Appendix B Service Instructions No. 0530-134, Rev. I
PART I REPAIR
1. If nicks are found in the spar or angle-doubler flanges, they should be sanded smooth to lessen the possibility of crack development.
2. If cracks are found in either the spar flanges or in the angle-doubler flanges but not in both on the same side, to a maximum depth of .25-inch, a repair may be made to the vertical stabilizer assembly as follows.
a. Slip a stainless steel shim between the spar flange and the angle-doubler flange to prevent damage to the adjacent flange and grind out the crack. Leave a smooth edge and flair the area out to the normal flange width. (Figure 3.)
b. Fabricate and install two doublers from .125-inch by 5.0-inches by 30.0-inches and two shim spacers from . 025-inch by 2.0-inches by 12.0-inches, 2024-T3 aluminum alclad, as shown in Figure 3.
c. Install one doubler and one shim on each side of the vertical stabilizer as shown in Figure 3.
Reinstall the rivets which were removed in Part I for inspection of the doublers.
d. Starting from a point approximately 8-inches forward of the vertical stabilizer main spar and aft from that point, drill out all rivets which attach the vertical stabilizer/fuselage angle-fairing to the fuselage.
e. Measure the width of the doublers at the vertical stabilizer skin lower edge. (See Figure 3.) The rectangular cutout in the upper fuselage should be lengthened to at least 1.5-inches longer than the width of the doublers to allow clearance between the stabilizer and the dorsal fairing during NOTE It may be necessary to relocate the small angle at the aft of the cutout in order to achieve the necessary clearance for the doublers.
f. Reinstall the vertical stabilizer as described in Chapter 55-30 of the Maintenance Manual.
NOTE Check the clearance between the forward surface of the main spar and the bulkhead. If the two surfaces are not flush the gap should be shimmed. (Shims may be fabricated locally from aluminum stock.)
g. Form the vertical stabilizer/fuselage angle-fairing around the doublers and reinstall the rivets which were removed in step d. Reinstall screws to attach the angle-fairing to the vertical stabilizer.
h. Reinstall and rerig the rudder and tab per Chapter 27-20 of the Maintenance Manual.
3. The preceding doubler installation is to be made on all affected airplanes for the vertical stabilizer may be replaced with a new P/N 115-640000-605 vertical stabilizer assembly), regardless of whether cracks are noted or not with the following exception:
8/14/97 AC 43-204 Appendix B Service Instructions No. 0530-134, Rev. I * LEAVE EXISTING FASTENERS INSTALLED AND ADD 16 EA CR 2249-5-6 FASTENERS
ON EACH SIDE AS SHOWN
• REMOVE EXISTING MS20426ADS FASTENERS AND REPLACE WITH CR 2249-5-6 AND ADD 6 EA CR 2249-5-6 FASTENERS ON EACH SIDE • VS 0.000
AS SHOWN
- 16 EQUAL SPACES 45° CHAMFER ALL AROUND
9.40 06 TYP
20.8 9.00R VS -8.500 DOUBLER (2 REQ.)
.125 X 5.0 X 30.0
- 16 EQUAL SPACES 2024-T3 ALUM ALCLAD
- JOGGLE AREA 0Q-A-250/5 OF
• + ANGLE-
DOUBLER
• CR 2249-5-5 (3 REQ.) ON EACH SIDE) O 4 ANGLE-
DOUBLER VS - 17.200 <10>
1.50 R MEASURE THIS DISTANCE ML
FRONT SPAR AREA CRACKING OCCURRED
- 10 EQUAL SPACES
10.01 INSTALL SHIM-SPACER (2 REQ.)
.025 X 2.0 X 12.0 2024 T3 ALUM ALCLAD
BETWEEN DOUBLER AND SPAR SHIM AS REQ. AND BELOW STABILIZER SKIN LINE
BETWEEN SPAR
AND BULKHEAD 48 25R
1.50 ® INDICATES EXISTING RIVETS Figure 3. Fabrication and Installation of Doublers and Spacer - Shims Ho Page 7
Appendix B Service Instructions No. 0530-134, Rev. I If cracks are found in both the spar and angle-doubler flanges on the same side and/or the cracks extend into the rivet holes or into the radius of the spar or angle-doubler, the vertical stabilizer assembly must be replaced. Removal and reinstallation of the rudder and the vertical stabilizer are described in Chapter 27-20 and 55-30 respectively of the Maintenance Manual. rerigging of the rudder and tab is described in Chapter 27-20 of the Maintenance Manual.
RECORD COMPLIANCE: Upon completion of these Service Instructions, make an appropriate maintenance record entry.
* Do Page 8
Appendix C APPENDIX C. PRATT & WHITNEY ENGINE GENERAL - INSPECTION/CHECK - 00
SAMPLE INSPECTION PROCEDURE Task 72-00-00-990-004 Paras 1-4 Task 72-31-82-990-001 Task 72-31-82-990-002 Task 72-31-82-200-003 Retyped with permission of Pratt & Whitney.
Appendix C
SAMPLE INSPECTION PROCEDURE ENGINE GENERAL - INSPECTION/CHECK-00 Task 72-00-00-990-004:
1. Preliminary Instructions CAUTION: TITANIUM WELDMENTS AND ASSEMBLIES SHOULD NOT BE
PROCESSED THROUGH TRICHLORETHYLENE DEGREASERS OR
ANY CLEANER CONTAINING CHLORIDES IN ORDER TO AVOID
POSSIBILITY OF STRESS CORROSION ASSOCIATED WITH
ENTRAPMENT OF CHLORINE-CONTAINING MATERIALS IN TIGHT FITTING AREAS. THIS RESTRICTION ALSO APPLIES TO
PARTS SUCH AS TITANIUM DISKS OR HUBS CONTAINING INSERTS, SLEEVES, OR PINS. DISKS MUST BE DEBLADED
PRIOR TO CLEANING AND PRIOR TO FLUORESCENT PENETRANT OR MAGNETIC PARTICLE INSPECTION.
Thorough and intelligent inspection of all engine parts is one of the controlling factors in efficient and dependable maintenance, and too much emphasis cannot be placed on the importance of careful inspection and the decisions it involves. Inspection personnel must be thoroughly familiar with instructions in this chapter, in the requirements of the Standard Practices Manual and in Repair Sections.
B. After engine is disassembled and cleaned, arrange all parts of engine on inspection table so that inspector can judge the condition of engine as a whole and can readily make reference to other engine parts which may have been affected by a worn part.
In this way, it will often be possible to determine at once the cause of any abnormal wear.
2. Records and Limits During inspection, keep a record of the condition of all parts and a record of all fits, clearances, and spring pressures. Refer to the specific fits and clearances requirements in the appropriate Inspection/Check sections of this manual for proper limits. Attach a tag, indicating that replacement is necessary, to any part which is found to be unfit for further service. Attach a tag describing necessary refurbisment to any part which requires repair. If refurbishment will affect a fit or clearance, tag must remain with part until final assembly and must be marked with a warning to check fit or clearance.
B. When a new part is to be installed and it is important that it be identified as to engine number or position in engine; mark it by appropriate method described in Marking of Parts in Standard Practices Manual.
C. When making out inspection records or reports, use only descriptive words which accurately qualify existing conditions. In order to eliminate confusion and to maintain consistent terminology, the various physical conditions and the determination of the usual causes of wear or damage to engine parts which might be encountered during inspection are defined in the Physical Inspection Section of Standard Practices a Manual.
Page 802 EFF: ALL Page 2
Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) ENGINE GENERAL - INSPECTION/CHECK-00 Task 72-00-00-990-004:
D. If inspection reveals it necessary to replace a fitted spacer, tag spacer to indicate that replacement must be made with a part of correct classification at assembly.
3. General Inspections A See Standard Practices Manual as follows:
(1) Physical Inspection
(2) Magnetic Particle Inspection
(3) Fluorescent Penetrant Inspection
(4) Surface Treatments
(5) Welding
(6) Gage Inspection Corrosion Prevention After Inspection Equipment and Materials:
Iter No. Designation P95-035 Corrosion Preventive Oil (AMS 3065) B. After inspection, whenever it is deemed that sufficient time will elapse before reassembly to allow damage to parts from corrosion, cover all unprotected surfaces of magnesium and steel parts, or any parts with which corrosion difficulties are experienced, with Corrosion Preventive Oil (P05-035). Unless the parts are otherwise preserved for longer periods of time, they should be recoated with Corrosion Prevention Oil (P05-035), every four days.
EFF: ALL Page 803 Page 3
Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-00 Task 72-31-82-990-001:
1. Inspection/Check Part Number Index - State 1 LPC Blade Assembly Inspection Functional Arrangement
(1) Inspection/Check-01 through Inspection/Check-06 contain procedures for complete inspection of Stage 1 LPC blade assembly. Inspection function and applicability for this part are shown in Table 801.
INSPECTION/CHECK INSPECTION/CHECK INSPECTION/CHECK
NUMBER CATEGORY APPLICABILITY +0-1 Preinspection Applicable Preparation
- 0-2 Non-destructive Applicable inspection -03 Visual inspection Applicable -04 Dimensional Applicable Inspection
- 05 Functional Check Applicable Inspection -06 Inspection Applicable Postrequisites Inspection Functional Arrangement Table 801 B. Inspection/Check Part Number Index
(1) Table 802 is a listing of part numbers and appropriate Inspection/Check Referenced service bulletins are listed for parts introduced or obtained by service bulletin incorporation.
PART SERVICE
NUMBER INSPECTION/CHECK BULLETIN 52A121 01.02,03,04,06 PW4ENG 72-132 53A321 01,02,03,04,06 PW4ENG 72-132 Inspection/Check Part Number Index Table 802 Page 804 EFF: ALL Pee Page 4
8/14/97 AC 43-204 Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01 Task 72-31-82-990-002:
1. Preinspection Preparation - Stage 1 LPC Blade Assembly A Prerequisites
(1) See Inspection/Check-00 (Task 72-31-82-990-001) for functional arrangement and part number applicability.
B. Equipment and Materials Required • None C. Procedure See Figures 801, 802 and 803.
WARNING TO AVOID POSSIBLE INJURY TO HANDS, GLOVES SHOULD BE WORN WHEN HANDLING BLADES.
CAUTION: NICKS IN LEADING AND TRAINING EDGES BECOME
INCREASINGLY CRITICAL THE CLOSER THEY ARE TO ROOT OF BLADE. THEREFORE, ANY INJURY TO THAT
PORTION OF BLADE FROM PART SPAN SHROUD TO PLATFORM MUST BE TREATED WITH EXTREME CARE.
(1) Following instructions are standard inspection criteria which apply throughout inspection procedures.
Blade limits are evaluated from a standpoint of structural integrity.
The use of a substantial number of blades repaired to or near maximum limits, or use of blades having many repaired areas, may affect compressor efficiency and therefore engine performance.
(b) All blade surfaces must be smooth and all evidence of previous leading and trailing edge repairs should be smooth with a minimum edge thickness as shown in Figure 802 maintained.
(c) All blade limits are based on original edge contour, therefore, all blends in one location are cumulative. For example, if blend depth limit is made, no further blend nor the sum of several future blends may exceed the maximum blend depth at that location. Blends directly opposite one another on leading and trailing edge are also cumulative and must not exceed maximum depth of single leading or trailing edge blend.
(d) Maximum depth blends on leading and trailing edges must be separated by minimum distance equal to mean chordal length of blade.
See Figure 803.
rel Limits apply to damaged area after blending and not to magnitude of damage measured before blending.
EFF: ALL Page 801 Page 5
Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
- BLADE TIP
OUTER PORTION - PART SPAN SHROUD
OF BLADE -
SHROUD TO AIRFOIL RADIUS (4 PLACES)
FRONT AND REAR
LEADING EDGE SHROUD RADIUS
AREA (FOUR PLACES)
INNER PORTION OF BLADE • TRAILING EDGE
- PLATFORM TO AIRFOIL
RADIUS (ALL AROUND BLADE
AIRFOIL PLATFORM AND BLADE
ROOT SECTION ROOT SECTION
• PLATFORM SEAL Blade Area Nomenclature Figure 801 (Task 72-31-82-990-002) Page 802 EFF: ALL Page 6
Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
SECTION A - A L-A0968 1285
1. Minimum Trailing Edge Thickness As Measured At Index 2 To Be 0.020 Inch (0.51 mm).
2. 0.040 Inch (1.02 mm) - Measure Leading And Trailing Edge Thickness At This Dimension
3. 12.229 Inch (310.617 mm) - Minimum Leading Edge Thickness As Measured At Index 2 To Be
0.038 Inch (0.965 mm).
4. Minimum Leading Edge Thickness As Measured At Index 2 To Be 0.027 Inch (0.686 mm).
Leading And Trailing Edge Minimum Thickness Limits Figure 802 (Task 72-31-82-990-002) Page 803 EFF: ALL Page 7
AC 43 - 204 8/14/97 Appendix C STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01 L-A0969 Mean Chordal Length Measured Equidistant Between Blends.
2. Blends Must Be separated By Minimum Dimension Equal To Index 1 Dimension.
Minimum Blend Separation Figure 803 (Task 72-31-82-990-002) Page 804 EFF: ALL Page 8
46/57/8 AC 43-204 Appendix C Pratt & Whitney PW4000 SERIES ENGINE MANUAL (PN 50A443) STAGE 1 LPC BLADE ASSEMBLY - INSPECTION/CHECK-01
(f) If two or more heavily blended blades are found grouped together, an attempt should be made to redistribute these blades and their matching blades evenly throughout rotor.
(g) Total Length of leading and trailing edge blends must not exceed four inches (101.600 mm) and there must not be more than two blends to maximum depth limit per blade.
(2) Visually check leading and trailing edges ofblade for damage whenever foreign NOTE: Use of strong lights and mirrors as well as fingernails and fingertips may aid in locating damaged areas.
CAUTION: USE EXTREME CAUTION WITH ANY ELECTRICAL EQUIP- MENT IN THE VICINITY OF BLADE. CONTACT WITH
ANY ELECTRICAL SOURCE THAT MAY PASS CURRENT TO BLADE SURFACE CAN CAUSE AN ARC BURN. ARC
BURN CAN RESULT IN LOCAL DEGRADATION MATERIAL PROPERTIES AND CRACK INITIATION.
(3) When checking blades for foreign object damage visually inspect for arc burn.
Arc burn is evidenced by a small circular or semi-circular bead affected area on blade surface that may contain shallow pitting, remelt or a crack. Blades with arc burn are not acceptable for further service.
(4) The following procedure is recommended for inspection of 1st stage blade assembly after refurbishment or repair.
Visually inspect blade using a bright light, mirrors, a 3X glass.
fingertips and fingernails, specifically looking for small depressions that interrupt surface contour. Refer to PWA Color Photographs for conditions that have been observed.
(b) Peening tends to remove evidence of heat discoloration and to smooth damage, making it less visually apparent.
(c) Electrical discharge damage has been observed in two different forms:
Strong geometric shapes such as ovals, crescents, or rectangles depressed into blade surface might be caused by contact with a rod or wire carrying an electrical charge.
Coarse linear indications, typically composed of small overlapping craters or pits.
NOTE: Regardless of form, damage is a local phenomenon.
unlike erosion pitting, and damage boundaries do not have raised material as does damage from foreign object damage.
Page 805 EFF: ALL Page 9