DMC:V2500-A1-72-41-3000-04A-710A-B|Issue No:004|Issue Date:2019-05-01

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 72-41-30-440-005-A00 HPC Front Case And Vane Assembly - Install The Stage 4 Variable Stator Vanes, Assembly-005

General

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

All of the temporary marks made in this procedure must be removed after completion of this task.

For standard torque data and procedures, refer to SPM TASK 70-41-01-400-501, SPM TASK 70-41-00-400-501 and SPM TASK 70-41-01-400-501.

Special torque data and assembly tolerances are included in the procedure.

Lubricate all threads and touch faces of nuts and bolts with CoMat 10-077 APPROVED ENGINE OILS, unless other lubricants are referred to in the procedure.

To identify, lubricate and install seal rings, refer to SPM TASK 70-64-02-640-501.

After assembly apply CoMat 07-038 AIR DRYING ENAMEL to any damaged surface protection, joint flanges and parts used to attach. Use the correct colour of the air drying enamel. Refer to SPM TASK 70-63-02-380-501.

The number for each radial location must be identified in a clockwise direction. These start at the engine top position when you look from the rear of the engine, unless stated differently in the procedure.

Pre SBE 72-0027: Refer to Figure for a sectional view of the HP compressor front case.

SBE 72-0027: Refer to Figure for a sectional view of the HP compressor front case.

The Fits and Clearances, NEW PART DIMENSIONS and REJECT IF MORE THAN columns will be used by most operators. This permits the full use of the maximum wear allowance and a reduction in the number of parts which are rejected, is possible.

As long as REJECT IF MORE THAN columns do not include reject values, NEW PART DIMENSIONS do not have to be measured before assembly, as there are no reject-if criteria. Values are only valid for new parts, not for worn parts.

The column WORN PART DIMENSIONS (Non-select) is included for operators who want to have full interchangeability. If this column is used an increase in the number of parts which are rejected is possible.

After the part has been in service for some time the REJECT IF MORE THAN and WORN PART DIMENSION could be changed. The operator must tell IAE and if agreed the manual will be changed.

The abbreviation Intf shows an interference or tight fit. This causes REJECT IF MORE THAN to become REJECT IF LESS THAN.

The abbreviation clear shows a clearance fit.

This TASK gives the procedure to install the stage 4 variable stator vanes (VSV). The subsequent TASKS give the procedure to assemble HP compressor front cases.

Install the Stage 3 to 6 Rotor Path Rings Pre SBE 72-0027 by TASK 72-41-30-440-001-A00 (ASSEMBLY-001).

Install the Stage 5 and 6 Rotor Path Rings SBE 72-0027 by TASK 72-41-30-440-001-B00 (ASSEMBLY-001).

Measure and then Machine the Stage 6 VSV and the Stage 3 to 6 Rotor Path Linings by TASK 72-41-30-440-002-A00 (ASSEMBLY-002).

Install the VIGV by TASK 72-41-30-440-003-A00 (ASSEMBLY-003).

Install the Stage 3 VSV by TASK 72-41-30-440-004-A00 (ASSEMBLY-004).

Install the Stage 5 VSV by TASK 72-41-30-440-006-A00 (ASSEMBLY-006).

Install the Stage 6 VSV by TASK 72-41-30-440-007-A00 (ASSEMBLY-007).

Install the VIGV and the Stage 3 to 6 Connector Assemblies by TASK 72-41-30-440-008-A00 (ASSEMBLY-008).

Measure the HP Compressor Front Cases by TASK 72-41-30-440-009-A00 (ASSEMBLY-009).

Disassemble the HP Compressor Front Cases by TASK 72-41-30-440-010-A00 (ASSEMBLY-010).

Check and Set VSV System with Optimised Build and Setting Clearances - SBE 72-0402 by TASK 72-41-30-440-011-A00 (ASSEMBLY-011).

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

Name	Manufacturer	Part Number / Identification	Quantity
IAE 1R18261 Bushing assembly tool	0AM53	IAE 1R18261	1
IAE 1R18262 Bushing assembly tool	0AM53	IAE 1R18262	1
IAE 1R18274 Air plug gage	0AM53	IAE 1R18274	1
IAE 1R18275 Setting ring	0AM53	IAE 1R18275	1
IAE 1R18276 Setting ring	0AM53	IAE 1R18276	1
IAE 1R18280 Air gage unit	0AM53	IAE 1R18280	1
IAE 1R18423 Rigging pin	0AM53	IAE 1R18423	6
IAE 1R18894 Rigging pin	0AM53	IAE 1R18894	6
IAE 1R18494 Seal fitting tool	0AM53	IAE 1R18494	1
IAE 1R18575 Bushing assembly tool	0AM53	IAE 1R18575
IAE 1R18573 Cylinder, hydraulic	0AM53	IAE 1R18573
IAE 1R18578 Pusher installation tool	0AM53	IAE 1R18578

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 02-363 MARKING PEN	LOCAL	CoMat 02-363
CoMat 04-007 SILICONE GREASE	LOCAL	CoMat 04-007
CoMat 07-038 AIR DRYING ENAMEL	k3504	CoMat 07-038
CoMat 10-077 APPROVED ENGINE OILS	X333X	CoMat 10-077
CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R)	LOCAL	CoMat 10-108

Spares

Name	Manufacturer	Part Number / Identification	Quantity	Remark
Sealing ring		Sealing ring	50

Safety Requirements

NONE

Procedure

SUBTASK 72-41-30-220-081 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1224 (Pre SBE 70-0052 and SBE 70-0052)

Refer to Figure.
SBE 70-0052: Engine - Additional source for variable stator vane spindle bushings.

Reference dimensions at location 1224. If required use the data written as a note in TASK 72-41-31-200-000 and TASK 72-41-32-200-000.

Table 1. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1224
Stage 4 Outer Pivot Bush Pre SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252 And 01-253)
SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252, 01-253, 01-255, 01-256 and 01-257) Locations At The Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500)
Stage 4 Outer Pivot Bush Internal Bore	0.4724
	0.4735	0.0018
Stage 4 VSV Spindle Diameter	0.4685	0.0050
	0.4705

Table 2. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1224
Stage 4 Outer Pivot Bush Pre SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252 And 01-253)
SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252, 01-253, 01-255, 01-256 And 01-257)
Locations At The Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500)
Stage 4 Outer Pivot Bush Internal Bore	12.000
	12.027	0.048
Stage 4 VSV Spindle Diameter	11.900	0.127
	11.952

SUBTASK 72-41-30-220-082 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1228

Refer to Figure.

Reference dimensions at location 1228. If required use the data written as a note in TASK 72-41-33-200-000.

Table 3. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1228
Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Location In The Stage 4 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200)
Half Bush Bore	0.3551
	0.3561	0.0000
Stage 4 Half Shroud Half Bush Location Diameter	0.3543	Intf
	0.3551	0.0018

Table 4. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1228
Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Location In The Stage 4 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200)
Half Bush Bore	9.022
	9.047	0.000
Stage 4 Half Shroud Half Bush Location Diameter	9.000	Intf
	9.022	0.047

SUBTASK 72-41-30-220-083 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1229

Refer to Figure.

Reference dimensions at location 1229. If required use the data written as a note in TASK 72-41-33-200-000.

Table 5. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1229
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Diameter	0.2709
	0.2730	0.0025
Half Bush Bore	0.2756	0.0055
	0.2765

Table 6. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1229
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Diameter	6.881
	6.933	0.067
Half Bush Bore	7.000	0.141
	7.022

SUBTASK 72-41-30-220-084 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1230

Refer to Figure.

Reference dimensions at location 1230. If required use the data written as a note in TASK 72-41-32-200-000 and TASK 72-41-33-200-000.

Table 7. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1230
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Length	6.4560	Intf
	6.4721	0.0094
Half Bush Outer Length	6.4691	Clear
	6.4626	0.0131

Table 8. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1230
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Length	163.9830	Intf
	164.3930	0.2405
Half Bush Outer Length	164.3175	Clear
	164.1525	0.3345

SUBTASK 72-41-30-220-085 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1231

Refer to Figure.

Reference dimensions at location 1231. If required use the data written as a note in TASK 72-41-33-200-000.

Table 9. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1231
Stage 4 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 Half Shroud Internal Length	6.5314
	6.5334	0.006
Half Bush Inner Length	6.5178	0.0156
	6.5254

Table 10. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1231
Stage 4 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 Half Shroud Internal Length	165.9000
	165.9500	0.1525
Half Bush Inner Length	165.5525	0.3975
	165.7475

SUBTASK 72-41-30-220-086 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1232

Refer to Figure.

Reference dimensions at location 1232. If required use the data written as a note in TASK 72-41-32-200-000 and TASK 72-41-33-200-000.

Table 11. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1232
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Length	3.2911	Intf
	3.2962	0.0068
Half Bush Outer Length	3.2893	Clear
	3.3015	0.0104

Table 12. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1232
Stage 4 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 03-500) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190)
Stage 4 VSV Inner Spindle Length	83.594	Intf
	83.724	0.174
Half Bush Outer Length	83.550	Clear
	83.860	0.266

SUBTASK 72-41-30-220-087 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1321

Refer to Figure.

Reference dimensions at location 1321. If required use the data written as a note in TASK 72-41-34-200-000.

Table 13. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1321
Stage 4 VSV Lever ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-100) Location In The Bush ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-560 And 04-460)
Stage 4 VSV Lever Pin Diameter	0.1960
	0.1965	0.0004
Bush Bore	0.1969	0.0016
	0.1976

Table 14. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1321
Stage 4 VSV Lever ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-100) Location In The Bush ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-560 And 04-460)
Stage 4 VSV Lever Pin Diameter	4.978
	4.990	0.01
Bush Bore	5.000	0.04
	5.018

SUBTASK 72-41-30-220-142 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1265 (Pre SBE 70-0052 and SBE 70-0052)

Refer to Figure.

Reference dimensions location 1265. If required use the data written as a note in TASK 72-41-30-200-000 and TASK 72-41-31-200-000.

Table 15. Fits and Clearances (all dimensions in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1265
Stage 4 Inner Bush Pre SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252 And 01-253)
SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252, 01-253, 01-255, 01-256 And 01-257) Location With The Sealing Washer ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-200)
Stage 4 Inner Bush Flange Thickness	0.055
	0.058	0.003
Sealing Washer Thickness	0.049	0.009
	0.052

Table 16. Fits and Clearances (all dimensions in millimetres)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1265
Stage 4 Inner Bush Pre SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252 And 01-253)
SBE 70-0052: ENGINE-HP COMPRESSOR SPLIT CASES (72-41-31, 01-251, 01-252, 01-253, 01-255, 01-256 And 01-257) Location With The Sealing Washer ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-200)
Stage 4 Inner Bush Flange Thickness	1.387
	1.463	0.077
Sealing Washer Thickness	1.250	0.213
	1.310

SUBTASK 72-41-30-220-441 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1258

Refer to Figure.

Reference dimensions at location 1258. If required use the data written as a note in TASK 72-41-33-200-000.

Table 17. Fits and Clearances (all dimensions are in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1258
Stage 3 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 02-200) Location At The Grooved Headless Pin ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 02-222)
Stage 3 Half Shroud Location Pin Hole Bore	0.1996
	0.2007	0.0018
Grooved Headless Pin Diameter	0.1973	0.0034
	0.1977

Table 18. Fits and Clearances (all dimensions are in millimeters)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1258
Stage 3 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 02-200) Location At The Grooved Headless Pin ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 02-222)
Stage 3 Half Shroud Location Pin Hole Bore	5.070
	5.100	0.046
Grooved Headless Pin Diameter	5.012	0.088
	5.024

1. Refer to Figure, Figure and Figure.
2. 1. Put the two stage 4 centralizing pads in to position on the stage 4 upper actuating ring.
  2. Install the four bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-682) to attach the two stage 4 centralizing pads to the stage 4 upper actuating ring.
  3. Tighten the bolts.
3. 1. Install the two stage 4 centralizing pads on to the stage 4 lower actuating ring as given in Step to Step.
4. 1. Put the two brackets ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-760) in to position on the stage 4 upper actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-440). Refer to the detail at E.
  2. Install the four hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-766) and the four bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-762) to attach the two brackets to the stage 4 upper actuating ring.
  3. Torque the four bolts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
  4. Put the bracket ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-770) in to position on the stage 4 lower actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-540). Refer to the detail at F.
  5. Install the two hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-776) and the two bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-772) to attach the bracket to the stage 4 lower actuating ring.
  6. Torque the two bolts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
1. Refer to Figure, Figure and Figure.
2. SBE 72-0084: H.P. compressor variable stator vanes - Reduced number of rigging pin brackets
  SBE 72-0385or SBE 72-0416: Introduction of revised actuating rings with increased dowel locations.
3. 1. Put the two stage 4 centralizing pads in to position on the stage 4 upper actuating ring.
  2. Install the four bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-682) to attach the two stage 4 centralizing pads to the stage 4 upper actuating ring.
  3. Tighten the bolts.
4. 1. Install the two stage 4 centralizing pads on to the stage 4 lower actuating ring as given in Step to Step.
5. 1. Put the bracket ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-770) in to position on the stage 4 lower actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-540). Refer to the detail at F.
  2. Install the two hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-776) and the two bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-772) to attach the bracket to the stage 4 lower actuating ring.
  3. Torque the two bolts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
1. Refer to Figure, Figure and Figure.
2. 1. Connect the IAE 1R18274 Air plug gage 1 off to the IAE 1R18280 Air gage unit 1 off. Connect an air supply to the air gage unit.
  2. Open the air supply valve, part of the air gage unit. Make sure the needle on the air supply gage reads between the two red lines.
  3. Set the needles A and B to the two 20 positions on the air gage unit main gage. Use the needle adjusters to set the needles to the required value.
  4. Install IAE 1R18275 Setting ring 1 off on to the air plug gage. Refer to Figure. The two air jets, on the air plug gage, must be approximately in the center of the setting ring bore.
  5. Align the needle C, on the air gage unit gage, to the same value as the needles A or B. Use the flow adjuster to align the needle C.
  6. Remove the setting ring from the air plug gage.
  7. Install IAE 1R18276 Setting ring 1 off on to the air plug gage. The two air jets, on the air plug gage, must be approximately in the center of the setting ring bore.
  8. Align the needle C, on the air gage unit gage, to the same value as the needles A or B. Use the flow adjuster to align the needle C.
  9. Remove the setting ring from the air plug gage.
3. 1. Install the air plug gage in to the stage 4 VSV outer bush location bore at the No. 1 position. Set the two air jets at approximately the center of the bush location bore.
  2. Write a record of the value shown on the air gage unit gage.
  3. Push the air plug gage in to the inner bush location bore. Set the two air jets at approximately the center of the inner bush location bore.
  4. Write a record of the value shown on the gage unit gage.
    NOTE
    Each location bore must be measured at the same angle to the case center line.
  5. Do Step to Step at the remaining 49 bush location bores.
1. Refer to Figure.
2. SBE 70-0052: Engine - Additional source for variable stator vane spindle bushings
3. 1. Pre SBE 70-0052: From the values written down in Step use the correct size of bush.
    Red segment - Fig/item 72-41-31,01-253.
    Yellow segment - Fig/item 72-41-31,01-251.
    Black segment - Fig/item 72-41-31,01-252.
  2. SBE 70-0052: From the values written down in Step use the correct size of bush.
    Red segment - Fig/item 72-41-31,01-253 or 72-41-31,01-255.
    Yellow segment - Fig/item 72-41-31,01-251 or 72-41-31,01-257.
    Black segment - Fig/item 72-41-31,01-252 or 72-41-31,01-256.
  3. Use IAE 1R18262 Bushing assembly tool 1 off to install the bushes. Refer to detail A on Figure.
  4. Remove the ring, handle, spacer and nylon washer B from the tool pin.
  5. Install the pin with the nylon washer A in to the stage 4 VSV bush location at the No. 1 position. Make sure the nylon washer is correctly located on the HP compressor front case outer surface.
  6. Locate the bush that is to be installed on the pin on the inside of the HP compressor front case.
  7. Install the nylon washer B, spacer, ring and handle on to the pin. Turn the handle until the nylon washer B abuts the bush that is to be installed.
  8. Make sure the bush assembly tool is correctly located and is at 90 degrees to the location bore.
  9. Hold the dowel, then continue to turn the handle to install the bush. Do not let the dowel turn.
  10. When the bush is installed remove the bush assembly tool.
  11. Do Step to Step to install the remaining 49 inner bushes.
4. 1. Pre SBE 70-0052: Select the correct size of bush. Refer to Step.
  2. SBE 70-0052: Select the correct size of bush. Refer to Step.
  3. Use IAE 1R18261 Bushing assembly tool 1 off to install the bushes. Refer to detail B on Figure.
  4. Remove the ring, handle, spacer and nylon washer B from the tool pin.
  5. Locate the bush that is to be installed on to the nylon washer A.
  6. Install the pin, nylon washer A and the bush in to the stage 4 VSV location at the No. 1 position. Make sure the bush is correctly located.
  7. Install the nylon washer B, spacer, handle and ring removed in Step.
  8. Turn the handle until the nylon washer B touches the inner bush.
  9. Make sure the bush assembly tool is correctly located and is at 90 degrees to the location bore.
  10. Hold the dowel, then continue to turn the handle to install the bush. Do not let the dowel turn.
  11. When the bush is installed remove the bush assembly tool.
  12. Do Step to Step to install the remaining 49 outer bushes.
1. Refer to Figure and Figure.
2. SBE 70-0052: Engine - Additional source for variable stator vane spindle bushings
3. 1. Pre SBE 70-0052: From the values written down in Step use the correct size of bush.
    Red segment - Fig/item 72-41-31,01-253.
    Yellow segment - Fig/item 72-41-31,01-251.
    Black segment - Fig/item 72-41-31,01-252.
  2. SBE 70-0052: From the values written down in Step use the correct size of bush.
    Red segment - Fig/item 72-41-31,01-253 or 72-41-31,01-255.
    Yellow segment - Fig/item 72-41-31,01-251 or 72-41-31,01-257.
    Black segment - Fig/item 72-41-31,01-252 or 72-41-31,01-256.
  3. Install the IAE 1R18581 1 off into the stage 4 VSV bush location at the No. 1 position. Make sure the pusher is correctly located on the HP compressor front case outer surface. Refer to detail A on Figure.
  4. Put the bush of the correct dimension on the pusher on the inside of the HP compressor front case.
  5. Install the IAE 1R18575 Bushing assembly tool 1 off, on the pusher.
  6. Install the IAE 1R18573 Cylinder, hydraulic 1 off, on the pusher until the cylinder comes against the bush assembly tool.
  7. CAUTION
    YOU MUST MAKE SURE THE ASSEMBLY TOOL IS CORRECTLY LOCATED AT 90 DEGREES TO THE LOCATION BORE TO PREVENT DAMAGE TO THE HP COMPRESSOR CASE.
    Apply hydraulic pressure to the cylinder until the bush is pushed into the HP compressor front case.
  8. Release the hydraulic pressure and remove the bush assembly tool.
  9. Do Step to Step again to install the remaining 49 inner bushes.
4. 1. Pre SBE 70-0052: Select the correct size of bush. Refer to Step.
  2. SBE 70-0052: Select the correct size of bush. Refer to Step.
  3. Put the bush of the correct dimension on the IAE 1R18578 Pusher installation tool 1 off. Refer to detail B on Figure.
  4. Install the pusher into the stage 4 VSV bush location at the No. 1 position. Make sure the bush is correctly located.
  5. Install the IAE 1R18575 Bushing assembly tool on the pusher.
  6. Install the IAE 1R18573 Cylinder, hydraulic on the pusher until the cylinder comes against the bush assembly tool.
  7. CAUTION
    YOU MUST MAKE SURE THE ASSEMBLY TOOL IS CORRECTLY LOCATED AT 90 DEGREES TO THE LOCATION BORE TO PREVENT DAMAGE TO THE HP COMPRESSOR CASE.
    Apply hydraulic pressure to the cylinder until the bush is pushed into the HP compressor front case.
  8. Release the hydraulic pressure and remove the bush assembly tool.
  9. Do Step to Step again to install the remaining 49 outer bushes.
1. Refer to Figure, Figure and Figure.
2. Pre SBE 72-0402: It is not necessary to lubricate the stage 4 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0402: Lubricate the stage 4 locations during these assembly operations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) as specified in TASK 72-41-30-440-011-A00, SUBTASK 72-41-30-440-208.
4. Install the 50 sealing washers ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-200) on to the stage 4 VSV inner bushes. Make sure the sealing washers are correctly located around the inner bushes.
5. 1. Install IAE 1R18494 Seal fitting tool 1 off on to the spindle of one of the stage 4 stator vanes to be installed.
  2. Install a sealing ring on to the seal fitting tool.
  3. Move the sealing ring down the seal fitting tool until it is located in the seal groove.
  4. Install the remaining 49 sealing rings as given in Step to Step.
6. 1. Temporary mark vane sequence number on each vane before it is installed.
    NOTE
    Do not vibropeen.
    Use CoMat 02-363 MARKING PEN.
    Refer to SPM TASK 70-09-01-400-501.
  2. Install the 25 stage 4 stator vanes in to the bushes in the upper and lower half HP compressor front case.
7. 1. Put two spacers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-060) on to the spindle of each stage 4 stator vane.
  2. Install the 50 stage 4 actuating levers on to the spindles of the stage 4 stator vanes.
    The eight actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-120) go at the positions 1, 2, 24, 25, 26, 27, 49 and 50.
    The 42 actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-100) go at the positions 3 to 23 and 28 to 48.
    NOTE
    The stage 4 actuating levers must be parallel with the casing center line when you torque the nuts. This is the null position.
  3. Install the 50 slave nuts to attach the stage 4 actuating levers to the stage 4 stator vanes. Torque the nuts to 85 lbfin to 105 lbfin (10.00 Nm to 12.00 Nm). The nuts that are used must have no run down torque.
  4. At each stage 4 stator vane apply a load at the inner pivot point, to push the stator vane radially out.
  5. Measure and write a record of the end float Dimension A Figure Measure between the actuating lever and the two installed spacers.
    NOTE
    Temporarily mark the actuating levers with their position numbers. These must be the same as the numbers on the stage 4 stator vanes.
  6. Remove the 50 slave nuts and actuating levers from the stage 4 VSV.
  7. Install the 50 slave nuts on to the stage 4 stator vane spindles. Tighten the nuts sufficiently to keep the two installed spacers on the stage 4 stator vane spindles.
1. Refer to Figure, Figure and Figure.
2. Pre SBE 72-0402 : It is not necessary to lubricate the stage 4 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0402 : Lubricate the stage 4 locations during these assembly operations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) as specified in TASK 72-41-30-440-011-A00, SUBTASK 72-41-30-440-208.
4. 1. Put the stage 4 upper actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-440) in to position on the upper half HP compressor front case. Install three of IAE 1R18423 Rigging pin 6 off or IAE 1R18894 Rigging pin 6 off to attach the stage 4 upper actuating ring to the upper half HP compressor front case.
  2. Remove the 21 slave nuts from the stage 4 stator vanes at the positions 3 to 23.
  3. Remove the two installed spacers from the spindles of the stator vanes at the positions 3 to 23. Measure and write down the total thickness of the two spacers.
  4. Install two spacers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-060) thru ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-078) on to the spindle of each stage 4 stator vane at the positions 3 to 23. The thickness of the spacers that are to be installed is equal to:
    The total thickness of the two spacers removed in Step, plus the end float, written down in Step minus 0.003 in. to 0.005 in. (0.08 mm to 0.13 mm).
  5. Install the 21 stage 4 actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-100) in to the locations in the stage 4 stator vane upper actuating ring. Engage the stage 4 actuating levers on the stage 4 stator vane spindles.
  6. Install the 21 nuts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-103) to attach the stage 4 actuating levers to the stage 4 stator vanes at positions 3 to 23.
  7. Remove the three rigging pins from stage 4 upper actuating ring.
    NOTE
    The stage 4 actuating levers must be parallel with the casing center line when you torque the nuts. This is the null position.
  8. Torque the 21 nuts to 85 lbfin to 105 lbfin (10.00 Nm to 12.00 Nm) plus the run down torque.
  9. At each stage 4 stator vane apply a load at the inner pivot point, to push the stator vane radially out.
  10. Measure and write down the stage 4 stator vane end float. Make sure it is 0.003 in. to 0.005 in. (0.08 mm to 0.13 mm).
5. 1. Install the stage 4 lower actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-540) and the stage 4 actuating levers, at the position 28 to 48 as given in Step to Step.
1. Refer to Figure.
2. SBE 72-0402: HP compressor variable vanes - inlet guide vane and stages 3 to 6 with optimised build and setting instructions.
  SBE 72-0422: HP compressor variable inner shrouds - Introduction of revised one piece bushes
3. Pre SBE 72-0402 : It is not necessary to lubricate the stage 4 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
4. SBE 72-0402 : Lubricate the stage 4 locations during these assembly operations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) as specified in TASK 72-41-30-440-011-A00, SUBTASK 72-41-30-440-208.
5. 1. Pre SBE 72-0422: Apply a thin layer of CoMat 04-007 SILICONE GREASE to the outer surfaces of the 50 half bushes ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190).
  2. SBE 72-0422: Apply a thin layer of CoMat 04-007 SILICONE GREASE to the outer surfaces of the 25 bushes ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-190).
  3. Pre SBE 72-0422: Install the 50 half bushes in to one half of the stage 4 half shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200).
  4. SBE 72-0422: Install the 25 bushes onto the stage 4 stator vanes.
    NOTE
    Make sure the three locating pins are correctly engaged in the stage 4 half shroud.
  5. Pre SBE 72-0422: Install the stage 4 half shroud, the half bushes and the stage 4 half seal ring ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-150) on to the stage 4 stator vanes at the inner pivot point.
    NOTE
    Make sure the three locating pins are correctly engaged in the stage 4 half shroud.
  6. SBE 72-0422: Install the stage 4 half shroud and the stage 4 half shroud with integral seal ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-200) on to the stage 4 stator vanes and bushes at the inner pivot point.
  7. Pre SBE 72-0422: Install the 12 bolts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-138), the 24 dee-headed washers ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-134) and the 12 nuts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-130). These attach the stage 4 half shroud, the half bushes and the stage 4 half seal ring to the stage 4 stator vanes.
  8. SBE 72-0422: Install the 12 bolts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-138), the 24 dee-headed washers ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-134) and the 12 nuts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 03-130). These attach the stage 4 half shroud, the bushes and the stage 4 half shroud with integral seal to the stage 4 stator vanes.
  9. Torque the nuts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
6. 1. Install the stage 4 half shroud and half seal ring as given in Step to Step.

Sheet 1

Sheet 2

Sheet 1

Sheet 2

Sheet 1

Sheet 2

Sheet 3

Sheet 1

Sheet 2

Details of the air plug gage and setting ring

Sheet 1

Sheet 2

Install the seals on the stator vane spindles

Locations for the stage 4 variable stator vanes

Install the stage 4 variable stator vanes

Measure the stage 4 variable stator vane end float

Requirements After Job Completion

Follow-On Conditions

NONE

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:	LOCAL
Enterprise Name:	LOCALLY SUPPLIED

Manufacturer Code:	X333X
Enterprise Name:	REFER TO V2500 SB ENG-79-0108

Manufacturer Code:	0AM53
Tool Number:	IAE 1R18261
Tool Name:	IAE 1R18261 Bushing assembly tool

TASK 72-41-30-440-005-A00 HPC Front Case And Vane Assembly - Install The Stage 4 Variable Stator Vanes, Assembly-005

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Common Information

TASK 72-41-30-440-005-A00 HPC Front Case And Vane Assembly - Install The Stage 4 Variable Stator Vanes, Assembly-005

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-41-30-220-081 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1224 (Pre SBE 70-0052 and SBE 70-0052)

SUBTASK 72-41-30-220-082 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1228

SUBTASK 72-41-30-220-083 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1229

SUBTASK 72-41-30-220-084 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1230

SUBTASK 72-41-30-220-085 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1231

SUBTASK 72-41-30-220-086 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1232

SUBTASK 72-41-30-220-087 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1321

SUBTASK 72-41-30-220-142 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1265 (Pre SBE 70-0052 and SBE 70-0052)

SUBTASK 72-41-30-220-441 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1258

SUBTASK 72-41-30-440-078-A00 Assemble the Stage 4 Variable Stator Vane Actuating Rings (Pre SBE 72-0084)

SUBTASK 72-41-30-440-078-B00 Assemble the Stage 4 Variable Stator Vane Actuating Rings (Pre SBE 72-0385or SBE 72-0416, SBE 72-0385or SBE 72-0416 and SBE 72-0084)

SUBTASK 72-41-30-220-145 Measure the Stage 4 VSV Spindle Bushes Location Bores

NOTE

SUBTASK 72-41-30-440-123-001 Install the Stage 4 VSV Spindle Bushes using IAE 1R18262 and IAE 1R18261 Bush Assembly Tools (Pre SBE 70-0052 and SBE 70-0052)

SUBTASK 72-41-30-440-123-002 Install the Stage 4 VSV Spindle Bushes using IAE 1R18581, IAE 1R18575, IAE 1R18573 and IAE 1R18578 Bush Assembly Tools, 72-41-30-990-040-001and (Pre SBE 70-0052 and SBE 70-0052)

CAUTION

CAUTION

SUBTASK 72-41-30-440-079 Install the Stage 4 Variable Stator Vanes (VSV) in the HP Compressor Front Case (Pre SBE 72-0402 and SBE 72-0402)

NOTE

NOTE

NOTE

SUBTASK 72-41-30-440-080 Install the Stage 4 Variable Stator Vane Actuating Rings (Pre SBE 72-0402, SBE 72-0402, Pre SBE 72-0385or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

NOTE

NOTE

SUBTASK 72-41-30-440-081 Install the Stage 4 Variable Stator Vane Half Shroud,and72-41-30-990-040-002 (Pre SBE 72-0402, SBE 72-0402, Pre SBE 72-0422 and SBE 72-0422)

NOTE

NOTE

Figure: Pre SBE 72-0027: View through the HP compressor front case

Sheet 1

Figure: SBE 72-0027: View through the HP compressor front case

Sheet 2

Figure: Locations for the fits and clearances

Sheet 1

Figure: Locations for the fits and clearances

Sheet 2

Figure: Install the stage 4 actuating ring centralizing pads and rigging pin brackets

Sheet 1

Figure: Install the stage 4 actuating ring centralizing pads and rigging pin brackets

Sheet 2

Figure: Install the stage 4 actuating ring centralizing pads and rigging pin brackets

Sheet 3

Figure: Details of the air gage unit

Sheet 1

Figure: Details of the air gage unit

Sheet 2

Figure: Details of the air plug gage and setting ring

Details of the air plug gage and setting ring

Figure: Install the stage 4 VSV spindle bushes

Sheet 1

Figure: Install the stage 4 stator vane spindle bushes

Sheet 2

Figure: Install the seals on the stator vane spindles

Install the seals on the stator vane spindles

Figure: Locations for the stage 4 variable stator vanes

Locations for the stage 4 variable stator vanes

Figure: Install the stage 4 variable stator vanes

Install the stage 4 variable stator vanes

Figure: Install the stage 4 variable stator vanes

Install the stage 4 variable stator vanes

Figure: Measure the stage 4 variable stator vane end float

Measure the stage 4 variable stator vane end float

Requirements After Job Completion

Follow-On Conditions