SOW Paragraph 2 Applicable Docs - MMD-020-Para 8.190.pdf

S9234-AB-MMD-020/LM2500

p. Retouch any missing anodize finish per para. 3.131.

8.190 REPLACEMENT OF VANE ACTUATION

LEVER BEARINGS.

NOTE

This procedure provides instructions for modify-ing pre GTC No. 78 vane actuation lever with self-aligning bear-ings to GTC No. 78 vane actuation lever with slot-loaded bearings and lever journal (trun-nion) bushing/sleeve. It also provides procedures for replacing individual slot-loaded bearings or individual bearing balls, replacing lever journal (trunnion) bushing/sleeve and provides machining information for installa-tion of oversize bearings if vane actuation lever bearing bores are worn.

a. Replace actuation lever arm spherical bearings with slot-loaded bearings or replace existing slot-loaded bearings as follows:

NOTE

To replace actuation lever arm individual slot-loaded bearing balls refer to step (16).

(1) Remove spherical or slot-loaded bearings using hydraulic press and P/N 1C7126 tooling. (See Figure 8-329 for illustration of setup). Re-fer to Table 8-71 for tool/bearing matrix.

(2) For machining setup information, (See Figure 8-330). Restrain sur-face SA flat within 0.002 inch.

(3) Dimensionally inspect diameter X for lever arms previously modified with slot-loaded bearings. Blend to remove high metal on diameter X.

(4) If diameter X is within standard slot-loaded bearing finish dimen-sion 0.8740-0.8751 inch, trial as-semble standard size bearing into lever arm. Assembly should be made using only finger pressure.

(5) If diameter X is greater than 0.8751 inch but less than 0.8951 inch for lever arms previously modified with slot-loaded bearings, select appro-priate finish dimension for next closest oversize slot-loaded bearing 0.8840-0.8851 inch; second over-size bearing 0.8940-0.8951 inch.

Refer to Table 8-71.

(6) Diameter X lever arm spherical bearing bore is undersized for re-placement of slot-loaded bearings.

Machine diameter X as follows:

(a) Set up lever arm in vertical jig borer. Refer to step a(2) (See Figure 8-329).

NOTE

Machining dimensions are nominal. Machine bore until slot-loaded bearing just slip fits into lever arm using finger pressure only.

(b) Machine diameter X to fin-ish dimension 0.8755 (+/- 0.005) inch for replacement of slot-loaded bearing. Oversize bearings are available if re-quired; refer to Table 8-71 for oversize dimension require-ments and machining dimen-sions.

(c) Chamfer both sides of diameter X (See Figure 8-330 Section B-B).

(d) Inspect finished diameter X for burrs or sharp edges. Re-ream as necessary.

(e) Visually inspect diameter X for cracks using 10x magnifying glass. If any suspect areas are found, penetrant inspect per para. 3.70. No cracks are al-lowed.

(f) Trial assemble a slot-loaded bearing. Bearing should just slip into bore using finger pres-sure only.

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(7) If diameter X is greater than 0.8951 inch but less than 0.9001 inch, repair per para 8.195, step a. (Refer to Table 8-71 for bore dimensions). If diameter X is greater than 0.9001 inch but less than 0.9071 inch, repair per para. 8.195, step b. (Refer to Table 8-71 for bore dimensions).

(8) Dimensionally inspect diameter Y.

Blend to remove high metal on di-ameter Y.

(9) Diameter Y may not require ma-chining. If diameter Y is within standard slot-loaded bearing fin-ish dimension, 0.9990-1.0000 inch, trial assemble standard size bearing into lever arm. Assembly should be made using only finger pressure.

(10) If diameter Y is greater than 1.0000 inch but less than 1.0200 inch, se-lect appropriate finish dimension for next closest oversize slot-loaded bearing 1.0090-1.0100 inch; second oversize bearing, 1.0190-1.0200 inch. Refer to Table 8-71. Machine lever arm diameter Y as follows:

(a) Set up lever arm in vertical jig borer. Refer to step a(2). (See Figure 8-329).

(b) Machine to finish dimension for next larger oversize slot-loaded bearing.

CAUTION

Chamfer raised pad side of diameter Y with a sin-gle point tool or equiv-alent to avoid removing material from edges of raised pads.

(c) Chamfer both sides of diameter Y (See Figure 8-330 Section A-A).

(d) Inspect finished diameter Y for burrs or sharp edges. Re-ream as necessary.

(e) Visually inspect diameter Y for cracks using 10x magnifying glass. If any suspect areas are found, penetrant inspect per para. 3.70. No cracks are al-lowed.

(11) If diameter Y is greater than 1.0200 inch but less than 1.0250 inch, repair per para. 8.195, step a. (Refer to Table 8-71 for bore dimensions). If diameter Y is greater than 1.0250 inch but less than 1.0320 inch, repair per para. 8.195, step b. (Refer to Table 8-71 for bore dimensions).

(12) Install slot-loaded bearings into actuation lever using finger pres-sure. Trial assemble bearing into the lever. If the assembly can be made by hand force, apply and air dry a light coat of zinc chro-mate primer (TT-P-1757) or it’s approved non-chromate alternate.

(See Figure 8-329) and Table 8-71 for illustration of setup and special tools. After installing the bearing ball with finger pressure, you may have approximately 0.000-0.005 inches of play both radially and ax-ially.

CAUTION

For replacement slot-loaded bearings, posi-tion bearing such that loading slot in outer race is aligned with axis PA, and on the side of actua-tion lever opposite raised pads. (See Figure 8-331).

NOTE

The swage load for the bearings (standard or oversize) to be installed in diameter X is 12,000 +/- 200 pounds. The swage load for the bear-ings (standard or over-size) to be installed in di-ameter Y is 18,800 +/- 200 pounds.

(13) Swage bearing into lever as follows:

(a) Select proper swaging tool from tooling P/N 1C7126 and coat conical surface of swag-ing tools with lubricant.

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NOTE

Setup for swaging re-quires piston rod of hy-draulic press to be per-pendicular to surface sup-porting the lower tools.

(b) Using hydraulic press, apply the swaging load of 12,000 +/- 200 pounds to diameter X and 18,800 +/- 200 pounds to diam-eter Y. Swaging pressure will be applied a total of 4 times for each bearing. Index P/N 1C7126 tooling 90 degrees to actuation lever between each swaging application.

CAUTION

Correct swaging may cre-ate very slight tension on bearing ball. Too much tension will seize the ball.

If greater than 3 in-lbs of torque Is required to move the ball, bearing may seize during gas tur-bine storage and subse-quent operation and may contribute to catastrophic engine damage.

(14) Once the bearings for diameter X and Y have been swaged into the lever, check ball for freedom of movement by using the following procedure:

(a) Use correct sized bolt, nut and washers, as required on each side of the bearing ball and at-tach bolt through the ball.

(b) Tighten nut and bolt enough to prevent bolt from slipping in ball.

(c) Utilize 0-30 in-lb dial type torque wrench to check torque required to turn ball within the race. For position X and Y, “ball may have play (radially and axially) of no more than

0.005 inches and shall require no more than 3 in-lbs to move with the torque wrench”. (See Figure 8-332). Each bearing ball shall be checked for proper freedom of movement.

(d) If bearing ball is too tight (greater than 3 in-lb), or if looseness of the ball is greater than 0.005, attempt using a different ball. If freedom of movement requirements can-not be met, replace bearing.

A bearing without the correct freedom of movement may seize during engine operation and contribute to catastrophic engine damage.

(15) Load test and inspect installation as follows:

(a) Use hydraulic press and P/N

1C7126 tooling to apply 300 pound force to outer race of swaged side of bearing. Hy-draulic press must have a cal-ibrated pressure gage accu-rately readable to 300 pounds.

(b) Visually inspect bearing for ax-ial shift. Re-swage or replace if bearing has shifted.

NOTE

Failure to meet load test requirements indicates in-adequate swaging.

(c) Recheck ball for freedom of movement, (See Figure 8-332).

With clevis bolt installed, in-spect ball for free movement in the race. If ball will not rotate at torque requirements stated in step (14) and/or the bearing outer race shifts at or before the 300 pounds load test before the ball rotates, replace bearing (outer race and ball).

(d) Use a plastic tie wrap or other non-metallic means to secure slot-loaded bearing ball to the lever arm until installation of clevises.

(16) Replace individual slot-loaded bear-ing balls as follows:

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(a) Rotate slot-loaded bearing ball so it aligns with outer race loading slot and remove.

(b) Select replacement slot-loaded bearing ball. Apply and air dry a light coat of zinc chro-mate primer (TT-P-1757) or its approved non-chromate alter-nate. Position ball such that the ball aligns with the outer race loading slot. Install bear-ing ball into the race using fin-ger pressure only.

(c) Check ball for freedom of movement refer to step (14).

(d) Use a plastic tie wrap or other non-metallic means to secure slot-loaded bearing ball to the lever arm until installation of clevises.

b. Install press fit bushing/sleeve on vane actuation lever journal (trunnion). If previously installed vane actuation lever journal (trunnion) bushing/sleeve requires replacement, remove bush-ing/sleeve and inspect diameter DC (See Figure 8-333). If diameter DC fin-ished dimension is 0.436-0.437 inch or if maximum wear on diameter DC is within 0.4357-0.437 inch, no repair is required. Assemble bushing/sleeve to journal (trunnion) as follows:

(1) Press fit bushing/sleeve (3) on vane actuation lever journal (trunnion), assuring that sleeve flange is seated against the forward face of lever.

NOTE

Bushing inside diame-ter is 0.4357-0.436 inch, 0.0000-0.0013 inch inter-ference fit. To ease as-sembly, the journal (trun-nion) may be pre-cooled using dry-ice.

(2) If wear on diameter DC is between 0.015-0.030 inch, repair as outlined in para. 8.196. If wear on diameter DC exceeds 0.030 inch replace ac-tuation lever journal (trunnion) per para. 8.197.

(3) Line out existing marking, except serial number (maintaining legi-bility) and remark lever arm using method-metal stamp 0.001-0.006 inch shallow markings as follows:

NOTE

P/N 9673M66G16 lever arms may or may not have slot-loaded bearings and/or trunnion bush-ing incorporated on in-ducted GGs. G16 lever arms from supply system may or may not Include slot-loaded bearings and do not have trunnion bushing Incorporated.

G16 arms, provided via NSWCCD-SSES Rotable Pool, have slot-loaded bearings installed and trunnion bushings Pack-aged separately for use on GGs with or without GTC No. 78 Incorporated.

(a) Previous P/N

9673M66G01/G08/G16, vane actuation lever, remark to P/N 9673M66G15.

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Figure 8-329. P/N 1C7126 Special Tooling Set-up

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Figure 8-330. Vane Actuation Lever Dimensions

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Figure 8-331. Vane Actuation Lever Slot-Loaded Bearing Assembly

Figure 8-332. Rotational Torque Check of Slot-Loaded Bearing

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Figure 8-333. Vane Actuation Lever Trunnion Bushing/Sleeve Installation

Table 8-71. Actuation Lever Bearing to Tool Set P/N 1C7126 and Bore Dimension Chart

BEARING #

Lever Arm (X)

PUNCH

SEAT-

ING

DIE

SEAT-

ING

ADAPTER

SEATING

PUNCH

SWAGE

DIE

SWAGE

DRILL REAMER COUNTER

SINK

1327M98P01 (standard)

2 5 8 17 19 25 28 30

1327M98P02 (1st Oversize)

2 5 8 18 19 Locally Procure

Locally Procure

BEARING #

Lever Arm Pivot (Y)

PUNCH

SEAT-

ING

DIE

SEAT-

ING

ADAPTER

SEATING

PUNCH

SWAGE

DIE

SWAGE

DRILL REAMER COUNTER

SINK

1333M67P01 (standard)

3 6 9 11 21 Not Needed

27 30

1333M67P02 (1st Oversize)

3 6 9 12 21 Locally Procure

Locally Procure

1333M67P03 (2nd Oversize)

3 6 9 13 21 Locally Procure

Locally Procure

REF NO. PART NUMBER NOMENCLATURE REF NO. PART NUMBER NOMEN-

CLATURE

2 1C7126P02 Punch, Seating 19 1C7126P19 Die, Swaging

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Table 8-71. Actuation Lever Bearing to Tool Set P/N 1C7126 and Bore Dimension Chart - Continued 3 1C7126P03 Punch, Seating 20 1C7126P20 Die, Swaging 4 1C7126P04 Punch, Seating 21 1C7126P21 Die, Swaging 5 1C7126P05 Die, Seating 22 1C7126P22 Container 6 1C7126P06 Die, Seating 23 1C7126P23 Assembly 7 1C7126P07 Die, Seating 25 1C7126P25 Core Drill

.8594 8 1C7126P08 Adapter, Seating 27 1C7126P27 Reamer

1.0100 9 1C7126P09 Adapter, Seating 28 1C7126P28 Reamer

0.8750 10 1C7126P10 Adapter, Seating 29 1C7126P29 Reamer

0.8225 11 1C7126P11 Punch, Swaging 30 1C7126P30 Counter

Sink 1.50 12 1C7126P12 Punch, Swaging 31 1C7126P31 Punch, Seating 13 1C7126P13 Punch, Swaging 32 1C7126P32 Punch, Seating 14 1C7126P14 Punch, Swaging 33 1C7126P33 Punch, Seating 15 1C7126P15 Punch, Swaging 34 1C7126P34 Die, Seating 16 1C7126P16 Punch, Swaging 17 1C7126P17 Punch, Swaging 18 1C7126P18 Punch, Swaging

BORE DIMENSIONS

LEVER ARM/CLEVIS BEARINGS Min Max 1327M98P01 Standard Diameter

X:

0.8740" 0.8751"

1327M98P02 1st Oversize Diameter X:

0.8840" 0.8851"

1327M98P03 2nd Oversize Diameter X:

0.8940" 0.8951"

LEVER ARM PIVOT/AFT MOUNT END BEARING

1333M67P01 Standard Diameter

Y:

0.9990" 1.0000"

1333M67P02 1st Oversize Diameter Y:

1.0090" 1.0100"

1333M67P03 2nd Oversize Diameter Y:

1.0190" 1.0200"

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