TASK 72-41-00-540-001 HPC Assembly - Unpack The HPC Assembly, Storage-002

DMC:V2500-A0-72-41-0000-00A-840A-B|Issue No:001.00|Issue Date:2013-11-01

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 72-41-00-540-001 HPC Assembly - Unpack The HPC Assembly, Storage-002

General

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.

Refer to the V2500 Illustrated Tool and Equipment Manual (ITEM) Publication Reference 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 Co-Mat 10-077 approved engine oils unless other lubricants are referred to 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 70-41-02-400-501.

All the parts must be visually examined for damage, corrosion and wear. Any defects that are not identified in the procedure must be referred to IAE.

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
Two legged slingLOCALTwo legged sling
Three legged slingLOCALThree legged sling
Four legged slingLOCALFour legged sling
IAE 1R18673 Dummy stub shaft0AM53IAE 1R186731
IAE 1R18075 Support pedestal0AM53IAE 1R180751
IAE 1R18090 Safety support stand0AM53IAE 1R180901
IAE 1R18214 Build stand0AM53IAE 1R182141
IAE 1R18217 Lift fixture0AM53IAE 1R182171
IAE 1R18222 Support rod0AM53IAE 1R182222
IAE 1R18234 Support rod0AM53IAE 1R182343
IAE 1R18247 Rigging pin0AM53IAE 1R182471
IAE 1R18423 Rigging pin0AM53IAE 1R184231
IAE 1R18892 Rigging pin0AM53IAE 1R188921
IAE 1R18893 Riggingpin0AM53IAE 1R188931
IAE 1R18894 Rigging pin0AM53IAE 1R188941
IAE 1R18895 Rigging pin0AM53IAE 1R188951
IAE 1R18896 Rigging pin0AM53IAE 1R188961
IAE 1R18441 Lifting adapter0AM53IAE 1R184411

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077
CoMat 01-001 SOLVENT, DELETED0AM53CoMat 01-001
CoMat 01-002 SOLVENT, DELETED.0AM53CoMat 01-002
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-00-540-051 Remove the HP Compressor 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 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 receptable.

    2. SUBTASK 72-41-00-540-052 Examine the HP Compressor Module

    1. Check the relevant documentation with the module details.

    2. Visually inspect the module for corrosion and damage.

    3. SUBTASK 72-41-00-540-053 Remove the HP Compressor Module from the HP Compressor Shipping Frame

    1. Refer to Figure.

    2. Attach an applicable two legged sling to a hoist.

    3. Move the hoist over the HP compressor module and attach the two legged sling to the conical rear support lift bobbins.

    4. Loosen the swing bolt and open the bearing collar.

    5. Use the hoist to move the HP compressor module to the vertical position.

    6. Adjust the hoist to permit the pin that attaches the transportation front support to the HP compressor shipping frame to be removed. Remove the pin.

    7. Move the HP compressor module away from the HP compressor shipping frame and put it on a suitable surface.

    4. SUBTASK 72-41-00-540-054 Remove the Conical Rear Support and Shaft Cover from the Rear of the HP Compressor Module

    1. Refer to Figure and Figure.

    2. Loosen the lock nut and the lock bolt.

    3. Support the conical rear support and shaft cover in the vertical position.

    4. Remove the 42 tool nuts and the 42 tool bolts.

    5. Carefully lift the conical rear support and shaft cover over the HP compressor shaft.

    6. Use the hoist to move the conical rear support and shaft cover over the HP compressor shipping frame.

    7. Lower the conical rear support until the trunnions are engaged in the bearing collar.

    8. Close the bearing collar and put the swing bolt into position. Tighten the nut.

    9. Turn the conical rear support and shaft cover to permit the pin, that attaches the shaft cover to the shipping frame, to be installed. Install the pin and safety with the safety pin.

    10. Remove the two legged sling from the hoist and the two lift bobbins.

    5. SUBTASK 72-41-00-540-055 Install the Lift Fixture and the Lifter on the HP Compressor Module

    1. Refer to Figure.

      2. Install IAE 1R18217 Lift fixture 1 off, on the HP compressor module.

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

      2. Move the hoist over the lift fixture and attach the three legged sling to the three lift eyes.

      3. Lift the lift fixture and position it over the HP compressor assembly. Carefully lower the lift fixture to the HP compressor shaft and the HP compressor rear outer case.

      4. Remove the three legged sling and hoist.

      5. Adjust the position of three thumbscrews so that the frame touches the HP compressor rear outer case flange in all positions. At the same time make sure the ring is correctly located on the HP compressor rotor.

      6. Install the six bolts the 12 washers and the six nuts that attach the lift fixture to the HP compressor rear outer case.

      7. Tighten the six nuts.

      3. Install IAE 1R18441 Lifting adapter 1 off, on the end of the HP compressor shaft.

      1. Engage the lifter on the end of the HP compressor shaft.

      2. Turn the lifter clockwise to move the lifter to the HP compressor shaft.

      3. Continue to turn the lifter clockwise until the location pin is clear of the sleeve and lifter touches the lift fixture.

      4. Tighten the lock screw into the lifter. Make sure that the lock screw goes in a slot in the end of the HP compressor shaft. If the lock screw does not go in a slot, then turn the lifter anti-clockwise until the lock screw will go in the first available slot.

      5. Turn the sleeve until a hoist can be attached to the lift eye.

    6. SUBTASK 72-41-00-540-056 Install the HP Compressor Support Rods

    1. Refer to Figure and Figure.

      1. Remove the transportation front support locking pin from the variable starter vane (VSV) crankshaft bearing housing. Put the locking pin in the stowage hole.

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

      3. Install IAE 1R18247 Rigging pin 1 off or IAE 1R18423 Rigging pin 1 off or (IAE 1R18892 Rigging pin thru IAE 1R18896 Rigging pin) 1 off, through the bracket and in the HP compressor case to lock the VSV's.

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

      5. Turn the adjustment handle to retract the blade of the support rods.

      6. Carefully install the support rods through the holes in the HP compressor split cases. Make sure the blades are rearwards.

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

      8. Turn the adjustment handle until the blades touch the HP compressor stage 3 disk and lightly tighten.

    7. SUBTASK 72-41-00-540-057 Remove the HP Compressor Module from the Transportation Front Support

    1. Refer to Figure.

    2. Remove the 18 tool nuts and the 18 tool bolts.

    3. Use the hoist to lift the HP compressor module away from the Transportation Front Support.

    4. Lower the HP compressor module to IAE 1R18090 Safety support stand 1 off. The HP compressor front flange should touch the safety support stand pads.

    8. SUBTASK 72-41-00-540-058 Install the Dummy Stub shaft on the HP Compressor Module

    1. Refer to Figure.

    2. Install IAE 1R18673 Dummy stub shaft 1 off in the IAE 1R18075 Support pedestal 1 off. Make sure the curvic protector is at the top.

      3. Remove the curvic protector, from the dummy stub shaft.

      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 on the dummy stub shaft and the HP compressor stage 3 disk.

      1. WARNING

        WHEN YOU USE COMAT 01-001 INHIBITED AND STABILISED TRICHLOROETHANE OR COMAT 01-002 INHIBITED AND STABILISED 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 VAPOUR CHANGES AND BECOMES TOXIC.

        Use a soft brush to apply CoMat 01-001 SOLVENT, DELETED or 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 the HP compressor module case assembly.

      1. Align the four tool location pins on the dummy stub shaft with the applicable location hole in the curvic coupling.

      2. Lift the HP compressor module from the safety support stand and position over the build pedestal.

      3. Carefully lower the HP compressor module to the dummy stub shaft and hold in position.

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

    9. SUBTASK 72-41-00-540-059 Install the HP Compressor Module on the Build Stand

    1. Refer to Figure.

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

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

    3. Lift the HP compressor module off the pedestal build stand and carefully lower to the build stand. Make sure the support ring split line is aligned with the HP compressor front cases split line. 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. Use the six HP compressor/support ring bolts.

    5. Release the hold on the lift sling.

    10. SUBTASK 72-41-00-540-060 Remove the Lifter and the Lift Fixture from the HP Compressor Module

    1. Refer to Figure.

      2. Remove the lifter from the HP compressor shaft.

      1. Turn the sleeve until the lockscrew can be released.

      2. Release the lockscrew from the slot in the HP compressor shaft.

      3. Turn the lifter anticlockwise until it can be lifted from the HP. compressor shaft.

      4. Remove the lifter from the HP compressor shaft.

      3. Remove the lift fixture from the HP compressor module.

      1. Attach the three legged sling to a hoist and the lift fixture.

      2. Remove the six nuts, the 12 washers and the six bolts which attach the lift fixture to the HP compressor rear outer case.

      3. Carefully lift and remove the lift fixture from the HP compressor module and put it on an applicable surface.

      4. Remove the three legged sling from the hoist and the lift fixture.

    11. SUBTASK 72-41-00-540-061 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. Attach two of the three blanks HP COMPRESSOR SPLIT CASE (72-41-31, 01-120) to the HP compressor lower split cases with four of the six bolts HP COMPRESSOR SPLIT CASE (72-41-31, 01-122).

    6. Put a thin layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE on the bracket HP COMPRESSOR SPLIT CASE (72-41-31, 01-115) where it touches the blank.

    7. Attach the other blank and the bracket on the HP compressor upper split case with the other two bolts.

    8. Torque the bolts in Step and Step to 85 to 105 lbfin (10 to 12 Nm).

    12. SUBTASK 72-41-00-540-062 Put the Transportation Front Support in the HP Compressor Shipping Container

    1. Refer to Figure.

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

    3. Use the hoist to lift the transportation front support and put it in position in the HP compressor shipping container.

    4. Install the two pins that attach the transportation front support to the HP compressor shipping frame. Safety the two pins with the two safety pins.

    5. Remove the hoist from the lift bobbin.

    13. SUBTASK 72-41-00-540-063 Remove the HP Compressor Module Blanks and Covers

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

    14. SUBTASK 72-41-00-540-064 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 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 lift sling from the four lid lift rings and the hoist.

    15. Figure: Remove the HP compressor module from the HP compressor shipping frame

    Remove the HP compressor module from the HP compressor shipping frame

    Figure: Remove the conical rear support and shaft cover from the HP compressor module

    Remove the conical rear support and shaft cover from the HP compressor module

    Figure: HP compressor shipping equipment

    HP compressor shipping equipment

    Figure: Install the lift fixture and lifter on the HP compressor module

    Install the lift fixture and lifter on the HP compressor module

    Figure: Install the lift fixture and lifter on the HP compressor module

    Install the lift fixture and lifter on the HP compressor 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: Remove the HP compressor module from the transportation front support

    Remove the HP compressor module from the transportation front support

    Figure: Remove the HP compressor module from the transportation front support

    Remove the HP compressor module from the transportation front support

    Figure: Install the dummy stub shaft on the HP compressor module

    Install the dummy stub shaft on the HP compressor module

    Figure: Install the HP compressor module into the build stand

    Install the HP compressor module into the build stand

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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X111X
Supply Number:CoMat 01-001
Type:sp01
Supply Short Name:CoMat 01-001 SOLVENT, DELETED
Supply Name:CoMat 01-001 SOLVENT, DELETED
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐001 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 01‐001 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: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: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 1R18075
Tool Name:IAE 1R18075 Support pedestal
Manufacturer Code:0AM53
Tool Number:IAE 1R18090
Tool Name:IAE 1R18090 Safety support stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18214
Tool Name:IAE 1R18214 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1R18217
Tool Name:IAE 1R18217 Lift fixture
Manufacturer Code:0AM53
Tool Number:IAE 1R18222
Tool Name:IAE 1R18222 Support rod
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 1R18423
Tool Name:IAE 1R18423 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18441
Tool Name:IAE 1R18441 Lifting adapter
Manufacturer Code:0AM53
Tool Number:IAE 1R18673
Tool Name:IAE 1R18673 Dummy stub shaft
Manufacturer Code:0AM53
Tool Number:IAE 1R18892
Tool Name:IAE 1R18892 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18893
Tool Name:IAE 1R18893 Riggingpin
Manufacturer Code:0AM53
Tool Number:IAE 1R18894
Tool Name:IAE 1R18894 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18895
Tool Name:IAE 1R18895 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18896
Tool Name:IAE 1R18896 Rigging pin
Manufacturer Code:LOCAL
Tool Number:Three legged sling
Tool Name:Three legged sling
Manufacturer Code:LOCAL
Tool Number:Two legged sling
Tool Name:Two legged sling