TASK 72-41-30-440-011-C00 HPC Front Case And Vane Assembly - Check And Set VSV System With Optimized Build And Setting Clearances, Assembly-011 - SBE 72-0564, SBE 72-0571 And SBE 72-0573 (SelectOne Production Standard)

DMC:V2500-A5-72-41-3000-10B-710A-B|Issue No:002.00|Issue Date:2013-11-01

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

Post SBE 72-564 AND Post SBE 72-0571 AND Post SBE 72-573 (SELECTONE PRODUCTION STANDARD)

Common Information

TASK 72-41-30-440-011-C00 HPC Front Case And Vane Assembly - Check And Set VSV System With Optimized Build And Setting Clearances, Assembly-011 - SBE 72-0564, SBE 72-0571 And SBE 72-0573 (SelectOne Production Standard)

General

Refer to Figure.

This TASK gives the general procedure to check and set the clearances between the HP compressor front cases (VIGV stage and stages 3 to 5) and the VSV upper and lower actuating ring assemblies, only for the engines, which have SBE 72-0564, SBE 72-0571 AND SBE 72-0573 (SelectOne Production Standard) incorporated. Do this procedure when instructed to do so from the applicable build procedures during the assembly of the HP compressor front case. Refer to the following procedures.

TASK 72-41-30-440-001-C00 (ASSEMBLY-001, CONFIG-003) Install the HP Compressor Stage 3 , 4 and 5 Rotor Path Rings and Stage 6 Rotor Ring Segments.

TASK 72-41-30-440-002-B00 (ASSEMBLY-002, CONFIG-002) Measure and then Machine the Stage 6 VSV and the Stage 3 to 6 Rotor Path Rings.

TASK 72-41-30-440-003-C00 (ASSEMBLY-003, CONFIG-003) Install the VIGV.

TASK 72-41-30-440-004-C00 (ASSEMBLY-004, CONFIG-003) Install the Stage 3 VSV.

TASK 72-41-30-440-005-C00 (ASSEMBLY-005, CONFIG-003) Install the Stage 4 VSV.

TASK 72-41-30-440-006-C00 (ASSEMBLY-006, CONFIG-003) Install the Stage 5 VSV.

TASK 72-41-30-440-007-B00 (ASSEMBLY-007, CONFIG-002) Install the Stage 6 Stator Vanes.

TASK 72-41-30-440-008-C00 (ASSEMBLY-008, CONFIG-003) Install the VIGV and the Stages 3 to 5 Bridge Pieces.

TASK 72-41-30-440-009-C00 (ASSEMBLY-009, CONFIG-003) Measure the HP Compressor Front Cases.

TASK 72-41-30-440-010-C00 (ASSEMBLY-010, CONFIG-003) Disassemble the HP Compressor Front Cases.

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 standard torque data and procedures, refer to the 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.

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

NOTE

To identify the consumable materials refer to the PCI.

NOTE

The tools specified are the minimum standard for this TASK. For subsequent standards of tools refer to the Illustrated Tools and Equipment Manual (ITEM).

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Feeler gageLOCALFeeler gage
Spray hand pumpLOCALSpray hand pump
Clean brushesLOCALClean brushes
IAE 1R18248 Rigging pin0AM53IAE 1R182482
IAE 1R18638 Rigging pin0AM53IAE 1R186382
IAE 1R18423 Rigging pin0AM53IAE 1R184232
IAE 1R18892 Rigging pin0AM53IAE 1R188922
IAE 1R18423 Rigging pin0AM53IAE 1R184236 per stage
IAE 1R18893 Riggingpin0AM53IAE 1R188936
IAE 1R18894 Rigging pin0AM53IAE 1R188946
IAE 1R18895 Rigging pin0AM53IAE 1R188956
IAE 1R18638 Rigging pin0AM53IAE 1R186382

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 07-038 AIR DRYING ENAMELK3504CoMat 07-038
CoMat 10-077 APPROVED ENGINE OILSLOCALCoMat 10-077
CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R)LOCALCoMat 10-108

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-30-440-253 Prepare the HP Compressor Front Cases for the Setting and Clearance Checks

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

    2. Install all the build pins for each stage in turn during this procedure. Do not rig the VSV system to the high speed position.

      3. Install the pins through the actuating ring and into the mating holes in the compressor case. If you cannot install a pin in an actuating ring hole because a component prevents this then omit that pin. It may be necessary to make small adjustments to the actuating ring to install all the pins.

      1. Install the pins for the VIGV stage, it is only possible to install the four pins at positions D and E (with the left and right hand connector housings installed). At position E install two flattened pins, refer to Figure and table 1.

      2. Install the pins for the stages 3 to 5, refer to Figure, Figure, Figure and table 1.

        TABLE 1

        VIGV STAGE :

        Standard build pin - position C

        Or

        Stepped build pin - position D

        Or

        Flatted build pin - position E

        STAGES 3 TO 5 :

        Standard build pin - position H

        Or

        Stage 3

        Stage 4

        Stage 5

    2. SUBTASK 72-41-30-440-254 Set the HP Compressor Front Case VSV Pad Clearances

    1. Refer to Figure and Figure.

      2. Preparation checks.

      1. Before installation inspect the left hand and right hand connectors for each stage and the mating surfaces of the actuating ring assembly for marks caused by previously misaligned dowels. This check will give some indication of the possible areas which could result in a misaligned assembly during the build procedure.

      2. Make sure that no adjusting washers are installed before you measure and calculate the pad clearances.

      3. During the assembly procedure lubricate the front compressor casing or mating pad surface for each stage with a thin layer of 10-108 teflon based lubricant, refer to Step.

      4. After the installation of the connectors make sure that the dowels are correctly installed.

      5. Make sure all 16 bolts which attach the connector and centralizing housing pads to the actuating ring are loosened. This will give a large clearance under each pad.

      6. Install all build pins in each stage in turn, refer to Step.

      3. Set the clearances between the compressor case and the actuating pads.

      1. For each stage in turn press each of the eight pads radially inward until the pad fully touches the HPC front case assembly.

        NOTE

        If you check the clearance with a feeler gauge in an axial position it will give large errors.

      2. Measure and make a record of the gap between the pad and the actuating ring at the adjusting washer position for that pad.

        The feeler gauge must be put under the pad circumferentially along the length of the actuating ring.

        NOTE

        Refer to the applicable Assembly TASK, see TASK 72-41-30-440-000 (ASSEMBLY-000) for part details of IPC Fig./item numbers for the adjusting washers for the specific configuration.

      3. Remove each bolt and washer, then calculate and install the applicable adjusting washer to give the correct clearance for each stage, refer to Table 2. It is recommended that the lower limit is achieved.

        A maximum allowable number of adjusting washers is two at each location.

        TABLE 2 :

        TABLE OF LIMITS - VSV CLEARANCE SETTING PROCEDURE

        VSV SYSTEM STAGE

        CLEARANCE - ALL PADS

        VIGV

        0.006 to 0.010 in.

        (0.15 to 0.25 mm)

        3

        0.010 to 0.014 in.

        (0.25 to 0.35 mm)

        4

        0.010 to 0.014 in.

        (0.25 to 0.35 mm)

        5

        0.004 to 0.008 in.

        (0.10 to 0.20 mm)

      4. Install the two bolts and washers to attach the pad and adjusting washer(s) to the actuating ring.

        NOTE

        Refer to the applicable Assembly TASK for bolt torque values, see TASK 72-41-30-440-000 (ASSEMBLY-000).

      5. Torque the bolts to the recommended torque value given in the applicable Assembly TASK.

        NOTE

        If you check the clearance with a feeler gauge in an axial position it will give large errors.

    4. Measure and make a record of the clearance between the pads and the case for each stage, refer to table 2. The clearance must agree with the limits given in table 2. If the clearance does not agree with the limits in table 2 then the clearance must be reset.

      Let the feeler gauge stay in position and then measure the next clearance at a circumferentially adjacent pad. When all eight pads are set there should be a feeler gauge remaining under each pad.

      The feeler gauge must be put under the pad circumferentially along the length of the actuating ring.

    5. Complete the above procedure for all pads in all stages and remove all the feeler gauges and build pins.

      6. Completion procedures.

      1. During disassembly of the connectors from the actuating ring look for new marks from misplaced dowels, refer to TASK 72-41-30-440-010-C00 (ASSEMBLY-010, CONFIG-002).

      2. If you can see new marks then the above setting procedure must be done again for the particular stage.

    3. SUBTASK 72-41-30-440-255 Lubricate the VSV Mechanism

      WARNING

      YOU MUST USE THE CORRECT PERSONNEL PROTECTION EQUIPMENT WHEN HANDLING AND APPLYING THE LUBRICANT, CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R).

    1. Refer to Figure and Figure.

      2. Apply CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R) to each of the locations which follow, the typical areas for the lubrication of the mechanism. Do these procedures during each applicable assembly procedure for this configuration when told to do so.

        Apply a thin layer of lubricant using an appropriately sized brush or hand pump spray. Not an aerosol.

      1. Each mating surface of the variable stator vane spindle in the outer pivot bush at location 2.

      2. Each sealing washer mating surface with the vane at location 3.

      3. The mating surface of the vane spindle (the inner pivot point) with the top of each half bush at location 4.

      4. The mating inner surface of each vane half bush with the vane spindle (the inner pivot point) at location 5.

      5. The mating surface of the vane spindle (the inner pivot point) with the bottom of each half bush at location 6.

        NOTE

        It is permitted to lubricate the pad surface or the case surface.

      6. Lubricate the following locations:

      7. Each VIGV actuating ring connector housing pad to case surface at location A.

      8. Each VIGV actuating ring centralizing pad to case surface at location B.

      9. Each stage 3 thru 5 actuating ring connector/compensating housing pad to case surface at location F.

      10. Each stage 3 thru 5 actuating ring centralizing pad to case surface at location G.

    4. Figure: HP Compressor Front Cases and VSV Actuating System

    HP Compressor Front Cases and VSV Actuating System

    Figure: Install the Pins - VIGV Actuating Ring

    Install the Pins - VIGV Actuating Ring

    Figure: Install the Pins - Stage 3 Actuating Ring

    Sheet 1

    Legend
    Install the Pins - Stage 3 Actuating Ring

    Sheet 1

    Close

    Figure: Install the Pins - Stage 4 Actuating Ring

    Sheet 2

    Legend
    Install the Pins - Stage 4 Actuating Ring

    Sheet 2

    Close

    Figure: Install the Pins - Stage 5 Actuating Ring

    Sheet 3

    Legend
    Install the Pins - Stage 5 Actuating Ring

    Sheet 3

    Close

    Figure: Set the HP Compressor Front Case (Left Hand Side) VSV Pad Clearances - Recommended Feeler Gauge Positions

    Set the HP Compressor Front Case (Left Hand Side) VSV Pad Clearances - Recommended Feeler Gauge Positions

    Figure: Set the HP Compressor Front Case (Right Hand Side) VSV Pad Clearances - Recommended Feeler Gauge Positions

    Set the HP Compressor Front Case (Right Hand Side) VSV Pad Clearances - Recommended Feeler Gauge Positions

    Figure: Lubrication Positions - Typical for All Stages

    Lubrication Positions - Typical for All Stages

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial correction due to conversion

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:K3504
Enterprise Name:INDESTRUCTIBLE PAINT CO LTD
BU Name:NULL
Street:25 PENTOS DRIVE
City:SPARKHILL
Province:BIRMINGHAM
Zip Code:B11 3TA
Country:GREAT BRITAIN
Phone Number:44-121-7022485
Fax Number:44-121-7784338
Email:sales@indestructible.co.uk
Internet:www.indestructible.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:00BB6
Supply Number:CoMat 07-038
Type:sp01
Supply Short Name:CoMat 07-038 AIR DRYING ENAMEL
Supply Name:CoMat 07-038 AIR DRYING ENAMEL
Specification Groups:
Doc NumberType
OMAT:7/22B (RR REF)IP9138 R1
JCR-029 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
K3504
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
Manufacturer Code:39428
Supply Number:CoMat 10-108
Type:sp01
Supply Short Name:CoMat 10-108 HIGH PERFORMANC EPENETRATING LUBRICANT WITH TEFLON (R)
Supply Name:CoMat 10-108 HIGH PERFORMANCE PENETRATING LUBRICANT WITH TEFLON (R)
Specification Groups:
Doc NumberType
OMAT: 1080 (RR Ref)TRI-FLOW
Suppliers:
ManufacturerRemarks
39428
K6835
KC4N1
Manufacturer Code:LOCAL
Tool Number:Clean brushes
Tool Name:Clean brushes
Manufacturer Code:LOCAL
Tool Number:Feeler gage
Tool Name:Feeler gage
Manufacturer Code:0AM53
Tool Number:IAE 1R18248
Tool Name:IAE 1R18248 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18423
Tool Name:IAE 1R18423 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18638
Tool Name:IAE 1R18638 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18892
Tool Name:IAE 1R18892 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18893
Tool Name:IAE 1R18893 Riggingpin
Manufacturer Code:0AM53
Tool Number:IAE 1R18894
Tool Name:IAE 1R18894 Rigging pin
Manufacturer Code:0AM53
Tool Number:IAE 1R18895
Tool Name:IAE 1R18895 Rigging pin
Manufacturer Code:LOCAL
Tool Number:Spray hand pump
Tool Name:Spray hand pump