TASK 72-38-11-300-005 Inlet Cone Assembly - Replace The Balance Weight, Repair-005 (VRS1464)

DMC:V2500-A0-72-38-1101-02A-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 72-38-11-300-005 Inlet Cone Assembly - Replace The Balance Weight, Repair-005 (VRS1464)

Effectivity

FIG/ITEM

PART NO.

01-200

5A0015

01-200

5A1452

01-200

5A1733

Material of component

PART IDENT

SYMBOL

MATERIAL

Inlet cone fairing

-

Laminates-glass fabric

General

Price and availability - not applicable

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Mass weighing scaleLOCALMass weighing scale

(Accuracy 3.5 x 0.0001 oz (0.01 g))

Balancing machineLOCALBalancing machine
IAE 3J12736 Hydraulic mandrel0AM53IAE 3J127361
IAE 3J12737 Balance adapter0AM53IAE 3J127371

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-149 DRY ICELOCALCoMat 02-149
CoMat 02-181 MODELLING CLAYLOCALCoMat 02-181
CoMat 05-016 GARNET PAPER, 80-GRITLOCALCoMat 05-016
CoMat 05-020 WATERPROOF SILICON CARBIDELOCALCoMat 05-020
CoMat 08-047 HARDENER0LCV8CoMat 08-047
CoMat 08-048 RESINLOCALCoMat 08-048
CoMat 08-049 FIBREGLASS CLOTHK6835CoMat 08-049
CoMat 08-070 STAINLESS STEEL POWDER 200-MESHK6835CoMat 08-070

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-38-11-330-054 Remove the Damaged Balance Weights from the Inlet Cone Assembly

      1. Inspect and identify the damaged balance weights.

      1. Refer to Figure.

      2. Remove the disengaged balance weight and laminate glass fabric without any damage to the parent material, and remove the remaining resin.

      1. Use a cutter knife, a scraper and CoMat 05-020 WATERPROOF SILICON CARBIDE.

      2. Refer to Figure.

    2. SUBTASK 72-38-11-220-076 Examine the Repair Surfaces of the Inlet Cone Assembly

      1. Visually examine the repaired surfaces.

      1. Make sure there are no cracks in the repaired surfaces.

    3. SUBTASK 72-38-11-290-051 Do the Static Balance for the Inlet Cone Assembly

      1. Make cool the IAE 3J12737 Balance adapter 1 off by dry ice at 04 deg F (-20 deg C) for 15 to 20 minutes.

    2. Inspect the seating surface of the inlet cone assembly for nicks or burrs.

      3. Attach the inlet cone assembly on the balance adapter and the tighten the bolts in a diagonal sequence.

      1. Torque: 210 lbfin (23.73 Nm).

      3. Refer to Figure.

      4. Install the hydraulic mandrel on the balancing machine.

      1. Use IAE 3J12736 Hydraulic mandrel 1 off and a balancing machine ZE40 or VE4L.

      5. Do the initial unbalance check.

      1. Initial limit: 4.16 oz in. (3000 gmm).

      2. Use a balancing machine ZE40 or VE4L.

      6. Attach the same amount of modelling clay on the diagonal position of the initial unbalance. Read and record the residual unbalance limit.

      1. Limit: 0.10 oz in. (75 gmm).

      3. Use a balancing machine ZE40 or VE4L.

      7. Turn the inlet cone fairing and the balance adapter 180 degrees. Read and record the residual unbalance limit.

      1. Limits: 0.10 oz in. (75 gmm).

      2. Use a balancing machine ZE40 or VE4L.

    4. SUBTASK 72-38-11-360-054 Prepare the Surfaces for the Steel Filled Putty

      1. Hand clean the surface of the removed balance weights and the area around.

      2. Refer to Figure.

    5. SUBTASK 72-38-11-360-055 Make-up of the Steel Filled Putty

      1. The steel filled putty is made-up from three parts: CoMat 08-048 RESIN 60 parts by weight, CoMat 08-070 STAINLESS STEEL POWDER 200-MESH 330 parts by weight and CoMat 08-047 HARDENER 6.6 parts by weight.

      1. CoMat 08-047 HARDENER must be mixed into CoMat 08-070 STAINLESS STEEL POWDER 200-MESH, CoMat 08-048 RESIN added and mixed until it becomes smooth.

    6. SUBTASK 72-38-11-360-056 Apply and Cure the Steel Filled Putty

      1. Weigh the steel filled putty which is mixed by Step.

      1. Weigh 95 percent of the attached modelling clay.

      2. Use a mass weighing scale.

      3. Accuracy: 3.5 x 0.0001 oz (0.01 g).

      2. Apply the steel filled putty to the prepared surface within 15 minutes after mixing.

        1. Apply the putty circumferentially.

        1. Refer to Figure.

    3. Cure for 16 hours at room temperature.

    7. SUBTASK 72-38-11-360-057 Make-up of the Resin Mixture

      1. NOTE

        Do not mix this material in amounts greater than 3.52 oz (100 g).

        The resin mixture is made-up from two parts: CoMat 08-047 HARDENER 10 to 12 parts by weight and CoMat 08-048 RESIN 100 parts by weight.

      1. The two parts are mixed at room temperature between 64.4 and 77.0 deg F (18 and 25 deg C).

    8. SUBTASK 72-38-11-360-058 Apply and Cure the Resin/Fibre Reinforcements by the Wet Lay-up

      1. CAUTION

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

        After applying the putty, cover the putty with one laminate of fiberglass cloth which overlaps the edge of the putty by 0.748 in. (19 mm).

        1. Apply it circumferentially.

        2. Refer to Figure.

      2. Coat the resin mixture which is made-up as specified in Step.

      1. Apply and work well with a brush until fully wetted.

      3. Cure for two hours at room temperature, followed by three hours at 131 to 149 deg F (55 to 65 deg C).

      1. Use an oven.

    9. SUBTASK 72-38-11-290-052 Examine the Final Unbalance of the Inlet Cone Assembly

      1. Attach the repaired inlet cone assembly on the balancing machine with the balance adapter.

      1. Refer to Step.

      2. Do the final balance check.

      1. Limit: 0.10 oz in. (75 gmm).

        Refer to Step.

    10. SUBTASK 72-38-11-350-053 Identify the Repair

      1. Mark VRS1464 adjacent to the part number.

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

    11. SUBTASK 72-38-11-220-077 Examine the Repaired Areas of the Inlet Cone Assembly

      1. Inspect the position of the repaired area.

      1. Refer to Figure.

      2. Visually inspect the gapping, filling, continuity and porosity of the joints.

      1. Refer to Figure.

    12. Figure: Replace the Balance Weight

    Replace the Balance Weight

    Figure: Balance Check of the Inlet Cone Assembly

    Balance Check of the Inlet Cone Assembly

Requirements After Job Completion

Follow-On Conditions

NONE
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:0LCV8
Enterprise Name:ROBNOR RESIN SYSTEMS
BU Name:ROBNOR RESIN SYSTEMS
Street:SOUTH MARSTON PARK, SWINDON
City:WILTSHIRE
State:HUNTS RISE
Zip Code:SN3 4TE
Country:GREAT BRITAIN
Phone Number:44-1793-823741
Fax Number:44-1793-827033
Email:robnorsales@line1.net
Manufacturer Code:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-149
Type:sp01
Supply Short Name:CoMat 02-149 DRY ICE
Supply Name:CoMat 02-149 DRY ICE
Specification Groups:
Doc NumberType
DRY ICE
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 02-181
Type:sp01
Supply Short Name:CoMat 02-181 MODELLING CLAY
Supply Name:CoMat 02-181 MODELLING CLAY
Specification Groups:
Doc NumberType
OMAT: 249PLASTICINE A-A-51006
Suppliers:
ManufacturerRemarks
LOCAL
K6835
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 05-020
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:0LCV8
Supply Number:CoMat 08-047
Type:sp01
Supply Short Name:CoMat 08-047 HARDENER
Supply Name:CoMat 08-047 HARDENER
Specification Groups:
Doc NumberType
ARALDITE HY951 OMAT: 802
ARALDITE HY951 JCR-259
Suppliers:
ManufacturerRemarks
0LCV8
IAE77
K1007
Manufacturer Code:LOCAL
Supply Number:CoMat 08-048
Type:sp01
Supply Short Name:CoMat 08-048 RESIN
Supply Name:CoMat 08-048 RESIN
Specification Groups:
Doc NumberType
ARALDITE MY750 OMAT: 803
ARALDITE MY750 JCR-260
Suppliers:
ManufacturerRemarks
LOCAL
IE432
0LCV8
IE200
IAE77
K1007
k3504
Manufacturer Code:K6835
Supply Number:CoMat 08-049
Type:sp01
Supply Short Name:CoMat 08-049 FIBREGLASS CLOTH
Supply Name:CoMat 08-049 FIBREGLASS CLOTH
Specification Groups:
Doc NumberType
TYGLASS Y0314/205-T5 0.003IN (0,076MM) MSRR 9049
TYGLASS Y0314/205-T5 0.003IN (0,076MM) OMAT: 887
TYGLASS Y0314/205-T5 0.003IN (0,076MM) JCR-261
Suppliers:
ManufacturerRemarks
K6835
Manufacturer Code:K6835
Supply Number:CoMat 08-070
Type:sp01
Supply Short Name:CoMat 08-070 STAINLESS STEEL POWDER 200-MESH
Supply Name:CoMat 08-070 STAINLESS STEEL POWDER 200-MESH
Specification Groups:
Doc NumberType
A1S 3041 304L S 304 POWDER, 200-MESH
Suppliers:
ManufacturerRemarks
K6835
Manufacturer Code:LOCAL
Tool Number:Balancing machine
Tool Name:Balancing machine
Manufacturer Code:0AM53
Tool Number:IAE 3J12736
Tool Name:IAE 3J12736 Hydraulic mandrel
Manufacturer Code:0AM53
Tool Number:IAE 3J12737
Tool Name:IAE 3J12737 Balance adapter
Manufacturer Code:LOCAL
Tool Number:Mass weighing scale
Tool Name:Mass weighing scale