GENX-1B - CLEANING,INSPECTION,AND REPAIR MANUAL

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 04/30/2018
	CIR 72-24-40 , REPAIR 002
	FORWARD FAN SHAFT - REPAIR - GENERAL BLEND REPAIR

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TASK 72-24-40-300-802

1 .

General Blend Repair.

This procedure gives instructions to repair the forward fan shaft (shaft) by blending. Refer to Figure 901.

The following maximum repairable limits apply to this repair:

NOTE:

The information below gives maximum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.

(4)

Visual Inspection.

(a)

Do an inspection of all surfaces of the shaft (all areas unless identified in other paragraphs) for:

Nicks, dents, and scratches:

Maximum repairable limit:

Any amount that you can remove by a blend to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm).

(b)

Do an inspection of shaft surface Z (including chamfer) for:

Nicks, dents, and scratches:

Maximum repairable limit:

Any amount that you can remove by a blend to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm).

(c)

Do an inspection of area P (forward shoulder edge of sump cover seating surface) for:

Nicks, dents, and scratches:

For 2321M44P01 and 2321M44P02:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.015 inch (0.38 mm).

For 2117M43P01:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm) and a minimum radius of 0.130 inches (3.31 mm).

(f)

Do an inspection of the mounting flange for:

Nicks, dents, scratches, and fretting on the inner diameter, scallop (configuration 1 flange only), and edge surfaces:

For 2321M44P01 and 2321M44P02:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.035 inch (0.88 mm), 1.0 inch (25 mm) in length, and a minimum blend radius of 0.0875 inch (2.223 mm).

For 2117M43P01:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm) and a minimum radius of 0.130 inches (3.31 mm).

Forward flange fillet for:

Nicks and dents:

For 2321M44P01 and 2321M44P02:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.035 inch (0.88 mm), and a minimum blend radius of 0.0875 inch (2.223 mm).

For 2117M43P01:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm) and a minimum radius of 0.130 inches (3.31 mm).

Scratches and fretting:

For 2321M44P01 and 2321M44P02:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.035 inch (0.88 mm), and a minimum blend radius of 0.0875 inch (2.223 mm).

For 2117M43P01:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm) and a minimum radius of 0.130 inches (3.31 mm).

Nicks, dents, scratches, and fretting in other areas:

For 2321M44P01 and 2321M44P02:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.035 inch (0.88 mm), 1.0 inch (25 mm) in length with a minimum distance between them of 2.0 inches (51 mm), and a minimum blend radius of 0.0875 inch (2.223 mm).

For 2117M43P01:

Maximum repairable limit:

Any amount that can be removed by blending to a maximum depth of 0.010 inch (0.25 mm) with a minimum separation of 2.0 inches (51 mm) and a minimum radius of 0.130 inches (3.31 mm).

The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.

Part Number(s)

2117M43P01

2321M44P01

2321M44P02

Proprietary/Complex Process Statement.

(1)

None.

2 .

Tools, Equipment, and Materials.

NOTE:

Repair sources can use equivalent alternatives for tools, equipment, and consumable materials, however, the repair source must demonstrate and document equivalency.

Tools and Equipment.

(1)

Special Tools. None.

(2)

Standard Tools and Equipment. None.

(3)

Locally Manufactured Tools. None.

Consumable Materials.

Code No.

Description

C04-271

Shot, Peening, Cast Steel (AMS 2431/2 ASH), Cast Steel Shot, High Hardness (55-62 HRc) (S110 steel shot)

C10-010

Abrasive Cloth

C10-021

Tape, Plastic

C10-205

Almen Test Strips (Almen N test strips)

Referenced Procedures.

ATA No.

Description

70-21-00

Chemical Cleaning

70-21-03

Cleaning Method No. 3 - Steam Cleaning

70-22-00

Special Cleaning Precautions

70-22-80

Special Cleaning Procedure No. 80 - Cleanliness Inspection

70-24-00

Etching Procedures for Fluorescent-Penetrant Inspection

70-24-01

Swab Etching Procedure

70-32-00

Indirect Inspection Methods

70-32-03

Spot-Fluorescent-Penetrant Inspection

70-42-00

Blending and Removal of High Metal Procedures

70-47-01

Shotpeening

72-24-40

Cleaning 001

72-24-40

Inspection 001

Expendable Parts. None.

SPD Information. None.

(1)

Locally Manufactured SPD. None.

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

Subtask 72-24-40-220-073

Refer to Figure 901 for specified dimensions and locations.

NOTE:

The dimensional data identified within this procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions, converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not reconvert from millimeters to inches.

NOTE:

Reference dimensions do not require inspection.

4 .

Setup Information.

None.

5 .

Procedure.

Subtask 72-24-40-160-002

Clean the shaft. Refer to TASK 72-24-40-100-801 (72-24-40, CLEANING 001).

Subtask 72-24-40-350-003

Blend the shaft damaged areas. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, and as follows:

(1)

Remove the minimum quantity of material until the shaft repair area agrees with the maximum repairable limits.

(a)

If there is no minimum blend radius specified in the maximum repairable limits, use the blend length to depth ratio. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).

(2)

If necessary, break all sharp edges to 0.015-0.030 inch (0.39-0.76 mm).

Subtask 72-24-40-160-003

If necessary, clean the shaft. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).

Subtask 72-24-40-110-008

Etch the shaft blended areas. Refer to TASK 70-24-00-110-033 (ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION), TASK 70-24-01-110-034 (SWAB ETCHING PROCEDURE), and as follows:

(1)

Use Class B etchant.

Subtask 72-24-40-230-002

Do an inspection of the shaft etched areas. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION), and as follows:

(1)

Use Class G penetrant.

(2)

Refer to TASK 72-24-40-200-801 (72-24-40, INSPECTION 001) for the acceptability limits.

Subtask 72-24-40-140-001

WARNING:

USE EYE PROTECTION WHEN YOU POLISH MATERIAL OR PARTS. THE PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. USE IN A WELL-VENTILATED AREA.

If necessary, polish the shaft to remove the effects of the swab etching procedure as follows:

(1)

Use C10-010 abrasive cloth.

Subtask 72-24-40-380-002

Peen the shaft repair areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 901, Figure 902, and as follows:

(1)

Apply C10-021 plastic tape to area N, area R, area V, surface AT, the bearing journals, and, if necessary, to all other adjacent surfaces that are not repaired by blending.

(2)

Use C04-271 S110 steel shot.

(3)

Peen the shaft to an intensity of 0.006-0.012N.

(4)

Ricochet peening is permitted in area CZ of the shaft.

(5)

Coverage must be a minimum of 100 percent.

(6)

Use C10-205 Almen N test strips to make sure that the intensity is correct in the shaft repair areas.

(7)

Remove the plastic tape from the shaft.

Subtask 72-24-40-160-004

Clean the shaft. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).

Subtask 72-24-40-160-005

CAUTION:

MAKE SURE THAT YOU COMPLETE ALL THE NECESSARY REPAIRS AND DRY FILM LUBRICANT APPLICATION BEFORE YOU DO THE CLEANLINESS INSPECTION. IF NOT, DAMAGE TO THE SHAFT AND THE ENGINE ASSEMBLY CAN OCCUR.

Do a cleanliness inspection of the shaft repaired areas. Refer to TASK 70-22-00-100-001 (SPECIAL CLEANING PRECAUTIONS), TASK 70-22-80-160-801 (SPECIAL CLEANING PROCEDURE NO. 80 - CLEANLINESS INSPECTION), and as follows:

(1)

Use Class C cleanliness.

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