TASK 72-00-40-700-001-B00 HP System Module - Check The Variable Inlet Guide Vane (VIGV) And Variable Stator Vane (VSV) Actuating Mechanism, Testing-001

DMC:V2500-A5-72-00-4000-01C-320A-B|Issue No:003.00|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-A5

Common Information

TASK 72-00-40-700-001-B00 HP System Module - Check The Variable Inlet Guide Vane (VIGV) And Variable Stator Vane (VSV) Actuating Mechanism, Testing-001

General

This TASK gives the procedure to check the VIGV and VSV actuating mechanism. It includes the procedure to examine the system and also check the high speed rigging position.

Fig/item numbers in parentheses 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.

Apply the approved CoMat 10-058 PENETRATING OIL before the removal of the threaded parts. Let the parts soak before removal.

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

For standard torque data and procedures, refer to the SPM TASK 70-41-01-400-501 and SPM TASK 70-41-02-400-501.

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

NameManufacturerPart Number / IdentificationQuantityRemark
Spring balance, 0 to 150 lbf (0 to 203.37 N) rangeLOCALSpring balance, 0 to 150 lbf (0 to 203.37 N) range
Vernier caliperLOCALVernier caliper
Dial gaugeLOCALDial gauge
IAE 1R18254 Rigging pin0AM53IAE 1R182541
IAE 1R18423 Rigging pin0AM53IAE 1R184231
IAE 1R18892 Rigging pin0AM53IAE 1R188921

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 10-077 APPROVED ENGINE OILSX333XCoMat 10-077
CoMat 10-058 PENETRATING OILX222XCoMat 10-058

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Cotter pinLOCALCotter pin1

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-40-220-147 Measure The Crankshaft Movement

    1. Refer to Figure.

      2. Axial movement.

        1. Up to 0.020 in. (0.51 mm).

        1. Accept.

        2. More than Step.

        1. Reject the crankshaft bearings.

      3. Radial movement at rear housing.

        1. Up to 0.008 in. (0.20 mm).

        1. Accept.

        2. More than Step.

        1. Reject the crankshaft bearings.

    2. SUBTASK 72-00-40-040-053 Disconnect the VSV Control Rod

    1. Refer to Figure and Figure.

    2. Remove the nut, washer and the bolt that attach the VSV actuator control rod to the VSV actuator.

    3. SUBTASK 72-00-40-220-114 Check the VIGV and VSV Actuating Mechanism

    1. Refer to Figure.

    2. Use an applicable wrench on the wrench flats of the crankshaft, turn the crankshaft to the high speed position and align the rig pins holes.

    3. Install the IAE 1R18254 Rigging pin 1 off, through the rig pin holes in the crankshaft front bearing housing and the crankshaft.

    4. Install the IAE 1R18423 Rigging pin 1 off or IAE 1R18892 Rigging pin 1 off in to the rig pin bracket on the VIGV unison ring and the VSV unison ring positions.

    5. Make sure that the rig pin engages with the hole in the compressor case.

      6. If the rig pin can not be easily installed at one or more of the positions, examine the VIGV and VSV system levers and control rods for damage.

      1. If one or more of the levers are damaged, reject the module.

      2. If one or more of the control rods are damaged, reject the module.

      3. If the rig pin can not be easily installed, reject the module.

    7. Remove the rig pin from the crankshaft.

    4. SUBTASK 72-00-40-220-139 Check the Force Necessary to move the VIGV/VSV Actuating Mechanism (Pre SBE 72-0366, SBE 72-0366, Pre SBE 72-0406, Pre SBE 72-0426, SBE 72-0406 and SBE 72-0426)

      SBE 72-0366: Actuating mechanism HPC variable vanes - introduction of a revised crankshaft assembly

      SBE 72-0406: Actuating mechanism HPC variable vanes - introduction of a fully machined from bar crankshaft assembly

      SBE 72-0426: Actuating mechanism HPC variable vanes - introduction of a revised crankshaft assembly with reduced front bearing interference

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

    2. Put a torque wrench with an applicable wrench adapter on to the wrench flats of the crankshaft. Measure the torque necessary to turn the crankshaft from the low speed position to the high speed position. If the torque necessary is more than 350 lbfin. (39.5 Nm) then lubricate the VSV system, refer to TASK 72-41-00-440-002-B00 (ASSEMBLY-002, CONFIG-002). Measure the torque after lubrication, if it is still in excess of 350 lbfin., do steps Step through Step.

    3. Do the following procedure to determine which unison ring stage(s) is the cause of the high torque figure of 350 lbfin. (39.5 Nm).

      4. Pre SBE 72-0366, SBE 72-0406 and SBE 72-0426: Disconnect the VIGV control rod from the crank lever bracket on the VSV crankshaft. Refer to Figure, detail C.

      1. Remove and discard the cotter pin.

      2. Remove the nut and bolt then disconnect the VIGV control rod from the crank lever bracket on the VSV crankshaft.

      5. SBE 72-0366, Pre SBE 72-0406 and Pre SBE 72-0426: Disconnect the VIGV control rod from the crank lever bracket on the VSV crankshaft. Refer to Figure, detail C.

      1. Remove and discard the cotter pin.

      2. Remove the nut, washer, bolt and two spacers then disconnect the VIGV control rod from the crank lever bracket on the VSV crankshaft.

      6. Disconnect the control rods from stages 3, 4 and 5 VSV unison rings, Figure, Figure, detail B and Figure.

      1. Remove the nut and bolt then disconnect the control rod.

      7. Measure the force necessary to move each unison ring from the low speed to the high speed position.

      1. Attach the spring balance to the control attachment point on each unison ring in turn. (VIGV, STG 3, 4 and 5).

      2. Pull the spring balance at a tangent to the unison ring. Make a note of the force necessary to move the unison ring.

    8. If the force necessary to move the unison ring is more than 100 lbf (444.82 N), reject the module.

    5. SUBTASK 72-00-40-210-052 Examine the Levers and Control Rods

      1. Examine the levers for damage.

      1. If one or more of the levers are damaged, reject the module.

      2. Examine the control rods for damage.

      1. If one or more of the control rods are damaged, reject the module.

    6. SUBTASK 72-00-40-440-055 Connect the Control Rods (Pre SBE 72-0366, SBE 72-0366, Pre SBE 72-0406, Pre SBE 72-0426, SBE 72-0406 and SBE 72-0426)

      SBE 72-0366: Actuating mechanism HPC variable vanes - introduction of a revised crankshaft assembly

      SBE 72-0406: Actuating mechanism HPC variable vanes - introduction of a fully machined from bar crankshaft assembly

      SBE 72-0426: Actuating mechanism HPC variable vanes - introduction of a revised crankshaft assembly with reduced front bearing interference

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

      2. Connect stage 3 unison ring control rod.

      1. Align the control rod V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-250) to the stage 3 unison ring. Refer to Figure, detail B and Figure.

      2. Install the bolt V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-236) and the nut V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-232).

      3. Torque the nut between 180 lbfin. and 220 lbfin. (20 Nm and 25 Nm).

      3. Connect stage 4 unison ring control rod.

      1. Align the control rod V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-300) to the stage 4 unison ring. Refer to Figure, detail B and Figure.

      2. Install the bolt V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-286) and the nut V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-282).

      3. Torque the nut between 180 lbfin. and 220 lbfin. (20 Nm and 25 Nm).

      4. Connect stage 5 unison ring control rod.

      1. Align the control rod V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-350) to the stage 5 unison ring. Refer to Figure, detail B and Figure.

      2. Install the bolt V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-334) and the nut V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-332).

      3. Torque the nut between 180 lbfin. and 220 lbfin. (20 Nm and 25 Nm).

      5. Pre SBE 72-0366, SBE 72-0406 and SBE 72-0426: Connect the VIGV control rod to the crank lever bracket on the VSV crankshaft. Refer to Figure, detail C.

      1. Align the control rod V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-200) to the crank lever bracket on the VSV crankshaft.

      2. Install the bolt V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-184) and the nut V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-182) to attach the VIGV control rod to the crank lever bracket on the VSV crankshaft.

      3. Torque the nut to between 170 lbfin. to 210 lbfin. (19 Nm to 24 Nm).

      4. Install the cotter pin V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-181) through the nut and the bolt to safety the assembly. Refer to Step for the procedure to install the cotter pin.

      5. Safety the nut with a new cotter pin V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-181).

      6. SBE 72-0366, Pre SBE 72-0406 and Pre SBE 72-0426: Connect the VIGV control rod to the crank lever bracket on the VSV crankshaft, Figure, detail C.

      1. Align the control rod V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-200) to the crank lever bracket on the VSV crankshaft.

      2. Install the bolt V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-184), two spacers V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-179), washer V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-183) and the nut V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-182) to attach right hand bearing to the integral VIGV crank lever of the VSV crankshaft.

      3. Torque the nut to 170 lbfin. to 210 lbfin. (19 Nm to 24 Nm). Install the cotter pin V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-181) through the nut and bolt to safety the assembly. Refer to Step for the procedure to install the cotter pin.

      4. Safety the nut with a new cotter pin V2500-A5-72-41-34-01A-941A-D (72-41-34, 01-181).

    7. SUBTASK 72-00-40-440-057 Install a Split Cotter Pin

    1. Refer to Figure

      2. CAUTION

        DO NOT TIGHTEN THE NUT MORE THAN THE MAXIMUM SPECIFIED TORQUE LOAD.

        CAUTION

        DO NOT LOOSEN THE NUT TO ALIGN THE SPLIT COTTER PIN HOLE WITH THE NUT SLOT.

        Torque the nut.

      1. Tighten the nut to the minimum specified torque load given in the procedure. If necessary, tighten the nut some more to align the split cotter pin hole with the nut slot.

      2. Replace the nut if the maximum specified torque load is reached before the split cotter pin hole and the nut slot are aligned.

    3. Install the split cotter pin, refer to Figure for the acceptable conditions.

    4. Discard used split cotter pins. Only use new split cotter pins.

    8. SUBTASK 72-00-40-440-056 Connect the Control Rod to the VSV Actuator

    1. Refer to Figure and Figure.

    2. Align the control rod ACTUATING MECHANISM HP COMPRESSOR VARIABLE VANES (72-41-34, 07-100) to the Actuator.

    3. Install the bolt HPC Variable Stator Vane Actuator (75-32-42, 01-084), the washer (75-32-42 01-083) and the nut HPC Variable Stator Vane Actuator (75-32-42, 01-082) to attach the control rod to the actuator.

    4. Torque the nut to between 290 lbfin. and 370 lbfin. (33 Nm and 42 Nm).

    9. Figure: Pre SBE 72-0366, Pre SBE 72-0406 and Pre SBE 72-0538: VSV Crankshaft and Unison Rings

    Pre SBE 72-0366, Pre SBE 72-0406 and Pre SBE 72-0538: VSV Crankshaft and Unison Rings

    Figure: SBE 72-0366 and SBE 72-0406: VSV Crankshaft and Unison Rings

    SBE 72-0366 and SBE 72-0406: VSV Crankshaft and Unison Rings

    Figure: SBE 72-0366 and SBE 72-0406: VSV Crankshaft and Unison Rings

    SBE 72-0366 and SBE 72-0406: VSV Crankshaft and Unison Rings

    Figure: SBE 72-0538: VSV Crankshaft and Unison Rings

    SBE 72-0538: VSV Crankshaft and Unison Rings

    Figure: Install a Split Cotter Pin

    Install a Split Cotter Pin

    Figure: Unison ring rig pin brackets

    Unison ring rig pin brackets

    Figure: Crankshaft Movement Check

    Crankshaft Movement Check

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add SB reference. (16VC427)

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:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:X333X
Enterprise Name:REFER TO V2500 SB ENG-79-0108
Link not Found
Manufacturer Code:X222X
Supply Number:CoMat 10-058
Type:sp01
Supply Short Name:CoMat 10-058 PENETRATING OIL
Supply Name:CoMat 10-058 PENETRATING OIL
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X333X
Supply Number:CoMat 10-077
Type:sp01
Supply Short Name:CoMat 10-077 APPROVED ENGINE OILS
Supply Name:CoMat 10-077 APPROVED ENGINE OILS
Specification Groups:
Doc NumberType
For V2500-A1/A5/D5 models - Refer to V2500 Service Bulletin ENG-79-0108
For V2500-E5 model - Refer to Service Bulletin E5-79-0001
Suppliers:
ManufacturerRemarks
X333X
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 1R18254
Tool Name:IAE 1R18254 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18423
Tool Name:IAE 1R18423 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18892
Tool Name:IAE 1R18892 Rigging pin
Manufacturer Code:LOCAL
Tool Number:Spring balance, 0 to 150 lbf (0 to 203.37 N) range
Tool Name:Spring balance, 0 to 150 lbf (0 to 203.37 N) range
Manufacturer Code:LOCAL
Tool Number:Vernier caliper
Tool Name:Vernier caliper