TASK 72-41-34-300-045 HPC Stage 3 Unison Rings - Replace The Bushes And Loose Fittings, Repair-045 (VRS6248)

DMC:V2500-A0-72-41-3423-00A-920A-C|Issue No:004.00|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 72-41-34-300-045 HPC Stage 3 Unison Rings - Replace The Bushes And Loose Fittings, Repair-045 (VRS6248)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

03-440

6A3539

A

03-440

6A3753

A

03-440

6A3982

C

03-440

6A7588

E

03-440

6A7861

G

03-440

6A7863

G

03-440

6A7903

I

03-440

6A8115

K

03-440

6A8117

K

03-540

6A3541

B

03-540

6A3987

D

03-540

6A7590

F

03-540

6A7865

H

03-540

6A7906

J

03-540

6A8119

L

Material of component

The HP compressor stage 3 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 72-41-34 Inspection/Check.

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

Price and availability

Refer to International Aero Engines

Related repairs

HP compressor stage 3 to 6 actuating ring assemblies and related housing assemblies - replacement of 0.190-32 wire screw thread inserts. Refer to VRS6155, TASK 72-41-34-300-013 (REPAIR-013).

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

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-11-26-300-503
SPM TASK 70-23-02-230-501
SPM TASK 70-23-05-230-501
SPM TASK 70-31-02-310-501-016

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. (8.79 mm) diameter

Heat protection glovesLOCALHeat protection gloves
Manual welding equipmentLOCALManual welding equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Portable Dressing EquipmentLOCALPortable Dressing Equipment
Standard Workshop EquipmentLOCALStandard Workshop Equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-195 WELDING WIRE TITANIUMLOCALCoMat 03-195
CoMat 04-366 WELD FILLER MATERIALX111XCoMat 04-366
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)X222XCoMat 06-064

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
PART IDENTPART NO.QTY

ASSEMBLY

BushUP1106924

A

Bracket assembly6A28692

A

Bracket assembly6A36601

A

Bracket assembly6A36621

A

Bracket assembly6A36782

A

BushUP1106924

A

Bracket assembly6A28692

A

Bracket assembly6A36601

A

Bracket assembly6A36621

A

Bracket assembly6A36782

A

BushUP1106924

B

Bracket assembly6A28692

B

Bracket assembly6A28771

B

Bracket assembly6A28731

B

Bracket assembly6A36781

B

BushUP1106924

C

Bracket assembly6A28692

C

Bracket assembly6A36601

C

Bracket assembly6A36621

C

Bracket assembly6A36781

C

BushUP1106924

D

Bracket assembly6A28692

D

Bracket assembly6A28771

D

Bracket assembly6A28731

D

BushUP1106924

E

Bracket assembly6A28692

E

Location pinUP110194

E

Bracket assembly6A36781

E

Dowel assembly6A75834

E

BushUP1106924

F

Bracket assembly6A28692

F

Location pinUP110195

F

Dowel assembly6A75834

F

Dowel assembly6A75921

F

BushUP1106924

G

Bracket assembly6A28692

G

Location pinUP110194

G

Bracket assembly6A36782

G

Dowel assembly6A75834

G

BushUP1106924

G

Bracket assembly6A28692

G

Location pinUP110194

G

Bracket assembly6A36782

G

Dowel assembly6A75834

G

BushUP1106924

H

Bracket assembly6A28692

H

Location pinUP110195

H

Bracket assembly6A36781

H

Dowel assembly6A75834

H

Dowel assembly6A75921

H

BushBRR1249612

I

Bracket assembly6A28692

I

Location pinUP110194

I

Bracket assembly6A79051

I

Dowel assembly6A75834

I

BushBRR1249612

J

Bracket assembly6A28692

J

Location pinUP110195

J

Dowel assembly6A75834

J

Dowel assembly6A75921

J

BushBRR1249612

K

Bracket assembly6A28692

K

Location pinUP110194

K

Bracket assembly6A79052

K

Dowel assembly6A75834

K

BushBRR1249612

K

Bracket assembly6A28692

K

Location pinUP110194

K

Bracket assembly6A79052

K

Dowel assembly6A75834

K

Bracket assembly6A79051

L

BushBRR1249612

L

Bracket assembly6A28692

L

Location pinUP110195

L

Dowel assembly6A75834

L

Dowel assembly6A75921

L

Safety Requirements

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, NO SPARKS ARE PRODUCED AND THE ADJACENT AREA IS MARKED OFF.

CAUTION

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

Procedure

    1. SUBTASK 72-41-34-350-123-A00 Remove the Worn Bushes and Brackets, from Upper and Lower Stage 3 Actuating Ring Assemblies, Assembly A to Assembly D

    2. Remove 24 off bushes from holes numbered 1 to 12 in actuating ring inner annulus and outer annulus.

      3. Drill the head of the bush until the head is released.

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

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

        Make sure the bush location hole in actuating ring is not damaged or increased.

      4. 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.

    5. Remove and hold loose bracket assemblies from inside actuator ring.

    2. SUBTASK 72-41-34-350-123-B00 Remove the Worn Bushes, Brackets and Dowel Assemblies, from Upper and Lower Stage 3 Actuating Ring Assemblies, Assembly E to Assembly H

    2. Remove 24 off bushes UP11069 from holes numbered 1 to 12 in actuating ring inner annulus and outer annulus.

      3. Drill the head of the bush until the head is released.

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

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

        Make sure the bush location hole in actuating ring is not damaged or increased.

      4. 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.

      5. Dress to remove location pins welded in 4 off positions for assembly E and assembly G or 5 off positions for assembly F and assembly H.

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

        Use portable dressing equipment to remove welds.

      6. Remove and hold dowel assemblies.

      1. Do not decrease the actuator wall thickness during dressing operation to remove the pin.

    7. Remove and hold loose bracket assemblies from inside actuator ring.

      8. Deburr location holes.

      1. Remove sharp edges around holes with standard workshop equipment.

    3. SUBTASK 72-41-34-350-123-C00 Remove the Worn Bushes, Brackets and Dowel Assemblies, from Upper and Lower Stage 3 Actuating Ring Assemblies, Assembly I to Assembly L

    2. Remove 12 off bushes from holes numbered 1 to 12 in actuating ring.

      3. Drill the head of the bush until the head is released.

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

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

        Make sure the bush location hole in actuating ring is not damaged or increased.

      4. 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.

      5. Dress to remove location pins welded in 4 off positions for assembly I and assembly K or 5 off positions for assembly J and assembly L.

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

        Use portable dressing equipment to remove welds.

      6. Remove and hold dowel assemblies.

      1. Do not decrease the actuator wall thickness during dressing operation to remove the pin.

    7. Remove and hold loose bracket assemblies from inside actuator ring.

      8. Deburr location holes.

      1. Remove sharp edges around holes with standard workshop equipment.

    4. SUBTASK 72-41-34-160-053 Clean the Location Holes

      2. Clean the location holes in the actuating ring.

      1. Air blast to remove debris.

        Swab degrease to clean holes.

    5. SUBTASK 72-41-34-220-255-A00 Examine the Upper Actuator Ring Location Holes, Assembly A, Assembly G and Assembly K

      2. Visually examine and measure 24 off bush location hole diameters marked No. 1 to 12 (12 off outer annulus, 12 off inner annulus).

      1. If location hole diameter is more than the specified, reject.

      3. Visually examine and measure 4 off bracket hole diameters marked No. 13 to 16, 4 off bracket hole diameters marked No. 17 to 20, 4 off attachment hole diameters marked No. 25, 26, 30 and 31 (each set of holes are in the outer annulus).

      1. If location hole diameter is more than the specified, reject.

      4. Visually examine locally around location pin holes.

      1. If dressing splatter, material discoloration and/or surface damage of more than 0.004 in. (0.10 mm) in depth are found on, reject the actuator ring.

    6. SUBTASK 72-41-34-220-255-B00 Examine the Upper Actuator Ring Location Holes, Assembly B, Assembly H and Assembly L

      2. Visually examine and measure 24 off bush location hole diameters marked No. 1 to 12 (12 off outer annulus, 12 off inner annulus).

      1. If location hole diameter is more than the specified, reject.

      3. Visually examine and measure 4 off bracket hole diameters marked No. 13 to 16, 2 off bracket hole diameters marked No. 21 and 22, 5 off attachment hole diameters marked No. 25, 26, 27, 30 and 31 (each set of holes are in the outer annulus).

      1. If location hole diameter is more than the specified, reject.

      4. Visually examine locally around location pin holes.

      1. If dressing splatter, material discoloration and/or surface damage of more than 0.004 in. (0.10 mm) in depth are found, reject the actuator ring.

    7. SUBTASK 72-41-34-220-255-C00 Examine the Upper Actuator Ring Location Holes, Assembly C, Assembly E and Assembly I

      2. Visually examine and measure 24 off bush location hole diameters marked No. 1 to 12 (12 off outer annulus, 12 off inner annulus).

      1. If location hole diameter is more than the specified, reject.

      3. Visually examine and measure 4 off bracket hole diameters marked No. 13 to 16, 2 off bracket hole diameters marked No. 19 and 20, 4 off attachment hole diameters marked No. 25, 26, 30 and 31 (each set of holes located in the outer annulus).

      1. If location hole diameter is more than the specified, reject.

      4. Visually examine locally around location pin holes.

      1. If dressing splatter, material discoloration and/or surface damage of more than 0.004 in. (0.10 mm) in depth are found, reject the actuator ring.

    8. SUBTASK 72-41-34-220-663 Examine the Lower Actuator Ring Location Holes, Assembly D, Assembly F and Assembly J

      2. Visually examine and measure 24 off bush location hole diameters marked No. 1 to 12 (12 off outer annulus, 12 off inner annulus).

      1. If location hole diameter is more than the specified, reject.

      3. Visually examine and measure 4 off bracket hole diameters marked No. 13 to 16, 5 off attachment hole diameters marked No. 25, 26, 27, 30 and 31 (each set of holes are in the outer annulus).

      1. If location hole diameter is more than the specified, reject.

      4. Visually examine locally around location pin holes.

      1. If dressing splatter, material discoloration and/or surface damage of more than 0.004 in. (0.10 mm) in depth are found, reject the actuator ring.

    9. SUBTASK 72-41-34-220-256 Examine the Retained Brackets, Assembly A to Assembly L

      2. Examine the brackets.

      1. Reject the damaged brackets.

      3. Visually examine the 0.190-32 wire thread inserts in bracket assemblies 6A2869 , 6A3678 and 6A7905 .

      1. Refer to repair VRS6155, TASK 72-41-34-300-013 (REPAIR-013) to replace the damaged wire thread inserts.

      4. Visually examine the 0.250-28 wire thread inserts in bracket assemblies 6A2873 , 6A2877 , 6A3660 and 6A3662 .

      1. Refer to repair VRS6156, TASK 72-41-34-300-014 (REPAIR-014) to replace the damaged wire thread inserts.

    10. SUBTASK 72-41-34-220-665 Examine the Retained Dowels, Assembly E to Assembly L

    1. Refer to: Figure and Figure.

      2. Visually examine and measure the set of dowel spigot diameters.

      1. If spigot diameter is less than the specified diameter, reject.

      3. Visually examine the wire screw thread inserts.

      1. Refer to repair VRS6156, TASK 72-41-34-300-014 (REPAIR-014) to replace the damaged or loose inserts.

    11. SUBTASK 72-41-34-230-102 Do a Crack Test, Assembly A to Assembly I

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

      1. Refer to the SPM TASK 70-23-01-230-501.

        Cracks are not permitted.

    12. SUBTASK 72-41-34-350-185 Temporary Install the Brackets, Assembly A to Assembly L

      2. Install existing or replacement bracket assemblies in upper and lower actuating rings, loosely attach and hold in position before installing the replacement bushes.

      1. For internal mid-ring bracket assemblies, use 6A2869 for assembly A to assembly L, 6A3678 for assembly B, assembly C, assembly E, assembly G and assembly H, 6A7905 for assembly I, assembly K and assembly L.

        Use hand tightened 0.190-32 UNF bolts if necessary to temporarily locate and hold bracket assemblies in their correct locations before the final installation and permanent assembly with the installed bushes.

        For internal end attachment bracket assemblies installed in the ends of the actuating ring, use 6A3660 or 6A3662 for assembly A to assembly C, use 6A2877 or 6A2873 for assembly B and assembly D.

        Use hand tightened 0.250-28 UNF bolts if necessary to temporarily locate and hold bracket assemblies before permanent assembly with installed bushes.

    13. SUBTASK 72-41-34-350-186 Install the Dowels, Assembly E to Assembly L

    1. Refer to: Figure and Figure.

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

      3. Install replacement location pins in upper and lower actuating rings to hold dowel assemblies.

      1. Refer to the SPM TASK 70-31-02-310-501-016.

        Tack weld at two places diagonally opposite to each of the location pin (UP11019) heads, to permanently keep correct dowel assemblies in the actuating ring.

      4. Examine the weld.

      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.

        Cracks are not permitted.

    14. SUBTASK 72-41-34-350-124 Install the Bushes, Assembly A to Assembly L

    2. Install the new bushes.

      3. Assembly A to Assembly H.

      1. Press fit bush UP11069 until retaining feature is engaged, typical 2 off at 12 locations.

      4. Assembly I to Assembly L.

      1. Press fit bush BRR12496 in the direction of outer annulus to inner annulus until the bush head touches on the actuator ring, typical 1 off at 12 locations.

      5. Remove the temporary bolts.

      1. Remove the bolts used to temporarily assemble the bracket assemblies, when made redundant by permanent location of brackets with the installation of the bushes.

    15. SUBTASK 72-41-34-220-257 Examine Stage 3 Upper and Lower Actuator Ring Assemblies, Assembly A to Assembly L

      2. Visually examine the installation of stage 3 upper and lower actuator ring assemblies bushes and loose fittings.

      1. Make sure all bushes, brackets, dowel assemblies and their location pins are installed correctly.

    16. SUBTASK 72-41-34-350-125 Identify the Repair, Assembly A to Assembly L

      1. Mark VRS6248 adjacent to the assembly number.

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

    17. Figure: Repair Details and Dimensions - Assembly A to Assembly L

    Repair Details and Dimensions - Assembly A to Assembly L

    Figure: Repair Details and Dimensions - Assembly A to Assembly I

    Repair Details and Dimensions - Assembly A to Assembly I

    Figure: Repair Details and Dimensions - Assembly A to Assembly I

    Repair Details and Dimensions - Assembly A to Assembly I

    Figure: Repair Details and Dimensions - Assembly A, Assembly C, Assembly E, Assembly G, Assembly I and Assembly K

    Repair Details and Dimensions - Assembly A, Assembly C, Assembly E, Assembly G, Assembly I and Assembly K

    Figure: Repair Details and Dimensions - Assembly B, Assembly H and Assembly L

    Repair Details and Dimensions - Assembly B, Assembly H and Assembly L

    Figure: Pre SBE 72-0418: Repair Details and Dimensions - Assembly A to Assembly H

    Pre SBE 72-0418: Repair Details and Dimensions - Assembly A to Assembly H

    Figure: SBE 72-0418: Repair Details and Dimensions - Assembly I to Assembly L

    SBE 72-0418: Repair Details and Dimensions - Assembly I to Assembly L

    Figure: Pre SBE 72-0385: Repair Details and Dimensions - Assembly A and Assembly C

    Pre SBE 72-0385: Repair Details and Dimensions - Assembly A and Assembly C

    Figure: Repair Details and Dimensions - Assembly B and Assembly D

    Repair Details and Dimensions - Assembly B and Assembly D

    Figure: Pre SBE 72-0385: Repair Details and Dimensions - Assembly A to Assembly D

    Pre SBE 72-0385: Repair Details and Dimensions - Assembly A to Assembly D

    Figure: SBE 72-0385: Repair Details and Dimensions - Assembly E to Assembly L

    SBE 72-0385: Repair Details and Dimensions - Assembly E to Assembly L

    Figure: Repair Details and Dimensions - Assembly A to Assembly L

    Repair Details and Dimensions - Assembly A to Assembly L

    Figure: Repair Details and Dimensions - Assembly A, Assembly B, Assembly C, Assembly E, Assembly G, Assembly H, Assembly I, Assembly K and Assembly L

    Repair Details and Dimensions - Assembly A, Assembly B, Assembly C, Assembly E, Assembly G, Assembly H, Assembly I, Assembly K and Assembly L

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added note. (20VG108)

Link not Found
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X111X
Enterprise Name:N/A – DELETED CONSUMABLE MATERIAL
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
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Manufacturer Code:LOCAL
Supply Number:CoMat 03-195
Type:sp01
Supply Short Name:CoMat 03-195 WELDING WIRE TITANIUM
Supply Name:CoMat 03-195 WELDING WIRE TITANIUM
Specification Groups:
Doc NumberType
MSRR9500/73IMI 318
MSRR8632 COMPAMS 4954
OMAT:3/145AMS 4954
TI 6-4
Suppliers:
ManufacturerRemarks
LOCAL
U9025
K6835
2R602
58401
3G172
Manufacturer Code:X111X
Supply Number:CoMat 04-366
Type:sp01
Supply Short Name:
Supply Name:CoMat 04-366 WELD FILLER MATERIAL
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
X111X
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 Dressing Equipment
Tool Name:Portable Dressing Equipment
Manufacturer Code:LOCAL
Tool Number:Standard Workshop Equipment
Tool Name:Standard Workshop Equipment
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment