TASK 72-41-13-300-024 HPC Rear Shaft - Repair Of The Front Seal, Seal Spacer, And HPT Location Diameter(s) By Chromium Plate, Repair-024 (VRS6509)

DMC:V2500-A0-72-41-1301-02A-647A-C|Issue No:003.00|Issue Date:2019-05-01

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 72-41-13-300-024 HPC Rear Shaft - Repair Of The Front Seal, Seal Spacer, And HPT Location Diameter(s) By Chromium Plate, Repair-024 (VRS6509)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-900

6A4151

A

01-900

6A7708

C

01-900

6A4158

B

01-900

6A5868

B

01-900

6A7712

D

01-900

6A7714

D

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor Rear Shaft Assembly

QYX

Inconnel 718

General

This TASK gives the procedure to repair the front seal, seal spacer and HPT location diameter(s) by chromium plate on the HP Compressor Rear Shaft Assembly.

This repair must only be done when the instruction to do so is given in the relevant inspection procedures (identified by the applicable part number) located in section 72-41-13.

This repair cannot be applied to a location that has been repaired previously in accordance with VRS6545. If VRS6545 has been previously applied at a repair location, this location should have the coating re-applied in accordance with VRS6545.

To put back the fatigue strength, it is necessary to shot peen surfaces, where the damaged material is removed prior to chromium plating.

This repair can only be done four times on each zone only. You must examine the component to see how many times this repair has been carried out before, refer to Step

Where reference is made to a SUBTASK within a TASK in the form "TASK, SUBTASK" the operator must read and apply the complete TASK. The SUBTASK is listed only when the TASK gives options for the processing of the component. The specified SUBTASK instructs what option must be used during application of the TASK for the successful completion of the Repair Scheme VRS6509.

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in SPM.

Price and Availability

Refer to International Aero Engines

Related Repairs - none

NOTE

More equipment and materials necessary to do this Repair are in SPM TASK 70-09-00-400-501, SPM TASK 70-11-01-300-503, SPM TASK 70-23-04-230-501, SPM TASK 70-23-05-230-501, SPM TASK 70-33-02-330-501, SPM TASK 70-38-04-300-503 and SPM TASK 70-38-24-300-503.

NOTE

It is possible that some materials in the consumable materials chart cannot be used for some or all of the necessary applications. Before you use the materials, make sure the types, quantities and applications of the materials necessary are legally permitted in your location. All persons must obey all applicable federal, state, local and provincial laws and regulations when it is necessary to work with these materials.

NOTE

To identify the consumable materials refer to the Overhaul Process Consumables Index (PCI).

NOTE

Other necessary consumable materials are referred to in SPM TASKS in this TASK.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical cleaning equipmentLOCALChemical Cleaning Equipment
Fluorescent penetrant inspection equipmentLOCALFluorescent Penetrant Inspection Equipment
Grinding MachineLOCALGrinding Machine

Cylindrical

Standard workshop equipmentLOCAL
Dial test indicatorLOCAL
Workshop inspection equipmentLOCALWorkshop inspection equipment
Shot peening equipmentLOCAL

Automatic

Chromium Plate equipmentLOCAL
Binocular inspection equipmentLOCAL

X10

Dimensional inspection equipmentLOCAL
Vibro-peen equipmentLOCAL
Grinding fixtureLOCAL

Locally made

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOFLOCALCoMat 02-003
CoMat 02-021 MASKING WAX COMPOUND59460CoMat 02-021
CoMat 02-034 METALLIC MASKING TAPE(LEAD FOIL)76381CoMat 02-034
CoMat 05-029 CAST STEEL SHOT, S110LOCALCoMat 05-029
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-13-220-152 Make Sure the HP Compressor Rear Shaft Assembly can be Repaired;

    1. CAUTION

      YOU MUST MAKE SURE THAT THE HP COMPRESSOR REAR SHAFT ASSEMBLY CAN BE REPAIRED.
      CHECK THE CODE SYMBOL TO MAKE SURE THAT THIS REPAIR CAN BE CARRIED OUT.

      NOTE

      There are three Zones for this repair. They are as follows:
      (a) Zone AD (Front Seal Diameter)
      (b) Zone AE (Seal Spacer Diameter)
      (c) Zone AF (HPT Location Diameter)

      NOTE

      If you see "VRS6509/3" or "VRS6509/4" you cannot carry out this repair again. The HP compressor rear shaft assembly is to be rejected.

      NOTE

      If you see a code symbol (a triangle with a letter in it ) refer to step (1). This is applicable to Zones AD, AE and AF.

      NOTE

      If the identity mark is a triangle with a letter in it you can do this repair unless you see these letters:
      (a) H for repairs to Zone AD
      (b) M for repairs to Zone AE
      (c) S for repairs to Zone AF

      Refer to Figure.

      2. Visually examine the HP Compressor Rear Shaft Assembly, to tell you if this repair has been done before.

      1. Look at the area adjacent to the Part Number.

      2. Keep a record of the identity mark(s) for use with Step

    2. SUBTASK 72-41-13-220-159 Examine for Previous Applications of VRS6545

    1. Refer to Figure and Figure.

      2. If the component is marked with the repair scheme number VRS6545 and one of the suffixes "/11", "/12", "/13", "/14" or "/15" and the proposed repair area is Locations AD.

      1. Reject, the repair area must be repaired in accordance with VRS6545.

      3. If the component is marked with the repair scheme number VRS6545 and one of the suffixes "/31", "/32", "/33", "/34" or /35" and the proposed repair area is Locations AE.

      1. Reject, the repair area must be repaired in accordance with VRS6545.

      4. If the component is marked with the repair scheme number VRS6545 and one of the suffixes "/41", "/42", "/43", "/44" or "/45" and the proposed repair area is Locations AF.

      1. Reject, the repair area must be repaired in accordance with VRS6545.

      5. If the component is marked with the repair scheme number VRS6545 and one of the suffixes "/21", "/22", "/23", "/24" or "/25":

      1. Continue with the repair.

      6. If the component is not marked as given in Step, Step or Step.

      1. Continue with the repair.

    3. SUBTASK 72-41-13-220-160 Examine for Combined Application of VRS6509 and SB 72-0403 or SB 72-0404

    1. Refer to Figure, Figure, Figure and Figure.

      2. Examine the component to see if it has been repaired in accordance with VRS6509 and reworked in accordance with SB 72-0403 or SB 72-0404.

        1. If the chromium plating from VRS6509 contacts the WC/Co coating applied as part of the relevant service bulletin.

        1. Reject.

        2. If the chromium plating from VRS6509 does not contact the WC/Co coating applied as part of the relevant service bulletin.

        1. Continue with the repair.

    4. SUBTASK 72-41-13-110-061 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the HP Compressor Rear Shaft Assembly.

    5. SUBTASK 72-41-13-230-077 Fluorescent Penetrant Inspect

      1. Do a local fluorescent penetrant inspection on the applicable diameter.

      1. Refer to SPM TASK 70-23-04-230-501.

          1. If cracking is detected.

          1. Reject.

          2. If no cracking is detected.

          1. Continue with the repair.

    6. SUBTASK 72-41-13-330-075 Chemically Strip the Chromium Plating, if Required

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      NOTE

      This SUBTASK is only required if there is existing chromium plating at the repair location(s).

      2. Chemically strip the chromium plating from the repair location(s).

      1. Refer to SPM TASK 70-33-02-300-503, SUBTASK 70-33-02-300-001.

    7. SUBTASK 72-41-13-324-053-A00 Grind the HP Compressor Rear Shaft Assembly, if Required

    1. CAUTION

      DO NOT REMOVE MORE MATERIAL THAN IS NECESSARY.

      For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      NOTE

      This SUBTASK can be used to remove damage at the repair location(s) or an existing coating.

      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.

      2. Make sure that Datums A, B and C are set to turn correctly.

      4. Grind the applicable diameter(s) to remove all of the damage or existing chromium plating.

      1. NOTE

        There are three diameters. They are at Zones:
        (a) AD (Front Seal Diameter)
        (b) AE (Seal Spacer Diameter)
        (c) AF (HPT Location Diameter)

        NOTE

        If a chromium plate layer has been applied before, make sure all chromium plate is removed.

        Use a cylindrical Grinding Machine.

      2. Machine only the minimum quantity of material to remove scores or coating.

      5. Remove burrs.

    8. SUBTASK 72-41-13-324-053-B00 Grind the HP Compressor Rear Shaft Assembly, Assembly B

    1. Deleted.

    9. SUBTASK 72-41-13-110-102 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the HP Compressor Rear Shaft Assembly.

      1. Refer to SPM TASK 70-11-01-300-503.

    10. SUBTASK 72-41-13-380-064 Swab Etch

    1. NOTE

      This SUBTASK is only required if damage or chromium plating has been removed by machining.

      For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      2. Cold ferric chloride swab etch the repair area(s) on the HP Compressor Rear Shaft Assembly.

      1. Refer to SPM TASK 70-11-39-300-503.

    11. SUBTASK 72-41-13-230-078-A00 Fluorescent Penetrant Inspect

      1. Do a local fluorescent penetrant inspection on the applicable diameter.

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

          1. If cracking is detected.

          1. Reject.

          2. If no cracking is detected.

          1. Continue with the repair.

    12. SUBTASK 72-41-13-230-078-B00 Do a Crack Test, Assembly B

    1. Deleted.

    13. SUBTASK 72-41-13-220-153-A00 Dimensionally Inspect the HP Compressor Rear Shaft Assembly

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      2. Dimensionally inspect the applicable diameter.

      2. Keep this dimension for use with Step.

    14. SUBTASK 72-41-13-220-153-B00 Examine the HP Compressor Rear Shaft Assembly, Assembly B

    1. Deleted.

    15. SUBTASK 72-41-13-110-062 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to SPM TASK 70-11-01-300-503.

    16. SUBTASK 72-41-13-380-061-A00 Shot Peen the Repair Area

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

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

      3. Shot peen the applicable diameter on the HP Compressor Rear Shaft Assembly.

      1. Refer to SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

      2. Use CoMat 05-029 CAST STEEL SHOT, S110 to get an almen intensity of 0.006 in. to 0.009 in. (0.15 mm to 0.23 mm) on 'A' type test strip.

      3. A coverage of 100 percent minimum, 150 percent maximum must be applied.

      4. It is recommended to use a single nozzle with a nozzle to work distance of 4.7 in. (120 mm).

      5. Use automatic Shot peening equipment.

    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 SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

    6. Remove mechanical seals and seal tape.

    17. SUBTASK 72-41-13-380-061-B00 Shot Peen the Repaired Areas, Assembly B

    1. Deleted.

    18. SUBTASK 72-41-13-350-073-A00 Seal Surfaces not to be Chromium Plated

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

    19. SUBTASK 72-41-13-350-073-B00 Seal Surfaces not to be Chromium Plated, Assembly B

    1. Deleted.

    20. SUBTASK 72-41-13-330-074-A00 Chromium Plate the HP Compressor Rear Shaft Assembly

    1. CAUTION

      NO HEAT TREATMENT IS REQUIRED BEFORE OR AFTER CHROMIUM PLATING.

      For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      2. Chromium plate the assembly on the applicable diameter.

      1. Refer to SPM TASK 70-33-02-330-501, SUBTASK 70-33-02-330-018.

      2. Use chromium plating equipment.

      3. Apply sufficient chromium plating to get the correct dimensions when machined, refer to Step.

    3. Remove the masking tape and compound.

    21. SUBTASK 72-41-13-330-074-B00 Chromium Plate the HP Compressor Rear Shaft Assembly, Assembly B

    1. Deleted.

    22. SUBTASK 72-41-13-324-054-A00 Grind the HP Compressor Rear Shaft Assembly

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      2. Install the fixture into the cylindrical Grinding Machine.

      1. Use a locally made Grinding fixture.

      3. Install the HP Compressor Rear Shaft Assembly onto the fixture and set to turn correctly.

      2. Make sure that Datums A, B and C are set to turn correctly.

      4. Machine the applicable diameter.

      1. Use a cylindrical Grinding Machine.

      5. NOTE

        You must remove all unwanted chromium plate from the adjacent area.

        Remove burrs.

    23. SUBTASK 72-41-13-324-054-B00 Grind the HP Compressor Rear Shaft Assembly, Assembly B

    1. Deleted.

    24. SUBTASK 72-41-13-110-063 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to SPM TASK 70-11-01-300-503.

    25. SUBTASK 72-41-13-220-154-A00 Visually and Dimensionally Inspect

    1. For Assembly A and Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C and Assembly D refer to Figure, Figure, Figure, Figure and Figure.

      2. Visually inspect the HP Compressor Rear Shaft Assembly.

          1. If the component has no cracking.

          1. Continue with the repair.

          2. If the component has cracking.

          1. Reject.

      3. Dimensionally inspect the HP Compressor Rear Shaft Assembly.

          1. If the HP Compressor Rear Shaft Assembly is within the given dimensions.

          1. Continue with the repair.

          2. If the HP Compressor Rear Shaft Assembly is not within the given dimensions.

          1. Reject.

    26. SUBTASK 72-41-13-220-154-B00 Examine the HP Compressor Rear Shaft Assembly, Assembly B

    1. Deleted.

    27. SUBTASK 72-41-13-350-075 Identify the Repair

    1. Refer to Figure and Figure.

      2. Make a mark adjacent to the assembly number.

      1. Refer to SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

    3. For Zones AD, AE and AF, if the previous identity mark was a code symbol use the next code symbol in the table for the relevant zone.

    28. Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly C

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly C

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly B and Assembly D

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly B and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    Figure: HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    HP Compressor Rear Shaft Assembly - Repair Details and Dimensions - Assembly A and Assembly B

    Figure: HP Compressor Rear Shaft Assembly - Identity Marking Locations Details - Assembly A, Assembly B, Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Identity Marking Locations Details - Assembly A, Assembly B, Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AD Pre-Coating Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AD Pre-Coating Dimensions - Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AD Final Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AD Final Dimensions - Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AE Pre-Coating Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AE Pre-Coating Dimensions - Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AE Final Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AE Final Dimensions - Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AF Pre-Coating Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AF Pre-Coating Dimensions - Assembly C and Assembly D

    Figure: HP Compressor Rear Shaft Assembly - Zone AF Final Dimensions - Assembly C and Assembly D

    HP Compressor Rear Shaft Assembly - Zone AF Final Dimensions - Assembly C and Assembly D

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised procedure to correct the note. (17VC025)

Manufacturer Code:59460
Enterprise Name:PYRAMID PLASTICS INC,
BU Name:PYRAMID PLASTICS INC,
Department:TOLBER DIV.
Street:220 WEST 5TH STREET
City:HOPE
State:AR
Zip Code:71801-5212
Country:USA
Phone Number:1-870-722-5739
Fax Number:1-870-777-8056
Internet:www.tolber.com
Manufacturer Code:76381
Enterprise Name:3M COMPANY
BU Name:3M COMPANY
Department:3M CENTER
City:ST PAUL
State:MN
Zip Code:55144-1000
Country:USA
Phone Number:1-651-733-1110
Fax Number:1-651-733-9973
Internet:www.mmm.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-003
Type:sp01
Supply Short Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Supply Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Specification Groups:
Doc NumberType
OMAT: 285ISATAPE 160
Suppliers:
ManufacturerRemarks
LOCAL
IE305
K6835
Manufacturer Code:59460
Supply Number:CoMat 02-021
Type:sp01
Supply Short Name:CoMat 02-021 MASKING WAX COMPOUND
Supply Name:CoMat 02-021 MASKING WAX COMPOUND
Specification Groups:
Doc NumberType
PMC 9551MICCROWAX C-562
Suppliers:
ManufacturerRemarks
59460
Manufacturer Code:76381
Supply Number:CoMat 02-034
Type:sp01
Supply Short Name:CoMat 02-034 METALLIC MASKING TAPE (LEADFOIL)
Supply Name:CoMat 02-034 METALLIC MASKING TAPE(LEAD FOIL)
Specification Groups:
Doc NumberType
PMC 4138-1 THRU -53M LEAD FOIL TAPE 420 (with linner) or 3M LEAD FOIL TAPE 421 (without linner)
Suppliers:
ManufacturerRemarks
76381
Manufacturer Code:55807
Supply Number:CoMat 05-029
Type:sp01
Supply Short Name:CoMat 05-029 CAST STEEL SHOT, S110
Supply Name:CoMat 05-029 CAST STEEL SHOT, S110
Specification Groups:
Doc NumberType
AMS 2431/1 ASR 110
Suppliers:
ManufacturerRemarks
55807
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
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Grinding Machine
Tool Name:Grinding Machine
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment
Link not Found