TASK 72-41-34-300-047 HPC Inlet Variable Stator Vane Unison Rings - Replace The Bushes And Loose Fittings, Repair-047 (VRS6265)

DMC:V2500-A0-72-41-3422-00A-920A-C|Issue No:005.00|Issue Date:2021-02-01

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 72-41-34-300-047 HPC Inlet Variable Stator Vane Unison Rings - Replace The Bushes And Loose Fittings, Repair-047 (VRS6265)

Effectivity

FIG/ITEM

PART NO

ASSEMBLY

02-440

A

02-440

B

02-440

C

02-440

D

02-440

E

02-540

A

02-540

B

02-540

C

02-540

D

02-540

E

Material of component

The HP compressor VIGV actuating ring connector assembly is manufactured from titanium alloy.

The bushes are manufactured from polymide resin.

The bracket assemblies and dowels are manufactured from corrosion resistant steel.

General

This repair must only be done when the instruction to do so is given in TASK 72-41-34 Inspection.

The practices and processes referred to in the procedure by TASK/SUBTASK numbers are in the SPM.

Price and availability

Refer to International Aero Engines

Related repairs

HP compressor VIGV and stage 3 to 5 actuating ring assemblies and related housing assemblies - replacement of 0.250-28 wire screw thread inserts. Repair-014, refer to TASK 72-41-34-300-014 (VRS6156).

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-09-00-400-501, Procedures to Make Identification
SPM TASK 70-23-02-230-501, Fluorescent Penetrant Inspection
SPM TASK 70-31-02-310-501-016, Argon Arc Welding

NOTE

To identify the consumable materials refer to the Overhaul Process and Consumables Index Manual.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Drilling machineLOCALDrilling machine
DrillLOCALDrill

0.346 in. (8.80 mm) dia

Standard workshop equipmentLOCALStandard workshop equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Heat protection glovesLOCALHeat protection gloves
Portablegrinding equipmentLOCALPortable grinding equipment
Manual welding equipmentLOCALManual welding equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-026 LIQUID NITROGENLOCALCoMat 03-026
CoMat 03-366 WELDING FILLER WIRELOCALCoMat 03-366
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)LOCALCoMat 06-063
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
VIGV Upper Variable Vane Actuating Ring Assembly6A3535

A

VIGV Upper Variable Vane Actuating Ring Assembly6A7580

B

VIGV Upper Variable Vane Actuating Ring Assembly6A7849

C

VIGV Upper Variable Vane Actuating Ring Assembly6A7899

D

VIGV Upper Variable Vane Actuating Ring Assembly6A8075

E

BushUP1106932

A

BushUP1106932

B

BushUP1106932

C

BushBRR1249616

D

BushBRR1249616

E

Spacer6A28604

A

Spacer6A28604

B

Spacer6A28604

C

Spacer6A28604

D

Spacer6A28604

E

Bracket Assembly6A28611

A

Bracket Assembly6A28631

A

VIGV Lower Variable Vane Actuating Ring Assembly6A3537

A

VIGV Lower Variable Vane Actuating Ring Assembly6A7584

B

VIGV Lower Variable Vane Actuating Ring Assembly6A7851

C

VIGV Lower Variable Vane Actuating Ring Assembly6A7901

D

VIGV Lower Variable Vane Actuating Ring Assembly6A8077

E

BushUP1106932

A

BushUP1106932

B

BushUP1106932

C

BushBRR1249616

D

BushBRR1249616

E

Spacer6A28604

A

Spacer6A28604

B

Spacer6A28604

C

Spacer6A28604

D

Spacer6A28604

E

Bracket Assembly6A28631

A

Bracket Assembly6A28611

A

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-34-350-086-A00 Remove the Worn Bushes, Brackets, Dowel Assemblies and Spacers of Assembly A, from Upper and Lower VIGV Actuating Ring Assemblies

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.

      CAUTION

      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU HAND DRESS TO REMOVE LOCATION PIN HEAD, OR BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED, MASK ADJACENT AREA TO REPAIR IF NECESSARY.

      CAUTION

      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.

      2. Drill the head of the bush until the head is released to remove the bushes HPC Variable Stator Vane Actuation System (72-41-34,02-460) and HPC Variable Stator Vanes (72-41-32,02-560) (32 off).

      1. Use a drilling machine with a 0.346 in. (8.80 mm) diameter drill bit.

        Drill into the bush head along axial centerline of the bush.

        Make sure that the bush location hole is not damaged or increased.

      3. Push the bush from the hole.

      1. Use a round bar.

        NOTE

        Pushing the bushing from the hole using a round bar, and on its own is sufficient to remove the bushings when needed.

    4. Drift out to remove the spacers HPC Variable Stator Vane Actuation System (72-41-34,02-462) and HPC Variable Stator Vane Actuation System (72-41-34,02-562) (4 off).

    5. Remove and retain loose bracket assemblies HPC Variable Stator Vane Actuation System (72-41-34,02-470), HPC Variable Stator Vane Actuation System (72-41-34,02-490), HPC Variable Stator Vane Actuation System (72-41-34,02-570) and HPC Variable Stator Vane Actuation System (72-41-34,02-590) from inside the actuator ring.

    2. SUBTASK 72-41-34-350-086-B00 Remove the Worn Bushes, Brackets, Dowel Assemblies and Spacers of Assembly B and Assembly C, from Upper and Lower VIGV Actuating Ring Assemblies

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.

      CAUTION

      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU HAND DRESS TO REMOVE LOCATION PIN HEAD, OR BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED, MASK ADJACENT AREA TO REPAIR IF NECESSARY.

      CAUTION

      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.

      2. Drill the head of the bush until the head is released to remove the bushes HPC Variable Stator Vane Actuation System (72-41-34,02-460) and HPC Variable Stator Vane Actuation System (72-41-34,02-560) (32 off).

      1. Use a drilling machine with a 0.346 in. (8.80 mm) diameter drill bit.

        Drill into the bush head along axial centreline of the bush.

        Make sure that the bush location hole is not damaged or increased.

      3. Push the bush from the hole.

      1. Use a round bar.

        NOTE

        Pushing the bushing from the hole using a round bar, and on its own is sufficient to remove the bushings when needed.

    4. Drift out to remove the spacers HPC Variable Stator Vane Actuation System (72-41-34,02-462) and HPC Variable Stator Vane Actuation System (72-41-34,02-562) (4 off).

      5. Grind to remove the location pins (UP11019) (4 off), welded in position.

      1. Refer to the SPM TASK 70-35-03-300-501.

        Use a portable grinding equipment to remove welds.

    6. Remove and retain dowel assemblies (4 off).

    3. SUBTASK 72-41-34-350-086-C00 Remove the Worn Bushes, Brackets, Dowel Assemblies and Spacers of Assembly D and Assembly E, from Upper and Lower VIGV Actuating Ring Assemblies

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.

      CAUTION

      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU HAND DRESS TO REMOVE LOCATION PIN HEAD, OR BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED, MASK ADJACENT AREA TO REPAIR IF NECESSARY.

      CAUTION

      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.

      2. SBE 72-0418: Drill the head of the bush until the head is released to remove the bushes HPC Variable Stator Vane Actuation System (72-41-34,02-460) and HPC Variable Stator Vane Actuation System (72-41-34,02-560) (16 off).

      1. Use a drilling machine with a 0.346 in. (8.80 mm) diameter drill bit.

        Drill out the bush along axial centreline of the bush.

        Make sure that the bush location holes are not damaged or increased.

      3. Push the bush from the hole.

      1. Use a round bar.

        NOTE

        Pushing the bushing from the hole using a round bar, and on its own is sufficient to remove the bushings when needed.

    4. Drift out to remove the spacers HPC Variable Stator Vane Actuation System (72-41-34,02-462) and HPC Variable Stator Vane Actuation System (72-41-34,02-562) (4 off).

      5. Grind to remove the location pins (UP11019) (4 off), welded in position.

      1. Refer to the SPM TASK 70-35-03-300-501.

        Use a portable grinding equipment to remove welds.

    6. Remove and retain dowel assemblies (4 off).

    4. SUBTASK 72-41-34-160-063 Clean the Location Holes

      2. Clean the location holes in the actuating ring.

      1. Refer to the SPM TASK 70-11-26-300-503.

        Remove sharp edges around the holes.

        Use standard workshop equipment.

        Use air blast to remove debris.

        Swab degrease to clean the holes.

    5. SUBTASK 72-41-34-220-217-A00 Examine the Upper and Lower Actuator Ring Location Holes for Assembly A

      2. Visually examine and measure the bush location hole diameters (32 off).

      1. Reject if the location hole is more than specified diameter.

      3. Visually examine and measure the spacer location hole diameters (4 sets of 2 off).

      1. Reject if the location hole is more than specified diameter.

      4. Visually examine and measure the holes (17, 18, 23 and 25) in outer actuating ring annulus and inter actuating ring annulus (18).

      1. Reject if the location hole is more than specified diameter.

    6. SUBTASK 72-41-34-220-217-B00 Examine the Upper and Lower Actuator Ring Location Holes for Assembly B and Assembly C

      2. Visually examine and measure the bush location hole diameters (32 off).

      1. Reject if the location hole is more than specified diameter.

      3. Visually examine and measure the spacer location hole diameters (4 sets of 2 off).

      1. Reject if the location hole is more than specified diameter.

      4. Visually examine and measure the dowel spigot diameters (4 off) and location hole diameters (4 off).

      1. Reject if the location hole is more than specified diameter.

    7. SUBTASK 72-41-34-220-217-C00 Examine the Upper and Lower Actuator Ring Location Holes for Assembly D and Assembly E

      2. Visually examine and measure the bush location hole diameters (16 sets of 2 off).

      1. Reject if the location hole is more than specified diameter.

      3. Visually examine and measure the spacer location hole diameters (4 sets of 2 off).

      1. Reject if the location hole is more than specified diameter.

      4. Visually examine and measure the dowel location hole diameters (4 off).

      1. Reject if the location hole is more than specified diameter.

    8. SUBTASK 72-41-34-220-218 Examine the Retained Bracket Assembly A

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

      2. Examine the brackets.

      1. Reject the damaged brackets.

      3. Replace damage wire screw thread inserts.

      1. Refer to VRS6156, TASK 72-41-34-300-014 for the replacement of damaged inserts.

    9. SUBTASK 72-41-34-220-558 Examine the Retained Dowel Assemblies B, C, D and E

    1. Refer to Figure, Figure and Figure.

      2. Visually examine and measure the dowel spigot diameters (4 off).

      1. Reject if spigot diameter is less than specified diameter.

    10. SUBTASK 72-41-34-230-088 Do a Crack Test

      1. Do a local penetrant crack test on the repair area.

      1. Refer to the SPM TASK 70-23-02-230-501.

        Cracks are not permitted.

    11. SUBTASK 72-41-34-350-087 Temporary Install Brackets, Assembly A

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

      2. Install the existing or replacement bracket assemblies in upper and lower actuating rings. Loosely fit and retain in position before installing the replacement bushes.

      1. Use hand tightened 0.250-28 UNF bolts, as assembly aids for fitting of bracket assemblies HPC Variable Stator Vane Actuation System (72-41-34,02-470) and HPC Variable Stator Vane Actuation System (72-41-34,02-490) into their respective actuator ring locations.

        For correct installation of bracket assembly at hole positions 23 and 25, check ring to bracket hole alignment at hole 24.

        Check 0.3125 thread is located at hole 18 position.

    12. SUBTASK 72-41-34-350-139 Install Dowels, Assembly B, Assembly C, Assembly D and Assembly E

    1. Refer to Figure, Figure and Figure.

    2. Install existing or replacement dowel assemblies in upper and lower actuating rings. Fit before installing the replacement location pins.

      3. Install replacement location pins in upper and lower actuating rings, to retain dowel assemblies (4 off).

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Procedure to tack weld location pin (UP11019) 4 off positions, to capture respective dowel assemblies in actuating ring.

      4. Inspection of welds.

      1. Refer to the SPM TASK 70-31-02-310-501-001, SUBTASK 70-31-02-220-002 and SPM TASK 70-23-05-230-501.

        Use penetrant crack test equipment.

        Cracks are not permitted.

    13. SUBTASK 72-41-34-350-140-A00 Install the Bushes in Upper and Lower Actuating Rings, Assembly A, Assembly B and Assembly C

    1. Refer to Figure, Figure and Figure.

      2. Install the new bushes.

      1. Press fit the bush HPC Variable Stator Vane Actuation System (72-41-34,02-560) until retaining feature engages in 2 sets of 16 locations.

    3. Remove the bolts used in Step.

    14. SUBTASK 72-41-34-350-140-B00 Install the Bushes in Upper and Lower Actuating Rings, Assembly D and Assembly E

    1. Refer to Figure, Figure and Figure.

      2. Install the new bushes.

      1. Press fit the bush V2500-A5-72-41-43-02A-941A-D (72-41-43, 02-460), until the bush head registers on outer diameter of the actuator ring in typical 16 locations.

    3. Remove the bolts used in Step.

    15. SUBTASK 72-41-34-350-088 Install the Spacers

    1. Refer to Figure, Figure and Figure.

      2. Freeze the spacers.

      1. Freeze fit the spacer HPC Variable Stator Vane Actuation System (72-41-34,02-562).

      3. Install the spacers.

      1. Install the spacers into the upper and lower actuating rings.

        Make sure the spacers are pushed fully into position immediately after immersion in the liquid nitrogen.

        Use shouldered mandrel.

        Use heat protective gloves.

    16. SUBTASK 72-41-34-220-551-A00 Examine VIGV Upper and Lower Actuator Ring Assembly for Assembly A

      2. Inspect the installation of the bushes in VIGV upper and lower actuator ring assemblies.

      1. Make sure all the bushes, the spacers and the brackets are fitted with correct hole alignment and 0.3125 thread located at hole 18.

        Use standard workshop equipment.

    17. SUBTASK 72-41-34-220-551-B00 Examine VIGV Upper and Lower Actuator Ring Assemblies for Assembly B, Assembly C, Assembly D and Assembly E

      2. Inspect the installation of the bushes in VIGV upper and lower actuator ring assemblies.

      1. Make sure the bushes, the spacers, the dowel assemblies and their location pins are fitted correctly.

        Use standard workshop equipment.

    18. SUBTASK 72-41-34-350-157 Identify the Repair

      1. Mark VRS6265 adjacent to the assembly number on both VIGV upper and lower actuator ring assembly.

      1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

        Use vibro-engraving eqipment.

    19. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added note. (20VG108)

Link not Found
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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Manufacturer Code:LOCAL
Supply Number:CoMat 03-026
Type:sp01
Supply Short Name:CoMat 03-026 LIQUID NITROGEN
Supply Name:CoMat 03-026 LIQUID NITROGEN
Specification Groups:
Doc NumberType
OMAT:220BB-N-411 T2GBC1
JCR-135BB-N-411 T2GBC1
Suppliers:
ManufacturerRemarks
LOCAL
U2046
U2096
Manufacturer Code:LOCAL
Supply Number:CoMat 03-366
Type:sp01
Supply Short Name:CoMat 03-366 WELDING FILLER WIRE
Supply Name:CoMat 03-366 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
AMS 4956TI 6-4
Suppliers:
ManufacturerRemarks
LOCAL
2R602
3G172
58401
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Drill
Tool Name:Drill
Manufacturer Code:LOCAL
Tool Number:Drilling machine
Tool Name:Drilling machine
Manufacturer Code:LOCAL
Tool Number:Heat protection gloves
Tool Name:Heat protection gloves
Manufacturer Code:LOCAL
Tool Number:Manual welding equipment
Tool Name:Manual welding equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment