JT8D Engine Depot Spec Rev 3 Sept 2009.pdf

REVISION 2

15 FEBRUARY 2008

C-9 / JT8D

NAVY / AIR FORCE

DEPOT LEVEL ENGINE SPECIFICATION

JT8D MODEL

TURBOFAN ENGINE

THIS PUBLICATION SUPERSEDES THE JOINT NAVY / AIR FORCE JT8D-9A DEPOT LEVEL ENGINE SPECIFICATION REVISION 1, DATED 01 OCTOBER 2004 AND ALL SUBSEQUENT CHANGES, WHICH SHOULD BE DESTROYED.

PUBLISHED BY NAVAIR PROGRAM MANAGER AIR 207 IN CONJUNCTION WITH OC-ALC/LKKA

THIS PUBLICATION SUPERSEDES THE JOINT NAVY / AIR FORCE JT8D-9A DEPOT LEVEL ENGINE SPECIFICATION REVISION 2, DATED 15 FEBRUARY 2008 AND ALL SUBSEQUENT CHANGES, WHICH SHOULD BE DESTROYED.

REVISION 3

15 SEPTEMBER 2009

15 SEPT 2009

C-9 JT8D DEPOT LEVEL ENGINE SPECIFICATION

LIST OF CHANGES

CHANGE INSERTION BY

NO. DATE

CHANGE INSERTION BY

NO. DATE

ii

C-9 JT8D DEPOT LEVEL ENGINE SPECIFICATION

DISTRIBUTION LIST

ORGANIZATION AND ADDRESS NUMBER OF

COPIES

NAVAL AIR SYSTEMS COMMAND PMA-207

46990 HINKLE CIRCLE BLDG 419 SUITE 200B

PATUXENT RIVER, MD 20670-1627

OC-ALC/727 ACSG/544 ACSS

3001 STAFF DRIVE

SUITE 1AG1105A

TINKER AFB, OK 73145-3018

COMMANDER

NAVAL AIR RESERVE FORCE

1915 FORRESTAL DR.

NORFOLK, VA 23551-4615

COMMANDER

FLEET LOGISTICS SUPPORT WING

1049 BOYINGTON DR

NAS FORT WORTH, TX 76127-1049

PRATT & WHITNEY REPRESENTATIVE

FLEET LOGISTICS SUPPORT SQUADRON (VR-56)

766 B AVENUE STE 200

NAS OCEANA, VA 23460

DCMA, SAN DIEGO-ESSOA

7675 DAGGET STREET, SUITE 200

SAN DIEGO, CA 92111-2241

DCMA, CENTRAL TEXAS

2116 ARLINGTON DOWNS ROAD

ARLINGTON, TX 76011

VMR-1, MARINE CORPS AIR STATION

PSC 8017

CHERRY POINT, NC 28533-0017

DCMA Orlando 6100 Hollywood Blvd, Suite 310 Hollywood, FL 33024

DCMA Detroit C/O Williams International 2280 West Maple Road Walled Lake, MI 48390

01 SEPT 2009

Page 1-1

C-9/JT8D DEPOT LEVEL ENGINE SPECIFICATION

SECTION I. GENERAL

1.0 SCOPE

1.1 Scope. This specification establishes the Joint Navy/Air Force requirements for Depot Level Maintenance of the C-9 aircraft’s Pratt & Whitney JT8D engine. The specification provides requirements for scheduled and unscheduled Engine Shop Visits (ESV’s), field team repair and inspection of engines, and incorporation of manufacturers Service Bulletins.

1.2 Scheduled Engine Shop Visits . Engines are periodically scheduled for two major inspections, ESV-1 and ESV-2. ESV-1 is scheduled every 6,300 for AF and 7,000 hours plus ten percent for Navy/Marine since last ESV-2. ESV-2 is scheduled every 12,000 for AF and 13,200 hours plus ten percent for Navy/Marine since last ESV-2. If conditions warrant, ESV-1 or 2 may be accomplished prior to the scheduled time. Scheduled ESV’s provide for thorough and comprehensive inspection and repair of the gas generator, components and accessories, and compliance with routine and Federal Aviation Administration (FAA) mandated Service Bulletins. Note: All Navy/Marine engines require a minus 20 degrees C to the Heavy Maintenance maximum EGT line for all ESV-2 inductions.

1.3 Unscheduled Engine Shop Visits. Unscheduled Engine Shop Visits are accomplished when repair requirements are beyond Organizational Level repair capability. Depot level repairs may be accomplished on-wing by a field team or the engine may be removed to the shop when conditions warrant. The decision to repair an engine on-wing or remove the engine to the shop shall be based on an assessment between the Government and the engine contractor performing the repairs. Additional repair or work requirements, beyond those for which the engine was inducted, shall only be accomplished upon approval by the C-9 Program Management Office via the ACO.

2.0 GENERAL REQUIREMENTS

2.1 Certification. The contractor shall possess and maintain a current FAA approved repair station certificate, rated specifically for the JT8D engine. Personnel performing maintenance, tests, inspections, etc., shall be FAA certified and qualified on the JT8D series engine. The contractor shall ensure subcontractors accomplishing component inspection or repair, possess and maintain a current FAA approved Repair Station Rating as applicable for the type of work being accomplished.

2.2 Specification Changes/Technical Guidance. When issued by Pratt & Whitney and the FAA, Service Bulletins, Airworthiness Directives and any revisions thereof, shall be reviewed by the Contractor for applicability to Navy and Air Force engines. The Contractor shall provide recommendations of compliance/non-compliance to the Navy and Air Force C-9 Program Management Offices. Revisions and changes, including Interim Change Notices (ICN’s), to this specification, will be issued as necessary to ensure maintenance requirements are maintained in a current and effective status. Revisions and changes will be issued by the applicable program office via the PCO. Technical questions, problems or recommendations concerning this specification, should be directed to the applicable program management office:

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(Navy) Naval Air Systems Command

PMA 207

46990 Hinkle Circle, Bldg. 419, Suite 200B Patuxent River, MD 20670-1627

OR

(Air Force) OC-ALC/727 ACSG/544 ACSS 3001 Staff Drive, STE 1AD2105E Tinker AFB, OK 73145-3018

2.3 Technical Reviews. An Engine Specification technical review shall be held at the contractor’s site annually or at any time if conditions warrant.

2.4 Applicable Maintenance Documents. Work accomplished to meet the requirements of this specification shall be done in accordance with applicable OEM manuals, Service Bulletins, Field Notes, All Operators Letters, etc., and applicable FAA regulations. The contractor shall ensure the latest change and revision information is incorporated into these documents.

2.5 Engine Applicability. The requirements of this specification apply to the following JT8D-9A engines.

2.5.1 Navy/Marine Engine Serial Numbers.

653509 656975 653699 657201 657591 657650

657699 657714 665566 666661 666778 666804

666874 666890 666918 667055 667056 667057

667060 667065 667067 667069 667070 667071

667129* 667130* 667131* 667135 667138* 667139*

667141* 667144 667146* 667148* 667149* 667172*

667203* 667216 667232* 667233* 667244 667245*

674547*

* Denotes Stage II Production Engines Underlined denotes Stage III Service Bulletin compliant USMC Engines

Page 1-3

2.5.2 Air Force C-9C Engine Serial Numbers.

655848 666738 666878 666879 666980 666991

666992 667007 667008 667010 687804

2.6 Definitions and Acronyms.

2.6.1 Definitions.

Check, Bench In-shop test using calibrated test equipment, to determine if component operating parameters meet component overhaul manual specifications.

Check, Functional The exercise of a component within its operating modes, to assure operation without interference and in proper direction and sequence of intended performance. Normal operation is verified through observation of overall performance without resort to measurement.

Condition To inspect for (condition) as used herein implies a visual examination to determine the existence of external damage and defects that could render the article unacceptable for continued use.

Defect Any nonconformance of a unit or part with specified requirements.

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Defect, Critical A defect that constitutes a hazardous or unsafe condition, or as determined by experience and judgment could conceivably become so, relative to the harmful effect on the prime intended function, safety of flight, or mission capability of the aircraft or its operating personnel.

Defect, Major A defect, other than critical, that could result in failure, materially reduce, or if not corrected, will degrade the usability of the unit or part for its intended purpose.

Insitu To accomplish in-place or without disassembly.

Maintenance, Heavy Procedures used primarily for the disassembly, repair and reassembly of engine sections to accomplish part life exchange or special repairs to various parts or components of the engine while it is removed from the aircraft.

Maintenance, Scheduled That maintenance performed to retain an item in serviceable condition by systematic inspection, detection, prevention of incipient failures, replacement of worn items, adjustment, calibration, cleaning, testing, etc.

Maintenance, Unscheduled That maintenance, not previously planned, which is performed to restore an item to a satisfactory condition by providing correction of a known or suspected malfunction and/or defect.

Module A combination of assemblies, subassemblies and parts, contained in one package, or so arranged as to be replaced in one maintenance action.

May also be referred to as a major assembly, assembly group or Major Engine Build Group

(MEBG).

Office, C-9 Program Management The C-9 Program Management Office refers to the Air Force or Navy Office responsible for C-9 Logistics and Engineering.

15 SEP 2009

Page 1-5

Overhaul The complete restoration of an item, or engine, in accordance with the instructions defined in the relevant overhaul manual.

Program, Maintenance A program which defines a logical sequence of maintenance actions to be performed as events or pieces of a whole which, when performed collectively, result in achievement of the desired maintenance standards.

Removal, Scheduled Removal of an item as a result of the item’s life having approached, or achieved, a previously defined limit.

Removal, Unscheduled Removal required to facilitate unanticipated repair.

2.6.2 Acronyms.

ACO Administrative Contracting Officer ASB Alert Service Bulletin ASSY Assembly AD Airworthiness Directive ALC Air Logistics Center CSD Constant Speed Drive DER Designated Engineering Representative EGT Exhaust Gas Temperature EB Electron Beam EO Engineering Order FCU Fuel Control Unit FIR Full Indicator Reading FOD Foreign Object Damage FPI Fluorescent Penetrant Inspection HPC High Pressure Compressor ID Inside Diameter JOAP Joint Oil Analysis Program LPC Low Pressure Compressor MEBG Major Engine Build Group MPI Magnetic Particle Inspection NDT Non-Destructive Test NGV Nozzle Guide Vane OHM Overhaul Manual

Page 1-6

OD Outside Diameter PCW Previously Complied With P&D Pressurization and Dump P/N Part Number PMA Program Manager Air/ Parts Manufacturing

Approval PRBC Pressure Ratio Bleed Control PW Pratt & Whitney PWA Pratt & Whitney Aircraft QEC Quick Engine Change SB Service Bulletin SPOP Service Process Operation Procedure TBO Time Between Overhaul

Page 2-1

SECTION II. ENGINE SHOP VISIT REQUIREMENTS

1.0 GENERAL

1.1 Configuration Management.

1.1.1 Inventory. The contractor shall at each shop visit and to the extent of disassembly record part number and when applicable, serial number, of all engine “significant parts”, QEC and accessory components removed from the “as received” engine, and upon reassembly, record part number and serial number of the parts installed. (CDRL)

1.1.2 Appendix A Compliance Codes. For purposes of this Specification the following compliance codes apply:

Joint Service Requirement (X) Navy only Requirement (XN) Air Force only Requirement (XA)

1.1.2.1 Service Bulletins/Technical Directives. Appendix C provides SB and Technical Directive requirements. To the extent of disassembly; accomplishment, or verification of accomplishment, of SB, shall be annotated at each engine shop visit. If a SB provides options, the option that was accomplished shall be recorded. Engines shall not be de-configured unless otherwise directed by the ACO. (CDRL)

1.1.2.2 Alert Service Bulletins. The contractor shall ensure all Pratt & Whitney ASB and FAA AD’s are reviewed for applicability to engines listed in Section I. If the ASB or AD requirements are different from the requirements of this Specification, the contractor shall seek disposition. The contractor shall provide an ASB/AD status report for each engine, to include necessary data for establishing and tracking repetitive inspection intervals at the Organizational level. (CDRL)

1.1.2.3 Modification Service Bulletins. SBs that modify the engine, that is, change form, fit or function, shall only be accomplished during ESV-1 or ESV-2, unless otherwise directed by the ACO.

Modification SBs shall not be accomplished unless they are listed in the Appendix. Revisions to Service Bulletins shall be incorporated provided the revision applies to Government engines.

1.1.2.4 Service Bulletin Compliance Codes. For purposes of this Specification, the following compliance codes apply:

Attrition (A) - SB shall be accomplished when the part affected is determined to be unserviceable.

Required (R) - SB accomplishment is required. Special remarks may be provided when applicability is related to compliance categories or compliance effectivity.

Mandatory (M) - SB accomplishment is mandatory and shall be accomplished. Mandatory compliance is usually associated with an ASB or AD.

Air Force (AF) - SB with designation (AF), apply to Air Force engines.

Navy (N) - SB with designation (N), apply to Navy engines.

Page 2-2

1.2 Maintenance History Data. The contractor shall at each engine shop visit, and to the extent of disassembly and inspection, record inspection results of engine QEC components, accessories and engine significant parts. (CDRL)

1.3 Life Limited Parts.

1.3.1 Removal Criteria. Prior to inspection for serviceability, all life-limited parts shall be evaluated for flight hours/cycles remaining. If a part has not reached its life limit, the determination to scrap, inspect, and reinstall, or inspect and hold for future utilization shall be made by the Government and contractor collectively. When evaluating the cost effectiveness of retaining disks in service, factors such as the average inspection and repair costs, and cost to replace at a future date by field team, etc., shall be weighed against the useful life remaining.

1.3.1.1 C-1 and C-2 Disks. First and second stage disks shall be fully utilized unless continued operation is determined to be uneconomical. Disks with sufficient time remaining may be removed and held as Customer Owned Property for future utilization.

1.3.1.2 All Other Disks. All other serviceable disks shall have sufficient hours/cycles remaining to reach next scheduled shop visit. Disks that do not have sufficient hours/cycles remaining to reach next scheduled shop visit shall be evaluated individually to determine disposition (that is, disks shall either be scrapped or preserved for future utilization). Disks to be scrapped shall be processed in accordance with contract requirements. Install only thick web C-9 disks.

1.3.2 Future Utilization. Disk overhaul date, total hours and cycles, type of coating processes used and any inspection due dates shall be clearly annotated on the serviceable tag and tracked by computer program. The utilization of these parts shall be coordinated with and approved by the applicable Navy/Air Force C-9 Program Manager.

1.3.3 Installed Parts Tracking. The contractor shall provide the required tracking data for each life-limited part delivered with the engine. (CDRL)

1.4 Parts Disposition. Parts, which are beyond repair, or parts which are serviceable or repairable, but are not to be reinstalled due to the requirements of this Specification, shall be disposed of by the contractor and credit provided to the government. The value of the credit shall be approved by the ACO. Life limited parts, which are scrapped, shall be adequately mutilated to preclude future use. Serviceable or repairable parts may be held for Customer Owned Property (COP), as required.

1.4.1 Customer Owned Property. A complete inventory, including hours/cycles remaining on all life limited parts, shall be maintained for Customer Owned Property (COP) parts being held for future utilization.

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1.5 Major or Critical Defects. Defects disclosed during a depot level shop visit, which are considered to be of such a nature as to warrant immediate attention (an urgent or dangerous condition that may exist in other JT8D engines and is sufficient to require an immediate one time inspection) shall be brought to the immediate attention of the Navy and Air Force C-9 Program Managers with a follow-up report.

1.6 Part/Component Replacement. When possible, engine parts and components shall be repaired.

However, if repair costs are projected to exceed 80% of the cost of a new part or component, it shall be replaced with a new part. The new replacement part shall be the latest, most reliable available that does not change form, fit or function (that is, the part number may be different, but it shall be a direct replacement part with no modifications required).

1.7 Engine Logbooks. Prior to induction, the contractor shall review the Engine Logbook to verify reason for removal and determine if any previously recorded depot level discrepancies exist. The contractor shall seek disposition instructions for discrepancies identified in the logbook, but not specifically mentioned in the work order. The Contractor shall ensure Engine Logbooks are annotated with required information upon completion of work.

1.8 Shipping and Handling. Engines shall be shipped and handled in accordance with the Pratt &

Whitney Standard Practices Manual No. 585005. When engines are shipped by ground transportation, only vehicles with air suspension or equivalent “soft” system shall be used. Use of spring type suspension system is not authorized.

1.9 Engine Preservation. Unless otherwise directed in the engine work order, the engine shall be preserved in accordance with Pratt & Whitney Manual P/N 481672.

2.0 ENGINE SHOP VISIT REQUIREMENTS (SCHEDULED)

2.1 Engine Shop Visit No.1 (ESV-1). When specifically directed by the ACO, the contractor shall accomplish ESV-1 in accordance with the following requirements. Accessory components shall be inspected in accordance with the requirements of Appendix B. QEC items shall be visually inspected.

2.1.1 Preinduction Evaluation.

1. Visually inspect engine exterior, accessories and QEC components for damage, security and leaks.

2. Visually inspect inlet and exhaust areas for evidence of FOD and oil leaks.

3. Inspect N1 for freedom of rotation.

4. Inspect 1st and 2nd stage fan blades for damage.

5. Borescope 6th, 7th and 13th stage compressor blades for damage.

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6. Conduct engine performance test and record parameters, as required.

7. Prior to disassembly, provide recommendations, with justification, of additional work required as a result of engine preinduction evaluation.

2.1.2 Disassembly. Disassemble engine as required by Appendix A.

2.1.3 Inspection. Major Engine Build Group (MEBG) inspection requirements are listed in Appendix A. As a minimum, all exposed parts shall be visually inspected. Refer to Appendix C for a complete listing of SB requirements.

2.2 Engine Shop Visit No. 2 (ESV-2). When specifically directed by the ACO, the contractor shall accomplish ESV-2 in accordance with the following requirements. Accessory components shall be inspected in accordance with the requirements of Appendix B. QEC items shall receive a visual inspection.

2.2.1 Disassembly. Disassemble engine as required by Appendix A.

2.2.2 Inspection. MEBG inspection requirements are listed in Appendix A. As a minimum, all exposed parts shall receive a visual inspection. Refer to Appendix C for a complete listing of Service Bulletin requirements.

2.3 Accessories. Check and inspect engine accessories in accordance with requirements given in

Appendix B.

2.4 DERs. A list of approved DER repairs is listed in Appendix E.

2.5.1 PMA Parts. A list of approved PMA parts is listed in Appendix F.

2.6 Quick Engine Change (QEC). At each scheduled or unscheduled shop visit, overhaul/exchange (Navy only) through the manufacturer, the following QEC items:

NOMENCLATURE PART NUMBER QUANTITY

Forward Cone Bolt R18210-2 2 each Aft Cone Bolt R18211-2 1 each

Note: The cone bolts shall be placed in a protective container and attached to the engine stand for shipment. Provide appropriate overhaul documentation.

All remaining QEC items shall as a minimum receive a visual inspection.

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3.0 UNSCHEDULED REPAIRS

3.1 Field Team. Upon notification by the ACO, the Contractor shall provide Field Team support to perform depot level repairs. The Contractor shall coordinate with the using activity for engine preparation prior to Field Team arrival. The Contractor shall provide details of repairs accomplished and/or inspection results to the applicable C-9 Program Manager.

3.2 Shop Visits. Upon notification by the ACO, the Contractor shall induct engines for unscheduled repairs. The Contractor shall perform engine inspections and tests as necessary to verify reason for removal. Following initial evaluation, provide applicable C-9 Program Office with scope of work, recommendations (also provide options), and estimated costs to repair based on options.

Accomplish repairs as directed by the ACO. ESV-1 or ESV-2 may be accomplished in conjunction with repair.

C-9/JT8D-9A DEPOT LEVEL ENGINE SPECIFICATION

APPENDIX A

A-1

ENGINE TEST

ENGINE CHANGE

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-00-00 Engine Testing 1 The engine shall be tested to a Type III overhaul X acceptance and performance test in accordance with PWA JT8D engine manual (P/N 481672).

Chapter 72-00-00.

2 Use MIL-L-23699 Oil or P & W approved oils X X 3 Vibration to be to overhaul limits. X 4 Perform serviceability test for fuel de-icing and anti-icing X X Whitaker valves.

5 Record #4 and #5 bearing scavenge oil temperatures X X during all engine tests.

6 Borescope engine after post-maintenance tests. X X 7 Preserve engine per Pratt & Whitney Engine Manual X X (P/N 481672). Marketing to contact customer to determine type of preservation 10 days prior to shipment.

8 Borescope prior to and after pre-induction test. X 9 Pre-induction test to be Type III Heavy Maintenance

Limits.

X

10 Post induction test to be Type III Heavy Maintenance Limits.

X

11 Obtain oil sample from N2 gearbox on pre-induction test X if recent JOAP data is not with engine records.

A-2

COMMON PARTS

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-09-00 Common Parts General 1 Accomplish receiving inspection of engine, noting general X X condition of external hardware.

2 Document shortages. X X 3 Refer to detail parts section for individual parts. X X NDT as required below.

72-09-70 Parts External 1 Clean. X X 2 Visually and dimensionally inspect. X X

72-09-71 Tubing, External 1 Clean. X X 2 Visually inspect X X 72-09-73 Brackets, External 1 Clean. X X 2 Visually inspect. X X

A-3

FRONT ACCESSORY DRIVE GROUP

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-21-00 Front Accessory Drive 1 Disassemble completely. X Group 2 Clean as specified by engine manual. X 3 Strip and recoat. X 4 Accomplish Service Bulletins listed in appendix. X X 5 Reassemble. X 6 Visual inspect. X X

72-21-01 Support, Front

Accessory

1 FPI. X

2 Visually and dimensionally inspect. Repair as required. X

72-21-02 Pump, No. 1 Bearing 1 FPI. and MPI. X Scavenge 2 Visually and dimensionally inspect. X

72-21-03 Gearshaft, Tachometer 1 MPI. X (N1) Drive Spacer 2 Visually and dimensionally inspect. X

72-21-05 Seal Housing and Seal, 1 Replace tach seal. X X N1 Tachometer Drive

Oil

A-4

FRONT COMPRESSOR GROUP

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-23-00 Fan Inlet Group 1 Disassemble completely to remove #1 bearing, Fan Inlet X Case, C-1 Disk Assy, Front Fan Case, C-1 Stator, Rear Fan Case, and C-2 Disk Assy. Remove No. 1 Bearing from Fan Inlet Case.

2 Disassemble to remove No.1 Bearing, Fan Inlet Case, C-1 X Disk Assy.

3 Disassemble to remove Front Fan Case, C-1 Stator and

Rear X

Fan case as one Unit.

4 Remove C-2 Disk Assy. X 5 Clean all parts as specified by engine manual. X X 6 Visually and dimensionally inspect as specified by engine X manual.

7 Comply with Service Bulletins listed in attached Appendix. X X 8 Reassemble per engine manual. X

72-23-01 Fan Inlet Case 1 Visually inspect. X X 2 Air and oil pressure check. X X 3 FPI and dimensionally inspect. X

72-23-02 No. 1 Bearing Housing 1 FPI as required. X 2 Visually and dimensionally inspect. X 3 Visually inspect. X

72-23-03 Support, Rear No. 1 1 FPI as required. X Bearing 2 Visually and dimensionally inspect. X

A-5

FRONT COMPRESSOR GROUP (cont.)

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-23-04 Tube, Connector 1 FPI as required. X 2 Visually and dimensionally inspect. X

72-23-06 Duct, Compressor Inlet 1 FPI as required. X 2 Visually and dimensionally inspect. X 3 Visually inspect. X

72-23-15 Plate, Bearing Retaining 1 FPI as required. X 2 Visually and dimensionally inspect. X 3 Visually inspect. X

72-23-18 Nut, No. 1 Bearing

Outer

1 MPI X

Race Retaining 2 Visually and dimensionally inspect. X 3 Plate per SPOP 23. X

72-23-81 Nut No. 1 Bearing Inner 1 MPI X

2 Visually and dimensionally inspect. X

3 Plate per SPOP 23. X

72-23-83 Seal No. 1 Bearing 1 FPI X

A-6

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-33-00 Front Compressor

Group 1 Disassemble completely. X

Disassemble 2 Review life remaining on all time/cycle controlled parts. X 3 Clean all parts as specified by engine manual. X 4 As required, check fits and clearances specified. X X 5 Comply with Service Bulletins listed in attached Appendix. X 6 Reassemble module. X X 7 Balance to 1/2 PWA limits. X

72-33-02 Disk & Blade

Assembly, 1 Deblade disk completely. X X

Stage 1 2 Re-assemble disk and blades per engine manual X X requirements.

3 Check balance assembly to 1/2 PWA limits. X X

72-33-04 Disk & Blade Assy

Stage 2 1 De blade disk completely. X X

2 Reassemble Disk and Blades per eng manual requirements X X 3 Check Balance Assy to ½ PWA limits. X X

72-33-05 Disk & Blade

Assembly, 1 Deblade disk completely. X

Stage 3 2 Reassemble disk and blades per engine manual X requirements.

3 Check balance assembly to 1/2 PWA limits. X

A-7

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-33-06 Disk & Blade

Assembly, 1 De-blade disk completely. X

Stage 4 2 Re-assemble disk and blades per engine manual X requirements.

3 Check balance assembly to 1/2 PWA limits. X

72-33-07 Disk & Blade

Assembly, 1 Deblade disk completely. X

Stage 5 2 Reassemble disk and blades per engine manual X requirements.

3 Check balance assembly to 1/2 PWA limits. X

72-33-08 Disk & Blade

Assembly, 1 Deblade disk completely. X

Stage 6 2 Reassemble disk and blades per engine manual X requirements.

3 Check balance assembly to 1/2 PWA limits. X

72-33-12 Tie Rods, Front 1 Clean per engine manual. X 2 MPI inspect. X 3 Visually and dimensionally inspect. X 4 Measure length. X 5 Ni-cad plate per SPOP 25. X 6 Apply anti-galling compound per SPOP 156. X

A-8

ENGINE CHANGE ENGINE

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-13 Tie Rods, Rear 1 Clean per engine manual. X 2 MPI inspect. X 3 Visually and dimensionally inspect. X 4 Measure length. X 5 Ni-cad plate per SPOP 25. X 6 Apply anti-galling compound PWA 550 Per SPOP 156. X

72-33-14 Nut, Front and Rear 1 Clean per engine manual. X Tie Rods 2 Visually inspect. X X

3 MPI X

4 Ni-cad plate per SPOP 25. X

72-33-15 Plate, 1st Stage Blade 1 Clean per engine manual. X X Retaining 2 Visually and dimensionally inspect for cracks and X X surface damage.

3 S/B 5841 required. X X

72-33-16 Air Seal, 2nd Stage 1 Clean per engine manual. X X 2 Visually and dimensionally inspect for knife edge wear, X X concentricity, and flatness.

3 FPI X

72-33-17 Front Comp. Hub Plug 1 Visually inspect. X X

A-9

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-21 Blade, 1st Stage 1 FPI X X 2 Eddy current inspect (S/B 5758) X X 3 Visually and dimensionally inspect. Overhaul/inspect. X X 4 Accomplish specialty repairs: X X

a) Hard coat PWA 46 or 256-4 to mid span shroud.

b) EB weld repair.

5 Restore surface finish as required per JT8D engine manual X X 6 Glass bead peen airfoil. X X 7 Shot peen blade root per SPOP 501. X X 8 Apply anti-galling compound per SPOP 160. X X 9 Moment weigh blades. X X

72-33-23 Blade, 2nd Stage 1 Clean per engine manual. X X 2 F.P.I. X X 3 Ultrasonic inspect blade lugs (S/B 5729). X X 4 Visually and dimensionally inspect as required by JT8D engine manual.

X X

5 Glass bead peen airfoil. X X 6 Shot peen root per SPOP 501 X X 7 Apply anti-galling compound to blade root per SPOP 160. X X 8 Moment weigh blades and classify. X X

A-10

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-24 Blade, Stage 3 1 Clean per engine manual. X

2 FPI X

3 Visually and dimensionally inspect. X 4 Vibratory burnish process per SPOP 186. X 5 Glass bead peen airfoil. X 6 Shot peen blade root per SPOP 501. X 7 Apply anti-galling compound per SPOP 160. X 8 Weigh blades. X 9 Visual inspect insitu. X X

72-33-25 Blade, Stage 4 1 Clean per engine manual. X

2 FPI X

3 Visually and dimensionally inspect. X 4 Vibratory burnish process per SPOP 186 X 5 Glass bead peen airfoil. X 6 Shot peen blade root per SPOP 501. X 7 Apply anti-galling compound per SPOP 160. X

72-33-26 Blade, Stage 5 1 Clean per engine manual. X

2 FPI X

3 Visually and dimensionally inspect. X 4 Vibratory burnish process per SPOP 186 X 5 Glass bead peen airfoil. X 6 Shot peen blade root per SPOP 501. X 7 Apply anti-galling compound per SPOP 160. X 8 Weigh blades. X

A-11

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-27 Blade, Stage 6 1 Clean per engine manual. X

2 FPI X

3 Visually and dimensionally inspect. X 4 Vibratory burnish process per SPOP 186 X 5 Glass bead peen airfoil. X 6 Shot peen blade root per SPOP 501. X 7 Apply anti-galling compound per SPOP 160. X 8 Weigh blades. X 9 If exposed, visually inspect insitu, otherwise borescope. X

72-33-28 Pins, 2nd Stage 1 Clean per SPOP 19, 203, and 209 X X 2 Visually and dimensionally inspect. X X

01 SPOP 19, 203, 209 X X

3 Pinhole taper wear max .0025". X X

72-33-31 Hub, 1st Stage Front 1 Visually and dimensionally inspect per engine manual. X X Overhaul/inspect.

2 FPI inspect "Ultra High Sensitivity". X X 3 Eddy current inspect rim slot and hub web. X X 4 Shot peen blade slots and web radius per SPOP 501. X X 5 Apply anti-galling compound per SPOP 160. X X 6 Comply with ASB 6104 as applicable. X X

72-33-33 Disk, 2nd Stage 1 F.P.I. X X 2 Visually and dimensionally inspect. Overhaul/inspect. X X 3 Shot peen disk tierod holes and rim per SPOP 501. Disk X X P/N 740502 does not require tie-rod hole peening.

4 Apply anti-galling compound per SPOP 160. X X

A-12

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-34 Disk, 3rd Stage 1 FPI (MPI steel disk). X 2 Visually and dimensionally inspect. X 3 Shot peen per SPOP 501 and Ni-cad plate steel disk (P/N

494903 or 745803) per SPOP 25.

X

4 Apply anti-galling compound to disk blade slot per X

SPOP 160.

72-33-35 Hub, 4th Stage 1 FPI or MPI (steel hub). X 2 Visually and dimensionally inspect. X 3 Corrosion protect Steel Hubs only with Ni-cad Plating. X 4 Shot peen blade slots per SPOP 501 steel hub. X 5 Apply anti-galling compound to splines and blade slots X per SPOP 160 (steel hub).

6 Comply with ASB 4151. X

72-33-36 Disk, 5th Stage 1 FPI X 2 Visually and dimensionally inspect. X 3 Shot peen blade slots as required per SPOP 501. X 4 Apply anti-galling compound per SPOP 160. X

72-33-37 Disk, 6th Stage 1 FPI X 2 Visually and dimensionally inspect. Overhaul inspect. X 3 Shot peen blade slots as required per SPOP 501. X 4 Apply anti-galling compound per SPOP 160. X 5 Check bore concentricity with snap diameter. X

A-13

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-41 Spacer, 1st to 2nd 1 FPI X X 2 Visually and dimensionally inspect per engine manual. X X 3 Static balance. X X

72-33-42 Spacer, 2nd to 3rd 1 Not applicable to -9A model.

72-33-43 Spacer, 3rd to 4th 1 FPI X 2 Visually and dimensionally inspect per engine manual. X 3 Static balance. X

72-33-44 Spacer 4th to 5th 1 FPI X 2 Visually and dimensionally inspect per engine manual. X 3 Static balance. X

72-33-45 Spacer, 5th to 6th 1 FPI X 2 Visually and dimensionally inspect per engine manual. X 3 Static balance. X

72-33-51 Stator Vane, Stage 1 1 Visually and dimensionally inspect. X 2 FPI reworked vanes. X

72-33-53 Stator, 2nd Stage 1 FPI or MPI (Steel Stator) X 2 Visually and dimensionally inspect. Overhaul inspect. X 3 Steel stator vibratory burnish. X 4 Restore coating as required per SPOP 148 (Steel X Stator SPOP 309).

A-14

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-54 Stator, 3rd Stage 1 FPI or MPI (Steel Stator) X 2 Visually and dimensionally inspect. Overhaul inspect. X 3 Steel stator vibratory burnish. X 4 Restore coating as required per SPOP 148 (Steel X Stator SPOP 309).

72-33-55 Stator, 4th Stage 1 FPI X 2 Visually and dimensionally inspect. Overhaul inspect. X 3 Coat with PWA 110-21-9 X 4 Check vane angle. X

72-33-56 Stator, 5th Stage 1 FPI X 2 Visually and dimensionally inspect. Overhaul and inspect. X 3 Coat with PWA 110-21-9. X 4 Check vane angle. X

72-33-66 Case Assembly, 1 Clean per engine manual. X Front Fan 2 Visually and dimensionally inspect for blade rub, wear X X and cracking.

72-33-67 Case Assembly, 1 Visually and dimensionally inspect for blade rub, wear, X X Rear Fan and cracking.

A-15

SECTION DESCRIPTION NO. ITEM SECTION ESV #1 ESV #2

72-33-81 Coupling, Turbine Shaft 1 MPI inspect. X 2 Visually inspect. X 3 Silver Plate IAW 72-33-81-30-002 X

72-33-82 Lock, Turbine Shaft 1 MPI X Coupling 2 Visually and dimensionally inspect. X 3 Cadmium Plate IAW 72-33-82-30-001 X

72-33-83 Case, Fan Exit 1 Visually and dimensionally inspect, repair as required. X 2 As required, apply protective coating to case per X

SPOP 148.

3 Visually inspect. X

A-16

COMPRESSOR INTERMEDIATE GROUP

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-34-00 Compressor

Intermediate 1 Disassemble completely. X

Group 2 Clean all parts as specified by engine manuals. X 3 Comply with Service Bulletins listed in appendix. X 4 Reassemble per engine manual. X

72-34-01 Case, Compressor 1 Chemical clean to remove carbon, or positive air pressure X Intermediate pyrolytic method clean to remove carbon.

2 Power Wash. X 3 X-Ray inspect. X

4 FPI X

5 Visually and dimensionally inspect per engine manual. X 6 Pressure check Intermediate Case 7 To improve on overall engine vibration, accomplish X engine build/stack up dimensions for run out and concentricity. The No. 2 and No. 3 bearing bore is to be concentric within .004" FIR and lips parallel within .002" FIR, when mounted on fixture which shall be restrained flat and concentric.

72-34-07 Duct, Front Compressor 1 FPI X Fan Outer 2 Visually and dimensionally inspect. X 3 Apply protective varnish per SPOP 152 as required. X 4 Visually inspect. X

A-17

COMPRESSOR INTERMEDIATE GROUP (cont.)

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-34-08 Duct, Fan Discharge 1 FPI X Rear Compressor Outer 2 Visually and dimensionally inspect. X 3 The rear flange shall be parallel to the front within .010" X the rear flange snap inner diameter shall be concentric to the front outer diameter within .010".

4 Apply protective coating per SPOP 152. X 5 Visually inspect. X

72-34-09 Nozzle, No.2 &3 bearing Oil Pressure 1 Visual Inspect X

2 Flow Check X

72-34-10 Housing, Assembly, 1 Visually and dimensionally inspect X Drive Bearing

72-34-13 Rings, No. 2 Bearing 1 Visually and dimensionally inspect. X Seal Rings

72-34-30 Housing Assembly, 1 FPI X No. 3 Bearing 2 Visually and dimensionally inspect. X 3 Assemble. X

72-34-31 Gearbox, Drive Bevel 1 MPI X Gear 2 Visually and dimensionally inspect. X

72-34-33 Bearing, No. 3 1 Overhaul X

A-18

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-34-34 Nut, No.3 Bearing 1 Visually and dimensionally inspect. X Retaining 2 Replace silver plate per SPOP 23 X

72-34-36 Spacer, No. 3 Bearing

Labyrinth Seal 1 Visually a& Dimensionally Inspect X

72-34-37 Nut, No. 3 Bearing

Inner

1 MPI X

Race Retaining 2 Visually and dimensionally inspect. X 3 Restore silver plate per SPOP 23. X

72-34-40 Seal, No. 3 Bearing 1 Visually and dimensionally inspect. X Labyrinth

72-34-43 Manifold, Front 1 FPI X Air bleed 2 Visually and dimensionally inspect. X 3 Visually inspect. X

72-34-44 Sleeves, Front Bleed 1 Visually and dimensionally inspect. X Manifold 2 Visually inspect. X

72-34-45 Liner, Front Bleed 1 Visually inspect. X X Expansion

A-19

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-34-46 Tubes, Rear

Compressor 1 Visually inspect. X X

Low Pressure Air Transfer

72-34-50 Gearshaft Assembly, 1 MPI X Gearbox Drive Bevel 2 Visually and dimensionally inspect. X 3 Assemble. X 72-34-51 Gearbox, Gearbox

Drive

1 MPI X

Bevel 2 Visually and dimensionally inspect. X (Front) 2 Visually and dimensionally inspect. X

72-34-52 Coupling, Gearbox

Drive

1 MPI X

2 Visually & Dimensionally Inspect. X

72-34-80 Drive Shaft, (Tower

Shaft) Gearbox

1 MPI X

2 Visually & Dimensionally Inspect. X

72-34-81 Seal, #2 bearing Air

(Front)

1 FPI X

2 Visually & Dimensionally Inspect. X

A-20

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-34-82 Seal, #2 Bearing Air 1 FPI X (Rear) 2 Visually and dimensionally inspect. X

72-34-83 No. 2 Bearing 1 MPI X 2 Visually and Dimensionally inspect. X

72-34-84 Nut, No.2 Bearing 1 MPI X Inner Race Retaining 2 Visually and dimensionally inspect. X 3 Plate per SPOP 23. X

72-34-85 Nut, No. 2 Bearing

Outer Race Retaining

1 MPI X

2 Visually and dimensionally inspect. X 3 Plate per SPOP 23. X

72-34-86 Baffle, No. 2 Bearing 1 Visually and dimensionally inspect. X Front Oil

72-34-87 Baffle, No. 2 Bearing 1 Visually and dimensionally inspect. X

A-21

N2 COMPRESSOR MODULE

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-00 Compressor Module 1 Disassemble compressor module completely XN X 2 Clean all parts as required per engine manual XN X 3 Review life remaining parts XN X 4 Comply with S/B listed in appendix XN X 5 Balance to 1/2 PWA limits XN X 6 Dimensional inspect, fits and clearances. XN X 7 Reassemble. XN X

72-36-02 Disk & Blade (C7) 1 De-blade disk completely XN X Assembly 2 Re-assemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X 4 Borescope inspect. X-AF

72-36-03 Disk & Blade (C8) 1 De-blade disk completely XN X Assembly 2 Re-assemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X

A-22

N2 COMPRESSOR MODULE (cont.)

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-04 Disk & Blade (C9) 1 Deblade disk completely XN X Assembly 2 Reassemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X

72-36-05 Disk & Blade (C10) 1 Deblade disk completely XN X Assembly 2 Reassemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X

72-36-06 Disk & Blade (C11) 1 Deblade disk completely XN X Assembly 2 Reassemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X

72-36-07 Disk & Blade (C12) 1 Deblade disk completely XN X Assembly 2 Reassemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X

72-36-08 Disk & Blade (C13) 1 Deblade disk completely XN X Assembly 2 Reassemble disk & blades XN X 3 Balance to 1/2 PWA limits. XN X 4 Visually inspect. XN

72-36-11 Compressor Spacers 1 Visually and dimensionally inspect. XN X Stages 2 MPI. XN X 72-36-16 7-8 3 Accomplish out-of-round limit & concentricity XN X 8-9 inspection requirements for snap diameter 9-10 (.015" 00R & .001" concentric) 10-11 4 Coat with Ni-cad per engine manual XN X 11-12 5 Comply with ASB 5649 integral sleeve spacers XN X 12-13 6 Balance XN X

A-23

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-17 Front Hub (Separable) 1 MPI XN X 2 Visually & dimensionally inspect per engine manual XN X repair as required 3 Ni-cad plate per SPOP 25 XN X 4 Balance. XN X

72-36-18 Rear Hub 1 FPI and eddy current inspect splines (SB 5975) XN X 2 Visually and dimensionally inspect per engine manual XN X 3 To assure uniform assembly stack-up which contributes to improved engine vibration maintain disk/hub fit clearance per JT8D EM

XN X

72-36-19 Rear Compressor 1 Visual and dimensionally inspect, repair as required. XN X Rotor Tube 2 Tubes with rear tip machined off may continue in service in this configuration.

72-36-20 Tie-Rods 1 FPI per SPOP 82 XN X 2 Visually and dimensionally inspect for thread XN X condition, corrosion, pitting and stretch 3 Shot peen per SPOP 501 XN X 4 Apply anti-galling compound per SPOP 139 XN X

72-36-21 Tie-Rod Nuts 1 FPI per 72-36-21 XN X 2 Strip and re-plate silver plating per SPOP 24. XN X

A-24

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-22 Stage 7 Air Seal 1 MPI XN X 2 Visually and dimensionally inspect, repair as necessary XN X 3 Coat per engine manual XN X

72-36-31 Stage 7 Blades 1 FPI XN X 2 Visually and dimensionally inspect per engine manual, XN X overhaul.

3 Maintain Category "A" requirements for blade chord XN X width.

4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

160.

72-36-32 Stage 8 Blade 1 FPI XN X 2 Eddy current inspect XN X 3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Maintain Category "A" requirements for blade chord width.

XN X

5 Vibratory burnish blades to improve surface finish XN X per SPOP 186 6 Shot peen blade root per SPOP 501. XN X 7 Apply PWA 474 anti-galling compound to roots per SPOP

A-25

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-33 Stage 9 Blades 1 FPI XN X 2 Visually and dimensionally inspect per engine manual, XN X overhaul.

3 Maintain Category "A" requirements for blade chord width. XN X 4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

72-36-34 Stage 10 Blades 1 MPI XN X 2 Visually and dimensionally inspect per engine manual, XN X overhaul.

3 Maintain Category "A" requirements for blade chord width. XN X 4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

72-36-35 Stage 11 Blades 1 MPI XN X overhaul.

3 Maintain Category "A" requirements for blade chord width. XN X 4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

A-26

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-36 Stage 12 Blades 1 MPI XN X 2 Visually and dimensionally inspect per engine manual, XN X overhaul.

3 Maintain Category "A" requirements for blade chord width. XN X 4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

72-36-37 Stage 13 Blades 1 MPI XN X overhaul. XN 3 Maintain Category "A" requirements for blade chord width. XN X 4 Vibratory burnish blades to improve surface finish XN X per SPOP 186 5 Shot peen blade root per SPOP 501. XN X 6 Apply PWA 474 anti-galling compound to roots per SPOP

72-36-38 Pins, 7th Stage Blades 1 Visually and dimensionally inspect per engine manual. XN X

A-27

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-41 Stage 7 Disk 1 Strip surface treatments and plated repairs XN X

2 MPI XN X

3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Perform butterfly polish of tie-rod holes as required XN X (Per SPOP 502).

5 Corrosion protect with Ni-cad XN X 6 Apply anti-gallant compound per SPOP 160. XN X 7 Comply with Alert Service Bulletin 4024 XN X 8 Balance XN X

72-36-42 Stage 8 Disk/Hub 1 Strip surface treatments. XN X

2 MPI XN X

3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Comply with Alert Service Bulletin 4723 and 5154 XN X 5 Shot peen disk blade slots per SPOP 501 XN X 6 Corrosion protect with Ni-cad XN X 7 Apply anti-galling compound per SPOP 160 XN X 8 Balance. XN X

A-28

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-43 Stage 9 Disk 1 Strip surface treatments. XN X

2 MPI XN X

3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Perform butterfly polish of tie-rod holes as required per XN X

SPOP 502.

5 Shot peen blade slots per SPOP 501 XN X 7 Corrosion protect with Ni-cad XN X 6 Apply anti-galling compound to blade slots per SPOP 160 XN X 8 Comply with Alert Service Bulletin 4723, tie-rod holes crack inspection.

XN X

9 Balance XN X

72-36-44 Stage 10 Disk 1 Strip surface treatments. XN X

2 MPI XN X

3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Perform butterfly polish of tie-rod holes as required per XN X

SPOP 502.

5 Shot peen blade slots per SPOP 501 XN X 6 Corrosion protect with Ni-cad XN X 7 Apply anti-galling compound to blade slots per SPOP 160 XN X 8 Comply with Alert Service Bulletin 4723, tie-rod holes crack inspection.

9 Balance XN X

A-29

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-45 Stage 11 Disk 1 Strip surface treatments. XN X

2 MPI XN X

3 Visually and dimensionally inspect per engine manual, XN X overhaul.

4 Perform butterfly polish of tie-rod holes as required per XN X

SPOP 502.

5 Shot peen blade slots per SPOP 501 XN X 6 Corrosion protect with Ni-cad XN X 7 Apply anti-galling compound to blade slots per SPOP 160 XN X 8 Comply with Alert Service Bulletin 4723, tie-rod holes crack inspection.

XN X

9 Balance XN X

72-36-46 Stage 12 Disk 1 Strip surface treatments. XN X

2 M.P.I. XN X

3 Visually and dimensionally inspect per engine manual, overhaul.

XN X

4 Perform butterfly polish of tie-rod holes as required per XN X

SPOP 502.

5 Shot peen blade slots per SPOP 501 XN X 6 Corrosion protect with Nicad XN X 7 Apply anti-galling compound to blade slots per SPOP 160 XN X 8 Comply with Alert Service Bulletin 4723, tie-rod holes crack inspection.

9 Balance XN X

A-30

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-47 Stage 13 Disk 1 Strip surface treatments. XN X

2 FPI XN X

3 Visually and dimensionally inspect per engine manual, overhaul.

XN X

4 Perform butterfly polish of tie-rod holes as required per XN X

SPOP 502.

5 Shot peen blade slots per SPOP 501 XN X 6 Apply anti-galling compound to blade slots per SPOP 160 XN X

72-36-51 7th Stage Vane and 1 Clean and strip stator vanes XN X Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for

FOD, erosion, braze joint condition and corrosion, overhaul.

XN X

4 Accomplish vane angle checks to prevent off idle stalls Ref. S/B 4420.

XN X

5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X 7 Coat with PWA 110 or PWA 77 XN X 8 Maintain stator air seal clearance to overhaul limits. XN X

A-31

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-52 8th Stage Vane and 1 Clean and strip stator vanes XN X Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for XN X FOD, erosion, braze joint condition and corrosion, overhaul.

4 Accomplish vane angle checks to prevent off idle stalls XN X Ref. S/B 4420.

5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X 7 Coat with PWA 110 or PWA 77 XN X 8 Maintain stator air seal clearance to overhaul limits. XN X

72-36-53 9th Stage Vane and 1 Clean and strip stator vanes XN X Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for XN X FOD, erosion, braze joint condition and corrosion, overhaul.

4 Accomplish vane angle checks XN X 5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X

A-32

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-54 10th Stage Vane 1 Clean and strip stator vanes XN X and Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for XN X FOD, erosion, braze joint condition and corrosion, overhaul.

4 Accomplish vane angle checks XN X 5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X 7 Coat with PWA 110 or PWA 77 XN X 8 Maintain stator air seal clearance to overhaul limits. XN X

72-36-55 11th Stage Vane 1 Clean and strip stator vanes XN X and Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for XN X FOD, erosion, braze joint condition and corrosion, overhaul.

4 Accomplish vane angle checks XN X 5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X

A-33

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-36-56 12th Stage Vane 1 Clean and strip stator vanes XN X and Shroud 2 FPI per SPOP 62 XN X 3 Visually and dimensionally inspect per engine manual for XN X FOD, erosion, braze joint condition and corrosion, overhaul.

4 Accomplish vane angle checks XN X 5 Replace damaged vane airfoils as required XN X 6 Glass bead peen airfoils per SPOP 500 XN X 7 Coat with PWA 110 or PWA 77 XN X 8 Maintain stator air seal clearance to overhaul limits. XN X

72-36-80 #4 Bearing Labyrinth 1 Clean and remove surface treatments. X Seal 2 Visually and dimensionally inspect, checking outer X diameter of knife edges, plating and anti-galling conditions.

3 Apply anti-galling compound per SPOP 139. X

A-34

DIFFUSER GROUP

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-37-00 Diffuser Assembly 1 Disassemble diffuser module completely. X 2 Clean all parts as specified by engine manual, overhaul. X 3 Pressure check oil tube bushings. X 4 Reassemble. X

72-37-01 Case, Diffuser 1 FPI X 2 Pressure test turbine cooling air pressure sense tube. X 3 Pressure test oil tube bushings. X 4 Visually and dimensionally inspect, repair as required by X engine manual.

5 The #4 bearing housing support flange face shall be X square with snap within .001" FIR and parallel to front and rear flanges within .002" FIR.

6 Surface treat per PWA 110-2 or 110-3. X 7 Visually inspect insitu. X

72-37-02 Stator Assembly, 1 Clean and strip stator assembly. X Compressor Exit 2 FPI X 3 Visually and dimensionally inspect. X 4 Accomplish vane angle checks. X 5 Glass bead peen airfoil per SPOP 500. X 6 Recoat with PWA 110-21-9 X 7 Visually inspect insitu. X

A-35

DIFFUSER GROUP (cont.)

SECTION DESCRIPTION NO. ITEM INSTRUCTIONS ESV #1 ESV #2

72-37-05 Ring Seal, 13th Stage 1 Visually and dimensionally inspect. X 2 Check fit to 13th disk to control P.C.P. X

72-37-07 Housing, #4 Bearing 1 FPI and MPI X 2 Pressure test. X 3 Visually and dimensionally inspect and repair as required. X

72-37-08 Seal Assembly, 1 Pyrolytic clean to remove coking as required. X #4 Bearing 2 Ultrasonic clean as required. X 3 Visually and dimensionally inspect. X 4 Reassemble and flow check. X

72-37-10 Heat Shield, #4 Bearing 1 Visually inspect. X

72-37-11 Tubing, Diffuser Case 1 FPI X 2 Visually and dimensionally inspect. Repair as necessary. X 3 Restore protective coating per SPOP 139 OR 174 X

72-37-13…