Appendix I - 9H2-7-42-3 (F110 IGVA).pdf

T.O. 9H2-7-42-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

INLET GUIDE VANE ACTUATOR

(USED ON F110-GE-100, F118-GE-100,

AND F110-GE-129-ENGINES)

PART NO. CONTROL DWG NO. ENGINE

3820071-113 1274M83P13 F110-GE-100

3820071-114 1274M83P14 F110-GE-100

3820071-115 1274M83P15 F118-GE-100

3820071-119 1274M83P19 F110-GE-129

3820071-123 1274M83P26 F118-GE-100

3820071-125 1274M83P25 F110-GE-100B

3820071-128 1274M83P28 F110-GE-129

(ATOS)

(Parker-Hannifin)

(GE Aircraft Engines)

F33657-84-C-2011

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that the individual or corporate rights originating in the information, whether planned or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromises, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D: Distribution authorized to the Department of Defense and U.S. DoD contractors only, Critical Technology, 15 January 2016. Refer other requests for this document to AFLCMC/LPSLB, Tinker AFB, OK 73145-3031.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

1 MARCH 2003 CHANGE 7 - 1 JULY 2016

BASIC AND ALL CHANGES HAVE BEEN

MERGED TO MAKE THIS A COMPLETE

PUBLICATION

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . 1 March 2003 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . 1 September 2005 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . 1 October 2005 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . 1 February 2011

Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . 15 November 2011 Change . . . . . . . . . . . . . . . . . . . . 5 . . . . . . . . . . 15 October 2013 Change . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . 15 January 2016 Change . . . . . . . . . . . . . . . . . . . . 7 . . . . . . . . . . . . . . . .1 July 2016

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 92, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - ii iii iv v vi Blank vii - viii 1-1 1-2 - 1-4 2-1 2-2 - 2-4 3-1 - 3-3 3-4 3-5 - 3-7 3-8 4-1 4-2 Blank 5-1 5-2 - 5-3 5-4 5-5 - 5-6 6-1 - 6-2 6-3 6-4 - 6-5 6-6 6-7 6-8 - 6-9 6-10 - 6-11 6-12 7-1 7-2 7-3 - 7-4 7-5 7-6 - 7-15 7-16 - 7-18 7-19 - 7-26 7-27 - 7-28 7-29 - 7-30

7-31 7-32 - 7-34 7-35 - 7-37 7-38 - 7-39 7-40 - 7-41 7-42 Blank 8-1 8-2 A-1 A-2 Blank

*Zero in this column indicates an original page

A Change 7 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION.......................................................iii

SAFETY SUMMARY...............................................vii

1 GENERAL INFORMATION...................................1-1

1.1 General........................................................1-1

1.2 Description..................................................1-1

1.3 Leading Particulars .....................................1-1

2 SPECIAL TOOLS, TEST EQUIPMENT

AND CONSUMABLE MATERIALS ................2-1

2.1 General........................................................2-1

2.2 Special Tools and Test Equip-

ment........................................................2-1

2.3 Consumable Materials ................................2-1

3 DISASSEMBLY .......................................................3-1

3.1 General........................................................3-1

3.2 Unpacking ...................................................3-1

3.3 Disassembly ................................................3-1

4 CLEANING ..............................................................4-1

4.1 General........................................................4-1

4.2 Cleaning ......................................................4-1

5 INSPECTION, REPAIR AND RE-

PLACEMENT ......................................................5-1

5.1 General........................................................5-1

5.2 Inspection....................................................5-1

5.2.1 Item Unique Identification

(IUID).....................................................5-1

5.3 Repair..........................................................5-1

5.4 Replacement................................................5-1

5.5 Lee Plug Replacement................................5-5

5.6 Preservation.................................................5-5

6 ASSEMBLY..............................................................6-1

6.1 General........................................................6-1

6.2 Assembly.....................................................6-1

7 TESTING ..................................................................7-1

7.1 General........................................................7-1

7.2 Testing.........................................................7-1

7.3 Troubleshooting ........................................7-38

7.4 Final Assembly and Adjustment..............7-38

7.5 Preservation After Tests ...........................7-41

8 TABLE OF LIMITS.................................................8-1

8.1 General........................................................8-1

8.2 Table of Limits ...........................................8-1

8.3 Torque Values.............................................8-1

A UNIQUE IDENTIFICATION (UID) SUP-

PORTING INFORMATION ..............................A-1

A.1 IUID Supplemental Information ...............A-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Inlet Guide Vane Actuator - Overall View ........................................................... 1-1

1-2 1274M83P13 and 1274M83P14/P25 In-let Guide Vane Actuators - Schemat-ic ................................................................. 1-2

1-3 1274M83P15/P26 and 1274M83P19/P28 Inlet Guide Vane Actuators - Schematic................................ 1-2

2-1 Special Tools and Test Equipment - Overall View .............................................. 2-3

3-1 Inlet Guide Vane Actuator - Exploded View ........................................................... 3-2

5-1 Lee Plug - Replacement ................................. 5-6

6-1 Channel Seal - Installation ............................. 6-2 6-2 Cleaning Wire Installation.............................. 6-3 6-3 LVDT Probe - Installation.............................. 6-5 6-4 Piston Rod Applicator - Installation .............. 6-5 6-5 LVDT Preadjustment - Test Connec-tions ............................................................ 6-7 6-6 Electrical Connector - Orientation ................. 6-9 6-7 Insulation Resistance - Test Connec-tions .......................................................... 6-11 7-1 Break-In, Rod-Seal Leakage, Friction

Drag and Cross-Piston Leakage Tests Without Servovalve - Typical Test Connections........................................ 7-2

Change 5 i

7-2 Proof-Pressure Without Servovalve - Test Connections........................................ 7-3

7-3 Proof-Pressure With Servovalve - Test Connections ................................................ 7-6

7-4 Break-In Without Servovalve - Test Connections ................................................ 7-8

7-5 Break-In With Servovalve - Test Con-nections..................................................... 7-11

7-6 Friction Drag Without Servovalve - Test Connections...................................... 7-15

7-7 Friction Drag With Servovalve - Test Connections .............................................. 7-17

7-8 Cross-Piston Leakage - Test Connec-tions .......................................................... 7-19

7-9 1274M83P13 and 1274M83P14/P25 Actuators Reset Piston Leakage Without Servovalve - Test Connec-tions .......................................................... 7-20

7-10 1274M83P13 and 1274M83P14/P25 Actuators Reset Piston Leakage With Servovalve - Test Connections................ 7-21

7-11 Rod-Seal Leakage Without Servovalve - Test Connections...................................... 7-22

7-12 Rod-Seal Leakage With Servovalve - Test Connections...................................... 7-25

7-13 Main Piston Stroke, LVDT Probe Ad-justment, Slew Rate and Servo Null With Servovalve - Test Connections....... 7-28

7-14 1274M83P13 and 1274M83P14/P25 Actuators Reset Piston Stroke With Servovalve - Test Connections................ 7-30

7-15 LVDT Output Versus Stroke - Graph.......... 7-35 7-16 Slew Rate Versus Milliamperes - Graph ..... 7-37 8-1 Limits - Locations........................................... 8-2 A-1 IUID Identification Plate Location................ A-1

LIST OF TABLES

Number Title Page Number Title Page

1-1 Leading Particulars............................................ 1-3 2-1 Special Tools and Test Equipment................... 2-1 2-2 Consumable Materials....................................... 2-2 5-1 Inspection .......................................................... 5-2 5-1 Inspection - Continued...................................... 5-4 7-1 Field Removal Disposition ............................... 7-2 7-2 Stroke Versus Output Voltage........................ 7-31

7-2 Stroke Versus Output Voltage - Contin-ued............................................................... 7-32

7-3 Slew Rate Versus Milliamperes ..................... 7-36 7-4 Troubleshooting............................................... 7-38 8-1 Table of Limits.................................................. 8-1 A-1 Item Unique Identification (IUID) Re-quired Information....................................... A-1 ii Change 5

TO 9H2-7-42-3

INTRODUCTION

Symbol Definition1. PURPOSE.

°F Degrees Fahrenheit

This technical manual provides information required for 4. LIST OF REFERENCED PUBLICATIONS.overhaul and testing of inlet guide vane (IGV) actuator.

The actuator is manufactured by Parker-Hannifin Corpora-

Referenced publications are as follows:tion, Parker-Bertea Aerospace Group Headquarters, 18321 Jamboree Boulevard, PO Box C-19510, Irvine, CA 92713- 1011. List of Related Publications

2. SCOPE.

Publication Number Publication Title

Chapter 1 through Chapter 8 of this manual provide over- TO 1-1-671 Aircraft Weapons Systemhaul and test procedures. A table of contents provides

- Cleaning and Corrosionchapter, paragraph title, and page numbers to help find information. A list of illustrations and a list of tables Control provide number, title, and page number of illustrations and

TO 33D4-6-670-1 Fuel Accessory Test Standtables.

(O&M)

3. ABBREVIATIONS AND SYMBOLS.

TO 33D4-6-670-4 Fuel Accessory Test Stand

Abbreviations and symbols used in this manual are in (IPB) accordance with MIL-STD-12, Abbreviations for Use on Drawings, and in Specifications, Standards and Technical TO 33D4-6-672-1 Electrical Accessory Test Documents, except as follows: Stand (O&M)

Abbreviation Definition TO 33D4-6-672-4 Electrical Accessory TestDMM Digital multimeter

Hz Hertz Stand (IPB) IGV Inlet guide vane mA Milliampere TO 44H1-1-117 General Installation of He- OOL Out-of-limits li-Coil InsertsPCR Publication change request PPH Pounds per hour

TO 9H2-7-42-4 Inlet Guide Vane ActuatorPSID Pounds per square inch differential VRMS Volts root mean square iii

CONFIGURATION CHART

F110-GE-100

IGV ACTUATOR

VIN 3820071-113 ECP F017-5 R2 VIN 3820071-114

GE PN 1274M83P13 - - - - - - - - > CID 882179 - - - - - - - - - - - - - - > GE PN 1274M83P14 - - - - - - - - >

VIN 3280071-125

CID 907662 - - - - - - - - - - - - - - > GE 1274M83P25

CONFIGURATION CHART

F118-GE-100

IGV ACTUATOR

VIN 3820071-115 VIN 3280071-123

GE PN 1274M83P15 - - - - - - - - > CID 907662 - - - - - - - - - - - - - - > GE PN 1274M83P26

CONFIGURATION CHART

F110-GE-129

IGV ACTUATOR

VIN 3820071-119 VIN 3280071-128

GE PN 1274M83P19 - - - - - - - - > CID 907662 - - - - - - - - - - - - - - > GE PN 1274M83P28 iv Change 5

5. The following list of Time Compliance Technical Orders (TCTOs) affect the technical content of this manual.

Only current TCTOs are listed. A TCTO is deleted from this list when rescinded, superseded, or fully incorporated.

List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

Change 7 v/(vi blank)

SAFETY SUMMARY

1. DEFINITIONS. 5. FINGER RINGS.

The following definitions apply to WARNINGS, CAU- Snagged finger rings have caused many serious injuries.

TIONS, and NOTES found throughout this publication. Unless specifically allowed by shop safety procedures, remove finger rings during all maintenance activity.

WARNING 6. KEEP AWAY FROM LIVE CIRCUITS.

Operating personnel shall think safety at all times. Do not An operational or maintenance procedure, prac- replace components or make adjustments inside equipment tice, condition, statement, etc., which if not with the electrical supply turned on. Under certain condi-strictly observed, could result in injury to or tions, danger may exist even when power control is in the death of personnel. off position due to charges retained by capacitors. To avoid injuries, always remove power, discharge, and ground a circuit before touching. Adhere to all lock out/tag outCAUTION requirements.

7. RESUSCITATION.An operational or maintenance procedure, prac-tice, condition, statement, etc., which if not

Personnel working with or near dangerous voltage shall bestrictly observed, could result in damage to or trained in modern methods of resuscitation. Informationdestruction of equipment or loss of mission and training sources may be obtained from Director of Baseeffectiveness.

Medical Services.

NOTE 8. LUBRICATING OIL/FUEL.

An essential operational or maintenance proce- Lubricating oil/fuel in liquid, vapor, or mist form is flam-dure, condition, or statement which shall be mable, irritating to the skin and respiratory tract, and highlighted. poisonous in the digestive tract. Remove saturated clothing, wash skin well, do not swallow liquid, and do not breathe2. GENERAL PRECAUTIONS.

mist and vapors.

The following are general safety precautions that are not 9. PERSONAL PROTECTIVE EQUIPMENT.

related to any specific procedure and therefore do not appear elsewhere in this publication. These are precautions Wear protective clothing/equipment (gloves, apron, eye that personnel shall understand and apply during the vari- protection, etc.) approved for materials, procedures, and ous phases of equipment operation and maintenance. tools being used. Contact supervisor for guidance. If neces-sary, Bioenvironmental Engineer or Base Safety Office3. DO NOT SERVICE OR ADJUST ALONE.

shall be contacted for guidance.

Do not attempt internal service or adjustment of equipment unless another person capable of rendering aid and resusci-tation is present.

4. DO NOT WEAR JEWELRY.

Remove rings, watches, and other metallic objects, which may cause shock or burn hazards.

vii

10. COMPRESSED AIR. • Parts: A limited number of parts, such as bolts, nuts, and fasteners, are cadmium-plated. Since you cannot

Air pressure used in work area for cleaning or drying visually determine if a part contains asbestos or cad-operations shall be regulated to 30 PSI or less. Use mium, or if it is cadmium-plated, refer to the appropri-approved safety equipment (goggles/face shield) to prevent ate Illustrated Parts Breakdown to find these parts.

injury to eyes. Do not direct jet of compressed air at self or Before handling, replacing, or disposing of parts con-other personnel; or so that refuse is blown onto adjacent taining asbestos or cadmium, ensure that all environ-workstation. If additional air pressure is required to dis- mental controls are strictly followed.

lodge foreign materials from parts, ensure that approved • Repairs: It is highly recommended that parts containing safety equipment is worn. Ensure air pressure is not detri- asbestos or cadmium not be repaired. If, however, mental or damaging to the parts before applying high- mechanical removal of material through grinding, buff-pressured jets of air. ing, drilling, or sanding is necessary, appropriate per-sonal protective equipment shall be used and national

11. DANGEROUS PRESSURES. environmental controls shall be strictly complied with.

Ensure that Material Safety Data Sheets are available Pressure system precautions apply to all ranges of pressure. and followed for all of the materials used during any Care shall be taken during testing to ensure that all test process or operation.

connections are proper and tight before applying pressure to the test setup; all system components shall be compatible with pressures applied. Personnel shall be protected by a safety shield or located at a distance sufficient to prevent injury.

12. ASBESTOS/CADMIUM.

This engine component, and the support equipment called out to maintain and repair it, may contain small amounts of asbestos or cadmium. When working with this component, the following precautions shall be rigidly adhered to:

viii

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL. are applied. Hydraulic force from servovalve moves actua-tor rod to extend or retract position. Schematics of the

This chapter provides description and leading particulars actuator are shown in Figure 1-2 and Figure 1-3.

for the IGV actuator (Figure 1-1). The IGV actuator will be

1.3 LEADING PARTICULARS.referred to as the actuator throughout this manual.

1.2 DESCRIPTION. Leading particulars for the actuator are listed in Table 1-1.

The actuator is used in an aircraft engine IGV control system. The system has one actuator. The actuator includes a servovalve to which system pressure and control signals

Figure 1-1. Inlet Guide Vane Actuator - Overall View

1-1

Figure 1-2. 1274M83P13 and 1274M83P14/P25 Inlet Guide Vane Actuators - Schematic

Figure 1-3. 1274M83P15/P26 and 1274M83P19/P28 Inlet Guide Vane Actuators - Schematic

1-2 Change 5

Table 1-1. Leading Particulars

Characteristics Specifications Fluid MIL-T-5624, JP-4 or JP-5 fuel filtered to 10 microns absolute

Actuator area:

Extend 4.889 square inches

Retract 4.467 square inches

Retracted length (bearing bores) 9.753-9.773 inches 1274M83P13

Retracted length (bearing bores) 9.390-9.410 inches 1274M83P14/P25

Retracted length (bearing bores) 9.030-9.050 inches 1274M83P15/P26 and 1274M83P19/P28

Stroke 1274M83P13 1.046-1.066 inches

Stroke 1274M83P14/P25 1.409-1.429 inches

Stroke 1274M83P15/P26 2.100-2.120 inches

Stroke 1274M83P19/P28 1.640-1.660 inches

Rod-end connections 0.3120-0.3125 inches diameter, both ends

Output force: Normal Range: Extreme Range:

Compression (extend) 1,480 LB 3,035 LB stalled load

Tension (retract) 1,100 LB 2,730 LB stalled load

Slew rate 2.41 IN/SEC at 990-1,010 pounds per square inch differential (PSID) JP-4 fuel, 150°F ambient and fluid temperatures and +50 MILLIAMPERES (mA) input current

Cooling flow 15-35 PPH at 60°F and 100 PSID

Temperature:

Ambient (steady-state) -65 to 388°F

Transient -65 to 476°F

Fuel (steady-state) -65 to 325°F

Operating pressures: Normal Range: Extreme Range:

Supply 270-1550 PSIG 1,645 PSIG maximum

Return 35-150 PSIG 465 PSIG maximum

Supply-Return 230-1450 PSID 1,500 PSID maximum

Proof-pressure (supply and return) 2,470 PSIG

Overall servoactuator gain 0.0643 IN/SEC/mA at 1,000 PSID (extend)

Servovalve gain 0.40 CU IN/SEC/mA at 1,000 PSIG, 150°F, JP-4 fuel

Null bias (no piston movement) -26 mA to -14 mA

No-load flow 26.4 CU IN/SEC at 1,000 PSID and 80 mA input (total)

Electrical connector M50TF3018 CL-B, Type 12-12-P-9

Torque motor ±40 mA per coil nominal. Each coil rated at 110 mA continuous

Transducer:

Excitation 7.035-7.105 VRMS at 2900-3100 HERTZ (Hz)

Gain 0.204 V/V/IN +0.5 percent of nominal required output at full electrical stroke at 150°F

Voltage output 1274M83P13 1.230 VOLTS nominal in retracted position

Voltage output 1274M83P14/P25 0.707 VOLTS nominal in retracted position

Voltage output 1274M83P15/P26 0.060 VOLTS in maximum retracted position

Change 5 1-3

Table 1-1. Leading Particulars - Continued

Characteristics Specifications Voltage output 1274M83P19/P28 0.354 VOLTS in maximum retracted position

Mounting provisions Four MS21209-15L threaded inserts provide for attachment to manifold

Port connections Two 0.189-0.195-inch-diameter port holes (P1 supply, P2 return). One 0.092-0.098-inch-diameter port hole (drain). One 0.146-0.166-inch-diameter reset port (for 1274M83P13 and P14 actuators)

Weight 1274M83P13 7.00 LB maximum dry

7.41 LB maximum wet

Weight 1274M83P14/P25 6.90 LB maximum dry

7.31 LB maximum wet

Weight 1274M83P15/P26 and 6.50 LB maximum dry 1274M83P19/P28

6.90 LB maximum wet

1-4 Change 5

CHAPTER 2

SPECIAL TOOLS, TEST EQUIPMENT AND CONSUMABLE MATERIALS

2.1 GENERAL.

This chapter provides special tools, test equipment and consumable materials required for actuator maintenance.

Equivalent items may be used if the recommended tool, test equipment or consumable is not available.

2.2 SPECIAL TOOLS AND TEST EQUIPMENT.

Special tools and test equipment required are listed in Table 2-1 and illustrated in Figure 2-1.

2.3 CONSUMABLE MATERIALS.

Consumable materials are listed in Table 2-2.

Table 2-1. Special Tools and Test Equipment

Figure 2-1 Part Number Index Number Nomenclature Use and Application 3840102-101 Overhaul tool set for (3C3259G02) 1274M83P13 and

1274M83P14/P25 actuators, consisting of the following:

3831097-101 1 Channel seal assembly tool Installing channel seal (3C3259P02) 3831098-101 2 Piston rod applicator Installing piston assembly into body of ac- (3C3259P03) tuator 3831102-101 3 LVDT assembly tool Installing and removing LVDT transducer (3C3259P05) probe 3831104-101 4 Wire-forming tool Forming cleaning wire on piston (3C3259P12) 3831275-101 5 Cap seal smoothing tool Installing reset piston (3C3259P13) 3831276-101 6 Cap seal sizing tool Installing main piston (3C3259P14) 3831277-101 7 Test manifold Replaces servovalve during test without (3C3259P16) servovalve installed *M25988/1-010 Preformed packing Manifold interface 3831278-101 8 Test manifold Connecting test pressure source to actuator (3C3259P17) *9384M55P03 Gasket Manifold interface 3840102-102 Overhaul tool set for (3C3259G03) 1274M83P15/P26 and

1274M83P19/P28 actuators, consisting of the following:

3831097-101 1 Channel seal assembly tool Installing channel seal (3C3259P02) 3831098-101 2 Piston rod applicator Installing piston assembly into body of ac- (3C3259P03) tuator 3831102-101 3 LVDT assembly tool Installing and removing LVDT transducer (3C3259P05) probe 3831276-101 6 Cap seal sizing tool Installing main piston (3C3259Pl4) 3831277-101 7 Test manifold Replaces servovalve during test without (3C3259P16) servovalve installed *M25988/1-010 Preformed packing Manifold interface

Change 5 2-1

Table 2-1. Special Tools and Test Equipment - Continued

Figure 2-1 Part Number Index Number Nomenclature Use and Application 3831278-101 8 Test manifold Connecting test pressure source to actuator (3C3259Pl7)

*9384M55P03 Gasket Manifold interface

3888015-101 Not illustrated Adjusting wrench Not used (3C3259P19)

3888016 9 Wire-forming tool Forming cleaning wire on piston (3C3259P20)

3C3586G01 Not illustrated IGV actuation preset fixture Adjusting final position of rod-end assem-bly

3C3960 Electrical accessory test stand Testing actuator

3C3970 Fuel accessory test stand Testing actuator

* Not part of tool, but required for tool use.

Table 2-2. Consumable Materials

Specification or Nomenclature Part Number Cage General Use

Acetone O-A-51 Removing ID plate

Alcohol, Isopropyl TT-I-735 Cleaning

Brush, nonmetallic MIL-B-15319 Cleaning

Cloth, abrasive, aluminum oxide P-C-451 Removing high metal

Cloth, abrasive, 600 grit P-C-458 Removing high metal

Cloth, cleaning CCC-C-46 Cleaning

Coating, chemical film conversion MIL-C-81706 Protecting bare metal

Compound, potting MIL-S-23586 Potting wire cavity

Fluid, calibration MIL-C-7024 Testing fluid

Oil, lubricating MIL-L-6081, Grade 1010 Lubricating and preserving

Paper, barrier MIL-B-121, Grade A Protecting steel parts

Petrolatum VV-P-236 Lubricating

Seal, yellow torque F-900 01195 Securing fasteners

Solvent, drycleaning P-D-680, Type II or III Cleaning

Stick, orange GG-O-671 Removing potting compound, MIL-S-23586

Wire, jumper MIL-W-16875/5 Servovalve jumper wire

Wire, safety MS20995C32 Safety-wiring

Wrap, plastic tie Commercial Securing ball bearings

2-2

Figure 2-1. Special Tools and Test Equipment - Overall View (Sheet 1 of 2)

2-3

Figure 2-1. Special Tools and Test Equipment - Overall View (Sheet 2)

2-4

CHAPTER 3

DISASSEMBLY

3.1 GENERAL.

This chapter provides unpacking and disassembly proce-dures for the actuator. Determine the extent of disassembly required by preliminary visual inspection, and by perform-ing tests (Chapter 7). No part shall be disassembled unless replacement or servicing is required, or removal is required to gain access to other parts requiring replacement or servicing. All steps apply unless specified by part number.

Preformed packings, rings, and channel seals shall be discarded following disassembly.

3.2 UNPACKING.

Remove shipping parts only when necessary to gain access to components. Remove shipping cover assembly (51, Figure 3-1, sheets 1 and 2) and drain preservative fluids or oils from actuator as follows:

CAUTION

Shipping cover assembly (51) shall be installed on manifold assembly (56) to prevent contamination.

a. Shipping Cover Assembly. If required, remove four screws (54) and remove shipping cover assem-bly (51) from manifold assembly (56). Remove plastic plug (66) from electrical connector (4).

WARNING

• Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

• Fuel, MIL-T-5624, is flammable and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

b. Preservative Oil or Fuel. After shipping cover assembly (51) and/or plastic plug (66) has been removed, drain any trapped fluids in actuator before beginning disassembly.

3.3 DISASSEMBLY.

The disassembly procedures are described in detail unless self-evident upon inspection. For 1274H83P13 and 1274M83P14/P25 actuators, use Figure 3-1, sheets 1 and 3.

For 1274M83P15/P26 and 1274M83P19/P28 actuators, use Figure 3-1, sheets 2 and 3. Disassemble the actuator as follows:

a. Secure ball bearing (24, sheets 1 and 2) in rod-end (25), using plastic tie wrap or equivalent. Secure ball bearing (13) in lug (14), using a plastic tie wrap or equivalent.

b. Remove screw (2) and inspection cover (1) from manifold assembly (56). Remove and discard preformed packing (3) from inspection cover.

c. Ensure shipping cover assembly (51) is installed on manifold assembly (56).

CAUTION

Use care when removing potting compound, MIL-S-23586, and pulling electrical connector

(4) from manifold assembly (56). Failure to comply may result in damage to insulation or wires.

d. Do not remove electrical connector (4) from actua-tor unless necessary. If connector removal is neces-sary, proceed as follows:

(1) Remove safety wire, MS20995C32, from four screws (6), then remove screws.

(2) Carefully remove potting compound, MIL-S- 23586, from wire cavity through inspection hole, using an orange stick, GG-O-671.

(3) Carefully pull electrical connector (4) from manifold assembly (56).

Change 5 3-1

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 1 of 2)

3-2 Change 5

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 2)

Change 5 3-3

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 3)

3-4

LEGEND

1. Inspection Cover (Sheet 1, 2)

2. Screw (Sheet 1, 2)

3. Preformed packing (Sheet 1, 2)

4. Electrical connector (Sheet 1, 2)

5. Contact (Sheet 1, 2)

6. Screw (5 required) (Sheet 1, 2)

7. Servovalve (Sheet 1, 2)

8. Bolt (4 required) (Sheet 1, 2)

9. Performed packing (4 required) (Sheet 1, 2)

10. Preformed packing (Sheet 1, 2)

11. Bolt (4 required) (Sheet 1, 2)

12. Lug assembly (Sheet 1, 2)

13. Ball Bearing (Sheet 1, 2)

14. Lug (Sheet 1, 2)

15. Antirotation pin (Sheet 1, 2)

16. Preformed packing (Sheet 1, 2)

17. Pin (2 required) (Sheet 1, 2)

18. Preformed packing (Sheet 1, 2)

19. Ring (Sheet 1, 2)

20. LVDT transducer (Sheet 1, 2)

21. LVDT probe (Sheet 1, 2)

22. LVDT housing (Sheet 1, 2)

23. Rod-end assembly (Sheet 1, 2)

24. Ball Bearing (Sheet 1, 2)

25. Rod-end (Sheet 1, 2)

26. Washer (Sheet 1, 2)

27. Nut (Sheet 1, 2)

28. Scraper (Sheet 1, 2)

29. Preformed packing (2 required) (Sheet 1, 2)

30. Channel Seal (2 required) (Sheet 1, 2)

31. Preformed packing (Sheet 1, 2)

32. Preformed packing (Sheet 1, 2)

33. Ring (Sheet 1, 2)

34. Bolt (4 required) (Sheet 1, 2)

35. Washer (4 required) (Sheet 1, 2)

36. End-cap assembly (Sheet 1, 2)

37. Lee plug (Sheet 1, 2)

38. End-cap (Sheet 1, 2)

39. Preformed packing (Sheet 1) *

40. Channel Seal (Sheet 1)*

41. Glyd ring (Sheet 1)*

42. Preformed packing (Sheet 1)*

43. Reset piston (Sheet 1, 2)

44. Lee plug (Sheet 1, 2)

45. Cleaning wire (Sheet 1, 2)

46. Glyd ring (Sheet 1, 2)

47. Preformed packing (Sheet 1, 2)

48. Main piston(Sheet 1, 2)

49. Piston (4 required) (Sheet 1, 2)

50. Insert (Sheet 1, 2)

51. Shipping cover assembly (Sheet 1, 2)

52. Gasket (Sheet 1, 2)

53. Cover (Sheet 1, 2)

54. Screw (4 required) (Sheet 1, 2)

55. Identification plate

56. Manifold assembly (Sheet 1, 2)

57. Insert (4 required) (Sheet 3)

58. Insert (5 required) (Sheet 3)

59. Insert (4 required) (Sheet 3)

60. Insert (4 required) (Sheet 3)

61. Insert (4 required) (Sheet 3)

62. Lee plug (Sheet 3)

63. Lee plug (Sheet 3)

64. Lee plug (Sheet 3)

65. Body (Sheet 3)

66. Plastic plug (Sheet 1, 2)

67. Preformed packing (Sheet 1, 2)

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 4)

* Used on 1274M83P13 and 1274M83P14/P25 actuators only.

Change 5 3-5

(4) Tag and mark servovalve (7) and LVDT trans-ducer (20) lead wires.

e. Carefully remove potting compound, MIL-S- 23586, from around lead wires attached to electri-cal connector (4) to gain access to contacts (5).

NOTE

Only those contacts required to replace applica-ble component (servovalve or LVDT) shall be removed.

f. Remove contacts (5) from electrical connector (4), using removal tool in accordance with MS24256R20 and as follows:

(1) Slide end of removal tool over pin end of contact (5) being removed. Push tool into insert hole until retention clip is fully opened.

(2) Keep pressure on removal tool body and slide plunger knob forward to loosen contact (5).

(3) Grasp wire on opposite side of electrical con-nector (4) and remove contact (5) from connector.

g. Remove as much potting compound, MIL-S- 23586, as possible, from electrical connector (4) and lead wires to prevent servovalve (7) contamination.

NOTE

Lead wires shall be cut as close as possible to contacts (5) to reduce wire loss.

h. Cut servovalve (7) lead wires (Figure 1-2 or Figure 1-3) as close as possible to contacts (5, Figure 3-1, sheets 1 and 2). Discard contacts.

i. Remove prefourmed packing (67) from electrical connector (4).

CAUTION

• Use care when removing servovalve (7) from manifold assembly (56) to prevent pulling electrical lead wires out of servovalve.

• Round part of servovalve (7) shall not be removed from plate of servovalve. Parts are secured by five screws and a plate on each side. All parts of servovalve shall be returned to vendor if separated (TO 9H2-7- 42-4).

j. Do not remove servovalve (7) from actuator unless necessary (Table 5-1). If replacement is necessary, proceed as follows:

(1) Remove four bolts (8) securing servovalve (7) to manifold assembly (56).

(2) Carefully pull servovalve (7) from manifold assembly (56) only enough to gain access to the lead wires, by pulling directly on lead wires.

CAUTION

Use care not to pull lead wires by pulling on servovalve (7). Pull directly on lead wires to prevent damage.

(3) Carefully separate servovalve (7) from manifold assembly (56) while pulling electrical lead wires out of manifold assembly.

k. If servovalve (7) is removed, remove four preformed packings (9) and preformed packing

(10) from servovalve or from manifold assembly (56).

l. Remove four bolts (34) and four washers (35) from end-cap assembly (36).

CAUTION

Use care not to pry end-cap assembly (36) from manifold assembly (56). Failure to comply may cause damage to LVDT probe (21).

NOTE

Reset piston (43, sheet 1) is not a part of 1274M83P15/P26 or 1274M83P19/P28 actuators.

m. Pull main piston (48, sheets 1 and 2), reset piston (43, sheet 1), and end-cap assembly (36, sheets 1 and 2) straight out of manifold assembly (56). If necessary, rotate end-cap assembly to ease removal.

3-6 Change 5

CAUTION

Do not twist or bend LVDT probe (21) on end of LVDT transducer (20). Failure to comply may cause damage to LVDT probe.

n. Install 3831102-101 LVDT assembly tool on LVDT probe (21) in main piston (48). Remove probe from piston, using care not to twist or bend probe. Temporarily store probe in LVDT housing

(22) to prevent damage.

o. Remove four bolts (11) and carefully pull lug assembly (12) from manifold assembly (56). Pull lug assembly straight out to prevent damage to LVDT housing (22).

p. If LVDT removal is necessary, cut four LVDT lead wires (Figure 1-2 or Figure 1-3) as close as possi-ble to contacts (5, Figure 3-1, sheets 1 and 2).

Discard contacts. While slowly pulling LVDT housing (22) from manifold assembly (56), care-fully feed LVDT lead wires through manifold assembly.

q. Remove antirotation pin (15) from lug assembly (12), if damaged (Table 5-1).

r. Remove preformed packing (16) from manifold assembly (56).

s. Remove two pins (17) from manifold assembly (56), if damaged (Table 5-1).

t. Remove ring (19) and preformed packing (18) from LVDT housing (22).

u. Loosen nut (27) on rod-end of main piston (48).

v. Remove rod-end assembly (23).

w. Remove nut (27) and washer (26) from main piston (48).

x. Remove end-cap assembly (36) from main piston (48).

y. Remove scraper (28), two channel seals (30), and two preformed packings (29) from end-cap assem-bly (36), using a brass rod. Discard scraper.

z. Remove preformed packing (31), ring (33), and preformed packing (32) from end-cap assembly (36).

aa. Remove main piston (48) from manifold assembly (56).

NOTE

• Reset piston (43, sheet 1) is not a part of 1274M83P15/P26 or 1274M83P19/P28 actuators.

• Steps ab, ac, and ad do not apply to 1274M83P15/P26 or 1274M83P19/P28 actuators.

ab. For 1274M83P13 and 1274M83P14/P25 actuators, remove reset piston (43, sheet 1) from main piston (48).

ac. For 1274M83P13 and 1274M83P14/P25 actuators, remove channel seal (40) and preformed packing

(39) from reset piston (43), using a brass rod.

ad. For 1274M83P13 and 1274M83P14/P25 actuators, remove glyd ring (41) and preformed packing (42) from reset piston (43).

ae. Remove glyd ring (46, sheets 1 and 2) and preformed packing (47) from main piston (48).

af. Remove cleaning wire (45) from main piston (48), if damaged (Table 5-1). Measure and record wire diameter.

ag. Remove insert (50) from main piston (48), if dam-aged (paragraph 5.4).

ah. Remove inserts (57, 58, 59, 60, and 61, sheet 3) from body (65), if damaged (paragraph 5.4).

ai. Remove identification plate (55) from manifold assembly (56, sheets 1 and 2), if damaged (Table 5-1). If plate will not pull off, proceed as follows:

Change 5 3-7

(1) Apply a small amount of acetone, O-A-51, under identification plate (55, sheet 3) to loosen

WARNING epoxy.

(2) Remove identification plate (55) from manifold Acetone, O-A-51: Explosive when subjected to assembly (56, sheets 1 and 2).

high temperature, source of ignition, high pres-sure, or other chemicals. Flammable near (3) Clean residual epoxy from manifold assembly sparks, open flames, welding areas, hot sur- (56), using a cleaning cloth, CCC-C-46, moist-faces, other sources of ignition, or while smok- ened with acetone, O-A-51.

ing. Inhalation, contact, or ingestion may cause irritation or burning of respiratory system, eyes, (4) Before discarding identification plate (55, sheet face, skin, or digestive system. Personal protec- 3), record all stamped information for transfer to tive equipment required when handling or a replacement identification plate.

using this material. May lead to allergic sensi-tivity in some individuals. Thermal decomposi-tion may release toxic by-products. Provide local exhaust or general dilution ventilation to meet published exposure limits. If these are not available, use respirator having NIOSH approval for the materials released.

3-8

CHAPTER 4

CLEANING

4.1 GENERAL.

CAUTIONThis chapter provides cleaning procedures for the actuator.

All dust, dirt, corrosion, and moisture shall be removed before inspecting or assembling parts. Electrical components shall not be soaked in drycleaning solvent, P-D-680, Type II. Failure4.2 CLEANING.

to comply may cause damage to components.

Clean as follows: d. Clean electrical components by wiping with a cleaning cloth, CCC-C-46, moistened in isopropyl alcohol, TT-I-735.WARNING

WARNINGDrycleaning solvent, P-D-680, Type II, is flam-mable and toxic to skin, eyes, and respiratory tract. Skin, eye, and respiratory protection is When using compressed air for cleaning, cool-required. Avoid repeated or prolonged contact. ing, or drying, do not exceed 30 psig. Wear eye protection and do not direct compressed air ata. Wash all parts thoroughly, using drycleaning sol-self or others.vent, P-D-680, Type II.

e. Dry parts thoroughly, using a cleaning cloth, CCC-b. Loosen dirt build up from exterior surfaces, using a C-46, or using compressed air.nonmetallic brush, MIL-B-15319.

f. Ensure parts are free of rust, corrosion, dirt, grease,c. Remove any obstructions from ports and passages, and other contaminants after cleaning.using a piece of soft copper wire, or equivalent.

WARNING

Alcohol is flammable and toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact.

Use in a well-ventilated area.

4-1/(4-2 blank)

CHAPTER 5

INSPECTION, REPAIR AND REPLACEMENT

5.1 GENERAL. Skin and eye protection and vapor control are

required. Avoid all contact.

This chapter provides procedures for inspection, repair and

c. Repair damage to anodized surfaces of aluminumreplacement of worn, damaged or defective parts. Exces-parts by applying chemical film conversion coat-sive wear is defined as any obvious deformation or deterio-ing, MIL-C-81706 (TO 1-1-671).ration of parts that may render the actuator inoperative. If any doubt exists concerning serviceability of a part, replace

5.4 REPLACEMENT.the part.

Replace all parts that do not meet inspection and limit5.2 INSPECTION.

requirements Table 5-1 and Table 8-1). The following steps provide replacement procedures for the actuator:All parts to be inspected are listed in Table 5-1. Parts with surfaces critical to the operation of the actuator have

a. If preliminary test reveals that actuator shall bedimensional limits provided in Table 8-1.

disassembled, replace the following (reference Figure 3-1):a. Visually check all parts to ensure they are clean and free from corrosion and deterioration. For

(1) Preformed packings (3, 9, 10, 16, 18, 29, 31, 32,cleaning, refer to Chapter 4.

39, 42, 47 and 67)

b. Check all metallic parts for burrs, dents, defective

(2) Channel seals (30 and 40)threads and other damage (Table 5-1). Replace or repair defective parts as applicable. (3) Rings (19, 33, 41 and 46)

c. Replace all nonmetallic parts whenever actuator is (4) Scraper (28) disassembled.

b. Replace ball bearings (13 and 24), ensuring bear-

d. Check components of actuator for excessive wear ings are seated securely into lug assembly (12) or

(Table 5-1 and Table 8-1). rod-end assembly (23). Ensure forces necessary to rotate spherical bearings inside related bearing5.2.1 Item Unique Identification (IUID). Visually races are within tolerances Table 5-1). Use the inspect the identification plate/item for the Unique Item following procedures for the 20 IN-LB torque Identifier (UII) marking. If present, visually inspect for inspection specified in Table 5-1:

damage to the symbol. Ensure readability by using hand-held electronic reader (Ref: T.O. 00-25-260). If symbol is (1) Slide washer onto 5/16-inch, 24 thread-per-inch not present or if damaged mark/restore IAW Drawing bolt (0.3125-24), 1.5 inch in length.

200945069-964 and Appendix A of this book and reference T.O. 00-25-260 and MIL-STD-130. (2) Carefully push bolt through ball bearing.

5.3 REPAIR. (3) Slide washer onto protruding end of bolt and

hand-start 0.3125-24 nut.

The following steps provide repair procedures for the

(4) Torque the nut to 25 IN-LB.actuator:

(5) Apply torque wrench to bolt head and attempt toa. Polish out all minor nicks, dents, scratches and rotate the bolt, taking note of torque required tocorrosion on metallic parts. Polish steel parts, using rotate the ball bearing.a 600 grit abrasive cloth, P-C-458. Polish alumi-num and aluminum alloy parts, using an aluminum

(6) If torque required is less than 20 IN-LB, the balloxide abrasive cloth, P-C-451.

bearing is serviceable.

b. After polishing parts, clean repaired parts

(7) If the torque is greater than 20 IN-LB, replace(Chapter 4).

the ball bearing.

c. Replace antirotation pin (15), if removed.WARNING

d. Replace cleaning wire (45) (paragraph 6.2), if removed.Chemical coating material, MIL-C-81706 is highly toxic to skin, eyes and respiratory tract.

Change 3 5-1

Table 5-1. Inspection

Part and index number Type of inspection Inspect for Corrective action Inspection cover (1, Visual Dirty or corroded Clean or remove corrosion Figure 3-1, sheets 1 and preformed packing groove (Chapter 4) 2)

Visual Protective coating worn Repair (paragraph 5.3) through to bare metal

Visual Bent or deformed Replace cover

Electrical connector (4) Visual Loose or damaged contacts Replace contacts (5) (5). None allowed

Heat damage to nonmetallic Replace connector insulator. None allowed

Visual Broken, cracked or nicked Replace preformed pack-preformed packing (3). ing (3) None allowed

Servovalve (7) Visual External damage, damaged Replace servovalve insulation and broken wires.

None allowed

Visual Dirty or obstructed parts Clean or remove obstruc-tion from servovalve (Chapter 4)

Visual Dirty or corroded Clean or remove corrosion preformed packing groove (Chapter 4)

Lug assembly (12) Mechanical Push-out force of ball bear- Replace ball bearing (13) ing (13) less than 150 LB if out-of-limits (OOL) in either direction (paragraph 5.4)

Mechanical Torque required to rotate Replace ball bearing (13) spherical ball bearing (13) if OOL (paragraph 5.4) exceeding 20 IN LB (para-graph 5.4.b.)

Antirotation pin (15) Visual Protective coating worn Repair (paragraph 5.3) through to bare metal

Visual Nicks, scratches, scoring, Replace pin wear or damage. None al-lowed

LVDT transducer (20) Visual External damage. None al- Replace transducer lowed

Visual Dirty, pitted, scratched or Clean or remove corrosion corroded preformed packing (Chapter 4). Replace if groove sealing surfaces are dam-aged

Visual External wires less than 2- Replace transducer 1/4 inches

Visual External Teflon sleeving Adjust minimum length or less than 1/4 inch replace Teflon sleeving

Visual Damage to insulation. None Replace transducer allowed

5-2 Change 2

Table 5-1. Inspection - Continued

Part and index number Type of inspection Inspect for Corrective action Visual Threads on end of probe Remove high metal from not damaged beyond 50 threads. Replace transduc-percent of one thread. Hex er for other damage nut not damaged

Visual Thread damage exceeding Replace transducer if OOL 50 percent of one thread or damaged hex nut

Rod-end assembly (23) Visual Thread damage shall be less Repair thread damage by than 50 percent of one en- chasing, using correct trance thread or less than 10 standard size tap and re-percent of two entrance move high metal. Replace threads assembly if OOL

Mechanical Push-out force of ball bear- Replace ball bearing (24) ing (24) less than 150 LB if OOL (paragraph 5.4) in either direction

Mechanical Torque required to rotate Replace ball bearing (24) spherical ball bearing (24) if OOL (paragraph 5.4) exceeding 20 IN LB (para-graph 5.4.b.)

Washer (26) Visual Plating worn through to Replace washer bare metal. Not allowed

Nut (27) Visual Minor nicks and scratches Repair thread damage by on threads chasing, using correct standard size tap and re-move high metal

Visual Missing threads. None al- Replace nut lowed

End-cap assembly (36) Visual Protective coating worn Repair (paragraph 5.3) through to bare metal

Visual External damage. None al- Replace assembly lowed

Visual Dirty or corroded grooves Clean or remove corrosion of scraper, preformed pack- (Chapter 4) ing and channel seals

Visual Lee plug (37) loose Replace Lee plug (37) (paragraph 5.5)

Dimensional Limits ( Table 8-1) Replace assembly if OOL

Dimensional Bore not smooth to touch Polish (paragraph 5.3)

Reset piston (43, sheet 1) Visual Protective coating worn Repair (paragraph 5.3) through to bare metal

Visual Dirty or corroded grooves Clean and remove corro-of preformed packing and sion (Chapter 4) channel seal

Dimensional Limits ( Table 8-1) Replace piston if OOL

Dimensional Outside diameter and bore Polish (paragraph 5.3) not smooth to touch

Cleaning wire (45, sheets Visual Movement in main piston Replace wire 1 and 2) (48) orifice restricted. Not allowed

Change 2 5-3

Table 5-1. Inspection - Continued

Part and index number Type of inspection Inspect for Corrective action Main piston (48) Visual Thread damage shall be less Repair thread damage by than 30 percent of one chasing, using correct thread or less than 20 per- standard size tap and re-cent of all threads move high metal. Replace piston if OOL Visual Cleaning wire in orifice Replace cleaning wire (45) does not spin freely Visual Plating worn through to Replace piston bare metal or plating is cracked or chipped

Visual Lee plug (44) loose Replace Lee plug (44) (paragraph 5.5)

Visual Dirty or corroded Clean and remove corro-preformed packing groove sion (Chapter 4)

Dimensional Surface finish of piston rod Replace piston exceeding 8 microinches

Dimensional Limits Table 8-1) Replace piston if OOL Identification plate (55, Visual, Machine readable Damage and illegible data. Replace plate sheet 3) UII Missing/damaged UII None allowed matrix.(Ref: T.O. 00-25- 260)

Manifold assembly (56, Visual Damaged or loose inserts Replace inserts (paragraph sheets 1 and 2) (57, 58, 59, 60 and 61, 5.4) sheet 3) Visual Damaged protective coating Repair (paragraph 5.3) on external surface Visual Damaged or corroded Remove high metal and grooves of seals and corrosion preformed packing

Visual Thread damage shall be less Repair thread damage by than 50 percent of one en- chasing, using correct trance thread or less than 10 standard size tap and re-percent of two entrance move high metal. Replace threads assembly if OOL

Visual Dirty or obstructed Clean or remove obstruc-passages. None allowed tion (Chapter 4)

Visual Lee plugs (62, 63 and 64, Replace Lee plug (62, 63 sheet 3) loose and 64, sheet 3) (para-graph 5.5) Visual Loose or damaged pin (17, Replace pin (17) sheets 1 and 2). None al-lowed

Visual Leakage residue from mani- Replace Lee plugs (62, 63 fold assembly cavity Lee and 64, sheet 3) (para-plugs (62, 63 and 64, sheet graph 5.5) 3). None allowed

Dimensional Limits Table 8-1) Replace assembly if OOL

e. If any thread inserts (50, sheet 1) (57, 58, 59, 60 (1) Collets shall be suitably sized and finished to and 61, sheet 3) are to be replaced, replace without prevent damage to operating surfaces.

causing damage to parent metal. Proceed as

(2) Install replacement inserts 1 to 1-1/2 turnsfollows:

below adjacent surfaces of part.

5-4 Change 3

(3) Remove drive tang from installed insert. (2) Insert Lee plug into hole until firmly seated against shoulder of reamed hole.

(4) Visually check insert threads for damaged or crossing threads. NOTE

f. Refer to general operating procedures when replac- Pins are pre-waxed. Additional lubrication shalling heli-coil inserts (TO 44H1-1-117).

not be used.

g. Install two pins (17, sheets 1 and 2) in body (65,

(3) Insert tapered pin, small end first, into Lee plug.sheet 3), if removed.

Avoid tilting pin.

5.5 LEE PLUG REPLACEMENT.

(4) Firmly support item to be plugged.

Remove, inspect and replace Lee plugs (37, 44, 62, 63 and (5) Press or drive tapered pin into Lee plug, using a 64, Figure 3-1, sheets 1, 2 and 3) as follows: punch. Drive pin until exposed end is flush with plug.a. Remove Lee plug as follows:

5.6 PRESERVATION.(1) Drill and tap a hole in the pin (Figure 5-1).

(2) Extract pin, using a long bolt and striker WARNINGbushing.

(3) Tap plug, using a suitable tap.

Lubricating oil, MIL-L-6081, is toxic to skin, eyes and respiratory tract. Skin and eye protec-(4) Extract plug, using a long bolt and striker tion is required. Avoid repeated or prolongedbushing.

contact. Use in a well-ventilated area.

b. Inspect Lee plug hole for damage.

Protect steel parts, using lubricating oil, MIL-L-6081. Wrap in barrier paper, MIL-B-121, to prevent corrosion of parts.c. Install Lee plug as follows:

(1) Ensure reamed hole and OD of Lee plug are clean and dry. Reamed holes in aluminum shall be anodized.

CAUTION

Ensure Lee plug is firmly inserted against shoulder of reamed hole. If plug is not seated, it may slide forward while driving pin in. This could cause scratches in reamed hole.

5-5

Figure 5-1. Lee Plug - Replacement

5-6

CHAPTER 6

ASSEMBLY

6.1 GENERAL.

This chapter provides…