This document transmits the Revision 3 of Non-Modification Service Bulletin V2500-ENG-72-0608. Document History Non-Modification Service Bulletin Revision Status Initial Issue. May 5/10. Revision 1. Aug. 6/10. Revision 2. Jan. 4/11.

Non-Modification Service Bulletin Revision 3 Remove Incorporate Reason for change Sep.20/11

V2500-D5 SERIES PROPULSION SYSTEM NON-MODIFICATION SERVICE BULLETIN



# V2500−ENG−72−0608 Transmittal - Page 1 of 2

IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG (date as above). All rights reserved. **CHECK THAT ALL PREVIOUS TRANSMITTALS HAVE BEEN INCORPORATED If any have not been received please advise IAE International Aero Engines AG** All Pages of the Non-Modification Service Bulletin. Pages 1 to 68 of the Non-Modification Service Bulletin. To revise the effectivity. To revise the compliance. To delete Part 2 and 3. Editorial changes. To update the illustrations.



# V2500−ENG−72−0608 Transmittal - Page 2 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.1. Planning Information A. Effectivity (1) Boeing MD-90 (a) All V2525-D5, V2528-D5 Engines.
NOTE : For an engine not to require an ultrasonic inspection in accordance with this Non-Modification Service Bulletin, the condition that follows must be achieved: R R R The engine must have a new HP compressor stage 3-8 drum of Service Bulletin V2500-ENG-72-0470 or Service Bulletin V2500-ENG-72-0606 and new nuts of Service Bulletin V2500-ENG-72-0596 installed together at the same time. R R R R B. Concurrent Requirements
None.
C. Reason (1) Condition: Crack indications have been found on the High Pressure (HP) compressor stage 3-8 drum assembly R during overhaul. (2) Background: Crack indications were highlighted during an Engine Manual crack inspection of the stage 7-8 disc internal cavity. (3) Objective: To do an ultrasonic inspection procedure of the HP compressor stage 8 disc. (4) Substantiation: Crack indications have been found on the HP compressor stage 3-8 drum assembly during overhaul. An ultrasonic inspection was developed and has shown the capability of detecting cracks in service. NON-MODIFICATION SERVICE BULLETIN - ENGINE - HIGH PRESSURE (HP) COMPRESSOR - STAGE 3 TO 8 COMPRESSOR DRUM - ULTRASONIC INSPECTION PROCEDURE



# V2500−ENG−72−0608 Page 1 of 68 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(5) Effects of Bulletin on: (a) Removal/Installation: Not affected. (b) Disassembly/Assembly: Not affected. (c) Cleaning: Not affected. (d) Inspection/Check: Not affected. (e) Repair: Not affected. (f) Testing: Not affected. (6) Supplemental Information
None. D. Description This R Non-Modification Service Bulletin instructs ultrasonic inspection procedures of the HP compressor stage 8 disc that can be carried out "In Service" or "At Overhaul/ Shop Visit". (1) The procedures are to inspect the internal stage 8 disc for cracks, on the outer diameter adjacent to the stage 7-8 EB weld land and on the inner diameter at the inner radius position. (2) A shear wave ultrasonic inspection probe is positioned on the ceramic lining of the stage 7 stator, located on the outer diameter of the disc. (3) Engines affected are listed in paragraph 1.A. Effectivity.
NOTE : The Accomplishment Instruction of R this Non-Modification Service Bulletin is divided into two INSTRUCTIONs as follows: INSTRUCTION I - Applicable for engines "In Service". INSTRUCTION II - Applicable for engines "At Overhaul/Shop Visit". 

# V2500−ENG−72−0608 Page 2 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.E. Compliance Category 3 Compliance times for Non-Modification Service Bulletin V2500-ENG-72-0608: Inspection

location R R HP compressor

3-8 Drum cycles since new R R R R R Threshold R From Regular Repeat Inspection

Interval R R

Outer and Inner Diameters R R R Refer to the USI drawdown plan. R R R Refer to the USI drawdown plan. Date of Revision 3 of NMSBV2500-ENGR R R R 72-0608. R Not more than 750 cycles. R R

NOTE : An engine which is already inspected remains in a repeat inspection interval of 750 cycles. R R
NOTE : To comply with the IAE design policy, IAE recommends to install a new HP compressor stage 3 to 8 drum together with partially silver plated nuts of Service Bulletin V2500-ENG-72-0596 standard by the 31st of December 2019. R R R R



# V2500−ENG−72−0608 Page 3 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

Compliance times R 

# V2500−ENG−72−0608 Page 4 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.NOTE : There are two conditions which can affect the inspection start but not the inspection interval, refer to the tables below: R R FPI Grace Period R Permitted Grace Period R Required Engine Condition (Shop Visit) R 2500 Cycles R Service Bulletin V2500-ENG-72-0596 incorporated Cleaned in accordance with EM TASK 72-41-11-110-001 R R Inspected in accordance with EM TASK 72-41-11-200-001 R R
NOTE : The FPI Grace Period interrupts/delays the ultrasonic inspection by 2500 cycles related to the achieved drum life. R R Figure 19 provides a calculation example for the FPI Grace Period. R ECI Grace Period R Permitted Grace Period R Required Engine Condition (Shop Visit) R 13000 Cycles R Inspected in accordance with Service Bulletin V2500-ENG-72-0625 R and R Service Bulletin V2500-ENG-72-0596 incorporated R
NOTE : The ECI Grace Period interrupts/delays the ultrasonic inspection by 13000 cycles related to the achieved drum life. R R On completion of a successful ECI inspection and the 13000 cycles Grace Period, the engine will return to the 750 cycles repeat inspection interval. R R R F. Approval The compliance statement and the procedures described in this Non-Modification Service Bulletin have been shown to comply with the applicable Federal Aviation Regulations and are FAA-APPROVED R for the engine models listed. G. Manpower Estimated man-hours to carry out this Non-Modification Service Bulletin in full: (1) In Service (a) Engines without heat shield retainers installed: 3 Hours 

# V2500−ENG−72−0608 Page 5 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(b) Engines with heat shield retainers installed: 7 Hours (2) At Overhaul (a) Engines without heat shield retainers installed: 3 Hours (b) Engines with heat shield retainers installed: 6 Hours
NOTE : The ultrasonic inspection defined in this Non-Modification Service Bulletin R R must only be performed by personnel qualified to ultrasonic inspection level 2 or higher in accordance with EN4179 and/or NAS410 or alternative standards/guidelines R accepted by the applicable National Aviation Authority. H. Weight and Balance (1) Weight Change
None. (2) Moment Arm No effect. (3) Datum Engine Front Mount Centerline (Power Plant Station (PPS) 100). I. Electrical Load Data This Non-Modification Service Bulletin has no effect on the aircraft electrical load. J. Software Accomplishment Summary Not applicable. R K. References (1) Boeing Aircraft Maintenance Manual (AMM) Chapters 36-11-10, 70-30-00, 70-35-03, 70-35-26, 71-00-02, 71-13-00, 72-00-00 and 75-32-51. (2) IAE V2500 Engine Manual (E-V2500-3IA), Chapters 71-00-02, 72-00-40 and 72-41-11. 

# V2500−ENG−72−0608 Page 6 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) Overhaul Processes and Consumables Index. (4) SEN5088 Issue 1. "Significant shop findings on HPC 3-8 drum". (5) SEN5088 Issue 2. "Significant shop findings on HPC 3-8 drum". (6) SEN5088 Issue 3. "Significant shop findings on HPC 3-8 drum". (7) Engineering Change No. 10VR659C. R L. Other Publications Affected
None. M. Interchangeability of Parts Not applicable.



# V2500−ENG−72−0608 Page 7 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.2. Material Information A. Material - Price and Availability
None. B. Industry Support Program Not Applicable. C. The material data that follows is for each engine. This Non-Modification Service Bulletin is for inspection only. D. Instructions/Disposition Code Statements: Parts Modification Conditions Not applicable. Spare Parts Availability Not applicable. R Cleaning, Inspection and Repair Information Inspection procedure (Refer to paragraph 3. Accomplishment Instructions). E. Tooling - Price and Availability The tooling to comply with the inspections will be provided to operators on free of charge (FOC) loan basis. To receive the FOC tooling, please follow the ordering procedure outlined below: (1) Submit a zero charge PO to IAE Spares (GPIAESPRTLG@IAEV2500.com) R with kit tool number and, if applicable, drilling guide tool number to address requested. (2) Shipping and customs costs are the responsibility of the operator Return of kits after use must use the following procedure: (3) Submit an e-mail request to GPIAESPRTLG@IAEV2500.com. R Return details will be provided by e-mail. (4) Upon issuance of a MRA all return details of the kit will be provided. Contact your CFD with any questions.



# V2500−ENG−72−0608 Page 8 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.F. Re-identified Parts Not applicable. G. Other Material Information Data Not applicable.



# V2500−ENG−72−0608 Page 9 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.3. Accomplishment Instructions
INSTRUCTION I - APPLICABLE FOR ENGINES "IN SERVICE" A. General

Use inspection kit IAE2R19873 to carry out an ultrasonic inspection on the outer diameter of the HP compressor stage 8 disc adjacent to the stage 7-8 EB weld land.
NOTE : In order to reduce the potential for multiple-engine in-flight shutdown, power loss, or other anomaly due to maintenance error, IAE recommends that Operators avoid performing maintenance on multiple engines installed on the same aircraft at the same time. If it is not possible to avoid maintenance on more than one engine of an aircraft at the same time, IAE recommends that additional controls are applied in order to ensure that maintenance tasks have been completed as defined.
WARNING : YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE IS STOPPED. THE ENGINE PARTS CAN STAY HOT FOR ALMOST ONE HOUR.
WARNING : DO NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE AN INJURY. R (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. (2) Consumable Materials (a) Refer to the table that follows:
MATERIAL NO. DESIGNATION V01-201 Distilled or De-ionised water V10-058 Penetrating Oil V06-064 Fluorescent Penetrant V05-020 Waterproof Abrasive Paper V05-021 Waterproof Abrasive Paper V05-074 Aluminum Oxide Abrasive Paper For the details of the consumable materials given in the table above, refer to the Aircraft Maintenance Manual (AMM) TASK 70-30-00-910-801. (3) Tools and Equipment (a) For inspection of the outer diameter location:
ITEM DESCRIPTION TOOL NUMBER



# V2500−ENG−72−0608 Page 10 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(a) Inspection kit contains the outer diameter location inspection items (b) to (e) listed in this table and the inner diameter location inspection items (b) to (e) listed in the table in section 3.K.(3)(a) of this

Non-Modification Service Bulletin IAE2R19873

(b) Ultrasonic probe manipulator assembly contains 45 degree shear wave ultrasonic inspection probe IAE2R19874

(c) Couplant feed system IAE2R19807 (d) Outer diameter location working standard IAE2R19854 (e) MCX/BNC lead IAE2R19755 (f) Ultrasonic flaw detector, frequency selectable in the 5.0 MHz range with audible/visual electronic alarm gate Not supplied

(g) Distilled or De-ionised water Not supplied (h) Turning tool (if applicable) Not supplied (i) 4 to 6 mm flexible borescope kit with image capture capability Not supplied (j) 8 mm NC-centralising drill bit (90 degree cutting angle, HSCO material, TiN coated) Generic, eg Forum # 4211506022 or equivalent - Not supplied (k) Outer diameter location drilling guide tool IAE1R19881 (l) Bolts (2 off) AS48516 or 4W0170 R R not supplied (m) Washers to fit item (l) Not supplied (n) Vacuum cleaner and hose Not supplied (o) Cloth Not supplied (p) Hand-held electric drill Not supplied (q) Penetrating oil Not supplied (r) Portable hand grinding equipment Not supplied
NOTE : 1. The lead for the ultrasonic probe is supplied with a BNC connector installed. An adaptor may be required if alternative equipment is used. 2. The compressor can be turned manually, but an electronic turning tool is recommended to perform the inspection. 3. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. 4. The outer diameter drilling guide tool number is identical to the inner diameter location drilling guide tool number. B. Get access to the HP compressor stage 7 bleed valve aperture that is installed 

# V2500−ENG−72−0608 Page 11 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.on the left upper side of the engine (1) Open the applicable cowl doors (Refer to the Aircraft Maintenance Manual, R Chapter 71-13-00). C. Remove the HP stage 7A bleed valve air duct from the left side of the engine. (1) Remove the HP stage 7A bleed valve air duct together with the HP compressor stage 7A bleed valve R R (Refer to Figure 1) (a) Allow the engine to cool for at least two hours with the cowl doors open. (b) Apply the approved penetrating oil CoMat 10-058 before the removal of threaded parts. Let the parts soak at least 15 minutes. (c) Seal all openings to prevent contamination from unwanted materials. (d) Carefully overcome the initial torque of each bolt of the flange to the duct. (e) Carefully loosen each bolt of the flange to the duct. If excessive resistance is encountered, apply more penetrating oil and allow the bolts to soak for at least 15 minutes before proceeding.
NOTE : Make sure you use the correct size tool for the bolt head and do not force the bolt excessively during the removal process. (f) Repeat step (e) until all bolts have been removed successfully. (g) Remove the duct. (h) If a bolt was broken during the removal process, perform the steps that follow: (i) Remove broken bolts and/or studs by mechanical removal methods. (ii) Drill a hole into the end of the broken bolt and/or stud. Refer to the tool manufacturer's instructions for the correct size of drill. (iii) Put an extraction tool into the drilled hole and lock into position. (iv) Turn the extraction tool to remove the broken bolt. (v) Tap the threads if necessary to clean or chase the threads. (vi) Examine the threads for damage or an oversize condition. 

# V2500−ENG−72−0608 Page 12 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(i) If required, replace any inserts (Refer to the Aircraft Maintenance Manual, TASK 70-35-26-300-801). (2) For engines which have HP compressor heat shield retainers (pre V2500-ENG-72-0296) or heat shield retainers with heat shields (pre V2500-ENG-72-0477), perform the rework that follows for probe access (a) Prepare inner free area of the bleed port by placing a clean cloth such that no cutting debris can fall into the engine. (b) Attach the drilling guide tool IAE1R19881 to one end of the slotted hole with two bolts R and two washers as shown in Figure 2. (c) Insert an 8,00 mm (0.315 in.) drill bit into the drilling guide tool and check whether the drill can reach the heat shield retainer without making contact with the rear outer case bleed port flange.
NOTE : On Pre/Post Service Bulletin V2500-ENG-72-0177 R standard rear outer cases (P/N 6A4407 and 6A5497) R the bleed port flange can prevent the drill from reaching the heat shield retainer. (i) If the drill cannot pass the rear outer case flange, go to Step. (d). (ii) If the drill passes without touching the rear outer case port flange, go to Step. (k). (d) Remove the drill, loosen the bolts and remove the drilling guide tools. (e) Blend to create a recess in the rear outer case port flange to enable drill access to the heat shield retainer. Remove minimum amount of material possible to enable access, do not exceed the given limits. Use abrasive stones and papers to create the recess ensuring a smooth finish and blend into adjacent areas is achieved. Ensure all burrs and sharp edges are removed and the surface finish is comparable to adjacent areas. Use V05-020, V05-021 and/or V05-074 abrasive papers and portable hand grinding equipment. Refer to Figures 3A and 3B.
CAUTION : NOTE THE MAXIMUM BLEND LIMITS DEFINED IN FIGURE 3B AND ENSURE THEY ARE NOT EXCEEDED AS THIS CAN LEAD TO THE ENGINE BEING REJECTED UPON INSPECTION. (f) Locally clean and fluorescent penetrant inspect the blended area. Refer to SPP TASK 70-23-05-230-801. Use CoMat V06-064 penetrant with a brush. If cracks are found, reject the engine. 

# V2500−ENG−72−0608 Page 13 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.CAUTION : ENSURE THE ENGINE IS SUFFICIENTLY PROTECTED WITH THE CLOTH PLACED IN STEP. (A) SO THAT NO SOLVENT OR PENETRANT CAN FALL INTO THE ENGINE. (g) Remove the cloth protecting the engine and wipe away any visible debris. If available, use a vacuum cleaner and hose to remove any further debris. (h) Inspect the case flange to ensure the blend limits were not exceeded. If the limits are exceeded, reject the engine. (i) Prepare inner free area of the bleed port by placing a clean cloth such that no cutting debris can fall into the engine. (j) Attach the drilling guide tool IAE1R19881 R to one end of the slotted hole with two bolts (AS48516) and two washers as shown in Figure 2. (k) Insert an 8,00 mm (0,315 in.) drill bit into the drilling guide tool and drill a hole until the second wall of the heat shield retainer is penetrated (Figure 2 thru Figure 5). (l) Remove the drill, loosen the bolts and slide the guide tool to the other end of the slotted hole and repeat step (k). (m) Repeat steps (k) and (l) between the previously drilled two holes, until the entire opening is created as shown in Figure 4 thru Figure 5. (n) Deburr and remove high material around the corners of the opening until the probe can be inserted easily. R R Refer to SPP TASK 70-35-03-300-501. (o) Remove the cloth and wipe away any visible debris. If available, use a vacuum cleaner and hose to remove any further debris. D. Install the HP system turning tool and the borescope (1) Install the turning tool (IAE2R18853) to the accessory gearbox in accordance with the manufacturer's operating instructions (Olympus tool quoted). Install the V2500-D5 software module on the control unit, set the HP compressor rotation speed to the slowest (10 minutes per revolution). Set the HP compressor stage to HPC8 and engage continuous rotation mode. (Refer to the Aircraft Maintenance Manual, R TASK 72-00-02-290-801).
OR (2) Install the hand turning tool to the accessory gearbox (Refer to the Aircraft Maintenance Manual, R TASK 72-00-00-810-801).



# V2500−ENG−72−0608 Page 14 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.CAUTION : IF MATERIAL IS MISSING FROM THE CERAMIC LINER, LIFT THE PROBE OFF THE LINER DURING INSPECTION TO PREVENT DAMAGE TO THE PROBE. (3) Access the liner through the HP compressor Stage 7A bleed valve manifold aperture on the upper left side of the engine (Refer to Figure 5). Insert the flexible borescope and position between the stage seven stator vanes to look down on the surface of the stage seven liner (Refer to Figure 6 thru Figure 8). Make sure the borescope is clear of the stage 8 rotor blades and use the turning tool to rotate the compressor one full revolution. Visually examine the ceramic liner for any missing material, which could damage the ultrasonic probe during the inspection rotation R and any staining or indications of axial cracking (Refer to Figure 9). R A wear line on the liner can be visible at the trailing edge of the stators, this is the approximate seating position of the ultrasonic probe and particular attention should be paid to this area around the circumference of the disc (Refer to Figure 6).
NOTE : If staining or indications of axial cracking is found, contact the local IAE office for further guidance before continuing. R R
NOTE : Missing stage 7-8 R liner material directly underneath the path of the probe can cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation.
NOTE : The borescope inspection for liner material loss is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the borescope inspection for liner cracks or staining determine further engine serviceability. E. Calibrate the ultrasonic equipment Range 28 mm (nominal) Material velocity 3100 m/s Delay 0.00 micro seconds Frequency Selectable in the 5.0 MHz range Damping 50 Ohms Rectify Full Pulser Single crystal



# V2500−ENG−72−0608 Page 15 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Gate position 4.0 - 6.0 time base position
NOTE : 1. The nominal settings above are for a USN 52 or equivalent flaw detector to achieve signal timebase positions. Alternative instruments can require different settings. 2. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. (1) Attach the lead to the manipulator/flaw detector, apply the distilled or de-ionised water and position the probe (IAE2R19874) on to the working standard (IAE2R19854) (Refer to Figure 10). (2) With the flat face of the probe seated on the rear face of the working standard and the chamfered corners outward facing, position the probe on the working standard (Refer to Figure 10). The 1.0 mm long by 0.50 mm deep EDM notch is located in the center of the base of the working standard.
NOTE : 1. If calibration is carried out with the working standard in contact with a secondary surface, excessive couplant on the working surface and EDM target surface, can allow transfer of sound into the secondary surface. This can result in a weak signal and incorrect calibration. 2. During calibration make sure that the probe is flat down on the two contact faces of the working standards. Failure to do so can result in incorrect calibration. 3. Make sure that the probe is positioned correctly on the working standard and the reflected signal is not from the corner of the block. (3) With the probe positioned on the working standard (Refer to Figure 10), identify the response from the EDM target at half skip distance. Maximise the signal response to achieve 70 percent Full Screen Height (FSH) and adjust the range control to position the EDM target signal at five on the timebase. (Refer to Figure 11). (4) Position the gate between the 4.0 and 6.0 divisions on the time base and set the alarm threshold level at 40 percent FSH.



# V2500−ENG−72−0608 Page 16 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.F. Install the manipulator (IAE2R19874) and ultrasonic probe into the engine
CAUTION : DUE TO THE SIMILARITY BETWEEN THE INNER AND OUTER DIAMETER INSPECTION TOOLS, CARE MUST BE TAKEN TO ENSURE THE CORRECT PROBE AND WORKING STANDARD HAVE BEEN SELECTED FOR THE RELEVANT INSPECTION. (1) Position the distilled or de-ionised water container at a suitable position on the engine. Make sure the container is supported above the probe position. Attach the end of the water supply tube to the connector on the rear of the manipulator. Open the valve on the water container and make sure that water flows from the probe face with no sign of air bubbles. When water flows from the probe, close the valve on the water container. (2) Before installing the manipulator/probe into the engine, make sure all parts are secure. Make sure the attachment bolt for the ultrasonic probe is secure, the spring is not bent and the cable is not damaged. Make sure the water tube is removed from the manipulator assembly to allow the probe to be inserted into the engine. R R R
NOTE : 1. Two standards of bleed air slots may be found on engines. The current modification standard has longer elongated slots (Refer to Figure 17) however a number of engines have an earlier modification standard with smaller square slots (Refer to Figure 18). The gaps between the stator platforms are identical, R however, the larger slot allows more freedom to allow the probe to fit easily into the gap between the stators. Installing the probe into the smaller slot is more difficult due to the smaller space available, R in this case, the probe face initially contacts the corner of the lower stator platform (Refer to figure 18). 2. To install the probe to the smaller slot, first angle the head of the probe upwards a few degrees by gently rotating the probe head on the attachment bolt. Holding the manipulator as low as possible during entry, will allow the probe to slide upwards as it enters the slot avoiding the corner of the stator. When installed, the manipulator assembly should be pushed on to the liner to ensure contact and to center the probe. 3. During withdrawal, the probe will contact the inner surface of the stator platform preventing withdrawal. By applying gentle pressure to the manipulator, and again adjusting the probe head angle, whilst the probe is still in the engine, the probe will be able to be withdrawn. Excessive force must not be used during removal.



# V2500−ENG−72−0608 Page 17 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) Use R CoMat 10-058 to lightly oil the threads of the mounting bolts. Offer the probe to the forward side of the HP compressor bleed valve port (Refer to Figure 12) through the bleed slot adjacent to the flat-headed D bolt. Carefully allow the probe to enter the HP compressor casing until it contacts the ceramic liner. Carefully slide the manipulator mounting plate up to the bleed valve flange. Manually screw the bolts into the bolt holes ensuring the mounting plate remains in contact with the bleed valve flange and the probe manipulator assembly is free to move. Tighten the bolts alternately whilst checking the probe manipulator assembly remains free to move. NOTE : Do not force the manipulator or damage may occur to the probe and engine. R R If the probe is difficult to insert, more material should be removed from the first and second walls of the heatshield retainer. R R (4) When correctly installed, the probe manipulator assembly should be able to slide freely in the mounting block and be able to make contact with the liner. Figure 13 shows the manipulator assembly correctly installed to the engine. G. Inspect the disc (1) Open the water couplant valve fully and turn the HP compressor in a clockwise direction until the probe is positioned between the two locking nuts of the stage 7 R locking blades (Refer to Figure 20). Apply light inward pressure and make sure the probe is coupled with the liner by watching the flaw detector time base response. Withdraw the probe manipulator assembly slightly and watch the change in time base display when the probe is not coupled. Return the probe to the coupled position.
NOTE : Water levels in the container must be monitored throughout the inspection. If the container is found to be empty during the inspection, the container must be refilled and the inspection repeated. (2) When the probe is coupled, zero the turning tool counter number datum and begin the inspection. If the HP compressor is being turned manually, use a borescope to locate a datum feature that can be used to confirm a complete rotation of the drum.
NOTE : 1. The flaw detector should be monitored for signals that move along the timebase in the gated area. Any ultrasonic responses that break the alarm gate, will cause the engine to be rejected (Refer to Figure 16). 2. During inspection monitor the distilled or de-ionised R water level, replenish as necessary. 

# V2500−ENG−72−0608 Page 18 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) The flaw detector should be monitored for signals that move along the timebase in the gated area. Any ultrasonic responses that break the alarm gate (40%), will cause the engine to be rejected (Refer to Figure 11). (4) Cracks that have developed on the inner surface of the disc will appear (maximize) R within the gate on the time base at half skip distance (Refer to Figure 11). (5) Inspect the full circumference of the disc, if the ceramic liner allows. R (6) If turning tool is used, record the amplitude and timebase position R indications over the threshold. Record R the degree position on the accomplishment proforma.
CAUTION : LIFT THE PROBE CLEAR OF THE CERAMIC LINER BEFORE YOU REVERSE THE DIRECTION OF THE HP COMPRESSOR, TO PREVENT DAMAGE TO THE PROBE. (7) If the probe 'picks up' or 'chatters' when the HP compressor is rotated in a clockwise direction, rotate R the HP compressor in a counterclockwise direction and repeat the inspection.
NOTE : 1. It is expected that there may be differences in signals when the HP compressor is rotated in different directions. This is because the direction of rotation changes the way the probe sits on the liner. Additionally, the water comes in from one direction only, which affects the function of the couplant, It is recommended not to change the direction of rotation during an inspection pass. 2. Missing stage 7-8 R liner directly underneath the path of the probe may cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation. 3. The borescope inspection is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the ultrasonic inspection determine further engine serviceability.



# V2500−ENG−72−0608 Page 19 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.H. Remove the probe manipulator assembly from the engine (1) On completion of the inspection, close the water valve and remove the water supply tube from the manipulator. Undo the bolts and carefully ease the manipulator from the bleed valve port.
NOTE : Remove with care. The socket of the spanner R can fall into the engine.
CAUTION : DO NOT USE EXCESSIVE FORCE TO REMOVE THE PROBE MANIPULATOR ASSEMBLY FROM THE ENGINE. R R (2) Close the lock plate and remove the flange mount bolts. Carefully remove the probe manipulator assembly from the engine. (3) Make sure all parts of the probe manipulator assembly are present and undamaged. I. Make a check of the ultrasonic equipment calibration (1) Make a check of the calibration of the ultrasonic equipment after the inspection is completed. Carry out the check in accordance with paragraph 3.E. (1) to (4). If the calibration is under sensitive by more than 3dB, re-calibrate the ultrasonic equipment and carry out an inspection of the disc again. J. Accept and reject criteria (1) Any ultrasonic response in the gated area above or at the amplitude of 40 percent FSH - reject the engine. R R (2) Any ultrasonic response in the gated area below the amplitude of 40 percent FSH - accept. R R K. General Use inspection kit IAE2R19873 to carry out an ultrasonic inspection on the inner diameter of the HP compressor stage 8 disc adjacent to the stage 7-8 EB weld land.
NOTE : In order to reduce the potential for multiple-engine in-flight shutdown, power loss, or other anomaly due to maintenance error, IAE recommends that Operators avoid performing maintenance on multiple engines installed on the same aircraft at the same time. If it is not possible to avoid maintenance on more than one engine of an aircraft at the same time, IAE recommends that additional controls are applied in order to ensure that maintenance tasks have been completed as defined.



# V2500−ENG−72−0608 Page 20 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.WARNING : YOU MUST BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE IS STOPPED. THE ENGINE PARTS CAN STAY HOT FOR ALMOST ONE HOUR.
WARNING : DO NOT TOUCH HOT PARTS WITHOUT APPLICABLE GLOVES. HOT PARTS CAN CAUSE AN INJURY. R (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. (2) Consumable Materials (a) Refer to the table that follows:
MATERIAL NO. DESIGNATION V01-201 Distilled or De-ionised water V10-058 Penetrating Oil For the details of the consumable materials given in the table above, refer to the Aircraft Maintenance Manual (AMM) TASK 70-30-00-910-801. (3) Tools and Equipment (a) Refer to the table that follows:
ITEM DESCRIPTION TOOL NUMBER (a) Inspection kit contains the inner diameter location inspection items (b) to (e) listed in this table and the outer diameter location inspection items (b) to (e) listed in the table in section 3.A.(3)(a) of this

Non-Modification Service Bulletin IAE2R19873

(b) Ultrasonic probe manipulator assembly contains 45 degree shear wave ultrasonic inspection probe IAE2R19876

(c) Couplant feed system IAE2R19807 (d) Inner diameter location working standard IAE2R19860 (e) MCX/BNC lead IAE2R19755 (f) Ultrasonic flaw detector, frequency selectable in the 5.0 MHz range with audible/visual electronic alarm gate Not supplied

(g) Distilled or De-ionised water Not supplied (h) Turning tool (if applicable) Not supplied (i) 4 to 6 mm flexible borescope kit with image capture capability Not supplied (j) 8 mm NC-centralising drill bit (90 degree cutting angle, HSCO material TiN coated) Generic, eg Forum # 4211506022 or equivalent - Not supplied (k) Inner diameter location drilling guide tool IAE1R19881 

# V2500−ENG−72−0608 Page 21 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(l) Bolts (2 off) AS48516 or 4W0170 R R not supplied (m) Washers to fit item (j) Not supplied (n) Vacuum cleaner and hose Not supplied (o) Cloth Not supplied (p) Hand-held electric drill Not supplied (q) Penetrating oil Not supplied (r) Portable hand grinding equipment Not supplied
NOTE : 1. The lead for the ultrasonic probe is supplied with a BNC connector installed. An adaptor may be required if alternative equipment is used. 2. The compressor can be turned manually, but an electronic turning tool is recommended to perform the inspection. 3. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. L. Calibrate the ultrasonic equipment Range 59mm (nominal) Material velocity 3100 m/s Delay 0.00 micro seconds Frequency Selectable in the 5.0 MHz range Damping 50 Ohms Rectify Full Pulser Single crystal Gate position 3.0 - 8.0 timebase position
NOTE : 1. The nominal settings above are for a USN 52 or equivalent flaw detector to achieve signal timebase positions. Alternative instruments can require different settings. R R R 2. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. R R (1) Attach the lead to the manipulator/flaw detector, apply the water couplant and position the probe (IAE2R19876) on to the working standard (IAE2R19860) (Refer to Figure 15).



# V2500−ENG−72−0608 Page 22 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(2) With the flat face of the probe seated on the rear face of the working standard and the chamfered corners outward facing, position the probe on the working standard approximately 10.00 mm from the end as shown (Refer to Figure 15). The EDM target is located on the lower rear edge of the working standard.
NOTE : 1. If calibration is carried out with the working standard in contact with a secondary surface, excessive couplant on the base of the working standard i.e. on the surface with EDM target, may allow transfer of sound through the base of the working standard into the secondary surface. This can result in a weak signal and incorrect calibration. R R R R R R 2. During calibration make sure that the probe is flat down on the two contact faces of the working standards. Failure to do so can result in incorrect calibration. R R R 3. Make sure that the probe is positioned correctly on the working standard and the reflected signal is not from the corner of the block. R R R (3) With the probe positioned on the working standard (Refer to Figure 15), identify the response from the EDM target at half skip distance. Maximise the signal response to achieve 70 percent Full Screen Height (FSH) and adjust the range control to position the EDM target signal at five on the timebase. (Refer to Figure 16). (4) Position the gate between the 3.0 and 8.0 divisions on the timebase and set the alarm threshold level at 30 percent FSH for HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386. For all other HP compressor drum P/Ns set the alarm threshold level at 55 percent FSH (Refer to Figure 16). M. Install the manipulator and ultrasonic probe (IAE2R19876) into the engine
CAUTION : DUE TO THE SIMILARITY BETWEEN THE INNER AND OUTER DIAMETER INSPECTION TOOLS, CARE MUST BE TAKEN TO ENSURE THE CORRECT PROBE AND WORKING STANDARD HAVE BEEN SELECTED FOR THE RELEVANT INSPECTION. (1) Position the distilled or de-ionised water container at a suitable position on the engine. Make sure the container is supported above the probe position. Attach the end of the water supply tube to the connector on the rear of the manipulator. Open the valve on the water container and make sure that water flows from the probe face with no sign of air bubbles. When water flows from the probe, close the valve on the water container.



# V2500−ENG−72−0608 Page 23 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(2) Before installing the manipulator/probe into the engine, make sure all parts are secure. Make sure the attachment bolt for the ultrasonic probe is secure, the spring is not bent and the cable is not damaged. Make sure the water tube is removed from the manipulator assembly to allow the probe to be inserted into the engine. R R R
NOTE : 1. Two standards of bleed air slots may be found on engines. The current modification standard has longer elongated slots (Refer to Figure 17) however a number of engines have an earlier modification standard with smaller square slots (Refer to Figure 18). The gaps between the stator platforms are identical, R however, the larger slot allows more freedom to allow the probe to fit easily into the gap between the stators. Installing the probe into the smaller slot is more difficult due to the smaller space available, R in this case, the probe face initially contacts the corner of the lower stator platform (Refer to figure 18). 2. To install the probe to the smaller slot, first angle the head of the probe upwards a few degrees by gently rotating the probe head on the attachment bolt. Holding the manipulator as low as possible during entry, will allow the probe to slide upwards as it enters the slot avoiding the corner of the stator. When installed, the manipulator assembly should be pushed on to the liner to ensure contact and to center the probe. 3. During withdrawal, the probe will contact the inner surface of the stator platform preventing withdrawal. By applying gentle pressure to the manipulator, and again adjusting the probe head angle, whilst the probe is still in the engine, the probe will be able to be withdrawn. Excessive force must not be used during removal.
CAUTION : DO NOT APPLY FORCE TO THE MANIPULATOR OR DAMAGE MAY OCCUR TO THE PROBE AND ENGINE. (3) Use R CoMat 10-058 to lightly oil the threads of the mounting bolts. Offer the probe to the forward side of the HP compressor bleed valve port (Refer to Figure 12) through the bleed slot adjacent to the flat-headed D bolt. Carefully allow the probe to enter the HP compressor casing until it contacts the ceramic liner. Carefully slide the manipulator mounting plate up to the bleed valve flange. Manually screw the bolts into the bolt holes ensuring the mounting plate remains in contact with the bleed valve flange and the probe manipulator assembly is free to move. Tighten the bolts alternately whilst checking the probe manipulator assembly remains free to move. (4) When correctly installed, the probe manipulator assembly should be able to slide freely in the mounting block and be able to make contact with the liner. Figure 13 shows the manipulator assembly installed to the engine. 

# V2500−ENG−72−0608 Page 24 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.N. Inspect the disc (1) Open the water couplant valve fully and turn the HP compressor in a clockwise direction until the probe is positioned between the two locking nuts of the stage 7 R locking blades (Refer to Figure 20). Apply light inward pressure and make sure the probe is coupled with the liner by watching the flaw detector time base response. Withdraw the probe manipulator assembly slightly and watch the change in time base display when the probe is not coupled. Return the probe to the coupled position.
NOTE : Water levels in the container must be monitored throughout the inspection. If the container is found to be empty during the inspection, the container must be refilled and the inspection repeated. (2) When the probe is coupled, zero the turning tool counter number datum and begin the inspection. If the HP compressor is being turned manually, use a borescope to locate a datum feature that can be used to confirm a complete rotation of the drum. R R R R
NOTE : 1. The flaw detector timebase signals must be constantly monitored during the inspection, as no back-wall or geometry signals appear on the timebase and loss of coupling could occur at any time. 2. During inspection monitor the distilled or de-ionised water level, replenish as necessary. (3) The flaw detector should be monitored for signals that move along the timebase in the gated area (30% or 55%). Any ultrasonic responses that break the alarm gate, will cause the engine to be rejected (Refer to Figure 16). (4) Cracks that have developed on the inner surface of the disc will appear (maximize) within the gate R on the time base at half skip distance (Refer to Figure 16). (5) Inspect the full circumference of the disc. (6) If turning tool is used, record the amplitude and timebase position indications over the threshold. Record the degree position on the accomplishment proforma. R R R



# V2500−ENG−72−0608 Page 25 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.CAUTION : LIFT THE PROBE CLEAR OF THE CERAMIC LINER BEFORE YOU REVERSE THE DIRECTION OF THE HP COMPRESSOR, TO PREVENT DAMAGE TO THE PROBE. (7) If the probe 'picks up' or 'chatters' when the HP compressor is rotated in a clockwise direction, rotate R the HP compressor in a counterclockwise direction and repeat the inspection.
NOTE : 1. It is expected that there may be differences in signals when the HP compressor is rotated in different directions. This is because the direction of rotation changes the way the probe sits on the liner. Additionally, the water comes in from one direction only, which affects the function of the couplant, It is recommended not to change the direction of rotation during an inspection pass. 2. Missing stage 7-8 R liner directly underneath the path of the probe may cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation. 3. The borescope inspection is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the ultrasonic inspection determine further engine serviceability. O. Remove the probe manipulator assembly from the engine (1) After R completion of the inspection, close the water valve and remove the water supply tube from the manipulator. Undo the bolts and carefully ease the manipulator from the bleed valve port.
NOTE : Remove with care. The socket of the spanner R can fall into the engine.
CAUTION : DO NOT USE EXCESSIVE FORCE TO REMOVE THE PROBE MANIPULATOR ASSEMBLY FROM THE ENGINE. R R (2) Make sure all parts of the probe manipulator assembly are present and undamaged.



# V2500−ENG−72−0608 Page 26 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.P. Make a check of the ultrasonic equipment calibration (1) Make a check of the calibration of the ultrasonic equipment after the inspection is completed. Carry out the check in accordance with paragraph 3.L. (1) to (4). If the calibration is under sensitive by more than 3dB, re-calibrate the ultrasonic equipment and carry out an inspection of the disc again. (2) If the calibration is satisfactory, disconnect the turning tool and remove it from the engine (a) Remove the turning tool from the accessory gearbox in accordance with the manufacturer's operating instructions (Refer to the Aircraft Maintenance Manual, R TASK 72-00-02-290-802) OR (b) Remove the hand turning tool from the accessory gearbox (Refer to the Aircraft Maintenance Manual, R TASK 72-00-00-810-801).
NOTE : 1. All equipment including the probe manipulator assembly water supply tube and the water bottle should be thoroughly drained and dried before storing, to prevent corrosion. 2. Due to the similarity between the inner and outer diameter inspection kits, care must be taken to ensure the correct probes and working standards are replaced in the correct storage cases. Part numbers of the individual tools are marked on the case labels and on the tools. Q. Accept and reject criteria (1) For HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386: R (a) Any ultrasonic response in the gated area above or at the amplitude of 30 percent FSH - reject the engine. R R (b) Any ultrasonic response in the gated area below the amplitude of 30 percent FSH - accept. R R (2) For all other HP compressor drum P/Ns: R (a) Any ultrasonic response in the gated area above or at the amplitude of 55 percent FSH - reject the engine. R R (b) Any ultrasonic response in the gated area below the amplitude of 55 percent FSH - accept. R R R. Install the HP stage 7A bleed valve air duct on the upper left side of the



# V2500−ENG−72−0608 Page 27 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.engine. (1) Install the HP stage 7A bleed valve air duct together with the HP compressor stage 7A bleed valve R R (a) Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 (approved engine oil) and CoMat 10-094 (anti seize compound). R (b) Put the duct in position on the HP compressor case (with the angle duct to the top) and align the bolt holes. (c) Install the 12 bolts together with the bracket. Torque the bolts to 85 to 105 lbf in. (10 to 12 Nm). S. Make sure that the work area is clean and clear of tools, equipment and other unwanted materials.

T. Close the access to the HP compressor stage 7A bleed valve aperture that is installed on the left side of the engine (1) Close the cowl doors (Refer to the Aircraft Maintenance Manual, Chapter 71-13-00). (2) Do a idle leak check (Refer to the Aircraft Maintenance Manual, Chapter 71-00-00). U. Recording Instructions (1) A record of accomplishment is required. Complete a separate Accomplishment Proforma for outer and inner diameter. R R (2) Record the incorporation of Non-Modification Service Bulletin V2500-ENG-72-0608 in the applicable engine records. R R (3) If the heatshield rework was performed make a note of this in the engine records. R R



# V2500−ENG−72−0608 Page 28 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.INSTRUCTION II - APPLICABLE FOR ENGINES "AT OVERHAUL/SHOP VISIT" V. General

Use inspection kit IAE2R19873 to carry out an ultrasonic inspection on the outer diameter of the HP compressor stage 8 disc adjacent to the stage 7-8 EB weld land. (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. (2) Consumable Materials (a) Refer to the table that follows:
MATERIAL NO. DESIGNATION CoMat 01-201 Distilled or De-ionised water CoMat 10-058 Penetrating Oil CoMat 06-064 Fluorescent Penetrant CoMat 05-020 Waterproof Abrasive Paper CoMat 05-021 Waterproof Abrasive Paper CoMat 05-074 Aluminum Oxide Abrasive Paper For the details of the consumable materials given in the table above, refer to the Overhaul Processes and Consumables Index (PCI).
TASKs R identified by SPP TASK are in the Standard Practices Manual. TASKs identified by EM TASK are in the Engine Manual. (3) Tools and Equipment (a) For inspection of the outer diameter location:
ITEM DESCRIPTION TOOL NUMBER (a) Inspection kit contains the outer diameter location inspection items (b) to (e) listed in this table and the inner diameter location inspection items (b) to (e) listed in the table in section 3.AF.(3)(a) of this

Non-Modification Service Bulletin IAE2R19873

(b) Ultrasonic probe manipulator assembly contains 45 degree shear wave ultrasonic inspection probe IAE2R19874

(c) Couplant feed system IAE2R19807 (d) Outer diameter location working standard IAE2R19854 (e) MCX/BNC lead IAE2R19755 (f) Ultrasonic flaw detector, frequency selectable in the 5.0 MHz range with audible/visual electronic alarm gate Not supplied

(g) Distilled or De-ionised water Not supplied (h) Turning tool (if applicable) Not supplied 

# V2500−ENG−72−0608 Page 29 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(i) 4 to 6 mm flexible borescope kit with image capture capability Not supplied (j) 8 mm NC-centralising drill bit (90 degree cutting angle, HSCO material, TiN coated) Generic, eg Forum # 4211506022 or equivalent - Not supplied (k) Outer diameter location drilling guide tool IAE1R19881 (l) Bolts (2 off) AS48516 or 4W0170 R R not supplied (m) Washers to fit item (l) Not supplied (n) Vacuum cleaner and hose Not supplied (o) Cloth Not supplied (p) Hand-held electric drill Not supplied (q) Penetrating oil Not supplied (r) Portable hand grinding equipment Not supplied
NOTE : 1. The lead for the ultrasonic probe is supplied with a BNC connector installed. An adaptor may be required if alternative equipment is used. 2. The compressor can be turned manually, but an electronic turning tool is recommended to perform the inspection. 3. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. 4. The outer diameter drilling guide tool number is identical to the inner diameter location drilling guide tool number. W. Get access to the HP compressor stage 7A bleed valve aperture that is installed on the upper left side of the engine.

X. Remove the HP stage 7 bleed valve air duct from the upper left side of the engine (1) Remove the HP stage 7A bleed valve air duct together with the HP compressor stage 7A bleed valve R R (Refer to Figure 1 and to the Engine Manual, Chapter 72-00-40) R R (a) Apply the approved penetrating oil CoMat 10-058 before the removal of threaded parts. Let the parts soak at least 15 minutes. (b) Seal all openings to prevent contamination from unwanted materials. (c) Carefully overcome the initial torque of each bolt of the flange to the duct. 

# V2500−ENG−72−0608 Page 30 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(d) Carefully loosen each bolt of the flange to the duct. If excessive resistance is encountered, apply more penetrating oil and allow the bolts to soak for at least 15 minutes before proceeding.
NOTE : Make sure you use the correct size tool for the bolt head and do not force the bolt excessively during the removal process. (e) Repeat step (d) until all bolts have been removed successfully. (f) Remove the duct. (g) If a bolt was broken during the removal process, perform the steps that follow: (i) Remove broken bolts and/or studs by mechanical removal methods. (ii) Drill a hole into the end of the broken bolt and/or stud. Refer to the tool manufacturer's instructions for the correct size of drill. (iii) Put an extraction tool into the drilled hole and lock into position. (iv) Turn the extraction tool to remove the broken bolt. (v) Tap the threads if necessary to clean or chase the threads. (vi) Examine the threads for damage or an oversize condition. (h) If required, replace any inserts (Refer to the Engine Manual, Chapter 70-35-26). (2) For engines which have HP compressor heat shield retainers (pre V2500-ENG-72-0296) or heat shield retainers with heat shields (pre V2500-ENG-72-0477), perform the rework that follows for probe access (a) Prepare inner free area of the bleed port by placing a clean cloth such that no cutting debris can fall into the engine. (b) Attach the drilling guide tool IAE1R19881 to one end of the slotted hole with two bolts R and two washers as shown in figure 2.



# V2500−ENG−72−0608 Page 31 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(c) Insert an 8,00 mm (0.315 in.) drill bit into the drilling guide tool and check whether the drill can reach the heat shield retainer without making contact with the rear outer case bleed port flange;
NOTE : On Pre/Post Service Bulletin V2500-ENG-72-0177 R standard rear outer cases (P/N 6A4407 and 6A5497) R the bleed port flange can prevent the drill from reaching the heat shield retainer. (i) If the drill cannot pass the rear outer case port flange, go to Step. (d). (ii) If the drill passes without touching the rear outer case port flange, go to Step. (k). (d) Remove the drill, loosen the bolts and remove the drilling guide tool. (e) Blend to create a recess in the rear outer case port flange to enable drill access to the heat shield retainer. Remove minimum amount of material possible to enable access, do not exceed the given limits. Use abrasive stones and papers to create the recess ensuring a smooth finish and blend into adjacent areas is achieved. Ensure all burrs and sharp edges are removed and the surface finish is comparable to adjacent areas. Refer to SPP TASK 70-35-03-300-501. Use CoMat 05-020, CoMat 05-021 and/or CoMat 05-074 abrasive papers and portable hand grinding equipment. Refer to Figures 3A and 3B.
CAUTION : NOTE THE MAXIMUM BLEND LIMITS DEFINED IN FIGURE 3B AND ENSURE THEY ARE NOT EXCEEDED AS THIS CAN LEAD TO THE CASE BEING REJECTED UPON INSPECTION. (f) Locally clean and fluorescent penetrant inspect the blended area. Refer to SPP TASK 70-23-05-230-501. Use CoMat 06-064 penetrant with a brush. If cracks are found, reject the case.
CAUTION : ENSURE THE ENGINE IS SUFFICIENTLY PROTECTED WITH THE CLOTH PLACED IN STEP. (A) SO THAT NO SOLVENT OR PENETRANT CAN FALL INTO THE ENGINE. (g) Remove the cloth protecting the engine and wipe away any visible debris. If available, use a vacuum cleaner and hose to remove any further debris. (h) Inspect the flange to ensure the blend limits were not exceeded. If limits are exceeded reject the case. (i) Prepare inner free area of the bleed port by placing a clean cloth such that no cutting debris can fall into the engine. 

# V2500−ENG−72−0608 Page 32 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(j) Attach the drilling guide tool IAE1R19881 to one end of the slotted hole with two bolts (AS48516) and two washers as shown in Figure 2. (k) Insert an 8,00 mm (0.315 in.) drill bit into the drilling guide tool and drill a hole until the second wall of the heat shield retainer is penetrated (Figure R 2 thru Figure 5). (l) Remove the drill, loosen the bolts and slide the guide tool to the other end of the slotted hole and repeat step (k). (m) Repeat steps (k) and (l) between the previously drilled two holes, until the entire opening is created as shown in Figure 4 thru Figure 5. (n) Deburr and remove high material around the corners of the opening using mechanical tools until the probe can be inserted easily. R R Refer to SPP TASK 70-35-03-300-501. (o) Remove the cloth and wipe away any visible debris. If available, use a vacuum cleaner and hose to remove any further debris. Y. Install the HP system turning tool and the borescope (1) Install the turning tool (IAE2R18853) to the accessory gearbox in accordance with the manufacturer's operating instructions (Olympus tool quoted). Install the V2500-D5 software module on the control unit, set the HP compressor rotation speed to the slowest (10 minutes per revolution). Set the HP compressor stage to HPC8 and engage continuous rotation mode. (Refer to the Engine Manual, TASK 72-00-00-200-002).
OR (2) Install the hand turning tool to the accessory gearbox.



# V2500−ENG−72−0608 Page 33 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.CAUTION : IF MATERIAL IS MISSING FROM THE CERAMIC LINER, LIFT THE PROBE OFF THE LINER DURING INSPECTION TO PREVENT DAMAGE TO THE PROBE. (3) Access the liner through the HP compressor Stage 7A bleed valve manifold aperture on the upper left side of the engine (Refer to Figure 5). Insert the flexible borescope and position between the stage seven stator vanes to look down on the surface of the stage seven liner (Refer to Figure 6 thru Figure 8). Make sure the borescope is clear of the stage 8 rotor blades and use the turning tool to rotate the compressor one full revolution. Visually examine the ceramic liner for any missing material, which could damage the ultrasonic probe during the inspection rotation R and any staining or indications of axial cracking (Refer to Figure 9). R A wear line on the liner may be visible at the trailing edge of the stators, this is the approximate seating position of the ultrasonic probe and particular attention should be paid to this area around the circumference of the disc (Refer to Figure 6).
NOTE : If staining or indications of axial cracking is found, contact the local IAE office for further guidance before continuing. R R
NOTE : Missing stage 7-8 R liner material directly underneath the path of the probe may cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation.
NOTE : The borescope inspection for liner material loss is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the borescope inspection for liner cracks or staining determine further engine serviceability. Z. Calibrate the ultrasonic equipment Range 28 mm (nominal) Material velocity 3100 m/s Delay 0.00 micro seconds Frequency Selectable in the 5.0 MHz range Damping 50 Ohms Rectify Full Pulser Single crystal



# V2500−ENG−72−0608 Page 34 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Gate position 4.0 - 6.0 timebase position
NOTE : 1. The nominal settings above are for a USN 52 or equivalent flaw detector to achieve signal timebase positions. Alternative instruments may require different settings. 2. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. (1) Attach the lead to the manipulator/flaw detector, apply the distilled or de-ionised water and position the probe (IAE2R19874) on to the working standard (Refer to Figure 10). (2) With the flat face of the probe seated on the rear face of the working standard and the chamfered corners outward facing, position the probe on the working standard (Refer to Figure 10). The 1.0 mm long by 0.50 mm deep EDM notch is located in the center of the base of the working standard.
NOTE : 1. If calibration is carried out with the working standard in contact with a secondary surface, excessive couplant on the working surface and EDM target surface, may allow transfer of sound into the secondary surface. This can result in a weak signal and incorrect calibration. R R R R R 2. During calibration make sure that the probe is flat down on the two contact faces of the working standards. Failure to do so can result in incorrect calibration. R R R 3. Make sure that the probe is positioned correctly on the working standard and the reflected signal is not from the corner of the block. R R R (3) With the probe positioned on the working standard (Refer to Figure 10), identify the response from the EDM target at half skip distance. Maximise the signal response to achieve 70 percent Full Screen Height (FSH) and adjust the range control to position the EDM target signal at five on the timebase. (Refer to Figure 11). (4) Position the gate between the 4.0 and 6.0 divisions on the time base and set the alarm threshold level at 40 percent FSH.



# V2500−ENG−72−0608 Page 35 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.AA.Install the manipulator (IAE2R19874) and ultrasonic probe into the engine
CAUTION : DUE TO THE SIMILARITY BETWEEN THE INNER AND OUTER DIAMETER INSPECTION TOOLS, CARE MUST BE TAKEN TO ENSURE THE CORRECT PROBE AND WORKING STANDARD HAVE BEEN SELECTED FOR THE RELEVANT INSPECTION. (1) Position the distilled or de-ionised water container at a suitable position on the engine. Make sure the container is supported above the probe position. Attach the end of the water supply tube to the connector on the rear of the manipulator. Open the valve on the water container and make sure that water flows from the probe face with no sign of air bubbles. When water flows from the probe, close the valve on the water container. (2) Before installing the manipulator/probe into the engine, make sure all parts are secure. Make sure the attachment bolt for the ultrasonic probe is secure, the spring is not bent and the cable is not damaged. Make sure the water tube is removed from the manipulator assembly to allow the probe to be inserted into the engine. R R R
NOTE : 1. Two standards of bleed air slots may be found on engines. The current modification standard has longer elongated slots (Refer to Figure 17) however a number of engines have an earlier modification standard with smaller square slots (Refer to Figure 18). The gaps between the stator platforms are identical; however, the larger slot allows more freedom to allow the probe to fit easily into the gap between the stators. Installing the probe into the smaller slot is more difficult due to the smaller space available; in this case, the probe face initially contacts the corner of the lower stator platform (Refer to Figure R 18). 2. To install the probe to the smaller slot, first angle the head of the probe upwards a few degrees by gently rotating the probe head on the attachment bolt. Holding the manipulator as low as possible during entry, will allow the probe to slide upwards as it enters the slot avoiding the corner of the stator. When installed, the manipulator assembly should be pushed on to the liner to ensure contact and to center the probe. 3. During withdrawal, the probe will contact the inner surface of the stator platform preventing withdrawal. By applying gentle pressure to the manipulator, and again adjusting the probe head angle, whilst the probe is still in the engine, the probe will be able to be withdrawn. Excessive force must not be used during removal.



# V2500−ENG−72−0608 Page 36 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) Use CoMat 10-058 to lightly R oil the threads of the mounting bolts. Offer the probe to the forward side of the HP compressor bleed valve port (Refer to Figure 12) through the bleed slot adjacent to the flat-headed D bolt. Carefully allow the probe to enter the HP compressor casing until it contacts the ceramic liner. Carefully slide the manipulator mounting plate up to the bleed valve flange. Manually screw the bolts into the bolt holes ensuring the mounting plate remains in contact with the bleed valve flange and the probe manipulator assembly is free to move. Tighten the bolts alternately whilst checking the probe manipulator assembly remains free to move. NOTE : Do not force the manipulator or damage may occur to the probe and engine. If the probe is difficult to insert, more material should be removed from the first and second walls of the heatshield retainer. R R (4) When correctly installed, the probe manipulator assembly should be able to slide freely in the mounting block and be able to make contact with the liner. Figure 13 shows the manipulator assembly correctly installed to the engine. AB.Inspect the disc (1) Open the water couplant valve fully and turn the HP compressor in a clockwise direction until the probe is positioned between the two locking nuts of the stage 7 R locking blades (Refer to Figure 20). Apply light inward pressure and make sure the probe is coupled with the liner by watching the flaw detector time base response. Withdraw the probe manipulator assembly slightly and watch the change in time base display when the probe is not coupled. Return the probe to the coupled position.
NOTE : Water levels in the container must be monitored throughout the inspection. If the container is found to be empty during the inspection, the container must be refilled and the inspection repeated. (2) When the probe is coupled, zero the turning tool counter number datum and begin the inspection. If the HP compressor is being turned manually, use a borescope to locate a datum feature that can be used to confirm a complete rotation of the drum.
NOTE : 1. The flaw detector should be monitored for signals that move along the timebase in the gated area. Any ultrasonic responses that break the alarm gate, will cause the engine to be rejected (Refer to Figure 16). 2. During inspection monitor the distilled or de-ionised water level, replenish as necessary. 

# V2500−ENG−72−0608 Page 37 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) The flaw detector should be monitored for signals that move along the timebase in the gated area. Any ultrasonic responses that break the alarm gate (40%), will cause the engine to be rejected (Refer to Figure 11). (4) Cracks that have developed on the inner surface of the disc will appear (maximise) within the gate R on the time base at half skip distance (Refer to Figure 11). R (5) Inspect the full circumference of the disc, if the ceramic liner allows. R (6) If turning tool is used, record indications over the threshold and the degree position in the accomplishment proforma. R R
CAUTION : LIFT THE PROBE CLEAR OF THE CERAMIC LINER BEFORE YOU REVERSE THE DIRECTION OF THE HP COMPRESSOR, TO PREVENT DAMAGE TO THE PROBE. (7) If the probe 'picks up' or 'chatters' when the HP compressor is rotated in a clockwise direction, rotate R the HP compressor in a counterclockwise direction and repeat the inspection.
NOTE : 1. It is expected that there may be differences in signals when the HP compressor is rotated in different directions. This is because the direction of rotation changes the way the probe sits on the liner. Additionally, the water comes in from one direction only, which affects the function of the couplant, It is recommended not to change the direction of rotation during an inspection pass. 2. Missing stage 7-8 R liner directly underneath the path of the probe may cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation. 3. The borescope inspection is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the ultrasonic inspection determine further engine serviceability.



# V2500−ENG−72−0608 Page 38 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.AC.Remove the probe manipulator assembly from the engine (1) After completion of the inspection, close the water valve and remove the water supply tube from the manipulator. Undo the bolts and carefully ease the manipulator from the bleed valve port.
NOTE : Remove with care. The socket of the spanner R can fall into the engine.
CAUTION : DO NOT USE EXCESSIVE FORCE TO REMOVE THE PROBE MANIPULATOR ASSEMBLY FROM THE ENGINE. R R (2) Make sure all parts of the probe manipulator assembly are present and undamaged. AD.Make a check of the ultrasonic equipment calibration (1) Make a check of the calibration of the ultrasonic equipment after the inspection is completed. Carry out the check in accordance with paragraph 3.Z. (1) to (4). If the calibration is under sensitive by more than 3dB, re-calibrate the ultrasonic equipment and carry out an inspection of the disc again. AE.Accept and reject criteria (1) Any ultrasonic response in the gated area above or at the amplitude of 40 percent FSH - reject the engine. R R (2) Any ultrasonic response in the gated area below the amplitude of 40 percent FSH - accept. R R AF.General Use inspection kit IAE2R19873 to carry out an ultrasonic inspection on the inner diameter of the HP compressor stage 8 disc adjacent to the stage 7-8 EB weld land. (1) Obey all the WARNINGS and CAUTIONS in the procedures that are referred to. (2) Consumable Materials (a) Refer to the table that follows:
MATERIAL NO. DESIGNATION CoMat 01-201 Distilled or De-ionised water CoMat 10-058 Penetrating Oil For the details of the consumable materials given in the table above, refer to the Overhaul Processes and Consumables Index. 

# V2500−ENG−72−0608 Page 39 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(3) Tools and Equipment (a) Refer to the table that follows:
ITEM DESCRIPTION TOOL NUMBER (a) Inspection kit contains the inner diameter location inspection items (b) to (e) listed in this table and the outer diameter location inspection items (b) to (e) listed in the table in section 3.V.(3)(a) of this

Non-Modification Service Bulletin IAE2R19873

(b) Ultrasonic probe manipulator assembly contains 45 degree shear wave ultrasonic inspection probe IAE2R19876

(c) Couplant feed system IAE2R19807 (d) Inner diameter location working standard IAE2R19860 (e) MCX/BNC lead IAE2R19755 (f) Ultrasonic flaw detector, frequency selectable in the 5.0 MHz range with audible/visual electronic alarm gate Not supplied

(g) Distilled or De-ionised water Not supplied (h) Turning tool (if applicable) Not supplied (i) 4 to 6 mm flexible borescope kit with image capture capability Not supplied (j) 8 mm NC-centralising drill bit (90 degree cutting angle, HSCO material TiN coated) Generic, eg Forum # 4211506022 or equivalent - Not supplied (k) Inner diameter location drilling guide tool IAE1R19881 (l) Bolts (2 off) AS48516 or 4W0170 R R not supplied (m) Washers to fit item (j) Not supplied (n) Vacuum cleaner and hose Not supplied (o) Cloth Not supplied (p) Hand-held electric drill Not supplied (q) Penetrating oil Not supplied (r) Portable hand grinding equipment Not supplied
NOTE : 1. The lead for the ultrasonic probe is supplied with a BNC connector installed. An adaptor may be required if alternative equipment is used. 2. The compressor can be turned manually, but an electronic turning tool is recommended to perform the inspection. 3. Care should be taken to keep the two working standards IAE2R19854 and IAE2R19860 separate. 

# V2500−ENG−72−0608 Page 40 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.AG.Calibrate the ultrasonic equipment Range 59mm (nominal) Material velocity 3100 m/s Delay 0.00 micro seconds Frequency Selectable in the 5.0 MHz range Damping 50 Ohms Rectify Full Pulser Single crystal Gate position 3.0 - 8.0 timebase position
NOTE : The nominal settings above are for a USN 52 or equivalent flaw detector to achieve approximate signal timebase positions. Alternative instruments may require different settings. (1) Attach the lead to the manipulator/flaw detector, apply the water couplant and position the probe on to the working standard (Refer to Figure 15). (2) With the flat face of the probe seated on the rear face of the working standard and the chamfered corners outward facing, position the probe on the working standard approximately 10.00 mm from the end as shown (Refer to Figure 15). The EDM target is located on the lower rear edge of the working standard.
NOTE : 1. If calibration is carried out with the working standard in contact with a secondary surface, excessive couplant on the base of the working standard i.e. on the surface with EDM target, may allow transfer of sound through the base of the working standard into the secondary surface. This can result in a weak signal and incorrect calibration. R R R R R R 2. During calibration make sure that the probe is flat down on the two contact faces of the working standards. Failure to do so can result in incorrect calibration. R R R 3. Make sure that the probe is positioned correctly on the working standard and the reflected signal is not from the corner of the block. R R R (3) With the probe positioned on the working standard (Refer to Figure 15), identify the response from the EDM target at half skip distance. Maximise the signal response to achieve 70 percent Full Screen Height (FSH) and adjust the range control to position the EDM target signal at five on the timebase. (Refer to Figure 16). (4) Position the gate between the 3.0 and 8.0 divisions on the timebase and set the alarm threshold level at 30 percent FSH for HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386. For all other HP compressor drum P/Ns set the alarm threshold level at 55 percent FSH (Refer to Figure 16). 

# V2500−ENG−72−0608 Page 41 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.AH.Install the manipulator and ultrasonic probe (IAE2R19876) into the engine
CAUTION : DUE TO THE SIMILARITY BETWEEN THE INNER AND OUTER DIAMETER INSPECTION TOOLS, CARE MUST BE TAKEN TO ENSURE THE CORRECT PROBE AND WORKING STANDARD HAVE BEEN SELECTED FOR THE RELEVANT INSPECTION. (1) Position the distilled or de-ionised water container at a suitable position on the engine. Make sure the container is supported above the probe position. Attach the end of the water supply tube to the connector on the rear of the manipulator. Open the valve on the water container and make sure that water flows from the probe face with no sign of air bubbles. When water flows from the probe, close the valve on the water container. (2) Before installing the manipulator/probe into the engine, make sure all parts are secure. Make sure the attachment bolt for the ultrasonic probe is secure, the spring is not bent and the cable is not damaged. Make sure the water R R tube is removed from the manipulator assembly to allow the probe to be inserted into the engine. R
NOTE : 1. Two standards of bleed air slots may be found on engines. The current modification standard has longer elongated slots (Refer to Figure 17) however a number of engines have an earlier modification standard with smaller square slots (Refer to Figure 18). The gaps between the stator platforms are identical; however, the larger slot allows more freedom to allow the probe to fit easily into the gap between the stators. Installing the probe into the smaller slot is more difficult due to the smaller space available; in this case, the probe face initially contacts the corner of the lower stator platform (Refer to figure 18). 2. To install the probe to the smaller slot, first angle the head of the probe upwards a few degrees by gently rotating the probe head on the attachment bolt. Holding the manipulator as low as possible during entry, will allow the probe to slide upwards as it enters the slot avoiding the corner of the stator. When installed, the manipulator assembly should be pushed on to the liner to ensure contact and to center the probe. 3. During withdrawal, the probe will contact the inner surface of the stator platform preventing withdrawal. By applying gentle pressure to the manipulator, and again adjusting the probe head angle, whilst the probe is still in the engine, the probe will be able to be withdrawn. Excessive force must not be used during removal.



# V2500−ENG−72−0608 Page 42 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.CAUTION : DO NOT APPLY FORCE TO THE MANIPULATOR OR DAMAGE MAY OCCUR TO THE PROBE AND ENGINE. (3) Use CoMat 10-058 to lightly R oil the threads of the mounting bolts. Offer the probe to the forward side of the HP compressor bleed valve port (Refer to Figure 12) through the bleed slot adjacent to the flat-headed D bolt. Carefully allow the probe to enter the HP compressor casing until it contacts the ceramic liner. Carefully slide the manipulator mounting plate up to the bleed valve flange. Manually screw the bolts into the bolt holes ensuring the mounting plate remains in contact with the bleed valve flange and the probe manipulator assembly is free to move. Tighten the bolts alternately whilst checking the probe manipulator assembly remains free to move. (4) When correctly installed, the probe manipulator assembly should be able to slide freely in the mounting block and be able to make contact with the liner. Figure 13 shows the manipulator assembly installed to the engine. AI.Inspect the disc (1) Open the water couplant valve fully and turn the HP compressor in a clockwise direction until the probe is positioned between the two locking nuts of the stage 7 R locking blades (Refer to Figure 20). Apply light inward pressure and make sure the probe is coupled with the liner by watching the flaw detector time base response. Withdraw the probe manipulator assembly slightly and watch the change in time base display when the probe is not coupled. Return the probe to the coupled position.
NOTE : Water levels in the container must be monitored throughout the inspection. If the container is found to be empty during the inspection, the container must be refilled and the inspection repeated. (2) When the probe is coupled, zero the turning tool counter number datum and begin the inspection. If the HP compressor is being turned manually, use a borescope to locate a datum feature that can be used to confirm a complete rotation of the drum.
NOTE : 1. The flaw detector timebase signals must be constantly monitored during the inspection, as no back-wall or geometry signals appear on the timebase and loss of coupling could occur at any time. 2. During inspection monitor the distilled or de-ionised water level, replenish as necessary. (3) The flaw detector should be monitored for signals that move along the timebase in the gated area (30% or 55%). Any ultrasonic responses that break the alarm gate, will cause the engine to be rejected (Refer to Figure 16). R R R R 

# V2500−ENG−72−0608 Page 43 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(4) Cracks that have developed on the inner surface of the disc will appear within the gate R on the time base at half skip distance (Refer to Figure 16). R (5) Inspect the full circumference of the disc, if the ceramic liner allows. R (6) If turning tool is used, record indications over the threshold and the degree position in the accomplishment proforma. R R
CAUTION : LIFT THE PROBE CLEAR OF THE CERAMIC LINER BEFORE YOU REVERSE THE DIRECTION OF THE HP COMPRESSOR, TO PREVENT DAMAGE TO THE PROBE. (7) If the probe 'picks up' or 'chatters' when the HP compressor is rotated in a clockwise direction, rotate R the HP compressor in a counterclockwise direction and repeat the inspection.
NOTE : 1. It is expected that there may be differences in signals when the HP compressor is rotated in different directions. This is because the direction of rotation changes the way the probe sits on the liner. Additionally, the water comes in from one direction only, which affects the function of the couplant, It is recommended not to change the direction of rotation during an inspection pass. 2. Missing stage 7-8 R liner directly underneath the path of the probe may cause damage to the probe, requiring the probe to be lifted off the liner during inspection. If liner loss under the path of the probe is found, this must be noted on the Accomplishment Proforma, as well as the percentage of the circumference which was not ultrasonically inspected. If damage is detected on the pre-inspection assessment, the borescope should be inserted during the ultrasonic inspection to monitor the liner during rotation. 3. The borescope inspection is required to ensure clearance of the rotor path for the ultrasonic probe. This is recorded for information only, and does not need to be stamped off as part of the formal accomplishment records. The results of the ultrasonic inspection determine further engine serviceability. AJ.Remove the probe manipulator assembly from the engine (1) On completion of the inspection, close the water valve and remove the water supply tube from the manipulator. Undo the bolts and carefully ease the manipulator from the bleed valve port.
NOTE : Remove with care. The socket of the spanner R can fall into the engine.
CAUTION : DO NOT USE EXCESSIVE FORCE TO REMOVE THE PROBE MANIPULATOR ASSEMBLY FROM THE ENGINE. R R 

# V2500−ENG−72−0608 Page 44 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.(2) Close the lock plate and remove the flange mount bolts. Carefully remove the probe manipulator assembly from the engine. (3) Make sure all parts of the probe manipulator assembly are present and undamaged. AK.Make a check of the ultrasonic equipment calibration (1) Make a check of the calibration of the ultrasonic equipment after the inspection is completed. Carry out the check in accordance with paragraph 3.AG. (1) to (4). If the calibration is under sensitive by more than 3dB, re-calibrate the ultrasonic equipment and carry out an inspection of the disc again. (2) If the calibration is satisfactory, disconnect the turning tool and remove it from the engine (a) Remove the turning tool from the accessory gearbox in accordance with the manufacturer's operating instructions (Refer to the Engine Manual, Chapter 72-00-00). R (b) Remove the hand turning tool from the accessory gearbox.
NOTE : 1. All equipment including the probe manipulator assembly water supply tube and the water bottle should be thoroughly drained and dried before storing, to prevent corrosion. 2. Due to the similarity between the inner and outer diameter inspection kits, care must be taken to ensure the correct probes and working standards are replaced in the correct storage cases. Part numbers of the individual tools are marked on the case labels and on the tools. AL.Accept and reject criteria (1) For HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386: R (a) Any ultrasonic response in the gated area above or at the amplitude of 30 percent FSH - reject the engine. R R (b) Any ultrasonic response in the gated area below the amplitude of 30 percent FSH - accept. R R (2) For all other HP compressor drum P/Ns: R (a) Any ultrasonic response in the gated area above or at the amplitude of 55 percent FSH - reject the engine. R R (b) Any ultrasonic response in the gated area below the amplitude of 55 percent FSH - accept. R R 

# V2500−ENG−72−0608 Page 45 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.AM.Install the HP stage 7A bleed valve air duct on the left side of the engine. (1) Install the HP stage 7A bleed valve air duct together with the HP compressor stage 7A bleed valve (Refer to the Engine Manual, Chapter 72-00-40) R R R (a) Lubricate all threads and abutment faces of nuts and bolts with CoMat 10-077 (approved engine oil) and CoMat 10-094 (anti seize compound). R (b) Put the duct in position on the HP compressor case (with the angle duct to the top) and align the bolt holes. (c) Install the 12 bolts together with the bracket. Torque the bolts to 85 to 105 lbf in. (10 to 12 Nm). AN.Make sure that the work area is clean and clear of tools, equipment and other unwanted materials.

AO.Recording Instructions (1) A record of accomplishment is required. Complete a separate R Accomplishment Proforma for outer and inner diameter. R (2) Record the incorporation of Non-Modification Service Bulletin V2500-ENG-72-0608 R in the applicable engine records. (3) If the heatshield and/or casing rework was performed make a note of this in the engine records.



# V2500−ENG−72−0608 Page 46 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

HP Compressor Bleed Valve and Support Duct R Figure 1 R 

# V2500−ENG−72−0608 Page 47 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 2 and Figure 3 

# V2500−ENG−72−0608 Page 48 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.View of Rear Outer Case Bleed Port Flange Blend Recess

Figure 3A 

# V2500−ENG−72−0608 Page 49 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Detailed View of Rear Outer Case Bleed Port Flange Showing Blend Limits Figure 3B 

# V2500−ENG−72−0608 Page 50 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.View of Finished Rework Opening Figure 4 

# V2500−ENG−72−0608 Page 51 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Diagrammatic Views for Rework Figure 5 

# V2500−ENG−72−0608 Page 52 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Boroscope View Showing the Liner, Stage 7 Stator Vanes and Stage 8 Rotor Blades Figure 6 

# V2500−ENG−72−0608 Page 53 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.HPC Outer Diameter Probe in Position Figure 7 

# V2500−ENG−72−0608 Page 54 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.HPC Section Figure 8 

# V2500−ENG−72−0608 Page 55 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

Typical Damage to the Ceramic Liner R Figure 9 R 

# V2500−ENG−72−0608 Page 56 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Ultrasonic Probe Positioned on Working Standard Figure 10 

# V2500−ENG−72−0608 Page 57 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Signal from EDM Target on Working Standard at Half Skip Distance Figure 11 

# V2500−ENG−72−0608 Page 58 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.View of Bleed Valve Port Access Point and Manipulator Attachment Bolt Holes Figure 12 

# V2500−ENG−72−0608 Page 59 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Manipulator Installed to the Bleed Valve Port Figure 13 

# V2500−ENG−72−0608 Page 60 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.HPC Section - Inner Diameter Probe in Position Figure 14 

# V2500−ENG−72−0608 Page 61 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Ultrasonic Probe Positioned on Working Standard Figure 15 

# V2500−ENG−72−0608 Page 62 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 16 (Sheet 1 of 2) 

# V2500−ENG−72−0608 Page 63 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 16 (Sheet 2 of 2) 

# V2500−ENG−72−0608 Page 64 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.Figure 17 and Figure 18 

# V2500−ENG−72−0608 Page 65 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

Explanation examples for the grace period (FPI) R Figure 19 R 

# V2500−ENG−72−0608 Page 66 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

Ultrasonic start position R Figure 20 R 

# V2500−ENG−72−0608 Page 67 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.R

Accomplishment Proforma R Table 1 R 

# V2500−ENG−72−0608 Page 68 May 5/10 Sep.20/11 Revision 3 IAE PROPRIETARY INFORMATION © IAE International Aero Engines AG. All rights reserved.

# SERVICE BULLETIN FEEDBACK FORM

Sep.20/11 IAE PROPRIETARY INFORMATION V2500-ENG-72-0 608 Revision 3 © IAE International Aero E ngines AG. All rights reserved. Page 1 of 1 

### Please use this form to give feedback on the quality of this Service Bulletin. The input you provide will be used to analyse areas of improvement and to take action to further improve on the quality of our Service Bulletins. We thank you for the time you spent in completing this form. Please rate on a scale of 1 to 5, with 5 being the highest score:

- General quality rating of this Service Bulletin W 1 W 2 W 3 W 4 W 5 - Quality rating of the Accomplishment Instructions W 1 W 2 W 3 W 4 W 5 - Quality rating of the Illustration W 1 W 2 W 3 W 4 W 5 - Is this Service Bulletin easy to understand ? W Yes W No If you have had difficulties to perform this Service Bulletin please quote below the area(s) and give a short description of the issue: Planning Information Section: Material Information Section: Accomplishment Instruction Section: W

1.A. W 1.I. W 2.A. W General W

1.B. W 1.J. W 2.B. W Get Access W

1.C. W 1.K. W 2.C. W Removal/Installation W

1.D. W 1.L. W 2.D. W Inspection W

1.E. W 1.M. W 2.E. W Test W

1.F. W 1.N. W 2.F. W Close the Access W

1.G. W 1.O. W Log Book Entry W

1.H W 1.P.

Operator: Explanatory notes:

Overhaul Site: Name/Title: Date: Please send the completed Service Bulleti n Feedback Form to IAE, Customer Support. Email: GPIAECUSTCOM@IAEV2500.COM