TASK 72-00-40-450-001-A00 HP System Module Components - Install The Variable Stator Vane (VSV) Actuator, Installation-011

DMC:V2500-A1-72-00-4050-00B-720A-B|Issue No:002.00|Issue Date:2013-11-01

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

V2500-A1

Common Information

TASK 72-00-40-450-001-A00 HP System Module Components - Install The Variable Stator Vane (VSV) Actuator, Installation-011

General

Fig/item numbers in parenthesis in the procedure agree with those used in the IPC. Only the primary Fig/item numbers are used. For the service bulletin alpha variants refer to the IPC.

For all parts identified in a different Chapter/Section/Subject, the applicable Chapter/Section/Subject comes before the Fig/item number.

For standard torque data and procedures refer to the SPM TASK 70-41-01-400-501.

Special torque data is identified with the symbol * after the torque value.

Assembly tolerances are included in this procedure.

For lockwire data and procedures refer to the SPM TASK 70-42-05-400-501.

For safety cable data and procedures refer to the SPM TASK 70-42-08-400-501.

Safety the threaded fasteners in this TASK with CoMat 02-274 SAFETY CABLE KIT or CoMat 02-275 SAFETY CABLE KIT for the ATA Chapter/Section/Subjects which follow:

A1 series engines:

71-51-41

71-52-43

72-41-34

73-22-49

75-23-49

75-31-42

75-31-43

75-32-42

75-00-49

Refer to the V2500 Illustrated Tool and Equipment Manual (ITE-V2500-1IA) for the illustrations of the special tools used in this procedure.

Transportation covers/blanks must not be removed until immediately before installation of the components.

Do not remove the special plastic caps from electrical connections or tube connections which are not applicable in this procedure. This will give protection from unwanted material.

Lubricate all threads and abutment faces or nuts and bolts with CoMat 10-039 ENGINE OIL engine oil unless other lubricants are referred to in this procedure.

After assembly apply CoMat 07-038 AIR DRYING ENAMEL damaged surface protection, joint flanges and attach parts. Use the correct color of air drying enamel. Refer to the SPM TASK 70-38-21-380-501.

NOTE

  1. To identify the consumable materials refer to the PCI.

  2. SBE 70-0813 : Announcement of introduction of safety cable as a preferred method to lockwire.

  3. Safety the threaded fasteners in this TASK with safety cable for the ATA Chapter/Section/Subjects detailed in 2. General.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Crowsfoot spannerLOCALCrowsfoot spanner

0.937 in. (24 mm)

IAE 1R18254 Rigging pin0AM53IAE 1R182541
IAE 1R18282 Rigging pin0AM53IAE 1R182821

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-001 SOLVENT, DELETED0AM53CoMat 01-001
CoMat 02-119 LOCKWIRELOCALCoMat 02-119
CoMat 02-126 LOCKWIRELOCALCoMat 02-126
CoMat 02-274 SAFETY CABLE KITLOCALCoMat 02-274
CoMat 02-275 SAFETY CABLE KITLOCALCoMat 02-275
CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADELOCALCoMat 04-005
CoMat 07-038 AIR DRYING ENAMELK3504CoMat 07-038
CoMat 10-038 PETROLEUM JELLYLOCALCoMat 10-038
CoMat 10-039 ENGINE OILLOCALCoMat 10-039
CoMat 10-060 LIQUID PARAFFINLOCALCoMat 10-060
CoMat 02-146 LOCKWIRELOCALCoMat 02-146

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Packing1
Packing1

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-40-450-051-A00 Install the VSV Actuator (Pre SBE 75-0055, SBE 72-0398, Pre SBE 72-0132, SBE 72-0132 and SBE 75-0034)

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

    2. WARNING

      WHEN YOU SEE CoMat 01-001 SOLVENT, DELETED INHIBITED AND STABILIZED TRICHLORETHANE YOU MUST USE THE NECESSARY PROTECTIVE CLOTHING. DO NOT GET THE SOLVENT ON YOUR SKIN OR IN YOUR EYES. YOU MUST NOT SMOKE WHEN YOU USE THE SOLVENT AS THE VAPOR CHANGES AND BECOMES TOXIC.

      With CoMat 01-001 SOLVENT, DELETED inhibited and stabilized trichloroethane; clean the bolts AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-082), AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-102) and AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-112), the brackets AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-070) and AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-080) and the attachment faces of the VSV actuator and the HP compressor case. Then apply a layer of CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE to the surfaces and the bolts.

    3. Attach the bracket AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-080) to the VSV actuator with the bolt AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-112) and tighten by hand.

    4. Attach the VSV actuator to the HP compressor case with the four bolts AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41, 01-102 and AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR01-082), the two washers AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-104) and the bracket AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-070). Tighten by hand.

    5. Torque the two bolts AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-102) to 180 to 220 lbfin (20 to 25 Nm).

    6. Torque the two bolts AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-082) to 180 to 220 lbfin (20 to 25 Nm).

    7. Torque the two bolts AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-112) to 180 to 220 lbfin (20 to 25 Nm).

      8. Connect the VSV actuator to the actuating mechanism.

      1. Move the VSV actuating mechanism to the high speed position.

      2. Install IAE 1R18254 Rigging pin rigging pin 1 off through the bearing housing and locate in the crankshaft recess.

      3. Install IAE 1R18282 Rigging pin rigging pin 1 off in the actuating ram.

        4. If necessary adjust the length of the control rod such that the bolt HP COMP VARIABLE STATOR VANE ACTUATOR LINKAGE (75-32-42,01-084) can be installed. Do the steps that follow:

        1. Remove and discard the lockwire that safeties the locknuts.

        2. Loosen the two locknuts and adjust the length.

      5. Install the washer HP COMP VARIABLE STATOR VANE ACTUATOR LINKAGE (75-32-42,01-083) and the nut HP COMP VARIABLE STATOR VANE ACTUATOR LINKAGE (75-32-42,01-082). Align the D-head of the bolt with the stepped section of the actuator fork. Torque the nut to 290 to 370 lbfin (33 to 42 Nm).

        6. Lock the control rod ends. Do the steps that follow:

        1. Make sure that the control rod ends are in safety with an applicable probe and lock them with the locknuts.

        2. Make sure control rod ends are aligned to less than 5 degrees.

        3. Tighten the locknuts and torque to between 205 and 220 lbfin (23 and 25 Nm).

        4. Safety the control rod locknuts with CoMat 02-119 LOCKWIRE.

      7. Remove the two rigging pins.

        Pre SBE 72-0132 : Assemble the clip positions 5745 and 5746 and torque the bolts to 36 to 45 lbfin (4 to 5 Nm).

        SBE 72-0132: Assemble the clip positions 5745 and 5746 and torque the bolts to 36 to 45 lbfin (4 to 5 Nm).

        SBE 75-0034: Clip position 5745 - make sure that the clip is aligned correctly with the lip on the bracket AIR-HP COMPRESSOR VARIABLE STATOR VANE ACTUATOR (75-32-41,01-070) to give a minimum clearance of 0.25 in (6.35 mm) between the master BSBVA actuator electrical connectors and the EEC harness.

    9. Connect the fuel drain tube 47 POWER PLANT-FUEL DRAIN TUBES-ENGINE (71-71-49,01-500) and torque the tube connector to 159 to 177 lbfin (18 to 20 Nm). Safety with CoMat 02-126 LOCKWIRE.

    10. Lightly lubricate a new packing ENGINE FUEL AND CONTROL-FUEL SYSTEM TUBES-ENGINE (73-11-49,12-496) 1 off with CoMat 10-060 LIQUID PARAFFIN or CoMat 10-038 PETROLEUM JELLY and install it on the VSV actuator.

    11. Connect the fuel servo tube 44 ENGINE FUEL AND CONTROL-FUEL SYSTEM TUBES-ENGINE (73-11-49,12-500) to the VSV actuator and with a 0.937 in. (24 mm) crowsfoot spanner torque the tube connector to 425 to 475 lbfin (48 to 53.7 Nm). Safety with CoMat 02-126 LOCKWIRE.

    12. Lightly lubricate a new packing ENGINE FUEL AND CONTROL-FUEL SYSTEM TUBES-ENGINE (73-11-49,19-096) 1 off with CoMat 10-060 LIQUID PARAFFIN or CoMat 10-038 PETROLEUM JELLY and install it on the VSV actuator.

    13. Connect the fuel servo tube 46 ENGINE FUEL AND CONTROL-FUEL SYSTEM TUBES-ENGINE (73-11-49,19-100) to the VSV actuator and torque the tube connector to 425 to 475 lbfin (48 to 53.7 Nm). Safety with CoMat 02-126 LOCKWIRE.

  2. SUBTASK 72-00-40-450-051-B00 Install the VSV Actuator (SBE 75-0055)

    NOTE

    SBE 72-0398 has removed the requirement for SBE 75-0055.

    SBE 75-0055: Introduce a new setting procedure for the re-scheduling of the HP Compressor Variable Vanes

    3. SUBTASK 72-00-40-420-250-A00 Connect the EEC Harness Electrical Connectors to the VSV Actuator (Pre SBE 71-0063)

    1. Refer to: Figure

    2. Connect the two electrical connectors 4022KS-B and 4022KS-C to the VSV actuator and torque to 8 * lbfin (0.9 Nm).

    3. Connect the two electrical connectors 4022KS-A and 4022KS-D to the VSV actuator and torque to 12 * lbfin (1.4 Nm).

    4. SUBTASK 72-00-40-420-250-B00 Connect the EEC Harness Electrical Connectors to the VSV Actuator (SBE 71-0063 and Pre SBE 71-0111)

    1. Refer to: Figure and Figure

    2. Connect the two electrical connectors 4022KS-B and 4022KS-C to the VSV actuator and torque to 8 * lbfin (0.9 Nm).

      3. Assemble the clip position 5798.

      1. Install the two clips ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-488 and ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE01-489) on the backshells of the two connectors 4022KS-B and 4022KS-C.

      2. Attach the two clips together with the bolt ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-486), the two washers ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-487) and the nut ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-493).

      3. Make sure the clips are in the correct position then torque the nut to 36 to 45 lbfin (4 to 5 Nm).

    4. Connect the two electrical connectors 4022KS-A and 4022KS-D to the VSV actuator and torque to 12 * lbfin (1.4 Nm).

      5. Assemble the clip positions 6060 and 6061.

      1. Install the two clips ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-505 and ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE01-513) on the backshells of the two connectors 4022KS-A and 4022KS-D.

      2. Put the bracket ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 05-940) in position. Attach the two clips to the bracket with the two bolts ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-502 and ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE01-510), the four washers ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-503 and ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE01-511) and the two nuts ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE (71-52-43, 01-509 and ELECTRICAL HARNESS-LIGHT DUTY-EEC HARNESS-CORE01-517).

      3. Make sure the bracket and the two clips are in the correct position then torque the two nuts to 36 to 45 lbfin (4 to 5 Nm).

      4. Safety the bracket to one of the connector backshells with CoMat 02-146 LOCKWIRE. Use the wire locking hole of the bracket and a wire locking hole in one of the backshell relief clamps.

    5. SUBTASK 72-00-40-420-250-C00 Connect the EEC Harness Electrical Connectors to the VSV Actuator (SBE 71-0111)

    1. Refer to: Figure

      SBE 71-0111: EEC harness fan/core - Deletion of clipping at VSVA and PMA harness connectors and introduction of wire locking to secure connectors.

    2. Connect the two electrical connectors 4022KS-B and 4022KS-C to the VSV actuator and torque to 8 * lbfin (0.9 Nm).

    3. Safety the two connectors to each other with CoMat 02-126 LOCKWIRE.

    4. Connect the two electrical connectors 4022KS-A and 4022KS-D to the VSV actuator and torque to 12 * lbfin (1.4 Nm).

    5. Safety the two connectors to each other with CoMat 02-126 LOCKWIRE.

    6. SUBTASK 72-00-40-210-061 Visually Inspect the Electrical Backshells and Cable Clamps

    1. Refer to Figure.

    2. Make sure that all the applicable connectors, backshells and cable clamps are secure.

    3. Make sure that all the applicable backshells and cable clamps are safetied with CoMat 02-126 LOCKWIRE. Refer to the SPM TASK 70-42-05-400-501.

    7. SUBTASK 72-00-40-210-062 Visually Inspect the EEC Harness (01-005) Electrical Backshells and Cable Clamps (SBE 70-0813)

      SBE 70-0813: Announcement of introduction of safety cable as a preferred method to lockwire.

      NOTE

      Use this procedure to safety the EEC harness backshells and cable clamps with safety cable.

    1. Refer to Figure.

    2. Make sure that all the EEC harness connectors, backshells and cable clamps are secure.

    3. Make sure that all the EEC harness backshells and cable clamps are safetied. Safety with CoMat 02-274 SAFETY CABLE KIT or with CoMat 02-275 SAFETY CABLE KIT. Refer to the SPM TASK 70-42-08-400-501.

    8. Figure: Install the VSV Actuator

    Sheet 1

    Legend
    Install the VSV Actuator

    Sheet 1

    Close

    Figure: Install the VSV Actuator

    Sheet 2

    Legend
    Install the VSV Actuator

    Sheet 2

    Close

    Figure: Install the VSV actuator

    sheet 3

    Legend
    Install the VSV actuator

    sheet 3

    Close

    Figure: Install the VSV Actuator

    Sheet 4

    Legend
    Install the VSV Actuator

    Sheet 4

    Close

    Figure: Connect the electrical harness connectors

    Sheet 1

    Legend
    Connect the electrical harness connectors

    Sheet 1

    Close

    Figure: Pre SBE 71-0111 : Connect the electrical harness

    Sheet 2

    Legend
    Pre SBE 71-0111 : Connect the electrical harness

    Sheet 2

    Close

    Figure: Visually inspect the backshells and cable clamps

    Visually inspect the backshells and cable clamps

Requirements After Job Completion

Follow-On Conditions

NONE
Link not Found
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:K3504
Enterprise Name:INDESTRUCTIBLE PAINT CO LTD
BU Name:NULL
Street:25 PENTOS DRIVE
City:SPARKHILL
Province:BIRMINGHAM
Zip Code:B11 3TA
Country:GREAT BRITAIN
Phone Number:44-121-7022485
Fax Number:44-121-7784338
Email:sales@indestructible.co.uk
Internet:www.indestructible.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:X111X
Supply Number:CoMat 01-001
Type:sp01
Supply Short Name:CoMat 01-001 SOLVENT, DELETED
Supply Name:CoMat 01-001 SOLVENT, DELETED
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐001 is specified to clean mechanical components, use one or more of the solvents that SPM TASK 70‐11‐26‐300‐503 specifies as applicable.DELETED. Where CoMat 01‐001 is specified to clean electrical contacts or wiring harnesses, use one or more of the solvents that SPM TASK 70‐11‐57‐110‐501 specifies to clean electrical contacts or
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:LOCAL
Supply Number:CoMat 02-119
Type:sp01
Supply Short Name:CoMat 02-119 LOCKWIRE
Supply Name:CoMat 02-119 LOCKWIRE
Specification Groups:
Doc NumberType
SAE AS9226 Part Number MS-9226-04 (0.032 IN DIA.)
Suppliers:
ManufacturerRemarks
LOCAL
51563
81343
V508V
Manufacturer Code:K6835
Supply Number:CoMat 02-126
Type:sp01
Supply Short Name:CoMat 02-126 LOCKWIRE
Supply Name:CoMat 02-126 LOCKWIRE
Specification Groups:
Doc NumberType
DTD 189A, 0.028 TO 0.032 IN DIA
Suppliers:
ManufacturerRemarks
K6835
KB362
LOCAL
U06C8
Manufacturer Code:LOCAL
Supply Number:CoMat 02-146
Type:sp01
Supply Short Name:CoMat 02-146 LOCKWIRE
Supply Name:CoMat 02-146 LOCKWIRE
Specification Groups:
Doc NumberType
AIA/NAS NASM20995 Part Number MS20995C20 (0,5 MM)
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 02-274
Type:sp01
Supply Short Name:CoMat 02-274 SAFETY CABLE KIT
Supply Name:CoMat 02-274 SAFETY CABLE KIT
Specification Groups:
Doc NumberType
SAE AS3510-0218K (DIA 0,032 IN LENGTH 18IN)
Suppliers:
ManufacturerRemarks
LOCAL
11851
U0419
70958
H7503
SA221
V384V
Manufacturer Code:X111X
Supply Number:CoMat 02-275
Type:sp01
Supply Short Name:CoMat 02-275 SAFETY CABLE KIT
Supply Name:CoMat 02-275 SAFETY CABLE KIT
Specification Groups:
Doc NumberType
Deleted. Use CoMat 02-274.
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:LOCAL
Supply Number:CoMat 04-005
Type:sp01
Supply Short Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Supply Name:CoMat 04-005 JOINTING COMPOUND, MEDIUM GRADE
Specification Groups:
Doc NumberType
OMAT: 4/47 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
JCR-026 (JAEC REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
DTD 900/4586 (RR REF, MOD UK REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), MEDIUM GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:00BB6
Supply Number:CoMat 07-038
Type:sp01
Supply Short Name:CoMat 07-038 AIR DRYING ENAMEL
Supply Name:CoMat 07-038 AIR DRYING ENAMEL
Specification Groups:
Doc NumberType
OMAT:7/22B (RR REF)IP9138 R1
JCR-029 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
K3504
Manufacturer Code:K6835
Supply Number:CoMat 10-038
Type:sp01
Supply Short Name:CoMat 10-038 PETROLEUM JELLY
Supply Name:CoMat 10-038 PETROLEUM JELLY
Specification Groups:
Doc NumberType
SILKOLENE 775 CERTIFIED TO DEF STAN 91-38 GRADE PX-7 OR TO NATO S-743
Suppliers:
ManufacturerRemarks
K6835
U1757
Manufacturer Code:LOCAL
Supply Number:CoMat 10-039
Type:sp01
Supply Short Name:
Supply Name:CoMat 10-039 ENGINE OIL
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 10-060
Type:sp01
Supply Short Name:CoMat 10-060 LIQUID PARAFFIN
Supply Name:CoMat 10-060 LIQUID PARAFFIN
Specification Groups:
Doc NumberType
OMAT:CoMat 1020BP TECHNICAL WHITE OIL
Suppliers:
ManufacturerRemarks
LOCAL
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 1R18254
Tool Name:IAE 1R18254 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18282
Tool Name:IAE 1R18282 Rigging pin