DMC:V2500-A1-72-41-3000-05A-710A-B|Issue No:006|Issue Date:2020-02-01

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

V2500-A1

Common Information

TASK 72-41-30-440-006-A00 HPC Front Case And Vane Assembly - Install The Stage 5 Variable Stator Vanes, Assembly-006

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 70-41-00-400-501, SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-400-501.

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 70-44-01-400-501.

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 PARTS 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 DIMENSIONS 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 5 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 4 VSV by TASK 72-41-30-440-005-A00 (ASSEMBLY-005).

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 1R18492 Seal fitting tool	0AM53	IAE 1R18492	1
IAE 1R18493 Seal fitting tool	0AM53	IAE 1R18493	1
IAE 1R18573 Cylinder, hydraulic	0AM53	IAE 1R18573
IAE 1R18575 Bushing assembly tool	0AM53	IAE 1R18575
IAE 1R18578 Pusher installation tool	0AM53	IAE 1R18578
IAE 1R18895 Rigging pin	0AM53	IAE 1R18895	6

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
RING - SEALING, TOROIDAL	U1653	AS43013-011	64	72-41-32, 04-495

Safety Requirements

NONE

Procedure

SUBTASK 72-41-30-220-090 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1236 (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 1236. 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 1236
Stage 5 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) Location At The Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600)
Stage 5 Outer Pivot Bush Bore	0.4724
	0.4735	0.0018
Stage 5 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 1236
Stage 5 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: Location At The Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600)
Stage 5 Outer Pivot Bush Bore	12.000
	12.027	0.048
Stage 5 VSV Spindle Diameter	11.900	0.127
	11.952

SUBTASK 72-41-30-220-091 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1240

Refer to Figure.

Reference dimensions at location 1240. 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 1240
Stage 5 Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190) Location In The Stage 5 Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200)
Stage 5 Half Bush Bore	0.3551
	0.3561	0.000
Stage 5 Shroud 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 1240
Stage 5 Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190) Location In The Stage 5 Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200)
Stage 5 Half Bush Bore	9.022
	9.047	0.000
Stage 5 Shroud Diameter	9.000	Intf
	9.022	0.047

SUBTASK 72-41-30-220-092 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1241

Refer to Figure.

Reference dimensions at location 1241. If required use the data written as a note in TASK 72-41-32-200-000 and 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 1241
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Diameter	0.2709
	0.2753	0.0003
Half Bush Bore	0.2756	0.0056
	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 1241
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Diameter	6.881
	6.993	0.007
Half Bush Bore	7.000	0.141
	7.022

SUBTASK 72-41-30-220-093 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1242

Refer to Figure.

Reference dimensions at location 1242. 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 1242
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	7.1962	Intf
	7.2124	0.0095
Half Bush Outer Length	7.2028	Clear
	7.2117	0.0154

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 1242
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 And 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	182.7850	Intf
	183.1950	0.2425
Half Bush Outer Length	182.9525	Clear
	183.1775	0.3925

SUBTASK 72-41-30-220-094 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1243

Refer to Figure.

Reference dimensions at location 1243. 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 1243
Stage 5 Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 Shroud Half Bush Location Diameter	7.2720
	7.2740	0.0052
Half Bush Inner Diameter	7.2591	0.0148
	7.2668

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 1243
Stage 5 Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200) Location At The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 Shroud Half Bush Location Diameter	184.7100
	184.7600	0.1325
Half Bush Inner Diameter	184.3825	0.3775
	184.5775

SUBTASK 72-41-30-220-095 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1244

Refer to Figure.

Reference dimensions at location 1244. 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 1244
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 and 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	7.9322	Intf
	7.9446	0.0057
Half Bush Outer Length	7.9330	Clear
	7.9381	0.0115

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 1244
Stage 5 VSV ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500 and 04-600) Location In The Half Bush ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	201.484	Intf
	201.794	0.146
Half Bush Outer Length	201.500	Clear
	201.630	0.294

SUBTASK 72-41-30-220-096 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1329

Refer to Figure.

Reference dimensions at location 1329. 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 1329
Stage 5 VSV Lever ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-100) Location In The Bush ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-460 And 05-560)
Stage 5 VSV Lever 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 1329
Stage 5 VSV Lever ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-100) Location In The Bush ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-460 And 05-560)
Stage 5 VSV Lever Diameter	4.978
	4.990	0.01
Bush Bore	5.000	0.04
	5.018

SUBTASK 72-41-30-220-442 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1261

Refer to Figure.

Reference dimensions at location 1261. If required use the data written as a note in TASK 72-41-33-200-000.

Table 15. 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 1261
Stage 5 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200)	0.1996
Location Pin Hole Bore	0.2007	0.0018
Grooved Headless Pin Diameter	0.1973	0.0034
	0.1977

Table 16. 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 1261
Stage 5 Half Shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200)	5.070
Location Pin Hole Bore	5.100	0.046
Grooved Headless Pin Diameter	5.012	0.088
	5.024

1. Refer to Figure, Figure and Figure.
2. SBE 72-0385or SBE 72-0416: Introduction of revised actuating rings with increased dowel locations.
3. 1. Put the two stage 5 centralizing pads in to position on the stage 5 upper actuating ring.
  2. Install the four bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-682) to attach the two stage 5 centralizing pads to the stage 5 upper actuating ring.
  3. Tighten the bolts.
4. 1. Install the two stage 5 centralizing pads on to the stage 5 lower actuating ring as given in Step to Step.
5. 1. Put the two brackets ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-760) in to position on the upper and lower stage 5 actuating rings ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-440 and ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES 05-540). Refer to the detail at E.
  2. Install the four hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-766) and the four bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-762) to attach the two brackets to the upper and lower stage 5 actuating rings.
  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, 05-770) in to position on the upper stage 5 actuating ring. Refer to the detail at F.
  5. Install the two hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-776) and the two bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-772) to attach the bracket to the upper stage 5 actuating ring.
  6. Torque the two bolts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
6. 1. Put the bracket ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-760) into position on the lower stage 5 actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-540). Refer to the detail at E.
  2. Install the two hollow dowels ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-766) and the two bolts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-762) to attach the bracket to the lower stage 5 actuating ring.
  3. Torque the 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 needle 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 needle 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 5 VSV outer bush location bore at the No. 1 position. Set the two air jets at approximately the center of the bush location bore. Refer to Figure.
  2. Write down 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 down a record of the value shown on the gage unit gage.
  5. Do Step to Step at the remaining 63 bush location bores.
    NOTE
    Each location bore must be measured at the same angle to the case center line.
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 5 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 63 stage 5 VSV 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 the nylon washer A.
  6. Install the pin, nylon washer A and the bush in to the stage 5 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 stage 5 VSV outer bushes.
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. Install the IAE 1R18581 1 off into the stage 5 VSV bush location at the No. 1 position. Make sure the pusher is correctly located on the HP compressor front case outer surface.
  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 assembly tool.
  9. Do Step to Step again to install the remaining 63 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.
  4. Install the pusher into the stage 5 VSV 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 assembly tool.
  9. Do Step to Step again to install the remaining stage 5 VSV outer bushes.
1. Refer to Figure and Figure.
2. Pre SBE 72-0402: It is not necessary to lubricate the stage 5 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0402: Lubricate the stage 5 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. Use IAE 1R18492 Seal fitting tool 1 off to install the sealing rings on to the stage 5 stator vanes ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-500).
  2. Use IAE 1R18493 Seal fitting tool 1 off to install the sealing rings on to the stage 5 stator vanes ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 04-600).
  3. Install a seal fitting tool on to the spindle of a stage 5 stator vane.
  4. Install a sealing ring on to the seal fitting tool.
  5. Move the sealing ring down the seal fitting tool until it is located in the seal groove.
  6. Install the remaining 63 sealing rings as given in Step to Step.
5. 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 30 stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500) and the two stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-600) in to the bushes in the upper half HP compressor front case.
    NOTE
    The two stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-600) with the long spindles must be installed at the positions 1 and 32.
6. 1. Install the 30 stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-500) and the two stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-600), in the lower half HP compressor front case as given in Step and Step.
    NOTE
    The two stage 5 stator vanes ENGINE-HP COMPRESSOR VARIABLE VANES (72-41-32, 04-600) with the long spindles must be installed at the positions 33 and 64.
7. 1. Put two spacers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 03-060) on to the spindle of each stage 5 stator vane.
  2. Install the 64 stage 5 actuating levers on to the spindles of the stage 5 stator vanes.
    The four actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-140) go at the positions 1, 32, 33 and 64.
    The eight actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-120) go at the positions 2, 3, 30, 31, 34, 35, 62 and 63.
    The 52 actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-100) go at the positions 4 to 29 and 36 to 61.
  3. Install the 64 slave nuts to attach the stage 5 actuating levers to the stage 5 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.
    NOTE
    The stage 5 actuating levers must be parallel with the casing center line, when you torque the nuts. This is the null position.
  4. At each stage 5 stator vane apply a load at the inner pivot point, to push the stator vane radially out.
  5. Measure and write down a record of the end float. Dimension A Fig. 72-41-32-990-047 Measure between the actuating lever and the two installed spacers.
  6. Remove the 64 slave nuts and actuating levers from the stage 5 stator vanes.
    NOTE
    Temporarily mark the actuating levers with their position numbers. These must be the same as the numbers on the stage 5 stator vanes.
  7. Install the 64 slave nuts on to the stage 5 stator vane spindles. Tighten the nuts sufficiently to keep the two installed spacers on the stage 5 stator vane spindles.
1. Refer to Figure, Figure and Figure.
2. Pre SBE 72-0402 : It is not necessary to lubricate the stage 5 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0402 : Lubricate the stage 5 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 5 upper actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-440) in to position on the upper half HP compressor front case. Install three of the IAE 1R18423 Rigging pin 6 off or IAE 1R18895 Rigging pin 6 off to attach the stage 5 actuating ring to the upper half HP compressor front case.
    NOTE
    Set the stage 5 upper actuating ring adjacent to the stage 5 VSV at the positions 4 to 29.
  2. Remove the 26 slave nuts from the stage 5 stator vanes at the positions 4 to 29.
  3. Remove the two installed spacers from the spindles of the stage 5 stator vanes at the positions 4 to 29. Measure and write down the total thickness of the two spacers.
  4. Install two spacers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-060) thru ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-078) on to the spindle of each stage 5 stator vane at the positions 4 to 29. The thickness of the spacers that are necessary are 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 26 stage 5 actuating levers ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-100) in to the locations in the stage 5 upper actuating ring. Engage the stage 5 actuating levers on the stage 5 stator vane spindles.
  6. Install the 26 nuts ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-103) to attach the stage 5 actuating levers to the stage 5 stator vanes.
  7. Remove the three rigging pins from the stage 5 upper actuating ring.
  8. Torque the nuts to 85 lbfin to 105 lbfin (10.00 Nm to 12.00 Nm) plus the run down torque.
    NOTE
    The stage 5 actuating levers must be parallel with the casing center line when you torque the nuts. This is the null position.
  9. At each stage 5 stator vane, apply a load at the inner pivot point to push the stator vane radially out.
  10. Measure and write down the stage 5 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 5 lower actuating ring ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 05-540) and the stage 5 actuating levers, at the positions 36 to 61, 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 5 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
4. SBE 72-0402 : Lubricate the stage 5 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 64 half bushes ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190) outer surfaces.
  2. SBE 72-0422: Apply a thin layer of CoMat 04-007 SILICONE GREASE to the 32 bushes ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-190) outer surfaces.
  3. Pre SBE 72-0422: Install the 64 half bushes on to one half of the stage 5 front and rear shroud ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-200).
  4. SBE 72-0422: Install the 32 bushes on to the stage 5 stator vanes.
  5. Pre SBE 72-0422: Install the stage 5 front and rear shroud with the half bushes on to the stage 5 stator vanes at the inner pivot point.
    NOTE
    Make sure the locating pins are correctly engaged in the stage 5 front shroud.
  6. SBE 72-0422: Install the stage 5 front shroud and the rear shroud on to the stage 5 stator vanes and bushes at the inner pivot point.
    NOTE
    Make sure the locating pins are correctly engaged in the stage 5 front shroud.
  7. Install the 16 dee headed bolts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-138) and nuts ENGINE-HP COMPRESSOR VARIABLE VANE INNER SHROUDS (72-41-33, 04-130). These attach the stage 5 front and rear shroud to the stage 5 stator vanes.
    NOTE
    Make sure the flat on the head of the bolts is in the correct position.
  8. Torque the nuts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
    NOTE
    Do not let the bolts turn when you torque the nuts. The bolts are a close tolerance fit.
6. 1. Install the stage 5 front and rear shroud 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 stage 5 stator vane seals

The positions of the stage 5 stator vanes

Install the stage 5 stator vanes

Measure the stage 5 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:	U1653
Enterprise Name:	Society Of British Aerospace Companies, LTD.

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

Part Number:	AS43013-011
Part Name:	RING - SEALING, TOROIDAL
Manufacturer Code:	U1653

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

TASK 72-41-30-440-006-A00 HPC Front Case And Vane Assembly - Install The Stage 5 Variable Stator Vanes, Assembly-006

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Common Information

TASK 72-41-30-440-006-A00 HPC Front Case And Vane Assembly - Install The Stage 5 Variable Stator Vanes, Assembly-006

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-41-30-220-090 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1236 (Pre SBE 70-0052 and SBE 70-0052)

SUBTASK 72-41-30-220-091 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1240

SUBTASK 72-41-30-220-092 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1241

SUBTASK 72-41-30-220-093 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1242

SUBTASK 72-41-30-220-094 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1243

SUBTASK 72-41-30-220-095 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1244

SUBTASK 72-41-30-220-096 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1329

SUBTASK 72-41-30-220-442 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1261

SUBTASK 72-41-30-440-082 Assemble the Stage 5 Actuating Rings (Pre SBE 72-0385 or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

SUBTASK 72-41-30-220-146 Measure the Stage 5 VSV Spindle Bushes Location Bores

NOTE

SUBTASK 72-41-30-440-124-001 Install the Stage 5 VSV Spindle Bushes using IAE 1R18262 and IAE 1R18261 Bush Assembly Tools (Pre SBE 70-0052 and SBE 70-0052)

SUBTASK 72-41-30-440-124-002 Install the Stage 5 VSV Spindle Bushes using IAE 1R18581, IAE 1R18575, IAE 1R18573 and IAE 1R18578 Bush Installation Tools (Pre SBE 70-0052 and SBE 70-0052)

CAUTION

CAUTION

SUBTASK 72-41-30-440-083 Install the Stage 5 Stator Vanes in the HP Compressor Front Case (Pre SBE 72-0402 and SBE 72-0402)

NOTE

NOTE

NOTE

NOTE

NOTE

SUBTASK 72-41-30-440-084 Install the Stage 5 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 72-41-30-440-085 Install the Stage 5 Variable Stator Vane (VSV) Half Shrouds (Pre SBE 72-0402, SBE 72-0402, Pre SBE 72-0422 and SBE 72-0422)

NOTE

NOTE

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 5 actuating ring centralizing pads and rigging pin brackets

Sheet 1

Figure: Pre SBE 72-0084 Install the stage 5 actuating ring centralizing pad and rigging pin brackets

Sheet 2

Figure: SBE 72-0084 Install the stage 5 actuating ring centralizing pad 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 5 VSV spindle bushes

Sheet 1

Figure: Install the stage 5 stator vane spindle bushes

Sheet 2

Figure: Install the seals on the stage 5 stator vane seals

Install the seals on the stage 5 stator vane seals

Figure: The positions of the stage 5 stator vanes

The positions of the stage 5 stator vanes

Figure: Install the stage 5 stator vanes

Install the stage 5 stator vanes

Figure: Measure the stage 5 stator vane end float

Measure the stage 5 stator vane end float

Requirements After Job Completion

Follow-On Conditions