TASK 72-00-40-560-003 HP System Module - Turn The HP System Module From Horizontal To Vertical, Removal-008

DMC:V2500-A0-72-00-4000-10A-520A-B|Issue No:002.00|Issue Date:2021-02-01

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 72-00-40-560-003 HP System Module - Turn The HP System Module From Horizontal To Vertical, Removal-008

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.

Apply the approved CoMat 10-058 PENETRATING OIL before the removal of threaded parts or parts with an interference fit. Let the parts soak before removal.

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 1F10052 Two cables sling0AM53IAE 1F100522
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 1R18673 Dummy stub shaft0AM53IAE 1R186731
IAE 1R18214 Build stand0AM53IAE 1R182141
IAE 1R18222 Support rod0AM53IAE 1R182222

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-002 SOLVENT, DELETED.X111XCoMat 01-002
CoMat 10-058 PENETRATING OILX222XCoMat 10-058
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-40-560-061-A00 V2500-A1: Install the Remove/Install Fixture and Tie-Rod Adapter on to the HP System Module Rear Flange

    1. Refer to Figure.

      2. Attach IAE 1P16057 Tie-rod adapter 1 off on to the center ring (part of IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off).

      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 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 move 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 13 of the tool bolts and 13 of the tool nuts.

      9. Tighten the 25 tool nuts.

      10. Remove the hoist from the lift eye.

    2. SUBTASK 72-00-40-560-061-B00 V2500-A5: Install the Remove/Install Fixture and Tie-Rod Adapter on to the HP System Module Rear Flange

    1. Refer to Figure.

      2. Attach IAE 1P16285 Tie-rod adapter 1 off on to the center ring (part of IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off).

      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 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 move 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 13 of the tool bolts and 13 of the tool nuts.

      9. Tighten the 25 tool nuts.

      10. Remove the hoist from the lift eye.

    3. SUBTASK 72-00-40-560-062 Install the Dummy Stub Shaft on to the Stage 3 Disk Curvic Coupling

    1. Refer to Figure.

    2. Remove the curvic protector from the stage 3 disk curvic coupling.

      3. Remove the curvic protector from IAE 1R18673 Dummy stub shaft 1 off.

      1. NOTE

        The bolts remain with the dummy stub shaft.

        Release the bolts and the nuts from the curvic protector.

      2. Remove the curvic protector.

      4. Clean the curvic teeth of the dummy stub shaft and the stage 3 disk.

      1. WARNING

        WHEN YOU USE COMAT 01-002 INHIBITED AND STABILIZED TRICHLOROETHANE YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.

        Use a soft brush and apply CoMat 01-002 SOLVENT, DELETED. to the curvic teeth.

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

      5. Install the dummy stub shaft on to the stage 3 disk curvic coupling.

      1. Align the four location pins on the dummy stub shaft with the applicable location holes on the curvic coupling.

      2. Safety the dummy stub shaft with the 20 curvic coupling tool bolts.

    4. SUBTASK 72-00-40-560-063 Prepare for the Lift and Turn of the HP System Module

    1. Refer to Figure.

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

    3. Make sure the lift brackets are in the inner position on the sling beam.

    4. Lift one of the lift slings and put it above the remove/install fixture.

    5. Adjust the height of the lift sling to permit the hook and bolt plates to be installed on to the remove/install fixture trunnions.

    6. Install the hook and bolt plates on to the remove/install fixture trunnions. Safety the hook and bolt plate with the safety clip.

    7. Lift the other lift sling and put above the front of the HP system module.

    8. Adjust the height of the lift sling to permit the hook and bolt plates to be installed on to the HP compressor trunnion assembly.

    9. Install the hook and bolt plates on to the trunnions. Safety the hook and bolt plate with the safety clip.

    5. SUBTASK 72-00-40-560-064 Lift and Turn the HP System Module

    1. Refer to Figure and Figure.

    2. Adjust the two lift slings to hold the weight of the HP system module.

      3. Remove the support posts and cradle pedestal.

      1. Remove the retaining pins from the forward support posts and lower the support brackets to their lowest position.

      2. Turn the adjustment handle on the rear cradle pedestal to lower the support bracket to its lowest position.

      3. Move the support posts and cradle pedestal away from the engine.

    4. NOTE

      The HP system module must not hit the ground.

      Use the rear lift sling to move the HP system module in to the vertical position.

    5. Remove the hook and bolt plate from the forward HP system module trunnions.

    6. Put the forward lift sling on to an applicable work surface.

    7. Remove the hoist from the forward lift sling.

    6. SUBTASK 72-00-40-560-065 Install the HP System Module on to the Build Stand

    1. Refer to Figure.

      2. Install IAE 1R18222 Support rod 2 off on to the IAE 1R18214 Build stand 1 off.

      1. Align the support ring end faces so that they are adjacent to the location pins on the build stand.

      2. Secure the support rings with the six build stand/support ring bolts.

    3. Carefully lower the HP system module on to the build stand. Make sure the support ring splitline is aligned with the HP compressor front cases splitline. Also align the support ring location pins with the applicable hole in the HP compressor front flange.

    4. Secure the HP compressor front flange to the support ring with the six HP compressor/support ring bolts.

    5. Release the hold on the lift sling.

    7. SUBTASK 72-00-40-560-066 Remove the Lift Equipment from the HP System Module

    1. Refer to Figure, Figure and Figure.

      2. Remove the support rods.

      1. Turn the adjustment handle to retract the blade.

      2. Release the six support rod tool bolts.

      3. Remove the support rod.

        4. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-118) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) in to the HP compressor at location C.

        1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on to the bracket where it touches the blank.

        2. Install the blank, the bracket and the bolts.

        3. Torque the bolts to 85 to 105 lbf.in (10 to 12 Nm).

        5. Install one of the blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120), the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-115) and two of the bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) in the HP compressor at location A.

        1. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on the bracket where it touches the blank.

        2. Install the blank, the bracket and the bolts.

        3. Torque the bolts to 85 to 105 lbf.in (10 to 12 Nm).

      6. Install the other blank HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) and the other bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) in to the HP compressor at location B. Torque the bolts to 85 to 105 lbf.in (10 to 12 Nm).

      7. Remove the rigging pin from the bracket in the stage 3 unison ring.

      3. Remove the remove/install fixture and the tie-rod adapter from the rear of the HP system module.

      1. Adjust the height of the lift sling to hold the remove/install fixture.

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

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

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

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

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

      7. Remove the remove/install fixture from the module and put it on to a suitable work surface. Remove the hoist.

      4. Remove the HP compressor trunnion assemblies.

        NOTE

        Keep the five nuts removed in Step.

      1. Remove the five tool bolts and the five nuts HPC Assembly (72-41-00, 01-302) that safety the right hand trunnion on to the module.

      2. Remove the right hand trunnion assembly from the module.

      3. Install the five bolts HPC Assembly (72-41-00, 01-308) and the five nuts removed in Step and torque to 180 to 220 lbf.in (20 to 25 Nm).

        NOTE

        Keep the five nuts removed in Step.

      4. Remove the five tool bolts and the five nuts that safety the left hand trunnion on to the module.

      5. Remove the left hand trunnion assembly from the module.

      6. Install the five bolts HPC Assembly (72-41-00, 01-308) and the five nuts removed in Step and torque to 180 to 220 lbf.in (20 to 25 Nm).

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

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

    Figure: Install the dummy stub shaft on to the stage 3 disk curvic coupling

    Install the dummy stub shaft on to the stage 3 disk curvic coupling

    Figure: Install the lift slings on to the trunnions

    Install the lift slings on to the trunnions

    Figure: Remove the forward lift sling from the HP compressor trunnions

    Remove the forward lift sling from the HP compressor trunnions

    Figure: Install the HP system module on to the build stand

    Install the HP system module on to the build stand

    Figure: Remove the HP compressor support rods

    Remove the HP compressor support rods

    Figure: Remove the HP compressor support rods

    Remove the HP compressor support rods

    Figure: Remove the HP compressor trunnions

    Remove the HP compressor trunnions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added IAE 1P16543 in support equipment table and revised procedural steps. (19VC640)

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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X111X
Enterprise Name:N/A – DELETED CONSUMABLE MATERIAL
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:X111X
Supply Number:CoMat 01-002
Type:sp01
Supply Short Name:CoMat 01-002 SOLVENT, DELETED.
Supply Name:CoMat 01-002 SOLVENT, DELETED.
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐002 is specified to clean mechanical components, use one or more of the solvents that SPM TASK 70‐11‐26‐300‐503 specifies as applicable.DELETED. Where CoMat 01‐002 is specified to clean electrical contacts or wiring harnesses, use one or more of the solvents that SPM TASK 70‐11‐57‐110‐501 specifies to clean electrical contacts or
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:LOCAL
Supply Number:CoMat 04-005
Type:sp01
Supply Short Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Supply Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Specification Groups:
Doc NumberType
OMAT: 4/47 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
JCR-026 (JAEC REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
DTD 900/4586 (RR REF, MOD UK REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:X222X
Supply Number:CoMat 10-058
Type:sp01
Supply Short Name:CoMat 10-058 PENETRATING OIL
Supply Name:CoMat 10-058 PENETRATING OIL
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:0AM53
Tool Number:IAE 1F10052
Tool Name:IAE 1F10052 Two cables sling
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 1R18214
Tool Name:IAE 1R18214 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18222
Tool Name:IAE 1R18222 Support rod
Manufacturer Code:0AM53
Tool Number:IAE 1R18673
Tool Name:IAE 1R18673 Dummy stub shaft