TASK 72-41-13-840-002 HPC Rear Shaft - Rework The Shaft For A Revised No. 4 Bearing Location Coating, Rework-002 - SBE 72-0403

DMC:V2500-A0-72-41-1301-01A-933A-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 72-41-13-840-002 HPC Rear Shaft - Rework The Shaft For A Revised No. 4 Bearing Location Coating, Rework-002 - SBE 72-0403

Effectivity

FIG/ITEM

PART NO.

01-850

6A4157

01-850

6A5867

General

The practices and procedures referred to in the procedure by the TASK number are in the SPM.

Refer to the indicated Service Bulletin for specific application requirements.

Estimated man-hours for this Rework is 14 hours.

Repair Facilities

This is a Source Demonstrated Rework which can only be done by approved vendors.

The Source Demonstration requirements of this rework means that any facility not authorized to accomplish this rework either utilize the Authorized Repair Vendors listed below or contact IAE Technical Services to determine if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG
C/O ROLLS-ROYCE PLC
P.O. BOX 31
DERBY
DE24 8BJ
ENGLAND

ATTN: Manager Technical Services

Authorized Rework Vendors for the Rework are listed below:

ROLLS-ROYCE - AERO REPAIR AND OVERHAUL
Mavor Avenue
Nerston
East Kilbride
Glasgow G74 4 PY
Scotland

The designation by IAE of an authorized Rework Vendor indicates that the Rework Vendor has demonstrated the necessary capability to enable it to carry out the listed Rework. However, IAE makes no warranties or representations concerning the qualifications or quality standards of the Rework Vendors to carry out the Rework, and accepts no responsibility whatsoever for any work that may be carried out by a Rework Vendor, other than when IAE is listed as the Rework Vendor. Authorized Rework Vendors do not act as agents or representatives of IAE.

NOTE

6A4157 is an assembly and contains the part 6A4158 HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-900)
6A5867 is an assembly and contains the part 6A5868 HPC Rear Shaft And Heatshield Assembly (72-41-13, 01-900)

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Grinding fixtureLOCALGrinding fixture

Locally made

Grinding fixtureLOCALGrinding fixture

Cylindrical

Dial test indicatorsLOCALDial test indicators
Standard workshop equipmentLOCALStandard workshop equipment
Workshop inspection equipmentLOCALWorkshop inspection equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
BinocularsLOCALBinoculars

10x

Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 06-003 DELETED0AM53CoMat 06-003
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-13-350-083 Make Sure the HP Compressor Rear Shaft Assembly can be Reworked

      1. Make sure the HP Compressor Rear Shaft Assembly can be reworked.

      1. You cannot rework the assembly if the assembly is identified 6A7711, 6A7713, VRS6509/1, VRS6509/2, VRS6509/3, VRS6509/4, and/or with a triangle with the letters A, B, C, or D inside it.

    2. SUBTASK 72-41-13-350-084 Grind the HP Compressor Rear Shaft Assembly

      1. Grind the HP compressor rear shaft assembly.

      1. Refer to Figure and Figure.

      2. Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture and cylindrical grinding machine.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

      1. Refer to Figure and Figure. Use a dial test indicator and standard workshop equipment. Make sure that datums A, B and C are set to turn correctly.

      4. Grind the HP compressor rear shaft assembly.

      1. Refer to Figure and Figure. Refer to the Approved Vendor process.

      5. Remove burrs.

      1. Use standard workshop equipment.

    3. SUBTASK 72-41-13-220-195 Inspect the HP Compressor Rear Shaft Assembly

      1. Inspect the HP compressor rear shaft assembly.

      1. Refer to the Approved Vendor process. Use standard workshop inspection equipment.

    4. SUBTASK 72-41-13-110-081 Chemically Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the HP compressor rear shaft assembly.

      1. Refer to the SPM TASK 70-11-01-300-503. Use chemical cleaning equipment.

    5. SUBTASK 72-41-13-110-082 Cold Ferric Chloride Etch Surface AB on the HP Compressor Rear Shaft

      1. Cold ferric chloride etch surface AB on the HP compressor rear shaft.

      1. Refer to Figure and Figure. Refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001. Use chemical cleaning equipment.

    6. SUBTASK 72-41-13-220-196 Visually Examine Surface AB on the HP Compressor Rear Shaft

      1. Visually Examine Surface AB on the HP Compressor Rear Shaft.

      1. Refer to Figure and Figure. Use X10 binoculars. Indications of defects are not permitted.

    7. SUBTASK 72-41-13-230-093 Do a Local Penetrant Crack Test on Surface AB of the HP Compressor Rear Shaft

      1. Do a Local Penetrant Crack Test on Surface AB of the HP Compressor Rear Shaft.

      1. Refer to Figure and Figure. Refer to the SPM TASK 70-23-05-230-501. Use CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY), with penetrant crack test equipment. Cracks are not permitted.

    8. SUBTASK 72-41-13-120-053 Shot Peen the Surface AB on the HP Compressor Rear Shaft

    1. Shot Peen the Surface AB on the HP Compressor Rear Shaft.

      2. Seal the full assembly but for the area which is to be shot peened.

      1. Refer to Figure and Figure. Use CoMat 06-003 DELETED or a mechanical seal. Patch mask all identification marks and symbols.

      3. Shot peen the area which is to be shot peened.

      1. Refer to Figure and Figure. Refer to Approved Vendor Process.

    4. Make sure all loose unwanted cast steel shot is removed.

      5. Remove iron contamination after you have shot peened, as necessary.

      1. Refer to Figure and Figure. Refer to Approved Vendor Process.

    6. Remove adhesive tape and/or mechanical seals.

      7. Examine the shot peened area.

      1. Refer to Figure and Figure. Refer to Approved Vendor Process.

    9. SUBTASK 72-41-13-330-057 Apply the Metal Spray Hard Coating to Surface AB on the HP Compressor Rear Shaft

      1. NOTE

        Overspray of the metal spray coating is permitted on surfaces AE.

        Apply the Metal Spray Hard Coating to Surface AB on the HP Compressor Rear Shaft.

      1. Refer to Figure and Figure. Refer to Approved Vendor Process.

    10. SUBTASK 72-41-13-350-085 Grind the Hard Coating on the HP Compressor Rear Shaft

    1. Grind the Hard Coating on the HP Compressor Rear Shaft.

      2. Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

      1. Refer to Figure and Figure. Use a dial test indicator and standard workshop equipment. Make sure that datums A, B and C are set to turn correctly.

      4. Grind the HP compressor rear shaft assembly.

      1. Refer to Figure and Figure. Refer to Approved Vendor Process.

      5. Remove burrs.

      1. Use standard workshop equipment.

    11. SUBTASK 72-41-13-220-197 Visually and Dimensionally Inspect the HP Compressor Rear Shaft Assembly

      1. Visually and Dimensionally Inspect the HP Compressor Rear Shaft Assembly.

      1. Refer to Figure and Figure. Use standard workshop inspection equipment.

    12. SUBTASK 72-41-13-230-094 Do a Local Penetrant Crack Test of the HP Compressor Rear Shaft

      1. Do a crack test.

      1. Refer to Approved Vendor Process.

    13. SUBTASK 72-41-13-110-083 Chemically Clean the Repaired Area

      1. Chemically Clean the Repaired Area.

      1. Refer to the SPM TASK 70-11-26-300-503, SUBTASK 70-11-26-300-002.

    14. SUBTASK 72-41-13-350-086 Identify the HP Compressor Rear Shaft

      1. Cancel the existing part number and re-identify the HP compressor rear shaft assembly with the new part number adjacent to the existing part number.

      1. Refer to the SPM TASK 70-09-00-400-001.

      2. Use vibro-engraving equipment.

      3. NUMBER BEFORE: 6A4157.

      4. NEW NUMBER: 6A7713.

      5. NUMBER BEFORE: 6A5867.

      6. NEW NUMBER: 6A7711.

    15. Figure: Rework details and dimensions

    Rework details and dimensions

    Figure: Rework details and dimensions

    Rework details and dimensions

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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:0AM53
Supply Number:CoMat 06-003
Type:sp01
Supply Short Name:CoMat 06-003 DELETED
Supply Name:CoMat 06-003 DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:X222X
Supply Number:CoMat 06-022
Type:sp01
Supply Short Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Supply Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
ARDROX 985-P14 OMAT: 652 (CHEMETALL OAKITE 985-P14)It is not permitted to mix the selected CoMat 06‐022 letter suffix material with other CoMat 06‐022 letter suffix materials. Where CoMat 06‐022 is specified with no suffix, use one of the CoMat 06‐ 022 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Binoculars
Tool Name:Binoculars
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Grinding fixture
Tool Name:Grinding fixture
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment