* * * FOR ALL PIP 2
TASK 72-00-01-300-816
1 . Unlimited Size Abradable Shroud Repair.
CAUTION:
INCORRECT REPAIR OF THE ABRADABLE SHROUD CAN CAUSE SEVERE ENGINE DAMAGE. DO THE REPAIR AS SPECIFIED IN THIS TASK.
A.This procedure gives instructions to repair the fan stator module assembly, forward fan case (fan case) abradable shroud (abradable shroud) by replacing the abradable material and restoring the contour with a grind tool. Refer to Figure 901.
NOTE:
If the repair source will perform this repair for the first time, please contact GE Aviation to submit a GT3029-1 form for repair source substantiation to begin. Approval by GE Aviation of clearance and run out data from the first fan case grind performed is necessary before it can be used on flight hardware.
 
GE Aviation
 
1 Neumann Way, Mail Drop: S171
 
Cincinnati, Ohio 45215-6301, U.S.A.
 
Attn: Repair Substantiation
B.The following maximum repairable limits apply to this repair:
NOTE:
The information below gives maximum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.
(4)Visual Inspection.
(a)Do an inspection of the forward fan case (01-011 , 72-21-00) (SIN 83500) or forward fan case (01-012 , 72-21-00) (SIN 83500) or forward fan case (01-013 , 72-21-00) (SIN 83500) for:
4Voids, wear grooves, rubs, and areas not bonded on the abradable material:
Maximum Repairable Limits:
Any amount, up to the full abradable surface.
5Spalled, loose, or missing abradable material in the transition zones:
Maximum Repairable Limits:
Any amount, up to the full abradable surface.
6Fan blade tip clearance, F1.0, F1.5 and F2.0:
Maximum Repairable Limits:
Any amount, up to the full abradable surface.
C.The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2447M10G01  
2447M10G02  
2447M10G03  
--
D.Proprietary/Complex Process Statement.
(1)None.
2 . Tools, Equipment, and Materials.
NOTE:
Repair sources can use equivalent alternatives for tools, equipment, and consumable materials, however, the repair source must demonstrate and document equivalency.
A.Tools and Equipment.
(1)Special Tools
 
Tool No.
Description
 
11C3001G03
Fixture, Machining Stage 1 Fan Case Shroud (grind tool)
 
11C3406G04
Runout Measurement Tool (runout tool)
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
0-0.150 inch (0-3.81 mm)
The L.S. Starret Company
 
Taper Gauge, No. 270
121 Crescent Street
 
(Starrett No. 270 taper gauge)
Athol, MA 01331 USA.
 
Telephone: (978) 249-3551
 
Fax: (978) 249-8495
 
Belt Sanderz (4643A71)
McMaster-Carr
 
P.O. Box 4355
 
Chicago, IL 60680-4355 USA
 
Telephone: (630) 833-0300
 
Fax: (630) 834-9427
 
or Local Purchase
 
Drive Mixer, Model 285 (Semkit mixer)
Courtaulds Aerospace Semco
 
Packaging and Application
 
Systems
 
5454 San Fernando Road
 
Glendale, CA 91203 USA
 
Wooden Roller
Local Purchase
 
1.00 inch (25.4 mm) x 1.00 inch
McMaster-Carr
 
(25.4 mm) x 0.200 inch (5.08 mm)
P.O. Box 4355
 
in thickness Gauge
Chicago, IL 60680-4355 USA
 
Block (2233A5) (gauge block)
Telephone: (630) 833-0300
 
Fax: (630) 834-9427
(3)Locally Manufactured Tools.
 
Description
Figure
 
Profile Template
902
 
Depth Gauge
904
 
Teflon Spatula
905
 
Steel Rod
906
B.Consumable Materials.
 
Code No.
Description
 
C01-155
Adhesive, Paste, Two Part (adhesive paste)
 
C01-161
Abradable Seal Material (abradable material)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C05-003
Marking Pen (pen)
 
C10-021
Tape, Plastic
 
C10-051
Film, Release, Perforated
 
C10-108
Brush, Disposable, Natural Bristle (brush)
 
C10-136
Tape, Pressure Sensitive (Flashbreaker tape)
 
C10-141
Abrasive Paper, 120/180 Grit, Sic, Wet/Dry (abrasive paper)
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cleaning cloth)
C.Referenced Procedures
 
ATA No.
Description
 
70-16-00
Marking Practices
 
70-16-02
Temporary Marking
 
70-16-04
Vibro-Peen Marking
 
70-46-01
Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials
 
70-46-02
Drying of Thermosetting Composite Materials
 
72-00-01
Inspection 001
 
72-00-01
Installation 001, Config 2
 
72-00-01
Removal 001
 
72-00-01
Repair 003
 
--
SAE ARP 5144 Heat Application for Thermosetting Resin Curing
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-00-01-220-318
A.Refer to Figure 901 for specified dimensions and locations.
NOTE:
The dimensional data identified within this repair procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
4 . Setup Information.
Subtask 72-00-01-350-258
CAUTION:
MAKE SURE THAT ALL MATING SURFACES OF THE GRIND TOOL, 11C3001, ARE CLEAN BEFORE YOU ASSEMBLE THE PARTS. DIRT CAN CAUSE AN UNWANTED PROFILE.
NOTE:
In this document the 6:00 o’clock position is defined as up to 3 inches circumferentially offset from the splitline, and not on the splitline.
A.Set-up the fan case for grinding. Refer to Figure 907 and as follows:
(1)Install the 11C3001   grind tool in the fan case.
(2)Put the protective mat in the bottom of the fan case from the front of the fan case to aft of the abradable shroud.
(3)Attach the 11C3001   grind tool to the fan rotor as follows:
NOTE:
The names of the parts of the 11C3001   grind tool specified in this document are the same as those used on the drawing. Use a copy of the drawing to refer to when this fixture is installed.
(a)Attach the rabbet plate to the aft spinner mounting holes on the fan rotor forward flange as follows:
1Get 14 socket head cap screws 0.3125-18-3A x 3.00 inch (76.2 mm) in length and 14 OD washers 0.688 inch (17.48 mm).
2Get 14 slave barrel nuts, 11C3001P09.
NOTE:
The slave barrel nuts are used to prevent damage to the locking feature of the flight hardware barrel nuts.
3Put the rabbet plate on the location rabbet of the fan rotor forward flange with the 0 mark at the post with the mark 1 which is clockwise when viewed forward looking aft of the adjacent rotor post with the mark 1. Refer to Figure 903.
4Install the 14 socket head cap screws 0.3125-18-3A x 3.00 inch (76.2 mm) in length as follows:
aUse the 14 0.688 inch (17.48 mm) OD washers.
bUse the 14 slave barrel nuts, 11C3001P09.
CAUTION:
DAMAGE TO THE FAN DISK CAN OCCUR IF YOU INSTALL THE SLAVE BARREL NUTS INCORRECTLY.
cInstall each slave barrel nut, 11C3001P09, with the flat facing aft.
5Tighten the 14 socket head cap screws, 0.3125-18-3A x 3.00 inch (76.2 mm) in length, in a criss-cross pattern to a torque to 80 to 100 lb in. (10 to 11 Nm).
6Make sure that the aft face of the rabbet plate touches the fan rotor forward flange at each bolt location as follows:
aGet a shim of 0.0015 inch (0.039 mm) in thickness.
bPut the shim between the aft face of the rabbet plate and the fan rotor forward flange.
cIf the shim will fit between the aft face of the rabbet plate and the fan rotor forward flange, loosen the bolts and do the installation again from paragraph 4.A.(3)(a)5 again.
dMake sure that you correctly install the rabbet plate on the rabbet. If you do not install correctly the rabbet plate, do the installation again as specified in paragraph 4.A.(3).
(b)Turn the rotor until the diamond pin on the rabbet plate is at the 6:00 o’clock position.
(c)Install the fixture frame as follows:
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
1If the cross slide assembly is attached to the frame, remove the cross slide assembly from the frame before you install the frame as follows:
aIf necessary, remove only the hex bolt, 0.500-13 UNC-2A x 3.50 inch (88.9 mm) in length to remove the dovetail attachment.
NOTE:
The cross slide assembly includes the router assembly, the two cross slides, and the slide mounting bracket.
2Get eight socket head cap screws 0.3125-16 UNC x 1.0 inch (25.4 mm) in length and eight OD flat washers 0.688 inch (17.48 mm) and as follows:
NOTE:
The fixture frame is heavy and the center of gravity will try to turn in your hands.
aMake sure that the fixture frame is lifted by two persons or more.
3Hold the fixture frame vertically against the rabbet plate with the indicator end down.
4Push the pins on the rabbet plate in the bushed holes in the fixture frame.
5Attach the fixture frame with the eight socket head cap screws 0.3125-16 UNC x 1.0 inch (25.4 mm) in length and the eight 0.688 inch (17.48 mm) OD flat washers.
6Tighten the eight socket head cap screws, 0.3125-16 UNC x 1.0 inch (25.4 mm) in length to a torque to 120 to 150 lb in. (13.6 to 16.9 Nm).
7Make sure that the forward face of the rabbet plate touches the frame at all bolt locations as follows:
aGet a shim of 0.0015 inch (0.038 mm) in thickness.
bTry to put the shim between the forward face of the rabbet plate and the frame.
cIf you can put the shim between the forward face of the rabbet plate and the frame, loosen the bolts and do the installation from paragraph 4.A.(2)(c)5 thru paragraph 4.A.(2)(c)6 again.
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
(d)Attach the cross slide assembly as follows:
1Use the radial slide to move the cutter to make sure that the cutter will not touch the case when you install the cross slide.
2Get the hex bolt, 0.500-13 UNC-2A x 3.50 inch (88.9 mm) in length, the 1.250 inch (31.7 mm) OD flat washer, and the 0.500-13 UNC-2A hex nut.
3Turn the fixture frame until the cross slide attachment end is at the 6:00 o’clock position.
4Push the cross slide assembly in the fixture frame dovetail with the handle of the large cross slide in the forward position.
5Align the 0.500 inch (12.7 mm) hole in the cross slide and fixture frame dovetail.
6Attach the cross slide assembly to the fixture frame with the hex bolt, 0.500-13 UNC-2A x 3.50 inch (88.9 mm) in length, the 1.250 inch (31.7 mm) OD flat washer, and the 0.500-13 UNC-2A hex nut, and do as follows:
CAUTION:
MAKE SURE THAT YOU TORQUE THE CROSS SLIDE BOLT. THE CORRECT TORQUE IS NECESSARY TO KEEP THE CROSS SLIDE IN THE CORRECT POSITION.
aTighten the bolt to a torque of 120 to 150 lb in. (13.6 to 16.9 Nm).
WARNING:
BALANCE THE PARTS TO BE LIFTED BEFORE YOU OPERATE THE EQUIPMENT. DO NOT STAY BELOW THE EQUIPMENT WHEN YOU LIFT THE PART. DO NOT LIFT MORE THAN THE SPECIFIED WEIGHT. IF THE PARTS ACCIDENTALLY MOVE OR FALL, A BAD INJURY CAN OCCUR.
(e)Attach the counterbalance weights as follows:
1Get the two counterbalance weights, two 0.500-13 UNC-2A wing nuts, and two 1.25 inch (31.8 mm) OD flat washers.
2Turn the fixture frame on the rotor until the counterbalance weight attachment studs, on the opposite end of the frame from the cross slide assembly, are at the 6:00 o’clock position, and do as follows:
aHold the rotor tightly.
3Put the two counterbalance weights on the studs and attach them with the two 0.500-13 UNC-2A wing nuts and the two 1.25 inch (31.8 mm) OD flat washers.
(f)If you do the runout measurements, attach the indicator on the frame as follows:
1Get the digital probe scooter block, 11C3001P12, and the knurled head screw.
NOTE:
The digital probe scooter block, 11C3001P12, is used to hold the indicator.
2Attach the digital probe scooter block, 11C3001P12, in the frame slot as follows:
aUse the knurled head screw to hold the digital probe scooter block, 11C3001P12, in the correct axial position.
3Attach the indicator to the digital probe scooter block, 11C3001P12, as follows:
aPut the indicator in the split bushing.
bUse the long socket head set screw, 0.190-24 UNC-3A x 0.375 inch (9.53 mm) in length to hold the indicator in the correct position.
4Connect the cable from the indicator to one of the readouts.
5Move the indicator radially to the inner side to make sure that the indicator is connected to the readout correctly.
6Make sure that the radially outward movement of the indicator reads positive on the readout.
7If the readout shows negative for a radially outward movement of the indicator, refer to the manufacturer’s instructions to change the sign of the display.
8Loosen the knurled head screw to move the digital probe scooter block, 11C3001P12, to the correct axial position that you will measure.
9Tighten the knurled head screw to keep the digital probe scooter block, 11C3001P12, in the correct axial position that you will measure.
(g)If you do the radial measurements, attach a depth micrometer scooter block, 11C3001P13, on the frame as follows:
1Get the depth micrometer scooter block, 11C3001P13, and the knurled head screw.
NOTE:
The depth micrometer scooter block, 11C3001P13, is used to hold the depth micrometer.
2Attach the depth micrometer scooter block, 11C3001P13, in the frame slot as follows:
aUse the knurled head screw to hold the depth micrometer scooter block, 11C3001P13, in the correct axial position.
3Tighten the knurled head screw to keep the depth micrometer in the correct axial position.
4Attach an air hose to the router.
5Attach a vacuum cleaner to the vacuum exhaust port.
6Remove the protective mat.
5 . Procedure.
Subtask 72-00-01-930-012
A.Make or buy the 11C3001   grind tool. Refer to Figure 907.
Subtask 72-00-01-930-013
B.Make or buy the locally manufactured tools as follows:
(1)A depth gauge. Refer to Figure 904.
(2)A steel rod. Refer to Figure 906.
Subtask 72-00-01-350-272
C.Put a mark on the abradable shroud profile template. Refer to TASK 70-16-00-350-001 (70-16-00, MARKING PRACTICES), TASK 70-16-04-350-019 (70-16-04, VIBRO-PEEN MARKING), Figure 902, and do as follows:
(1)If necessary, make a profile template for repairs with an axial dimension of more than 8.0 inches (204 mm). Refer to Figure 902 and Figure 918.
NOTE:
The profile template can also be used for repairs with an axial dimension less than 8.0 inches (203 mm). The marks on the template will help get the axial measurements.
(2)Make a line on the profile template for each axial angle change.
(3)Write the axial dimensions on the profile template.
(4)Write the angle dimensions for each axial angle change on the template.
NOTE:
The marks will be used to make the axial measurements and 11C3001   grind tool adjustments.
Subtask 72-00-01-020-007
D.Remove the forward spinner. Refer to TASK 72-00-01-020-801 (72-00-01, REMOVAL 001).
Subtask 72-00-01-220-319
CAUTION:
DO NOT TOUCH THE FAN BLADE. IF YOU TOUCH THE FAN BLADE THE MEASUREMENT WILL BE INNACCURATE.
E.Alternative Procedure Available. If you use the 11C3406   runout tool to get the abradable shroud runout measurements. Refer to TASK 72-00-01-420-802 (72-00-01, INSTALLATION 001 - CONFIG 02), Figure 911, and do as follows:
NOTE:
If the runout measurements cannot be measured as a result of a large damaged area, the runout and clearance measurements can be ignored. The correct profile will be machined with the nominal abradable shroud dimensions in Subtask 72-00-01-320-011 (paragraph 5.Z.B.) and in Figure 901.
(1)Measure the fan blade clearances and the abradable shroud runout at F1.0 location, F1.5 location, and F2.0 location.
(2)Use the 11C3406   runout tool to get the axial locations and runout measurements as follows:
(a)Put a mark on the abradable shroud in the area that you will measure. Refer to TASK 70-16-00-350-001 (70-16-00, MARKING PRACTICES), TASK 70-16-02-350-017 (70-16-02, TEMPORARY MARKING), and as follows:
1Find the lowest axial splitline between the forward acoustic liners.
NOTE:
This is the 6:00 o’clock position of the engine.
NOTE:
If the engine is on wing, the axial splitline will not be at the lowest position of the case.
2Put a mark at the F1.0 location, F1.5 location, and F2.0 location on the abradable shroud surface at the 6:00 o’clock position, and do as follows:
aGet the axial locations from the indicator point on the 11C3406   runout tool.
(3)Use the tables in Figure 912 and Figure 913 to record the measurements.
(4)Calculate to find the minimum, maximum, and average blade tip clearances. Refer to Figure 915.
NOTE:
The calculations in Figure 915 will be used to make a decision on the abradable shroud areas that will be repaired.
Subtask 72-00-01-220-320
E.A.Alternative Procedure. If you use the 11C3001   grind tool to get the abradable shroud runout measurements. Refer to Figure 911 and do as follows:
NOTE:
Make the runout measurements in Subtask 72-00-01-350-264 (paragraph 5.K.).
NOTE:
If the runout measurements cannot be measured as a result of a large damaged area, the runout and clearance measurements can be ignored. The correct profile will be machined with the nominal abradable shroud dimensions in Subtask 72-00-01-320-011 (paragraph 5.Z.B.) and in Figure 901.
(1)Put a mark on the abradable shroud area where you will measure. Refer to TASK 70-16-00-350-001 (70-16-00, MARKING PRACTICES), TASK 70-16-02-350-017 (70-16-02, TEMPORARY MARKING), and as follows:
(a)Find the lowest axial splitline between the forward acoustic liners.
NOTE:
This is the 6:00 o’clock position of the engine.
NOTE:
If the engine is on wing, the axial splitline will not be at the lowest position of the case.
(b)Put a mark at the F1.0 location, F1.5 location, and F2.0 location on the abradable shroud surface at the 6:00 o’clock position.
CAUTION:
DO NOT TOUCH THE FAN BLADE THAT YOU MEASURE. IF YOU TOUCH THE FAN BLADE THE MEASUREMENT WILL BE INACCURATE.
(2)Measure the fan blade tip clearance dimension at the F1.0 location, F1.5 location, and F2.0 location, and as follows:
NOTE:
If the runout measurements cannot be measured as a result of a large damaged area, the runout and clearance measurements can be ignored. The correct profile will be machined with the nominal abradable shroud dimensions in paragraph Subtask 72-00-01-320-011 (paragraph 5.Z.B.) and in Figure 901.
(a)Hold the blades near the spinner and turn the fan clockwise, forward looking aft, when you move the blades.
(b)Turn the fan blades for two full revolutions.
(c)Turn the fan blade numbered 1 to the 6:00 o’clock position.
(d)Measure the fan blade tip clearance. Refer to Figure 911 and as follows:
CAUTION:
MAKE SURE THAT THE GAUGE BLOCK IS IN THE CORRECT POSITION. THE MEASUREMENT WILL BE INACCURATE IF THE GAUGE BLOCK IS IN THE INCORRECT POSITION.
1Put a gauge block of 0.200 inch (5.08 mm) in thickness on the F1.0 mark that was made on the abradable shroud surface, and do as follows:
aUse sufficient shims of 0.010 inch (0.25 mm) in thickness to make a 0.200 inch (5.08 mm) thickness.
bMake sure that the gauge block is fully against the abradable shroud surface.
2Use the gauge block and the Starrett No. 270 taper gauge to measure between the fan blade and the abradable shroud at the F1.5 position. Put the starrett taper gauge in a direction approximately 45 degrees to the forward edge of the abradable from the convex side of the blade and read the measurement on the concave side of the blade.
CAUTION:
MAKE SURE THAT THE GAUGE BLOCK IS FULLY AGAINST THE ABRADABLE SURFACE THAT YOU WILL MEASURE. CLEARANCE UNDER THE GAUGE BLOCK WILL MAKE THE MEASUREMENT INACCURATE.
3Install the gauge block to let the Starrett No. 270 taper gauge move freely below the blade.
4Add the gauge block thickness and the taper gauge reading and record the clearance measurement. Refer to Figure 913.
(e)Turn the adjacent fan blade to the 6:00 o’clock position.
NOTE:
The blade must be turned clockwise, forward looking aft.
(f)Do paragraph Subtask 72-00-01-220-320 (paragraph 5.E.A.(2)(d)) and Subtask 72-00-01-220-320 (paragraph 5.E.A.(2)(e)) again for blades number 2 through blade 18.
(g)Do paragraph Subtask 72-00-01-220-320 (paragraph 5.E.A.(2)(d)) thru Subtask 72-00-01-220-320 (paragraph 5.E.A.(2)(f)) again for the F1.5 location and the F2.0 location.
Subtask 72-00-01-020-008
F.Remove the aft spinner, all the fan platforms, all the fan blades, all the retainers, and the dovetail shims. Refer to TASK 72-00-01-020-801 (72-00-01, REMOVAL 001).
Subtask 72-00-01-020-009
G.Remove all the barrel nuts and barrel nut retainers from the fan disk. Refer to TASK 72-00-01-020-801 (72-00-01, REMOVAL 001).
Subtask 72-00-01-350-260
H.Apply masking to the fan case. Refer to TASK 70-46-01-350-030 (70-46-01, MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS) and do as follows:
(1)Apply masking to the fan case areas adjacent to the repair area as follows:
(a)Aft inner and aft outer acoustic liners.
(b)Outlet guide vanes.
(c)Forward acoustic liners.
(d)The acoustically treated areas of the inlet.
(e)All core engine openings, the booster and the variable bypass valve (VBV) doors.
(f)The face of the fan rotor and the slots between the fan rotor hubs.
(2)Use Composite Masking Method No. 3.
(3)Apply C10-021  plastic tape to make a flap on the rotating joints, but let the fan rotor free to turn.
(4)Apply C10-021  plastic tape to the glass fiber areas forward and aft of the abradable shroud surface.
(5)Apply C10-021  plastic tape to the fan rotor.
NOTE:
The C10-021  plastic tape will keep the dust out of the fan blade dovetail areas.
Subtask 72-00-01-350-261
I.Set-up the abradable shroud for grinding by installing the 11C3001   grind tool. Refer to Subtask 72-00-01-350-258 (paragraph 4.A).
Subtask 72-00-01-350-262
J.Put a mark on the abradable shroud in the area where you will machine. Refer to TASK 70-16-00-350-001 (70-16-00, MARKING PRACTICES), TASK 70-16-02-350-017 (70-16-02, TEMPORARY MARKING), and as follows:
(1)Put a mark at the F1.0 location, F1.5 location, and F2.0 location on the abradable shroud surface at the 6:00 o’clock position as follows:
(a)Find the lowest axial splitline between the forward acoustic liners.
NOTE:
This is the 6:00 o’clock position of the engine.
NOTE:
If the engine is on wing, the axial splitline will not be at the lowest position of the case.
(b)Put a mark on the abradable shroud, axially across the abradable shroud, at the 6:00 o’clock position.
(c)Put an X mark on the 6:00 o’clock axial mark on the abradable material at the F1.0 location, F1.5 location, and F2.0 location. Refer to Figure 911.
NOTE:
If marks were made at F1.0 location, F1.5 location and F2.0 location in Subtask 72-00-01-220-319 (paragraph 5.E), these marks can be used again.
(d)Put a mark on the 6:00 o’clock axial mark on the abradable material for all the axial positions as follows:
Subtask 72-00-01-220-321
1Alternative Procedure Available. Use the profile template to get the axial measurements. Refer to Figure 902.
Subtask 72-00-01-220-322
1.A.Alternative Procedure. Use a measuring tape to get the axial measurements. Refer to Figure 902.
Subtask 72-00-01-350-263
(e)Write the axial measurement and angle for each angle change between the marks.
Subtask 72-00-01-350-264
K.If you did not get the runout measurements in Subtask 72-00-01-220-319 (paragraph 5.E.), and do as follows:
NOTE:
If the runout measurements cannot be measured as a result of a large damaged area, the runout and clearance measurements can be ignored. The correct profile will be machined with the nominal abradable shroud dimensions in 72-00-01-320-011 (paragraph 5.Z.B.) and in Figure 901.
(1)Put a mark on the abradable shroud surface to find the runout measurement locations. Refer to TASK 70-16-00-350-001 (70-16-00, MARKING PRACTICES), TASK 70-16-02-350-017 (70-16-02, TEMPORARY MARKING), and as follows:
(a)Use a C05-003  pen or C10-021  plastic tape to mark the locations.
(b)Start at the 6:00 o'clock position.
(c)Make 18 equally spaced marks around the fan case to make the measurements.
NOTE:
Get these mark locations before the fan blades are removed in Subtask 72-00-01-020-008 (paragraph 5.F). This will make the marks easy to find.
(2)Attach the electronic indicator. Refer to paragraph Subtask 72-00-01-350-258 (paragraph 4.A.(2)(f)3).
(3)Put the indicator tip on the axial mark that you will measure.
(4)Make sure that the indicator is free to move at least 0.200 inch (5.08 mm) up and down.
(5)Hold the 11C3001   grind tool to turn the fan rotor, clockwise, forward looking aft.
(6)Turn the fan disk two complete turns as follows:
(a)Make sure that the indicator reads zero, at the same location of each turn, before you measure the runouts.
NOTE:
The fan rotor must not be turned counterclockwise when the runouts are measured.
(7)Make the abradable shroud runout measurements at the F1.0 location, F1.5 location, or F2.0 location as follows:
(a)Put the indicator tip on the axial mark on the abradable shroud and make the indicator display read zero.
(b)Hold the 11C3001   grind tool to turn the fan rotor, and do as follows:
1Read the display on the electrical remote display unit to the dial indicator. Refer to the Starrett instruction book to use the electrical remote display unit and do as follows:
NOTE:
The remote display unit will work properly if the readings decrease when the indicator tip is lifted off the abradable shroud surface.
aIf necessary, you can move indicator tip in the opposite direction.
bMake sure that the indicator value decreases as the fan case radius decreases.
2Find the minimum case radius at the axial position that you will measure to zero the gage.
(c)Make the electronic display show zero at the minimum case radius.
NOTE:
This will cause all the runout measurements to be positive numbers.
(d)Turn the fan rotor to put the indicator at the 6:00 o'clock position.
(e)Make a record of the runout in the table. Refer to Figure 912.
(f)Turn the fan rotor clockwise, forward looking aft, until the indicator is in position at the adjacent mark.
(g)Do Subtask 72-00-01-350-264 (paragraph 5.K.(7)(e)) thru Subtask 72-00-01-350-264 (paragraph 5.K.(7)(f)) again until you get all 18 dimensions around the abradable shroud.
(h)Do Subtask 72-00-01-350-264 (paragraph 5.K.(3)) thru Subtask 72-00-01-350-264 (paragraph 5.K.(7)(g)) again for the remaining axial locations.
(8)Measure to find the minimum, maximum, and average blade tip clearances. Refer to Figure 915.
NOTE:
The measurements in Figure 915 will be used to make a decision on the abradable shroud areas that will be repaired.
Subtask 72-00-01-350-265
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR CAUSE IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
CAUTION:
FOR ALL SURFACES WHERE YOU WILL APPLY ABRADABLE MATERIAL, YOU MUST MACHINE OR SAND TO GET A CLEAN SURFACE. INSUFFICIENT SURFACE PREPARATION WILL CAUSE A WEAK BOND FOR THE ABRADABLE MATERIAL.
L.Alternative Procedure Available. Remove the abradable shroud damaged areas, and do as follows:
(1)If the trenchfiller face sheet is damaged, the abradable shroud is not repairable by this procedure. Refer to TASK 72-00-01-300-801 (72-00-01, REPAIR 003).
(2)Adjust the axial cross slide for the angle that you will use for the axial location that you will machine as follows:
(a)Loosen the four 0.3125-18 UNC-3A x 1.25 inch (31.8 mm) long socket head cap screws that attach the axial cross slide.
(b)Put the ball lock pin in the correct bushing plate location for the angle that you will machine. Refer to Figure 908.
(c)Tighten the four 0.3125-18 UNC-3A x 1.25 inch (31.8 mm) long socket head cap screws that attach the axial cross slide.
CAUTION:
INCREASE THE ROUTER CUTTER DEPTH SLOWLY. THE ABRADABLE MATERIAL IS APPROXIMATELY 0.62 INCH (15.7 MM) IN THICKNESS. BE CAREFUL WHEN YOU INCREASE THE DEPTH OF THE ROUTER. DO NOT MACHINE INTO THE GLASS FIBER LAYER. THIS WILL CAUSE DAMAGE THE GLASS FIBER LAYER.
(3)If you cannot see the glass fiber layer, find the depth of cut of the router as follows:
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(a)Carefully sand down to the adhesive in a local area manually or with a small belt sander, and do as follows:
NOTE:
The adhesive is of a creamy/white color.
1Stop when you see the adhesive.
(b)Make an allowance for the fan case runout when you set the router depth.
(4)Start the vacuum cleaner.
WARNING:
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(5)Start the cutter.
(6)Move the cutter with the radial cross slide to sufficient depth to remove the remaining damaged abradable material.
CAUTION:
HOLD THE GRIND TOOL TIGHTLY. MAKE SURE THAT YOU KEEP THE CUTTER IN THE REPAIR AREA. MOVEMENT OF THE GRIND TOOL EXTERNAL TO THE REPAIR AREA WILL INCREASE THE DAMAGE DIMENSION. DAMAGE TO THE FAN CASE CAN OCCUR.
(7)Machine the abradable shroud as follows:
NOTE:
It is not necessary to remove all the abradable material. Stop the machining procedure when the abradable material that is correctly bonded is found.
(a)Machine a minimum quantity of C01-161   abradable material to remove the damage and do as follows:
CAUTION:
HOLD THE GRIND TOOL TIGHTLY. MAKE SURE THAT YOU KEEP THE CUTTER IN THE REPAIR AREA. MOVEMENT OF THE GRIND TOOL AROUND THE CASE WILL INCREASE THE DAMAGE DIMENSION. DAMAGE TO THE FAN CASE CAN OCCUR.
1Move the 11C3001   grind tool and the fan rotor to make circumferential cuts.
2Move the router axially on the cross slide to cut out the damaged area.
3Make sure that the edges of the cavity have straight sides or are undercut. Refer to Figure 909.
(8)Stop the cutter.
(9)Do Subtask 72-00-01-350-265 (paragraph 5.L.(3)) thru Subtask 72-00-01-350-265 (paragraph 5.L.(10)) again to remove all the damage.
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(10)If necessary, sand the abradable shroud with C10-141  abrasive paper and a sanding block to remove the remaining damaged abradable material.
(11)Tap the repair area lightly with the steel rod. Listen to the sound it makes and do as follows:
NOTE:
The different thickness of the facesheet and the C01-161  abradable material will make a different sound. This difference in sound does not show a disbond or delamination.
(a)If you hear a solid click, there is no disbond or delamination.
(b)If you do not hear a solid click, there is a disbond or delamination.
(12) If you find a disbond or delamination, do Subtask 72-00-01-350-265 (paragraph 5.L.(1)) thru Subtask 72-00-01-350-265 (paragraph 5.L.(11)(b)) again to remove all the disbonds or delaminations.
Subtask 72-00-01-350-266
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
CAUTION:
FOR ALL SURFACES WHERE YOU WILL APPLY ABRADABLE MATERIAL, YOU MUST MACHINE OR SAND TO GET A CLEAN SURFACE. INSUFFICIENT SURFACE PREPARATION WILL CAUSE A WEAK BOND FOR THE ABRADABLE MATERIAL.
L.A.Alternative Procedure. Remove the abradable shroud damaged area as follows:
(1)Use a router or small belt sander to remove the remaining defective abradable material down to abradable material that is correctly bonded to the fan case.
NOTE:
It is not necessary to remove all the abradable material. Stop the machining procedure when you find abradable material that is correctly bonded.
(2)If you cannot see the glass fiber layer, find the depth of cut of the router and do as follows:
(a)Carefully sand down to the adhesive in a local area manually or with a small belt sander and do as follows:
NOTE:
The adhesive is of a creamy/white color.
1Stop when you see the adhesive.
(3)Make sure that the edges of the cavity have straight sides or are undercut by a small amount. Refer to Figure 909.
(4)If necessary, sand the abradable shroud with C10-141   abrasive paper to remove the remaining damaged abradable material.
(5)Tap the repair area lightly with the steel rod. Listen to the sound it makes and do as follows:
NOTE:
The different thickness of the facesheet and the abradable will make a different sound. This difference in sound does not show a disbond or delamination.
(a)If you hear a solid click, there is no disbond or delamination.
(b)If you do not hear a solid click, there is a disbond or delamination.
(6)If you find a disbond or delamination, do Subtask 72-00-01-350-266 (paragraph 5.L.A.(1)) thru Subtask 72-00-01-350-266 (paragraph 5.L.A.(5)(b)) again to remove all the disbonds.
Subtask 72-00-01-160-037
M.Remove all the unwanted material from the repair area with a vacuum cleaner.
Subtask 72-00-01-360-055
N.Look for areas moist with water in the abradable shroud repair area and do as follows:
NOTE:
The areas that are moist with water will be of a darker color.
(1)Dry the abradable shroud areas moist with water. Refer to TASK 70-46-02-360-002 (70-46-02, DRYING OF THERMOSETTING COMPOSITE MATERIALS) and as follows:
(a)Use Absorbed Moisture Removal - Method 3 (Hot Air Dryer).
(b)Attach a thermocouple to the moist area.
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(c)Increase the temperature of the repair area to 180°F (82°C) maximum.
(d)Keep the repair area at a temperature of 180°F (82°C) maximum until you cannot see the water.
(e)Continue to dry the repair area for 30 more minutes at 180°F (82°C) maximum.
Subtask 72-00-01-220-323
O.If you can see the glass fiber facesheet in the repair area, do as follows:
(1)Do an inspection of the glass fiber surface for damage as follows:
(a)If the glass fiber layer is damaged, the abradable shroud is not repairable with this procedure. Refer to TASK 72-00-01-300-801 (72-00-01, REPAIR 003).
Subtask 72-00-01-350-267
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(2)Sand the fan case with C10-141  abrasive paper to make the glass fiber surface smooth.
NOTE:
The glass fiber surface must be sanded manually to keep the repair area at room temperature.
Subtask 72-00-01-350-268
P.Clean the abradable shroud repair area. Refer to TASK 70-46-01-350-030 (70-46-01, MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS) and as follows:
WARNING:
USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (207 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.
(1)Remove the dust from the repair area with compressed air that contains no oil.
(2)Use Composite Cleaning Method No. 5.
Subtask 72-00-01-110-055
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(3)Use C04-035  isopropyl alcohol.
Subtask 72-00-01-350-269
Q.Apply masking to the repair area. Refer to TASK 70-46-01-350-030 (70-46-01, MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS) and as follows:
(1)Use Composite Masking Method No. 3.
(2)If necessary, apply masking to the repair area until you apply the C01-161  abradable material and as follows:
(a)Use Composite Masking Method No. 4.
Subtask 72-00-01-360-056
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
CAUTION:
THE ABRADABLE MATERIAL IS VERY REACTIVE. MIX ONLY ONE KIT AT A TIME. THE MIXED RESIN AND CATALYST CAUSE HEAT. THIS CAN CAUSE DAMAGE TO THE MATERIAL AND CAUSE A FIRE HAZARD.
CAUTION:
IF THE ADHESIVE WAS STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE EPOXY.
R.Mix the C01-161  abradable material as follows:
(1)If you stored the C01-161  abradable material in a freezer, let the C01-161  abradable material increase to room temperature before you open the container.
Subtask 72-00-01-360-057
(2)Alternative Procedure Available. Prepare the C01-161   abradable material in the 1.5 lb (0.7 kg) 1 pint (0.473 liters) kit as follows:
CAUTION:
THE ABRADABLE MATERIAL IS IN PRE-MEASURED KITS TO MAKE SURE THAT THE MIXTURE IS IN CORRECT PROPORTIONS. USE ALL THE CONTENTS OF EACH CONTAINER TO GET THE CORRECT RATIO OF RESIN AND CATALYST. INCORRECT RATIO OF MIXTURE WILL MAKE THE ABRADABLE MATERIAL WEAK.
(a)Put each component of the C01-161  abradable material on a clean, metal plate and mix each component individually with spatulas.
NOTE:
The plastic containers can be cut to get all of the resin and the catalyst out of the containers.
(b)Make sure that you mix fully each component of the C01-161   abradable material before you mix them together.
NOTE:
There must be a constant color in each component before they are mixed together.
(c)Use a spatula to mix the resin and catalyst until you can see no streaks of the two components.
NOTE:
Usually 4 or 5 minutes are necessary to do this task.
NOTE:
The pot life of the C01-161  abradable material will increase when the mixed C01-161   abradable material is applied in a thin layer on a clean metal sheet until it is used. This will also remove the caught air in the C01-161  abradable material.
(d)The pot life of the C01-161  abradable material will be approximately 20 minutes at 77°F (25°C).
NOTE:
The pot life starts when the mix of the two components starts as in Subtask 72-00-01-360-056 (paragraph 5.R.(2)(c)).
Subtask 72-00-01-360-058
(2).A.Alternative Procedure. Prepare the C01-161  abradable material in the 6 oz (170 gm) Semkit style cartridge. Refer to Figure 910 and as follows:
(a)Remove the cinch tape from the cartridge body.
(b)Pull the dasher rod up to the end threaded neck of the cartridge to get the foil apart from the mixing dasher.
(c)Push the cartridge sides in the area of the foil to cause damage to the foil barrier.
(d)Push the dasher rod to the plunger end of the cartridge to remove the damaged foil barrier.
(e)Put the dasher rod onto the spindle of the Semkit mixer.
(f)Turn on the Semkit mixer.
(g)Hold the cartridge body and push and pull the cartridge body up and down for 4 minutes.
(h)Make sure that the dasher rod touches the end of the cartridge at the two ends of the travel.
(i)Complete a minimum of 120 travels in the 4 minutes.
(j)Remove the bottom cap.
(k)Push the dasher rod to the plunger end of the cartridge and hold the cartridge firmly at the plunger end.
(l)Turn the dasher rod counterclockwise to disconnect the dasher rod from the mixing dasher.
(m)Remove the dasher rod from the cartridge.
(n)Put the nozzle into the neck end of the cartridge.
(o)Put the cartridge into a Semkit dispensing gun.
(p)Make sure that you remove all the abradable material from the cartridge in 2 minutes or less after you mixed it.
(q)You can apply the C01-161  abradable material to the fan case or in a clean metal sheet.
NOTE:
The pot life of the C01-161  abradable material will increase when the mixed C01-161   abradable material is applied in a thin layer of a clean metal sheet until it is used. This will also remove the caught air in the C01-161  abradable material.
NOTE:
If the C01-161  abradable material starts to make too much heat, it must be put in a steel or aluminum container with a minimum of 10 gal (38 liters) of water. The water will decrease the temperature of the C01-161  abradable material to prevent it is burned and decomposed. The C01-161  abradable material that was on the water cannot be used.
Subtask 72-00-01-360-059
S.Rub the C01-161  abradable material on all of the surfaces of the repair areas with a rigid bristle C10-108  brush and do as follows:
WARNING:
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
(1)Use scissors to cut the bristles of the C10-108  brush to make the rigid bristle C10-108   brush.
(2)Use force to rub the C01-161  abradable material to fully wet all the surfaces of the repair area.
(3)Use a Teflon spatula to push the C01-161  abradable material on the repair area as follows:
(a)Hold the Teflon spatula at a low angle to prevent caught air in the C01-161  abradable material.
(b)Apply a layer of approximate 0.10 inch (2.5 mm) of C01-161  abradable material at a time.
NOTE:
Thick layers of C01-161  abradable material will make too much heat and voids in the repair area.
(4)Use the Teflon spatula to make the repair area smooth and remove the caught air.
(5)If the repair area is more than 0.10 inch (2.5 mm) in depth, let the C01-161  abradable material cure for a minimum of 1 hour before you apply more C01-161   abradable material.
(6)If necessary, do Subtask 72-00-01-360-059 (paragraph 5.S.(1)) thru Subtask 72-00-01-360-059 (paragraph 5.S.(5)) again to get the correct C01-161   abradable material thickness for the repair area.
Subtask 72-00-01-380-014
WARNING:
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
T.Optional Procedure. Cut a piece of C10-051  perforated release film to use as a cover on the abradable shroud repair area and do as follows:
NOTE:
This optional procedure uses the profile template to make the repair area contour smooth.
NOTE:
If this optional procedure is not used to cover the repair area, sufficient C01-161  abradable material for machining must be used.
(1)Make the C10-051  perforated release film approximately 10.0-12.0 inches (254-304 mm) larger all round than the repair area.
(2)Put a small quantity of the C01-161  abradable material at one end of the repair cavity to increase the thickness to above the height of the remaining C01-161  abradable material.
(3)Fill approximately 3.0-4.0 inches (77-101 mm) of the circumferential length of the repair area with C01-161  abradable material at the increased thickness.
(4)Put the C10-051  perforated release film on the repair area and as follows:
(a)The caught air below the C10-051  perforated release film will make voids in the abradable material. Carefully apply the C10-051  perforated release film to make the repair area smooth and remove the caught air.
(5)Pull the C10-051  perforated release film tightly and keep in position with C10-136  Flashbreaker tape or with your hands.
(6)Use the profile template or a wooden roller to push the C01-161  abradable material to the contour of the template.
(7)Use shims on the glass fiber surfaces forward and aft of the repair area under the template to give extra C01-161  abradable material for the machining procedure after you apply it.
NOTE:
The template is the shape of the correct cross section.
(8)Do Subtask 72-00-01-380-014 (paragraph 5.T.(1)) thru Subtask 72-00-01-380-014 (paragraph 5.T.(7)) again until the repair area is filled.
(9)Make sure that you do not remove the C10-051  perforated release film until after the cure is completed in Subtask 72-00-01-360-060 (paragraph 5.W.).
Subtask 72-00-01-160-038
U.If necessary, use a C10-182  cleaning cloth to remove the unwanted abradable material from the repair area.
Subtask 72-00-01-380-015
V.Monitor the C01-161  abradable material on the abradable shroud repair area and do as follows:
(1)If the C01-161  abradable material moves, use the wooden roller or template on the film to push the material back to the correct contour.
Subtask 72-00-01-360-060
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
CAUTION:
THE ABRADABLE MATERIAL IS VERY REACTIVE. DO NOT APPLY HEAT ABOVE 100°F (38°C) TO THE ABRADABLE MATERIAL. IT CAN OVERHEAT THE MIXED RESIN AND CATALYST. THIS CAN CAUSE DAMAGE TO THE ABRADABLE MATERIAL AND CAUSE A FIRE HAZARD.
W.Alternative Procedure Available. Cure the C01-161  abradable material on the abradable shroud repair area. Refer to SAE ARP 5144, Heat Application for Thermosetting Resin Curing, and as follows:
(1)Cure the C01-161  abradable material for a minimum of 24 hours at a minimum temperature of 77°F (25°C).
(2)If the room temperature is less than 77°F (25°C), you can use heat lamps or a thermal blanket to increase the temperature to 77°F (25°C) and do as follows:
(a)Use a thermocouple to monitor the temperature.
(b)Keep the temperature between 77 to 100°F (25 to 38°C).
(3)If the room temperature is more than 77°F (25°C), do not apply more heat.
NOTE:
The C01-161  abradable material can be machined or sanded after it was cured at a temperature of 77°F (25°C) for 3 hours. To find out when the C01-161   abradable material can be machined at other temperatures, its hardness can be measured. The C01-161   abradable material that has a Shore D Hardness of more than 60 can be machined or when a fine dust is observed when the material is manually sanded.
Subtask 72-00-01-360-061
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
W.A.Alternative Procedure. Cure the C01-161  abradable material on the abradable shroud repair area. Refer to SAE ARP 5144, Heat Application for Thermosetting Resin Curing, and as follows:
(1)Let the C01-161  abradable material cure for 3 hours at a minimum temperature of 77°F (25°C) and do as follows:
(a)If the room temperature is less than 77°F (25°C) you can use heat lamps or a thermal blanket to increase the temperature to 77°F (25°C) and as follows:
1Use a thermocouple to monitor the temperature.
2Keep the temperature at a range of 77 to 100°F (25 to 38°C).
(b)If the room temperature is above 77°F (25°C) do not increase the temperature.
(2)Increase the temperature of the C01-161  abradable material to a range of 100 to 120°F (38 to 49 °C) for a minimum of 2 hours and do as follows:
(a)Use a heat lamp, a thermal blanket, or a heat gun on the repair area to increase the temperature.
(b)Use a minimum of three thermocouples, equally spaced around the repair area.
Subtask 72-00-01-350-270
X.If you did not use the 11C3001   grind tool to remove the damaged abradable material from the abradable shroud repair area, install the 11C3001   grind tool. Refer to Subtask 72-00-01-350-258 (paragraph 4.A.).
Subtask 72-00-01-370-024
CAUTION:
MAKE SURE THAT THE FAN CASE AND THE GRIND TOOL ARE NEAR THE SAME TEMPERATURE WHEN YOU USE THE GRIND TOOL. IF THE TEMPERATURE OF THE FAN CASE CHANGES FROM THE TEMPERATURE OF THE GRIND TOOL DURING MACHINING, YOU CAN MACHINE THE FAN CASE INCORRECTLY.
Y.Calculate the average temperature of the 11C3001   grind tool, the fan rotor, the fan case, and the ambient air around the engine as follows:
NOTE:
The engine fan case and the fan rotor must be near the same temperature as the air around the engine before this task is started. If possible, the temperature measurements can be done indoors to prevent changes in temperatures because of the sun and the wind.
NOTE:
To grind the abradable shroud to the correct dimension, the 11C3001   grind tool, fan rotor, and the fan case must be close to the temperature of the ambient air around the engine.
(1)Use a digital thermometer with a probe or a thermocouple to measure the average temperature of the 11C3001   grind tool, fan rotor, fan case, and the ambient air around the engine.
(2)Calculate the average temperature of the 11C3001   grind tool, and do as follows:
(a)Record the temperature of the cross slide assembly, the frame, and the support ring.
(b)Calculate the average of the recorded temperatures.
(3)Calculate the average temperature of the fan case and do as follows:
(a)Record the temperature around on the outer diameter of the fan case at the 1:30 o’clock position, the 4:30 o’clock position, the 7:30 o’clock position, and the 10:30 o’clock position.
(b)Calculate the average of the recorded temperatures.
(4)Calculate the average temperature of the fan rotor and do as follows:
(a)Record the temperature around the fan rotor forward flange at the 1:30 o’clock position, the 4:30 o’clock position, the 7:30 o’clock position, and the 10:30 o’clock position.
(b)Calculate the average of the recorded temperatures.
(5)Calculate the average temperature of the ambient air and do as follows:
(a)Record the temperature of the ambient air inside the case and at two positions outside the case.
(b)Calculate the average of the recorded temperatures
(6)The permitted differences in temperature between the 11C3001   grind tool, the fan rotor, the fan case, and the ambient air are as follows:
(a)The difference between the average temperature of the 11C3001   grind tool, and the average temperature of air around the fan case must not be more than 7°F (4°C).
(b)The difference between the average temperature of the fan rotor and the average temperature of air around the fan case must not be more than 7°F (4°C).
(c)The difference between the average temperature of the fan case and the average temperature of air around the fan case must not be more than 7°F (4°C).
(d)The difference between the average temperature of the 11C3001   grind tool, and the average temperature of the fan case must no be more than 5°F (3°C).
(7)If the average temperature measurements are more than these limits, let the engine temperature to normalize.
Subtask 72-00-01-320-009
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
Z.Alternative Procedure Available. Set the cutter depth and machine the C01-161  abradable material to get the correct profile. Refer to Figure 918 and as follows:
NOTE:
This procedure uses the average tip clearance to get the depth of cut. Before this procedure is done, the average tip clearances specified in Figure 915 must be calculated.
(1)Put a mark on the abradable shroud surface F1.0 location at the 6:00 o’clock position. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), Figure 911, and as follows:
NOTE:
If the initial marks you made on the abradable shroud are not damaged, these marks can be used again.
(a)Find the lowest axial split line between the forward acoustic liners.
NOTE:
This is the 6:00 o’clock position of the engine.
NOTE:
If the engine is on wing, the axial split-line will not be at the lowest position of the case.
(b)Put a mark from the forward edge of the glass fiber layer axially across the abradable, at the 6:00 o’clock position.
(c)At the 6:00 o’clock position, use the profile template to put marks on the C01-161  abradable material at each change in angle. Refer to Figure 902.
(d)Put an X mark on the 6:00 o’clock axial mark on the C01-161  abradable material at the F1.0 location, F1.5 location, and F2.0 location.
(2)Find the depth of cut at F1.0 location, F1.5 location, and F2.0 location. Refer to Figure 917.
NOTE:
When a repair does not include the area at the 6:00 o’clock position, the calculated depth of cut at the 6:00 o’clock position can be negative. In this condition, the cutter will be set above the surface by the quantity calculated. For example, for a calculated nominal depth of cut of -0.005 inch (-0.13 mm), the cutter will be set 0.005 inch (0.13 mm) above the surface at F1.5, 6:00 o’clock position, with feeler gauges.
(3)Set the cutter position as follows:
(a)Move the 11C3001   grind tool, until the router cutter is at the 6:00 o’clock position.
(b)Adjust the angle of the axial cross slide and put the ball lock pin in the preset angle hole with the 0 degrees mark. Refer to Figure 908 and do as follows:
1Tighten the four 0.3125-18 UNC-3A x 1.25 inch (31.8 mm) socket head cap screws to keep the axial cross slide in the correct position.
(c)Move the axial cross slide until the aft edge of the cutter is over the 20.39 inches (517.9 mm) mark that you made before, and do as follows:
NOTE:
This will put the center of the cutter on the F1.0 location mark.
1Lock the axial cross slide.
(d)Adjust the radial cross slide until the router cutter touches the abradable surface at the F1.0 mark, and do as follows:
1Set the radial cross slide to zero and lock the adjustable vernier scale.
(e)If the adjustment for the nominal depth of cut on Subtask 72-00-01-320-009 (paragraph 5.Z.(2)), is above the surface at F1.0 location, do as follows:
1Use feeler gauges to set the router cutter to the height above the abradable surface.
2Continue the repair at Subtask 72-00-01-320-009 (paragraph 5.Z.(3)(p)) .
(f)Start the router cutter.
(g)Use the radial cross slide vernier graduations to adjust the router cutter depth to a portion of the nominal depth of cut. Refer to Figure 917 for the nominal depth.
(h)Turn the 11C3001   grind tool, to make approximately a 2.0 inches (51 mm) long cut at the F1.0 position at the 6:00 o’clock position.
(i)Stop the router cutter.
(j)Use the depth gauge to measure the depth of the cut. Refer to Figure 904 and do as follows:
1Put the base of the depth gauge on the more cylindrical (forward) part of the profile and slide the depth gauge circumferentially to make the measurements more accurate.
(k)From the measured depth, calculate the remaining depth of cut necessary to get the calculated nominal depth of cut.
(l)Start the router and do as follows:
1Use the radial cross slide vernier graduations to adjust the router cutter depth.
(m)Turn the tool again to make approximately a cut of 2.0 inches (51 mm) in length at the F1.0 location at the 6:00 o’clock position.
(n)Stop the router.
(o)Use the depth gauge to confirm the depth is no more than 0.005 inch (0.13 mm) of the nominal depth of cut. Refer to Figure 904 and Figure 917.
NOTE:
The depth can be machined in multiple cuts.
NOTE:
If you keep the depth of cut within 0.005 inch (0.12 mm) for the depth you calculate, you will machine the abradable shroud profile to the nominal profile dimension. This will give additional abradable shroud thickness for erosion and wear caused by service conditions.
(p)Set the radial cross-slide to zero, lock the adjustable vernier scale, and as follows:
1Lock the radial cross slide.
CAUTION:
MAKE SURE THAT THE HOSES FOR THE AIR LINE TO THE ROUTER AND THE VACUUM LINE ARE FREE OF THE TOOL WHEN YOU TURN IT. THE HOSES CAN CATCH THE TOOL WHEN YOU TURN IT.
(4)Start the vacuum cleaner and do as follows:
(a)Start the router cutter.
(b)Hold the 11C3001   grind tool, near the fan rotor, and do as follows:
1Turn the 11C3001   grind tool, very slowly clockwise, forward looking aft.
(c)Turn the 11C3001   grind tool, around the complete abradable shroud circumference.
(5)Unlock the axial cross slide, and do as follows:
(a)Use the axial cross slide to move the router cutter to a new position forward and overlapping the previous cut by small distance.
(b)Lock the axial cross slide.
(6)Hold the 11C3001   grind tool and do as follows:
(a)Turn the 11C3001   grind tool, very slowly around the abradable shroud circumference, clockwise, forward looking aft.
(7)Do paragraph Subtask 72-00-01-320-009 (paragraph 5.Z.(5)) and Subtask 72-00-01-320-009 (paragraph 5.Z.(6)) again until you get to the forward location mark for the angle that you made.
(8)Stop the router cutter and do as follows:
(a)Unlock the radial cross slide.
(b)Use the radial cross slide to move the cutter 0.100 inch (2.54 mm) away from the C01-161  abradable material.
(9)If the repair area extends forward or aft of this angle, machine the area of the next angle as follows:
NOTE:
Machining the abradable shroud in the correct sequence will make the machined profile more accurate.
(a)Machine the abradable shroud contour segments in the sequence that follows:
10 degree angle, aft to forward, set depth of cut at the F1.0 mark.
23.0 degree angle, aft to forward, set depth of cut to blend with cut 1.
30 degree angle, forward to aft, set depth of cut to blend with cut 2.
4-7.4 degree angle, aft to forward, set depth of cut at the F1.5 mark.
5-4.9 degree angle, forward to aft, set to depth of cut to blend with cuts 1 and 4.
6-7.4 degree angle, forward to aft, set depth of cut at the F2.0 mark.
7-7.4 degree angle, aft to forward, continuing the previous cut (cut 6).
8-10.7 degree angle, forward to aft, set depth of cut to blend with cuts 4 and 7.
9-4.9 degree angle, forward to aft, set depth of cut to blend with cut 6.
100 degree angle, forward to aft, set depth of cut to blend with cut 9.
(b)Reset the angle of the axial cross slide and put the ball lock pin in the hole with the mark of the next angle. Refer to Figure 907, Figure 908, and do as follows:
1Tighten the four 0.3125-18 UNC-3A x 1.25 inch (31.8 mm) socket head cap screws to keep the axial cross slide in the correct position.
(c)Unlock the axial cross slide and do as follows:
1Use the axial cross slide to put the forward edge of the cutter on the aft edge of the cut before.
2Lock the axial cross slide.
(d)Use the marks on the C01-161  abradable material to set the axial cross slide to the correct location for the angle that you will cut.
(e)Start the router cutter.
(f)Lower the cutter until the forward edge of the cutter is level with the cut immediately forward, and do as follows:
1Lock the radial cross slide.
NOTE:
It is important to adjust the cutter to make a smooth change with no step. The more accurate the adjustments the more accurate the remaining cuts will be.
(g)Do Subtask 72-00-01-320-009 (paragraph 5.Z.(7)) again to machine the C01-161  abradable material in the area of this angle.
(h)Stop the cutter and do as follows:
1Unlock the radial cross slide.
2Use the radial cross slide to move the cutter 0.100 inch (2.54 mm) away from the C01-161  abradable material.
(i)If the repair area is more than the axial limits of this angle, do Subtask 72-00-01-320-009 (paragraph 5.Z.(9)(a)) thru Subtask 72-00-01-320-009 (paragraph 5.Z.(9)(g)) again to machine the remaining angle segments.
(j)If this is the last angle that you will machine, do as follows:
CAUTION:
DO NOT CUT THE GLASS FIBER LAYER OR THE TRENCHFILLER. THIS WILL CAUSE DAMAGE TO THE FACESHEET AND MAKE THE REPAIR MORE DIFFICULT.
1Keep the cutter at a minimum of 0.5 inch (13 mm) from the forward and aft glass fiber layer.
WARNING:
DO NOT BREATHE THE PARTICLES WHEN GRINDING OR SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
CAUTION:
DO NOT SAND THE GLASS FIBER LAYER. THIS WILL MAKE THE REPAIR AREA LARGER AND MORE DIFFICULT.
2If there is a remaining step or if the area in 0.5 inch (13 mm) of the aft edge of the C01-161  abradable material was replaced, use C10-141  abrasive paper to make the C01-161  abradable material smooth to the limits that follow:
aThe change from repair area to adjacent abradable shroud surface must be 0.020 inch (0.50 mm) maximum forward facing surface.
bThe change from repair area to adjacent fan case surface must be 0.040 inch (1.01 mm) maximum aft facing surface.
Subtask 72-00-01-320-010
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
Z.A.Alternative Procedure. Set the cutter depth and machine the C01-161  abradable material on the abradable shroud repair area to get the correct profile. Refer to Figure 918 and as follows:
NOTE:
This procedure can be used only if the circumference of the repair abradable material is less than 25 percent of the case circumference and the local depth of cut is less than 0.005 inch (0.13 mm).
(1)Make sure that the difference between the average temperature of the 11C3001   grind tool, and the average temperature of the fan case is not more than 10°F (6°C) and as follows:
NOTE:
For narrow circumferential damage, it is possible that the repair area will not extend into the F1.0 axial location. For this damage, the indicator can be re-positioned in one of the other axial locations on the damaged area.
(a)Calculate the local depth of cut for the repair area as follows:
1Move the indicator to the actual abradable surface below the lower edge of the repair area.
2Put a mark at the position of the indicator on the case. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES) and TASK 70-16-02-350-017 (TEMPORARY MARKING).
NOTE:
This mark is the indicator position mark
3Set the indicator to zero.
4Move the indicator to the actual abradable surface above the upper edge of the repair area.
5Record the reading.
6Get half of the upper edge indicator reading as follows:
NOTE:
This is the depth of cut.
 
Example
Description
 
1
When the reading is positive
If the upper edge indicator reading is 0.004 inch (0.10 mm), then half the reading is 0.004/2 = 0.002 inch (0.10/2 = 0.05 mm). The depth of cut is 0.002 inch (0.05 mm).
 
2
When the reading is negative
If the upper edge indicator reading is -0.006 inch (-0.15 mm), then half the average is -0.006/2 = -0.003 inch (-0.15/2 = -0.008 mm). The depth of cut is -0.003 inch (-0.08 mm).
NOTE:
In this example, the cutter will be set 0.003 inch (0.08 mm) above the surface of the existing abradable material.
NOTE:
The indicators supplied with the tool have readouts in inches, so inches were used in the examples.
(b)If the depth of cut is more than 0.005 inch (0.13 mm), positive or negative, do not use this alternative procedure.
(2)Put a mark on the abradable shroud. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:
(a)At the indicator position mark, use the profile template to put a mark on the forward and aft limits for the segment angles that you will use.
(3)Set the cutter depth as follows:
(a)Adjust the angle of the axial cross slide and put the ball lock pin in the hole marked 0 degrees.
NOTE:
It is possible that some damage will not be in the -4.9 degree angle area. If there is damage, Figure 902 must be referred to find the axial cross slide angle to set the cutter depth and make the cuts that overlap.
(b)Move the 11C3001   grind tool, until the router cutter is at the lower edge of the repair area.
(c)Move the axial cross slide until the aft edge of the cutter is at the indicator position mark that you made before.
(d)Lock the axial cross slide.
(e)Adjust the radial cross slide until the router immediately touches the abradable surface.
(f)Set the radial cross-slide vernier to zero and lock the adjustable vernier scale.
(g)If the depth of cut adjustments from Subtask 72-00-01-320-010 (paragraph 5.Z.A.(1)(a)) is above the surface or a negative depth of cut adjustment, then use the feeler gauges to set the router cutter to the height above the abradable surface, and do as follows:
1Continue with Subtask 72-00-01-320-010 (paragraph 5.Z.A.(3)(m)) .
(h)Start the router cutter.
(i)Use the radial cross slide vernier graduations to adjust the router cutter depth to the calculated depth.
(j)Turn the tool to make approximately a cut of 2.0 inches (51 mm) in length.
(k)Stop the router cutter.
(l)Use the depth gauge to make sure that the depth is correct to no more than 0.005 inch (0.12 mm) of the depth of cut from Subtask 72-00-01-320-010 (paragraph 5.Z.A.(1)(a)6).
NOTE:
If you keep the depth of cut to a maximum of 0.005 inch (0.12 mm) for the depth you calculate, you will machine the abradable shroud profile to the nominal profile dimension. This will give more abradable shroud thickness for erosion and wear caused by service conditions.
(m)Set the radial cross slide to zero and lock the adjustable vernier scale.
(n)Lock the radial cross slide.
CAUTION:
MAKE SURE THAT THE HOSES FOR THE AIR LINE TO THE ROUTER AND THE VACUUM LINE ARE FREE OF THE TOOL WHEN YOU TURN IT. THE HOSES CAN CATCH THE TOOL WHEN YOU TURN IT.
CAUTION:
ONLY CUT IN THE REPAIR AREA. DO NOT MOVE THE TOOL ON OTHER AREAS OF THE FAN ABRADABLE. THIS CAN MAKE THE DIAMETER OF THE ABRADABLE OUT OF TOLERANCE.
(4)Start the vacuum cleaner.
(5)Start the router cutter.
(6)Turn the tool very slowly around the abradable shroud from the lower edge of the repair area to the upper edge.
(7)Unlock the axial cross slide.
(8)Use the axial cross slide to move the router cutter to a new position forward and overlapping the previous cut by a small distance.
(9)Lock the axial cross slide.
(10)Pull the 11C3001   grind tool, around the abradable shroud very slowly across the repair area.
(11)Do Subtask 72-00-01-320-010 (paragraph 5.Z.A.(7)) to Subtask 72-00-01-320-010 (paragraph 5.Z.A.(10)) again while you move the 11C3001   grind tool, between the upper and lower edges of the repair area until you get to the forward mark for this angle area.
(12)Stop the router cutter.
(13)Unlock the radial cross slide.
(14)Use the radial cross slide to move the cutter 0.100 inch (2.54 mm) away from the C01-161  abradable material.
(15)If the repair area extends forward or aft of this angle, machine the area of the next angle as follows:
(a)Machine the area of the remaining angle segments in the sequence that follows:
NOTE:
Machining the abradable shroud in the correct sequence will make the machined profile more accurate.
10 degree angle, aft to forward, set depth of cut at the F1.0 mark.
23.0 degree angle, aft to forward, set depth of cut to blend with cut 1.
30 degree angle, forward to aft, set depth of cut to blend with cut 2.
4-7.4 degree angle, aft to forward, set depth of cut at the F1.5 mark.
5-4.9 degree angle, forward to aft, set to depth of cut to blend with cuts 1 and 4.
6-7.4 degree angle, forward to aft, set depth of cut at the F2.0 mark.
7-7.4 degree angle, aft to forward, continuing the previous cut (cut 6).
8-10.7 degree angle, forward to aft, set depth of cut to blend with cuts 4 and 7.
9-4.9 degree angle, forward to aft, set depth of cut to blend with cut 6.
100 degree angle, forward to aft, set depth of cut to blend with cut 9.
(b)Reset the angle of the axial cross slide and put the ball lock pin in the hole with the mark of the next angle.
(c)Unlock the axial cross slide.
(d)Use the axial cross slide to put the forward edge of the cutter on the aft edge of the cut before, and do as follows:
NOTE:
The cut mark to be used cannot be at the 6:00 o'clock position.
1Lock the axial cross slide.
(e)Put a mark on the abradable shroud. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:
1If necessary, use the profile template to make a mark on the C01-161  abradable material at the aft end of this angle.
(f)Start the router cutter.
(g)Lower the cutter until the forward edge of the cutter is leveled with the cut immediately forward.
(h)Lock the radial cross slide.
NOTE:
It is important to adjust the cutter to make a smooth change without steps. The more accurate the setting the more accurate the remaining cuts will be.
(i)Do Subtask 72-00-01-320-010 (paragraph 5.Z.A.(12)) again to machine the C01-161  abradable material in the area of this angle.
(j)Stop the router cutter.
(k)Unlock the radial cross slide.
(l)Use the radial cross slide to move the cutter 0.100 inch (2.54 mm) away from the abradable.
(m)If the repair area extends forward or aft of this angle, do Subtask 72-00-01-320-010 (paragraph 5.Z.A.(15)(a)) thru Subtask 72-00-01-320-010 (paragraph 5.Z.A.(15)(l)) again to machine the area of the next angle.
(n)If this is the last angle to be machined, do as follows:
1Make the last cut with the aft edge of the cutter 0.5 inch (13 mm) forward of the glass fiber layer.
Subtask 72-00-01-140-025
WARNING:
DO NOT BREATHE THE PARTICLES WHEN GRINDING OR SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
CAUTION:
DO NOT CUT THE GLASS FIBER LAYER OR THE TRENCHFILLER. THIS WILL CAUSE DAMAGE TO THE FACESHEET AND MAKE THE REPAIR MORE DIFFICULT.
2If there are remaining steps or if the area in 0.5 inch (13 mm) or less of the aft edge of the C01-161  abradable material was replaced, sand the C01-161  abradable material as follows:
aIf necessary, use 120 grit C10-141  abrasive paper.
bThe change from the repair area to the adjacent abradable shroud surface must be 0.020 inch (0.50 mm) maximum forward facing surface.
cThe change from the repair area to the adjacent abradable shroud surface must be 0.040 inch (1.01 mm) maximum aft facing surface.
Subtask 72-00-01-320-011
WARNING:
DO NOT BREATHE THE PARTICLES WHEN GRINDING OR SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
Z.B.Alternative Procedure. Set the cutter depth and machine the C01-161  abradable material on the abradable shroud repair area to get the correct profile as follows:
NOTE:
This procedure is used only if the full abradable shroud was replaced and there is no undamaged abradable shroud to measure.
(1)Calculate the depth of cut at the F1.0 location, F1.5 location, and F2.0 location as follows:
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(a)If necessary, sand the abradable shroud with C10-141  abrasive paper to make a flat surface at the measurement location.
NOTE:
The flat surface will make the measurement more accurate.
(b)Use a depth micrometer to get the dimension H, dimension J, and dimension K at the 6:00 o'clock position. Refer to Figure 916 and do as follows:
1Make a record of the measurements in the table.
(c)Use the table in Figure 916 to calculate the radius at the 6:00 o’clock position as follows:
1Add the radius of the scooter block, 11C3001P13, to dimension H, dimension J, and dimension K that was measured.
2Add the temperature correction factor for the 11C3001   grind tool. Refer to Figure 914.
NOTE:
The temperature correction is necessary because the tool is made of aluminum and the fan case is a composite laminate.
(d)Subtract the calculated abradable shroud radius from the nominal case radius for the F1.0 location, F1.5 location, and F2.0 location. The difference is the nominal depth of cut at the 6:00 o’clock position.
Subtask 72-00-01-360-062
(e)If the calculated depth of cut at the 6:00 o’clock position is negative, do Subtask 72-00-01-360-056 (paragraph 5.R.) thru Subtask 72-00-01-360-060 (paragraph 5.W.) again to add more C01-161  abradable material.
Subtask 72-00-01-320-012
(2)Cut the abradable shroud contour. Refer to Subtask 72-00-01-320-009 (paragraph 5.Z.(3)) thru Subtask 72-00-01-320-009 (paragraph 5.Z.(9)(j)2) , and as follows:
(a)Use the calculated depth of cut. Refer to Figure 916.
NOTE:
If the depth of cut is kept in 0.005 inch (0.12 mm) for the depth calculated, the abradable shroud profile must be cut to the nominal profile dimension. This will give additional abradable shroud thickness for erosion and wear caused by service conditions.
Subtask 72-00-01-160-039
AA.Clean the repair area as follows:
Subtask 72-00-01-160-041
(1)Alternative Procedure Available. Remove the dust and debris with a dustpan and a C10-108  brush.
Subtask 72-00-01-160-040
(1).A.Alternative Procedure Available. Remove all the abradable dust and debris with a vacuum cleaner.
Subtask 72-00-01-160-042
WARNING:
USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (207 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.
(2)Remove the remaining dust from the repair area with compressed air that contains no oil.
Subtask 72-00-01-220-324
AB.Do an inspection of the abradable shroud repair area for voids and missing C01-161   abradable material. Refer to TASK 72-00-01-200-801 (72-00-01, INSPECTION 001) and as follows:
(1)Areas with a shore D hardness less than 50 are not permitted.
(2)Do an inspection of the abradable surface. The defects that follow are permitted:
(a)Three voids for each 30 inches (762 mm) of circumference are permitted as follows:
1If the void is no more than 0.10 inch (2.5 mm) at the maximum dimension.
2If the void is no more than 0.060 inch (1.52 mm) in depth.
(b)A number of voids for each 30 inches (762 mm) of circumference are permitted as follows:
1If the void is no more than 0.06 inch (1.5 mm) at the maximum dimension.
2If the void is no more than 0.03 (0.7 mm) in depth.
3The total area of the collected voids must not be more than 20 square inches (129 square cm).
(c)Any number of voids less than 0.03 inch (0.7 mm) at the maximum dimension are permitted.
(d)Forward facing steps of a maximum of 0.02 inch (0.5 mm) are permitted.
(e)Aft facing or axial steps of a maximum of 0.04 inch (1.0 mm) are permitted.
(3)Loose material or foreign material is not permitted.
(4)Cracks or unbonded areas are not permitted.
Subtask 72-00-01-350-271
(5)If the inspection does not agree with the specified limits, do as follows:
(a)For defects more than 0.10 inch (2.5 mm) at the maximum dimension, do Subtask 72-00-01-350-262 (paragraph 5.J.) thru Subtask 72-00-01-360-060 (paragraph 5.W.) again to fill the defects.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
WARNING:
DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR.
CAUTION:
IF THE ADHESIVE WAS STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE ADHESIVE.
(b)If necessary, fill the defects not more than 0.10 inch (2.5 mm) at the maximum dimension as follows:
1Prepare the C01-155  adhesive paste as follows:
aMake an estimate of the quantity of the C01-155   adhesive paste that you will use.
2Use a clean metal or paper container that has no wax.
3Mix each component in the ratio that follows:
aPart A (adhesive) - 100 parts by weight.
bPart B (catalyst) - 17 parts by weight.
4Mix the two C01-155  adhesive paste components until you cannot see streaks of the components.
NOTE:
The pot life of the mixed C01-155  adhesive paste is approximately 90 minutes. The mixed C01-155  adhesive paste can be used until 90 minutes after the mixing procedure.
5Use the teflon spatula to push the C01-155  adhesive paste in the defects that you will repair.
6Use a C10-182  cleaning cloth to remove the unwanted C01-155  adhesive paste.
7Cure the C01-155  adhesive paste. Refer to SAE ARP 5144 Heat Application for Thermosetting Resin Curing and as follows:
aLet the mixed C01-155  adhesive paste cure for 8 hours at a minimum temperature of 65°F (18°C) followed by a minimum of 1 hour at a temperature range of 180 to 200°F (82.2 to 93.3°C).
Subtask 72-00-01-140-026
WARNING:
DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(c)Sand the abradable shroud with C10-141  abrasive paper to make the repair area smooth and agree with the adjacent contour.
Subtask 72-00-01-220-325
AC.Do the measurements for the fan blade tip clearances and the abradable shroud runout as follows:
NOTE:
In this procedure, the individual fan blade tip clearances and the average fan blade tip clearances must be checked.
NOTE:
The engine, fan case, and fan rotor must be near the same temperature as the air around the engine. If possible, the temperature measurements can be done indoors to prevent changes in temperatures because of the sun and the wind.
Subtask 72-00-01-220-330
(1)Alternative Procedure Available. If you use the 11C3001   grind tool, to get the runout measurements, do as follows:
(a)Do Subtask 72-00-01-350-264 (paragraph 5.K.)again to get the runout measurements for the F1.0 location, F1.5 location, and F2.0 location.
(b)Record the runout measurements in Figure 912.
(c)Remove the 11C3001   grind tool, from the fan disk.
(d)Remove the masking from the fan disk and the outlet guide vanes.
(e)Install the fan blades, the fan platforms, and aft spinner.
(f)Do paragraph Subtask 72-00-01-220-319 (paragraph 5.E.) or Subtask 72-00-01-220-320 (paragraph 5.E.A.) to get the clearances at the F1.0 location, F1.5 location, and F2.0 location.
(g)Make a record of the clearance measurements. Refer to Figure 913.
Subtask 72-00-01-220-326
(1).A.Alternative Procedure. If you use the 11C3406   runout tool, to get the abradable shroud runout measurements, do as follows:
(a)Remove the 11C3001   grind tool, from the fan disk.
(b)Remove the masking from the fan disk and outlet guide vanes.
(c)Install the fan blades, the fan platforms and the aft spinner. Refer to TASK 72-00-01-420-802 (72-00-01, INSTALLATION 001 - CONFIG 02).
(d)Do Subtask 72-00-01-220-319 (paragraph 5.E.). again to get the runout measurements and the clearance measurements at the F1.0 location, F1.5 location, and F2.0 location.
Subtask 72-00-01-220-327
AD.Calculate the maximum single blade, the minimum single blade and the corrected average F1.0 dimensions, of the blade tip clearance, for each of the 18 blades. Refer to Figure 915 and do as follows:
(1)Use the data that you recorded in the F1.0 clearance dimension form in Figure 913, and the F1.0 FIR dimensions form in Figure 912 to calculate the corrected F1.0 fan blade tip clearance maximum and minimum dimensions.
(2)The corrected average fan blade tip clearance dimensions must be in the limits that follow:
(a)F1.0 = 0.299-0.329 inch (7.60-8.35 mm).
(b)F1.5 = 0.275-0.305 inch (6.99-7.74 mm).
(c)F2.0 = 0.373-0.403 inch (9.48-10.23 mm).
(3)The single blade tip clearance dimensions must be in the limits that follow:
(a)F1.0 = 0.265-0.363 inch (6.74-9.22 mm).
(b)F1.5 = 0.241-0.339 inch (6.13-8.61 mm).
(c)F2.0 = 0.339-0.437 inch (8.62-11.09 mm).
(4)If the clearances do not agree with the limits, do the repair procedure again.
Subtask 72-00-01-220-328
AE.For the first fan case repaired by the Repair Source with this document, submit the information that follows to GE Aviation for approval.
NOTE:
Shops that want to make changes to the repair sequence or to significant operation in the shop manual must submit proposed changes to GE Aviation before the changes are done.
NOTE:
After repair source substantiation, it is the responsibility of the repair source to keep the repair current with the shop manual repair procedure. Approval of planned changes to significant operations or repair sequence must be obtained thru GE Aviation Form GT3029-1 before the changes are done.
NOTE:
The significant operation of this repair is as follows:
(1)These are significant operations and it is necessary to get the approval of GE Aviation before the repair shop changes what follows:
(a)Fan blade tip clearances and measurement method.
(2)Facilities:
(a)All facilities (tooling) used in the fan blade tip clearances procedure must be defined and as applicable, calibration, and control of these facilities must be documented.
(3)Routing sheets:
(a)Necessary in English.
(4)Process sheets:
(a)Necessary for grinding operations in English.
(5)Data requirements:
(a)Submit worksheets and datasheets used to calculate fan blade tip clearances.
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Figure 901   (Sheet 1 ) Forward Fan Case
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Figure 901   (Sheet 2 ) Forward Fan Case
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Figure 901   (Sheet 3 ) Forward Fan Case
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Figure 902   (Sheet 1 ) Profile Template
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Figure 902   (Sheet 2 ) Profile Template
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Figure 903   Position of Offset Hole in Fan Rotor
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Figure 904   Depth Gauge
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Figure 905   Teflon Spatula
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Figure 906   Steel Rod
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Figure 907   (Sheet 1 ) Grind Tool - Setup Information
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Figure 907   (Sheet 2 ) Grind Tool - Setup Information
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Figure 907   (Sheet 3 ) Grind Tool - Setup Information
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Figure 908   Detail of Router and Axial Cross Slide Angle Setting
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Figure 909   Types of Router Cut
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Figure 910   Adhesive Cartridge
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Figure 911   (Sheet 1 ) Detail of Measurement Method
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Figure 911   (Sheet 2 ) Detail of Measurement Method
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Figure 911   (Sheet 3 ) Detail of Measurement Method
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Figure 912   Measured F1.0, F1.5, and F2.0 Dimension Form
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Figure 913   Measured F1.0, F1.5, and F2.0 Clearance Dimension Form
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Figure 914   (Sheet 1 ) Temperature Correction Factors
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Figure 914   (Sheet 2 ) Temperature Correction Factors
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Figure 914   (Sheet 3 ) Temperature Correction Factors
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Figure 915   (Sheet 1 ) Calculate the Corrected Fan Tip Clearance Dimensions
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Figure 915   (Sheet 2 ) Calculate the Corrected Fan Tip Clearance Dimensions
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Figure 915   (Sheet 3 ) Calculate the Corrected Fan Tip Clearance Dimensions
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Figure 915   (Sheet 4 ) Calculate the Corrected Fan Tip Clearance Dimensions
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Figure 916   (Sheet 1 ) Calculate the Depth of Cut by Radial Dimension
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Figure 916   (Sheet 2 ) Calculate the Depth of Cut by Radial Dimension
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Figure 917   (Sheet 1 ) Calculation to Find the Depth of Cut
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Figure 917   (Sheet 2 ) Calculation to Find the Depth of Cut
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Figure 917   (Sheet 3 ) Calculation to Find the Depth of Cut
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Figure 917   (Sheet 4 ) Calculation to Find the Depth of Cut
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Figure 917   (Sheet 5 ) Calculation to Find the Depth of Cut
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Figure 918   Abradable Shroud Machining Sequence