TASK 72-38-11-300-002 Inlet Cone Assembly - Replace The Inlet Cone Tip, Repair-002 (VRS1462)

DMC:V2500-A0-72-38-1101-00A-920A-C|Issue No:001.00|Issue Date:2013-11-01

Export Control

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

Copyright

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

Applicability

All

Common Information

TASK 72-38-11-300-002 Inlet Cone Assembly - Replace The Inlet Cone Tip, Repair-002 (VRS1462)

Effectivity

FIG/ITEM

PART NO.

01-200

5A0015

01-200

5A1452

01-200

5A1733

Material of component

PART IDENT

SYMBOL

MATERIAL

Inlet cone

-

Fibre-reinforced plastic

with polyurethane coating

General

Price and availability - none

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
LatheLOCALLathe
Milling machineLOCALMilling machine
Drilling machineLOCALDrilling machine
Standard workshop equipmentLOCALStandard workshop equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 05-016 GARNET PAPER, 80-GRITLOCALCoMat 05-016
CoMat 05-019 WATERPROOF SILICON CARBIDELOCALCoMat 05-019
CoMat 05-020 WATERPROOF SILICON CARBIDELOCALCoMat 05-020
CoMat 08-012 COLD CURING SILICONE COMPOUND0AM53CoMat 08-012
CoMat 08-013 COLD CURING SILICONE COMPOUNDLOCALCoMat 08-013
CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT0AM53CoMat 08-014

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Tip holder5A00051
Inlet cone tip5A00161

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-38-11-330-053 Remove the Damaged Inlet Cone Tip from the Inlet Cone Assembly

    1. Refer to Figure and Figure.

    2. Examine and identify damaged inlet cone tip.

      3. Remove damaged inlet cone tip without any damage to the parent material, and remove the remaining compound.

    2. SUBTASK 72-38-11-110-056 Clean the Inlet Cone Tip Locating Hole

      1. Wipe and clean the tip locating hole area of the inlet cone.

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

    3. SUBTASK 72-38-11-210-053 Do an Alignment Check of the Inlet Cone Tip Locating Hole

    1. Refer to Figure and Figure.

      2. Set up and check for alignment of the tip locating hole and the inlet cone centerline.

      1. If the concentricity of the locating hole is out of limit defined in the Figure, do Step.

    4. SUBTASK 72-38-11-320-054 Machine the Inlet Cone Tip Locating Hole

    1. Refer to Figure and Figure.

      2. NOTE

        Do this SUBTASK only if the concentricity of the locating hole is out of limit in Step.

        Install the inlet cone on the lathe or milling machine.

      1. Use a locally fabricated machining fixture.

      2. Hold the Inlet cone aft flange ID (Datum B) concentric within 0.002 in. (0.05 mm).

      3. Drill and ream new locating hole concentric with the centerline of the inlet cone.

      1. The diameter of the new hole must be held to the minimum size necessary to fully incorporate the existing hole.

      2. Maximum hole diameter must not be more than 0.364 in. (9.25 mm).

      5. Dimensionally examine the hole.

      1. The concentricity of the hole must be within 0.005 in. (0.12 mm) in relation to the inlet cone aft flange ID (Datum B).

      6. Visually examine the repaired area and adjacent surface.

        1. Use 10X magnifying glass.

        1. Cracks, chips, sharp edges, burrs, delamination and fabric are not permitted.

    5. SUBTASK 72-38-11-360-052 Prepare the Mating Surfaces for the Cold Curing Silicone Rubber Compound

      1. Hand clean the mating surfaces of the inlet cone.

      2. Wipe the mating surface.

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

    6. SUBTASK 72-38-11-360-053 Apply and Cure the Cold Curing Silicone Rubber Compound

    1. CAUTION

      DO NOT EAT ANYTHING OR SMOKE AT LOCATIONS WHERE THESE MATERIAL ARE USED.

      CAUTION

      AFTER PREPARATION THE MATING SURFACES MUST BE FULLY CLEANED AND MUST NOT BE TOUCHED BY HAND, TO PREVENT CONTAMINATION.

      NOTE

      The primer must be applied immediately after the mating surfaces are prepared.
      If the parts are not used immediately after the primer is applied, the parts can be kept in polyethylene bags for use within 24 hours.

      Refer to Figure and Figure.

      2. Apply a thin layer of primer only to the prepared mating surface of the inlet cone, other than elastomeric surfaces. Dry in air for 30 minutes.

      1. NOTE

        Do not apply the primer to the mating surface of the inlet cone tip.

      2. Refer to the SPM TASK 70-36-02-360-501, SUBTASK 70-36-02-360-020.

      3. Swab degrease the mating surface of the inlet cone tip.

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

      4. Apply the cold curing silicon rubber compound to each of the mating surfaces of the inlet cone tip and inlet cone. Thickness to be 0.010 to 0.015 in. (0.25 to 0.38 mm).

      2. Refer to the SPM TASK 70-36-02-360-501, SUBTASK 70-36-02-360-020.

      5. Assemble the inlet cone tip, the inlet cone and the tip holder immediately or within three minutes after the compound is applied.

      1. Make sure that compound can be seen around the sealed surfaces.

      6. Cut off the tail of the inlet cone tip.

      1. Use a knife, avoid damage to the inside of the composite section of the inlet cone.

      7. After cutting off the tail wrap up with the compound.

      8. Blend in the joint portion of inlet cone and the tip with the compound.

      1. Use CoMat 08-012 COLD CURING SILICONE COMPOUND and make smooth without waves.

      9. Cure the compound at 68 deg F (20 deg C) for 48 hours.

      1. Do not apply a load during this time. Refer to the SPM TASK 70-36-02-360-501.

    7. SUBTASK 72-38-11-220-075 Examine the Repaired Areas of the Inlet Cone

    1. Refer to Figure.

    2. Visually examine gapping and filling, and examine for no peeling on the inlet cone tip.

    3. Dimensionally inspect the inlet cone assembly.

      4. Do an alignment check of the inlet cone assembly.

      1. If the concentricity of the inlet cone tip is out of limit, repeat steps 4 through 10.

    8. SUBTASK 72-37-11-350-001 Identify the Repair

      1. Mark VRS1462 adjacent to the part number.

      1. Use the ink method.

      2. Refer to the SPM TASK 70-09-00-400-501.

    9. Figure: Repair Details and Dimensions

    Sheet 1

    Legend
    Repair Details and Dimensions

    Sheet 1

    Close

    Figure: Repair Details and Dimensions

    Sheet 2

    Legend
    Repair Details and Dimensions

    Sheet 2

    Close

    Figure: Repair Details and Dimensions

    Sheet 3

    Legend
    Repair Details and Dimensions

    Sheet 3

    Close

    Figure: Repair Details and Dimensions

    Sheet 4

    Legend
    Repair Details and Dimensions

    Sheet 4

    Close

Requirements After Job Completion

Follow-On Conditions

NONE
Link not Found
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Link not Found
Manufacturer Code:0KHE3
Supply Number:CoMat 05-016
Type:sp01
Supply Short Name:CoMat 05-016 GARNET PAPER, 80-GRIT
Supply Name:CoMat 05-016 GARNET PAPER, 80-GRIT
Specification Groups:
Doc NumberType
GARNET PAPER, CAMI GRIT SIZE 80 GRADE 0 (ANSI B74.18)
Suppliers:
ManufacturerRemarks
0KHE3
1E1X8
LOCAL
C4347
K0993
K2F42
K6835
V571V
Manufacturer Code:1E1X8
Supply Number:CoMat 05-019
Type:sp01
Supply Short Name:CoMat 05-019 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-019 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/31 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 400 (ANSI B74.18)
JCR-184 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
LOCAL
K6835
Manufacturer Code:1E1X8
Supply Number:CoMat 05-020
Type:sp01
Supply Short Name:CoMat 05-020 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-020 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/33 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 320 (ANSI B74.18)
JCR-027 (JAEC REF)
JCR-186 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
LOCAL
K6835
Manufacturer Code:X222X
Supply Number:CoMat 08-012
Type:sp01
Supply Short Name:CoMat 08-012 COLD CURING SILICONE COMPOUND
Supply Name:CoMat 08-012 COLD CURING SILICONE COMPOUND
Specification Groups:
Doc NumberType
If CoMat 08-012 is specified without an asterisk or a letter suffix, use one of the letter suffix alternative materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 08-013
Type:sp01
Supply Short Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Supply Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Specification Groups:
Doc NumberType
If CoMat 08-013 is specified without an asterisk or a letter suffix, use one of the letter suffix alternative materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 08-014
Type:sp01
Supply Short Name:CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT
Supply Name:CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT
Specification Groups:
Doc NumberType
Use the applicable letter suffix material. Refer to SPM TASK 70-36-02-360-501.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Drilling machine
Tool Name:Drilling machine
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Milling machine
Tool Name:Milling machine
Link not Found