TASK 72-38-11-300-007 Inlet Cone Fairing - Replace The Balance Weight, Repair-007 (VRS1459)

DMC:V2500-A0-72-38-1102-00A-609A-C|Issue No:002.00|Issue Date:2019-08-01

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 72-38-11-300-007 Inlet Cone Fairing - Replace The Balance Weight, Repair-007 (VRS1459)

Effectivity

FIG/ITEM

PART NO.

01-100

5A0017

Assembly A

01-100

5A1833

Assembly B

01-100

5A1834

Assembly B

Material of component

PART IDENT

SYMBOL

MATERIAL

Intlet cone assembly

Titanium alloy

General

Price and availability - not applicable.

NOTE

To identify the consumable materials, refer to the Consumable Materials Index.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Balancing machineLOCALZE40 or VE4L

Fluorescent penetrant inspection equipmentLOCALFluorescent Penetrant Inspection Equipment
Mass weighing scaleLOCAL

(Accuracy: 0.00035 oz (0,01 g))

IAE 3J12735 Balance adapter0AM53IAE 3J127351
IAE 3J12736 Hydraulic mandrel0AM53IAE 3J127361

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-124 ISOPROPYL ALCOHOLLOCALCoMat 01-124
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 72-38-11-330-055 Remove the Damaged Balance Weights from the Inlet Cone Fairing

      1. Inspect and identify damaged balance weights.

      1. Refer to Figure.

      2. CAUTION

        TITANIUM COMPONENT SILICON CARBIDE TYPE WHEELS, STONES AND ABRASIVE PAPERS ARE TO BE USED FOR THIS REPAIR.

        CAUTION

        ALUMINIUM OXIDE MUST NOT BE USED.

        CAUTION

        THE MATERIAL WILL OXIDIZE AND CRACK IF MECHANICAL CUTTERS ARE USED HEAVILY. THIS HAS OCCURRED IF THE COMPONENT SHOWS DARK STRAW TO BLUE DISCOLORATION.

        Remove disengaged balance weight and laminate of without any damage to the parent material.

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

      2. Refer to Figure and Figure.

    2. SUBTASK 72-38-11-230-054 Examine the Inlet Cone Fairing for Cracks

      1. Fluorescent penetrant examine the repaired surfaces.

      1. Make sure there is no cracks in the repair surfaces.

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

    3. SUBTASK 72-38-11-290-053 Do the Static Balance for the Inlet Cone Fairing

    1. Refer to Figure, Figure and Figure.

      2. Clean the seating surface of the inlet cone with isopropyl alcohol.

      3. Attach the inlet cone fairing on the balance adapter and tighten bolts in the diagonal sequence. Torque: 210 lbfin (23.73 Nm).

      4. Install the hydraulic mandrel on the balancing machine.

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

      5. Do the initial unbalance check. Initial limit 2.08 oz in. (1500 gmm).

      1. Use a balancing machine ZE40 or VE4L.

      6. Attach the same amount of the modelling clay on the diagonal position of the initial unbalance. Read and record the residual unbalance. Limit: 0.011 oz in. (8 gmm).

      2. Use a balancing machine ZE40 or VE4L.

      7. Turn the fairing and balance adapter 180 degrees. Read and record the residual unbalance. Limit: 0.011 oz in. (8 gmm).

      1. Use a balancing machine ZE40 or VE4L.

    4. SUBTASK 72-38-11-360-059 Prepare the Surfaces for the Steel Filled Putty

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

      2. Refer to Figure and Figure.

    5. SUBTASK 72-38-11-360-060 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 CoMat 08-047 HARDENER 6.6 parts by weight.

      1. Hardener must be mixed into CoMat 08-070 STAINLESS STEEL POWDER 200-MESH, CoMat 08-048 RESIN added and fully mixed until it become evenly.

    6. SUBTASK 72-38-11-260-061 Apply and Cure the Steel Filled Putty

    1. Refer to Figure, Figure and Figure.

      2. Weigh the steel filled putty which is mixed in Step.

      1. Weigh the 95 percent amount of the attached modelling clay.

      2. Use mass weighing scale.

      3. Accuracy: 0.00035 oz (0.01 g).

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

      1. Apply the putty within circumferential area F of plane G.

    4. Cure 16 hours at room temperature.

    7. SUBTASK 72-38-11-360-062 Make-up of the Resin Mixture

      1. NOTE

        Do not mix this material in amounts greater than 3.53 oz (100 g).

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

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

    8. SUBTASK 72-38-11-360-063 Apply and Cure the Resin/Fiber Reinforcements by the Wet Lay-up

    1. Refer to Figure, Figure and Figure.

      2. CAUTION

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

        CAUTION

        DO NOT APPLY GLASS FIBRE TO BOSS AREA.

        After applying putty, cover putty with one laminate of glass fabric with overlapping edge of putty by 0.748 in. (19.00 mm).

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

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

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

    9. SUBTASK 72-38-11-290-054-A00 Examine the Final Unbalance of the Inlet Cone Fairing, Assembly A

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

      1. Refer to Step.

      2. Do the final balance check:

      1. Limit: 0.011 oz in. (8 gmm).

      2. Refer to Step.

    10. SUBTASK 72-38-11-290-054-B00 Examine the Final Unbalance of the Inlet Cone Fairing, Assembly B

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

      1. Refer to Step.

      2. Do the final balance check:

      1. Limit: 0.138 oz in. (100 gmm).

      2. Refer to Step.

    11. SUBTASK 72-38-11-350-054 Identify the Repair

      1. Mark the VRS1459 adjacent to the part number.

      1. Use a vibro-peen.

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

    12. SUBTASK 72-38-11-220-078 Examine the Repaired Areas of the Inlet Cone Fairing

      1. Inspect the position of the repaired area.

      1. Refer to Figure and Figure.

      2. Visually inspect grapping, filling, continuity and porosity of joints.

      1. Refer to Figure and Figure.

    13. 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

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised note, steps and SPM task reference. (19VC194)

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 01-124
Type:sp01
Supply Short Name:CoMat 01-124 ISOPROPYL ALCOHOL
Supply Name:CoMat 01-124 ISOPROPYL ALCOHOL
Specification Groups:
Doc NumberType
OMAT:1/40GPR TECHNICAL GRADE
PMC 9094GPR TECHNICAL GRADE
JCR-011GPR TECHNICAL GRADE
Suppliers:
ManufacturerRemarks
LOCAL
U1185
24853
K6835
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
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3J12735
Tool Name:IAE 3J12735 Balance adapter
Manufacturer Code:0AM53
Tool Number:IAE 3J12736
Tool Name:IAE 3J12736 Hydraulic mandrel
Link not Found