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

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 10/31/2018
	CIR 72-32-01 , REPAIR 002
	HIGH PRESSURE COMPRESSOR STATOR FORWARD CASE ASSEMBLY - REPAIR- SELF-LOCKING INSERT REPLACEMENT

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TASK 72-32-01-300-802

1 .

Repair for the High Pressure Compressor Stator Forward Case.

This procedure gives instructions to repair the HPC stator forward case assembly (forward case) by replacing damaged self-locking inserts. 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.

NOTE:

For 72-00-02, Inspection 001, refer to TASK 72-00-02-200-801 (72-00-02, INSPECTION 001).

(4)

Visual Inspection.

(ad)

Do an inspection of the HPC stator forward case assembly (forward case assembly) (073A0) of the HPC assembly (00108) as follows. Refer to Figure 801 and Figure 810.

Damaged insert threads on the mounting pads or bosses:

Maximum repairable limit:

Any amount.

(ae)

Do an inspection of the machine bolts (bolt) (07320) in the unused forward case assembly mounting bosses (case bosses) as follows. Refer to Figure 810.

Damaged insert threads on the bosses:

Maximum repairable limit:

Any amount.

NOTE:

For 72-00-32, Inspection 001, refer to TASK 72-00-32-200-801 (72-00-32, INSPECTION 001).

(4)

Visual Inspection.

(a)

Do an inspection of the HPC stator forward case assembly (case assembly) (073A0) as follows. Refer to Figure 801.

Loose, missing, or damaged insert threads on the mounting pads, bosses, and aft circumferential flange:

Maximum repairable limit:

Any amount.

NOTE:

For 72-32-01, Inspection 001, refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001).

(4)

Visual Inspection.

(h)

Do an inspection of the self-locking inserts of the mounting pads, bosses, and aft circumferential flange for:

Loss of self-locking quality of the 0.250-28UNF-3B insert (mounting pads and bosses):

Maximum repairable limit:

Any amount.

Loss of self-locking quality of the 0.375-24UNF-3B insert (aft circumferential flange):

Maximum repairable limit:

Any amount.

Loose or missing insert:

Maximum repairable limit:

Any amount.

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)

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.

Description

Manufacturer

Drill

Local Purchase

Drill Stop Collar Set (drill stop collar)

Local purchase

Hex Head Drive Wrench (allen key)

Local Purchase

Pointed Punch

Local Purchase

(3)

Locally Manufactured Tools. None.

Consumable Materials. None.

Referenced Procedures.

ATA No.

Description

72-00-02

Inspection 001

72-00-32

Inspection 001

72-32-01

Cleaning 001

72-32-01

Inspection 001

AS3507, Installation and Removal of Thin Wall, Self-Locking, Short and Long Length Inserts

Expendable Parts. None.

SPD Information.

CSN

Description

Insert-Screw (1693M83P04) (insert)

Deleted

Ring-Locking (1689M74P02) (locking ring)

Deleted

Insert and Ring-Locking Kit (738L579G04)

Primary: Insert 1693M83P14 must be used with locking-ring 1689M74P09 no mixing permitted.

Insert and Ring-Locking Kit (738L579G03)

Alternative: Insert 1693M83P12 must be used with locking-ring 1689M74P07 no mixing permitted.

Insert and Ring-Locking Kit (738L579G02)

Alternative: Insert 1693M83P11 must be used with locking-ring 1689M74P05 no mixing permitted.

NOTE:

Deleted.

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

Subtask 72-32-01-220-066

Refer to Figure 901 for specified dimensionsand locations.

NOTE:

The dimensional data identified within this procedurewas designed using inches as the base unit of measurement for dimensionalvalues. The conversion to millimeters is rounded to one less decimaldigit than inches. For minimum dimensions, converted values are roundedup. For maximum dimensions, converted values are rounded down. Toavoid conversion errors, do not reconvert from millimeters to inches.

NOTE:

Reference dimensions do not require inspection.

4 .

Setup Information.

None.

5 .

Procedure.

Subtask 72-32-01-100-002

If necessary, cleanthe forward case. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING001).

Subtask 72-32-01-350-003

Remove the damagedinsert from the forward case. Refer to AS3507, Installation and Removalof Thin Wall, Self-Locking, Short and Long Length Inserts, Figure 902, and as follows:

NOTE:

Insert 1693M83P04 has a 0.250 inch (6.35 mm)diameter internal thread.

NOTE:

Insert 1693M83P11 , 1693M83P12 , or 1693M83P14 has a 0.375 inch (9.53 mm) diameter internal threads.

(1)

Set-up the drill to drill a depth of0.090 inch (2.28 mm) or less as follows:

(a)

For insert 1693M83P04 , usea 0.3125 inch (7.938 mm) diameter drill.

NOTE:

(HES) GE Repair Engineering has reviewed your request and agrees with your observation to use and 0.4375 inch (11.113 mm) inch diameter drill bit in paragraph 5.B. of GEnx-1B CIR 72-32-01, Repair 002. By using a 0.4375 inch diameter drill bit and drilling a maximum of 0.090 inch deep, you remove the swaged contact between the insert and the locking ring thus allowing removal of the locking ring with a pointed punch (paragraph 5.B.(4). GE will revise Repair 002 to correct the drill bit diameter from 0.375 inch (9.53 mm) to 0.4375 inch (11.113 mm) in paragraph 5.B.(1)(b). Until the revision is made, GE recommends you use a 0.4375 inch diameter drill bit in paragraph 5.B(1)(b). Refer to Case #01802788.

(b)

For insert 1693M83P11 , 1693M83P12 , or 1693M83P14 , use a 0.375 inch (9.53 mm) diameterdrill.

(c)

Install a drill stop collar on thedrill.

(2)

Align the drill with the center-lineof the damaged insert.

Subtask 72-32-01-320-001

WARNING:

METAL PARTICLES FROM MACHINING CAN CAUSE DAMAGE, INJURY,OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT.

CAUTION:

DO NOT DRILL INTO THE FORWARD CASE WALL. DAMAGE TOTHE FORWARD CASE WILL OCCUR.

(3)

Drill into the insert 1693M83P04 , 1693M83P11 , 1693M83P12 , or 1693M83P14 to a depth, of 0.090 inch(2.28 mm) or less.

NOTE:

Do not let the forward case move during the drill procedure.

WARNING:

BE CAREFUL WHEN YOU USE SHARP OR POINTED TOOLS. THESETOOLS CAN CAUSE AN INJURY TO YOU.

(4)

Use a pointed punch to remove the locking ring.

Subtask 72-32-01-350-004

(5)

Use an allen key to remove the damagedinsert.

NOTE:

The damaged threaded insert cannot be used again and canbe discarded.

(6)

Remove all unwanted material from therepair area and forward case.

Subtask 72-32-01-220-067

(7)

Do an inspection of the threads andcounterbore of the forward case repair area. Refer to Figure 903.

Subtask 72-32-01-350-005

CAUTION:

INSERT 1693M83P14 MUST BE USED WITH LOCKING RING 1689M74P09,INSERT 1693M83P12 MUST BE USED WITH LOCKING RING 1689M74P07, INSERT1693M83P11 MUST BE USED WITH LOCKING RING 1689M74P05. NO MIXING PERMITTED.DAMAGE TO THE PART CAN OCCUR.

Install the new insert and locking ring in the forward case.Refer to AS3507, Installation and Removal of Thin Wall, Self-Locking,Short and Long Length Inserts, TASK 72-32-01-300-802 (paragraph 2.E.),SPD Information, Figure 903,and as follows:

(1)

Use insert 1693M83P04 for bosses.

(2)

Use insert 1693M83P11 , 1693M83P12 , or 1693M83P14 for the aft circumferential flange.

(3)

Install the new threaded insert intothe threaded hole of the forward case as follows:

(a)

Turn the insert until the top faceof the insert is 0.010-0.030 inch (0.25-0.76 mm) below the locationface surface of the forward case.

(4)

Install the new locking ring on theinsert and into the oval shaped hole as follows:

(a)

For insert 1693M83P04 , uselocking ring 1689M74P02 .

(b)

For insert 1693M83P11 , uselocking ring 1689M74P05 .

(c)

For insert 1693M83P14 , uselocking ring 1689M74P09 .

(d)

For insert 1693M83P12 , use locking ring 1689M74P07 .

(e)

The word TOP on the locking ring must face out fromthe forward case.

(5)

Swage the new insert into the lockingring as follows:

(a)

Installation of insert and ring-locking kits 738L579G03 and 738L579G04 require a reduced value of 0.032inch (0.81 mm) for dimension C (refer to table 4 of AS3507).

To achieve a reduced value of 0.032 inch (0.81 mm) fordimension C an additional 0.059 inch (1.50 mm) Nylon washer can berequired for the swage tool.

(b)

After swage of insert and ring-locking kits 738L579G03 and 738L579G04 , check dimension B (refer to table5 of AS3507) to a minimum depth, of 0.027 inch (0.69 mm).

Subtask 72-32-01-220-068

Do an inspection ofthe insert and locking ring. Refer to TASK 72-32-01-300-802 (paragraph 2.E.),SPD Information, and as follows:

(1)

Use 10X magnification.

(2)

Make sure that the insert serrationsare swaged into the serrations of the locking ring.

(3)

Make sure that the locking ring andinsert are below the surface of the forward case.

Subtask 72-32-01-350-006

Remove all the unwantedmaterial from the forward case repair area.

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