TASK 72-00-00-300-013 Repair Damaged Thinwall Insert(s) In The HP Compressor, Rear Outer Case Assembly, With Oversized Insert (KEENSERTS Inserts), Repair-011 (VRS9170)

DMC:V2500-A0-72-00-0000-02A-920A-C|Issue No:002.00|Issue Date:2020-05-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-00-00-300-013 Repair Damaged Thinwall Insert(s) In The HP Compressor, Rear Outer Case Assembly, With Oversized Insert (KEENSERTS Inserts), Repair-011 (VRS9170)

Effectivity

FIG/ITEM

PART NO.

02-400

6A2949

02-400

6A3557

02-400

6A4154

02-400

6A5495

02-400

6A5682

02-400

6A8162

02-400

6B1427

Material of component

DESCRIPTION

SYMBOL

MATERIAL

HP Compressor, Rear Outer Case Assembly

EEJ

or

ENH

Corrosion resistant steel

Chrome cobalt molybdenum

electro flux remelted steel

General

This repair must only be done when the instruction is given in the relevant inspection procedures (identified by the applicable part number) located in section 72-00-00.

This repair is to replace the thinwall insert(s) with Self-Broaching KEENSERTS when they are broken, worn, cross threaded or missing.

For price and availability, Refer to International Aero Engines (IAE).

NOTE

More equipment and materials necessary to do this repair are in SPM TASKS given below:
SPM TASK 70-23-05-230-501,
SPM TASK 70-11-26-300-503,
SPM TASK 70-35-26-300-501.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Approved workshop equipmentLOCALApproved workshop equipmentAR
Basic Power UnitLOCAL70951-6AR
Broaching ToolLOCALB397-2AR

Use this tool for insert MS51831CA202L

Broaching ToolLOCALB453-4AR

Use this tool for insert MS51832CA202L

Broaching ToolLOCALB543-4AR

Use this tool for insert MS51831CA203L

Installation ToolLOCALTHD 428LAR

Use this tool for insert MS51831CA202L

Installation ToolLOCALTHXHD428LAR

Use this tool for insert MS51832CA202L

Installation ToolLOCALTHD524AR

Use this tool for insert MS51831CA203L

Nose AssemblyLOCAL70947ASBK-202HAR
Tang Removal ToolLOCAL2R19618AR

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 02-005 ADHESIVE TAPE (MASKING)LOCALCoMat 02-005
CoMat 04-004 JOINTING COMPOUND, LIGHT GRADELOCALCoMat 04-004
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)X222XCoMat 06-064

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
INSERT0AM53KU37022AR
INSERT96906MS51831CA202LAR

KEENSERTS

INSERT96906MS51832CA202LAR

KEENSERTS

INSERT96906MS51831CA203LAR

KEENSERTS

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-00-00-220-176 Examine the Damaged Area

    1. Refer to Figure.

      2. Examine the damaged area.

      1. Ensure that the condition is as reported.

    2. SUBTASK 72-00-00-350-053 Mask the Repair Area

      1. Mask the repair area.

        NOTE

        This step is to prevent foreign objects falling into the engine.

      1. Mask and cover all holes and openings to the inner side of the case which need to be repaired. Prepare inner-free area of the hole(s) by placing a clean cloth over hole(s) such that no cutting debris can fall into the engine; mask the holes by taping the cloth, use CoMat 02-001 ADHESIVE TAPE (MASKING).

      2. Mask all open holes adjacent to the repair area, use CoMat 02-001 ADHESIVE TAPE (MASKING) or CoMat 02-005 ADHESIVE TAPE (MASKING).

    3. SUBTASK 72-00-00-350-054 Remove the Damaged Thinwall Insert(s)

      1. Remove the damaged thinwall insert(s).

      1. Refer to SPM TASK 70-35-26-300-501.

      2. Discard the insert and continue with Step.

    4. SUBTASK 72-00-00-110-058 Clean the Hole

    1. Refer to Figure.

      2. Clean the hole.

        1. All the debris must be removed from the hole.

        1. Use a vacuum cleaner.

    5. SUBTASK 72-00-00-350-055 Drill, Counterbore and Tap the Insert Hole

    1. Refer to Figure.

      2. Drill, counterbore and tap the insert hole for fitment of Self-Broaching KEENSERTS Insert.

        1. CAUTION

          BE CAREFUL TO ALIGN THE DRILL WITH THE HOLE SO THE RESULTANT TAPPED HOLE WILL NOT BE OFF IN AN ANGLE.

          Determine the proper oversize insert required for replacement. The size required can be determined by using standard equipment for measuring diameters.

        1. Use KU37022 INSERT for holes identified as 1A.

        2. Use MS51831CA202L INSERT for holes identified as 2B; if a bleed port hole requires a 0.25 - 28 internal thread for the screw use MS51832CA202L INSERT.

        3. Use MS51831CA203L INSERT for holes identified as 3C.

          4. For MS51831CA202L INSERT, MS51832CA202L INSERT or MS51831CA203L INSERT use drilling machine, standard drill, standard countersink (82 deg to 100 deg) and standard unified thread series tap.

          1. Refer to Figure.

          2. Refer to Figure.

          3. Refer to Figure.

          5. For KU37022 INSERT drill the hole for repair insert then tap the hole for repair insert.

          1. Refer to Figure.

          2. Refer to Figure.

    6. SUBTASK 72-00-00-110-059 Clean the Self-Broaching KEENSERTS Insert Hole

      1. Clean the Self-Broaching KEENSERTS insert hole.

        1. Clean the KEENSERTS insert hole to remove debris.

        1. Remove unwanted material from the machined Self-Broaching KEENSERTS insert hole. All the debris must be removed from the tapped hole to permit the correct installation of the insert.

        2. Use a vacuum cleaner.

        3. Chemically clean the Self-Broaching KEENSERTS insert hole. Refer to SPM TASK 70-11-26-300-503.

    7. SUBTASK 72-00-00-230-053 Do a Crack Test

      1. Do a crack test.

      1. Refer to SPM TASK 70-23-05-230-501.

        2. Do a local fluorescent penetrant inspection of the repair area.

        1. Locally clean and fluorescent penetrant inspect the repair area.

        2. Use CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY) with a clean paint brush. If cracks are found the part is to be rejected.

    8. SUBTASK 72-00-00-220-177 Do a Visual Inspection

      1. Do a visual inspection of the Self-Broaching KEENSERTS insert hole.

        1. Do a visual inspection of the tapped hole.

        1. Make sure that there are no burrs, unwanted particles, grease or oil.

        2. Use visual inspection equipment, 10X Magnification.

    9. SUBTASK 72-00-00-350-056 Install the Self-Broaching KEENSERTS (Method A)

    1. Refer to Figure, Figure and Figure.

      2. Install the Self-Broaching MS51831CA202L INSERT, MS51832CA202L INSERT or MS51831CA203L INSERT - Power Installation Tool (Method A).

        NOTE

        If only KU37022 INSERT is required skip to Step.

        NOTE

        The power installation tool is composed of a power unit and a nose assembly. Refer to Support Equipment section.

        NOTE

        Take care to align the power installation tool with the axis of the insert hole.

        1. Before the installation of Self-Broaching KEENSERTS insert apply a thin layer of jointing compound to the internal threads and to the external surface of the Self-Broaching KEENSERTS insert.

        1. Use CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE. Air-dry the jointing compound to the manufacturer's instructions before installing the insert.

        2. Use a clean paint brush.

        2. Screw in the Self-Broaching KEENSERTS insert using the power installation tool.

        1. Refer to the manufacturer's instructions.

        3. Use Self-Broaching KEENSERTS insert.

        3. Drive KEENSERTS into position.

        1. Refer to the manufacturer's instructions. The Self-Broaching KEENSERTS insert should be positioned with KEENSERTS maximum offset from flange edge.

      4. Remove the power installation tool.

    10. SUBTASK 72-00-00-350-057 Install the Self-Broaching KEENSERTS (Method B)

    1. Refer to Figure, Figure and Figure.

      2. Install the Self-Broaching MS51831CA202L INSERT, MS51832CA202L INSERT or MS51831CA203L INSERT - Hand Tools Installation (Method B).

        NOTE

        If only KU37022 INSERT is required skip to Step.

        NOTE

        This hand tools installation is an alternative method to Step. Method A (Install the Self- Broaching KEENSERTS Insert - Power Installation Tool) is the preferred insert installation procedure. If necessary, Method B (Install the Self-Broaching KEENSERTS Insert- Hand Tools Installation) may be used.

        1. Install the Self-Broaching KEENSERTS insert using fingers or installation tool.

          NOTE

          Insert is designed to stop at the correct depth below the surface.

        1. Use Self-Broaching KEENSERTS insert.

        2. Mark the location of the KEENSERTS stopped on the port flange material.

        1. The Self-Broaching KEENSERTS insert should be positioned with KEENSERTS maximum offset from flange edge.

        3. Remove the Self-Broaching KEENSERTS Insert - Hand Tools Installation (Method B).

        1. Remove the Self-Broaching KEENSERTS insert.

        4. Cut the KEEways - Hand Tools Installation (Method B).

          1. Insert the pilot of the Broaching Tool, Broaching Tool or Broaching Tool into the insert hole aligning the blades with the location markings of the KEENSERTS.

          2. NOTE

            Ensure the blades in the Broaching Tool, Broaching Tool or Broaching Tool are sharp. Replace as required.

            Cut the KEEways into the port flange material by strike a blow to the top of the broach tool.

          1. Use a hammer and the Broaching Tool, Broaching Tool or Broaching Tool.

          2. Use a vacuum cleaner.

        3. NOTE

          To complete the broaching process likely several cuts are necessary.

          Remove the Broaching Tool, Broaching Tool or Broaching Tool.

        5. Remove unwanted Material - Hand Tools Installation (Method B).

          1. Remove the burrs in the Self-Broaching KEENSERTS insert hole by using the tap.

          1. Use Standard Unified Thread Series Tap.

        6. Clean the Self-Broaching KEENSERTS insert hole - Hand Tools Installation (Method B).

          1. Clean the Self-Broaching KEENSERTS insert hole to remove debris.

          1. Remove unwanted material. All the debris must be removed from the tapped hole to permit the correct installation of the insert.

          2. Use a vacuum cleaner.

          2. Chemically clean the Self-Broaching KEENSERTS insert hole.

          1. Refer to SPM TASK 70-11-26-300-503.

        7. Install the Self-Broaching KEENSERTS insert - Hand Tools Installation (Method B).

          NOTE

          Replace the blades in the Broaching Tool, Broaching Tool or Broaching Tool as required (one or three cut per blade are allowed in rear case).

          1. Before the installation of Self-Broaching KEENSERTS insert apply a thin layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to the internal threads and to the external surface of the Self-Broaching KEENSERTS insert.

          1. Use CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE. Air-dry the jointing compound to the manufacturer's instructions before installing the insert.

          2. Use a clean paint brush.

          2. Install the Self-Broaching KEENSERTS insert using fingers or Installation Tool, Installation Tool or Installation Tool.

          1. Use Self-Broaching KEENSERTS insert.

          2. Use the Installation Tool, Installation Tool or Installation Tool. Refer to the manufacturer's instructions.

        3. Immediately align the KEENSERTS to the keyways.

          4. Tap down the KEENSERTS using the Installation Tool, Installation Tool or Installation Tool.

        8. Do a visual inspection of the repair area.

        1. Make sure the insert is correctly installed.

        2. Make sure that there are no burrs, unwanted particles, grease or oil.

        3. Use visual inspection equipment, 10X Magnification.

    11. SUBTASK 72-00-00-350-058 Install the Self-Broaching KEENSERTS Insert KU37022 (If Required)

      2. Install the Self-Broaching KU37022 INSERT if required.

        1. Apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to newly tapped threads and repair insert outer threads.

        2. Use repair KU37022 INSERT.

        2. Install repair insert.

        1. Refer to Figure for 0.4375 - 20 thread Insertion Tool PN 2R19644 and Figure for installation.

        3. Visually inspect the repair inserts.

        1. Refer to Figure.

        2. Ensure repair insert is fitted under flush to internal counterbore (i.e. below the damaged broached serrations).

        1. Apply a layer of CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE to repair insert threads and wire thread insert outer threads.

        2. Use wire thread insert AGS3707.

        5. Install the wire insert thread.

        1. Refer to Figure.

        6. Remove the tang on the wire thread insert.

        1. Refer to Figure and Figure for proper thread Tang Removal Tool.

        7. Inspect wire thread insert.

        1. Ensure wire thread insert is fitted slightly under flush to repair insert.

        8. Torque check the wire thread insert.

        1. Refer to Figure for proper thread and instructions given in Figure.

    12. SUBTASK 72-00-00-350-059 Remove the Cloth and Masking

    1. Remove the cloth and masking from the repair area.

    2. Wipe the area clean of tape residue. Refer to SPM TASK 70-11-26-300-503.

    13. SUBTASK 72-00-00-350-060 Make a Record of the Repair

    1. Make a record of VRS9170 in the relevant engine documentation.

    14. Figure: Repair Details

    Repair Details

    Figure: Dimensions for the Tapped Insert Hole using MS51831CA202L

    Dimensions for the Tapped Insert Hole using MS51831CA202L

    Figure: Dimensions for the Tapped Insert Hole using MS51832CA202L or MS51831CA203L

    Dimensions for the Tapped Insert Hole using MS51832CA202L or MS51831CA203L

    Figure: Installation Sequence

    Installation Sequence

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Approved Hand Tools

    Approved Hand Tools

    Figure: Installation of Repair Inserts

    Installation of Repair Inserts

    Figure: Installation Procedure

    Installation Procedure

    Installation Procedure

    Figure: Removal of Insert Tag

    Removal of Insert Tag

    Figure: Torque Check of Screw Lock Inserts

    Torque Check of Screw Lock Inserts

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add support equipment tools. (19VG333)

Change Type:

Update task number for duplication (CAS-65061-G1D1R6)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:96906
Enterprise Name:MILITARY STANDARDS MANUAL 4120 3-M
BU Name:MILITARY STANDARDS MANUAL 4120 3-M
Street:NONE
City:NONE
Country:USA
Phone Number:NONE
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Part Number:KU37022
Part Name:INSERT
Manufacturer Code:0AM53
Part Number:MS51831CA202L
Part Name:INSERT
Manufacturer Code:96906
Part Number:MS51831CA203L
Part Name:INSERT
Manufacturer Code:96906
Part Number:MS51832CA202L
Part Name:INSERT
Manufacturer Code:96906
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:LOCAL
Supply Number:CoMat 02-005
Type:sp01
Supply Short Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 2/94 (RR REF)AT 7 BLACK, WATERPROOF
Suppliers:
ManufacturerRemarks
LOCAL
U0415
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 04-004
Type:sp01
Supply Short Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Supply Name:CoMat 04-004 JOINTING COMPOUND, LIGHT GRADE
Specification Groups:
Doc NumberType
OMAT: 4/46 (REF RR)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
JCR-025 (JAEC REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
MSRR 9055 (RR REF)HYLOMAR AEROGRADE (PL32), LIGHT GRADE
Suppliers:
ManufacturerRemarks
LOCAL
460Y4
CJ731
K3237
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:2R19618
Tool Name:Tang Removal Tool
Manufacturer Code:LOCAL
Tool Number:70947ASBK-202H
Tool Name:Nose Assembly
Manufacturer Code:LOCAL
Tool Number:70951-6
Tool Name:Basic Power Unit
Manufacturer Code:LOCAL
Tool Number:Approved workshop equipment
Tool Name:Approved workshop equipment
Manufacturer Code:LOCAL
Tool Number:B397-2
Tool Name:Broaching Tool
Manufacturer Code:LOCAL
Tool Number:B453-4
Tool Name:Broaching Tool
Manufacturer Code:LOCAL
Tool Number:B543-4
Tool Name:Broaching Tool
Manufacturer Code:LOCAL
Tool Number:THD524
Tool Name:Installation Tool
Manufacturer Code:LOCAL
Tool Number:THD 428L
Tool Name:Installation Tool
Manufacturer Code:LOCAL
Tool Number:THXHD428L
Tool Name:Installation Tool