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

Alternative Procedure Available. Do a Class A fluorescent penetrant inspection of the HPC hardware (this does not include the turnbuckle bodies). Refer to TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION).

(1)

Cracks are not permitted.

Subtask 72-30-99-230-002

A.A.

Alternative Procedure. Do a spot-fluorescent-penetrant inspection of the HPC hardware (this does not include the turnbuckle bodies). Refer to TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION).

(1)

Cracks are not permitted.

Subtask 72-30-99-230-003

Do a class D fluorescent penetrant inspection of the external areas of the turnbuckle bodies. Refer to TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION).

(1)

Cracks are not permitted.

4 .

Visual Inspection.

Subtask 72-30-99-220-004

Do an inspection of each spline seal for. Refer to Figure 801.

(1)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the spline seal.

Subtask 72-30-99-220-005

(2)

Fretting, galling, and wear:

Maximum serviceable limit:

Any amount, if the damage is in the limits of TASK 70-33-03-220-006 (SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING) .

Repair method:

Replace the spline seal.

Subtask 72-30-99-220-006

(3)

Distortion:

Maximum serviceable limit:

Any amount, if it does not prevent assembly.

Repair method:

Replace the spline seal.

Subtask 72-30-99-220-007

(4)

Wear and missing material on the ends:

Maximum serviceable limit:

Any amount less than 0.04 inch (1.0 mm) in length.

Repair method:

Replace the spline seal.

* * * FOR ALL

* * * SB 72-0023( PIP2 Configuration )

* * * SB 72-0158( PIP2 Configuration )

Figure 801 HPC Hardware - Inspection

* * * FOR ALL

* * * PRE SB 72-0005( Slab Head Bolt with Round Head Shape )

Figure 802 HPC Hardware - Inspection

* * * FOR ALL

* * * SB 72-0005( Slab Head Bolt with Square Head Shape )

Figure 802A HPC Hardware - Inspection

* * * FOR ALL

* * * SB 72-0158( PIP2 Configuration )

Figure 803 (Sheet 1 ) HPC Hardware - Inspection

* * * FOR ALL

* * * SB 72-0158( PIP2 Configuration )

Figure 803 (Sheet 2 ) HPC Hardware - Inspection

Subtask 72-30-99-220-008

Do an inspection of all areas of each turnbuckle or fixed link for. Refer to Figure 803.

(1)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-009

* * * PRE SB 72-0483

(2)

Looseness of either nut:

Maximum serviceable limit:

Not serviceable.

Maximum repairable limit:

Any amount.

Repair method:

Check the turnbuckle length and tighten the nut.

* * * END PRE SB 72-0483

Subtask 72-30-99-220-011

Do an inspection of the spherical bearings of each turnbuckle or fixed link for. Refer to Figure 803.

(1)

Circumferential movement of ball:

Maximum serviceable limit:

Any amount, if it takes less the 8 lb in. (0.9 N.m) to move the bearing.

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-012

(2)

A ball that will not turn side-to-side (pivot) in the spherical bearing outer race:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-013

(3)

Radial clearance of the balls in the spherical bearings in the outer race:

Maximum serviceable limit:

0.0016 inch (0.041 mm).

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-014

(4)

Nicks, dents, scratches, and galling on each spherical bearing inner race:

Maximum serviceable limit:

Any amount 0.003 inch (0.08 mm) in depth, if in the limits of TASK 70-33-03-220-006 (SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING) .

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-015

(5)

Nicks, dents, scratches, and pits on the lateral faces of each spherical bearing outer race:

Maximum serviceable limit:

Any amount, 0.005 inch (0.13 mm) in depth.

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-016

(6)

Axial looseness of each spherical bearing outer race in the rod ends:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-017

(7)

Axial looseness of the ball in each spherical bearing outer race:

Maximum serviceable limit:

Any amount, 0.010 inch (0.25 mm) in depth after the removal of high metal. None permitted in the fillet radius. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Repair method:

Replace the turnbuckle.

Subtask 72-30-99-220-018

Do an inspection of the rod end assemblies of each turnbuckle for. Refer to Figure 803.

(1)

Damage to the threads:

Maximum serviceable limit:

25 percent of the entrance thread can be damaged, if there is no damage to the other threads.

Maximum repairable limit:

Complete removal of the entrance thread.

Repair method:

Remove the damage with a fine file or honing stone.

Subtask 72-30-99-220-019

(2)

Nicks, dents, scratches, and pits (this does not include the spherical bearing outer race):

Maximum serviceable limit:

Any amount 0.003 (0.08 mm) in depth, if in the limits of TASK 70-33-03-220-006 (SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING) .

Maximum repairable limit:

Any amount, 0.030 (0.76 mm) in depth after the removal of high metal.

Repair method:

Blend to remove the high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Subtask 72-30-99-220-045

* * * SB 72-0483

Do an inspection of the fixed link body for. Refer to Figure 804.

(1)

Nicks, dents, scratches, and pits (this does not include the spherical bearing outer race):

Maximum serviceable limit:

Any amount, 0.003 inch (0.08 mm) in depth, if in the limits of TASK 70-33-03-220-006 (SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING) .

Maximum repairable limit:

Any amount, 0.030 inch (0.76 mm) in depth, after the removal of high metal.

Repair method:

Blend to remove the high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

* * * END SB 72-0483

* * * FOR ALL

* * * SB 72-0483

Figure 804 HPC Hardware - Inspection

* * * FOR ALL

* * * SB 72-0027( VSV Torque Shaft Linkage with an Adjustable Clevis - Configuration 1 )

* * * SB 72-0158( PIP2 Configuration )

Figure 805 HPC Hardware - Inspection

* * * FOR ALL

* * * SB 72-0158( PIP2 Configuration )

Figure 806 Shaft Nut - Inspection

Subtask 72-30-99-220-020

* * * DELETED( )

Do an inspection of the clevises for. Refer to Figure 805.

NOTE:

PRE SB 72-0027 (Configuration 2) and SB 72-0027 (Configuration 3) do not require inspection of clevis.

(1)

Nicks, dents, scratches on each clevis:

Maximum serviceable limit:

Any amount, 0.005 inch (0.13 mm) in depth after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Maximum repairable limit:

Any amount, 0.02 inch (0.5 mm) in depth.

Repair method:

Blend to remove the high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Subtask 72-30-99-220-021

(2)

Rub marks on the bolthead, turnbuckle, and nut mating surface:

Maximum serviceable limit:

Any amount, 0.002 inch (0.05 mm) in depth.

Repair method:

Replace the clevis.

Subtask 72-30-99-220-022

(3)

Thread damage:

Maximum serviceable limit:

25 percent of the entrance thread can be damaged, if there is no damage on the other thread.

Maximum repairable limit:

Complete removal of the entrance thread is permitted.

Repair method:

Remove the damage with a fine file or honing stone.

Subtask 72-30-99-220-046

(4)

Wear due to contact with turnbuckle rod end on inner surface of the shaft stage clevises (IGV through stage 4):

Maximum serviceable limit:

Any amount, 0.010 inch (0.25 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Repair method:

Replace the torque shaft.

* * * DELETED

Subtask 72-30-99-220-023

Do an inspection of the shaft nut for. Refer to Figure 806.

(1)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the shaft nut.

Subtask 72-30-99-220-024

(2)

Nicks, dents, and scores:

Maximum serviceable limit:

Any amount 0.005 inch (0.13 mm) in depth, after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Repair method:

Replace the shaft nut.

Subtask 72-30-99-220-027

(3)

High metal in the safety wire holes:

Maximum serviceable limit:

Any amount 0.005 inch (0.13 mm), after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Repair method:

Replace the shaft nut.

Subtask 72-30-99-220-031

Do an inspection of the spacers for. Refer to Figure 801.

(1)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the spacer.

Subtask 72-30-99-220-032

(2)

Fretting and galling:

Maximum serviceable limit:

Any amount, 0.002 inch (0.05 mm) in depth.

Repair method:

Replace the bolt spacer.

Subtask 72-30-99-220-033

(3)

Nicks, dents, and scratches:

Maximum serviceable limit:

Any amount, 0.002 inch (0.05 mm) in depth after the removal of high metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Repair method:

Replace the spacer.

Subtask 72-30-99-220-034

Do an inspection of all other bolts for. Refer to Figure 801, Figure 802, Figure 802A, and Figure 803.

(1)

Damaged threads:

Maximum serviceable limit:

25 percent of the entrance thread can be damaged, if there is no damage on the other threads.

Maximum repairable limit:

Complete removal of the entrance thread is permitted.

Repair method:

Remove the damage with a fine file or honing stone.

Subtask 72-30-99-220-036

(2)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the bolt.

Subtask 72-30-99-220-040

(3)

Axial scratches on the shank:

Maximum serviceable limit:

Any amount, 0.010 inch (0.25 mm) in depth after the removal of high metal. None permitted in the fillet radius.

Repair method:

Blend. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) .

Subtask 72-30-99-220-041

Do an inspection of all other nuts for. Refer to Figure 801 and Figure 803.

(1)

Cracks:

Maximum serviceable limit:

Not serviceable.

Repair method:

Replace the nut.

Subtask 72-30-99-220-042

(2)

Damage to the threads:

Maximum serviceable limit:

25 percent of the entrance thread can be damaged, if there is no damage to the other threads.

Maximum repairable limit:

Complete removal of the entrance thread is permitted.

Repair method:

Remove the damage with a fine file or honing stone.

Subtask 72-30-99-220-043

(3)

Loss of the self-locking quality:

Maximum serviceable limit:

Any amount, if the bolt can not be hand tightened past locking feature.

Repair method:

Replace the nut.

Subtask 72-30-99-220-048

Do an inspection of the alignment pin for. Refer to Figure 807 and as follows:

(1)

Wear on outer diameter (OD):

Maximum serviceable limit:

Any amount, if diameter D is in limits of 0.0986 inch (2.505 mm) to 0.0994 inch (2.524 mm).

Repair method:

Replace the alignment pin.

* * * FOR ALL

Figure 807 HPC Hardware - Alignment Pin Inspection

GE Designated: - CONFIDENTIAL Subject to the restrictions on the media