Description

1. TASK 05-10-00-990-000-A00 Instructions For Continued Airworthiness (V2500-A1)

   1. Airworthiness Limitations

      THE AIRWORTHINESS LIMITATIONS SECTION IS FAA APPROVED AND SPECIFIES MAINTENANCE REQUIRED UNDER SECTION 43.16 AND 91.403 OF THE FEDERAL AVIATION REGULATIONS UNLESS AN ALTERNATIVE PROGRAM HAS BEEN FAA APPROVED.

      Refer to Chapter/Section 05-10-01 of this Manual for information that sets forth those parts that must be replaced on a mandatory basis upon the expiration of the Flight Cycles stated therein.

      In computing part life, calculations must include hours and/or cycles since time of manufacture.

      Refer to Paragraph B. Maintenance Scheduling for information that sets forth the operators maintenance requirements for the V2500 On-Condition engine.

   2. Maintenance Scheduling

      1. The V2500 is designed as an On-Condition engine. Whenever a scheduled inspection specified in the Operator's Approved Maintenance Program leads to removal of an engine or module for disassembly, the Operator is expected to review the condition and past performance of the engine in order to determine what preventative maintenance actions are to be carried out in accordance with FAA approved procedures prior to re-installation.

      The Operator should use the opportunity of engine/module disassembly to sample the condition of parts/components in the area associated with the module or assembly being refurbished and its interfaces.

      Whenever a Group A part is identified in this paragraph (Refer to Paragraph C for Definition of a Group A Part/Component) satisfies both of the following conditions:

      The part is considered completely disassembled when done in accordance with the disassembly instructions in the Engine Manual.

      and

      The part has accumulated more than 100 cycles in service since the last piece-part opportunity inspection, provided that the part was not damaged or related to the cause for the removal from the engine; then that part is considered to be at the piece-part level and it is mandatory to perform the inspections for that part as specified in the following table:

      PART NOMENCLATURE	PART NUMBER	INSPECTION (ENGINE MANUAL REFERENCE)
      LPC Fan Disk	All	TASK 72-31-12-200-002, SUBTASK 72-31-12-230-054
      HPC Stage 3 To 8 Disk	All	TASK 72-41-11-230-002, SUBTASK 72-41-11-230-104
      HPC Stage 9 To 12 Disk	All	TASK 72-41-12-200-004, SUBTASK 72-41-12-230-079
      HPC Rear Shaft	All	TASK 72-41-13-200-010, SUBTASK 72-41-13-230-098
      HPC Rear Rotating Seal	All	TASK 72-41-14-200-003, SUBTASK 72-41-14-230-064
      HPT Stage 1 Hub	All	TASK 72-45-11-200-002
      HPT Stage 2 Hub	All	TASK 72-45-31-200-004
      LPT Stage 3 Disk	All	TASK 72-50-31-200-006
      LPT Stage 4 Disk	All	TASK 72-50-31-200-006
      LPT Stage 5 Disk	All	TASK 72-50-31-200-006
      LPT Stage 6 Disk	All	TASK 72-50-31-200-006
      LPT Stage 7 Disk	All	TASK 72-50-31-200-006

      These maintenance reviews, actions and schedules are to be documented in the Operator's FAA Approved Maintenance and Reliability Programs in order to show compliance with FAR Part 33 Appendix A33.4 requirements.

      2. The diffuser case rear outer flange is cycle limited and requires maintenance by flange replacement when the rear outer flange accumulates 20,000 cycles. The flange must be replaced by Modification Service Bulletin ENG-72-0709 in order to return the diffuser case to a serviceable condition. See Table for diffuser case part number applicability.

      Table 2.

      PART NOMENCLATURE	PART NUMBER	CYCLIC LIFE*	REQUIRED MAINTENANCE ACTION
      Diffuser Case	2A0051-001	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A0051-002	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A0051-003	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A0051-004	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2883-101	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2883-201	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2883-301	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2883-401	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2889-101	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2889-201	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2889-301	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2889-401	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2891-101	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2891-201	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2891-301	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2891-401	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2896-101	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2896-201	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2896-301	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A2896-401	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A3132-001	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A3132-002	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A3132-003	20,000	Service Bulletin ENG-72-0709
      Diffuser Case	2A3132-004	20,000	Service Bulletin ENG-72-0709

      NOTE

      *The diffuser case is not a life limited cycle part, and is not subject to IAE's approved lifing methodology. The diffuser case rear outer flange will require cyclic maintenance.

   3. Definition of a Group A Part/Component

      Group A critical parts are those parts shown by failure analysis as likely to have hazardous effects on the aircraft if they fail and which require special controls in order to achieve an acceptable low probability of individual failure. Group A Parts have Approved Lives.

      Refer to TASK 05-10-01-200-001-A00 for Group A Parts Lives.

   4. Definition of an Engine Cycle

      An engine cycle is defined as any flight consisting of one take-off and landing, regardless of length of flight, or whether or not thrust reverser is used on landing. Each touch and go is considered an additional cycle. For further clarification refer TASK 05-00-01-220-501.

   5. Group A Parts Life Management

      This section defines the methods for establishing total part life limits for engines without the incorporation of the Consolidated Bump Rating (CBR) and with the CBR Utilization on any life limited part.

      1. The part lives listed in TASK 05-10-01-200-001-A00 give the Approved Life for each part that is life limited in the V2500 engine. If an engine is exposed to the CBR then the operator must ensure that any life limited part in the engine does not exceed the Certified life limit specified in the above TASK. A record of the engine model or models, for the accumulated cycles should be kept.

         The method requires the recording of the total number of times the CBR is not used (normal cycles) and the total number of times when the CBR is used. The total number of times a Group A part is exposed to the CBR must in accordance with the Certified life listed in TASK 05-10-01-200-001-A00. A record of the engine model or models, for the accumulated cycles should be kept.

         Example - Requirement for 20 percent bump usage on Group A part 2A3200 in TASK 05-10-01-200-001-A00. Approved life with no bump usage is 14,600 cycles. For bump usage between 15 percent and 30 percent, the total certified life is 12,000 cycles. In this case, 20 percent of these (3,000 cycles) are bump cycles and the remaining 80 percent (9,000 cycles) are normal cycles.

   6. Group A Parts Life Management Across Multiple engine models (V2500-A1, V2500-A5 and V2500-D5)

      1. It is acceptable to operate a life limited part in multiple engine models that it is certified for.

      2. If a Group A part life is model dependent, it will be stated in Group A part section.

      3. If the certified life is the same across multiple models, total cycles on part would be the sum of cycles accrued with each model.

      4. If certified life is different across multiple models, the lowest certified life applies.

      5. If a thrust bump has been used, see Time Limits Manual for cycle life change for individual parts.

      6. A record of the engine model or models for the accumulated cycles should be kept. If there is no record of engine model or models, then the model that results in the lowest certified life applies.

      7. V2500-E5 LLPs are not certified for use in V2500-A1, A5 or D5 models.