SECTION 4

ENGINE CONSTRUCTION

WHEN YOU COMPLETE THIS LESSON, YOU WILL BE ABLE TO:

1. LIST THE SIX MAJOR AREAS THAT MAKE UP THE GASPATH CONFIGURATION.

2. IDENTIFY EACH STATION IN THE ENGINE GASPATH BY LOCATION AND NUMBER.

3. IDENTIFY THE FIVE BEARINGS THAT SUPPORT THE TWO SPOOLS IN THE ENGINE.

4. LIST THE MAJOR ASSEMBLIES AND BUILD GROUPS OF THIS ENGINE.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4-1
 ENGINE CONSTRUCTION
ENGINE SPECIFICATIONS AND CONFIGURATION

GASPATH CONFIGURATION

• Low Pressure Compressor (LPC) • High Pressure Turbine (HPT)

– 6 stages – 2 stages
• 1 fan stage – Drives HPC
• 5 primary stages • Low Pressure Turbine (LPT)
– Modulating 2.5 bleed valve (4th stage air) for engine – 5 stages
stability and dirt removal. – Drives LPC
• High Pressure Compressor (HPC) • T bi Exhaust
Turbine E h t Case
C
– 11 stages – Exhaust gas temperature and pressure sensing probes
– 4 stages of variable vanes for optimum performance – Rear engine mount
• Combustion Section
– Diffuser case
– Annular combustion chamber

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4-2
 GASPATH CONFIGURATION AREAS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4-3
 ENGINE CONSTRUCTION
ENGINE SPECIFICATIONS AND CONFIGURATION

ENGINE FLANGES1 ENGINE STATIONS2

• A: Intake cowl attachment • 0: Ambient

• B: Front fan case to fan exit outer case • 1: Intake cowl inlet*
• C: Fan exit outer case to intermediate case • 2: Engine core inlet
• C1: Stiffness and bracket attachment • 2.5: LPC exit
• D: “V" ring groove - cowl load sharing, front ground • 2.9: HPC 9th stage exit
handling pads positioned aft of D flange at 9:00, 12:00 and
3:00 locations
• 3: HPC exit

• D1 “V" ring
D1: i groove - cowll load
l d sharing
h i
• 4: Combustor exit

• E: Intermediate case to HPC front case

• 4.5: LPT inlet

• H: HPC front case to HPC rear case

• 4.95: LPT exit (at turbine exhaust case rear flange)

• J: Stiffness and bracket attachment

• 5: Exhaust nozzle exit*

• K: HPC C rear case to diffuser

diff case
• 12: Fan inlet

• M: Diffuser case to HPT case

• 14: Fan exit

• N: HPT case to LPT case

• 15: Thrust reverser translating cowl exit*

• N1: LPT case to spool case

• P: Spool case to turbine exhaust case
• R, S: Aft mount attachment at 12:00 position, ground * Nacelle station (not shown)
handling attachments at 3:00 and 9:00 positions
• T: Exhaust nozzle attachment 1
Physically located on the outside of the engine.
• T1 Exhaust
T1: E h plug
l attachment
h 2
Location points in the engine gaspath.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4-4
 ENGINE FLANGES AND STATIONS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4-5
 ENGINE CONSTRUCTION
ENGINE MAIN BEARINGS AND BEARING COMPARTMENTS

Description and Operation:

• No 1,
No. 1 1.5,
1 5 and 2 bearing compartment • No 1.5
No. 1 5 bearing
– The number 1, 1.5, and 2 bearings are found in the – The No. 1.5 bearing gives radial support to the low
same bearing compartment at the front of the engine. pressure compressor shaft and has:
The turbine coupling shaft and intermediate case give • A cylindrical roller bearing.
structural support to these three bearings. • An inner race and rollers mounted on the LPC-
– The number 1, 1.5, and 2 bearing compartment has LPT coupling.
provision for the N1 speed sensing probe and the No. • A bearing support mounted to the intermediate
1 bearing vibration accelerometer. case.
• No. 1 bearing • Dry-face, spring-loaded carbon seals pressurized
– The
Th No.N 1 bearing
b i is i the
h thrust
h b i for
bearing f the
h low
l by 9th stage air.
pressure rotor and has: • Lubrication and cooling oil supplied by an oil jet
• A split inner race. directed at the front seal plate and bearing. A
• An angular contact ball bearing. second oil jet is directed at an axial scoop that
• A bearing
b i supportt mounted t d to
t the
th intermediate
i t di t supplies oil to cool the rear plate.
plate
case.
• Dry-face, spring-loaded carbon seals pressurized
by station 2.5 air.
• Lubrication and cooling oil supplied under the
inner race and sent to the bearing through the
split inner race.
• A vibration accelerometer mounted to the bearing
support flange.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4-6
 ENGINE BEARINGS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4-7
 ENGINE CONSTRUCTION
ENGINE MAIN BEARINGS AND BEARING COMPARTMENTS

Description and Operation (cont):

• No. 2 bearing • No. 4 bearing:

– The No. 2 bearing is the thrust bearing for the high – The No. 4 bearing gives radial support to the LPC
pressure rotor and: driveshaft and LPT and:
• Has a split inner race. • Is a cylindrical roller bearing.
• Is an angular contact ball bearing mounted in the • Is supported by the turbine exhaust case.
intermediate case. • Is an oil-damped bearing.
• Has lubrication and cooling oil flowing to the • Is lubricated by splash oil from the scoop.
b i through
bearing th h a split
lit inner
i race.
• Has a ring-type, dry-face carbon seal pressurized
• Is oil damped with a damper shutoff valve to by station 2.5 air that enters the LPT shaft
keep vibration out of the aircraft. forward of the No. 1 bearing.
• Aft carbon seal is a dry-face, spring-loaded
carbon seal pressurized by 2.52 5 air.
air
• Forward carbon seal is a wet-faced, spring-
loaded carbon seal pressurized by 9th stage air.
• No. 3 bearing:
– Thee No. 3 bea
bearingg ggives
ves radial
ad a suppo
supportt to tthee HPC
C aandd DC Monitor oil consumption
p to identify
fy No. 2
HPT and: IFSD dry-face carbon seal failure.
• Is a cylindrical roller bearing.
• Is supported by the diffuser combustor case.
• Has an elliptical
p outer race.
• Has wet-faced carbon seals pressurized by 12th
stage buffer cooling air.
• Is lubricated by splash oil from the scoop.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4-8
 ENGINE BEARINGS DC
IFSD
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4-9
 ENGINE CONSTRUCTION
ENGINE MAIN BEARINGS AND BEARING COMPARTMENTS

Description and Operation (cont):

• No. 3 bearing buffer cooling air

– 12th stage air is taken from the diffuser combustor
case at the 5:00 position and sent to the No. 3 bearing
buffer air cooler found at the 2:00 position in the
intermediate case.
– The No. 3 bearing buffer air cooler is an air-to-air heat
exchanger using 4th stage air taken from the
LPC/HPC transition duct to cool 12th stage air
coming from the diffuser combustor case.
– The cooled 12th stage air is carried to the No. 3
bearing cooling duct by tubes.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 10
 NO 3 BEARING BUFFER COOLER
NO.
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 11
 ENGINE CONSTRUCTION
ENGINE MAIN BEARINGS AND BEARING COMPARTMENTS

Description and Operation (cont):

• No. 3 bearing buffer cooling air (cont)

– The cooled 12th stage air flows through the No. 3
bearing cooling duct carrying heat away from the No.
3 bearing
b i as it i flows.
fl Flowing
l i 12th 12 h stage air
i also
l
pressurizes the forward and aft carbon seals.
– After pressurizing the carbon seals, the cooling air
flows:
• Aft between the 1st and 2nd HPT disks.
disks
• Through holes in the 2nd HPT disk.
• Into the hollow roots of the 2nd HPT blades.
• Through the hollow 2nd HPT blades to cool
them.
them
• And out of the cooling holes of the 2nd HPT
blades into the gaspath.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 12
 NO 3 BEARING BUFFER AIR COOLING
NO.
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 13
 ENGINE CONSTRUCTION
BUILD GROUPS AND ASSEMBLY PARTS

General:

• A build group is the largest assembly of engine parts that

can be:
– Removed from the engine as a unit, or installed on the
engine
i as a unit.i
– Disassembled or preassembled by a P&W customer,
independent of the other build groups.
• The PW4168 has a modular design. It is divided into
twelve build groups plus two other major assemblies.
assemblies
Each build group has its own reference subchapter in the
engine manual and IPC.
• The non-build group assemblies are referred to as
assembly parts. They are:
– Removed from and installed on the engine separately
from the build groups.
– Attached to build groups or to other assembly parts.
– Used to connect some of the build groups together,
thus, are interfaces between those build groups.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 14
 MAJOR ASSEMBLIES / BUILD GROUPS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 15
 ENGINE CONSTRUCTION
BUILD GROUPS AND ASSEMBLY PARTS

BUILD GROUP / ASSEMBLIES

• Compressor inlet cone

• Fan blades
• LPC-LPT coupling group
• Low Pressure Compressor (LPC) group
• Fan case group
• Intermediate case group
• High
g Pressure Compressor
p ((HPC)) ggroupp
• Diffuser and combustor group
• Turbine nozzle group
• High Pressure Turbine (HPT) group
• Low Pressure Turbine ((LPT)) ggroupp
• Turbine Exhaust Case (TEC) group
• Angle Gearbox (AGB) group
• Main Gearbox (MGB) group

Note: The section numbers shown below are from the Engine
Manual (EM) and not from the Aircraft Maintenance Manual
(AMM).

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 16
 PW4164 / PW4168 ENGINE BUILD GROUPS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 17
 ENGINE CONSTRUCTION
COLD SECTION

COMPRESSOR INLET CONE

Purpose:

• The compressor inlet cone is an aerodynamic fairing that

helps to cause a smooth airflow into the engine.

Description and Operation:

• Kevlar and epoxy resin with a polyurethane coating.

• Two cone segments
– Rear segment (bolted to the front of the LPC hub)
– Front segment (bolted to the rear cone segment)
• Pre–balanced assembly
• 12 vent holes for anti–ice air (equally spaced around the
rear cone segment)
• Line replaceable unit
– Note: The compressor inlet cone is also referred to as
the nose cone or spinner.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 18
 COMPRESSOR INLET CONE
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 19
 ENGINE CONSTRUCTION
COLD SECTION

FAN BLADES

Purpose:

• The fan blades are used to: • The fan blades can be replaced as moment–weighted pairs
– Compress the air that goes into the engine. or individually if the replacement blade is within the
required moment weight on installed engines.
– Send the compressed air to the core and fan gaspaths.
• Each fan blade has a rubber seal below the blade platform.
Description and Operation: • The fan blades are line replaceable units.
• The LPC first stage has 34 wide–chord fan blades. Each
blade:
– Is a titanium forging.
– Has a single part–span shroud.
MAINTENANCE TIP: Procedures for removal and
– Has its moment weight marked on its concave surface. replacement of antigalling compound on the root of the
– Has its part number and serial number marked on the fan blades is found in ATA Chapter 70: Standard
bottom of the blade root section. Practices.
• The fan blades are installed in dovetail slots in the LPC
hub. These slots hold the blades radially.
• The fan blades are held axially by a split–ring blade lock
which has an anti–rotation pin and a lock removal hole.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 20
 FAN BLADE ASSEMBLY
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 21
 ENGINE CONSTRUCTION
COLD SECTION

LOW PRESSURE COMPRESSOR (LPC)

Purpose:

• The low pressure compressor is used to increase the • The LPC rotor is:
pressure of the primary airstream. – A titanium drum supported by the No. 1 ball bearing
which is on the front compressor hub.
Description and Operation:
– Turned by the low pressure turbine (LPT).
• The LPC build group • The fan exit fairing of the LPC build group is attached to
– A 6–stage rotor assembly (stages 1, 1.3, 1.6, 2, 3, 4) the fan exit inner case assembly which supports the LPC
stator
t t assembly.
bl
• Blades for stages 1.3, 1.6, 2, 3, and 4 are made
of titanium Note: The fan exit inner case assembly (not shown) is part of
the fan cases build group.
– A 5–stage stator assembly (stages 1, 1.3, 1.6, 2, 3)
• Vanes for stages 1, 1.3, 1.6, 2, and 3 are made of
titanium
• Stator cases are made of aluminum
• The first stage of the LPC rotor is the fan stage. The
blades are assembly parts.
• A the
At h entrance to theh primary
i gaspathh the:
h
– First stage of the stator assembly is located aft of the
fan blades.
– Fan exit fairing divides the primary and secondary
airstreams.
airstreams
• The fan exit fairing is made of a composite
material of Kevlar and epoxy with a steel mesh
outer surface.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 22
 LOW PRESSURE COMPRESSOR
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 23
 ENGINE CONSTRUCTION
COLD SECTION

LPC-LPT COUPLING

Purpose:

• The LPC-LPT coupling is used to connect the LPC rotor to • 4th stage air continuously enters the LPC-LPT coupling
the LPT shaft. through holes which are aft of its front splines. The fourth
stage air:
Description and Operation: – Fills the LPC rotor and pressurizes the No. 1 bearing
carbon seal.
• The LPC-LPT coupling, made of titanium, is:
– Fills the internal space in the coupling.
coupling
– Splined to the LPC rotor hub and to the LPT shaft.
– Goes through a hole in the turbine shaft plug to anti–
– Supported by the No. 1.5 bearing. ice the inlet cone.
• A ferrous-material motional pickup wheel is on the
• Note: The turbine shaft plug is also referred to
coupling.
as tthee cove
cover plate.
p ate.
– The pickup wheel has 60 teeth - 59 long teeth and one – Goes aft to cool the LPT and pressurize the No. 4
short tooth which is used in the trim balance of the N1
bearing carbon seal.
rotor.
– The rotational movement of the teeth on the pickup
wheel is sensed by the N1 speed transducer (not
shown).
– The transducer sends a signal that transmits the N1
(LPC rotor) speed as an input to the EEC.
• The LPC-LPT coupling:
p g
– Gives improved support for the LPC through the No.
1 and No. 1.5 bearings.
– Permits split engine transportation.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 24
 LPC-LPT COUPLING
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 25
 ENGINE CONSTRUCTION
COLD SECTION

FAN CASES

Purpose:

• The fan cases:
– Make a flowpath for the fan discharge air.
– Are the part of the engine structure that supports the
nacelle intake cowl.
Description and Operation:
• The fan front case:
– Is made of titanium.
– Supports the intake cowl.
– Has plastic-filled honeycomb fan blade tip rubstrips.
– Prevents the fan blades from going out of the engine
radially if they break (referred to as fan blade
containment).
– Has perforated Kevlar/epoxy face sheet acoustic
treatment which is used to lessen the noise.
• The fan exit inner and outer cases are:
– Made of aluminum.
– Connected by 72 fan exit guide vanes made of
composite material (graphite/epoxy) with a stainless
steel mesh leading edge.
• The fan exit case and fan exit guide vane assembly makes
the fan discharge air straight before it goes into the thrust
reverser fan air duct.
– The fan exit guide vanes are a composite with:
• A solid metal leading edge.
edge
• Fiberglass plies.
Put a protective mat in the intake cowl and
DC fan case whenever you work in the area. If
IFSD you damage the acoustic treatment it could
be liberated and taken into the engine.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 26
FOR TRAINING PURPOSES ONLY
FAN CASE ASSEMBLY DC
IFSD
623 NOVEMBER 1999 4 - 27
 ENGINE CONSTRUCTION
COLD SECTION

INTERMEDIATE CASE

Purpose:

• The intermediate case is the primary structural component

of the engine. It has attachment points for many of the
engine components.

Description and Operation:

• The intermediate case is made of cast steel with:

– Welded-on cast steel struts.
– Forged steel forward engine mount thrust brackets.
• The intermediate case has the supports for three main
engine
i bearings
b i which
hi h are the:
h
– No. 1 bearing (LPC).
– No. 1.5 bearing (LPC-LPT shaft).
– No. 2 bearing (HPC).
• The intermediate case includes the:
– 4th stage compressor stator assembly.
– Nine fan struts.
– Towershaft drive gear.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 28
 INTERMEDIATE CASE - FRONT
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 29
 ENGINE CONSTRUCTION
COLD SECTION
INTERMEDIATE CASE REAR
•Forward mount pad
– Found at the 12:00 position
– Attached engine mount:
• Is a puck and gimbal type.
• Can take torque, vertical, and growth loads.
•Starter air valve solenoid
– Found at the 12:30 position
– Controls the starter air valve
•Three 4–way valve solenoids
– Found at the 1:30 pposition to control the:
• Right TVBC air shutoff valve/nacelle core
compartment cooling air valve solenoid.
– Found at the 11:00 position to control the:
• 2.9 start bleed valve (right).
• 2.9 stability bleed valve (left).
– Found at the 10:30 position to control the:
• Left TVBC air shutoff valve/anti-ice valve
solenoid.
•Pneumatic relay valve
•Forward mount thrust brackets
– Found at the 11:00 and 1:00 positions
– Can take torque and thrust loads
•No. 3 bearing buffer air cooler
– Found at the 2:00 position
– Precools the cooling air for the No. 3 bearing
compartment
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999
• IDG air/oil heat exchanger and valve
– Found at the 4:00 position
– Uses fan air to cool the IDG system oil
• Remote charge converter
– Found at the 5:00 position
– Transmits engine vibration signals to the engine
indicating and vibration monitoring unit (EIVMU)
• Accelerometer
• N1 speed (P2.5/T2.5) probe
– Found at the 5:00 position
– Senses N1 speed
• Angle gearbox
– Found at the 6:00 position
– Driven by the towershaft which is turned by the HPC
• Cooling air line
– Found at the 6:30 position
– Supplies 2.5 or fan cooling air to the PMA, oil filter
differential pressure switch, oil quantity sensor, and
the oil pressure sensor.
– 2.5 bleed valve actuator
– Found at the 7:00 position attached to the fan exit case
– Hydraulic
y actuator to move the 2.5 bleed valve
• Engine air/oil heat exchanger and valve
– Found at the 8:00 position
– Uses fan air to cool the engine oil
4 - 30
 INTERMEDIATE CASE - REAR
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 31
 ENGINE CONSTRUCTION
COLD SECTION

HIGH PRESSURE COMPRESSOR (HPC)

Purpose:

• The high pressure compressor is used to increase the • The HPC supplies the following bleed air.
pressure of the primary air from the low compressor and – 8th stage air for:
send it to the diffuser. • Aircraft use.
Description and Operation: – 9th stage air for:
• Engine stability.
• The HPC has an 11 stage rotor and stator assembly. • Rotor cooling.
– The first set of airfoils is the inlet guide vane (IGV) • No. 1.5 bearing seal pressurization.
assembly. – 12th stage air:
– Each of the first four stator stages has: • To cool the No. 3 bearing.
• Variable
V i bl vanes. • To cool parts of the turbine.
• A unison ring assembly. • For No. 3 bearing seal pressurization.
• The HPC is a five-piece rotor supported at the: – 15th stage air:
– Front by the No. 2 bearing. • To reduce the thrust load on the No. 2 bearing.
– Rear by the No. 3 bearing. • For muscle pressure.
• The HPC is turned by the HPT. • For aircraft use.
• The HPC turns the towershaft to drive the angle gearbox. • For No. 3 bearing seal pressurization.
• To cool parts of the turbine.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 32
 HIGH PRESSURE COMPRESSOR (HPC)
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 33
 ENGINE CONSTRUCTION
HOT SECTION

DIFFUSER CASE
Purpose:
• The diffuser: – Has 24 fuel injectors which are attached around the
– Makes the airflow (from the compressor exit) straight. diffuser case.
– Diffuses (increases the pressure and reduces the speed – Has 2 igniter plug bosses which provide ignition for
of) the primary air.
air combustion.
– Sends the air into and around the combustor • The combustion chamber is an annular design that is
(combustion chamber). formed by the:
– Outer combustion chamber liner, which is part of this
Description and Operation: build group.
• In the combustor the: – Inner combustion chamber liner, which is part of the
– Fuel is mixed with the air. turbine nozzle build group.
– Fuel/air mixture is burned to add energy to the • The combustion chamber liners have floatwall segments
primary gaspath. bolted inside them. They also have holes that permit air to
• The diffuser case: enter
t the
th chamber
follows.
h b for f combustion,
b ti dil ti
dilution, andd cooling
li as
– Is attached with bolts to the high pressure compressor
rear case. • The air that is used for combustion goes through the large
holes near the front of the chamber.
– Contains the compressor exit stator which:
– The air that is used for dilution (to reduce the
• Is the last HPC stator stage.
temperature of the very hot combustion gases) enters
• Helps to make the HPC airflow straight when it the smaller holes near the rear of the chamber.
enters the diffuser.
– The cooling air enters the chamber through the small
– Supports the No. 3 bearing. holes at each segment. It then flows against the inner
– Has
H ports to supply l 15th
15 h stage bleed
bl d air
i from
f the
h HPC and outer surface floatwall segments as a cooling film.
for use by the engine and aircraft. • The combustion chamber is held by 12 doweled end bolts.
– Has eight fuel injector manifolds which transmit fuel (referred to as combustion chamber retaining bolts).
to the injectors.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 34
 DIFFUSER CASE
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 35
 ENGINE CONSTRUCTION
HOT SECTION

TURBINE NOZZLE

Purpose:

• The turbine nozzle guide vanes send hot gases from the
combustion chamber to the 1st stage turbine blades at the
correct angle and speed.
• The cooling duct sends cooling air to the 1st stage turbine
rotor and blades.
Description
esc pt o aand
d Ope
Operation:
at o :
• The turbine nozzle build group has:
– The inner combustion chamber.
– The 1st stage HPT cooling duct.
– Thirty-four 1st stage HPT nozzle guide vanes.
• The inner combustion chamber liner:
– Is made of sheet metal with floatwall segments bolted
inside.
– Has holes that permit air to enter the chamber for
combustion, dilution, and cooling.
• Cooling air from the diffuser flows around the inner and
outer combustion chamber liners.
– Air enters the chamber through small holes at each
segment. It then flows against the inner and outer
surface of the chamber liner and the floatwall
segments as a cooling film.
– It also enters the internal passages of each vane and
goes out of each vane through a pattern of holes to
give a protective film on the surfaces of the vanes in
the gaspath.
– The air goes into the annular cooling duct which
operates as a metering nozzle. It goes out of the
metering nozzle and flows against the turbine rotor.
– There is one honeycomb seal and one brush seal at the
interfaces with the 1st stage turbine rotor to minimize
leakage of the cooling air that is used for the 1st stage
turbine rotor and blades.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 36
 TURBINE NOZZLE
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 37
 ENGINE CONSTRUCTION
HOT SECTION

HIGH PRESSURE TURBINE (HPT)

Purpose:

• The high pressure turbine is used to supply the force to
turn the high pressure compressor.
Description and Operation:
• The high pressure turbine has:
– One case and vane assembly.
– Two disk and blade rotor assemblies.
– One rotating inner airseal.
• Air-cooled parts are the.
– 1st stage disk and blade assembly.
– 2nd stage disk and blade assembly.
– 2nd stage vanes.
– 2nd stage inner airseal.
• Turbine blades
– The 60 1st stage turbine blades are made using a
single crystal casting process.
• Abradable ceramic outer airseal segments g are found
around the blade tips.
• 2nd stage turbine vanes
– 21 vane cluster assemblies (2 vanes per cluster)
– Inner airseal land at the inner diameter of the 2nd
stage vanes
– Cooled internally by 12th stage HPC air which enters
the cooling air annulus through cooling air ports
• Turbine Case Cooling (TCC) system components:
– Are not part of this (or any) build group.
– Include cooling air manifolds which are attached to
brackets on the outside of the HPT case.
– Control the flow of fan air through those manifolds to
cool the HPT case to:
• Reduce its diameter and thus reduce the HPT
blade tip clearances.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 38
 HIGH PRESSURE TURBINE (HPT)
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 39
 ENGINE CONSTRUCTION
HOT SECTION

LOW PRESSURE TURBINE (LPT)

Purpose:
p

• The low pressure turbine is used to supply the force to turn • The 5th stage disk supports the other four disks as follows.
the low pressure compressor through a driveshaft. – The 3rd and 4th stage disks are cantilevered from the
front of it.
Description
p and Operation:
p
– The 6th and 7th stage disks are attached to the rear of
it.
• The low pressure turbine has five stages.
– 3rd stage • Internal cooling air from the HPC 9th stage is supplied to
the LPT to reduce the temperature at the:
• 39 nozzle guide vane clusters (3 vanes per
cluster)
l t )
– Inner wall of the transition duct.
• 128 blades
– 3rd, 4th, and 5th stage disks.
– 4th stage – Inner seal areas of the 3rd, 4th, and 5th stage stators.
• 44 vane clusters (3 vanes per cluster)
• The 12th stage HPC air that cools the 2nd stage HPT vanes
also cools the outer areas of the transition duct.
• 130 blades
bl d
– 5th stage
• 4th stage LPC air cools the:
– Inner seal area of the 6th and 7th stage stators.
• 38 vane clusters (3 vanes per cluster)
– 6th and 7th stage disks.
• 126 blades
– 6thh stage
• Turbine Case Coolingg ((TCC)) system
y components:
p
– Are not part of this (or any) build group.
• 36 vane clusters (3 vanes per cluster)
– Include cooling air manifolds which are attached to
• 124 blades brackets on the outside of the turbine case.
– 7th stage – Control the flow of fan air through those manifolds to
• 37 vane clusters (3 vanes per cluster) cool the turbine case to:
• 102 blades • Reduce its diameter and thus reduce the LPT
blade tip clearances.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 40
 LOW PRESSURE TURBINE (LPT)
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 41
 ENGINE CONSTRUCTION
HOT SECTION

TURBINE EXHAUST CASE (TEC)

Purpose:

• The turbine exhaust case is used to:

– Support the No. 4 bearing.
– Hold the exhaust nozzle and plug.
– Transmit the turbine discharge gases through its struts
to the exhaust nozzle and plug.

Description and Operation:

• The TEC has attachment points for the:

– Rear engine mount.
– Ground handling tools.
• The struts make the primary airflow straight before it
enters the area of the exhaust plug and nozzle.
• The TEC has openings and attachment points (not shown)
for four combination P4.95/T4.95 probes.
– Note: Oil in the No. 3 bearing weep means a carbon
seal in the No. 3 bearing has failed.

Inspect clamp location at three places on the

DC No. 4 bearing scavenge tube if SB PW4G-
IFSD
100-72-53 has not been done.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 42
 TURBINE EXHAUST CASE DC
IFSD

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999
ASSEMBLY 4 - 43
 ENGINE CONSTRUCTION
HOT SECTION

TURBINE EXHAUST CASE (TEC)

Description and Operation (cont):

• The TEC holds

Th h ld the
h No.
N 4 bearing
b i aft f packings.
ki
• The No. 4 bearing aft packings are LRUs.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 44
 NO 4 BEARING COVER
NO. COVER, SHIELD AND HEATSHIELD
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 INSTALLATION 4 - 45
 ENGINE CONSTRUCTION
GEARBOXES

ANGLE GEARBOX (AGB) MAIN GEARBOX (MGB)

Purpose: Purpose:

• The angle
g ggearbox is used to drive the main ggearbox. • The main ggearbox drives the accessories for the engine
g
and aircraft.
Location:
Location:
• The AGB is installed at the rear of the intermediate case:
– Att tthee 6:00 pos
position.
to . • The MGB is installed under the high compressor case at
the 6:00 position.
– Between the primary and secondary gaspaths.
Description and Operation:
Description and Operation:

• The AGB is supported by:

– Two mount lugs at the front.
– The layshaft housing at the rear.
• The AGB is driven by the towershaft, which is turned by
the HPC. The AGB turns the horizontal layshaft
y (gearbox
(g
driveshaft) which drives the main gearbox.
• The AGB housing is an aluminum casting.
• The AGB is a line replaceable unit.
• The MGB is supported by:
– The layshaft link at the front.
– Two side mounts to the HPC rear case.
– An anti-sway bracket to prevent lateral movement.
• The MGB:
– Is driven by the horizontal layshaft which is turned by
the AGB.
– Housing is an aluminum casting.
– Has a chip detector.
– Has a Permanent Magnet Alternator (PMA) mounted
to the front.
• The MGB is a line replaceable unit.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 46
 ANGLE AND MAIN GEARBOXES
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 47
 ENGINE CONSTRUCTION
GEARBOXES

MAIN GEARBOX (MGB)

Description and Operation (cont):

• All of the main gearbox accessory drives:

– Are
A modules
d l that
th t can be
b easily
il putt into
i t (or
( pulled
ll d outt
of) the MGB.
– Have replaceable carbon seals.
– Permit seal drain leakage by components to be sent
overboard.
overboard
– Are wet spline drives (except for the starter drive).
• Found on the front of main gearbox is the:
– Fuel pump drive pad.
– N2 crank pad.
pad
– Permanent magnet alternator.
– Layshaft housing.
– Deoiler.
– Main oil filter housing.
housing
– Pressure oil fitting to the front hydraulic pump drive
gearbox.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 48
 MAIN GEARBOX - FRONT
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 49
 ENGINE CONSTRUCTION
GEARBOXES

MAIN GEARBOX (MGB)

Description and Operation (cont):

• Found on the rear of the main gearbox is the:

– Gearbox oil storage cavity which:
• Gives more volume to keep the oil.
• Contains an oil check valve.
– Oil tank mount pad.
p
– Breather air discharge port.
– IDG drive pad.
– Lubrication and scavenge oil pump.
– Rear hydraulic
y ppumpp drive ppad.
– Starter drive pad.
– Pressure oil tube fitting to the deoiler drive.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 50
 MAIN GEARBOX - REAR
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 51
 ENGINE CONSTRUCTION
AIRFLOW

FAN AIR
• Fan air is used for:
– Turbine case cooling (HPT/LPT).
– Accessory cooling (ignition system and starter receive
cooling air from the TCC inlet duct).
– Nacelle core compartment cooling.
– Aircraft pneumatic system precooler.
– Remote Charge Converter (RCC) cooling.
– To the IDG air/oil heat exchanger and valve.
– From a tap located at the 7:00 position on the fan exit
inner case to the:
• Permanent magnetg alternator ((PMA). )
• Oil pressure sensor.
• Oil quantity sensor.
• Oil filter differential pressure switch.

4TH STAGE AIR 8TH STAGE AIR

• 4th stage (2.5 air, LPC discharge) flows internally to: • 8th stage air is supplied to the aircraft Environmental
– Stabilize the LPC drum rotor. Control System (ECS) from three ducts on the HPC.
– Pressurize both the No.
No 1 bearing forward carbon seal
and the No. 2 bearing aft carbon seal. 9TH STAGE AIR
– Anti-ice the inlet cone (spinner). • 9th stage (station 2.9) air flows internally to:
– Pressurize the No. 4 (forward) carbon seal and cool – Pressurize the No. 1.5 aft carbon seal and the No. 2
the LPT inside diameter. forward carbon seal.
seal
– Cool 12th stage air in the No. 3 bearing buffer air – Cool the inside diameter of the HPC, and the inside
cooler. diameter and forward portions of the LPT.
• 2.5 air from an open 2.5 bleed valve or fan air (when the • 9th stage air flows overboard through an open start or
2.5 bleed valve is closed) flows to the plenum on the fan start/stabilityy bleed valve.
exit
i inner
i case. From
F the
h plenum,
l cooling
li airi is
i supplied:
li d
– To the engine air/oil heat exchanger and valve.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 52
 PW4164 / PW4168 AIRFLOWS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 53
 ENGINE CONSTRUCTION
AIRFLOW

12TH STAGE AIR

• 12th stage air flows to the: – Through the smaller duct for more cooling
– No. 3 bearing buffer air cooler where it is cooled by air around the No. 3 bearing buffer air
2.5 air. area. The air then flows between the 1st
• The cooled 12th stage air then flows to the No. 3 and 2nd stage HPT disks to openings in
b i buffer
bearing b ff air i area to
t cooll the
th No.
N 3 bearing
b i the HPT 2nd stage disk. The openings
forward and aft carbon seals. This air will flow permit cooling air to flow to the 2nd stage
between and cool the 1st and 2nd stage HPT HPT blades.
disks and the 2nd stage HPT blades. This is
normal HPT cooling when the engine is in cruise 15TH STAGE AIR
power.
• 15th stage air (station 3, N2 compressor discharge air) is
• No. 3 bearing breather restrictor valve as muscle known as:
and sense pressure.
– Burner pressure (Pb), which is:
– TVBC air system. • Sent to the EEC where it is used to sense an
• 12th
12 h stage cooling
li air
i flows
fl through
h h 2 ducts
d ( ih
(with impending surge and calculate fuel flow/burner
no valves) to the 2nd stage HPT vanes, the 2nd pressure (Wf/Pb) ratios.
turbine blade outer airseal, and the outer diameter
– Muscle pressure (Ps3), which is:
of the HPT/LPT transition duct into the gaspath.
• Sent to the solenoid valves and used as muscle
• 12th stage cooling air flows to the valves attached
pressure for
f the:
th
to the HPC case. There are two valves, each with
2 outlets. When the valves are opened at high – TVBC system.
power 12th stage air flows: – Nacelle core compartment cooling system.
• Through the large duct to the 2nd stage HPT – Start bleed.
vanes, the
h 2nd
2 d stage turbine
bi blade
bl d outer airseal,
i l – Start/stability
S / bili bleed.bl d
and the outer diameter of the HPT/LPT transition – Intake anti-ice system.
duct and into the gaspath.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 54
 PW4164 / PW4168 AIRFLOWS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 55
 ENGINE CONSTRUCTION
AIRFLOW

15TH STAGE AIR (cont)

• 15th stage air is used to:
– Atomize and finely divide fuel coming out of the fuel
injectors.
– Supply cooling and dilution air to the combustion
chamber.
– Internally and externally cool the 1st stage turbine
nozzle guide vanes.
• 15th stage
g air flows to the meteringg nozzle to reduce the
load on the No. 2 bearing and supply cooling air to the 1st
stage HPT blades.
• 15th stage air flows through tubes and across brush seals to
the 3i area (inboard of the 15th stage discharge) where the:
– Thrust balance vent tubes permit 3i air to flow to the
12th stage plenum to reduce the load on the No. 2
bearing.
– Cooling air flows past brush seals around the No. 3
bearing area,
area between the 1st and 2nd stage HPT
disks, through the 2nd stage HPT disk to the 2nd stage
HPT blades.
– Note: This is the usual No. 3 bearing and HPT
cooling when the engine is at cruise power or less.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 56
 PW4164 / PW4168 AIRFLOWS
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 4 - 57
 ENGINE CONSTRUCTION
REVIEW QUESTIONS

1
1. The engine station numbering system is used to: 4
4. The combustion chamber is a:
A. Standardize. A. Two-piece annular design.
B. Abbreviate terms. B. One-piece annular design.
C. Locate points in the gaspath. C. Multi-can annular design.
D Locate points on the engine cases.
D. cases D Three-piece
D. Th i annular
l design.
d i

2. Rotational energy for the main gearbox is received from 5. The purpose of the angle gearbox is to:
the: A. Drive the starter.
A Front of the N1 rotor.
A. rotor B Give
B. Gi horsepower
h to the
h aircraft.
i f
B. Rear of the low compressor. C. Power the aircraft hydraulic system.
C. Front of the N2 compressor. D. Drive the main gearbox.
D. Rear of the high compressor.
6. The
h high
hi h turbine
bi has:
h
3. The number of stages in the low and high compressor A. 1 stage.
sections are:
B. 2 stages.
A. 3 stages of low and 14 stages of high.
C. 3 stages.
B 4 stages of low and 13 stages of high.
B. high
D. 4 stages.
C. 5 stages of low and 12 stages of high.
D. 6 stages of low and 11 stages of high.

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 58
 ENGINE CONSTRUCTION
REVIEW QUESTIONS

7. The six major gaspath areas are: 9. Bearings used to support the high pressure rotor are
the:
1.) _______________________________________
A. No. 1 and No. 2.
2 ) _______________________________________
2.) B. No. 2 and No. 3.
3.) _______________________________________ C. No. 3 and No. 4.
4.) _______________________________________ D. No. 1.5, No. 2, and No. 3.

5 ) _______________________________________
5.)
10. Using the illustration shown on page 4-60, identify each
6.) _______________________________________ major assembly and build group in the space provided.

8. Match each station number to its correct engine gaspath

location.
A. 2.9 ___ 1. Combustor exit
B. 15 ___ 2. LPT inlet
C. 0 ___ 3. LPT exit ((at TEC rear flange)
g )
D. 4.5 ___ 4. Exhaust nozzle exit
E. 12 ___ 5. Fan inlet
F. 3 ___ 6. Fan exit
G 2.5
G. 25 ___ 7.
7 T/R translating cowl exit
H. 14 ___ 8. Ambient
I. 1 ___ 9. Intake cowl inlet
J. 4.95 ___ 10. Engine core inlet
K. 2 ___ 11. LPC exit
L. 4 ___ 12. HPC 9th stage exit
M. 5 ___ 13. HPC exit

FOR TRAINING PURPOSES ONLY

623 NOVEMBER 1999 4 - 59
 IDENTIFY THE MAJOR ASSEMBLIES
FOR TRAINING PURPOSES ONLY
623 NOVEMBER 1999 AND BUILD GROUPS 4 - 60