TASK 72-40-00-530-001 HP System Module - Pack The HP System Module

DMC:V2500-A0-72-40-0000-01A-830A-C|Issue No:002.00|Issue Date:2017-08-01

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 72-40-00-530-001 HP System Module - Pack 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.

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.

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.

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.

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

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 1F10262 Lift sling0AM53IAE 1F102621
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P16046
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P16543
IAE 5F10124 Shipping equipment0AM53IAE 5F101241
IAE 5F10206 HP system shipping frame0AM53IAE 5F10206
IAE 5R18235 Transportation front support0AM53IAE 5R18235
IAE 5R18288 Shipping container0AM53IAE 5R18288

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077
CoMat 12-013 PRINTED, WAXED, VCI COATED PAPERLOCALCoMat 12-013
CoMat 12-022 DESICCANT SELF INDICATINGLOCALCoMat 12-022
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005
CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYONK6835CoMat 02-122

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-40-00-530-051 Remove the HP System Shipping Container Lid

    1. Attach a suitable four legged sling to a hoist.

    2. Move the hoist over IAE 5F10124 Shipping equipment 1 off and attach the four legged sling to the four lid lift rings.

    3. Release the 20 butterfly catches.

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

    5. Remove the sling from the hoist.

    2. SUBTASK 72-40-00-530-052 Install the Remove/Install Fixture on to the HP System Module Rear Flange

    1. Refer to Figure and Figure.

      2. Make sure that the HP system module is in the horizontal position. If it is not, refer to TASK 72-00-40-560-004. It is not necessary to remove the remove/install fixture, but it is necessary to remove the tie-rod adaptor, in this TASK.

      1. If you do TASK 72-00-40-560-004 use the remove and install fixture in the shipping container. To remove the remove/install fixture from the module refer to Step.

      3. Remove the remove/install fixture from the shipping frame.

      1. Attach the hoist to the lift eye on the remove/install fixture.

      2. Adjust the height of the hoist so that it holds the remove/install fixture.

        3. Remove the support bracket from the remove/install fixture.

        1. Remove the nut, the bolt and the washer that attach the support bracket to the remove/install fixture.

        2. Remove the nut that attaches the support bracket to the shipping frame. Put the support bracket in to the horizontal position. Replace and tighten the nut.

        3. Use the bolt, the washer and the nut removed in Step to hold the support bracket in position. Tighten the nut.

      4. Loosen the two trunnion collar nuts and open the two trunnion collars.

      5. Lift the remove/install fixture away from the shipping frame.

      4. Attach the remove/install fixture on to the HP system module rear flange.

      1. Loosen the eight knobs. Do not allow the center ring to become separate from the remove/install fixture.

      2. Put the remove/install fixture in position on the rear of the HP system module. Make sure that the hand knobs are rearwards.

      3. 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.

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

      5. Tighten the 25 tool nuts.

      6. Remove the hoist from the lift eye.

    3. SUBTASK 72-40-00-530-053 Install the Transportation Front Support on to the HP System Module Front Flange

    1. Refer to Figure and Figure

    2. NOTE

      The HP system module front flange bolt holes must be kept clear.

      Put a cover on the HP system module front flange. Use CoMat 12-013 PRINTED, WAXED, VCI COATED PAPER to make the cover.

      3. Remove the transportation front support, from the HP compressor shipping frame.

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

      2. Remove the two pins that attach the transportation front support to the HP system shipping frame.

      3. Lift the transportation front support and put it in position on the HP system module front flange. Make sure that the curvic protector is correctly located. At the same time locate the two location dowels.

    4. Attach the transportation front support to the HP system module with the 18 tool bolts and the 18 tool nuts.

    5. Remove the hoist from the lift bobbin.

    6. Torque the tool bolts to 168 * lbfin. (19 Nm).

    4. SUBTASK 72-40-00-530-054 Remove the HP Compressor Support Rods

    1. Refer to Figure.

    2. Turn the adjustment handles to retract the blades.

    3. Remove the six support rod tool bolts.

    4. Remove the three support rods.

    5. Remove the rigging pin from the variable stator vane (VSV) crankshaft bearing housing.

    6. Use a suitable spanner to turn the VSV actuating mechanism crankshaft and put the VSVs in to the high speed position.

    7. Install the transportation front support locking pin in to the VSV crankshaft bearing housing, to lock the VSVs.

      8. 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 A.

      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 lbfin (10 to 12 Nm).

      9. 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 C.

      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 lbfin (10 to 12 Nm).

    10. 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 lbfin (10 to 12 Nm).

    5. SUBTASK 72-40-00-530-055 Prepare the HP System Module for Storage

    1. Put a cover on to, and seal, all the openings on the HP system module and the tools. Use CoMat 12-013 PRINTED, WAXED, VCI COATED PAPER to make the covers.

    6. SUBTASK 72-40-00-530-056 Install the HP System Module in to the HP System Shipping Frame

    1. Refer to Figure.

      2. Prepare the HP system shipping frame.

      1. Release the two eye bolts on the two trunnion collars. Move the two trunnion collars in to the open position.

      2. Turn the adjustment handle to move the front support post in to the vertical position.

      3. Make sure that the support bracket is locked in the horizontal position.

      3. 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.

      4. Remove the support posts and cradle pedestal.

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

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

      3. Move the support posts away from the module.

    5. Move the module and put it over the shipping frame.

    6. Lower the module in to the shipping frame so that the trunnions are located in the trunnion collars.

    7. Use the adjustment handle and the hoist to align the holes in the front support post and the transportation front support.

    8. Install the applicable pin through the holes in the front support post and the transportation front support. Install the other pin in to the shipping frame. Safety the pins with the applicable safety pins.

    9. Close the two trunnion collars and put the swing bolt in to position. Tighten the trunnion collar nut.

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

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

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

    7. SUBTASK 72-40-00-530-057 Remove the Trunnion Assemblies from the HP System Module

    1. Refer to Figure.

    2. NOTE

      Keep the five nuts removed in this step.

      Remove the five tool bolts and the five nuts that safety the right hand trunnion assembly on to the module.

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

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

    5. NOTE

      Keep the five nuts removed in this step.

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

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

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

    8. SUBTASK 72-40-00-530-058 Seal the Shipping Container

    1. Refer to Figure.

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

    3. Lift the shipping container lid put it over the HP system module.

    4. Lower the shipping container lid on to the shipping container base.

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

    6. Remove the four legged sling from the four lid lift rings.

    7. Remove the four legged sling from the hoist and put it on an applicable work surface.

    9. SUBTASK 72-40-00-530-059 Put the Desiccant and the Records in to the Shipping Container

    1. Refer to Figure.

    2. Put the correct amount of desiccant in to the desiccant receptacle. Follow the instructions given on the shipping container lid adjacent to the desiccant receptacle. Use CoMat 12-022 DESICCANT SELF INDICATING. Replace the desiccant receptacle cover.

    3. Complete the relevant documentation. Put the documentation into the record receptacle. Put the cover on to the record receptacle.

    10. SUBTASK 72-40-00-530-060 Do the Subsequent Checks after the Shipping Container is Sealed

    1. Examine the humidity indicator to make sure it is safe at the times shown.

      24 hours, 7 days and then at regular 28 day cycles.

      2. If the humidity indicator changes color from blue, do the subsequent steps.

        1. Remove the shipping container lid from the base.

        1. Attach a four legged sling to a hoist.

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

        3. Release the 20 butterfly catches.

        4. Remove the shipping container lid and put it on a suitable surface.

      2. Do a visual inspection for corrosion and damage.

        3. Install the shipping container lid on to the base.

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

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

      4. Remove the desiccant from the desiccant receptacle and replace it with new desiccant. Follow the instructions given on the shipping container lid, adjacent to the desiccant receptacle for the correct amount. Use CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON. Replace the desiccant receptacle cover.

      5. Do Step again.

    11. Figure: Install the remove/install fixture on to the HP system module

    Install the remove/install fixture on to the HP system module

    Figure: HP system module shipping equipment

    HP system module shipping equipment

    Figure: Install the transportation front support on to the HP system module

    Install the transportation front support 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: Install the HP system module in to the shipping frame

    Install the HP system module in to the shipping frame

    Figure: Install the HP system module in to the shipping frame

    Install the HP system module in to the shipping frame

    Figure: Remove the HP compressor trunnions

    Remove the HP compressor trunnions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add IAE 1P16543 as an option to IAE 1P16046. (14VC396)

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:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:K6835
Supply Number:CoMat 02-122
Type:sp01
Supply Short Name:CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON
Supply Name:CoMat 02-122 TEMPORARY MARKER PENCIL/CRAYON
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
K6835
IE133
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: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:K6835
Supply Number:CoMat 12-013
Type:sp01
Supply Short Name:CoMat 12-013 PRINTED, WAXED, VCI COATED PAPER
Supply Name:CoMat 12-013 PRINTED, WAXED, VCI COATED PAPER
Specification Groups:
Doc NumberType
MIL-P-3420
Suppliers:
ManufacturerRemarks
K6835
K8888
Manufacturer Code:K6835
Supply Number:CoMat 12-022
Type:sp01
Supply Short Name:CoMat 12-022 DESICCANT SELF INDICATING
Supply Name:CoMat 12-022 DESICCANT SELF INDICATING
Specification Groups:
Doc NumberType
SILICA GEL B.S.3523 COBALT CHLORIDE TYPE
Suppliers:
ManufacturerRemarks
K6835
22627
LOCAL
K8888
KD685
Manufacturer Code:LOCAL
Tool Number:Four legged sling
Tool Name:Four legged sling
Manufacturer Code:0AM53
Tool Number:IAE 1F10262
Tool Name:IAE 1F10262 Lift sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 5F10124
Tool Name:IAE 5F10124 Shipping equipment
Manufacturer Code:0AM53
Tool Number:IAE 5F10206
Tool Name:IAE 5F10206 HP system shipping frame
Manufacturer Code:0AM53
Tool Number:IAE 5R18235
Tool Name:IAE 5R18235 Transportation front support
Manufacturer Code:0AM53
Tool Number:IAE 5R18288
Tool Name:IAE 5R18288 Shipping container