TASK 72-00-31-420-001 LPC Fan Module - Install The LPC Fan Module, Installation-001

DMC:V2500-A0-72-00-3100-01A-720A-B|Issue No:001.00|Issue Date:2014-05-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-00-31-420-001 LPC Fan Module - Install The LPC Fan Module, Installation-001

General

This TASK gives procedures for removal of the LP compressor (fan) module from the storage stand and installation on to the engine. There are two types of the storage stands (vertical type and horizontal type), and two different methods in this TASK.

- If the module is installed on the storage stand (vertical type, IAE 1J12110 Transportation and storage stand, select the method 1.

- If the module is installed on the storage stand (horizontal type), IAE 1J12019 Storage stand, select the method 2.

Fig/item numbers in parentheses in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

For standard torque data and procedures, refer to the SPM TASK 70-41-00-400-501 and SPM TASK 70-41-02-400-501.

Special torque data and assembly tolerances are included in the procedure.

Special torque data is identified with the symbol * after the torque value.

Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS, unless other lubricants are referred to in the procedure.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Transportation covers/blanks must be removed immediately before the installation of the components.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1J12026 Turning handle0AM53IAE 1J120261
IAE 1J12016 Special wrench0AM53IAE 1J120161
IAE 1J12017 Special wrench0AM53IAE 1J120171
IAE 1J12105 Cantileer sling0AM53IAE 1J121051
IAE 1J12104 Sling adapter0AM53IAE 1J121041
IAE 1J12106 Aligning pin set0AM53IAE 1J121061
IAE 1J12180 Hub protector0AM53IAE 1J121801
IAE 1J12019 Storage stand0AM53IAE 1J12019
IAE 1J12110 Transportation and storage stand0AM53IAE 1J12110

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077
CoMat 06-069 MARKERIE207CoMat 06-069
CoMat 01-124 ISOPROPYL ALCOHOLLOCALCoMat 01-124

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-31-420-052-001 Method 1: Install the Sling and Adapter Assembly to the LP Compressor (Fan) Module

    1. Remove the wingnut and the clamp which safety the LP compressor (fan) module to the storage stand, Figure.

      2. Install IAE 1J12104 Sling adapter 1 off on to the LP compressor (fan) module, Figure and Figure.

      1. Attach a hoist to the link of the sling adapter and move it above the LP compressor (fan) module.

      2. Lower the sling adapter on to the forward flange of the LP compressor (fan) module. Attach it with the 12 bolts. Tighten the bolts.

      3. Install IAE 1J12105 Cantileer sling 1 off to the sling adapter, Figure.

      1. Attach the second hoist to the shackle of the cantilever sling and move it adjacent to the sling adapter.

      2. Install the cantilever sling to the sling adapter and safety with quick release pin.

      4. Adjust the center of the gravity of the sling and adapter asssembly and the LP compressor (fan) module, Figure.

      1. Turn the adjustment handle to align the witness hole in the side plate with the S2-mark on the cantilever sling beam.

      2. Lock the adjustment handle in position.

    5. Attach the first hoist to the lifting ring of the cantilever sling, Figure and Figure.

    6. Engage the quick release pin to the outer holes of bracket of cantilever sling.

    7. Make the rope/chains of the first hoist tighter.

    8. Move the second hoist from the shackle of cantilever sling to the link of sling adapter.

    2. SUBTASK 72-00-31-020-052-002 Method 2: Install the Sling and Adapter Assembly to the LP Compressor (Fan) Module

    1. Attach the first hoist to the link (part of IAE 1J12104 Sling adapter) and lift up, Figure.

    2. Move the sling adapter on to the work bench and remove the first hoist from the link of the sling adapter.

    3. Attach the second hoist to the shackle (part of IAE 1J12105 Cantileer sling 1 off).

    4. Lift and attach the cantilever sling to the sling adapter and safety them with the quick release pin.

    5. Attach the first hoist to the lifting ring of the cantilever sling.

    6. Remove the second hoist from the shackle of the cantilever sling and attach to the link of the sling adapter.

    7. Adjust the two hoists to turn the sling and adapter assembly to the horizontal position, Figure.

      8. Remove the guards from the storage stand to make space for removal of the module from the storage stand, Figure.

      1. Remove the two quick release pins from each guard.

      2. Remove the guards from the storage stand.

    9. Install IAE 1J12180 Hub protector 1 off into the fan disk, Figure.

    10. CAUTION

      DO NOT HIT THE STAGE 1 FAN DISK WITH THE SPECIAL WRENCH WHEN YOU INSTALL AND TIGHTEN THE CURVIC COUPLING BOLTS. THE TOOL CAN CAUSE DAMAGE TO THE DISK.

      Remove the 21 screws which attach the LP compressor (fan) module to the support (part of IAE 1J12019 Storage stand 1 off) with IAE 1J12016 Special wrench 1 off, Figure.

    11. Remove the hub protector from the fan disk.

      12. Adjust the center of the gravity of the sling and adapter assembly, Figure.

      1. Turn the adjustment handle to align the witness hole in the side plate with the S1-mark on the cantilever sling beam.

      2. Lock the adjustment handle in position.

    13. Install IAE 1J12104 Sling adapter 1 off to the LP compressor (fan) module, Figure.

      14. Adjust the center of the gravity of the sling and adapter assembly and the LP compressor (fan) module, Figure.

      1. Turn the adjustment handle to align the witness hole in the side plate with the S2-mark on the cantilever sling beam.

      2. Lock the adjustment handle in position.

    15. Remove the remaining three screws which attach the LP compressor (fan) module to the support of storage stand.

    3. SUBTASK 72-00-31-420-053-001 Method 1: Remove the LP Compressor (Fan) Module from the Storage Stand

    1. NOTE

      Do this operation with the two hoist operators and the two persons to assure.

      Slowly lift the two hoists equally at the same time until the LP compressor (fan) module is clear of the storage stand, Figure.

    2. Disengage the quick release pin from the outer holes and engage to inner holes of bracket of cantilever sling.

    3. Adjust the two hoists to turn the LP compressor (fan) module to the horizontal position, Figure.

    4. Remove the second hoist from the link of the sling adapter, Figure.

    5. Remove the protection cover from the flange of the stage 1 fan disk, Figure.

    4. SUBTASK 72-00-31-420-053-002 Method 2: Remove the LP Compressor (Fan) Module from the Storage Stand

    1. Refer to Figure.

    2. CAUTION

      REMOVE THE LP COMPRESSOR (FAN) MODULE CAREFULLY TO PREVENT DAMAGE.

      Slowly remove the LP compressor (fan) module from the storage stand.

    3. Remove the storage stand.

    5. SUBTASK 72-00-31-420-054 Attach the Aligning Pins to the Stub Shaft

    1. Refer to Figure, Figure and Figure.

    2. Replace the three bolts (part of the retaining protector) with the three aligning pins (part of IAE 1J12106 Aligning pin set 1 off) one at a time. Tighten the pins lightly.

    3. Remove the retaining protector from the stub shaft.

    4. NOTE

      The aligning pin has two marks. One of the two lines is identified by the letter 'R'. Use the identified line for correlation.

      Tighten each aligning pin and align the correlation line with the Face C on the stub shaft.

    6. SUBTASK 72-00-31-420-068 Clean the Curvic Coupling for Assembly

      1. Clean the curvic teeth on the stage 1 fan disk and the LP compressor stub shaft.

      1. Use a soft bristle brush or swab and apply CoMat 01-124 ISOPROPYL ALCOHOL to the curvic teeth. Refer to the SPM TASK 70-11-26-300-503.

      2. Dry the curvic teeth with a clean dry air blast.

    7. SUBTASK 72-00-31-420-055-A00 V2500-A1: Adjust the Angular Position of the Stub Shaft

      1. Make a mark on the stage 1 fan disk, Figure.

      1. Find the correlation mark "*" on the disk outer diameter face.

      2. Mark a line on the disk inner diameter face with a CoMat 06-069 MARKER at the same position as the correlation mark "*".

    2. Install the IAE 1J12026 Turning handle 1 off to the stub shaft with the two washers and wing bolts, Figure. Tighten the wing bolts.

    3. NOTE

      The stub shaft has the four U-slots. One of them is identified by marks of "*". Use the identified U-slot for correlation.

      Turn the stub shaft with the turning handle and align the correlation U-slot with the line on the disk, Figure and Figure.

    4. Remove the turning handle from the stub shaft.

    5. Lift the LP compressor (fan) module and move in to the fan case, Figure. Make sure that the correlation U-slot and the line on the disk are aligned.

    8. SUBTASK 72-00-31-420-055-B00 V2500-A5: Adjust the Angular Position of the Stub Shaft

      1. Make a mark on the stage 1 fan disk, Figure.

      1. Find the correlation mark "*" on the disk outer diameter face.

      2. Mark a line on the disk inner diameter face with a CoMat 06-069 MARKER at the same position as the correlation mark "*".

    2. Install the IAE 1J12026 Turning handle 1 off to the stub shaft with the two washers and wing bolts, Figure. Tighten the wing bolts.

    3. Turn the stub shaft with the turning handle and align the correlation mark "*" on the stub shaft with the line on the disk, Figure and Figure.

    4. Remove the turning handle from the stub shaft.

    5. Lift the LP compressor (fan) module and move in to the fan case, Figure. Make sure that the correlation mark "*" on the stub shaft and the line on the disk are aligned.

    9. SUBTASK 72-00-31-420-056 Install the LP Compressor (Fan) Module on the LP Compressor Intermediate Case Module

    1. Move the LP compressor (fan) disk rearwards until the two halves of the curvic coupling are engaged, Figure. Make sure the three guide pins are engaged with the small holes in the fan disk rear flange Figure and Figure.

    2. Apply CoMat 10-077 APPROVED ENGINE OILS to the threads and mating faces of the 24 curvic coupling bolts.

      3. Attach the stage 1 fan disk to stub shaft with four curvic coupling bolts (01-100) at No.5, 6, 7 and 8 positions, Figure and Figure.

      1. Find the three aligning pins. The positions are No. 1, 18 and 23.

      2. Find No. 5 thru 8 positions.

      3. CAUTION

        DO NOT HIT THE STAGE 1 FAN DISK WITH THE SPECIAL WRENCH WHEN YOU INSTALL AND TIGHTEN THE CURVIC COUPLING BOLTS. THE TOOL CAN CAUSE DAMAGE TO THE DISK.

        Tighten the bolts at No. 5 thru 8 positions with IAE 1J12016 Special wrench 1 off in the sequence given in Figure and Figure.

      4. Remove the sling and adapter assembly from the LP compressor (fan) module, Figure and Figure.

        1. Adjust the center of gravity of the sling and adapter assembly.

        1. Turn the adjustment handle to align the witness hole in the side plate with the S1-mark on the cantilever sling beam.

        2. Lock the adjustment handle in position.

      2. Remove the 12 bolts which attach the sling adapter to the forward flange of the LP compressor (fan) module.

      3. Slowly move the sling and adapter assembly forward until they are clear of the fan case.

    10. SUBTASK 72-00-31-420-057 Disassemble the Sling and Adapter Assembly

    1. Refer to Figure.

    2. Attach the second hoist to the link (part of IAE 1J12104 Sling adapter) and turn the sling and adapter assembly to the vertical position.

    3. Lower the sling and adapter assembly on to a work bench.

    4. Disengage the quick release pin which attaches the cantilever sling to the sling adapter.

    5. Remove the second hoist from the link of sling adapter and attach to the shackle (part of IAE 1J12105 Cantileer sling).

    6. Remove the first hoist from the lifting ring (part of cantilever sling).

    7. Lift up the cantilever sling with the second hoist and remove it from the sling adapter.

    11. SUBTASK 72-00-31-420-058 Torque the Curvic Coupling Bolts

    1. Install IAE 1J12180 Hub protector 1 off in stage 1 fan disk, Figure.

    2. Remove the three aligning pins from stub shaft, Figure and Figure.

    3. Install the 20 curvic coupling bolts (01-100) at No. 1 thru No. 4 and No. 9 thru No. 24 positions, Figure and Figure.

    4. CAUTION

      DO NOT HIT THE STAGE 1 FAN DISK WITH THE SPECIAL WRENCH WHEN YOU INSTALL AND TIGHTEN THE CURVIC COUPLING BOLTS. THE TOOL CAN CAUSE DAMAGE TO THE DISK.

      Tighten the 20 bolts lightly in the sequence given in Figure and Figure. with the IAE 1J12016 Special wrench.

      5. Install the locating ring and the adapter ring on to the front blade retaining ring Figure.

      1. Install the locating ring (part of IAE 1J12017 Special wrench 1 off) on to the front blade retaining ring with the four screws.

      2. Tighten the screws.

      3. Install the adapter ring (part of the special wrench) on to the locating ring with four nuts. The No. 1 position in adapter ring must be at the top position.

      4. Tighten the nuts lightly.

      5. Adjust position of the adapter ring so that the 24 holes in the ring are aligned with the curvic coupling bolts.

      6. Tighten the nuts.

    6. Make sure that the spigot (part of the special wrench) is attached to the arm with the four bolts.

      7. CAUTION

        WHEN YOU TORQUE, IT IS IMPORTANT THAT THE TORQUE VALUE IS ON THE INCREASE, A NEW BOLT MUST BE INSTALLED IF THE TORQUE VALUE IS CONSTANT OR DECREASES.

        CAUTION

        THE BOLTS MUST NOT BE POWER WRENCHED.

        Torque the 24 bolts to 443 to 567* lbf.in (50 to 64 Nm) in the sequence given in Figure and Figure and on the adapter ring.

      1. Make sure that the socket (part of the special wrench) is attached to the arm.

      2. Put the arm in position so that:

        - The spigot is engaged with the hole in the adapter ring.

        - The socket is installed on the curvic coupling bolt.

      3. Install a wrench in to wrench hole in the spigot.

      4. Hold the fan blades and apply the specified torque value to the curvic coupling bolt.

      5. Do steps G. (1) through (4) to tighten each curvic coupling bolt.

    8. Torque all the 24 bolts to 885 to 1133* lbf.in (100 to 128 Nm) in the same tightening sequence as in step G.

      9. Make sure that the 24 bolts are at the required torque of 885 to 1133* lbf.in (100 to 128 Nm).

      1. Torque the bolt at the No. 1 position.

      2. Torque the bolt adjacent to first bolt when you move in a clockwise direction.

      3. Do step (2) again until all of the bolts are torqued.

    10. Remove all parts of the special wrench from the engine.

    11. Remove the hub protector from the fan disk.

    12. SUBTASK 72-00-31-420-059 Install the Inlet Cone

    1. Install the inlet cone. Refer to TASK 72-38-11-420-001 (INSTALLATION).

    13. Figure: The sling and adapter assembly

    The sling and adapter assembly

    Figure: The sling and adapter assembly

    The sling and adapter assembly

    Figure: Method 1: Install the sling and adapter assembly

    Method 1: Install the sling and adapter assembly

    Figure: Method 1: Remove the LP compressor (fan) module from the storage stand

    Method 1: Remove the LP compressor (fan) module from the storage stand

    Figure: Method 2: Remove the LP compressor (fan) module from the storage stand

    Method 2: Remove the LP compressor (fan) module from the storage stand

    Figure: Install the LP compressor (fan) module

    Install the LP compressor (fan) module

    Figure: Method 1: Remove the protection cover from the disk curvic teeth

    Method 1: Remove the protection cover from the disk curvic teeth

    Figure: Remove the retaining protector from the stub shaft

    Remove the retaining protector from the stub shaft

    Figure: The stage 1 fan disk - Correlation

    The stage 1 fan disk - Correlation

    Figure: V2500-A1: The LP compressor stub shaft - Correlation

    Sheet 1

    Legend
    V2500-A1: The LP compressor stub shaft - Correlation

    Sheet 1

    Close

    Figure: V2500-A5: The LP compressor stub shaft - Correlation

    Sheet 2

    Legend
    V2500-A5: The LP compressor stub shaft - Correlation

    Sheet 2

    Close

    Figure: Install the turning handle

    Install the turning handle

    Figure: Install the curvic coupling bolts

    Sheet 1

    Legend
    Install the curvic coupling bolts

    Sheet 1

    Close

    Figure: V2500-A1: Install the curvic coupling bolts

    Sheet 2

    Legend
    V2500-A1: Install the curvic coupling bolts

    Sheet 2

    Close

    Figure: V2500-A5: Install the curvic coupling bolts

    Sheet 3

    Legend
    V2500-A5: Install the curvic coupling bolts

    Sheet 3

    Close

    Figure: The torque tightening sequence for the curvic coupling bolts

    The torque tightening sequence for the curvic coupling bolts

    Figure: Install the LP compressor (fan) module

    Install the LP compressor (fan) module

    Figure: Install the special wrench to the LP compressor (fan) module

    Install the special wrench to the LP compressor (fan) module

Requirements After Job Completion

Follow-On Conditions

NONE
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:IE207
Enterprise Name:DELETED, REFER TO 16956
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 01-124
Type:sp01
Supply Short Name:CoMat 01-124 ISOPROPYL ALCOHOL
Supply Name:CoMat 01-124 ISOPROPYL ALCOHOL
Specification Groups:
Doc NumberType
OMAT:1/40GPR TECHNICAL GRADE
PMC 9094GPR TECHNICAL GRADE
JCR-011GPR TECHNICAL GRADE
Suppliers:
ManufacturerRemarks
LOCAL
U1185
24853
K6835
Manufacturer Code:IE207
Supply Number:CoMat 06-069
Type:sp01
Supply Short Name:CoMat 06-069 MARKER
Supply Name:CoMat 06-069 MARKER
Specification Groups:
Doc NumberType
OMAT:262TMARKS-A-LOT
JCR-085MARKS-A-LOT
Suppliers:
ManufacturerRemarks
IE207
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Manufacturer Code:0AM53
Tool Number:IAE 1J12016
Tool Name:IAE 1J12016 Special wrench
Manufacturer Code:0AM53
Tool Number:IAE 1J12017
Tool Name:IAE 1J12017 Special wrench
Manufacturer Code:0AM53
Tool Number:IAE 1J12019
Tool Name:IAE 1J12019 Storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1J12026
Tool Name:IAE 1J12026 Turning handle
Manufacturer Code:0AM53
Tool Number:IAE 1J12104
Tool Name:IAE 1J12104 Sling adapter
Manufacturer Code:0AM53
Tool Number:IAE 1J12105
Tool Name:IAE 1J12105 Cantileer sling
Manufacturer Code:0AM53
Tool Number:IAE 1J12106
Tool Name:IAE 1J12106 Aligning pin set
Manufacturer Code:0AM53
Tool Number:IAE 1J12110
Tool Name:IAE 1J12110 Transportation and storage stand
Manufacturer Code:0AM53
Tool Number:IAE 1J12180
Tool Name:IAE 1J12180 Hub protector