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

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 03/26/2024
	CIR 72-30-74 , REPAIR 001
	VARIABLE STATOR VANE TORQUE SHAFT - REPAIR - BUSHING REPAIR ON THE ACTUATOR CLEVIS

* * * FOR ALL

TASK 72-30-74-300-801

1 .

Bushing Repair on the Actuator Clevis.

This procedure gives instructions to repair the variable stator vane (VSV) torque shaft by machining the actuator clevis to remove wear and installing new bushings. 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.

(d)

Do an inspection of the actuator clevis, IGV clevis, and stage 1 through stage 4 clevises for integral clevis or casting configuration. Refer to Figure 803.

Wear due to contact with actuator rod end on inner surface of the shaft actuator clevis for torque shaft part number 2500M83P01 without bushings installed in the actuator clevis.

Maximum repairable limit:

Any amount.

Wear due to contact with actuator rod end on the bushings for torque shaft part number 2500M83P01 with bushings installed in the actuator clevis.

Maximum repairable limit:

Any amount.

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

Part Number(s)

2500M83P01

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.

Figure

Description

904

Bushing Installation Tool

Consumable Materials.

Code Number

Description

Ice, Dry

Nitrogen, Liquid

Referenced Procedures.

ATA Number

Description

70-00-03

Machining Data

70-10-00

Assembly and Disassembly Techniques

70-24-00

Etching Procedures for Fluorescent-Penetrant Inspection

70-24-01

Swab Etching Procedure

70-31-02

Acceptability Limits for Fluorescent-Penetrant Inspection

70-32-00

Indirect Inspection Methods

70-32-03

Spot-Fluorescent-Penetrant Inspection

72-30-74

Cleaning 001

Expendable Parts. None.

SPD Information.

(1)

Spares Supplied. None.

(2)

Protected Spares. None.

(3)

Locally Manufactured Spares.

Figure

Description

903

Bushing

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

Subtask 72-30-74-220-029

Refer to Figure 901, Figure 902, and Figure 903 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 re-convert from millimeters to inches.

NOTE:

Reference dimensions do not require inspection.

4 .

Setup Information.

Subtask 72-30-74-350-001

Set-up the torque shaft on a machining table to machine the clevis or the bushings if necessary. Refer to Figure 901, Figure 902, and as follows:

CAUTION:

DO NOT PUT THE SHAFT DIRECTLY ON THE MACHINING TABLE. DAMAGE TO THE TORQUE SHAFT CAN OCCUR.

(1)

Put diameter E and diameter F onto ground V-blocks or equivalent.

(2)

Hold the torque shaft with machining clamps.

(3)

Make sure that the centerline of the shaft is parallel to the machine spindle axis. The runout must be 0.001 inch (0.03 mm) maximum or better, then do as follows:

(a)

Use diameter E and diameter F to find the shaft centerline. If necessary add shims to find parallelism.

(4)

Diameter HA must have a runout that is 0.0005 inch (0.013 mm) maximum or better to the machine spindle.

(5)

Surface D must be perpendicular to diameter HA and must have a runout that is 0.0005 inch (0.013 mm) maximum or better.

(6)

Diameter HA must be concentric to diameter HB and must have a runout that is 0.0005 inch (0.013 mm) maximum or better.

5 .

Procedure.

Subtask 72-30-74-160-003

Clean the repair area of the torque shaft. Refer to TASK 72-30-74-100-801 (72-30-74, CLEANING 001).

Subtask 72-30-74-320-001

If the clevis has not been previously repaired with this procedure, machine the integral bosses and clevis counterbores. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and as follows:

(1)

Set-up the torque shaft to machine the clevis. Refer to Subtask 72-30-74-350-001 (paragraph 4.A.).

(2)

Machine the integral bosses.

(3)

Machine the clevis counterbores.

(4)

Measure and record the machined diameter and depth of clevis counterbore HC and clevis counterbore HD.

Subtask 72-30-74-350-002

If the clevis bosses have bushings installed, remove the bushings. Refer to Figure 901, Figure 902, and as follows:

(1)

Set-up the torque shaft on a machining table to machine the bushings. Refer to Subtask 72-30-74-350-001 (paragraph 4.A.).

CAUTION:

DO NOT MACHINE THE FULL LENGTH OF THE BUSHING. THIS CAN CAUSE DAMAGE TO THE COUNTERBORE IN THE CLEVIS.

(2)

Machine the bushing inner diameters (IDs) as follows:

(a)

Machine the IDs to a diameter less than the bushing outer diameters (ODs) to decrease the bushing wall thickness.

(b)

Do not machine surface HC or surface HD of the clevis counterbore during the removal of the bushing material.

CAUTION:

DO NOT CAUSE DAMAGE TO THE COUNTERBORE DURING REMOVAL OF BUSHING MATERIAL. THIS CAN MAKE THE VSV TORQUE SHAFT UNSERVICEABLE.

(3)

Use a punch to carefully remove the remaining bushing material from the counterbore.

(4)

Measure and record the machined diameter of each clevis counterbore and the depth of each counterbore from the machined clevis surfaces.

Subtask 72-30-74-350-003

Make the new bushings. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 903, and as follows:

(1)

Each bushing OD must have a diametric interference fit of 0.0006-0.0012 inch (0.016-0.030 mm) with the related machined counterbore where it will be installed.

(2)

Measure and record the bushings OD and full length.

Subtask 72-30-74-350-004

Etch the machined areas of the torque shaft. 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 72-30-74-230-003

Do an inspection of the machined counterbores and bushings. 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 D penetrant.

(2)

Refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION), and as follows:

(a)

Use Class A limits.

Subtask 72-30-74-160-004

Clean the torque shaft repair areas and the bushings. Refer to TASK 72-30-74-100-801 (72-30-74, CLEANING 001).

Subtask 72-30-74-350-005

Install the bushings into the torque shaft machined counterbores. Refer to TASK 70-10-00-800-009 (ASSEMBLY AND DISASSEMBLY TECHNIQUES), and as follows:

(1)

For bushing installation, use assembly procedure for interference-fit parts.

WARNING:

REFER TO THE PRODUCT LABEL AND MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.

WARNING:

NITROGEN CAN DISPLACE OXYGEN IN ENCLOSED AREAS. USE IN WELL-VENTILATED AREA.

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(2)

Chill the bushings with dry-ice or liquid nitrogen to help with the installation.

(3)

Select the new bushing for the related counterbore to get the correct interference fit.

(4)

Make the bushing installation tool to install the bushings into the torque shaft. Refer to Figure 904.

(5)

Make sure that the bushings are fully installed in the counterbores as follows:

(a)

Measure the distance from the bushing outer surface to the machined clevis surface, and as follows:

Add the recorded depth of the counterbore. The sum of these two values must be equal to the recorded overall bushing length when made.

(b)

If the sum is not equal to the overall bushing length remove the bushing and do Subtask 72-30-74-350-005 (paragraph 5.H.(1)) thru Subtask 72-30-74-350-005 (paragraph 5.H.(4)) again.

Subtask 72-30-74-320-002

Machine the protruding surface of the bushings to get the final dimensions for the clevis width. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 905, and as follows:

(1)

Do a dimensional inspection of the final machined distance between the two bushings in the clevis.

Subtask 72-30-74-220-030

Do a dimensional inspection of the bushing IDs. Refer to Figure 905 and as follows:

(1)

Measure the IDs of the bushings.

(2)

Measure the concentricity and true position of the bushing IDs.

(3)

If the IDs of the bushings do not agree with the limits, do the repair again.

Subtask 72-30-74-350-006

Etch the bushing machined surface. 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: