Inspection of the High Pressure Compressor Rotor Assembly [CFMB]

A. Do a borescope installation:
   (1) Use the 856A1323 MONITOR, RESOLUTION BORESCOPE (856A1323G01) to make sure that the borescope or fiberscope and light source are serviceable. See the Non-Destructive Test Manual for this procedure NTM 720000.
   (2) Install the tools to turn the core engine.
     (a) To turn the core manually with a breaker bar, do the steps that follow:
       1 Remove the handcranking drive cover from the core rotation pad on the left side of the accessory gearbox (AGB), opposite the starter. (Ref. AMM TASK 72-63-00-000-002)
       2 Install a SPEED BRACE 3/4 IN - SQUARE DRIVE with a BAR LENGTH 60 CM (2 FT) BREAKER into the handcranking drive pad. When you do the borescope inspection, turn the core engine clockwise (CW, aft looking forward).
     (b) To turn the core with a drive motor, do the steps that follow:
       1 Remove the starter (Ref. AMM TASK 80-11-10-000-002).
       2 Install the 856A1488 MOTOR, DRIVE - CORE ENGINE ROTATION (856A1488P0/P02) into the accessory gearbox (AGB) starter drive pad. Align the drive shaft of the drive motor with the starter drive pad drive shaft and engage the splines.
       3 Turn the tool until the captive bolts align with the gearbox bolt holes.
       4 Tighten the two captive bolts by hand.
       5 Install the clamp to secure the drive motor.
       6 Attach the foot or hand control air hoses to the quick disconnects on the tool.
       7 Connect the air supply to the drive motor. The air supply must be capable of 100 psi (6.9 bar). The air supply must be lubricated and filtered at 6 SCFM (170 L/minute).
   (3) Actuate the VSV system to the full open position as follows:
     (a) Disconnect the VSV rod-end and head-end flex-hoses from the hydromechanical unit (HMU).
     (b) Remove the caps from the 856A1084 CART-STATOR ACTUATOR (856A1084G02 or 856A1084G04).
     (c) Attach the rod-end and head-end hoses from the cart to rod-end and head-end connectors of the rod-end and head-end hoses you disconnected from the HMU.
     (d) Actuate the variable stator system
       1 Pump the actuator until the VSV system is at the open position (actuator rod retracted).
     (e) Disconnect the 856A1084 CART-STATOR ACTUATOR (856A1084G02 or 856A1084G04).
       1 Follow the instructions for use of the 856A1084 CART-STATOR ACTUATOR (856A1084G02 or 856A1084G04) to relieve any static pressure existing in the supply hoses. Gages on the 856A1084 CART-STATOR ACTUATOR (856A1084G02 or 856A1084G04) should read zero and the selector valve should be in the OFF position.
       2 Disconnect the hoses of the cart from the rod-end and head-end hoses.
       3 Install the caps on the cart hoses.
     (f) Connect the rod-end and head-end hoses to the HMU.
       1 TORQUE the head-end hose to between 550 and 450 lbf.in (6.22 and 5.09 m.daN ) .
       2 TORQUE the rod-end hose to between 300 and 270 lbf.in (3.39 and 3.05 m.daN ) .
   (4) Remove the borescope plugs from the stages to be inspected as follows. Tag each borescope plug to identify the stage from which it was removed:

NOTE: The borescope plugs are located along the compressor case between the 4 and 5 o'clock positions, aft looking forward.

     (a) Remove the lockwire:

WARNING: USE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

       1 Cut and remove the lockwire from the borescope plugs to be removed.
     (b) Remove the IGV borescope plug (S1), if necessary, as follows:
       1 Remove the two screws (20) that attach the borescope access blanking plate (10) at 5 o'clock, aft looking forward, on the fan frame inner flange.
       2 Remove the borescope access blanking plate (10).
       3 Remove the IGV borescope plug (S1).
       4 Tag the plug to ensure it will be reinstalled in the correct port.
     (c) Remove the stage 1 through stage 5 borescope plugs (S2 through S6), as necessary. Tag each plug to ensure it will be reinstalled in the correct port.
     (d) Remove the stage 6, 7 and 8 borescope plugs (S7 through S9), as necessary, as follows:

CAUTION: DO NOT APPLY A TORQUE OF MORE THAN 280 lbf.in. (3.164 m.daN) TO THE 6TH, 7TH AND 8TH STAGE BOROSCOPE PLUGS WHEN YOU REMOVE THEM. IF YOU DO NOT OBEY THIS INSTRUCTION, THE INNER PLUG SHAFT CAN BREAK.

       1 Loosen the outer borescope plug.
       2 Pull the outer borescope plug straight out as far as possible to engage the internal shaft spline.
       3 Remove the borescope plug.
       4 Tag each plug to ensure it will be reinstalled in the correct port.
       5 If the borescope plug is broken or if the inner plug does not come out with the outer plug, remove the broken inner plug with a deep socket wrench (Ref. AMM TASK 72-31-00-300-002).
   (5) Connect the fiber light cable to the fiberscope (green or blue band) from the 856A1320 BORESCOPE-KIT (856A1320P04 or P05) and to the port on the 856A1322 BORESCOPE-LIGHT SOURCE SET (856A1322P01 through P07). Turn the light source on.
   (6) If you use the 856A1488 MOTOR, DRIVE - CORE ENGINE ROTATION (856A1488P01 or P02) to turn the core engine, do an inspection of the compressor blades as follows. If you use the breaker bar to turn the core, go to step (7).
     (a) Index the core engine to zero as follows:
       1 Put the fiberscope into the stage 3 borescope port (S4) and look aft to the stage 4 compressor blade platform.
       2 While you look in the fiberscope turn the core clockwise (CW), as seen from the front of the engine, using the 856A1488 MOTOR, DRIVE - CORE ENGINE ROTATION (856A1488P01 or P02).
       3 Turn the core until you see the first blade slot locking lug.
       4 Continue to turn the core until you see the second locking lug. The second locking lug is 2 blades past the first locking lug.
       5 Align the leading edge of the first blade past the second locking lug with the leading edge of the nearest stage 4 vane. This is the zero index point and blade number 1.
       6 Set the pointer on the protractor to the zero degree mark. The core engine is now set to the zero index point for inspection of all stages of the compressor rotor.
     (b) Do an inspection of stage 4 compressor blades while you turn the core engine using the 856A1488 MOTOR, DRIVE - CORE ENGINE ROTATION (856A1488P01 or P02).
     (c) Use the limits found in step 4.B.
     (d) Remove the fiberscope.
     (e) Insert the fiberscope in the borescope plug of the next stage to be inspected and repeat step (b) thru (d) for the other stages to be inspected.
     (f) If the vane segments in stages 6, 7 and 8 have moved to partially cover the borescope port, do step (8).
   (7) If you use the breaker bar to turn the core engine, do an inspection of the compressor blades as follows:
     (a) Insert the fiberscope in the borescope port of the stage you want to inspect.
     (b) Do an inspection of the compressor blade you see. Use the limits found in the inspection table.
     (c) Rotate the core engine so that you can see the next blade. Use the breaker bar to turn the core engine clockwise (CW).
     (d) Repeat steps (b) and (c) until you have inspected all of the blades in that stage. Count the blades as you inspect them to make sure all of the compressor blades are inspected. The number of blades in each stage is:
       1 Stage 1 : 38 blades
       2 Stage 2 : 53 blades
       3 Stage 3 : 60 blades
       4 Stage 4 : 68 blades
       5 Stage 5 : 75 blades
       6 Stage 6 : 82 blades
       7 Stage 7 : 82 blades
       8 Stage 8 : 80 blades
       9 Stage 9 : 76 blades
     (e) Repeat steps (a) thru (d) for the other stages to be inspected.
     (f) If the vane segments in stages 6, 7 and 8 have moved to partially cover the borescope holes (S7 through S9), do step (8).
   (8) To inspect the stages 6, 7, 8 and 9 blades when the vane segments have moved to partially cover the borescope holes, use the alternatives that follow:
     (a) If the diameter of the borescope holes are larger than 0.24 in. (6.01 mm) , do the borescope inspection using the 856A1321 FIBERSCOPE SET (856A1321P01 through P03).
     (b) If the diameter of the borescope holes are less than 0.24 in. (6.01 mm) , do the following steps:
       1 Put a tapered rod in the borescope hole. The rod must be made from 0.37 in. (9.40 mm) diameter aluminum, 18 in. (0.46 m) long, with a 4 in. (101.60 mm) taper at one end. The tapered end must be rounded to 0.062 in. (1.57 mm) radius, accurate radius not necessary.
       2 Apply a light downward force on the end of the tapered rod to move the vane segments.
     (c) If the stage 7 borescope hole (S8) is not fully open, inspect the aft part of the compressor through the stage 8 borescope hole (S9). If the stage 8 borescope hole (S9) is not fully open, try to do the inspection through the stage 6 borescope port (S7).

C. Remove the borescope equipment
   (1) When inspection is complete, turn the lamp switch off. Keep the main light source blower on until the lamp and housing cools down.
   (2) Before you install the borescope plugs, put the 0.37 in. (9.40 mm) diameter tapered rod into the borescope hole. This will make sure the hole is open.
   (3) Install the IGV borescope plug (S1) as follows:
     (a) Apply graphite grease (Material No.CP2101) or CP2619Never Seez-Pure Nickel, Special or milk of magnesia (Material No.CP1064) to the threads and pressure face of the borescope plug.
     (b) Put the borescope plug in the correct borescope port. Tighten the plug by hand.
     (c) TORQUE the plug to between 63 and 57 lbf.in (0.71 and 0.64 m.daN ) .

WARNING: USE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

     (d) Wirelock the plugs with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia or CP8006safety cable 0.032 in. (0.8 mm) dia..
     (e) Install the borescope access blanking plate (10) using the two screws (20).
   (4) Install the stage 1 through 5 borescope plugs (S2 through S6) as follows:
     (a) Apply graphite grease (Material No.CP2101) or CP2619Never Seez-Pure Nickel, Special or milk of magnesia (Material No.CP1064) to the threads and pressure face of the borescope plugs.
     (b) Install the borescope plug in the borescope port. Tighten the borescope plug by hand.
     (c) TORQUE the borescope plugs to between 63 and 57 lbf.in (0.71 and 0.64 m.daN ) .

WARNING: USE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

     (d) Wirelock the borescope plugs. Use CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia or CP8006safety cable 0.032 in. (0.8 mm) dia..
   (5) Install the stage 6, 7 and 8 borescope plugs (S7, S8 and S9) as follows:

CAUTION: MAKE SURE YOU FULLY SCREW THE INNER CAP IN. IF NOT FULLY SCREWED IN, THE INNER CAP OF THE BORESCOPE PLUG WILL DEFLECT THE COMPRESSOR REAR CASE AS THE OUTER CAP IS TIGHTENED. THIS WILL CAUSE BINDING OF THE COMPRESSOR ROTOR.

     (a) Make sure the borescope port is open. Insert the 0.37 in. (9.40 mm) diameter tapered rod in the borescope port.
     (b) Apply graphite grease (Material No.CP2101) or CP2619Never Seez-Pure Nickel, Special or milk of magnesia (Material No.CP1064) to the threads and pressure face of the borescope plugs.
     (c) Put the plug in the correct borescope port and tighten the inner plug by hand. Use the outer plug to turn the inner plug.
     (d) TORQUE the inner plug to between 85 and 75 lbf.in (0.96 and 0.85 m.daN ) . Loosen half a turn and RETORQUE to between 20 and 15 lbf.in (0.23 and 0.17 m.daN ) more than the running torque.
     (e) Compress the plug spring and tighten the outer plug by hand.

NOTE: If the inner plug is correctly installed and the threads are not damaged, you can install the outer plug by hand. If the outer plug cannot be fully installed by hand, the inner plug is not correctly installed. Remove the plug and repeat steps (c), (d) and (e).

     (f) TORQUE the outer plug to between 63 and 57 lbf.in (0.71 and 0.64 m.daN ) .

WARNING: USE GOGGLES AND GLOVES WHEN YOU REMOVE OR INSTALL LOCKWIRE. EACH TIME YOU CUT LOCKWIRE, REMOVE AND DISCARD IT IMMEDIATELY. LOOSE LOCKWIRE CAN CUT YOU OR MAKE YOU BLIND, AND/OR CAN CAUSE DAMAGE.

     (g) Wirelock all 3 outer plugs together with CP8001lockwire 0.032 in. (0.8 mm) dia. or CP8002lockwire 0.032 in. (0.8 mm) dia or CP8006safety cable 0.032 in. (0.8 mm) dia..
   (6) Remove the tools used to rotate the core as follows:

NOTE: If the breaker bar is installed, see steps (a) and (b). If the drive motor is installed, see steps (c) and (d).

     (a) Remove the SPEED BRACE 3/4 IN - SQUARE DRIVE and BAR LENGTH 60 CM (2 FT) BREAKER from the handcranking drive pad.
     (b) Install the handcranking drive pad cover (Ref. AMM TASK 72-63-00-400-002).
     (c) Remove the 856A1488 MOTOR, DRIVE - CORE ENGINE ROTATION (856A1488P01 or P02) from the starter pad of the AGB.
     (d) Install the starter (Ref. AMM TASK 80-11-10-400-002).