TASK 72-40-00-540-001 HP System Module - Unpack The HP System Module

DMC:V2500-A0-72-40-0000-00A-840A-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 72-40-00-540-001 HP System Module - Unpack The HP System Module

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.

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

Refer to the V2500 Illustrated Tool and Equipment Manual (ITEM) Pub.ref. ITE-V2500-1IA, for the illustrations of the special tools given in this procedure.

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.

Make sure that all flange faces and tool faces that touch are very clean.

For standard torque data and procedures, refer to the SPM TASK 70-41-00-400-501, SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-410-501.

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
Four legged slingLOCALFour legged sling
IAE 1F10028 Support Pedestal0AM53IAE 1F100282
IAE 1F10262 Lift sling0AM53IAE 1F102621
IAE 1P16002 Cradle pedestal0AM53IAE 1P160021
IAE 1R18234 Support rod0AM53IAE 1R182343
IAE 1R18247 Rigging pin0AM53IAE 1R182471
IAE 1R18325 Trunnion assembly0AM53IAE 1R183252

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-40-00-540-051 Remove the HP System Shipping Container Lid

    1. Check the humidity indicator.

    2. Use the relief valve to make the containers internal pressure the same as the external pressure.

    3. Attach a four legged sling to a hoist.

    4. Move the hoist over the shipping container and attach the four legged sling on to the four lid lift rings.

    5. Release the 20 butterfly catches.

    6. Lift the shipping container lid away from the shipping container base and put it on a suitable surface.

    7. Remove the sling from the hoist.

    8. Empty the desiccant receptacle.

    2. SUBTASK 72-40-00-540-052 Examine the HP System Module

    1. Check the relevant documentation with the module details.

    2. Visually inspect the module for corrosion and damage.

    3. SUBTASK 72-40-00-540-053 Install the HP Compressor Trunnions 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 split line, at the No. 8, 10, 16, 17, 19, 35, 37, 38, 44 and 46 positions. The No. 1 position is to be right of TDC.

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

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

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

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

    4. SUBTASK 72-40-00-540-054 Remove the HP System Module from the HP System Shipping Frame

    1. Refer to Figure.

      2. Attach IAE 1F10262 Lift sling 1 off to the HP system module.

        1. Prepare the lift sling.

        1. Make sure that the cross beam is in the correct position to lift the HP system module.

        2. NOTE

          If necessary, turn the adjustment wheel to put the eye plate in to the identified position.

          Make sure that the eye plate is at the identified position for the center of gravity for the lift sling only.

      2. Attach a hoist to the eye plate.

      3. Lift the lift sling and put it over the HP system module.

      4. Adjust the height of the lift sling to permit the hook and bolt plates to be installed.

      5. Install the hook and bolt plates on to the outer trunnions.

      6. Use the adjustment wheel to move the eye plate to the identified position for the center of gravity for the HP system module lift.

      7. NOTE

        Small adjustments may be necessary to get the correct center of gravity for the assembly.

        Adjust the height of the hoist to hold the HP system module.

    3. Loosen the trunnion collar nuts and put the trunnion collars in to the open position.

    4. Remove the pin that attaches the front support to the shipping frame.

    5. Lift the HP system module clear of the shipping frame.

      6. Install the HP System Module on to the support posts and cradle pedestal.

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

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

      3. CAUTION

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

        Lower the HP system module until the trunnion assemblies are located in the trunnion supports.

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

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

      6. Adjust the height of the lift sling to permit the hook and bolt plates to be removed.

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

      8. Move the lift sling away and put it on an applicable work surface. Remove the hoist.

    5. SUBTASK 72-40-00-540-055 Install the HP Compressor Support Rods

    1. Refer to Figure.

    2. Remove the transportation front support locking pin from the variable stator vane (VSV) crankshaft bearing housing. Put the locking pin into the stowage hole.

    3. Use a suitable spanner to turn the VSV actuating mechanism crankshaft and put the VSV's in to the low speed position.

    4. Install IAE 1R18247 Rigging pin 1 off, through the bracket and in to the HP compressor case, to lock the VSVs.

    5. Remove the six bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-115), and the three blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-122) from the HP compressor front cases at the positions B.

      6. Install IAE 1R18234 Support rod 3 off in to 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 cases. 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.

    6. SUBTASK 72-40-00-540-056 Remove the Remove/Install Fixture from the HP System Module Rear Flange

    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 and install fixture.

    3. Remove the 25 nuts and the 25 bolts which safety the remove/install fixture to the HP system module rear flange. Remove the two split rings.

    4. Carefully move the remove/install fixture away from HP system module.

      5. Put the remove/install fixture in to the HP system shipping frame.

      1. Lower the remove/install fixture in to the shipping frame until the trunnions are located in the trunnion collars.

      2. Put the trunnion collars in to the closed position and tighten the nut.

      3. Remove the nut, the bolt and the washer that holds the support bracket in to the horizontal position. Loosen the other bolt.

      4. Turn the support bracket in to the vertical position and attach it to the remove/install fixture with the bolt, the washer and the nut removed in Step.

      5. Tighten the bolts and nuts.

      6. Attach the two split rings to the remove/install fixture with the 25 tool bolts and the 25 tool nuts.

      7. Remove the hoist from the lift eye.

    7. SUBTASK 72-40-00-540-057 Remove the Transportation Front Support from the HP System Module

    1. Refer to Figure and Figure.

    2. Attach a hoist to the lift bobbin on the transportation front support. Adjust the hoist to hold it.

    3. Remove the 18 tool nuts and the 18 tool bolts that attach the transportation front support to the HP system module front flange.

    4. Move the transportation front support away from the HP system module and lower it in to the HP system shipping frame.

    5. Align the hole in the transportation front support with the hole in the shipping frame front support post. Install the pin and safety with the safety pin.

    6. Align the hole in the transportation front support with the hole in the shipping frame. Install the pin and safety with the safety pin.

    7. Remove the hoist from the lift bobbin.

    8. SUBTASK 72-40-00-540-058 Remove the HP System Module Blanks and Covers

    1. Remove all VPI impregnated paper covers from the HP system module.

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

    9. SUBTASK 72-40-00-540-059 Install the HP Compressor Shipping Container Lid

    1. Attach the four legged sling, that is attached to the shipping container lid, to a hoist.

    2. Lift the shipping container lid and put it on to the shipping container base.

    3. Attach the shipping container lid to the shipping container base with the 20 butterfly catches.

    4. Remove the four legged sling from the four lid lift rings and the hoist.

    10. Figure: Install the HP Compressor Trunnions

    Install the HP Compressor Trunnions

    Figure: Remove the HP System Module From the HP System Shipping Frame

    Remove the HP System Module From the HP System Shipping Frame

    Figure: Remove the HP System Module From the HP System Shipping Frame

    Remove the HP System Module From the HP System Shipping Frame

    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: Remove the Remove/Install Fixture

    Remove the Remove/Install Fixture

    Figure: Remove the Remove/Install Fixture

    Remove the Remove/Install Fixture

    Figure: Remove the Transportation Front Support

    Remove the Transportation Front Support

    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 9 and step references. (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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:LOCAL
Tool Number:Four legged sling
Tool Name:Four legged sling
Manufacturer Code:0AM53
Tool Number:IAE 1F10028
Tool Name:IAE 1F10028 Support Pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1F10262
Tool Name:IAE 1F10262 Lift sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16002
Tool Name:IAE 1P16002 Cradle pedestal
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