TASK 72-00-40-560-004 HP System Module - Turn The HP System Module From Vertical To Horizontal, Installation-003

DMC:V2500-A0-72-00-4000-09A-720A-B|Issue No:003.00|Issue Date:2018-08-01

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 72-00-40-560-004 HP System Module - Turn The HP System Module From Vertical To Horizontal, Installation-003

General

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

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1F10028 Support Pedestal0AM53IAE 1F100282
IAE 1F10052 Two cables sling0AM53IAE 1F100522
IAE 1P16002 Cradle pedestal0AM53IAE 1P160021
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P160461
IAE 1P16057 Tie-rod adapter0AM53IAE 1P160571
IAE 1P16285 Tie-rod adapter0AM53IAE 1P162851
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P165431
IAE 1R18234 Support rod0AM53IAE 1R182343
IAE 1R18247 Rigging pin0AM53IAE 1R182471
IAE 1R18325 Trunnion assembly0AM53IAE 1R183252

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-40-560-067-A00 V2500-A1 Install the Remove/Install Fixture and Tie-rod Adapter on to the HP System Module Rear Flange

    1. Refer to Figure.

      1. Put the puck and shaft through the center ring until the tie-rod adapter touches the rear face of the center ring.

      2. Align the two holes on the tie-rod adapter with the two opposite holes in the center ring. Install the two tool screws. Tighten the screws.

      3. Attach the remove/install fixture and tie-rod adapter to the HP system module.

      1. Move the locknut until it is adjacent to the wrench location.

      2. Push the tie-rod adapter in to the engine until the puck engages on the HP compressor front shoulder. At the same time push the center ring over the HP compressor shaft until it touches the stage 2 HP turbine disk.

      3. NOTE

        If necessary use a wrench on the wrench location so that the shaft does not turn.

        Turn the locknut until the puck is against the HP compressor front shoulder. Tighten the locknut.

      4. Attach a hoist to the remove/install fixture lift eye.

      5. Lift the remove/install fixture and put it adjacent to the rear of the HP system module. Make sure the hand knobs are rearwards.

      6. Move the remove/install fixture along the center ring until it touches the HP turbine case rear flange.

      7. Put the upper split ring on to the front of the HP turbine case rear flange. Install 12 of the tool bolts and 12 of the tool nuts.

      8. Put the lower split ring on to the front of the HP turbine case rear flange. Install the other 13 tool bolts and the nuts.

      9. Tighten the 25 tool nuts.

      10. Remove the hoist from the lift eye.

    2. SUBTASK 72-00-40-560-067-B00 V2500-A5 Install the Remove/Install Fixture and Tie-rod Adapter on to the HP System Module Rear Flange

    1. Refer to Figure.

      1. Put the puck and shaft through the center ring until the tie-rod adapter touches the rear face of the center ring.

      2. Align the two holes on the tie-rod adapter with the two opposite holes in the center ring. Install the two tool screws. Tighten the screws.

      3. Attach the remove/install fixture and tie-rod adapter to the HP system module.

      1. Move the locknut until it is adjacent to the wrench location.

      2. Push the tie-rod adapter in to the engine until the puck engages on the HP compressor front shoulder. At the same time push the center ring over the HP compressor shaft until it touches the stage 2 HP turbine disk.

      3. NOTE

        If necessary use a wrench on the wrench location so that the shaft does not turn.

        Turn the locknut until the puck is against the HP compressor front shoulder. Tighten the locknut.

      4. Attach a hoist to the remove/install fixture lift eye.

      5. Lift the remove/install fixture and put it adjacent to the rear of the HP system module. Make sure the hand knobs are rearwards.

      6. Move the remove/install fixture along the center ring until it touches the HP turbine case rear flange.

      7. Put the upper split ring on to the front of the HP turbine case rear flange. Install 12 of the tool bolts and 12 of the tool nuts.

      8. Put the lower split ring on to the front of the HP turbine case rear flange. Install the other 13 tool bolts and the nuts.

      9. Tighten the 25 tool nuts.

      10. Remove the hoist from the lift eye.

    3. SUBTASK 72-00-40-560-068 Install the HP Compressor Support Rods

    1. Refer to Figure.

    2. Make sure that the variable stator vanes (VSV) are in the low speed position.

    3. Install IAE 1R18247 Rigging pin 1 off through the bracket and into the HP compressor cases to lock the VSV's.

    4. Remove the six bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122), the two brackets HP COMPRESSOR SPLIT CASE (72-41-31, 01-115 and HP COMPRESSOR SPLIT CASE 01-118) and the three blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) from the HP compressor front cases.

      5. Install IAE 1R18234 Support rod 3 off into the holes in the split cases.

      1. Turn the adjustment handle to retract the blade of the tool.

      2. Install the support rods through the holes in the HP compressor split case. Make sure the tool blades are rearwards.

      3. Safety the support rods to the HP compressor split cases with the six tool bolts.

      4. Turn the adjustment handles until the tool blades touch the HP compressor stage 3 disk then hand tighten the handles.

    4. SUBTASK 72-00-40-560-069-A00 V2500-A1 Install the Trunnion Assemblies on to the HP System Module

    1. Refer to Figure.

      NOTE

      Keep the 10 nuts removed in Step. so that they can be used to install the trunnion assemblies.

    2. Remove the 10 nuts and the 10 bolts from the HP compressor front and rear cases splitline at the No. 8, 10, 16, 17, 19, 35, 37, 38, 44 and 46 positions. The No. 1 hole position is to the right of TDC.

      1. Locate the right hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 9 and 18 positions.

      2. Attach the trunnion assembly to the module with the five tool bolts and five of the nuts removed in Step. Tighten the nuts to safety the trunnion assembly.

      3. Locate the left hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 36 and 45 positions.

      4. Attach the trunnion assembly to the module with the five tool bolts and the other five nuts removed in Step. Tighten the nuts to safety the trunnion assembly.

    5. SUBTASK 72-00-40-560-069-B00 V2500-A5 Install the Trunnion Assemblies on to the HP System Module

    1. Refer to Figure and Figure.

      NOTE

      Keep the 10 nuts removed in Step. so that they can be used to install the trunnion assemblies.

    2. Remove the 10 nuts and the 10 bolts from the HP compressor front and rear cases splitline at the No. 8, 10, 16, 17, 19, 35, 37, 38, 44 and 46 positions. The No. 1 hole position is to the right of TDC.

      1. Locate the right hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 9 and 18 positions.

      2. Attach the trunnion assembly to the module with the five tool bolts and five of the nuts removed in Step. Tighten the nuts to safety the trunnion assembly.

      3. Locate the left hand trunnion assembly on to the HP compressor front and rear cases splitline. Make sure the clearance holes engage on the head of the bolts at the No. 36 and 45 positions.

      4. Attach the trunnion assembly to the module with the five tool bolts and the other five nuts removed in Step. Tighten the nuts to safety the trunnion assembly.

    6. SUBTASK 72-00-40-560-070 Remove the HP System Module from the Build Stand

    1. Refer to Figure.

    2. Attach a hoist to the lift eye on IAE 1F10052 Two cables sling 1 off.

      3. Attach the lift sling to the remove/install fixture trunnions.

      1. Use the hoist to position the lift sling over the HP system module.

      2. Adjust the height of the lift sling to permit the hook and bolt plate to be attached to the remove/install fixture trunnions.

      3. Attach the hook and bolt plate to the remove/install fixture trunnions.

    4. Remove the six HP compressor/support ring bolts.

    5. Lift and remove the HP system module from the build stand.

    6. Move the build stand away from the module.

    7. SUBTASK 72-00-40-560-071 Turn the HP System Module and Install on to the Support Posts and Cradle Pedestal

    1. Refer to Figure and Figure.

    2. Attach a hoist to the lift eye on a second IAE 1F10052 Two cables sling 1 off.

      3. Attach the lift sling to the HP compressor trunnion assemblies.

      1. Use the hoist to position the lift sling adjacent to the HP system module.

      2. Adjust the height of the lift sling so that the hook and bolt plate can be attached to the HP compressor trunnion assemblies.

      3. Attach the hook and bolt plate to the trunnions.

    4. Use the forward lift sling to move the HP system module in to the horizontal position.

      5. Install the HP system module on to the support posts and cradle pedestal.

      1. Make sure that the trunnion support brackets, part of IAE 1F10028 Support Pedestal 2 off are at their lowest position.

      2. Put the support posts adjacent to the trunnion assemblies with the trunnion supports below the trunnions.

      3. CAUTION

        YOU MUST MAKE SURE THAT THE HEIGHT OF THE MODULE IS SUFFICIENT FOR THE CRADLE PEDESTAL TO BE INSTALLED.

        Move the trunnion support brackets up the support posts until they touch the trunnions.

      4. Look at the holes in the trunnion support brackets and the support posts to see if they are aligned.

      5. If necessary adjust the height of the HP system module to make the holes align.

      6. Install the retaining pins through the holes.

      7. Put IAE 1P16002 Cradle pedestal 1 off under the HP system module with the support bracket slightly forward of the diffuser case rear flange. Make sure that the large face of the support bracket is forward.

      8. Turn the adjustment handle on the cradle pedestal to move the support bracket upwards. When the cradle pedestal has taken the weight of the module stop the procedure.

      9. Remove the retaining pins from the lift sling hook and bolt plates.

      10. Adjust the height of the lift slings so that the hook and bolt plates can be removed.

      11. Remove the hook and bolt plates from the trunnions.

      12. Put the lift slings on an applicable work surface.

      13. Remove the hoists from the lift slings.

    8. SUBTASK 72-00-40-560-072 Remove the Remove/Install Fixture and the Tie-Rod Adapter from the Rear of the HP System Module

    1. Refer to Figure.

    2. Attach a hoist to the lift eye on the remove/install fixture and adjust the hoist to hold the remove/install fixture.

    3. Remove the 25 nuts and the 25 bolts which safety the remove/install fixture to the HP Turbine case. Remove the two split rings.

    4. Release the locknut on the end of the tie-rod shaft. Do not remove the locknut.

    5. Remove the two screws that safety the tie-rod adapter on to the remove/install fixture.

    6. Move the shaft in to the engine to disengage the puck from the HP compressor shaft front shoulder.

    7. Remove the tie-rod adapter from the module.

    8. Remove the remove/install fixture from the module and put it on an applicable work surface. Remove the hoist.

    9. SUBTASK 72-00-40-560-073 Remove the Dummy Stub Shaft from the HP System Module

    1. Refer to Figure.

    2. NOTE

      The 20 curvic coupling tool bolts remain with the dummy stub shaft.

      Release the 20 curvic coupling tool bolts.

    3. Remove the dummy stub shaft from the curvic coupling.

      4. Install the curvic protector on to the dummy stub shaft.

      1. Align the location pins on the dummy stub shaft with the applicable location holes in the curvic protector.

      2. Secure the curvic protector with four of the dummy stub shaft curvic coupling bolts and the curvic protector nuts.

      3. Put the dummy stub shaft on to an applicable work surface.

    5. Install the curvic protector on to the stage 3 disk curvic coupling.

    10. Figure: Install the remove/install fixture and the tie-rod adapter on to the HP system module

    Install the remove/install fixture and the tie-rod adapter on to the HP system module

    Figure: Install the HP compressor support rods

    Install the HP compressor support rods

    Figure: Install the HP compressor support rods

    Install the HP compressor support rods

    Figure: V2500-A1: Install the HP compressor trunnions

    V2500-A1: Install the HP compressor trunnions

    Figure: V2500-A1: Install the HP compressor trunnions

    V2500-A1: Install the HP compressor trunnions

    Figure: V2500-A5: Install the HP compressor trunnions

    V2500-A5: Install the HP compressor trunnions

    Figure: V2500-A5: Install the HP compressor trunnions

    V2500-A5: Install the HP compressor trunnions

    Figure: Remove the HP system module from the build stand

    Remove the HP system module from the build stand

    Figure: Install a second lift sling to the HP compressor trunnions

    Install a second lift sling to the HP compressor trunnions

    Figure: Install the HP system module on to the support posts

    Install the HP system module on to the support posts

    Figure: Remove the dummy stub shaft from the stage 3 disk curvic coupling

    Remove the dummy stub shaft from the stage 3 disk curvic coupling

    Figure: Compressor Rear Outer Case Front Flange (From Rear of Engine)

    Compressor Rear Outer Case Front Flange (From Rear of Engine)

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add figure 12. (17VG172A)

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:0AM53
Tool Number:IAE 1F10028
Tool Name:IAE 1F10028 Support Pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1F10052
Tool Name:IAE 1F10052 Two cables sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16002
Tool Name:IAE 1P16002 Cradle pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16057
Tool Name:IAE 1P16057 Tie-rod adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16285
Tool Name:IAE 1P16285 Tie-rod adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18234
Tool Name:IAE 1R18234 Support rod
Manufacturer Code:0AM53
Tool Number:IAE 1R18247
Tool Name:IAE 1R18247 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18325
Tool Name:IAE 1R18325 Trunnion assembly