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

R during overhaul. stage 3-8 drum assembly

(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

R Non-Modification Service Bulletin instructs ultrasonic inspection This

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.

R this Non-Modification Service Bulletin NOTE: The Accomplishment Instruction of

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

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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

R Threshold 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

NMSB

V2500-ENGR

R

R

R

R 72-0608.

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

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R Compliance times

V2500−ENG−72−0608

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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

R FPI Grace Period

R Permitted Grace Period Required Engine Condition

R (Shop Visit)

R 2500 Cycles 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

R Figure 19 provides a calculation example for the FPI Grace Period.

R ECI Grace Period

R Permitted Grace Period Required Engine Condition

R (Shop Visit)

R 13000 Cycles Inspected in accordance with Service Bulletin

R V2500-ENG-72-0625

R and

R Service Bulletin V2500-ENG-72-0596 incorporated

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

R for the engine models listed. Regulations and are FAA-APPROVED

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

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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

R accepted by the applicable National alternative standards/guidelines

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

R Not applicable.

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

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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".

R (7) Engineering Change No. 10VR659C.

L. Other Publications Affected

None.

M. Interchangeability of Parts

Not applicable.

V2500−ENG−72−0608

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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

R Not applicable.

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:

R (1) Submit a zero charge PO to IAE Spares (GPIAESPRTLG@IAEV2500.com) 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:

R (3) Submit an e-mail request to GPIAESPRTLG@IAEV2500.com. 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

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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

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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

R AN INJURY.

(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

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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

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
on the left upper side of the engine

R (1) Open the applicable cowl doors (Refer to the Aircraft Maintenance Manual,

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

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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

R and two washers as shown in Figure 2. hole with two bolts

(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.

R NOTE: On Pre/Post Service Bulletin V2500-ENG-72-0177 standard rear

R outer cases (P/N 6A4407 and 6A5497) 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

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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.

R (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 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.

R (Refer to the Aircraft Maintenance Manual, TASK 72-00-02-290-801).

OR

(2) Install the hand turning tool to the accessory gearbox (Refer to the

R TASK 72-00-00-810-801). Aircraft Maintenance Manual,

V2500−ENG−72−0608

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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,

R which could damage the ultrasonic probe during the inspection rotation and

R any staining or indications of axial cracking (Refer to Figure 9). 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

R liner material directly underneath the path of NOTE: Missing stage 7-8

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

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© 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.

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© 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

R however, the larger slot allows more freedom to identical,

allow the probe to fit easily into the gap between the stators.

Installing the probe into the smaller slot is more difficult

R 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.

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© IAE International Aero Engines AG. All rights reserved.
R CoMat 10-058 to lightly oil the threads of the mounting bolts. Offer (3) Use

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

R locking blades (Refer to Figure 20). Apply light nuts of the stage 7

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).

R 2. During inspection monitor the distilled or de-ionised water

level, replenish as necessary.

V2500−ENG−72−0608

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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

R within the gate on the time base at half skip distance (Refer (maximize)

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 the amplitude and timebase position

R the degree position on the indications over the threshold. Record

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

R the HP compressor in a counterclockwise a clockwise direction, rotate

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.

R liner directly underneath the path of the 2. Missing stage 7-8

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

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© 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.

R NOTE: Remove with care. The socket of the spanner 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

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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

R AN INJURY.

(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

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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).

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© 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.

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© 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

R however, the larger slot allows more freedom to identical,

allow the probe to fit easily into the gap between the stators.

Installing the probe into the smaller slot is more difficult

R 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.

CAUTION: DO NOT APPLY FORCE TO THE MANIPULATOR OR DAMAGE MAY OCCUR TO THE

PROBE AND ENGINE.

R CoMat 10-058 to lightly oil the threads of the mounting bolts. Offer (3) Use

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

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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

R locking blades (Refer to Figure 20). Apply light nuts of the stage 7

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

R on the time base at half skip distance (Refer (maximize) within the gate

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

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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

R the HP compressor in a counterclockwise a clockwise direction, rotate

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.

R liner directly underneath the path of the 2. Missing stage 7-8

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

R completion of the inspection, close the water valve and remove the (1) After

water supply tube from the manipulator. Undo the bolts and carefully ease

the manipulator from the bleed valve port.

R NOTE: Remove with care. The socket of the spanner 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.

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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

R TASK 72-00-02-290-802) OR Maintenance Manual,

(b) Remove the hand turning tool from the accessory gearbox (Refer to the

R TASK 72-00-00-810-801). Aircraft Maintenance Manual,

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

R (1) For HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386:

(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

R (2) For all other HP compressor drum P/Ns:

(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

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© 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

R 10-077 (approved engine oil) and CoMat 10-094 (anti seize compound).

(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

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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).

R identified by SPP TASK are in the Standard Practices Manual. TASKs

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

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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.

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© 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

R and two washers as shown in figure 2. hole with two bolts

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© 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;

R NOTE: On Pre/Post Service Bulletin V2500-ENG-72-0177 standard rear

R outer cases (P/N 6A4407 and 6A5497) 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.

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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

R 2 thru Figure 5). penetrated (Figure

(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

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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,

R which could damage the ultrasonic probe during the inspection rotation and

R any staining or indications of axial cracking (Refer to Figure 9). 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

R liner material directly underneath the path of NOTE: Missing stage 7-8

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

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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

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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

R 18). (Refer to Figure

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

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R oil the threads of the mounting bolts. Offer (3) Use CoMat 10-058 to lightly

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

R locking blades (Refer to Figure 20). Apply light nuts of the stage 7

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.

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© 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

R on the time base at half skip distance (Refer (maximise) within the gate

R to Figure 11).

R (5) Inspect the full circumference of the disc, if the ceramic liner allows.

(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

R the HP compressor in a counterclockwise a clockwise direction, rotate

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.

R liner directly underneath the path of the 2. Missing stage 7-8

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

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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.

R NOTE: Remove with care. The socket of the spanner 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

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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

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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

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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

R to be inserted into the engine.

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

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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.

R oil the threads of the mounting bolts. Offer (3) Use CoMat 10-058 to lightly

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

R locking blades (Refer to Figure 20). Apply light nuts of the stage 7

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

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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

R on the time base at half skip distance (Refer to Figure within the gate

R 16).

R (5) Inspect the full circumference of the disc, if the ceramic liner allows.

(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

R the HP compressor in a counterclockwise a clockwise direction, rotate

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.

R liner directly underneath the path of the 2. Missing stage 7-8

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.

R NOTE: Remove with care. The socket of the spanner 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

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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

R Manual, Chapter 72-00-00).

(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

R (1) For HP compressor drum P/N 6A7705, 6A8316, 6B1385 and 6B1386:

(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

R (2) For all other HP compressor drum P/Ns:

(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

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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

R 10-077 (approved engine oil) and CoMat 10-094 (anti seize compound).

(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

R (1) A record of accomplishment is required. Complete a separate Accomplishment

R Proforma for outer and inner diameter.

(2) Record the incorporation of Non-Modification Service Bulletin

R in the applicable engine records. V2500-ENG-72-0608

(3) If the heatshield and/or casing rework was performed make a note of this

in the engine records.

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R HP Compressor Bleed Valve and Support Duct

R Figure 1

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
Figure 2 and Figure 3

V2500−ENG−72−0608

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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

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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

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
View of Finished Rework Opening

Figure 4

V2500−ENG−72−0608

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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

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Sep.20/11 Revision 3

IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
HPC Section

Figure 8

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R Typical Damage to the Ceramic Liner

R Figure 9

V2500−ENG−72−0608

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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

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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

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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

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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

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
Figure 16 (Sheet 2 of 2)

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
Figure 17 and Figure 18

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R Explanation examples for the grace period (FPI)

R Figure 19

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R Ultrasonic start position

R Figure 20

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
R

R Accomplishment Proforma

R Table 1

V2500−ENG−72−0608

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IAE PROPRIETARY INFORMATION

© IAE International Aero Engines AG. All rights reserved.
 

SERVICE BULLETIN FEEDBACK FORM

Sep.20/11 IAE PROPRIETARY INFORMATION V2500-ENG-72-0608 

Revision 3 © IAE International Aero Engines 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 Bulletin Feedback Form to IAE, Customer Support. 

Email: GPIAECUSTCOM@IAEV2500.COM