Repair by Replacement of the Attrition Linings - VRS1843 [IAE]

TASK 72-32-85-300-022-A
Repair by Replacement of the Attrition Linings - VRS1843

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

CAUTION: YOU MUST KEEP ALL SURFACES CLEAN DURING THIS REPAIR. DIRT OR GREASE ON BONDING SURFACES WILL CAUSE UNSATISFACTORY BONDS. CLEAN COTTON OR POLYTHENE GLOVES MUST BE WORN BY ALL PERSONS TOUCHING THE PARTS TO BE BONDED. THE TOUCHING OF PARTS MUST BE KEPT TO A MINIMUM AND COMPONENTS MUST NOT BE TOUCHED ON THEIR PREPARED SURFACES.

CAUTION: TO GET GOOD BONDING, YOU MUST TAKE CARE TO CORRECTLY PREPARE THE ABRADED SURFACES AND TO USE THE ADHESIVE CORRECTLY.

NOTE: This repair procedure is estimated to take less than 15 hours in the hangar when done by skilled mechanics familiarized with the procedure.

ZONE: 400
FIN: 1000EM1 ** ON A/C NOT FOR ALL
FIN: 1000EM2 ** ON A/C NOT FOR ALL

1. Reason for the Job
Self explanatory
2. Job Set-up Information
A. Fixtures, Tools, Test and Support Equipment

REFERENCE	QTY	DESIGNATION
No specific	AR	ACCESS PLATFORM 1M(3 FT)
No specific	AR	BLASTING EQUIPMENT - SAND, PORTABLE
No specific	AR	BRUSH - BRISTLED
No specific	AR	FILM - POLYETHYLENE
No specific	2	GUN - SEALANT, AIR POWERED
No specific	AR	HAMMER - AIR
No specific	2	KNIFE - PUTTY
No specific	AR	MACHINE - AIR GRINDER
No specific	AR	MACHINE - FLUX CHIPPER
No specific	1	SCRAPER
No specific	AR	VACUUM CLEANER
No specific	AR	VACUUM SANDBLASTER
No specific	AR	WARNING NOTICE(S)
IAE3J13052	1	FIXTURE - BONDING

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.V01-031)	Acetone, Technical grade
(Material No.V01-060)	Acetone, Analar grade
(Material No.V01-076)	Methyl Ethyl Ketone, Technical grade
(Material No.V01-124)	Isopropyl Alcohol, Technical grade
(Material No.V01-131)	acetone
(Material No.V01-201)	distilled or deionized water
(Material No.V02-005)	adhesive tape
(Material No.V02-097)	lint free gloves
(Material No.V02-099)	lint free cloth
(Material No.V02-100)	white nylon gloves
(Material No.V02-166)	breather cloth
(Material No.V02-222)	bagging film
(Material No.V02-223)	release film
(Material No.V02-224)	silicone adhesive polyester tape
(Material No.V02-334)	porous release film
(Material No.V05-003)	abrasive medium
(Material No.V05-016)	garnet paper
(Material No.V05-020)	waterproof silicon carbide
(Material No.V05-185)	polishing discs
(Material No.V05-186)	conditioning disc
(Material No.V08-006)	filler, two pack
(Material No.V08-154A)	sealant
(Material No.V08-155)	adhesive promoter
(Material No.V12-045)	vacuum bag sealant tape
(Material No.V12-046)	vacuum bag sealant tape

C. Work Zones and Access Panels

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

D. Referenced Information

REFERENCE	DESIGNATION
TASK 72-31-00-000-010-B	Removal of the LP Compressor (Fan) Module
TASK 72-31-00-400-010-B	Installation of the LP Compressor (Fan) Module
TASK 72-31-11-000-010-B	Removal of the LP Compressor Fan Blades
TASK 72-31-11-400-010-C	Installation of the LP Compressor Fan Blades
TASK 72-32-85-350-015-A	Repair of the Fan Case - VRS1824 - PRE SBE 72-0160
Repair of Attrition Linings
Aluminum Chisel for Air Hammers or Flux Chippers
Detail in Coverage of Sealant
Vacuum Bag
Curing Chart of Filling Material (V08-006)
Curing Chart of Filling Material (V08-006)

3. Job Set-up
Subtask 72-32-85-941-091-A ** ON A/C NOT FOR ALL

A. Safety Precautions
(1) On the center pedestal, on the ENG panel 115VU:
(a) Put a WARNING NOTICE(S) to tell persons not to start the engine 1(2).
(2) Make sure that the engine 1(2) shutdown occurred not less than 5 minutes before you do this procedure.
(3) On the overhead maintenance panel 50VU:
(a) Make sure that the ON legend of the ENG/FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) to tell persons not to energize the FADEC 1(2).
(4) Put the ground support equipment into position.
(a) Put the ACCESS PLATFORM 1M(3 FT) into position to give access to the engine.
(b) Put the workmat into position in the fan case or air intake cowl.

NOTE: Make sure that the red warning pennants of the workmat can be seen externally.
Make sure that the workmat has sufficient dimensions to give full protection to the lower half of the fan case or air intake cowl.

Subtask 72-32-85-010-124-A ** ON A/C NOT FOR ALL

B. Method A: Remove the LP compressor blades and fillers (Ref. AMM TASK 72-31-11-000-010).

NOTE: - Either the removal of the fan blades and annulus fillers (Method A) or the removal of the fan module (Method B) is necessary.
- If the vacuum bag method is used, the removal of all fan blades may not be necessary to do the repair.

Subtask 72-32-85-010-080-A ** ON A/C NOT FOR ALL

C. Method B: Remove the LP compressor (fan) module (Ref. AMM TASK 72-31-00-000-010).

4. Procedure
Subtask 72-32-85-340-113-A ** ON A/C NOT FOR ALL

A. Preparation of the Repair Surfaces
(1) Prepare areas of damaged area.
(a) Use adhesive tape (Material No.V02-005) and FILM - POLYETHYLENE or equivalent to protect the engine opening.

NOTE: Make sure the masking sheet has sufficient dimensions to give full protection to the inlet of the LP guide vane assembly, outlet of the stage 2.5 bleed duct and inside of the LP stub shaft.

(2) Prepare the repair area.

Repair of Attrition Linings ** ON A/C NOT FOR ALL

WARNING: DO NOT OPERATE WITHOUT SAFETY GOGGLES AND OTHER GUARD EQUIPMENT. FLYING PARTICLES CAN CAUSE INJURY.

CAUTION: DO NOT USE POWERED TOOLS WITH STEEL CHISEL OR SIMILAR BITS.

CAUTION: THE FAN CASE IS MADE FROM TITANIUM ALLOY AND IS THIN IN SOME AREAS. IF YOU HIT THE FAN CASE WITH A CHISEL OR SCRAPER YOU CAN MAKE IT UNSERVICEABLE.

CAUTION: YOU MUST USE THE CHISEL, SHARP BLADE OR SCRAPER IN A CIRCUMFERENTIAL DIRECTION TO PREVENT THE EDGES OF THE BLADE SCORING THE FAN CASE.

CAUTION: YOU MUST ALWAYS TRY TO POINT THE CHISEL OR SHARP BLADE PARALLEL WITH THE SURFACE OF THE FAN CASE.

(a) Remove most of the damaged linings. Use HAMMER - AIR or MACHINE - FLUX CHIPPER with aluminum chisel

Aluminum Chisel for Air Hammers or Flux Chippers ** ON A/C NOT FOR ALL

CAUTION: PREVENT TOO MUCH SURFACE ABRASION OF THE FAN CASE MATERIAL SURFACE FINISH USING ABRASIVE BLASTING IS NECESSARY. THIS WILL GIVE THE BEST BONDING RESULT.

CAUTION: THE GRINDER IS NOT TO BE USED AT THE SAME LOCATION, STOPPING FOR 30 SECONDS OR MORE.

(b) Remove all unwanted material and adhesive from the fan case with MACHINE - AIR GRINDER and polishing discs (Material No.V05-185) or conditioning disc (Material No.V05-186) .
(c) Remove all remaining unwanted material with a VACUUM CLEANER.
(d) Make sure that the replacement linings can be placed in position.
(e) Remove all grease from the repair area with V01-031Acetone, Technical grade, V01-060Acetone, Analar grade, V01-076Methyl Ethyl Ketone, Technical grade or V01-124Isopropyl Alcohol, Technical grade and a BRUSH - BRISTLED.
(f) Fully mask off all areas except the bonding area with silicone adhesive polyester tape (Material No.V02-224) and/or other applicable procedure.

CAUTION: USE THE VACUUM SANDBLASTER FOR THE BEST BONDING SURFACE OF THE TITANIUM PARTS.

CAUTION: YOU MUST USE OIL-FREE DRY AIR ONLY.

(g) Make the repair area rough with dry abrasive blast with abrasive medium (Material No.V05-003) and BLASTING EQUIPMENT - SAND, PORTABLE or VACUUM SANDBLASTER.

NOTE: Examine the surface finish and repaired marks of the bonding area of the fan case assembly. The wall thickness can be measured with the ultrasonic wall thickness measuring equipment or equivalent, if necessary (Ref. AMM TASK 72-32-85-350-015)

NOTE: Remove the glossy surface from the repair area of the fan case assembly. Make sure that there is a constant matt surface on the repair area.

NOTE: IAE recommends that the working pressure of the vacuum sandblaster or portable sandblaster is approximately 70 psi to 100 psi (480 KPa to 690 KPa).

NOTE: IAE recommends that the minimum time of operation for a blasting of repair area is 40 minutes for each panel area.

(h) Remove all remaining unwanted material with a VACUUM CLEANER.
(i) Immediately blow out the area with a clean, dry air blast.

NOTE: Continue with the bonding process in less than 8 hours after the cleaning procedure.

Subtask 72-32-85-210-093-A ** ON A/C NOT FOR ALL

B. Do a Water-break Inspection of the Repair Area

CAUTION: DO NOT TOUCH THE PREPARED SURFACE, BETWEEN THE PROCEDURE TO CLEAN AND THE BONDING PROCEDURE.

(1) Clean the bonding surface with V01-076Methyl Ethyl Ketone, Technical grade.
(2) Use a clean soft BRUSH - BRISTLED to quickly apply a layer of clean distilled or deionized water (Material No.V01-201) to the mating surface.
(3) Look immediately to see if the layer has a break in continuity.
(4) If a break in continuity occurs in less than 30 seconds, clean the surface again until a continuous layer is seen.
(5) Remove the water with clean V01-031Acetone, Technical grade or V01-060Acetone, Analar grade then let the surface dry.

NOTE: Continue with the bonding process in less than 8 hours after the water break check.

Subtask 72-32-85-340-224-A ** ON A/C NOT FOR ALL

C. Apply Adhesion Promoter
(1) Surface preparation

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

(a) Remove all grease from the repair area with acetone (Material No.V01-131) , V01-060Acetone, Analar grade, V01-076Methyl Ethyl Ketone, Technical grade or V01-124Isopropyl Alcohol, Technical grade and lint free cloth (Material No.V02-099) .

NOTE: Always pour cleaning fluid on the cloth to avoid contaminating the cleaning fluid supply. Wash one small area at a time.

NOTE: It is important that the surface is dried with a second clean cloth prior to the cleaning fluid evaporating to prevent the redeposition of contaminants on the fan case surface.

(2) Apply a thin coat of adhesive promoter (Material No.V08-155) to the cleaned surface by brush or clean gauze and allow to dry for approximately 30 minutes at room temperature.

NOTE: If primed surface is contaminated or bonding is not accomplished within 8 hours after application of the adhesion promoter, repeat priming procedure.

Subtask 72-32-85-340-114-A ** ON A/C NOT FOR ALL

D. Bond the New Linings

Repair of Attrition Linings ** ON A/C NOT FOR ALL

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

(1) Make the bonding surfaces on the replacement linings rough with garnet paper (Material No.V05-016) .
(2) Remove all remaining unwanted material with a VACUUM CLEANER.
(3) Prepare the sealant (Material No.V08-154A) .

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

WARNING: DO NOT MIX QUANTITIES MORE THAN 1 POUND (454 GRAMS) AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE.

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

(a) Use the sealant (Material No.V08-154A) . Weigh out 100 parts of base compound (white compound) and 18.5 parts of curing compound (black compound). If using SEMKIT form sealant, prepare either by hand, or using a mixing machine as described in the manufacturer's leaflet.

NOTE: This sealant is supplied in several forms. The preferred form is SEMKIT, alternative is the tin form.

(b) Mix the two parts together until the paste is a constant color. No streaks are permitted.

NOTE: The life of the mixed sealant is approximately 2 hours at 77 deg.F (25 deg.C).

NOTE: Application life is dependent upon ambient environmental conditions. Increases in temperature and low humidity will shorten application time. Conversely, lower temperatures and high humidity will increase application life. For the examples, the life of the mixed sealant is approximately 2 hours, at 77 deg.F (25 deg.C) and 50 percent RH.

(4) Apply a thin layer of sealant to the hook. Use GUN - SEALANT, AIR POWERED or KNIFE - PUTTY. Be careful not to touch prepared surface.
(5) Use KNIFE - PUTTY or GUN - SEALANT, AIR POWERED to apply the sealant to mating surfaces of both components to a thickness of between 0.08 in. (2.03 mm) and 0.12 in. (3.04 mm) and between 0.015 in. (0.38 mm) and 0.024 in. (0.61 mm).

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

NOTE: In order to ensure that front attrition area of the panel honeycomb has contact with the surface of the sealant it is necessary to apply the sealant to the maximum specified thickness 0.12 in. (3.04 mm). The sealant layer thickness must not fall below the specified minimum of 0.08 in. (2.03 mm).

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

NOTE: For the best results apply a thin layer of the sealant for rear attrition area but satisfactory results can be achieved with layers as much as 0.02 in. (0.51 mm) thick. (For filling honeycomb area only, refer to the figure that follows.)

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

NOTE: Wear lint free gloves (Material No.V02-097) or white nylon gloves (Material No.V02-100) when you touch the parts.

NOTE: If it is necessary, remove the sealant to around the panels. This step is dispensed with "apply the V08-006filler, two pack to the gaps".

(6) Put the replacement panels into position and hold them with silicone adhesive polyester tape (Material No.V02-224) .

NOTE: Move the new panels into position with the shim plates (locally made) between the panels, if necessary.

Subtask 72-32-85-340-115-A ** ON A/C NOT FOR ALL

E. Hold the New Linings in Position

Repair of Attrition Linings ** ON A/C NOT FOR ALL

Vacuum Bag ** ON A/C NOT FOR ALL

(1) Method 1: Hold the new linings in position with a vacuum bag:

CAUTION: THE MAXIMUM TEMPERATURE WHICH CAN BE USED TO CURE THE FILLER IS 176 DEG.F (80 DEG.C)

(a) Make up the annular vacuum bag.
1 Cover the replacement linings with a sheet of porous release film (Material No.V02-334) that is 3.00 in. (76.1999 mm) longer than each end of the linings, 3 plies of breather cloth (Material No.V02-166) and one ply of release film (Material No.V02-223) .
2 Over them apply a bagging film (Material No.V02-222) between the area of the middle or the rear anti ice impact panels and the metal surface of the fan case.
3 Install the vacuum valve to the bagging film.
4 Seal the edges of the bagging film to the anti-ice impact panels and the metal surface of the fan case with vacuum bag sealant tape (Material No.V12-045) or vacuum bag sealant tape (Material No.V12-046) .
(b) Remove the air from the vacuum bag with the vacuum pump. Do a check for leaks with your ears or with an ultrasonic leak detector.
(c) Apply and keep a vacuum of 10.2 psi (0.7033 bar).This must be kept during cure time.
(d) Cure the sealant.
1 Allow the sealant (Material No.V08-154A) to cure for 9 hours at ambient temperature 77 deg.F (25.00 deg.C) to 95 deg.F (35.00 deg.C).
2 Cure may be hastened by applying heat. The sealant (Material No.V08-154A) can obtain a serviceable cure hardness after four hours at 113 deg.F (45.00 deg.C)
3 If the remaining sealant material after repair exceeds the limit, dress the sealant material with waterproof silicon carbide (Material No.V05-020) , if necessary.

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

NOTE: Make sure that you monitor the ambient temperature of the sealant and work area with suitable instruments, across all of the lining.

NOTE: Make sure the full cure time is used and correct temperature maintained.

NOTE: If the bonding process passes 48 hours though is a condition of any humidity if the curing temperature is secured 50 deg.F (10.00 deg.C) or more, necessary strength is secured.

(e) Remove the vacuum bag and the sealant tape.
(2) Method 2: Hold the new linings in position with the bonding fixture:

Repair of Attrition Linings ** ON A/C NOT FOR ALL

(a) Install the IAE3J13052 FIXTURE - BONDING, to hold the new linings in position.
(b) Cure the sealant.

CAUTION: THE MAXIMUM TEMPERATURE WHICH CAN BE USED TO CURE THE FILLER IS 176 DEG.F (80 DEG.C)

1 Allow the sealant (Material No.V08-154A) to cure for 9 hours at ambient temperature 77 deg.F (25 deg.C) to 95 deg.F (35 deg.C).
2 Cure may be hastened by applying heat. The sealant (Material No.V08-154A) can obtain a serviceable cure hardness after four hours at 113 deg.F (45 deg.C).
3 If the remaining sealant material after repair exceeds the limit, dress the sealant material with waterproof silicon carbide (Material No.V05-020) , if necessary.

Detail in Coverage of Sealant ** ON A/C NOT FOR ALL

NOTE: Make sure that you monitor the ambient temperature of the sealant and work area with suitable instruments, across all of the lining.

NOTE: Make sure that the full cure time is used and correct temperature maintained.

NOTE: If the bonding process passes 48 hours though is a condition of any humidity if the curing temperature is secured 50 deg.F (10 deg.C) or more, necessary strength is secured.

Subtask 72-32-85-340-116-A ** ON A/C NOT FOR ALL

F. Prepare the Filler Material

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

(1) Use V08-006filler, two pack. Measure 100 parts of the blue paste (part B) and 94 parts of the white paste (part A).
(2) Mix the two parts together until the paste is a constant blue colour. No streaks are permitted.

NOTE: Minimum cure time is one hour at 140 deg.F (60 deg.C).

NOTE: The life of the mixed filler is approximately one hour at 72 deg.F (22 deg.C).

Subtask 72-32-85-340-117-A ** ON A/C NOT FOR ALL

G. Apply the Filler to the Lining Honeycomb and the Gap around the Replacement Linings

Repair of Attrition Linings ** ON A/C NOT FOR ALL

Curing Chart of Filling Material (V08-006) ** ON A/C NOT FOR ALL

(1) Use the GUN - SEALANT, AIR POWERED to put the filler into the repair area to slightly more than the necessary level. Do not put the filler into the slots between the acoustic linings.
(2) When the filler starts to feel hard, remove all unwanted filler.
(3) Use the KNIFE - PUTTY or the SCRAPER to get a burnished effect.
(4) If necessary, to get a smooth finish apply a small quantity of cold water to the putty knife.

NOTE: Do not use too much water because it will cause the filler to plasticize.

(5) Option: Apply the sealant to the cross-hatched area.

Repair of Attrition Linings ** ON A/C NOT FOR ALL

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

(a) Use sealant (Material No.V08-154A) . Weigh out 100 parts of base compound (white compound) and 18.5 parts of curing compound (black compound). If using SEMKIT form sealant, prepare either by hand, or using a mixing machine as described in the manufacturer's leaflet.

NOTE: This sealant is supplied in several forms. The preferred form is SEMKIT, alternative is the tin form.

(b) Mix the two parts together until the paste is a constant color. No streaks are permitted.

NOTE: The life of the mixed sealant is approximately two hours at 77 deg.F (25 deg.C).

(c) Apply the sealant to the cross-hatched area with the GUN - SEALANT, AIR POWERED or the KNIFE - PUTTY. Be careful not to touch prepared surface.
(6) Curing of the filler and sealant

CAUTION: THE MAXIMUM TEMPERATURE WHICH CAN BE USED TO CURE THE FILLER IS 176 DEG.F (80 DEG.C)

(a) Cure the filler and sealant. The cure time given in Figure "Curing Chart of Filling Material" is determined by the selected temperature.

Curing Chart of Filling Material (V08-006) ** ON A/C NOT FOR ALL

NOTE: Minimum cure time is one hour at 140 deg.F (60 deg.C).

NOTE: The adhesive will not cure at a temperature of less than 54 deg.F (12 deg.C).

NOTE: Curing of the sealant by this step only has to apply the curing time of the filler. The sealant becomes durometer 30A or more in hardness in the condition that curing of the filler is completed, and there is no problem of the workshop.

(7) Blend the filler to the contour with garnet paper (Material No.V05-016) , if necessary.
(8) Remove all unwanted material with the VACUUM CLEANER.

Subtask 72-32-85-340-118-A ** ON A/C NOT FOR ALL

H. Dress the Linings

Repair of Attrition Linings ** ON A/C NOT FOR ALL

WARNING: DO NOT INHALE DUST. USE A BREATHING PROTECTION MASK DURING THIS OPERATION.

(1) Use garnet paper (Material No.V05-016) to dress the linings to the necessary contour.
(2) Remove all unwanted material with a vacuum cleaner.

Subtask 72-32-85-210-094-A ** ON A/C NOT FOR ALL

I. Examine the Repaired Area

Repair of Attrition Linings ** ON A/C NOT FOR ALL

(1) Make sure that the surface of the filler is smooth and flat.
(2) Accept a step if it is less than 0.020 in. (0.5080 mm).
(3) If necessary, apply more filler.
(4) Press or tap the linings to do a check for unsatisfactory bond.
(5) If an unsatisfactory bond is apparent, do this TASK again.

5. Close-up
Subtask 72-32-85-410-081-A ** ON A/C NOT FOR ALL

A. Method A: Install the LP compressor (fan) module (Ref. AMM TASK 72-31-00-400-010).

Subtask 72-32-85-410-120-A ** ON A/C NOT FOR ALL

B. Method B: Install the LP compressor blades and fillers (Ref. AMM TASK 72-31-11-400-010).

Subtask 72-32-85-942-080-A ** ON A/C NOT FOR ALL

C. Remove the Ground Support Equipment
(1) Remove the workmat from the fan case.
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 13:01:05 UTC