2022-11 · NASA ASRS report 1953570
Technicians reported misindexing a fan blade set during a routine fan blade lube procedure. The aircraft was returned to the hangar and the fan blades were removed and reinstalled in their correct positions.
On Day 0; we performed a blade lube on the #1 engine of Aircraft X. All was normal as we finished up and went to do the high power runs. After completing the high power runs the vibe were high so we brought the aircraft back to the hanger to adjust the weights to the solution given by the AVM (Airborne Vibration Monitoring). Once back at the hangar the AMTs (Aviation Maintenance Technicians) on the ground noticed then spinner cone to be clocked wrong. Upon a closer look we noticed that the blades were in at the wrong position. Being off by one blade (ex: #1 was in #24; #2 was in #1 etc) once that was discovered we decided to bring the Aircraft into the hangar and correct the problem. Aircraft X was brought into the hangar and we removed the forward spinner cone along with the aft spinner and blades. During removal sufficient lubricant was on the blades to allow us to remove them and correct the issue. After we removed corrected the misplaced blades to the correct position we reinstalled the aft spinner and forward cone and torqued to the correct values given in the task. All the while working off of the original task that was issued to the #1 Engine to begin with and never closed as we were the original AMTS to be working the card. We then went back out to run the motor again and completed the vibration survey satisfactorily according to the task.
On Day 0; Aircraft X; #1 engine (serial # XXXXXX) myself along with another Aviation Maintenance Technician (AMT) and an Inspector performed Fan Blade Lubrication task # XXX-XX-XX. After UT (Ultrasonic Testing) inspection was performed and no defects were found; the engine was lubricated and put back together. The other AMT and myself performing task accomplished takeoff power engine runs on both engines; the #1 engine produced a vibration over limit of 1.4 units per task. We returned to hangar after solution run to have #1 engine balanced. The AMT on the ground went to install AVM (Airborne Vibration Monitoring) weights solution into rear spinner and noticed spinner was 'clocked' incorrectly. After further investigation it was discovered that the #1 Blade was installed one position counter clockwise in #24 Blade position and all of the other blades were positioned one position counter clockwise as well (in order 1-24). We pulled the aircraft into the hangar in order to fix the mistake. We're removed front and aft spinner along with retaining ring and cycled blades into original position. Blades had lubrication for reinstallation as no alcohol was needed for removal. Blades were reinstalled and all work; including removal; was accomplished according to originally issued task by original AMTs and Inspector. The other AMT and myself performed #1 engine vibration survey engine run with vibration indication within limits (below 1.4 units). Aircraft was returned to service.
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Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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