Preliminary Requirements

Procedure

1. SUBTASK 72-41-10-440-345 Set up tools used to install nuts onto the special head bolts

   1. 

      CAUTION

      NEVER "FORCE" THE GEARBOX AND OTHER ITEMS INTO POSITION. IF A PART DOES NOT MOVE FREELY, PLEASE INVESTIGATE, AND RECTIFY THE ISSUE BEFORE PROCEEDING WITH AN ENGINE BUILD.

      

      CAUTION

      MAKE CERTAIN YOU HAVE INSTALLED ANY BLADE OR ENGINE PROTECTORS REQUIRED BEFORE PROCEEDING WITH TOOL INSTALLATION.

      

      CAUTION

      AFTER TOOL INSTALLATION, MAKE CERTAIN THE TOOL DOES NOT INTERFERE WITH ANY ENGINE FEATURE. IF YOU FEEL "TOOL TO ENGINE" HINDRANCE, STOP IMMEDIATELY AND INVESTIGATE BEFORE PROCEEDING WITH THE ENGINE BUILD.

      

      CAUTION

      MAKE SURE A CALIBRATED GEARBOX IS IN USE. PLEASE REFER TO YOUR CALIBRATION DEPARTMENT FOR A CALIBRATED GEARBOX.

      

      CAUTION

      MAKE SURE GEARBOXES CALIBRATED TOGETHER ARE USED DURING THE ASSEMBLY PROCESS.

      Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.

   2. Install the Engine Bore Protector (Figure, Item 7), into the HP Compressor 12th stage disc bore.

   3. Using a Three point sling, carefully lower the Main Tool Body (Figure, Item 1), into the HP Compressor Rotor Assembly.

      1. Align the pilot pin on the main tool body with the locating hole on the rear flange of the HP Compressor 9-12 Drum.

      2. Rotate the position locator to position #1.

      3. 

         CAUTION

         GEARBOXES MUST BE IN CALIBRATION. FAILURE TO DO SO CAN ALLOW FOR IMPROPER ASSEMBLY.

         Confirm that a calibrated Production Front Gearbox (Figure, Item 3) is installed into the Main Tool Body.

         NOTE

         It is acceptable to use the Spare Front Gearbox and Spare Rear Gearbox as an alternative to the Production Front Gearbox and Production Rear Gearbox. To use these gearboxes these gearboxes must be in calibration and calibrated together.

   4. Position the Front Gearbox.

      1. Remove the "red" hold down screw from the Production Front Gearbox.

         1. Set this screw aside for later use.

      2. Using the 3/16" Hex key, loosen the three bolts and remove Input Block (Figure, Item 26) from the Main Tool Body.

         1. Set the Input Block aside for later use.

      3. Using the Nut Installation/Removal Tool (Figure, Item 14) install a U755872 NUT - SPLINE, UNCOATED into the socket on the Production Front Gearbox.

         1. Turn nut the Nut Installation/Removal Tool clockwise until a gear tooth is in line with the white stripe on the gearbox.

            NOTE

            The nut must not remain in the gearbox.

      4. Using the 3/8" x 24" Extension (Figure, Item 22), rotate the rack driver on the Production Front Gearbox clockwise until the gearbox socket is in line with the rack driver.

         1. Continue to rotate the rack driver counter-clockwise until the 2 arrow position screw holes are aligned with the 2nd row of tapped holes on the slide assembly.

            NOTE

            Do not allow the slide to move. Only the gearbox should slide.

            NOTE

            A minimum of three tapped holes on the slide must be visible.

      5. Using the S.H.C.S Installation Tool (Figure, Item 13), install two (2) 10-32 x 3/8" cap screws at the arrow positions on the rear of the Production Front Gearbox.

      6. 

         CAUTION

         DO NOT TIGHTEN THE SCREWS. TIGHTENING THE SCREWS WILL PREVENT FURTHER ASSEMBLY.

         With your hand, push the gearbox forward until the gearbox reaches the "detent" position.

         NOTE

         This "detent" position will provide additional space for Production Rear Gearbox installation.

   5. Install the Production Rear Gearbox.

      NOTE

      It is acceptable to use the Spare Front Gearbox and Spare Rear Gearbox as an alternative to the Production Front Gearbox and Production Rear Gearbox. To use these gearboxes these gearboxes must be in calibration and calibrated together.

      1. Install one (1) 1/4-20 x 1" cap screw into the middle of the calibrated Production Rear Gearbox (Figure, Item 3).

         NOTE

         Installation of the cap screw will assist in lowering the rear gearbox into the proper position.

      2. Using your hand, rotate the gear located at the front of the Production Rear Gearbox until the gear teeth align with the two white stripes.

      3. Install the Production Rear Gearbox into the Main Tool Body so the gear on the Production Front Gearbox installs onto the gear in the rear gearbox.

         NOTE

         It is acceptable to slightly turn the rack driver to assist in proper alignment.

         NOTE

         The rear gearbox may need to be angled to install the gear into position.

         NOTE

         The gearbox must be installed flush before continuing to next step.
      4. 

         CAUTION

         IMPROPERLY INSTALLATION OF THE GEAR BOX CAN CAUSE DAMAGE TO THE SYSTEM. INSTALLATION MUST BE CONFIRMED PRIOR TO CONTINUING.

         Remove the cap screw installed in Step.

      5. Using the extension turn the rack driver to check the system for smooth translation.

      6. Turn the rack driver until four (4) tapped holes with arrows to the front of the Production Rear Gearbox input drive are accessible.

         1. 

            CAUTION

            DO NOT OVERTIGHTEN THE CAP SCREWS. OVERTIGHTENING CAN DAMAGE THE SYSTEM.

            Install and tighten the four (4) 10-32 x 3/8" cap screws at the four (4) tapped holes to the front of the Production Rear Gearbox.

      7. Using the extension, turn the rack driver until the cap screws installed in Step are accessible.

         1. 

            CAUTION

            DO NOT OVERTIGHTEN THE CAP SCREWS. OVERTIGHTENING CAN DAMAGE THE SYSTEM.

            Tighten the cap screws.

   6. Final Gearbox assembly.

      1. Using the extension turn the rack driver until the gearbox assembly has moved forward to its full travel position.

      2. Install Left Top "A" Cap to the "A" position on the gearbox assembly.

         1. 

            CAUTION

            DO NOT OVERTIGHTEN THE CAP SCREWS. OVERTIGHTENING CAN DAMAGE THE SYSTEM.

            Install and tighten one (1) 10-32 x 3/8" cap screw to secure position.

      3. Install Right Top "B" Cap to the "B" position on the gearbox assembly.

         1. 

            CAUTION

            DO NOT OVERTIGHTEN THE CAP SCREWS. OVERTIGHTENING CAN DAMAGE THE SYSTEM.

            Install and tighten two (2) 10-32 x 3/8" cap screw to secure position.

   7. Final Tool Assembly.

      1. 

         CAUTION

         DO NOT OVERTIGHTEN THE SCREWS. OVERTIGHTENING CAN DAMAGE THE SYSTEM.

         Re-install the Input Block removed in Step.

2. SUBTASK 72-41-10-440-346 Install the Anti-score Plates and the Splined Nuts onto the Special Head Bolts

   1. Refer to Figure, Figure, Figure, Figure, Figure and Figure.

   2. 
      WARNING
      IF FULL ASSEMBLY SEQUENCE IS NOT COMPLETED IN LESS THAN 240 MINUTES ALL NUTS (INSTALLED OR UNINSTALLED) WHICH HAVE HAD COMAT 10-142 APPLIED MUST BE REJECTED.
      
      WARNING
      IF FULL ASSEMBLY SEQUENCE IS NOT COMPLETED IN LESS THAN 240 MINUTES ALL BOLTS WHICH HAVE HAD A NUT INSTALLED MUST BE REJECTED.
      
      CAUTION
      DO NOT LET LUBRICANT CONTAMINATE THE COMPONENTS OR THE TOOLING. USE GLOVES TO PREVENT CONTAMINATION OF THE WORKSTATION, TOOLING AND ENGINE HARDWARE.
      
      CAUTION
      THE FULL ASSEMBLY SEQUENCE MUST BE DONE IN LESS THAN 240 MINUTES. OXYGEN CAUSES DEGRADATION OF THE LUBRICANT. THIS CAN CAUSE INSUFFICIENT LUBRICATION PROPERTIES AND CAUSES ASSEMBLY INTERRUPTIONS DUE TO INTERCHANGE OF NUTS.

      NOTE

      Mix the CoMat 10-142 ANTI-SEIZE PASTE fully to get the full lubricant properties.

      Lubricate the threads of the 34 splined U755872 NUT - SPLINE, UNCOATED and the nuts mating surface with CoMat 10-142 ANTI-SEIZE PASTE.

      1. Do a visual examination of the lubrication and make sure a smooth film of CoMat 10-142 ANTI-SEIZE PASTE on the full threads of the 34 splined U755872 NUT - SPLINE, UNCOATED and the nuts mating surface is applied.

   3. Start the nut installation at position #1.

   4. 

      CAUTION

      BE CAREFUL NOT TO DISLODGE THE ANTI-SCORE PLATE AND NUT WHEN REMOVING THE NUT INSERTER ASSEMBLY.

      Using the Nut Installation/Removal Tool (Figure, Item 14), carefully place one nut and washer into the gearbox socket.

   5. Using the extension, turn the rack driver to move the gearbox assembly forward to its full travel position.

   6. Install the Teardown/Nut Runner Assembly (Figure, Item 8) through the Input Block and into the gearbox input drive.

      NOTE

      Ensure that the torque drive engages with the gearbox input drive before continuing to next step.

   7. Engage the nut by lifting the handles on the Main Tool Body.

   8. Using the ratchet, turn the Teardown/Nut Runner Assembly for a minimum of 7 full rotations until the nut has engaged on the bolt.

   9. Push the handles down to disengage the gearbox assembly from the nut.

   10. Remove the Teardown/Nut Runner Assembly from the gearbox input drive and Input Block.

   11. Using the extension, turn the rack driver to move the gearbox assembly rearward to the full travel position.

       NOTE

       The gearbox socket must be accessible.

   12. Rotate the Main Tool Body position locator to the next bolt position.

   13. Repeat Step to Step until all 34 bolts are installed.

3. SUBTASK 72-41-10-440-347 Set the Tooling for the Seating Nut Sequence

   1. Refer to Figure, Figure, Figure and Figure.

   2. Install two (2) 10-32 x 1" cap screws into the tapped holes on the rear of the Rear Production Gearbox.

      NOTE

      If a nut change is required, the cap screws installed in Step must be removed.

   3. Install the Torque Shaft Assembly (Figure, Item 2) through the Input Block.

      1. Ensure that the torque drive engages with the gearbox input drive.

   4. Install the Torque Multiplier (Figure, Item 15) onto the top of the Torque Shaft Assembly.

   5. Connect the Bolt Locator Cable to the Data Acquisition Console Bolt Connector.

   6. Connect the Torque/Angle Cable (Figure, Item 12) to the Data Acquisition Console Angle B Connector (Figure, Item Q).

      1. Connect the remaining end of the Torque/Angle Cable to the Torque Shaft Assembly.

   7. Turn the Main Tool Body position locator to position #1 and engage the gearbox.

4. SUBTASK 72-41-10-440-348 Torque the Nuts

   1. Refer to Figure.

   2. Confirm the minimum software Mod Version 1.10 and minimum Calibration Version 1.20 is installed.

      NOTE

      Software version is found on the Start Up screen.

   3. Initialize the software program and continue to the Bolt Torque Sequence program.

      NOTE

      The torque and angles appear on-screen. Follow on screen instructions.

   4. Bolt Seating Sequence.

      1. Disengage the gearbox from position #1.

      2. Turn the position locator to position # 34 and engage the gearbox onto the nut.

         NOTE

         Seating Torque sequence begins at bolt number 34.

         1. Torque the nut to 86 lbfin to 94 lbfin (9.716 Nm to 10.620 Nm).

      3. Disengage the gearbox and turn the position locator to the next lower number.

      4. Engage the gearbox onto the nut and torque the nut to 86 lbfin to 94 lbfin (9.716 Nm to 10.620 Nm).

      5. Repeat Step to Step until all 34 nuts have been seated.

   5. Torqueing Sequence

      1. Disengage the gearbox from position #1.

      2. Turn the position locator to position # 34 and engage the gearbox onto the nut.

      3. Torque the nut to 86 lbfin to 94 lbfin (9.71 Nm to 10.62 Nm).

      4. In the counter clockwise direction, turn the system until the nut rotates - 360 degrees.

      5. 

         CAUTION

         A FINAL TORQUE OF 150 LBF.IN. MUST NOT BE EXCEEDED. IF 150 LBF.IN. IS EXCEEDED THE BOLT MUST BE REPLACED.

         Torque the nut until the prevailing torque is calculated and the system reaches a nut angle between 26 and 30 degrees and the nut is torqued to between 70 lbfin and 150 lbfin (7.90 Nm and 16.94 Nm).

         NOTE

         If the prevailing torque is below limits, the nut must be replaced

      6. Disengage the gearbox and turn the nut locator until it reaches the next sequential position.

      7. Continue to the next lower number and engage the gearbox onto the nut.

      8. Repeat Step to Step until all 34 nuts have been torqued.

5. SUBTASK 72-41-10-440-349 Disassemble and Remove the Tool from the HP Compressor Rotor Assembly

   1. Refer to Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure, Figure and Figure.

   2. Rotate the Main Tool Body position locator to position # 1.

   3. Disconnect the Torque/Angle Cable from the Torque Shaft Assembly and Data Acquisition Console Angle B Connector.

   4. Disconnect the Bolt Locator Cable from the Data Acquisition Console Bolt Connector.

   5. Remove the Torque Multiplier from the Torque Shaft Assembly.

   6. Remove the Torque Shaft Assembly from the Input Block.

   7. Remove the Input block for the Main Tool Body.

   8. Remove the two (2) 10-32 x 1" cap screws installed in the rear of the Production Rear Gearbox.

   9. Remove the three (3) 10-32 x 3/8" cap screws holding the Left Top "A" Cap and Right Top "B" Cap.

      1. Remove the Left Top "A" Cap and Right Top "B" Cap from the Gearbox Assembly and Main Tool Body.

   10. Using the Extension turn the rack driver until the four (4) cap screws on the Production Rear Gearbox are visible.

       1. Remove the four (4) 10-32 x 3/8" cap screws installed in the Production Rear Gearbox.

   11. Using the Extension turn the rack driver until the two (2) cap screws on the Production Front Gearbox are visible.

       1. Remove the two (2) 10-32 x 3/8" cap screws installed in the Production Front Gearbox.

   12. Push the gearbox assembly forward until the "detent" position is reached.

       1. Install a 1/4-20 x 1" cap screw into the middle for the Production Rear Gearbox.

       2. Carefully lift the Production Rear Gearbox out of the Main Tool Body.

   13. Install the "red" hold down screw into the 2nd tapped hole from the rear of the slide to maintain current position.

       1. Do not tighten the screw.

          NOTE

          The slide must be in the central position.

   14. Using your hand, move the gearbox assembly rearward until the Front Gearbox stops against the "red" hold down screw.

       NOTE

       The extension and rack driver may be used for proper positioning.

   15. Remove the "red" hold down screw installed in Step.

   16. 

       WARNING

       THE SLIDE MUST NOT MOVE. FAILURE TO HOLD THE SLIDE IN POSITION CAN ALLOW DAMAGE TO THE TOOL OR ROTOR ASSEMBLY.

       Using the extension and the rack turn the driver until the Production Front Gearbox aligns with the tapped holes on the slide.

   17. Install the "red" hold down screw into Production Front Gearbox position.

       NOTE

       Do not tighten the red hold down screw.

   18. Re-install the Input Block.

   19. Using the Three point sling remove the Main Tool Body from the Engine Bore Protector and the HP Compressor Rotor Assembly.

   20. Remove the Engine Bore Protector from the HP Compressor Rotor Assembly.

Figure: HP Compressor Rotor Joint Assembly

HP Compressor Rotor Joint Assembly



Figure: HP Compressor Rotor Joint Tooling IAE1P16616

HP Compressor Rotor Joint Tooling IAE1P16616



Figure: HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-740 Storage Console Drawer #1)

HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-740 Storage Console Drawer #1)



Figure: HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-740 Storage Console Drawer #2)

HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-740 Storage Console Drawer #2)



Figure: HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-109-156)

HP Compressor Rotor Joint Tooling IAE1P16616 (AMD-109-156)



Figure: AMD-740-32 Engine Bore Protector

AMD-740-32 Engine Bore Protector



Figure: AMD-740-6 Input Block

AMD-740-6 Input Block



Figure: Production Front Gearbox

Production Front Gearbox



Figure: Align Gearbox Socket and Rack Driver

Align Gearbox Socket and Rack Driver



Figure: Production Front Gearbox Cap Screws

Production Front Gearbox Cap Screws



Figure: Production Front Gearbox Detent Position

Production Front Gearbox Detent Position



Figure: Production Rear Gearbox with Cap Screw

Production Rear Gearbox with Cap Screw



Figure: Production Rear Gearbox Installed in Main Tool Body

Production Rear Gearbox Installed in Main Tool Body



Figure: Production Gearbox Assembly - Full Travel Position

Production Gearbox Assembly - Full Travel Position



Figure: Top Caps

Top Caps



Figure: Final Torque Cap Screws

Final Torque Cap Screws



Figure: Main Tool Body Position Indicator

Main Tool Body Position Indicator



Figure: Dissasembly "Red" Hold Down Screw

Dissasembly "Red" Hold Down Screw