LM2500_HSCS_Refurbish_Procedure.pdf

LM2500 HSCS

Refurbish Procedure

Table of Contents

Complete Assembly Exploded View ____Figure 1.0 ................................. pg. 1

Match-Marking Detail____Figure 1............................................................ pg. 2

Section 1.0 Assembly of Small Components ............................................... pg. 3

Section 2.0 Bolts .......................................................................................... pg. 5

Section 3.0 Assembly of Forward End Sub Assembly for VB ................... pg. 6

Section 4.0 Assembly of Aft End Sub Assembly for VB ............................ pg. 9

Section 5.0 Final Assembly ......................................................................... pg. 12

Section 6.0 Final Assembly Balance ........................................................... pg. 15

Appendix A Dimensional Records .............................................................. pg. 17

Appendix B Inspection Process ................................................................... pg. 24

Figure 1-0. Exploded View

Figure 1-1. Match Mark Assembly

1.0 ASSEMBLY OF SMALL COMPONENTS

1.1 Distance Piece (item 17 ASSY)

a. Use internal snap ring pliers to compress the radial damper springs. Once compressed use a wire of approximately 1/16” diameter to hold ring compressed.

Insert ring (item 19) into tube (item 18) and align holes and match marks on tube with holes on damper ring (see Figure 1-2). Each ring is marked with the end it is to be installed in. (NOTE: After inserting damper rings into tube, you may have to release wire from damper ring to line up holes.)

b. Insert shoulder bolts (item 20) from the inside of tube with one large washer (item 21, replacement part # 2889600). Apply medium lock-tite to threads of bolt, then add one small washer (item 22, replacement part # 2889599) over bolt. Add bolt (item

23) and torque to approximately 80 in-lbs. Note that the nut will bottom out on the oversized shoulder of bolt, this allows the bolt nut assembly move radially relative to the tube by design. Repeat with all radial dampening spring hardware.

Figure 1-2. Installed radial springs

1.2 Piston Assembly (item 36 ASSY)

a. Taking piston damper rod (item 40), attach damper adapter (item 38) and tighten nut to 1200 in-lbs. (item 39). (See Figure 1-3)

Figure 1-3. Piston Damper Rod Assembly w/Damper Adapter

b. On opposite end of piston damper rod, attach the piston assembly rings (items 41, 42), and piston assembly plate (item 43) with a nut (item 44) torque to 1200 in-lbs.

on the end. (See Figure 1-0 and Figure 1-4 for proper order and orientation of items on piston damper rod.)

Figure 1-4. Piston Damper Rod Assembly w/Rings and Plate

1.3 Damper Assembly (item 30 ASSY)

a. Using the damper plug tool ET-12503 (as seen in Figure 1-5). Tighten the threaded damper plug (item 33) to the diaphragm (item 24), once a reasonable resistance is felt tighten until match marks line up (as seen in Figure 1-6). This will ensure that enough torque has been applied.

Figure 1-5. Damper Plug Tool Figure 1-5a. Damper Plug Tool

Figure 1-6. Item 30 ASSY

b. Then, take the 3 D headed bolts (item 34) and place them into the holes of the threaded damper plug (as seen in Figure 1-7), followed by inserting the damper spacer ring (item 32) and the internal retaining ring (item 31), which must be compressed in order to place into groove of threaded damper plug (as seen in Figure 1-7 and Figure 1-8). Note use internal snap ring pliers to compress the snap ring

Figure 1-7. Forward Side of Item 24

1 of 3 bolts that go in threaded damper plug, which attach the cylindrical damper

Damper Spacer Ring Groove in threaded damper plug that the internal retaining ring snaps into

Figure 1-8 Forward Side of Item 24

With internal retaining ring

Use internal Snap ring pliers to install snap ring

c. Before you secure the cylinder damper to the threaded damper plug, place the retainer ring (item 28) onto the threaded damper plug (as seen in Figure 1-9). As you continue to attach the cylinder damper (item 29) onto the threaded damper plug, check the orientation with the diaphragm (item 24 see Figure 1-6) and make sure the match marks align with each other. Then, secure using the nuts (item 35), tightening them to 7-10 ft-lbs. of torque (as seen in Figure 1-10).

Retainer Ring (item 28) Nuts (item 35)

Figure 1-9 Aft Side of Item 24 Figure 1-10 Aft Side of Item 24 w/Retainer Ring Attached with Cylinder Damper Attached

2.0 Bolts

2.1 Bolt Identification and installation

a. Below in figure 2-1, The main torque carrying bolts are identified. Note part “A” was not refurbished or inspected for this order, this is the bolt that connects the coupling to the gearbox. Also note the difference in bolt diameters, Parts “B” & ”C” have .375” shank diameters, while Parts “D” &”E” have .4375” shank diameters. Furthermore note the difference in grip lengths for each diameter bolt.

Figure 2-1. Bolt Identification Table

b. Figure 2-2 Shows the installation location. Note in the final assembly there are 48 bolts per interface, 3 large diameter bolts and 45 small diameter bolts per interface.

Also note that for subassembly balance certain bolts will be left out for balance tooling, detailed procedure to follow. Since bolts are not weight matched, weighing bolts and separating them into interface is required to minimize weight removal.

Figure 2-2. Bolt Location Diagram

2.2 Method for installing bolts into diaphragm

a. Using the diaphragm spreader jack, separate the diaphragm pack (item 2), only spreading the pack wide enough to insert 2 bolts in on either side of the spreader.

See Figure 2-3 for details.

Figure 2-3 – Diaphragm Spreader Tool

3.0 Forward End Sub Assembly for Vertical Balance

a. Install bolts into forward diaphragm pack (scribed with a “B”) per figure 3-1 using the installation procedure in section 2-2. Note the Diaphragms are marked with a permanent marker (Side “1 & 2”). Also note that not all the holes will be filled, the three large bolts are left out for balance tooling (see figure 3-3).

Figure 3-1. Forward End Bolt Layout for sub assembly balance

b. Add retaining washers (figures- 3-2 and 3-2a) onto the bolts to keep them in place, ensuring that the D headed part of the bolt is rotated into the correct position so that the they seat on the inner rim of the diaphragm. All the bolts will sit the same height, so if one appears shorter it is probably not seated. Note we found that a 7/16” twelve point deep well socket works well for pushing the retaining washers into place.

Figure 3-2. Small Retaining washers

Replacement part 2889633

Figure 3-2a. Large Retaining washers

Replacement part 2889632

c. In the three large holes left open on side “1” install diaphragm spreaders studs and jam nuts (shown in figure 3-3). Ensure there is a small amount of pre-load on the studs and the nut is locked on the rim that the D head bolts seat against. These will be used to adjust the subassembly so that it is aligned, as it would be when installed in the turbine.

Figure 3-3. Weight matched Diaphragm Spreader Studs

d. Lay diaphragm down on side “2” supporting diaphragm at the center so that bolts do not get pushed back by the weight of the diaphragm. Verify side “1” is facing up and there is a slight pre-load on diaphragm spreader studs with jam nuts in place.

e. Next slowly lower splined forward hub (item 1) down on to side “1” of the diaphragm ensuring the match marks are lined up. Care should be taken not to push the retained bolts back into the diaphragm pack.

f. Next slowly lower the anti-flail ring (item “3”) down onto the diaphragm - forward adapter assembly. Again care should be taken not to push any of the D headed bolts back into the diaphragm pack. The anti-deflection ring may require light blows from a soft hammer to align. Note- the Anti-deflection ring will not sit all the way down flush to the forward adapter until the nuts are installed and pilot is engaged.

g. Install flat washers (item “7”, replacement part # 2889593) on the each of the bolts on side “1”.

h. Next, start each weight matched nut (item “9”, replacement part # NAS1805-6P) onto each bolt. Using a crisscrossing pattern begin to draw the anti-flail ring pilot onto the forward hub. Note this will require the force from nearly every nut in order to draw the ring on.

i. Next, using a crisscross method- torque each of the 45 nuts on side ”1” to 350-400 in-lbs. of torque.

j. Next mount balance-tooling T67E2979-A on the vertical balance machine and balance or null out the machine. See figure 3-4.

Figure 3-4. Vertical Balance Tooling T67E2979-A on vertical balance machine

k. Next slowly lower the forward sub-assembly onto the vertical balance tooling, ensuring that the bolts are not pushed back into the assembly. Attach the subassembly to the balance adapter and secure the 3 large nuts behind washers, do not torque yet.

Figure 3-5. Forward Sub-Assembly on Vertical Balance machine

l. In order to represent the splined adapter installation in the turbine, the two balance journals need to be aligned so they are running concentric to each other. The balance adapter (T67E2979-A ) has oversized holes in it to allow centering the subassembly relative to the lower balance journal. Therefore first align the lower journal to achieve 0-.

0005” circular run-out, then slightly snug up the bolts. Next use the diaphragm spreader studs to bring the top journal in to 0-. 0005” run-out relative to the bottom journal. This may take a few trials and tweaking to establish both journals running concentric to each other.

m. Once the alignment is set torque 3 bolts holding subassembly to balance adapter to 350- 400 in-lbs. Also use a jam nut on each of the diaphragm spreader studs to ensure they do not loosen up.

n. The subassembly balance requirement is 12 gram-in (0.4233 oz-in) static balance. Due to subassembly geometry, we have chosen to dynamically balance the subassembly to 6 gram-in (0.2115 oz –in) per plane using the two plane method. We will then verify that the single plane balance tolerance was met in order to be customer compliant. See figure 3-6 below for material removal locations.

Lower Plane Drill .25” dia.

.25” deep between bolt holes

Figure 3-6. Weight removal location for forward subassembly balance

Upper Plane Grind ID

4.0 Aft End Sub Assembly for Vertical Balance

a. Install bolts into Aft End diaphragm pack (scribed with a “A”) per figure 4-1 using the installation procedure in section 2.2. Note the Diaphragms are marked with a permanent marker (Side “1 & 2”). Also note that not all the holes will be filled, the three large bolts are left out for balance tooling. (See figure 3-3).

Figure 4-1. Aft End Bolt Layout for sub assembly balance

b. Add retaining washers (figures- 3-2 and 3- 2a) onto the bolts to keep them in place, ensuring that the D headed part of the bolt is rotated into the correct position. All the bolts will sit the same height, so if one appears shorter it is probably not seated. Note we found that a 7/16” twelve point deep well socket works well for pushing the retaining washers into place.

c. In the three large holes left open on side “1” install weight matched diaphragm spreaders studs and jam nuts (shown in figure 3-3). Ensure there is a small amount of pre-load on the studs and the nut is locked on the rim that the D head bolts seat against. These will be used to adjust the subassembly so that it is aligned, as it would be when installed in the turbine.

d. Next slowly lower aft end hub (item 26) down on to side “1” of the diaphragm ensuring the match marks are lined up. Care should be taken not to push the retained bolts back into the diaphragm pack.

e. The assembly from Figure 1-10 can be placed onto side “2” of the diaphragm pack. Care should be taken not to push any of the D-headed bolts back into the diaphragm. This assembly can then be placed onto the balance tooling T67E2979-A (Figure 3-4). Which has already been balanced and is mounted to the vertical balance machine. Again care should be taken not to unseat any of the D-headed bolts, verify they are all the same length. Install 3 washers and nuts for side “2” but do not torque yet.

f. Next slowly lower the anti-flail ring(item “27”) down onto the diaphragm –Aft adapter assembly. Again care should be taken not to push any of the D headed bolts back into the diaphragm pack. The anti-deflection ring may require light blows from a soft hammer to align. Note- the Anti-flail ring will not sit all the way down flush to the forward adapter until the nuts are installed and pilot is engaged.

g. Install flat washers (item “7”, replacement part # 2889593) on the each of the bolts on side “1”. Verify that all bolts have the same length sticking out of the anti-deflection ring, this is a double check that they are still seated-Repeat if necessary.

h. Next, start each weight matched nut (item “9”, replacement part # NAS1805-6P) onto each bolt. Using a crisscrossing pattern begin to draw the anti-flail ring pilot onto the Aft hub. Note this will require the force from nearly every nut in order to draw the ring on.

Next, using a crisscross method- torque each of the 45 nuts on side “1” to 350-400 in-lbs. of torque.

i. Next assemble the subassemblies from Figure 1-3 and Figure 1-4 securing each silver plated nut to 1200 in-lbs. This forms assembly item 36 in figure 1 and figure 4-2.

Figure 4-2 Piston Dampener Assembly

j. Next install Piston Dampener Assembly (Figure 4-2) into Aft adapter Aligning match-marks as shown in Figure 4-3. Install Socket head cap screws (item # 37 in figure 1) and torque to 55-70 in-lbs. Note the damper assembly may require a few light blows at the shaft center from a soft hammer to seat, until the pilot cap screws engage.

Figure 4-3 Match-mark alignment of damper Assembly and Aft Hub

k. Add all washers and nuts to side “2” readying the subassembly for fastening to the vertical balance adapter -do not torque nuts yet. To mimic how the Aft end will be installed center adapter about its balance journal to 0-. 0005” concentricity. Then snug up three large bolts to prevent movement away from concentric. Next use diaphragm spreader studs to indicate bolting face perpendicular about balance journal rotation of 0- 0.0002”. This may take a few trials and tweaking to meet both requirements. Once the alignment is set torque all nuts holding subassembly to balance adapter to 350-400 in-lbs. Also use a jam nut on each of the diaphragm spreader studs to ensure they do not loosen up.

l. The subassembly balance requirement is 20 gram-in ( .7055 oz-in) static balance. Due to subassembly geometry, we will dynamically balance the subassembly to 10 gram-in (.353 oz –in) per plane using the two plane method. We will then verify that the single plane balance tolerance was met in order to be customer compliant. See figure 4-4 below for material removal locations.

Upper Plane Grind on OD back edge

Figure 4-4 Weight removal location for forward subassembly balance

Upper Plane .25” dia holes

.25”deep .25” apart

Lower Plane .25” dia. Holes

.25”deep between drive bolts

5.0 Final Assembly

a. Install all D-headed bolts to Figure 5-1 below using the installation method in section 2.2.

Figure 5-1. Final Assembly Bolt layout

b. Add retaining washers (figures- 3-2 and 3-2a) onto all bolts, except the tube side large bolts. Ensure that the D headed part of the bolt is rotated into the correct position. All the bolts will sit the same height, so if one appears shorter it is probably not seated. Note we found that a 7/16” twelve point deep well socket works well for pushing the retaining washers into place.

c. Install Damper Diaphragm (from figure 1-8) onto side 2 of diaphragm “A”, aligning match-marks. Care should be taken not to push bolts back into diaphragm pack.

d. Next install Aft end Diaphragm / Dampener Assembly onto tube side “A”, aligning match-marks. Care should be taken not to push bolts back into diaphragm back. Add a few washers and nuts to temporarily secure. See Figure 5-2 below. Caution: Be sure to support tube at both ends, it may become top heavy.

Figure 5-2. Aft End Final Assembly

e. Install Forward End Diaphragm (scribed with “B”) onto “B” side of center tube with side

“2” of diaphragm toward tube, aligning match-marks. Use a few washers and nuts to temporarily secure diaphragm pack to the tube.

f. All washers and nuts can be added to the tube side bolts. Nuts can then be tightened using a crisscross method to a torqued of 350-400 in-lbs. Not on each end leave the three large nuts loose along with each small nut on either side of the large nuts. See Figure 5-3 below for clarification. There should be 9 loose nuts per end, these will be used for assembly balance tooling.

Figure 5-3. Nuts left loose for Assembly balance tooling

g. Next install Forward Adapter onto diaphragm side “1”, aligning “B” match-marks. Care should be taken not to push any bolts back into the diaphragm pack, continue to support forward adapter. Verify that all bolts have the same length protruding out of the hub interface before proceeding.

h. Next install the “B” Anti-Deflection Ring over the Forward adapter so that the matchmarks are aligned, again being sure not to push any of the D-headed bolts back into the diaphragm pack. If any of the D-headed bolts get pushed back in this step must be repeated. Note the anti-deflection ring will not pull up the entirely until the nuts are tightened.

i. Install flat washers on the each of the bolts on side “1”. Verify that all bolts have the same length sticking out of the anti-deflection ring, this is a double check that they are still seated-Repeat if necessary.

j. Next, start each weight matched nut (item “9”, replacement part # NAS1805-6P &

NAS1805-7P) onto each bolt. Using a crisscrossing pattern begin to draw the anti-flail ring pilot onto the forward hub. Note this will require the force from nearly every nut in order to draw the ring on. Next, using a crisscross method, torque each of the 48 nuts on side “1” to 350-400 in-lbs. of torque. See figure 5-4 for complete forward side.

Figure 5-4. Assemble Forward End

k. Now install Aft End to “A” side diaphragm aligning match-marks. Be sure not to unseat any of the D-headed bolts. Keep weight of Aft end supported.

l. Next install the “A” Anti-Deflection Ring over the Aft adapter so that the matchmarks are aligned, again being sure not to push any of the D-headed bolts back into the diaphragm pack. If any of the D-headed bolts get pushed back in this step must be repeated. Note the anti-deflection ring will not pull up the entirely until the nuts are tightened.

m. Install flat washers on the each of the bolts on side “1”. Verify that all bolts have the same length sticking out of the anti-deflection ring, this is a double check that they are still seated-Repeat if necessary.

n. Next, start each weight matched nut (item “9”, replacement part # NAS1805-6P &

NAS1805-7P) onto each bolt. Using a crisscrossing pattern begin to draw the anti-flail ring pilot onto the Aft hub. Note this will require the force from nearly every nut in order to draw the ring on. Next, using a crisscross method- torque each of the 45 nuts on side ”1” to 350-400 in-lbs. of torque.

o. Next install Piston Dampener Assembly (Figure 4-2) into Aft adapter Aligning match-marks as shown in Figure 3.1.7. Install Socket head cap screws (item # 37 in figure 1) and torque to 55-70 in-lbs. Note the damper assembly may require a few light blows at the shaft center from a soft hammer to seat in pilot cap screws engage.

p. Next install weight-matched assembly balance tooling shown in figure 5-5 below. Use the outside nuts and washers to secure the tool with 350-400 in-lbs of torque. This tool will fit on the nuts left loose on the inside of the tube shown in Figure 5-3. The large center bolts will be pushed in by the center stud and used to pre-load diaphragms.

Figure 5-5. Assembly balance tooling

q. Figure 5-6 below represents the assembled coupling ready for assembly balance

Figure 5-6. Assembled coupling ready for Assembly balance

6.0 Final Assembly Balance

a. Before the coupling can be assembly balanced, it must be indicated to represent the actual installation between the turbine and gearbox. Using the balance-tooling studs both ends are indicated in. See Figure 5-7 and Figure 5-8. Also see figure 5-9 for indicating requirements.

Figure 5-7. Indicating Forward End

Figure 5-8. Indicating Aft End

b. The coupling was indicated to the requirements shown in Figure 5-9. This was done by adjusting the balance tooling shown in figure 5.5. The weight matched balance tooling pushes on 3 of the large D-headed bolts against the inner rim of the diaphragm putting a pre-load on the diaphragms. This balance option was chose since it allows the unit to remain assembled after assembly balance is complete.

Figure 5-9 Assembly balance-indicating requirements

c. After the coupling is indicated, it is then taken to the assembly balance stand. The assembly balance requirement is .35 in-oz per end. The coupling is then run up to 500 rpm and the first reading is taken. Washers are added as compensating weights, then nuts are re-torqued. This procedure is repeated until the balance requirement is met. The coupling was balanced down to.15 oz-in on the Aft End and .11 oz-in on the Forward end.

d. After assembly balance is complete the balance tooling is removed, the large D-headed bolts are extracted from their holes, and all nuts torqued to 350 –400 in-lbs. All nuts are then doubled checked to verify they are tight.

e. The coupling is then boxed for shipping as shown in figure 5-10.

Figure 5-10 Shipping crate

Appendix A

Dimensional Summary LM2500_Refurb 2889580 Anti Deflection Ring JPL 5/12/03 Customer Part #3

Pilot Diameter = 21.9981

Concentricity of pilot to bolt circle = 0.0025

Hole Sizes

1 0.411 L 2 0.4376 3 0.4111 4 0.4104 5 0.4107 6 0.4105 7 0.4105 8 0.4105 9 0.4105 10 0.4103 11 0.4106 12 0.4104 13 0.412 14 0.4105 15 0.4123 16 0.4106 17 0.4125

L 18 0.4378 19 0.4114 20 0.4137 21 0.4115 22 0.4108 23 0.4115 24 0.4103 25 0.4119 26 0.411 27 0.4112 28 0.4109 29 0.4116 30 0.4106 31 0.4159 32 0.4112 33 0.4126

L 34 0.4378 35 0.4107

36 0.4132 37 0.4106 38 0.4107 39 0.4114 40 0.4105 41 0.4108 42 0.4105 43 0.4114 44 0.4103 45 0.4111 46 0.4105 47 0.4109 48 0.4105

AVERAGE 0.4112 0.4377

2889586 Anti Deflection Ring JPL 5/12/03 Customer Part #27

Pilot Diameter = 21.9979

Concentricity of pilot to bolt circle = 0.0032

Hole Sizes 1 0.4312 2 0.4131 3 0.4134 L 4 0.4375 5 0.4133 6 0.4131 7 0.4131 8 0.4126 9 0.4127 10 0.4134 11 0.4132 12 0.4133 13 0.4126 14 0.4133 15 0.4122 16 0.4132 17 0.4132 18 0.4128 19 0.4141 L 20 0.4408 21 0.4141 22 0.4138

23 0.412 24 0.4137 25 0.4139 26 0.4139 27 0.4131 28 0.4131 29 0.4133 30 0.4116 31 0.4127 32 0.4138 33 0.413 34 0.4121 35 0.414 L 36 0.4385 37 0.4135 38 0.4129 39 0.4129 40 0.414 41 0.4141 42 0.413 43 0.4128 44 0.4127 45 0.4132 46 0.4131 47 0.4132 48 0.412

AVERAGE 0.4135 0.4389

Dimensional Summary LM2500 Refurb 2889583 Cylinder Dampener JPL 5/19/03 Customer Part #29 *dimensions in inches

Hole Sizes 1 0.2834 2 0.2835 3 0.2834

AVERAGE 0.2834

Bolt Circle Diamter of 3 Holes= 2.1523 Diameter of piloting OD= 4.6507 Concentricity of 3 hole patten to OD = 0.0038

ID of Straight section of bore = 3.5076 Concentricity of Straight bore to pilot OD= 0.0003 Perpendicularity of straight bore to bolting face= 0.0001

Leading Edge ID of tapered section of bore = 3.7383 (measured form intersecting face)

Taper per foot of leading edge of bore= 2.0133 Concentricity of tapered section of bore = 0.0003 Perpendicularity of tapered section of to bolting face = 0.0001

2889596 Damper Adapter JPL 5/12/03 Customer Part # 38

Bolt circle = 6.5992 Concentricity of pilot to bolt circle = 0.0048

Hole Sizes 1 0.2832 2 0.2824 3 0.2832 4 0.2824

AVERAGE 0.2828

Dimensional Records LM2500 Refurb 2889582 Damper Diaphragm JPL 5/12/03 Customer Part #26

* All dimensions in inches

Threaded Damper Plug in place

Bolt circle of 3 hole pattern = 2.1493

Damper Diaphragm

Bolt Circle using large holes= 21.1226 Hole Sizes

1 0.4377 2 0.4374 3 0.4373

AVERAGE 0.4375

Piloting OD = 21.997

Concentricity of 3 hole pattern to pioting OD= 0.0024

Hole Sizes (All) 1 0.3758 2 0.4373 3 0.3757 4 0.3757 5 0.3757 6 0.3757 7 0.3759 8 0.3757 9 0.3757

10 0.3757 11 0.3756 12 0.3757 13 0.3757 14 0.3757 15 0.3754 16 0.3758 17 0.3755 18 0.4376 19 0.3756 20 0.3756 21 0.3755 22 0.3758

Hole Sizes 1 0.2641 2 0.2632 3 0.2629

AVERAGE 0.2634

Bolt circle of 6 hole pattern= 3.3501

Hole Sizes

1 0.3079 2 0.3097 3 0.3098 4 0.311 5 0.3099 6 0.3086

AVERAGE 0.3095

23 0.3755 24 0.3757 25 0.3758 26 0.3757 27 0.3758 28 0.3756 29 0.3756 30 0.3757 31 0.3756 32 0.3757 33 0.3756 34 0.4373 35 0.3757 36 0.3757 37 0.3757 38 0.3757 39 0.3756 40 0.3757 41 0.3757 42 0.3758 43 0.3756 44 0.3758 45 0.3754 46 0.3758 47 0.3758 48 0.3754

Average 0.3757 0.4374

Bolt Circle using all holes= 21.1254

Concentricity of all hole pattern to pioting OD= 0.0014

2889575 Diaphragm Pack JPL 5/12/03 Customer Part #2 Scribed with "B"

Side 1 Adapter Side

OD Size = 21.997

Side 2 Tube Side

OD Size = 21.9996

Hole Sizes Hole Sizes 1 0.3753 1 0.3749 2 0.4376 2 0.437 3 0.375 3 0.375 4 0.3752 4 0.3748 5 0.3751 5 0.375 6 0.3754 6 0.3753 7 0.375 7 0.3749 8 0.3752 8 0.3751 9 0.375 9 0.3752 10 0.3752 10 0.3753 11 0.375 11 0.375 12 0.3752 12 0.3751 13 0.375 13 0.3748 14 0.3752 14 0.375 15 0.3752 15 0.3752 16 0.3751 16 0.375 17 0.3751 17 0.3751 18 0.4374 18 0.4371 19 0.3753 19 0.3753 20 0.3749 20 0.3751 21 0.3752 21 0.3748 22 0.3749 22 0.3749 23 0.3751 23 0.375 24 0.3748 24 0.375 25 0.3752 25 0.3752 26 0.3751 26 0.3752 27 0.3752 27 0.3752 28 0.3749 28 0.3759 29 0.3753 29 0.3751 30 0.375 30 0.3753 31 0.3753 31 0.375 32 0.3751 32 0.3749 33 0.3752 33 0.3752 34 0.4381 34 0.4371 35 0.3752 35 0.3756 36 0.375 36 0.3753 37 0.3745 37 0.3751 38 0.375 38 0.3749

39 0.3759 39 0.3752 40 0.3751 40 0.3751 41 0.3755 41 0.375 42 0.3751 42 0.375 43 0.3753 43 0.3748 44 0.375 44 0.3777 45 0.3752 45 0.375 46 0.375 46 0.3759 47 0.3753 47 0.3751 48 0.3751 48 0.375

Average 0.3751 0.4377 Average 0.3752 0.4371

Bolt Circle diameter = 21.1242 Concentricity of BC to OD = 0.0009

Bolt Circle Diameter = 21.1236 Concentricity of BC to OD = 0.0005

2889581 Diaphragm Pack "A" Scribed JPL 5/12/03 Customer Part #25

Side 1 Adapter Side

OD Size = 21.997

Side 2 Tube Side

OD Size = 21.9996

Hole Sizes Hole Sizes 1 0.3756 1 0.3755 2 0.4375 2 0.4372 3 0.3755 3 0.3757 4 0.3763 4 0.3754 5 0.3756 5 0.3754 6 0.375 6 0.3754 7 0.3756 7 0.3754 8 0.3749 8 0.3755 9 0.3754 9 0.3752 10 0.3751 10 0.3755 11 0.3754 11 0.3753 12 0.3756 12 0.3754 13 0.3751 13 0.3755 14 0.3757 14 0.3753 15 0.3758 15 0.3753 16 0.3754 16 0.3754 17 0.3757 17 0.3753 18 0.4382 18 0.4375 19 0.3755 19 0.3753 20 0.3758 20 0.3754 21 0.3759 21 0.3749 22 0.3754 22 0.3755 23 0.3756 23 0.3753 24 0.3755 24 0.3753 25 0.3758 25 0.3754 26 0.3756 26 0.3754 27 0.3755 27 0.3754 28 0.3757 28 0.3754 29 0.3752 29 0.3753 30 0.3756 30 0.3754 31 0.3752 31 0.3754 32 0.3756 32 0.3755 33 0.3754 33 0.3753 34 0.437 34 0.4372 35 0.376 35 0.3756 36 0.3755 36 0.3753 37 0.3751 37 0.3757 38 0.3755 38 0.3753 39 0.3754 39 0.3755

40 0.3755 40 0.3752 41 0.3752 41 0.3755 42 0.3755 42 0.3753 43 0.3753 43 0.3756 44 0.3756 44 0.3753 45 0.3755 45 0.3755 46 0.3755 46 0.3754 47 0.3752 47 0.3756 48 0.3757 48 0.3753

Average 0.3755 0.4376 Average 0.3754 0.4373

Bolt Circle diameter = 21.1247 Concentricity of BC to OD = 0.0006

Bolt Circle Diameter = 21.1254 Concentricity of BC to OD = 0.0013

Dimensional Summary 2889606 Forward Adapter Customer Part #1

Hole Sizes OD of Spline = 6.1683

1 0.3758 Turbine side journal dia = 5.8783

2 0.437

3 0.3755 Concentricity of BC to turbine side journal dia = 0.0009

4 0.3757 Diameter of Large piloting OD = 22.0011

5 0.3758 Concentricity of piloting OD to turbine side balance journal = 0.0005

6 0.3759 Concentricity of piloting OD to bolt circle diameter = 0.0005

7 0.3756

8 0.3758

9 0.3759

10 0.3755

11 0.3755

12 0.3758

13 0.3754

14 0.3757

15 0.3756

16 0.3762

17 0.3757

18 0.4371

19 0.3757

20 0.3757

21 0.3758

22 0.3757

23 0.3756

24 0.3758

25 0.3756

26 0.3761

27 0.3777

28 0.3759

29 0.3759

30 0.3759

31 0.3761

32 0.3759

33 0.3757

34 0.4371

35 0.376

36 0.3757

37 0.376

38 0.3758

39 0.3758

40 0.3759

41 0.376

42 0.3754

43 0.3755

44 0.3757

45 0.3754

46 0.3757

47 0.3759

48 0.3756

Average 0.3758 0.4371

Appendix B Inspection Process

Operation Description Accepted Stamp Rejected Stamp Check # Date Completed

Aft Adapter Part # 26 10 Scribe matchmark line on Aft and Damper Adapter per AMS 2800 (AS478-2D) 20 Degrease 30 Blast per PS242 method F mask as notes and all capped holes 40 Visually inspect; contact engineering if part is rejected [E] 50 Magnetic Particle inspect per MIL-STD-1907 (B) 60 Bolt hole (GO I NO GO) Smallest (43) 375- 376. Larger (3) .437-.438, Largest (12).749-

.750

70 inspect 4 tapped holes to -3B tolerances and measure piloting ID 80 Measure pilot OD and concentricity to bolt circles and record along with BCDs, determine if a balance journal exists. [E]

90 Measure length and total runout; record N100 Weigh part without bolts or nuts; record 110 Component balance to TBD [E] 120 Paint per ESI-U1309 mask as noted (sermetel only, cork and mask holes)

Bolts (12)

10 Degrease 20 Visual inspect 30 Dye Penetrant per MIL -STD-1907 A 40 inspect threads to -3A tolerances and record diameters of shank [E] 50 report if replacements are needed [E]

Nuts (12)

10 Degrease 20 Visual inspect 30 Dye Penetrant per MIL -STD-1907 A 40 inspect 4 tapped holes to -3B tolerances and measure piloting ID 50 report to JJMA if replacements are needed [E]

[E] Hold point see Engineering

Anti-Deflection Ring Part # 3 10 Scribe matchmark line(s) where marked with pen per AMS2800 (AS478-

2D)

20 Degrease 30 Blast per PS242 method F mask piloting diameter and as noted 40 Visually inspect [E] 60 Bolt hole check; record sizes 70 Measure and record piloting ID & concentricity to BC 80 Thread check tapped holes for function

[E] N90 Weigh part without hardware; record 100 Component balanceto 0.01 oz-in.

[E] 110 Paint per ESI-U1309 part B Sermetel only

Cylinder Dampener Part # 29 10 Scribe mm line already marked with marker per AMS2800 (AS478-2D) 20 Clean 30 Blast per PS242 method F, mask as noted 40 Visually inspect [E] 50 Magnetic particle inspect per MIL-STD-1907 (B) 60 Measure and record bolt hoe size and bore, and concentricity to piloting OD

N70 Weigh part with hardware, will be component balanced with Damper Diaphragm 80 Paint per ESI-U1309 part B Sermetel only

Bolts (3) Part # 34

10 Clean with acetone (soft brush permitted) 20 Visually inspect [E] 30 Zyglow inspect per MIL-STD-1907 (B) 40 Thread check to -2a tolerances

NUTS (3) Part # 35

10 Vendor clean with acetone (soft brush permitted) 20 Vendor remove plating 30 Visually inspect [E] 40 Dye penetrant inspect per MIL-STD-1907 (B) 50 Silover plate per AMS 2410 60 Thread check to -2a tolerances

Operation Description Accepted

Stamp Rejected Stamp Check #

Date Completed

Damper Diaphragm Part # 26 10 Disassemble 20 Scribe mm line already marked with marker per

AMS 2800 (AS478-2D)

30 Clean 40 Blast per PS242 method F, mask as noted 50 Visually inspect [E] 60 Magnetic particle inspect per MIL-STD-1907 (B) 70 Measure and record bolt hoe size and bore, and concentricity to piloting OD 80 Weigh part without hardware 90 Paint per ESI-U1309 part B Sermetel only; see masking notes 100 Component balance to TBD [E] balance as assembly with Cylinder Dampener

Damper Spacer Ring Part # 32

10 Clean with acetone (brush permitted) 20 Visually inspect [E] 30 Magnetic particle inspect per MIL-STD-1907 (B)

Internal Retaining Ring Part # 32

10 Clean with acetone (brush permitted)

30 Magnetic particle inspect per MIL-STD-1907 (C)

Internal Retaining Ring Part # 32

Retainer Ring

Threaded Damper Plug

20 Visually inspect [E]

Diaphragm Pack Part # 2 10 Remove D headed bolts using spreader tool. CAUTION should be taken not to over spread profile. Expand only wide enough to remove 4 bolts at a time. Save bolts for inspection box.

20 Vibroscribe per AMS 2800 (AS478-2D) on flange face aligned with marker line scribed with B

30 Clean per ESI-U1309 part 5 (acetone, soft cloth) 40 Visually inspect [E] 50 Zyglow inspect per MIL-STD-1907 (A) 60 Bolt hole inspection record Large holes (3) 0.437 - 0.438

Small holes (43) 0.375 – 0.376

70 Measure and record total runout from flange face to flange face 80 Measure and record concentricity between 2 BCs

N90 Weigh part without hardware installed; record [E] 100 Install inspected/new hardware using spreader tool 110 Will be balanced as a subassembly [E]

Bolts (3) Parts # 10 & 16

10 Clean with acetone (soft brush permitted) 20 Visually inspect [E] 30 Zyglow inspect per MIL-STD-1907 (B) 40 Inspect threads to -3A tolerances and check diameters of shanks

Large (0.436 - 0.437) Small (0.373 - 0.374)

50 Run failed bolts through die to correct [E] 60 Report if replacements are required [E]

Nuts (3) Parts # 9 & 15

10 Replace with new

2889588 Center Tube Customer Part Page 1A

Operation Description Accepted

Stamp Rejected Stamp

Check # Date

Completed Center Tube Part # 18

10 Matchmark break and side of radial springs with permanent marker 20 Vibroscribe matchmarks already marked with marker per AMS 2800-(AS478-2D) on OD 30 Remove radial springs, care should be taken not to scratch Sermetel 40 Degrease 50 Visually inspect 60 Blast per PS 242 Method F, mask ID 70 Dye penetrant inspect OD and flanges, not ID, per MIL-STD-1907 (B) 80 Measure and record bolt hole sizes Small (0.375-0.376) Large (0.437-0.438) GO 90 Measure length (flange to OD); Record

HOLD 100 Reinstall radial springs 110 Sermetel per ESI-U1309 Sermetel W only, touch up on ID, entire OD, burnish OD, mask as noted

120 Weigh part; Record

Radial Springs 10 Remove 20 Clean with acetone (soft brush permitted) 30 Visually inspect 40 Zyglow inspect per MIL-STD-1907 (B) 50 Weigh part with hardware installed; record 60 Do not remove matchmark(s)

Bolts

10 Remove, save washers (if they exist note location) 20 Clean with acetone (soft brush permitted)

40 Inspect threads to -2A tolerances [E]

Nuts

10 Remove, save washers (if they exist note location) 20 Clean with acetone (soft brush permitted)

40 Inspect threads to -2B tolerances [E]

Washers

10 Replace with new

Hardness Test Procedure

Objective: To determine if the hardness ot the material has changed after going through a sermetel curing cycle.

1) Cut as marked below

2) Scribe part 1 with a “T”

3) Send part 1 with “T” scribe through standard Sermetel cure cycle (675 degrees F ±25 degrees for 45-60 minutes)

4) After cooling, measure hardness in 5 places

Heat Cycled

Piece Normal Piece 1 Rc 1 Rc 2 Rc 2 Rc 3 Rc 3 Rc 4 Rc 4 Rc 5 Rc 5 Rc

Stamp Rejected Stamp

Check # Date

Completed Forward Adapter Part # 1

10 scribe matchmark line already marked with marker per AMS 2800-(AS478-2D) 20 Degrease with acetone (Soft brush permitted) 30 Visually inspect 40 Zyglow inspect per MIL-STD-1907 (A) 50 External spline inspection, record OD 60 Examine ratcheting internal spline for broken threads 70 Bolt hole check Go/No Go (Lg - 3) 0.437-0.438 (Sm - 43) 0.375-0.376 80 Check concentricity of BC to suspect balance journals and pilot OD; Record 90 Weigh part; Record

Stamp Rejected Stamp

Check # Date

Completed Damper Diaphragm

10 Disassemble 20 Scribe matchmark line already marked with marker per AMS 2800-(AS478-2D) 30 Clean 40 Blast per PS 242 method F, masked as noted 50 Visually inspect 60 Magnetic particle inspect per MIL-STD 1907 (B) 70 Measure and record bolt hole sizes and concentricity to pilot 80 Weight part; record 90 Paint per SEI U-1309 part B Sermetel only; see notes

100 Balanced as a sub-assembly

Piston Cap Screw 10 Degrease with acetone (Soft brush permitted) 20 Visually inspect 30 Zyglow inspect per MIL-STD-1907 (A) 40 Inspect threads to -2A tolerances

Stamp

Rejected Stamp

Check # Date

Completed Piston Assembly Plate (Both)

10 Note end before removal 20 Clean with acetone (Soft brush permitted) 30 Visually inspect 40 Magnetic particle inspect per MIL-STD 1907 (B)

Piston Assembly Ring (S)

10 Note direction and end before removal 20 Clean with acetone (Soft brush permitted) 30 Visually inspect 40 Measure OD & ID: Record 50 Magnetic particle inspect per MIL-STD 1907 (B)

Piston Assembly Ring (L)

10 Note direction and end before removal 20 Clean with acetone (Soft brush permitted) 30 Visually inspect 40 Measure ID, OD & Gap: Record 50 Magnetic particle inspect per MIL-STD 1907 (B)

Stamp

Rejected Stamp

Check # Date

Completed Rod

10 Clean with acetone (Soft brush permitted) 20 Blast per PS 242 Method F, mask as noted 30 Visually inspect 40 Magnetic particle inspect per MIL-STD 1907 (B) 50 Inspect threads to -2A tolerances 60 Measure concentricity using shank diameters for V block to determine if bent; Record 70 Weigh part; Record

Locking Nut

10 Note end and color for reassembly 20 Clean 30 Visually inspect 40 Dye penetrant inspect per MIL-STD 1907 (B) 50 Inspect threads to -2A tolerances