TASK 72-60-21-300-059 Main Gearbox Casing - Double Helical Insert Repair at Lay Shaft Bearing Location, Repair-059 (VRS5711)

DMC:V2500-A0-72-60-2101-04A-920A-C|Issue No:001.00|Issue Date:2021-02-01

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 72-60-21-300-059 Main Gearbox Casing - Double Helical Insert Repair at Lay Shaft Bearing Location, Repair-059 (VRS5711)

Effectivity

FIG/ITEM

PART NO.

02-050

4B0053

02-050

4B0054

02-050

4B0055

02-050

4B0057

02-050

4B0400

02-050

4B0402

02-050

4B0423

Material of component

DESCRIPTION

RR SYMBOL

MATERIAL

Casing, Main Gearbox

A357/T61 (AMS4219)

Aluminum alloy

General

Price and availability - none

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

Kit PN 3178-4 consists of quantity 25 outer coils, quantity 25 inner coils, the tap, and tang break-off tools applicable for this repair.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Break-off tool (outer insert)LOCALBreak-off tool (4032-4)
Extracting tool (1227-6)LOCALExtracting tool (1227-6)
Fluorescent Penetrant Inspection EquipmentLOCALFluorescent penetrant inspection equipment
Helicoil Twinsert Kit Number 3178-401556Helicoil Twinsert Kit Number 3178-4
Inserting tool (outer insert)LOCALInserting tool (2705-4)
Magnifying GlassLOCALMagnifying Glass
Standard Workshop EquipmentLOCALStandard Workshop Equipment
Tap tool, double insertLOCALTap tool, double insert (3893-4)
Vibration peen equipmentLOCALVibration peen equipment
Workshop Inspection Equipment0AM53Workshop Inspection Equipment

Consumables, Materials and Expendables

NONE

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
PLUGAR
PLUG - EXPANSION, OVERSIZEDU1653AS3123-60AR

Double Helical Coil Insert

PINAR
Insert - Double Helical CoilLOCAL2391-4CN375AR

Double Helical Coil Insert

Insert - Double Helical CoilLOCAL4691-4CN339AR

Double Helical Coil Insert

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-60-21-350-215 Remove the Expansion Plugs and Pins

      1. Refer to Figure and Figure.

      1. Drill and tap a hole into the pin.

      2. Extract the pin using a bolt and striker.

      3. Tap the inner diameter of the expansion plug.

      4. Extract the expansion plug using a bolt and striker.

    2. SUBTASK 72-60-21-350-216 Remove the Helical Insert

    1. Refer to Figure.

      2. Apply the Extracting tool (1227-6) into the insert.

      1. Drive the Extracting tool (1227-6) into the insert at approximately a quarter of a coil from the end of the insert.

      3. Arrange the Extracting tool (1227-6) into the insert.

      1. Hit the head of the tool lightly to dig the blade into the top of the coil of the insert. Use a hammer.

      4. Complete removal of the insert.

      1. Bear down hard on the handle of the tool.

      2. Turn the tool slowly counterclockwise.

      3. Maintain a hard pressure on the handle when the insert backs out.

    3. SUBTASK 72-60-21-350-217 Repair the Helical Insert Holes

      1. Refer to Figure.

      2. Drill hole to a minor diameter of 0.3041 in. - 0.3110 in. (7.724 mm - 7.899 mm).

      3. Tap the hole using Tap tool, double insert. Tap the entire depth of the hole.

    4. SUBTASK 72-60-21-220-199 Check the Bore Dimensions

    1. Refer to Figure.

      2. Diameter A

        1. Between 0.4687 in. - 0.4712 in. (11.900 mm - 11.965 mm).

        1. Proceed to the next step. Use the expansion plug. Additional machining is not necessary.

        2. Damaged or more than 0.4712 in. (11.965 mm).

        1. Machine the diameter to 0.4787 in. - 0.4812 in. (12.159 mm - 12.222 mm) to accept an oversized plug. Use a reamer.

        2. Replace the Surface Protection with SPM TASK 70-38-02-300-503.

    5. SUBTASK 72-60-21-350-218 Insert Double Helical Coil Threaded Insert

    1. Refer to Figure.

    2. Refer to SPM TASK 70-35-27-300-501, paragraph C.

      3. Install the double helical coil threaded insert.

      1. Install the2391-4CN375 0.25 in. - 0.50 in. (6.35 mm - 12.70 mm) pitch below the inside surface of the Gearbox Casing. Use the Inserting tool (outer insert).

      2. Install the 4691-4CN339 so that the end of the last coil is flush with the end of the outer insert. Use the Inserting tool (outer insert).

    4. Break off the installation tangs at the notch using Break-off tool (outer insert).

    5. Collect and remove all broken tangs.

    6. SUBTASK 72-60-21-350-219 Install the new Plugs and Pins

    1. Refer to Figure.

      2. Use the following parts:

      1. PLUG, if the bore dimension is between 0.4687 in. - 0.4712 in. (11.900 mm - 11.965 mm).

      2. AS3123-60 PLUG - EXPANSION, OVERSIZED, if the bore was machined to accept the oversized plug in Step.

      3. Insert the plug into hole until it is firmly seated on the shoulder at the bottom of the hole.

      1. Apply an axial load of 50 lbs - 100 lbs (23 kg - 45 kg) or tap the plug lightly with a punch to seat the plug in the bottom of the hole.

      2. The plug must be at least 0.010 in. (0.25 mm) below the surface of the part.

      4. Insert the pin into the installed plug.

      1. Insert the pin small end first.

      2. Do not degrease the pin. Supplementary lubricant must not be used.

      3. Press or drive the pin using a vented driver until the large end of the pin is 0.005 in. (0.125 mm) above to 0.003 in. (0.076 mm) below the end of the plug.

    7. SUBTASK 72-60-21-350-220 Identify the Repair

      1. Vibro-engrave VRS5711 adjacent to the part number.

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

    8. Figure: Helical Insert Locations

    Helical Insert Locations

    Figure: Hole Preparation

    Hole Preparation

    Figure: Installation Of Plug And Pin

    Installation Of Plug And Pin

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new repair. (19VF846)

Link not Found
Manufacturer Code:01556
Enterprise Name:EMHART TEKNOLOGIES
BU Name:EMHART TEKNOLOGIES
Department:INDUSTRIAL DIVISION
Street:50 SHELTON TECHNOLOGY CENTER
P.O. Box:859
City:SHELTON
State:CT
Zip Code:06484
Country:USA
Phone Number:1-203-924-9341
Fax Number:1-203-925-3109
Internet:www.helicoil.com, www.emhart.com
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:U1653
Enterprise Name:Society Of British Aerospace Companies, LTD.
Link not Found
Link not Found
Part Number:AS3123-60
Part Name:PLUG - EXPANSION, OVERSIZED
Manufacturer Code:U1653
Link not Found
Manufacturer Code:LOCAL
Tool Number:Break-off tool (4032-4)
Tool Name:Break-off tool (outer insert)
Manufacturer Code:LOCAL
Tool Number:Extracting tool (1227-6)
Tool Name:Extracting tool (1227-6)
Manufacturer Code:LOCAL
Tool Number:Fluorescent penetrant inspection equipment
Tool Name:Fluorescent Penetrant Inspection Equipment
Manufacturer Code:01556
Tool Number:Helicoil Twinsert Kit Number 3178-4
Tool Name:Helicoil Twinsert Kit Number 3178-4
Manufacturer Code:LOCAL
Tool Number:Inserting tool (2705-4)
Tool Name:Inserting tool (outer insert)
Manufacturer Code:LOCAL
Tool Number:Magnifying Glass
Tool Name:Magnifying Glass
Manufacturer Code:LOCAL
Tool Number:Standard Workshop Equipment
Tool Name:Standard Workshop Equipment
Manufacturer Code:LOCAL
Tool Number:Tap tool, double insert (3893-4)
Tool Name:Tap tool, double insert
Manufacturer Code:LOCAL
Tool Number:Vibration peen equipment
Tool Name:Vibration peen equipment
Manufacturer Code:0AM53
Tool Number:Workshop Inspection Equipment
Tool Name:Workshop Inspection Equipment