PW1-27H maintenance manual chapter 72-03

PRATT & WHITNEY CANADA MAINTENANCE MANUAL MANUAL PART NO. 3045542

LIST OF EFFECTIVE PAGES

CHAPTER SECTION

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Contents

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72-03-00 Removal

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CHAPTER SECTION

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72-03-00 Installation

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72-03 LEP

Page 1 Nov 04/2005



CHAPTER SECTION

72-03-00 Inspection Check

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DATE

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CHAPTER SECTION

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72-03 LEP

DATE Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005 Nov 04/2005

Page 2 Nov 04/2005



CHAPTER SECTION

72-03-00 Cleaning/ Painting

PAGE

DATE

653 654 655 656 657 658 659 660 661 662 663 664 665 666 667 668 669 670 671 672 673 674 675 676 677 678 679 680 681 682 683 684 685 686

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701 702 703 704 705 706

Sep 03/99 Sep 03/99 Sep 03/99 Sep 03/99 Sep 03/99 Sep 03/99

CHAPTER SECTION 72-03-00 Approved Repairs

PAGE 801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821 822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840

72-03 LEP

DATE Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001

Page 3 Nov 04/2005



CHAPTER SECTION

PAGE 841 842 843 844 845 846 847 848 849 850 851 852 853 854 855 856 857 858 859 860 861 862 863 864 865 866 867 868 869 870 871 872 873 874 875 876

DATE Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Mar 09/2001 Aug 13/2004 Mar 09/2001 Mar 09/2001 Mar 09/2001

72-03 LEP

Page 4 Nov 04/2005


TABLE OF CONTENTS SUBJECT

PAGE

TURBOMACHINERY - REMOVAL

72-03-00

1.

General

401

2.

Consumable Materials

401

3.

Special Tools

401

4.

Fixtures, Equipment and Supplier Tools

403

5.

Hot Section Components - Removal

403

A.

Engine External Components

403

B.

Power Turbine Assembly and Exhaust Duct

405

C.

LP and HP Turbine Assemblies

406

D.

Turbine Support Case Assembly

421

E.

HP Turbine Vane Ring, Combustion Chamber Liner and HP Turbine Stubshaft

425

TURBOMACHINERY - INSTALLATION

72-03-00

1.

General

401

2.


401

3.

Special Tools

402

4.


403

5.

Hot Section Components - Installation

403

A.

HP Turbine Vane Ring, Combustion Chamber Liner and HP Turbine Stubshaft

403

B.

Turbine Support Case Assembly

416

C.

HP and LP Turbine Assemblies

425

D.

Power Turbine and Exhaust Duct

447

E.

Engine External Components

455

TURBOMACHINERY - INSPECTION/CHECK

72-03-00

1.

General

601

2.


602

72-03 CONTENTS

Page 1 Nov 04/2005



PAGE

TURBOMACHINERY - INSPECTION/CHECK (Cont’d)

72-03-00

3.

Special Tools

602

4.


603

5.

Gas Generator Case and Diffuser Exit Duct

603

A.

Gas Generator Case

603

B.

Diffuser Exit Ducts

603

6.

7.

8.

9.

10.

11.

12.

13.

Small Exit Duct, Inner and Outer Combustion Chamber Liner Assemblies

605

A.

Small Exit Duct

605

B.

Inner Liner

608

C.

Outer Liner

610

Fuel Nozzles

614

A.

614

Inspection

Igniters

616

A.

616

Inspection

HP Turbine Stubshaft

616

A.

616

Inspection

HP Turbine Stubshaft Securing Nut

616

A.

616

Inspection

HP Turbine Vane Ring Segments

616

A.

616

Inspection

Vane Ring Outer Support Housing

623

A.

623

Inspection

Cooling Air Nozzle Housing

623

A.

623

Inspection

72-03 CONTENTS

Page 2 Nov 04/2005



PAGE

TURBOMACHINERY - INSPECTION/CHECK (Cont’d) 14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

72-03-00

HP Turbine Vane Ring/Turbine Support Case Sealing Ring

625

A.

625

Inspection

HP Turbine Disk Assembly

625

A.

625

Inspection

Interstage Air Seal Assembly

632

A.

632

General Inspection

HP Turbine Shroud Segments

634

A.

634

Inspection

LP Turbine Stator Assembly

634

A.

634

Inspection

LP Stator Sealing Rings

636

A.

636

Inspection

LP Turbine Disk Assembly

637

A.

637

Inspection

LP Turbine Shroud Segments

638

A.

638

Inspection

LP Turbine Interstage Sealing Ring

641

A.

641

Inspection

Turbine Support Case

641

A.

641

Inspection

Thermocouple Adapters

643

A.

643

Inspection

Low Pressure Turbine Housing Assembly

643

A.

643

Inspection

72-03 CONTENTS

Page 3 Nov 04/2005



PAGE


27.

28.

29.

30.

31.

32.

33.

34.

35.

36.

37.

72-03-00

Turbine Interstage Case No. 6 and 7 Bearing Housing

646

A.

646

Inspection

First-stage Power Turbine Stator

647

A.

647

Inspection

Power Turbine Stator Retaining Ring

648

A.

648

Inspection

Power Turbine Stator Baffle Assembly

648

A.

648

Inspection

Power Turbine Assembly

648

A.

648

Inspection

Second-stage Power Turbine Stator

650

A.

650

Inspection

Power Turbine Sealing Ring

653

A.

653

Inspection

Turbine Exhaust Duct

653

A.

653

Inspection

Power Turbine Shaft

653

A.

653

Inspection

Spacers

657

A.

657

Inspection

Thermocouples and Harness

657

A.

657

Inspection

No. 6 and 7 Bearing Pressure, Scavenge and Vent Transfer Tubes

657

A.

657

Inspection

72-03 CONTENTS

Page 4 Nov 04/2005



PAGE


39.

40.

41.

42.

72-03-00

Air Seals

657

A.

657

Inspection

Bearings

658

A.

658

Inspection

HP and LP Turbine Disk Assembly Tip Clearances

658

A.

658

Procedure

First and Second-stage Power Turbine Assembly Blade Tip Clearance

661

A.

Procedure

661

Fits and Clearances

663

A.

General

663

B.

Terms and Symbols

663

TURBOMACHINERY - CLEANING/PAINTING

72-03-00

1.

General

701

2.


701

3.

Special Tools

701

4.


702

5.

Hot Section Gas Path Components

702

A.

General

702

B.

Turbine Interstage Case

704

TURBOMACHINERY - APPROVED REPAIRS

72-03-00

1.

General

801

2.


801

3.

Special Tools

802

4.


803

72-03 CONTENTS

Page 5 Nov 04/2005



PAGE

TURBOMACHINERY - APPROVED REPAIRS (Cont’d) 5.

6.

7.

8.

9.

10.

11.

12.

72-03-00

Turbine Vane Rings

803

A.

803

General

Engine Rotor Speed Matching

804

A.

Introduction

804

B.

Procedure

805

Replacement of HP Turbine Vane Ring Segments

824

A.

General

824

B.

Disassembly

827

C.

Assembly

827

Removal/Installation of No. 6 Bearing Inner Race and Rotor Air Seal from/on LP Turbines

830

A.

Removal

830

B.

Installation

830

High and Low Pressure Turbine Shrouds - Grinding

830

A.

General

830

B.

Procedure Using Portable Grinding Fixture (PWC37919)

831

Low Pressure (LP) Stator Seal Diameters - Grinding and Machining

855

A.

General

855

B.

Procedure Using Portable Grinding Fixture (PWC37918)

856

Shanknut Replacement

870

A.

870

Procedure

Removal/Installation of Power Turbine Rotor Air Seal

870

A.

Removal

870

B.

Installation

873

72-03 CONTENTS

Page 6 Nov 04/2005



PAGE

TURBOMACHINERY - APPROVED REPAIRS (Cont’d) 13.

72-03-00

HP Turbine Stubshaft Securing Nut Thread Coating

873

A.

873

Procedure

72-03 CONTENTS

Page 7/8 Nov 04/2005


TURBOMACHINERY - REMOVAL 1.

General A.

This section provides instructions for removing hot section gas path components.

B.

Use engine oil (PWC03-001) to lubricate packings, threads and mating faces, unless otherwise stated, and as a heating medium in oil baths.

C.

Operators may choose to carry out a repair and not an HSI (e.g. to replace life limited or defective components or for scheduling purposes etc.). If a repair is carried out, Hot Section Borescope Inspection Criteria (Ref. 72-00-00, INSPECTION/CHECK) may be used to determine serviceability/airworthiness of hot end components. Using this criteria may not improve performance/increase ITT margin (lower ITT). It should be noted that returning an engine to service after using the Borescope Inspection Criteria may substantially increase the cost of subsequent repairs/refurbishments.

WARNING:

WEAR GOGGLES WHEN CUTTING LOCKWIRE.

WARNING:

GLOVES MUST BE WORN TO PROTECT SKIN WHEN DECONTAMINATING AREAS CONTAINING GASKETS OR PACKINGS WHICH HAVE DECOMPOSED DUE TO HIGH TEMPERATURES. HYDROFLUORIC ACID IS PRODUCED WHEN THE MATERIAL DECOMPOSES. MEDICAL TREATMENT IS REQUIRED AS SOON AS POSSIBLE IF THE ACID TOUCHES BARE SKIN.

CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLE COMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLE WITH THOSE REPLACED. CAUTION: CORROSION HAS BEEN ATTRIBUTED TO THE BREAKDOWN OF ‘‘WD-40’’ AT HIGH TEMPERATURES. THEREFORE THIS COMPOUND MUST NOT BE USED ON ENGINE COMPONENTS. 2.

Consumable Materials The consumable materials listed below are referred to in this section. For more data, refer to the CONSUMABLE MATERIALS section at the beginning of this manual. WARNING:

3.

READ THE MATERIAL SAFETY DATA SHEETS BEFORE YOU USE THESE MATERIALS. SOME MATERIALS CAN BE DANGEROUS.

Item No.

Name

PWC03-001 PWC05-002

Oil, Engine Dye, Layout

Special Tools Special tools are identified in procedural text by part number in parentheses. Tool No.

Name

PWC31050

Wrench

72-03-00 TURBOMACHINERY - REMOVAL

Page 401 Nov 04/2005


Tool No.

Name

PWC32396 PWC32506 PWC37047 PWC37054 PWC37137 PWC37138 PWC37151 PWC37159 PWC37217 PWC37445 PWC37458 PWC37459 PWC37462 PWC37515-06 PWC37540 PWC37547 PWC37740 PWC37741 PWC37747 PWC37748 PWC37759 PWC37760 PWC37761 PWC37807 PWC37906 PWC37939 PWC38247 PWC38553 PWC38667 Rev. C or subsequent PWC54020 PWC54072 PWC54100 PWC54147 PWC54351 PWC54912 PWC56254

Jackscrew Cylinder Nut Puller Socket Adapter Adapter Puller Puller Support Adapter Socket Puller Bar Holder Support Puller Pad Pad Puller Pad Adapter Support Pump Adapter Sling Adapter Puller Puller Gage Guide Puller Unstaking Tool Protractor Socket Drilling Fixture


Page 402 Nov 04/2005


4.

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Bolts, Slave (0.190-32 UNJF-3A x 0.375) Cleaner, Vacuum Collar, Set, Screw No. BAS-A1-2, or equivalent Drill Drill Bit, Aircraft Extension, No. 578, 3/32 in. (2.38 mm), or equivalent Feeler Taper Gun, Heat - Thermofit Minigun (with reflector) Wire Gage

5.

Hot Section Components - Removal A.

Engine External Components (1)

Remove oil filler valve (Ref. 72-01-50, OIL SYSTEM - REMOVAL/INSTALLATION) and test per ‘‘PTM INTERNATIONAL, CMM 79-20-01’’. NOTE:

If the oil filler valve does not show evidence of oil leakage during an engine run with the oil filler cap removed (2 minutes at 80%), the valve testing per CMM is not required. CAUTION: Do not look directly into the valve while operating the engine. Take precaution during testing to avoid exposure to possible oil spray.

(2) Remove accessory gearbox breather tube (Ref. 72-01-50, REMOVAL/INSTALLATION). (3)

Remove No. 5 bearing vent tube (Ref. 72-01-50, REMOVAL/INSTALLATION).

(4)

Remove intercompressor drain tube (Ref. 72-01-50, REMOVAL/INSTALLATION).

(5)

Remove sealing tubes (1, Fig. 401).

(6)

Remove No. 6 and 7 bearing oil pressure, scavenge and vent tubes (Ref. 72-01-50, REMOVAL/INSTALLATION).

(7)

Remove No. 6 and 7 bearing oil pressure (1, Fig. 404), scavenge and vent transfer tube assemblies.

(8)

Remove strainer (9) from oil pressure transfer tube (1).

CAUTION: GASKET (7) MUST BE REMOVED AND DISCARDED. (9) (10)

Remove retaining ring (4), plate (5), seal ring (6) and gaskets (7, 36) from transfer tubes. Discard seal ring and gasket. Remove sealing tubes (8) using puller (PWC37217).


Page 403 Nov 04/2005


VIEW

13

12

A

A

1 10 MARK AT T.D.C. 11 8 9 6 3

7 1

5 4 2 3

C65718A Power Turbine Assembly - Removal Figure 401


Page 404 Nov 04/2005


Key to Figure 401 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

B.

Tube Bolt (MS9696-08, Qty 24) Bolt (MS9217-06, Qty 3) Exhaust Duct Bolt Cover Retaining Ring Keywasher Nut Power Turbine Rotor Assembly Sealing Ring Spacer Shaft

(11)

Remove T6 thermocouple trim cable assembly (Ref. 72-01-60, REMOVAL/ INSTALLATION).

(12)

Remove T6 bus-bars (Ref. 72-01-60, REMOVAL/INSTALLATION).

(13)

Remove sealing plates and T6 thermocouples (Ref. 72-01-60, REMOVAL/ INSTALLATION).

(14)

Disconnect fuel line. Remove flow divider and dump valve (Ref. 72-01-40, REMOVAL/INSTALLATION).

(15)

Remove fuel manifold (Ref. 72-01-40, REMOVAL/INSTALLATION).

(16)

Remove fuel adapter assemblies (Ref. 72-01-40, REMOVAL/INSTALLATION).

(17)

Remove igniters (Ref. 72-01-20, REMOVAL/INSTALLATION).

(18)

Remove insulation blankets from turbine support case assembly (Ref. 72-50-00, MAINTENANCE PRACTICES).

(19)

Remove insulation blankets from rear of gas generator case (Ref. 72-40-00, MAINTENANCE PRACTICES).

Power Turbine Assembly and Exhaust Duct (1)

Remove bolts (2, 3). To remove exhaust duct assembly (4), pull and rotate 5 degrees counterclockwise.

(2)

Find longest blade and check tip clearance in eight positions using taper feeler or wire gage.

(3)

Add clearances and divide by eight to obtain the actual tip clearance.


Page 405 Nov 04/2005


(4)

Compare with the recommended tip clearance (F & C REF. NO. 1177). NOTE:

Tip clearances greater or smaller than those specified in Fits and Clearances may have an adverse effect on engine performance. Tip clearances outside specified limits are acceptable for power turbine assemblies which are reinstalled in the same engine they were removed from, providing engine performance is satisfactory and no power turbine lockup has been reported.

(5)

Using layout dye (PWC05-002), mark top dead center (TDC) on power turbine stator flange rear face (Ref. Fig. 401).

(6)

Remove bolts (5).

(7)

Remove power turbine disk cover (6) using puller (PWC37159).

(8)

Remove retaining ring (7) and keywasher (8). Discard keywasher.

(9)

Install socket (PWC37137) (1, Fig. 402), adapter (PWC37138) (2), bar (PWC37515-06) (4) and wrench (PWC31050) (3), and remove nut (9, Fig. 401) from shaft (13).

(10)

Remove tools.

CAUTION: ENSURE THAT NUT (11) IS REMOVED BEFORE INSTALLATION OF POWER TURBINE ROTOR ASSEMBLY REMOVAL TOOLING, AND THAT STATOR ASSEMBLY MOVES FREELY DURING COMPLETE DISASSEMBLY SEQUENCE.

C.

(11)

Install holder (PWC37540) (5, Fig. 403), pad (PWC37741) (1), puller (PWC37740) (2), cylinder (PWC32506) (3) and pump (PWC37807) (4). Pull holder rearward until lugs clear slots. Then rotate stator counterclockwise until index mark is 15 degrees before TDC. Operate pump to release power turbine rotor assembly, taking care to ensure lugs on stator assembly pass through slots in turbine support case assembly. Remove pump, cylinder, puller, pad and holder.

(12)

Install sling (PWC37939) (6) and remove power turbine rotor assembly (10, Fig. 401), ensuring labyrinth air seal is secure.

(13)

Install rotor assembly on support (PWC37761).

(14)

Remove sealing ring (11) and spacer (12).

(15)

Mark (using vibropeen) an X on power turbine stator in line with mark previously applied (Ref. step (5) and Fig. 401).

LP and HP Turbine Assemblies (1)

Remove baffle assembly (10) using puller (PWC54100).


Page 406 Nov 04/2005


(2)

Remove bolts (11) (Pre-SB21618) or (41) (Post-SB21618) and retaining rings (12, 13) (Pre-SB21618) or (37, 38) (Post-SB21618). Discard bolts. NOTE:

(3)

Before removal, check retaining ring for cracks. If cracked, use layout dye (PWC05-002) to number ring segments, No. 1 TDC and remaining ring segments clockwise.

Install guide (PWC54072).

CAUTION: TAKE EXTREME CARE WHEN REMOVING TURBINE INTERSTAGE CASE AND ASSOCIATED PARTS TO ENSURE NO. 6 BEARING IS NOT DAMAGED. (4)

Remove turbine interstage case and associated parts (15) (Pre-SB21618) or (39) (Post-SB21618), using jackscrews (PWC32396). Place case on bench and remove power turbine stator assembly (14), using fiber drift on airfoil.

(5)

Remove sealing ring (16).

(6)

Remove guide (PWC54072).

(7)

Install sealing ring (16) with gap at TDC in seal housing (26). Check radial clearance is less than 0.001 in. (0.025 mm) over at least 300 degrees, and less than 0.002 in. (0.050 mm) over the remaining circumference (Ref. Fig. 410). If necessary, rotate ring until clearance is within limits. Reject ring if correct clearance is unobtainable. Remove ring.

CAUTION: HANDLING OF BEARINGS MUST BE KEPT TO A MINIMUM. WEAR SYNTHETIC RUBBER OR NYLON MESH GLOVES WITH POLYETHYLENE PALMS AND FINGERS. WHEN RUBBER OR NYLON GLOVES ARE NOT AVAILABLE, COTTON GLOVES MAY BE WORN IF THEY ARE CHANGED FREQUENTLY TO ENSURE THE FABRIC DOES NOT BECOME IMPREGNATED WITH SWEAT. REFER TO 72-00-00, MAINTENANCE PRACTICES, FOR ADDITIONAL INFORMATION. (8)

Remove No. 7 bearing inner race (17, Fig. 404) and labyrinth seal (18) using pad (PWC37741), puller (PWC37054), adapter (PWC37906), cylinder (PWC32506) and pump (PWC37807).

(9)

If required (Ref. Note), check LP turbine blade tip clearance as follows: NOTE:

An LP turbine blade tip clearance check is only required if a repair (component replacement) is being carried out. Refer to Inspection/Check for procedure used during an HSI.

(a) Align hole with dowel and install support (PWC37445) (1, Fig. 405) using slave bolts (0.190-32 UNJF-3A thread). (b) Using a dial indicator at point A, move disk assembly and measure total play of bearing. (c) Divide total play by two and record as bearing radial play. (d) Check tip clearance at 12 o’clock position as follows:


Page 407 Nov 04/2005


1 4

2 3

C11133C Power Turbine Assembly Retaining Nut - Removal Figure 402


Page 408 Nov 04/2005


Key to Figure 402 1. 2. 3. 4.

Socket Adapter Wrench Bar

1

Find and position longest blade at 12 o’clock position.

2

Load LP disk assembly away from shroud at 12 o’clock position.

3

Using a 0.250 in. (6.350 mm) wide taper feeler or wire gage, measure clearance. Record as total tip clearance.

4

Calculate actual tip clearance as shown below: Actual tip clearance = A - B NOTE:

The definition of the variables used in the formula are as follows: v A = total tip clearance (Ref. step 3). v B = bearing radial play (Ref. step (c)).

(e) Repeat procedure at 3, 6 and 9 o’clock positions. NOTE:

(f)

Tip clearance at the 6 o’clock position should exceed the clearance at the other positions by 0.004 in. (0.101 mm) due to offset ground shrouds.

Compare actual tip clearance with value specified in Fits and Clearances, REF. NO. 1382. NOTE:

Tip clearances greater or smaller than those specified in Fits and Clearances may have an adverse effect on engine performance.

(g) Remove support (PWC37445). (10)

Uncrimp No. 6 bearing rotor keywasher (21, Fig. 404), using unstaking tool (PWC54147) and taking care not to damage No. 6 bearing retaining nut. NOTE:

It is not necessary to remove retaining ring from nut.

(11)

Remove No. 6 bearing rotor nut (19) using support (PWC37445) (1, Fig. 407), socket (PWC54912) (2), adapter (PWC38247) (3), bar (PWC37515-06) (5) and wrench (PWC31050) (4). Remove tools.

(12)

Remove spacer (20, Fig. 404) and keywasher (21). Discard keywasher.


Page 409 Nov 04/2005


3

1

2

4

6

5

C11162B Power Turbine Assembly - Removal Figure 403


Page 410 Nov 04/2005


Key to Figure 403 1. 2. 3. 4. 5. 6. (13)

Pad Puller Cylinder Pump Holder Sling

Remove low pressure turbine disk assembly (22) using pad (PWC37747), puller (PWC37748), cylinder (PWC32506) and pump (PWC37807). NOTE: 1. If turbine assembly is to be replaced or refurbished, information covering the position of trim balance rivets and weights shown on engine reference data plate must be supplied to the overhaul/refurbishment facilities which refurbish or supply replacement turbine assemblies. NOTE: 2. Position of trim balance rivets and weights shown on engine reference data plate, will ensure rivet holes required for trim balancing, are not occupied during detail balancing. Record the position (orientation) of the off-set side of non-symetrical trim balance weights before removal (if applicable) to enable reinstallation in the same orientation. NOTE: 3. If during a borescope inspection (routine or troubleshooting), a Hot Section Inspection (HSI), or caused by a Performance Deterioration / ECTM shift, a fracture of one or several HP, LP or PT blade is observed. The workscope to be performed must be in accordance with the associated Engine-Light Overhaul procedure for: v HP Blade Fracture v LP Blade Fracture v PT Blade Fracture

CAUTION: ENSURE THAT LP STATOR IS NOT DROPPED IF IT COMES OUT WITH TURBINE HOUSING. (14)

Remove bolts (24), shroud segments (25) and seal housing (26) (Pre-SB21618) or (40) (Post-SB21618), using jackscrews (PWC32396).

(15)

Remove shroud segments from housing.

(16)

Remove stator assembly (28) and sealing rings (27, 29).


Page 411 Nov 04/2005


1

2

A

3

2 6

4

5 7 8 36

5

9 22

1

21

6

20 19

4

7

18 17

8

8 4

7 36 ROLL GASKET (7) INTO GROOVE AND AROUND EDGE IF EXTENDING BEYOND TUBE. GASKET MUST BE IN FIRM CONTACT WITH CONICAL SURFACE OF TUBE.

5 6

3

11 15

14

10

13

16

VIEW

12

A C25823A Low and High Pressure Turbine Assemblies - Removal Figure 404 (Sheet 1 of 3)


Page 412 Nov 04/2005


Key to Figure 404 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Oil Pressure Transfer Tube Vent Transfer Tube Scavenge Transfer Tube Retaining Ring Plate Seal Ring Gasket Sealing Tube Strainer Baffle Assembly Bolt (Pre-SB21618) Retaining Ring, Upper (Pre-SB21618) Retaining Ring, Lower (Pre-SB21618) Stator Assembly Interstage Case and Associated Parts (Pre-SB21618) Sealing Ring Bearing Inner Race Labyrinth Seal Rotor Nut Spacer Keywasher LP Turbine Disk Assembly

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.

Spacer Bolt LP Turbine Shroud Segments Seal Housing (Pre-SB21618) Sealing Ring LP Stator Assembly Sealing Ring Nut Interstage Air Seal HP Turbine Assembly HP Turbine Shroud Segments Bolt Turbine Support Case Gasket Retaining Ring (Lower) (Post-SB21618) (not illustrated) Retaining Ring (Upper) (Post-SB21618) (not illustrated) Interstage Case and Associated Parts (Post-SB21618) (not illustrated) Seal Housing (Post-SB21618) (not illustrated) Bolt (Post-SB21618) (not illustrated)


Page 413 Nov 04/2005


26 24

TURBINE SUPPORT CASE 25 23

C25824 Low and High Pressure Turbine Assemblies - Removal Figure 404 (Sheet 2)


Page 414 Nov 04/2005


33 32 31

30 34 35

29 28

27

C25825 Low and High Pressure Turbine Assemblies - Removal Figure 404 (Sheet 3)


Page 415 Nov 04/2005


1

A

TIP CLEARANCE

2

3

C21963 LP Turbine Blade Tip Clearance Check Figure 405


Page 416 Nov 04/2005


Key to Figure 405 1. 2. 3. (17)

Support No. 6 Bearing LP Turbine Shroud

Check runout of HP turbine (Ref. Fig. 406). Record the results. NOTE: 1. Before checking runout when the turbomachinery is horizontal, load turbine axially 10 to 50 lbs. (4.54-22.68 kg) in direction of reduction gearbox to remove bearing play. NOTE: 2. If runout value is greater than 0.001 in. (0.025 mm), record angular location of high point relative to offset hole (marked by X on rear cover plate), using protractor (PWC54351).

(18)

Install adapter (PWC37151) and remove nuts (30).

(19)

Remove adapter (PWC37151).

(20)

Remove interstage air seal (31, Fig. 404) using puller (PWC38667C or subsequent) , adapter (PWC37906), cylinder (PWC32506) and pump (PWC37807).

(21)

Remove spacer (23).

CAUTION: IF HP TURBINE BLADE(S) ARE TIGHT (NO RADIAL MOVEMENT), DISK ASSEMBLY MUST BE DISASSEMBLED. REFER TO INSPECTION/CHECK FOR INFORMATION COVERING SPECIAL INSPECTION REQUIREMENTS. (22)

Check HP turbine blades. If tight (no radial movement), disk assembly must be disassembled, cleaned, crack checked, assembled and balanced in accordance with the instructions in the PW100 Overhaul Manual or the PW100 CIR Manual P/N 3043515.

(23)

If required (Ref. Note), the following preliminary steps must be carried out to determine HP turbine tip clearance. NOTE:

An HP turbine blade tip clearance check is only required if a repair (component replacement) is being carried out. Refer to Inspection/Check for procedure used during an HSI.

(a) Using a dial indicator on the HP turbine disk, measure total play in No. 5 bearing. (b) Divide total play by 2 and record value as bearing radial play. (c) Mark blades at 3, 6, 9 and 12 o’clock positions, using layout dye (PWC05-002). (d) At the 12 o’clock position, load disk assembly in a direction away from shroud.


Page 417 Nov 04/2005


CHECK RUN−OUT AT THIS POINT AFTER INSTALLATION

A b

4

3

5

MARK ’V’

c

VIEW A

1

2

6

a LOAD HP SHAFT IN THIS DIRECTION 3.500 IN. (88.90 mm) REF.

C25843 HP Turbine Disk Spacer - Dimension Check Figure 406


Page 418 Nov 04/2005


Key to Figure 406 1. 2. 3. 4. 5. 6.

Adapter Nozzle Housing Spacer Stubshaft Turbine Disk Assembly Oil Slinger

(e) Using a 0.250 in. (6.350 mm) wide feeler or wire gage, measure tip clearance at 12 o’clock position. Record as total tip clearance. (f)

Repeat steps (d) and (e) at the 3, 6 and 9 o’clock positions. Record the results.

CAUTION: REFER TO INSPECTION/CHECK FOR INFORMATION COVERING SPECIAL INSPECTION REQUIREMENTS FOR HP TURBINE BLADES. CAUTION: IF DISK ASSEMBLY IS DISASSEMBLED, DISK AND FRONT AND REAR COVER PLATES MUST BE CHECKED FOR CRACKS IN ACCORDANCE WITH THE INSTRUCTIONS IN THE PW100 CIR MANUAL P/N 3043515. CAUTION: TURN THE PULLER BOLTS 1⁄4 AT A TIME IN A STAR PATTERN (1, 3, 5, 2, 4). THIS IS TO PREVENT THE HP TURBINE DISK BEING REMOVED AT AN ANGLE AND POSSIBLY DAMAGING THE HP STUBSHAFT SPIGOT. (24)

Remove high pressure turbine assembly (32, Fig. 404) using puller (PWC37853). NOTE: 1. If turbine assembly is to be replaced or refurbished, information covering the position of trim balance rivets and weights shown on engine reference data plate must be supplied to the overhaul/refurbishment facilities which refurbish or supply replacement turbine assemblies. NOTE: 2. Position of trim balance rivets and weights shown on engine reference data plate, will ensure rivet holes required for trim balancing, are not occupied during detail balancing. Record the position (orientation) of the off-set side of non-symetrical trim balance weights before removal (if applicable) to enable reinstallation in the same orientation.

(25)

If required (Ref. Note), check HP turbine blade tip clearance as follows: NOTE:

An HP turbine blade tip clearance check is only required if a repair (component replacement) is being carried out. Refer to Inspection/Check for procedure used during an HSI.

(a) Install HP turbine disk assembly on gage (PWC54020). (b) Load the marked blades (Ref. step (23)) radially by hand, radially outwards towards the dial indicator and record the reading. Load the blades towards the disk center and record reading. The difference obtained is blade radial play.


Page 419 Nov 04/2005


2

1

3

5

4

C11243A No. 6 Bearing Rotor Nut - Removal Figure 407


Page 420 Nov 04/2005


Key to Figure 407 1. 2. 3. 4. 5.

Support Socket Adapter Wrench Bar

(c) Calculate actual tip clearance as shown below: Actual tip clearance = A - (B + C) NOTE:

The definition of the variables used in the formula are as follows; v A = total tip clearance (Ref. step (23)(e)). v B = bearing radial play (Ref. step (23)(b)). v C = blade radial play (Ref. step (b)).

(d) Repeat calculation using blade radial play (Ref. step (b)) and total tip clearances at 3, 6 and 9 o’clock positions (Ref. step (23)(f)). (e) Compare actual tip clearance with value specified in Fits and Clearances, REF. NO. 1092. NOTE: D.


Turbine Support Case Assembly (1)

Remove nuts (1, 4, Fig. 408), brackets (2, 10, 11, 13, 15, 17, 18, 19, 21, 22, 23, 24, 27, 29, 30) and (32) (Post-SB21674), washer (14), spacers (26), lockplate (25), heat shields (13, 20), plate (31) and bolts (5, 6, 7, 8, 28) from flange K of turbine support case assembly (35, Fig. 404).

(2)

Remove turbine support case assembly (35) using jackscrews (PWC32396).

(3)

Remove bolts (3, Fig. 408) from turbine support case assembly.

(4)

Remove insulation blankets from turbine support case (Ref. 72-50-00, MAINTENANCE PRACTICES).

(5)

Remove turbine shroud segments from turbine support case as follows: (a) Pre-SB21588 1

Use a soft face hammer and a teflon drift to remove the HP turbine shroud segments from the turbine support case.

(b) Post-SB21588


Page 421 Nov 04/2005


27

26

31

2 10 11

K

1

30

L

A

A

K

13

C

29

D

28

14

20

29

25

J

K

15

20

32

D

G 24

10

C

15

17

48

D

LOCKPLATE / BRACKET / HEATSHIELD ARRANGEMENT AT LOCATION J

C G

23

C

D C

22

17 20

D

E

C 33

18

21

6

4 10

13

19 10

LOCATION 1−4 5−12 13 14−32 33 34−52 53−56 57−61 62 63−64

BOLT 5 6 7 6 7 6 28 6 5 8

QTY 4 8 1 19 1 19 4 5 1 2

25 29

HEAT SHIELD ARRANGEMENT AT LOCATION K

4 30

7

4 20

32

28 VIEW K−K

HEAT SHIELD ARRANGEMENT AT LOCATION E

C69132D Turbine Support Case Flange (K) - Location of Bolts, Brackets, Heat Shields and Nuts Figure 408 (Sheet 1 of 2)


Page 422 Nov 04/2005


Key to Figure 408 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Nut Bracket (3122936-01) Bolt (3029778) Nut Bolt (MS9697-14) Bolt (MS9697-12) Bolt (MS9706-12) Bolt (MS9697-16) DELETED Bracket (3108597-01) Bracket (MS9593-556) DELETED Heat Shield (3112177-01) Washer (3010086) Bracket (MS9552-118) DELETED Bracket (3115566-01) Bracket (3108599-01) Bracket (MS9593-366) Heat Shield (3118935-01) Bracket (MS9593-672) Bracket (MS9593-195) Bracket (3108938-01) Bracket (MS9593-134) Lockplate (3053837-01) Spacer (3109805-01) Bracket (3108597-03) Bolt (MS9490-16) Bracket (3053836-01) Bracket (3108597-03) Plate Bracket (MS9593-434) (Post-SB21674)


Page 423 Nov 04/2005


11 12 15 19 21

2 3 4

1

6

23 18 10 4

BRACKET ARRANGEMENT AT LOCATION D

BOLT AND BRACKET ARRANGEMENT AT LOCATION A

6 TYPICAL BRACKET ARRANGEMENT AT LOCATION C

2

16 22 24

26 27

4

4 6

8 TYPICAL BRACKET ARRANGEMENT AT LOCATION G

BRACKET ARRANGEMENT AT LOCATION L

17 4

6

4 6

TYPICAL BOLT ARRANGEMENT

TERMINAL ARRANGEMENT

C79696 Turbine Support Case Flange (K) - Location of Bolts, Brackets, Heat Shields and Nuts Figure 408 (Sheet 2)


Page 424 Nov 04/2005


E.

1

Remove retaining wires (1, 2, Fig 409).

2

Remove HP turbine shroud segments (3).

HP Turbine Vane Ring, Combustion Chamber Liner and HP Turbine Stubshaft (1)

Mark, with layout dye (PWC05-002), position of TDC on combustion chamber inner liner assembly (2, Fig. 410). Remove bolts (1) and combustion chamber inner liner assembly.

(2)

Remove bolts (8) and keywashers (9). Discard keywashers.

(3)

Remove HP turbine vane ring (10) assembly and sealing ring (11) using jackscrews (PWC32396). NOTE:

If the small exit duct was previously repaired for a heatshield replacement, inspection of the heatshield weld attachment is recommended. Refer to INSPECTION/CHECK, small exit duct, for information covering inspection requirements.

(4)

Heat inner flange 15 minutes minimum using heat gun and remove combustion chamber outer liner (12) assembly.

(5)

Remove turbine stubshaft as follows: (a) Remove retaining ring (3) and keywasher (4). CAUTION: ROTATE SOCKET CLOCKWISE TO REMOVE NUT. CAUTION: DO NOT EXCEED 1200 FT. LB. WHEN USING WRENCH (PWC31050) TO REMOVE NUT (5). (b) Remove stubshaft retaining nut (5) using anti-rotation adapter (PWC37458), socket (PWC37459), bar (PWC37515-06), wrench (PWC31050) and support (PWC37547). (c) If nut (5) does not loosen, remove as follows: 1

Remove tools.

2

Install drilling fixture (PWC56254) (1, Fig. 411) on stubshaft bolts (4).

3

Install nuts (PWC37047) (3) on stubshaft bolts (4). Torque nuts fingertight.

CAUTION: ENSURE ALL INTERNAL HOLES AND CAVITIES LOCATED OUTWARD OF STUBSHAFT ARE BLANKED OFF TO ENSURE DRILLING DEBRIS DOES NOT ENTER ENGINE. 4

Using plastic sheeting and tape, blank off all holes and cavities located outward of stubshaft (2).


Page 425 Nov 04/2005


3

4

1

1 2

SECTION E−E WITH RETAINING WIRES INSTALLED AND BENT SECTION G−G SIMILAR 4 3

D DETAIL D SHOWING RETAINING WIRES INSTALLED AND BENT DETAIL F SIMILAR

E

2

#2 #3

#1

E

#14 #13

#4

#12

#5

A #6

#11

#7

FWD

#10

G #8

F

#9

G

VIEW A SHOWING RETAINING WIRES INSTALLED AND BENT

C68526 High Pressure Turbine Shroud Segments (Post-SB21588) - Removal Figure 409


Page 426 Nov 04/2005


Key to Figure 409 1. 2. 3. 4.

Turbine Support Case Assembly HP Turbine Shroud Segments Retaining Wire Retaining Wire

CAUTION: DIM. a MUST BE LESS THAN 1.230 in. (31.240 mm) TO ENSURE STUBSHAFT IS NOT DAMAGED. 5

Install 3⁄32 in. (2.38 mm) aircraft extension drill bit No. 578 (5) in drill (6). Install collar No. BAS-A1-2 (8) and ensure Dim. a between end of drill and collar is 1.220 to 1.230 in. (30.990-31.240 mm).

6

Drill hole in stubshaft retaining nut (7) until collar (8) touches bushing (9) on drilling fixture (1).

7

Remove drill (6), nuts (3) and drilling fixture (1).

8

Rotate drilling fixture 180 degrees and reinstall it on stubshaft bolts (4).

9

Install nuts (PWC37047) (3). Torque fingertight.

10

Drill another hole in stubshaft retaining nut (7) until collar (8) touches bushing (9) on drilling fixture (1).

11

Remove drill (6), nut (3) and drilling fixture (1).

12

Rotate drilling fixture 90 degrees and reinstall it on stubshaft bolts (4).

13

Drill another hole in stubshaft retaining nut (7) until collar (8) touches bushing (9) on drilling fixture (1).

14

Remove drill (6), nuts (3) and drilling fixture (1).

15

Using a vacuum cleaner, remove drilling debris from engine.

16

Remove plastic sheeting and tape blanking holes and cavities.

CAUTION: ROTATE SOCKET CLOCKWISE TO REMOVE NUT. CAUTION: DO NOT EXCEED 1200 FT. LB. WHEN USING WRENCH (PWC31050) TO REMOVE NUT (7). 17

Remove stubshaft retaining nut (7), using anti-rotation adapter (PWC37458), socket (PWC37459), bar (PWC37515-06), wrench (PWC31050) and support (PWC37547). Discard nut and remove tools.


Page 427 Nov 04/2005


15

14

12 10 9

8 11 2

1

7

6 13

5

4 3

RADIAL CLEARANCE

11

TURBINE SUPPORT CASE

C25827 HP Turbine Vane Ring and Combustion Chamber Liner - Removal Figure 410


Page 428 Nov 04/2005


Key to Figure 410 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Bolt Combustion Chamber Inner Liner Retaining Ring Keywasher Nut HP Turbine Stubshaft Bolt Bolt Keywasher HP Turbine Vane Ring Sealing Ring Combustion Chamber Outer Liner Spacer Bolt Support Housing

CAUTION: ENSURE HP TURBINE STUBSHAFT BOLTS ARE MARKED 1 TO 5 (REF. FIG. 412) BEFORE REMOVAL FROM STUBSHAFT. CAUTION: NEW HP TURBINE STUBSHAFT BOLTS ARE RECOMMENDED TO BE INSTALLED. USE THE CALCULATION DETAILED IN INSTALLATION, TO ENSURE WEIGHTS ARE WITHIN LIMITS AND BALANCING IS NOT AFFECTED. REMOVED BOLTS ARE UNSERVICEABLE AND MUST BE DISCARDED AFTER WEIGHTS ARE RECORDED. CAUTION: IF STUBSHAFT REQUIRES REPLACEMENT, THE NEW STUBSHAFT WITH THE ASSOCIATED BOLTS AND DISK ASSEMBLY MUST BE RETURNED TO AN OVERHAUL FACILITY TO BE BALANCED AS A SET. (d) Mark bolts 1 to 5 (Ref. Fig. 412), using vibropeen. (e) Remove stubshaft (6, Fig. 410) using pad (PWC37759), adapter (PWC37760), spacers (5 each; 0.375 ID), nuts (PWC37047), cylinder (PWC32506) and pump (PWC37807). (f)

Remove bolts (7) from stubshaft. Discard all the bolts.

(g) Check engine log book to ensure weights of the original bolts installed at previous rotor balancing are recorded. If weights are not recorded, clean and weigh bolts removed from stubshaft. Record individual weights in engine log book. These weights must be used to determine the weights of replacement bolts when the rotor is not rebalanced. Discard bolts after weights are recorded. (h) Remove spacer (13).


Page 429 Nov 04/2005


4 3

2

7

1

9

SECTION

A-A

8

5

6

a

C34105A HP Turbine Stubshaft Retaining Nut - Removal After Seizure Figure 411


Page 430 Nov 04/2005


Key to Figure 411 1. 2. 3. 4. 5. 6. 7. 8. 9. (6)

Drilling Fixture Stubshaft Nut Bolt Bit Drill Nut Collar Bushing

If required, remove bolts (14) and vane ring inner front support housing (15) using puller (PWC37462).


Page 431 Nov 04/2005


NO.1

IDENTIFIES OFFSET HOLE

X NO.5

NO.2

NO.4

NO.3

REAR VIEW

C11774A Stubshaft - Numbering of Bolts Figure 412


Page 432 Nov 04/2005


TURBOMACHINERY - INSTALLATION 1.

General A.

This section provides instructions for assembling hot section gas path components.

B.

Use engine oil (PWC03-001) to lubricate packings, threads and mating faces, unless otherwise stated, and as a heating medium in oil baths.

C.

Parts heated or cooled before assembly must be at room temperature when final securing torque is applied.

D.

Special assembly instructions, torques and dimensional tolerances applicable to assembly are contained in Inspection/Check and identified in text by Fits and Clearances (F & C) reference numbers.

E.

Operators may choose to carry out a repair and not an HSI (e.g. to replace life limited or defective components or for scheduling purposes etc.). If a repair is carried out, Hot Section Borescope Inspection Criteria (Ref. 72-00-00, INSPECTION/CHECK) may be used to determine serviceability/airworthiness of hot end components. Using this criteria may not improve performance/increase ITT margin (lower ITT). It should be noted that returning an engine to service after using the Borescope Inspection Criteria may substantially increase the cost of subsequent repairs/refurbishments.

WARNING:

GLOVES MUST BE WORN TO PROTECT SKIN WHEN DECONTAMINATING AREAS CONTAINING GASKETS OR PACKINGS WHICH HAVE DECOMPOSED DUE TO HIGH TEMPERATURES. HYDROFLUORIC ACID IS PRODUCED WHEN THE MATERIAL DECOMPOSES. MEDICAL TREATMENT IS REQUIRED AS SOON AS POSSIBLE IF THE ACID TOUCHES BARE SKIN.

CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLE COMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLE WITH THOSE REPLACED. CAUTION: CORROSION HAS BEEN ATTRIBUTED TO THE BREAKDOWN OF ‘‘WD-40’’ AT HIGH TEMPERATURES. THEREFORE THIS COMPOUND MUST NOT BE USED ON ENGINE COMPONENTS. 2.



Item No.

Name

PWC03-001 PWC04-001 PWC05-002 PWC05-089

Oil, Engine Grease Dye, Layout Lockwire

72-03-00 TURBOMACHINERY - INSTALLATION

Page 401 Nov 09/2001


Item No.

Name

PWC05-102 PWC05-295

Dry Ice Lockwire (may be used instead of PWC05-089 for external applications only) Metal Marking Compound, Anti-seize Beeswax

PWC05-352 PWC06-009 PWC06-015 3.


Name

PWC31050 PWC32396 PWC32506 PWC37047 PWC37068 PWC37093 PWC37137 PWC37138 PWC37151 PWC37351 PWC37441 PWC37442 PWC37445 PWC37458 PWC37459 PWC37490 PWC37515-06 PWC37532 PWC37540 PWC37547 PWC37560 PWC37562 PWC37563 PWC37564 PWC37807 PWC37844 PWC37845 PWC37869 PWC37939 PWC37949

Wrench Jackscrew Cylinder Nut Bar Crimper Socket Adapter Adapter Fixture Pusher Locator Support Adapter Socket Crimper Bar Riveter Holder Support Adapter Adapter Adapter Fixture Pump Guide Drift Base Sling Pusher


Page 402 Nov 09/2001


4.

Tool No.

Name

PWC38197 PWC38220 PWC38247 PWC54020 PWC54072 PWC54082 PWC54281 PWC54351 PWC54700 PWC54701 PWC54816 PWC54912 PWC56226

Fixture Spacer Adapter Gage Guide Adapter Pusher Protractor Slave Spacer Slave Keywasher Drift Socket Pusher

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Bolts, Slave (0.190-32 UNJF-3A x 0.375) Feeler Gage, Taper Gun, Heat - Thermofit Minigun (with reflector) Pin, Guide (0.190-32 UNJF-3A thread) Socket Extention, Square-drive (3/8 in.) Wire Gage

5.

Hot Section Components - Installation A.

HP Turbine Vane Ring, Combustion Chamber Liner and HP Turbine Stubshaft (1)

If removed, install vane ring inner front support housing as follows: (a) Freeze support housing (15, Fig. 401) at -40°C (-40°F) for 15 minutes minimum. NOTE:

If a freezer is not available, cool, using dry ice (PWC05-102), for 15 minutes minimum.

(b) Align offset holes in support housing (15) and gas generator case. (c) Using guide pins (0.190-32 UNJF-3A thread), install housing and bolts (14). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm). (2)

Install combustion chamber outer liner assembly (12) as follows:


Page 403 Nov 09/2001


15

14

12 10 9

8 11 2

1

7

6 13

5

4 3

RADIAL CLEARANCE

11


C25827 HP Turbine Vane Ring and Combustion Chamber Liner - Installation Figure 401


Page 404 Nov 09/2001


Key to Figure 401 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Bolt Combustion Chamber Inner Liner Retaining Ring Keywasher Nut HP Turbine Stubshaft Bolt Bolt Keywasher HP Turbine Vane Ring Sealing Ring Combustion Chamber Outer Liner Spacer Bolt Support Housing

(a) Using a locator (PWC37442) as a go gage, check fuel nozzle adapter holes in combustion chamber outer liner are free of raised material or ceramic. If necessary, use a fine file to remove excess material. (b) Heat inner flange for 15 minutes minimum using heat gun. (c) Align offset holes in inner flange and support housing and install liner assembly using guide pins (0.190-32 UNJF-3A thread). (d) Install locators (PWC37442) in fuel adapter apertures. (e) Seat inner flange using slave bolts (0.190-32 UNJF-3A × 0.375).


Page 405 Jan 16/2004


CAUTION: AN INCREASE IN HIGH PRESSURE VANE FLOW AREA IS RECOMMENDED WHEN ENGINE IS REBUILT AFTER HOT SECTION REFURBISHMENT. CAUTION: REFER TO APPROVED REPAIRS FOR PROCEDURE TO DETERMINE VANE CLASS REQUIRED TO OBTAIN RECOMMENDED FLOW AREA. CAUTION: IF THE SMALL EXIT DUCT HAS NOT BEEN REPLACED AND WAS PREVIOUSLY REPAIRED FOR HEATSHIELD REPLACEMENT, INSPECTION OF THE HEATSHIELD WELD ATTACHMENT IS RECOMMENDED BEFORE RE-INSTALLATION. REFER TO ‘‘INSPECTION/CHECK’’. SMALL EXIT DUCT, FOR INFORMATION COVERING INSPECTION REQUIREMENTS. (3)

Heat HP turbine vane ring segment assembly (10) in oven at 149 ± 6°C (300 ± 10°F) for 15 minutes minimum. NOTE:

If an oven is not available, use a heat gun, noting heat must be applied evenly over the surface of the segment assembly. Sufficient time must be taken to ensure the complete assembly is heated, thereby ensuring distortion does not occur.

(4)

Align offset holes in cooling air nozzle housing and vane ring support housing and install HP turbine vane ring segment assembly using guide pins (0.190-32 UNJF-3A thread).

(5)

Install keywashers (9, Fig. 401) and bolts (8) as follows: NOTE:

Do not lubricate bolts.

CAUTION: ENSURE CLEARANCE EXISTS BETWEEN COOLING AIR NOZZLE HOUSING AND VANE SEGMENT INNER FLANGE AFTER VANE RING SEGMENT ASSEMBLY (10) HAS BEEN INSTALLED AND BEFORE BOLTS (8) HAVE BEEN TORQUED. (a) Install keywashers (9) and bolts (8). (b) Using a 0.001 in. (0.025 mm) feeler gage over 360 degrees, ensure clearance exists between cooling air nozzle housing and vane ring segment inner flange (Ref. Fig. 402). If clearance is less than 0.001 in. (0.025 mm) at any point, remove segment assembly using jackscrews (PWC32396) and check that inner support housing lugs are correctly installed in nozzle housing. Reassemble (Ref. Approved Repairs) and reinstall vane ring segment assembly (Ref. step (3)). Repeat procedure until clearance check is satisfactory. (c) Torque bolts 19.5 to 26.0 lb.in. (2.20-2.94 Nm). Allow assembly to cool to room temperature. Retorque bolts 19.5 to 26.0 lb.in. (2.20-2.94 Nm) and lock keywashers. (6)

Install combustion chamber inner liner assembly (2, Fig. 401) (with mark at TDC) and bolts (1). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm). NOTE:

The mark at TDC requirement does not apply to new liner assemblies.


Page 406 Jan 16/2004


(7)

If required (Ref. Note 2 following step (e)), establish HP disk spacer thickness required as follows (Ref. Fig. 403): (a) Install adapter (PWC37560) (1) and load HP turbine shaft in direction shown. Measure and record Dim. a from cooling air nozzle housing (2) to top surface of adapter flange. (b) Measure and record Dim. b of turbine stubshaft (4). (c) Measure Dim. c in five positions, adjacent to bolt holes; record average. (d) Calculate spacer thickness (in inches) required: Dim. (3.500 + c + 0.115) - (a + b) = thickness required ± 0.005 NOTE: 1. For spacer thickness calculation, average axial dimension 0.115 in. (2.92 mm) called up at F & C REF. NO. 1247 must be used. NOTE: 2. Oil slinger (6, Fig. 403) remains in place during measurement.


Page 406A/406B Jan 16/2004


(e) Check thickness of existing spacer. If necessary, grind to thickness required or replace with spacer ground to correct dimensions. NOTE: 1. Spacers must be ground at a qualified overhaul or heavy maintenance facility. NOTE: 2. If ground, spacers must be demagnetized before installation. NOTE: 3. Spacer thickness must be between 0.035 to 0.095 in. (0.889-2.410 mm). If spacer thickness is not within the above limits, check measurements and recalculate. NOTE: 4. Both sides of spacer must be parallel within 0.0002 in. (0.005 mm). NOTE: 5. An HP turbine disk spacer thickness check is necessary: v When one or more components shown in Figure 404 are replaced, and the sum of the dimensions of the replacement components deviate by more than 0.0065 in. (0.165 mm) when compared to the sum of the corresponding dimensions of the replaced components. (8)

Install turbine stubshaft (6, Fig. 401) as follows: CAUTION: NEW HP TURBINE STUBSHAFT BOLTS ARE RECOMMENDED TO BE INSTALLED. SELECT REPLACEMENT BOLTS USING THE CALCULATION PROCESS DETAILED BELOW TO ENSURE WEIGHTS ARE WITHIN LIMITS AND BALANCING IS NOT AFFECTED. REPLACED BOLTS ARE UNSERVICEABLE AND MUST BE DISCARDED AFTER WEIGHTS ARE RECORDED. BOLT MARKED NO. 1 MUST BE INSTALLED IN OFFSET HOLE IDENTIFIED BY X AND BOLTS 2 TO 5 CLOCKWISE (REF. FIG. 405) IN THE REMAINING HOLES. CAUTION: NEW HP TURBINE BOLTS ARE RECOMMENDED TO BE INSTALLED.


Page 407 Nov 09/2001


A

1 FEELER GAGE

2

0.001 in. (0.025 mm) MINIMUM VIEW

A

C30395 Cooling Air Nozzle Housing/Vane Ring Segment - Clearance Check Figure 402


Page 408 Nov 09/2001


Key to Figure 402 1. 2.

Vane Ring Segment Cooling Air Nozzle Housing

CAUTION: IF STUBSHAFT REQUIRES REPLACEMENT, NEW STUBSHAFT WITH THE ASSOCIATED BOLTS AND DISK ASSEMBLY MUST BE RETURNED TO AN OVERHAUL FACILITY TO BE REBALANCED AS A SET. CAUTION: THE POSITIVE (+) AND NEGATIVE (-) SIGNS IN THE FOLLOWING CALCULATION ARE EXTREMELY IMPORTANT AND MUST BE CORRECTLY USED TO ENSURE BALANCING IS NOT AFFECTED. (a)

The formula shown in Table 401 must be used to determine the weight of replacement bolts: NOTE: 1. New bolts may be lighter or heavier than the original bolts installed at previous rotor balancing. The following procedure must be used to maintain, between the new bolts, the same weight relationship that existed between the original bolts to ensure balancing/vibration level is not affected. NOTE: 2. If the weight ranges for individual replacement bolts overlap, use the heaviest replacement bolt where the heaviest of the original bolts was installed.

(b) Example 1

Determine known variables as shown in Table 402:

2

Determine (P - A) as follows: (P - A) = (23.75 - 23.98) = - 0.23 gm (negative 0.23 gm)

3

Determine weight range of replacement bolts 2, 3, 4 and 5 by applying known variables to the formula (Ref. Table 401) as shown in Table 403. NOTE:

4

To permit the use of bolts in stock, the weight range of the replacement bolts may be shifted up or down by using a heavier or lighter bolt for position No. 1 (P).

Select replacement bolts 2, 3, 4 and 5 within the weight range of Q, R, S and T respectively as shown in Table 404. NOTE:

If the weight ranges for individual bolts overlap, use the heaviest replacement bolt where the heaviest of the original bolts was installed.


Page 409 Nov 09/2001


CHECK RUN−OUT AT THIS POINT AFTER INSTALLATION

A b

4

3

5

MARK ’V’

c

VIEW A

1

2

6

a LOAD HP SHAFT IN THIS DIRECTION 3.500 IN. (88.90 mm) REF.

C25843 HP Turbine Disk Spacer - Dimension Check Figure 403


Page 410 Nov 09/2001


Key to Figure 403 1. 2. 3. 4. 5. 6.

Adapter Nozzle Housing Spacer Stubshaft Turbine Disk Assembly Oil Slinger

TABLE 401, Formula Used to Determine Replacement Bolt Weights Bolt Location

Weight of Original Bolts

Formula

Weight of Replacement Bolts

1

A

‘‘P’’

P

2

B

(B + (P-A)) ±0.10 gm =

Q

3

C

(C + (P-A)) ±0.10 gm =

R

4

D

(D + (P-A)) ±0.10 gm =

S

5

E

(E + (P-A)) ±0.10 gm =

T

NOTE: 1. Letters A, B, C, D and E represent the weight of the original bolts, P, Q, R, S and T represent the weight of the replacement bolts. NOTE: 2. ‘‘P’’ represents the weight of a bolt selected by the operator from stock. Refer to the engine log book for weight of original bolts installed at previous rotor balancing.

TABLE 402, Determining Known Variables Bolt Location

Original Bolt Weight (grams) Refer to Engine Log Book

Weight of Replacement Bolt (P) (grams)

1

23.98 (A)

23.75 (P) (Ref. NOTE)

2

23.90 (B)

3

24.18 (C)

4

24.14 (D)

5

23.95 (E)

NOTE: ‘‘P’’ represents the weight of a bolt selected by the operator from stock to use in location No. 1.


Page 411 Nov 09/2001


a

d 4

1

3

2

b

c

C12749B HP Turbine Disk Spacer Thickness Requirement - Component Dimensional Checks Figure 404


Page 412 Nov 09/2001


Key to Figure 404 1. 2. 3. 4.

HP Turbine Disk Assembly Combustion Chamber Outer Liner Cooling Air Nozzle Housing HP Turbine Stubshaft

TABLE 403, Determining Weight Range of Replacement Bolts 2, 3, 4 and 5 Bolt Location

Weight of Original Bolts

FORMULA

Weight Range of Replacement Bolts (grams)

1

23.98 (A)

23.75 (P)

P = 23.75

2

23.90 (B)

(23.90 + (- 0.23)) - 0.10 gm = Q

Q = 23.57

(23.90 + (- 0.23)) + 0.10 gm = Q

Q = 23.77

(24.18 + (- 0.23)) - 0.10 gm = R

R = 23.85

(24.18 + (- 0.23)) + 0.10 gm = R

R = 24.05

(24.14 + (- 0.23)) - 0.10 gm = S

S = 23.81

(24.14 + (- 0.23)) + 0.10 gm = S

S = 24.01

(23.95 + (- 0.23)) - 0.10 gm = T

T = 23.62

(23.95 + (- 0.23)) + 0.10 gm = T

T = 23.82

3

4

5

24.18 (C)

24.14 (D)

23.95 (E)


Page 413 Nov 09/2001


NO.1

IDENTIFIES OFFSET HOLE

X NO.5

NO.2

NO.4

NO.3

REAR VIEW

C11774A Stubshaft - Numbering of Bolts Figure 405


Page 414 Nov 09/2001


TABLE 404, Determining Actual Weight of Replacement Bolts 2, 3, 4 and 5

Bolt Location

Weight of Original Bolts (grams)

Replacement Bolt Weight Range (grams)

Replacement Bolt Actual Weight (grams)

1

23.98 (A)

23.75

23.75 (P)

2

23.90 (B)

23.57 to 23.77 (Ref. NOTE 1)

23.70 (Q) (Ref. NOTE 2)

3

24.18 (C)

23.85 to 24.05 (Ref. NOTE 1)

24.02 (R) (Ref. NOTE 2)

4

24.14 (D)

23.81 to 24.01 (Ref. NOTE 1)

23.89 (S) (Ref. NOTE 2)

5

23.95 (E)

23.62 to 23.82 (Ref. NOTE 1)

23.74 (T) (Ref. NOTE 2)

NOTE: 1. If the weight ranges for individual bolts overlap, use the heaviest replacement bolt at the location where the heaviest of the original bolts was installed. NOTE: 2. Weight of replacement bolts selected by the operator from stock to match the appropriate weight range. NOTE: 3. The weight of individual bolts may be reduced to get within the applicable weight range by the incorporation of SB21301. (c) Mark (by vibropeen) end of each new bolt with the appropriate number established in the calculation process. (d) Install new bolts (7, Fig. 401) in stubshaft (6). NOTE:

Install bolt marked No. 1 in offset hole identified by X and bolts No. 2 to 5 clockwise in the remaining holes (Ref. Fig. 405).

(e) Install adapter (PWC54082) and nuts (PWC37047) on stubshaft bolts (7, Fig. 401). Torque nuts fingertight. Heat at 146 ± 6°C (300 ± 10°F) in oven for 5 to 7 minutes maximum. NOTE:

(f)

If an oven is not available, use a heat gun. Note heat must be applied evenly over the surface of the stubshaft. Sufficient time must be taken to ensure the complete stubshaft is heated to ensure distortion does not occur.

Install spacer (13) as follows: 1

Existing spacer: install with V-mark aligned with master spline.

2

New spacer (Ref. Fig. 403): mark V, using electrolytic etch. Install with V-mark aligned with master spline.


Page 415 Nov 09/2001


CAUTION: DO NOT USE THE HYDRAULIC PUMP, CYLINDER AND PUSHER TO INSTALL THE STUBSHAFT. STUBSHAFT SPLINES AND MOST OF THE SPIGOT MUST BE ENGAGED BEFORE THE PUSHER IS INSTALLED. CYLINDER STROKE SHOULD NOT EXCEED 0.250 IN. IF THE SPLINES ARE FULLY ENGAGED. (g) Align master spline and install heated stubshaft. Remove nuts and adapter. Do step (h) immediately after stubshaft is installed. CAUTION: ENSURE STUBSHAFT IS AT ROOM TEMPERATURE BEFORE RELEASING HYDRAULIC PRESSURE. (h) Use pusher (PWC54281), cylinder (PWC32506) and hydraulic pump (PWC37807) to seat stubshaft, using a hydraulic pressure of 4700 to 5100 psig (axial load 13000 to 14000 lb.). Release hydraulic pressure when stubshaft is at room temperature. Remove tools. CAUTION: RECOATED NUTS MUST NOT BE LUBRICATED. (i)

Lubricate HP turbine stubshaft retaining nut (5, Fig. 401) as follows: 1

Recoated nut (P/N 01R3109640-01). Do not lubricate

2

New nut (P/N 3109640-01). Lubricate threads and thrust face of nut with anti-seize compound (PWC06-009).

(j)

Install nut using anti-rotation adapter (PWC37458), socket (PWC37459), bar (PWC37515-06), wrench (PWC31050) and support (PWC37547).

(k) Using procedure detailed in F & C REF. NO. 1708, torque nut (5). (l)

Install keywasher (4) and retaining ring (3), aligning V on retaining ring with HP turbine stubshaft bolt marked No. 1. NOTE:

B.

If required, mark V (by vibropeen) on retaining ring.

Turbine Support Case Assembly NOTE:

HP turbine shroud segments are installed after shroud grinding (Ref. Approved Repairs).

(1)

Install bolts (19, Fig. 407), bracket (18) and nuts (17) in turbine support case (35, Fig. 406). Torque nuts 36 to 40 lb.in. (4.07-4.52 Nm).

(2)

Install insulation blankets on turbine support case (Ref. 72-50-00, MAINTENANCE PRACTICES).


Page 416 Nov 09/2001


1

2

A

3

2 6

4

5 7 8 36

5

9 22

1

21

6

20 19

4

7

18 17

8

8 4

7 36 ROLL GASKET (7) INTO GROOVE AND AROUND EDGE IF EXTENDING BEYOND TUBE. GASKET MUST BE IN FIRM CONTACT WITH CONICAL SURFACE OF TUBE.

5 6

3

11 15

14

10

13

16

VIEW

12

A C25823A Low and High Pressure Turbine Assemblies - Installation Figure 406 (Sheet 1 of 3)


Page 417 Nov 09/2001


Key to Figure 406 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Oil Pressure Transfer Tube Vent Transfer Tube Scavenge Transfer Tube Retaining Ring Plate Seal Ring Gasket Sealing Tube Strainer Baffle Assembly Bolt (Pre-SB21618) Retaining Ring, Upper (Pre-SB21618) Retaining Ring, Lower (Pre-SB21618) Stator Assembly Interstage Case and Associated Parts (Pre-SB21618) Sealing Ring Bearing Inner Race Labyrinth Seal Rotor Nut Spacer Keywasher LP Turbine Disk Assembly

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39.

40. 41.

Spacer Bolt LP Turbine Shroud Segments Seal Housing (Pre-SB21618) Sealing Ring LP Stator Assembly Sealing Ring Nut Interstage Air Seal HP Turbine Assembly HP Turbine Shroud Segments Bolt Turbine Support Case Gasket Retaining Ring (Lower) (Post-SB21618) (not illustrated) Retaining Ring (Upper) (Post-SB21618) (not illustrated) Interstage Case and Associated Parts (Post-SB21618) (not illustrated) Seal Housing (Post-SB21618) (not illustrated) Bolt (Post-SB21618) (not illustrated)


Page 418 Nov 09/2001


26 24

TURBINE SUPPORT CASE 25 23

C25824 Low and High Pressure Turbine Assemblies - Installation Figure 406 (Sheet 2)


Page 419 Nov 09/2001


33 32 31

30 34 35

29 28

27

C25825 Low and High Pressure Turbine Assemblies - Installation Figure 406 (Sheet 3)


Page 420 Nov 09/2001


27

26

31

2 10 11

K

1

30

L

A

A

K

13

C

29

D

28

14

20

29

25

J

K

15

20

32

D

G 24

10

C

15

17

48

D

LOCKPLATE / BRACKET / HEATSHIELD ARRANGEMENT AT LOCATION J

C G

23

C

D C

22

17 20

D

E

C 33

18

21

6

4 10

13

19 10

LOCATION 1−4 5−12 13 14−32 33 34−52 53−56 57−61 62 63−64

BOLT 5 6 7 6 7 6 28 6 5 8

QTY 4 8 1 19 1 19 4 5 1 2

25 29

HEAT SHIELD ARRANGEMENT AT LOCATION K

4 30

7

4 20

32

28 VIEW K−K

HEAT SHIELD ARRANGEMENT AT LOCATION E

C69132D Turbine Support Case Flange (K) - Location of Bolts, Brackets, Heat Shields and Nuts Figure 407 (Sheet 1 of 2)


Page 421 Jul 12/2002


Key to Figure 407 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Nut Bracket (3122936-01) Bolt (3029778) Nut Bolt (MS9697-14) Bolt (MS9697-12) Bolt (MS9706-12) Bolt (MS9697-16) DELETED Bracket (3108597-01) Bracket (MS9593-556) DELETED Heat Shield (3112177-01) Washer (3010086) Bracket (MS9552-118) DELETED Bracket (3115566-01) Bracket (3108599-01) Bracket (MS9593-366) Heat Shield (3118935-01) Bracket (MS9593-672) Bracket (MS9593-195) Bracket (3108938-01) Bracket (MS9593-134) Lockplate (3053837-01) Spacer (3109805-01) Bracket (3108597-03) Bolt (AS3307-16) Bracket (3053836-01) Bracket (3108597-03) Plate Bracket (MS9593-434) (Post-SB21674)


Page 422 Jul 12/2002


11 12 15 19 21

2 3 4

1

6

23 18 10 4

BRACKET ARRANGEMENT AT LOCATION D

BOLT AND BRACKET ARRANGEMENT AT LOCATION A

6 TYPICAL BRACKET ARRANGEMENT AT LOCATION C

2

16 22 24

26 27

4

4 6

8 TYPICAL BRACKET ARRANGEMENT AT LOCATION G

BRACKET ARRANGEMENT AT LOCATION L

17 4

6

4 6

TYPICAL BOLT ARRANGEMENT

TERMINAL ARRANGEMENT

C79696 Turbine Support Case Flange (K) - Location of Bolts, Brackets, Heat Shields and Nuts Figure 407 (Sheet 2)


Page 423 Nov 09/2001


(3)

Install sealing ring (11, Fig. 401), with gap at TDC in turbine support case (35, Fig. 406). Check clearance is less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference, using feeler gage (Ref. Fig. 401). If necessary, rotate ring until clearance within limits. Record position of gap. Reject ring if correct clearance is unobtainable. NOTE:

If required, polish ring contact area on turbine support case to obtain correct clearance.

(4)

Remove sealing ring from turbine support case and install on vane ring outer support in same position as previously recorded. Use beeswax (PWC06-015) to secure ring and keep it compressed.

(5)

Install turbine support case (35, Fig. 406) as follows: (a) Install bolts (3, Fig. 407) in flange K of turbine support case (b) Heat flange K of turbine support case, using heat gun. (c) Align offset holes and install turbine support case on gas generator case. (d) Install bolts (5, 6, 7, 8), plate (31), spacers (26), washer (14), brackets (2, 10, 11, 15, 17, 18, 19, 21, 22, 23, 24, 27, 29, 30) and (32) (Post-SB21674), lockplate (25), heat shields (13, 20) and nuts (1, 4). Torque nuts 85 to 95 lb.in. (9.61-10.74 Nm).

(6)

Install insulation blankets on rear of gas generator case (Ref. 72-40-00, MAINTENANCE PRACTICES).

(7)

Install fuel adapters (Ref. 72-01-40, REMOVAL/INSTALLATION).

(8)

Install flow divider and dump valve. Connect fuel line (Ref. 72-01-40, REMOVAL/INSTALLATION).

(9)

Install fuel manifold (Ref. 72-01-40, REMOVAL/INSTALLATION).

(10)

Install igniters (Ref. 72-01-20, REMOVAL/INSTALLATION).


Page 424 Jul 12/2002


C.

HP and LP Turbine Assemblies CAUTION: BEFORE FURTHER ASSEMBLY, REFER TO ENGINE LOG BOOK, TO ENSURE LIFED TURBINE COMPONENTS CAN CONTINUE IN SERVICE UNTIL ENGINE REFURBISHMENT AND TO DETERMINE ENGINE BUILD STANDARD. CAUTION: DURING DETAIL BALANCING, REPLACEMENT OR REFURBISHMENT, TURBINE ASSEMBLIES MUST BE BALANCED WITH RIVET HOLES REQUIRED FOR TRIM BALANCING LEFT UNOCCUPIED. THEREFORE, INFORMATION COVERING POSITION OF TRIM BALANCE WEIGHTS AND RIVETS SHOWN ON ENGINE REFERENCE DATA PLATE MUST BE SUPPLIED TO OVERHAUL/REFURBISHMENT FACILITIES BEFORE ASSEMBLIES ARE BALANCED. (1)

Heat interstage air seal (31, Fig. 406) in oven at 149 ± 6°C (300 ± 10°F) for 15 minutes minimum (Ref. Note). Install on HP turbine, using aligning fixture (PWC37351) and drift (PWC54816). NOTE:

If an oven is not available, use a heat gun. Note heat must be applied evenly over the surface of the seal. Sufficient time must be taken to ensure the complete seal is heated to ensure distortion does not occur.

CAUTION: NOTE THE ORIENTATION OF UNSYMETRICALLY SHAPED BALANCE WEIGHTS ON REPLACED TURBINE AND ENSURE THEY ARE INSTALLED IN THE SAME ORIENTATION ON THE REPLACEMENT TURBINE. (2)

Install trim balance weights and rivets on a replacement turbine assembly in accordance with engine reference data plate (Ref. Fig. 408), using riveter (PWC37532). NOTE:

(3)

Shroud replacement and/or grinding (Ref. Approved Repairs) may be required, depending on diameter of replacement turbine assembly.

The following procedure is used to determine blade radial play which is required when calculating tip clearance: (a) Install disk assembly on gage (PWC54020). CAUTION: IF HP TURBINE BLADE(S) ARE TIGHT (NO RADIAL MOVEMENT), DISK ASSEMBLY MUST BE DISASSEMBLED. REFER TO INSPECTION/CHECK FOR INFORMATION COVERING SPECIAL INSPECTION REQUIREMENTS. (b) Check HP turbine blades for movement. If tight (no radial movement), refer to Inspection/Check for information covering special inspection requirements. (c) Select the longest and mark as 3, 6, 9 and 12, four equispaced blades, using layout dye (PWC05-002).


Page 425 Nov 09/2001


HIGH PRESSURE ROTOR TURBINE NO. 1 RIVET IS THE NEAREST TO V AND COUNTS COUNTER−CLOCKWISE DIRECTION

NO. 1 RIVET IS THE NEAREST TO V AND COUNTS CLOCKWISE DIRECTION V ON REAR COVER BALANCE RIM

1 2 3

4

5

5 6 7 8

6 7 8

RIVET WEIGHT

4

HIGH PRESSURE TURBINE DOWNSTREAM FACE (REAR PLANE)

V ON FRONT COVER BALANCE RIM

1 3 2

RIVET WEIGHT

HIGH PRESSURE TURBINE UPSTREAM FACE (FRONT PLANE)

ENGINE REFERENCE DATA

AT 59 F

SERIAL NO. ENGINE BUILD SPEC AT

SHP 6 θ NH

θ

H FG3 H RG3 L L

Ω

T 6 TRIM NL

θ

FA5 RA5

WHERE: H. F. R. A THRU E . 5. G.

DENOTES H.P. TURBINE TRIM BALANCE. DENOTES THE TURBINE FRONT PLANE. DENOTES THE TURBINE REAR PLANE. DENOTES THE CLASS OF BALANCE WEIGHT. (SEE NOTES) DENOTES THE FIRST RIVET HOLE OCCUPIED BY THE BALANCE WEIGHT OR RIVET IN THE DIRECTION OF COUNTING. DENOTES BALANCE RIVET.

NOTES: 1) UNSYMMETRICAL BALANCE WEIGHTS MAY BE INSTALLED EITHER WAY. 2) A THRU E DENOTES CLASS 1 THRU 5. (REF. IPC)

C25841 High Pressure Turbine Trim Balance Weights - Installation and Data Plate Marking Figure 408


Page 426 Nov 09/2001


(d) Load a marked blade by hand radially outward towards the dial indicator and record reading. Load the blade towards the disk center and record reading. The difference obtained is blade radial play. Repeat the procedure at blades marked 6, 9 and 12. (4)

Freeze HP turbine assembly (32, Fig. 406) to -40°C (-40°F) for 15 minutes minimum. NOTE:

If freezer is not available, cool turbine, using dry ice (PWC05-102) for 15 minutes minimum.

(5)

Using engine oil (PWC03-001), lubricate turbine disk stubshaft spigot.

(6)

Using a heat gun (Max. temperature 260°C (500°F) (Ref. Note)), heat turbine stubshaft for 15 minutes minimum, noting heat must be applied over complete surface of stubshaft to ensure distortion does not occur. NOTE:

(7)

Using thermocouple, check temperature of hot air produced by heat gun. If necessary, reduce temperature to below 260°C (500°F).

Install HP turbine disk, aligning offset hole (identified by an X) with stubshaft bolt (34) marked as No. 1. The disk should touch the HP stubshaft flange. Do steps (8) and (9) immediately after HP disk is installed.

CAUTION: INSTALL USED NUTS TO SEAT HP TURBINE. REPLACE WITH NEW NUTS, WHICH MUST NOT BE REMOVED DURING TORQUING PROCEDURE - i.e., ENSURE NEW NUTS ARE USED ONLY ONCE. CAUTION: ENSURE TURBINE DISK IS AT ROOM TEMPERATURE BEFORE APPLYING FINAL TORQUE. (8)

Install adapter (PWC37151) and used nuts on turbine bolts. Lubricate the nuts and bolts with engine oil (PWC03-001) and use a speed wrench to bring the nuts into contact with disk surface.

(9)

The bolts and nuts should be consecutively numbered 1 to 5. Torque tighten the nuts in a star sequence pattern (1, 3, 5, 2, 4), 180 to 190 lb.in. (20.34-21.47 Nm), in increments of 50 lb.in. (5.65 Nm).

(10)

To make sure the HP turbine disk and stubshaft are at room temperature, let the assembly to become stable for 20 minutes minimum.

(11)

Torque tighten the nuts in a star sequence pattern (1, 3, 5, 2, 4), 250 to 260 lb.in. (28.25-29.38 Nm),

CAUTION: REPLACE WITH NEW NUTS, WHICH MUST NOT BE REMOVED DURING TORQUING PROCEDURE - i.e., ENSURE NEW NUTS ARE USED ONLY ONCE. CAUTION: ENSURE TURBINE DISK IS AT ROOM TEMPERATURE BEFORE APPLYING FINAL TORQUE. (12)

Remove one used nut at a time and replace with new nut. Torque each nut as it is replaced to the final torque (F & C REF. NO. 1707, steps (5) and (6), Fig. 406).


Page 427 Nov 09/2001


(13)

Check runout of HP turbine (Ref. Fig. 403). Runout on replacement turbine must be within 0.004 in. (0.101 mm) FIR. Runout on a reinstalled turbine must be within 0.004 in. (0.101 mm) and 0.001 in. (0.025 mm) FIR (Ref. Note 2) of value recorded before removal (Ref. Removal, LP and HP Turbine Assembly Removal, HP Turbine Runout Check). NOTE: 1. Before checking runout when the turbomachinery is horizontal, load turbine axially 10 to 50 lb. (4.54-22.68 kg) in direction of reduction gearbox to remove bearing play. NOTE: 2. If runout value on a reinstalled turbine is more than 0.001 in. (0.025 mm) of value recorded before removal, record angular location of high point relative to offset hole (marked by an X on rear cover plate), using protractor (PWC54351). The location of high point must be within ± 45 degrees of high point recorded during disassembly (Ref. Removal, LP and HP Turbine Assembly Removal, HP Turbine Runout Check). NOTE: 3. If runout exceeds limits, remove the disk assembly and check fits, parallelism and for the presence of foreign material. Reinstall the disk assembly, using the recommended procedure (Ref. steps (4) to (13) inclusive). NOTE: 4. Runout value must be recorded in engine log book.

(14)

Check HP turbine blade tip clearance as follows: (a) Using a dial indicator, move disk assembly and measure total play in No. 5 bearing. (b) Divide value by 2 and record value as bearing radial play. (c) Position blade marked 12 at 12 o’clock position. (d) Load disk assembly in a direction away from the shroud located at 12 o’clock. (e) Using a 0.250 in. (6.35 mm) wide feeler or wire gage, measure tip clearance at 12 o’clock position. Record as total tip clearance. (f)

Repeat steps (d) and (e) at the 3, 6 and 9 o’clock positions. Record the results as total tip clearance.

(g) Calculate actual tip clearance as shown below: Actual tip clearance = A - (B + C) NOTE:

The definition of the variables used in the formula are as follows; v A = total tip clearance (Ref. step (e)). v B = bearing radial play (Ref. step (b)). v C = blade radial play (Ref. step (3)(d)).


Page 428 Nov 09/2001


(h) Repeat calculation using blade radial play (Ref. step (3)(d)) and total tip clearances at 3, 6 and 9 o’clock positions (Ref. step (f)). (i)

Compare actual tip clearance with value specified in Fits and Clearances, REF. NO. 1092. NOTE:

Tip clearance greater or smaller than those specified in Fits and Clearances may have an adverse effect on engine performance.

CAUTION: TO ENSURE ADEQUATE SURGE MARGIN, LOW PRESSURE TURBINE STATOR VANE FLOW AREA MUST NOT BE LESS THAN THAT SHOWN (REF. APPROVED REPAIRS) FOR DIFFERENT BUILD STANDARDS. LARGER FLOW AREAS INCREASE FUEL CONSUMPTION AND REQUIRE HIGH PRESSURE AND FIRST STAGE POWER TURBINE VANE FLOW AREAS TO BE ALTERED TO MAINTAIN LP/HP COMPRESSOR SPEED MATCH. CAUTION: REFER TO ENGINE LOG BOOK TO DETERMINE VANE FLOW AREA AND SB INCORPORATION DURING BUILD. CAUTION: THE SEAL DIAMETERS OF REPLACEMENT LP STATORS MUST BE MACHINED TO OBTAIN CORRECT CLEARANCE WITH HP TURBINE DISK REAR COVER PLATE AND INTERSTAGE SEAL (REF. APPROVED REPAIRS). (15)

Install sealing rings (1, 2, Fig. 409) on LP stator (3), positioning split in rings 180 degrees diametrically apart.

(16)

Install LP turbine stator (28, Fig. 406), seal housing (26) (Pre-SB21618) or (40) (Post-SB21618) and LP turbine shrouds (25) as follows: (a) Place seal housing (26) (Pre-SB21618) or (40) (Post-SB21618) on bench. (b) Using teflon drift, install LP turbine shrouds (25) (Ref. Fig. 410) in turbine housing, with No. 1 segment center slot aligned with hole on dowel RH side and segments No. 2 to 14 installed clockwise. Check gap between segments (F & C REF. NO. 1805). (c) Turn LP turbine housing over. (d) Align X-mark on lug with hole on LH side of dowel hole and install LP turbine stator (28, Fig. 406) in housing. Load stator clockwise and, using feeler gage, check that minimum gap between lugs and opposite side of slots is 0.001 in. (0.025 mm). NOTE:

If necessary, remove material from lugs to obtain minimum gap.

(e) Turn assembly over and, using appropriately sized packings or string, secure stator to housing. (f)

Heat associated turbine support case flange area using heat gun, then align dowel pin with hole and, using guide pins (0.190-32 UNJF-3A thread), install turbine housing and stator assembly, ensuring LP stator lugs engage in HP shroud segment slots. Remove packings or string securing stator to housing.


Page 429 Nov 09/2001


2

SPLIT IN RING

3

A

A

SPLIT IN RING

1 SECTION

A−A C25842

LP Turbine Stator and Sealing Rings - Assembly Figure 409


Page 430 Nov 09/2001


Key to Figure 409 1. 2. 3.

Sealing Ring Sealing Ring LP Stator

(g) Install bolts (24) and torque 36 to 40 lb.in. (4.07-4.52 Nm). (17)

Determine spacer (23) class required as follows: (a) Install sleeve (PWC38220) (3, Fig. 411) on LP shaft. (b) Install adapter (PWC37562) (4), using slave bolts (0.190-32 UNJF-3A x 0.375). (c) Load LP stator and LP turbine shaft, as shown. (d) Measure Dim. a at three locations 120 degrees apart. Record average dimension. (e) Measure and record Dim. c. (f)

Measure and record Dim. b.

(g) Calculate spacer thickness (in inches) required as follows: Spacer thickness = (c + d + e) - (b + a + 0.084 in.)) ± 0.005 (h) Establish class required (Ref. IPC). NOTE: 1. For Dim. d, use actual dimension marked on screw of adapter (PWC37562). NOTE: 2. Both sides of spacer must be parallel within 0.0002 in. (0.005 mm). NOTE: 3. For Dim. e, use actual dimension marked as ’b’ on spacer (PWC38220). NOTE: 4. 0.084 in. is a nominal dimension (Ref. F & C REF. NO. 1355). NOTE: 5. If ground, spacer must be demagnetized before installation. (18)

Install spacer as follows: (a) Existing spacer: align V-mark with V at end of LP shaft. (b) New spacer: mark V (by vibropeen method or metal marking PWC05-352) on OD. Install with Vs on LP shaft and spacer aligned.


Page 431 Jul 12/2002


C11594 Installation of HP (Pre-SB21588) and LP Turbine Shroud Segments Figure 410


Page 432 Nov 09/2001


CAUTION: BEFORE FURTHER ASSEMBLY, REFER TO ENGINE LOG BOOK TO ENSURE LIFED TURBINE COMPONENTS CAN CONTINUE IN SERVICE UNTIL ENGINE REFURBISHMENT. CAUTION: NOTE ORIENTATION OF UNSYMMETRICALLY SHAPED BALANCE WEIGHTS ON REPLACED TURBINE AND ENSURE THEY ARE INSTALLED IN THE SAME ORIENTATION ON REPLACEMENT TURBINE. CAUTION: DURING DETAIL BALANCING, REPLACEMENT OR REFURBISHMENT, TURBINE ASSEMBLIES MUST BE BALANCED WITH RIVET HOLES REQUIRED FOR TRIM BALANCING LEFT UNOCCUPIED. THEREFORE, INFORMATION COVERING POSITION OF TRIM BALANCE WEIGHTS AND RIVETS SHOWN ON ENGINE REFERENCE DATA PLATE MUST BE SUPPLIED TO OVERHAUL/REFURBISHMENT FACILITIES BEFORE ASSEMBLIES ARE BALANCED. (19)

Before further assembly, check LP turbine blades for movement. Radial and axial movement of blade tips is acceptable. Axial movement of blade platforms, found when pushing with fingers at blade root, is unacceptable, and LP turbine disk assembly must be rejected.

(20)

Install trim balance weights and rivets on a replacement LP turbine assembly in accordance with engine reference data plate (Ref. Fig. 412) using riveter (PWC37532). NOTE: 1. Shroud replacement and/or grinding (Ref. Approved Repairs) may be required depending on diameter of replacement turbine. NOTE: 2. Rotor air seal and No. 6 bearing inner race must be transferred from replaced to replacement turbine (Ref. Approved Repairs).

(21)

Heat LP turbine at 149 ± 6°C (300 ± 10°F) in oven for 15 minutes minimum (Ref. Note). NOTE:

If an oven is not available, use a heat gun. Note heat must be applied evenly over the surface of the disk. Sufficient time must be taken to ensure the complete disk is heated to ensure distortion does not occur.

(22)

Align master spline and install LP turbine assembly (22, Fig. 406), using pusher (PWC37949), cylinder (PWC32506) and pump (PWC37807).

(23)

To seat turbine, lubricate threads and faces, using oil (PWC03-001), install slave keywasher (PWC54701) (see Note 2, following), slave spacer (PWC54700) and nut (19), then proceed as follows: NOTE: 1. Let the turbine cool to room temperature before installing nut. NOTE: 2. As an optional slave washer, use a keywasher with the tangs removed in lieu of the tool.


Page 433 Nov 09/2001


C20350B Low Pressure Turbine Spacer - Dimension Check Figure 411


Page 434 Jul 12/2002


Key to Figure 411 1. 2. 3. 4.

LP Turbine Disk Turbine Support Case Spacer Adapter

(a) Align hole with dowel and install support (PWC37445) (1, Fig. 413), socket (PWC54912) (2), adapter (PWC38247) (3), bar (PWC37515-06) (5) and wrench (PWC31050) (4). NOTE:

Ensure support (PWC37445) is bolted securely to the turbine support case to prevent damage to the LP turbine disk assembly.

CAUTION: ENSURE LP TURBINE IS AT ROOM TEMPERATURE BEFORE APPLYING FINAL TORQUE. (b) Torque nut 3600 lb.in. (406.80 Nm). (c) Remove nut, support, adapter, socket, wrench, slave spacer and slave keywasher. (24)

Determine spacer (20, Fig. 406) class required as follows (Ref. Fig. 414): (a) Install adapter (PWC37563) (2) fingertight. Rotate ring and cap assembly (3) to load LP rotor shaft in forward direction and power turbine rotor shaft in rearward direction. (b) Measure and record Dim. a in three positions, using depth gage. Record average dimension. (c) Measure and record keywasher thickness. (d) Measure and record Dim. b. (e) Calculate spacer thickness (in inches) required: (2.000 + 0.430) - (a + b + 0.250 + keywasher thickness) ± 0.005 NOTE: (f)

For the spacer thickness calculation, average axial dimension 0.430 in. (10.922 mm) called up at F & C REF. NO. 1368 is used.

Establish class required (Ref. IPC). NOTE: 1. Both sides of spacer must be parallel within 0.0002 in. (0.005 mm). NOTE: 2. If ground, spacer must be demagnetized before installation.

(25)

Install keywasher (21, Fig. 406) as follows: (a) Clean and dry face on No. 6 bearing contacting keywasher.


Page 435 Mar 01/2002


LOW PRESSURE ROTOR TURBINE NO. 1 RIVET IS THE NEAREST TO V AND COUNTS COUNTER−CLOCKWISE DIRECTION

NO. 1 RIVET IS THE NEAREST TO V AND COUNTS CLOCKWISE DIRECTION V ON REAR BALANCE RIM

1 2 3

4

5

5 6 7 8

6 7 8

RIVET WEIGHT

4

LOW PRESSURE TURBINE DOWNSTREAM FACE (REAR PLANE)

V ON FRONT BALANCE RIM

1 3 2

RIVET WEIGHT

LOW PRESSURE TURBINE UPSTREAM FACE (FRONT PLANE)

ENGINE REFERENCE DATA

AT 59 F

SERIAL NO. ENGINE BUILD SPEC AT

SHP 6 θ

Ω

T 6 TRIM

NH

θ

NL

θ

H H L L

FB3

FG5

RB3

RG5

WHERE: L. F. R. A THRU E . 3. G.

DENOTES L.P. TURBINE TRIM BALANCE . DENOTES THE TURBINE FRONT PLANE. DENOTES THE TURBINE REAR PLANE. DENOTES THE CLASS OF BALANCE WEIGHT. (SEE NOTES) DENOTES THE FIRST RIVET HOLE OCCUPIED BY THE BALANCE WEIGHT OR RIVET IN THE DIRECTION OF COUNTING. DENOTES BALANCE RIVET.

NOTES: 1) UNSYMMETRICAL BALANCE WEIGHTS MAY BE INSTALLED EITHER WAY. 2) A THRU E DENOTES CLASS 1 THRU 5. (REF. IPC)

C25840 Low Pressure Turbine Trim Balance Weights - Installation and Data Plate Marking Figure 412


Page 436 Nov 09/2001


(b) Lubricate, with engine oil (PWC03-001), keywasher face that contacts spacer. Opposite face must be clean and dry. (c) Install keywasher. (d) Align hole with dowel and install support (PWC37445) (1, Fig. 413), using slave bolts (0.190-32 UNJF-3A x 0.375). (26)

Install spacer (20, Fig. 406) in nut (19). NOTE:

Check that retaining ring is installed in nut.

(27)

Install nut (19), spacer (20), socket (PWC54912) (2, Fig. 413), adapter (PWC38247) (3), bar (PWC37515-06) (5) and wrench (PWC31050) (4).

(28)

Torque nut (F & C REF. NO. 1706).

(29)

Remove wrench, adapter, bar and socket.

(30)

Check runout of disk adjacent to blade root (Ref. Fig. 414). Runout must not exceed 0.004 in. (0.101 mm) FIR. Remove support.

(31)

Crimp keywasher (21, Fig. 406) in 4 positions, using crimper (PWC37490).

(32)

Heat labyrinth seal (18) in oven at 149 ± 6°C (300 ± 10°F) for 15 minutes minimum. Install seal using pusher (PWC37441), aligning V with V-mark or air holes in power turbine shaft. NOTE:

If an oven is not available, use a heat gun. Note heat must be applied evenly over the surface of the seal. Sufficient time must be taken to ensure the complete seal is heated evenly to ensure distortion does not occur.

CAUTION: TIP CLEARANCE AT 6 O’CLOCK POSITION MUST NOT BE LESS THAN 0.026 in. (0.660 mm) WITH ENGINE HORIZONTAL. DO NOT FORCE FEELER GAGE. WHEN CHECKING CLEARANCE, ENSURE TURBINE ASSEMBLY IS AT ROOM TEMPERATURE. (33)

When components are at room temperature, check LP turbine tip clearance as follows: (a) Install support (PWC37445). (b) Using a dial indicator at point A (Ref. Fig. 415), move disk assembly and measure total play of bearing. (c) Divide total bearing play by 2 and record as bearing radial play. (d) Check tip clearance at 12 o’clock position as follows: 1

Find and position longest blade at 12 o’clock position.

2

Load LP turbine disk assembly away from shroud at 12 o’clock position.


Page 437 Nov 09/2001


2

1

3

5

4

C11243A No. 6 Bearing Rotor Nut - Installation Figure 413


Page 438 Nov 09/2001


Key to Figure 413 1. 2. 3. 4. 5.

Support Socket Adapter Wrench Bar

3

Using a 0.250 in. (6.35 mm) wide taper feeler or wire gage, measure clearance. Record as total tip clearance.

4

Calculate actual tip clearance as shown below: Actual tip clearance = A - B NOTE:

The definition of the variables used in the formula are as follows; v A = total tip clearance (Ref. step 3). v B = bearing radial play (Ref. step (c)).

(e) Repeat procedure at 3, 6 and 9 o’clock positions. (f)

Compare actual tip clearance with value specified in Fits and Clearances, REF. NO. 1382. NOTE: 1. Tip clearances greater or smaller than those specified in Fits and Clearances may have an adverse effect on engine performance. NOTE: 2. Tip clearance at the 6 o’clock position should exceed the clearance at the other positions by 0.004 in. (0.101 mm) due to offset ground shrouds.

(g) Remove support (PWC37445). CAUTION: HANDLING OF BEARINGS MUST BE KEPT TO A MINIMUM. WEAR SYNTHETIC RUBBER OR NYLON MESH GLOVES WITH POLYETHYLENE PALMS AND FINGERS. WHEN RUBBER OF NYLON GLOVES ARE NOT AVAILABLE, COTTON GLOVES MAY BE WORN IF THEY ARE CHANGED FREQUENTLY TO ENSURE THE FABRIC DOES NOT BECOME IMPREGNATED WITH SWEAT. REFER TO 72-00-00, MAINTENANCE PRACTICES, FOR ADDITIONAL INFORMATION. (34)

Install No. 7 bearing inner race (17, Fig. 406) as follows: (a) Heat inner race at 115 ± 5°C (238 ± 10°F) in oil or in a bearing oven at 135 ± 14°C (275 ± 25°F) (Ref. Note) for 60 minutes (1 hour) minimum. NOTE:

Ensure a thin layer of engine oil (PWC03-001) covers bearings before they are heated in an oven.


Page 439 Nov 09/2001


b

1

2

LOAD POWER TURBINE SHAFT IN THIS DIRECTION 3

a

CHECK RUN OUT AT THIS POINT

LOAD LOW PRESSURE TURBINE SHAFT IN THIS DIRECTION

C25357 No. 6 Bearing Rotor Nut Spacer - Dimension Check Figure 414


Page 440 Nov 09/2001



Nut Adapter Ring and Cap Assembly

(b) Apply dry ice (PWC05-102) in plastic bag to shaft bearing journal for 15 minutes minimum. (c) Install race using pusher (PWC56226), ensuring serial number is visible (facing rear of engine) and aligned with master spline of shaft. (d) Allow race to cool. Visually inspect; if race is cracked, reject complete bearing. (e) If necessary, remove condensation, using a lint-free cloth, and lubricate the area with engine oil (PWC03-001). CAUTION: TO ENSURE LP COMPRESSOR SPEED AND LP/HP COMPRESSOR SPEED MATCH ARE NOT AFFECTED BY DIFFERENT BUILD STANDARDS, FIRST-STAGE POWER TURBINE STATOR VANE-FLOW AREA MUST BE REVIEWED (REF. APPROVED REPAIRS). (35)

Install power turbine stator assembly (14) and sealing ring (16) on turbine interstage case as follows: (a) Place turbine interstage case and associated parts (15) (Pre-SB21618) or (39) (Post-SB21618) on bench, downstream end uppermost. (b) Heat power turbine stator assembly (14) in oven at 149 ± 6°C (300 ± 10°F) for 15 minutes minimum (Ref. Note). NOTE:

If an oven is not available, use a heat gun. Note heat must be applied evenly over the surface of the stator assembly. Sufficient time must be taken to ensure the complete stator assembly is heated evenly to ensure distortion does not occur.

(c) Heat Area a on interstage case assembly, using a heat gun for 10 minutes minimum. (d) Align pin with dowel hole and install alignment guide (PWC37844) on interstage case. (e) Install power turbine stator assembly on interstage case. Using drift (PWC37845) and a soft hammer, tap stator assembly around inner platform to ensure the stator seats correctly. Remove alignment guide.


Page 441 Nov 09/2001


1

A

TIP CLEARANCE

2

3

C21963 LP Turbine Blade Tip Clearance Check Figure 415


Page 442 Nov 09/2001



Support No. 6 Bearing LP Turbine Shroud

CAUTION: CLEARANCE BETWEEN FLANGES MUST BE LESS THAN 0.001 in. (0.025 mm) OVER 300 DEGREES TO ENSURE STATIC COMPONENTS DO NOT CONTACT ROTATING COMPONENTS DURING RUNNING CONDITIONS. (f)

Ensure clearance between outer flanges of interstage case (2, Fig. 416) and power turbine stator (1) is less than 0.001 in. (0.025 mm) over 300 degrees. Remove and reinstall power turbine stator (1) if clearance is not within limits.

(g) Install sealing ring (16, Fig. 406), with gap at TDC in seal housing (26) (Pre-SB21618) or (40) (Post-SB21618). Check that radial clearance is less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference (Ref. Fig. 417). If necessary, rotate ring until clearance is within limits. Record position of gap. Reject ring if correct clearance is unobtainable. Remove ring and install in turbine interstage case, ensuring word PRESS is facing forward and gap is in position previously recorded. CAUTION: TAKE EXTREME CARE WHEN INSTALLING TURBINE INTERSTAGE CASE AND ASSOCIATED PARTS TO ENSURE NO. 6 AND 7 BEARINGS ARE NOT DAMAGED. (h) Install turbine interstage case and associated parts (15, Fig. 406) (Pre-SB21618) or (39) (Post-SB21618) as follows: 1

Install guide (PWC54072).

2

To facilitate assembly, push No. 7 bearing rollers toward power turbine shaft centerline. Ensure they stay in position as close as possible to the centerline during assembly sequence.

3

Heat turbine housing outside diameter 10 minutes minimum, using a heat gun.

4

Using dry ice (PWC05-102), cool outer flange area of interstage case.

5

Align dowel hole and, using guide pins (0.190-32 UNJF-3A thread), install turbine interstage case and associated parts.

6

Remove guide (PWC54072).


Page 443 Nov 09/2001


CLEARANCE MUST BE LESS THAN 0.001 IN. (0.025 mm) OVER 300 DEGREES 1

INNER PLATFORM

a

2

C12844B Power Turbine Stator - Assembly Figure 416


Page 444 Nov 09/2001



Power Turbine Stator Assembly Interstage Case Assembly

CAUTION: ENSURE ONLY NEW BOLTS ARE USED TO SECURE RETAINING RINGS. (i)

Install retaining rings (12, 13) (Pre-SB21618) or (37, 38) (Post-SB21618) and bolts (11) (Pre-SB21618) or (41) (Post-SB21618). Torque bolts (Pre-SB21618), 36 to 40 lb.in. (4.07-4.52 Nm) or bolts (Post-SB21618), 50 to 56 lb.in. (5.65-6.33 Nm). NOTE: 1. If retaining ring is in marked segments, install No. 1 segment TDC, remaining segments clockwise. NOTE: 2. Before installation, lubricate threads and underside of heads of bolts with engine oil (PWC03-001).

(36)

Install baffle assembly (10) as follows: (a) Freeze baffle assembly at -40°C (-40°F) for 30 minutes minimum. NOTE:

If a freezer is not available, cool, using dry ice (PWC05-102) for 30 minutes minimum.

(b) Heat seat for baffle assembly (10) in turbine support case (35) for 10 minutes minimum, using heat gun. (c) Align guide pin on baffle assembly with slot in retaining ring (at approx. 10 o’clock position). (d) Install baffle assembly using, if necessary, a soft hammer. (37)

Carry out an audio/visual check as follows: (a) Remove starter-generator cover (Ref. 72-20-00) and install a 3⁄8 in. square-drive socket extension or, if starter-generator is not installed, use gear train. (b) Rotate HP turbine rotor. NOTE:

If rubbing is evident and/or LP turbine and PT shafts turn, determine and rectify cause before proceeding with assembly.

(c) Remove tool and, if required, install starter-generator cover (Ref. 72-20-00). (38)

Install gaskets (36) on pressure oil transfer tubes (1) and scavenge oil transfer tube (3). NOTE:

Rotate gaskets during installation. When completely installed, straighten gaskets.


Page 445 Nov 09/2001


TURBINE HOUSING

SEAL RING WORD "PRESS" THIS SIDE

C33975 LP Turbine/Interstage Case Seal Ring - Clearance Check Figure 417


Page 446 Nov 09/2001


CAUTION: TO PREVENT OIL LEAKS, NEW GASKETS MUST BE USED. (39)

Install gaskets (7) on transfer tubes (1, 2, 3) using crimper (PWC37093).

(40)

Install strainer (9) in transfer tube (1) using a small amount of grease (PWC04-001) to retain the strainer in position.

(41)

Install seal rings (6), plates (5) and retaining rings (4) on transfer tubes (1, 2, 3).

CAUTION: DO NOT LUBRICATE TRANSFER TUBE THREADS. (42)

Install sealing tubes (8) and transfer tubes (1, 2, 3) (Ref. Note). Torque transfer tubes 100 lb.in. (11.30 Nm). Remove transfer tubes and examine gaskets to ensure each has 100% surface contact with its seat. If contact is satisfactory, reinstall transfer tubes and torque 400 to 450 lb.in. (45.19-50.84 Nm). If contact is unsatisfactory, replace transfer tube and gasket and repeat assembly procedure. NOTE:

D.

During initial assembly, transfer tubes are marked BR (vent), PR (pressure) and SC (scavenge) to identify locations at which they are installed. If required, mark replacement tubes. Install at location marked.

(43)

Install No. 6 and 7 bearing oil pressure, scavenge and vent tubes (Ref. 72-01-50, REMOVAL/INSTALLATION).

(44)

Install T6 thermocouples, adapters and sealing plates (Ref. 72-01-60, REMOVAL/INSTALLATION).

Power Turbine and Exhaust Duct (Ref. Fig. 418) (1)

Determine spacer (12) thickness required as follows (Ref. Fig. 419): (a) Install fixture (PWC37564) (1) using slave bolts (0.190-32 UNJF-3A threads). Screw head (2) until it is completely seated on shaft. Rotate knurled knob (3) to load shaft. (b) Install base (PWC37869) (4) and bar (PWC37068) (5). CAUTION: IF POWER TURBINE STATOR INNER PLATFORM IS CRACKED, DIM. a MUST BE MEASURED 90 DEGREES FROM CRACK. (c) Measure and record Dim. a. (d) Measure and record Dim. b. (e) Measure and record Dim. c (from first-stage power turbine blade platform to stubshaft seal face).


Page 447 Nov 09/2001


VIEW

13

12

A

A

1 10 MARK AT T.D.C. 11 8 9 6 3

7 1

5 4 2 3

C65718A Power Turbine Assembly - Installation Figure 418


Page 448 Nov 09/2001


Key to Figure 418 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. (f)

Tube Bolt (MS9696-08, Qty 24) Bolt (MS9217-06, Qty 3) Exhaust Duct Bolt Cover Retaining Ring Keywasher Nut Power Turbine Rotor Assembly Sealing Ring Spacer Shaft

Calculate spacer thickness (in inches) required as follows: (b + d + c) - (a + 0. 020) = Spacer thickness ± 0.005 NOTE: 1. For Dim. d use actual dimension marked on head (part of PWC37564) (1). NOTE: 2. For spacer thickness calculation, average axial dimension 0.020 in. (0.508 mm) called up at F & C REF. NO. 1381 must be used.

(g) Check thickness of existing spacer. If necessary, grind to thickness required or replace with new spacer ground to correct dimensions. NOTE: 1. Both sides of spacer must be parallel within 0.0002 in. (0.005 mm). NOTE: 2. Spacers must be ground at a qualified overhaul or heavy maintenance facility. NOTE: 3. If ground, spacer must be demagnetized before installation. (h) Remove tools. (2)

Install spacer as follows: (a) Existing spacer: align V-mark with V at end of power turbine shaft. (b) New spacer: mark V (by vibropeen) on OD. Install with V-marks on power turbine shaft and spacer aligned.


Page 449 Nov 09/2001


FIRST STAGE POWER TURBINE

c

MOUNTED ON BENCH

a b

1

5

4

2

3

LOAD POWER TURBINE SHAFT IN THIS DIRECTION

C33976 Power Turbine Rotor - Spacer Thickness Check Figure 419


Page 450 Nov 09/2001


Key to Figure 419 1. 2. 3. 4. 5.

Fixture Head Knurled knob Base Bar

CAUTION: BEFORE FURTHER ASSEMBLY, REFER TO AIRWORTHINESS LIMITATIONS, AND ENGINE LOG BOOK, TO ENSURE LIFED TURBINE COMPONENTS CAN CONTINUE IN SERVICE UNTIL ENGINE REFURBISHMENT. (3)

Install power turbine rotor balancing assembly (13, Fig. 418) as follows: (a) Install sealing ring (11) with gap at TDC in turbine support case with marking HIGH PRESS facing forward (Ref. Fig. 420). Check that radial clearance is less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference. If necessary, rotate ring until clearance is within limits. Record position of gap. Reject ring if correct clearance is unobtainable. (b) Remove sealing ring and install on PT rotor balancing assembly (10, Fig. 418), with marking HIGH PRESS toward PT blades and gap in position previously recorded. Use beeswax (PWC06-015) to hold sealing ring in compression. (c) Install sling (PWC37939) (5, Fig. 421) and if required, holder (PWC37540) (4) on rotor balancing assembly. NOTE:

Holder (PWC37540) is required only after difficulty is experienced when aligning the lugs/slots during the installation procedure.

(d) Heat turbine stubshaft for 10 minutes minimum using heat gun. (e) Locate X-mark on stator and split of sealing ring at TDC. NOTE: (f)

X-mark may be on either the rear flange or outer diameter of the stator.

Align master spline on shaft with X-mark on stator and install power turbine rotor balancing assembly in turbine support case.

CAUTION: GUIDE LABYRINTH SEAL DURING INITIAL ASSEMBLY. CAUTION: ENSURE POWER TURBINE STATOR MOVES FREELY DURING COMPLETE ASSEMBLY SEQUENCE. (g) Use heat gun to melt beeswax. Ensure sealing ring expands. (h) Push rotor assembly forward until power turbine stator lugs A rest on Surface C (Ref. Fig. 422).


Page 451 Nov 09/2001


0.016 IN. MINIMUM (0.406 mm)

AREA

0.019 IN. MAXIMUM (0.482 mm)

b

MARKING "HIGH PRESS" THIS SIDE

b

a

CHECK RUN OUT AT THIS POINT

C25839 Power Turbine Rotor - Assembly Checks Figure 420


Page 452 Nov 09/2001


(i)

Rotate stator assembly 15 degrees counterclockwise.

(j)

Push rotor assembly forward until stator lugs A pass through support case slots F, and lugs B and rest on Surface D.

(k) Rotate stator assembly clockwise until lugs B engage slot G. (l)

Remove sling and, if installed, holder.

(m) Seat rotor assembly on shaft, using pusher (PWC56226) (1, Fig. 421), cylinder (PWC32506) (2) and pump (PWC37807) (3). (4)

Push stator assembly forward as far as possible and check that Dim. a on Figure 420 is 3.430 in. (87.122 mm) minimum.

(5)

Lubricate with anti-seize compound (PWC06-009), the power turbine shaft thread and rotor face contacting nut (9, Fig. 418).

(6)

Install nut (9), socket (PWC37137) (1, Fig. 423), adapter (PWC37138) (2), bar (PWC37515-06) (4) and wrench (PWC31050) (3). Torque nut (F & C REF. NO. 1701). (a) Remove tools. (b) Check that power turbine stator moves freely.

(7)

Install keywasher (8, Fig. 418) and retaining ring (7).

(8)


(9)


(10)

Compare with the recommended tip clearance (F & C REF. NO. 1177). NOTE:

(11)


Using loading fixture (PWC38197), ensure runout on disk platform (Ref. Fig. 420) does not exceed 0.002 in. (0.050 mm) FIR. NOTE:

If runout exceeds 0.002 in. (0.050 mm), check the following components and if necessary, rectify before proceeding with assembly: v Turbine assembly not seated correctly. v Parallelism of No. 7 bearing air seals is out of tolerance (front seal 0.0005 in. (0.0127 mm); rear seal 0.0002 in. (0.0050 mm)).


Page 453 May 02/2003


1

2

3

5

4

C14330A Power Turbine Assembly - Installation Figure 421


Page 454 Nov 09/2001


Key to Figure 421 1. 2. 3. 4. 5.

Pusher Cylinder Pump Holder Sling

v Parallelism at No. 7 bearing rear spacer is out of tolerance (0.0002 in. (0.0050 mm)). v Spigot diameter (turbine assembly-to-turbine shaft) runout and/or concentricity out of tolerance (runout 0.0005 in. (0.0127 mm); concentricity 0.002 in. (0.050 mm)). v Spline is defective. (12)

Freeze power turbine disk cover (6, Fig. 418) to -40°C (-40°F) for 15 minutes minimum. NOTE:

If a freezer is not available, cool using dry ice (PWC05-102) for 15 minutes minimum.

(13)

Install disk cover and bolts (5). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).

(14)

Rotate propeller shaft manually and check that rotation is free and there are no unusual noises. If rubbing is evident, determine and rectify cause before proceeding with assembly.

(15)

Install exhaust duct assembly (4) as follows: (a) Locate top hole on duct flange 5 degrees counterclockwise of top hole on turbine support case flange. CAUTION: DO NOT USE LOCKWIRE (PWC05-295) TO SECURE BOLTS (2). THIS LOCKWIRE MUST BE USED FOR EXTERNAL APPLICATIONS ONLY. (b) Install duct in support case, push in and rotate clockwise 5 degrees to line up with top hole. Install bolts (2, 3) (1, 2, Fig. 424). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm). Secure bolts (2, Fig. 418) (2, Fig. 424) with lockwire (PWC05-089).

E.

Engine External Components (1)

Install T6 trim cable (Ref. 72-01-60).

(2)

Install T6 bus-bars and connect trim cable (Ref. 72-01-60).

(3)

Install sealing tubes (1, Fig. 418) and intercompressor case drain tube assembly (Ref. 72-01-50).


Page 455 Nov 09/2001


ROTATE


SLOT G LUG

A STATOR ASSEMBLY

SLOT F LUG

B

SURFACE C

SURFACE D

C11571B Power Turbine Stator - Installation Figure 422


Page 456 Nov 09/2001


(4)

Install No. 5 bearing vent tube (Ref. 72-01-50).

(5)

Install accessory gearbox breather tube (Ref. 72-01-50).

(6)

Install oil filler valve (Ref. 72-01-50, OIL SYSTEM - REMOVAL/INSTALLATION)


Page 457 Jan 16/2004


1 4

2 3

C11133C Power Turbine Assembly Retaining Nut - Installation Figure 423


Page 458 Nov 09/2001


Key to Figure 423 1. 2. 3. 4.

Socket Adapter Wrench Bar


Page 459 Nov 09/2001


2

3

1 1

1 1 2

1 1

2

C12565 Exhaust Duct Attaching Bolts - Location Figure 424


Page 460 Nov 09/2001



Bolt Bolt Exhaust Duct


Page 461/462 Nov 09/2001


TURBOMACHINERY - INSPECTION/CHECK 1.

General A.

This section provides instructions for inspecting hot section gas path components.

B.

Use engine oil (PWC03-001) for general lubrication, unless stated otherwise.

C.

Special assembly instructions, torques and dimensional tolerances are identified in text by Fits and Clearances (F & C) reference numbers.

D.

The condition of air seals and hot-end components located in the gas path deteriorates during the life of an engine, and this deterioration can adversely affect engine performance. The following inspection criteria define limits to which components may deteriorate without affecting engine performance or maximum service life of the component. The criteria given are for maintenance use only. No repairs are specified, although if the HSI is carried out at an overhaul facility, components may be refurbished as specified in the applicable CIR Manual.

E.

Operators may choose to carry out a repair and not an HSI (e.g. to replace life limited or defective components, or for scheduling purposes etc.) If a repair is carried out, Hot Section Borescope Inspection Criteria (Ref. 72-00-00, INSPECTION/CHECK) may be used to determine serviceability/airworthiness of hot end components. Using this criteria may not improve performance/increase ITT margin (lower ITT). It should be noted returning an engine to service after using the Borescope Inspection Criteria may substantially increase the cost of subsequent repairs/refurbishments.

F.

If during a borescope inspection (routine or troubleshooting), a Hot Section Inspection (HSI), or caused by a Performance Deterioration / ECTM shift, a fracture of one or several HP, LP or PT blade is observed. The workscope to be performed must be in accordance with the associated Engine-Light Overhaul procedure for: v HP Blade Fracture v LP Blade Fracture v PT Blade Fracture

G. Operators having no overhaul capability are recommended to send rejected components to an overhaul facility for an inspection in accordance with the PW100 CIR Manual instructions. The inspections are to be carried out to determine if a repair is available, feasible and economically justified. H.

Fuel nozzles must be marked during disassembly to enable identification of the engine location at which they were installed. This will permit component distress to be related to individual nozzles.

I.

When high and low pressure turbine balancing assembly components are changed, the assembly must be rebalanced (or a balanced assembly installed). This involves transferring trim balance weights from the replaced to the replacement turbine assembly (Ref. Engine Data Plate) and may also involve shroud grinding to restore tip clearance.

72-03-00 TURBOMACHINERY - INSPECTION/CHECK

Page 601 Nov 04/2005


J.

A borescope inspection of LP and HP impellers should be carried out prior to hot section inspection to ensure cold end gas path components are within limits.

K.

A borescope inspection of ICC cavity should be carried out prior to hot section inspection to check for oil accumulation.

L.

To control component life (Ref. AIRWORTHINESS LIMITATIONS), operators returning turbine assemblies for repair should also complete and return disk history sheets and, if required, life limited parts log sheet for HP turbine covers. After repair, without the information contained on the sheets, overhaul facilities are unable to suitably mark and return assemblies as serviceable to the operator.

M. To ensure best possible engine performance after shroud grinding, LP and HP turbine shrouds must be ground to give minimum tip clearance with the associated blades. N.

Power assurance checks should be carried out both prior to, and subsequent to, hot section inspections to determine the effectiveness of refurbishment and assembly procedures.

O. To facilitate vane matching on subsequent occasions, complete, as far as possible, Engine Build and Test Data sheet detailed in Figure 601. CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLE COMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLE WITH THOSE REPLACED. 2.


3.


Item No.

Name

PWC03-001 PWC05-002 PWC06-009

Oil, Engine Dye, Layout Compound, Antiseize


Name

PWC32396 PWC32506 PWC37807 PWC38217 PWC38487 PWC54020

Jackscrew Cylinder Pump Holder Gage Gage


Page 602 Nov 04/2005


4.

Tool No.

Name

PWC54281

Pusher

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Drill Gages, Feeler Gages, Wire Magnifying Glass (10X) Micrometer, Internal Pin, Guide (0.190-32 UNJF-3A thread) Tap (0.500-20 UNJF-3B) Wheel, Rotary, Scotchbrite, or equivalent

5.

Gas Generator Case and Diffuser Exit Duct A.

Gas Generator Case (1)

Visually inspect for: (a) Raised metal or burrs: Stone to remove. (b) Dents/nicks/scores/scratches from 0.005 to 0.008 in. (0.127-0.203 mm) deep: Blend up to 0.010 in. (0.254 mm) deep maximum. (c) Loose or damaged pins: Replace loose or damaged pin. (d) Loose or damaged shanknuts or shanknuts with low rundown torque: Replace shanknuts if loose, damaged or with low rundown torque. (e) Cracked P3 bleed and fuel nozzle bosses: Replace gas generator case if cracks are found.

B.

Diffuser Exit Ducts (1)

Inspect gas generator case diffuser exit ducts for cracks using a light and mirror. Engines having gas generator cases with cracked diffuser exit ducts must be returned to an overhaul facility for repair.


Page 603 Nov 04/2005


ENGINE BUILD & TEST DATA RECORD PW127G / PW127H / PW127J THIS SHEET IS USED TO RECORD DATA WHICH WILL HELP WITH FUTURE VANE MATCHING AIRLINE / FACILITY:

DATE:

ENGINE MODEL:

TSN /CSN:

ENGINE S/N:

TSO / CSO:

BUILD STANDARD:

TSHSI / CSHSI : RECORD NO.:

WORK PERFORMED :

REPAIR

HSI

OVERHAUL

ROTATING COMPONENT DATA LP* HP* HP TURBINE LP TURBINE TIP TIP DIA* IMPELLER INDUCER DIA* CLEARANCE* CLEARANCE* CLEARANCE IMPELLER CONDITION

1st. PT TIP CLEARANCE*

FOR CONDITION INDICATE : NEW / REPAIRED / USED * INDICATE UNITS

VANES INSTALLED HP VANE (A4) FLOW CLASS* CONDITION

LP VANE (A5) FLOW CLASS* CONDITION

FOR CONDITION INDICATE : NEW / REPAIRED / USED

1st. PT VANE (A6) FLOW CLASS* CONDITION

*FOR FLOW CLASS INDICATE VALUE AS FLOWED

3. TEST CELL DATA ENGINE TEST CELL PERFORMANCE AT MAXIMUM T.O. POWER SHP (TQ)

NH*

NL*

NP*

WF (PPH)

T6H*

ITT*

T6C* UNTRIMMED TRIMMED

P3/P1

P2.5/P2

* INDICATE UNITS ADDITIONAL INFORMATION

UPON COMPLETION, STORE THIS RECORD IN THE ENGINE LOG BOOK

C27064B Engine Build and Test Data Sheet Figure 601


Page 604 Nov 04/2005


6.

Small Exit Duct, Inner and Outer Combustion Chamber Liner Assemblies NOTE: A.

These components are inspected for cracks, buckling and burning. Cracks normally relieve stress and the rate of progression decreases as the cracks lengthen.

Small Exit Duct (Ref. Fig. 602) (1)

Area a: CAUTION: ENSURE INNER WALL IS NOT AFFECTED WHEN STOP-DRILLING CRACKS. (a) Cracks up to 0.250 in. (6.350 mm) in length, originating at inner diameter, are acceptable providing they are stop-drilled with a 1⁄16 in. or equivalent size drill. NOTE:

Stop-drilling is not considered a long term repair; cracks eventually lengthen and will have the potential to cause downstream damage. Therefore, if possible, cracked ducts are recommended to be sent to a suitably equipped facility for the cracks to be welded.

(b) No burning or erosion of base material is permitted. (c) Coating loss is acceptable. (d) Bulging up to 0.015 in. (0.381 mm) is acceptable. (2)

Machined Surfaces (a) Raised metal. Stone to remove. (b) Nicks, scores or scratches from 0.005 to 0.008 in. (0.127-0.203 mm) deep. Blend up to 0.010 in. (0.254 mm) deep maximum.

(3)

Weld Joint ‘‘b’’ (a) If the small exit duct was previously repaired by replacing the heatshield, the assembly is recommended to be returned to a suitable equipped facility, for a fluorescent penetrant inspection (FPI) of the weld joint, in accordance with the CIR manual instructions (Ref. Small Exit Duct repair/service records).

(4)

Repairs (Ref. Fig. 603) (a) Replacement of heatshield. (b) Weld repair of cracks up to 1.0 in. (25.4 mm) in length in heatshield and inner flange support. (c) Patch repair by supplier of a maximum of two cracks in heatshield between 1.0 to 3.0 in. (25.4-76.2 mm) in length. Each crack must be separated by at least 3.0 in. (76.2 mm) of undamaged material.


Page 605 Nov 04/2005


b

a

C14569A Small Exit Duct - Inspection Figure 602


Page 606 Nov 04/2005


A

F

A

HEAT SHIELD REPLACEMENT

INNER FLANGE SUPPORT

PLASMA SPRAY RECOATING

CRACKS WELDED

3.00 IN. MAX. (76.2 mm) SECTION

INNER FLANGE SUPPORT HEAT SHIELD

A−A HOLES PATCHED

VIEW F (TYPICAL REPAIRABLE CONDITION)

C22700B Small Exit Duct - Repairs Figure 603


Page 607 Nov 04/2005


(d) Patch repair by supplier of a maximum of two areas of damage (holes and/or erosion) in heatshield and inner flange support. Each area must be less than 3.0 in. (76.2 mm) in length and separated by at least 3.0 in. (76.2 mm) of undamaged material. (e) Heatshield can be recoated by supplier. NOTE: B.

Repairs must be carried out at an authorized facility.

Inner Liner (Ref. Fig. 604) (1)

All surfaces (a) Shallow buckling not having abrupt changes of contour is acceptable. (b) Deep buckling having abrupt changes of contour is not acceptable. (c) Minor, non-converging cracks less than 2.0 in. (50.8 mm) in length and more than 0.500 in. (12.7 mm) apart, not caused by burning, buckling or deformation of cooling ring and not found in seam areas, are acceptable providing they are stop-drilled. (d) Cracks in excess of 2.0 in. (50.8 mm) in length and multiple cracks more than 0.030 in. (0.762 mm) wide are not acceptable. (e) Straight-line cracks between cooling air holes are acceptable providing individual cracks do not extend beyond adjacent holes. (f)

(2)

Burning and/or erosion of base metal is not acceptable.

Cooling ring: non-converging cracks not less than 0.250 in. (6.35 mm) apart which would not result in metal breaking off are acceptable. Circumferential cracks are not acceptable. Dress any buckling and regap ring at Gap h 0.075 to 0.095 in. (1.905-2.413 mm). NOTE:

Only visual traces of coating are permissible inside cooling ring louvres.

(3)

Area a: dress any buckling and regap ring at Gap j 0.070 to 0.090 in. (1.778-2.285 mm).

(4)

Plasma top coating (ceramic) loss revealing undercoat is acceptable, providing there is no burning or erosion of base metal. Even though total loss of the plasma top coating (ceramic) is acceptable, hot section life may be adversely affected. For economic reasons only, operators should seriously consider having the liner recoated if one or more of the following criteria are observed: NOTE: 1. Plasma coating of areas other than those indicated in figure 606 may cause HP blade erosion due to carbon formation. Replace inner liner if plasma coating is outside indicated areas. NOTE: 2. Only visual traces of coating are permissible inside cooling ring louvres. (a) One or more areas exceeds 1.00 in. (25.4 mm) in length.


Page 608 Nov 04/2005


h

a

j

C18577 Combustion Chamber Inner Liner - Inspection Figure 604


Page 609 Nov 04/2005


(b) One affected area is located within 4.00 in. (101.6 mm) of similarly damaged area. (c) Total affected area exceeds 2.00 sq.in. (1290.0 sq.mm). (5)

Machined surfaces (a) Raised metal. Stone to remove. (b) Nicks, scores or scratches from 0.005 to 0.008 in. (0.127-0.203 mm), blend up to 0.010 in. (0.254 mm) deep maximum.

(6)

Cooling holes must be free of dirt or foreign material.

(7)

Repairs (Ref. Fig. 605) (a) Weld repair of cracks. (b) Patch repair of damage (multiple cracks, holes, erosion). Area of individual patch must not exceed 15 sq.in. (9677 sq.mm). Total maximum surface area of patches is 30 sq.in. (19354 sq.mm) per liner assembly. At least 2.0 in. (50.8 mm) of unrepaired metal must separate patches. (c) Cooling ring replacement. (d) Coating can be restored by supplier. NOTE:

C.


Outer Liner (Ref. Fig. 606) (1)

All surfaces (a) Shallow buckling not having abrupt changes in contour is acceptable. (b) Deep buckling having abrupt changes in contour is not acceptable. (c) Minor, non-converging cracks less than 2.0 in. (50.8 mm) in length and more than 0.500 in. (12.7 mm) apart, not caused by burning, buckling or deformation of cooling ring and not found in seam areas, are acceptable providing they are stop-drilled. (d) Cracks in excess of 2.0 in. (50.8 mm) in length and multiple cracks more than 0.030 in. (0.762 mm) wide are not acceptable. (e) Straight-line cracks between cooling holes are acceptable providing individual cracks do not extend beyond two holes. (f)

Burning and/or erosion of base metal is not acceptable.


Page 610 Nov 04/2005


CRACK WELD REPAIRED

PATCH REPAIRS

COOLING RING REPLACEMENT PLASMA SPRAY RECOAT AS REQUIRED

C22734 Combustion Chamber Inner Liner Assembly - Repairs Figure 605


Page 611 Nov 04/2005


q r r d c x r r

p

s s

C18576A Combustion Chamber Outer Liner Assembly - Inspection Figure 606


Page 612 Nov 04/2005


(2)

Cooling rings (except cooling ring x) NOTE: 1. Dimensional inspection of the cooling ring gaps should be carried out if HP blades are eroded by carbon or carbon is formed on the outer liner. NOTE: 2. Only visual traces of coating are permissible inside cooling ring louvres. (a) Localized burning at lips of cooling rings is acceptable provided cooling holes are not affected. (b) Cracks across width of cooling ring and not less than 0.250 in. (6.35 mm) apart are acceptable provided the lip gap is restored. (c) Converging cracks which could result in metal breaking off are not acceptable. (d) Circumferential cracks are not acceptable. (e) Buckled cooling rings: restore to original contour; gap ring at Gap q 0.070 to 0.090 in. (1.778-2.286 mm), and gap ring at Gap r 0.050 to 0.070 in. (1.270-1.778 mm), gap ring at Gap p 0.035 to 0.068 in. (0.89-1.72 mm) and gap ring at Gap s 0.042 to 0.075 in. (1.06-1.90 mm).

(3)

Cooling ring x NOTE: 1. Dimensional inspection of the cooling ring gaps should be carried out if HP blades are eroded by carbon or carbon is formed on the outer liner. NOTE: 2. Only visual traces of coating are permissible inside cooling ring louvres. (a) Converging cracks which could result in metal breaking off are not acceptable. (b) Axial cracks across width of ring are acceptable providing they are not less than 1.000 in. (25.4 mm) apart and lip gap is restored. (c) Circumferential cracks are not acceptable. (d) Buckled cooling ring is acceptable providing lip gap at Gap r is restored to 0.050 to 0.070 in. (1.270-1.778 mm). (e) Plasma coating loss is acceptable providing base metal is not burnt or eroded.

(4)

Cracks in vicinity of fuel nozzle suspension brackets (Area c) are not acceptable. NOTE:

Dimensional inspection of the fuel nozzle bore diameters should be carried out if HP blades are eroded by carbon or carbon is formed on the outer liner. If at any bore location, the diameter exceeds 0.930 in. (23.62 mm) or the average diameter of the bore exceeds 0.925 in. (23.49 mm) or the diameter cannot be measured, the outer liner should be sent for inspection/repair to an authorized supplier.


Page 613 Nov 04/2005


(5)

Plasma top coating (ceramic) loss revealing undercoat (diffused allumide) is acceptable, providing there is no burning or erosion of base metal. Even though total loss of the plasma top coating (ceramic) is acceptable, hot section life may be adversely affected. For economic reasons only, operators should seriously consider having the liner recoated if one or more of the following criteria are observed: v One or more areas exceeds 1.00 in. (25.4 mm) in length. v One affected area is located within 4.00 in. (101.6 mm) of similarly damaged area. v Total affected area exceeds 2.00 sq.in. (1290.0 sq.mm). NOTE:

(6)

Only visual traces of coating are permissible inside cooling ring louvres.

Machined surfaces (a) Raised metal. Stone to remove. (b) Nicks, scores or scratches from 0.005 to 0.008 in. (0.127-0.203 mm) deep. Blend up to 0.010 in. (0.254 mm) maximum.

(7)

Cooling holes must be free of dirt and foreign material.

(8)

Repairs (Ref. Fig. 607) (a) Weld repair of cracks. (b) Patch repair of damage (multiple cracks, holes, erosion). Area of individual patch must not exceed 15 sq.in. (9677 sq.mm). Total maximum surface area of patches is 30 sq.in. (19354 sq.mm) per liner assembly. At least 2.0 in. (50.8 mm) of unrepaired metal must separate patches. (c) Cooling ring replacement. (d) Coating can be restored by supplier. NOTE:

7.


Fuel Nozzles A.

Inspection (1)

Inspect fuel nozzles (Ref. 72-01-40, INSPECTION/CHECK).

(2)

P&WC recommends that a flow check be carried out on fuel nozzles during hot section inspection providing: (a) Fuel nozzles not on a sampling program. 1

The nozzles did not have a flow check carried out within the previous 500 hours.

(b) Fuel nozzles on a sampling program.


Page 614 Nov 04/2005


CRACKS WELD REPAIRED

PATCH REPAIRS

COOLING RINGS REPLACED

PLASMA SPRAY RECOAT AS REQUIRED

C22739 Combustion Chamber Outer Liner Assembly - Repairs Figure 607


Page 615 Nov 04/2005


1 8.

Igniters A.

Inspection (1)

9.

The nozzles have not been changed or had a flow check carried out within the previous 50% of the sampling inspection interval.

Inspect igniters (Ref. 72-01-20, INSPECTION/CHECK).

HP Turbine Stubshaft A.

Inspection NOTE:

The Fits and Clearances for the HP turbine stubshaft airseals should only be checked if the engine had a history of high oil consumption prior to the shop visit (Ref. Para. 38.).

CAUTION: NEW REPLACEMENT STUBSHAFTS WITH THE ASSOCIATED BOLTS AND DISK MUST BE RETURNED TO AN OVERHAUL FACILITY TO BE BALANCED AS A SET. BOLTS ARE SELECTED USING THE CRITERIA GIVEN IN THE INSTALLATION PROCEDURE.

10.

Check for raised metal. Stone to remove sharp edges.

(2)

Check for indentations on involute tooth surfaces. Stone to remove raised metal only.

(3)

Check for sharp edges. Blend to original profile.

HP Turbine Stubshaft Securing Nut (Ref. Fig. 608) A.

11.

(1)

Inspection (1)

Polish threads using a rotary scotchbrite wheel, or equivalent, to remove nicks, burrs and raised material.

(2)

Lap Area C to remove burrs and raised material. Damage blended to a maximum depth of 0.010 in. (0.254 mm) and width of 0.100 in. (2.54 mm) is acceptable.

(3)

Coat Area A with anti-galling compound (Ref. Approved Repairs).

HP Turbine Vane Ring Segments A.

Inspection NOTE: (1)

Limits apply to each surface individually. Use a 10X magnifying glass to inspect for cracks.

Visually inspect vane ring segments for damage as follows: (a) Inspect airfoil leading edge for:


Page 616 Nov 04/2005


A

C

A

B SECTION

A−A A

B

VIEW B

COATING OPTIONAL AND MAY BE INCOMPLETE

C35315 HP Turbine Stubshaft Securing Nut - Inspection Figure 608


Page 617 Nov 04/2005


1

Cracks between cooling holes. Accept, provided cracks do not pass through more than four consecutive holes and do not tend to form a circular pattern. NOTE:

Multiple cracks must be separated by at least two undamaged cooling hole spaces for their entire length.

2

Erosion. Accept provided base material is not damaged or exposed and coating loss limits in step (3) are not exceeded.

3

Reject segment if burnt or missing material is found.

(b) Inspect airfoil trailing edge for:

(2)

1

Accept hairline cracks through or between trailing edge cooling holes, provided there is no missing material.

2

Cracks. Accept non-converging hairline cracks, including cracks which pass through the cooling holes, providing they do not exceed the following limits: a

0.600 in. (15.24 mm) long if cracks are in line on both sides of airfoil, up to a maximum of 1 pair.

b

1.00 in. (25.40 mm) long if cracks on one side of airfoil are not in line with cracks on opposite side of airfoil.

3

Erosion. Accept localized erosion provided airfoil surface is not distorted into cooling core, the core is not exposed and coating loss limits in step (3) are not exceeded.

4

Reject segment if burnt or missing material is found.

Inspect airfoil surfaces for: (a) Cracks. Accept non-converging hairline cracks up to 0.100 in. (2.540 mm) long. (b) Cracks with areas of missing material. Accept non-converging hairline cracks up to 0.100 in. (2.540 mm) long provided areas of missing material do not exceed 0.020 in. (0.508 mm) wide. (c) Reject segment if multi-pronged cracks are found. No repair permitted. (d) Erosion. Accept localized erosion provided airfoil surface is not distorted into cooling core, the core is not exposed and coating loss limits in step (3) are not exceeded. (e) Reject segment if airfoil surface is burnt. No repair permitted.

(3)

Inspect airfoil and gas path surfaces for: (a) Coating loss. Accept a maximum of 5 areas of coating loss per airfoil and shroud surface up to 0.100 in. (2.540 mm) in diameter.


Page 618 Nov 04/2005


C AIRFOIL LEADING EDGE

A GAS PATH OUTER SHROUD SURFACE GAS PATH INNER SHROUD SURFACE

B AIRFOIL TRAILING EDGE

A TRAILING EDGE LIPS

FACE

FACE

H

AIRFOIL TRAILING EDGE SLOTS

A VIEW

SHROUD FEATHER SEAL FACES

B

AIRFOIL TRAILING EDGE

FEATHER SEAL SLOT VIEW

A SUPPORT RIBBING

BAFFLE

BAFFLE JOINT VIEW

C

C22019 High Pressure Turbine Vane Ring Segments - Inspection Figure 609 (Sheet 1 of 3)


Page 619 Nov 04/2005


CRACKS WITH MISSING MATERIAL

F

CONVERGING CRACKS

G

F

MULTI-PRONGED CRACKS

EROSION

D

D

NON-CONVERGING HAIRLINE CRACKS BETWEEN GAS PATH AND FEATHER-SEAL SLOT

NON-CONVERGING HAIRLINE CRACKS CRACK EXTENDING INTO SUPPORT RIBBING AND BAFFLE JOINT

TRAILING EDGE LIP END FACES

NON-CONVERGING HAIRLINE CRACKS AT TRAILING EDGE LIPS

C33453 High Pressure Turbine Vane Ring Segments - Inspection Figure 609 (Sheet 2)


Page 620 Nov 04/2005


E

E SECTION

D-D

BAFFLE

CROSS SECTION THROUGH CRACK LENGTH

BAFFLE WIDTH OF DAMAGE AT AIRFOIL GAS PATH SURFACE

x

GAS PATH TRAILING EDGE LIP WIDTH OF DAMAGE AT CORE SECTION

E-E DETAIL

G

FACE

H

WIDTH OF DAMAGE AT GAS PATH SURFACE

WIDTH OF DAMAGE AT OUTER SURFACE

SECTION

F-F C33452

High Pressure Turbine Vane Ring Segments - Inspection Figure 609 (Sheet 3)


Page 621 Nov 04/2005


(b) Nicks, dents or pitting. Accept local damage up to 0.005 in. (0.127) deep and 0.100 in. (2.540 mm) in diameter. (4)

Inspect airfoil trailing edge slots and all cooling holes for blockage. Reject if cleaning does not remove blockage.

(5)

Inspect gas path inner shroud surface for: NOTE:

These limits only apply to the trailing edge lip.

(a) Cracks. Accept non-converging hairline cracks providing they do not extend into Face A and are spaced 0.150 in. (3.81 mm) minimum apart and 0.300 in. (7.620 mm) from trailing edge lip end faces. (b) Reject segment if burnt or eroded (other than coating loss (Ref. step (3)) or missing material is found. (6)

Inspect gas path outer shroud surface for: (a) Accept surface cracks with no visible depth up to 0.600 in. (15.24 mm) in length. (b) Non-converging hairline cracks at both trailing-edge lips. Accept cracks provided they do not extend into Face H and are spaced 0.200 in. (5.08 mm) minimum apart and 0.400 in. (10.160 mm) from trailing edge lip end faces. (c) Non-converging hairline cracks on remaining surface. Accept cracks up to 0.600 in. (15.24 mm) long. (d) Reject if burnt, eroded, (erosion other than coating loss (Ref. step (3)) or missing material is found.

(7)

Inspect inner and outer shroud feather seal faces for: NOTE:

For damage in trailing edge lip areas, refer to limits in step (5) and (3).

(a) Cracks. Accept non-converging hairline cracks up to 0.200 in. (5.08 mm) long, provided they are between the gas path surface and feather seal slot, and do not extend into the airfoil. (b) Localized fretting, burning and erosion. Accept damage up to 0.010 in. (0.25 mm) deep. (c) Reject segment if missing material is found. (8)

Inspect outer shroud surface for cracks. Accept non-converging hairline cracks up to 0.600 in. (15.24 mm) long, providing they do not extend into supporting ribs, baffle joints or baffle.

(9)

Inspect baffles for: (a) Cracks. Reject segment if cracks are found on supporting ribs, baffle joints or baffles. No repair permitted.


Page 622 Nov 04/2005


(b) Reject segment if baffle is distorted. No repair permitted. (c) Reject segment if gaps are found at baffle joints. No repair permitted. (10)

Inspect all other surfaces for: (a) Cracks. Reject segment if cracks are found. No repair permitted (b) Nicks, dents, scores or scratches on machined surfaces. Accept damage up to 0.005 in. (0.127 mm) deep. Blend to remove raised material.

12.

(11)

Inspect airfoil trailing edge slot widths. Slots must be 0.020 in. (0.508 mm) wide minimum.

(12)

If above limits are exceeded, reject vane segments. Retain segments for future evaluation and possible repair.

Vane Ring Outer Support Housing (Ref. Fig. 610) A.

Inspection (1)

Inspect sealing ring groove (Area a) for fretting which is acceptable providing width of groove does not exceed 0.140 in. (3.556 mm).

(2)

Inspect air holes for obstructions, rectify if necessary.

(3)

Inspect anti-rotation lugs for fretting which is acceptable providing the widths (Ref. Dims. b and d) are not less than 0.194 in. (4.928 mm).

(4)

Inspect all other surfaces for: (a) Raised material. Blend to remove sharp edges. (b) Dents, nicks, scores or scratches: damage up to 0.005 in. (0.127 mm) deep is acceptable: damage from 0.005 to 0.008 in. (0.127-0.203 mm) deep may be blended to a maximum depth of 0.010 in. (0.254 mm).

13.

Cooling Air Nozzle Housing (Ref. Fig. 611) A.

Inspection (1)

Inspect Dia. A for evidence of seal rubbing. Damage is acceptable up to 0.007 in. (0.178 mm) deep and 0.010 in. (0.254 mm) wide. Reject if not within limits.

(2)

Inspect all other surfaces for dents, nicks, scores or scratches: damage 0.005 to 0.008 in. (0.127-0.203 mm) deep may be blended to a maximum depth of 0.010 in. (0.254 mm).

(3)

Check air holes for obstructions, rectify if necessary.

(4)

Inspect jacking inserts for looseness or damaged threads. Replace if defective (Ref. 72-00-00, APPROVED REPAIRS).


Page 623 Nov 04/2005


C

d

C

0.140 IN. (3.556 MM) MAX.

a

b

VIEW

A SECTION

C−C

C21679B Vane Ring Outer Support Housing - Inspection Figure 610


Page 624 Nov 04/2005


(5) 14.

HP Turbine Vane Ring/Turbine Support Case Sealing Ring A.

15.

Inspect lugs. Replace housing if lugs are bent or width is less than 0.194 in. (4.927 mm).

Inspection (1)

Fretting is acceptable providing axial width of ring is not less than 0.100 in. (2.540 mm).

(2)

Radial clearance, when sealing ring is installed with gap at TDC in turbine support case, must be less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference using feeler gage. If necessary, rotate ring until clearance is within limits. Reject ring if correct clearance is not obtainable.

(3)

Check gap in seal ring at 11.200 in. (284.480 mm) gage diameter (F & C REF. NO. 1365).

HP Turbine Disk Assembly A.

Inspection (1)

If the disk assembly is debladed, it must be returned to a suitably equipped facility for the following fluorescent penetrant inspections to be carried out in accordance with the PW100 CIR Manual instructions: (a) High pressure turbine disk: inspect, using SPOP 84. (b) Front and rear cover plates: inspect using SPOP 84. (c) HP turbine blades: inspect using SPOP 84. Balancing is required after assembly.

(2)

Information covering position of trim balance rivets and weights shown on engine reference data plate must be supplied to overhaul/refurbishment facilities which refurbish or supply replacement turbine assemblies. The information will ensure rivet holes required for trim balancing are not occupied during detail balancing.

CAUTION: HP TURBINE BLADES MUST BE HANDLED AS FOLLOWS TO MINIMIZE THE POSSIBILITY OF FAILURES OCCURRING IN SERVICE. (3)

Before inspecting the turbine disk assembly, review the HP turbine blade service bulletin standard to determine if deblading is required. This entails returning the disk assembly to a suitably equipped facility for the disk assembly to be balanced. (a)

Blades. 1

Blades with part number 3115601-01 have an initial cyclic limit (Ref. 05-20-00) with an abbreviated cycle factor of 1 and a flight count factor of 1.0. The blades must be handled as follows:


Page 625 Nov 04/2005


DIA.

A

JACKING INSERT

SECTION

A−A

C21680 Cooling Air Nozzle Housing Assembly - Inspection Figure 611


Page 626 Nov 04/2005


2

If the disk is not debladed, inspect using the inspection criteria specified in step (4) (e).

3

If the disk is debladed, clean and inspect in accordance with the CIR Manual instructions, with the exception of the heat tint inspection which may be omitted.

4

Initial cyclic limit for HP turbine blades (Ref. 05-20-00) may be increased by up to 750 cycles based on sampling of individual operator’s blades. Operators wishing to escalate their limit should contact their local P&WC Field Service Representative or PW100 Technical Support Representative, who will coordinate the evaluation of the blades and provide a recommendation to escalate, if acceptable (Ref. NOTES 1, 2, 3, 4).

5

If cracks are found, evaluate blades per CIR Manual inspection criteria and handle the blades accordingly. Blades or blade sets having fixing-serration cracks exceeding CIR Manual limits must be returned to P&WC (Ref. NOTES 1, 2, 3).

6

Notify PW100 technical support immediately if blades are found with cracks below blade platform exceeding CIR Manual limits. NOTE: 1. Blades being returned to P&WC must clearly specify reason for return on documentation with returned blades, i.e., warranty claim, investigation only, etc. NOTE: 2. Include blade total time, blade total cycles, and engine serial number with returned blades. NOTE: 3. HP turbine blade samples returned for evaluation, must be within 500 cycles of the blade total cycle limit. NOTE: 4. Return blades, suitably protected, to: PRATT & WHITNEY CANADA CORP. 7007 de la Savanne St. Hubert, Quebec Canada J3Y 3X7 Att: Manager, Repair and Overhaul Shop Support

(4)

Inspect the HP turbine disk assembly as follows: (a) Loose balance weight rivets must be replaced. CAUTION: IF DISK ASSEMBLY IS DISASSEMBLED, BLADES, DISK AND FRONT AND REAR COVER PLATES MUST BE CHECKED FOR CRACKS IN ACCORDANCE WITH CIR MANUAL INSTRUCTIONS. (b) Inspect front and rear cover plates for damage or visual cracks. Return assembly to an overhaul facility if damage or cracks are observed.


Page 627 Nov 04/2005


(c) Inspect rear cover plate knife edge seal. Minimum diameter is 7.610 in. (193.290 mm). (d) Inspect bore of disk for recent (surface not oxidized) scores, nicks and dents. If unoxidized scores, nicks and dents are found, return disk to an overhaul facility for a full inspection. (e) Inspection criteria for installed HP turbine blades. If blades are not within the following acceptance criteria (Ref. Fig. 612), return assembly to an overhaul facility. 1

Check blades for radial movement. If blades are tight, return assembly to an overhaul facility.

2

Inspect airfoil tip (Area j) for cracks which extend through thickness of material. Accept cracks up to 0.200 in. (5.080 mm) in length, provided the cracks are outside 1⁄3 blade chord length from trailing edge and are spaced as follows:

3

4

a

Converging cracks: 0.100 in. (2.54 mm) minimum apart.

b

Non-converging cracks: 0.025 in. (0.635 mm) minimum apart.

Inspect airfoil leading edge tip (Area f) for : a

Erosion with complete coating removal. Acceptable if within 0.050 in. (1.270 mm) of blade tip and wall thickness is no less than 0.020 in. (0.508 mm).

b

Nicks, burrs and raised material. Blend to remove sharp edges.

Inspect airfoil leading edge (Area d) for: NOTE: a

Area d extends 0.100 in. (2.54 mm) from airfoil leading edge.

Hairline cracks starting in Area m. Accept cracks up to 0.100 in. (2.54 mm). NOTE:

b

Area m starts 0.025 in. (0.635 mm) from tip of blade.

Erosion of coating exposing base material. Accept this damage, provided: v Coating loss covering less than 40% of leading edge surface or inferior to 0.350 inch in height, is acceptable. v Coating loss (Ref. Fig. 612, Sheet 2) is acceptable. However, borescope inspections must be done at intervals not to exceed 1500 flight hours, depending upon the rate of progression and level of deterioration seen (Ref. 72-00-00).


Page 628 Nov 04/2005


POCKET

LEADING EDGE

j m

d

b

e TRAILING EDGE

c

n 50% BLADE HEIGHT

PLATFORM

f

B

C33505B HP Turbine Blade - Inspection Figure 612 (Sheet 1 of 3)


Page 629 Nov 04/2005


COATING LOSS

TRAILING EDGE

LEADING EDGE

C100164 HP Turbine Blade - Inspection Figure 612 (Sheet 2)


Page 630 Nov 04/2005


TRAILING EDGE

EROSION, COATING LOSS OR BURNT MATERIAL

LEADING EDGE

NOTE:

THE ABOVE LEADING EDGE EROSION IS ACCEPTABLE FOR FURTHER SERVICE, REFER TO PARA 15.A.(4).(e).4.b FOR RECOMMENDED SERVICE ACTION.

C100165 HP Turbine Blade - Inspection Figure 612 (Sheet 3)


Page 631 Nov 04/2005


v Defects exceeding above, but not exceeding the acceptable defect shown (Ref. Fig. 612, Sheet 3) are acceptable for further service providing engine performance is within limits. A repeat borescope inspection and PAC must be done within 300 flight hours (Ref. 72-00-00). c 5

Nicks, dents and pits. One area of damage up to 0.005 in. (0.127 mm) deep is acceptable.

Inspect airfoil surface (Area b) for: v Nicks, dents and pits. Three areas of damage up to 0.003 in. (0.076 mm) deep are acceptable.

6

Inspect airfoil trailing edge (Area e) for: NOTE:

7

Area e extends 0.100 in. (2.54 mm) from airfoil trailing edge.

a

Cracks. If cracks are found, return assembly to an overhaul facility.

b

Nicks, dents and pits. A maximum of one area of damage up to 0.005 in. (0.127 mm) deep is acceptable.

Inspect airfoil root (Area c) for: v Nicks, dents or pits. One area of damage up to 0.005 in. (0.127 mm) deep is acceptable. NOTE:

(f)

Area c extends 0.100 in. (2.54 mm) from platform Surface n.

8

Inspect air holes. If holes are blocked, return assembly to an overhaul facility.

9

Erosion of coating without exposing base metal is acceptable.

Disk assemblies which give a minimum tip clearance of 0.023 in. (0.584 mm) are acceptable, providing associated shroud rubs do not extend circumferentially over more than one and a half shrouds (two locations).

(g) Clean up tips if blade rub has occurred. If necessary, replace and grind shrouds to restore tip clearance. 16.

Interstage Air Seal Assembly A.

General Inspection (Ref. Fig. 613) (1)

Visually inspect Dia. A and C as follows: (a) Check for rubbing marks and/or wear; reject seal if clearance with associated LP stator is not within limits (F & C REF. NO. 1107). (b) Check for nicks, burrs or raised material; blend to remove sharp edges.


Page 632 Nov 04/2005


A

a

A

a

DIA

A DIA

SECTION

C

AA

C31443A Interstage Air Seal Assembly - Inspection Figure 613


Page 633 Nov 04/2005


(2)

Visually inspect all other surfaces for dents, nicks, scores or scratches. Damage up to 0.002 in. (0.05 mm) deep is acceptable; damage from 0.002 to 0.005 in. (0.05-0.12 mm) deep may be blended to a maximum depth of 0.005 in. (0.12 mm).

(3)

Visually inspect Area a as follows: (a) Check for any defects within 0.100 in. (2.54 mm) of hole (including ID of hole); If defects found, reject cover; no repair permitted. (b) Check for dents, nicks, scores or scratches on adjacent surface outside 0.100 in. (2.54 mm) boundary; blend to a maximum depth of 0.003 in. (0.07 mm).

17.

HP Turbine Shroud Segments A.

Inspection (1)

Inspect shroud segments and reject if any of the following defects exist: v Burnt material v Cracks v Irregular surface v Severe erosion, oxidization v Heavy rubbing NOTE:

18.

Shroud grinding is necessary to restore tip clearance if segments are replaced.

(2)

Cooling holes must be free from dirt or foreign material.

(3)

Blend and polish to remove sharp edges caused by metal pickup, taking care to remove the minimum amount of material, to ensure blade clearance is not affected.

LP Turbine Stator Assembly (Ref. Fig. 614) A.

Inspection (1)

Inspect stator outer shroud. The following cracks are acceptable: (a) Multiple non-converging hairline cracks less than 0.500 in. (12.70 mm) in length. (b) Up to five non-converging cracks, maximum 0.005 in. (0.127 mm) wide, which extend less than 20% of axial length. (c) Multiple non-converging cracks, less than 0.015 in. (0.381 mm) wide and 0.250 in. (6.350 mm) in length. (d) Up to five non-converging cracks, less than 0.015 in. (0.381 mm) wide and 0.250 to 0.500 in. (6.350-12.700 mm) in length.


Page 634 Nov 04/2005


OUTER SHROUD

INNER SHROUD

NON-ABRADABLE SEAL

C22023 Low Pressure Turbine Stator Assembly - Inspection Figure 614


Page 635 Nov 04/2005


(e) Cracks over 0.015 in. (0.381 mm) wide, cracks in sealing face or exceeding the above limits are unacceptable, and the stator must be rejected. (2)

Inspect stator inner shroud. The following cracks are acceptable: (a) Multiple non-converging cracks less than 0.015 in. (0.381 mm) wide and 0.250 in. (6.350 mm) in length. (b) Up to five non-converging cracks less than 0.015 in. (0.381 mm) wide extending part way or completely through inner shroud.

(3)

Inspect stator airfoils. The following defects are acceptable: (a) Airfoil leading edge. 1

Multiple hairline, non-converging cracks less than 0.500 in. (12.700 mm) in length.

(b) Airfoil trailing edge. 1

Multiple hairline, non-converging cracks less than 0.500 in. (12.700 mm) in length.

2

Up to 10 cracks per stator less than 0.015 in. (0.381 mm) wide and 0.250 in. (6.350 mm) in length.

(c) Airfoil surfaces.

19.

1

Coating loss on each airfoil must be less than 0.500 in. (12.700 mm) in diameter and the erosion of base metal not greater than 0.010 in. (0.254 mm) deep.

2

Dents and nicks up to 0.010 in. (0.254 mm) deep, providing any raised metal is removed.

(4)

Cracks exceeding the above limits are unacceptable and the stator must be rejected.

(5)

Inspect sealing ring grooves. Fretting is acceptable, providing width does not exceed 0.135 in. (3.429 mm). Distortion is not acceptable.

LP Stator Sealing Rings A.

Inspection (1)


(2)

Radial clearance, when sealing ring is installed with gap at TDC in turbine support case, must be less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference using feeler gage. If necessary, rotate ring until clearance is within limits. If clearance is beyond limits, even with a new sealing ring, replace the associated component.


Page 636 Nov 04/2005


(3) 20.

Check gap in sealing rings at 11.200 in. (284.480 mm) and 11.530 in. (292.862) gage diameters respectively (F & C REF. NO. 1378 and 1379).

LP Turbine Disk Assembly A.

Inspection NOTE:

(1)

Information covering position of trim balance rivets and weights shown on engine reference data plate must be supplied to overhaul/refurbishment facilities which refurbish or supply replacement turbine assemblies. The information will ensure rivet holes required for trim balancing are not occupied during detail balancing.

Circumferential and axial movement of blade tips is acceptable. Axial movement of blade platforms, found when pushing with fingers at blade root, is unacceptable, and assembly must be rejected. NOTE:

Repair re-riveting is required only at the location of the blade platform with axial movement.

CAUTION: UNDER NO CIRCUMSTANCES MUST BLADE PLATFORMS BE KNOCKED DOWN OR UP TO ACHIEVE CORRECT PROTRUSION. (2)

Inspect blade platforms to ensure they do not protrude more than 0.016 in. (0.406 mm) from disk surface (both sides of disk). Reject assembly if limit is exceeded.

(3)

The LP Turbine blades can continue in service, providing they meet the following criteria (Ref. Fig. 616): (a) area a (airfoil): a maximum of three nicks, dents or pits 0.003 in. (0.07 mm) deep maximum. (b) area b (leading edge): a maximum of one nick, dent or pit 0.005 in. (0.12 mm) deep maximum. NOTE:

Area b includes an area 0.100 in. (2.54 mm) wide from the leading edge.

(c) area c (trailing edge): a maximum of one nick, dent or pit 0.005 in. (0.12 mm) deep maximum. NOTE:

Area c includes an area 0.100 in. (2.54 mm) wide from the trailing edge.

(d) area d (root area): a maximum of one nick, dent or pit 0.005 in. (0.12 mm) deep maximum. NOTE:

Area d includes an area 0.100 in. (2.54 mm) wide from the platform surface.

(e) area e (leading edge tip): erosion up to a 0.025 in. (0.63 mm) tip radius.


Page 637 Nov 04/2005


(4)

Inspect blade retaining rivets. Reject assembly if rivets are loose.

(5)

Visually inspect disk for cracks. Reject assembly if cracks are found.

(6)

Inspect bore of disk for scores, nicks and dents. If damage is not oxidized, return disk to an overhaul facility for an inspection to be carried out in accordance with the instructions in the CIR Manual.

(7)

Inspect balance weight rivets. Replace loose rivets.

(8)

Inspect LP turbine blades. Reject assembly if blades have any of the following defects: v Burnt tips v Severe erosion of base metal v Severe oxidation v Corrosion of base metal (which appears as blisters) (Ref. Fig. 615) v Cracks

(9)

(10) 21.

Disk assemblies which give a minimum tip clearance of 0.022 in. (0.559 mm) are acceptable, providing the associated shroud rubs do not extend over more than one-and-a-half shrouds (two locations). Clean up tips if blade rub has occurred. If necessary, replace and grind shrouds to restore tip clearance.

LP Turbine Shroud Segments A.

Inspection (1)

Inspect shroud segments and reject if any of the following defects exists: v Burnt material v Cracks v Irregular surface v Severe erosion or oxidation v Heavy rubbing NOTE:

(2)

Shroud grinding is necessary to restore tip clearance if segments are replaced.

Blend and polish to remove sharp edges from metal pickup, taking care to remove the minimum amount of material, to ensure blade tip clearance is not affected.


Page 638 Nov 04/2005


ACCEPTABLE FOR SERVICE


REJECT

C26043 LP Turbine Blade - Inspection Figure 615


Page 639 Nov 04/2005


a TRAILING EDGE

LEADING EDGE

e

c 0.100 in. WIDE (2.54 mm)

A d

b DETAIL

0.100 in. (2.54 mm) WIDE

C C

VIEW

A

C71325 LP Turbine Blade Visual Inspection Figure 616


Page 640 Nov 04/2005


22.

LP Turbine Interstage Sealing Ring A.

23.

Inspection (1)

Radial clearance check done during disassembly when associated seal housing is in a constrained state.

(2)

Radial clearance, when sealing ring is installed in original position in seal housing, is less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over the remaining circumference. If clearance is beyond limits, even with a new sealing ring, replace seal housing.

(3)

Check gap in sealing ring at 11.860 in. (301.244 mm) gage diameter (F & C REF. NO. 1354).

(4)


Turbine Support Case (Ref. Fig. 617) A.

Inspection (1)

Inspect for nicks and dents. Stone to remove raised metal.

(2)

Inspect for cracks, paying close attention to Areas a and d: reject case if cracks are found (except in Area j).

(3)

Cracks in Area j are acceptable providing they are not less than 2.750 in. (69.85 mm) apart and the material is not burnt or buckled.

(4)

Replace loose shanknuts and those which have a rundown torque of less than 2 lb.in. (0.23 Nm).

(5)

Use a 0.500-20 UNJF-3B tap with thread lubricant to clean up the threads in the thermocouple bosses. Reject case if threads do not clean up. NOTE:

Experience has shown three different 0.500-20 UNJF-3B taps are used in the most effective cleaning procedure. The first pass is made with a worn tap, the second pass is made with a newer tap and the third is made with a brand new tap modified by the removal of the tapered end. This ensures the complete cleaning of the thread.

(6)

Power turbine stator lug slot width Dim. h must not exceed 0.266 in. (6.756 mm).

(7)

Inspect Dia. B, C and Dfor fretting and wear. Stone to remove raised metal.

(8)

Inspect for coating loss. Coating may be incomplete outside Area F. Coating loss within Area F is unacceptable.


Page 641 Nov 04/2005


THERMOCOUPLE BOSS

a

d VIEW

VIEW

B

E

A DIA.

DIA.

C

C

D

d WELD BEAD DIA.

B J h

VIEW

AREA

RADIAL CRACKS

A

F

VIEW

CIRCUMFERENTIAL CRACKS FOLLOWING WELD BEAD

E

0.025 IN. (0.635 mm)

0.025 IN. (0.635 mm)

AREA

COATED SURFACE

F 0.025 IN. (0.635 mm)

0.025 IN. (0.635 mm)

COATED SURFACE

SEAL RING (MARKED POSITION) VIEW

B

VIEW

C

SEAL RING (MARKED POSITION)

C18581C Turbine Support Case - Inspection Figure 617


Page 642 Nov 04/2005


24.

Thermocouple Adapters A.

Inspection (1)

Inspect for nicks and dents. Stone to remove raised metal.

(2)

Use a 0.375-24 UNJF-3B tap with thread lubricant to clean up the internal thread in the thermocouple adapters. Reject adapter if threads do not clean up. NOTE:

25.

Experience has shown three different 0.375-24 UNJF-3B taps are used in the most effective cleaning procedure. The first pass is made with a worn tap, the second pass is made with a newer tap and the third is made with a brand new tap. This ensures the complete cleaning of the thread.

Low Pressure Turbine Housing Assembly (Ref. Fig. 618) A.

Inspection (1)

Inspect the two sealing diameters (Area a) for: (a) Raised material. Blend to remove raised material only. (b) Dents, nicks, scores and scratches. Accept damage to a maximum depth of 0.003 in. (0.07 mm) deep. Reject if limit is exceeded.

(2)

Inspect Area b for: (a) Raised material. Blend to remove raised material only. (b) Dents, nicks, scores and scratches. Blend damage from 0.005 to 0.008 in. (0.13-0.20 mm) deep to a maximum depth of 0.010 in. (0.25 mm). Reject if limits are exceeded.

(3)

Inspect Face E and Area c for: (a) Raised material. Blend to remove raised material only. (b) Fretting or wear. Reject if damage exceeds 0.003 in. (0.07 mm) deep.

(4)

Inspect Area e for: (a) Cracks. Reject if found. Send housing to an approved overhaul facility for an inspection and repair to be carried out in accordance with CIR Manual criteria. NOTE:

(5)

Area e is found 0.100 in. (2.54 mm) downsteam of weld.

Inspect locating pin for: (a) Raised material. Blend to remove raised material only. (b) Looseness and wear. Replace if worn or loose.

(6)

Check to ensure air holes are unobstructed.


Page 643 Nov 04/2005


A

A

b

e FUSION WELD

x

c

a a

b SECTION

A−A C32954A

Low Pressure Turbine Seal Housing Assembly - Inspection Figure 618 (Sheet 1 of 2)


Page 644 Nov 04/2005


A

A

FACE

A FACE

DIA. DIA.

A−A

FACE

C

B

F AIR HOLES

DIA.

FACE

E

DIA.

DIA.

G SECTION

D

H

A−A

C38367 Low Pressure Turbine Seal Housing Assembly - Inspection Figure 618 (Sheet 2)


Page 645 Nov 04/2005


26.

(7)

Replace shanknuts.

(8)

Inspect for missing, loose, cracked or thread-damaged jacking inserts. Replace as required.

Turbine Interstage Case No. 6 and 7 Bearing Housing A.

Inspection (1)

Remove No. 6 and 7 bearing housing (Ref. 72-50-00, MAINTENANCE PRACTICES) to prevent contamination when corrosion is removed from the turbine interstage case outer flange.

(2)

Clean outer flange of turbine interstage case to remove corrosion (Ref. Cleaning/Painting).

(3)

Inspect outer flange. The following damage is acceptable: (a) Local surface damage on flange faces, providing: 1

Not more than six areas are affected (excluding areas of damage centered on bolt holes) .

2

Damage on one face is not directly opposite damage on other face.

3

Width of damage does not exceed 0.200 in. (5.08 mm) and depth does not exceed 0.010 in. (0.254 mm).

4

Width of damage (centered on bolt holes) does not exceed 0.100 in. (2.54 mm) measured from edge of hole and depth does not exceed 0.005 in. (0.127 mm).

(b) Local damage on snap diameters adjacent to flange is acceptable providing: 1

Not more than six areas are affected.

2

Width of damage does not exceed 0.200 in. (5.08 mm) and depth does not exceed 0.010 in. (0.254 mm).

(c) Elongation of bolt and jacking insert holes is acceptable 0.030 in. (0.762 mm) maximum. Maximum elongated bolt hole diameter 0.250 in. (6.35 mm) (Pre-SB21618) or 0.280 in. (7.11 mm) (Post-SB21618). Maximum jacking insert hole diameter 0.325 in. (8.25 mm). (d) Local thinning around holes 0.030 in. (0.762 mm) maximum. (e) Cracks running into flange holes are not permitted. (f)

Material missing from flange is not permitted.

(g) Turbine interstage cases with damage in excess of above limits must be replaced. Cases may be returned to P&WC for repair evaluation.


Page 646 Nov 04/2005


(4)

Inspect airfoils. The following defects are acceptable: (a) On leading and trailing edges, non-converging surface cracks up to 0.010 in. (0.254 mm) wide and 0.500 in. (12.700 mm) long maximum. (b) Nicks and dents up to 0.010 in. (0.254 mm) deep and 0.200 in. (5.080 mm) diameter maximum. Stone to remove raised metal.

27.

(5)

Inspect remaining surfaces for nicks and dents. Stone to remove raised metal.

(6)

Fretting wear of the sealing ring groove in turbine interstage case is acceptable, providing width of groove does not exceed 0.138 in. (3.505 mm). Stone to remove metal pickup.

(7)

Inspect for carbon buildup. Remove excess.

(8)

Inspect T6 thermocouple boss bores for fretting and wear which is acceptable up to 0.005 in. (0.127 mm) deep.

First-stage Power Turbine Stator A.

Inspection (1)

Inspect inner and outer shrouds. The following defects are acceptable: (a) Multiple, non-converging hairline cracks on both inner and outer shrouds. NOTE:

A mismatch not exceeding 0.010 in. (0.254 mm) is acceptable at the crack area.

(b) On outer shroud: individual, non-converging cracks, maximum 0.005 in. (0.127 mm) wide and not more than 80% of shroud axial length, providing no distortion exists. (c) On inner shroud: individual, non-converging cracks, maximum 0.040 in. (1.016 mm) wide and extending across full length of shroud providing there is no distortion. (2)

Inspect airfoils. The following defects are acceptable: (a) Leading and trailing edges: non-converging, multiple cracks, maximum 0.005 in. (0.127 mm) wide and 0.250 in. (6.350 mm) long. (b) Airfoil surfaces (including leading and trailing edges): maximum five nicks or dents per vane, not more than 0.005 in. (0.127 mm) deep and 0.100 in. (2.540 mm) diameter. Stone to remove sharp edges.

(3)

Inspect baffles: cracks up to 0.250 in. (6.350 mm) long on inner diameter are acceptable.

(4)

Inspect rivets for security and damage. Replace if loose or damaged.


Page 647 Nov 04/2005


28.

Power Turbine Stator Retaining Ring A.

Inspection (1)

Visually inspect retaining ring. Retaining rings split into segments due to cracks extending from the inner and outer diameters are acceptable providing: (a) The cracks pass through jacking insert holes (0.330 to 0.340 in. dia.) and not through retaining bolt holes (0.216 to 0.226 in. dia.) or the lug retaining slots. (b) There are a minimum of 4 bolt holes per segment (6 segments maximum) and a minimum of one bolt hole each side of lug retaining slots. (c) Segments are stoned to remove sharp edges and material liable to break off from the area which cracked.

(2) 29.

Power Turbine Stator Baffle Assembly A.

Inspection (1)

30.

Stone to remove sharp edges from nicks and dents.

Inspect for nicks, dents and scoring. Stone to remove raised metal.

Power Turbine Assembly A.

Inspection NOTE:

The power turbine assembly inspection criteria applies only to surfaces which are visible without disassembly.

(1)

Replace loose shanknuts and those which have a rundown torque of less than 2 lb.in. (0.23 Nm).

(2)

Inspect blades per Step (7).

(3)

First-stage power turbine blades are serialized and the serial numbers of the blades must be recorded in the engine log book.

(4)

When fractured blade(s) are found, inspect the following components to determine if the vibration produced by the blade(s) was sufficient to cause secondary damage requiring return of the engine to an overhaul facility. (a) Inspect the labyrinth air seals in and adjacent to the No. 6 and 7 bearing housing for excessive clearance (Ref. 72-03-00, F & C REF. NOS. 1123, 1124, 1133, 1299 and 1300). (b) Visually inspect No. 6 and 7 bearing housing for signs of damage (Ref. Para. 26.). (c) Inspect second-stage power turbine stator inner diameter for signs of rubbing with the first-stage power turbine blade platform (Ref. Para. 31.).


Page 648 Nov 04/2005


(d) Inspect No. 6 and 7 bearing transfer tubes for damage and signs of oil leaks (Ref. Para. 37.). (e) Borescope inspect LP and HP impellers (Ref. 72-00-00). (f)

Borescope inspect LP and HP turbine blades (Ref. 72-00-00).

(g) Inspect power turbine stator for excessive tip rub (not secondary damage from the fractured blade(s)) with the first and second-stage power turbine blades. (h) Inspect for signs of rubbing between the low pressure and power turbine shafts. (5)

If the results of the inspections called up in step (4) are satisfactory, inspect turbine support case for impact damage, replace case if necessary. Replace No. 7 bearing, first-stage power turbine stator bolts and power turbine rotor balancing assembly, then return engine to service.

(6)

If results of the inspections called up in step (4) are not satisfactory, return engine to an overhaul facility for an inspection to be carried out in accordance with CIR Manual instructions.

(7)

Inspect power turbine blades: (a) Inspect airfoil surface for FOD. Minor surface irregularities in the form of up to (3) nicks and dents not exceeding a depth of 0.005 in. (0.127 mm) and at least 0.100 in. (2.54 mm) apart are acceptable. Damage must not protrude more than 0.005 in. (0.127 mm) above airfoil surface and must not have any indication of cracking. Ensure damage on one side of airfoil is not directly opposite to damage on the other side. Stone to remove sharp edges from nicks and dents. (b) Using a 10X power magnifying glass, inspect for cracks on airfoil, including fillet radii. If cracks are found, return assembly to an overhaul shop for full inspection. Cracked blades should be handled as follows: 1

If any blade is found cracked due to impact and/or FOD, return power turbine assembly to an overhaul facility for replacement of only the cracked blade(s).

2

If it is evident that the crack(s) are not associated with any impact and/or FOD, return power turbine assembly to an overhaul facility for replacement of the complete set of blades.

(c) Check blade tip clearance (F & C REF. NO. 1177 and 1346). NOTE:



Page 649 Nov 04/2005


CAUTION: UNDER NO CIRCUMSTANCES MUST BLADE PLATFORMS BE KNOCKED DOWN TO ACHIEVE CORRECT PROTRUSION. (d) Tip clearance requirements clarified. Inspect blade fir-tree face to ensure blade platforms do not protrude more than 0.016 in. (0.406 mm) from disk surface. Reject assembly if limit exceeded. (e) Inspect blade retaining rivets. Reject assembly if rivets are loose or heads are cracked. (f)

Circumferential and axial movement of blade tips is acceptable. Axial movement of blade platforms, found when pushing with fingers at blade root, is unacceptable, and assembly must be rejected. NOTE:

Repair re-riveting is required only at the location of the blade platform with axial movement.

(g) Using a 10X power magnifying glass, visually inspect the first- and second-stage power turbine blade surfaces for sulphidation (Ref. Fig. 619). Reject assembly if blistering is found.

31.

(8)

Inspect for nicks and dents on remaining components. Stone to remove raised metal.

(9)

Fretting wear of sealing ring groove in stator assembly is acceptable, providing width of groove does not exceed 0.119 in. (3.022 mm) and step wear on faces is not more than 0.003 in (0.076 mm) deep.

(10)

Check Rad. A for cracks (Ref. Fig. 620). Reject power turbine assembly if cracks are found.

(11)

Inspect stubshaft bore. Stone to remove raised metal.

Second-stage Power Turbine Stator A.

Inspection (Ref. Fig. 621) (1)

Inspect inner and outer shrouds. The following defects are acceptable: (a) Multiple, non-converging hairline cracks on both inner and outer shrouds. (b) Inner shroud: 1

No open cracks allowed in area ‘‘B’’

2

One crack, maximum 0.040 in. (1.016 mm) wide and extending across full length of shroud for each section of area ‘‘A’’, is acceptable if there is no distortion. NOTE:

(2)

A mismatch not exceeding 0.010 in. (0.254 mm) is acceptable at the crack area.

Inspect airfoils. The following defects are acceptable:


Page 650 Nov 04/2005




REJECT

C18578C First- and Second-stage Power Turbine Blades - Inspection Figure 619


Page 651 Nov 04/2005


A

C18770 Power Turbine Stator - Crack Check Figure 620


Page 652 Nov 04/2005


(a) Leading and trailing edges: non-converging, multiple cracks, maximum 0.005 in. (0.127 mm) wide and 0.250 in. (6.350 mm) long. (b) Airfoil surfaces (including leading and trailing edges): maximum five nicks or dents per vane, not more than 0.005 in. (0.127 mm) deep and 0.100 in. (2.540 mm) diameter. Stone to remove sharp edges. 32.

Power Turbine Sealing Ring A.

33.

Inspection (1)


(2)

Check gap in sealing ring at 16.770 in. (425.958 mm) gage diameter (F & C REF. NO. 1353).

(3)

Radial clearance, when sealing ring is installed with gap at TDC in turbine support case, is less than 0.001 in. (0.025 mm) over at least 300 degrees and less than 0.002 in. (0.050 mm) over remaining circumference, using feeler gage. If necessary, rotate ring until clearance is within limits. Reject ring if correct clearance is unobtainable.

Turbine Exhaust Duct (Ref. Fig. 622) A.

Inspection (1)

Inspect for nicks, dents, scores, raised material and scratches. Stone to remove sharp edges to a maximum depth of 0.010 in. (0.254 mm).

(2)

Visually Inspect for cracks at Area a and rad b (leading and trailing edge), cracks up a maximum depth of 0.060 in. (1.524 mm) are acceptable and maybe blended, maintaining a minimum blend radius at 0.150 in. (3.810 mm) . NOTE:

(3) 34.

If limits are exceeded, return to an approved Overhaul Facility for weld-repair.

Inspect fuel drain hole at bottom of duct for obstruction. Clear as required.

Power Turbine Shaft (Ref. Fig. 623) A.

Inspection (1)

Inspect shaft seal, bearing and turbine seating diameters (Areas a, b, c and d): (a) Nicks and/or dents not exceeding 0.010 in. (0.254 mm) deep by 0.040 in. (1.016 mm) wide and at least 0.050 in. (1.270 mm) apart must be blended to remove sharp edges and polished to restore surface smoothness. (b) Axial scores (except in Area d) less than 0.005 in. (0.127 mm) deep by 0.010 in. (0.254 mm) wide and at least 0.100 in. (2.540 mm) apart are acceptable. Stone to remove raised metal.


Page 653 Nov 04/2005


USE THESE LUGS FOR ANGULAR REFERENCE TOP DEAD CENTER

B A

A

B

B

A

INSPECT EVERY AREA B ON INNER SHROUD

A

B

B

A

A

PERMISSIBLE CRACK IN AREA A ON INNER SHROUD

B 0.040 IN. MAX

0.010 IN. MAX

C103871 Second- stage PT Stator Inspection Figure 621


Page 654 Nov 04/2005


AREA

Z A

a

a

TYPICAL CRACK AREA

b

A

(TYPICAL)

PRE−SB20363 SECTION

A−A b

(TYPICAL)

a

a

TYPICAL CRACK AREA

POST−SB20363 SECTION

A−A

C31439B Turbine Exhaust Duct - Inspection Figure 622


Page 655 Nov 04/2005


A

A

a

d b 0.150 IN. (3.81 mm) SECTION

c

A-A

C18579A Power Turbine Shaft - Inspection Figure 623


Page 656 Nov 04/2005


(c) Area d: axial scores less than 0.005 in. (0.127 mm) deep are acceptable. Stone to remove raised metal. (d) Circumferential scores less than 0.005 in. (0.127 mm) deep and 0.010 in. (0.127 mm) wide and at least 0.100 in. (2.540 mm) apart are acceptable. (e) Corrosion pitting not exceeding 0.005 in. (0.127 mm) deep is acceptable. Stone to remove raised metal and polish to restore surface smoothness. (2)

35.

Spacers A.

Inspection (1)

36.

Inspection (1)

Inspect thermocouples and harness (Ref. 72-01-60, INSPECTION/CHECK).

No. 6 and 7 Bearing Pressure, Scavenge and Vent Transfer Tubes A.

Inspection (1)

38.

Inspect for nicks and burrs. Stone to remove raised metal.

Thermocouples and Harness A.

37.

Inspect splines; nicks, burrs and/or galling not exceeding 0.005 in. (0.127 mm) deep is acceptable. Stone to remove raised metal and polish to restore surface smoothness.

Inspect for carbon buildup. Clean using carbon removal compound (Ref. 72-01-50, CLEANING/PAINTING).

Air Seals (Ref. Fits and Clearances and Fig. 626) A.

Inspection (1)

The clearances between sealing surfaces on the following air seals must be dimensionally checked to ensure clearances are within limits: (a) Low pressure turbine stator abradable seal and HP turbine rear air seal (F & C REF. NO. 1107). (b) Turbine interstage stator and rotor air seal (F & C REF. NO. 1299). (c) High pressure turbine front cover and cooling air nozzle housing assembly (F & C REF. NO. 1091).

(2)

The clearances between No. 6 bearing rotor and No. 6 and 7 bearing housing air seal must be checked using a feeler gage to ensure clearance is within limits (F & C REF. NO. 1300).


Page 657 Nov 04/2005


39.

(3)

Inspect air seals covered by F & C REF. NO. 1108, 1123, 1124, 1133 and 1383 for condition. Use a stone to remove raised metal. Check clearance only if engine has high oil consumption.

(4)

If HP turbine stubshaft is removed and engine has high oil consumption, inspect air seal runners covered by F & C REF. NO. 1075, 1078, 1084, 1328, 1458, 1459 and 1460 for condition and complete seals for clearances. Stone to remove raised material.

Bearings A.

Inspection CAUTION: HANDLING OF BEARINGS MUST BE KEPT TO A MINIMUM. WEAR SYNTHETIC RUBBER OR NYLON MESH GLOVES WITH POLYETHYLENE PALMS AND FINGERS. WHEN RUBBER OR NYLON GLOVES ARE NOT AVAILABLE, COTTON GLOVES MAY BE WORN IF THEY ARE CHANGED FREQUENTLY TO ENSURE THE FABRIC DOES NOT BECOME IMPREGNATED WITH SWEAT. REFER TO 72-00-00, MAINTENANCE PRACTICES, FOR ADDITIONAL INFORMATION. (1)

Visually inspect bearings for scoring, spalling, pitting, galling, skidding and corrosion. Inspect in accordance with CIR Manual instructions if any of the defects listed are found. NOTE:

40.

The inner and outer races of No. 6 and 7 bearings may be replaced as sets only. This can be done without rebalancing.

HP and LP Turbine Disk Assembly Tip Clearances A.

Procedure NOTE:


(1)

If necessary, install HP turbine shroud segments (Ref. Approved Repairs).

(2)

Pre-SB21588: Align X-mark with dowel pin and install LP stator (3, Fig. 624) or holder (PWC38217) (7), ensuring lugs engage in shroud segment slots.

(3)

Install LP shroud segments and associated parts as follows: (a) Place seal housing (2) on bench. (b) Using teflon drift, install LP shroud segments (1) in housing (2) (Ref. Fig. 625) with No. 1 segment center slot aligned with hole on RH side of dowel and segments No. 2 through 14 installed clockwise; using feeler gages check gap between segments (F & C REF. NO. 1805). (c) Heat associated turbine support case flange area for 10 minutes minimum, then align dowel pin with hole and, using guide pins (0.190-32 UNJF-3A thread), install seal housing (2, Fig. 624), ensuring LP stator or holder lugs engage in slots.


Page 658 Nov 04/2005


(4)

Check HP turbine disk assembly tip clearance as follows: (a) Measure average HP turbine disk assembly outer diameter and runout using gage (PWC54020). NOTE:

Maximum runout: v Blade tips not ground, 0.004 in. (0.101 mm). v Blade tips ground, 0.003 in. (0.076 mm).

(b) Measure HP shroud segment internal diameter adjacent to joints (14 places) using an internal micrometer. NOTE: 1. If old segments incorporating curl have been retained, an average should be taken between the end and center of each segment when calculating shroud inner diameter. Ensure tip clearance is not below minimum value at joints (F & C REF. NO. 1092). NOTE: 2. Maximum runout: v Existing shroud not ground, 0.002 in. (0.050 mm). v Existing and new shroud ground, 0.001 in. (0.025 mm). Tip clearance =

average shroud ID - disk assembly average OD 2

(c) Replace and/or grind shrouds if clearance is outside limits (F & C REF. NO. 1092) or if runout of HP shroud segments is more than 0.002 in. (0.050 mm). (5)

Check LP turbine disk assembly tip clearance as follows: (a) Measure average LP turbine disk assembly outer diameter and runout using gage (PWC38487). NOTE:

Maximum runout: v Blade tips not ground, 0.002 in. (0.050 mm). v Blade tips ground, 0.001 in. (0.025 mm).

(b) Measure LP shroud segment internal diameter, adjacent to joints (14 places), using an internal micrometer. NOTE: 1. If old segments incorporating curl have been retained, an average should be taken between the end and center of each segment when calculating shroud inner diameter. Ensure tip clearance is not below minimum value at joints (F & C REF. NO. 1382). NOTE: 2. Maximum runout: v Existing shroud not ground, 0.002 in. (0.050 mm).


Page 659 Nov 04/2005


5


4 2 1

3

C27109 HP (Pre-SB21588) and LP Turbine Shrouds - Installation for Tip Clearance Check Figure 624


Page 660 Nov 04/2005


Key to Figure 624 1. 2. 3. 4. 5.

LP Turbine Shroud Segments LP Turbine Seal Housing LP Turbine Stator HP Turbine Shroud Segments (Pre-SB21588) Holder (PWC38217) (Pre-SB21588) v Existing and new shroud ground, 0.001 in. (0.025 mm). Tip clearance =

average shroud ID - disk assembly average OD 2

(c) Replace and/or grind shrouds if clearance is outside limits or if runout of LP shroud segments is more than 0.002 in. (0.050 mm). (6)

Remove bolts (1), seal housing (2) and LP shroud segments (3) using jackscrews (PWC32396).

(7)

(Pre-SB21588): Remove LP stator assembly (3) or holder (7).

(8)

Remove HP shroud segments (Ref. Approved Repairs). NOTE:

41.

Retain shroud segments in position if engine is to be reassembled.

First and Second-stage Power Turbine Assembly Blade Tip Clearance NOTE:

A.


Procedure (1)

Place power turbine disk balancing assembly on bench with first-stage power turbine on top.

(2)

Use shims or feeler gages set in four positions, 90 degrees apart, to centralize first-stage power turbine assembly in shroud.

(3)


(4)


(5)

Compare with the recommended tip clearance (F & C REF. NO. 1177).

(6)

Remove shims or feeler gages and invert power turbine disk assembly.

(7)

Use shims or feeler gages set in four positions, 90 degrees apart, to centralize second-stage power turbine assembly in shroud.


Page 661 Nov 04/2005


C11594 Installation of HP (Pre-SB21588) and LP Shroud Segments - Typical Figure 625


Page 662 Nov 04/2005


42.

(8)


(9)


(10)

Compare with the recommended tip clearance (F & C REF. NO. 1346).

(11)

Remove shims or feeler gages.

Fits and Clearances A.

General The following pages provide the fits and clearances (Table 601), torques (Table 602), spring pressure (Table 603), special assembly (Table 604), as applicable, to the repair, overhaul and assembly of various engine components. All tables have metric equivalents given in parentheses either beside or beneath the imperial measurements. For all tables, the indicated REF. NO. can be found in Figure 626. NOTE:

B.

Clearances are measured in ‘‘free-state’’ unless otherwise specified.

Terms and Symbols CAUTION: ALL FITS AND CLEARANCES ARE DIAMETRAL, UNLESS OTHERWISE SPECIFIED. The terms and symbols used in Fits, Clearances and Torque Loading tables are: (1)

REF. DIMENS. Column - This column lists, for reference only, the minimum and maximum manufacturing dimensions of two mating parts.

(2)

LIMITS Column - This column indicates the minimum and maximum fit or clearance between parts, and also the allowable limit to which these parts may wear before replacement is necessary. NOTE:

When the REPL Column is left blank, the MIN. or MAX. limits apply.

(3)

The symbol T indicates a tight fits. The symbol L or no letter after a fit denotes a loose fit.

(4)

The term BY SELECTION indicates that the parts must be chosen and matched to provide the correct fit.

(5)

The expression FIT TO is used when an operation may be required as assembly to obtain the required fit.

(6)

An asterisk (*) in the replace column indicates that parts should be replaced if any looseness is found.

(7)

The number symbol (#) indicates that parts should be replaced when scuffing, pitting, galling or excessive wear has taken place.


Page 663 Nov 04/2005


(8)

Spline fits are calculated from chordal dimensions; unless otherwise specified. all other fits are diametrical. TABLE 601, Fits and Clearances

REF. NO. 1075

Dim. for Ref. inches (mm) Name Shaft, Stub, High Pressure Turbine (Pre-SB21683) Cover Assy, No. 5 Bearing

1075

Shaft, Stub, High Pressure Turbine (Post-SB21683) Cover Assy, No. 5 Bearing

1078

Shaft, Stub, High Pressure Turbine (Pre-SB21683) Cover Assy, No. 5 Bearing

1078

Shaft, Stub, High Pressure Turbine (Post-SB21683) Cover Assy, No. 5 Bearing

1079

Impeller - Centrifugal Shaft, Stub, High Pressure Turbine

1080

Impeller - Centrifugal Shaft, Stub, High Pressure Turbine

Min.

Max.

Limits inches (mm) Min.

Max.

Replace

0.022 0.027 (0.559) (0.686) Diametral Clearance





0.0065T 0.005T (0.165T) (0.127T)


Page 664 Nov 04/2005


TABLE 601, Fits and Clearances (Cont’d)

REF. NO. 1084

Dim. for Ref. inches (mm) Name Shaft - Stub, High Pressure Turbine (Pre-SB21683) Housing - Support, Inner Front, Vane Ring, Assy of

1084

Shaft - Stub, High Pressure Turbine (Post-SB21683) Housing - Support, Inner Front, Vane Ring, Assy of

1087

Disk - High Pressure Turbine Shaft, Stub, High Pressure Turbine (Pre-SB21683)

1087

Disk - High Pressure Turbine Shaft, Stub, High Pressure Turbine (Post-SB21683)

1091

Cover, High Pressure Turbine, Front Housing Assy, Cooling Air Nozzle

1092

Balancing Assy - High Pressure Turbine Shroud Segment High Pressure Turbine (Fit to) (After shroud grinding)

Min.

Max.


Max.

Replace



0.0060T 0.0047T (0.152T) (0.119T)

0.0044T 0.0031T (0.112T) (0.079T)


0.026 0.028 (0.660) (0.711) Radial Clearance Cold


Page 665 Nov 04/2005


TABLE 601, Fits and Clearances (Cont’d) Dim. for Ref. inches (mm)

REF. NO.

Name

1107

Seal - Air Interstage Seal - Turbine Interstage

1108

Disk - Turbine, Low Pressure Housing - Seal, Turbine Interstage

1123

Seal - Labyrinth, Assy of Nut - No. 6 Bearing Rotor

1124

Seal - Labyrinth, Assy of Nut - No. 6 Bearing Rotor

1133

Seal - Air, Power Turbine Rotor Housing - No. 6 & 7 Bearing, Assy of

1177

Power Turbine Stator Assy Disk Balancing Assy Second-stage Power Turbine

1247

Rotor Balancing Assy HP Housing - Nozzle, Cooling Air, Assy of

Min.

Max.


Max.

Replace






0.016 0.019 (0.406) (0.483) Radial Clearance

0.110 0.120 (2.794) (3.048) Axial Dimension


Page 666 Nov 04/2005



REF. NO. 1299

Dim. for Ref. inches (mm) Name Seal - Air, Turbine Interstage, Stator Seal - Air, Turbine Interstage, Rotor

1300

Seal - Air, No. 6 Bearing Rotor Seal - Air, No. 6 Bearing Housing

1328

Shaft, Stub, High Pressure Turbine (Pre-SB21683) Housing, Support, Inner Front, Vane Ring

1328

Shaft, Stub, High Pressure Turbine (Post-SB21683) Housing, Support, Inner Front, Vane Ring

1330

Baffle, Power Turbine Stator Case, Turbine Support

1346

Power Turbine Stator Assy Disk Balancing Assy First-stage Power Turbine

1353

Seal Ring - Metal Gap at 16.622 in. (422.199 mm) Gage Diameter

Min.

Max.


Max.

Replace





0.002T 0.006T (0.050) (0.152)


0.210 0.246 (5.334) (6.248)


Page 667 Nov 04/2005



REF. NO. 1354

1355

Dim. for Ref. inches (mm) Name Seal Ring - Metal Gap at 11.860 in. (301.244 mm) Gage Diameter Rotor Balancing Assy LP Vane Ring - LP Turbine

1361

Duct, Combustion Chamber, Exit, Small Housing, Support, Outer, Front Vane Ring

1365

1368

Seal Ring - Metal Gap at 11.200 in. (284.480 mm) Gage Diameter Shaft, PT Assy Nut, No. 6 Bearing Rotor

1378

1379

1381

Min.

Max.


Max.

0.135 0.196 (3.429) (4.978)

0.079 0.089 (2.006) (2.261) Axial Dimension

0.009 0.016 (2.229) (0.406) Gap

0.155 0.200 (2.667) (5.080)

0.425 0.435 (10.795) (11.049) Axial Dimension


0.155 0.200 (3.397) (5.080)


0.175 0.220 (4.445) (5.588)

PT Disk Assy PT Stator Assy (Fit to)

Replace

0.015 0.025 (0.381) (0.635) Axial Dimension


Page 668 Nov 04/2005



REF. NO. 1382

Dim. for Ref. inches (mm) Name

Min.

Balancing Assy - Low Pressure Turbine Shroud Segment - Low Pressure Turbine (Fit to) (After shroud grinding)

1383

Rotor Balancing Assy High Pressure Turbine Stator - Low Pressure (Axis X-X)

1383

Rotor Balancing Assy High Pressure Turbine Stator - Low Pressure (Axis Y-Y) NOTE:

1458

Seal, Air, Inner Front Vane Ring

Seal, Air, Inner Front Vane Ring Shaft, Stub, High Pressure Turbine (Post-SB21683)

1459

Min.

Max.

Replace

0.026 0.028 (0.660) (0.711) Radial Clearance Cold



Stator is ground concentric to give a radial clearance of 0.010 to 0.014 in. (0.254-0.356 mm). It is then ground 0.009 in. (0.229 mm) offset to give the 0.019 to 0.023 in. (0.483-0.584 mm) radial clearance at bottom of axis Y-Y.

Shaft, Stub, High Pressure Turbine (Pre-SB21683) 1458

Max.

Limits inches (mm)

Housing Assy, Inner Front Vane Ring Shaft, Stub, High Pressure Turbine (Pre-SB21683)





Page 669 Nov 04/2005



REF. NO. 1459

Dim. for Ref. inches (mm) Name

Min.

Max.

Housing Assy, Inner Front Vane Ring


Max.

Replace


Shaft, Stub, High Pressure Turbine (Pre-SB21683) 1460

Min.


Shaft, Stub, High Pressure Turbine (Post-SB21683) 1460

Limits inches (mm)



Shaft, Stub, High Pressure Turbine (Post-SB21683)

TABLE 602, Torque and Stretch Limits REF. NO. 1701

Name

Min.

Max.

Power Turbine Nut Retaining CAUTION: DO NOT USE IMPACT DRIVE. (1)

Apply torque using hand crank to slowly rotate input device to desired torque value.

(2)

Time-saving pneumatic or electric tools can be used as input devices when starting to apply torque, but the desired final torque value must be obtained using a hand crank.

(3)

Lubricate with engine oil (PWC03-001) bearing faces, diameters and threads of stacked components retained by nut.

(4)

Torque nut 1800 to 2000 lb.in. (203.37-225.97 Nm); untorque to 0 lb.in. (0.0 Nm).

(5)

Torque to 300 lb.in. (33.90 Nm) and apply sufficient torque to rotate nut between 13 and 17 degrees to lock it. Record torque.

(6)

Untorque and repeat step (5).


Page 670 Nov 04/2005


TABLE 602, Torque and Stretch (Cont’d) Limits REF. NO.

Name (7)

1706

Min.

Max.

If new torque is more than that previously recorded, repeat step (5) until a lower torque within 10% of the former torque is achieved.

Low Turbine Disk Locknut CAUTION: DO NOT USE IMPACT DRIVE.

1707

(1)

Apply torque using hand crank to slowly rotate input device to desired torque value.

(2)


(3)

Torque to 3600 lb.in. (406.75 Nm) and untorque.

(4)

Torque to 300 lb.in. (33.90 Nm) and apply sufficient torque to rotate nut between 37 to 39 degrees further; record torque.

(5)

Untorque and repeat step (4).

(6)

If new torque reading is more than that previously recorded, repeat step (4) until a lower torque within 10% of the torque recorded in step (4) is achieved.

High Pressure Turbine Disk Bolts (1)

Assemble stubshaft and disk balancing assemblies to butt against flanges. Lubricate nut and bolt threads when tightening nuts, using engine oil (PWC03-001).

(2)

With nuts and bolts consecutively numbered from 1 to 5, tighten nuts to 180 to 190 lb.in. (20.34-21.47 Nm) in 50 lb.in. (5.65 Nm) increments and in following sequence: 1, 3, 5, 2, 4.

(3)

To ensure components are at room temperature, allow assembly to stabilize for 20 minutes minimum.

(4)

Tighten nuts to 250 to 260 lb.in. (28.25-29.38 Nm) in the following sequence: 1, 3, 5, 2, 4.

(5)

Replace one used nut at a time with a new nut which is torqued as follows: Measure rundown torque (torque required to drive nut on bolt just before it contacts flange). To be usable, a nut must have a minimum rundown torque of 10 lb.in. (1.13 Nm). To this rundown torque, add 25 lb.in. (2.82 Nm) to obtain a seating torque. Seating Torque = Rundown Torque + 25 lb.in. (2.82 Nm) Seat nut, using the seating torque.


Page 671 Nov 04/2005



Name

Min.

Max.

To the rundown torque, add 250 to 260 lb.in. (28.25-29.38 Nm) to obtain final torque value. Final Torque = Rundown Torque + 250 to 260 lb.in. (28.25-29.38 Nm) CAUTION: REMOVE STUBSHAFT AND REPLACE BOLT WITH A BOLT HAVING THE SAME WEIGHT ±0.10 gm. IF NUT ROTATES MORE THAN 180 DEGREES WHEN APPLYING FINAL TORQUE. THE REPLACED BOLT IS UNSERVICEABLE AND MUST BE DISCARDED. (6) 1708

Torque nut using the final torque.

Nut - Locking (Stubshaft) CAUTION: DO NOT USE IMPACT DRIVE. (1)

Apply torque, using hand crank to slowly rotate input device to desired torque value.

(2)


(3)

For engine assembly prior to installing the stubshaft onto the shaft, heat the stubshaft 150 to 205°C (300-400°F).

(4)

Install pusher (PWC54281), cylinder (PWC32506) and hydraulic pump (PWC37807 ) to seat stubshaft, using a hydraulic pressure of 4700 to 5100 psig (axial load 13000 to 14000 lb.) (5896-6350 kg). Release load when stubshaft is at room temperature. Remove tools.

CAUTION: DO NOT LUBRICATE WITH ENGINE OIL. (5)

Pre-SB21518: Lubricate threads and contact face of stubshaft retaining nut with anti-seize compound (PWC06-009). Install retaining nut fingertight.

CAUTION: DO NOT LUBRICATE WITH ENGINE OIL OR ANTI-SEIZE COMPOUND. (6)

Post-SB21518: Install retaining nut fingertight.

(7)

Using the engine nut apply a torque of 640 to 720 lbf.in. (72.31-81.35 Nm).

(8)

Using layout dye (PWC05-002), mark reference points in line with one another on nut and mating part.

(9)

Torque nut to turn an additional 46 to 48 degrees. Torque required should not exceed 6600 lbf.in. (745.8 Nm).


Page 672 Nov 04/2005



Name

Min.

(10)

Loosen to 0 lbf.in. (0.0 Nm) and repeat step (7).

(11)

If the nut reference point is in line with the mating reference point or beyond it within 3 degrees maximum, apply final angle of turn per step (9).

(12)

If reference points are not within limits, repeat steps (8), (9) and (10) in order until reference points are within limits; then perform step (11).

(13)

After torquing, remove excess anti-seize compound

Max.

TABLE 603, Spring Pressure Limits REF. NO.

Name

Min.

Max.

Not Applicable

TABLE 604, Special Assembly Limits REF. NO.

Name

Min.

Max.

1804

High Pressure Vane Ring Segments Gap

0.010 0.018 (0.254) (0.457)

1805

Low Pressure Shroud Segments Gap

0.013 0.017 (0.330) (0.432)

1806

High Pressure Shroud Segments Gap (Pre-SB21588/SB21652)

0.018 0.022 (0.457) (0.559)

1806

High Pressure Shroud Segments Gap (Post-SB21588/SB21652)

0.016 0.020 (0.406) (0.508)

2011

Dimension from retaining wires to edge of HP turbine shroud segments. (Post-SB21588/SB21652)

0.060 0.560 (1.52) (14.22)


Page 673 Nov 04/2005


TABLE 604, Special Assembly (Cont’d) Limits REF. NO.

Name NOTE:

2012

Min.

To be measured simultaneously at both ends of wire (4 places).

Protrusion of end of wires from turbine support case. (Post-SB21588/SB21652) NOTE:

Max.

-0.010 +0.030 (-0.025) (+0.76)

Wires may be cut to achieve this requirement (4 places)


Page 674 Nov 04/2005


1354

SECTION

1379

1378

1365

V−V

SECTION BM−BM

SECTION

BN−BN

SECTION

1353

1330

1346 1177

R

M

SECTION

1805 1382

1361

1092 1806

U

D V

1804

F

S−S

S

I

1383

T−T

BN BM

1381

T

L

S

1299

A−A

O BN BM

V

T

1133

T 1355

H 1708

1247

B

C

1075 1078 1079 1080 1084 1087 1328 1458 1459 1460

1104 1107 1106 1108 G 1485

1707 1091

E

S

1300

P

1706

J

1123 1124 1368

1701

N

K

Q C25850C Hot Section - Fits and Clearances Figure 626 (Sheet 1 of 12)


Page 675 Nov 04/2005


1804

HP VANE H.P. TURBINE STUBSHAFT LOCKING NUT 1708

HP VANE SECTION

COOLING AIR NOZZLE HOUSING

A−A

VIEW

Z

B

HP ROTOR BALANCING ASSEMBLY

1247 VIEW

Z

VIEW C

C18900C Hot Section - Fits and Clearances Figure 626 (Sheet 2)


Page 676 Nov 04/2005


X H.P. TURBINE SHROUD SEGMENT

RADIAL CLEARANCE

C

WITNESS OF THIS DIA. MUST BE EVIDENT AFTER GRINDING

Y

X

VIEW

Y 1806

H.P. TURBINE BALANCING ASSEMBLY

SECTION

X−X

D

VIEW D TIP CLEARANCE MUST BE OBTAINED BY FITTING AND GRINDING SHROUD SEGMENTS OF REQUIRED CLASSES

D POST−SB21588

2012

VIEW C WITH RETAINING WIRE INSTALLED AND BENT

H.P. TURBINE DISK BOLT

2011 1707

SCALLOP EDGE

1806 VIEW E

POST−SB21588 SECTION D−D SHOWING RETAINING WIRES INSTALLED AND BENT

C68720 Hot Section - Fits and Clearances Figure 626 (Sheet 3)


Page 677 Nov 04/2005


TDC Y

X

X

Y LOW−PRESSURE TURBINE STATOR NON−ABRADABLE SEAL RADIAL CLEARANCE AXIS 1383

LP TURBINE STATOR HP ROTOR BALANCING ASS’Y

A

1383 VIEW VIEW

F

A



Page 678 Nov 04/2005


1107

Y

1107

Z

HP TURBINE DISK

VIEW

Y

VIEW

Z

1108

VIEW

G



Page 679 Nov 04/2005


LP ROTOR BALANCING ASSY LP TURBINE VANE RING

1355

V

VIEW

VIEW

H

V

T LP TURBINE SHROUD SEGMENT

U

WITNESS OF THIS DIA. MUST BE EVIDENT AFTER GRINDING VIEW

U

T TIP CLEARANCE MUST BE OBTAINED BY FITTING AND GRINDING SHROUD SEGMENTS OF REQ’D CLASSES

LP TURBINE BALANCING ASSY

1805

1382 VIEW

I

SECTION

T−T



Page 680 Nov 04/2005


LP TURBINE DISK LOCKNUT

PT SHAFT ASSY 1368

NO.6 BEARING ROTOR NUT

1124 1123

1123, 1124, 1368

VIEW

K

1706 VIEW

J

S

VIEW

L

1381

VIEW

S

C31222A Hot Section - Fits and Clearances Figure 626 (Sheet 7)


Page 681 Nov 04/2005


RADIAL CLEARANCE

R

RADIAL CLEARANCE

R PT DISK BALANCING ASSY

PT STATOR 1346

1177 VIEW

M POWER TURBINE STATOR REQUIRES FREE MOVEMENT WITHIN TURBINE SUPPORT CASE

PT SHAFT (REF.)

PT RETAINING NUT

SECTION

1701 VIEW

R−R

N



Page 682 Nov 04/2005


PT DISK

RADIAL CLEARANCE

1299

VIEW

O

RADIAL CLEARANCE

NO. 6 BEARING

1300

VIEW

P



Page 683 Nov 04/2005


POWER TURBINE

NO.6 AND 7 BEARING HOUSING

1133

VIEW

T

1330 TURBINE SUPPORT CASE

P.T. STATOR BAFFLE ASSY. 1721 VIEW

R



Page 684 Nov 04/2005


COOLING AIR NOZZLE HOUSING ASSEMBLY

1091

VIEW

HP TURBINE FRONT COVER

S

COMBUSTION CHAMBER SMALL EXIT DUCT

OUTER VANE RING SUPPORT HOUSING

1361 VIEW

U C21681A

Hot Section - Fits and Clearances Figure 626 (Sheet 11)


Page 685 Nov 04/2005


1459 1328 1458 1460 1084 1078

1075

1087 H.P. TURBINE STUBSHAFT

1080

1079 VIEW

Q



Page 686 Nov 04/2005


TURBOMACHINERY - CLEANING/PAINTING 1.

General A.

This section provides instructions and information necessary for cleaning hot section gas path components.

B.

Unless otherwise stated, clean hot section gas path components with petroleum solvent (PWC11-027) or cleaner (PWC11-031).

WARNING:

NOTE:

2.

REFER TO MANUFACTURER’S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS INFORMATION SUCH AS: HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES. Tergit (PWC11-031) and Magkleen 4 (PWC11-032) are recommended to be used as an alternative to petroleum solvent and trichloroethane respectively when the use of these products is restricted by local environmental and/or health legislation.


3.


Item No.

Name

PWC05-033 PWC05-075* PWC11-002 PWC11-004A PWC11-009 PWC11-010 PWC11-012 PWC11-014 PWC11-016 PWC11-018 PWC11-022 PWC11-025 PWC11-027 PWC11-031 PWC11-032

Grit, Abrasive, Aluminum Oxide Grit, Abrasive, Aluminum Oxide Trichloroethane 1,1,1 (Inhibited) Alkaline Cleaner (General Purpose) Alcohol, Ethyl, Denatured Alcohol, Methyl (Methanol) Acetone Alcohol, Isopropyl Perchlorethylene Alkaline Cleaner (General Purpose, Low Foam) Methyl-ethyl-ketone Solvent, Cleaner Solvent, Petroleum Cleaner, Engine Parts Solvent, Degreasing

Special Tools Not Applicable

72-03-00 TURBOMACHINERY - CLEANING/PAINTING

Page 701 Sep 03/99


4.

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Brush, Bristle, Non-metallic (soft)

5.

Hot Section Gas Path Components WARNING:

NOTE:

A.

REFER TO MANUFACTURER’S MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS INFORMATION SUCH AS: HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE, EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES.

Tergit (PWC11-031) and Magkleen 4 (PWC11-032) are recommended to be used as an alternative to petroleum solvent and trichloroethane respectively when the use of these products is restricted by local environmental and/or health legislation.

General (1)

Unless otherwise stated, clean hot section gas path components with petroleum solvent (PWC11-027) or cleaner (PWC11-031).

(2)

Vapor Degreasing


Page 702 Sep 03/99


WARNING:

PARTS SHOULD ENTER OR BE REMOVED FROM THE DEGREASER AT A VERTICAL SPEED OF 15 FEET PER MINUTE MAXIMUM. LOADED BASKETS AND LARGE PARTS ENTERING THE DEGREASER AT A FASTER RATE ACT AS A PISTON FORCING VAPOR FROM THE DEGREASER. WHEN WORK IS REMOVED TOO RAPIDLY, MUCH OF THE VAPOR WILL BE PULLED OUT. THIS WASTES SOLVENT, INCREASES DEGREASING TIME, AND CREATES A HEALTH HAZARD.

WARNING:

SOLVENT SHOULD NEVER BE REMOVED FROM A DEGREASER.

CAUTION: THE DEGREASER SHOULD BE OPERATED SO AS TO CREATE A MINIMUM DISTURBANCE OF THE VAPORS. CAUTION: IF EXCESSIVE LOADS ARE INTRODUCED INTO THE MACHINE, A DROP IN THE VAPOR LEVEL WILL RESULT. CONSEQUENTLY, AIR WILL BE SUCKED INTO THE MACHINE AND MIXED WITH SOLVENT VAPOR. WHEN THE VAPOR LINE IS GRADUALLY RESTORED, THESE MIXED VAPORS WILL BE FORCED OUT OF THE DEGREASER. CAUTION: DO NOT SUBMERGE COMPONENTS IN BOILING SOLVENT. CAUTION: THE CONDENSER WATER JACKET OF A VAPOR DEGREASER IS WHERE THE VAPOR LEVEL MUST BE MAINTAINED (NO WORK IN TANK). CAUTION: DO NOT USE MAGKLEEN 4 IN A VAPOR DEGREASER. (a) Lower into degreaser at 15 feet per minute maximum. The degreasing fluid must be one of the following: 1

Inhibited 1,1,1-trichloroethane (PWC11-002) maintained at 72 to 77°C (162-170°F).

2

Perchlorethylene (PWC11-016) maintained at 120 to 124°C (248-256°F). NOTE: 1. Parts must be suspended in the vapor in baskets, from hooks, or in nylon slings. Rope or canvas slings must not be used, as they become soaked with and carry out the solvent. NOTE: 2. Parts must be stacked in baskets or hung in slings in the position which affords the best drainage, so that solvent will not become entrapped and carried out of the degreaser. NOTE: 3. The differences in the solvents and their operating temperatures must be noted and considered at each degreasing operation.


Page 703 Sep 03/99


(b) Hold in vapor and spray, as required, with the nozzle well below the vapor level. NOTE:

The work must remain in the vapor until it has reached vapor temperature. When this occurs, condensation will cease. This provides a maximum of cleaning and assures rapid drying of the work as it passes from the vapor phase.

(c) Raise the part to drain. NOTE: 1. All work should be dry before it is removed from the degreaser. NOTE: 2. When degreaser is not in use: v Covers should be closed, whether machine is shut off or on stand-by. v Canvas degreaser covers should not be allowed to hang down into the degreaser. This acts as a wick and will drain the solvent. v Degreasers should be turned off if they will be inactive for a few hours, a holiday, or a weekend. B.

Turbine Interstage Case (1)

Pre-cleaning Methods (a) Vapor Degrease per Para. A.(2) (b) Solvent Wiping 1

Wipe part with a clean, white, lint-free, unsized cloth moistened with one of the following solvents: v Acetone (PWC11-012). v Methyl-ethyl-ketone (PWC11-022). v Isopropyl alcohol (PWC11-014). v Petroleum solvent (PWC11-027). v Denatured alcohol (PWC11-009). v Perchlorethylene (PWC11-016). v Trichloroethane 1,1,1-inhibited (PWC11-002). v Methyl alcohol (PWC11-010). v Solvent cleaner (PWC11-025). v Engine parts cleaner (PWC11-031). v Degreasing solvent (PWC11-032).

2

Air dry.


Page 704 Sep 03/99


(c) Solvent Immersion or Spray 1

Immerse or spray parts with one of the following solvents: v Petroleum solvent (PWC11-027). v Denatured alcohol (PWC11-009). v Perchlorethylene (PWC11-016). v Trichloroethane 1,1,1-inhibited (PWC11-002). v Methyl alcohol (PWC11-010). v Engine parts cleaner (PWC11-031) v Degreasing solvent (PWC11-032)

2

Rinse with clean solvent, if required.

3

Air dry.

(d) Alkaline Immersion or Spray Cleaning 1

Do either of the following: a

Immersion in Tank Put the component fully in a tank of alkaline cleaner (PWC11-004A) at 32 to 66°C (90-150°F) for 5 to 30 minutes; or

b

Spray Wash Machine Spray component with alkaline cleaner (PWC11-004A) at 32 to 60°C (90-140°F). Use a 5- to 30-minute wash cycle.

2

If necessary, scrub component with a soft, non-metallic bristle brush.

3

Immerse part in warm water at 32 to 38°C (90-100°F).

4

Pressure-spray-rinse with warm or hot water at 32 to 93°C (90-200°F).

5

Immerse part in hot water at 66 to 93°C (150-200°F).

WARNING:

6

WHEN USING COMPRESSED AIR FOR DRYING, REGULATE PRESSURE TO 29 psig (200 kPa) OR LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES.

Blow dry with clean, low pressure compressed air.

(e) Alkaline-wipe Cleaning 1

Wipe part using clean, white, lint-free, unsized cloth moistened with alkaline cleaner (PWC11-004A) or (PWC11-018). NOTE:

Agitate solution before use.


Page 705 Sep 03/99


(2)

2

Rinse part with warm or hot water.

3

Air-dry.

Grit-blasting Outer Flange CAUTION: DO NOT DWELL IN ONE AREA FOR MORE THAN TWO SECONDS; USE CONTINUOUS MOTION. (a)

Blast outer flange and adjacent snap diameters with aluminum oxide grit (PWC05-033) or (PWC05-075*), as required, to remove corrosion. Maintain a 3- to 4-inch nozzle-to-part distance at a 45- to 60-degree angle to the work surface. NOTE: 1. For pressure-type machine use 25 to 30 psig (172-207 kPa). NOTE: 2. For suction-type machine use 50 to 60 psig (344-414 kPa).

WARNING:

(b)

WHEN USING COMPRESSED AIR FOR CLEANING, REGULATE PRESSURE TO 29 psig (200 kPa) OR LESS. WEAR GOGGLES OR FACE SHIELD TO PROTECT EYES.

Blow clean with clean, low pressure compressed air.


Page 706 Sep 03/99


TURBOMACHINERY - APPROVED REPAIRS 1.

General A.

This section provides instructions for repairing hot section gas path components.

B.

Parts heated or cooled before assembly must be at room temperature when final securing torque is applied.

C.

Special assembly instructions, torques and dimensional tolerances applicable to assembly are contained in Inspection/Check and identified in text by Fits and Clearances (F & C) reference numbers.

WARNING:

WEAR GOGGLES WHEN REMOVING LOCKWIRE AND DURING GRINDING OPERATIONS.

CAUTION: TO ENSURE COMPATIBILITY WITH ASSOCIATED SERVICEABLE COMPONENTS, NEW COMPONENTS MUST BE FULLY INTERCHANGEABLE WITH THOSE REPLACED. NOTE: 2.

Use engine oil (PWC03-001) to lubricate packings, threads and mating faces, unless stated otherwise.



Item No.

Name

PWC03-001 PWC04-001 PWC05-002 PWC05-068 PWC05-070 PWC05-089 PWC05-102 PWC05-253 PWC06-032 PWC11-027 PWC11-030 PWC11-031

Oil, Engine Grease Dye, Layout Masking Tape Tape, Pressure-sensitive Lockwire Dry Ice Plastic Masking Tape Compound, Anti-galling Solvent, Petroleum Thinner Cleaner, Engine Parts

72-03-00 TURBOMACHINERY - APPROVED REPAIRS

Page 801 Mar 09/2001


3.


Name

PWC31771-100 PWC31771-102 PWC32396 PWC32506 PWC37275 PWC37276 PWC37310 PWC37528 PWC37586 PWC37736 PWC37807 PWC37839 PWC37850 PWC37852 PWC37911 PWC37913 PWC37914 PWC37917 PWC37918 PWC37919 PWC37919-29 PWC37980 PWC37990 PWC37994 PWC38101 PWC38217 PWC38231 PWC38290 PWC38291 PWC38308 PWC38309 PWC38487 PWC38589 PWC54020 PWC56341 (Post-SB21588/ SB21652)

Spreader Spreader Jackscrews Cylinder Puller Drift Drift Grinding Wheel Grinding Fixture Plate Pump Grinding wheel Base Base Fixture Locator Support Dresser Grinder Fixture Pin (Component of PWC37919) Gage Adapter Adapter Fixture Holder Adapter Adapter Gage Assembly Pad Puller Gage Support Gage Gage, Shroud Segment Retaining Wire


Page 802 Mar 09/2001


4.

Tool No.

Name

PWC56365 (Post-SB21588/ SB21652) PWC56366 (Post-SB21588/ SB21652) PWC56367 (Post-SB21588/ SB21652)

Cutter, Shroud Segment Retaining Wire

Punch, Shroud Segment Retaining Wire

Lever, Shroud Segment Retaining Wire

Fixtures, Equipment and Supplier Tools The fixtures, equipment and supplier tools listed below are referred to in procedural text. Name Bolts, Slave (0.190-32 UNJF-3A × 0.625) Brush Feeler Gage Felt Pad Hammer, Ball Peen (2 lb.) Heat gun, Thermofit Minigun (with reflector) Micrometer (internal) Micrometer (external) Oven Pin, Guide (0.190-32 UNJF-3A thread) Shims, Brass, 0.010 in. (0.254 mm) Shims, Brass, 0.018 in. (0.457 mm) Wheel, Rotary, Scotchbrite or Equivalent

5.

Turbine Vane Rings A.

General (1)

Vane-ring classes are values which are proportional and have a relation to the mechanically measured throat area (sum of the dimensions of the individual vane openings) of vane-ring assemblies. The values measured by the air-flow test machines are different from the mechanically measured values in the class group because of the effects of the vane shape and its surface finish on the air flow.

(2)

The class group is only used for inventory purposes and for ordering vane rings from the parts catalog. The class group must not be used in place of the actual flow class when performing matching procedures.

(3)

Flow-class and operation identification markings are as follows:


Page 803 Mar 09/2001


(a) TC may be present, and indicates the class of tool used to manufacture the vane ring. This is only marked by the manufacturer on new vane rings. (b) CL followed by a four digit number indicates the flow class. (c) Class Group is a measured flow class, rounded-off to the tens unit and is shown beside the part number. This is only marked by the manufacturer when the vane-ring is new, and is used for inventory purposes. (d) RC indicates the initial raw flow class measured at manufacturing. (e) FC indicates the flow class after an air-flow test in which no class adjustment was done. This would be performed after a vane-ring has been removed from an engine and before any adjustments were made. (f)

R1, R2, etc. indicates the class after a flow-class adjustment rework and identifies each rework in numerical order.

(g) These markings are laid-out on the vane-ring outer shroud as follows (Ref. Fig. 801):

6.

RC

FC

R1

R2

CL1670

CL1662

CL1657

CL1631

Engine Rotor Speed Matching A.

Introduction (1)

Engine rotor speed matching is achieved through the selection of vane-ring flow areas. Altering the vane-ring flow area changes the temperature as well as the pressure ratio across the turbine, thus altering the rotor speed.

(2)

Matching is affected by the standard of modification from the incorporation of SB’s and by variation in parts due to the repair and re-use of worn parts with different assembly clearances.

(3)

Rotor speed is not only influenced by the vane-ring associated with the turbine driving the rotor, but also by the vane-ring located immediately downstream of the turbine. This is because the upstream vane-ring controls the velocity of the gas flow and the downstream vane-ring controls the back pressure.

(4)

If the impellers have been blend-repaired or have experienced erosion, some loss of compressor efficiency and an increase in rotational speed will result.


Page 804 Mar 09/2001


(5)

The recommended method for vane-ring matching procedure is to maintain a fixed minimum LP (A5) vane-ring area to avoid engine surging and to restore rotor speeds by increasing the HP (A4) vane-ring flow area to lower NH, and to decrease the 1st stage PT (A6) vane-ring flow area to lower NL. NOTE:

If an LP vane-ring (A5) with a flow-area lower than the minimum recommended (Ref. Table 801) is required to match the engine, contact Pratt & Whitney Canada, Technical Support.

(6)

A flow check to determine actual flow class of the vane ring is required as exact values allow for more accurate matching. This is true, even if installing the same vane rings as original build, since vane-ring flow areas can change during engine operation due to erosion and deterioration.

(7)

Use one of the following procedures when matching vane rings: (a) A vane-ring matching work sheet which is to be completed and faxed to P&WC, who will recommend new vane-ring flow areas. NOTE:

This procedure is temporary and is intended to support the facilities during the setting-up phase of HSI’s or overhaul until experience is gained.

(b) A table listing fixed flow areas based on build standards. The table is recommended to be followed because when changes made to the engine are so extensive, it is very difficult to calculate the compensation required to allow for engine deterioration and the incorporation of modifications, and there is an increased chance of significant error. (c) A detailed procedure which can be used to calculate required changes in vane-ring flow areas relative to previous build, and is based on dimensions and readings taken from the engine. NOTE:

B.

This method is accurate when minor changes are made to the engine (i.e., incorporation of service bulletins and changes requiring small variations in vane-flow areas). If major changes are incorporated, use method outlined in step (b).

Procedure (1)

Vane Class Matching Work Sheet (Ref. Fig. 802) (a) If required, complete the Vane Matching Work Sheet as detailed in Figure 802 and return it to Pratt & Whitney Canada.

(2)

Vane-ring Class Matching Table (Ref. Table 801) (a) The table can be used without further calculations to determine recommended vane-ring class matches. (b) The table can also be used to determine a vane-ring class match based on build-standard.


Page 805 Mar 09/2001


CLASS IDENTIFICATION LOCATION

B A

A

INITIAL FLOW−CLASS

SECTION

FLOW−CLASS AFTER AIR− FLOW−CLASS AFTER CLASS FLOW TEST ADJUSTMENT REWORK

A−A CLASS GROUP

ASSY 3049662 CL1500

RC CL1496

VIEW

FC CL1499

R1 CL1506

B C32951A

Typical Vane-ring Class Identification - LP Figure 801 (Sheet 1 of 2)


Page 806 Mar 09/2001


A

FLOW−CLASS AFTER AIR FLOW TEST FLOW−CLASS AFTER CLASS ADJUSTMENT REWORK

INITIAL FLOW CLASS

ASSY 3037053 RC CL2720 CL2716

FC CL2720

CLASS IDENTIFICATION MAY ALSO APPEAR IN THIS AREA

RI CL2726

CLASS GROUP VIEW

A

C32818B Typical Vane-ring Class Identification - LP Figure 801 (Sheet 2)


Page 807 Mar 09/2001


VANE MATCHING WORK−SHEET PW100 ENGINES THIS SHEET IS COMMON TO HSI AND OVERHAUL. FILL IN DATA AS APPLICABLE. AIRLINE / FACILITY:

NAME OF SENDER:

FAX NUMBER:

PHONE NUMBER:

ENGINE MODEL:

TSN / CSN:

ENGINE S/N:

TSO / CSO:

NO. OF HSI SINCE NEW OR LAST O/H:

TSHSI / CSHSI:

REASON FOR REMOVAL: ON WING ENGINE PERFORMANCE DATA ENGINE RUNNING PROCEDURE

TQ (%)

NH (%)

NL (%)

NP 1 (%)

ITT/T6 ( O C)

WF (PPH)

OAT ( O C)

PRESSURE ALTITUDE*

POWER ASSURANCE CHECK

PRIOR TO HSI

RECORD 2 PARAMETERS AT 80% TQ ** RECORD 2 PARAMETERS AT 70% TQ ** RECORD 2 PARAMETERS AT 60% TQ **

AFTER HSI

POWER ASSURANCE CHECK * INDICATE UNITS ** STABILIZE FOR 3 MINUTES BEFORE RECORDING PARAMETERS NOTE : 1 SELECT 100% NP, RECORD INDICATED NP 2 BLEED AIR OFF AND MINIMUM ACCESSORY LOAD

C33235B Vane-ring Matching Work Sheet Figure 802 (Sheet 1 of 2)


Page 808 Mar 09/2001


SHP (TQ)

NOTE:

LAST ENGINE TEST CELL PERFORMANCE AND BUILD DATA WF ITT* T6H* A4 A5 A6 NL* T6C* (UNTRIMMED) (TRIMMED) P3/P1 P2.5/P2 (PPH) CLASS AS FLOWED

NH*

IF NO TEST CELL RUN HAS BEEN PERFORMED SINCE NEW, GIVE ON WING PERFORMANCE DATA AT LAST HSI (AS APPLICABLE) TEST CELL ON WING

LP* HP* IMPELLER INDUCER CLEARANCE

HP TURBINE TIP DIA* CLEARANCE*

LP TURBINE TIP DIA* CLEARANCE*

1st. PT TIP CLEARANCE*

ORIGINAL ACTUAL * INDICATE UNITS

HP VANE FLOW CLASS CONDITION

VANES INTENDED FOR INSTALLATION 1st. PT VANE LP VANE FLOW CLASS FLOW CLASS CONDITION CONDITION

FOR CONDITION INDICATE: NEW / REPAIRED / USED

UPON COMPLETION, SEND COPIES TO: PW100 TECH SUPPORT, FAX NO. 450−647−2888 TURBOPROP PERFORMANCE B, FAX NO. 450−647−7461

ACTUAL INSTALLED

RECOMMENDED BY P&WC A4

A5

A6

A4

A5 CLASS AS FLOWED

INDICATE:

A6

N (NEW) R (REPAIRED) U (USED)

RETURN COPIES TO ABOVE SOURCES INDICATING ACTUAL VANE−AREAS INSTALLED SHEET 2 OF 2

C33190B Vane-ring Matching Work Sheet Figure 802 (Sheet 2)


Page 809 Mar 09/2001


TABLE 801, Recommended Turbine Vane Ring Flow Areas (Refer to engine log book to determine build standard) ENGINE BUILD STANDARD

HPT VANE AREA (A4) (SEE NOTE 1)

HPT VANE AREA PLUS 2.2% (A4) (SEE NOTE 2)

LPT VANE AREA (A5) (SEE NOTES 3 & 4)

1st STAGE PT VANE AREA (A6) (SEE NOTE 4)

BASIC ENGINE

8.10 in2 (±0.05)

8.28 in2 (±0.05)

15.00 in2 (±0.05)

34.65 in2 (±0.15)

BASIC ENGINE PLUS SB21588 SB21652

8.42 in2 (±0.05)

8.60 in2 (±0.05)

15.00 in2 (±0.05)

34.65 in2 (±0.15)

NOTE: 1. Applies to an overhauled engine where both impellers and both shroud housings are new. NOTE: 2. Applies to engines where one or both impellers were changed for new at last overhaul or shop visit. Flow area listed applies to first and subsequent HSI’s for the given build standard. NOTE: 3. LP turbine vane ring flow area for the various engine build standards must not be less than the values listed. NOTE: 4. Applies to all impeller conditions. (3)

Vane-ring Class Matching Calculation Procedure (a) This method starts with original build data and assumes that if engine is built with same components and clearances as were in original build, NH and NL will also remain the same. It then calculates changes in NH and NL due to hardware condition, incorporation of SB’s and changes in clearances and dimensions. This data is used to calculate recommended changes in vane-ring flow areas to bring NH and NL to mid-band of the acceptance performance limits. (b) An on-wing engine test is recommended to be carried out before HSI/overhaul. Typical engine performance deterioration is caused by loss in HP and LP turbine efficiency due to blade oxidation which causes an increase in tip clearance leading to increased T6/ITT. Decreased HP turbine efficiency results in less energy extracted from the gas stream, causing a lower NH. The LP turbine is less affected by oxidation so the efficiency loss is low. Since less energy is used by the HP turbine, more is available for the LP resulting in an unchanged or slightly higher NL. (c) If when comparing the on-wing engine test before HSI with the test at installation after previous shop visit, the engine trend of NH lower than original build and NL equal or higher has not occurred (NH is higher), contact Pratt & Whitney Canada, Technical Support, as hot section deterioration is not typical and a supplementary compressor deterioration compensation may have to be added.


Page 810 Mar 09/2001


(d) Figure 803 gives guidelines on the effect of clearance, dimensional, rotor speed and vane-ring flow area deviations on various engine parameters. In addition, the following component deterioration also affects rotor speeds: 1

Leaking HP vane seal rings, which have the effect of increasing the effective HP vane-ring flow area.

2

Leaks around the LP turbine housing seal face or seal rings, which have the effect of increasing the effective LP vane-ring flow area.

3

Leaking PT vane seal ring, which has the effect of decreasing the PT efficiency and increasing ITT/T6.

(e) The following terms are used in the text: 1

ORIGINAL: what was installed at last overhaul or HSI when a test-cell run was carried out and data was available.

2

ACTUAL: what is intended for installation at present build.

3

BUILD: overhaul or HSI where components, impellers or vanes may have been changed.

4

RTH: Root Theta (temperature correction coefficient) is used during test to obtain corrected NH and NL values which reflect the OAT: v CORRECTED NH = v CORRECTED NL = NOTE:

NH RTH NL RTH

Root theta is derived as follows: v Degrees Fahrenheit RTH =

Rankine OAT°F + 459 'OAT°519 =' 519

v Degrees Centigrade RTH = (f)

'OAT°288Kelvin = 'OAT°C288+ 273

For use as a baseline, determine the following: v ORIGINAL A4 :__________ v ORIGINAL A5 :__________ v ORIGINAL A6 :__________ v ORIGINAL NH/RTH :__________ v ORIGINAL NL/RTH :__________

(g) Determine required change in A4 due to changes in engine configuration and condition of HP and LP impellers to restore NH to original value, as follows:


Page 811 Mar 09/2001


EFFECT OF DEVIATION FROM NOMINAL DIMENSION ITT

DIMENSIONS

VARIATIONS

NL RPM

NH RPM

LP Impeller Inducer Clearance

+ 0.005 in (0.127 mm)

+ 100

+ 100

+

8° C (14.4 ° F)

+ 8

HP Impeller Inducer Clearance

+

--

+ 50

+

3° C (5.4 ° F)

+ 3

HP Tip Clearance

+

LP Tip Clearance PT Tip Clearance HP Turbine Diameter

0.005 in (0.127 mm)

0.005 in (0.127 mm) 0.005 in + (0.127 mm) 0.010 in + (0.254 mm) 0.032 in + (0.813 mm)

260

+

90

+ 130

+

+ 50

+ 50

+

--

--

LP Turbine Diameter

+

NL Speed

+ 100

+ 100

--

NH Speed

+ 100

--

+ 100

A4 (HP Vane)

+

1%

--

150

A5 (LP Vane)

+

1%

100

A6 (PT Vane)

+

1%

+ 100

0.032 in (0.813 mm)

50

+

150 + 80

+

WF (PPH)

11 ° C (19.8 ° F) 4° C (7.2° F) 2° C (3.6° F) 1° C (1.8° F) 2° C (3.6° F) 3° C (5.4° F) 1° C (1.8° F) 1° C (1.8° F)

+ 8 + 4 + 2 + 1 + 3 + 1 - 0.5 + 1

--

+ 150

--

3° C (5.4° F)

--

+ 1

These reactions are only supplied as a general guideline. If the reactions are not confirmed, it is most likely due to component condition.

C32952D Effects of Deviations in Dimensions Figure 803 (Sheet 1 of 2)


Page 812 Mar 09/2001


EFFECTS OF VANE AREA VARIATIONS VANE

VANE AREA

NH

A4 (HP VANE)

NL

P3 / P2.5

P2.5 / P2

NONE

−−

NONE

−−

A5 (LP VANE)

A6 (PT VANE)

NONE

−−

NONE

−−

ITT

WF

−−

−−

−−

−−

These reactions are only supplied as a general guideline. If the reactions are not confirmed, it is most likely due to component condition.

C32953A Effects of Deviations in Dimensions Figure 803 (Sheet 2)


Page 813 Mar 09/2001


1

Determine % change in original A4: NOTE:

If one impeller is used and one is new, impeller condition is considered to be used.

HP & LP IMPELLER CONDITION ORIGINAL NEW USED A4% change:

RECOMMENDED CHANGE IN ACTUAL USED USED

A4 +2.2% (Ref. Note) 0 -3.0%

NOTE: Valid for typical engine performance deterioration as described above. These values may have to be altered if deterioration is not typical. 2

Calculate required A4 to restore NH to original value as follows: a

ORIGINAL A4 + (ORIGINAL A4 x A4__________

A4% 100

change) = CORRECTED

(h) Determine the effect engine clearance has on the original NH and NL by comparing changes in dimensions with Figure 803: NOTE: 1

If data is not available from previous build (overhaul, HSI or when new), contact P&WC who will supply data from the initial (new) build.

Measure LP impeller inducer clearance as follows (Ref. Table 802): a

Go through air intake, with two feeler gages 180 degrees apart, and measure gaps between impeller and associated housing at engine centerline.

b

Average results and record as LP inducer clearance.

TABLE 802, Component Clearance and Effect on NL/NH CHANGE IN

ORIGINAL

ACTUAL

∆NL RPM

∆NH RPM

LP Impeller Inducer Clearance LPT Tip Clearance HPT Tip Clearance 1st Stage PT Tip Clearance


Page 814 Mar 09/2001


TABLE 802, Component Clearance and Effect on NL/NH (Cont’d) CHANGE IN

ORIGINAL

ACTUAL

∆NL RPM

∆NH RPM

HP Turbine Diameter LP Turbine Diameter Net Total Change in RPM: (i)

(j)

Using NH and NL from original engine test as a base, calculate new (expected) NH and NL for this build as follows: 1

NEW NH/RTH = ∆NH (Step (h)) + ORIGINAL NH/RTH (Step (f))

2

NEW NL/RTH = ∆NL (Step (h)) + ORIGINAL NL/RTH (Step (f))

Determine baseline for A4, A5, A6, NH, NL and Target NH/RTH and NL/RTH as follows: CORRECTED A4 (step (g))__________NEW NH/RTH (step (i))__________ TARGET NH/RTH__________ TARGET NL/RTH__________ NOTE: 1. NH limits are 97.3 to 99.1% (32400 to 33000 rpm). Target NH is 98.2% (32700 rpm). NOTE: 2. NL limits are 97.8 to 100.0% (27100 to 27700 rpm). Target NL is 98.9% (27650 rpm). NOTE: 3. For a higher NL, a lower T6/ITT is expected. If targeting for a higher NL than the mid-band and minimum possible T6, ensure NH/NL ratio is 1.182 Min. NOTE: 4. Use rpm when calculating the NH/NL ratio.

(k) Find A4 to achieve TARGET NH, using values in Step (j) as follows: (TARGET NH/RTH) - (NEW NH/RTH) = ∆NH:__________ RPM From Fig. 804, find required ∆A4% to effect ∆NH required......................... ∆A4:___________ % A4 required: (CORRECTED A4 + (CORRECTED A4 x A4:__________

∆A4%) 100 ))

= CALCULATED

MAXIMUM A4 obtainable (Ref. Note 2):__________


Page 815 Mar 09/2001


Use lowest flow area obtainable between CALCULATED A4 and MAXIMUM A4 as NEW A4:__________ ± 0.05 in2 NOTE: 1. If MAXIMUM A4 is lower than CALCULATED A4, A5 must be changed to adjust NH by performing Step (l). If CALCULATED A4 is lower than MAXIMUM A4, go directly to Step (m). NOTE: 2. MAXIMUM A4 obtainable is the flow area of the highest class HP vane segments sold by P&WC (Ref. Table 803). (l)

Calculate NEW A5 to adjust NH if A4 maximum flow-area was exceeded in Step (k) as follows: 1

CALCULATED A4:__________ MAXIMUM A4:__________ % Difference in A4:_____ =

2

CALCULATED A4 - MAXIMUM A4 CALCULATED A4

x 100

From Fig. 804, determine ∆RPM in NH from % difference in A4: ∆NH:__________ RPM

3

From Fig. 804, determine ∆A5% required to compensate for difference in ∆NH (Step 2): ∆A5:__________ %

4

New A5 required: (ORIGINAL A5 + (ORIGINAL A5 x in2 NOTE:

5

∆A5% 100 ))

= NEW A5:__________ ± 0.10

If NEW A5 is lower than minimum recommended A5 (Ref. Table 801), contact Pratt & Whitney Canada, Technical Support.

From Fig. 804, determine ∆RPM in NL from % change in A5 (Step 3): ∆NL:__________ RPM

6

Calculate new NL as follows: a

∆NL + NEW NL/RTH (Step (j)) =__________ CALCULATED NL/RTH

(m) Find A6 to achieve TARGET NL using values in Step (j) as follows: NOTE:

If Step (l) was performed, use CALCULATED NL/RTH in place of NEW NL/RTH.

1

(TARGET NL/RTH) - (NEW NL/RTH) = ∆NL:__________ RPM

2

From Fig. 804, find required ∆A6% to effect ∆NL required. ∆A6:__________ %

3

New A6 required:


Page 816 Mar 09/2001


NH SPEED

N H EFFECT FROM A 4

+600

− INDICATES N H REACTION FROM A 4 CHANGE.

+500

− ALL SPEEDS IN RPM’S. − A 4 = HP VANE.

+400 +300 +200 +100 +1

−4

−3

−2

+2

+3

+4

−1

% CHANGE IN VANE AREA

−100 −200 −300 −400 −500 −600

C31892 Vane-ring Matching - Rotor Speed Rate of Change vs. Vane Area Figure 804 (Sheet 1 of 4)


Page 817 Mar 09/2001


N H RATE OF CHANGE FROM A 5

+600

− INDICATES AMOUNT

NEEDED TO BE REMOVED TO OBTAIN REQUIRED SPEED

− ALL SPEEDS IN RPM − A 5 = LP VANE.

NH SPEED

+500

EXAMPLE IF: N H IS 300 RPM OVERSPEED USE −300

+400 +300 +200 +100 +1

−5

−4

−3

−2

+2

+3

+4

+5

−1


−100 −200 −300 −400 −500 −600

C31889 Vane-ring Matching - Rotor Speed Rate of Change vs. Vane Area Figure 804 (Sheet 2)


Page 818 Mar 09/2001


N L EFFECT FROM A 5

− INDICATES N L REACTION FROM A 5 CHANGE. TO CORRECT N H − ALL SPEEDS IN RPM’S. − A 5 = LP VANE.

+600

NL SPEED

+500 +400 +300 +200 +100 +1 −5

−4

−3

−2

+2

+3

+4

+5

−1


−100 −200 −300 −400 −500 −600



Page 819 Mar 09/2001


N L RATE OF CHANGE FROM A 6

+600

− INDICATES AMOUNT

NEEDED TO BE REMOVED TO OBTAIN REQUIRED SPEED

− ALL SPEEDS IN RPM’S. − A 6 = 1st PT VANE.

NL SPEED

+500

EXAMPLE IF: N L IS 300 RPM OVERSPEED USE −300

+400 +300 +200 +100 +1

−5

−4

−3

−2

−1 −100

+2

+3

+4

+5


−200 −300 −400 −500 −600



Page 820 Mar 09/2001


(CORRECTED A6 + (CORRECTED A6 x in2 (ORIGINAL A6 + (ORIGINAL A6 x

∆A6% 100 ))

∆A6% 100 ))

= NEW A6: _____ ± 0.15

= NEW A6: _____ ± 0.15 in2

(n) Select vane rings and flow-check as follows: 1

NEW A4 (HP Vane) required (Step (k)):__________ Actual as flowed:__________

2

NEW A5 (LP Vane) (Step (l)):__________ Actual as flowed:__________ NOTE:

3

If a new A5 was not calculated in Step (l), use value from ORIGINAL A5 (Step (g)).

NEW A6 (1st PT Vane) required (Step (m)):__________ Actual as flowed:__________

(o) Evaluate % difference in vane-ring flow areas to determine if NH and NL speeds are still within test acceptance limits, using values in Step (n): 1

New A4, A5, A6 a

NEW A4__________ Actual as flowed__________ % Change in A4__________ =

b

Actual as flowed - NEW A5 NEW A5

x 100


2

x 100


c



x 100

From Fig. 804, determine the effect the % change in vane-ring flow areas will have on NH and NL: ∆NH: (∆NH for % Change A4) + (∆NH for % Change A5) = __________ ∆RPM ∆NL: (∆NL for % Change A5) + (∆NL for % Change A6) = __________∆RPM

3

Determine if NH and NL are within limits (Ref. Step (j)): v TARGET NH/RTH (Step (j)) + ∆NH = __________RPM v TARGET NL/RTH (Step (j)) + ∆NL = __________RPM


Page 821 Mar 09/2001


4

Ensure NH/NL ratio is 1.182 Min. NOTE:

(4)

Use rpm when calculating the NH/NL ratio.

Vane-ring Class Re-matching After Test (If Required) (a) This procedure allows for more accurate calculation and adjustment of vane-ring flow classes if NL or NH are found to be outside limits during test. 1

Determine baseline for A4, A5, A6, NH, NL and target NH and NL: ACTUAL installed A4_____ ACTUAL NH/RTH_____TARGET NH/RTH_____ ACTUAL installed A6_____ ACTUAL NL/RTH_____TARGET NL/RTH_____ ACTUAL installed A5_____

2

Find A4 to adjust NH as follows: (TARGET NH/RTH) - (ACTUAL NH/RTH) = ∆NH:__________ RPM From Fig. 804, find required ∆A4% to effect ∆NH required........... ∆A4:__________ % A4 required is defined as: (ACTUAL A4 + (ACTUAL A4 x

∆A4 100 ))

= CALCULATED A4:__________

MAXIMUM A4 obtainable (Ref. Note 2):__________ Use lowest flow obtainable between CALCULATED A4 and MAXIMUM A4 as REQUIRED A4:__________ NOTE: 1. If MAXIMUM A4 is lower than CALCULATED A4, A5 must be changed to adjust NH by performing Step 3. If CALCULATED A4 is lower than MAXIMUM A4, go directly to Step 4. NOTE: 2. MAXIMUM A4 obtainable is the flow area of the highest class HP vane segments sold by P&WC (Ref. Table 803). 3

Determine the following: a

CALCULATED A4 (Step 2):__________ MAXIMUM A4:__________ % Difference in A4:_____ =

b

CALCULATED A4 - MAXIMUM A4 CALCULATED A4

x 100

From Fig. 804, determine ∆RPM in NH from % difference in A4: ∆NH:__________ RPM

c

From Fig. 804, determine ∆A5% to compensate for difference in ∆NH (Step b):


Page 822 Mar 09/2001


∆A5:__________ % d

New A5 required: (ACTUAL A5 + (ACTUAL A5 x NOTE:

e

∆A5% 100 )

= REQUIRED A5:__________

If REQUIRED A5 is lower than minimum recommended A5 (Ref. Table 801), contact Pratt & Whitney Canada, Technical Support.

From Fig. 804, determine ∆RPM in NL from % change in A5 (Step c): ∆NL:__________ RPM

f

Calculate new NL as follows: ∆NL + ACTUAL NL/RTH = __________ NEW NL/RTH

4

Find new A6 to compensate and adjust NL as follows: (TARGET NL/RTH) - (ACTUAL NL/RTH) = ∆NL:__________ RPM From Fig. 804, find required ∆A6% to effect ∆NL required........... ∆A6:___________ % New A6 required: (ACTUAL A6 + (ACTUAL A6 x in2 NOTE:

5

∆A6% 100 )

= REQUIRED A6:_________ ± 0.15

If Step 3 was performed, use NEW NL/RTH in place of ACTUAL NL/RTH (Step 1).

Select vane rings and flow-check as follows: REQUIRED A4 (HP Vane) (Step 2):__________ ACTUAL as flowed:__________ REQUIRED A5 (LP Vane) (Step 3):__________ ACTUAL as flowed:__________ REQUIRED A6 (1st PT Vane) (Step 4):__________ ACTUAL as flowed:__________ NOTE:

6

If a new A5 was not calculated in Step 3, use ACTUAL A5 installed (Step 1).

Evaluate % difference in vane-ring flow areas to determine if NH and NL speeds are still within test acceptance limits, using values in Step 5: a

Required A4, A5, A6 REQUIRED A4__________ Actual as flowed__________


Page 823 Mar 09/2001


% Change in A4_____ =

Actual as flowed - REQUIRED A4 REQUIRED A4

x 100

REQUIRED A5__________ Actual as flowed__________ % Change in A5_____ =


x 100

REQUIRED A6__________ Actual as flowed__________ % Change in A6_____ = b


x 100

From Fig. 804, determine the effect the % change in vane-ring flow areas will have on NH and NL: ∆NH: (∆NH for % Change A4) + (∆NH for % Change A5) =__________ ∆RPM ∆NL: (∆NL for % Change A5) + (∆NL for % Change A6) =__________ ∆RPM

c

Determine if NH and NL are within limits (Ref. step (j)). TARGET NH/RTH (Step (j)) + ∆NH =__________ RPM TARGET NL/RTH (Step (j)) + ∆NL =__________ RPM

d

Ensure NH/NL ratio is 1.182 Min. NOTE:

7.

Use rpm when calculating the NH/NL ratio.

Replacement of HP Turbine Vane Ring Segments A.

General (1)

If vane class combination, listed in Table 803, to give required flow area is not available, flow area can be produced using a different class combination. Use the following formula to define number and class of vanes required to produce specific flow areas.

(2)

Triple Segment Vanes VANE CLASS

FLOW AREA PER TRIPLE SEGMENT

0230 0265 0290 0310

0.941 0.987 1.046 1.106

(a) Vane classes may be combined to produce specific areas as follows: e.g., a flow area of 7.97 ± 0.05 is required using a mixture of class 0230, 0265 and 0290 vanes.


Page 824 Mar 09/2001


Class 0230..................2 x 0.941 = 1.882 Class 0265....................3 x 0.987 = 2.961 Class 0290....................3 x 1.046 = 3.138 Total flow area for 8 segments = 1.882 + 2.961 + 3.138 = 7.981 Various vane class combinations can be used to obtain same flow area using the above formula.


Page 825 Mar 09/2001


TABLE 803, High Pressure Turbine (Triple) SegmentVane Class Mix Required To Produce Specific Flow Areas CLASS

0230

0265

0290

0310

8

FLOW AREA 7.53

7

1

7.57

6

2

7.62

5

3

7.67

4

4

7.71

3

5

7.76

2

6

7.80

1

7

7.85

8

7.90

7

1

7.96

6

2

8.01

5

3

8.07

4

4

8.13

3

5

8.19

2

6

8.25

1

7

8.31

8

8.37

7

1

8.43

6

2

8.49

5

3

8.55

4

4

8.61

3

5

8.67

2

6

8.73

1

7

8.79

8

8.85


Page 826 Mar 09/2001


B.

Disassembly (1)

Using layout dye (PWC05-002), add an alignment mark to the cooling air nozzle housing opposite a vane ring segment airfoil trailing edge. Identify the segment as No. 1 and mark clockwise the remaining segments 2 to 8. NOTE:

C.

During normal engine running, combustion chamber exit temperature varies circumferentially. Vane ring segments located in high temperature zones of the gas stream deteriorate more rapidly than those located in low temperature zones. To maximize vane segment life, segments should be marked to identify the location before disassembly. At assembly, new segments are recommended to be installed in the locations where unrepairable segments were located. Repaired segments should be installed at locations where segments considered repairable were located.

(2)

Remove sealing ring (1, Fig. 805) and bolts (2).

(3)

Place assembly on base (PWC37850) and remove small exit duct (3), using a suitable drift.

(4)

Turn assembly over and, using a suitable drift, remove outer support housing (4), nozzle housing (5) and inner support housing (6).

(5)

Remove vane ring segments (7) and feather seals (8).

Assembly CAUTION: BEFORE ASSEMBLY, ENSURE NEW COMPONENTS ARE TO THE CORRECT SB STANDARD AND FULLY INTERCHANGEABLE WITH THOSE REPLACED. (1)

If required, freeze nozzle housing (5) to -40°C (-40°F) for 15 minutes minimum.

(2)

Install inner support housing (6) on base (PWC37852).

CAUTION: TO COMPENSATE FOR COLD END DETERIORATION AND COMPONENT CHANGES DUE TO INCORPORATION OF SERVICE BULLETINS, REVIEW VANE-RING FLOW AREA (REF. PARA. 6.). CAUTION: IDENTIFY REPLACEMENT SEGMENTS WITH SAME LOCATION NUMBER AS THOSE REPLACED AND INSTALL IN SAME POSITION. (3)

Install vane-ring segments (7) (No. 1 TDC and remaining 8 to 2 counterclockwise) and feather seals (8). NOTE:

(4)

Use grease (PWC04-001) to secure the last two seals in position.

Install nozzle housing (5), ensuring lugs on nozzle assembly are not aligned with lugs on inner support housing. Rotate vanes until airfoil trailing edge of vane marked No. 1 is opposite mark on cooling air nozzle housing. Install nozzle housing using a teflon drift.


Page 827 Mar 09/2001


7

8

2

3 6

5

4 1

C17592 HP Turbine Vane Ring Segments - Assembly/Disassembly Figure 805


Page 828 Mar 09/2001


Key to Figure 805 1. 2. 3. 4. 5. 6. 7. 8.

Sealing Ring Bolt Small Exit Duct Outer Support Housing Nozzle Housing Inner Support Housing Vane Ring Segments Feather Seals

(5)

Position vanes equidistant from one another and install outer support housing (4), aligning offset hole with one in nozzle housing.

(6)

Install 16 brass shims (0.010 in. (0.254 mm)) between inner and outer vane platforms to check minimum clearance (F & C REF. NO. 1804). Remove shims.

(7)

Install 16 brass shims (0.018 in. (0.457 mm)) between inner and outer platforms to check maximum clearance (F & C REF. NO. 1804). Remove shims.

(8)

Apply two turns of tape (PWC05-070) to outer edge of vane segments.

WARNING:

(9)

Remove tape and clean up surface, using solvent (PWC11-027) or cleaner (PWC11-031). NOTE:

(10)


Tergit (PWC11-031) is recommended to be used as an alternative to petroleum solvent when the use of this product is restricted by local environmental and/or health legislation.

Install nozzle housing (5) and bolts (2). Torque bolts 20 to 26 lb.in. (2.26-2.94 Nm). Secure bolts in pairs, using lockwire (PWC05-089). NOTE: 1. Do not use engine oil to lubricate bolt threads, which are silver-plated. NOTE: 2. Before installation, P&WC recommends that the HP turbine vane assembly is checked in a flow rig to verify the vane area is the correct area required for engine build. Repaired and used vane segments frequently flow differently from new production segments.

(11)

Using feeler gage, check clearance between small exit duct and nozzle housing (F & C REF. NO. 1361).

(12)

Install sealing ring (1).


Page 829 Mar 09/2001


8.

Removal/Installation of No. 6 Bearing Inner Race and Rotor Air Seal from/on LP Turbines A.

Removal CAUTION: HANDLING OF BEARINGS MUST BE KEPT TO A MINIMUM. WEAR SYNTHETIC RUBBER OR NYLON MESH GLOVES WITH POLYETHYLENE PALMS AND FINGERS. WHEN RUBBER OR NYLON GLOVES ARE NOT AVAILABLE, COTTON GLOVES MAY BE WORN IF THEY ARE CHANGED FREQUENTLY TO ENSURE THE FABRIC DOES NOT BECOME IMPREGNATED WITH SWEAT. REFER TO 72-00-00, MAINTENANCE PRACTICES FOR ADDITIONAL INFORMATION. (1)

Remove No. 6 bearing inner race and rotor air seal using pad (PWC38308), puller (PWC38309), cylinder (PWC32506) and pump (PWC37807). NOTE:

B.

Installation (1)

Heat rotor air seal in oven at 149 ± 6°C (300 ± 10°F) for 15 minutes minimum. NOTE:

If an oven is not available, use a heat gun, noting heat must be applied evenly over the surface of the seal. Sufficient time must be taken to ensure the complete seal is heated, thereby ensuring distortion does not occur.

(2)

Align V-mark on seal with X-mark on turbine disk within ± 5 degrees. Install on turbine disk using drift (PWC37310).

(3)

Heat No. 6 bearing inner race in oil (PWC03-001) at 115 ± 5°C (239 ± 10°F) or in a bearing oven at 135 ± 14°C (275 ± 25°F) for 60 minutes (1 hour) minimum. NOTE:

(4)

9.

No. 6 bearing inner and outer races can be replaced only as a set. This can be done without rebalancing.

Ensure a thin layer of engine oil (PWC03-001) covers bearings before they are heated in an oven.

Aligning V-mark with X-mark on disk assembly within ± 5 degrees, install No. 6 bearing inner race using drift (PWC37310). Allow race to cool and visually inspect. Reject complete bearing if race is cracked.

High and Low Pressure Turbine Shrouds - Grinding A.

General NOTE: (1)

An alternate grinding procedure using a vertical grinder and grinding fixture (PWC37586) is detailed in the Overhaul Manual.

LP and HP turbine shrouds are ground using different datums (No. 7 bearing air seal and the inner diameter of flange K respectively). In addition, LP shrouds are ground concentric and then 0.004 in. (0.101 mm) offset at the bottom. The offset requirement and different datums dictate the assembly, positioning and grinding procedures summarized below.


Page 830 Mar 09/2001


(a) Subpara. B., Steps (1) to (9) Inclusive Assembly procedure including methods used to establish LP and HP shroud classes required to give correct grinding allowance. (b) Subpara. B., Step (10) Assembly procedure using No. 7 bearing air seal to centralize the LP shrouds and the initial concentric and offset grinding procedures. (c) Subpara. B., Step (11) Assembly procedure using the inner diameter of flange K to centralize the turbine support case together with the HP shroud grinding procedure. B.

Procedure Using Portable Grinding Fixture (PWC37919) (1)

If required, reposition plate (PWC37736) (1, Fig. 806) on grinding fixture (PWC37919) (2) as follows: (a) Loosen capscrews (3) securing plate to fixture. (b) Align hole marked NOMINAL on plate with associated hole in fixture and install pin (PWC37919-29) (4). (c) Tighten capscrews.

(2)

Align offset hole with pin in fixture and install turbine support case (5).

(3)

Install capscrews (6). Do not tighten.

(4)

Install centering support (PWC37914) (7).

(5)

Centralize turbine support case within 0.0005 in. (0.0127 mm) FIR using centering support (Ref. Fig. 807). Tighten capscrews (6, Fig. 806). Remove centering support.

(6)

Establish HP turbine shroud segment class required as follows (Ref. Fig. 810 and Table 804): (a) Measure average diameter of HP turbine disk assembly using gage (PWC54020): 1

Pre-SB21588/SB21652 Dim. A (inches) = Dim. A (mm) =

2

10.420 - (HP turbine disk assy Dia. + 0.044) 2


Post-SB21588/SB21652 Dim. A (inches) = Dim. A (mm) =




Page 831 Mar 09/2001


12 11 10 7 8

9

5

6 1 4 3 2

C11222C LP and HP Turbine Shroud Diameter - Gaging and Grinding Figure 806


Page 832 Mar 09/2001


Key to Figure 806 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Plate Grinding Fixture Capscrew Pin Turbine Support Case Capscrew Centering Support Shroud Gage Grinding Wheel Grinder Case Locator Centering Fixture

(b) Determine segment class required (Ref. Table 804). TABLE 804, HP Turbine Shroud Classes (Ref. Fig. 810) CLASS

DIMENSION A in. (mm)

Pre-SB21588/SB21652 5

over 0.238 - 0.242 (6.045- 6.147)

6

over 0.242 - 0.246 (6.147 - 6.248)

7

over 0.246 - 0.250 (6.248 - 6.350)

8

over 0.250 - 0.254 (6.350 - 6.542)

9

over 0.254 - 0.258 (6.542 - 6.553)

10

over 0.258 - 0.262 (6.553 - 6.655)

11

over 0.262 - 0.264 (6.655 - 6.756)

12

over 0.266 - 0.270 (6.756 - 6.858)

13

over 0.270 - 0.274 (6.858 - 6.960)

14

over 0.274 - 0.278 (6.960 - 7.061)

15

over 0.278 - 0.282 (7.061 - 7.163)

Post-SB21588/SB21652

(7)

6

over 0.260 - 0.264 (6.604 - 6.705)

7

over 0.264 - 0.268 (6.705 - 6.807)

8

over 0.268 - 0.272 (6.807 - 6.908)

9

over 0.272 - 0.276 (6.908 - 7.010)

10

over 0.276 - 0.280 (7.010 - 7.112)

Install HP shroud segments as follows:


Page 833 Mar 09/2001


TURBINE SUPPORT HOUSING

CENTRALIZE CASE USING THIS SURFACE DOWEL PIN

C11789A HP Turbine Shroud Segment Support - Centralizing Datum Surface Figure 807


Page 834 Mar 09/2001


(a) Pre-SB21588/SB21652 1

Install HP shroud segments (6, Fig. 808) in turbine support housing (Ref. Fig. 811), with No. 1 segment center slot aligned with hole on RH side of dowel and segments No. 2 to 14 installed clockwise. Using feeler gages check gap between segments (F & C REF. NO. 1806).

2

Set dial test indicator (DTI) to zero in gage master at radius dimension for HP shroud; install gage (PWC37980) (8, Fig. 806) in fixture.

3

Calculate tip clearances in 14 positions adjacent to joints as follows: turbine disk assy dia. 2

Tip clearance = shroud segment radius 4

If necessary, replace segments with others having a different class until the required tip clearance of 0.022 in. (0.558 mm) (which provides an adequate grinding allowance), is obtained.

5

Check runout of shroud segments as follows: a

Set dial test indicator (DTI) of gage (PWC37980) (8) to zero at radius dimension for HP Shroud.

b

Install gage (PWC37980) in fixture (PWC37919) (2).

c

Check that runout is within 0.005 in. (0.12 mm) FIR. NOTE: 1. If required, use different segments to bring runout and taper within 0.005 in. (0.12 mm) FIR. NOTE: 2. Ensure tip clearance of 0.022 in. (0.558 mm) is maintained if segments are changed.

d 6

New shroud segments must be numbered according to position and number marked by vibropeen (Ref. Fig. 810).

Install holder (PWC38217) (5, Fig. 808).

(b) Post-SB21588/SB21652 (Ref. Fig. 809) 1

Apply two layers of tape (PWC05-253) on turbine support case as shown (Ref. Section B-B)

2

Install the first shroud segment (2) with its center over shroud anti-rotation pin (5) at the right of TDC.

3

Install remaining segments counterclockwise.

4

Set dial test indicator (DTI) of gage (PWC37980) (8, Fig. 806) to zero at radius dimension for HP shrouds. Install gage (PWC37980) (8) in fixture (PWC37919) (2).


Page 835 Mar 09/2001


5

Calculate tip clearances in 14 positions adjacent to joints as follows: Tip clearance = shroud segment radius -

turbine disk assy dia. 2

6

If necessary, replace segments with others having a different class until the required tip clearance of 0.022 in. (0.558 mm) is obtained.

7

Check runout of shroud segments as follows: a

Set dial test indicator (DTI) of gage (PWC37980) (8) to zero at radius dimension for HP shroud.

b

Install gage (PWC37980) in fixture (PWC37919) (2).

c

Check that runout is within 0.005 in. (0.12 mm) FIR. NOTE: 1. If required, use different segments to bring runout and taper within 0.005 in. (0.12 mm) FIR. NOTE: 2. Ensure tip clearance of 0.022 in. (0.558 mm) is maintained if segments are changed.

8

Using vibropeen, mark shroud segments according to position. No. 1 is positioned to the right of TDC and Nos. 2 to 14 located counterclockwise.

9

Lightly lubricate the retaining wire with engine oil (PWC03-001).

10

Install retaining wires (3, 4, Fig. 809) as follows: a


CAUTION: THE END OF THE RETAINING WIRES WILL OVERLAP AT TDC AND BDC. DO NOT REMOVE EXCESS WIRE UNTIL AFTER THE SHROUD SEGMENTS HAVE BEEN GROUND, REMOVED, CLEANED AND REINSTALLED.

(8)

b

Install retaining wire (3) in the groove in the turbine support case starting at TDC in a clockwise direction making sure the wire passes behind all seven shroud segments.

c

Install retaining wire (4) in the groove in the turbine support case starting at BDC in a clockwise direction making sure the wire passes behind all seven shroud segments.

d

Using feeler gages to check gap between segments (F & C REF. NO. 1806).

Establish LP turbine shroud segment class required as follows (Ref. Fig. 810 and Table): (a) Determine segment class required (Ref. Table 805).


Page 836 Mar 09/2001


TABLE 805, LP Turbine Shroud Classes (Ref. Fig. 810)

(9)

CLASS

DIMENSION A in. (mm)

8

0.332 - 0.336 (8.433 - 8.534)

9

over 0.336 - 0.340 (8.534 - 8.636)

10

over 0.340 - 0.344 (8.636 - 8.738)

11

over 0.344 - 0.348 (8.738 - 8.839)

12

over 0.348 - 0.352 (8.839 - 8.941)

13

over 0.352 - 0.356 (8.941 - 9.042)

14

over 0.356 - 0.360 (9.042 - 9.144)

15

over 0.360 - 0.364 (9.144 - 9.246)

16

over 0.364 - 0.368 (9.246 - 9.347)

17

over 0.368 - 0.372 (9.347 - 9.449)

18

over 0.372 - 0.376 (9.449 - 9.550)

19

over 0.376 - 0.380 (9.550 - 9.652)

Install LP shroud segments in housing as follows: (a) Place LP turbine housing (4, Fig. 808) on bench. (b) Using a teflon drift, install LP turbine shrouds (3) (Ref. Fig. 811) with No. 1 segment center slot aligned with hole on RH side of dowel and No. 2 through 14 segments installed clockwise. Using feeler gages check gap between segments (F & C REF. NO. 1805). (c) Heat associated turbine support case flange area using a heat gun for ten minutes minimum, then align dowel pin with hole and, using guide pins (0.190-32 UNJF-3A thread), install LP turbine housing (4, Fig. 808) in turbine support case, ensuring LP stator lugs engage in slots.

(10)

Grind LP shroud segments as follows: (a) Initial grinding 1

Install centering support (PWC37914) (7, Fig. 806). NOTE:

Remove locking knob and bar carrying DTI to ensure interference does not occur with adjacent parts.

2

Install guide pins (0.190-32 UNJF-3A thread) and heat turbine housing (4, Fig. 808) 10 minutes minimum using heat gun. Using dry ice (PWC05-102), cool outer flange area of turbine interstage case.

3

Align dowel hole and install turbine interstage case and associated parts (7), six washers (8) (MS9320-09) and bolts (9) (MS9696-09). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).


Page 837 Mar 09/2001



6 5 4 2 1

8 9

10 3

7

C27068

Pre-SB21588/SB21652 HP and LP Turbine Shrouds - Installation for Grinding Figure 808


Page 838 Mar 09/2001


Key to Figure 808 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Bolts Adapter LP Shroud Segments Turbine Housing Holder (Pre-SB21588/SB21652) HP Shroud Segments (Pre-SB21588/SB21652) Turbine Interstage Case and Associated Parts Washer Bolt No. 6 and 7 Bearing Housing (Ref.)

4

Slacken capscrews (6, Fig. 806) to loosen turbine support case on fixture.

5

Install case centering locator (PWC37913) (11). If required, reposition case to ensure locator is seated correctly on centering support (7).

6

Install dial indicator on centering fixture (PWC37911) (12).

7

Remove locator and install centering fixture (PWC37911) (12).

CAUTION: ENSURE PIN (PWC37919-29) IS INSTALLED IN HOLE MARKED ‘‘NOMINAL’’. 8

Centralize turbine support case within 0.0005 in. (0.0127 mm) FIR (Ref. Fig. 812) and tighten capscrews (6, Fig. 806).

9

Remove centering fixture (12), bolts (9, Fig. 808) and washers (8).

10

Remove turbine interstage case and associated parts (7) using jackscrews (PWC32396).

11

Remove centering support (7, Fig. 806).

12

Install adapter (PWC38231) (2, Fig. 808) and bolts (1). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm).

13

Check LP turbine tip clearance as follows: a

Measure average diameter of LP turbine disk assembly using gage (PWC38487).

b

Set DTI to zero in gage master at radius dimension for LP shroud.

c

Install gage (PWC37980) (8, Fig. 806) in fixture (2).


Page 839 Mar 09/2001


5

APPLY TWO LAYERS OF MASKING TAPE FEED RETAINING WIRE THROUGH GROOVE ON T.S.C. SECTION B−B 2 WITHOUT RETAINING WIRES INSTALLED SECTION E−E SIMILAR

4

3

C

B

F & C REF. NO. 1806 (14 PLACES)

#2

DETAIL C SHOWING RETAINING WIRES INSTALLED BEFORE BENDING DETAIL F SIMILAR

#3

#1

B

#14 #13

#4 1

#12

#5

#6

A

#11

#7

#10

E #8

FWD

F

#9

E

VIEW A SHOWING RETAINING WIRES INSTALLED BEFORE BENDING

C68538

Post-SB21588/SB21652 HP Turbine Shroud Segments - Installation Figure 809 (Sheet 1 of 2)


Page 840 Mar 09/2001


Key to Figure 809 1. 2. 3. 4. 5.

Turbine Support Case HP Turbine Shroud Segments Retaining Wire Retaining Wire Anti-rotation Pin


Page 841 Mar 09/2001


5 3

2011

4

SCALLOP EDGE 2012

1

SECTION E−E WITH RETAINING WIRE INSTALLED AND BENT SECTION G−G SIMILAR

2

D

E

DETAIL D SHOWING RETAINING WIRES INSTALLED AND BENT DETAIL F SIMILAR #2 #3

#1

E

#14 #13

#4

#12

#5

A

#6

#11

#7

#10

G #8

#9

FWD 1

F

G


C68539

Post-SB21588/SB21652 HP Turbine Shroud Segments - Installation Figure 809 (Sheet 2)


Page 842 Mar 09/2001


MARK LOCATION NUMBER HERE

A

DO NOT GRIND BELOW THIS SURFACE

MARK LOCATION NUMBER HERE

A

DO NOT GRIND BELOW THIS SURFACE

HIGH PRESSURE TURBINE SHROUD (POST−SB21588)

C68923 Typical HP and LP Turbine Shroud Segment - Dimension A Figure 810


Page 843 Mar 09/2001


C11594

Pre-SB21588 Installation of HP and LP Turbine Shroud Segments Figure 811


Page 844 Mar 09/2001


d

Check LP shroud radius dimension adjacent to joints (14 places), using gage DTI. Tip clearance = shroud radius -

e 14

turbine average diameter 2

If necessary, replace segments with others having a different class until required tip clearance of 0.022 in. (0.558 mm) is obtained.

Check that concentricity is within 0.005 in. (0.127 mm) FIR. NOTE: 1. If required, use different segments to bring concentricity within 0.005 in. (0.127 mm). NOTE: 2. Ensure tip clearance of 0.022 in. (0.558 mm) is maintained if segments are changed.

15

Shroud segments must be numbered according to position and number marked (by vibropeen) (Ref. Fig. 810). Marking to be done in groove.

16

Install grinding wheel (PWC37528) (9) on grinder (PWC37918) (10).

17

Remove gage and install grinder (PWC37918) (10) on fixture. Connect compressed air line to grinder and dress grinding wheel using dresser (PWC37917) to ensure a clean and even contact surface.

18

Position wheel adjacent to LP shroud.

19

Rotate grinder around shroud, gradually turning radial adjustment until grinding wheel makes light contact with thickest segment area. Back-off radial adjustment one complete turn.

20

Operate grinding wheel.

CAUTION: TO OBTAIN GOOD RESULTS, GRINDER MUST BE ROTATED SLOWLY AND ADJUSTED IN SMALL INCREMENTS TO AVOID EXCESSIVE REMOVAL OF MATERIAL IN ONE PASS. DRESS WHEEL AT FREQUENT INTERVALS. 21

Rotate grinder and slowly turn radial vernier adjustment one complete turn until wheel contacts high spots. Continue rotating grinder until high spots are removed. NOTE:

On pronounced high spots, oscillate grinder through an arc of 40 to 50 degrees before continuing with normal rotation in one direction.

22

Continue rotating grinder and adjust radial vernier until wheel just contacts segments. Rotate grinder several times before making further adjustments to radial vernier.

23

Repeat grinding operation until required amount of material is removed, ensuring grinding limit is not exceeded (Ref. Fig. 810)


Page 845 Mar 09/2001


1 2

CENTRALIZE CASE USING THIS SURFACE

C12542 LP Turbine Shroud Grinding - Centralizing Turbine Support Case Figure 812


Page 846 Mar 09/2001



Turbine Support Case (Ref.) No. 6 and 7 Bearing Housing (Ref.)

24

Disconnect air line and remove grinder (10, Fig. 806).

25

Check LP turbine tip clearance and shroud segment runout as follows: NOTE:


a

Set DTI to zero in gage master at radius dimension for LP shroud.

b

Install gage (PWC37980) (8) in fixture (2).

c

Check that LP shroud runout and taper do not exceed 0.001 in. (0.025 mm) FIR.

d

Check LP shroud segment radius diameter adjacent to joints (14 places), using gage DTI. Tip clearance = shroud radius -


e

Replace and/or grind shrouds if clearance is outside limits (F & C REF. NO. 1382).

f

Remove gage.

(b) Offset grinding 1

Install grinder (PWC37918) (10) on fixture.

2

Connect compressed air line to grinder and dress grinding wheel, using dresser (PWC37917), to ensure a clean and even contact surface.

3

Position grinding wheel adjacent to the LP shrouds.

4

Rotate grinder around shroud, gradually turning radial adjustment until grinding wheel makes light contact with shroud. Continue rotating grinder to ensure contact is made over full circumference of shroud.

5

Position grinding wheel adjacent to hole marked NOMINAL in plate (1).

6

Back-off grinding wheel radial vernier adjustment 0.004 in. (0.102 mm).

7

Remove pin (4); slacken capscrews (3).

8

Align hole marked 0.004 OFFSET on plate with associated hole in fixture, and install pin (4).


Page 847 Mar 09/2001


9

Tighten capscrews (3).

10


CAUTION: TO OBTAIN GOOD RESULTS, GRINDER SHOULD BE ROTATED SLOWLY AND ADJUSTED IN SMALL INCREMENTS TO AVOID EXCESSIVE REMOVAL OF MATERIAL IN ONE PASS.

(11)

11

Rotate grinder one full pass around shroud.

12

Turn radial vernier adjustment 0.002 in. (0.051 mm) and repeat pass around shroud.

13

Adjust vernier and repeat passes until 0.004 in. (0.102 mm) of material is removed from bottom of shroud.

14

Disconnect air line and remove grinder from fixture.

15

Using internal micrometer, check that ovality is 0.004 in. (0.102 mm).

Grind HP shrouds as follows: (a) Remove turbine support case assembly (5) from fixture (PWC37919) (2). (b) Remove pin (PWC37919-29) (4) and plate (PWC37736) (1). (c) Install support (PWC38589) (3, Fig. 813) and adapter (PWC37990) (1) on fixture (2). Do not tighten capscrews (4). (d) Align hole marked NOMINAL on support with associated hole in fixture and install pin (PWC37919-29) (5). (e) Tighten capscrews (4). (f)

Align offset hole with pin on support (3) and install turbine support case and associated parts (6).

(g) Install washers (7) and capscrews (8). Do not tighten capscrews. (h) Install gage assembly (PWC38291) (9). (i)

Using gage assembly (PWC38291) (2, Fig. 814) centralize turbine support case and associated parts (3) within 0.001 in. (0.025 mm) FIR.

(j)

Tighten capscrews (8, Fig. 813).

(k) Remove gage assembly (9) and install adapter (PWC38290) (10). (l)


(m) Install grinder on fixture. Connect compressed air line to grinder and dress grinding wheel using dresser (PWC37917) to ensure a clean and even surface.


Page 848 Mar 09/2001


(n) Position wheel adjacent to HP shroud. (o) Rotate grinder around shroud, gradually turning radial adjustment until grinding wheel makes light contact with thickest segment area. Back-off radial adjustment one complete turn. (p) Operate grinding wheel. CAUTION: TO OBTAIN GOOD RESULTS, GRINDER MUST BE ROTATED SLOWLY AND ADJUSTED IN SMALL INCREMENTS TO AVOID EXCESSIVE REMOVAL OF MATERIAL IN ONE PASS. DRESS WHEEL AT FREQUENT INTERVALS. (q) Rotate grinder and, slowly, turn radial vernier adjustment one complete turn until wheel contacts high spots. Continue rotating grinder until high spots are removed. NOTE: (r)

On pronounced high spots, oscillate grinder through an arc of 40 to 50 degrees before continuing with normal rotation in one direction.

Continue rotating grinder and adjust radial vernier until wheel just contacts segments. Rotate grinder several times before making further adjustments to radial vernier.

(s) Repeat grinding operation until required amount of material is removed, ensuring grinding limit is not exceeded (Ref. Fig. 810). (t)

Disconnect air line and remove grinder.

(u) Check HP turbine tip clearance and shroud segment runout as follows: NOTE:


1

Set DTI to zero in gage master at radius dimension for HP shroud.

2

Install gage (PWC37980) (13, Fig. 813) in fixture.

3

Check that HP shroud runout and taper do not exceed 0.001 in. (0.025 mm) FIR.

4

Check HP shroud segment radius diameter adjacent to joints (14 places), using gage DTI. Tip clearance = shroud radius -

(12)


5

Replace and/or grind shrouds if clearance is outside limits (F & C REF. NO. 1092).

6

Remove gage and adapter.

Remove turbine support case and associated parts (6) from fixture (2).


Page 849 Mar 09/2001


9 12 8

7 13

11 6 5

1

4

3

10

2

C18133 HP Turbine Shroud - Grinding Figure 813


Page 850 Mar 09/2001


Key to Figure 813 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. (13)

Grinding Adapter Fixture Case Support Capscrew Pin Turbine Support Case and Associated Parts Washer Capscrew Gage Assembly Adapter Grinding Wheel Grinder Gage Assembly

Remove HP turbine shroud segments as follows: (a) Pre-SB21588/SB21652 1

Remove slave bolts (1, Fig. 808), adapter (PWC38231) (2), turbine housing (4), using jackscrews (PWC32396).

2

Remove holder (PWC38217) (5).

3

Remove LP turbine shroud segments (3) from LP turbine housing (4) and using a soft hammer and teflon drift, remove HP turbine shroud segments (6) from turbine support case (1).

(b) Post-SB21588/SB21652 1

Remove LP turbine shroud segments (3, Fig. 808) from LP turbine housing (4) and if necessary, number according to position, segment No. 1 is at TDC (Ref. Fig. 811) and Segments 2 to 14 clockwise. Marking to be done in groove (Ref. Fig. 810).

2

Using lever (PWC56367) remove retaining wires (3, 4, Fig 815).

3

Remove HP turbine shroud segments (2) and if necessary, number according to position, Segment No. 1 is installed with its center over shroud anti-rotation pin (5, Fig. 809) and Segments 2 to 14 counterclockwise. Marking to be done in groove (Ref. Fig. 810).


Page 851 Mar 09/2001


2

3

4

1

C18134 Turbine Support Case - Centralizing Datum Surface Figure 814


Page 852 Mar 09/2001


Key to Figure 814 1. 2. 3. 4. WARNING:

(14)


Clean all components, using solvent (PWC11-027) or cleaner (PWC11-031). NOTE:

(15)

Grinding Adapter (Ref.) Gage Assembly Turbine Support Case and Associated Parts Support (Ref.)


Install HP shroud segments as follows: (a) Pre-SB21588/SB21652 (Ref. Fig. 808) 1

Install HP shroud segments (6) in turbine support case with segment No. 1 center slot aligned with hole on RH side of dowel and segments No. 2 through 14 installed clockwise (Ref. Fig. 811).

2

Use feeler gages to check gap between segments (F & C REF. NO. 1806).



2

Install remaining segments counterclockwise (Ref. View A).

3


4


Using a minimal amount of engine oil (PWC03-001), lubricate retaining wires (3, 4).

b


c

Install retaining wire (4) in the groove in the turbine support case starting at BDC in a clockwise direction making sure the wire passes behind all seven shroud segments.


Page 853 Mar 09/2001


3

4

1

1 2

SECTION E−E WITH RETAINING WIRES INSTALLED AND BENT SECTION G−G SIMILAR 4 3

D DETAIL D SHOWING RETAINING WIRES INSTALLED AND BENT DETAIL F SIMILAR

E

2

#2 #3

#1

E

#14 #13

#4

#12

#5

A #6

#11

#7

#10

G #8

FWD

#9

F

G


C68526

Post-SB21588/SB21652 High Pressure Turbine Shroud Segments - Removal Figure 815


Page 854 Mar 09/2001


Key to Figure 815 1. 2. 3. 4. d


e

Using pliers, bend the ends of retaining wire (3) against the scallops of shroud segments numbers nine and one.

f

Using pliers, bend the ends of retaining wire (3) as shown on Detail D, Sheet 2, Fig. 809.

g

Using pliers, bend the ends of retaining wire (4) against the scallops of shroud segments numbers eight and two.

h

Using pliers, bend the ends of retaining wire (4) as shown on Detail D, Sheet 2, Fig. 809.

i

Using cutter (PWC56365), remove excess wire (F & C REF. NO. 2011).

j

Using gage (PWC56341) and punch (PWC56366), position the four ends of retaining wires (3, 4) as shown on Section E-E, Sheet 2, Fig. 809 (F & C REF. NO. 2012).

WARNING:

5


Remove tape (PWC05-068) from the turbine support case and clean up surface using solvent (PWC11-027) or cleaner (PWC11-031). NOTE:

10.

Turbine Support Case Assembly HP Turbine Shroud Segments Retaining Wire Retaining Wire


Low Pressure (LP) Stator Seal Diameters - Grinding and Machining A.

General NOTE:

An alternate grinding procedure using a vertical grinder is detailed in the Overhaul Manual.


Page 855 Mar 09/2001


(1)

The LP stator non-abradable seal is ground concentric with turbine support case flange K inner diameter. The material of the abradable seal is toxic and must be machined, not ground. Therefore, the stator is removed from the grinding fixture, and the abradable seal machined concentric to the non-abradable seal in a lathe. After machining, the stator is reinstalled in the fixture and the non-abradable seal ground 0.009 in. (0.228 mm) offset at the bottom. The procedures used are summarized as follows: (a) Subpara. B., Steps (1) to (16) Inclusive Assembly procedure using inner diameter of turbine support case flange K as a datum and including a method to establish the non-abradable seal inner diameter required to give the correct clearance with the HP turbine disk rear cover plate. (b) Subpara. B., Step (17) (b) Procedure to grind the non-abradable seal concentric with flange K. (c) Subpara. B., Step (17) (c) Procedure to machine the abradable seal to give correct clearance with the turbine interstage seal and concentric with the non-abradable seal. (d) Subpara. B., Step (17) (d) Procedure to grind non-abradable seal 0.009 in. (0.228 mm) offset at the bottom.

B.

Procedure Using Portable Grinding Fixture (PWC37918) (1)

Install HP turbine shroud segments as follows: (a) Pre-SB21588/SB21652 (Ref. Fig. 816) 1

Install the HP segments (4) in the turbine support case (5). Install No. 1 segment with the slot aligned with the hole on RH side of the dowel pin on the case. (Ref. Fig. 811)

2

Install the remaining segments (No. 2 thru 14) in the clockwise direction.

3

Use feeler gages to check the clearance between each segment (F & C REF. NO. 1806).


Apply two layers of tape (PWC05-253) on turbine support case as shown (Ref. Section B-B)

2


3

Install remaining segments counterclockwise.


Page 856 Mar 09/2001


4


5



b

Install retaining wire (4) in the groove in the turbine support case starting at BDC in a clockwise direction making sure the wire passes behind all seven shroud segments. NOTE:

c (2)

The end of the retaining wires will overlap at TDC and BDC. Do not cut or bend excess wire.


Place LP turbine housing (2, Fig. 816) on bench. Align X-mark or XX mark (repaired stator) on lug with hole at LH of dowel hole and install LP stator (3) in housing. Rotate stator clockwise until lugs contact side of slots. Using feeler gage, check minimum gap between lugs and opposite side of slots is 0.001 in. (0.025 mm).

CAUTION: IF STATOR HAS BEEN REPAIRED (MARKED WITH AN XX), TURNING STATOR 180 DEGREES IS NOT PERMITTED. (3)

For LP stator (3) which has only one X-mark, sometimes difficulty is experienced during installation. Turn stator 180 degrees and align alternate X-mark on lug with hole at LH of dowel hole. If necessary, remove material from lugs to obtain minimum gap. Using vibropeen, delete X-mark on lug not used for alignment.

(4)

Turn assembly over and, using appropriately sized packings or string, secure stator to housing.

(5)

Heat associated turbine support case flange area, using a heat gun. Then align dowel pin with hole and, using guide pins (0.190-32 UNJF-3A thread), install turbine housing and stator assembly, ensuring LP turbine stator lugs engage in HP shroud segment slots.

(6)

Install ten slave bolts (1) (0.190-32 UNJF-3A x 0.625) to secure turbine housing (2). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm). Remove string or packings.

(7)

Install grinding adapter (PWC37990) (1, Fig. 817) on fixture (PWC37919) (2). Tighten capscrews (8).

(8)

Align slots and install support (PWC38589) (3).

(9)

Align hole marked NOMINAL on support with associated hole in fixture and install pin (PWC37919-29) (4).

(10)

Install and tighten bolts (5).


Page 857 Mar 09/2001


5 4

3 2

1

C16206 LP Turbine Stator - Installation for Non-abradable Seal Grinding Figure 816


Page 858 Mar 09/2001


Key to Figure 816 1. 2. 3. 4. 5.

Bolt Turbine Housing LP Stator HP Shroud Segments (Pre-SB21588/SB21652) Turbine Support Case

(11)

Install turbine support case and associated parts (6), washers (7) and capscrews (8). Do not tighten capscrews.

(12)

Install centering gage assembly (PWC38291) (10). Tighten retaining bolts.

(13)

Using gage assembly (PWC38291) (2, Fig. 814), centralize turbine support case and associated parts (3) within 0.001 in. (0.025 mm) FIR.

(14)

Tighten capscrews (8, Fig. 817) and remove gage assembly.

(15)

Install grinding adapter (PWC37994) (9). Tighten retaining capscrews (8).

(16)

Measure HP turbine disk rear cover plate seal diameter, using an external micrometer. Calculate inner diameter required for LP stator sealing surface to give correct clearance (F & C REF. NO. 1383).

(17)

Grind LP stator seal diameters as follows: NOTE:

After grinding non-abradable seal concentric to give correct clearance (Ref. step (b) following), the LP stator is removed from assembly and abradable seal machined (Ref. step (c) following). The stator is then reinstalled in turbine support case and non-abradable seal ground offset (Ref. step (d) following).

(a) Non-abradable sealing surface 1


2

Install grinder on fixture. Connect compressed air line to grinder and dress grinding wheel using dresser (PWC37917) to ensure a clean and even contact surface.

3

Position wheel adjacent to stator non-abradable sealing surface.

4

Rotate grinder around surface, gradually turning radial adjustment until grinding wheel makes light contact with high spots. Back-off radial adjustment one complete turn.

5



Page 859 Mar 09/2001


C14001B LP Turbine Stator - Non-abradable Seal Grinding Figure 817


Page 860 Mar 09/2001


Key to Figure 817 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

Grinding Adapter Fixture Case Support Pin Bolt Turbine Support Case and Associated Parts Washer Capscrew Grinding Adapter Centering Gage Grinding Wheel Grinder


Rotate grinder and, slowly, turn radial vernier adjustment one complete turn until wheel contacts high spots. Continue rotating grinder until high spots are removed.

7

Continue rotating grinder and adjust radial vernier until wheel just contacts surface. Rotate grinder several times before making further adjustments to radial vernier.

8

Repeat grinding operation until required amount of material is removed.

9


10

Check that clearance between stator non-abradable sealing surface and HP turbine rear cover plate is within limits (F & C REF. NO. 1383), using internal and external micrometers.

11

Remove grinding adapter (9).

12

Remove capscrews (8), washers (7) and turbine support case and associated parts (6).


Page 861 Mar 09/2001


WARNING:

13


Clean all components using solvent (PWC11-027) or cleaner (PWC11-031). NOTE:


(b) Non-abradable sealing surface 1

Install grinding wheel (PWC37839) (11, Fig. 817) on grinder (PWC37918) (12).

2

Install grinder on fixture. Connect compressed air line to grinder and dress grinding wheel using dresser (PWC37917) to ensure a clean and even contact surface.

3

Using a feeler gage, position grinding wheel 0.001 in. (0.025 mm) from highest rivet head (Ref. Fig. 818).

4

Rotate grinding wheel around stator to ensure there is no interference with other rivets.

5

Lock grinding wheel in position to ensure it cannot move axially.

6

Position grinding wheel radially until it is adjacent to stator non-abradable sealing Surface C.

7

Rotate grinder around surface, gradually turning radial adjustment until grinding wheel makes light contact with high spots. Back off radial adjustment one complete turn.

8


CAUTION: TO OBTAIN GOOD RESULTS, GRINDER MUST BE ROTATED SLOWLY AND ADJUSTED IN SMALL INCREMENTS TO AVOID EXCESSIVE REMOVAL OF MATERIAL IN ONE PASS. DRESS WHEEL AT FREQUENT INTERVALS. WHEEL MUST BE DRESSED IMMEDIATELY BEFORE FINAL OPERATION. 9

Rotate grinder and slowly turn radial vernier adjustment one complete turn until wheel contacts high spots. Continue rotating grinder until high spots are removed.

10

Continue rotating grinder and adjust radial vernier until wheel just contacts surface. Rotate grinder several times before making further adjustments to radial vernier.


Page 862 Mar 09/2001


SURFACE B

A SURFACE C

BREAK EDGES 0.003 − 0.015 IN. (0.076 − 0.381 mm)

D 0.020 IN. MAX. (0.508 mm) 0.001 IN. (0.025 mm) VIEW

A C22025

Second-stage Stator Non-abradable Seal - Machining Figure 818


Page 863 Mar 09/2001


11

Repeat grinding operation until required amount of material is removed from Surface C to give required clearance (Dia. D).

12

Break sharp edges 0.003 to 0.015 in. (0.076-0.381 mm).

13

Check radius does not exceed 0.020 in. (0.508 mm) maximum.

14


15

Check clearance between stator non-abradable sealing surface and HP turbine rear cover plate is within limits (F & C REF. NO. 1383), using internal and external micrometers.

16

Remove grinding adapter (9, Fig. 817).

17


18

Remove bolts (1, Fig. 816) and turbine housing (2) from turbine support case (5) using jackscrews (PWC32396).

19

Remove LP stator (3).

20

Remove HP shroud segments (Ref. Para. 9.B., Step (13)).

WARNING:

21




(c) Abradable sealing surface 1

Determine Dim. a as follows (Ref. Fig. 819): a

Measure Dim. a from lug to Surface B in 3 equispaced positions. If required, machine Surface B to obtain an average dimension of 0.953 ± 0.005 in. (24.206 ± 0.127 mm). Record average dimension.

2

Install LP stator (2, Fig. 820) in holding fixture (PWC38101) (1).

3

Centralize Dia. I within 0.001 in. (0.025 mm) FIR, 4 places equispaced. Secure stator with ring (4) and capscrews (5).


Page 864 Mar 09/2001


4

Using a micrometer, measure Dia. C and D of turbine interstage seal (3) and calculate Dia. E and F required for LP stator abradable seal surfaces to give correct clearance (F & C REF. NO. 1107).

5

Calculate Dim. g from Surface B as follows: a

Use average Dim. a previously recorded (Ref. step 1). Dim. a + 0.0375 = Dim. g ± 0.0075 in. Example: 0.953 + 0.0375 = 0.9905 ± 0.0075 in. or 24.206 + 0.952 = 25.158 ± 0.190 mm

6

Calculate Dim. h from Surface B as follows: a

Use Dim. a previously recorded (Ref. step 1). Dim. a - 0.240 = Dim. h ± 0.005 in. Example: 0.953 - 0.240 = 0.713 ± 0.005 in. or 24.206 - 6.096 = 18.110 ± 0.127 mm

WARNING:

ABRADABLE SEAL (NICKEL GRAPHITE) DUST IS TOXIC. MASKS MUST BE WORN AND COOLANT USED TO SUPPRESS DUST.

CAUTION: ABRADABLE SEALS MUST BE MACHINED. DO NOT GRIND. 7

Machine Dia. E to required dimensions (axial and radial), ensuring finished diameter is within 0.001 in. (0.025 mm) FIR of Dia. I. NOTE:

8

Machining of seal housing is permitted if necessary to obtain Dim. g, providing dimension is not exceeded.

Machine Dia. F to required dimensions (axial and radial), ensuring finished diameter is within 0.001 in. (0.025 mm) FIR of Dia. I.

(d) Non-abradable sealing surface (0.009 in. (0.228 mm) offset) 1

Place LP turbine housing (2, Fig. 816) on bench. Align X-mark on lug with hole at LH of dowel hole and install LP turbine stator (3) in housing.

2

Turn assembly over and, using appropriately sized packings or string, secure stator to housing.

3

Install HP turbine shroud segments (Ref. Subpara. B., Step (1)).


Page 865 Mar 09/2001


LUG

a

SURFACE

B

C22026 Second-stage Stator Abradable Seal - Determining Datum Dimension Figure 819


Page 866 Mar 09/2001


4

Heat associated turbine support case flange area, using a heat gun. Then align dowel pin with hole and, using guide pins (0.190-32 UNJF-3A thread), install turbine housing and stator assembly, ensuring LP turbine stator lugs engage in HP shroud segment slots.

5

Install ten slave bolts (1) (0.190-32 UNJF-3A x 0.625) to secure turbine housing (2). Torque bolts 36 to 40 lb.in. (4.07-4.52 Nm). Remove string or packings.

6

Install grinding adapter (PWC37990) (1, Fig. 817) on fixture (PWC37919) (2). Tighten capscrews.

7

Align slots and install support (PWC38589) (3).

8

Align hole marked NOMINAL on support with associated hole on fixture and install pin (PWC37919-29) (4).

9

Install and tighten bolts (5).

10

Install turbine support case and associated parts (6), washers (7) and capscrews (8). Do not tighten capscrews.

11

Install centering gage assembly (PWC38291) (10). Tighten retaining bolts.

12

Using gage assembly (PWC38291) (2, Fig. 814), centralize turbine support case and associated parts within 0.001 in. (0.025 mm) FIR.

13

Tighten capscrews (8, Fig. 817) and remove gage assembly.

14

Install grinding adapter (PWC37994) (9). Tighten retaining bolts.

15


16

Install grinder. Tighten retaining bolts.

17

Connect compressed air line to grinder and dress grinding wheel to ensure a clean and even contact surface, using dresser (PWC37917).

18

Position grinding wheel as follows ; a

Using a feeler gage, position grinding wheel 0.001 in. (0.025 mm) from highest rivet head (Ref. Fig. 818).

b

Rotate grinding wheel around stator to ensure there is no interference with other rivets.

c

Lock grinding wheel in position to ensure it cannot move axially.

19

Position wheel adjacent to non-abradable seal.

20

Rotate grinder around seal, gradually turning radial adjustment until grinding wheel makes light contact with seal. Continue rotating grinder to ensure contact is made over full circumference of seal.


Page 867 Mar 09/2001


2

5

4

A

1

SURFACE B

3

DIA. DIA.

DIA.

F

DIA.

C

I

MINOR TOOL MARKS ALLOWED IN THIS AREA

J DIA.

D

E H

0.240 ± 0.005 IN. (6.096 ± 0.127 mm)

G VIEW

A

DIA.

E

0.045 IN. MAX. (1.143 mm)

G VIEW

J C22027

LP Stator Abradable Seal Machining Figure 820


Page 868 Mar 09/2001


Key to Figure 820 1. 2. 3. 4. 5.

Fixture Stator Turbine Interstage Seal Ring Capscrew

21

Position grinding wheel adjacent to hole marked NOMINAL in support (3, Fig. 817).

22

Back off radial vernier adjustment 0.009 in. (0.228 mm).

23

Remove pin (4); slacken bolts (5).

24

Align hole marked 0.009 OFFSET on support with associated hole in fixture and install pin (PWC37919-29) (4).

25

Tighten bolts (5).

26

Connect compressed air line to grinder and operate grinding wheel.

27



Rotate grinder one full pass around seal.

29

Turn radial vernier adjustment 0.002 in. (0.051 mm) and repeat pass around seal.

30

Continue adjusting vernier and repeating passes until 0.009 in. (0.228 mm) of material is removed from bottom of seal.

31

Disconnect air line and remove grinder and adapter.

32

Using internal micrometer, check ovality is 0.009 in. (0.228 mm).

33

Break sharp edges 0.003 to 0.015 in. (0.076-0.381 mm).

34


35

Remove bolts (1, Fig. 816) and turbine housing (2) from turbine support case (5), using jackscrews (PWC32396).

36

Remove LP stator (3).

37

Remove HP shroud segments (Ref. Para. 9.B., Step (13)).


Page 869 Mar 09/2001


WARNING:

38


11.



39

Using vibropeen, mark a V on stator in line with X (Ref. Fig. 821). This enables stators having a 0.009 in. (0.228 mm) offset to be identified.

40

Install HP turbine shroud segments (Ref. Subpara. B., Step (1)).

Shanknut Replacement (Ref. Fig. 822) A.

Procedure CAUTION: INSTALL TWO PACKINGS P/N AS3209-010 ON THREADED END OF SPREADER (PWC31771). (1)

Using spreader (PWC31771), remove shanknut as follows: (a) Screw threaded end of tool into flared end of shanknut. (b) Using a two-pound ball peen hammer, tap end of tool until shanknut releases from its seated position.

12.

(2)

Unscrew shanknut from spreader (PWC31771) and discard shanknut.

(3)

Hold new shanknut against flange.

(4)

Lubricate, using a minimum amount of oil (PWC03-001), tapered portion of spreader (PWC31771-100) or (PWC31771-102) and screw into shanknut until shank end is flared against flange.

(5)

Remove spreader and examine flared end of shanknut for correct forming with no evidence of deformation or cracks.

(6)

Check gap between shanknut and flange is 0.010 in. (0.254 mm) max. (Ref. Fig. 822).

Removal/Installation of Power Turbine Rotor Air Seal (Ref. Fig. 823) A.

Removal (1)

Remove rotor air seal (2) from power turbine stubshaft, using puller (PWC37275).


Page 870 Mar 09/2001


X

V

C22028 LP Turbine Stator - 0.009 in. (0.228 mm) Offset Identification Figure 821


Page 871 Mar 09/2001


FLARE MUST BE FLUSH OR BELOW THIS SURFACE

0.010 IN 0.254 mm MAX

C30220 Shanknut - Installation Figure 822


Page 872 Mar 09/2001


B.

Installation (1)

Heat rotor air seal (2) in oven at 149 ± 6°C (300 ± 10°F) for a minimum of 15 minutes. NOTE:

(2) 13.

If an oven is not available, use a heat gun, noting heat must be applied evenly over the surface of the seal. Sufficient time must be taken to ensure the complete seal is heated thereby ensuring distortion does not occur.

Install rotor air seal (2) on power turbine stubshaft, using drift (PWC37276).

HP Turbine Stubshaft Securing Nut Thread Coating (Ref. Fig. 824) CAUTION: EXCESS AMOUNTS OF COMPOUND (PWC06-032) OR EQUIVALENT, MUST BE COMPLETELY REMOVED AFTER APPLICATION, BY WIPING WITH A CLEAN, LINT-FREE CLOTH OR OTHER SUITABLE NON-INJURIOUS METHOD BEFORE BAKING. FAILURE TO DO SO MAY LEAD TO CORROSION OF PARTS. CAUTION: COATED PARTS MUST NOT BE CLEANED WITH PETROLEUM SOLVENTS OR PRESERVED WITH PETROLEUM COMPOUNDS. A.

Procedure (1)

If required, remove existing coating from Area a, using a rotary scotchbrite wheel or equivalent.

(2)

Vapour degrease nut (Ref. Cleaning/Painting).

(3)

Do a fluorescent penetrant inspection per SPOP 62.

(4)

Heat nut to 93°C (200°F) to facilitate application of compound.

(5)

Apply an even coat of compound (PWC06-032) or equivalent, using a suitable brush or felt pad on Area a. If necessary, thin, using toluene (PWC11-030) to obtain the correct consistency.

(6)

Bake nut at 260 to 288°C (500-550°F) for approximately 30 minutes.

(7)

Air cool.

(8)

Using vibropeen, strike out the old part number and reidentify to 01R3109640-01 in the same general area.


Page 873 Aug 13/2004


1

2

C31218 Power Turbine Rotor Air Seal - Removal/Installation Figure 823


Page 874 Mar 09/2001



Power Turbine Rotor Balancing Assembly (Ref.) Air Seal


Page 875 Mar 09/2001


A

C

A

B SECTION

A−A A

B

VIEW B

COATING OPTIONAL AND MAY BE INCOMPLETE

C35315 HP Turbine Stubshaft Securing Nut - Coating Figure 824


Page 876 Mar 09/2001

PW1-27H maintenance manual chapter 72-03

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