MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE

PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
72-40-01
Engine Model(s): MODEL(S)JT15D-5 AND JT15D-5R

COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE

PRACTICES
1. General
A. The following are the maintenance practices for the combustion chamber and LP turbine stator
support assembly.
2. Consumable Materials
The consumable materials listed below are used in the following procedures.

Item No. Name

PWC05-151 Filler Rod

3. Special Tools
The special tools listed below are used in the following procedures.

Tool No. Name

PWC31058 Adapter
PWC31195 Adapter

4. Fixtures, Equipment and Supplier Tools

Not Applicable
5. Removal/Installation (Heavy Maintenance Only)
A. Removal of LP Turbine Stator Support Assembly and Combustion Chamber Liner (Ref. Fig. 201)
Figure 201 Removal/Installation - Combustion Chamber Liner and Low
Turbine Stator Support Assembly

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
1. LP Turbine Stator Support Assembly
2. Combustion Chamber Liner
3. Swaged Shanknut
4. Gas Generator Case
5. Igniter Plug Housing
6. Fuel Nozzle Housing
7. Combustion Liner Support Bosses
8. Keywasher
9. Support Pin
10. Bolt
11. Washer, JT15D-5 (Post-SB7250)

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

(1) Remove turbine exhaust duct and No. 4 bearing housing assembly (Ref. 72-50-
06).
(2) Remove LP turbine rotor balancing assembly (Ref. 72-50-
03).
(3) Remove spark igniters (Ref. 74-20-
02).
(4) Remove primary and secondary fuel pressure tubes and associated fairing (Ref. 73-10-
03).
(5) Remove rear engine mount (Ref. 72-70-
04).
(6) Remove front inner bypass duct assembly (Ref. 72-70-
01).
(7) Remove bolts (10) and, if applicable, washers (11), from Flange C. Retain or discard
Flange C bolts at Hot Section Inspection (HSI) as follows:
(a) For JT15D-5 (Pre-SB7249/Pre-SB7245/Post-SB7250/Pre-SB7324) engines:
Discard 15 bolts and retain 30 washers (11) (two for each bolt) at HSI.
(b) For JT15D-5 (Post-SB7249/Pre-SB7324) engines with P/N MS9696-09 bolts,
and JT15D-5 (Post-SB7245/Pre-SB7324) engines: Discard 45 bolts at HSI.
(c) For JT15D-5 (Post-SB7249/Pre-SB7324) engines with P/N 3111850-01 bolts
(10) and JT15D-5 (Post-SB7324) or JT15D-5R engines: Retain 45 bolts at HSI.

CAUTION: IF ENGINE IS ON AIRCRAFT, SECURE REAR MOUNT ADAPTER

(PWC31058) TO GAS GENERATOR CASE AND TO AIRCRAFT REAR
ENGINE MOUNT AFTER REMOVAL OF ASSEMBLED SUPPORT AND LINER.

(8) Remove assembled LP turbine stator support (1) and combustion chamber liner (2) and
place on a clean, level wooden surface with combustion chamber down.
(9) Separate the combustion chamber liner (Ref. Fig. 201) from the LP turbine stator
support assembly as follows:
(a) Remove six keywashers (8) and support pins (9) from low pressure turbine
stator assembly.
(b) Position LP turbine stator support assembly (1) with open end of combustion
chamber liner assembly (2) facing up and remove liner.

B. Pre-assembly of LP Turbine Stator Assembly and Combustion Chamber Liner (Ref. Fig. 201)
(1) Assemble combustion chamber liner assembly (2) and LP turbine stator support (1) on
a bench.
(2) Position combustion chamber liner assembly (2) on LP turbine stator support (1). Align
spark igniter holes with igniter plug housings (5) at 5 and 7 o'clock positions.
(3) Install keywashers (8) on support pins (9) and install six support pins (9) into bosses
in LP turbine support assembly through bosses on dome of combustion chamber liner.
Tighten and torque support pins to 225 to 300 lb.in. and lock keywashers.
C. Installation of LP Turbine Stator Assembly and Combustion Chamber Liner (Ref. Fig. 201)
(1) Check all Flange C shank nuts (3) on gas generator case (4). Replace missing or
damaged nut (Ref. 70-00-00, REPAIR).
(2) Secure clips on adapter (PWC31195) to interstage seal ring previously installed on the
HP turbine stator shroud support (Ref. 72-50-01).
(3) Remove rear engine mount adapter (PWC31058), if

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
installed.
(4) Mate assembled LPT stator support and combustion chamber liner assembly to gas
generator case at Flange C, with fuel inlet and shut-off valve housing assembly at 6
o'clock position.
(5) Remove adapter
(PWC31195).
(6) Secure LP turbine stator support assembly (1) to gas generator case as follows:
(a) For JT15D-5 (Pre-SB7249/Pre-SB7245/Post-SB7250/Pre-SB7324) engines:
Use new bolts only. Install fifteen new bolts (10) with two washers under each
bolt head. First bolt with washers must be installed in third hole from top dead
center, and remaining bolts and washers in every fourth hole. Flats on washers
should be on body of LP turbine stator support assembly (1).
(b) For JT15D-5 (Post-SB7245/Pre-SB7324) engines or JT15D-5 (Post-
SB7249/Pre-SB7324) engines incorporating P/N MS9696-09 bolts: Use new
bolts only. Install 45 new bolts (10) with first three bolts in third, fourth and
fifth holes from top dead center position. Install remaining bolts in every
fourth, fifth and sixth holes after.
(c) For Post-SB7249/Pre-SB7324 engines incorporating P/N 3111850-01 bolts:
Use existing bolts. Install 45 existing bolts (10) with first three bolts in third,
fourth and fifth holes from top dead center position. Install remaining bolts in
every fourth hole.
(d) For JT15D-5 (Post-SB7324) and JT15D-5R engines: Use existing bolts. With
top dead center hole as location No. 1, install first three bolts at fourth, fifth
and sixth locations clockwise. Leave next five holes empty. Install three bolts
at next three locations. Repeat this step for remaining thirteen sets of three
bolts.

(7) Tighten all bolts gradually and progressively until resistance is felt to snap fit between
LP turbine stator support and gas generator case.
NOTE: Do not exceed final torque (REF. NO. 1740, Table 201) during seating
operation.
(8) Gradually and progressively, tighten bolts one half turn at a time and in a diametrically
opposing (star) pattern until support is fully seated on gas generator case flange.
(9) Install spark igniters and tighten handtight (Ref. 74-20-02). If spark igniters do not fit,
LP turbine stator support is not seated correctly. Remove and reinstall spark igniters
and LP turbine stator support.
(10)Torque bolts in a star pattern (Ref. step (8) preceding) (REF. NO. 1740, Table 202) and
remove clips installed at step (2) , preceding.
(11)Install front inner bypass duct assembly (Ref. 72-70-
01).
(12)Install rear engine mount (Ref. 72-70-
04).
(13)Install primary and secondary fuel pressure tubes and associated fairing (Ref. 73-10-
03).
(14)Install spark igniters and ignition cable coupling nuts (Ref. 74-20-
02).
(15)Install LP turbine stator assembly and LP turbine rotor balancing assembly (Ref. 72-50-
03).
(16)Install turbine exhaust duct and No. 4 bearing housing (Ref. 72-50-

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
06).
(17)If a replacement or repaired combustion chamber liner or LP turbine stator support was
installed, perform required ground checks (Ref. 71-00-00, ADJUSTMENT/TEST).
6. Inspection/Check
A. LP Turbine Stator Support Assembly - Wear and Fretting (Ref. Fig. 202)
(1) Inspect inner sealing ring contact circumference for wear (Ref. Fig. 202, Detail A). If

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
wear limit is not met, return assembly to an approved overhaul facility for repair.
Figure 202 Inspection/Check - LP Turbine Stator Support
Assembly

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

(2) Inspect nine narrow slots for fretting wear (Ref. Fig. 202, Detail B).
(a) Wear, up to a maximum slot width of 0.280 inch, is an acceptable condition,
providing lateral movement of No.2 vane ring in LP turbine stator support does
not exceed 0.016 inch in any direction.
(b) Return assembly to an approved overhaul facility, if preceding limits are
exceeded.

(3) Inspect six support pin bosses for security and condition of
threads.
B. Combustion Chamber Liner and Support Pins (Ref. Figs. 203 and 204)
(1) General
(a) Problems most commonly affecting the combustion chamber liner are cracks,
buckling and burning. These may occur separately or in combinations.
Depending on the extent and location of the problem, the damage may be
allowable without repair; repairable using local resources; or non-repairable,
requiring rejection of the liner. Cracks in liner surfaces are usually caused by
stress-relief and, if so, are not serious in that as a crack lengthens, its rate of
growth diminishes. Typical liner distress consists of buckling and cracking of
cooling rings, and cracking of the liner wall adjacent to the dome.

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
Figure 203 Inspection/Check - Combustion Chamber Liner
(SHEET 1 OF 2)

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MAINTENANCE MANUAL 72-40-01 - COMBUSTION CHAMBER, LPT STATOR SUPPORT - MAINTENANCE
PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22
(SHEET 2 OF 2)

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

(2) Allowable Condition - Repair Not Required

(a) A maximum of seven cracks, each less than 1.5 inches in length are allowable
without repair. Conditions in steps (b), (c) and (e) are subject to these limits.
(b) Straight line circumferential cracks between adjacent cooling holes.
(c) A maximum of three cracks in any one plane (each less than 1.5 inches long)
in inner wrapper and adjacent to dome end. Cracks are allowable only if
separated by at least three inches of sound metal.
(d) Localized areas of shallow buckling, provided there is no evidence of burning
which would reduce wall thickness, and no abrupt change of contour (kinking)
or cracks.
(e) Cracks in cooling rings are acceptable except as stated in step (4) , following.
(f) Fretting wear of corrugated strips at open end of inner and outer liners up to
50 percent of thickness at any number of pads.
(g) Wear at hole in combustion chamber liner support boss (six places), provided
that hole diameter is not greater than 0.260 inch.
(h) Wear to six combustion chamber liner support pins, provided that pin locating
diameter Z is not less than 0.200 inch (Ref. Fig. 204). Check condition of
threads.

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

Figure 204 Inspection/Check - Combustion Chamber Liner

Support Pin

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

(3) Allowable Conditions - Repair Required

(a) Repair a maximum of three cracks only if each is separated by at least three
inches of sound metal (Ref. Para. 7., Approved Repair). Conditions in steps (b)
and (c) are subject to these limits.
(b) Circumferential cracks in cooling ring seam welds which do not exceed 0.030
inch wide or 0.300 inch long (Ref. Para. 7.).
(c) Circumferential cracks adjacent to seam welds if not exceeding 0.030 inch
wide and less than 1.500 inches long (Ref. Para. 7.).
(d) Buckled cooling rings must be reworked using a suitable forming bar to
restore a uniform gap.

(4) Unacceptable Conditions - Reject Combustion Chamber Liner

NOTE: Rejected combustion chamber liners removed during maintenance practices
should be returned to an approved overhaul facility for possible restoration.
(a) Any crack exceeding 1.500 inches long.
(b) Cracks open more than 0.030 inch.
(c) Multiple cracks; cracks clustered in one area; branching cracks; cracks which
might progress so as to meet and allow metal to break off.
(d) Severe buckling with abrupt change of contour (kinks); buckling associated
with burning and resultant reduction of metal thickness.
(e) Any cracking or buckling in the combustion chamber dome; cracks in fuel
nozzle adapter housings or igniter plug grommet housing.
(f) Wear at hole in combustion chamber liner support bosses, such that hole
diameter is greater than 0.260 inch.
(g) Wear to combustion chamber liner support pins, such that pin locating
diameter is less than 0.200 inch.

7. Approved Repairs
A. Crack Repair by Welding
(1) Stop-drill both ends of a crack using 1/16 (0.0625) inch drill. Wire brush to obtain bright
metal.
(2) Weld crack using inert gas fusion method (Ref. 70-00-00, STANDARD PRACTICES -
REPAIR) and filler rod (PWC05-151). Use copper back-up plate to reduce distortion,
with recommended addition of Argon gas backup, if available. Stress relief after
welding is not required.
(3) Dress excessive weld beads to meet "Nominal Weld" conditions specified in Chapter 70-
00-00, STANDARD PRACTICES - INSPECTION.
B. Cooling Ring Repair
(1) Rework buckled cooling rings using a suitable forming bar to restore a uniform
gap.
8. Fits, Clearances and Torque Loadings
Refer to Tables 201 and 202 and Figure 205.
Table 201 Fits and Clearances

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

Dim. for Ref.

REF. inches Limits inches
No.
Name Min. Max. Min. Max. Replace

Duct Assembly, Combustion 14.3160 14.3400

Chamber Exit, Small 0.0050 0.0370
1075
RADIAL
Liner Assembly, Combustion 14.3500 14.3900
Chamber

Liner Assembly, Combustion 13.9400 13.9600

Chamber 0.0000 0.0200
1077
RADIAL
Duct Assembly, Combustion 13.9600 13.9800
Chamber, Small

JT15D-5 (Pre-SB7545): 11.5880 11.5920

Turbine Stator, HP 0.0150 0.0270
1078
RADIAL
Duct, Combustion Chamber Exit, 11.6220 11.6420
Small

JT15D-5 (Post-SB7545) and 11.5880 11.5920

JT15D-5R:
Turbine Stator, HP 0.0175 0.0295
1078
RADIAL
Duct, Combustion Chamber Exit, 11.6270 11.6470
Small

JT15D-5 (Pre-SB7545): 11.3000 11.3200

Duct, Combustion Chamber Exit, 0.0080 0.0200
1079 Small RADIAL
Turbine Stator, HP 11.3360 11.3400

JT15D-5 (Post-SB7545) and 11.2950 11.3150

JT15D-5R:
Duct, Combustion Chamber Exit, 0.0105 0.0225
1079
Small RADIAL

Turbine Stator, HP 11.3360 11.3400

Case Assembly, Gas Generator 21.4790 21.4830

1107 0.0000 0.0080T
Support Assembly, LP Turbine 21.4750 21.4790
Stator

JT15D-5 (Pre-SB7432): 0.0050 0.0160

1189 Support, HPT Shroud Segments SIDE
CLEARANCE
Seal Ring, Interstage

JT15D-5 (Post-SB7432) and

JT15D-5R: 0.0040 0.0130
1189 Support, HPT Shroud Segments SIDE
CLEARANCE
Seal Ring, Metal, High Pressure
Stator

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

Dim. for Ref.

REF. inches Limits inches
No.
Name Min. Max. Min. Max. Replace
JT15D-5 (Pre-SB7432): 0.1700 0.2000
Gap, Seal Ring (at 12.910 Gage
1190 Dia.) 0.1700 0.2250
Support, LP Turbine Stator, 12.9100 12.9180
Assembly

JT15D-5 (Post-SB7432) and 0.0850 0.1150

JT15D-5R:
Gap, Seal Ring (at 12.910 Gage
1190 Dia.) 0.0850 0.1270

Support, LP Turbine Stator, 12.9100 12.9140

Assembly

Table 202 Torque and Stretch

Limits
REF.
No. Name Min. Max.

Bolts, Gas Generator Case, LP Turbine Stator Support Flange

1740 46 lb.in. 52 lb.in.
Assembly

Table 203 Spring Pressure

Limits

REF. No. Name Min. Max.

NOT APPLICABLE

Table 204 Special Assembly

Limits

REF. No. Name Min. Max.

NOT APPLICABLE

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PRACTICES
Manual Part No.3033442 Rev. 50.0 - 25/APR/22

Figure 205 Fits, Clearances and Torque Loadings

JT15D-5 SHOWN (JT15D-5R SIMILAR)

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