DMC:V2500-A5-72-41-3000-05A-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-A5

Common Information

TASK 72-41-30-440-006-B00 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 70-41-01-400-501 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 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 HP Compressor Stage 4 and 5 Rotor Path Rings and Stage 6 Rotor Ring Segments by TASK 72-41-30-440-001-C00 (ASSEMBLY-001).

Measure and then machine the Stage 6 Stator Vanes and the stage 4, 5 and 6 Rotor Path Rings by TASK 72-41-30-440-002-B01 (ASSEMBLY-002).

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

Install the Stage 3 VSV by TASK 72-41-30-440-004-B00 (ASSEMBLY-004).

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

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

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

Measure the HP Compressor front cases by TASK 72-41-30-440-009-B00 (ASSEMBLY-009).

Disassemble the HP Compressor front cases by TASK 72-41-30-440-010-B00 (ASSEMBLY-010).

Check and Set VSV System with Optimised Build and Setting Clearances - SBE 72-0400 by TASK 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 1R18261 Bushing assembly tool	0AM53	IAE 1R18261	1
IAE 1R18262 Bushing assembly tool	0AM53	IAE 1R18262	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		(alternative to IAE 1R18261 and IAE 1R18262)
IAE 1R18575 Bushing assembly tool	0AM53	IAE 1R18575		(alternative to IAE 1R18262 and IAE 1R18261)
IAE 1R18578 Pusher installation tool	0AM53	IAE 1R18578		(alternative to IAE 1R18261)
IAE 1R18581 Pusher installation tool	0AM53	IAE 1R18581		(alternative to IAE 1R18262)
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 72-41-30-220-185 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1236

Refer to Figure.

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 HP COMPRESSOR SPLIT CASE (72-41-31, 01-254)
Location At The Stage 5 VSV HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Stage 5 Outer Pivot Bush Bore	0.4740
	0.4749	0.0035
Stage 5 VSV Spindle Diameter	0.4685	0.0064
	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 HP COMPRESSOR SPLIT CASE (72-41-31, 01-254)
Location At The Stage 5 VSV HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Stage 5 Outer Pivot Bush Bore	12.040
	12.062	0.088
Stage 5 VSV Spindle Diameter	11.900	0.162
	11.952

SUBTASK 72-41-30-220-186 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1240

Refer to Figure.

Reference dimensions the fit 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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190) Location In The Stage 5 Shroud HPC Variable Stator Vane Shrouds And Related Part (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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Location In The Stage 5 Shroud HPC Variable Stator Vane Shrouds And Related Part (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 72-41-30-220-187 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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Diameter	6.881
	6.993	0.007
Half Bush Bore	7.000	0.142
	7.023

SUBTASK 72-41-30-220-188 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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	7.1950
	7.2131	0.004
Half Bush Outer Length	7.2170	0.023
	7.2177

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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	182.754
	183.214	0.096
Half Bush Outer Length	183.310	0.586
	183.330

SUBTASK 72-41-30-220-189 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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-200)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 Shroud, Half Bush Location Diameter	7.2720
	7.2740	0.0037
Half Bush Inner Diameter	7.2631	0.0109
	7.2683

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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-200)
Location At The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 Shroud, Half Bush Location Diameter	184.7100
	184.7600	0.096
Half Bush Inner Diameter	184.4840	0.276
	184.6140

SUBTASK 72-41-30-220-190 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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	7.9430
	7.9454	0.0048
Half Bush Outer Length	7.9330	0.0124
	7.9381

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 HPC Variable Stator Vanes (72-41-32, 04-500 And 04-600)
Location In The Half Bush HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190)
Stage 5 VSV Inner Spindle Length	201.754
	201.814	0.124
Half Bush Outer Length	201.500	0.314
	201.630

SUBTASK 72-41-30-220-191 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1331

Refer to Figure.

Reference dimensions at location 1331. 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 1331
Stage 5 VSV Lever HPC Variable Stator Vane Actuation System (72-41-34, 05-100)
Location In The Bush HPC Variable Stator Vane Actuation System (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 1331
Stage 5 VSV Lever HPC Variable Stator Vane Actuation System (72-41-34, 05-100)
Location In The Bush HPC Variable Stator Vane Actuation System (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 72-41-30-220-444 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1261

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 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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-200), Location
Pin Hole Bore	0.1996
	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 HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-200), Location
Pin Hole Bore	5.070
	5.100	0.046
Grooved Headless Pin Diameter	5.012	0.088
	5.024

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 5 centralizing pads in to position on the stage 5 upper actuating ring.
  2. Install the four bolts HPC Variable Stator Vane Actuation System (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 bracket HPC Variable Stator Vane Actuation System (72-41-34, 05-760) into position on the lower stage 5 actuating ring HPC Variable Stator Vane Actuation System (72-41-34, 05-540). Refer to the detail at E.
  2. Install the two hollow dowels HPC Variable Stator Vane Actuation System (72-41-34, 05-766) and the two bolts HPC Variable Stator Vane Actuation System (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. 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 1R18262 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 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.
  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 63 stage 5 VSV inner bushes.
4. 1. Use IAE 1R18261 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 the nylon washer A.
  4. 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.
  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 stage 5 VSV 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 1R18581 Pusher installation tool 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. 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 1R18575 Bushing assembly tool 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 tool.
  7. Do Step to Step again to install the remaining 63 inner bushes.
4. 1. Put the bush on the IAE 1R18578 Pusher installation tool 1 off. Refer to detail B on Figure.
  2. Install the pusher into the stage 5 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 5 VSV outer bushes.
1. Refer to Figure and Figure.
2. Pre SBE 72-0400: 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 72-0400: 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-B00, SUBTASK 72-41-30-440-211.
4. 1. Use IAE 1R18492 Seal fitting tool 1 off to install the sealing rings on to the stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-500).
  2. Use IAE 1R18493 Seal fitting tool 1 off to install the sealing rings on to the stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 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. NOTE
    The two stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-600) with the long spindles must be installed at the positions 1 and 32.
    Install the 30 stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-500) and the two stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-600) in to the bushes in the upper half HP Compressor front case.
6. 1. Install the 30 stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-500) and the two stage 5 stator vanes HPC Variable Stator Vanes (72-41-32, 04-600), in the lower half HP Compressor front case as given in Step and Step.
7. 1. Put two spacers HPC Variable Stator Vane Actuation System (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 HPC Variable Stator Vane Actuation System (72-41-34, 05-140) go at the positions 1, 32, 33 and 64.
    The eight actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 05-120) go at the positions 2, 3, 30, 31, 34, 35, 62 and 63.
    The 52 actuating levers HPC Variable Stator Vane Actuation System (72-41-34, 05-100) go at the positions 4 to 29 and 36 to 61.
    NOTE
    The stage 5 actuating levers must be parallel with the casing center line, when you torque the nuts. This is the null position.
  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.
  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 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 5 stator vanes.
  6. Remove the 64 slave nuts and actuating levers from 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, Figure and Figure.
2. Pre SBE 72-0400: 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 72-0400: 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-B00, SUBTASK 72-41-30-440-211.
4. 1. Put the stage 5 upper actuating ring HPC Variable Stator Vane Actuation System (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.
  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 HPC Variable Stator Vane Actuation System (72-41-34, 05-060) thru HPC Variable Stator Vane Actuation System (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 HPC Variable Stator Vane Actuation System (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 HPC Variable Stator Vane Actuation System (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.
    NOTE
    The stage 5 actuating levers must be parallel with the casing center 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 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 HPC Variable Stator Vane Actuation System (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 72-0400: 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 5 locations with CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) during this SUBTASK.
4. SBE 72-0400 : 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-B00, SUBTASK 72-41-30-440-211.
5. 1. Pre SBE 72-0410: Apply a thin layer of CoMat 04-007 SILICONE GREASE to the 64 half bushes HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190) outer surfaces.
  2. SBE 72-0410: Apply a thin layer of CoMat 04-007 SILICONE GREASE to the 32 bushes HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-190) outer surfaces.
  3. Pre SBE 72-0410: Install the 64 half bushes on to one half of the stage 5 front and rear shroud HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-200).
  4. SBE 72-0410: Install the 32 bushes on to the stage 5 stator vanes.
    NOTE
    Make sure the locating pins are correctly engaged in the stage 5 front shroud.
  5. Pre SBE 72-0410: 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 72-0410: Install the stage 5 front and rear shroud on to the stage 5 stator vanes and bushes at the inner pivot point.
    NOTE
    Make sure the flat on the head of the bolts is in the correct position.
  7. Install the 16 dee headed bolts HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-138) and nuts HPC Variable Stator Vane Shrouds And Related Part (72-41-33, 04-130). These attach the stage 5 front and rear shroud to the stage 5 stator vanes.
  8. CAUTION
    DO NOT LET THE BOLTS TURN WHEN YOU TORQUE TIGHTEN THE NUTS. THE BOLTS ARE A CLOSE TOLERANCE FIT.
    Torque the nuts to 36 lbfin to 45 lbfin (4.00 Nm to 5.00 Nm).
6. 1. Install the stage 5 front and rear 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 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-B00 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-B00 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 72-41-30-220-185 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1236

SUBTASK 72-41-30-220-186 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1240

SUBTASK 72-41-30-220-187 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1241

SUBTASK 72-41-30-220-188 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1242

SUBTASK 72-41-30-220-189 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1243

SUBTASK 72-41-30-220-190 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1244

SUBTASK 72-41-30-220-191 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1331

SUBTASK 72-41-30-220-444 Reference Fits and Clearances of the HP Compressor Front Cases and Vanes at Location 1261

SUBTASK 72-41-30-440-153 Assemble the Stage 5 Actuating Rings (Pre SBE 72-0385or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

SUBTASK 72-41-30-440-154-001 Install the Stage 5 VSV Spindle Bushes using IAE 1R18262 and IAE 1R18261 Bush Assembly Tools (Pre SBE 70-0984 and SBE 70-0984)

NOTE

SUBTASK 72-41-30-440-154-002 Install the Stage 5 VSV Spindle Bushes using IAE 1R18581, IAE 1R18575, IAE 1R18573 and IAE 1R18578 Bush Installation Tools (Pre SBE 70-0984 and SBE 70-0984)

NOTE

CAUTION

CAUTION

SUBTASK 72-41-30-440-155 Install the Stage 5 Stator Vanes in the HP Compressor Front Case (Pre SBE 72-0400 and SBE 72-0400)

NOTE

NOTE

NOTE

NOTE

NOTE

SUBTASK 72-41-30-440-156 Install the Stage 5 Actuating Rings (Pre SBE 72-0400, SBE 72-0400, Pre SBE 72-0385or SBE 72-0416 and SBE 72-0385or SBE 72-0416)

NOTE

NOTE

SUBTASK 72-41-30-440-157 Install the Stage 5 Variable Stator Vane (VSV) Half Shrouds (Pre SBE 72-0400, SBE 72-0400, Pre SBE 72-0410 and SBE 72-0410)

NOTE

NOTE

NOTE

CAUTION

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 5 Actuating Ring Centralizing Pads and Rigging Pin Brackets

Sheet 1

Figure: Install the Stage 5 Actuating Ring Centralizing Pad and Rigging Pin Brackets

Sheet 2

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