TASK 72-41-34-300-049 HPC Stage 4 Unison Rings - Replace Bushes And Loose Fittings, Repair-049 (VRS6247)

DMC:V2500-A0-72-41-3424-00A-920A-C|Issue No:002.00|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 72-41-34-300-049 HPC Stage 4 Unison Rings - Replace Bushes And Loose Fittings, Repair-049 (VRS6247)

Effectivity

FIG/ITEM

PART NUMBER

ASSEMBLY

04-440

6A3543

A

04-440

6A3983

C

04-440

6A7596

D

04-440

6A7868

F

04-440

6A7888

G

04-440

6A8121

I

04-540

6A3545

B

04-540

6A7599

E

04-540

6A7890

H

Material of component

DESCRIPTION

MATERIAL

HP Compressor VIGV actuating ring connector assembly

Titanium alloy

Bush

Polymide resin

Bracket assembly and dowels

Corrosion resistant steel

General

This repair must only be done when the instruction to do so is given in TASK 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 the 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 the 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 70-31-02-310-501-001
SPM TASK 70-31-02-310-501-016
SPM TASK 70-35-03-300-501

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

0.307 in. (7.80 mm) diameter

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

Consumables, Materials and Expendables

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

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
BushUP1081542
Bracket assembly6A28814
Bracket assembly6A28832
BushUP1081542
Bracket assembly6A28813
Bracket assembly6A36851
Bracket assembly6A28832
BushUP1081542
Bracket assembly6A28812
Bracket assembly6A28832
BushUP1081542
Bracket assembly6A28812
Location pinUP110194
Dowel assembly6A75984
BushUP1081542
Bracket assembly6A28812
Bracket assembly6A36851
Location pinUP110194
Dowel assembly6A75984
Bracket assembly6A76011
BushUP1081542
Bracket assembly6A28814
Location pinUP110194
Dowel assembly6A75984
BushUP1220621
Bracket assembly6A28812
Location pinUP110194
Dowel assembly6A75984
BushUP1220621
Bracket assembly6A28812
Bracket assembly6A78921
Location pinUP110194
Dowel assembly6A75984
Bracket assembly6A76011
BushUP1220621
Bracket assembly6A28814
Location pinUP110194
Dowel assembly6A75984

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-34-350-117-A00 Remove the Worn Bushes and Brackets from Upper and Lower Stage 4 Actuating Ring Assemblies, Assembly A, Assembly B and Assembly C

    2. Remove 42 off bushes from the holes numbered 1 to 21 in actuating ring inner and outer annuli.

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

      1. Use a drilling machine with a 0.307 in. (7.80 mm) diameter drill bit.

        Drill into bush head along the axial centre line of the bush.

        Make sure that the bush location hole of the 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 72-41-34-350-117-B00 Remove the Worn Bushes, Brackets and Dowel Assemblies from Upper and Lower Stage 4 Actuating Ring Assemblies, Assembly D, Assembly E and Assembly F

      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 TOOLING 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 THE REPAIR.

      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. Remove 42 off bushes from the holes numbered 1 to 21 in actuating ring inner and outer annuli.

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

      1. Use a drilling machine with a 0.307 in. (7.80 mm) diameter drill bit.

        Drill into bush head along axial centre line of the bush.

        Make sure that the bush location hole of the 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 4 off location pins welded in position.

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

        Use portable dressing equipment to remove welds.

      6. Remove and hold 4 off dowel assemblies.

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

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

      8. Deburr location holes.

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

    3. SUBTASK 72-41-34-350-117-C00 Remove the Worn Bushes, Brackets and Dowel Assemblies from Upper and Lower Stage 4 Actuating Ring Assemblies, Assembly G, Assembly H and Assembly I

      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 TOOLING 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 THE REPAIR.

      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. Remove 21 off bushes from the holes numbered 1 to 21 in actuating ring.

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

      1. Use a drilling machine with a 0.307 in. (7.80 mm) diameter drill bit.

        Drill out bush along the axial centre line.

        Make sure the bush location holes are 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 4 off location pins welded in position.

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

        Use portable dressing equipment to remove welds.

      6. Remove and hold 4 off dowel assemblies.

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

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

      8. Deburr location holes.

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

    4. SUBTASK 72-41-34-160-051 Clean the Location Holes

      2. Clean the location holes in the actuating ring.

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

        Air blast to remove debris.

        Swab degrease to clean holes.

    5. SUBTASK 72-41-34-220-242-A00 Examine the Upper Actuator Ring Location Holes, Assembly A, Assembly F and Assembly I

      2. Visually examine and measure 42 off bush location hole diameters marked No. 1 to No. 21 (21 off outer annuli and 21 off inner annuli).

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

      3. Visually examine and measure 8 off bracket hole diameters marked No. 26 to No. 33, 4 off attachment hole diameters marked No. 22 to No. 25 (both sets of holes located in outer annuli).

      1. If the attachment hole diameter is more than the specified diameter, 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) is found, reject the actuator ring.

    6. SUBTASK 72-41-34-220-242-B00 Examine the Lower Actuator Ring Location Holes, Assembly B, Assembly E and Assembly H

      2. Visually examine and measure 42 off bush location hole diameters marked No. 1 to No. 21 (21 off outer annuli and 21 off inner annuli).

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

      3. Visually examine and measure 8 off bracket hole diameters marked No. 26 to No. 33, 4 off attachment hole diameters marked No. 22 to No. 25 (both sets of holes located in outer annuli).

      1. If the location hole diameter is more than the specified diameter, 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) is found, reject the actuator ring.

    7. SUBTASK 72-41-34-220-242-C00 Examine the Upper and Lower Actuator Ring Location Holes, Assembly C, Assembly D and Assembly G

      2. Visually examine and measure 42 off bush location hole diameters marked No. 1 to No. 21 (21 off outer annuli and 21 off inner annuli).

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

      3. Visually examine and measure 4 off bracket hole diameters marked No. 28 to No. 31, 4 off attachment hole diameters marked No. 22 to No. 25 (both sets of holes located in outer annuli).

      1. If the location hole diameter is more than the specified diameter, 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) is found, reject the actuator ring.

    8. SUBTASK 72-41-34-220-243 Examine the Retained Bracket Assemblies, Assembly A to Assembly I

      2. Examine the brackets.

      1. If damaged, reject.

      3. Visually examine the 0.190-32 wire screw thread inserts in bracket assemblies 6A2881 , 6A3685 , 6A7601 and 6A7892 .

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

      4. Visually examine the 0.250-28 wire thread inserts in bracket assembly 6A2883 .

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

    9. SUBTASK 72-41-34-220-668 Examine the Retained Dowel Assemblies, Assembly D to Assembly I

    1. Refer to Figure and Figure.

      2. Visually examine and measure set of 4 off dowel spigot diameters.

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

      3. Visually examine the wire screw thread inserts.

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

    10. SUBTASK 72-41-34-230-099 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 70-23-02-230-501.

        Cracks are not permitted.

    11. SUBTASK 72-41-34-350-118 Temporary Install Bracket Assemblies, Assembly A to Assembly I

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

        1. For internal mid-ring bracket assemblies, use 6A2881 for Assembly A to Assembly I, 6A3685 for Assembly B and Assembly E, 6A7601 for Assembly E and Assembly H, 6A7892 for Assembly H.

        1. 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.

        2. For internal end attachment bracket assemblies installed in the ends of the actuating ring, use 6A2883 for Assembly A to Assembly C.

        3. Use hand tightened 0.250-28 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.

    12. SUBTASK 72-41-34-350-196 Install the Dowel Assemblies, Assembly D to Assembly I

    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 heads, to permanently keep correct dowel assemblies in the actuating ring.

      4. Examine the 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.

        Cracks are not permitted.

    13. SUBTASK 72-41-34-350-197 Install the Bushes, Assembly A to Assembly I

    2. Install new bushes.

      3. For Assembly A to Assembly F.

      1. Press fit bush UP10815 until retaining feature is engaged, typical 2 off at 21 locations.

      4. For Assembly G to Assembly I.

      1. Press fit bush UP12206 in the direction of outer to inner annuli until bush head touches the actuator ring, typical 21 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.

    14. SUBTASK 72-41-34-220-244 Examine the Stage 4 Upper and Lower Actuator Ring Assemblies, Assembly A to Assembly I

      2. Visually examine the installation of stage 4 upper and lower actuator ring assemblies bushes and loose fit.

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

    15. SUBTASK 72-41-34-350-119 Identify the Repair, Assembly A to Assembly I

      1. Mark VRS6247 adjacent to the assembly number.

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

        Use vibro-engraving equipment.

    16. 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 F and Assembly I

    Repair Details and Dimensions - Assembly A, Assembly F and Assembly I

    Figure: Repair Details And Dimensions - Assembly B, Assembly E And Assembly H

    Repair Details And Dimensions - Assembly B, Assembly E And Assembly H

    Figure: Repair Details and Dimensions - Assembly C, Assembly D and Assembly G

    Repair Details and Dimensions - Assembly C, Assembly D and Assembly G

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

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

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

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

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

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

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

    SBE 72-0385: Repair Details and Dimensions - Assembly D 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 B, Assembly E and Assembly H

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

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedural step and figure. (20VG110)

Change Type:

Added note. (20VG108)

Link not Found
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Link not Found
Link not Found
Link not Found
Link not Found
Link not Found
Link not Found
Link not Found
Link not Found
Link not Found
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: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
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