TASK 72-42-11-300-036 Diffuser Case - Repair The Thread Of The Igniter Boss, Repair-036 (VRS3819)

DMC:V2500-A0-72-42-1100-00A-659A-C|Issue No:002.00|Issue Date:2015-08-01

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 72-42-11-300-036 Diffuser Case - Repair The Thread Of The Igniter Boss, Repair-036 (VRS3819)

FIG/ITEM

PART NO.

01-010

2A0051

01-010

2A2081-01

01-010

2A2581-01

01-010

2A2883-01

01-010

2A2885-01

01-010

2A2889-01

01-010

2A2891-01

01-010

2A2896-01

01-010

2A2897-01

01-010

2A3132

Material of component

PART IDENT

IAE SYMBOL

MATERIAL

Diffuser Case Assembly

-

PWA 1469

General

Price and availability - refer to IAE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Tap 1.0625-16UNJ-3BLOCALTap 1.0625-16UNJ-3B

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
CoMat 03-209 WELDING FILLER WIRE, NiBASE 5% CrLOCALCoMat 03-209
SleeveLOCALLocally fabricated

AMS 5663

PinLOCALSAE AS9389-80

AMS 5735

Spares

NONE

Safety Requirements

NONE

Procedure

    1. Subtask 72-42-11-320-099 Method A

      1. Refer to Figure thru Figure and Figure thru Figure.

        NOTE

        This repair is for cases that have not undergone this repair before.

        1. Repair thread damage by the procedure that follows:

        1. Machine bosses to the dimensions shown in Figure.

        2. Clean the diffuser case. Refer to SPM TASK 70-11-03-300-503.

        3. Do a fluorescent penetrant inspection of machined bosses by TASK 70-23-05-230-501.

        4. Clean the sleeve. Refer to SPM TASK 70-11-03-300-503.

        5. Locally make a sleeve to the dimensions shown in Figure. Use AMS 5663 material.

        6. Do a fluorescent penetrant inspection of sleeve by TASK 70-23-05-230-501.

        7. Heat the boss and chill the sleeve. Refer to SPM TASK 70-46-04-400-501.

          NOTE

          The next step must be done immediately after you remove the sleeve from its cooling medium and the igniter boss from its heating medium because both the sleeve and the case will normalize quickly.

          8. Install the sleeve in the part.

          1. Install the sleeve into the machined boss, lead-in chamfer first, until outer sleeve face is flush to 0.002 in. (0.051 mm) below outer boss face.

          2. Drill and ream two holes through boss and sleeve. Refer to Figure.

          3. Clean the drilled and reamed holes. Refer to SPM TASK 70-11-03-300-503.

          4. Install the twoPins through boss and sleeve to the depth given in Figure.

          5. Clean the areas to be tack-welded as shown in Figure. Refer to SPM TASK 70-11-26-300-503.

          6. Tack-weld each pin at two locations per IAE 16-3322 as shown in Figure. Refer to SPM TASK 70-31-13-310-501. Use the Manual Gas Tungsten Arc Weld (GTAW-MA) method and CoMat 03-284 WELDING FILLER WIRE, NiBASE or CoMat 03-209 WELDING FILLER WIRE, NiBASE 5% Cr.

          7. Do a fluorescent penetrant inspection of tack weld areas by TASK 70-23-05-230-501.

        9. Trim each installed pin flush with the inside diameter of the sleeve before finish machining the threads.

        10. Machine the threads in the installed sleeve to the limits shown in Figure.

        11. Clean the diffuser case. Refer to SPM TASK 70-11-03-300-503.

        12. Do an inspection of the repaired area to the limits given in Figure and Figure.

    2. SUBTASK 72-42-11-320-100 Method B

      1. Refer to Figure thru Figure and Figure thru Figure.

        NOTE

        This repair is for cases that have undergone this repair before.

        1. Repair thread damage or sleeves that are loose, missing or damaged by the procedure that follows:

        1. Machine sleeve to a thin wall condition.

        2. Grind to remove tack welds at pins.

        3. Push pins out using a drift. Remove and discard.

        4. Collapse sleeve, remove and discard.

          5. Visually inspect the repair area. No damage permitted:

          1. Machine the bosses to remove any damage, to the dimensions shown in Figure.

          2. For pin holes that you use again, any damage must be removed by machining within the limits as given in Figure, Index 12. Machining is necessary in this step may be done concurrently with Step.

          3. For pin holes that you will not use again, any damage must be removed by machining the hole to maximum diameter of 0.207 in. (5.258 mm)

        6. Clean the diffuser case. Refer to SPM TASK 70-11-03-300-503.

        7. Do a fluorescent penetrant inspection of machined bosses by TASK 70-23-05-230-501.

        8. Locally make a sleeve to the dimensions shown in Figure. Use AMS 5663 material.

        9. Clean the sleeve. Refer to SPM TASK 70-11-03-300-503.

        10. Do a fluorescent penetrant inspection of sleeve by TASK 70-23-05-230-501.

        11. Heat the boss and chill the sleeve. Refer to SPM TASK 70-46-04-400-501.

          NOTE

          The next step must be done immediately after you remove the sleeve from its cooling medium and the igniter boss from its heating medium because both the sleeve and the case will normalize quickly.

          12. Install the sleeve in the part.

          1. Install the sleeve into the machined boss, lead-in chamfer first, until outer sleeve face is flush to 0.002 in. (0.051 mm) below outer boss face.

          2. If necessary, drill and ream two new holes through boss and sleeve. See Figure. If any existing hole(s) on the boss are used, transfer drill onto the new sleeve.

          3. Clean the drilled and reamed holes (both new and existing). Refer to SPM TASK 70-11-03-300-503.

          4. Install the two Pin through boss and sleeve to the depth given in Figure. Pins can only be installed in holes meeting the limits as given in Figure, Index 12.

          5. Clean the areas to be tack-welded as shown in Figure. Refer to SPM TASK 70-11-26-300-503.

          6. Tack-weld each pin at two locations per IAE 16-3322 as shown in Figure. Refer to SPM TASK 70-31-13-310-501. Use the Manual Gas Tungsten Arc Weld (GTAW-MA) method and CoMat 03-284 WELDING FILLER WIRE, NiBASE or CoMat 03-209 WELDING FILLER WIRE, NiBASE 5% Cr.

          7. Do a fluorescent penetrant inspection of tack weld areas by TASK 70-23-05-230-501.

        13. Trim each installed pin, flush with the inside diameter of the sleeve before finish machining the threads.

        14. Machine the threads in the installed sleeve to the limits shown in Figure.

        15. Clean the diffuser case. Refer to SPM TASK 70-11-03-300-503.

        16. Do an inspection of the repaired area to the limits given in Figure.

    3. Figure: Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Figure: Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

    Diffuser Case Assembly, Igniter Boss Thread - Sleeve Repair

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Reformatted subtask numbering. (editorial)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 03-209
Type:sp01
Supply Short Name:CoMat 03-209 WELDING FILLER WIRE, Ni BASE5% Cr
Supply Name:CoMat 03-209 WELDING FILLER WIRE, NiBASE 5% Cr
Specification Groups:
Doc NumberType
MSRR9500/213HASTELLOY W AMS 5786 MIL-R-5031 CLASS 12
OMAT:333HASTELLOY W AMS 5786 MIL-R-5031 CLASS 12
Suppliers:
ManufacturerRemarks
LOCAL
K6835
80357
Manufacturer Code:LOCAL
Supply Number:CoMat 03-284
Type:sp01
Supply Short Name:CoMat 03-284 WELDING FILLER WIRE, Ni BASE
Supply Name:CoMat 03-284 WELDING FILLER WIRE, NiBASE
Specification Groups:
Doc NumberType
INCONEL 718 AMS 5832 AWS 5.14 MSRR9500/220
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2 OMAT:3/206
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2
Suppliers:
ManufacturerRemarks
LOCAL
28553
IE137
08489
IE508
0ZDB5
2R602
55596
58401
80357
K6835
Manufacturer Code:LOCAL
Supply Number:Locally fabricated
Type:sp01
Supply Short Name:
Supply Name:Sleeve
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:SAE AS9389-80
Type:sp01
Supply Short Name:
Supply Name:Pin
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Tool Number:Tap 1.0625-16UNJ-3B
Tool Name:Tap 1.0625-16UNJ-3B