last boltholes in the forward flange are aligned with the holes in the support. Refer to Figure 1003.
(3)Attach the case half assembly to the adapter (item 2) as follows:
(a)Put the washers (item 4) on the top of the first and last holes of the forward flange.
(b)Install the capscrews (item 3) through the washers, flange holes, and adapter (item 2) holes.
(c)Attach the washers (item 4) and the nuts (item 5) to the capscrews (item 3) and tighten them.
(4)Install the 26 bushings (01-070) (SIN 071T1) on the upper forward case assembly.
(5)Install the 25 remaining bushings on the lower forward case assembly.
(6)Make sure that the bushings are fully seated.
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Figure 1001   Forward Stator Case Assembly
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Figure 1002   Installation of 11C3297 Lift Fixture
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Figure 1003   Installation of the Case Assembly on the Adapter Stand, 11C3301
Subtask 72-32-00-440-056
B.Assemble the variable stator vanes (VSV) adjusting pad screws and lever pin bushings (01-020) (SIN 071TB) into each of the stage 1-4 actuating rings (ring segments). Refer to Figure 1004 and do as follows:
(1)Find all eight ring segments and make sure that you have the correct ring segments for each case half. The ring segments have marks for the correct identification as follows:
•
Stage 1 upper (01-030) (SIN 071A1) ring segment with the mark AFT UPPER STAGE 1 on the ring segment
•
Stage 1 lower (01-040) (SIN 071A6) ring segment with the mark AFT LOWER STAGE 1 on the ring segment
•
Stage 2 upper and lower ring segments (01-080) (SIN 071A2) (interchangeable) with the mark AFT STAGE 2 on the ring segment
•
Stage 3 upper and lower ring segments (01-110) (SIN 071A3) (interchangeable) with the mark AFT STAGE 3 on the ring segment
•
Stage 4 upper (01-140) (SIN 071A4) ring segment with the mark AFT STAGE 4 on the ring segment
•
Stage 4 lower (01-150) (SIN 071A9) ring segment with the mark AFT LOWER STAGE 4 on the ring segment.
(2)From the inboard side of the ring segment, install the long threaded end of the VSV adjusting pad screws into the ring insert. Turn the VSV adjusting pad screw clockwise (CW) in the ring segment until it turns freely. Refer to Figure 1004.
NOTE:
There are six VSV adjusting pad screws for each ring segment. There are 48 VSV adjusting pad screws for the complete forward stator assembly.
NOTE:
The VSV adjusting pad screw must turns freely in the actuating ring.
(3)Attach the self-locking nut (nut) (01-010) (SIN 071K0) to the VSV adjusting pad screw on the outer side of the ring segment.
(4)Adjust each of the VSV adjusting pad screws of the ring segment to the limit of dimension A and dimension B. Refer to Figure 1005 and do as follows:
NOTE:
The VSV adjusting pad screw can be turned counterclockwise (CCW) to increase dimension A or B and CW to decrease dimension A or B.
(a)Stage 1 upper/lower ring segments (01-030) (SIN 071A1), (01-040) (SIN 071A6), dimension A: 0.301-0.311 inch (7.65-7.90 mm).
(b)Stage 2 upper/lower ring segments (01-080) (SIN 071A2), dimension A: 0.386-0.396 inch (9.80-10.06 mm).
(c)Stage 3 upper/lower ring segments (01-110) (SIN 071A3), dimension A: 0.296-0.306 inch (7.52-7.77 mm).
(d)Stage 4 upper/lower ring segments (01-140) (SIN 071A4), (01-150) (SIN 071A9), dimension B: 0.296-0.300 inch (7.52-7.62 mm).
(5)Hold the threaded end of the VSV adjusting pad screws with a hex-head wrench and torque the self-locking nut to 60.0-70.0 lb in. (6.78-7.91 N.m). Make sure that you do not turn the VSV adjusting pad screw, or dimension A or B can change.
(6)Use the 11C3302   bushing pusher to install the lever pin bushings from the outboard side of the ring segment. Refer to Figure 1006 and do as follows:
(a)Do not install a lever pin bushing in the last two holes on either side of a ring segment next to the splitline flange (eight holes in each stage). Those bushings will be installed in a later step.
(b)Make sure that each bushing is fully installed in each hole where a connector arm will be installed.
(c)Install the support bed (items 8 through 11) under the actuator ring segment.
NOTE:
The support bed is only required when the actuator ring is installed on the forward stator case.
(d)Align the lever pin bushing in the bore where it will be installed with its protrude opposite to the segment ring.
(e)Insert the mounting pin (item 2) in the internal diameter of the lever pin bushing.
(f)Carefully tap the mounting pin (item 2) as necessary with a rubber hammer, until the lever pin bushing is fully seated.
(7)Install the lever pin bushings in stage 1-4 ring segments. Refer to Subtask 72-32-00-440-056 (paragraph 3.B.(6)) and Figure 1004.
(a)Install 43 lever pin bushings in the stage 1 ring segments.
(b)Install 60 lever pin bushings in the stage 2 ring segments.
(c)Install 74 lever pin bushings in the stage 3 ring segments.
(d)Install 83 lever pin bushings in the stage 4 ring segments.
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Figure 1004   (Sheet 1 ) Assembly of the VSV Adjusting Pad Screws
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Figure 1004   (Sheet 2 ) Assembly of the VSV Adjusting Pad Screws
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Figure 1005   (Sheet 1 ) Assembly of the VSV Adjusting Pad Screws Stage 1-3
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Figure 1005   (Sheet 2 ) Assembly of the VSV Adjusting Pad Screws Stage 4
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Figure 1006   Lever Pin Bushing Installation on the Actuator Ring Segment
Subtask 72-32-00-440-057
C.Install the VSV and washers, into the upper and lower case half assemblies. Refer to Figure 1007 and do as follows:
NOTE:
This procedure is the same for all four stages of the two case assembly halves, unless specified differently. Do this procedure for all stages in this order: stage 4, stage 3, stage 2, and stage 1.
(1)Install the VSV with the leading edge forward from the inside of the case into the vane holes. Make sure that the leading edge of each VSV is facing forward (down) as follows:
•
51 stage 1 VSV (10-042) (SIN 072A1) and washers (10-010) (SIN 071J1)
•
68 stage 2 VSV (10-092) (SIN 072A2)
•
82 stage 3 VSV (10-131) (SIN 072A3)
•
91 stage 4 VSV (10-172) (SIN 072A4).
Subtask 72-32-00-440-058
(2)Find each of the eight actuation ring segments and make sure that you have the correct ring segments for each case half. The ring segments have marks for the correct identification. Find the correct type and quantity lever arms for the segment you will install.
•
Stage 1 ring segments: upper (01-030) (SIN 071A1) and lower (01-040) (SIN 071A6)
•
39 stage 1 lever arms (01-050) (SIN 071D1) and four rigging lever arms (01-180) (SIN 071C0)
•
43 sleeves (01-190) (SIN 071T3) on the upper and lower case
•
43 bushings (01-070) (SIN 071T1) on the upper and lower case
•
Stage 2 ring segments: upper and lower (01-080) (SIN 071A2)
•
56 stage 2 lever arms (01-090) (SIN 071D2), four rigging lever arms (01-180) (SIN 071C0), and 60 sleeves (01-190) (SIN 071T3) on the upper and lower case
•
Stage 3 ring segments: upper and lower (01-110) (SIN 071A3)
•
70 stage 3 lever arms (01-120) (SIN 071D3), four rigging lever arms (01-180) (SIN 071C0), and 74 sleeves (01-190) (SIN 071T3) on the upper and lower case
•
Stage 4 ring segments: upper (01-140) (SIN 071A4) and lower (01-150) (SIN 071A9)
•
79 stage 4 lever arms (01-160) (SIN 071D4), four rigging lever arms (01-180) (SIN 071C0), and 83 sleeves (01-200) (SIN 071T4) on the upper and lower case.
Subtask 72-32-00-220-007
(3)Do an inspection of all the VSV vanes for correct orientation as follows:
Subtask 72-32-00-440-080
(a)Alternative Procedure Available. Install the 11C4657 installation tool on the stage 1 vanes (10-042) (SIN 072A1). Starting from the left when facing the inside of a stator half-case, slide the stage 1/1 over the first several vanes. Resistance to the tool fitting over the vanes is likely an indication that there is a reversed vane. If there is resistance to the tool fitting over the vanes, remove the tool and do an inspection of the vane section for a reversed vane. If a vane is found in the reverse direction, correct the vane orientation. Refer to Figure 1008 and Figure 1009.
WARNING:
DO NOT FORCE THE TOOL ONTO THE VANES. IF YOU FORCE THE TOOL, YOU CAN CAUSE INJURY TO YOUR HANDS.
CAUTION:
IF YOU FORCE THE TOOL ONTO THE VANES, DAMAGE TO ENGINE HARDWARE CAN OCCUR.
CAUTION:
MAKE SURE THAT THE HOLDERS SIT DOWN FLUSH ON THE VANES OR DAMAGE TO THE ENGINE HARDWARE CAN OCCUR.
1Do this procedure again for the remaining sections of stage 1 as well as for the tool stages 2-4.
2Do not remove this tool now, this tool will also be used to restrain rotation while torquing the nuts (01-010) (SIN 071K0).
Subtask 72-32-00-220-008
(a).A. Alternative Procedure. Do a visual inspection to all the vanes to make sure that they are installed in right direction. No vane must be installed in the reverse direction.
Subtask 72-32-00-440-059
CAUTION:
MAKE SURE THAT THE CRIMPING PINS OF ALL OF THE LEVER ARMS ARE FULLY ENGAGED IN THE ACTUATING RING SEGMENTS OR DAMAGE TO THE ENGINE CAN OCCUR.
(4)Put a ring segment in position on the outside of the case and temporarily attach it to the case half assembly with three equally spaced sleeves (01-190) (SIN 071T3), (01-200) (SIN 071T4), and lever arms (01-050) (SIN 071D1), (01-090) (SIN 071D2), (01-120) (SIN 071D3), and (01-160) (SIN 071D4) (stage 1, 2, 3, and 4 respectively) and pushed onto the VSV.
(a)Insert the crimping pin of each lever arm into the related bushing in the ring segment.
(b)Make sure that the flat side of the lever arm hole touches the flat side of the tip of the VSV. Make sure that the rounded side of the lever arm hole touches the rounded side of the tip of the VSV. Refer to Figure 1007.
NOTE:
The three lever arms will be sufficient to temporarily hold the ring segment in place.
Subtask 72-32-00-440-060
(5)Install the remaining lever arms (01-050) (SIN 071D1), (01-090) (SIN 071D2), (01-120) (SIN 071D3), and (01-160) (SIN 071D4) (stage 1, 2, 3, and 4 respectively), and rigging lever arms (01-180) (SIN 071C0) on the ring segments. Make sure that four rigging lever arms (01-180) (SIN 071C0) are installed in correct vane locations as follows:
•
Stage 1 - No. 6, 15, 32, and 40
•
Stage 2 - No. 8, 24, 42, and 58
•
Stage 3 - No. 11, 31, 52, and 72
•
Stage 4 - No. 14, 33, 56, and 74.
NOTE:
The lever arm No. 1 is the first vane on the upper case at the 9:00 o'clock position ALF.
Subtask 72-32-00-440-061
(6)Push the lever arms on the VSV with the crimping pin pointed inward into the ring segment.
(7)Make sure that the flat side of the lever arm hole touches the flat side of the tip of the VSV.
(8)Make sure that the rounded side of the lever arm hole touches the rounded side of the tip of the VSV. Refer to Figure 1007.
(9)Do not install lever arms on the last two vanes on each side of the split line flange on any of the stages 1-4. Those lever arms will be installed in a later step.
(10)Attach the nuts (01-010) (SIN 071K0) to the threads of the VSV and tighten them by hand.
Subtask 72-32-00-440-081
(11)Alternative Procedure Available. Torque the nuts (01-010) (SIN 071K0) as follows:
(a)For the installation of the 11C4657 installation tool on stages 1, 2, 3, and 4. Refer to Subtask 72-32-00-440-080 (paragraph 3.C.(3)(a)), Figure 1008, and Figure 1009.
(b)Torque the nuts (01-010) (SIN 071K0) to 58 to 66 lb in. (6.6 to 7.4 Nm).
(c)Manually turn the VSVs to make sure that they do not interfere with the case half assembly.
Subtask 72-32-00-440-082
(11).A. Alternative Procedure. Torque the nuts (01-010) (SIN 071K0) as follows:
(a)Install the 11C3305 countertorque tool to hold the stages 1, 2, 3, and 4 ring segments (01-030) (SIN 071A1), (01-040) (SIN 071A6), (01-080) (SIN 071A2), (01-110) (SIN 071A3), (01-140) (SIN 071A4), and (01-150) (SIN 071A9). Refer to Figure 1010 and do as follows:
1Put the block (item 6) on the stages 1,2, 3, and 4 upper/lower sectors (item 2, item 3, item 4, item 5, item 13, and item 14).
2Install the capscrew (item 19) to attach the block (item 6) to the stages 1, 2, 3, and 4 upper/lower sectors (item 2, item 3, item 4, item 5, item 13, and item 14).
3Put the upper stage 1 sector (item 2) (STG 1 UPPER) on the stage 1 upper ring segment (01-030) (SIN 071A1).
4Put the lower stage 1 sector (item 14) (STG 1 LOWER) on the stage 1 lower ring segment (01-040) (SIN 071A6).
5Put the stage 2 sector (item 3) (STG 2) on the upper and lower stage 2 ring segment (01-080) (SIN 071A2).
6Put the stage 3 sector (item 4) (STG 3) on the upper and lower stage 2 ring segment (01-110) (SIN 071A3).
7Put the upper stage 4 sector (item 5) (STG 4 UPPER) on the stage 4 upper ring segment (01-140) (SIN 071A4).
8Put the lower stage 4 sector (item 13) (STG 4 LOWER) on the stage 4 lower ring segment (01-150) (SIN 071A9).
9Tighten the two threaded screws (item 17) to attach the stages 1, 2, 3, and 4 upper/lower sectors (item 2, item 3, item 4, item 5, item 13, and item 14) to the stages 1, 2 ,3 and 4 ring segments (01-030) (SIN 071A1), (01-040) (SIN 071A6), (01-080) (SIN 071A2), (01-110) (SIN 071A3), (01-140) (SIN 071A4), and (01-150) (SIN 071A9).
NOTE:
The upper stage 1 sector (item 2) (STG 1 UPPER) and the lower stage 1 sector (item 14) (STG 1 LOWER) only have one threaded screw (item 17).
10Torque the nuts (01-010) (SIN 071K0) to 58 to 66 lb in. (6.6 to 7.4 Nm).
(b)Manually turn the VSVs to make sure that they do not interfere with the case half assembly.
(c)Remove the 11C3305 countertorque tool from stages 1, 2, 3, and 4.
Subtask 72-32-00-440-083
(12)Deleted.
Subtask 72-32-00-440-062
(13)Install the lever arms with the crimping pins pointed outward on the last two VSVs on each side of the split line flange on the stages 1-4 on the upper and lower case assemblies as follows:
•
Eight stage 1 lever arms (01-060) (SIN 071D6) with the eight bushings (01-070) (SIN 071T1) and eight sleeves (01-190) (SIN 071T3) on the upper and lower case assembly
•
Eight stage 2 pin-up lever arms (01-100) (SIN 071D7) and eight sleeves (01-190) (SIN 071T3) on the upper and lower case assembly
•
Eight stage 3 pin-up lever arms (01-130) (SIN 071D8) and eight sleeves (01-190) (SIN 071T3) on the upper and lower case assembly
•
Eight stage 4 pin-up lever arms (01-170) (SIN 071D9) and eight sleeves (01-200) (SIN 071T4) on the upper and lower case assembly.
Subtask 72-32-00-440-063
(14)Attach the nuts (01-010) (SIN 071K0) to the threads of the tip of the VSV and tighten them by hand.
Subtask 72-32-00-440-084
(15)Alternative Procedure Available. Torque the nuts (01-010) (SIN 071K0) as follows:
(a)For the installation of the 11C4657 installation tool on the stages 1, 2, 3 and 4 vanes. Refer to Subtask 72-32-00-440-080 (paragraph 3.C.(3)(a)) , Figure 1008 and Figure 1009.
(b)Torque the nuts (01-010) (SIN 071K0) to 58 to 66 lb in. (6.6 to 7.4 Nm).
(c)Remove the 11C4657 installation tool from all stages 1, 2, 3, and 4.
Subtask 72-32-00-440-085
(15).A. Alternative Procedure. Torque the nuts (01-010) (SIN 071K0) as follows:
(a)Put the stage 1 stator vane holder (item 16) of the 11C3305 countertorque tool on the stage 1 VSV (10-042) (SIN 072A1).
(b)Put the stages 2, 3, and 4 stator vane holder (item 17) of the 11C3305 countertorque tool on the stages 2, 3, and 4 VSV (10-092) (SIN 072A2), (10-131) (SIN 072A3), and (10-172 ) (SIN 072A4).
(c)Torque the nuts (01-010) (SIN 071K0) to 58 to 66 lb in. (6.6 to 7.4 Nm).
(d)Remove the 11C3305 countertorque tool from the stage 1 stator vane holder (item 16) and the stages 2, 3, and 4 stator vane holder (item 17).
Subtask 72-32-00-440-086
(16)Deleted.
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Figure 1007   (Sheet 1 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1007   (Sheet 2 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1007   (Sheet 3 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1007   (Sheet 4 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1007   (Sheet 5 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1007   (Sheet 6 ) Installation of the Stages 1-4 VSV, Vane Shrouds and Stator Seals
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Figure 1008   Installation Tool, 11C4657
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Figure 1009   Installation of Installation Tool, 11C4657
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Figure 1010   (Sheet 1 ) Stator Vane Countertorque Tool, 11C3305
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Figure 1010   (Sheet 2 ) Stator Vane Countertorque Tool, 11C3305
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Figure 1010   (Sheet 3 ) Stator Vane Countertorque Tool, 11C3305
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Figure 1010   (Sheet 4 ) Stator Vane Countertorque Tool, 11C3305
Subtask 72-32-00-440-064
D.Install the stages 1-4 compressor stator vane shrouds (vane shrouds) (10-050) (SIN 071B1), (10-060) (SIN 071B6), (10-100) (SIN 071B2), (10-140) (SIN 071B3), (10-180) (SIN 071B4), and (10-190) (SIN 071B9). Refer to Figure 1007 and do as follows:
NOTE:
Shrouds are a matched set and must be installed as a matched set.
(1)Install the stage 4 shrouds (10-180) (SIN 071B4), (10-190) (SIN 071B9) as follows:
NOTE:
This procedure is the same for the two case assembly halves, unless specified differently.
(a)Install the upper case vane shroud (10-180) (SIN 071B4) on the inner trunnions of the vanes and on the upper case half assembly.
(b)Install the lower case vane shroud (10-190) (SIN 071B9) on the inner trunnions of the vanes and on the lower case half assembly.
(c)Install the bolts (10-020) (SIN 071F1) and nuts (10-030) (SIN 071K2) with the flat of the bolt head facing inboard on the stage 4 upper/lower case vane shrouds.
(d)Torque the nuts to 32-38 lb in. (3.7-4.3 N.m).
(2)Install the stage 3 vane shrouds (10-140) (SIN 071B3) as follows:
NOTE:
This procedure is the same for the two case assembly halves, unless specified differently.
(a)Put the upper and lower case vane shrouds (10-140) (SIN 071B3) on the inner trunnion of the vanes.
(b)Install the bolts (10-020) (SIN 071F1) and nuts (10-030) (SIN 071K2) with the flat of the bolt head pointing inboard on the stage 3 upper/lower case shrouds.
(c)Torque the nuts to 32-38 lb in. (3.7-4.3 N.m).
(3)Install the stage 2 vane shrouds (10-100) (SIN 071B2) as follows:
NOTE:
This procedure is the same for the two case assembly halves, unless specified differently.
(a)Put the upper and lower case vane shrouds (10-100) (SIN 071B2) on the inner trunnions of the vanes.
(b)Install the bolts (10-020) (SIN 071F1) and nuts (10-030) (SIN 071K2) with the flat of the bolt head facing inboard on the stage 2 upper/lower case shrouds.
(c)Torque the nuts to 32-38 lb in. (3.7-4.3 N.m).
(4)Install the stage 1 vane shrouds (10-050) (SIN 071B1), (10-060) (SIN 071B6) as follows:
NOTE:
This procedure is the same for the two case assembly halves, unless specified differently.
(a)Install the upper case vane shroud (10-050) (SIN 071B1) on the inner trunnions of the vanes and on the upper case half assembly.
(b)Install the lower case vane shroud (10-060) (SIN 071B6) on the inner trunnions of the vanes and on the lower case half assembly.
(c)Install the bolts (10-020) (SIN 071F1) and nuts (10-030) (SIN 071K2) with the flat of the bolt head facing inboard on the stage 1 upper/lower case vane shrouds.
(d)Torque the nuts to 32-38 lb in. (3.7-4.3 N.m).
Subtask 72-32-00-440-065
E.Install the stages 1-4 HPC compressor stator seals (stator seals). Refer to Figure 1007 and do as follows:
•
Stage 1 stator seals (10-080) (SIN 076AA), (10-070) (SIN 076A1)
•
Stage 2 stator seals (10-120) (SIN 076AB), (10-110) (SIN 076A2)
•
Stage 3 stator seals (10-160) (SIN 076AC), (10-150) (SIN 076A3)
•
Stage 4 stator seals (10-210) (SIN 076AD), (10-200) (SIN 076A4).
NOTE:
This procedure is the same for all four stages and the two case assembly halves, unless specified differently.
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.
(1)Apply a large quantity of C02-008  petrolatum to the stator seals where they will mate with the vane shroud slots.
CAUTION:
DO NOT APPLY FORCE INCORRECTLY TO INSTALL THE STATOR SEAL. YOU CAN EASILY DAMAGE THE STATOR SEAL.
(2)Use your hand to slide the stator seals into place against the vane shroud slots. Begin sliding the stator seals at the horizontal split line as follows:
(a)The stator seals (10-070) (SIN 076A1), (10-110) (SIN 076A2), (10-150) (SIN 076A3), (10-200) (SIN 076A4) will be installed from the 3:00 o'clock split line to the 12:00 o'clock position and from the 9:00 o'clock split line to the 6:00 o'clock position.
(b)The stator seals (10-080) (SIN 076AA), (10-120) (SIN 076AB), (10-160) (SIN 076AC), (10-210) (SIN 076AD) will be installed from the 3:00 o'clock split line to the 6:00 o'clock position and from the 9:00 o'clock split line to the 12:00 o'clock position.
(3)Make sure that the stator seals are seated correctly against the upper and lower vane shrouds. Make sure that the ends of the stator seals do not extend past the split line flange. Make sure that after assembly, the stage 3 stator seal (10-160) (SIN 076AC) and stage 4 stator seal (10-210) (SIN 076AD) sit flush with the upper and lower vane shrouds. Refer to Figure 1011 for comparison. If the seals do not sit flush per Figure 1011, refer to TASK 72-32-09-100-803 (72-32-09, INSPECTION 001) Subtask 72-32-09-220-031 for HPC stator stage 3 vane shrouds or TASK 72-32-10-200-801 (72-32-10, INSPECTION 001) Subtask 72-32-10-220-004 for HPC stator stage 4 vane shrouds, for repair options.
* * * FOR ALL PIP 2
Figure 1011   Stage 3 and 4 Stator Seal Shroud Clearance
Subtask 72-32-00-440-066
F.Actuate by hand each ring segment and each lever arm that is not captured by a ring segment. Make sure that the ring segment moves smoothly with no binding. If too much force is necessary, do a check for assembly errors and correct.
Subtask 72-32-00-440-067
* * * PRE SB   72-0305( Old Aft Covers Configuration )
G.Install the aft covers (15-021) (SIN 070AG) and (15-041) (SIN 070AJ) on the rear flanges of the compressor case half assembly. Refer to Figure 1012.
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.
(1)If necessary, clean the rails on the upper/lower case half assembly and the aft covers with C04-035  isopropyl alcohol.
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.
(2)Apply a thin film of C02-008  petrolatum to the edges installed first in the case assembly.
(3)Manually move the aft covers (15-021) (SIN 070AG) and (15-041) (SIN 070AJ) in the upper half case assembly. The aft cover (15-041) (SIN 070AJ) will be installed from the 12:00 o'clock to the 3:00 o'clock of the case assembly. The aft cover (15-021) (SIN 070AG) will be installed from the 9:00 o'clock to the 12:00 o'clock of the case assembly. Move the aft cover around until the stop seats against the case assembly.
(4)Manually move the aft covers (15-021) (SIN 070AG) and (15-041) (SIN 070AJ) in the lower half case assembly. The aft cover (15-021) (SIN 070AG) will be installed from the 3:00 o'clock to the 6:00 o'clock of the case assembly. The aft cover (15-041) (SIN 070AJ) will be installed from the 6:00 o'clock to the 9:00 o'clock of the case assembly. Move the aft cover around until the stop seats against the case assembly.
* * * END PRE SB   72-0305( )
Subtask 72-32-00-440-087
* * * SB   72-0305( New Aft Covers Configuration )
G.A.Install the aft covers (15-021) (SIN 070AG), (15-041) (SIN 070AJ), (15-030) (SIN 070AR), and (15-050) (SIN 070AS) or (15-021) (SIN 070AG), (15-040) (SIN 070AJ), (15-030) (SIN 070AR), and (15-050) (SIN 070AS) on the rear flanges of the compressor case half assembly. Refer to Figure 1012 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.
(1)If necessary, clean the rails on the upper/lower case half assembly and the aft covers with C04-035  isopropyl alcohol.
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.
(2)Apply a thin film of C02-008  petrolatum to the edges installed first in the case assembly.
(3)Manually move the aft covers (15-041) (SIN 070AJ) or (15-040) (SIN 070AJ) and (15-050) (SIN 070AS) in the upper half case assembly. The aft cover (15-041) (SIN 070AJ) or (15-040) (SIN 070AJ) will be installed from the 12:00 o'clock to the 3:00 o'clock position of the case assembly. The aft cover (15-050) (SIN 070AS) will be installed from the 9:00 o'clock to the 12:00 o'clock position of the case assembly. Move the aft cover around until the stop seats against the case assembly.
NOTE:
Attachment could be done either manually or with the 11C4803   install fixture.
(4)Manually move the aft covers (15-021) (SIN 070AG) and (15-030) (SIN 070AR) in the lower half case assembly. The aft cover (15-021) (SIN 070AG) will be installed from the 3:00 o'clock to the 6:00 o'clock position of the case assembly. The aft cover (15-030) (SIN 070AR) will be installed from the 6:00 o'clock to the 9:00 o'clock position of the case assembly. Move the aft cover around until the stop seats against the case assembly.
NOTE:
Attachment could be done either manually or with the 11C4803   install fixture.
* * * END SB   72-0305
* * * FOR ALL PIP 2
* * * PRE SB   72-0305( Old Aft Covers Configuration )
Figure 1012   (Sheet 1 ) Installation of the Aft Covers and Borescope Plugs
* * * FOR ALL PIP 2
* * * SB   72-0305( New Aft Covers Configuration )
Figure 1012   (Sheet 2 ) Installation of the Aft Covers and Borescope Plugs
* * * FOR ALL PIP 2
* * * PRE SB   72-0305( Old Aft Covers Configuration )
Figure 1012   (Sheet 3 ) Installation of the Aft Covers and Borescope Plugs
* * * FOR ALL PIP 2
* * * SB   72-0305( New Aft Covers Configuration )
Figure 1012   (Sheet 4 ) Installation of the Aft Covers and Borescope Plugs
Subtask 72-32-00-220-010
H.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 72-32-00-440-068
* * * PRE SB   72-0246
I.Install the borescope plugs (05-010) (SIN 070AK) stage 2, (05-020) (SIN 070AL) stage 3, (05-030) (SIN 070AM) stage 4, and (05-040) (SIN 070AB) stage 5 into the upper half case assembly. Refer to Figure 1012 and do as follows:
(1)Make sure that a 0.250 inch (6.35 mm) minimum diameter pin will pass through each borescope hole in the upper half case assembly.
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.
(2)Apply C02-071  anti-seize to the threads and friction surfaces of each borescope plug.
(3)Turn the borescope plugs into the borescope ports until tight.
(4)Torque the borescope plugs to 81-95 lb in. (9.2-10.7 N.m).
(5)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 1013.
* * * END PRE SB   72-0246
Subtask 72-32-00-440-091
* * * SB   72-0246
I.A.Install the borescope plugs (05-010) (SIN 070AK) stage 2, (05-020) (SIN 070AL) stage 3, (05-030) (SIN 070AM) stage 4, and (05-040) (SIN 070AB) stage 5 into the upper half case assembly. Refer to Figure 1012 and do as follows:
(1)Make sure that a 0.250 inch (6.35 mm) minimum diameter pin will pass through each borescope hole in the upper half case assembly.
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.
(2)Apply C02-071  anti-seize to the threads and friction surfaces of each borescope plug.
(3)Turn the borescope plugs into the borescope ports until tight.
(4)Torque the borescope plugs to 81 to 95 lb in. (9.2 to 10.7 Nm).
* * * END SB   72-0246
* * * FOR ALL PIP 2
* * * PRE SB   72-0246
Figure 1013   (Sheet 1 ) Correct/Incorrect Installation of BSI Plugs
* * * FOR ALL PIP 2
* * * SB   72-0246
Figure 1013   (Sheet 2 ) Correct/Incorrect Installation of BSI Plugs
Subtask 72-32-00-440-069
J.Install the 32 lever pin bushings (02-470 , 72-30-00) (SIN 071TB) into the stages 1-4 actuation ring bridges (bridges) (01-320 , 72-30-00) (SIN 071E1), (01-270 , 72-30-00) (SIN 071E2), (01-280 , 72-30-00) (SIN 071E3), (01-310 , 72-30-00) (SIN 071E4), (01-260 , 72-30-00) (SIN 071E6), and (01-290 , 72-30-00) (SIN 071E9). Refer to Figure 1014 and do as follows:
NOTE:
Four bushings are installed into each bridge.
(1)Align the lever pin bushing in the bore where it will be installed with its protrude opposite to the bridge.
(2)Insert the mounting pin (item 2) of the 11C3302   bushing pusher in the internal diameter of the lever pin bushing.
(3)Carefully tap the mounting pin (item 2) as necessary with a rubber hammer, until the bushing is fully seated.
* * * FOR ALL PIP 2
Figure 1014   Installation of the Lever Pin Bushing into the Bridge
Subtask 72-32-00-440-070
K.Install the two VSV actuator supports (05-050) (SIN 075C0). Refer to Figure 1015 and do as follows:
(1)Install one VSV actuator support on each case assembly half with the bolts (05-060) (SIN 075F3). The VSV actuator support boltholes are between the stages 1 and 2 VSV holes, between 35 and 60 degrees CCW from the horizontal centerline of the case assembly.
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.
(2)Lubricate the threads of the bolts with C02-058  lubricant.
(3)Torque the bolts (05-060) (SIN 075F3) to 106-124 lb in. (12.0-14.0 N.m).
(4)Make sure that all of the vane holes in each stage of the case half assembly have a inner bushing and an outer bushing.
* * * FOR ALL PIP 2
Figure 1015   Installation of the VSV Actuator Supports
Subtask 72-32-00-440-071
L.Put the remaining parts that you will install at the next higher assembly level in bags as follows:
•
Actuation ring bridge attach bolts: eight stage 1 (01-240 , 72-30-00) (SIN 075F2), 12 each stage 2 (01-240 , 72-30-00) (SIN 075F2), stage 3 (01-240 , 72-30-00) (SIN 075F2), and stage 4 (01-240 , 72-30-00) (SIN 075F2)
•
Horizontal mating flange: 32 bolts (05-170 , 72-30-00) (SIN 073G3) and self-locking nuts (05-160 , 72-30-00) (SIN 073L2)
•
Horizontal mating flange: two aft bolts (05-190 , 72-30-00) (SIN 073G5) and self-locking nuts (05-180 , 72-30-00) (SIN 073L3)
•
Actuation ring bridges: stage 1 (01-320 , 72-30-00) (SIN 071E1), (01-260 , 72-30-00) (SIN 071E6), two stage 2 (01-270 , 72-30-00) (SIN 071E2), two stage 3 (01-280 , 72-30-00) (SIN 071E3), and stage 4 (01-310 , 72-30-00) (SIN 071E4), (01-290 , 72-30-00) (SIN 071E9)
•
Actuation ring bridge: 16 alignment pins (01-250 , 72-30-00) (SIN 075V1).