C. Removal and Installation
a. Rear Casing Halves
1. General
a) Provides the tools and procedures necessary for removal and
installation of the Rear Stator Casing Halves
2. Tools and Materials
Tool No.
Description
CRSA-0001
Tool Set, Jackscrews
CRSA-0002
Puller, No. 4 Bearing Split Nut Lock
Ring
CRSA-0003
Wrench, No. 4 Bearing Split Nut
Collar
CRSA-0004
Tool, Installation - No. 4 Bearing Split
Nut Collar
CRSA-0005
Tool, Installation - No. 4 Bearing Split
Nut
CRSA-0006
Adapter, Puller - Aft Air Seals No. 4
Bearing Split Nut
CRSA-0007
Puller, No. 4 Bearing Races and Seals
CRSA-0008
Adapter, Puller No. 4 Bearing Air/Oil
Seals
CRSA-0009
Adapter, Puller - No. 4 Bearing Inner
Race
CRSA-0010
Pilot, Installation/Removal - CRF
CRSA-0011
Sling, Frames - Lift & Turning Vertical
CRSA-0012
Bracket, CRF to Subassembly Stand
CRSA-0013
Stand, Subassembly - Frames
CRSA-0014
Adapter, Puller - Rotating Air/Oil
Seal, BRG. 4R
CRSA-0015
Puller, No. 4 Bearing Races and Seals
CRSA-0016
Pusher, No. 4 Bearing Races and
Seals
CRSA-0017
Ring Compressor (3 1/2-7, 9-12 Inch)
CRSA-0018
Fixture, Installation - No. 4B Bearing
CRSA-0019
Platform, Maintenance - Core
Engine, Vertical
CRSA-0020
Guide Pins - Frames, Seals, Bearings
Material No.
C02-019
C02-026
C02-001
Description
Oil, Engine
Oil, Penetrating (GE Spec A50TF54
Class A) Liquid Wrench (Industrial
Grade)
Compound, Anti-Seize MIL-T-5544
C04-001
Solvent, Methyl-Ethyl-Ketone
(MEK)
3. Procedure
a) Removal (Refer to Figure A.1)
1) Remove the pressure balance air seal by removing the 56 bolts.
Use jackscrews CRSA-0001 lubricated with C02-019 to break
seals loose.
2) Remove splined locking ring from rear of compressor rotor rear
stud-shaft using puller, CRSA-0002.
Note: The split nut lock ring has non-symmetrical holes and the
plate of CRSA-0002 is similar. During installation of tool, rotate
the plate to match to assure that the rods will not bind in the
plate.
3) Apply penetrating oil, C02-026 to split nut and soak for 15
minutes.
Caution: IF COMPRESSOR STATOR BRIDGE CONNECTORS ON
STAGES 3, 4, 5 AND 6 ARE REMOVED, VANE POSITION TOOL,
2C6259 MUST BE INSTALLED AT SPLIT LINES TO BE SURE VANES
ARE IN PROPER POSITION SO ROTOR MAY BE ROTATED
WITHOUT DAMAGING SPACERS FROM EXCESSIVE RUB FROM
VANE TIP.
4) Loosen split nut and split nut collar using wrench CRSA-0003 as
follows:
i.
Install torque tube of wrench CRSA-0003 into the rear
of the compressor rotor locknut and secure to the aft
flange of the compressor case. Use a hoist.
ii.
Install torque wrench CRSA-0003 to the center of the
torque tube.
iii.
Install torque multiplier to the wrench. Use a hoist.
iv.
Rotate rotor 2 or 3 turns and lift wrench, sleeve and
multiplier out of CRF.
5) Remove No. 4 bearing split nut collar as follows:
i.
Install tool, CRSA-0004 in the groove of the ID of the
split nut collar.
ii.
Remove tool and split nut collar by hand.
6) Remove split nut as follows:
i.
Thread tool, CRSA-0005 on split nut rear face into
tapped holes, one-half or split nut at a time.
ii.
Remove split nut and tool.
7) Remove rear rotating air seal using puller adapter, CRSA-0006
and hydraulic puller, CRSA-0007. Engage puller adapter fingers'
rear tangs in aft flange of seal. Puller adapter should exert force
on forward face of spring ring retainer flange.
8) Remove rear insulation blankets by cutting lockwire and pulling
blankets to rear.
9) Remove rear rotating air/oil seal from compressor rear stubshaft using puller CRSA-0007 and adapter, CRSA-0008.
10) Remove rear stationary air/oil seal using jackscrews CRSA-0001
or engine bolts lubricated with engine oil C02-019. Discard
preformed packing.
11) Remove No. 4 ball bearing rear inner race with adapter, CRSA0009 and hydraulic puller, CRSA-0007.
12) Remove No. 4 ball bearing housing assembly (with outer race
and ball-cage assembly still installed) using jackscrews, CRSA0001 or engine bolts lubricated with engine oil C02-019. Discard
preformed packings.
13) Remove forward inner race as follows:
i.
Install puller adapter, CRSA-0009 and puller, CRSA0007 to rear compressor stub-shaft.
14) Install pilot, CRSA-0010 to CRF.
15) Install lift sling, CRSA-0011 to the aft flange of CRF.
Note: Remove the horizontal split line bolt on each side that
interferes with the removal of the circumferential flange bolts.
Make certain the weight of CRF is on the hoist.
16) Loosen horizontal split line bolts near rear of compressor casing
to free CRF.
17) Remove pilot, CRSA-0010 from CRF.
18) Raise CRF until free of engine.
19) Install adapters, CRSA-0012 at the 3 and 9 o'clock positions on
forward flange of CRF.
20) Install CRF in stand, CRSA-0013 and cover.
21) Remove No. 4R rotating air/oil seal and No. 4R bearing inner
race using puller adapter, CRSA-0014 and puller CRSA-0015.
b) Installation (Refer to Figure B.1)
1) Attach a hoist to lift sling, CRSA-0011 and position sling over
CRF. Secure each leg of sling to frame rear flange using threaded
pins provided. Position legs approximately 120 degrees apart.
2) Install pilot guide, CRSA-0010 to the compressor rear stub shaft.
3) Position frame above compressor and slowly lower over guide,
CRSA-0010.
Caution: BE SURE THE CRF IS ORIENTED PROPERLY BY
DETERMINING THAT THE 3 AND 9 O'CLOCK CRF FLANGE
POSITIONS, WHICH HAVE NO BOLT HOLES, ARE AT THE
HORIZONTAL SPLIT LINES OF THE COMPRESSOR REAR CASE AFT
FLANGE. THE CRF VENT TUBE IS AT 12 O'CLOCK.
4) Lower CRF until the forward flange or frame mates with rear
flange of compressor case.
5) This step applies to compressor rear frames with sixteen bolt
holes, eight at both 3 and 9 o'clock positions, having nominal
size of 5/16 inch (7.94 mm). Install the 5/16 inch (7.94 mm)
bolts, nuts, adapters, spacers and brackets at the sixteen
locations per Figure B.2 and Figure B.3.
6) Lubricate threads of bolts with anti-seize compound, C02-001,
and install bolts in flanges of CRF and compressor case. Tighten
bolts per applicable torque values as shown:
i.
5/16 inch (7.92 mm) bolts: 210-230 lb in. (23.7025.96 N.m)
ii.
3/8 inch (9.52 mm) bolts: 380-420 lb in. (42.89-47.40
N.m)
7) Remove lift sling and hoist from CRF. Remove guide, CRSA-0010.
8) Place forward inner race of No. 4 ball bearing in an oven for
approximately 20 minutes at 300°F (149°C).
9) Remove forward inner race of No. 4 ball bearing from oven and
install on compressor rotor rear stub-shaft (wide end forward).
Seat race using pusher, CRSA-0016. When race reaches room
temperature remove pusher.
10) Lubricate preformed packings with engine oil C02-019 and
install in grooves in OD of No. 4 ball bearing housing assembly.
Compress preformed packings into grooves using clamping set,
CRSA-0017.
11) Insert ball and cage into No. 4B outer race using installation
fixture, CRSA-0018 on No. 4 bearing outer race housing.
12) Chill bearing housing assembly and tool, with clamp installed, in
dry ice for approximately 20 minutes.
Note: Balls of No. 4 bearing shall seat against forward inner race
at same time bearing housing seats against frame. If housing
seats before ball bearings compressor rotor can be moved up or
down as required using right hand handle of stand, CRSA-0019.
13) Remove bearing housing assembly from dry ice and remove
clamping set. Install bearing housing assembly into rear frame.
Align bolt holes and seat housing using 4 equally spaced slave
bolts and alignment guide pins, CRSA-0020.
14) Adjust position of compressor rotor as necessary to ensure that
bearing balls seat on forward inner race at same time housing
seats on rear frame. Remove installation tool, CRSA-0018.
15) Heat No. 4 ball bearing rear inner race in an oven at 300°F
(149°C) for approximately 20 minutes.
16) Remove race from oven and install over compressor rotor rear
stub-shaft (puller groove on race faces aft). Seat race using
pusher, CRSA-0016. When race reaches room temperature,
remove pusher.
17) Lubricate preformed packing with engine oil C02-019 and install
into grooves on OD of rear stationary air/oil seal. Compress
preformed packing into grooves using clamping set, CRSA-0017.
18) Chill air/oil seal with clamping set installed, in dry ice for
approximately 20 minutes.
19) Remove air/oil seal from Dry Ice and remove CRSA-0017.
Remove slave bolts from housing and install air/oil seal over
bearing housing and guide pins. Seat seal using 4 equally spaced
slave bolts.
20) Heat rear rotating oil and air seal in an oven at 300°F (149°C) for
approximately 20 minutes.
21) Remove seal from oven and install on compressor rotor rear
stub shaft (with largest outside diameter aft). Seat seal using
pusher, CRSA-0016. When seal reaches room temperature,
remove pusher.
22) Remove slave bolts securing air/oil seal. Secure housing and
air/oil seal with 20 bolts. Remove guide pins as last bolts are
installed. Tighten bolts to 100-130 lb in. (11.3-14.7 N.m) of
torque and safety wire.
23) Install two piece rear insulation blanket around sump walls and
secure with safety wire utilizing capstans on blankets.
24) Heat rear rotating air seal in an oven at 300°F (149°C) for
approximately 20 minutes.
25) Remove rear rotating air seal from oven and install on
compressor rotor rear stub-shaft. Seat seal using pusher, CRSA0016. When seal reaches room temperature, remove pusher.
26) Measure actual seating dimension from aft face of rear stubshaft to aft face of inner seating shoulder of rotating air seal.
Actual Dimension L must equal computed Dimension L minus
0.001 inch (0.025 mm) to plus 0.005 inch (0.13 mm) or seal is
not seated properly. Refer to Figure B.4.
27) Place both halves of split nut forward ends down, on a surface
plate and measure height (Dimension M, Figure B.4) of each half
using a depth micrometer. Record this height. Heights on both
halves must be equal.
Note: Split nut halves are a matched set and they must bear
the same serial number.
28) Compute split nut seating dimension (Dim N, Figure B.4) by
subtracting height of nut (measured in step xxvi) from actual
dimension L. Record this difference as split nut computed
seating dimension N.
29) Install split nut installation tool rods, of CRSA-0005 to 4
threaded holes in aft face of split nut halves.
30) Clean threads of split nut and compressor rotor rear stub-shaft
with C04-001. Lubricate rotor stub shaft threads and forward
face of split nut with C02-001.
Note: Be sure not to over-lubricate rotor and split nut. Too
much lubrication will prevent proper seating of nut.
31) Install split nut halves over compressor rotor rear stub-shaft.
When nut is forward of stub shaft splines, push body of
installation tool, CRSA-0005 forward over rods, of CRSA-0005
and position bolt halves of nut together on stub-shaft threads.
Do not remove tool. Check that aft faces of both halves of split
nut are even. No step greater than 0.003 inch (0.08 mm)
permitted between them.
Caution: THE SPLIT NUT COLLAR INSIDE SPLINE MINOR
DIAMETER MUST NOT EXCEED MAXIMUM SERVICEABLE LIMIT
OF 7.052 INCH (179.12 MM) AVERAGE.
32) Heat split nut collar in an oven at 300°F (149°C) for
approximately 20 minutes.
33) Remove collar from oven and install installation tool, CRSA0004. Tool will engage puller groove in ID of collar near aft end.
34) Install heated collar over split nut and seat against forward
shoulder of split nut. Remove installation tool. If necessary,
ensure complete seating of collar by tapping with a plastic bar
or mallet.
35) When collar reaches room temperature, remove tool, CRSA0005 from aft face of split nut. Turn split nut and collar by hand
as far as possible. Do not torque split-nut at this time.
36) Install a dial indicator in the compressor rear frame and position
the indicator tip against the aft face of the compressor rotor
stub-shaft.
37) Lower the compressor rotor to its most forward (lowest) point
by turning the RH handle of the stand, CRSA-0019,
counterclockwise. Most forward point will be reached when the
dial indicator shows no more movement.
38) To be sure that it is supported by the 4B bearing, turn the
compressor rotor clockwise through 2 complete revolutions,
using LH handle of stand CRSA-0019.
39) Position the indicator tip against the pilot journal of the shaft.
The pilot journal is immediately aft of the spline. Refer to Figure
B.4.
40) Rotate the rotor, using the LH handle of stand CRSA-0019
41) , and check the runout of the pilot journal, in 12 places. Record
this reading to the nearest 0.0001 inch (0.003 mm). Using C05002 or C05-003 mark the highest point on this journal as
determined by the maximum area of concentricity.
42) Support the compressor rotor on stand CRSA-0019, by turning
the RH handle of the stand clockwise.
43) Install split nut wrench, CRSA-0003, as follows:
i. Install protector cap, of CRSA-0003, over the end of the
compressor rotor rear shaft.
ii. With a hoist install the anti-rotational tube and support
into the CRF, engaging the split nut collar splines on the
inner end and with the wings of the support resting on
the CRF rear flange.
iii. Insert the four ball lock pins in the CRF rear flange.
iv. Using a hoist install the torque tube in the support and
engage the splines on the compressor rotor.
44) Install torque multiplier onto rear of wrench.
45) Torque nut and collar (7000-7500) lb-ft. (84,000-90,000 lb-in.)
(9481.2-10,158.4 N.m) break torque to 1000 lb-ft. (12,000 lb-in.)
(1354.5 N.m) and retorque to 6200 lb-ft. (74,400 lb-in.) (8397.6
N.m) minimum to obtain actual dimension N.
46) Remove torque multiplier and wrench, CRSA-0003.
47) Measure actual seating dimension (Dim. N, Figure B.4) from aft
face of compressor rotor rear shaft to aft face of each half of
split nut. Dimensions to each half must be equal within 0.001
inch (0.0254 mm) or split nut is not properly installed. Actual
dimension N shall be 0.014-0.020 inch (0.36-0.53 mm) larger
than computed dimension N. Increase in dimension is due to
design feature of shaft stretch.
48) Install a dial indicator in the compressor rear frame and position
the indicator tip against the aft face of the compressor rotor
shaft.
49) Lower the compressor rotor to its most forward (lowest) point
by turning the RH handle of the stand, CRSA-0019,
counterclockwise. Most forward point will be reached when the
dial indicator shows no more movement.
50) Turn the compressor rotor clockwise through 2 complete
revolutions, using LH handle of stand CRSA-0019, to assure that
the rotor is supported by the 4B bearing.
51) Position the indicator tip against the pilot journal of the shaft.
The pilot journal is immediately aft of the spline. Refer to Figure
B.4.
52) Rotate the rotor, using the LH handle of stand CRSA-0019, and
check the runout of the pilot journal in 12 places. Record this
reading to the nearest 0.0001 inch (0.003 mm). Using C05-002
or C05-003 mark the highest point on this journal as determined
by the maximum area of concentricity. Establish the angular
difference between the high point marked in this sub-step with
53)
54)
55)
56)
57)
58)
59)
the high point found with split-nut loose (sub-step 39) (Subtask
72-00-34-220-054).
The concentricity of the pilot journal should not exceed 0.0015
inch (0.38 mm). The concentricity change, before and after splitnut torque, should not exceed 0.001 inch (0.025 mm). The
location of the journal high point should not change more than
60 degrees (before and after split-nut torque) if the pilot journal
concentricity is in excess of 0.0005 inch (0.013 mm).
If the preceding values cannot be met replace the split-nut
and/or rotate the rear air seal race. Repeat procedure starting
with sub-step (23).
Position the indicator tip against the mating face, adjacent to
the pilot journal. Refer to Figure B.4.
Rotate the rotor, using the LH handle of the stand CRSA-0019
and check the runout of the mate face, in 12 places. Record this
reading to the nearest 0.0001 inch (0.003 mm). Using C05-002
or C05-003 mark the lowest (most forward) point on the mate
face. Also mark this point on the aft face of the rear stub-shaft.
Install splined locking ring to lock split-nut collar to compressor
rotor rear stub-shaft, as follows:
i. Locate and mark spot on locking ring where inside and
outside spline slot are in line with each other.
ii. Locate and mark spot on split collar where a spline
tooth is in line with a spline tooth on rotor stub-shaft.
Note: Splined locking ring shall slide freely into
position. If ring binds, rotate ring one tooth clockwise or
counter clockwise.
iii. Install splined locking ring with marks aligned and seat
firmly against split nut.
Install piston rings to grooves in the four tubes extending thru
sump housing.
Install pressure balance air seal to frame. Make certain male
tubes in frame enter tubes on seal. If necessary, heat sump
flange with heat gun to allow installation. Align bolt holes and
secure with 56 bolts lubricated with C02-001. Torque 120-130
lb-in. (13.56-14.69 N.m). Check with a 0.001 inch (0.0254 mm)
shim to assure seating of seal.
b. Vanes
1. General
a) Provides the tools and procedures necessary for removal and
installation of the Vanes
2. Tools and Materials
Tool No.
Description
CRSA-0021
Material No.
C05-003
C02-001
Driver Set, Compressor Stator
Vane
Description
Carter's Marks-A-Lot (Black or
Blue)
Compound, Anti-Seize MIL-T-5544
3. Procedure
a) Removal
1) Place casing assembly on bench, forward flange down.
2) Remove vane retaining keys from horizontal flange of upper
casing. Lower casing has no keys.
3) Number all vanes to be removed and mark casing as required to
provide for installation of removed parts in original location; use
C05-003.
4) Remove vanes by sliding circumferentially from retaining slots.
Use proper tool from driver set CRSA-0021 to drive against vane
base, not airfoil.
Caution: USE CARE WHEN REMOVING AND HANDLING VANE
SLOT LINERS. THEY CAN BE KINKED OR BENT.
5) If any stage has been repaired by installation of vane slot liners,
remove liners. Indicate which stages had liners by marking with
marker C05-003 in vane slot.
b) Installation
Note: Check horizontal flange of both casings for marking to
identify repaired slots and required liner size. Markings apply to
both case halves.
1) Hand grind replacement vane to length of original vane.
2) Install vanes by sliding circumferentially into retaining slots;
install required number of vanes (Refer to Figure B.5).
3) Install vanes in repaired slots as follows:
i. Install liners with the longer cross section legs in the
forward grooves and the shorter in the rear. Position
the joint near the centerline (vertical).
ii. Apply C02-001 lubricant (or equivalent) to the vane
dovetails and install the first vane so that the joint
between liners is bridged.
Note: If the liners have not previously been installed,
the vanes will require driving with a plastic mallet and
driver set CRSA-0021 (or equivalent). Tool must drive
against vane base, not against airfoil.
iii. When all vanes are installed, trim excess length of liners
flush with end of slot.
4) Check cumulative end-gap as follows:
Note: Cumulative end-gap can be adjusted by selecting vanes
with wide and/or narrow platforms as required.
i. Clamp a parallel bar to one horizontal flange of casing.
Push all vanes circumferentially until against parallel
bar; measure gap between last vane and surface of
adjacent flange.
ii. Gap must be within limits of Figure B.5. Obtain proper
gap by selecting vanes of varied platform widths as
required. Position platform widths as required to align
borescope hole vanes with holes in casing.
iii. Vane platforms may be stoned by hand to minimum
width (Figure B.5) but no more than 0.005 inch (0.13
mm) may be removed from each side of platform.
5) Install serviceable retaining keys in upper casing: (Refer to
Figure B.6)
i. Position keys with chamfered edges into slot.
ii. Secure by staking keys to casing flanges. Stake each key
two places at four locations as shown.
6) Remove borescope plugs and check hole alignment a 0.400 inch
(10.16 mm) minimum diameter rod (simulates borescope) must
pass freely through case and vane platforms.
7) Coat borescope plug threads and pressure faces lightly with
compound C02-001 and install; tighten to 80-100 lb-in. (9.0-11.3
N.m) and safetywire.
c. Stationary Seals
1. General
a) Provides the tools and procedures necessary for removal and
installation of the Stationary Seal
2. Tools and Materials
Tool No.
Description
CRSA-0001
Tool Set, Jackscrews
CRSA-0017
Ring Compressor (3 1/2-7, 9-12
Inch)
Material No.
C02-019
Description
Oil, Engine
3. Procedure
a) Removal (refer to Figure A.1)
1) Remove rear stationary air/oil seal using jackscrews CRSA-0001
or engine bolts lubricated with engine oil C02-019.
2) Discard preformed packings.
b) Installation
1) Lubricate preformed packing with engine oil C02-019 and install
into grooves on outer diameter of rear stationary air/oil seal.
Compress preformed packing into grooves using clamping set,
CRSA-0017.
2) Chill air/oil seal with clamping set installed, in dry ice for
approximately 20 minutes.
3) Remove air/oil seal from Dry Ice and remove CRSA-0017.
Remove slave bolts from housing and install air/oil seal over
bearing housing and guide pins. Seat seal using 4 equally spaced
slave bolts.