SOW Paragraph 2 Applicable Docs - MMD-020-Para 8.196 & 8.197.pdf

S9234-AB-MMD-020/LM2500

Figure 8-339. Repair of Vane Actuation Lever - Bearing Bores

Table 8-73. Vane Actuation Lever Bearing Bore Dimensions

In Process Dimension Finish Dimension Description Min Max Min Max Reference

Dimensions Bore Dia. X - 0.745 inch 0.7395 inch 0.7400 inch

- 0.752 inch Bore Dia. Y - 1.005 inches 0.9995 inch 1.0000 inches

- 1.012 inches

8.196 REPAIR OF WORN ACTUATION LEVER

JOURNAL (TRUNNION).

(See Figure 8-340)

NOTE

If wear of diameter DC exceeds 0.015 inch max depth or 0.030 inch max depth in a local area and 40 percent of circumfer-ence, repair in accordance with para. 8.197.

a. When wear of diameter DC does not ex-ceed 0.015 inch, repair worn actuation lever journal (trunnion) as follows:

(1) Set-up actuation lever on grinding machine on surface SA. Establish axis concentric with diameter DB and on a plane with the center of diameter DE. (See Figure 8-340)

8-511

Figure 8-340. Repair of Worn Vane Actuation Lever Journal (Trunnion)

(2) If required formachining, machine a tool center using a No. 2 center drill with a 0.1875 inch body diameter x

0.078 inch point diameter. Machine tool center concentric with diameter DB, within 0.005 inch.

(3) Set-up the actuation lever in a ma-chine equipped with a 2 or 4 jaw chuck to grip on surface SA and sur-face SB. Support the trunnion with a tailstock center engaged in the tool center. Independently adjust the chuck jaws to establish surface SA and surface SC parallel with the axis of the machine as determined with a spirit level.

(4) Machine diameter, DC to 0.424-

0.426 inch.

(5) Mask adjacent surfaces and grit blast diameter DC per para. 3.18.

(6) Thermal spray diameter DC per para. 3.121 with Tribaloy 400.

cobalt molybdenum chromium sili-con alloy (GE Spec B50TF155, C1 A) to a thickness of 0.010-0.020 inch.

(7) Set-up actuation lever on grinding machine in accordance with step (1) and step (3) above.

(8) Machine diameter DC to 0.436-

0.437 inch with a maximum sur-face finish of 32AA. Recommended grinding parameters are as follows:

-Grinding wheel Norton 32A60K8VBE or Norton 39C80H12V or equivalent

-Wheel speed 6000 sfm -Stock removal 0.0005 inch/pass -Cooling Flood type water with 1/2 percent rust inhibitor

(9) Visually inspect coating per para.

3.121.

b. When wear of diameter DC does not ex-ceed 0.030 inch, repair worn actuation lever journal (trunnion) as follows:

(1) Mask adjacent surfaces and grit blast diameter DC per para. 3.18.

8-512

(2) Thermal spray diameter DC per para. 3.121 using aluminum nickel chromium powder (GE Spec B50TF119, Cl A) to a thickness of 0.010-0.020 inch.

(3) Set-up actuation lever on grinding machine in accordance with step a(1) and (3) above.

(4) Machine diameter DC to 0.424-

0.426 inch.

(5) Again mask adjacent surfaces and grit blast diameter DC per para.

3.18.

(6) Thermal spray diameter DC per para. 3.121 with Tribaloy 400, cobalt molybdenum chromium sili-con alloy (GE Spec B50TF155, C1 A) to a thickness of 0.010-0.030 inch.

(7) Set-up actuation lever on grinding machine in accordance with step a(1) and step a(5) above.

(8) Machine diameter DC to 0.436-

0.437 inch with a maximum surface finish of 32AA. See step a(8) above for recommended grinding parame-ters.

(9) Visually inspect coating per para.

3.121.

8.197 REPLACEMENT OF WORN ACTUATION

LEVER JOURNAL (TRUNNION).

(See Figure 8-341 through Figure 8-347)

NOTE

This procedure provides instructions for replace-ment of actuation lever trunnion when wear of di-ameter DC exceeds the limits of para. 8.196.

a. Set-up actuation lever on machine, on surface SA, and establish datum planes PA, PB, and PC as follows (see Figure 8-341)

(1) Plane PA is established by aligning the fore and aft spherical bearing holes.

(2) Plane PB is defined as a plane lo-cated dimension W/2 from surface

SA.

(3) Plane PC is perpendicular to planes PA and PB and is located at the cen-ter of the aft spherical bearing hole.

Figure 8-341. Vane Actuation Lever, Establishment of Datum Plane

8-513

Figure 8-342. Vane Actuation Lever, Removal of Forward Journal (Trunnion)

b. Machine to remove forward trunnion per Figure 8-342, maintaining dimension A, Table 8-74, and squareness specified in Figure 8-341.

c. Machine and ream diameter DA hole at forward end per Figure 8-343. Hole will break through the wall at the thinner web section.

d. Locally manufacture a replacement trun-nion per Figure 8-344 from AMS 5662 material (Inconel 718). Material shall be in the solution heat-treated and aged con-dition prior to machining.

e. Assemble replacement trunnion to lever per Figure 8-345, assuring that the trun-nion shoulder is seated against the ma-chined forward face of the lever. To ease assembly (this is 0.0000-0.0015 inch in-terference fit), the trunnion may be pre-cooled using Dry Ice.

f. Initially weld trunnion to web of the lever at four locations per Figure 8-345. Weld per para. 3.91 using AMS 5786 (Hastel-loy W) filler material.

g. Remove excess material at four places from replacement trunnion shoulder to conform to surfaces of the actuation lever. (See Figure 8-346)

h. Final weld trunnion to lever. (See Figure 8-346) Weld per para. 3.91 using AMS 5786 (Hastelloy W) filler material.

i. Machine forward end of trunnion per Figure 8-346, maintaining dimensions H, J, and K. Remove all sharp edges and burrs.

j. Locally heat-treat repaired trunnion end of the lever as follows:

8-514

Figure 8-343. Vane Actuation Lever, Machining and Reaming Hole in Forward End

Figure 8-344. Locally Manufactured Replacement Trunnion

8-515

Figure 8-345. Replacement Trunnion, Assembly and Initial Weld

Figure 8-346. Replacement Trunnion, Final Machining and Welding

8-516

Table 8-74. Actuation Lever Journal (Trunnion) Dimensions

In-Process Dimension Finish Dimension Description Min Max Min Max Reference

Dimensions Dimension A 34.497 34.507 - - -

Dimension B - - 34.667 34.682 -

Diameter DA 0.3750 0.3755 - - -

Diameter DB - - 0.290 0.300 -

Diameter DC - - 0.4360 0.4370 -

Diameter DD - - 0.420 0.430 -

Diameter DE 0.3755 0.3765 - - -

Diameter DF 0.92 0.94 - - -

Dimension C - - 1.23 1.25 -

Dimension D - - 1.110 1.115 -

Dimension E - - 0.42 0.44 -

Dimension F 0.170 0.175 - - -

Dimension G 1.23 1.25 - - -

Dimension H - - 0.085 0.095 -

Dimension J - - 0.17 0.19 -

Dimension K - - 1.095 1.105 -

CAUTION

Do not use gas torch for heat-treating.

(1) With safety-wire, attach two three inch x 1/2 inch diameter Chroma-lox cartridge heaters, Catalog No.

CIR 3031 (Edwin L. Weigand Di-vision, Emerson Electric Co., Pitts-burgh, PA 15208) to sides of lever arm at locations shown in Figure 8-347.

(2) Attach two thermocouples to lever at locations. (See Figure 8-347)

(3) Completely cover the trunnion end of the lever and the cartridge heaters with Kaowool bulk insulation (Bab-cock andWilcox Co.) or equivalent.

Do not cover No. 2 thermocouple on web of lever or the remainder of the lever with insulation.

(4) Attach thermocouple leads to com-patible potentiometers and temper-ature read-out equipment. Attach heater leads to a variable power con-trol unit.

WARNING

When handling heated or chilled parts, wear ther-mally insulated gloves to prevent burning or freez-ing of hands.

CAUTION

In the following heat-treat cycle, do not allow tem-perature, as measured at thermocouple No. 2, to exceed 800°F (427° C);

use supplemental air as necessary for cooling.

8-517

NOTE

During heat-treat cycle, monitor temperature con-stantly.

(5) Apply power to cartridge heaters and heat reworked end of part to 1150°F (621° C) as measured at thermocouple No. 1. Heat at a rate of 10° -20°F (6°-11°C) per minute.

(6) Maintain temperature of reworked end of part at 1150° ±25°F (621°

±14°C) for two hours; then reduce temperature to 600°F (316°C) at a rate of 10°-20°F (6°-11°C) per minute. Turn off power, remove insulation, and allow part to cool to room temperature.

(7) Fluorescent-penetrant inspect re-paired end of actuation lever per para. 3.70. No cracks allowed.

Figure 8-347. Vane Actuation Lever, Local Heat-Treat of Repaired Area

8.198 COMPRESSOR ROTOR COMPONENTS.

8.199 DIMENSIONAL INSPECTION OF

COMPRESSOR ROTOR COMPONENTS.

When performing dimensional inspection of com-pressor rotor rabbets and actual measured disk di-ameters, use a single purpose, non adjustable gage with an accuracy of 0.0001 inch. All measurements shall be taken at room temperature.

8.200 STAGE 1 COMPRESSOR ROTOR DISK

INSPECTION AND REPAIR.

Inspect to Table 8-75.

a. Clean per Table 3-1.

b. Inspect per para. 3.70, paying particular attention to dovetail slots and flange bolt holes.

c. If repairs have been made, shot peen and grit blast disk per para. 8.201.

d. If repairs have not been made, wet grit blast surface T (Figure 8-348) per para

8.201 step c.

8-518