GE XV-5A Manual

AUG
Book No.
SPECIFICATION
NO. 124
INSTALLATION,
OPERATION
AND
o
MAINTENANCE
INSTRUCTIONS
r FOR
X353-5B
AND
X376
FANS
,4
LIFT FAN FLIG
lACK Al FT GRAM
CONTRACT
NUMBER
DA44-177-TC-715
WIIT UTIN,
NFV $ECTIOIE"
09RWCEN 1
,;..*
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..............
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DDC AVAILABILITY NOTICES
1. Distribution of this document is unlimited.
2. This document is subject to special
export controls and each trans-
mittal to foreign
governments
or foreign
nationals may
be made only
with prior
approval
of
US Army Aviation
Materiel
Laboratories,
Fort
Eustip,
Virginia
23604.
3. In
addition
to security
requirements
which
must be
met, this
docu-
ment
is subject to special export controls and
each transmittal to
foreign
governments or foreign nationals may be made only with prior approval of
USAAVLABS, Fort Eustis, Virginia 23604.
4. Each transmittal of this document outside the agencies of
the US
Government
mt~st have prior approval
of US Army Aviation Materiel Laboratories,
Fort
Eustis, Virginia
23604.
5. In addition to security requirements which apply to this document
and must be met, each transmittal outside the agencies of the US Government
must have prior approval of US Army Aviation Materiel Laboratories, Fort
Eustis, Virginia 23604.
6. Each transmittal
of this document outside the Department of Defense
must have prior approval of US Army Aviation Materiel Laboratories, Fort
Eustis, Virginia. 23604.
7. In addition to security requirements which apply to this document
and must be met, each transmittal outside the Department of Defense must have
prior approval of US Army Aviation Materiel Laboratories, Fort Eustis,
Virginia 23604.
8. This document may be further distributed
by any holder only with
specific prior
approval of US Army Aviation Materiel Laboratories, Fort
Eustis, Virginia 23604.
9. In addition
to security
requirements
which apply
to this document
and must be met, it may be further distributed by the holder only with
specific prior approval of US Army Aviation Materiel Laboratories, Fort
Eustis, Virginia 23604.
DISCLAIMER
The findings
in this
report are
not to be
construed
as an official
Dep-ment
of the Army
position unless
so designated
by other authorized
documents.
When Government drawings, specifications,
or other data are used
for
au n se other
than in connedtion
with
a definitely related
Government
procurement operation, the United States Government thereby incurs
no responsi-
bility nor any obligation whatsoever; and the fact that the Government may
have formulated, furnished,
or in any way supplied the said drawings, speci-
fications, or other data is nvL to be regarded by implication or
otherwise as

+*
---__ -....
*
,,1
TALE
OF
CONTENTS
PAGE
SECTION
1.
INTRODUCTION
................... 1
1.1 GENERAL ................
.. .. ... *.................... . -i
1.2 SCOPE
.....
.. ....................
... .......... .
..... .. -1,1
1.3 REPLACEMENT OF PARTS ....................... .......
I-.1
SECTION
2.
SYSTEM DESCRIPTION
............................. .....
1-2.1
2
1
GENERAL
,
.. . . ..........
.* .......... .
1-2. 1
2.2
BASIC
FAN
DESCRIPTION
.......................... * ... .......
1-2.1
2.3
SYSTEM ORIENTATION
.......................
.....
# ............
1-2.3
2.4
ROTOR
COMPONENT
DESCRIPTION
...............................
1-2.4
2.5
Shaft
and
Disc ...................
0 , ..... ...... .. ......
1-2.4
2.6
Blade Retainer
Rings
.....................
o ............
1-2.4
2.7
Rotor
Blades
.......................
..
....
....
...
1-2.4
2.8
Blade Platforms .................................
o
........
. 1-2.5
2.9
Torque
Band
Segments
..--.................
.....
..
1-2.5
2.10
Carrier
Segment
Seal
.....................................
1-2.5
2.11
Blade Shroud
Cover ........................................
1-2.6
2.12
.3lade
Carrier
Pins.
...................................
..
1-2.5
2.13
Lock
Pin
..................................................
.. 1-2.6
2.14
Lock Strip
...........
#.......
............
0...........
0........
1-2.6
2.15
Turbine
Bucket Carrier
Assembly
.........................
1-2.7
2.16
Turbine Buckets
...................... .........
#
......
1-2.7
2.17
Bucket Tip Shrouds
................... ............. ........
1-2.7
2.18
Bucket Caryier
...
. ...................
...
1-2.7
2.19
Bucket
Carrier
Tabs
.................................
.....
1-2.8
2.20
Balance
Weight
. ........
...
..................
1-2.8
2.21
Tie Bolts,
Washers and
Nuts
.... ... ................
1-2.8
2.22
FRONT
FRAME
DESCRIPTION
.. ...... ......... ..................
1-2.9
2.23
Hub
............................... .....
....
...
..
......
1-2.9
2.24
Housing
- Roller Bearing
....... o....... o.....
pit*
... .i-2.10
2.25
Bearing
System
.............. o
......... ......... o....
1-2.10
I-i

PAGE
2.26
Grease
Seals ..................................
*9*9
9 1-211
2.7I
-2.
1
2.27
Retainer
Seal
- Ball
Bearing.......121
2.28
Grease
Shield
-
Ball
Bearing
.......
1-2.11
2.29
Retiiner-
Roller
Bearing
1-2.12
2.30
Grease Shield- Roller
Bearing
.....
........
-2.12
2.31
Boss-
Speed Picek-up
Sensor
1 - 2 . 1 2
2.32
Magnetic
Rotor
Speed
Pick-up
Sensor
.......... .....
1-2.12
2.33
Struts
I.................
................ ...............
1-2.12
2.34
Bellmouth ...........
. ..... ... ....
.................
1-2.14
2.35 Pin - Support Beam ........................................ 1-2.15
2.36 Clevis - Scroll Mounting..................................
1-2.15
2.37
Shoulder
Bolt
- Scroll
Mounting...........................
1-2.15
2.38
Shim
- Scroll
Mounting
Clevis
......
1-2.15
2.39 Forward Compressor Seal ....
1-2.16
2.40 Insulation Blanket
........... .
so, 1-2.16
2.41 INLET VANE DESCRIPTION
...... I....o.... 1-2.17
2.42
SCROLL DESCRIPTION
99.99.99.... o
...
.......
-2.19
2.43 REAR FRAME ......... ..... @ .... ............... # ... 1-2.22
2.44 HONEYCOMB AIR
SEALS ................ * ... .............
1-2.24
2.45 TURNBUCKLE
- REAR FRAME
TO SCROLL
1-2.25
2.46
INSULATION
BLANKET
- INNER
............. *9
.....
99 .....
o * *
1-2.25
2.47
INSULATION
BLANKET
- OUTER
I
.. ....
9
1-2.25
2.48
EXIT LOUVER SYSTEM
.......... ...
T-2.25
249
Exit Louvers
..................
*so
.......
*
.. 99999.994.9
1-2.26
2.50
Actuator
Linkage
I...
.. ... *9 499999
999*
.......
1-2.27
2.51
DIVERTER
VALVE
DESCRIPTION
1-2.41
SECTION
3.
SPECIAL TOOLS
I..........
...999 ...
1-3.1
3 .1
GENERAL
I
-3.1
3.2
BEARING,
BALL,
INNER
RACE
........
.
1-3.1
3.3
BEARING,
BALL,
OUTER
RACE
.99999999999
1-3.1
3
.4 BEARING,
ROLLER,
INNER
RACE
...... ........ .
1-3
.2
3.5
BEARING,
ROLLER,
OUTER
RACE
I.............
...............
1-3.2
I-i
i

PAGE
3.6
EXIT
LOUVERS
......................
1-3.2
3.7 FRONT
FRAME AND
SCROLL
.I..*..................*.......
1-3.2
3.8
LIFT
FAN
........
...................................
1-3.2
3 9
REAR
FRAm,
............
# ........
. .............
.. . .*.
I-3
2
3.10
ROTOR...............
..
.............
1-3.3
3.11
TURBINE
BUCKET
CARRIER SEGMENT
.
.......................
1-3.3
3.12
NUMERICAL TOOL LIST
.. .
..
......
.................
1-3.4
SECTION
4.
ASSEMBLY
OF
X353-5B
........................
....
1-4.1
4.1
GENERAL
ASSEMBLY
PROCEDURE
.... .........
#
..............
1-4
.1
4.2
Scope .I..... ...
......
.....*.. .....
..... .
*. 1-4.1
4.3
ASSEMBLY
TOOLING
....................
.... ....
1-4.1
4.4
ROTOR
ASSEMBLY
(REFERENCE FIGURE
4.2)
.................
1-4.2
4.5
Disc
and
Shaft Assembly.
0.0.0
..
1-4.2
4.8 Assembly
of Rear
Blade Retainer Ring
......................
1-4.4
4.9
Assembly
of Blade
Platforms
.......
I......0.............. 1-4.4
4.10 Assembly
of Torque Band Segments ..........................
1-4.4
-.
4.11 Assembly of Carrier
Seals ...............................
1-4.5
4.12 Assembly of Bucket Carrier Segments
...................
1-4.6
4.13 BAI.ANCE
PROCEDURE
I..............o... 1-4.8
4.14 TOhOUINGPROCEDURE
.............
... ..
*. .............
.o.. 1-4.9
4.15 .9
1ADIAL INSPECTION
..................
I-4.11
4.16
FRONT FRAMZ ASSEMBLY ..........
. . ......... .
1-4.11
4 J7 ORIENTATION
.................
t.... * o., .........
1-4.11
4.18 ASSEMBLE
INSULATION BLANKET
I....................... 1-4.11
4.19 ASSEMBLY OF 810 SCROLL MOUNTS .......................... 1-4.12
4.20 SCROLL ASSEMBLY
................... . ... .. to 1-4.13
4.21
Inspection and Adjustment
of the Scroll to the
Front Frame
............. ..........
-4.15
4.22 Assembly
of Scroll Finger Seals
I.................... 1-4.16
4.23 Assembly
of Scroll Insulation .......................
1-4.17
4.24 Final Assembly of
Scroll to Front Frame ...................
1-4.17
4.25 Assemble Scroll Seals and
Air Seal Supports ...............
1-4.17
'-iii

PAGE
4.26
Assemble Honeycomb
Air
Seal .........
........
1-4.18
4.27
Assembly
of Thrust
Bearing
Outer
Race .....................
1-4.18
4.28 Assemble
Rear Frame Insulation Blankets ...................
1-4.19
4.29 Assembly
of
Rear Frame
Air
Seal Segments
..................
1-4.20
4.30 Assemble Rotor to Front Frame and Scroll ..........
1....... -4.21
4.31 Assemble Bearing Inner Races
to Rotor Shaft ............... 1-4.21
4.32
Assemble
the
Rotor to
the Thrust
Bearing
..................
1-4.22
4.33
Assemble the Roller Bearing
.........................
1-4.23
4.34
Clearance Inspection Prior to Assembly
of Rear Frame ...... 1-4.24
4.35
Assembly
of Rear
Frame
to Front
Frame .....................
1-4.25
4.36
Clearance Inspection
after
Assembly of Rear
Frame .........
1-4.26
4.37
Assemble
and Adjust
Magnetic
Speed
Pickup
.........
00#......
1-4.27
4.38 Setting
of Nozzle
Area Adjustment
Vanes ...................
1-4.27
4.39 EXIT LOUVER
ASSEMBLY .
1-4.28
4.40 Orientation of the Exit
Louver Push Rods .................. 1-4.28
4.41
Assembly
of Exit
Louver
Push
Pods
1-4.29
4.42
Assemble
Bushings
to
Supports
......................
1-4.29
4.43 Assemble
Louver Port
Bushing
to
Strut .....................
1-4.29
4.44 Assemble
the Lever
Arms
to Louvers
................
.....
1-4.30
4.45
Assemble Exit Louver #14 ...................
..
1-4.30
4.46
Assemble
Louver
#38 .... ..
& .......
..... ...
1-4.31
4.47
Assemble
Louver
#13 ...............
. ....
......
. 1-4.31
4.48
Assemble Louver
#15 .................
...........
. 1-4.31
4.49
Assembly
of
Remaining
Louvers
........................
1-4.31
4.50
ASSEMBLY
OF
CIRCULAR
VANE ...............
.....
.. ........
1-4.32
4.51
DIVERTER VALVE ASSEMBLY
....................................
1-4.107
4.52 GENERAL
.................................... #.......#........
1-4.107
4.53
ASSEMBLE INSULATION
BLANKET
...............................
1-4.107
4.54
ASSEMBLE
DOORS
............
.
.......... .
.. ................
1-4.107
4.55 Assemble
Seals Springs,
Seal
Segments
and
Tube Seals
......
1-4.107
4.56
Assemble
Doors to
Valve Body
..............................
1-4.108
4.57
ASSEMBLE
DIFFUSER
CONE
................
* .................
1-4.109
4.58 INSPECTION
...............
.....
.........
1-4.109
I-iv

PAGE
4.9 AO-4
4.59
ASSEMBLE ACTUATOR
LINKAGE ...........
..........
1-4.109
4 60ASSEMBLE ACTUATOR
IU*~**~*******~******* -4.110
4.61 ASSEMBLE
DOOR LIMIT
SWITCHES ..............................
1-4.111
4.62 Assemble
Diverter
Valve
to J85-5 1ngine
...................
1-4.112
4.63 Disassembly
of Actuator .....................
.. ...... 1-4.113
4.64 Assembly
.. . ....... . . .o. . Ioo.
... . . .
-4.113
4.65
Actuator Pressure Test ..................... .............
1-4.114
4.66
Diverter
Valve Coupling
Description
I............... 1-4.114
4.67
Divertor Valve
Splined Torque
Shaft Assmnbly
.............
1-4.115
4.68 Diverter
Valve Coupling Assembly
o..............
.. 1-4.115
SECTION 5.
INSTALLATION ....
o .... o. ...... ................
1-5.1
5.1
INDUCTION SYSTEM ........... ... ........ .. . ... ..o. ...
1-5.1
5.2 General
.. . . .. . . . . . .. .I0. . .0. . -5.1
5.3 Inlet Closure
.... o.............
...... ..... **... ..
1-5.1
5.4
Inlet Seal
.
1-5.2
5o5 Inlet Connection
.. I.... ...
..... ~o....
-5.2
SECTION
6. X353-5B LIFT
FAN DISASSEMBLY
1-6.1
6.1
PREPARATION FOR TEARDOWN
. ......... o.............. o.
.... 1-6.1
6.2 REMOVE REAR FRAME
........... . ... .s
.o. . .
...
1-6.1
6.3 REMOVE
ROTOR FROM FRONT
FRAME...........................
I-6.1
6.4 REMOVE SCROLL
FROM FRONT FRAME .................
*..so.....
1-6.2
6.5
DISASSEMBLE FRONT
FRAME ......................
1-6.2
6.6
Remove Circular Vane o.. . . . ... ............
1-6.2
6.7 Remove
Thrust Bearing Outer
Race
... 1-6.2
6.8 Remove the
Roller Bearing
.............. I..............6.
1-6.3
6.9 Remove the
Insulation Blanket
I............... 1-6.3
6.10 Remove Scroll
End Clevises
..........
I..0.
... 0....
... 1-6.3
6.11
Remove Speed Pick-up Bushing
.....
I.so
.......
...... I-6.3
6.12
DISASSEMBLE
ROTOR o.......... ......... ,....
1-6.3
6.13
Remove Carrier Segments
.....
. .. . . .o. ....... ......
1-6.3
I-V

PAGE
6.14
Disassemble
Blades
........................................
...
......
1-6.4
6.15
Disassemble Bearings
..............
..............
1-6.4
6.16
DISASSEMBLE
REAR
FRAME
.............. ...
*. ................
...
1-6.4
6.17
Remove Exit
Louvers
............................ ...........
1-6.4
6.18
Remove
Push
Rods
................. 0. ............... .
....
1-6.5
6.19
Remove Insulation
Blanket ................................
1-6.5
6.20
Remcve
Air
Seals
..............................
...
1-6.5
6.21
DISASSEMBLE
DIVERTER
VALVE
.......
...........
1-6.6
6.22
Actuation
Removal
............................
....... .
1-6.6
6.23
Door
Removal
.............................
.........
.
... .
1-6.6
6.24
Insulation
Blanket
Removal
..............
...
........
1-6.6
6.25
Diffuser
Removal
....................
....
...
..........
1-6.6
SECTION
7.
INSPECTION,
REPAIR
AND
REPLACEMENT
...................
1-7.1
7.1
GENERAL .......................................
..........
1-7.1
7.2
CLEANING
AND
INSPECTION
...................... ........
1-7.1
7.3
Cleaning
of
Bearings
....
................
,
.................
1-7.1
7.4
Fluorescent-Penetrant Method
of
Inspection
(Zyglo)
........
1-7.3
7.5
General
.............................. ....................
1-7.3
7.6
Cleaning Prior
to
Application
of
Fluoreqcent-Penetrant
....
1-7.3
7.7
Application
of
Fluorescent-Penetrant
(,il
..................
1-7.3
7.8
Application
of Developer
.................................
1-7.3
7.9
BLADE TANG
AND
BLADE/DISC
DOVETAIL
COATING
................
1-7.4
7.10
PERIODIC
INSPECTION
REQUIREMENTS
..........................
1-7.32
7.11
LIFT
FAN
SERIAL
NUMBERS
................................
1-7.33
SECTION
8.
TESTING AFTER OVERHAUL
OR
MAINTENANCE
................
1-8.1
8.1
GENERAL
.........
.............. .
.........
..
............
1-8.1
SECTION
9.
OPERATION
OF
X353-5B PROPULSION SYSTEM
..........
1-9.1
9.1
GENERAL
............................. .......... ...
....
.
I-9.1
I-vi

LIST
OF
ILLUSTRATIONS
FIGURE
TITLE PAGE
1.1
X353-5B
Propulsion
System...............
1-1.2
2.1
Typical
Fan-In-Wing
X353-5B
Installation
............... 1-2.28
2.2
Major
Components
of
X353-SB
Lift
Fan
System
............
1-2.29
2.3
System Orientation
.................... ........
..
1-2.30
2.4
Lift
Fan Rotor
Component
..........
1-2.31
2.5
Lift
Fan Front
Frame
............................
. 1-2.32
2.6
Lift
Fan
Assembly
Showing
Inlet
Vane
..............
t....
1-2.33
2.7
Lift Fan Scroll,
View
of
Inlet .....................
1-2.34
2.8
Lift Fan
Scroll, View
of.Nozzle
............
....
1-2.35
2.9
Lift
Fan Scroll,
ToP View
...................
1-2.36
2.10
Sketch
of Turbine
Nozzle
Partitions
..................
1-2.37
2.11
Scroll Area Adjustment
Mechanism
1-2.38
2.12 Lift
Fan Rear Fra:ae
............... .. ..o... ......... 1-
2.39
2.13 Exit
Louver System
i.
.......
-2.40
2.14
Diverter Valve
Asse~nb .............
1-2.45
2.15 Diverter
Valve Actuation
System......
I-2.46
2.16 Sketch
of Actuation Linkage
in Straight-Through
and
Diverted Positions
I... 1-2.47
3.1
Rotor Balance
Arbor
1-3.5
3.2
Rotor Turnover
Dolly .
I-3.5
3.3 Front
Frame, Scroll and-Fan
Turnover Dolly .....
* ...... 1-3.6
3.4
Ball Bearing
Inner Race Puller
1-3.6
3.5 Rotor
Vertical Lift Fixture
...... ....
1-3.7
3.6
Roller
Bearing
Inner Race
Puller
1-3.7
3.7 Spanner Wrench
.............................
......
1-3 .8
3.8 Ball
Bearing Outer Race
Puller
1-3.8
3.9 Roller Bearing
Outer Race Puller
..................
1-3.9
3.10 Tab
Bender, Front Frame and
Bearing Assembly
........... 1-3.9
3.11 Lift Fan Shipping Container .. 1-3.10
3.12 Lift
Fan Transportation
Dolly ..........................
1-3.10
3.13 Front
Frame and Scroll Lift
Fixture ...................
1-3.11
0
I-vi

FIGURE
TITLE
PAGE
3.14
Rotor Support
Stand
.....
* .......
..........
1-3.11
3.15
Rotor
Balance
and Inspection Stand
...........
1-3.12
3.16
Front Frame Air Seal Grinding (lift)
and
Inspection (Right) Fixtures
............................
1-3.12
,3.17
Carrier Retaining
Pin
Inserting and
Removal Tool
(Tool
for Left Hand
Carriers
on Left;
Tool
for
Right Hand
Carriers
on Right)
*.........................
1-3.13
3:18 Exit Louver
Protractor
................................
13.13
3.19
Bearing
Cage
Support
...................................
1-3.13
3.20 Exit Louver
Template
..... .....
* ........ *.. I-S.14
4.0
Balance
Plot
-Top
Looking
Down........................
1-4.9
4.1
Lift
Fan Basic Assembly Drawing
(Left) "..
......
14.49
4.2 Lift Fan Rotor Assembly
Drawing (Left) ................. 1-4.53
4.1A Lift Fan
Basic
Assembly
Drawing
(Right)
.................
1-4.71
4.2A Lift Fan
Rotor Assembly
Drawing
(Right) ................ 1-4.75
4.2B
X353-5B
Lift Fan
Configuration
(left)
.................
1-4.76
4.2C
X353-5B Lift Fan Installation
.................
1-4.79
4.3
Rotor Tie
Bolt Torquing
Procedure
.....................
1-4.83
4,4 Rotor Air
Seal and Tip Seal Inspection
................
1-4.84
4.5 Front
Frame Insulation
Blanket Inspection
..............
1-4.85
4.6
Inspection and
Adjustment of
Scroll to Front
Frame ..... 1-4.96
4.7 Insepction
of Scroll
to Front Frame
............
0....... 1-4.87
4.8 Inspection and Adjustment of Scroll Center Mount
Uniba! Slot .................... . . . I-4.88
4.9 Inspection and Adjustment
of Scroll Seal Overlap .... ,.. 1-4.89
4.10 Honeycomb
Ar Seal Attachment .............
1-4.90
4.11 Honeycomb Seal Grinding Instructions and Inspections ... 1-4.91
4.12 Rear Frame Assembly Drawing (Left Hand)
................ 1-4.93
4.12A Rear Frame
Assembly Drawing (Right Hand) ............... 1-4.95
4.13 Inspection
of Rear
Frame Insulation
Blanket Radius
..... 1-4.97
4.14 Assembly
of Bearing Retaining Nut Tabwasher
............
1-4.98
4.15 Inspection of
Rotor Axial Clearances
....... 1-4.99
4.16A
Reference
Sketch
for
Final
Inspection
of
Assembly
......
1-4.1n
4.16B Rotor
Bearing and Speed Sensor Clearance
Inspection .... 1-4.101
I-viii