Repair the External Surface Damage of the Inlet Cone Assembly (Rear Segment) [PW11]

TASK 72-11-01-300-803-A
Repair the External Surface Damage of the Inlet Cone Assembly (Rear Segment)

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE AFTER SHUTDOWN. THE ENGINE CAN STAY HOT FOR A LONG TIME. IF YOU DO NOT OBEY THIS INSTRUCTION, INJURY CAN OCCUR.

WARNING: BE CAREFUL WHEN YOU USE CONSUMABLE MATERIALS. OBEY THE MATERIAL MANUFACTURER'S INSTRUCTIONS AND YOUR LOCAL REGULATIONS.

ZONE: 400

1. Reason for the Job
Use this procedure to fill repair the external surface damage to the inlet cone assembly (rear segment). Do not repair more than the fiberglass layer.
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	1	KNIFE- RAZOR
No specific	1	MAT - PROTECTIVE
636-1100-3GSE	1	INLET COWL PROTECT COVER

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.P05-005)	cloth, cotton, lint free
(Material No.P05-055)	emery paper
(Material No.P05-094)	paper, aluminum oxide
(Material No.P05-138)	cloth, aluminum oxide
(Material No.P05-153)	abrasive paper, silicon carbide
(Material No.P05-204)	cloth, aluminum oxide abrasive
(Material No.P05-253)	paper, abrasive
(Material No.P08-002)	PWA 421-2 liquid epoxy resin
(Material No.P08-012)	PWA 422-1 epoxy resin curing agent (amine type)
(Material No.P08-039)	PWA 457-4 adhesive paste, epoxy, unfilled resin
(Material No.P11-078)	PMC 9016 alcohol, isopropyl

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
400	POWER PLANT, NACELLES AND PYLONS

D. Referenced Information

REFERENCE	DESIGNATION
TASK 70-27-00-910-804-A	SPOP 208 - Degreasing of Parts by Solvent Wiping
TASK 71-00-00-860-833-A	Procedure to Prevent Engine Motoring
TASK 72-11-01-000-801-A	Removal of the Inlet Cone
TASK 72-11-01-300-801-A	Repair of the Inlet Cone
TASK 72-11-01-400-801-A	Installation of the Inlet Cone
Inlet Cone Rear Segment

3. Job Set-up
Subtask 72-11-01-941-055-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) Do the procedure to prevent engine motoring
(Ref. AMM TASK 71-00-00-860-833)
(2) Put the 636-1100-3GSE INLET COWL PROTECT COVER or MAT - PROTECTIVE in the intake cowl.

4. Procedure
Subtask 72-11-01-320-050-A ** ON A/C NOT FOR ALL

A. Repair the External Surface Damage of the Inlet Cone Assembly (Rear Segment)

CAUTION: WIPE CLEAN ALL PARTS AND TOOLS AS NECESSARY TO REMOVE UNWANTED DEBRIS AND PREVENT DAMAGE TO THE ENGINE.

CAUTION: DO NOT REPAIR MORE THAN THE FIBERGLASS LAYER. REPLACE THE CONE SEGMENT IF THERE IS DAMAGE TO MORE THAN THE FIBERGLASS LAYER. IF YOU DO NOT OBEY THIS CAUTION, DAMAGE TO ENGINE COMPONENTS CAN OCCUR.

CAUTION: WHEN YOU USE A RAZOR KNIFE TO REMOVE THE DAMAGED PROTECTIVE COAT, BE CAREFUL NOT TO CAUSE MORE DAMAGE TO THE FIBERGLASS LAYER.

(1) If necessary, remove the inlet cone assembly (Ref. AMM TASK 72-11-01-000-801).
(2) Use a KNIFE- RAZOR to cut the loose or lifted fluoroelastomer layer around the damage in the repair area. See figure:

Inlet Cone Rear Segment ** ON A/C NOT FOR ALL

NOTE: The local surface damage limit is 1.000 in. (25.40 mm) maximum diameter, with a minimum distance of 1.000 in. (25.40 mm) between repair areas. The maximum total repair area is 7.000 in.2 (4516.12 mm2).

(3) Prepare the repair area with emery paper (Material No.P05-055) , P05-094paper, aluminum oxide, P05-138cloth, aluminum oxide or P05-204cloth, aluminum oxide abrasive, to remove all damaged fiberglass and make sure that all loose or lifted fluoroelastomer is removed around the repair area.

NOTE: Be careful not to damage the Kevlar(R) layers below the fiberglass.

NOTE: You can make minor chips and scratches smooth. It is not necessary to repair this damage.

(4) Lightly prepare the repair area with P05-153abrasive paper, silicon carbide or P05-253paper, abrasive.
(5) Clean the prepared surface by SPOP 208, with a clean P05-005cloth, cotton, lint free and P11-078PMC 9016 alcohol, isopropyl (Ref. AMM TASK 70-27-00-910-804).
(6) Let the area dry for 15 minutes minimum.
(7) Do a visual inspection of the internal and external surfaces of the repair areas. If there is no damage through the fiberglass, go to Step 4.A.(13).

NOTE: Damage to more than the fiberglass into the Kevlar(R) is not repairable.

NOTE: If you can see the black fluoroelastomer coat, the surface is repairable by this procedure.

NOTE: If you can see the white-green fiberglass layer, the surface is repairable by this procedure.

NOTE: If you can see the yellow-brown Kevlar(R) layer, the surface is not repairable by this procedure.

NOTE: Cracks found on external or internal surfaces are not repairable and make the part unserviceable.

NOTE: Material delamination found on external or internal surfaces are not repairable and make the part unserviceable.

(8) Prepare one of the fill compounds by one of the procedures that follow:
(a) Mix 100 parts of PWA 421-2 liquid epoxy resin (Material No.P08-002) by weight with 25 parts of P08-012PWA 422-1 epoxy resin curing agent (amine type) at room temperature.
(b) Mix 100 parts of P08-039PWA 457-4 adhesive paste, epoxy, unfilled resin Part-A by weight with 30 parts of P08-039PWA 457-4 adhesive paste, epoxy, unfilled resin Part-B at room temperature.

NOTE: The two materials have a pot life of 20 to 30 minutes at room temperature.

(9) Fill the damaged areas with fill compound until the filled surface is above the adjacent fiberglass layer. Do not fill bolt hole or air hole locations.
(10) Cure the adhesive compound by one of the procedures that follow:
(a) Cure for 24 hours, minimum, at room temperature, 60 deg.F (16 deg.C) to 90 deg.F (32 deg.C).
(b) Cure for two hours, minimum, at 150 deg.F (66 deg.C) to 200 deg.F (93 deg.C).
(11) Lightly prepare the filled layer with P05-094paper, aluminum oxide, P05-153abrasive paper, silicon carbide or P05-253paper, abrasive to make the surface contour level with the adjacent fiberglass layer.
(12) Clean the prepared surface by SPOP 208 with a clean P05-005cloth, cotton, lint free and P11-078PMC 9016 alcohol, isopropyl (Ref. AMM TASK 70-27-00-910-804).
(13) Let the area dry for 15 minutes minimum.
(14) Apply the protective coat to the repaired areas (Ref. AMM TASK 72-11-01-300-801).
(15) If necessary, install the inlet cone assembly (Ref. AMM TASK 72-11-01-400-801).
(16) Examine the assembly for foreign objects, damage and correct assembly.

5. Close-up
Subtask 72-11-01-942-051-A ** ON A/C NOT FOR ALL

A. Put the aircraft back to its initial configuration.
(1) Remove the 636-1100-3GSE INLET COWL PROTECT COVER and MAT - PROTECTIVE from the inside of the fan case.
(2) Make sure that the work area is clean and clear of tools and other items.
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 13:02:13 UTC