Repair of the Fuel Nozzles Pad Inserts [CFML]

TASK 73-11-30-300-801-A
Repair of the Fuel Nozzles Pad Inserts

WARNING: BE CAREFUL WHEN YOU DO WORK ON THE ENGINE PARTS AFTER THE ENGINE SHUTDOWN. USE APPLICABLE THERMAL GLOVES. THE ENGINE PARTS CAN STAY HOT FOR ONE HOUR AFTER SHUTDOWN AND CAN BURN YOU.

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

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

REFERENCE	QTY	DESIGNATION
No specific	1	ABRASIVE STONE
No specific	1	ACCESS PLATFORM 1M(3 FT)
No specific	1	AIR SOURCE FILTERED, DRY
No specific	1	DRIVE - HANDLE
No specific	1	FILE - FINE
No specific	1	HAMMER - NON METALLIC
No specific	1	MAGNIFYING GLASS POWER 10X
No specific	1	PUNCH - POINTED
No specific	1	SCREW-TAP
No specific	1	VACUUM CLEANER
No specific	AR	WARNING NOTICE(S)
No specific	1	WRENCH - HEXAGONAL
No specific	1	WRENCH - TORQUE, STANDARD

B. Consumable Materials

REFERENCE	DESIGNATION
(Material No.CP2185)	masking tape 3M 202
(Material No.CP2189)	durite G422
(Material No.CP2191)	durite G421
(Material No.CP2635)	synthetic beeswax
No specific	duct tape

C. Work Zones and Access Panels

ZONE/ACCESS	ZONE DESCRIPTION
FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL, 438AR, 451AL, 452AR
FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL, 448AR, 461AL, 462AR

D. Referenced Information

REFERENCE	DESIGNATION
TASK 70-25-00-910-802-A	Fluorescent-Penetrant Inspection-Portable-Water Washable
TASK 71-13-00-010-803-A	Opening of the Fan Cowl Doors
TASK 71-13-00-410-803-A	Closing of the Fan Cowl Doors
TASK 78-30-00-040-809-A	Deactivation of the Thrust Reverser System for Ground Maintenance
TASK 78-30-00-440-809-A	Reactivation of the Thrust Reverser System after Ground Maintenance
TASK 78-36-00-010-806-A	Opening of the Thrust Reverser Cowl Doors
TASK 78-36-00-410-806-A	Closing of the Thrust Reverser Cowl Doors
SPM 702000100001
SPM 702100
SPM 702123
SPM 704400
Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes
Locking Removal
Installation of the Screw Insert
Screw Insert and Locking Ring After Swaging
Local Manufacture Drill Fixture
Local Manufacture Swage Tool

3. Job Set-up
Subtask 73-11-30-941-058-A

A. Safety Precautions
(1) On the center pedestal, on ENG panel 115VU:
(a) Make sure that the ENG/MODE selector switch is in the NORM position.
(b) Make sure that the ENG/MASTER 1(2) control switch was in the OFF position not less than five minutes before you do this procedure.
(c) Put WARNING NOTICE(S) in position to tell persons not to operate:

The ENG/MODE selector switch
The ENG/MASTER 1(2) control switch.

(2) On the ENG section of maintenance panel 50VU:
(a) Make sure that the ON legend of the FADEC GND PWR/1(2) pushbutton switch is off.
(b) Put a WARNING NOTICE(S) in position to tell persons not to energize FADEC 1(2).

Subtask 73-11-30-010-067-A

B. Get Access
(1) Open the fan cowl doors (Ref. AMM TASK 71-13-00-010-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Put an ACCESS PLATFORM 1M(3 FT) in position.

Subtask 73-11-30-040-059-A

C. Deactivation of the Thrust Reverser System for Maintenance

WARNING: YOU MUST DEACTIVATE THE THRUST REVERSER BEFORE YOU DO WORK ON OR AROUND IT. IF YOU DO NOT, THE THRUST REVERSER CAN OPERATE ACCIDENTALLY AND CAUSE AN INJURY AND/OR DAMAGE.

(1) Do the deactivation of the thrust reverser system for ground maintenance (Ref. AMM TASK 78-30-00-040-809).

Subtask 73-11-30-010-068-A

D. Get Access
(1) Open the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-010-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL 462AR

4. Procedure
Subtask 73-11-30-140-050-A

A. If Necessary, Clean the Propulsor Assembly, Refer to SPM 702000100001.

Subtask 73-11-30-010-069-A

B. Removal of the Hoses, Tubes and Brackets

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

CAUTION: PROTECT THE ENGINE TO PREVENT THE ENTRY OF UNWANTED MATERIAL.

(1) If necessary, remove the hoses, tubes and brackets to give access to the fuel nozzle pad.
(a) Put the masking on all tube ends and holes in the case with duct tape to prevent machining chips or dust from entering the engine.

Subtask 73-11-30-911-050-A

C. Setup the Locally Manufactured Drill Fixture

WARNING: BE CAREFUL WHEN YOU USE SHARP OR POINTED TOOLS. THESE TOOLS CAN CAUSE AN INJURY TO YOU.

CAUTION: PROTECT THE ENGINE TO PREVENT THE ENTRY OF UNWANTED MATERIAL.

(1) If necessary, make the locally manufactured drill fixture.

Local Manufacture Drill Fixture

(a) Put the drill plate (2) on the fuel nozzle pad as follows:
1 Align the 0.500 in. (12.70 mm) diameter hole with the damaged insert.
(b) Firmly attach the drill plate (2) to the fuel nozzle pad as follows:
1 Use three 1/4-28 UNJF clamp screws (5) in the undamaged inserts.
(c) Fill the chip containment cup (6) with synthetic beeswax (Material No.CP2635) or equivalent to 0.350 in. (8.89 mm) deep as follows:
1 Insert the containment cup through the fuel nozzle pad bore.
2 Put the cup behind the damaged insert as follows:
a Align the slot in the handle of the containment cup diagonally with the opposite hole in the pad/fixture.
3 Attach the cup to the base plate of the fixture and the pad as follows:
a Use one of the three 1/4-28 UNJF clamp screws (5).
4 Make sure that the synthetic beeswax (Material No.CP2635) is in contact with the internal diameter of the pad.
5 If the synthetic beeswax (Material No.CP2635) is not in contact with the internal diameter of the pad, do as follows:
a Remove the cup.
b Add more synthetic beeswax (Material No.CP2635) .
c Do Para. 4.C. (1).(c). again.

NOTE: The center of the damage insert should be near the center of the wax in the containment cup.

(d) Put masking tape 3M 202 (Material No.CP2185) or equivalent to cover the drill plate center bore.
(e) Install the drill bushing (7) to the drill base plate over the damaged insert hole in the pad as follows:
1 Attach the bushing to the base plate with the screw (4).

Subtask 73-11-30-320-050-A

D. Removal of the Non-Serviceable Locking Ring and Screw Insert
(1) Drill the combustion case to remove the non-serviceable locking ring and screw insert from the fuel nozzle pad, Refer to SPM 704400 and do as follows:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

Locking Removal

Installation of the Screw Insert

Screw Insert and Locking Ring After Swaging

(a) Sep-up the locally manufactured drill fixture, refer to Para. 4.C.(1).
(b) Install the air powered self-feed drill unit to the taper-lock bushing (7) in the drill fixture.
(c) Set the drill stop (stake) of the self-feed air-powered drill to drill a 0.3125 in. (7.94 mm) diameter hole in the insert and lock ring to a depth of 0.08 in. (2.03 mm) - 0.09 in. (2.29 mm) from the face of the fuel nozzle pad.
(d) Install the self-feeding air-powered drill to the taper-lock insert (7) in the drill fixture.
(e) Drill a 0.3125 in. (7.94 mm) diameter hole into the fuel nozzle screw insert to 0.08 in. (2.03 mm) - 0.09 in. (2.29 mm) in depth.
(f) Use a VACUUM CLEANER to put all chips out of the repaired hole.
(g) Remove the chip containment cup from the fixture.
(h) Remove the drill fixture from the fuel nozzle pad.
(i) Use masking tape 3M 202 (Material No.CP2185) or equivalent to cover the fuel nozzle pad center bore.
(j) Use a PUNCH - POINTED to remove the locking ring as follows:
1 Put the PUNCH - POINTED in one end of the locking ring and use HAMMER - NON METALLIC to tap the PUNCH - POINTED lightly.
2 Carefully lift out the locking ring from the oval shaped counterbore hole.
(k) Use a WRENCH - HEXAGONAL ( 5 mm (0.20 in.)) to remove the screw insert.
(l) Remove all the unwanted material from the threaded hole and the counterbore.

Subtask 73-11-30-140-051-A

E. Removal of the High Metal
(1) If necessary, remove the high metal from the threaded hole as follows:

WARNING: WHEN YOU USE COMPRESSED AIR:

USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS
DO NOT LET THE PRESSURE BE MORE THAN 30 PSIG (200 KPA).

LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.

CAUTION: MAKE SURE THAT CONTAMINATION DOES NOT FALL IN THE COMBUSTION CASE THROUGH THE OPEN PADS. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO THE EQUIPMENT.

(a) Use a 0.3125-24 UNJF-3B SCREW-TAP to chase the threads in the hole where repair of the combustion case is necessary. See the Sheets 1 and 2 of the figure:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

(b) Use an AIR SOURCE FILTERED, DRY to remove loose metal chips from the tapped hole.
(c) Clean the threads, Refer to SPM 702100, SPM 702123 and do as follows:
1 Clean the threads through the full depth.
(d) Do an inspection of the threads in the hole that are in the pads of the combustion case. (Ref. ARD-A120-259-S1), (REF. Table 801R) and do as follows:
1 Do an inspection of the threads of the fuel nozzle pads, igniter pads, environmental control system port and modulated turbine cooling port. See the Sheets 1 and 2 of the figure:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

2 If the damage in the threads is more than the serviceable limits, you cannot repair the combustion case with this procedure.

Subtask 73-11-30-320-051-A

F. Blending of the Countersink for Removal of High Metal
(1) Blend countersink to remove high metal as follows: See the Sheets 1 and 2 of the figure:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

(a) Blend the part with a FILE - FINE or durite G422 (Material No.CP2189) or durite G421 (Material No.CP2191) or ABRASIVE STONE.
(b) Remove the smallest quantity of the parent metal possible.

Subtask 73-11-30-230-053-A

G. Fluorescent Penetrant Inspection

WARNING: WHEN YOU USE COMPRESSED AIR:

USE THE CORRECT PROTECTION (FACE SHIELD OR GOGGLES)
DO NOT POINT THE AIRFLOW AT YOURSELF OR OTHER PERSONS
DO NOT LET THE PRESSURE BE MORE THAN 30 PSIG (200 KPA).

LOOSE PARTICLES AND/OR HIGH PRESSURE AIR CAN CAUSE INJURY.

CAUTION: MAKE SURE THAT CONTAMINATION DOES NOT FALL IN THE COMBUSTION CASE THROUGH THE OPEN PADS. IF YOU DO NOT OBEY THIS PRECAUTION, YOU CAN CAUSE DAMAGE TO THE EQUIPMENT.

(1) Do a fluorescent penetrant inspection of all the blended areas. No cracks are permitted (Ref. AMM TASK 70-25-00-910-802).

NOTE: Full removal of high metal in the countersink will decrease the risk of interference in the locking ring installation and prevent further removal of the locking ring.

(2) Use an AIR SOURCE FILTERED, DRY to remove loose metal chips from tapped hole.
(3) Do an inspection of the threads in the hole that is being repaired in the fuel nozzle pad of the propulsor assembly and do as follows:
(a) If the threads are not serviceable, you cannot repair the combustion case with this procedure.

Subtask 73-11-30-320-052-A

H. Blending of the Counterbore

CAUTION: MAKE SURE THAT REMOVED MATERIAL, TOOLS OR CONSUMABLE MATERIALS DO NOT FALL INTO THE COMBUSTION CASE. IF YOU DO NOT OBEY THIS PRECAUTION, ENGINE DAMAGE CAN OCCUR.

(1) If necessary, blend the counterbore to remove high metal as follows:
(a) Blend the part with FILE - FINE or durite G422 (Material No.CP2189) or durite G421 (Material No.CP2191) or ABRASIVE STONE.
(b) Remove the smallest quantity of the parent metal possible.

Subtask 73-11-30-230-054-A

I. Fluorescent Penetrant Inspection
(1) Do a fluorescent penetrant inspection of all the blended areas. No cracks are permitted (Ref. AMM TASK 70-25-00-910-802).

Subtask 73-11-30-220-050-A

J. Dimensional Inspection of the Counterbore
(1) Do a dimensional inspection of the counterbore as follows:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

(a) If the dimensions do not agree with the limits, you cannot repair the propulsor assembly with this procedure.

Subtask 73-11-30-350-050-A

K. Installation of the New Insert and Locking Ring
(1) Install the new screw insert and locking ring in the threaded hole as follows: See the Sheets 1 and 2 of the figure:

Combustion Case-Screw Insert Locations and Oval Counterbore Threaded holes

and

Screw Insert and Locking Ring After Swaging

(a) Make sure that you remove all the unwanted material from the threaded hole and the counterbore before you install the new screw insert and the locking ring as follows:
1 Use a VACUUM CLEANER to remove unwanted material.
(b) Install the screw inserts as follows:
1 Put the screw insert (1693M83P19 or 1693M83P18) into the threaded hole.
2 Turn the screw insert clockwise and do as follows:

Installation of the Screw Insert

a Use a WRENCH - HEXAGONAL, or DRIVE - HANDLE.
b Install the screw insert in the case until the top face of the screw insert is 0.01 in. (0.25 mm) - 0.03 in. (0.76 mm) below the top surface of the fuel nozzle pad.
3 Put the locking ring (1689M74P08 or 1689M74P06) on the screw insert and into the oval shaped hole of the propulsor assembly as follows:
a Make sure that the word TOP on the locking ring shows at the outer side of the combustion case.

Screw Insert and Locking Ring After Swaging

b Align the serrations on the screw insert with the serrations of the locking ring.

Screw Insert and Locking Ring After Swaging

c Swage the screw insert as follows:

Use the locally manufactured swage tool or equivalent.
Local Manufacture Swage Tool
Put the swage tool into the screw insert.
Push the locking ring to make sure that it makes contact with the bottom of the counterbore.
Use a hammer to tap the drive/swage tool until the nylon stop washer of the drive/swage tool touches the pad on the combustion case.

d Remove the swage tool.

Subtask 73-11-30-220-051-A

L. Inspection of the Screw Insert and Locking Ring
(1) Do an inspection of the screw insert and locking ring as follows:

Screw Insert and Locking Ring After Swaging

(a) Use a MAGNIFYING GLASS POWER 10X.
(b) Make sure that the screw insert serrations are aligned with the locking ring serrations.
(c) Make sure that the screw insert is 0.01 in. (0.25 mm) - 0.03 in. (0.76 mm) below the propulsor assembly surface.
(d) Make sure that the locking ring is a minimun of 0.002 in. (0.05 mm) below the propulsor assembly surface.
(e) Use a pointed pick, to try to lift locking ring with light hand pressure on the pick as follows:
1 Make sure that the locking ring does not lift out of the counterbore.

Subtask 73-11-30-280-055-A

M. Check of the Self-Locking Torque of the Screw Insert
(1) Do a check of the self-locking torque of the screw insert as follows:

NOTE: Do not continue to screw the standard bolt 0.250-28 through the screw insert when you do a check of the minimun locking torque. Damage to the propulsor assembly will occur.

(a) Put a 0.25 in. (6.35 mm) heavy-duty flat washer 0.03 in. (0.76 mm) minimun thickness by 0.50 in. (12.70 mm) minimun over the repaired hole.
(b) Put a standard 0.250-28 UNJF-3A bolt through the washer and into the threads of the inserts.
(c) Use a WRENCH - TORQUE, STANDARD to measure the torque of the screw insert.
(d) Make sure that the lock ring keeps from rotating when a minimun torque of 5.3 lbf.in (0.06 m.daN) is applied to the WRENCH - HEXAGONAL, feature in the insert.

Subtask 73-11-30-140-052-A

N. Cleaning of the Combustion Case
(1) If it is necessary, clean the combustion case, Refer to SPM 702000100001.

Subtask 73-11-30-950-050-A

O. Remove all the masking from the fuel nozzle pad.

Subtask 73-11-30-410-066-A

P. Installation of the Hoses, Tubes, or Brackets
(1) Install any hoses, tubes or brackets that were removed at the beginning of this procedure.

5. Close-up
Subtask 73-11-30-410-064-A

A. Close Access
(1) Make sure that the work area is clean and clear of tools and other items.
(2) Close the thrust reverser cowl-doors (Ref. AMM TASK 78-36-00-410-806):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
451AL 452AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
461AL 462AR

Subtask 73-11-30-440-057-A

B. Do the reactivation of the thrust reverser system after nacelle maintenance (Ref. AMM TASK 78-30-00-440-809).

Subtask 73-11-30-410-065-A

C. Close Access
(1) Close the fan cowl doors (Ref. AMM TASK 71-13-00-410-803):
(a) FOR [4020KM1] (POWER PLANT-DEMOUNTABLE, ENGINE 1)
437AL 438AR
(b) FOR [4020KM2] (POWER PLANT-DEMOUNTABLE, ENGINE 2)
447AL 448AR
(2) Remove the access platform(s).
(3) Remove the WARNING NOTICE(S).

[Rev.10 from 2021] 2026.04.01 03:04:12 UTC