* * * FOR ALL
TASK 72-00-01-200-801
1 . General.
A.This procedure gives instructions to do an inspection of the fan stator module assembly (fan stator module):
•
(30-010 , 72-00-00) (SIN 00103)
•
(30-011 , 72-00-00) (SIN 00103) (SB 72-0156).
B.Any sub-assembly or part removed for access or limited workscope must be inspected in accordance with criteria in this section. If there is no criteria, the sub-assembly or part must receive a general visual inspection (GVI) for continued serviceability. Refer to TASK 72-00-00-200-805 (72-00-00, INSPECTION 001) . If required, the component can be hand-cleaned to do a visual inspection. Refer to TASK 70-21-01-110-001 (CLEANING METHOD 1 - SOLVENT DEGREASING) or TASK 70-21-03-160-001 (CLEANING METHOD 3 - STEAM CLEANING) . GVI can not be done to components identified in TASK 05-21-00-200-801 (05-21-00, LIFE LIMITS 001) that become piece part. These components must have their appropriate mandatory inspections done, unless stated differently in an applicable Service Bulletin.
C.When you do this procedure and you find an assembly or part that is unserviceable, refer to the applicable section of the engine manual for more disassembly and inspection procedures for the part or assembly.
D.If you will fully disassemble the fan stator module, this inspection is not necessary. Refer to the applicable section of the engine manual for the inspection procedure for each part.
E.The maintenance instructions in this Manual do not purport to cover all details or variations in equipment, nor do they provide for every possible contingency to be met in connection with installation, operation, maintenance, or GEAE certified repair facilities. The maintenance instructions are intended to be all-inclusive for a complete teardown and overhaul of the component or sub assembly. The individual procedures as written are one sequence based on General Electric experience. Alternate sequences to these maintenance instructions are at the discretion of the operator and/or overhaul shop provided the intent of the maintenance instructions is met. The operator and/or overhaul shop can select specific tasks to partially disassemble and assemble hardware or subassemblies based upon the on demand maintenance requirement of the individual engine work scope provided the final assembly configuration and requirements contained in the manual have been met.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment.
 
Description
Manufacturer
 
Non-Metallic Spatula or Equivalent
--
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C01-136
Deleted
 
C01-159
Primer, RTV (RTV primer)
 
C01-176
RTV, Silicone Elastomer (RTV 133)
 
C01-217
Primer (primer)
 
C01-218
Adhesive System, Two part, Gray Silicone (adhesive system)
 
C03-006
Deleted
 
C03-007
Primer, Epoxy (A50TF82) (primer)
 
C03-077
Primer, Epoxy, Water-Reducible, (BMS-10-11Y Type I, Class A, Grade E) (primer)
 
C03-079
Primer, Epoxy (primer)
 
C03-085
Primer, Epoxy, Yellow Zinc Phosphate (primer)
 
C03-100
Primer, Paint, Zinc-Molybdate, Alkyd Type (primer)
 
C03-109
Paint, Polyurethane, Semi-gloss, Gray 26270 (paint)
 
C03-115
Primer, Epoxy, Green (primer)
 
C03-119
Paint, Polyurethane, Gloss, Gray (polyurethane coating)
 
C03-123
Primer, Epoxy (GE Spec. A8B128A1) (primer)
 
C04-003
Solvent, General (acetone)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C10-012
Tape, Masking, High Temperature (tape)
C.Referenced Procedures.
 
ATA No.
Description
 
05-21-00
Life Limits 001
 
70-21-01
Cleaning Method 1 - Solvent Degreasing
 
70-21-03
Cleaning Method 3 - Steam Cleaning
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-43-07
Chemical Touch-Up Surface Refinishing Process for Aluminum
 
70-43-22
Paint - Epoxy Coating for Aluminum and Ferrous Alloys
 
72-00-00
Inspection 001
 
72-21-01
Repair 003
 
72-21-01
Repair 004
D.Expendable Parts. None.
3 . Specific Inspection Procedure.
Subtask 72-00-01-230-001
A.Do a spot-fluorescent-penetrant inspection to confirm cracks or crack indications found during visual inspection on the aft fan case (01-020 , 72-21-00) (SIN 84100) or aft fan case (01-021 , 72-21-00) (SIN 84100). Refer to TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION).
NOTE:
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) and the stator/aft fan case (001A9) are subassemblies of the fan stator assembly (01-020) (SIN 00109) or fan stator assembly (01-021) (SIN 00109), which is a subassembly of the fan stator module (30-010 , 72-00-00) (SIN 00103) or (30-011 , 72-00-00) (SIN 00103). The aft fan case (01-020 , 72-21-00) (SIN 84100) or aft fan case (01-021 , 72-21-00) (SIN 84100) is a subassembly of the stator/aft fan case (001A9).
Subtask 72-00-01-280-001
B.Do an inspection of the abradable shroud for looseness with a 0.375 inch (9.53 mm) diameter, 2.0 inches (51 mm) in length, round end rod as follows:
(1)Tap on the shroud while you listen for a clicking sound. Refer to Subtask 72-00-01-220-004 (Paragraph 4.A.(4)).
* * * FOR ALL
* * * PRE SB   72-0039( Heavier Forward Fan Case )
* * * PRE SB   72-0156( PIP2 Configuration )
Figure 801   (Sheet 1 ) Fan Stator Module - Inspection
* * * FOR ALL
* * * SB   72-0039( Lighter Forward Fan Case )
* * * SB   72-0156( PIP2 Configuration )
Figure 801   (Sheet 2 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 3 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 4 ) Fan Stator Module - Inspection
* * * FOR ALL
* * * SB   72-0034( Inco 718 Vapor Barrier )
* * * SB   72-0035( PIP2 Configuration )
* * * SB   72-0156( PIP2 Configuration )
Figure 801   (Sheet 5 ) Fan Stator Module - Inspection
* * * FOR ALL
* * * PRE SB   72-0039( Heavier Forward Fan Case )
Figure 801   (Sheet 6 ) Fan Stator Module - Inspection
* * * FOR ALL
* * * SB   72-0039( Lighter Forward Fan Case )
Figure 801   (Sheet 7 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 8 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 9 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 10 ) Fan Stator Module - Inspection
* * * FOR ALL
Figure 801   (Sheet 11 ) Fan Stator Module - Inspection
4 . Visual Inspection.
Refer to Figure 801.
Subtask 72-00-01-220-001
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:
(1)Surface cracks on the abradable shroud:
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
Subtask 72-00-01-220-002
(2)Axial crack and separation adjacent to the abradable panel joints:
Maximum serviceable limit:
Any length adjacent to each abradable panel joint and located between the forward and aft polysulfide ply.
Repair method:
Not applicable.
Subtask 72-00-01-220-003
(3)Diagonal abradable panel joint cracks and separations:
NOTE:
This appears as a diagonal crack and separations that start at the axial panel joint (sometimes axial crack and separations) and move toward the polysulfide ply or facesheet joint at the aft side of the abradable panel.
Maximum serviceable limit:
Any amount adjacent to or between each abradable panel joint and the aft polysulfide ply.
Repair method:
Not applicable.
Subtask 72-00-01-220-004
(4)Voids, wear grooves, rubs, and areas not bonded to the facesheet:
Maximum serviceable limit:
Any amount, 0.08 inch (2.0 mm) in depth, if:
•
The largest area of damage is not more than 6.0 sq in. (39 sq cm)
•
The total damage is not more than 40.0 sq in. (258 sq cm)
•
There is a minimum distance of the maximum dimension of adjacent voids between the damaged areas.
Maximum repairable limit:
Any amount, up to the full abradable surface, if the fan case is not damaged.
Repair method:
Repair. Refer to TASK 72-00-01-300-803 (72-00-01, REPAIR 002) or TASK 72-00-01-300-801 (72-00-01, REPAIR 003) or TASK 72-00-01-300-816 (72-00-01, REPAIR 014) .
Subtask 72-00-01-220-092
(5)Spalled, loose, or missing abradable material in the transition zones:
Maximum serviceable limit:
Any amount, if the trench filler facesheet is not exposed.
Maximum repairable limit:
Any amount, up to the full abradable surface, if the fan case is not damaged.
Repair method:
Repair. Refer to TASK 72-00-01-300-803 (72-00-01, REPAIR 002) or TASK 72-00-01-300-801 (72-00-01, REPAIR 003) or TASK 72-00-01-300-816 (72-00-01, REPAIR 014) .
Subtask 72-00-01-220-121
(6)Fan blade tip clearance, F1.5:
Maximum serviceable limit:
The F1.5 corrected average fan blade tip clearance dimensions must be 0.275-0.315 inch (6.99-8.00 mm). The F1.5 single blade tip clearance dimensions must be 0.241-0.339 inch (6.12-8.61 mm). Refer to TASK 72-00-01-420-801 (72-00-01, INSTALLATION 001), transition zones.
Maximum repairable limit:
Any amount, up to the full abradable surface, if the fan case is not damaged.
Repair method:
Repair. Refer to TASK 72-00-01-300-803 (72-00-01, REPAIR 002) or TASK 72-00-01-300-808 (72-00-01, REPAIR 004) or TASK 72-00-01-300-816 (72-00-01, REPAIR 014) .
Subtask 72-00-01-220-148
(7)Damaged polysulfide coating in the trench filler panel spaces:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-00-01-300-805 (72-00-01, Repair 007) .
Subtask 72-00-01-220-149
(8)Surface defects and punctures in the trench filler facesheet of area A. Refer to Figure 802, Figure 816, and Figure 817.
Maximum serviceable limit:
0.03 inch (0.7 mm) in depth and 0.50 inch (12.7 mm) in diameter, if there is no delamination, disbond or visible exposed fibers.
Repair method:
Repair. Refer to TASK 72-00-01-300-806 (72-00-01, REPAIR 008) or TASK 72-21-01-300-804 (72-21-01, REPAIR 006) .
Subtask 72-00-01-220-107
(9)Surface defects and punctures in the trench filler facesheet outside of area A. Refer to Figure 802, Figure 816, and Figure 817.
Maximum serviceable limit:
0.03 inch (0.7 mm) in depth and 0.50 inch (12.7 mm) in diameter, if there is no delamination, disbond or visible exposed fibers.
Repair method:
Repair. Refer to TASK 72-00-01-300-801 (72-00-01, REPAIR 003) or TASK 72-21-01-300-804 (72-21-01, REPAIR 006).
Subtask 72-00-01-220-119
(10)Abradable panel joint cracks and separations:
Maximum serviceable limit:
Any amount at eight equally spaced locations.
Repair method:
Not applicable.
Subtask 72-00-01-220-120
(11)Axial crack and separations adjacent to the abradable panel joints:
Maximum serviceable limit:
Any length adjacent to each abradable panel joint and located between the forward and aft polysulfide ply.
Repair method:
Not applicable.
* * * FOR ALL
* * * PRE SB   72-0039( Heavier Forward Fan Case )
* * * PRE SB   72-0156( PIP2 Configuration )
Figure 802   (Sheet 1 ) Fan Stator Module Assembly - Facesheet Repair Area
* * * FOR ALL
* * * SB   72-0039( Lighter Forward Fan Case )
* * * SB   72-0156( PIP2 Configuration )
Figure 802   (Sheet 2 ) Fan Stator Module Assembly - Facesheet Repair Area
* * * FOR ALL
Figure 802   (Sheet 3 ) Fan Stator Module Assembly - Facesheet Repair Area
* * * FOR ALL
Figure 802   (Sheet 4 ) Fan Stator Module Assembly - Facesheet Repair Area
Subtask 72-00-01-220-006
B.Do an inspection of the forward “A” and aft “B” mounting flanges 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:
(1)Missing glass plies or tear outs:
Maximum serviceable limit:
0.020 inch (0.50 mm) in depth and 0.50 inch (12.7 mm) in diameter, if carbon plies are not exposed.
NOTE:
Glass plies will be in yellowish shade while carbon plies will be in black shade.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 003).
Subtask 72-00-01-220-007
(2)Cracks on the outer diameter surface:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-082
(3)Delamination in the flanges:
Maximum serviceable limit:
0.016 inch (0.406 mm) in depth at flanges "A" and "B".
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 003).
Subtask 72-00-01-220-083
(4)Nicks, dents, scratches, rubs, and scuffs in the flanges (except the OD surface of flanges) and casing shell:
Maximum serviceable limit:
0.016 inch (0.406 mm) in depth at flanges "A" and "B". Open indications with visible fiber damage are not serviceable.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-367
(5)Nicks, dents, scratches, rubs, scuffs, and fretting on the OD surface of flanges in area C (tear out zone). Refer to Figure 803 (Sheet 1):
Maximum serviceable limit:
Not serviceable.
Repair method:
Contact GE Engineering.
Subtask 72-00-01-220-368
(6)Nicks, dents, scratches, rubs, scuffs, and fretting on the OD surface of flanges in area D (outside of tear out zone). Refer to Figure 803 (Sheet 1):
Maximum serviceable limit:
0.050 inch (12.7 mm) in depth, at flanges “A” and “B”. Open indications with visible fiber damage are not serviceable.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-175
(7)Fraying at the bolthole edges:
Maximum serviceable limit:
Any amount provided, there are no glass plies missing and no delamination or cracks are found in the bolthole inner surface.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-176
(8)Bolthole edge ply damage “sun spot”:
NOTE:
Bolthole edge ply damage can result in discoloration in the resin material of the laminates.
Maximum serviceable limit:
Any amount, 0.100 inch (2.54 mm) in depth and 1.00 inch (25.4 mm) in diameter, if there are no missing glass plies, no delamination or cracks in the bolthole inner surface.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-177
(9)Pitting in the flanges and the casing shell:
NOTE:
Surface condition in which pin holes or pits are evident in the surface resin only, but no fibers are visible or exposed.
Maximum serviceable limit:
Any amount, up to 0.100 inch (2.54 mm) in diameter and 0.01 inch (0.3 mm) in depth and the fibers are not exposed and broken.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003).
Subtask 72-00-01-220-369
(10)Missing epoxy resin on the flange faces, edges and casing shell. Refer to Figure 804:
NOTE:
Glass plies beneath the epoxy resin will be exposed when the epoxy resin is missing.
Maximum serviceable limit:
Any amount, if carbon fibers are not exposed.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003).
Subtask 72-00-01-220-370
(11)Crazing on resin rich areas at corner of flange with inner diameter. Refer to Figure 805:
NOTE:
Crazing is minute cracks in the surface resin. Crazing can have no broken fibers.
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
* * * FOR ALL
Figure 803   (Sheet 1 ) Forward Containment Case “A” Flange - Tear-Out Zone Definition
* * * FOR ALL
Figure 803   (Sheet 2 ) Forward Containment Case “B” Flange - Tear-Out Zone Definition
* * * FOR ALL
Figure 804   Missing Epoxy Resin on Flange Faces, Flange Edge and Casing Shell
* * * FOR ALL
Figure 805   Crazing on Resin Rich Areas at Corner of Flanges with Inner Diameter
* * * FOR ALL
Figure 806   Missing Adhesive at the Joint of Forward Face of Forward Acoustic Treatment With “A” Flange of Fan Containment Case
Subtask 72-00-01-220-008
C.Do an inspection of all areas of each mid-outer acoustic liner (01-500 , 72-21-00) on the forward fan case for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the mid-outer acoustic liner.
Subtask 72-00-01-220-009
(2)Nicks and scratches on the facesheet:
Maximum serviceable limit:
Any amount, if the facesheet has no cracks, cuts, or tears.
Repair method:
Not applicable.
Subtask 72-00-01-220-010
(3)Cracks, cuts, and tears in the face:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-03-300-803 (72-21-03, REPAIR 002).
Subtask 72-00-01-220-011
(4)Delamination:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the mid-outer acoustic liner.
Subtask 72-00-01-220-012
(5)Screws that are loose:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Tighten the loose screws.
Subtask 72-00-01-220-013
(6)Screws that are missing:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the screws.
Subtask 72-00-01-220-354
(7)Chipped/missing bushing flange:
Maximum serviceable limit:
No more than 1/3 of the flange area at any location.
Maximum repairable limit:
Any missing amount.
Repair method:
Repair. Refer to TASK 72-21-03-300-805 (72-21-03, REPAIR 005).
Subtask 72-00-01-220-362
(8)Missing RTV around boltheads:
Maximum serviceable limit:
Any amount.
Maximum repairable limit:
Not applicable.
Repair method:
Not applicable.
Subtask 72-00-01-220-014
D.Do an inspection of the captive nut assemblies on 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:
(1)Loose or missing rivets:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the rivets. Use wet installation. Refer to TASK 70-13-00-390-001 (RIVETED JOINTS).
Subtask 72-00-01-220-084
(2)Damaged captive nut cage:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the captive nut assembly. Use wet installation to replace rivets. Refer to TASK 70-13-00-390-001 (RIVETED JOINTS) .
Subtask 72-00-01-220-085
E.Do an inspection of the trench filler panel joints on 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:
(1)Cracks:
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
Subtask 72-00-01-220-086
F.Do an inspection of the casing shell outer diameter on 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:
(1)Nicks, dents, scratches, rubs, and scuffs:
Maximum serviceable limit:
Any amount, up to 0.125 inch (3.18 mm) in width and 0.016 inch (0.41 mm) in depth and no delamination.
Repair method:
Repair. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-087
(2)Damage to the carbon fibers (below the protective plies 0.016 inch (0.41 mm) in depth):
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-178
(3)Axial and circumferential shiny tool marks/steps near the forward flange:
NOTE:
Axial steps are typically separated by 5.0 inches (127 mm) to 6.0 inches (152 mm) with some only separated by 2.0 inches (51 mm).
Maximum serviceable limit:
Any amount, any length permitted in 5.0 inches (127 mm) of the forward flange.
Subtask 72-00-01-220-348
(4)Circumferential 360 degree channel located 19.0 inches (483 mm) forward of the aft flange:
Maximum serviceable limit:
Permitted up to 2.0 inches (51 mm) in width.
Repair method:
Not applicable.
Subtask 72-00-01-220-179
(5)In-plane wrinkles in the flanges and casing shell:
NOTE:
Condition in which fabric gathers in creases, furrows, ridges, or folds and the distortion is within the surface or plane of the part contour.
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
Subtask 72-00-01-220-180
(6)Resin ridges in the casing shell:
NOTE:
A raised surface condition consisting of resin formed in areas that do not contain fiber.
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
Subtask 72-00-01-220-181
(7)Outer case surface crazing:
NOTE:
Crazing is minute cracks in the surface resin. Crazing can have no broken fibers.
Maximum serviceable limit:
Any amount.
Repair method:
Not applicable.
Subtask 72-00-01-220-182
(8)Outer case surface cracks:
NOTE:
Cracks can be identified by exposed fibers where the crack has resulted in a separation of protective plies.
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-183
(9)Surface porosity:
NOTE:
Surface condition in which pin holes or pits are evident in the surface resin only, but no fibers are visible or exposed.
Maximum serviceable limit:
Any amount, if porosity does not extend below the first protective ply, 0.016 inch (0.41 mm) in depth and the fibers are not exposed and broken.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 003).
Subtask 72-00-01-220-371
(10)Missing epoxy resin on casing shell outer diameter. Refer to Figure 804:
NOTE:
Glass plies beneath the epoxy resin will be exposed when the epoxy resin is missing.
Maximum serviceable limit:
Any amount, if carbon fibers are not exposed.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003).
* * * FOR ALL
* * * PRE SB   72-0039( Heavier Forward Fan Case )
* * * PRE SB   72-0156( PIP2 Configuration )
Figure 807   (Sheet 1 ) Tool Mark-Off Areas on Forward Fan Case
* * * FOR ALL
* * * SB   72-0039( Lighter Forward Fan Case )
* * * SB   72-0156( PIP2 Configuration )
Figure 807   (Sheet 2 ) Tool Mark-Off Areas on Forward Fan Case
* * * FOR ALL
Figure 807   (Sheet 3 ) Tool Mark-Off Areas on Forward Fan Case
* * * FOR ALL
Figure 807   (Sheet 4 ) Features on Outer Diameter of the Forward Containment Case
* * * FOR ALL
Figure 807   (Sheet 5 ) Features on Outer Diameter of the Forward Containment Case
* * * FOR ALL
Figure 807   (Sheet 6 ) Indications at Forward and Aft Flange Boltholes
Subtask 72-00-01-220-088
G.Do an inspection of the stiffening hats on 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:
(1)Nicks, dents, scratches, rubs, and scuffs:
•
Use a steel rod 0.375 inch (9.53 mm) in diameter and 2.0 inches (51 mm) in length with a round end to tap on the stiffening cap in the damaged area, while listening for clicking sounds.
•
If a solid click sound is heard, the area does not have a delamination.
•
If a hollow or dull sound is heard, the area has a delamination.
Maximum serviceable limit:
Any amount up to 0.030 inch (0.76 mm) in depth and 3.00 inches (76.2 mm) in length. No delamination is permitted.
Repair method:
Repair. If no delamination is found, refer to TASK 72-21-01-300-801 (72-21-01, REPAIR 004). If a delamination is found, replace the forward fan case.
Subtask 72-00-01-220-089
(2)Disbonds between stiffening hats to casing shell:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-372
(3)Missing epoxy resin. Refer to Figure 804:
NOTE:
Glass plies beneath the epoxy resin will be exposed when the epoxy resin is missing.
Maximum serviceable limit:
Any amount, if carbon fibers are not exposed.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-801 (72-21-01, REPAIR 004).
Subtask 72-00-01-220-090
H.Do an inspection of the stiffening caps on the forward fan case (01-011 , 72-21-00) or forward fan case (01-012 , 72-21-00) for:
(1)Nicks, dents, scratches, rubs, and scuffs:
•
Use a steel rod 0.375 inch (9.53 mm) in diameter and 2.0 inches (51 mm) in length with a round end to tap on the stiffening cap in the damaged area, while listening for clicking sounds.
•
If a solid click sound is heard, the area does not have a delamination.
•
If a hollow or dull sound is heard, the area has a delamination.
Maximum serviceable limit:
Any amount in depth. No delamination is permitted.
Repair method:
If no delamination is found, refer to TASK 72-21-01-300-801 (72-21-01, REPAIR 004). If a delamination is found, replace the forward fan case.
Subtask 72-00-01-220-091
(2)Disbonds between stiffening caps to stiffening hats:
Maximum serviceable limit:
Not serviceable.
Repair method:
Contact GE Engineering.
Subtask 72-00-01-220-373
(3)Missing epoxy resin. Refer to Figure 804:
NOTE:
Glass plies beneath the epoxy resin will be exposed when the epoxy resin is missing.
Maximum serviceable limit:
Any amount, if carbon fibers are not exposed.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-801 (72-21-01, REPAIR 004).
Subtask 72-00-01-220-184
I.Do an inspection of the forward acoustic treatment for:
(1)Cracks:
Maximum serviceable limit:
Any amount, 6.0 inches (152 mm) in length and 0.060 inch (1.52 mm) in width, if:
•
No crack in the facesheet material is nearer than 10.0 inches (254 mm) to an adjacent area with a cracked facesheet material
•
Disbonds to the honeycomb core and delaminations within the facesheet are not permitted.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 001) .
Subtask 72-00-01-220-185
(2)Nicks, dents, and scratches on the facesheet:
Maximum serviceable limit:
Any amount, if the facesheet is not cracked.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 001) .
Subtask 72-00-01-220-186
(3)Tears and cuts on the facesheet:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 001) .
Subtask 72-00-01-220-187
(4)Delaminations on the facesheet:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 001) .
Subtask 72-00-01-220-188
(5)Punctures and holes on the facesheet:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-01-300-803 (72-21-01, REPAIR 001) .
Subtask 72-00-01-220-374
(6)Missing closeout plies:
Maximum serviceable limit:
Any amount, along the circumference if the width of closeout plies in axial direction is 0.200 inch (5.08 mm) or more. Refer to Figure 818.
Repair method:
Repair. Refer to TASK 72-21-01-300-805 (72-21-01, REPAIR 007) .
Subtask 72-00-01-220-375
(7)Missing adhesive at the joint of forward face with flange “A” and forward wall of the forward acoustic treatment. Refer to Figure 806.
Maximum serviceable limit:
Any amount, if there is no delamination or disbond.
Repair method:
Repair the fan case. Refer to TASK 72-21-01-300-802 (72-21-01, REPAIR 003) .
Subtask 72-00-01-220-379
(8)Delaminations on the closeout plies:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-01-300-805 (72-21-01, REPAIR 007) .
Subtask 72-00-01-220-380
(9)Cracks on the closeout plies:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-21-01-300-805 (72-21-01, REPAIR 007) .
Subtask 72-00-01-220-015
J.Do an inspection of the aft fan case (01-020 , 72-21-00) (SIN 84100) or (01-021 , 72-21-00) (SIN 84100) for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-016
(2)Nicks and scratches (does not include the mounting flanges, the outlet guide vane (OGV) boltholes, or the aft fan case ribs):
Maximum serviceable limit:
Any amount, 0.005 inch (0.13 mm) in depth, after removal of high metal, with no less than 1.0 inch (25 mm) between defects. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.040 inch (1.02 mm) in depth, after removal of high metal, with no less than 1.0 inch (25 mm) between defects. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-068
(3)Nicks and scratches on the mounting flanges:
Maximum serviceable limit:
Any amount, 0.010 inch (0.38 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.030 inch (0.76 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-069
(4)Nicks and scratches around the OGV boltholes:
Maximum serviceable limit:
Any amount, 0.005 inch (0.13 mm) in depth, after removal of high metal, with no less than 1.0 inch (25 mm) between defects. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
•
One for each bolthole 0.050 inch (1.27 mm) in depth, after removal of high metal on 0.406 inch (10.31 mm) diameter boltholes. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
•
One for each bolthole 0.010 inch (0.25 mm) in depth and 0.10 inch (2.5 mm) in length, after removal of high metal on 0.502 inch (12.75 mm) diameter boltholes. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
•
One for each bolthole 0.050 inch (1.27 mm) in depth, after removal of high metal on 0.656 inch (16.66 mm) diameter boltholes. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-070
(5)Nicks and scratches on the aft fan case rib web:
Maximum serviceable limit:
Any amount, 0.020 inch (0.51 mm) in depth, after removal of high metal, with no less than 1.0 inch (25 mm) between defects. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.025 inch (0.64 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-071
(6)Wear (does not include the mounting flanges):
Maximum serviceable limit:
Any amount, 0.005 inch (0.13 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.010 inch (0.25 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-072
(7)Wear in the mounting flanges:
Maximum serviceable limit:
Any amount, 0.005 inch (0.13 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.020 inch (0.51 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Blend to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-017
(8)Dents (does not include the fan case ribs):
Maximum serviceable limit:
Smooth contour dents, 0.125 inch (3.18 mm) in depth, with no less than 6.0 inches (152 mm) between defects.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-073
(9)Dents on the fan case ribs:
Maximum serviceable limit:
Smooth contour dents not more than 0.125 inch (3.18 mm) in depth, with no less than 36.0 inches (914 mm) between defects, if the bracket assembly is not damaged.
Repair method:
Replace the fan stator module.
Subtask 72-00-01-220-018
(10)Rivets and locknuts that are loose or missing:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the rivet or locknut. Refer to TASK 70-13-00-390-001 (RIVETED JOINTS).
Subtask 72-00-01-220-074
(11)Damaged anchor nut cage:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the anchor nut cage as follows:
NOTE:
Remove the mid outer liner bolt for inspection. Refer to TASK 72-00-01-040-805 (72-00-01, DISASSEMBLY 001). Do an inspection of the mid outer liner bolt for corrosion/pitting. Refer to TASK 72-21-99-200-801 (72-21-99, INSPECTION 001).
(a)Remove the anchor nuts. Refer to TASK 70-13-00-390-001 (RIVETED JOINTS).
(b)Do an inspection of the aft fan case shell for pitting. Refer to TASK 72-21-02-200-801 (72-21-02, INSPECTION 001) (Subtask 72-21-02-220-024 (paragraph 3.C.(11))).
(c)Apply coating in free state before the anchor installation. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM).
(d)Apply C03-077  primer (for example, primer P/N 10P4-2NF/EC-117S   ) to the aft fan case mating surface with the anchor nut.
(e)Perform a wet installation of the replacement anchor nuts P/N MS21076L4N   and rivets P/N 9025M79P06   as follows:
1Use C03-001  primer for the installation of the rivets.
2Rivet head must be within 0.0095-0.0105 inch (0.242-0.266 mm) below the surface of the aft fan case.
3Do an inspection of the formed rivets. Refer to TASK 70-13-01-390-002 (ACCEPTABILITY LIMITS FOR FORMED RIVETS).
(f)Install the mid outer liner bolt. Refer to TASK 72-00-01-430-803 (72-00-01, ASSEMBLY 001).
Subtask 72-00-01-220-019
(12)Missing primer:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM). Apply C03-077  primer or C03-079  primer or C03-115  primer or C03-123   primer, and as follows:
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:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(a)Alternative Procedure Available. Apply C03-077  primer as follows:
1Apply C03-077  primer to the case to a thickness of 0.0004-0.0054 inch (0.011-0.137 mm).
2You must apply primer in multiple layers with a maximum layer thickness of 0.0018 inch (0.045 mm).
3Alternative Procedure Available. Mix the C03-077   primer. Refer to the manufacturer's recommendations and do as follows:
aUse the mix ratio 2 parts base, 1 part catalyst, and 2.0-2.5 parts DI water by volume.
3.A.Alternative Procedure. Mix the C03-077  primer. Refer to the manufacturer's recommendations.
4Alternative Procedure Available. Dry each layer of C03-077  primer as follows:
aDry the C03-077  primer for a minimum of 4 hours between layers in a 30-75 percent RH environment at a minimum room temperature of 70°F (21°C).
4.A. Alternative Procedure. Dry each layer of C03-077  primer. Refer to the manufacturer's recommendations and as follows:
aMake sure that you do not increase the temperature of the case more than 200°F (93°C).
5Alternative Procedure Available. Complete the final cure of the C03-077  primer as follows:
aCure the C03-077  primer for a minimum of 7 days and at a minimum room temperature of 70°F (21°C) in a 30-75 percent RH.
5.A.Alternative Procedure. Complete the final cure of the C03-077  primer. Refer to the manufacturer's recommendations and as follows:
aMake sure that you do not increase the temperature of the case more than 200°F (93°C).
(a).A.Alternative Procedure. Apply C03-115  primer. Refer to the manufacturer's recommendations and as follows:
1Make sure that you do not increase the temperature of the case more than 200°F (93°C).
(a).B.Alternative Procedure. Apply C03-123  primer. Refer to the manufacturer's recommendations and as follows:
1Make sure that you do not increase the temperature of the case more than 200°F (93°C).
(a).C.Alternative Procedure. Apply C03-079  primer. Refer to the manufacturer's recommendations and as follows:
1Make sure that you do not increase the temperature of the case more than 200°F (93°C).
Subtask 72-00-01-220-365
(13)Corrosion and pitting at and around the mounting flanges (forward and aft fan case) and case surfaces:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount, up to 0.030 inch (0.76 mm) in depth.
Repair method:
Repair the mounting flanges and case surfaces as follows:
(a)Clean aft fan case corrosion residue. Refer to TASK 72-21-02-100-801 (72-21-02, CLEANING 001). The use of C10-010  scotch brite is recommended to assist with the removal. Make sure not to use C10-010  scotch brite on the composite forward fan case.
(b)Clean the composite forward fan case corrosion residue. Refer to TASK 72-21-01-100-801 (72-21-01, CLEANING 001).
(c)Blend to remove corrosion to a radius of 0.250 inch (6.35 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
(d)Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM).
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:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(e)Alternative Procedure Available. Apply C03-077  primer as follows:
1Apply C03-077  primer to the case to a thickness of 0.0004-0.0054 inch (0.011-0.137 mm).
2You must apply primer in multiple layers with a maximum layer thickness of 0.0018 inch (0.045 mm).
3Alternative Procedure Available. Mix the C03-077   primer. Refer to the manufacturer's recommendations and as follows:
aUse the mix ratio 2 parts base, 1 part catalyst, and 2.0-2.5 parts DI water by volume.
3.A.Alternative Procedure. Mix the C03-077  primer. Refer to the manufacturer's recommendation.
4Alternative Procedure Available. Dry each layer of C03-077  primer as follows:
aDry the C03-077  primer for a minimum of 4 hours between layers in a 30-75 percent RH environment at a minimum room temperature of 70°F (21°C).
4.A.Alternative Procedure. Dry each layer of C03-077  primer. Refer to the manufacturer's recommendations and as follows:
aMake sure that you do not increase the temperature of the case more than 200°F (93°C).
5Alternative Procedure Available. Complete the final cure of the C03-077  primer as follows:
aCure the C03-077  primer for a minimum of 7 days and at a minimum room temperature of 70°F (21°C) in a 30-75 percent RH.
5.A.Alternative Procedure. Complete the final cure of the C03-077  primer. Refer to the manufacturer's recommendations and do as follows:
aMake sure that you do not increase the temperature of the case more than 200°F (93°C).
(e).A.Alternative Procedure. Apply C03-115  primer. Refer to the manufacturer's recommendations and as follows:
1Make sure that you do not increase the temperature of the case more than 200°F (93°C).
(e).B.Alternative Procedure. Apply C03-123  primer. Refer to the manufacturer's recommendations and as follows:
1Make sure that you do not increase the temperature of the case more than 200°F (93°C).
Subtask 72-00-01-220-366
(14)Corrosion and pitting of the anchor nut cages and rivets:
Maximum serviceable limit:
Not serviceable.
Maximum repairable method:
Any amount.
Repair method:
Replace the rivets and anchor nuts as follows:
NOTE:
Remove the mid outer liner bolt for inspection. Refer to TASK 72-00-01-040-805 (72-00-01, DISASSEMBLY 001). Do an inspection of the mid outer liner bolt for corrosion/pitting. Refer to TASK 72-21-99-200-801 (72-21-99, INSPECTION 001).
(a)Remove the anchor nuts. Refer to TASK 70-13-00-390-001 (RIVETED JOINTS).
(b)Do an inspection of the aft fan case shell for pitting. Refer to TASK 72-21-02-200-801 (72-21-02, INSPECTION 001) (Subtask 72-21-02-220-024 (paragraph 3.C.(11))).
(c)Blend to remove corrosion with pitting. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
1Maximum depth must not be more than 0.040 inch (1.02 mm).
2Blend to a minimum radius of 0.250 inch (6.35 mm).
3Blend minimum material thickness to completely remove pitting.
4Do an inspection if there is any evidence of corrosion or pitting in boltholes.
5Blend to make a smooth adjacent surface ensuring proper contact surface between aft fan case and anchor nut.
(d)The gap between the anchor nut and the blended surface of the aft fan case, before the anchor installation in free state, must be not more than 0.015 inch (0.38 mm).
(e)Apply coating. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM).
(f)Apply C03-077  primer (for example, primer P/N 10P4-2NF/EC-117S   ) to the aft fan case mating surface with the anchor nut.
(g)Perform a wet installation of the replacement anchor nuts P/N MS21076L4N   and rivets P/N 9025M79P06   as follows:
1Use C03-001  primer for the installation of the rivets.
2Rivet head must be within 0.0095-0.0105 inch (0.242-0.266 mm) below the surface of the aft fan case.
3Do an inspection of formed rivets. Refer to TASK 70-13-01-390-002 (ACCEPTABILITY LIMITS FOR FORMED RIVETS).
(h)Install the mid outer liner bolt. Refer to TASK 72-00-01-430-803 (72-00-01, ASSEMBLY 001).
Subtask 72-00-01-220-020
K.Do an inspection of each fan OGV fairing assembly (OGV fairing assembly) (10-010 , 72-21-00, 10-020 , 72-21-00, 10-030 , 72-21-00, 10-040 , 72-21-00, 10-050 , 72-21-00, 10-060 , 72-21-00, 10-070 , 72-21-00, 10-080 , 72-21-00, 10-090 , 72-21-00, 10-100 , 72-21-00, 10-110 , 72-21-00, 10-120 , 72-21-00, 10-130 , 72-21-00, 10-140 , 72-21-00, 10-150 , 72-21-00, 10-160 , 72-21-00, 10-170 , 72-21-00, 10-180 , 72-21-00, 10-190 , 72-21-00) on the stator/aft fan case (001A9) for:
(1)Missing pieces:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the OGV fairing assembly.
Subtask 72-00-01-220-021
(2)Shallow nicks, scratches, and wear on all surfaces:
Maximum serviceable limit:
Any amount.
Repair method:
Replace the OGV fairing assembly.
Subtask 72-00-01-220-022
(3)Cracks in all areas of the flowpath surface:
Maximum serviceable limit:
One crack, not more than 0.500 inch (12.70 mm) in length, if there are no other cracks on the edges of the flowpath surface.
Repair method:
Replace the OGV fairing assembly.
Subtask 72-00-01-220-363
(4)Distortion:
Maximum serviceable limit:
0.750 inch (19.05 mm) radially from either the trailing edge of the aft acoustic panel, the OVG flowpath, and the adjacent fairing flowpath material.
Repair method:
Replace the OGV fairing.
Subtask 72-00-01-220-364
(5)Missing RTV around boltheads:
NOTE:
RTV is only applicable to the aft row of boltheads.
Maximum serviceable limit:
Any amount on the forward row of bolts.
Maximum repairable limit:
Any amount on the aft row of bolts.
Repair method:
Apply C01-176  RTV 133 to the aft row of bolts.
Subtask 72-00-01-220-026
L.Do an inspection of each fan (OGV) (10-220 , 72-21-00, 10-230 , 72-21-00, 10-240 , 72-21-00, 10-250 , 72-21-00, 10-260 , 72-21-00, 10-270 , 72-21-00, 10-280 , 72-21-00, 10-290 , 72-21-00, 10-300 , 72-21-00, 10-310 , 72-21-00, 10-320 , 72-21-00) as follows. Refer to Figure 801 and to Figure 808.
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the OGV.
Subtask 72-00-01-220-060
(2)Nicks and scratches (does not include inner and outer mounting flanges or flowpath surfaces of the inner platform):
Maximum serviceable limit:
•
Area A, 0.0250 inch (0.635 mm) in depth, 0.5 inch (13 mm) in length.
•
Area B, one each side 0.010 inch (0.25 mm) in depth, 0.5 inch (13 mm) in length.
Repair method:
Replace the OGV.
Subtask 72-00-01-220-061
(3)Nicks and scratches on the inner and outer mounting flanges:
Maximum serviceable limit:
Any amount, 0.030 inch (0.76 mm) in depth, 0.150 inch (3.81 mm) in length, 0.050 inch (1.27 mm) in width.
Maximum repairable limit:
0.040 inch (1.02 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES). No more than 20 percent of any surface can be removed.
Subtask 72-00-01-220-376
(4)Nut plates, rivets, lock nuts, and machine screw (retaining bolts) that are damaged, loose, or missing:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace the rivet, locknut, bolt, or nut plates. Refer to TASK 72-21-20-300-801 (72-21-20, REPAIR 001) .
Subtask 72-00-01-220-062
(5)Nicks and scratches on the flowpath surface of the inner platform:
Maximum serviceable limit:
Any amount, 0.030 inch (0.76 mm) in depth, 2.00 inches (50.8 mm) in length, 0.050 inch (1.27 mm) in width.
Maximum repairable limit:
0.040 inch (1.02 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-063
(6)Dents/distortion (Does not include flowpath surfaces of the inner platform):
Maximum serviceable limit:
•
Area A, four smooth contoured dents each strut 0.090 inch (2.29 mm) in depth, if there is no connected distortion in area B.
•
Area B, four smooth contoured dents each strut 0.040 inch (1.02 mm) in depth. Dents that connect area A and area B must not be more than 0.040 inch (1.02 mm) in depth.
Repair method:
Replace the OGV.
* * * FOR ALL
Figure 808   OGV Inspection Areas
Subtask 72-00-01-220-064
(7)Dents on the flowpath surface of the inner platform:
Maximum serviceable limit:
Any amount, 0.030 inch (0.76 mm) in depth, 2.00 inches (50.8 mm) in length, 0.050 inch (1.27 mm) in width.
Maximum repairable limit:
0.040 inch (1.02 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-065
(8)Fretting on the inner mounting flange inner flange face:
Maximum serviceable limit:
Any amount, 0.010 inch (0.25 mm) in depth, after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Repair method:
Replace the OGV.
Subtask 72-00-01-220-066
(9)Missing, disbonded or damaged metal covers on the outer diameter (OD) of the outer mounting flange:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace metal cover with MIL-P-19834   or B12B27A2   (G13 material 0.008 inch PSA tape via 3M Co. designated Y435).
Subtask 72-00-01-220-341
* * * PRE SB   72-0156( PIP2 Configuration )
(10)Missing, disbonded or damaged metal covers on the inner diameter (ID) of the inner mounting flange of OGVs 41 thru 9 (numbers in accordance with Figure 809):
Maximum serviceable limit:
Any amount.
Maximum repairable limit:
None.
Repair method:
None.
Subtask 72-00-01-220-360
(11)Missing, disbonded or damaged metal covers on the ID of the inner mounting flange of OGVs 10 thru 40 (numbers in accordance with Figure 809):
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Replace metal cover with MIL-P-19834   or B12B27A2   (G13 material 0.008 inch PSA tape via 3M Co. designated Y435).
* * * END PRE SB   72-0156( PIP2 Configuration )
Subtask 72-00-01-220-361
* * * SB   72-0417( Elastomer Plug Configuration )
(12)Missing, disbonded or damaged rubber plug on the ID of the inner mounting flange:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the plug.
* * * END SB   72-0417
Subtask 72-00-01-220-067
(13)Missing paint:
Maximum serviceable limit:
Any amount, not more than 50 percent.
Maximum repairable limit:
Any amount.
Repair method:
Do the steps that follow:
WARNING:
ACETONE IS EXPLOSIVE, AN IRRITANT, AN ALLERGEN, AND HAS POISONOUS DETERIORATION. USE VAPOR/FUME CONTROL OR USE A RESPIRATOR.
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(a)Solvent wipe the area that has missing paint. Use C04-003   acetone or C04-035  isopropyl alcohol to clean the fan OGV. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS).
(b)Touch-up the area. Apply coating to the area. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM).
1Wipe all unwanted solution.
(c)Apply C03-007  primer, C03-079  primer, C03-085  primer, or C03-100  primer to the chemical touch-up areas to a dry thickness of 0.0002-0.0006 inch (0.005-0.015 mm). Refer to TASK 70-43-22-380-014 (PAINT - EPOXY COATING FOR ALUMINUM AND FERROUS ALLOYS).
(d)Apply C03-119  polyurethane coating to the epoxy primed areas to a dry thickness of 0.001-0.005 inch (0.026-0.127 mm). Refer to TASK 70-43-22-380-014 (PAINT - EPOXY COATING FOR ALUMINUM AND FERROUS ALLOYS).
Subtask 72-00-01-220-358
(14)Missing sealant in the spaces of the OGV platforms (at inner diameter). Refer to Figure 810:
Maximum serviceable limit:
Any amount, as long as RTV is present between the OGVs and seals a space between the OGV platforms.
Maximum repairable limit:
Any amount.
Repair method:
Replace the sealant between the OGV platforms as follows:
(a)Remove all the existing RTV sealant around the OGV platforms and in the seams with a non-metallic spatula.
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.
(b)Use a clean cloth moistened with C04-035  isopropyl alcohol to clean all surfaces.
Subtask 72-00-01-350-325
(c)Alternative Procedure Available. Apply sealant between the OGV platforms as follows:
1The total width of the C01-176  RTV 133 and the space must be approximately 0.500-0.625 inch (12.70-15.88 mm). Make sure that the space width is the same for all locations.
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.
2Apply C01-159  RTV primer to all surfaces where sealant is needed. Let the RTV primer dry for 15 minutes.
3Apply C01-176  RTV 133 to the spaces between the OGV platforms. If necessary, use C10-012  tape and a caulking gun to apply the sealant.
4Make the contour of the C01-176  RTV 133 flush with, or below, the surface of the OGV platform, and make all changes in the contour smooth. Do not let any of the contour surfaces be irregular.
5Let the C01-176  RTV 133 cure according to the manufacturer's instructions.
Subtask 72-00-01-350-326
(c).A.Alternative Procedure. Apply sealant between the OGV platforms as follows:
1The total width of the C01-218  adhesive system and the space must be approximately 0.500-0.625 inch (12.70-15.88 mm). Make sure that the space width is the same for all locations.
2Apply C01-217  primer to all surfaces where sealant is needed. Let the primer dry for 30 minutes.
3Apply C01-218  adhesive system to the spaces between the OGV platforms. If necessary, use C10-012  tape and a caulking gun to apply the sealant.
NOTE:
When applied, C01-218  adhesive system is in a shade of gray.
4Make the contour of the C01-218  adhesive system flush with, or below, the surface of the OGV platform, and make all changes in the contour smooth. Do not let any of the contour be irregular.
5Let the C01-218  adhesive system cure according to the manufacturer's instructions.
* * * FOR ALL
Figure 809   Fan Outlet Guide Vanes - Inspection Areas
* * * FOR ALL
Figure 810   OGV Inner Platform Sealant with Serviceable Missing RTV
Subtask 72-00-01-220-189
M.Do an inspection of each surface cooler fairing assembly (surface cooler fairing) (01-510 , 72-21-00, 01-520 , 72-21-00, 01-530 , 72-21-00, 01-630 , 72-21-00, 01-640 , 72-21-00, 01-650 , 72-21-00, 01-660 , 72-21-00, 01-670 , 72-21-00) on the stator/aft fan case (001A9) for:
(1)Missing pieces:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the surface cooler fairing.
Subtask 72-00-01-220-190
(2)Shallow nicks, scratches, and wear on all surfaces:
Maximum serviceable limit:
Any amount.
Repair method:
Replace the surface cooler fairing.
Subtask 72-00-01-220-191
(3)Cracks in all areas of the flowpath surface:
Maximum serviceable limit:
One crack, not more than 0.500 inch (12.70 mm) in length, if there are no other cracks on the edges of the flowpath surface.
Repair method:
Replace the surface cooler fairing.
Subtask 72-00-01-220-030
N.Do an inspection of the electronic engine control (EEC) (01-010 , 73-21-20) for:
(1)Looseness of EEC mounting bolts:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Tighten the EEC mounting bolts.
Subtask 72-00-01-220-031
(2)Looseness of EEC plumbing connections:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Tighten the EEC plumbing connections.
Subtask 72-00-01-220-032
(3)Other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the EEC.
Subtask 72-00-01-220-033
O.Do an inspection of each harness in the EEC harness assembly for:
(1)Looseness:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Tighten the harness connections.
Subtask 72-00-01-220-034
(2)Other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the harness(es).
Subtask 72-00-01-220-035
P.Do an inspection of each EEC mounting support bracket (support bracket) (05-040, 05-080 , 72-21-00, 05-070, 05-140 , 72-21-00, 65H14, 65H15) for:
(1)Broken or missing brackets:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the bracket.
Subtask 72-00-01-220-036
Q.Do an inspection of the oil tank (01-010 , 79-00-00) for:
(1)Looseness:
Maximum serviceable limit:
Not serviceable.
Maximum repairable limit:
Any amount.
Repair method:
Tighten the oil tank connections.
Subtask 72-00-01-220-037
(2)Other damage:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the oil tank.
Subtask 72-00-01-220-108
(3)Missing paint on the oil tank cap and scupper assembly:
Maximum serviceable limit:
Any amount permitted.
Repair method:
Remove any loose paint.
Subtask 72-00-01-220-194
(4)Dents or deformation of the scupper lip:
Maximum serviceable limit:
Any amount, if the interface with oil tank is not affected.
Repair method:
Replace the scupper assembly.
Subtask 72-00-01-220-195
(5)Cracks or missing material on the scupper assembly:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the oil tank cup and scupper assembly.
Subtask 72-00-01-220-196
(6)Nicks on the oil scupper:
Maximum serviceable limit:
Not serviceable.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating to the repaired surface. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-038
R.Do an inspection of the oil vent tube and hose (01-010 , 79-22-30) (SIN 46000), oil supply tube and hose (01-010 , 79-22-10) (SIN 44000), and oil return tube and hose (01-010 , 79-22-20) (SIN 45304) or (01-011 , 79-22-20) (SIN 45304) for:
(1)Splits, cracks, and kinks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the oil tube and hose.
Subtask 72-00-01-220-039
(2)Broken, missing, deformed, or twisted clamps:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the clamp.
Subtask 72-00-01-220-040
(3)Dents:
Maximum serviceable limit:
Six in each linear 12.0 inches (305 mm), if the depth of the dents is not more than 20 percent of the nominal OD of the oil tube and hose.
Repair method:
Replace the oil tube and hose.
Subtask 72-00-01-220-041
S.Do an inspection of the forward engine mount yoke (05-010 , 72-21-00) for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the forward engine mount yoke.
Subtask 72-00-01-220-042
(2)Nicks and scratches in the mount yoke clevis bores and edges:
Maximum serviceable limit:
Any amount, 0.001 inch (0.03 mm) in depth. Scratches must not touch each other.
Maximum repairable limit:
Any amount, 0.005 inch (0.13 mm) in depth.
Repair method:
Do not blend. Remove high metal, if present. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-043
(3)Nicks in all other areas:
Maximum serviceable limit:
Any amount, 0.015 inch (0.38 mm) in depth and 0.25 inch (6.4 mm) in length. Sharp edges are not permitted. Nicks must have a distance of 0.35 inch (8.9 mm) between them.
Maximum repairable limit:
Any amount, 0.05 inch (1.2 mm) in depth and 1.00 inch (25.4 mm) in length.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-044
(4)Scratches in all other areas:
Maximum serviceable limit:
Any amount, 0.005 inch (0.13 mm) in depth. Scratches must not touch each other.
Maximum repairable limit:
Any amount, 0.015 inch (0.38 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-312
(5)Alternative Procedure Available. Bushing migration. Refer to Figure 811:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Maximum serviceable limit:
Any amount, if the dimensions CLZ, CLW, CMZ, CRZ, and CRW are serviceable. Refer to Subtask 72-00-01-220-313 (paragraph 4.S.(6)) , Subtask 72-00-01-220-314 (paragraph 4.S.(7)) , Subtask 72-00-01-220-315 (paragraph 4.S.(8)) , Subtask 72-00-01-220-316 (paragraph 4.S.(9)) , and Subtask 72-00-01-220-317 (paragraph 4.S.(10)) .
Repair method:
•
If the bushings are migrated and within the maximum serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002).
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-342
(5).A.Alternative Procedure. Bushing migration. Refer to Figure 811:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Maximum serviceable limit:
Any amount, if the dimensions CLZ, CLW, CMZ, CRZ, and CRW are serviceable. Refer to Subtask 72-00-01-220-313 (paragraph 4.S.(6)) , Subtask 72-00-01-220-314 (paragraph 4.S.(7)) , Subtask 72-00-01-220-315 (paragraph 4.S.(8)) , Subtask 72-00-01-220-316 (paragraph 4.S.(9)) , and Subtask 72-00-01-220-317 (paragraph 4.S.(10)) .
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
Subtask 72-00-01-220-313
(6)Alternative Procedure Available. Dimension CLZ:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
•
If the bushings are migrated and within the maximum serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002).
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-343
(6).A.Alternative Procedure. Dimension CLZ:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
Subtask 72-00-01-220-314
(7)Alternative Procedure Available. Dimension CLW:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Minimum serviceable limit:
1.135 inches (28.83 mm), if the bushings are not migrated.
Repair method:
•
If the bushings are migrated and within the serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002).
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-344
* * * FOR ALL.ALL
(7).A.Alternative Procedure. Dimension CLW:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Minimum serviceable limit:
1.135 inches (28.83 mm), if the bushings are not migrated.
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
Subtask 72-00-01-220-315
(8)Alternative Procedure Available. Dimension CMZ:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
•
If the bushings are migrated and within the maximum serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002).
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-345
* * * FOR ALL.ALL
(8).A.Alternative Procedure. Dimension CMZ:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
Subtask 72-00-01-220-316
(9)Alternative Procedure Available. Dimension CRZ:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
•
If the bushings are migrated and within the maximum serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002).
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-346
* * * FOR ALL.ALL
(9).A.Alternative Procedure. Dimension CRZ:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Maximum serviceable limit:
2.955 inches (75.06 mm), if the bushings are not migrated.
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
Subtask 72-00-01-220-317
(10)Alternative Procedure Available. Dimension CRW:
NOTE:
This procedure is applicable only, if the same bushing is never pushed back before.
Minimum serviceable limit:
1.135 inches (28.83 mm), if the bushings are not migrated.
Repair method:
•
If the bushings are migrated and within the serviceable limit above, the condition can be accepted to fly as it is for 5000 cycles. It must be replaced in less than 5000 cycles.
•
If the bushings are migrated and outside the serviceable limit above, the bushing has to be re-positioned back. Refer to TASK 72-00-01-800-802 (72-00-01, SPECIAL PROCEDURE 002) .
NOTE:
Re-positioned bushings must be replaced in less than 5000 flight cycles.
Subtask 72-00-01-220-347
* * * FOR ALL.ALL
(10).A.Alternative Procedure. Dimension CRW:
NOTE:
If the bushing is pushed back before, re-positioned bushings must be replaced in less than 5000 flight cycles.
Minimum serviceable limit:
1.135 inches (28.83 mm), if the bushings are not migrated.
Repair method:
Remove and install the new bushing. Refer to TASK 72-00-01-800-803 (72-00-01, SPECIAL PROCEDURE 003) .
* * * FOR ALL
Figure 811   (Sheet 1 ) Forward Engine Mount Yoke - Dimensional Inspection
* * * FOR ALL
Figure 811   (Sheet 2 ) Forward Engine Mount Yoke - Dimensional Inspection
* * * FOR ALL
Figure 811   (Sheet 3 ) Forward Engine Mount Yoke - Dimensional Inspection
* * * FOR ALL
Figure 811   (Sheet 4 ) Forward Engine Mount Yoke - Dimensional Inspection
Subtask 72-00-01-220-046
T.Do an inspection of each bracket assembly mounted on the stator/aft fan case for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the bracket.
Subtask 72-00-01-220-047
(2)Nicks, dents, and scratches:
Maximum serviceable limit:
Any amount 0.015 inch (0.38 mm) in depth and a minimum of 0.500 inch (12.70 mm) between indications.
Maximum repairable limit:
Any amount 0.32 inch (8.1 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-048
U.Do an inspection of the vapor barrier (01-190 , 72-21-00) or vapor barrier (01-190A , 72-21-00) for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the vapor barrier.
Subtask 72-00-01-220-049
(2)Nicks, dents, and scratches:
Maximum serviceable limit:
0.010 inch (0.25 mm) in depth.
Repair method:
Replace the vapor barrier.
Subtask 72-00-01-220-050
V.Do an inspection of the thrust reverser seal (01-080 , 72-21-00) for:
(1)Wear and abrasions:
Maximum serviceable limit:
Not through the fabric.
Repair method:
Repair the thrust reverser seal. Refer to TASK 72-00-01-300-804 (72-00-01, Repair 010).
Subtask 72-00-01-220-051
(2)Punctures, cracks, and tears through the fabric:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair the thrust reverser seal. Refer to TASK 72-00-01-300-804 (72-00-01, Repair 010).
Subtask 72-00-01-220-052
(3)Cuts and tears in the pressurization tube:
Maximum serviceable limit:
Any amount, 1.0 inch (25 mm) in length with no less than 1.0 inch (25 mm) between defects, and not through the fabric.
Repair method:
Repair the thrust reverser seal. Refer to TASK 72-00-01-300-804 (72-00-01, Repair 010).
Subtask 72-00-01-220-053
W.Do an inspection of the upper firewall (01-150 , 72-21-00) (SIN 84401) or (01-151 , 72-21-00) (SIN 84401) or (01-152 , 72-21-00) (SIN 84401), and lower firewall (01-370 , 72-21-00) (SIN 84501) or (01-371 , 72-21-00) (SIN 84501) or (01-372 , 72-21-00) (SIN 84501) for:
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the firewall.
Subtask 72-00-01-220-054
(2)Nicks, dents, and scratches:
Maximum serviceable limit:
Any amount, 0.015 inch (0.38 mm) in depth, with no less than 0.50 inch (12.7 mm) between defects after removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Maximum repairable limit:
Any amount, 0.032 inch (0.81 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-00-01-220-055
X.Do an inspection of each extension panel (panel) (01-160 , 72-21-00, 01-170 , 72-21-00, 01-380 , 72-21-00, 01-390 , 72-21-00) and each fillet fairing (fillet) (25-100 , 72-00-00, 25-110 , 72-00-00, 25-430 , 72-00-00, 25-440 , 72-00-00) as follows. Refer to Figure 812 and Figure 813.
NOTE:
Boltheads can sit proud even after torque. Do not over torque. If necessary, examine torque for extension panel, 70 to 80 lb in. (7.9 to 9.0 Nm), and for fillet fairing, 60 to 70 lb in. (6.8 to 7.9 Nm).
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the panel or fillet.
Subtask 72-00-01-220-056
(2)Nicks and scratches:
Maximum serviceable limit:
Any amount.
Subtask 72-00-01-220-057
(3)Dents, holes, or punctures:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the panel or fillet.
Subtask 72-00-01-220-058
(4)Delamination on the corner of the panel or fillet:
Maximum serviceable limit:
Any amount, not more than 0.5 sq in. (323 sq mm).
Repair method:
Replace the panel or fillet.
Subtask 72-00-01-220-059
(5)Delamination on all other areas of the panel or fillet:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the panel or fillet.
* * * FOR ALL
Figure 812   Extension Panels - Inspection
* * * FOR ALL
Figure 813   Fillet Fairings - Inspection
Subtask 72-00-01-220-129
Y.Do an inspection of each thrust reverser channel (01-060 , 72-21-00, 01-070 , 72-21-00) as follows. Refer to Figure 814.
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the thrust reverser channel.
Subtask 72-00-01-220-197
(2)Nicks, dents, scratches, and gouges in area C. Refer to Figure 815.
Maximum repairable limit:
Any amount, 0.100 inch (2.54 mm) in depth and 1.00 inch (25.4 mm) in length with no less than 1.00 inch (25.4 mm) between defects.
Repair method:
Blend to 1.25 times defect depth with a minimum radius of 0.250 inch (6.35 mm). Maximum blend length 2.00 inches (50.8 mm) with a minimum distance between blends of 1.00 inch (25.4 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating to the repair area. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-130
(3)Nicks, dents, and scratches in all other areas. Refer to Figure 814.
Maximum serviceable limit:
Any amount, 0.015 inch (0.38 mm) in depth, with a minimum distance of 1.0 inch (25 mm) between defects.
Maximum repairable limit:
Any amount, 0.032 inch (0.81 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating to the repair area. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-131
(4)Oxidation deposits or discoloration:
Repair method:
Replace the thrust reverser channel.
* * * FOR ALL
* * * SB   72-0047( Additional Clearance for Thrust Reverser Bolt )
* * * SB   72-0035( PIP2 Configuration )
* * * SB   72-0156( PIP2 Configuration )
Figure 814   Thrust Reverser Channel - Inspection
* * * FOR ALL
Figure 815   Thrust Reverser Channel - Inspection of Area C
Subtask 72-00-01-220-132
Z.Do an inspection of the upper seal retainer (01-181 , 72-21-00) or upper seal retainer (01-182 , 72-21-00) and upper seal retainer (01-341 , 72-21-00) as follows. Refer to Figure 814.
(1)Cracks:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the upper seal retainers.
Subtask 72-00-01-220-133
(2)Nicks, dents, and scratches:
Maximum serviceable limit:
Any amount, 0.015 inch (0.38 mm) in depth after removal of high metal, if the minimum distance between defects is more than 1.0 inch (25 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Maximum repairable limit:
Any amount, 0.032 inch (0.81 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating to the repair area. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-134
(3)Oxidation deposits or discoloration:
Maximum serviceable limit:
Any amount, 0.015 inch (0.38 mm) in depth after removal of high metal, if the minimum distance between defects is more than 1.0 inch (25 mm). Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .
Maximum repairable limit:
Any amount, 0.032 inch (0.81 mm) in depth.
Repair method:
Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) . Apply coating to the repair area. Refer to TASK 70-43-07-380-007 (CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM) .
Subtask 72-00-01-220-334
AA.Do an inspection of each fire shield (01-680 , 72-21-00) (SIN 844A1), (01-690 , 72-21-00) (SIN 844A2), (01-700 , 72-21-00) (SIN 844A3), (01-710 , 72-21-00) (SIN 844A4) on the upper firewall (01-150 , 72-21-00) (SIN 84401), (01-151 , 72-21-00) (SIN 84401), (01-152 , 72-21-00) (SIN 84401) and the insulation blanket (01-720 , 72-21-00) (SIN 844A5) on the lower firewall (01-370 , 72-21-00) (SIN 84501), (01-371 , 72-21-00) (SIN 84501), (01-372 , 72-21-00) (SIN 84501) for:
(1)Loose, missing, or torn fire shield aluminum foil:
Maximum serviceable limit:
Any amount, if not more than 1.00 sq in. (645.1 sq mm) each.
Repair method:
Repair. Refer to TASK 72-00-01-300-817 (72-00-01, REPAIR 013) or TASK 72-00-01-300-818 (72-00-01, REPAIR 012) .
Subtask 72-00-01-220-335
(2)Gouges in fire shield with the same depth as the outer glass fiber layer or red RTV:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-00-01-300-817 (72-00-01, REPAIR 013) or TASK 72-00-01-300-818 (72-00-01, REPAIR 012) .
Subtask 72-00-01-220-336
(3)Gouges in fire shield with the same depth as the inner glass fiber layer or white insulation material:
Maximum serviceable limit:
Not serviceable.
Repair method:
Repair. Refer to TASK 72-00-01-300-817 (72-00-01, REPAIR 013) or TASK 72-00-01-300-818 (72-00-01, REPAIR 012) .
Subtask 72-00-01-220-337
(4)Missing or non-repairable fire shield(s)/insulation blanket:
Maximum serviceable limit:
Not serviceable.
Repair method:
Replace the fire shields/insulation blanket. Refer to TASK 72-00-01-300-818 (72-00-01, REPAIR 012) .
* * * FOR ALL
Figure 816   (Sheet 1 ) Trenchfiller Panel Facesheet - Repair Areas
* * * FOR ALL
Figure 816   (Sheet 2 ) Trenchfiller Panel Facesheet - Repair Areas
* * * FOR ALL
Figure 817   Trenchfiller Panel Facesheet - Typical Defects
* * * FOR ALL
Figure 818   (Sheet 1 ) Forward Containment Case - Forward Acoustic Treatment Closeout Plies
* * * FOR ALL
Figure 818   (Sheet 2 ) Forward Containment Case - Forward Acoustic Treatment Closeout Plies