DMC:V2500-A5-72-41-3000-03A-710A-B|Issue No:005|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-A5

Common Information

TASK 72-41-30-440-004-B00 HPC Front Case And Vane Assembly - Install The Stage 3 Variable Stator Vanes, Assembly-004

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 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.

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 DIMENSION (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 3 Variable Stator Vanes (VSV). The subsequent TASKs give the procedure to assemble the HP Compressor front cases.

Install the Stage 4 and 5 Rotor Path Rings and Stage 6 Rotor Ring Segments TASK 72-41-30-440-001-C00 (ASSEMBLY-001-003).

Measure and then machine the Stage 6 Stator Vanes and the Stage 4, 5 and 6 Rotor Path Rings TASK 72-41-30-440-002-B00 (ASSEMBLY-002).

Install the VIGV TASK 72-41-30-440-003-B00 (ASSEMBLY-003).

Install the Stage 4 VSV TASK 72-41-30-440-005-B00 (ASSEMBLY-005).

Install the Stage 5 VSV TASK 72-41-30-440-006-B00 (ASSEMBLY-006).

Install the Stage 6 Stator Vanes TASK 72-41-30-440-007-B00 (ASSEMBLY-007).

Install the VIGV and the Stage 3 to 5 Bridge Pieces TASK 72-41-30-440-008-B00 (ASSEMBLY-008).

Measure the HP Compressor Front Cases TASK 72-41-30-440-009-B00 (ASSEMBLY-009).

Disassemble the HP Compressor Front Cases TASK 72-41-30-440-010-B00 (ASSEMBLY-010).

Check and Set VSV System with Optimised Build and Setting Clearances - SBE 72-0400TASK 72-41-30-440-011-B00 (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	Remark
IAE 1R18258 Bushing assembly tool	0AM53	IAE 1R18258	1
IAE 1R18259 Bushing assembly tool	0AM53	IAE 1R18259	1
IAE 1R18423 Rigging pin	0AM53	IAE 1R18423	6
IAE 1R18893 Riggingpin	0AM53	IAE 1R18893	6
IAE 1R18495 Seal fitting tool	0AM53	IAE 1R18495	1
IAE 1R18583 Pusher installation tool	0AM53	IAE 1R18583		(alternative to IAE 1R18259)
IAE 1R18574 Bushing assembly tool assembly	0AM53	IAE 1R18574		(alternative to IAE 1R18259)
IAE 1R18573 Cylinder, hydraulic	0AM53	IAE 1R18573		(alternative to IAE 1R18258 and IAE 1R18259)
IAE 1R18584 Pusher installation tool	0AM53	IAE 1R18584		(alternative to IAE 1R18258)
IAE 1R18575 Bushing assembly tool	0AM53	IAE 1R18575		(alternative to IAE 1R18258)

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 02-363 MARKING PEN	0AM53	CoMat 02-363
CoMat 04-007 SILICONE GREASE	LOCAL	CoMat 04-007
CoMat 07-038 AIR DRYING ENAMEL	00BB6	CoMat 07-038
CoMat 10-077 APPROVED ENGINE OILS	X333X	CoMat 10-077
CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R)	39428	CoMat 10-108

Spares

Name	Manufacturer	Part Number / Identification	Quantity	Remark
RING - SEALING, TOROIDAL	U1653	AS43013-013	30	02-495

Safety Requirements

NONE

Procedure

SUBTASK 72-41-30-220-166 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1212

Refer to Figure.

Reference dimensions at location 1212. If required use the data written as a note in TASK 72-41-32-200-000 and TASK 72-41-31-200-000.

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 1212
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Stage 3 Outer Pivot Bush HP COMPRESSOR SPLIT CASE (72-41-31, 01-264)
Stage 3 VSV Spindle Diameter	0.6260
	0.6280	0.0027
Stage 3 Outer Pivot Bush Bore	0.6307	0.0062
	0.6322

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 1212
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Stage 3 Outer Pivot Bush HP COMPRESSOR SPLIT CASE (72-41-31, 01-264)
Stage 3 VSV Spindle Diameter	15.900
	15.952	0.070
Stage 3 Outer Pivot Bush Bore	16.022	0.160
	16.060

SUBTASK 72-41-30-220-167 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1216

Refer to Figure.

Reference dimensions at location 1216. 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 1216
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 Half Shroud Location Diameter	0.3543
	0.3552	0.0000
Half Bush Outer Diameter	0.3552	Intf
	0.3562	0.0019

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 1216
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 Half Shroud Location Diameter	9.000
	9.022	0.000
Half Bush Outer Diameter	9.022	Intf
	9.047	0.047

SUBTASK 72-41-30-220-168 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1217

Refer to Figure.

Reference dimensions at location 1217. 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 1217
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 VSV Inner Spindle Diameter	0.2709
	0.2730	0.0026
Half Bush Inner 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 1217
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 VSV Inner Spindle Diameter	6.881
	6.933	0.067
Half Bush Inner Bore	7.000	0.141
	7.022

SUBTASK 72-41-30-220-169 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1218

Refer to Figure.

Reference dimensions at location 1218. 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 1218
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 VSV Inner Spindle Length	5.5036
	5.5105	0.009
Half Bush Outer Length	5.5205	0.0175
	5.5212

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 1218
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 VSV Inner Spindle Length	139.793
	139.969	0.251
Half Bush Outer Length	140.220	0.447
	140.240

SUBTASK 72-41-30-220-170 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1219

Refer to Figure.

Reference dimensions at location 1219. 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 1219
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 Half Inner Shroud Length	5.5760
	5.5775	0.010
Half Bush Inner Length	5.5600	0.018
	5.5657

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 1219
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 3 Half Inner Shroud Length	141.6200
	141.6700	0.251
Half Bush Inner Length	141.2230	0.457
	141.3690

SUBTASK 72-41-30-220-171 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1220

Refer to Figure.

Reference dimensions at location 1220. 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 1220
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33,02-190)
Stage 3 VSV Inner Spindle Length	6.2375	Intf
	6.2405	0.0022
Half Bush Outer Length	6.2346	Clear
	6.2397	0.006

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 1220
Stage 3 VSV HPC Variable Stator Vanes (72-41-32, 02-500 and 02-600)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190)
Stage 2 VSV Inner Spindle Length	158.433	Intf
	158.509	0.057
Half Bush Outer Length	158.360	Clear
	158.490	0.149

SUBTASK 72-41-30-220-172 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1255

Refer to Figure.

Reference dimensions at location 1255. If required use the data written as a note in TASK 72-41-33-200-000.

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 1255
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location At The Grooved Headless Pin HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-222)
Stage 3 Half Shroud Location Pin Hole Bore	0.1996
	0.2008	0.0018
Grooved Headless Pin Diameter	0.1973	0.0035
	0.1978

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 1255
Stage 3 Half Shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200)
Location At The Grooved Headless Pin HPC Variable Stator Vane Shrouds And Related Part (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

SUBTASK 72-41-30-220-173 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1311

Refer to Figure.

Reference dimensions at location 1311. If required use the data written as a note in TASK 72-41-34-200-000.

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 1311
Stage 3 VSV lever HPC Variable Stator Vane Actuation System (72-41-34, 03-100 and 03-140)
Location In The Bush HPC Variable Stator Vane Actuation System (72-41-34, 03-460 and 03-560)
Stage 3 VSV Lever Pin Diameter	0.2353
	0.2358	0.0004
Bush Bore	0.2362	0.0016
	0.2369

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 1311
Stage 3 VSV lever HPC Variable Stator Vane Actuation System (72-41-34, 03-100 and 03-140)
Location In The Bush HPC Variable Stator Vane Actuation System (72-41-34, 03-460 and 03-560)
Stage 3 VSV Lever Pin Diameter	5.978
	5.990	0.01
Bush Bore	6.000	0.04
	6.018

SUBTASK 72-41-30-220-174 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1264

Refer to Figure.

Reference dimensions at Location 1264. If required use the data written as a note in TASK 72-41-31-200-000 and TASK 72-41-30-300-000.

Table 17. Fits and Clearances (all dimensions in inches)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1264
Stage 3 Inner Bush HP COMPRESSOR SPLIT CASE (72-41-31, 01-264)
Location With The Sealing Washer ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-150)
Inner Bush Flange Thickness	0.0546
	0.0576	0.003
Sealing Washer Thickness	0.0492	0.0084
	0.0516

Table 18. Fits and Clearances (all dimensions in millimetres)
	NEW PART		WORN PART
	DIMENSIONS		DIMENSIONS
PART IDENT	Size	Clearance	Non-select	REJECT IF MORE THAN
LOCATION 1264
Stage 3 Inner Bush HP COMPRESSOR SPLIT CASE (72-41-31, 01-264)
Location With The Sealing Washer ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-150)
Inner Bush Flange Thickness	1.387
	1.463	0.077
Sealing Washer Thickness	1.250	0.213
	1.310

1. Refer to Figure.
2. SBE 72-0385 or SBE 72-0416: Introduction of revised actuating rings with increased dowel locations.
3. 1. Put the two stage 3 centralizing pads in position in the stage 3 upper actuating ring.
  2. Install the four bolts HPC Variable Stator Vane Actuation System (72-41-34, 03-682) to attach the two stage 3 centralizing pads to the upper actuating ring.
  3. Tighten the bolts.
4. 1. Install the two stage 3 centralizing pads on the stage 3 lower actuating ring as given in Step to Step.
5. 1. Put the bracket HPC Variable Stator Vane Actuation System (72-41-34, 03-770) in position on the stage 3 upper actuating ring. Refer to detail at E.
  2. Install the two hollow dowels HPC Variable Stator Vane Actuation System (72-41-34, 03-776) and the two bolts HPC Variable Stator Vane Actuation System (72-41-34, 03-772) to attach the bracket to the stage 3 upper actuating ring.
  3. Torque the two bolts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
1. SBE 70-0984: Information - Engine - HP Compressor variable stator split cases - VSV bushes of new material.
2. Refer to Figure.
  NOTE
  Old and new parts (SBE 70-0984 standard) are not interchangeable. All new parts (SBE 70-0984 standard) must be installed as a set.
3. 1. Use IAE 1R18259 Bushing assembly tool 1 off to install the bushes. Refer to detail A on Figure.
  2. Remove the ring, handle, spacer and nylon washer B from the tool pin.
  3. Install the pin with the nylon washer A in to the Stage 3 VSV bush location at the No. 1 position. Make sure the nylon washer is correctly located on the HP Compressor front case outer surface.
  4. Locate the bush that is to be installed on the pin on the inside of the HP Compressor front case.
  5. 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.
  6. Make sure the bush assembly tool is correctly located and is at 90 degrees to the location bore.
  7. Hold the dowel, then continue to turn the handle to install the bush. Do not let the dowel turn.
  8. When the bush is installed remove the bush assembly tool.
  9. Do Step to Step to install the remaining 31 inner bushes.
4. 1. Use IAE 1R18258 Bushing assembly tool 1 off to install the bushes. Refer to detail B on Figure.
  2. Remove the ring, handle, spacer and nylon washer B from the tool pin.
  3. Locate the bush that is to be installed on to the nylon washer A.
  4. Install the pin, nylon washer A and the bush in to the Stage 3 VSV location at the No. 1 position. Make sure the bush is correctly located.
  5. Install the nylon washer B, spacer, handle and ring removed in Step.
  6. Turn the handle until the nylon washer B touches the inner bush.
  7. Make sure the bush assembly tool is correctly located and is at 90 degrees to the location bore.
  8. Hold the dowel, then continue to turn the handle to install the bush. Do not let the dowel turn.
  9. When the bush is installed remove the bush assembly tool.
  10. Do Step to Step to install the remaining 31 outer bushes.
1. SBE 70-0984: Information - Engine - HP Compressor variable stator split cases - VSV bushes of new material.
2. Refer to Figure.
  NOTE
  Old and new parts (SBE 70-0984 standard) are not interchangeable. All new parts (SBE 70-0984 standard) must be installed as a set.
3. 1. Install the IAE 1R18583 Pusher installation tool 1 off into the stage 3 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.
  2. Put the bush on the pusher on the inside of the HP Compressor front case.
  3. Install the IAE 1R18574 Bushing assembly tool assembly 1 off, on the pusher.
  4. Install the IAE 1R18573 Cylinder, hydraulic 1 off, on the pusher until the cylinder comes against the bush assembly tool.
  5. 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.
  6. Release the hydraulic pressure and remove the assembly.
  7. Do Step to Step again to install the remaining inner bushes.
4. 1. Put the bush on the IAE 1R18584 Pusher installation tool 1 off. Refer to detail B on Figure.
  2. Install the pusher into the Stage 3 VSV location at the No. 1 position. Make sure the bush is correctly located.
  3. Install the IAE 1R18575 Bushing assembly tool on the pusher.
  4. Install the IAE 1R18573 Cylinder, hydraulic on the pusher until the cylinder comes against the bush assembly tool.
  5. 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.
  6. Release the hydraulic pressure and remove the assembly tool.
  7. Do Step to Step again to install the remaining stage 3 VSV outer bushes.
1. Refer to Figure and Figure.
2. Pre SBE 72-0400: It is not necessary to lubricate the stage 3 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0400: Lubricate the stage 3 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-B00, SUBTASK 72-41-30-440-211.
4. Install the 32 sealing washers ENGINE-HP COMPRESSOR FRONT CASES AND VANES (72-41-30, 01-150) on to the inner bushes. Make sure the sealing washers are correctly located around the inner bush.
  NOTE
  There are no sealing rings installed on the two short spindled Stage 3 Stator Vanes HPC Variable Stator Vanes (72-41-32, 02-600).
5. 1. Install IAE 1R18495 Seal fitting tool 1 off on to the spindle of one of the stage 3 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 29 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. NOTE
    The two stage 3 stator vanes HPC Variable Stator Vanes (72-41-32, 02-600) with the short spindles must be installed at the positions 8 and 9.
    NOTE
    There are no 'O'-ring seals on the short spindled stage 3 stator vanes.
    Install the 14 stage 3 stator vanes HPC Variable Stator Vanes (72-41-32, 02-500) and the two Stage 3 Stator Vanes HPC Variable Stator Vanes (72-41-32,02-600) into the bushes in the upper half HP Compressor front case.
7. 1. Install the 16 stage 3 stator vanes HPC Variable Stator Vanes (72-41-32,02-500) in the lower HP Compressor half front case a given in Step and Step.
8. 1. Put two spacers HPC Variable Stator Vane Actuation System (72-41-34, 03-060) on to the spindle of each Stage 3 Stator Vane.
  2. Install the 32 stage 3 actuating levers on to the spindles of the Stage 3 Stator Vanes.
    The two actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-140) go at the positions 8 and 9.
    The eight actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-120) go at the positions 1,2,15,16,17,18,31 and 32.
    The 22 actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-100) go at the positions 3 to 7, 10 to 14 and 19 to 30.
    NOTE
    The stage 3 actuating levers must be parallel with the casing centre line when you torque the nuts. This is the null position.
  3. Install the 32 slave nuts to attach the actuating levers to the stage 3 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 3 VSV apply a load at the inner pivot point, to push the stator vane radially out.
  5. Measure and write down 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 3 Stator Vanes.
  6. Remove the 32 slave nuts and actuating levers from the Stage 3 VSV.
  7. Install the 32 slave nuts on to the Stage 3 Stator Vane spindles. Tighten the nuts sufficiently to keep the two installed spacers on the Stage 3 Stator Vane spindles.
1. Refer to Figure and Figure.
2. Pre SBE 72-0400 : It is not necessary to lubricate the stage 3 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
3. SBE 72-0400 : Lubricate the stage 3 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-B00, SUBTASK 72-41-30-440-211.
4. 1. Put the stage 3 upper actuating ring HPC Variable Stator Vane Actuation System (72-41-34, 03-440) into position on the upper half HP Compressor front case. Install three of IAE 1R18423 Rigging pin 6 off or IAE 1R18893 Riggingpin 6 off to attach the stage 3 upper actuating ring to the upper half HP Compressor front case.
  2. Remove the 12 slave nuts from the Stage 3 Stator Vanes at the positions 3 to 14.
  3. Remove the two installed spacers from the spindles of the stator vanes at positions 3 to 14. Measure and write down the total thickness of the two spacers.
  4. Install two spacers HPC Variable Stator Vane Actuation System (72-41-34, 03-060 to HPC Variable Stator Vane Actuation System (03-076) on to the spindle of each Stage 3 Stator Vanes at the position 3 to 14. The thickness of the spacers that are to be installed is equal to:
    The total thickness of the two spacers removed in step (3) plus the end float, written down in Step, minus 0.003 in. to 0.005in. (0.08 mm to 0.13 mm).
    NOTE
    The two stage 3 actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-140) are for the Stage 3 Stator Vanes installed at the positions 8 and 9.
  5. Install the 10 stage 3 actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-100) and the two stage 3 actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 03-140) into the locations in the Stage 3 Stator Vane upper actuating ring. Engage the stage 3 actuating levers on the Stage 3 Stator Vane spindles.
  6. Install the 12 nuts HPC Variable Stator Vane Actuation System (72-41-34, 03-103 and HPC Variable Stator Vane Actuation System (03-143) to attach the stage 3 actuating levers to the Stage 3 Stator Vanes.
  7. Remove the three rigging pins from the stage 3 upper actuating ring.
    NOTE
    The stage 3 actuating levers must be parallel with the casing centre line when you torque the nuts. This is the null position.
  8. Torque the nuts to 85 lbfin to 105 lbfin (10.00 Nm to 12.00 Nm) plus the run down torque.
  9. At each Stage 3 Stator Vane apply a load at the inner pivot point, to push the stator vane radially out.
  10. Measure and write down the Stage 3 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 3 lower actuating ring and the levers on to the lower half HP Compressor front case at the Stage 3 Stator Vane positions 19 to 30. Use the procedure given in Step to Step.
1. Refer to Figure.
2. SBE 72-0400: HP Compressor variable vanes - inlet guide vane and stages 3 to 5 with optimised build and setting instructions.
  SBE 72-0410: HP Compressor variable inner shrouds - Introduction of revised one piece bushes
3. Pre SBE 72-0400 : It is not necessary to lubricate the stage 3 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
4. SBE 72-0400 : Lubricate the stage 3 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-B00, SUBTASK 72-41-30-440-211.
5. 1. Pre SBE 72-0410: Apply a thin layer of CoMat 04-007 SILICONE GREASE on to the 32 half bushes HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190) outer surface.
  2. SBE 72-0410: Apply a thin layer of CoMat 04-007 SILICONE GREASE on to the 16 bushes HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-190) outer surface.
  3. Pre SBE 72-0410: Install the 32 half bushes into one half of the stage 3 half shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200).
  4. SBE 72-0410: Install the 16 bushes onto the stage 3 stator vanes.
    NOTE
    Make sure the three locating pins are correctly engaged in the stage 3 half shroud.
  5. Pre SBE 72-0410: Install the stage 3 half shroud, the half bushes and one half of the the stage 3 half seal ring HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-150) on to the Stage 3 Stator Vanes at the inner pivot.
    NOTE
    Make sure the three locating pins are correctly engaged in the stage 4 half shroud.
  6. SBE 72-0410: Install the stage 3 half shroud and the stage 3 half shroud with integral seal HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-200) on to the Stage 3 Stator Vanes at the inner pivot point.
  7. Pre SBE 72-0410: Install the eight bolts HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-138), the 16 dee-headed washers HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-134) and the eight nuts HPC Variable Stator Vane Shrouds And Related Part (72-41-33,02-130). These attach the stage 3 half shroud, the half bushes and the stage 3 half seal ring to the Stage 3 Stator Vanes.
  8. SBE 72-0410: Install the eight bolts HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-138), the 16 dee-headed washers HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 02-134) and the eight nuts HPC Variable Stator Vane Shrouds And Related Part (72-41-33,02-130). These attach the stage 3 half shroud, the bushes and the stage 3 half shroud with integral seal to the Stage 3 Stator Vanes.
  9. Torque the nuts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
6. 1. Install the stage 3 half shroud as given in Step to Step.

View through the HP Compressor front case

Sheet 1

Sheet 2

Sheet 1

Sheet 2

Sheet 1

Sheet 2

Install the seals on the stage 3 VSV spindles

Install the stage 3 variable stator vanes

Locations for the stage 3 variable stator vanes

Measure the stage 3 stator vane end float

Requirements After Job Completion

Follow-On Conditions

NONE

Manufacturer Code:	00BB6
Enterprise Name:	INDESTRUCTIBLE PAINT INC
BU Name:	INDESTRUCTIBLE PAINT INC
Street:	1 INDEPENDENCE DRIVE
City:	MONROE
State:	CT
Zip Code:	06468
Country:	USA
Phone Number:	1-203-880-9130
Fax Number:	1-203-880-9133
Email:	dave@indestructiblepaint.com
Internet:	www.indestructiblepaint.com

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:	39428
Enterprise Name:	McMASTER-CARR SUPPLY CO.
BU Name:	McMASTER-CARR SUPPLY CO.
Street:	600 COUNTY LANE ROAD
City:	ELMHURST
State:	IL
Zip Code:	60126-2081
Country:	USA
Phone Number:	1-630-833-0300, 1-630-600-3600
Fax Number:	1-630-834-9427
Internet:	www.mcmaster.com

Manufacturer Code:	LOCAL
Enterprise Name:	LOCALLY SUPPLIED

Manufacturer Code:	U1653
Enterprise Name:	Society Of British Aerospace Companies, LTD.

Part Number:	AS43013-013
Part Name:	RING - SEALING, TOROIDAL
Manufacturer Code:	U1653

Manufacturer Code:	0AM53
Tool Number:	IAE 1R18258
Tool Name:	IAE 1R18258 Bushing assembly tool

TASK 72-41-30-440-004-B00 HPC Front Case And Vane Assembly - Install The Stage 3 Variable Stator Vanes, Assembly-004

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Common Information

TASK 72-41-30-440-004-B00 HPC Front Case And Vane Assembly - Install The Stage 3 Variable Stator Vanes, Assembly-004

General

NOTE

NOTE

Preliminary Requirements

Pre-Conditions

Support Equipment

Consumables, Materials and Expendables

Spares

Safety Requirements

Procedure

SUBTASK 72-41-30-220-166 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1212

SUBTASK 72-41-30-220-167 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1216

SUBTASK 72-41-30-220-168 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1217

SUBTASK 72-41-30-220-169 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1218

SUBTASK 72-41-30-220-170 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1219

SUBTASK 72-41-30-220-171 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1220

SUBTASK 72-41-30-220-172 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1255

SUBTASK 72-41-30-220-173 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1311

SUBTASK 72-41-30-220-174 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1264

SUBTASK 72-41-30-440-142 Install the Stage 3 VSV Actuating Ring Centralizing Pads (Pre SBE 72-0385 or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

SUBTASK 72-41-30-440-143-001 Install the Stage 3 VSV Spindle Bushes using IAE 1R18259 and IAE 1R18258 Bush Assembly Tools (Pre SBE 70-0984 and SBE 70-0984)

NOTE

SUBTASK 72-41-30-440-143-002 Install the Stage 3 VSV Spindle Bushes using IAE 1R18583, IAE 1R18574, IAE 1R18584, IAE 1R18575 and IAE 1R18573 (Pre SBE 70-0984 and SBE 70-0984)

NOTE

CAUTION

CAUTION

SUBTASK 72-41-30-440-144 Install the Stage 3 Variable Stator Vanes in the HP Compressor Front Case (Pre SBE 72-0400 and SBE 72-0400)

NOTE

NOTE

NOTE

NOTE

NOTE

NOTE

NOTE

SUBTASK 72-41-30-440-145 Install the Stage 3 Variable Stator Vane Actuating Rings (Pre SBE 72-0400, SBE 72-0400, Pre SBE 72-0385 or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

NOTE

NOTE

NOTE

NOTE

SUBTASK 72-41-30-440-146 Install the stage 3 Variable Stator Vane Half Shroud,72-41-30-990-149-002 (Pre SBE 72-0400, SBE 72-0400, Pre SBE 72-0410 and SBE 72-0410)

NOTE

NOTE

Figure: View through the HP Compressor front case

View through the HP Compressor front case

Figure: Locations for the fits and clearances

Sheet 1

Figure: Locations for the fits and clearances

Sheet 2

Figure: Install the stage 3 actuating ring centralizing pads and rigging pin bracket

Sheet 1

Figure: Install the stage 3 actuating ring centralizing pads and rigging pin bracket

Sheet 2

Figure: Install the stage 3 VSV spindle bushes

Sheet 1

Figure: Install the stage 3 VSV spindle bushes

Sheet 2

Figure: Install the seals on the stage 3 VSV spindles

Install the seals on the stage 3 VSV spindles

Figure: Install the stage 3 variable stator vanes

Install the stage 3 variable stator vanes

Figure: Install the stage 3 variable stator vanes

Install the stage 3 variable stator vanes

Figure: Locations for the stage 3 variable stator vanes

Locations for the stage 3 variable stator vanes

Figure: Measure the stage 3 stator vane end float

Measure the stage 3 stator vane end float

Requirements After Job Completion

Follow-On Conditions