TASK 72-40-00-030-001-A00 HP System Module - Remove The HPT Assembly (Vertical) - Method 2, Disassembly-001

DMC:V2500-A1-72-40-0000-02B-530A-B|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

V2500-A1

Common Information

TASK 72-40-00-030-001-A00 HP System Module - Remove The HPT Assembly (Vertical) - Method 2, Disassembly-001

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.

Remove the HP turbine assembly with the HP system module installed in the workshop stand. The procedure for the installation of the HP system module in to the workshop stand is given in TASK 72-00-40-560-003 (REMOVAL-008).

Remove and discard the lockwire before parts are disconnected or removed.

Discard all rubber seal rings, cotter pins and seal washers removed in this procedure.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 1F10015 Hydraulic wrench0AM53IAE 1F100151

(alternative to IAE 1F10016)

IAE 1F10016 Mechanical wrench0AM53IAE 1F100161

(alternative to IAE 1F10015)

IAE 1F10026 Hydraulic hand pump0AM53IAE 1F100261
IAE 1F10052 Two cables sling0AM53IAE 1F100521
IAE 1P16011 Wrench0AM53IAE 1P160111
IAE 1P16028 Build stand0AM53IAE 1P160281
IAE 1P16046 Removal/Installation fixture0AM53IAE 1P160461
IAE 1P16048 Heater0AM53IAE 1P160481
IAE 1P16056 Hand wrench0AM53IAE 1P160561
IAE 1P16058 Removal/installation jaws assembly0AM53IAE 1P160581
IAE 1P16060 Protective cover0AM53IAE 1P160601

(alternative to IAE 1P17758)

IAE 1P16109 cover0AM53IAE 1P161091
IAE 1P16125 Puller0AM53IAE 1P161251
IAE 1P16225 Adapter0AM53IAE 1P162251
IAE 1P16264 Dry ice fixture0AM53IAE 1P162641
IAE 1P16272 Adapter0AM53IAE 1P162721
IAE 1P16543 Removal/Installation fixture0AM53IAE 1P165431
IAE 1P17509 Protective cover0AM53IAE 1P175091
IAE 1P17758 Protective cover0AM53IAE 1P177581

(alternative to IAE 1P16060)

IAE 6F10027 Heater control unit0AM53IAE 6F100271

Consumables, Materials and Expendables

NONE

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-40-00-030-054 Remove the Bearing Retaining Nut

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

    2. Remove the cover from the rear of the HP turbine rotor and stator assembly.

    3. Remove the retaining ring which holds the No. 4 bearing lock in position.

    4. Remove the No. 4 bearing lock.

    5. Install the IAE 1P17509 Protective cover 1 off to the rear flange of the HP turbine rotor and stator assembly.

      6. Install the bearing retaining nut tools.

      1. Release the wingnuts on the four clamp assemblies on the IAE 1P16225 Adapter 1 off.

      2. Move the clamps in the clockwise direction (opposite direction of the arrows).

      3. Pull up on the clamp until the clamp foot makes a continuous surface with the surface of the tooth on the adapter.

      4. Tighten the wingnuts to hold the clamps in this position.

      5. Attach two nylon straps to the slots in the side of the adapter.

      6. NOTE

        Turn the adapter to locate the slots with the locks between the adapter teeth.

        Lift the adapter in position with a hoist and engage the teeth of the adapter with the slots on the stage 2 turbine hub.

      7. Loosen the wingnuts and push the clamps in until the clamp foot contacts the hub.

      8. Move the clamp assemblies in the counterclockwise direction (direction of the arrows). Tighten the wingnuts.

      9. Install the IAE 1P16011 Wrench 1 off through the adapter to engage the retaining nut spline.

      10. Lift the IAE 1F10015 Hydraulic wrench 1 off with a hoist and install over the wrench and engage the anti-torque pins on the hydraulic wrench with the holes in the adapter.

        NOTE

        You can use IAE 1F10016 Mechanical wrench as an alternative to IAE 1F10015 Hydraulic wrench.

      11. Tighten the hex head bolts to hold the hydraulic wrench to the adapter.

    7. Operate the hydraulic wrench to release the retaining nut.

      8. Remove the bearing retaining nut tools.

      1. Release the hex head bolts and remove the hydraulic wrench from the adapter.

      2. Remove the wrench from the nut.

      3. Release all the wingnuts on the clamp assemblies.

      4. Move the clamp assemblies in the clockwise direction (opposite direction of the arrows).

      5. Remove the adapter from the stage 2 turbine hub.

    9. Remove the bearing retaining nut from the engine with the IAE 1P16056 Hand wrench 1 off.

      NOTE

      The bearing retaining nut must be silver plated when you install or remove the nut more than five times or engine operation has occurred.

    10. Remove the protective cover.

    2. SUBTASK 72-40-00-030-055 Install the Tooling to Remove the HP Turbine Rotor and Stator Assembly

    1. Refer to Figure and Figure.

      2. Install the IAE 1P16048 Heater 1 off to the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off before the fixture is installed to the engine.

      1. Lift the fixture with a hoist (in one of the hoist rings) to the horizontal position.

      2. Install the heater to the front face of the fixture with the four capscrews, washers and nuts. Tighten the nuts.

      3. Remove the fixture and heater assembly from the hoist.

      3. Install the fixture with the heater to the HP turbine rotor and stator assembly.

      1. Attach a standard two cable sling to the two hoist rings on the fixture and attach the sling to a hoist. Lift the fixture and heater assembly.

      2. Loosen the hand knobs and move the center ring of the fixture to the rear until the flanged end is in line with the front surface of the hub of the fixture.

      3. Tighten two of the hand knobs (one in each row) to hold the center ring in this position.

      4. Install the fixture and heater assembly to the rear flange of the HP turbine case with the offset hole in the fixture over the dowel pin in the HP turbine case flange.

      5. Attach the fixture with the two piece ring against the HP turbine case rear flange front face and the large offset hole over the flare of the dowel pin. Hold in position with the 25 bolts and nuts.

      6. Hold the fixture center ring and release the hand knobs.

      7. Move the center ring down until it touches the rear face of the stage 2 turbine hub.

      8. Remove the sling and the hoist.

      1. Install the four jaws in to the stage 2 turbine hub bore.

      2. Move the jaws radially out so the lip on the jaws engage the groove on the hub and the socket head capscrews engage the flange of the fixture center ring.

      3. Install the jaw assembly sleeve in to the jaws to move the jaws out.

      4. Align the slots in the sleeve with the large socket head capscrews.

      5. Install the sleeve until the flange contacts the jaws.

      6. Attach the jaws to the sleeve with the eight capscrews. Tighten the four socket head capscrews.

      7. Tighten all the hand knobs on the fixture to keep the rotor to stator relation.

    5. Install the IAE 6F10027 Heater control unit 1 off to the heater installed on the fixture.

    6. Heat the stage 2 turbine hub to 400 deg F (204 deg C).

    7. Install IAE 1F10052 Two cables sling 1 off to a hoist and to the two lifting spools on the fixture.

    8. Lift the fixture until the cables have the correct tension.

    3. SUBTASK 72-40-00-030-056 Remove the HP Turbine Rotor and Stator Assembly from the Engine

    1. Refer to Figure.

    2. Remove the bolts and the nuts which hold the HP turbine case front flange to the rear flange of the diffuser case. Remove the brackets, refer to Figure, Figure, Figure, Figure and Figure.

      3. SBE 72-0079 Engine - HP Compressor - Introduce a strengthened No. 4 bearing buffer air tube bracket assembly.

      1. Remove the brackets, refer to Figure.

    4. Install jackscrews in the threaded holes around the case front flange.

      5. Install the IAE 1P16264 Dry ice fixture 1 off into the inner diameter of the HP compressor rear shaft.

      1. Make sure the stage 2 turbine hub has reached the necessary temperature of 400 deg F (204 deg C).

      2. Remove the puck from the fixture freeze pot and fill with dry ice. Install the puck on to the freeze pot.

      3. NOTE

        Do not connect the air to the fixture at this time.

        Install the fixture into the inner diameter of the HP compressor rear shaft.

      6. Install the IAE 1P16272 Adapter 1 off to the rear flange of the IAE 1P16046 Removal/Installation fixture or IAE 1P16543 Removal/Installation fixture 1 off.

      1. Attach the adapter to the fixture with the 12 hexagon headed bolts. Tighten the bolts.

      2. Install the hydraulic cylinder into the adapter.

        NOTE

        The small threaded adapter for the hydraulic cylinder is not used for removal.

      3. Attach the IAE 1F10026 Hydraulic hand pump 1 off to the hydraulic cylinder.

    7. Put a 10000 lbf (44482.2 N) hydraulic load on the stage 2 turbine hub.

    8. Apply air to the dry ice fixture.

    9. Turn the jackscrews in on the case front flange sufficiently to loosen the case diameter fit.

    10. Apply hydraulic pressure and pump the HP turbine off until the turbine is released from the HP compressor rear shaft.

    11. Release the hydraulic pressure and remove the jackscrews from the case.

    4. SUBTASK 72-40-00-030-057 Remove the Tooling from the HP Turbine Rotor and Stator Assembly

    1. Refer to Figure and Figure.

    2. Disconnect the heater control from the heater Figure.

    3. Disconnect the hand pump from the hydraulic cylinder.

    4. Disconnect the air supply from the dry ice fixture.

    5. Lower the HP turbine rotor and stator assembly (front end down) to the IAE 1P16028 Build stand 1 off, Figure.

    6. Remove the hoist and the sling.

    7. Raise the center of the stand to contact the front face of the rotor.

      8. Remove the adapter from the rear face of the fixture Figure.

      1. Remove the hydraulic cylinder from the adapter.

      2. Remove the 12 hex head bolts which hold the adapter to the fixture and remove the adapter from the fixture.

      3. Install the 12 bolts in to their storage positions.

    9. Remove the bolts which secure the jaw assembly sleeve to the jaws on the rear of the stage 2 turbine hub.

    10. Remove the sleeve and the four jaws.

      11. Remove the fixture from the rear of the HP turbine rotor and stator assembly.

      1. Remove the bolts and the nuts which secure the fixture to the rear face of the rear flange of the HP turbine case and the two rings to the front face of the flange.

      2. Attach a standard two point sling to the two hoist rings on the fixture and attach the sling to a hoist.

      3. Remove the fixture from the HP turbine rotor and stator assembly.

      4. Remove the four bolts, washers and nuts which secure the heater to the fixture and remove the heater.

    12. Remove the dry ice fixture from the HP compressor rear shaft.

    5. SUBTASK 72-40-00-030-058 Remove the No. 4 Bearing Spacer

    1. Refer to Figure.

    2. Install the IAE 1P16125 Puller 1 off to the No. 4 bearing spacer (03-001) with the lip of the jaws on the puller grooves on the spacer.

    3. Install the ring of the puller over the jaws of the puller until it is seated.

    4. Turn in the center bolt of the puller to release the spacer from the HP compressor shaft.

    5. Remove the puller and the spacer from the engine.

    6. Remove the spacer from the puller.

    7. Install the IAE 1P16109 cover 1 off (with the center flap open) over the stage 1 turbine nozzle assembly. Put equal hand pressure on the outer edge of the cover to hold in position.

    8. Install the IAE 1P16060 Protective cover 1 off or the IAE 1P17758 Protective cover 1 off to the rear flange of the HP turbine rotor and stator assembly. Put equal hand pressure on the outer edge of the cover to hold in position.

    6. Figure: HP Turbine Rotor and Stator Assembly and Related Parts

    HP Turbine Rotor and Stator Assembly and Related Parts

    Figure: Release the Bearing Retaining Nut

    Release the Bearing Retaining Nut

    Figure: Hydraulic Wrench Package

    Hydraulic Wrench Package

    Figure: Remove the Bearing Retaining Nut

    Remove the Bearing Retaining Nut

    Figure: Removal Tooling for the HP Turbine Rotor and Stator Assembly

    Removal Tooling for the HP Turbine Rotor and Stator Assembly

    Figure: Removal Tooling for the HP Turbine Rotor and Stator Assembly

    Removal Tooling for the HP Turbine Rotor and Stator Assembly

    Figure: Install the HP Turbine Rotor and Stator Assembly to the Stand

    Install the HP Turbine Rotor and Stator Assembly to the Stand

    Figure: Remove the No. 4 Bearing Spacer

    Remove the No. 4 Bearing Spacer

    Figure: Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 1

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 1

    Close

    Figure: Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 2

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 2

    Close

    Figure: Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 3

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 3

    Close

    Figure: Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 4

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 4

    Close

    Figure: Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 5

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange

    Sheet 5

    Close

    Figure: Remove the Brackets from the HP Turbine Case Front Flange SBE 72-0079

    Sheet 6

    Legend
    Remove the Brackets from the HP Turbine Case Front Flange SBE 72-0079

    Sheet 6

    Close

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:0AM53
Tool Number:IAE 1F10015
Tool Name:IAE 1F10015 Hydraulic wrench
Manufacturer Code:0AM53
Tool Number:IAE 1F10016
Tool Name:IAE 1F10016 Mechanical wrench
Manufacturer Code:0AM53
Tool Number:IAE 1F10026
Tool Name:IAE 1F10026 Hydraulic hand pump
Manufacturer Code:0AM53
Tool Number:IAE 1F10052
Tool Name:IAE 1F10052 Two cables sling
Manufacturer Code:0AM53
Tool Number:IAE 1P16011
Tool Name:IAE 1P16011 Wrench
Manufacturer Code:0AM53
Tool Number:IAE 1P16028
Tool Name:IAE 1P16028 Build stand
Manufacturer Code:0AM53
Tool Number:IAE 1P16046
Tool Name:IAE 1P16046 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16048
Tool Name:IAE 1P16048 Heater
Manufacturer Code:0AM53
Tool Number:IAE 1P16056
Tool Name:IAE 1P16056 Hand wrench
Manufacturer Code:0AM53
Tool Number:IAE 1P16058
Tool Name:IAE 1P16058 Removal/installation jaws assembly
Manufacturer Code:0AM53
Tool Number:IAE 1P16060
Tool Name:IAE 1P16060 Protective cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16109
Tool Name:IAE 1P16109 cover
Manufacturer Code:0AM53
Tool Number:IAE 1P16125
Tool Name:IAE 1P16125 Puller
Manufacturer Code:0AM53
Tool Number:IAE 1P16225
Tool Name:IAE 1P16225 Adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16264
Tool Name:IAE 1P16264 Dry ice fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P16272
Tool Name:IAE 1P16272 Adapter
Manufacturer Code:0AM53
Tool Number:IAE 1P16543
Tool Name:IAE 1P16543 Removal/Installation fixture
Manufacturer Code:0AM53
Tool Number:IAE 1P17509
Tool Name:IAE 1P17509 Protective cover
Manufacturer Code:0AM53
Tool Number:IAE 1P17758
Tool Name:IAE 1P17758 Protective cover
Manufacturer Code:0AM53
Tool Number:IAE 6F10027
Tool Name:IAE 6F10027 Heater control unit